GP MK40A Betriebsanleitung
MK
Repair Manual
General Pump is a
Member of
The Interpump Group
Ref 300679 Rev.F
03-20
MK40A-MK45A-MK50A
MK55A-MK60A-MK65A
GENERAL PUMP A member of the Interpump Group MK SERIES
Page 2
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 13
2.1.3 Refurbishing the Crank Mechanism ..........................Page 23
2.2 Fluid End Repair ...............................................Page 24
2.2.1 Head Disassembly - Valve Units ............................Page 24
2.2.2 Head Assembly - Valve Units...............................Page 27
2.2.3 Disassembling the Plunger Unit - Supports - Seals ..............Page 33
2.2.4 Assembly of the Plunger Unit - Suports - Seals.................Page 36
2.2.5 Manifold Refurbishment ...................................Page 41
3. SCREW CALIBRATION ............................................Page 43
4. REPAIR TOOLS ..................................................Page 44
5. MAINTENANCE LOG ..............................................Page 45
Ref 300679 Rev.F
03-20
1. INTRODUCTION
This manual describes the instructions for Repairing MK 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 refill cap 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.
MK SERIES
Page 3
GENERAL PUMP A member of the Interpump Group
Ref 300679 Rev.F
03-20
MK SERIES
Page 4
2.1.1 Crank Mechanism Disassembly
The correct sequence is the following
Completely drain the oil from the pump, then remove the key from the shaft (1, fig.2).
Unscrew the reducer flange fastening screws (1, fig. 3) and remove the flange from the shaft.
On the opposite side, unfasten the screws (1, fig. 4) and therefore remove the bearing cover.
GENERAL PUMP A member of the Interpump Group
Ref 300679 Rev.F
03-20
MK SERIES
Page 5
Unfasten the reducer cover screws (1, fig. 6).
Insert 3 dowels, or 3 M8 threaded screws (1, fig. 7) in the appropriate holes to aid extraction, and two
sufficiently long M10 screws in order to support the cover (2, fig. 7).
Disassemble the crankcase cover by unfastening the relevant screws (1, fig. 5).
GENERAL PUMP A member of the Interpump Group
Ref 300679 Rev.F
03-20
MK SERIES
Page 6
Screw on the 3 threaded screws (1, fig. 8) and simultaneously, using the appropriate tool (p/n 27516700),
hammer on the tool itself so that the bearing remains on the pinion when extracting the cover (1, fig. 9).
When this operation is complete, remove the reducer cover and then slip off the bearing from the pinion.
Remove the screws that fasten the ring gear stopper (1, fig. 10), and remove the stopper itself (1, fig. 11).
Remove the ring gear (1, fig. 12). If necessary, use a slide hammer applying it to the 2 M8 holes (2, fig. 12).
GENERAL PUMP A member of the Interpump Group
Ref 300679 Rev.F
03-20
MK SERIES
Page 7
Remove the pinion by using a slide hammer applying it to the M14 hole (1, fig. 14).
Lift the safety washer key (1, fig. 15)
Remove the key from the shaft (1, fig. 13).
GENERAL PUMP A member of the Interpump Group
Ref 300679 Rev.F
03-20
MK SERIES
Insert a spacer under the connecting rod to block shaft rotation (1, fig. 16).
Using an appropriate wrench, unscrew and remove the ring nut (1, fig. 17) and then remove the safety
washer (1, fig 18).
Screw a SKF KM19 type ring nut onto the pressure sleeve (1, fig. 19), then loosen the sleeve using an
appropriate wrench (1, fig. 20).
Page 8
GENERAL PUMP A member of the Interpump Group
Ref 300679 Rev.F
03-20
MK SERIES
Page 9
On the opposite side, unfasten the reducer case screws (1, fig. 21), and then remove the case (1, fig. 22).
Unscrew the connecting rod screws (1, fig. 23).
Disassemble the connecting rod caps with the split bearings; be particularly aware of disassembly order.
The connecting rod caps and the related connecting rods must be reassembled in the
exact order and coupling as during disassembly.
To avoid error, caps and connecting rods are numbered on one side (1, fig. 24).
GENERAL PUMP A member of the Interpump Group
Ref 300679 Rev.F
03-20
MK SERIES
Page 10
Remove the pressure sleeve (1, fig. 26).
Remove the upper split bearing of the connecting rods (1, fig. 27).
Push the connecting rods forward in the direction of the hydraulic side in order to push out the crankshaft.
Use the appropriate tool (p/n 27566200) to facilitate this operation (1, fig. 25)
GENERAL PUMP A member of the Interpump Group
Ref 300679 Rev.F
03-20
Dieses Handbuch passt für folgende Modelle
6
Inhaltsverzeichnis
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