Pratissoli KT16A Betriebsanleitung

KT16A/18A/20A/22A

Repair Manual

General Pump is a

member of the

Interpump Group

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T16A, T18A, T20A, T22A

GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES

Page 2

I DEX

1. I TRODUCTIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3

2. REPAIR I STRUCTIO S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3

2.1 Repairing Mechanical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3

2.1.1 Disassembly of Mechanical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4

2.1.2 Reassembly of Mechanical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6

2.1.3 Increase and Reduction Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8

2.1.4 Disassembly / Reassembly of Bearings and Shims . . . . . . . . . . . . . .Page 8

2.2 Repairing Hydraulic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11

2.2.1 Dismantling the Head-Valve Units . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11

2.2.2 Reassembling the Head-Valve Units . . . . . . . . . . . . . . . . . . . . . . . . .Page 13

2.2.3 Dismantling the Head-Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 15

2.2.4 Dismantling the Piston Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16

2.2.4 Assembling the Head - Seals - Piston Unit . . . . . . . . . . . . . . . . . . . . .Page 17

3. SCREW CALIBRATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18

4. REPLACI G THE CO -ROD FOOT BUSHI GS . . . . . . . . . . . . . . . . . . . . . . . . .Page 19

5. REPAIR TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20

6. MAI TE A CE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 21

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1. I TRODUCTIO

This manual describes the instructions for repairing T 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 I STRUCTIO S

2.1 Repairing Mechanical Parts

Mechanical parts repair must be performed after removal of oil from the casing. To drain

the oil, remove the oil dipstick, (1, fig. 1) and then the draining plug (2, fig. 1).

The oil must be placed in a suitable container and disposed of in special centers.

It absolutely must not be discarded into the environment.

GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES

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GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES

Page 4

2.1.1 Disassembly of Mechanical Parts

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. 2)

paying atention to the numbered sequence during disassembly.

To avoid possible errors, caps and con-ro shanks have been numbered on one side (1, fig. 2/a).

- Push the piston guides forward with their con-rods to facilitate side extraction of the pump as

indicated in fig. 4.

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- The side covers using - for extraction 3 fully threaed M6 x 50 screws, inserting them in the

threaded holes as indicated in fig. 3

GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES

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• 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. 5/a), subsequently screwing the extractor to

the gripper, and use the extractor hammer (fig. 5/b) until the ring to be replaced is removed (fig. 5/c).

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GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES

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2.1.2 Reassembly of mechanical parts

• Insert the piston/con-rod guide units into the pump casing, directing the numbering on the con-rod

shank towards the top of the casing.

To facilitate pump chaft insertion (without the tab), it is essential to repeat the operation performed during

disassembly, pushing the piston/con-rod guide units as far down as possible (paragraph 2.1.1).

• Before assembling the side cover on the PTO side, check the conditions of the radial ring lip seal

and relative contact area on the shaft.

Make sure that the reference marks on the upper half-bearing (1, fig. 6) and lower half-

bearings (2, fig. 6/a) are positioned in their respective seats in the con-rod and cap.

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.

If replacement is necessary, position the new ring using tool p/n F27904500 as incicated in fig. 7

If the pump shaft shows diametrical wear in the area of contact with the lip seal, in order to

prevent the grinding operation, it is possible to reposition the ring in abutment with the cover

as shown in fig. 7.

Before assembling the side covers, make sure there are O-rings on both of them and shim rings on

the indicator side cover only. To facilitate filling of the first section and relative insertion of the covers on

the casing, we recommend using three partially threaded M6x40 screws (1, fig. 8), then completing the

operation with the screws supplied (M6x16).

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GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES

Page 7

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:

• Couple the con-rod caps to their shanks, referring to the numbering (1, fig. 9).

ote the correct assembly direction of the caps.

1. Manually turn the screws until they begin to tighten

2. Tightening torque: 22 Ft. Lbs. (30 m)

Alternatively, ensure:

1. Pre-tightening torque: 7-11 Ft. Lbs. (10-15 m)

2. Tightening torque: 22 Ft. Lbs. (30 m)

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• After having completed tightening operations, check that the con-rod head has a side clearance in

both directions.

• Assemble the new piston guide seal ring with the relative seats on the pump casing (fig. 11)

following the procedure described:

Using tool p/n F27904200 composed of a tapered bushing and a buffer, screw the tapered bushing into the

hole in the piston guide (fig. 11a), insert the new seal ring on the buffer as far as it will go (determined by

the height of the buffer) into its seat on the pump casing (fig. 11b), remove the tapered bushing (fig. 11/c).

GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES

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• 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 REDUCTIO S FOR CRA KSHAFTS A D CO -ROD HALF-BEARI GS

Recovery Classes

(mm)

Part umber

Half-bearing

Upper

Part umber

Half-bearing

Lower

Correction on the Shaft Pin

Diameter

(mm)

0.25 F90922100 F90922400 Ø39.75 0/-0.02 Ra 0.4 Rt 3.5

0.50 F90922200 F90922500 Ø39.50 0/-0.02 Ra 0.4 Rt 3.5

2.1.4 Disassembly/Reassembly of Bearing and Shims

The type of bearings (taper roller) ensures the absence of axial clearance on the crankshaft. The shims are

defined to meet this necessity. For disassembly-reassembly and for any replacements, carefully observe the

following directions:

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.

Once the complete unit is mounted (indicator side flange and shaft and motor side flange), check that the

rotation torque of the shaft - with the con-rod disconnected - is a minimum 3 Ft.Lbs. (4 Nm), max. 4.5 Ft.Lbs

(6 Nm).

To bring the two side covers closer to the casing, it is possible to use 3 M6x40 screws for the first positioning

phase as indicated in fig. 8 and the screws provide for final fastening.

Shaft rotation torque (with the con-rod connected) should not exceed 6 Ft.Lb. (8 Nm).

A) Disassembly/Reassembly of the crankshaft with bearings replacement

After removing the side covers, as described above, remove the outer ring nut on the bearings from its seat

on the covers, using an appropriate extractor as shown in fig. 12 and 12a.

Remove the inner ring on the bearings from the two ends of the shaft, again using an appropriate extractor

or, alternatively, a simple “pin punch” as shown in fig. 13.

The new bearings can be mounted cold with a press or rocker, supporting it on the lateral surface of the

ring nuts involved in press fitting with the rings. The press fitting operation can be facilitated by heating the

involved parts to a temperature between 250o-300oF(120o-300o C), ensuring that the ring nuts go down to

end stroke in their housings.

ever exchange the parts of the two bearings. Page 9

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GENERAL PUMP A member of the Interpump Group KT16A/18A/20A/22A SERIES

Page 10

Determining the shim pack:

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. Then feed the flange on the

indicator side without shims in the case and start to move it closer, manually screwing the M6x40 service

screws in equally, with small rotations such as to move the cover in slowly and correctly.

At the same time, check that the shaft rotates freely by turning it manually.

Continuing the procedure in this way, a sudden increase in difficulty during shaft rotation will soon be

experienced.

At this point, halt the forward movement of the cover and loosen the fixing screws completely.

With the aid of a thickness gauge, measure the clearance between the side cover and pump casing (fig. 4).

Detected

Measurement Shim

Type # Pieces

From: 0.05 to: 0.10 / /

From: 0.11 to: 0.20 0.1 1

From: 0.21 to: 0.30 0.1 .2

From: 0.31 to: 0.35 0.25 1

From: 0.36 to: 0.45 0.35 1

From: 0.46 to: 0.55 0.35

0.10 1

From: 0.56 to: 0 .60 0.25 2

From: 0.61 to: 0.70 0.35

0.25 1

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Once the type and number of shims have been determined using the table, check the following: assemble the

shim pack on the indicator side cover centring (fig. 15), secure the cover to the casing, following the proce-

dure in paragraph 2.1.2 and tighten the screws to their recommended torque. Check that the shaft rotation

stall torque is between 3-4.5 Ft. Lbs.(4-6 Nm). If this torque is correct, connect the con-rods to the crankshaft

and to the next stages. If it is not, redefine the shim pack, repeat the operations.

Proceed to detemine the shim pack, using the table below:

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