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Pratissoli SK Series, Repair Manual, Page: 4 / 46

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Pratissoli SK Series Repair Manual Download Page 4

                                                           

SK

  

4 

 

 

1. INTRODUCTION 

This manual contains the instructions for the repair of the SK family of pumps. It must be carefully read and 
understood before any operation is carried out on the pump.  
The proper functioning and lifetime of the pump depends on correct use and proper maintenance. 
Interpump Group declines all responsibility for damage caused due to negligence and/or failure to observe 
the instructions described in this manual. 
 

2. REPAIR INSTRUCTIONS 

 
 
 
 
 
 

2.1  Repair of the mechanical part 

Repairs on the mechanical part must be carried out after removing the oil from the casing. 

To remove the oil, remove the oil filling plug pos.

c

, fig.1 and then the drain plug pos.

d

, fig.1 present on 

both sides of the casing.  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

 
 
 
 
 

The spent oil must be placed in a suitable container and disposed of properly at an 
authorised centre. 
Do not under any circumstances discard it in the environment. 

 

 

fig. 1 

Summary of Contents for SK Series

Page 1: ...SK 1 SK Series Repair Manual Menu ...

Page 2: ...SK 2 ...

Page 3: ...ssembling the mechanical part 16 2 1 3 Classes of increase 31 2 2 Repair of the hydraulic part 32 2 2 1 Dismantling the head liners valves 32 2 2 2 Assembling the head liners valves 35 2 2 3 Dismantling the piston supports seals assembly 36 2 2 4 Assembling the piston supports seals assembly 38 3 SCREW CALIBRATION 42 4 REPAIR TOOLS 45 ...

Page 4: ... caused due to negligence and or failure to observe the instructions described in this manual 2 REPAIR INSTRUCTIONS 2 1 Repair of the mechanical part Repairs on the mechanical part must be carried out after removing the oil from the casing To remove the oil remove the oil filling plug pos c fig 1 and then the drain plug pos d fig 1 present on both sides of the casing The spent oil must be placed i...

Page 5: ...move the upper inspection cover and the lower inspection cover by unscrewing the 4 4 attachment screws as shown in point 2 2 3 fig 120 and fig 121 Slip off the O rings and replace them if necessary Remove the three pistons with an open ended spanner as shown in 2 2 3 fig 122 Remove the three spray guards complete with O rings pos c and d fig 2 Unscrew the M6 locking grub screws from the three oil ...

Page 6: ...ractor M6 screw in the holes in the cover pos c fig 4 and take out the covers from the pump group pos c fig 5 Take out the radial seal ring pos c fig 6 and the outside O ring pos c fig 7 Remove the lug from the PTO shaft pos c fig 8 1 fig 8 fig 4 1 fig 5 1 fig 7 1 1 fig 6 ...

Page 7: ...attachment screws pos c fig 10 and remove it Slip off the O ring and replace it if necessary Now remove the two bearing covers by unscrewing the screws pos c fig 11 To help with their removal use 2 x M8 grub screws or screws pos c fig 12 as extractors Slip off the O ring and replace it if necessary 1 fig 9 fig 11 1 fig 12 1 1 fig 10 ...

Page 8: ...nge attachment screws from both sides pos c fig 14 The bush locking flanges must be left in position pos c fig 15 On one side screw a ferrule type SKF KM20 onto the pressure bush pos c fig 16 and then unblock the bush using a striking hammer pos c fig 17 but do not remove it Repeat the operation on the other side fig 14 1 fig 16 1 fig 17 1 fig 13 1 fig 15 1 ...

Page 9: ...der in which the parts are removed The connecting rod small ends and the big end halves must be reassembled in exactly the same order and pairings in which they were dismantled To prevent any errors small ends and big end halves are numbered on one side pos c fig 19 Advance the three big end halves as far as possible in the direction of the head Slip off the three upper half bearings of the big en...

Page 10: ...ke out both of the pressure bushes pos c fig 21 Separate the bush locking flange from the pressure bush pos c fig 22 Unscrew the screws of the two bearing support covers pos c fig 23 fig 21 1 1 fig 23 fig 22 1 ...

Page 11: ...ig 24 as extractors Repeat the operation on the other side Lay the crankshaft on the bottom of the casing Separate the bearing support cover from the bearing using a striking hammer pos c fig 26 Unscrew the attachment screws of the left and right PTO bearing cover pos c fig 27 and slip the two covers off the PTO shaft To help with their removal use 3 x M8 grub screws or screws pos c fig 28 as extr...

Page 12: ...he lubrication hole O ring pos c fig 31 Roll back the three connecting rods as far as possible until they touch the crankshaft Using a striking hammer or mallet pos c fig 32 take out the PTO crankshaft from either one of the two sides pos c fig 33 fig 29 1 1 fig 32 1 fig 33 1 fig 30 fig 31 1 ...

Page 13: ...ng rings must be reassembled in exactly the same order and pairings in which they were dismantled Using a sufficiently long bar pos c fig 35 and a striking hammer take the bearing rings out of the pump casing pos c fig 36 along with the external bearing spacer pos c fig 37 and the bearing lubrication bush pos c fig 38 fig 34 2 1 fig 35 1 fig 36 1 fig 37 1 fig 38 1 ...

Page 14: ...6200 pos c fig 39 Move the crankshaft from the lower part of the casing pos c fig 40 Proceed to unscrew the screws of the device order code 27566200 to unlock the connecting rods pos c fig 41 and then take out the connecting rod piston head assemblies from the rear opening of the casing pos c fig 42 fig 39 1 fig 40 1 1 fig 41 fig 42 1 ...

Page 15: ...previously dismantled with reference to their numbering scheme pos c fig 43 Remove the two pin locking Seeger rings using the correct tool pos c fig 44 Slip out the pin pos c fig 45 and take out the connecting rod pos c fig 46 1 fig 43 fig 44 1 fig 45 1 fig 46 1 ...

Page 16: ...e mechanical part by removing the oil level lights the eyebolts and the 90 quick fit connection 2 1 2 Assembling the mechanical part Proceed with the assembly following the reverse of the procedure shown in 2 1 1 The correct sequence is as follows Attach the two oil level lights the two oil drain plugs and the 90 quick fit connection pos c d and e fig 48 fig 47 1 fig 48 2 1 3 ...

Page 17: ...od into the piston head pos c fig 46 and then insert the pin pos c fig 45 Apply the two shoulder Seeger rings using the correct tool pos c fig 44 Separate the small ends from the big end halves Correct pairing is ensured by the numbering on one side pos c fig 43 After verifying that the casing is perfectly clean insert the big end half piston head assembly into the cylinder tube in the casing pos ...

Page 18: ...rankshaft must be inserted into the casing so that the teeth on the ring bevel gears are oriented as shown in fig 52 Pre assemble the PTO shaft Onto the PTO shaft slip on the 2 internal rings of the bearings one per side pos c fig 53 The internal and external bearing rings must be reassembled in exactly the same order and pairings in which they were dismantled fig 52 1 fig 53 1 1 ...

Page 19: ...the crankshaft Insert the pre assembled PTO shaft into the casing pos c fig 56 Insert it from the other side to the side where the external bearing ring and the bearing lubrication bush were inserted The PTO shaft must be inserted into the casing so that the teeth are oriented as shown in fig 56 It is easier to insert the PTO shaft completely inside the bearing by applying an M16 screw to the end ...

Page 20: ...bearing ring pos c fig 59 using a pad and a mallet or striking hammer At both sides insert the internal bearing spacers pos c fig 60 and the external bearing spacers pos c fig 61 Insert the internal ring pos c fig 62 and external ring pos c fig 63 of a bearing from one side of the pump only fig 58 1 fig 59 1 fig 60 1 fig 61 1 fig 62 1 fig 63 1 ...

Page 21: ...the new ring as shown in fig 65 If the PTO shaft shows diametral wear corresponding to the seal lip then to avoid grinding you can position the ring as a second step as shown in fig 65 TRADUZIONE TERMINI POSIZIONE ANELLO AL PRIMO MONTAGGIO RING POSITION AT FIRST ASSEMBLY POSIZIONE ANELLO PER RECUPERO ALBERO SE USURATO RING POSITION TO RECOVER SHAFT IF WORN Apply the external O ring pos c fig 66 an...

Page 22: ...n the other side Insert the internal ring pos c fig 62 and external ring pos c fig 63 of the second bearing Mount the second PTO bearing cover on the pump casing pos c fig 68 and attach it with 4 x M8x30 screws pos c fig 69 Set the 4 4 screws with a torque wrench as shown in section 3 Pre assemble the two bearing support covers Insert the bearing using a mallet or striking hammer pos c fig 70 unti...

Page 23: ...pport cover pos c fig 72 Repeat the operation with the other cover Lock the three connecting rod assemblies using the special device order code 27566200 pos c fig 41 Apply two M16 threaded pins to the end of the crankshaft and while keeping it raised pos c fig 73 insert the bearing support cover complete with bearing and O ring pos c fig 74 using a mallet or striking hammer Repeat the operation on...

Page 24: ...ench as shown in section 3 Partly insert the two pressure bushes keeping the crankshaft lifted up by means of the previously mounted M16 pin pos c fig 76 Insert the pressure bush completely onto the crankshaft pos c fig 77 and fig 78 using a mallet striking hammer and a pad fig 75 1 fig 76 1 fig 77 1 fig 78 1 ...

Page 25: ...9 Apply a sufficiently long 35 40 mm M16 screw to the M16 hole on the crankshaft and screw it in until the flange is touching the bush pos c fig 80 Do not tighten the screw Repeat the operation on the other side Remove the device for locking the connecting rods order code 27566200 pos c fig 41 Insert the upper half bearings between the connecting rods and the crankshaft pos c fig 81 To correctly a...

Page 26: ...d halves using the M12x1 25x87 screws pos c fig 84 Set the screws with a torque wrench as shown in section 3 at the same time bringing the screws to the tightening torque Be careful of the correct direction of assembly of the small ends The numbering must face upwards Insert a shim under the shank of the central connecting rod to stop the rotation of the crankshaft pos c fig 85 fig 83 1 fig 84 1 2...

Page 27: ...X of between 0 7 mm and 0 8 mm fig 87 Repeat the operation on the other side Remove the M16 screw from the crankshaft Screw the two bush locking flanges onto the crankshaft using 4 4 x M12x25 screws pos c fig 89 Apply LOCTITE 243 to the threads of the M12x25 screws pos c fig 88 Set the screws with a torque wrench as shown in section 3 fig 86 fig 87 fig 88 1 fig 89 1 ...

Page 28: ... fig 91 Set the screws with a torque wrench as shown in section 3 Insert the O ring into the rear cover pos c fig 92 and affix it to the casing using 10 x M8x20 screws pos c fig 93 Set the screws with a torque wrench as shown in section 3 Mount the radial seal ring onto the oil seal cover pos c fig 94 using a pad order code 27910900 fig 90 1 fig 91 1 fig 92 1 fig 93 1 fig 94 1 ...

Page 29: ...pletely enters its seat pos c fig 97 being careful not to damage the lip of the radial seal ring Screw in the oil seal covers using 2 x M6x30 grub screws pos c fig 98 Set the screws with a torque wrench as shown in section 3 Position the spray guard complete with O ring in the seat on the piston head pos c fig 99 and 100 fig 95 1 fig 96 1 fig 97 1 fig 98 1 fig 99 1 fig 100 1 ...

Page 30: ...o inspection covers pos c fig 102 and mount the covers using 4 4 x M6x14 screws pos c fig 103 Set the screws with a torque wrench as shown in section 3 Mount the shaft end cover and affix it to the casing using 3 x M8x20 screws pos c fig 104 Set the screws with a torque wrench as shown in section 3 fig 102 1 fig 103 1 fig 101 1 fig 104 1 ...

Page 31: ...es mm Upper Half bearing Code Lower Half bearing Code Grinding on shaft pin diameter mm 0 25 90931100 90930100 Ø92 75 0 0 03 Ra 0 4 Rt 3 5 0 50 90931200 90930200 Ø92 50 0 0 03 Ra 0 4 Rt 3 5 INCREASE TABLE FOR PUMP CASING AND PISTON HEAD Recovery classes mm Piston Head Code Grinding on Pump Casing seat mm 1 00 74050243 Ø81 H6 0 022 0 Ra 0 8 Rt 6 1 fig 105 ...

Page 32: ... follows Loosen without removing the M10x140 screws affixing the liners to the head pos c fig 106 to make them free Unscrew two diametrically opposite M16x280 head affixing screws pos c and d fig 107 and replace them with two service pin screws order code 27540200 pos c fig 108 and then proceed to remove the remaining screws Separate the head and the spacer for liners from the pump casing pos c fi...

Page 33: ...40 screws affixing the liners to the head pos c fig 112 and take out the liner assemblies pos c fig 113 When removing the liners be careful not to lose the valve springs and their flat valves pos c and d fig 114 Because they are only held in position by the surrounding parts they could easily fall out 1 fig 110 fig 111 1 fig 112 1 fig 113 1 fig 114 2 1 ...

Page 34: ...tlet hole pos c fig 115 Take out the valve seats and check the state of wear of the gaskets If necessary replace them pos c fig 116 At each inspection of the valves replace the seal rings and the frontal seal O rings between liner and head and between head and liner spacer in the recirculation hole area Before reassembly clean and dry the various components and all their seats inside the head 1 fi...

Page 35: ...se the operations listed previously paying particular attention to the correct assembly of the spacer for liners the two as cast discharges present on one of the two sides must be facing towards the lower part of the casing the pump support side after assembly Head liners proceed with assembly and setting of the head affixing screws and then proceed with setting the affixing screws for the liners ...

Page 36: ... checked and if necessary replaced To extract the piston assemblies work as follows Separate the head and the spacer for liners from the pump casing as shown in 2 2 1 from fig 106 to fig 113 Remove the upper inspection cover pos c fig 120 and the lower inspection cover pos c fig 121 by unscrewing the 4 4 attachment screws Slip off the O rings and replace them if necessary Remove the pumping elemen...

Page 37: ...port from the liner pos c fig 125 Remove the Seeger ring and the seal retainer ring pos c fig 126 and with a special plastic pin take out the LP low pressure gasket seal pos c fig 127 At every dismantling the low pressure seals and the O rings must be replaced fig 124 1 fig 125 1 fig 126 1 fig 127 1 ...

Page 38: ...s reverse the operations paying particular attention to the sequence outlined below For the tightening torque values and for the tightening sequence follow the specifications given in section 3 Insert the upper bush into the liner For correct axial positioning of the bush use the special device order code 27911200 for SK20 code 27911400 for SK22 code 27911500 for SK24 code 27911600 for SK26 code 2...

Page 39: ...s shown in fig 132 and 134 Before inserting the H P seals they must be lubricated with silicone grease type OKS 1110 following the instructions below The external diameter must be only lightly lubricated On the internal diameter the grease must be applied taking particular care to fill all the indentations between the seal lips as shown in fig 135 TRADUZIONE TERMINI Direzione lavoro pistone Direct...

Page 40: ...d the gasket bush pos c and d fig 136 137 and 138 The gasket bush d must be inserted into the liner with the two discharges facing outside casing side as shown in fig 137 TRADUZIONE TERMINI Lato carter Casing side fig 138 fig 136 1 fig 137 2 ...

Page 41: ...139 and 140 lightly lubricating the outside diameter with silicone grease OKS 1110 type Replace the L P seal when it is worn TRADUZIONE TERMINI Direzione lavoro pistone Direction of travel of piston Reassemble the seal support assembly fig 141 and 142 replacing the c and d components fig 140 1 fig 142 1 2 fig 139 fig 141 ...

Page 42: ...5x87 screw connecting rod tightening 40 75 M10x35 screw piston head 38 60 M12x25 screw bush locking flange 51 68 5 Complete piston 16 50 Choke fitting D 3 3 8M 3 8F 72 45 M8x50 screw supports 26 40 M16x280 screw head 14 333 M10x140 screw liners 13 83 The screws in positions 13 14 26 must be tightened with a torque wrench and the threaded shaft must be lubricated with molybdenum bisulphide grease o...

Page 43: ...K 43 TRADUZIONE Tightening of screws for gasket supports position 26 Tighten M8x50 screws in the sequence indicated 1 2 3 4 5 6 7 8 9 10 performed in a single phase and with the specified torque fig 144 ...

Page 44: ...ners positions 14 and 13 OPERATION 1 Tightening M16x280 screws position 14 in two phases 1 st phase 250 Nm 2 nd phase 333 Nm OPERATION 2 Tightening M10x140 screws position 13 in four phases 1 st phase 40 Nm 2 nd phase 65 Nm 3 rd phase 83 Nm 4 th phase 83 Nm fig 145 ...

Page 45: ...shaft radial seal ring code 27539500 Gasket bush code 27911200 SK20 code 27911400 SK22 code 27911500 SK24 code 27911600 SK26 code 27911700 SK28 code 27911800 SK30 HP seal packing code 27540100 SK20 SK22 SK24 code 27540900 SK26 SK28 SK30 Head liner spacer code 27540200 For disassembly Valve seat code 034300020 SK20 22 24 code 034300010 SK26 28 30 Head liner spacer code 27540200 Shaft for locking co...

Page 46: ...nor distributed to third parties in any form without authorised written consent Offenders will be prosecuted according to the laws in force 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 pratissolipompe com http www pratissolipompe com Code 78980103 rev 0 Code IE 2860000020 20 02 2009 The information contained in thi...

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