GP KFZ Series Repair Manual Download | Manualshive

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K

KFFZZ

Repair Manual

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Summary of Contents for KFZ Series

Page 1: ...K KF FZ Z Repair Manual ...

Page 2: ...k mechanism assembly Page 5 2 1 3 Disassembly Assembly of bearings and shims Page 6 2 2 Fluid End Repair Page 9 2 2 1 Disassembly of the head valve units Page 9 2 2 2 Head assembly valve units Page 10 2 2 3 Disassembly of the head seals Page 11 2 2 4 Plunger unit disassembly Page 12 2 2 5 Head assembly seals plunger unit Page 12 3 SCREW CALIBRATION Page 13 4 REPAIR TOOLS Page 14 5 MAINTENANCE LOG ...

Page 3: ...p s regular operation and long duration General Pump declines any responsibility for damage caused by misuse or the non observance of the instructions described in this manual 2 1 Crank Mechanism Repair Crank mechanism repair operations must be carried out after draining the oil from the crankcase To drain the oil remove the oil dipstick 1 and then the plug 2 in fig 1 Exhausted oil must be collect...

Page 4: ...n in fig 2 B Push the plunger guides and connecting rods forward in order to facilitate the lateral extraction of the crankshaft Two marks are visible on the crankshaft 3 as shown in fig 3 and fig 3a they must be turned towards the operator in order to facilitate extraction NOTE to extract the plunger guide it is necessary to remove the ceramic plunger and wiper first C Disassemble the crankshaft ...

Page 5: ...ank mechanism assembly After cleaning the crankcase reassemble the crankcase mechanism as follows A Thoroughly fit the plunger guide seals into their seat on the crankcase as shown in fig 5a using the proper tool p n F27904900 B Introduce the pre assembled plunger guide connecting rod units into their seat to facilitate tightening of the connecting rod cap we advise to position the connecting rod ...

Page 6: ...ankshaft the shims are to be determined to reach this purpose Tp disassemble assemble or to replace them if needed carefully follow the instructions below A Disassembly Assembly of the crankchaft without replacing the bearings After removing the side covers as indicated in paragraph 2 1 1 check the rollers and their faces for wear if all parts are in good condition accurately clean the components ...

Page 7: ...t After disassembling the side covers as indicated in paragraph 2 1 1 remove the outer ring nut of the bearings from their covers and the inner ring nut with the remaining part of the bearing from the two shaft extremities using a standard pin extractor or similar tool as indicated in figures 8 and 9 The new roller bearing can be mounted at room temperature with a press or fly press it is necessar...

Page 8: ...ankcase using the appropriate screws and verifying that the stall torque is between 3 5 ft lbs 4 7 Nm F If the torque values is correct connect the rods to the crankshaft otherwise reassemble the shims again repeating the operations from point C Page 8 The shim pack must be redefined as follows A Insert the crankshaft in the crankcase being sure that the P T O shank comes out of the correct side B...

Page 9: ...he manifold i e due to inactivity for a long period make use of the extracting tool part F27516900 combined with the tool 26019400 Disassembly the suction and delivery valve units by screwing on an M10 screw long enough to act on the valve and extract the valve guide from the valve seats 4 fig 13 Page 9 GENERAL PUMP A member of the Interpump Group KFZ SERIES 2 2 Fluid End Repair 2 2 1 Disassembly ...

Page 10: ... Page 10 fig 14 Proceed with reassembly by inverting the proceedure indicated in paragraph 2 2 1 During the assembly of the suction and delivery valve units fig 15 fig 16 do not invert the suction springs with the previously disassembled delivery springs a Suction springs white b Delivery springs black To facilitate insertion of the valve guide on the seat you can use a pad placed on the horizonta...

Page 11: ...ble in fig 14 Chapter 11 of the Owner s Manual A Unscrew the M12 x 150 head screws as shown in fig 17 B Remove the head from the crankcase C Extract the high pressure seals from the head and the low pressure seals from their related support by using standard tools as shown in fig 18 5 be careful not to damage the seats Pay careful attention to the order of seal packing disassembly as shown in fig ...

Page 12: ...mponents by inverting the operations previously listed in paragraph 2 2 3 paying careful attention to the following A Seal packing respect the same order followed during disassembly B Lubricate components 1 and 3 with silicone grease type F12001600 only on the outside diamerer C For correctly assembling the HP seals in their related seats on the head without damaging the lips use the correct tools...

Page 13: ...t fastening screws 58 74 100 Oil Discharge plug 11 30 40 Delivery duct plug 11 30 40 The connecting rod caps fastening screws must be tightened respecting the phases indicated in Point D of page 6 The head screws and nuts exploded view position 45 and 48 must be fastened using a torque wrench lubricating the threaded stem respecting the order shown in the scheme in fig 21 The valve cover screws ex...

Page 14: ...aling ring H P Ø40 x 55 x 10 F27473100 F27356300 Basket Brush Øe 46 15 Alternative sealing ring L P Ø40 x 46 15 F27471200 F26406300 Pump Shaft Oil Seal Stopper F27904800 Plunger Guide Oil Seal Stopper F27904900 For Disassembly Suction Delivery Valves F26019400 F27513600 Suction Delivery Valve Seats F26019400 F27516900 Suction and Delivery Valve Plug F26019400 Plunger Guide Oil Seal F27503900 ...

Page 15: ...Rev A 05 10 Page 16 MAINTENANCE LOG OIL CHANGE GREASE PACKING REPLACEMENT PLUNGER REPLACEMENT VALVE REPLACEMENT HOURS DATE 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 ...

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