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INDEX ASSEMBLING THE H-100 PUMP POWER END ASSEMBLING THE SAP G-IV PLUNGER KIT (FROM P-18 TO P-30) ASSEMBLING THE SAP G-IV PLUNGER KIT (FROM P-32 TO P-40) ASSEMBLING THE SAP G-IV PUMP HEAD POWER END PARTS CONNECTING RODS OIL SEAL CAGE PUMP HEAD PLUNGER KIT (P-18) PLUNGER KIT (P-20)
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ASSEMBLING THE H-100 PUMP POWER END HEAT THE FIRST BEARING OF THE GEAR SHAFT FOR 10 MINUTES AT 110°C. Fig. 01 MOUNT THE FIRST BEARING IN THE GEAR SHAFT WHILE IT IS WARM. Fig. 02...
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ASSEMBLING THE H-100 PUMP POWER END INSERT THE GEAR SHAFT INTO THE HOUSING. Fig. 03 MOUNT THE SECOND BEARING. IT WILL BE NECESSARY TO HEAT THE BEARING FOR 10 MINUTES AT 110°C BEFORE MOUNTING (SEE FIG. 01). Fig. 04...
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE OIL SEAL ON THE GEAR SHAFT FLANGE AND ENSURE THAT THE SEAL APERTURE IS INWARDS. Fig. 05 USE COPPER GREASE TO COVER THE THREAD OF THE M10 SCREWS FIXING THE ALIGNMENT CRANKCASE FLANGE. TIGHT TO “X” TO TORQUE OF 64 Nm. Fig.
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ASSEMBLING THE H-100 PUMP POWER END INSERT THE SHAFT EXTENSION WITH ITS KEY AND FIX IT ON THE SHAFT. Fig. 07 INSERT THE BEARING AND THE SEEGER RING. Fig. 08...
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE BUSHING AND THE BEARING SHELLS INTO THE CONNECTING ROD. ATTENTION: MOUNT THE PAIR OF BEARING SHELLS CONTAINED IN THE BOX. Fig. 09 ASSEMBLE THE GUIDE PISTON WITH THE CONNECTING ROD USING THE PIN AND SEEGER RINGS.
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ASSEMBLING THE H-100 PUMP POWER END INSERT THE KIT INTO THE HOUSING. REPEAT THE PROCESS FOR THE OTHER 2 KITS. Fig. 11 HEAT THE PAIR OF CRANKSHAFT BEARINGS AT 115°C FOR 10 MINUTES. Fig. 12...
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE BEARINGS ON THE CRANKSHAFT WHILE THEY ARE STILL WARM. Fig. 13...
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE CRANKSHAFT KEY. Fig. 14 HEAT THE CROWN GEAR AT 120°C FOR 10 MINUTES. Fig. 15...
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE CROWN GEAR IN THE CRANKSHAFT WHILE IT IS WARM WITH THE THREADS FACING OUT. Fig. 16 MOUNT THE SEEGER RING. Fig. 17...
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ASSEMBLING THE H-100 PUMP POWER END LIFT THE CRANKSHAFT USING LIFTING EYES APPLIED ON THE APPROPRIATE THREADS. THE GEAR CROWN MUST BE POSITIONED FACING THE SHAFT GEAR SIDE. Fig. 18 MOUNT O-RINGS (APPLY “ROCOL” TYPE GREASE TO SEAL) AND THE BEARING FLANGES WITH THE “HALF-MOON”...
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ASSEMBLING THE H-100 PUMP POWER END MOUNT BEARINGS ON BOTH CRANKSHAFT SIDES. Fig. 20 MOUNT THE SLEEVE ON THE CRANKSHAFT (PINION SIDE). APPLY LOCTITE 577 ON THE THREAD OF THE M16 SCREWS TO A TORQUE OF 232 Nm. Fig. 21...
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE O-RING (USE “ROCOL” TYPE GREASE TO SEAL) AND FIX THE CRANKSHAFT COVER (PINION SIDE). APPLY GREASE ON THE THREAD OF THE M10 SCREWS. TIGHT “X” TO A TORQUE OF 64 Nm. Fig. 22 MOUNT THE O-RING AND THE BEARING SEAT ON THE CRANKSHAFT.
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE ROTO GLYD AND ITS COVER ON THE BEARING SEAT. TIGHT THE M6 SCREWS TO A TORQUE OF 13 Nm. (PAY ATTENTION: DO NOT USE GREASE OR ANYTHING SIMILAR). Fig. 24 MOUNT THE O-RING (APPLY “ROCOL” TYPE GREASE TO SEAL) AND FIX THE CRANKSHAFT COVER (SHAFT SIDE).
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE ADAPTOR, THE O-RING AND THE ROTO GLYD ALIGNMENT IN THE CRANKSHAFT COVER. TIGHT THE ADAPTOR TO A TORQUE OF 60 Nm. (PAY ATTENTION: DO NOT USE GREASE OR ANYTHING SIMILAR). Fig. 26 MOUNT THE FIRST ROD CAP (PINION SIDE).
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ASSEMBLING THE H-100 PUMP POWER END MOUNT THE FIRST BEARING CAP (PINION SIDE). TIGHT THE M16 SCREWS TO A TORQUE OF 232 Nm. (PAY ATTENTION: DO NOT USE GREASE OR ANYTHING SIMILAR). TURN THE SHAFT TO ENSURE A PERFECT FIX BETWEEN COMPONENTS. REPEAT THE PROCESS FOR THE OTHER 2 BEARINGS, ALWAYS TURNING THE SHAFT AND CHECKING THE ASSEMBLY.
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ASSEMBLING THE SAP G-IV PLUNGER KIT PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) ARRANGE ALL PLUNGER KIT COMPONENTS ON SEPARATE ALL SUPPORT FLANGE COMPONENTS THE WORK BENCH. ON THE WORK BENCH. Fig. 01 Fig. 02 INSERT THE SLIDING BUSH INTO THE SUPPORT OVERLAP THE O-RING.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSERT THE LOW PRESSURE SEAL WITH THE OPENED SIDE TURNED TO THE SUPPORT FLANGE (APPLY “ROCOL” TYPE GREASE TO SEAL). Fig. 05 INSERT THE SPACER AND THE SEEGER RING TO INSERT THE O-RING INTO THE SUPPORT FIX THE ASSEMBLED PARTS.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSERT THE GUIDE PIN INTO THE SLEEVE MOUNT THE SUPPORT FLANGE ON THE SLEEVE. (SOME MODELS COULD BE SUPPLIED WITH PIN ALREADY MOUNTED). Fig. 09 Fig. 08 CHECK HOLE ALIGNMENT. INSERT THE ALLEN SCREW WITHOUT HEAD AND FIX IT.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) APPLY “ROCOL” TYPE GREASE ON THE THREAD OF THE M10 SCREWS THAT FIX THE SUPPORT ARRANGE THE PLUNGER, THE BACK RING, FLANGE WITH THE SLEEVE, TIGHT “X” TO A THE O-RING AND THE G-IV SELF-CENTERING TORQUE OF 60Nm.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSERT THE SECOND BACK RING ON THE INSERT THE G-IV SELF-CENTERING ADAPTER ON PLUNGER. THE SET. Fig. 16 Fig. 17 Fig. 05 INSERT THE SLEEVE ASSEMBLED WITH THE ARRANGE THE SEALING KIT ON THE FLANGE INTO THE PLUNGER UNTIL IT ...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSERT THE LOWER SUPPORTING RING (WITH THE CHANFER FACING DOWN) AND USE A NYLON TOOL AND A HAMMER TO PUSH IT UNTIL IT REACHES THE BOTTOM. Fig. 20...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSERT THE FIRST SCRAPER RING AND USE THE NYLON TOOL AND A HAMMER TO PUSH IT TO THE BOTTOM. Fig. 21...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSER THE KEVLAR SEALING AND USE THE NYLON TOOL AND A HAMMER TO PUSH IT TO THE BOTTOM. Fig. 22...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSERT THE BRAIDED SEALING PAYING ATTENTION TO KEEP ITS CHANFER AT A 180° WITH RESPECT TO THE KEVLAR SEALING. USE THE NYLON TOOL AND A HAMMER TO PUSH IT TO THE BOTTOM.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSERT THE SECOND SCRAPER RING AND USE THE NYLON TOOL TO PUSH IT TO THE BOTTOM. Fig. 24...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) INSERT THE UPPER SUPPORTING RING AND USE THE NYLON TOOL TO PUSH IT TO THE BOTTOM. Fig. 25...
PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) ARRANGE THE COMPONENTS FOR PACKING INSERT THE PACKING SPRING ALREADY SPRING ASSEMBLY. ASSEMBLED. Fig. 26 Fig. 27 Fig. 05 INSERT THE LOWER METAL RING WITH THE ASSEMBLE THE FRONTAL SLEEVE ON THE RADIUS FACING DOWNWARDS.
PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-18 TO P-30) PRESS IT UNTIL IT REACHES THE BOTTOM AND INSERT THE O-RING ON THE FRONTAL SLEEVE. ROTATE 90° TO LOCK THE FRONTAL Fig. 30 Fig. 31 Fig. 05 SLEEVE IN THE RIGHT POSITION. INSERT THE UPPER METAL RING WITH THE TIGHT COOLING SYSTEM CONNECTIONS.
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ASSEMBLING THE SAP G-IV PLUNGER KIT PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) ARRANGE ALL THE PLUNGER KIT COMPONENTS MOUNT THE SUPPORT FLANGE WITH THE ON THE WORK BENCH. SLEEVE. Fig. 01 Fig. 02 CHECK HOLE ALIGNMENT. INSERT THE ALLEN SCREW WITHOUT HEAD AND FIX IT.
PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) INSERT THE SLIDING BUSH INTO THE SLEEVE. OVERLAP THE O-RING. Fig. 05 Fig. 06 INSERT THE LOW PRESSURE SEAL WITH THE OPENED SIDE TURNED TO THE SUPPORT FLANGE (APPLY “ROCOL” TYPE GREASE TO SEAL). Fig.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) USE THE SPACER AND THE SEEGER RING TO FIX ARRANGE THE PLUNGER, THE BACK RINGS, THE ASSEMBLED PARTS. THE O-RING AND THE G-IV SELF-CENTERING ADAPTER. Fig. 08 Fig. 09 INSERT FIRST BACK RING ON THE PLUNGER.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) INSERT SECOND BACK RING ON THE PLUNGER. INSERT THE G-IV SELF-CENTERING ADAPTER ON THE PLUNGER. Fig. 12 Fig. 13 INSERT THE SLEEVE ASSEMBLED WITH FLANGE ARRANGE THE SEALING KIT ON THE INTO THE PLUNGER UNTIL IT REACHES WORK BENCH.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) INSERT THE LOWER SUPPORTING RING (WITH THE CHANFER FACING DOWN) AND USE A NYLON TOOL AND A HAMMER TO PUSH IT UNTIL IT REACHES THE BOTTOM. Fig. 16...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) INSERT THE FIRST SCRAPER RING AND USE THE NYLON TOOL AND A HAMMER TO PUSH IT TO THE BOTTOM. Fig. 17...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) INSER THE KEVLAR SEALING AND USE THE NYLON TOOL AND A HAMMER TO PUSH IT TO THE BOTTOM. Fig. 18...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) INSERT THE BRAIDED SEALING PAYING ATTENTION TO KEEP ITS CHANFER AT A 180° WITH RESPECT TO THE KEVLAR SEALING. USE THE NYLON TOOL AND A HAMMER TO PUSH IT TO THE BOTTOM.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) INSERT THE SECOND SCRAPER RING AND USE THE NYLON TOOL TO PUSH IT TO THE BOTTOM. Fig. 20...
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) INSERT THE UPPER SUPPORTING RING AND USE THE NYLON TOOL TO PUSH IT TO THE BOTTOM. Fig. 21...
PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) ARRANGE THE COMPONENTS FOR PACKING INSERT THE PACKING SPRING ALREADY SPRING ASSEMBLY. ASSEMBLED. Fig. 22 Fig. 23 INSERT THE LOWER METAL RING WITH THE ASSEMBLE THE FRONTAL SLEEVE ON THE RADIUS FACING DOWNWARDS.
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PLUNGER KIT – ASSEMBLY STEPS – SAP IV (FROM P-32 TO P-40) PRESS AND ROTATE 90° TO LOCK THE FRONTAL MOUNT THE O-RING ON THE FRONTAL SLEEVE. SLEEVE IN THE RIGHT POSITION. Fig. 26 Fig. 27 INSERT THE UPPER METAL RING WITH THE TIGHT COOLING SYSTEM CONNECTIONS.
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ASSEMBLING THE SAP G-IV PUMP HEAD ARRANGE THE INTELLIVALVES. Fig. 01 PUT THE MANIFOLD ON SUPPORTING SHIMS. Fig. 02...
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ASSEMBLING THE SAP G-IV PUMP HEAD BEFORE INSERTING THE INTELLIVALVE IN THE HOLE, APPLY “ROCOL” TYPE GREASE ON ALL SEAL RINGS TO AVOID DAMAGE DURING ASSEMBY. Fig. 03 FIX THE INTELLIVALVE MANUALLY IN THE HOLE. Fig. 04...
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ASSEMBLING THE SAP G-IV PUMP HEAD CHECK THE INTELLIVALVE ASSEMBLY: ITS OUTSIDE SURFACE MUST BE A LITTLE BIT FURTHER IN COMPARISON WITH THE PUMP HEAD SURFACE. CHECK IF THE VALVE IS COMPLETELY Fig. 05 MOUNTED. REPEAT THE PROCESS FOR THE OTHER TWO INTELLIVALVES. Fig.
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ASSEMBLING THE SAP G-IV PUMP HEAD APPLY COPPER GREASE ON THE THREAD OF THE M24 SCREWS THAT FIX THE ASSEMBLED HEAD WITH THE FORK. TIGHT “X” WITH 100Nm, 250Nm AND 400Nm TORQUE STEPS. PAY ATTENTION! IN ORDER TO SIMPLIFY THE DRAWING, ON FIG. 8, 9, 10, 11, 12 AND 13 THE FORK AND THE PUMP CRANKCASE ARE NOT SHOWN.
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ASSEMBLING THE SAP G-IV PUMP HEAD WITH THE PLUNGER KIT ALREADY ASSEMBLED, APPLY “ROCOL” TYPE GREASE TO AVOID SEALS BEING DAMAGED DURING ASSEMBLY. INSERT THE PLUNGER KIT INTO THE MANIFOLD (CHECK CONNECTION PARTS SIDE) AND INSERT SCREWS (APPLY COPPER GREASE ON THREADS). Fig.
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ASSEMBLING THE SAP G-IV PUMP HEAD REPEAT THE PROCESS FOR THE OTHER TWO PLUNGERS. Fig. 10 ASSEMBLE THE O-RING ON THE FRONT FLANGE (APPLY “ROCOL” TYPE GREASE ON THE SEAL). Fig. 11...
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ASSEMBLING THE SAP G-IV PUMP HEAD APPLY COPPER GREASE ON THE THREAD OF THE M12 SCREWS THAT FIX THE FRONT FLANGE WITH THE MANIFOLD. TIGHT “X” TO A TORQUE OF 100Nm. Fig. 12 REPEAT THE PROCESS FOR THE OTHER TWO FLANGES. Fig.
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POWER END PARTS (see codes on the next page)
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POWER ENDS - H100/2 CODE DESCRIPTION Q2310100110812 H100/2 HORIZONTAL POWER END 1800 RPM (60 Hz) Q2310100110811 H100/2 HORIZONTAL POWER END 1500 RPM (50 Hz) POWER END PARTS ITEM CODE DESCRIPTION QTY. Q231300005350 OIL SEAL Q231110010990 AXIS TRASMISSION FLANGE Q231200005500 ALLEN SCREW M8X20mm Q231300001110 O-RING Q231700001160...
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POWER END PARTS ITEM CODE DESCRIPTION QTY. Q231300001060 O-RING Q231200001070 LOCK WASHER M8 Q232320018110 COUPLING AC16 X 3/4" UNF ON REQUEST HOSE ON REQUEST HOSE Q232320018680 COUPLING AC16 X 7/8" UNF Q231200001400 ALLEN SCREW M10x25mm Q231200001030 LOCK WASHER M10 Q231300005820 O-RING Q231200008260 SEEGER I-52...
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CONNECTING RODS - CODE Q231010011120 BOLT TORQUE: 110 N 3 SETS PER PUMP ITEM CODE DESCRIPTION QTY. Q231110022250 ARM OF CONNECTING ROD Q231110022260 BEARING OF CONNECTING ROD Q231200001870 HEX BOLT M12x70 Q231200001900 TOOTHED WASHER M12 Q231200008810 ELASTIC GUIDE BUSHING ATTENTION! ASSEMBLE WITH NUMBERS FACING THE SAME SIDE Attention!
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OIL SEAL CAGE - CODE Q231010010971 ITEM CODE DESCRIPTION QTY. Q231200001070 WASHER * Note: Common wear parts or disposable Q231110044260 OIL SEAL CAGE Q231300011340 OIL SEAL Q231300011210 SLIDING RING Q231300001910 O-RING Q231200001540 SEEGER RING Q231200007960 SCREW M8X20mm Q231300001170 O-RING...
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PUMP HEAD - CODE Q231010 0181400 ITEM CODE DESCRIPTION QTY. Q231010018150 INTELLIVALVE SAP IV Q231110034610 SAP IV HEAD ASSEMBLY Q231200009410 ALLEN SCREW M24x200mm Q231200003630 LOCK WASHER M24 Q231200009980 ALLEN SCREW M24x180mm Q231300001790 O-RING 24 x 2 (90 SHORE) Q231110036020 FLANGE FRONTAL SAP IV Q231200002930 ALLEN SCREW M12x35mm Q231300001930...
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Ø Nominal Appropriate Critical Change -0,01 -0,07 26 mm -0,1 -0,06 -0,09 ANALYSE PLUNGER DIMENSIONS WHEN CHANGING THE SEALS OR EVERY 500 HOURS RESPECT THE WEAR LIMIT. PLUNGER KIT (P-26) - CODE Q231010019980 ITEM CODE DESCRIPTION QTY. Q231010020220 PLUNGER P-26 G IV Q231200003270 ALLEN SCREW PLAN HEAD Q231110008580...
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Ø Nominal Appropriate Critical Change -0,01 -0,07 28 mm -0,1 -0,06 -0,09 ANALYSE PLUNGER DIMENSIONS WHEN CHANGING THE SEALS OR EVERY 500 HOURS RESPECT THE WEAR LIMIT. PLUNGER KIT (P-28) - CODE Q231010019990 ITEM CODE DESCRIPTION QTY. Q231010020230 PLUNGER P-28 G IV Q231200003270 ALLEN SCREW PLAN HEAD Q231110008590...
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Ø Nominal Appropriate Critical Change -0,01 -0,07 30 mm -0,1 -0,06 -0,09 ANALYSE PLUNGER DIMENSIONS WHEN CHANGING THE SEALS OR EVERY 500 HOURS RESPECT THE WEAR LIMIT. PLUNGER KIT (P-30) - CODE Q231010020000 ITEM CODE DESCRIPTION QTY. Q231010020240 PLUNGER P-30 G IV Q231200003270 ALLEN SCREW PLAN HEAD Q231110008600...
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Ø Nominal Appropriate Critical Change -0,01 -0,07 32 mm -0,1 -0,06 -0,09 ANALYSE PLUNGER DIMENSIONS WHEN CHANGING THE SEALS OR EVERY 500 HOURS RESPECT THE WEAR LIMIT. PLUNGER KIT (P-32) - CODE Q231010020490 ITEM CODE DESCRIPTION QTY. Q231010004340 HARD METAL PLUNGER P-32 Q231110036010 FLANGE G IV Q231200003270...
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Ø Nominal Appropriate Critical Change -0,01 -0,07 35 mm -0,1 -0,06 -0,09 ANALYSE PLUNGER DIMENSIONS WHEN CHANGING THE SEALS OR EVERY 500 HOURS RESPECT THE WEAR LIMIT. PLUNGER KIT (P-35) - CODE Q231010020490 ITEM CODE DESCRIPTION QTY. Q231010004060 HARD METAL PLUNGER P-35 Q231110036010 FLANGE G IV Q231200003270...
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