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Summary of Contents for General Pump KV Series
- Page 1 Repair Manual KV12 - KV14 General Pump is a member of Ref 310084 Rev. A the Interpump Group 08-17...
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Page 2: Table Of Contents
KV SERIES GENERAL PUMP A member of the Interpump Group INDEX INTRODUCTION ..........Page 3 REPAIR INSTRUCTIONS . -
Page 3: Introduction
A member of the Interpump Group 1. INTRODUCTION This manual describes the instructions for repairing KV 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. General Pump declines any responsibility for damage caused by the misuse or the non-observance of the instructions described in this manual. -
Page 4: Crank Mechanism Disassembly
KV SERIES GENERAL PUMP A member of the Interpump Group 2.1.1 Crank Mechanism Disassembly The operations described must be performed after removing the hydraulic part, ceramic pistons and splash guards from the pump (par. 2.2.3, 2.2.4). The correct sequence is the following Disassemble: •... - Page 5 KV SERIES GENERAL PUMP A member of the Interpump Group • Push the plunger guides forward with their con-rods to facilitate side extraction of the pump shaft as shown in fig. 4. • Remove the pump shaft • Complete disassembly of the con-rod units by removing them from the crankcase and removing the plunger guilde pins.
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Page 6: Crank Mechanism Assembly
KV SERIES GENERAL PUMP A member of the Interpump Group 2.1.2 Crank Mechanism Assembly After cleaning the crankcase, reassemble the crankcase mechanism as follows: • Assemble the upper and lower half-bearings in their seats in the con-rods and caps. Make sure that the reference marks on the upper half- bearings (1, fig. 6) and lower half-bearing (2, fig. - Page 7 KV SERIES GENERAL PUMP A member of the Interpump Group • Insert the plunger/con-rod guide units into the crankcase, directing the numbering on the con-rod shank towards the top of the casting. To facilitate pump shaft insertion (without the key), it is essential to repeat the operation performed during disassembly, pushing the plunger/con-rod guide units as far down as possible (paragraph.
- Page 8 KV SERIES GENERAL PUMP A member of the Interpump Group • Couple the con-rod caps to their shanks, referring to the numbering (1, fig. 9). Not the correct assembly direction of the caps. • Fasten the caps to their repective con-rod shanks by means of M8 x 1 x 48 screws (fig. 10) lubricating both the underhead and the threaded shank, proceeding in two different stages: 1.
- Page 9 KV SERIES GENERAL PUMP A member of the Interpump Group • After having completed tightening operations, check that the con-rod head has a side clearance in both directions. • Insert the new plunger guide seal rings as far as possible into the relative seat on the crankcase (fig.
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Page 10: Reduction Classes
KV SERIES GENERAL PUMP A member of the Interpump Group 2.1.3 Reduction Classes TABLE OF REDUCTION FOR CRANKSHAFT AND CON-ROD HALF-BEARINGS Recovery classes Upper half-bearing Lower half-bearing Grinding on the shaft pin diameter (mm) code code (mm) 0.25 F90922100 F90922400 Ø39.75 0/-0.02 Ra 0.4 Rt3.5... - Page 11 KV SERIES GENERAL PUMP A member of the Interpump Group The new bearings can be mounted cold with a press or rocker, supporting it on the lateral surface of the ring nuts involved in press fitting with the rings. The press fitting operation can be assisted by heating the involved parts to a temperature between 250°F - 300°F (120°C - 150°C), ensuring that the ring nuts fit fully into their...
- Page 12 KV SERIES GENERAL PUMP A member of the Interpump Group Determine the shim pack as indicated in the table below: Shim No. of Measurement Type Pieces From: 0.05 to 0.10 From: 0.11 to 0.20 From: 0.21 to 0.30 From: 0.31 to 0.35 0.25...
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Page 13: Fluid End Repair
KV SERIES GENERAL PUMP A member of the Interpump Group 2.2 Fluid End Repair 2.2.1 Disassembly of the Head - Valve Units The head dose not require any routine maintenance. Operations are limited to inspections or replacement of valves, if necessary. - Page 14 KV SERIES GENERAL PUMP A member of the Interpump Group Separate the head and the spacer for the liners from the crankcase as shown in fig. 19 and fig. 20. Take out the m6 x 75 screws fastening the liners to the head as shown in fig. 21 and proceed as shown in fig.
- Page 15 KV SERIES GENERAL PUMP A member of the Interpump Group If the valve seats are blocked on the head due to the formation of scale or oxide, they must be freed by inserting the tool (#F27508000) into the suction hole and operating as in fig.
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Page 16: Reassembling The Head - Liners - Valves
KV SERIES GENERAL PUMP A member of the Interpump Group Extract the outlet plates (pos. 3) and their guides (pos. 4) with the springs, as shown in fig. 27 and fig. 28, check for wear and replace if necessary, and in any case within the times indicated in the “PREVENTIVE MAINTENCE”... - Page 17 KV SERIES GENERAL PUMP A member of the Interpump Group Remove the pumping element with a fork wrench and check for wear as indicated in fig. 29 and fig. 30, replace them if necessary. Remove the M6 x 65 screws that fix the LP seals supports, HP seals support and liner as shown in fig. 31, and proceed to the separation of all the components as indicated in fig.
- Page 18 KV SERIES GENERAL PUMP A member of the Interpump Group Remove the seeger ring and the seal retainer ring as shown in fig. 34, and using a special plastice pin extract the LP (low pressure) seal (5, fig. 35). At each disassembly, the low pressure seals and all the O-rings must be replaced.
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Page 19: Reassembly Of The Plunger Unit - Supports - Seals
KV SERIES GENERAL PUMP A member of the Interpump Group At each disassembly, the HP packing (fig. 39) must be replaced. 2.2.4 Reassembly of the plunger unit - support - seals To reassemble the components, reverse the operations described above, paying attention to the sequences listed below;... - Page 20 KV SERIES GENERAL PUMP A member of the Interpump Group The H.P. seal must be placed in the support as indicated in fig. 41 and Fig. 43. Before inserting them into their seats, the H.P. seals must be lubricated with silicone grease Type OKS 1110, following the operations listed below: A) The external diameter must only be slightly greased;...
- Page 21 KV SERIES GENERAL PUMP A member of the Interpump Group Ref 310087 Rev. A 08-17 Page 21...
- Page 22 KV SERIES GENERAL PUMP A member of the Interpump Group Insert the anti-extrusion ring (pos. 1) and the gasket bushing (pos. 2) arranged as shown in fig. 45. fig. 46, and fig. 47. The gasket bushing (pos. 2) must be introducted into the support with outlets facing outwards (casing side) as shown in fig.
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Page 23: Screw Calibration
KV SERIES GENERAL PUMP A member of the Interpump Group Assemble the L.P. and H.P. seals support units. Liner manually screwing the screws M6 x 65 as indicated in fig. 52. Then proceed with calibration using a torque wrench as indicated in chapter 3. - Page 24 KV SERIES GENERAL PUMP A member of the Interpump Group The screws - pos. 44-56 - must be tightened by means of a torque wrench after lubri- cating the thread. It is recommended to use Molybdenum Disulfide grease code #F12001500.
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Page 25: Repair Tools
F26019400 COPYRIGHT The copyright of these operating instructions is property of General Pump/ the Interpump Group. The instructions contain technical descriptions and illustrations that may not be electronically copied or reproduced, entirely or in part, nor distributed to third parties in any form without authorized written permission. -
Page 26: Maintenance Log
KV SERIES GENERAL PUMP 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 Phone:651.686.2199 Fax: 800.535.1745 www.generalpump.com email: sales@gpcompanies.com Ref 310087 Rev.
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