GEARBOX-71 & 72 SERIES
8
Owner’s Manual
• Installation
• Use
• Maintenance
Ref 300761 Rev.B
12-11
General Pump is a
member of the
Interpump Group
GENERAL PUMP
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2. SYMBOL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
4. CHOICE OF REDUCTION GEAR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
4.1 Identification of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
4.2 Identification of the reduction gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
4.2.1 Gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
5. DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
6. INSTRUCTIONS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
6.1 Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
6.2 Connection to the reduction gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
6.3 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
7. INSTALLING THE REDUCTION GEAR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
7.1 Choice of drive position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
7.2 Installation of the reduction gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
A member of the Interpump Group
Gearbox-71 & 72 Series
8. DISMANTLING THE REDUCTION GEAR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
9. SCREW TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
10. TOOLS TO BE USED FOR REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
11. WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
12. EXPLODED VIEWS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12
13. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
Ref 300761 Rev.B
12-11
Page 2
GENERAL PUMP
A member of the Interpump Group
Gearbox-71 & 72 Series
1. INTRODUCTION
This manual provides instructions for use, maintenance and repair of the speed reduction unit for 71 and 72 Series pumps
and must be read carefully before the gearbox is installed and used. Unless otherwise stated, reference should be made
to the specific manual for each pump. The regular functioning and working life of the pump require that the latter be used
and maintained correctly. General Pump will accept no responsibility for damage caused by negligence or by failure to
abide by the specifications given in this manual.
On receiving the reduction gear unit, check that it is complete and report any irregularities before installing on the pump.
2. SYMBOL DESCRIPTIONS
Warning
Potential Danger
Read carefully and understand
the manual before operating
the pump
3. SAFETY
Improper use of pumps and high pressure systems, and refusal to comply with regulations for installation and
maintenance, may lead to serious damage to persons and/or objects. Personnel who either install or use high pressure
systems must have the required qualifications, must know the characteristics of the components to be assembled or used
and, finally, must adopt all precautions necessary to ensure maximum safety under any type of operating conditions. In the
interests of safety, no reasonable precaution should be omitted either by the installer or the operator.
4. CHOICE OF REDUCTION GEAR UNIT
4.1 Identification of the pump
Note the RPM given on the plate in Fig. 1, position 2.
The plate also gives the model, version and
serial number which, together with the
serial number to be found the side of the
crankcase (Fig. 1, position 1), must always
be specified when ordering parts.
Ref 300761 Rev.B
12-11
Page 3
GENERAL PUMP
4.2 Identification of the gear unit
The unit can be identified by the symbol on the outside
of the housing. The plates indicating the gear ratio and
the direction of rotation are affixed (see Fig. 2).
The plate giving the direction of rotation is present if the
gear unit is supplied with the pump. Conversely, it must
be affixed by the user and include the direction of
rotation given in section 6.3.
4.2.1 Gear ratio
A member of the Interpump Group
Gearbox-71 & 72 Series
The gearbox is available in three different ratios:
1.25:1
1.50:1
1.83:1
4.2. On the job test
The maximum rated RPM of the pump must never be exceeded
Example: Pump KF40A
Maximum Internal Pump Speed: 900 RPM
Input Shaft Speed: 1500 (set by the user)
Input Speed/Internal Speed = Gear Ratio or Input Speed/Gear Ratio = Internal Speed
In this case the only ratio possible which does not exceed the maximum pump rated RPM is 1.83:1, in as
much as: 1500/1.25 = 1200 RPM Internal speed, 1500/1.5 = 1000 RPM Internal Speed and 1500/1.83 =
820 RPM Internal Speed. Therefore 1.83:1 is the only gear ratio permissable.
Ref 300761 Rev.B
12-11
Page 4
GENERAL PUMP
A member of the Interpump Group
5. DIMENSIONS AND WEIGHTS
The dry weight of the gear unit is 30.8 lbs. (14 Kg).
6. INSTRUCTIONS FOR USE
Gearbox-71 & 72 Series
6.1 Lubricating oil
After the gear unit has been installed, the prescribed
volume of pump oil must be increased by ~ 15.5 ounces
(0.5 L.). Check the level using the dipstick shown in Fig. 4,
position 1.
Oil check are best carried out with the pump at room
temperature and in a perfectly horizontal position. The oil
must be changed when the pump is at operating
temperature.
To drain the old oil, remove the dipstick (Fig. 4, position 1)
and then the cap (Fig. 4, position 2).
The oil must be poured into an appropriate container
and disposed of in the correct manner. Under no
circumstances should it be dispersed into the
environment.
Ref 300761 Rev.B
12-11
Page 5
GENERAL PUMP
In order to confirm the removal of the seal ring as shown below in section 7.2, Fig. 7 and Fig. 8,
the oil level must also be visible on the gauge (Fig 4, position 3).
6.2 Connection to the gear unit
The gear unit PTO drive shaft must not be rigidly attached to the engine.
The following types of drives are recommended:
• with flexible joint;
• cardan (please follow the maximum operating angles recommended by the manufacturer);
• hydraulic, by means of a flange (for correct installation, request assistance from the Customer Service
Department).
Belt transmission is prohibited.
6.3 Direction of rotation
The direction of rotation of the pump is indicated by an arrow found on the crankcase and should always be
followed:
A member of the Interpump Group
Gearbox-71 & 72 Series
When facing the pump head, the direction of rotation of the drive should be:
• as per Fig. 5 for versions without gear reduction unit;
• as per Fig. 5a for verions with gear reduction unit.
Ref 300761 Rev.B
12-11
Page 6
GENERAL PUMP
A member of the Interpump Group
7. INSTALLING THE REDUCTION GEAR UNIT
The pump version can be modified only by qualified personnel.
7.1 Choice of drive position
Depending on specific needs, before installing the gear unit it is wise to define the drive position, choosing from
among the four available (D1, D2, D3, D4 for right-hand pumps, or S1, S2, S3, S4 for left-hand pumps), as
shown in Fig. 6.
Gearbox-71 & 72 Series
7.2 Installing the reduction gear unit
Before installing the reduction gear unit, remove the pump shaft oil seal (Fig. 8, position 1) and insert the Ø8
pin into the crankcase (Fig. 8, position 2). See also the drawing given in Fig. 7. Then proceed with the
operations described:
Omission of the operations described
may compromise pump performance
and operator safety.
Ref 300761 Rev.B
12-11
Page 7
GENERAL PUMP
Insert the packing (Fig. 9) and assemble the gear housing, taking care to fit the hole onto the correct pin present on the
crankcase (Fig. 10, position 1).
Fasten the gear housing with the 6 M8 x 50 screws and tighten the latter with a torque wrench (Fig. 11 and 12) as
indicated in section 9.
A member of the Interpump Group
Gearbox-71 & 72 Series
Insert the crown into the pump shaft, apply the washer and use the wrench (Fig. 13) to tighten the screws to the torque
level indicated in section 9. Fix the two Ø5 pins to the gear housing (Fig. 14, position 1).
Ref 300761 Rev.B
12-11
Page 8
GENERAL PUMP
Mount the bearing onto the pinion, pushing it as far as possible into the housing socket using a striking hammer
(Fig. 15). Bearings and crown can be cold-inserted (Fig. 15). The operation can be facilitated by heating the parts in
question to a temperature of between 250o- 300oF (120o- 150oC), ensuring that the ring nuts are fitted snugly into their
housings. Fix the o-rings into the appropriate slots in the reduction gear unit (Fig. 16).
Place the cover over the pinion bearing using two M8 screws or grub screws to keep it in position during assembly
(Fig. 17, position 1). Abut the cover with the housing using a buffer and pressing directly on the former. Alternatively, use
tool par number F27517400 (Fig. 18). The operation can be made easier by tightening several screws at once
(Fig. 17, position 2).
A member of the Interpump Group
Gearbox-71 & 72 Series
Affix the gear unit housing lid with 10 M8 x 50 screws and tighten with a torque wrench (Fig. 19), as shown in section 10.
When the complete gear reduction unit has
been installed, check that the pinion is
turning correctly.
Ref 300761 Rev.B
12-11
Page 9
GENERAL PUMP
A member of the Interpump Group
Gearbox-71 & 72 Series
8. DISMANTLING THE REDUCTION GEAR UNIT
Remove the gear housing lid screws. Place 3 M8 grub screws or threaded screws (which will serve the function of
extractors) into the holes and tighten (Fig. 20, position 1) and at the same time strike on the pinion so that the bearing
remains attached to it during removal of the lid (Fig. 21).
Using standard tools, remove the gear housing lid and take the bearing out of the pinion (Fig. 22). Remove the crown
screws and washer and extract out the crown. If necessary, use a percussion extractor on the two M8 holes (Fig. 23)
or a standard extraction tool (Fig. 23).
Remove the pinion using a percussion extractor on the M12 hole (Fig 24). Loosen the gear housing screws and remove
the housing screws and remove the housing (Fig. 25).
Ref 300761 Rev.B
12-11
Page 10
GENERAL PUMP
A member of the Interpump Group
9. SCREW TIGHTENING TORQUES
Gearbox-71 & 72 Series
POSITION IN
DESCRIPTION
Housing / lid screws 6 30 40
Crown screws 9 52 70
EXPLODED
DRAWING (page 12)
TORQUE
FT./LBS.
TORQUE
(Nm)
10. TOOLS TO BE USED FOR REPAIRS
Pump repairs can be facilitated by using the appropriate tools, part numbers of which are given below:
For assembly:
Pump shaft/gear pinion oil seal buffer F27904800
Buffer for gear unit housing lid F27517400
11. WARRANTY CONDITIONS
Warranty conditions for the gear reduction unit fall under the general warranty conditions for the pump.
Ref 300761 Rev.B
12-11
Page 11
GENERAL PUMP
A member of the Interpump Group
12. EXPLODED VIEW AND PARTS LIST
Gearbox-71 & 72 Series
POS.
1 F72210784 Gear Housing Packing 1
2 F97618500 Straight pin, Ø8 x 10 1
3 F72210820 Gear Housing 1
4 F97615200 Straight pin, Ø 5 x 10 2
5 F90394800 O-ring, Ø209.22 x 2.62 1
6 F99314600 Screw, TCEI, M8 x 50 16
7
8 F72211055 Crown Fixing Washer 1
9 F99430700 Screw, M12 x 40 1
10 F91857700 Ball Bearing, 45 x 100 x 25 1
11
12 F91500000 Tongue, 12 x 8 x 70 1
13 F91859300 Ball Bearing, 50 x 110 x 27 1
14 F72210920 Gear Housing Lid 1
15 F97594000 Oil Level Gauge 1
16 90170000 Ring, Ø50 x 65 x 8 1
PART
NUMBER
F10071135 Z34 Gear, 1.25:1
F10071335 Z40 Gear, 1.83:1
F10070835 Z27 Pinion, 1.25:1
F10071035 Z22 Pinion, 1.83:1
DESCRIPTION QTY.
1F10071235 Z37 Gear, 1.50:1
1F10070935 Z25 Pinion, 1.50:1
Ref 300761 Rev.B
12-11
Page 12
GENERAL PUMP
MAINTENANCE LOG
OIL CHANGE
GREASE
PACKING
REPLACEMENT
A member of the Interpump Group
HOURS & DATE
Gearbox-71 & 72 Series
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 300761 Rev.B
12-11
Page 13
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