General-pump MK Repair Manual Bedienungsanleitung

MMKKRepair ManualMK40A-MK45A-MK50AMK55A-MK60A-MK65A

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 10Remove the pressure sleeve (1, fig. 26).Remove the upper split bearing of the connecting ro

GENERAL PUMPA member of the Interpump GroupMK SERIESRemove the crankshaft with the help of a hammer on the PTO side (1, fig. 28). Remove the shaft and

GENERAL PUMPA member of the Interpump GroupMK SERIESCouple the connecting rods with the previously disassembled caps; be sure to respect numbering (1,

GENERAL PUMPA member of the Interpump GroupMK SERIESTo separate the rod from the plunger guide, unfasten the M10 hexagonal-head screws using a size 17

GENERAL PUMPA member of the Interpump GroupMK SERIESBlock the rod using a clamp, and proceed with calibration using a torque wrench (1, fig. 40) as in

GENERAL PUMPA member of the Interpump GroupMK SERIESInsert the shaft (1, fig. 29) until the pre-assembled bearing is aligned with the edge of the cran

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 16Completely insert the pressure sleeve on the shaft from the opposite side of the PTO (1, fi

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 17Screw the ring nut and fasten the sleeve until the dimension “X” is reduced by a value rang

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 18Remove the device that blocks the connecting rods using p/n 27566200 (1, fig. 31).Insert th

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 19Once tightened on the crankshaft, make sure that conrods still have axial right-left endpla

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 2INDEX1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 20Assemble the bearing on the reducer cover (1, fig. 66).Assemble the reducer cover (1, fig.

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 21Insert the oil seal inside the reducer flange using the proper tools, p/n 27515900 and 2754

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 22Insert the key 16 x 10 x 90 in the pinion.Insert the O-ring in the rear cover (1. fig. 74)

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 23Complete the assembly of the crank mechanism by applying the plugs and lifting eyebolts wit

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 242.2 Fluid End Repair2.2.1 Head Disassembly - Valve UnitsThe head requires preventive mainte

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 25Extract the delivery valve unit using a slide hammer applied to the M10 hole of the valve g

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 26Disassemble the suction and delivery valve units by screwing on an M10 screw long enough to

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 272.2.2 Head Assembly - Valve UnitsPay careful attention to state of wear of the various comp

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 28Proceed with the insertion of the valve units (suction and delivery) into the head, payinga

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 29Be sure that the O-ring and the anti-extrusion ring are perfectly fit into their seats. Ins

1. INTRODUCTIONThis manual describes the instructions for Repairing MK Series pumps, and must be carefully read andunderstood before performing any re

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 30Insert the anti-extrusion ring, exploded view item 16 in Owner’s Manual (1, fig. 99).Pay pa

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 31Insert the valve seat ring (1, fig 102) and the spring (1, fig. 103).Assemble the O-ring, e

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 32Assemble the head on the pump casing (1, fig. 107) being careful not to bump against the pl

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 332.2.3 Disassembling the Plunger Unit - Supports - SealsThe plunger unit requires a periodic

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 34Manually rotate the shaft so that the 3 plungers are in the top dead center position.Insert

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 35Remove the wiper rings from the plunger guides (1, fig. 116).If replacement of the plunger

GENERAL PUMPA member of the Interpump GroupMK SERIESSeparate the packing support from the liner (1, fig. 121) to access the pressure packings (1, fig

GENERAL PUMPA member of the Interpump GroupMK SERIESReplace the pressure packings by applying a small amount of silicone grease to the lips, being car

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 38Position the O-ring (1, fig. 130) in its seat on the oil seal cover, and insert the assembl

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 39Insert the 14 x 2 O-ring in its correct seat on the plunger bolt (1, fig. 136).Assemble the

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 42.1.1 Crank Mechanism DisassemblyThe correct sequence is the followingCompletely drain the o

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 40Be sure that the liner-support unit is correctly positioned in its seat (1, fig. 141).Assem

GENERAL PUMPA member of the Interpump GroupMK SERIESCalibrate the screws with the torque wrench as indicated in paragraph 3. “SCREW CALIBRATION”Insert

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 42After re-tooling, three steel bushings designed to restore the original bores have to be dr

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 433. SCREW CALIBRATIONScrews are to be fastened exclusively using a torque wrench.Description

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 444. REPAIR TOOLSPump maintenance may be carried out using simple tools for assembling and di

GENERAL PUMPA member of the Interpump GroupMK SERIESRef 300679 Rev.A11-09Page 45MAINTENANCE LOGOIL CHANGEGREASEPACKINGREPLACEMENTPLUNGER REPLACEMENTVA

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 5Unfasten the reducer cover screws (1, fig. 6).Insert 3 dowels, or 3 M8 threaded screws (1, f

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 6Screw on the 3 threaded screws (1, fig. 8) and simultaneously, using the appropriate tool (p

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 7Remove the pinion by using a slide hammer applying it to the M14 hole (1, fig. 14).Lift the

GENERAL PUMPA member of the Interpump GroupMK SERIESInsert a spacer under the connecting rod to block shaft rotation (1, fig. 16).Using an appropriate

GENERAL PUMPA member of the Interpump GroupMK SERIESPage 9On the opposite side, unfasten the reducer case screws (1, fig. 21), and then remove the cas