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MW

  

2 

 

INDEX 

1. INTRODUCTION 

3

 

2. REPAIR GUIDELINES 

3

 

2.1  Repairing mechanical parts................................................................................................. 3

 

2.1.1 Disassembly of mechanical parts........................................................................ 4

 

2.1.2 Assembly of mechanical parts .......................................................................... 15

 

2.1.3 Increase and reduction classes .......................................................................... 27

 

2.2  Repairing hydraulic parts.................................................................................................. 27

 

2.2.1 Dismantling the MW32 MW36 MW40 head – valve units .............................. 27

 

2.2.1 Dismantling the  MW32 MW36 MW40 – valve units...................................... 31

 

2.2.3 Dismantling the MW45 MW50 MW55 head – valve units .............................. 37

 

2.2.4 Assembling the MW45 MW50 MW55 head – valve units............................... 40

 

2.2.5 Dismantling the piston unit  –  supports –  seals............................................... 45

 

2.2.6 Dismantling the piston unit  –  supports –  seals............................................... 48

 

3. SCREW TIGHTENING CALIBRATION 

52

 

4. REPAIR TOOLS 

53

 

 

 
 
 

 
 
 

Summary of Contents for MW Series

Page 1: ...MW 1 MW Series Repair manual MW45 MW50 MW55 MW32 MW36 MW40 Menu ...

Page 2: ...Repairing hydraulic parts 27 2 2 1 Dismantling the MW32 MW36 MW40 head valve units 27 2 2 1 Dismantling the MW32 MW36 MW40 valve units 31 2 2 3 Dismantling the MW45 MW50 MW55 head valve units 37 2 2 4 Assembling the MW45 MW50 MW55 head valve units 40 2 2 5 Dismantling the piston unit supports seals 45 2 2 6 Dismantling the piston unit supports seals 48 3 SCREW TIGHTENING CALIBRATION 52 4 REPAIR TO...

Page 3: ...sponsibility for damage caused by negligence or failure to observe with the standards described in this manual 2 REPAIR GUIDELINES 2 1 Repairing mechanical parts Mechanical parts repair must be performed after removal of oil from the casing To take out the oil remove the oil dipstick pos c fig 1 and then the discharge plug pos d fig 1 The oil must be placed in a suitable container and disposed of ...

Page 4: ...as follows Fully empty the oil from the pump then disassemble the casing cover and relative O ring unscrewing the 6 M10 screws pos c fig 2 Remove the tab from the PTO shaft pos c fig 3 Unscrew the reduction gear cover fixing screws pos c fig 4 1 fig 3 1 fig 2 fig 4 1 ...

Page 5: ...rews with the function of supporting the cover pos d fig 5 Slowly screw in the 3 M8 screws pos c fig 6 with the function of extractors to fully remove the cover unit and pinion Complete disassembly of the reduction gear cover from the pinion is possible following these steps Remove the Seeger ring Ø120 pos c fig 7 fig 5 1 2 fig 6 1 fig 7 1 2 1 ...

Page 6: ...er on the pinion itself pos c fig 8 Remove the Seeger ring Ø55 pos c fig 9 and the bearing support ring pos c fig 10 from the pinion Extract the seal ring from the reduction gear cover working from the inner side of the cover pos c fig 11 fig 8 1 fig 9 1 fig 10 1 fig 11 1 ...

Page 7: ... fig 12 and remove it pos c fig 13 Remove the ring gear pos c fig 14 Where necessary it is possible to utilise an extractor hammer to be applied on the 2 M8 holes pos d fig 14 Remove the tab from the shaft pos c fig 15 fig 12 1 fig 13 1 1 2 fig 14 fig 15 1 ...

Page 8: ...bearings taking special care of the disassembly sequence during disassembly The con rod caps and their relative half supports must be reassembled in exactly the same order and coupling with which they were disassembled To avoid possible errors caps and half supports have been numbered on one side pos c fig 18 1 fig 17 fig 18 1 fig 16 1 ...

Page 9: ...to allow the bend shaft to come out To facilitate this operation use special tool code 27566200 pos c fig 19 Remove the three upper half bearings of the half supports pos c fig 20 Unscrew the reduction gear box fixing screws pos c fig 21 and fig 22 fig 19 1 fig 20 1 fig 21 1 fig 22 ...

Page 10: ... supporting the reduction gear box pos d fig 23 Slowly screw in the 3 M8 screws pos c fig 24 to prevent that the box can tilt too far and get locked in the housing Remove the box while supporting the shaft to prevent damage pos c fig 25 Unscrew the bearing cover fixing screws from the opposite side pos c fig 26 and fig 27 fig 23 1 2 fig 24 1 1 fig 26 1 2 fig 25 fig 27 1 ...

Page 11: ...he holes Slowly screw in the 3 M8 screws pos c fig 29 to prevent that the cover can tilt too far and get locked in the housing Remove the bearing cover while supporting the shaft to prevent damage pos c fig 30 Remove the bend shaft casing from the PTO side pos c fig 31 fig 31 1 fig 28 1 fig 29 1 fig 30 1 ...

Page 12: ...emble the piston guide seal rings taking care to not damage the piston guide sliding rod Whenever it becomes necessary to replace the piston guide seal rings without dismantling the entire mechanical part it is possible to extract the seal rings with the use of tool code 27918500 operating as follows Insert the tool between the rod and the seal ring pos c fig 34 and with the extractor hammer compl...

Page 13: ...eal ring using the tool extractor hammer pos c fig 36 Remove the two spindle locking Seeger rings Ø120 pos c fig 37 Remove the spindle pos c fig 38 and extract the con rod pos c fig 39 fig 37 1 fig 38 1 fig 39 1 fig 36 1 ...

Page 14: ...viously disassembled caps referring to the numbering pos c fig 40 To separate the rod from the piston guide unscrew the hexagonal head M10 screws with a 17 socket wrench pos c fig 41 blocking the rod with the 36 fork spanner fig 41 1 1 fig 40 ...

Page 15: ...raph 3 Screw tightening calibration Insert the con rod in the piston guide pos c fig 39 and then insert the spindle pos c fig 38 Apply the two shoulder Seeger rings pos c fig 37 Assembly has been carried out properly if the con rod foot piston guide and spindle rotate freely Separate the caps from the half supports Proper coupling can be verified by the numbering on the side pos c fig 40 After hav...

Page 16: ... inner and outer rings of the bearings must be reassembled keeping the same coupling with which they were disassembled Insert the shaft from the PTO side taking care not to hit the previously assembled con rod shanks pos c fig 48 and pos c fig 49 The bend shaft must always be assembled with the PTO on the opposite side with respect to the G1 2 holes for the oil discharge plugs on the pump casing p...

Page 17: ...aid of special tool code 27604900 pos c fig 52 inserting fully down to end stroke pos c fig 53 From the opposite side of the reduction gear box pre assemble the external ring of the bend shaft bearing with the use tool code 27605000 pos c fig 54 inserting fully down to end stroke pos c fig 55 fig 50 fig 51 1 1 2 fig 52 fig 53 1 1 fig 54 fig 55 1 1 ...

Page 18: ...ly down to end stroke pos c fig 57 Insert the side seal on the bearing cover pos c fig 58 and lift the bend shaft to favour cover insertion pos c fig 59 Assemble the bearing cover and relative seal using an extractor hammer pos c fig 60 Position the bearing cover in such a way that the Pratissoli logo is perfectly horizontal fig 58 1 fig 59 1 fig 56 fig 57 1 1 fig 60 1 ...

Page 19: ...ragraph 3 Screw tightening calibration From the opposite side insert the side seal on the reduction gear box pos c fig 62 and lift the bend shaft to favour cover insertion pos c fig 63 Assemble the reduction gear box and relative seal using an extractor hammer pos c fig 64 fig 62 1 fig 63 1 fig 61 1 fig 64 1 ...

Page 20: ... bearings are positioned in their housing on the half support pos c fig 67 Apply the lower half bearings to the caps pos c fig 68 ensuring that the half bearing reference notches are positioned in their housing on the cap pos d fig 68 Fasten the caps to the half supports by means of M10x1 5x80 screws pos c fig 69 Note the correct assembly direction of the caps Numbering must be turned upward Calib...

Page 21: ...ctions Insert the piston guide seal rings in their casing housing by means of a special tool code 27605300 pos c fig 70 Insert the O ring on the rear cover pos c fig 71 and assemble the cover on the casing with the aid of 6 M10x30 screws pos c fig 72 fig 68 1 fig 69 1 2 fig 71 1 fig 72 1 fig 70 1 ...

Page 22: ...aph 3 Screw tightening calibration Insert the ring gear support ring in the bend shaft shank pos c fig 73 to end stroke pos c fig 74 Apply tab 22x14x80 in the shaft housing pos c fig 75 and insert the ring gear on the shaft pos c fig 76 The ring gear must be assembled making sure that the two M8 holes to be used for extraction be turned outward of the pump pos d fig 76 fig 75 1 fig 76 1 2 fig 73 f...

Page 23: ...g calibration pos c fig 78 Apply the two Ø10x24 pins on the reduction gear box pos c fig 79 and insert the O ring pos c fig 80 Complete assembly of the pinion on the reduction gear cover proceeding as follows Pre assemble the inner bearing ring 40x90x23 on the pinion pos c fig 81 positioning it to end stroke fig 79 1 1 fig 80 fig 81 1 fig 77 1 fig 78 1 ...

Page 24: ...d stroke using tool code 27604800 pos c fig 83 Insert the bearing support ring pos c fig 84 and position the Seeger ring Ø55 pos c fig 85 Insert the pinion pre assembled inside its housing in the reduction gear cover with the aid of an extractor hammer pos c fig 86 fig 82 fig 83 1 1 fig 84 fig 85 1 1 fig 86 1 ...

Page 25: ...indicated in paragraph 3 Screw tightening calibration Insert the seal ring inside the reduction gear cover with the use of special tool code 27605200 pos c fig 90 Before proceeding with seal ring assembly check lip seal conditions If replacement is necessary position the new ring on the bottom of the groove as indicated in fig 91 If the shaft should present a diameter wear corresponding to the lip...

Page 26: ...d in paragraph 3 Screw tightening calibration Insert the tab 14x9x60 on the pinion Apply plugs and lifting brackets with the use of M16x30 screws pos c fig 94 Calibrate the screws with a torque wrench as indicated in paragraph 3 Screw tightening calibration Insert oil in the casing as indicated in the use and maintenance manual point 7 4 fig 91 fig 90 1 fig 94 1 fig 92 1 fig 93 1 RING POSITION AT ...

Page 27: ...ts 2 2 1 Dismantling the MW32 MW36 MW40 head valve units The head requires preventive maintenance as indicated in the use and maintenance manual Operations are limited to inspection or replacement of valves if necessary Proceed as follows to extract valve groups Unscrew the 8 M16x55 screws of the valve cover pos c fig 95 and remove the cover pos c fig 96 INCREASE TABLE FOR PUMP CASING AND PISTON G...

Page 28: ...er to be applied on the M10 hole of the valve plug pos c fig 97 Remove the spring pos c fig 98 Extract the outlet valve unit with the use of an extractor hammer code 27516400 to be applied on the M10 hole of the valve guide pos c fig 99 fig 97 fig 98 1 1 fig 99 1 ...

Page 29: ...e spacer inserting a 8mm hexagon spanner in the housing and lifting it to facilitate removal pos c fig 101 Extract the suction valve unit with the use of an extractor hammer code 27516400 to be applied on the M10 hole of the valve guide pos c fig 102 fig 101 1 fig 102 1 fig 100 1 ...

Page 30: ...os c fig 103 as indicated Unscrew the valve opening device by means of a 30 mm spanner pos c fig 104 Remove the suction and outlet valve units unscrewing an M10 screw in such a way to press on the inner guide and remove the valve guide from the valve housing pos c fig 105 Complete disassembly removing the G1 4 plugs on the front of the head fig 103 fig 104 1 fig 105 1 ...

Page 31: ...valve units Pay particular attention to the conditions of the various components and replace if necessary At every valve inspection replace all OR rings and both in the valve unit and in the valve plugs Before repositioning the valve unit thoroughly clean and dry the relative housings on the head indicated by the arrows pos c fig 108 Proceed with reassembly following the reverse order indicated in...

Page 32: ...ig 111 and use an extractor hammer acting on the whole circumference Proceed with insertion of the valve units suction and outlet in the head taking care to follow the correct insertion sequence of O rings and anti extrusion rings The proper sequence of valve unit assembly on the head is as follows Insert the anti extrusion ring explod posit 5 pos c fig 112 Insert the O ring explod posit 6 pos c f...

Page 33: ...mplete valve unit must be fully inserted into the bottom and should look like the image in pos c fig 115 Insert the valve housing spacer ring pos c fig 116 resting on the spacer pos c fig 117 Assemble the O ring explod posit 6 pos c fig 118 and the anti extrusion ring explod posit 16 pos d fig 118 on the outlet valve housing fig 118 2 1 fig 114 1 fig 115 1 fig 116 1 fig 117 1 ...

Page 34: ...The valve unit must be fully inserted into the bottom and should look like the image in pos c fig 120 Insert the anti extrusion ring explod posit 18 pos c fig 121 Insert the O ring explod posit 19 pos c fig 122 fig 119 1 fig 120 1 fig 121 1 fig 122 1 ...

Page 35: ... prevent that the O ring can cut itself during insertion Insert the valve housing ring pos c fig 124 and the spring pos c fig 125 Assemble the O ring explod posit 19 pos c fig 126 and the anti extrusion ring explod posit 23 pos d fig 126 on the outlet valve plug fig 123 fig 124 1 fig 125 1 fig 126 1 2 ...

Page 36: ... and the valve plug apply the valve cover pos c fig 127 and screw in the 8 M16x55 screws pos c fig 128 Apply 6 front O rings on the pump casing pos c fig 129 Assemble the pump casing head pos c fig 130 taking care not to hit the pistons and screw in the 8 M16x180 screws pos c fig 131 fig 127 1 fig 128 1 fig 130 1 fig 131 1 fig 129 1 ...

Page 37: ...hem in with the use of a 30 mm spanner pos c fig 133 Apply the G1 4 plugs on the front of the head with relative O rings Proceed with calibration of the G1 4 plugs with a torque wrench as indicated in paragraph 3 Screw tightening calibration 2 2 3 Dismantling the MW45 MW50 MW55 head valve units The head requires preventive maintenance as indicated in the use and maintenance manual Operations are l...

Page 38: ...f the valve guide pos c fig 136 Unscrew the 8 M16x45 screws of the suction valve cover pos c fig 137 and remove the cover pos c fig 138 Extract the suction valve unit with the use of an extractor hammer code 27516400 to be applied on the M10 hole of the valve guide pos c fig 139 fig 136 1 fig 139 1 fig 137 1 fig 138 1 ...

Page 39: ...e the valve guide from the valve housing pos c fig 141 Complete disassembly removing the G1 4 plugs on the front of the head and the G1 2 plugs on the lower part of the head It is now possible to remove the head from the pump casing unscrewing the 8 M16x150 screws pos c fig 142 During disassembly of the head pay special attention not to hit the pistons fig 143 fig 140 1 fig 141 1 fig 142 1 fig 143...

Page 40: ...ted by the arrows pos c fig 144 Proceed with reassembly following the reverse order indicated in point 2 1 3 Assemble the suction and outlet valve units fig 145 and fig 146 To facilitate insertion of the valve guide in its housing you can use a pipe resting on the horizontal guide planes fig 147 and use an extractor hammer acting on the whole circumference Proceed with insertion of the valve units...

Page 41: ...s c fig 148 Insert the O ring explod posit 7 pos c fig 149 Ensure that the O ring and anti extrusion ring are perfectly placed in their housings Insert the suction valve unit pos c fig 150 The complete valve unit must be fully inserted into the bottom and should look like the image in pos c fig 151 fig 148 1 fig 149 1 fig 150 1 fig 151 1 ...

Page 42: ... completed assembly of the suction valve units apply the suction valve cover pos c fig 153 and screw in the 8 M16x45 screws pos c fig 154 Proceed with outlet valve units assembly Insert the anti extrusion ring explod posit 23 pos c fig 155 fig 153 1 fig 154 1 fig 155 1 fig 152 1 ...

Page 43: ... ring are perfectly placed in their housings Insert the outlet valve unit pos c fig 157 The complete valve unit must be fully inserted into the bottom and should look like the image in pos c fig 158 Insert the front O ring in the outlet valve pos c fig 159 fig 156 1 fig 157 1 fig 158 1 fig 159 1 ...

Page 44: ...Apply 6 front O rings on the pump casing pos c fig 162 Assemble the pump casing head pos c fig 163 taking care not to hit the pistons and screw in the 8 M16x150 screws pos c fig 164 Proceed with calibration of the M16x150 screws with a torque wrench as indicated in paragraph 3 Screw tightening calibration fig 160 1 fig 161 1 fig 163 1 fig 164 1 fig 162 1 ...

Page 45: ...relative O rings Proceed with calibration of the G1 4 plugs with a torque wrench as indicated in paragraph 3 Screw tightening calibration 2 2 5 Dismantling the piston unit supports seals The piston unit requires preventive checks as indicated in the preventive maintenance table in the use and maintenance manual Maintenance is limited to visual inspection of any drainage from the hole present on th...

Page 46: ...resent any scratches signs of wear or cavitation Remove the upper inspection cover unscrewing the 2 fixing screws pos c fig 168 Manually turn the shaft in such a way to bring the 3 pistons to the upper dead centre position Insert the buffering tool code 27632500 between the piston guide and the piston pos c fig 169 fig 167 1 fig 168 1 fig 169 1 ...

Page 47: ...xpel the seal support and the entire piston unit pos c fig 170 Extract the seal support unit and the buffering tool Remove the seal support bottom O ring should it remain inside the pump casing pos c fig 171 Remove the spray rings from the piston guides pos c fig 172 fig 170 1 fig 171 1 fig 172 1 ...

Page 48: ...pport housing pos c fig 175 2 2 6 Dismantling the piston unit supports seals Proceed with reassembly following the reverse order indicated in point 2 2 5 Replace the pressure seals moistening the lips with silicone grease without spreading it taking extra care not to damage them during liner insertion The O rings and the low pressure seals must be replaced at each disassembly fig 173 1 fig 174 1 f...

Page 49: ... mounting direction which requires that the sealing lip be set forward towards the head Install the head ring pos c fig 177 the high pressure seal pos c fig 178 and the restop ring pos c fig 179 Join the seals support to the liner pos c fig 180 fig 176 1 fig 177 fig 178 fig 179 1 1 1 fig 180 1 ...

Page 50: ...8x0 9 washer in the piston fixing screw pos c fig 182 Install the pistons on their respective guides pos c fig 183 and fasten them as per pos c fig 184 Calibrate the screws with a torque wrench as indicated in paragraph 3 Screw tightening calibration fig 181 1 fig 182 1 fig 183 1 fig 184 1 ...

Page 51: ...ck complete with the same O ring to end stroke pos c fig 186 Ensure that the liner support block is positioned correctly down to the bottom of the housing pos c fig 187 Install the front O ring in the liner pos c fig 188 and the recirculation hole O ring pos c fig 189 fig 185 1 fig 186 1 fig 187 1 fig 188 1 fig 189 1 ...

Page 52: ... L P 45 Ring gear stop M10x25 screw 76 H P 78 L P 45 Reduction gear box M10x40 screw 81 H P 83 L P 45 Upper and lower cover M6x14 screw 60 H P 62 L P 10 Bearing cover M10x30 screw 89 H P 91 L P 45 Con rod fixing M10x1 5x80 screw 53 H P 55 L P 65 Piston guide M10x35 screw 48 H P 50 L P 60 Piston fixing M10x140 screw 30 H P 18 L P 40 HP Valve cover M16x55 screw 26 333 LP Valve cover M16x45 screw 19 ...

Page 53: ...Bend shaft bearing on the reduction gear box cod 27605000 Bend shaft bearing on the bearing cover cod 27605000 Piston guide oil seal cod 27605300 Bearing on pinion cod 27604800 Pinion seal ring cod 27605200 Outlet valve housing O ring MW32 MW36 MW40 cod 27516000 For disassembly Piston guide oil seal cod 27918500 Shaft con rod interlocking cod 27566200 Outlet and suction valve unit cod 27516400 Suc...

Page 54: ...third parties in any form and in any case without written permission from the owner Violators will be prosecuted according to law with appropriate legal action Code 73980103 rev 0 Cod IE 2860000086 28 04 2010 Data contained in this document may change without notice PRATISSOLI a brand of INTERPUMP GROUP S P A 42049 S ILARIO REGGIO EMILIA ITALY Tel 39 0522 904311 Fax 39 0522 904444 E mail info prat...

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