General Pump VF Repair Manual

V

V

Repair Manual

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F

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 9

2.2.1 Disassembly of the Head - Liners - Valves . . . . . . . . . . . . . . . . . . . . .Page 9

2.2.2 Assembly of the Head - Liners - Valves . . . . . . . . . . . . . . . . . . . . . . .Page 12

2.2.3 Disassemnly of the Plunger Unit - Supports - Seals . . . . . . . . . . . . . .Page 12

2.2.4 Assembly of the Plunger Unit - Supports - Seals . . . . . . . . . . . . . . . .Page 14

3. SCREW CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18

4. REPAIR TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20

5. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 21

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VF SERIES

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GENERAL PUMP

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VF SERIES

1. INTRODUCTION

This manual describes the instructions for Repairing VF Series pumps, and must be carefully read and
understood before performing any repair intervention on the pump. Correct use and adequate maintenance is
fundamental for the pump’s regular operation and long wear. 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 carried out after draining the oil from the crankcase. To drain
the oil, remove the oil dipstick, 1, Fig. 1, and then the draining plug (2, fig. 1).

Exhausted oil must be collected in an appropriate receptacle and disposed of in
designated locations. In absolutely no case may it be disposed of in the environment.

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GENERAL PUMP

2.1.1 Crank Mechanism Disassembly

The correct sequence is the following

A) Drain oil and then remove:

• pump shaft key

• connecting rod cap

• side covers using 3 wholly threaded M6 x 50 screws, inserting them in the opposite holes
as shown in fig. 2

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VF SERIES

B) Push the plunger guides and connecting rods forward in order to facilitate the lateral

extraction of the pump shaft. Two marks are visible on the crankshaft, as shown in fig. 3; 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.

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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. 5a,

using the appropriate tool (p/n 27904900).

B) Introduce the pre-assembled plunger guide/connecting rod units into their seats; 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 the
plunger guide/connecting rod unit, as indicated in paragraph 2.1.2, Section B as shown in
fig. 4.

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VF SERIES

C) Before assembly of the side covers, check the seal lips for wear. If replacement is necessary,

position the new ring using the appropriate tool (p/n 27904800) as shown in fig. 5.

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 indicated in fig. 5.

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GENERAL PUMP

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 to use 3 screws M6 x 40, and then finish the operation with the
screws supplied (M6 x 18) as shown in fig. 6.

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VF SERIES

D) Install the connecting rod cap respecting numbering, and fasten the relevant bolts (lubricating

both the head and the threaded stem with the same oil used for the crankcase) proceeding in
three different steps. see fig. 7:

1. Approaching torque 4.3-7 Ft. Lbs. (6-8 Nm)

2. Pre fastening torque 18.4-21 Ft. Lbs. (25-28 Nm)

3. Fastening torque 28 Ft. Lbs. (38 Nm)

E) Install the rear cover positioning the oil dipstick hole upward.
F) Fill the crankcase with oil as indicated in the use and maintenance manual in paragraph 7.4.

2.1.3 Disassembly / Assembly of Bearings and Shims

The type of bearings used (tapered roller bearings), ensures the absence of axial play on the crankshaft; the
shims are to be determined to reach this purpose. To assemble / disassemble, or to replace them if needed,
carefully follow the indications below:

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GENERAL PUMP

A) Assembly / Disassembly of the crankshaft without replacing the bearings

After removing the side covers, as indicated in paragraph 2.1.2, check the rollers and their races for wear; if
all parts are in good condition, fully clean the components with a suitable degreaser and grease them again
evenly using the same oil in the crankcase. The same shims can be used again, being careful to fit them
under the cover on the site glass side. After installing the complete unit (sight glass side flange and engine
side flange), check that the shaft’s rolling torque - with the connecting rods free - is at least 3 Ft. Lbs. (4 Nm),
Max 5 Ft. Lbs. (7 Nm). To position the two side covers on the crankcase, initially use 3 M6 x 40 screws as
shown in fig. 6, and then the fastening screws. The shafts rolling torque (with connecting rods coupled must
not exceed 6 Ft. Lbs. (8 Nm).

B) Disassembly / Assembly of the Crankshaft With Bearings Replacement

After disassembling the side covers as indicated in paragraph 2.1.2, remove the outer ring nut of the bearings
from their covers and the inner ring nut, with the remaining part of the bearing, from the two shaft extremities
using a standard pin extractor or similar tool as indicated in figures 8 and 9.

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VF SERIES

The new roller bearing can be mounted at room temperature with press; it is necessary to lay them on the
lateral side of the relevant ring nuts with opposite rings. The driving operation can be facilitated by heating
the relevant parts to a temperature ranging between 250
ring nuts are correctly fitted in their seats.

Never invert the parts of the two bearings.

0

- 3000F, (1200- 1500C), making sure that the

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