KF Repair Manual General Pump is a member of the Interpump Group 8 Ref 300917 Rev.
GENERAL PUMP INDEX 1. 2. 3. 4. 5. A member of the Interpump Group KF SERIES INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 2.1 Crank mechanism repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 2.1.1 Crank mechanism disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL PUMP A member of the Interpump Group 1. INTRODUCTION KF SERIES This manual describes the instructions for repairing KF 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. General Pump declines any responsibility for damage caused by the misuse or the non-observance of the instructions described in this manual. 2. REPAIR INSTRUCTIONS 2.
GENERAL PUMP A member of the Interpump Group KF SERIES 2.1.1 Crank mechanism disassembly The correct sequence is the following: Disassemble: • The pump shaft key • The rear cover • The connecting rod cap • The side covers using for extraction 3 fully threaded M6x50 screws, inserting them in the threaded holes as indicated in fig. 2. B) Push the plunger guides and connecting rods forward to facilitate lateral extraction of the pump shaft. Two marks are visible on the crankshaft (3, fig.
GENERAL PUMP A member of the Interpump Group KF SERIES 2.1.2 Crank mechanism assembly After cleaning the crankcase, reassemble the crankcase mechanism as follows: A B Thoroughly fit the plunger guide seals into their seat on the crankcase as shown in fig 4a, using the appropriate tool, part #F27904900.
GENERAL PUMP A member of the Interpump Group KF SERIES Before assembling the cover (sight glass side), be sure that the shim rings have been inserted. To help the covers fit onto the crankcase, we advise using 3 screws M6x40, and then finish the operation with the screws supplied (M6x18) as shown in fig. 6. D) Install the connecting rod cap respecting numbering, and fasten the relevant bolts (lubricating both the head and the threaded stem) proceeding in three different steps, see fig. 8: 1.
GENERAL PUMP A member of the Interpump Group KF SERIES A) Disassembly/Assembly of the crankshaft without replacing the bearings After removing the side covers, as indicated in paragraph 2.1.1, check the rollers and their races for wear; if all parts are in good condition, thoroughly clean the components with a suitable degreaser and grease them again evenly using the same oil used in the crankcase. The same shims can be used again, being careful to fit them under the cover on the sight glass side.
GENERAL PUMP A member of the Interpump Group KF SERIES B) Fit the PTO side flange to the crankcase paying great attention to the seal lip as indicated in paragraph 2.1.2., section C. C) Position the flange on the sight glass side as indicated in paragraph 2.1. D) 2 using a thickness gauge (see fig. 10). Determine the shim pack as indicated in the table below: Measurement Shim Type No. of Pieces From: 0.11 to: 0.20 0.1 1 From: 0.31 to: 0.35 0.25 1 From: 0.46 to: 0.55 0.35 0.10 From: 0.
GENERAL PUMP A member of the Interpump Group KF SERIES A) Unfasten the (7) M12x35 valve cover screws, and remove the cover, fig. 12. B) Extract the valve plugs using a slide hammer (part #F26019400, fig. 12.
GENERAL PUMP A member of the Interpump Group KF SERIES Proceed with reassembly by inverting the procedure indicated in paragraph 2.2.1. During the assembly of the suction and delivery valves (fig. 15 - fig. 16) do not invert the springs with the previously disassembled delivery springs: a) Suction spring “white” b) Delivery spring “black” To facilitate the insertion of the valve guide into its seat, use a pipe that lays on the horizontal shoulders of the guide (fig.
GENERAL PUMP A member of the Interpump Group KF SERIES 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 5, fig. 18; be careful not to damage the seats. Pay careful attention to the order of sealing pack disassembly as shown in fig. 19, composed of: 1. 2. 3. 4. 5. 6. 7. 8. Head ring HP seal Re-stop ring Packings support LP seal Sealing ring Circlip O-ring Ref 300917 Rev.
GENERAL PUMP A member of the Interpump Group KF SERIES 2.2.4 Plunger unit disassembly The plunger unit does not require periodical maintenance. Service interventions are limited to visual inspections only. For plunger unit extraction, operate as follows: A) Unfasten the M7x1 plunger screws as shown in fig. 20. Check for wear; replace them if necessary. At each disassembly, all the o-rings of the plunger unit must be replaced (1, fig. 42). 2.2.
GENERAL PUMP KF SERIES A member of the Interpump Group 3. SCREW CALIBRATION Screws are to be fastened exclusively using a torque wrench. Description * Cover Fastening Screws Plunger Fastening Screws Connecting Rod Fastening Screws Head Fastening Screws Valve Cover Screws Lifting Bracket Fastening Screws Oil Discharge Plug Delivery Duct Plug Exploded View Position Fastening Fastening (From Owner’s Manual) Ft. Lbs. Nm 9 29 16 39 40 56 11 58 7.4 14.8 28 59 88.5 73.8 29.5 29.
GENERAL PUMP 4. REPAIR TOOLS A member of the Interpump Group KF SERIES Pump repairs can be facilitated by special tools. Part numbers are as follows: For assembly: For Assembling Part: Gasket Bushing Øe 45; H.P. alternative sealing ring Ø 28x45x5.5/5 Øe 45: H.P. alternative sealing ring Ø 30x45x7.5/4.5 Gasket Bushing Øe 55: H.P. alternative sealing ring Ø 40x55x7.5/4.5 Gasket Bushing Gasket Bushing Gasket Bushing Gasket Bushing Gasket Bushing Øe 48: H.P. alternative sealing ring Ø 36x48x6/3.
GENERAL PUMP A member of the Interpump Group 5. MAINTENANCE LOG KF SERIES 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 www.generalpump.com email: sales@gpcompanies.com Ref 300917 Rev.
