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GP MKS40A Repair Manual

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MKS
Repair Manual
MKS40A-MKS45A-MKS50A
MKS55A-MKS60A-MKS65A
General Pump is a
member of the
Interpump Group
Ref 300699 Rev C
01-16

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Summary of Contents for GP MKS40A

  • Page 1 Repair Manual MKS40A-MKS45A-MKS50A MKS55A-MKS60A-MKS65A General Pump is a member of the Interpump Group Ref 300699 Rev C 01-16...

  • Page 2: Table Of Contents

    MKS SERIES GENERAL PUMP A member of the Interpump Group INDEX INTRODUCTION ..........Page 3 REPAIR INSTRUCTIONS .

  • Page 3: Introduction

    MKS SERIES GENERAL PUMP A member of the Interpump Group 1. INTRODUCTION This manual describes the instructions for Repairing MKS Series pumps, and must be carefully read and understood before performing any repair intervention on the pump. Correct use and adequate maintenance is fundamental for the pump’s regular operation and long wear.

  • Page 4: Crank Mechanism Disassembly

    MKS SERIES GENERAL PUMP A member of the Interpump Group 2.1.1 Crank Mechanism Disassembly The correct sequence is the following Completely drain the oil from the pump, then remove the key from the shaft (1, fig.2). Unscrew the reducer flange fastening screws (1, fig. 3) and remove the flange from the shaft. On the opposite side, unfasten the screws (1, fig.

  • Page 5: Disassemble The Crankcase Cover By Unfastening The Relevant Screws (1, Fig

    MKS SERIES GENERAL PUMP A member of the Interpump Group Disassemble the crankcase cover by unfastening the relevant screws (1, fig. 5). Unfasten the reducer cover screws (1, fig. 6). Insert 3 dowels, or 3 M8 threaded screws (1, fig. 7) in the appropriate holes to aid extraction, and two sufficiently long M10 screws in order to support the cover (2, fig.
  • Page 6 MKS SERIES GENERAL PUMP A member of the Interpump Group Screw on the 3 threaded screws (1, fig. 8) and simultaneously, using the appropriate tool (p/n F27516700), hammer on the tool itself so that the bearing remains on the pinion when extracting the cover (1, fig. 9). When this operation is complete, remove the reducer cover and then slip off the bearing from the pinion.
  • Page 7 MKS SERIES GENERAL PUMP A member of the Interpump Group Remove the key from the shaft (1, fig. 13). Remove the pinion by using a slide hammer applying it to the M14 hole (1, fig. 14). Lift the safety washer key (1, fig. 15) Ref 300699 Rev C 01-16 Page 7...
  • Page 8 MKS SERIES GENERAL PUMP A member of the Interpump Group Insert a spacer under the connecting rod to block shaft rotation (1, fig. 16). Using an appropriate wrench, unscrew and remove the ring nut (1, fig. 17) and then remove the safety washer (1, fig 18).
  • Page 9 MKS SERIES GENERAL PUMP A member of the Interpump Group On the opposite side, unfasten the reducer case screws (1, fig. 21), and then remove the case (1, fig. 22). Unscrew the connecting rod screws (1, fig. 23). Disassemble the connecting rod caps with the split bearings; be particularly aware of disassembly order. The connecting rod caps and the related connecting rods must be reassembled in the exact order and coupling as during disassembly.
  • Page 10 MKS SERIES GENERAL PUMP A member of the Interpump Group Push the connecting rods forward in the direction of the hydraulic side in order to push out the crankshaft. Use the appropriate tool (p/n F27566200) to facilitate this operation (1, fig. 25) Remove the pressure sleeve (1, fig.
  • Page 11 MKS SERIES GENERAL PUMP A member of the Interpump Group Remove the crankshaft with the help of a hammer on the PTO side (1, fig. 28). Remove the shaft and the bearing (1, fig. 29). On the opposite side, extract the bearing (1, fig. 30) If the replacement of one or more connecting rods or plunger guides is necessary, please operate as follows: Unfasten the screws of the tool (p/n F27566200 to unlock the connecting rods (1, fig.

  • Page 12: Ref 300699 Rev C

    MKS SERIES GENERAL PUMP A member of the Interpump Group Couple the connecting rods with the previously disassembled caps; be sure to respect numbering (1, fig. 33). Remove the two seeger rings that block the plunger pin by using the appropriate tool (1, fig. 34). Remove the pin (1, fig.

  • Page 13: Crank Mechanism Assembly

    MKS SERIES GENERAL PUMP A member of the Interpump Group To separate the rod from the plunger guide, unfasten the M10 hexagonal-head screws using a size 17 socket wrench (1, fig. 37). 2.1.2 Crank Mechanism Assembly Proceed with assembly by inverting the precedure indicated in paragraph 2.1.1. The correct sequence is the following: Connect the rod to the plunger guide Insert the Ø5 pin in the appropriate hole on the plunger guide (1, fig.
  • Page 14 MKS SERIES GENERAL PUMP A member of the Interpump Group Block the rod using a clamp, and proceed with calibration using a torque wrench (1, fig. 40) as indicated in paragraph 3. “SCREW CALIBRATION” Insert the connecting rod in the plunger guide (1, fig. 36) and then insert the pin (1, fig. 35). Apply the two seeger rings using the correct tool (1, fig.
  • Page 15 MKS SERIES GENERAL PUMP A member of the Interpump Group Insert the shaft (1, fig. 29) until the pre-assembled bearing is aligned with the edge of the crankcase (1, fig. 43). Manually insert the pressure sleeve to maintain the shaft alignment (1, fig. 44). Assemble the reducer case (1, fig.
  • Page 16 MKS SERIES GENERAL PUMP A member of the Interpump Group Completely insert the pressure sleeve on the shaft from the opposite side of the PTO (1, fig. 49 and fig. 50). Pressure sleeve insertion must be done without oil or lubricants. Insert the sleeve until the external surface (tapered) couples perfectly with the inside of the bearing.
  • Page 17 MKS SERIES GENERAL PUMP A member of the Interpump Group Measure the dimension “X” indicated in fig. 51. Screw the ring nut and fasten the sleeve until the dimension “X” is reduced by a value ranging between 0.7 and 0.8 mm (fig. 52). Unscrew the ring nut, insert the safety washer (1, fig.
  • Page 18 MKS SERIES GENERAL PUMP A member of the Interpump Group Remove the device that blocks the connecting rods using p/n F27566200 (1, fig. 31). Insert the upper split bearings between the connecting rods and the shaft (1, fig. 56). In order to correctly assemble the split bearings, be sure that the split bearings’ reference key in the appropriate seat on the connecting rod (1, fig.
  • Page 19 MKS SERIES GENERAL PUMP A member of the Interpump Group Once tightened on the crankshaft, make sure that conrods still have axial right-left endplay. Preassemble the bearing on the pinion (1, fig. 60) and fully insert the pinion in the seat on the reducer case (1, fig.
  • Page 20 MKS SERIES GENERAL PUMP A member of the Interpump Group Apply the 3 Ø 12 x 40 pins to the reducer case (1, fig. 64) and insert the gasket (1, fig. 65). Assemble the bearing on the reducer cover (1, fig. 66). Assemble the reducer cover (1, fig.
  • Page 21 MKS SERIES GENERAL PUMP A member of the Interpump Group Insert the oil seal inside the reducer flange using the proper tools, p/n F27515900 and F27548200 (1, fig. 70). Before proceeding with oil seal assembly, verify the conditions of the sealing lip. If replacement is necessary, position the new ring as indicated in fig.
  • Page 22 MKS SERIES GENERAL PUMP A member of the Interpump Group Insert the key 16 x 10 x 90 in the pinion. Insert the O-ring in the rear cover (1. fig. 74) and fasten it to the crankcase using 10 M8 x 18 screws (1, fig.

  • Page 23: Refurbishing The Crank Mechanism

    MKS SERIES GENERAL PUMP A member of the Interpump Group Complete the assembly of the crank mechanism by applying the plugs and lifting eyebolts with the related sealing O-ring. Fill the crankcase with oil as indicated in the use and maintenance manual, paragraph 7.4. 2.1.3 Refurbishing the crank mechanism TABLE UNDERSIZED DIAMETERS FOR CRANKSHAFT AND CONROD BUSHINGS Upper half...

  • Page 24: Fluid End Repair

    MKS SERIES GENERAL PUMP A member of the Interpump Group 2.2 Fluid End Repair 2.2.1 Head Disassembly - Valve Units The head requires preventive maintenance as indicated in the use and maintenance manual. Interventions may be limited to valve inspection, or replacement as needed. To extract the valve units operate as follows: Unfasten the 8 M16 x 55 screws of the valve cover (1, fig.
  • Page 25 If the extraction of the delivery valve unit is particularly difficult (for ex. due to incrustations caused by prolonged pump inactivity) use the extraction tool, p/n F27516400 (for MKS40A, MKS45A or MKS50A, or p/n F27516500 (for MKS55A, MKS60A and MKS65A).
  • Page 26 If the extraction of the of the suction valve unit is particularly difficult (for ex. due to incrustations caused by prolonged pump inactivity) use the extraction tool p/n F27516200 (for MKS40A, MKS45A, MKS50A) or p/n F27516300 (for MKS55A, MKS60A and MKS65A) (1, fig. 85) and act as indicated.

  • Page 27: Head Assembly - Valve Units

    MKS SERIES GENERAL PUMP A member of the Interpump Group 2.2.2 Head Assembly - Valve Units Pay careful attention to state of wear of the various components; replace them if necessary. At each valve inspection, replace all valve units and valve plug O-rings. Before repositioning the valve units, clean and perfectly dry the relevant seats in the head indicated by the arrows (1, fig.
  • Page 28 MKS SERIES GENERAL PUMP A member of the Interpump Group Proceed with the insertion of the valve units (suction and delivery) into the head, paying attention to the correct insertion sequence of the O-rings and anti-extrusion rings. The correct assembly sequence of the valve units in the head is the following: Insert the anti-extrusion ring, exploded view item 4 from Owner’s Manual (1, fig.
  • Page 29 MKS SERIES GENERAL PUMP A member of the Interpump Group Be sure that the O-ring and the anti-extrusion ring are perfectly fit into their seats. Insert the suction valve unit together with the spacer (1, fig. 94). The valve unit must be fully inserted, as shown in 1, fig. 95. Mount the O-ring, exploded view item 5 from Owner’s Manual (1, fig.
  • Page 30 Pay particular attention when inserting the O-ring indicated in 1, fig. 101. We advise to use the correct tool p/n F27516000 (for MKS40A, MKS45A and MKS50A) or p/n F27516100 (for MK55SA, MKS60A and MKS65A) in order to avoid cutting the O-ring during insertion.
  • Page 31 MKS SERIES GENERAL PUMP A member of the Interpump Group Insert the valve seat ring (1, fig 102) and the spring (1, fig. 103). Assemble the O-ring, exploded view item 17 in Owner’s Manual, (1, fig. 104) and the anti-extrusion ring, exploded view item 21 in Owner’s Manual (2, fig.
  • Page 32 MKS SERIES GENERAL PUMP A member of the Interpump Group Assemble the head on the pump casing (1, fig. 107) being careful not to bump against the plungers, and fasten the 8 M16 x 180 screws (1, fig. 108). Proceed with calibrating the M16 x 180 screws with the torque wrench as indicated in paragraph 3. “SCREW CALIBRATION”...

  • Page 33: Disassembling The Plunger Unit - Supports - Seals

    MKS SERIES GENERAL PUMP A member of the Interpump Group 2.2.3 Disassembling the Plunger Unit - Supports - Seals The plunger unit requires a periodical inspection as indicated in the preventive maintenance table of the Owner’s Manual. Interventions only require visual inspections of the draining from the hole in the lower cover. In case of anomolies/oscillations on the delivery pressure gauge, or leaking from the drain hole, proceed with seal inspection and replacement if necessary.
  • Page 34 MKS SERIES GENERAL PUMP A member of the Interpump Group Manually rotate the shaft so that the 3 plungers are in the top dead center position. Insert the stopper tool p/n F27516600 between the plunger guide and the plunger (1, fig 113). Turning the shaft, move the plunger forward so that the stopper, moving forward itself, can push out the packing support and the entire plunger unit (1, fig.
  • Page 35 MKS SERIES GENERAL PUMP A member of the Interpump Group Remove the wiper rings from the plunger guides (1, fig. 116). If replacement of the plunger guide oil seal is needed, disassemble the oil seal cover by operating as follows: Unfasten the two screws of the oil seal cover (1, fig.
  • Page 36 MKS SERIES GENERAL PUMP A member of the Interpump Group Replace the oil seal (1, fig. 120) and the external O-ring (2, fig. 120). Separate the packing support from the liner (1, fig. 121) to access the pressure packings (1, fig 122). To remove the low pressure packing, use a shim or another tool that doesn’t damage the seat of the packing support (1, fig.

  • Page 37: Assembly Of The Plunger Unit - Suports - Seals

    MKS SERIES GENERAL PUMP A member of the Interpump Group 2.2.4 Assembly of the Plunger Unit - Support - Seals Proceed with reassembly by inverting the disassembly procedure indicated in paragraph 2.2.3. Replace the pressure packings by applying a small amount of silicone grease to the lips, being careful not to damage them when inserting the liner.
  • Page 38 MKS SERIES GENERAL PUMP A member of the Interpump Group Insert the oil seal in its cover (1, fig. 129) using a stopper p/n F27910900. Position the O-ring (1, fig. 130) in its seat on the oil seal cover, and insert the assembled unit inside the crankcase in the correct space (1, fig.
  • Page 39 MKS SERIES GENERAL PUMP A member of the Interpump Group Position the wiper complete with its O-ring in its seat on the plunger guide (1, fig. 134 and fig. 135). Insert the 14 x 2 O-ring in its correct seat on the plunger bolt (1, fig. 136). Assemble the plungers on their respective guides (1, fig.
  • Page 40 MKS SERIES GENERAL PUMP A member of the Interpump Group Insert the O-ring inside the pump case (1, fig. 139), followed by the previously assembled liner-packing support unit (complete with the O-ring), (1, fig. 140). Be sure that the liner-support unit is correctly positioned in its seat (1, fig. 141). Assemble the liner’s front O-ring (1, fig.

  • Page 41: Manifold Refurbishment

    2.2.5 Manifold Refurbishment Manifold cavitation damages around the three cylinder bores can be fixed by re-tooling the damaged bores to a larger diameter (see fig. 146 for MKS40A, 45A-50A and fig. 148 for MKS55A-60A-65A). Page 41 Ref 300699 Rev C...
  • Page 42 After re-tooling, three steel bushings designed to restore the original bores have to be driven in the manifold along with relevant O-rings and anti-extrusion rings as shown in fig. 148 and 149. 1. 3 pcs. x p/n F74215156 bushings MKS40A-45A-50A 2. 6 pcs. x p/n F90525880 anti-extrusion rings 3.

  • Page 43: Screw Calibration

    MKS SERIES GENERAL PUMP A member of the Interpump Group 3. SCREW CALIBRATION Screws are to be fastened exclusively using a torque wrench. Exploded View Description Position Fastening Fastening (From Owner’s Manual) Ft. Lbs. Crankcase cover screws M8x18 14.8 Crankcase plug G1/2x13 29.5 Reducer flange screw M8x18 14.8...

  • Page 44: Repair Tools

    MKS SERIES GENERAL PUMP A member of the Interpump Group 4. REPAIR TOOLS Pump maintenance may be carried out using simple tools for assembling and disassembling components. The following tools are available: For Assembly: For Assembly: • Plunger guide oil seal ..........F27910900 •...

  • Page 45: Maintenance Log

    A member of the Interpump Group MAINTENANCE LOG HOURS & DATE OIL CHANGE GREASE PACKING REPLACEMENT PLUNGER REPLACEMENT VALVE REPLACEMENT GP Companies, Inc. 1174 Northland Drive Mendota Heights, MN 55120 Ref 300699 Rev.C Phone:651.686.2199 Fax: 800.535.1745 01-16 www.generalpump.com email: sales@gpcompanies.com Page 45...

This manual is also suitable for:

Mks45aMks seriesMks55aMks50aMks60aMks65a

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