60PFR PLUNGER PUMP SERVICE MANUAL
Contents
1. Diameter 45 90 Close Thru Thru Inches Inches Elbow Elbow Ret Run Branch 2 067 1 35 61 5 30 8 2 59 5 55 12 30 3 08 11 60 2 469 1 62 73 5 36 8 3 09 6 61 14 70 3 68 13 20 3 068 2 01 91 5 45 8 3 84 8 23 18 20 4 57 16 40 4 026 2 64 120 01 60 0 5 03 10 80 23 90 6 00 21 60 Arriving at a total line pressure loss consideration should then be given to pressure loss created by valves fittings and elevation of lines If a sufficient number of valves and fittings are incorporated in the system to materially affect the total line loss add to the total line length the equivalent length of line of each valve or fitting TYPICAL RESERVOIR TANK RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY x Supply Line Bypass Line from regulator or unloader Level Sensing T Dia of pipe Device X D lt 7A Flexible Hose to Pump aren Bypass Line y from regulator or h unloader FILTER Minimum Two Baffles Sealed at Bottom Handy Formulas to Help You Q How can I find the RPM needed to get specific GPM Gallons Per Minute want A Desired RPM Desired GPM x Rated RPM Rated GPM Q Ihave to run my pump ata certain RPM How do figure the GPM I ll get A Desired GPM Desired RPM x Rated GPM Rated RPM Q Is there a simple way to find the approximate horsepower lIl need to run the pump A Electric Brake GPM x PSI 7 Standard 852. STORING For extended storing or between use in cold climates drain all pumped liquids from pump and flush with antifreeze solution to prevent freezing and damage to the pump DO NOT RUN PUMP WITH FROZEN LIQUID refer to Tech Bulletin 083 WARNING All systems require both a primary pressure regulating device i e regulator unloader and a secondary pressure safety relief device i e pop off valve safety valve Failure to install such relief devices could result in personal injury or damage to the pump or to system components CAT PUMP S does not assume any liability or responsibility for the operation of a customer s high pressure system PIJTTERSEN Pijttersen B V Tel Postbus 262 8500 AG Joure Transportwei 26 8501 ZP Joure The Netherlands 31 0 513 414040 Fax 31 0 513 414066 E mail info pijttersen nl info catpumps nl Internet www pijttersen nl www catpumps nl UMP The Pumps with Nine Lives Removing Valve Plug 6760 Complete Valve Assembly SERVICING THE VALVES Disassembly 1 On the models 6747 6760 and 6767 remove six 6 M70 Hex Valve Plugs On the model 6761 remove four 4 Hex Socket Screws from each Valve Plug then remove Valve Plug Remove Coil Spring and Washer under Valve Plug Thread an M12 bolt into the top of the Spring Retainer and pull out the Valve Assembly including Retainer Spring Valve Seat O Ring and Back up Ring from the valve chamber The valve asse
3. cuts or deterioration and replace as needed ber with V Packings facing into the manifold chamber NOTE When using alternate materials the fit of the 17 On the models 6760 6761 6767 place Female Adapter special materials may be snug and require gently with flat side down V side up inside each seal chamber driving the LPS into position with a cylinder of the 18 same diameter to assure a square seating and no damage to the LPS Insert two V Packings with V side down into each seal chamber The V will mate with V side of the Female Adapter 3 On the model 6747 press new Lo Pressure Seal into 19 each LPS Adapter with the garter spring up Press Male Adapter with V side down into each seal chamber 4 Place Inlet Manifold on flat work surface with crankcase 20 Position Spacer w Coil Springs so that the small springs Side tip do not line up with grooves on top surface of Male 5 On the model 6747 press LPS Adapter Assembly into Adapter each a chamber of the Inlet Manifold with the garter 21 On the model 6747 install two O Rings and two Spring Gown Back up Rings on V Packing Spacer w Coil Springs with 6 On the models 6760 6761 6767 press Lo Pressure Seal O Rings to the outside Press V Packing Spacer into each into each seal chamber with the garter spring down V Packing Cylinder 7 Examine the V Packing Cylinders V Packing Spacers 22 On the models 6760 6761 6767 install O Rings on each a
4. the desired flow from Horsepower Requirement and Pulley Selection Chart refer to Tech Bulletin 003 or individual Data Sheet DRIVE SELECTION The motor or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load Select the electric motor from the Horsepower Requirement Chart according to required pump discharge flow maximum pressure at the pump and drive losses of approximately 3 5 Consult the manufacturer of gas or diesel engine for selection of the proper engine size MOUNTING Mount the pump on a rigid horizontal surface in a manner to permit drainage of crankcase oil An uneven mounting surface will cause extensive dam age to the pump base To minimize piping stress use appropriate flexible hose to inlet and discharge ports Use the correct belt make sure pulleys are aligned Excessive belt tension may be harmful to the bearings Hand rotate pump before starting to be certain shaft and bearings are free moving LOCATION If the pump is used in extremely dirty or humid conditions it is recom mended pump be enclosed Do not store or operate in excessively high temperature areas or without proper ventilation INLET CONDITIONS Refer to complete Inlet Condition Check List in this manual before starting system DO NOT STARVE THE PUMP OR RUN DRY Temperatures above 130 F are permissible Add 1 2 PSI inlet pressure per each degree F over 130 F Elastomer or RPM changes may be required Se
5. 0 6761 6767 remove Lo Pressure Seal from each seal chamber Removing Inlet Spacer from Inlet Manifold Complete packing arrangement 6760 6767 Complete packing arrangement 6747 Matching the spacer with coil springs and the Packings Removing the Lo Pressure Seals from the Inlet Manifold Lo Pressure Seals and Adapter arrangement 6747 SERVICING THE SEALS ALL MODELS Reassembly NOTE If your pump has been built with special seals 12 On the model 6747 install O Ring on grooved end of and O Rings service same type of special parts V Packing Cylinder Place V Packing Cylinder with large Refer to pump Data Sheet for correct parts and kits opening facing up on work surface NOTE For certain applications apply liquid gasket to 13 Place Female Adapter with flat side down V side up the O Ring crevices and seal surfaces See Tech inside each V Packing Cylinder Bulletin 053 for model identification 14 Insert two V Packings with V side down into the NOTE EPDM elastomers require silicone base lubricant V Packing Cylinder The V will mate with V side of the Female Adapter 1 Examine Lo Pressure Seals for wear to the internal ridges p and outer surfaces or for broken springs and replace as 15 Place Male Adapter with V side down inside each needed V Packing Cylinder 2 Examine LPS Adapters for scale build up or wear and the 16 Press V Packing Cylinder Assembly into each seal cham O Rings for
6. 60PFR PLUNGER PUMP SERVICE MANUAL Be PIJTTERSEN E mail info pijttersen nl info catpumps nl Internet www pijttersen nl www catpumps nl 60 FRAME SPLIT MANIFOLD a T TAF S 6747 6760 6761 6767 INSTALLATION AND START UP INFORMATION Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only with the proper selection installation of plumbing and operation of the pump and accessories SPECIFICATIONS Maximum specifications refer to individual attributes It is not implied that all maximums can be performed simultaneous y If more than one maximum is considered check with your CAT PUMP S supplier to confirm the proper performance and pump selection Refer to individual pump Data Sheet for complete specifications parts list and exploded view LUBRICATION Fill crankcase with special CAT PUMP oil per pump specifications 60FR 10 Qts DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE Change ini tial fill after 50 hours running period Thereafter change oil every 3 months or 500 hour intervals Additional lubrication may be required with increased hours of oper ation and temperature PUMP ROTATION Pump was designed for forward rotation to allow optimum lubrication of the crosshead area Reverse rotation is acceptable if the crankcase oil level is increased slightly above center dot to assure adequate lubrication PULLEY SELECTION Select size of motor pulley required to deliver
7. GE MANIFOLD 1 Remove eight 8 M16 Hex Socket Head Screws 2 To assure alignment use two M16 Studs PN 88902 as guides while removing manifold Tap the back side of the Discharge Manifold with a soft mallet and gradually work head from pump Properly support Discharge Manifold to avoid damage to the Ceramic Plungers REMOVING THE INLET MANIFOLD 1 Remove the center four 4 M16 Hex Head Screws and the two 2 M16 Hex Nuts from the Studs Rotate Crankshaft to separate Inlet Manifold from the Crankcase Tap the rear of the Inlet Manifold with a soft mallet and gradually work from pump NOTE Exercise caution and keep Manifold aligned with Plungers to avoid damage to the Plungers as the Inlet Manifold is removed Gently working Discharge Manifold over plungers SERVICING THE SEALS ALL MODELS Disassembly 1 To service the seals and packings it is necessary to remove both the Discharge Manifold and the Inlet Manifold Follow disassembly procedures for REMOVING THE DISCHARGE MANIFOLD and REMOVING THE INLET MANIFOLD NOTE The V Packing Spacer with Coil Springs and V Packing Cylinder 6747 or V Packing Spacer 6760 6761 6767 Assemblies may stay in the Discharge Manifold or Inlet Manifold If the V Packing Spacer 6760 6761 6767 stays in either the Discharge or Inlet Manifold insert two screwdrivers on opposite sides of the secondary groove and pry from the valve chamber CAUTION Exercise caution a
8. Horsepower Required 1460 Mech Efficiency Q What size motor pulley should use Pump RPM Motor Engine RPM Q How do calculate the torque for my hydraulic drive system A Torque ft lbs 3 6 Consult A Pump Pulley Outer Diameter x Engine Mfr RPM Avoid Cavitation Damage One or several of the conditions shown in the chart below may contribute to cavitation in a system resulting in premature wear system downtime and unnecessary operating costs CONDITION SOLUTION Inadequate inlet e Increase line size to the inlet port or one size line size larger e Install C A T Tube e Move pump closer to liquid supply Water hammering liquid acceleration deacceleration Rigid Inlet Plumbing e Use flexible wire reinforced hose to absorb pulsation and pressure spikes Excessive Elbows in Keep elbows to a minimum and less than 90 Inlet Plumbing Excessive Liquid e Use Thermo Valve in bypass line Temperature e Do not exceed pump temperature specifications e Substitute closed loop with baffled holding tank e Adequately size tank for frequent or high volume bypass e Pressure feed high temperature liquids e Properly ventilate cabinets and rooms e Check all connections e Use PTFE thread tape or pipe thread sealant e Size tank according to pump output Minimum 6 10 times system GPM e Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids Verify viscosity
9. against pump specifications before operation e Elevate liquid temperature enough to reduce viscosity e Lower RPM of pump e Pressure feed pump e Increase inlet line size e Perform regular maintenance or use clean filters to monitor build up e Use adequate mesh size for liquid and pump specifications Air Leaks in Plumbing Agitation in Supply Tank Clogged Filters DIAGNOSIS AND MAINTENANCE One of the most important steps in a high pressure system is to establish a regular maintenance program This will vary slightly with each system and is determined by various elements such as the duty cycle the liquid being pumped the actual specifications vs rated specifications of the pump the ambient conditions the inlet conditions and the accessories in the system A careful review of the necessary inlet conditions and protection devices required before the system is installed will eliminate many potential problems CAT PUMPS are very easy pumps to service and require far less frequent service than most pumps Typically only common tools are required making in field service convenient however there are a few custom tools special to certain models that do simplify the process This service manual is designed to assist you with the disassembly and reassembly of your pump The following guide will assist in determining the cause and remedy to various operating conditions You can also review our FAQ or SERVICE sections on our WEB SITE for more fa
10. aring Cover Screws Connecting Rod Screws M10 32 5 44 Bubble Oil Gauge TECHNICAL BULLETIN REFERENCE CHART No Subject Models 002 Inlet Temperature VS Liquid Temperature Models 003 Drive Packages Power Units FR 68FR PFR 024 Lubrication of Lo Pressure Seals Models 036 Cylinder and Plunger Reference Chart Models Plunger Pump LPS and HPS Servicing Plunger Models 052 Plunger Rod and Stud Change CR Pumps PFR 5PFR 15PFR 35PFR 60PFR 053 Liquid Gasket Plunger NAB SS Models Piston and Plunger Pump Torque Chart Models Oil Drain Kit I Models Discharge Manifold 61 Winterizing a Pump I Models Crankcase Change 60 Frame 60FR Female Adapters 15PFR 35PFR 60PFR o gt Orprprw a a i gt INLET CONDITION CHECK LIST Review Before Start Up Inadequate inlet conditions can cause serious malfunctions in the best designed pump Surprisingly the simplest of things can cause the most severe problems or go unnoticed to the unfamiliar or untrained eye REVIEW THIS CHECK LIST BEFORE OPERATION OF ANY SYSTEM Remember no two systems are alike so there can be no ONE best way to set up a system All factors must be carefully considered INLET SUPPLY should exceed the maximum flow being delivered by the pump to assure proper performance QO Open inlet shut off valve and turn on water supply to avoid starving pump DO NOT RUN PUMP DRY Temperatures above 130 F are permissible Add 1 2 PSI inlet pressure per each
11. be exercised not to undersize the by pass hose diameter and length Refer to Technical Bulletin 064 for additional information on the size and length of the by pass line T Check the pressure in the by pass line to avoid over pressurizing the inlet m The by pass line should be connected to the pump inlet line at a gentle angle of 45 or less and no closer than 10 times the pump inlet port diameter e g 1 1 2 port size 15 distance from pump inlet port HOSE FRICTION LOSS PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES Water Hose Inside Diameters Inches Flow Gal Min 0 5 1 162 235 370 At a fixed flow rate with a given size hose the pressure drop across a given hose length will be directly proportional A 50 ft hose will exhibit one half the pressure drop of a 100 ft hose Above values shown are valid at all pressure levels WATER LINE PRESSURE LOSS PRESSURE DROP IN PSI PER 100 FEET Water Steel Pipe Nominal Dia Brass Pipe Nominal Dia Copper Tubing O D Type L GPM 1 4 3 8 1 2 3 4 1 1 4 1 2 1 4 3 8 1 2 3 4 1 14 12 1 4 3 8 1 2 5 8 3 4 7 8 120 13 400 45 94 100 28 9 0 2 2 230 50 17 330 86 220 62 21 5 2 1 6 500 120 40 520 130 320 90 30 7 8 2 4 180 56 270 90 190 62 16 5 0 1 5 120 670 240 470 150 40 12 3 8 1 7 330 110 39 11 5 0 550 200 150 36 37 52 210 107 Nominal Equivalent Length of Standard Pipe in Feet Pipe Inside 180 Tee Tee Size
12. ber of elbows and joints to a minimum ideally no elbows and the inlet accessories to a minimum 0 Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of the pump Acceleration loss of liquids may be increased by high RPM high temperatures low vapor pressures or high viscosity and may require pressurized inlet and C A T to maintain adequate inlet supply DO NOT USE C A T WITH SUCTION INLET T Optimum pump performance is obtained with 20 PSI 1 4 BAR inlet pressure and a C A T for certain applications With adequate inlet plumbing most pumps will perform with flooded suction Maximum inlet pressure is 50 PSI 3 5 BAR After prolonged storage pump should be rotated by hand and purged of air to facilitate priming Disconnect the discharge port and allow liquid to pass through pump and measure flow INLET ACCESSORIES are designed to protect against over pressurization control inlet flow contamination or temperature and provide ease of servicing A shut off valve is recommended to facilitate maintenance g Installation of a C A T is essential in applications with stressful conditions such as high temperatures booster pump feed or long inlet lines Do not use C A T with negative inlet pressure A stand pipe can be used in some applications to help maintain a positive head at the pump inlet line Inspect and clean inlet filters on a regular schedul
13. ck is used on 6747 Rotate Crankshaft by hand so the two outside Plungers are extended equally Carefully slide Inlet Manifold over Plungers and press towards Crankcase Keep manifold aligned to avoid dam aging Plungers To assure alignment use two M16 studs PN 88902 as guides and remove when manifolds are in place Replace four 4 Hex Head Screws and two 2 Hex Nuts and torque per chart Lubricate the exposed O Rings on the V Packing Spacer and valve chamber walls and carefully slip Discharge Manifold over Plungers and snug up to the Inlet Manifold Hand tighten the outer top two 2 Hex Socket Head Screws first Then hand tighten the remaining six 6 Hex Socket Head Screws Torque in sequence to specifications in torque chart TORQUE SEQUENCE 5 1 3 7 pe ka 0 0 0 0 ya oe SERVICING THE CRANKCASE SECTION 1 While Manifolds Plungers and Seal Retainers are re moved examine Crankcase Oil Seals for wear Check oil level and check for evidence of water in oil Rotate Crankshaft by hand to feel for smooth bearing movement Check for any signs of leaking at Rear Cover Drain Plug and Bubble Gauge Examine Crankshaft Oil Seals externally for drying crack ing or leaking Consult CAT PUMPS or your local distributor if Crankcase service is required Refer to Tech Bulletin 035 See Section V of the Plunger Pump Service Video for additional information PREVENTATIVE MAINTENANCE CHECK LIST Fok ay Wes 0 ore 00
14. cts or contact CAT PUMPS directly PROBLEM Low pressure Pulsation Water leak Under the manifold eInto the crankcase Knocking noise Inlet supply Bearing Pulley Oil leak Crankcase oil seals Crankshaft oil seals and o rings Drain plug Bubble gauge Rear cover Filler cap Pump runs extremely rough Inlet conditions Pump valves Pump seals Premature seal failure PROBABLE CAUSE Worn nozzle Belt slippage Air leak in inlet plumbing Pressure gauge inoperative or not registering accurately Relief valve stuck partially plugged or improperly adjusted Inlet suction strainer filter clogged or improperly sized Abrasives in pumped liquid Leaky discharge hose Inadequate liquid supply Severe cavitation Worn seals Worn or dirty inlet discharge valves Faulty Pulsation Dampener Foreign material trapped in inlet discharge valves Worn V Packings or Lo Pressure Seals Worn adapter o rings Humid air condensing into water inside the crankcase Excessive wear to seals and V Packings Inadequate inlet liquid supply Broken or worn bearing Loose pulley on crankshaft Worn crankcase oil seals Worn crankshaft oil seals or o rings on bearing cover Loose drain plug or worn drain plug o ring Loose bubble gauge or worn bubble gauge gasket Loose rear cover or worn rear cover o ring Loose filler cap or excessive oil in crankcas
15. degree F over 130 F Elastomer or RPM changes may be required See Tech Bulletin 002 or call CAT PUMPS for recommendations Avoid closed loop systems especially with high temperature ultra high pressure or large volumes Conditions vary with regulating unloader valve O Low vapor pressure liquids such as solvents require a booster pump and C A T to maintain adequate inlet supply Q Higher viscosity liquids require a positive head and a C A T to assure adequate inlet supply 1 Higher temperature liquids tend to vaporize and require positive heads and C A T to assure adequate inlet supply When using an inlet supply reservoir size it to provide adequate liquid to accom modate the maximum output of the pump generally a minimum of 6 10 times the GPM however a combination of system factors can change this requirement provide adequate baffling in the tank to eliminate air bubbles and turbulence install diffusers on all return lines to the tank INLET LINE SIZE should be adequate to avoid starving the pump 4 Line size must be a minimum of one size larger than the pump inlet fitting Avoid tees 90 degree elbows or valves in the inlet line of the pump to reduce the risk of flow restriction and cavitation O The line MUST be a FLEXIBLE hose NOT a rigid pipe and reinforced on SUCTION systems to avoid collapsing The simpler the inlet plumbing the less the potential for problems Keep the length to a minimum the num
16. e Restricted inlet or air entering the inlet plumbing Stuck inlet discharge valves Leaking V Packings or Lo Pressure seals Scored plungers Over pressure to inlet manifold Abrasive material in the liquid being pumped Excessive pressure and or temperature of pumped liquid Running pump dry Starving pump of adequate liquid Eroded manifold SOLUTION Replace with properly sized nozzle Tighten belt s or install new belt s Tighten fittings and hoses Use PTFE liquid or tape eCheck with new gauge Replace worn or damaged gauge Clean adjust relief valve Replace worn seats valves and o rings Clean filter Use adequate size filter Check more frequently Install proper filter Replace discharge hose with proper rating for system Pressurize inlet and install C A T eCheck inlet conditions Install new seal kit Increase frequency of service Clean inlet discharge valves or install new valve kit eCheck precharge If low recharge or install a new dampener Clean inlet discharge valves or install new valve kit Install new seal kit Increase frequency of service Install new o rings Install oil cap protector Change oil every 3 months or 500 hours Install new seal kit Increase frequency of service eCheck liquid supply Increase line size pressurize or install C A T Replace bearing eCheck key and tighten set screw Replace crankcase oil seals Remove bearing c
17. e Tech Bulletin 002 or call CAT PUMPS for recommendations C A T Installation of a C A T Captive Acceleration Tube is recommended in appli cations with stressful inlet conditions such as high temperatures booster pump feed long inlet lines or quick closing valves DISCHARGE CONDITIONS OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system Install a Pulsation Dampenin g device on the discharge head or in the discharge line as close to the head as possible Be certain the pulsation dampener Prrrrr o lator is properly precharged for the system pressure see individual Data Sheet A reliable Pressur e Gauge should be installed near the discharge outlet of the high pressure manifold This is extremely important for adjusting pressure regulating devices and also for proper sizing of the nozzle or restricting orifice The pump is rated for a maximum pressure this is the pressur e which would be read at the discharge manifold of the pump NOT AT THE GUN OR NOZZLE Use PTFE thread tape or pipe thread sealant sparingly to connect accessories or plumbing Exercise caution not to wrap tape beyond the last thread to avoid tape from becoming lodged in the pump or accessories This condition will cause a malfunction of the pump or system PRESSURE REGULATION All systems require both a primary pressure regulating device i e regulator unloader and a secondary pressure safe
18. e chart SERVICING THE PLUNGERS Disassembly 1 To secure the plungers it is necessary to remove both the Discharge and Inlet Manifolds Follow disassembly proce dures for REMOVING THE DISCHARGE MANIFOLD and REMOVING THE INLET MANIFOLD Remove the Seal Retainers from each Ceramic Plunger Remove the Adapter Front Seal Retainer from the Rear Seal Retainer Remove the used Wick and install new wick Replace Front and Rear Seal Retainer Loosen Plunger Retainer 4 to 5 turns Push Plunger to wards Crankcase until Plunger Retainer pops out 7 Unscrew and remove Plunger Retainer Gasket O Ring Back up Ring Ceramic Plunger Keyhole Washer and Barrier Slinger Reassembly 1 Replace Barrier Slinger then Keyhole Washer on each Plunger Rod 2 Carefully examine each Plunger for scoring or cracks and replace if worn NOTE Ceramic Plunger can only be installed one di rection front to back Do not force onto rod 3 Examine Gasket O Ring and Back up Ring on Plunger Retainer and replace if cut or worn Lubricate O Ring for ease of installation and to avoid damaging O Rings First install Gasket O Ring then Back up Ring 10 Apply a small amount of Loctite 242 to exposed threaded end and thread Plunger Retainer onto Plunger Rod Torque per chart Slip Seal Retainers over Plungers Insert smaller diameter first NOTE Line up Wicks with the oil holes in the Crankcase and tabs down towards the Oil Pan NOTE No wi
19. e to avoid flow restriction A pressure transducer is necessary to accurately read inlet pressure Short term intermittent cavitation will not register on a standard gauge T All accessories should be sized to avoid restricting the inlet flow All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction O Optional inlet protection can be achieved by installing a pressure cut off switch between the inlet filter and the pump to shut off pump when there is no positive inlet pressure BY PASS TO INLET Care should be exercised when deciding the method of by pass from control valves T It is recommended the by pass be directed to a baffled reservoir tank with at least one baffle between the by pass line and the inlet line to the pump Although not recommended by pass liquid may be returned to the inlet line of the pump if the system is properly designed to protect your pump When a pulsation dampener is used a PRESSURE REDUCING VALVE must be installed on the inlet line BETWEEN THE BY PASS CONNECTION AND THE INLET TO THE PUMP to avoid excessive pressure to the inlet of the pump It is also recommend ed that a THERMO VALVE be used in the by pass line to monitor the temperature build up in the by pass loop to avoid premature seal failure T A low pressure flexible cloth braid not metal braid hose should be used from the by pass connection to the inlet of the pump T Caution should
20. mbly should remain together If the valve assembly separates the parts can easily be removed without any tools except for the Seat Use a reverse pliers or slip the head of a bolt under the edge of the Valve Seat to remove Reassembly NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 053 for model identification Examine the O Rings on the Valve Seat and replace if cut or worn Lubricate the O Rings before installing on the Valve Seat Examine the surface of the Valve and Valve Seat for pit ting grooves or wear and replace if necessary Examine the Spring for fatigue scale or breaks and replace The Valve Assembly comes as one piece in the service kit Using individual parts assemble Valve Retainer Spring Valve and Seat with O Ring and Back up Ring and snap together securely Lubricate the O D of the Valve Assembly and the I D of the valve chamber and press Valve Assembly squarely into chamber until completely seated Replace Washer over top of Retainer then Coil Spring Examine the O Ring on the Valve Plug and replace if cut or worn Lubricate new O Ring before installing on Valve Plug Exercise caution not to cut O Ring on threads of Valve Plug Lubricate O D of Valve Plug O Ring and thread into valve chamber Exercise caution to avoid extruding O Ring Torque to specifications in chart Removing screws from Discharge Manifold REMOVING THE DISCHAR
21. nd V Packing Spacer w Coil Springs for scale build up end of V Packing Spacer Press Spacer into each seal and wear Examine O Rings and Back up Rings for cuts chamber or deleroralorrand replaced negdad 23 Examine Inlet Spacer for scale build up wear and replace 8 Examine Male Adapters and Female Adapters for wear as needed Examine Inlet Spacer O Rings for cuts and and replace as needed deterioration and replace as needed 9 Examine Spacer w Coil Springs for scale build up wear 24 Press Inlet Spacer into each lower manifold chamber broken or fatigued Coil Springs and replace as needed 10 Examine V Packings for frayed edges or uneven wear and replace as needed 1 ai Place Inlet Manifold on flat work surface with crankcase side down Complete plunger arrangement 25 26 27 Support the Inlet Manifold from the under side and align manifold with Crankcase Guide Pins Keep manifold aligned to avoid damaging Plungers To assure alignment use two M16 studs PN 88902 as guides and remove when manifolds are in place Apply Loctite 242 to Hex Head screw threads and thread in hand tight Torque in sequence to specification in torque chart Lubricate the exposed O Rings on the V Packing Spacer and valve chamber walls Support the Discharge Manifold from the under side and align with Inlet Manifold holes Apply Loctite 242 to HSH screw threads and thread in hand tight Torque in se quence to specifications in torqu
22. over and replace o rings and or oil seals Tighten drain plug or replace o ring Tighten bubble gauge or replace gasket Tighten rear cover or replace o ring Tighten filler cap Fill crankcase to specified capacity Correct inlet size plumbing Check for air tight seal Clean out foreign material or install new valve kit Install new seal kit Increase frequency of service Replace plungers Reduce inlet pressure per specifications Install proper filtration at pump inlet and clean regularly eCheck pressure and inlet liquid temperature DO NOT RUN PUMP WITHOUT LIQUID Increase hose one size larger than inlet port size Pressurize and install C A T Replace manifold Check liquid compatibility
23. s 00 Ws e x _ oa Dra fee e m x Peete Puy _ x coa x iia oH Ghange _ x __ O A _ _ Seal Changs rvahe Grange Paecessores _ If other than CAT PUMPS special multi viscosity ISO68 oil is used change cycle should be every 300 hours Each system s maintenance cycle will be exclusive If system per formance decreases check immediately If no wear at 1500 hours check again at 2000 hours and each 500 hours until wear is ob served Valves typically require changing every other seal change Duty cycle temperature quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and service cycle Remember to service the regulator unloader at each seal servicing and check all system accessories and connections before resuming operation Refer to video for additional assistance TORQUE CHART Thread Tool Size Part No Pump Item Pump Model Torque in lbs ft lbs Nm M30 Hex 520 M24Hex 565 44046 M14 Allen 565 33049 M41 Hex 1390 115 7 157 Plunger Retainer M14 Inlet Manifold Screws M16 43 4 59 47 0 64 Discharge Manifold Screws M16 47 0 64 Valve Plugs M70 6747 6760 6767 Valve Plugs Screws M16 21 0 28 M14 Allen 250 6761 33049 M17 He 220 181 25 25083 M17 He 390 25083 M28 Oil Gauge Tool 45 36 5 44050 Crankcase Cover M10 Be
24. s the screwdrivers may score o ring sealing surface If the V Packing Spacer with Coil Springs and V Packing Cylinder 6747 stays in either the Discharge or Inlet Manifold remove exposed O Rings and Back up Rings and insert two screwdrivers into the groove on opposite sides and pry from valve chamber CAUTION Exercise caution as the screwdrivers may score o ring sealing surface On the model 6747 separate V Packing Spacer from V Packing Cylinder by inserting two screwdrivers on opposite sides of the groove formed between components and pry apart Remove one Male Adapter two V Packings and one Female Adapter from each V Packing Cylinder Gently removing Inlet Manifold over plungers Removing V Packing Spacer from Inlet Manifold On the models 6760 6761 6767 remove one Spacer w Coil Spring one Male Adapter two V Packings and one Female Adapter from each seal chamber Place Inlet Manifold on the work surface crankcase side up Using a screwdriver remove LPS from each seal cham ber CAUTION Exercise caution as the screwdriver may damage sealing surface On the model 6747 place the Inlet Manifold on blocks with crankcase side down using a screwdriver tap on op posite sides of the LPS Adapter to drive out LPS Adapter and Lo Pressure Seal from each chamber Remove Lo Pressure Seals from backside of LPS Adapter CAUTION Exercise caution as the screwdrivers may damage sealing surface On the models 676
25. ty relief device i e pop off valve safety valve The primary pressure device must be installed on the discharge side of the pump The function of the primary pressure regulating device is to protect the pump from over pressurization which can be caused by a plugged or closed off discharge line Over pressurization can severely damage the pump other system components and can cause bodily harm The secondary safety relief device must be installed between the primary device and pump This will ensure pressure relief of the system if the primary regulating device fails Failure to install such a safely device will void the warranty on the pump If a large portion of the pumped liquid is by passed not used when the high pressure system is running this by pass liquid should be routed to an adequately sized baffled supply tank or to drain If routed to the pump inlet the by pass liquid can quickly develop excessive heat and result in damage to the pump A tem perature control device to shut the system down within the pump limits or multiple THERMO VALVES must be installed in the by pass line to protect the pump NOZZLES A worn nozzle will result in loss of pressure Do not adjust pressure regulating device to compensate Replace nozzle and reset regulating device to system pressure PUMPED LIQUIDS Some liquids may require a flush between operations or before storing For pumping liquids other than water contact your CAT PUMP S supplier
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