General Pump KF Repair Manual
KF
8
Repair Manual
General Pump is a
member of the
Interpump Group
Ref 300917 Rev.A
12-12
GENERAL PUMP
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2. REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2.1 Crank mechanism repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2.1.1 Crank mechanism disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
2.1.2 Crank mechanism assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
2.1.3 Disassembly / Assembly of bearings and shims . . . . . . . . . . . . . . . . .Page 6
2.2 Fluid end repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
2.2.1 Disassembly of the Head-Valve Units . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
2.2.2 Head Assembly - Valve Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
2.2.3 Disassembly of the head - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
2.2.4 Plunger Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12
2.2.5 Head Assembly - Seals - Plunger Unit . . . . . . . . . . . . . . . . . . . . . . . .Page 12
3. SCREW CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
4. REPAIR TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
5. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 15
A member of the Interpump Group
KF SERIES
Ref 300917 Rev.A
12-12
Page 2
GENERAL PUMP
A member of the Interpump Group
KF SERIES
1. INTRODUCTION
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
2.1 Crank Mechanism Repair
Crank mechanism repair operations must be performed after removal of oil from the crankcase. To drain
the oil, remove the oil dipstick, (1, fig. 1) and then the draining plug (2, fig. 1).
The used oil must be placed in a suitable container and disposed of in special centers.
It absolutely must not be discarded into the environment.
Ref 300917 Rev.A
12-12
Page 3
GENERAL PUMP
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.
A member of the Interpump Group
KF SERIES
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. 3 and 3a); they must be turned towards the operator in
order to facilitate extraction.
Note: To extract the plunger guide it is necessary to remove the ceramic plunger and wiper first.
C) Disassemble the crankshaft oil seals and the plunger guides using standard tools.
Ref 300917 Rev.A
12-12
Page 4
GENERAL PUMP
2.1.2 Crank mechanism assembly
After cleaning the crankcase, reassemble the crankcase mechanism as follows:
A Thoroughly fit the plunger guide seals into their seat on the crankcase as shown in fig 4a, using the
appropriate tool, part #F27904900.
B Introduce the pre-assembled plunger guide / connecting rod units into their seat; to facilitate tightening
of the connecting rod cap, we advise to position the connecting rod so you can easily read the number. To easily introduce the crankshaft, without the key, fully push in the plunger guide / connecting rod
unit, as indicated in section B, paragraph 2.1.1, and shown in figure 4.
A member of the Interpump Group
KF SERIES
c) Before reassembly of the side covers, check the condition on the radial ring lips. If replacement is
needed, position the new ring using the too part #F27904800 as shown in fig. 6.
If the shaft presents diameter wear corresponding to the sealing lip, to avoid the need for
grinding it’s possible to position the ring as shown in fig. 5.
Ref 300917 Rev.A
12-12
Page 5
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