SM Repair Manual General Pump is a member of the Interpump Group 8 Ref 300894 Rev.
GENERAL PUMP INDEX 1. 2. 3. 4. 5. 6. A member of the Interpump Group SM SERIES INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 2.1 Repairing Mechanical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 2.1.1 Disassembly of Mechanical Parts . . . . . . . . . . . . . . . . . . . . . .
GENERAL PUMP A member of the Interpump Group 1. INTRODUCTION SM SERIES This manual describes the instructions for Repairing SM 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 INSTRUCTIONS 2.
GENERAL PUMP A member of the Interpump Group 2.1.1 Disassembly of Mechanical Parts The correct sequence is the following: SM SERIES Completely empty the pump of oil, then disassemble the casing cover (and relative o-ring), unscrewing the (6) M10 screws (1, fig. 2). Remove the tab from the PTO shaft (1, fig. 3). Unscrew the reduction gear cover fixing screws (1, fig. 4). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES Position the 3 grub screws or M8 threaded screws (1, fig. 5) with the function of extractors in the holes and two sufficiently long M10 screws with the function of supporting the cover (2, fig. 5). Slowly screw in the 3 M8 screws (1. fig. 6) with the function of extractors to fully remove the cover unit and pinion.
GENERAL PUMP A member of the Interpump Group SM SERIES Separate the pinion from the cover, working with an extractor hammer on the pinion itself (1, fig. 8) Remove the Seeger ring Ø 55 (1, fig. 9) and the bearing support ring (1, fig. 10) from the pinion. Extract the seal ring from the reduction gear cover, working from the inner side of the cover (1, fig. 11). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES Unscrew the screws holding in the ring gear (1, fig. 12) and remove it (1, fig. 13). Remove the ring gear (1, fig. 14). Where necessary, it is possible to utilize an extractor hammer to be applied on the (2) M8 holes (2, fig. 14). Remove the tab from the shaft (1, fig. 15). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group Remove the ring gear support ring (1, fig. 16). SM SERIES Unscrew the connecting rod screws (1, fig. 17). Remove the connecting rod caps with the lower semi-bearings, taking special care of the disassembly sequence during disassembly. The connecting rod caps and their relative half supports must be reassembled in exactly the same order and coupling with which they were disassembled.
GENERAL PUMP A member of the Interpump Group SM SERIES Advance the half supports completely in the direction of the hydraulic part to allow the crankshaft to come out. To facilitate this operation, use special too part #F27566200 (1, fig. 19). Remove the three upper half bearings of the half supports (1, fig. 20). Unscrew the reduction gear box fixing screws (1, fig. 22). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES Position the 3 grub screws or M8 threaded screws (1, fig. 23) with the function of extractors in the holes and two sufficiently long M10 screws with the function of supporting the reduction gear box (2, fig. 23). Slowly screw in the 3 M8 screws (1, fig. 24) to prevent the box from tilting too far and getting locked in the housing. Remove the box while supporting the crankshaft to prevent damage (1, fig. 25).
GENERAL PUMP A member of the Interpump Group SM SERIES Position the 3 grub screws or M8 threaded screws (1, fig. 28) with the function of extractors in the holes. Slowly screw in the 3 M8 screws (1, fig. 29) to prevent the cover from tilting too far and getting locked in the housing. Remove the bearing cover while supporting the shaft to prevent damage. (1. fig. 30). Remove the crankshaft casing from the PTO side (1, fig. 31). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES In the event that it is necessary to replace one or more connecting rods or plunger guides, operate as follows: unscrew the screws with tool part #F27566200 to unlock the connecting rods (1, fig. 32) and then extract the connecting rod/plunger guide units from the back casing opening (1, fig. 33). It is now possible to disassemble the plunger guide seal rings, taking care to not damage the plunger guide sliding rod.
GENERAL PUMP A member of the Interpump Group Extract the seal ring using the tool extractor hammer (1, fig. 36). SM SERIES Remove the two spindle locking Seeger rings Ø 120 (1, fig. 37). Remove the spindle (1, fig. 38) and extract the connecting rod (1, fig. 39). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES Couple the half supports to the previously disassembled caps, referring to the numbering (1, fig. 40). To separate the rod from the plunger guide, unscrew the hexagonal head M10 screws with a 17 socket wrench (1, fig. 41), blocking the rod with the 36 fork spanner. Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES 2.1.2 Assembly of Mechanical Parts Proceed with assembly following the reverse order indicated in point 2.1.1. The proper sequence is as follows: Assemble the rod to the plunger guide. Insert the elastic pin Ø 5 in its hole on the plunger guide (1, fig. 42) and join the rod to the plunger guide by means of M10x35 screws (1, fig. 43). Lock in the rod in correspondence with the two planes with a 36 fork spanner (1, fig.
GENERAL PUMP A member of the Interpump Group SM SERIES Block the three units with the use of special tool part #F27566200 (1, fig. 32) Preassemble the ring inside the crankshaft bearings (on both sides of the shaft down to the stroke) using special tool part #F27604700 (1, fig. 46) (1, fig. 47). The inner and outer rings of the bearings must be reassembled keeping the same coupling with which they were disassembled.
GENERAL PUMP A member of the Interpump Group Fully insert the shaft in the casing (1, fig. 50 and fig. 51). SM SERIES Pre-assemble the outer ring of the pinion bearing on the reduction gear with the aid of special tool part #F27604900 (1, fig. 52), inserting fully down to end stroke (1, fig. 53). From the opposite side of the reduction gear box, preassemble the external ring of the crankshaft bearing with the use of tool part #F27605000 (1, fig. 54), inserting fully down to end stroke (1, fig. 55).
GENERAL PUMP A member of the Interpump Group SM SERIES Repeat this operation on the bearing box, preassembling the external crankshaft bearing ring with the help of special tool part #F27605000 (1, fig. 56), inserting fully down to end stroke (1, fig. 57). Insert the side seal on the bearing cover (1, fig. 58) and lift the crankshaft to favor cover insertion (1, fig. 59). Assemble the bearing cover (and related seal) using an extractor hammer (1, fig. 60).
GENERAL PUMP A member of the Interpump Group SM SERIES Tighten the (8) M10x30 screws (1, fig. 61). Calibrate the screws with a torque wrench as indicated in Section 3 “Screw Tightening Callibration”. From the opposite side, insert the side seal on the reduction gear box (1, fig. 62) and lift the crankshaft to favor cover insertion (1, fig. 63). Assemble the reduction gear box (and related seal) using an extractor hammer (1. fig. 64). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES Tighten the (8) M10x40 screws (1, fig. 65). Calibrate the screws with a torque wrench as indicated in Section 3, “Screw Tightening Calibration”. Remove the tool for blocking the connecting rods tool part #F27566200 (1, fig. 32) Insert the upper half-bearings between the connecting rods and the shaft (1, fig. 66).
GENERAL PUMP A member of the Interpump Group SM SERIES After finishing this operation, verify that the connecting rods have axial clearance in both direction. Insert the plunger guide seal rings in their casing by means of special tool part #F27605300. Position the component on the rod (1, fig. 70a) and strike on the tool until the seal ring is fully inserted in the housing (1, fig. 70b). Insert the o-ring on the rear cover (1, fig.
GENERAL PUMP A member of the Interpump Group SM SERIES Take care to fully and properly insert the o-ring in its housing on the cover to prevent them from being damaged during screw tightening. Calibrate the screws with a torque wrench as indicated in Section 3, “Screw Tightening Calibration”. Insert the ring gear support ring in the crankshaft shank (1, fig. 73) to end stroke (1, fig. 74). Apply tab 22x14x80 in the shaft housing (1, fig. 75) and insert the ring gear on the shaft (1, fig. 76).
GENERAL PUMP A member of the Interpump Group SM SERIES Fasten the ring gear stop (1, fig. 77) using (2) M10x25 screws. Calibrate the screws with a torque wrench as indicated in Section 3, “Screw Tightening Calibration” (1, fig 78). Apply the two Ø 10x24 pins on the reduction gear box (1, fig. 79) and insert the o-ring (1, fig. 80). Complete assembly of the pinion on the reduction gear cover, proceeding as follows: Preassemble the inner bearing ring 40x90x23 on the pinion (1, fig.
GENERAL PUMP A member of the Interpump Group SM SERIES From the other side of the pinion, preassemble the bearing 55x120x29 (1, fig. 82) positioning it to end stroke using tool #F27604800 (1, fig. 83). Insert the bearing support ring (1, fig. 84) and position the Seeger ring Ø 55 (1, fig. 85). Insert the pinion preassembled inside its housing in the reduction gear cover, with the aid of an extractor hammer (1, fig. 86). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group Insert the Seeger ring Ø 120 in the housing (1, fig. 87). SM SERIES Assemble the reduction gear cover with the aid of an extractor hammer (1, fig. 88) and fasten them with (7) M10x40 screws (1, fig. 89). Take care to properly couple the two components on the bearing 40x90x23. Calibrate the screws with a torque wrench as indicated in Section 3 “Screw Tightening Calibration”.
GENERAL PUMP A member of the Interpump Group SM SERIES To prevent damage to the seal ring, take special care when inserting the seal ring on the pinion. Apply o-rings on the inspection covers (1, fig. 92 and tighten with 2+2 M6x14 screws (1, fig. 93). Calibrate the screws with a torque wrench as indicated in Section 3 “Screw Tightening Calibration”. Insert the tab 14x9x60 on the pinion. Apply plugs and lifting brackets with the use of M16x30 screws (1, fig. 94).
GENERAL PUMP SM SERIES A member of the Interpump Group 2.1.3 Increase and Reduction Classes INCREASE TABLE FOR CRANKSHAFT AND CONNECTION ROD HALF-BEARINGS Recovery classes (mm) P/N Half-bearing Upper P/N Half-bearing Lower 0.50 F90928200 F90928500 0.25 F90928100 F90928400 Correction on the shaft pin diameter (mm) Ø79.75 0/0.02 Ra 0.4 Rt 3.5 Ø79.50 0/0.02 Ra 0.4 Rt 3.5 INCREASE TABLE FOR PUMP CASING AND PLUNGER GUIDE Recovery classes (mm) 1.00 2.
GENERAL PUMP A member of the Interpump Group SM SERIES Unscrew two diametrically-opposite M16 x 80 head fixing screws (1 and 2, fig. 96) and replace them with two service pin-screws (part #F27540200)(1, fig. 97), and then proceed to remove the remaining screws. Separate the head and the spacer from the pump casing liners (1 fig. 98). Remove the spacer for pump casing liner from the liner units (1, fig. 99). Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES Remove the M10x140 head liner fixing screws (1, fig. 100) and remove the liner units (1, fig. 101). During assembly of the liners, take care not to disperse the valve springs and the flat valves (1 and 2, fig. 102) as, not being locked, they could fall. If the valve housings should become blocked on the head due to the forming of limestone or oxide, they must be unblocked by inserting a special tool part #F034300020 in the outlet hole.
GENERAL PUMP A member of the Interpump Group SM SERIES Extract the valve housings and check the conditions of the various components. If necessary, make any replacements (1, fig. 104). At every valve inspection, always replace all seal rings and relative o-rings between the liner and head, between the head and liner spacer in the recirculation inlet area. Clean and dry components and all relative housings inside the head before replacing. Extract the outlet plates (1, fig.
GENERAL PUMP A member of the Interpump Group SM SERIES 2.2.2 Assembling the Head-Liners-Valves To reassemble the various components, reverse the operations listed previously, paying particular attention to the correct assembly of the spacer for liners: the hole Ø6 (seal cooling circuit) must correspond to the same hole for the head (with o-ring). Heads - liners: proceed with assembly and calibration of the head fixing screws and then with calibration of the liner fixing screws.
GENERAL PUMP A member of the Interpump Group SM SERIES Remove the M8x50 liner support fixing screws (1, fig. 111) and separate the support from the liner (1, fig. 112). Remove the Seeger ring and the seal ring (1, fig. 113) and with a special plastic pin, remove the low pressure ring seal (1, fig. 114). The o-rings and the low pressure seals must be replaced at each disassembly. Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES With the liner separate from the seal support and with the special plastic pin (1, fig. 115), have the high pressure packing come out (1, fig. 116). The HP packing (1, fig. 116) will have to be replaced at each disassembly. 2.2.4 Assembling the Plunger Unit - Supports - Seals To reassemble the various components, reverse the operations paying special attention to the various sequences listed below.
GENERAL PUMP A member of the Interpump Group SM SERIES Insert the high pressure packing (1, fig. 119). Given the slight interference between the seal and the liner, use special tool part #F27673200 for SM14, SM16, and SM18, and part #F27673300 for SM20, SM22 and SM24 to prevent damage. The HP seal must be placed in the liner as indicated in fig. 121 and 122.
GENERAL PUMP A member of the Interpump Group SM SERIES Insert the anti-extrusion ring and the seals bushing (1 and 2, fig. 123, 123, 125). The seal bushing (2) must be inserted in the liner with the two discharges turned outward (casing side) as indicated in fig. 124. Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group SM SERIES The LP seal must be inserted into the liner with the seal lip in the direction of plunger operation (1, fig. 126 and 127), lightly lubricating the outside diameter with silicone grease (OKS 1110 type). Replace the LP seal when it is worn. Reassemble the seal support assembly (1, fig. 128 and 129), replacing the 1 and 2 components). Ref 300894 Rev.
GENERAL PUMP SM SERIES A member of the Interpump Group Assemble the support/liner assembly, manually tightening the M8 x 50 screws as shown in fig. 130, and then proceeding with setting the torque wrench as shown in Section 3. 3. SCREW CALIBRATION Screws are to be fastened exclusively using a torque wrench. Exploded View Position (From Owner’s Manual) 1 15 22 26 29 38 41 43 50 66 71 79 81 * Fastening Fastening Ft. Lbs. Nm 207 30 30 61 33 44 148 48 7.
GENERAL PUMP A member of the Interpump Group SM SERIES Ref 300894 Rev.
GENERAL PUMP 4. REPAIR TOOLS A member of the Interpump Group SM SERIES Pump maintenance may be carried out using simple tools for assembling and disassembling components. The following tools are available: For Assembly: • Shaft (connecting rod interlocking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F27566200 • Pinion bearing on reduction gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F27604900 • Plunger guide oil seal . . . . . . . . . . . . . . . . . . . . .
GENERAL PUMP A member of the Interpump Group SM SERIES 5. REPLACING THE CONNECTING ROD FOOT BUSHING Carry out bushing fitting at room temperature and perform subsequent processing according to the dimensions and tolerances below in fig. 133. Ref 300894 Rev.
GENERAL PUMP A member of the Interpump Group 5. MAINTENANCE LOG SM SERIES HOURS & DATE OIL CHANGE GREASE PACKING REPLACEMENT PLUNGER REPLACEMENT VALVE REPLACEMENT 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 Ref 300894 Rev.
