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KT24A/28A/30A/32A/36A/40A
Repair Manual
KT24A, KT28A, KT30A, KT32A, KT36A, KT40A
General Pump is a
member of the
Interpump Group
Ref 300943 Rev.A
03-14

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Summary of Contents for Pratissoli KT24A

  • Page 1 KT24A/28A/30A/32A/36A/40A Repair Manual KT24A, KT28A, KT30A, KT32A, KT36A, KT40A General Pump is a member of the Interpump Group Ref 300943 Rev.A 03-14...
  • Page 2: Table Of Contents

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group INDEX INTRODUCTION ..........Page 3 REPAIR INSTRUCTIONS .
  • Page 3: Introduction

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group 1. INTRODUCTION This manual describes the instructions for repairing KT Series pumps, and must be carefully read and understood before performing any repair intervention on the pump. Proper pump operation and longevity depend on the correct use and maintenance.
  • Page 4: Disassembly Of Mechanical Parts

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group 2.1.1 Disassembly of Mechanical Parts The operations described must be performed after removing the hydraulic part, ceramic pistons and splash guards from the pump (paragraphs 2.2.3, 2.2.4). Remove in the following order: •...
  • Page 5 KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group • Remove the pump shaft • Complete the disassembly of the con-rod units by removing them from the pump casing and removing the piston guide pins • Remove the pump shaft seal rings using common tools •...
  • Page 6: Reassembly Of Mechanical Parts

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group 2.1.2 Reassembly of mechanical parts After having checked that the casing is clean, proceed with assembly of the mechanical part as described below: • Assemble the upper and lower half-bearings in their seats in the con-rods and caps.
  • Page 7 KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group • Couple the con-rod caps to their shanks, referring to the numbering (1, fig. 9). Note the correct assembly direction of the caps. Fasten the caps to their respective con-rod shanks by means of M8x1x42 screws (fig. 10) lubricating both the underhead and the threaded shank, proceeding in two stages: 1.
  • Page 8: Increase And Reduction Classes

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group • Mount the rear cover complete with the O-ring, positioning the dipstick hole upward. • Insert Oil in the casing as indicated in the use and maintenance manual. 2.1.3 Reduction Classes...
  • Page 9 KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group A) Disassembly/Reassembly of the crankshaft without bearings replacement After having removed the side covers as indicated in point 2.1.1, check the conditions of the rollers and their relative tracks. If all parts are in good condition, clean the components carefully with a degreaser and redistribute lubricant oil uniformly.
  • Page 10 KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group Determining the shim pack: Perform the operation while the piston/con-rod guide units are assembled, the con-rod caps are disconnected and the con-rods are pushed downwards. Insert the crankshaft in the casing, checking that the PTO shank comes out from the provided side.
  • Page 11: Repairing Hydraulic Parts

    (fig, 16 and 16a) using the extractor hammer p/n F26019400 combined with tool F27726200 extract • The KT24A, 28A, 30A, 32A suction and outlet valve units and KT36A or 40A inlet valve units using a simple tool as indicated in fig. 18 •...
  • Page 12 KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group Dismantling of the suction and outlet valve units can be carried out screwing in a sufficiently long M10 screw which can move the valve plate and remove the valve guide from the seat (1, fig. 20). If the threaded holes should not be present on the valve guides, dismantling can be easily carried out by leveraging with simple tools (fig 21).
  • Page 13 If the suction valve seats remain stuck on the head (for example scaling due to prolonged pump activity), operate as follows: Suction and outlet valves: For KT24A, 28A, 30A, 32A use tools #F26019400, and F27513700 (fig. 22) Suction valves: For KT36A and 40A use tools #F26019400, F27516900 (fig. 22)
  • Page 14: Reassembling The Head-Valve Units

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group 2.2.2 Reassembling the Head - Valve Units Pay particular attention to the conditions of the various components and replace if necessary, and at the intervals indicated in the “Preventative Maintenance” table in chapter 11 of the use and maintenance manual.
  • Page 15: Dismantling The Head-Seals

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group To reassemble the various components, follow the reverse operations listed above as described in point 2.2.1. Reassemble the valve unit (fig. 24) to facilitate insertion of the valve guide in the seat, use a hammer, acting on the whole circumference (fig.
  • Page 16 KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group B) Separate the head from the pump casing. C) Extract the high pressure seals from the head and the low pressure ones from the support, using simple tools as indicated in fig. 27, being careful not to damage the respective housings.
  • Page 17: Dismantling The Piston Unit

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group 2.2.4 Dismantling the Piston Unit The piston unit does not require any routine maintenance. Maintenance is limited to visual checks only. To extract piston units: loosen the M7x1 piston fixing screws as indicated in fig. 29.
  • Page 18: Assembling The Head - Seals - Piston Unit

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group 2.2.5 Reassembling the Head - Seals - Piston Unit To reassemble the various components, follow the reverse operations listed above as described in pint 2.2.3, taking particular care: A) Seals pack Respect the same order used during disassembly operations.
  • Page 19: Screw Calibration

    KT24A/28A/30A/32A/36A/40A 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. Cover Fixing Screw Oil Discharge Plug Piston Fixing Screw 14.8...
  • Page 20: Replacing The Con-Rod Foot Bushings

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group 4. REPLACING THE CON-ROD FOOT BUSHING During maintenance, if it becomes necessary to replace the con-rod foot bushing, proceed as follows: When removing the worn bushing, take great care not to damage or scratch the seat on the con-rod.
  • Page 21: Repair Tools

    Piston guide oil seal F27904200 Head F27726000 For Disassembling Part: Tool Part Number F26019400 Pump suction valve KT24A, KT26A, KT28A and KT30A F27513700 F26019400 Pump suction valve KT36A and KT40A F27516900 F26019400 Pump outlet valve version KT24A, KT26K, KT28A, KT30A...
  • Page 22: Maintenance Log

    KT24A/28A/30A/32A/36A/40A SERIES GENERAL PUMP A member of the Interpump Group 5. 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 Ref 300943 Rev.A 03-14 www.generalpump.com email: sales@gpcompanies.com Page 22...

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