Interpump General Pump EV Series, Repair Manual

Page 1: ...EV Repair Manual Ref 301038 Rev A 07 20 General Pump is a member of the Interpump Group EV20A EV22A EV25A EV26A EV28A ...

Page 2: ...assembly Assembly of bearings and shims Page 8 2 2 Repairing Hydraulic Parts Page 11 2 2 1 Disassembly of The Head Valve Units Page 11 2 2 2 Assembly of The Head Unit Valves Page 13 2 2 3 Disassembly of The Head Seals Page 14 2 2 4 Disassembly of The Piston Unit Page 15 2 2 5 Assembly of The Head Seals Piston Unit Page 16 3 SCREW CALIBRATION Page 17 4 REPAIR TOOLS Page 18 5 MAINTENANCE LOG Page 19...

Page 3: ...CRIPTION OF SYMBOLS 2 REPAIR INSTRUCTIONS 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 GENERAL PUMP A member of the Interpump Group Page 3 EV SERIES Warning Potential Danger Danger Wear goggles Danger Wear protective gloves Read carefully and understa...

Page 4: ... follows unscrew the cap fixing screws remove the con rod caps Fig 2 paying attention to the sequence during disassembly The side covers using for extraction 3 fully threaded M6x50 screws inserting them in the threaded holes as indicated in Fig 3 GENERAL PUMP A member of the Interpump Group Page 4 EV SERIES Fig 2 Fig 3 Push the piston guides forward with their con rods to facilitate side extractio...

Page 5: ...s described below Use the extractor code 26019400 Fig 5 pos 1 and the pliers code 25027000 Fig 5 pos 2 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 6 until the ring to be replaced is removed Fig 7 GENERAL PUMP A member of the Interpump Group Page 5 EV SERIES Fig 5 Fig 5 ...

Page 6: ...ly pushing the piston con rod guide units as far down as possible par 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 If replacement is necessary position the new ring using a tool code 27904500 as shown in Fig 8 Before assembling the side covers make sure there are O rings on both of them and shim rings...

Page 7: ...g 10 lubricating both the underhead and the threaded shank proceeding in two different stages Fig 9 Fig 10 After having completed tightening operations check that the con rod head has a side clearance in both directions Insert the new piston guide seal rings as far as possible into the relative seat on the pump casing Fig 11 following the procedure described use tools code 25027100 and code 279366...

Page 8: ...overs as indicated in par 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 redis tribute 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 shaft motor side flange check...

Page 9: ...s from the two ends of the shaft again using an appropriate extractor or alternatively a simple pin punch as shown in Fig 13 Fig 12 Fig 12 a 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 fitting operation could be facilitated by heating the parts involved at a temperature between...

Page 10: ...ewing 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 hardness during shaft rotation will soon be experi enced At this point halt the forward movement of the cover and loosen the fixing screws completely Wit...

Page 11: ... bend shaft and to the next stages If it is not redefine the shim pack repeating the operations 2 2 Repairing Hydraulic Parts 2 2 1 Disassembly of The Head Valve Units Operations are limited to inspection or replacement of valves if necessary and however at the intervals indi cated in the PREVENTIVE MAINTENANCE table in chapter 11 of the Owner s Manual The valve units are assembled inside the head...

Page 12: ...mp inactivity operate as follows Suction and outlet valves Use tools code 26019400 code 27513700 Fig 20 Page 12 GENERAL PUMP A member of the Interpump Group EV SERIES Fig 18 The suction and outlet valve units dismantling can be carried out by levering with simple tools Fig 19 Fig 19 Fig 20 Ref 301038 Rev A 07 20 ...

Page 13: ...nual At every valve inspection replace all O rings and all anti extrusion rings in the valve units Before repositioning the valve units thoroughly clean and dry the relative seats in the head as shown in Fig 21 Fig 21 To reassemble the various components perform the operations listed above in reverse order to par 2 2 1 Reassemble the valve units Fig 22 and Fig 22 a to facilitate insertion of the v...

Page 14: ...isassembly of The Head Seals Replacement of the seals is necessary from the moment you begin to detect water leaks from the drain age holes provided on the back of the pump casing and at the intervals indicated in the PREVENTIVE MAINTENANCE table in chapter 11 of the Owner s Manual A Unscrew the M12x130 head fixing screws as indicated in Fig 24 B Separate the head from the pump casing C Extract th...

Page 15: ...6 composed of 1 Head Ring 2 HP Seal 3 Restop Ring 4 LP Seal 5 LP Seal 6 Seal Ring 7 O Ring Fig 26 2 2 4 Disassembly of The Piston Unit The piston unit does not require any routine maintenance Maintenance is limited to visual checks only To extract piston units Loosen the M 7x1 piston fixing screws as indicated in Fig 27 Ref 301038 Rev A 07 20 ...

Page 16: ...ecessary to facilitate the lip seal adjustment on the piston C For correct assembly of HP seals in their seats on the head without causing any damage to lip seals use suitable tools according to the pump diameters as indicated in chapter 4 D Remount the pistons tightening the screws with a torque wrench respecting the tightening torque value as indicated in chapter 4 E Replace the head as follows ...

Page 17: ... 120 Inlet Valve Cover Screws 10 13 88 50 120 Manifold Screws 13 88 50 120 Pressure Gauge Plug 68 29 50 40 The con rod cap fixing screws must be tightened simulta neously respecting the phases indicated on page 15 The head fixing screws exploded view pos 13 must be tightened with a torque wrench respecting the order shown in the diagram in Fig 29 The valve cover fixing screws exploded view pos 10 ...

Page 18: ...00 Seal bush extØ 38 HP alternative seal ring Ø 25x38x7 4 6 Code 27385400 Code 27472900 Seal bush extØ 38 HP alternative seal ring Ø 26x38x6 3 5 Code 27385400 Code 27472900 Seal bush extØ 45 HP alternative seal ring Ø 28x45x8 5 5 Code 26406300 Code 25027300 Pump shaft oil seal Code 27904500 Piston guide oil seal Code 27904200 Head Code 27508200 For disassembly phases Inlet outlet valve seats Code ...

Page 19: ...ACEMENT VALVE REPLACEMENT HOURS DATE GP Companies Inc 1174 Northland Drive Mendota Heights MN 55120 Phone 651 686 2199 Fax 800 535 1745 www generalpump com email sales gpcompanies com GENERAL PUMP A member of the Interpump Group Page 19 EV SERIES Ref 301038 Rev A 07 20 ...