KT16A/18A/20A/22A Repair Manual KT16A, KT18A, KT20A, KT22A General Pump is a member of the Interpump Group 8 Ref 300942 Rev.
GENERAL PUMP INDEX 1. 2. 3. 4. 5. 6. A member of the Interpump Group KT16A/18A/20A/22A SERIES INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 2.1 Repairing Mechanical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 2.1.1 Disassembly of Mechanical Parts . . . . . . . . . . . . . .
GENERAL PUMP A member of the Interpump Group 1. INTRODUCTION KT16A/18A/20A/22A SERIES 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. 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 2.1.1 Disassembly of Mechanical Parts KT16A/18A/20A/22A SERIES 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: • The pump shaft tab • The rear cover • The connecting rod cap as follows: unscrew the cap fixing screws, remove the con-rod caps with their lower half-bearings (fig.
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES • 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 • Remove the piston guide seal rings as described below: Use the extractor, p/n F26019400 (1, fig. 5) and the gripper, p/n F27503800 (2, fig. 5). Insert the gripper as far as possible onto the seal ring with the aid of a hammer (fig.
GENERAL PUMP A member of the Interpump Group 2.1.2 Reassembly of mechanical parts KT16A/18A/20A/22A SERIES 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. Make sure that the reference marks on the upper half-bearing (1, fig. 6) and lower halfbearings (2, fig. 6/a) are positioned in their respective seats in the con-rod and cap.
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES • 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. Manually turn the screws until they begin to tighten 2. Tightening torque: 22 Ft. Lbs. (30 Nm) Alternatively, ensure: 1.
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES • 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 TABLE OF REDUCTIONS FOR CRANKSHAFTS AND CON-ROD HALF-BEARINGS Recovery Classes (mm) Part Number Half-bearing Upper Part Number Half-bearing Lower Correction on the Shaft Pin Diameter (mm) 0.50 F90922200 F90922500 Ø39.50 0/-0.02 Ra 0.4 Rt 3.
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES 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. The previous shims can be reused, taking care to insert them only under the indicator side cover.
GENERAL PUMP A member of the Interpump Group Determining the shim pack: KT16A/18A/20A/22A SERIES 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. Secure the PTO side flange to the casing, taking care with the lip seal as described previously and tighten the fixing screws to the recommended torque.
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES 2.2 REPAIRING HYDRAULIC PARTS 2.2.1 Dismantling the Head - Valve Units Operations are limited to inspection or replacement of valves, if necessary and, however, at the intervals indicated in the “Preventative Maintenance” table in chapter 11 of the use and maintenance manual. The valve units are assembled vertically inside the head. Operate as follows to extract them: Unscrew the 8 M14x40 valve cover fixing screws (fig. 16).
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES Disassemble the suction and outlet valve units, screwing a sufficiently long M8 screw in such a way as to be able to reach the valve plate and extract the valve guide from the seat, 1, fig. 22. If the M8 threaded holes should not be present on the valve guide, dismantling can be easily carried out by leveraging with simple tools (fig. 23).
GENERAL PUMP A member of the Interpump Group 2.2.2 Reassembling the Head - Valve Units KT16A/18A/20A/22A SERIES 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. At every valve inspecting, replace all O-rings and all anti-extrusion rings both in the valve groups and on the valve plugs.
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES Insert the suction and outlet valve units, checking that they are down to end stroke in the head. Take special care not to damage the anti-extrusion rings on the bushings (3, fig. 28). For correct postioning and adjustment of rings in their respective seats: • Insert the bushings completely in the head, lubricating the external OR-anti-extrusion rings diameter with OCILIS type silicone grease p/n &12001600.
GENERAL PUMP A member of the Interpump Group 2.2.3 Dismantling the Head - Seals KT16A/18A/20A/22A SERIES Replacement of the seals is necessary from the moment you begin to detect water leaks from the drainage holes provided on the back of the pump casing, and a the intervals in the “Preventative Maintenance” table in chapter 11 of the Use and Maintenance manual. A) Unscrew the M10x140 head fixing screws as indicated in fig. 29. B) Separate the head from the pump casing.
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES Pay attention to the order of seal pack disasembly as indicted in fig. 31 for KT20A and KT22A, and in fig. 31/a for KT16A and KT18A, composed of: 1. 2. 3. 4. 5. 6. 7. Head ring HP seals Restop ring Seals support LP seals Seal ring O-ring 2.2.4 Dismantling the Piston Unit The piston unit does not require any routine maintenance. Maintenance is limited to visual checks only.
GENERAL PUMP A member of the Interpump Group 2.2.5 Reassembling the Head - Seals - Piston Unit KT16A/18A/20A/22A SERIES 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. B) Lubricate components 2,3 and 5 with OCILIS silicone grease p/n F12001600; this operation is also deemed necessary to facilitate adjustment of the lip seal on the piston.
GENERAL PUMP A member of the Interpump Group 3. SCREW CALIBRATION KT16A/18A/20A/22A SERIES Screws are to be fastened exclusively using a torque wrench. Description Cover Fixing Screw Oil Discharge Plug Piston Fixing Screw Con-rod Fixing Screw Valve Cover Fixing Screw Head Fixing Screw 2nd PTO Flange Fixing Screw * Exploded View Position Fastening Fastening (From Owner’s Manual) Ft. Lbs. Nm 9 11 27 18 45 47 96 7.4 30 14.8 22.1* 132.
GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES 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. Perform cold press fitting of the new bushing.
GENERAL PUMP 4. REPAIR TOOLS A member of the Interpump Group KT16A/18A/20A/22A SERIES Pump repairs can be facilitated by special tools. Part numbers are as follows: For Assembling Part: Seal bushing Ø 30; HP alternative seal ring Ø 16x30x7/4 Seal bushing Ø 32; HP alternative seal ring Ø 18x32x7/4.5 Seal bushing Ø 35; HP alternative seal ring Ø 20x35x7.5/4.5 Seal bushing Ø 35; HP alternative seal ring Ø 22x25x7/4.
GENERAL PUMP A member of the Interpump Group 5. MAINTENANCE LOG KT16A/18A/20A/22A 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 300942 Rev.
