Pump service manual - Fluid Systems Incorporated
Contents
1. International Inquiries a FAX 763 785 4329 e mail intisales catpumps com L The Pumps with Nine Lives CAT PUMPS U K LTD 1 Fleet Business Park Sandy Lane Church Crookham FLEET Hampshire GU52 8BF England Phone Fleet 44 1252 622031 Fax 44 1252 626655 e mail sales catpumps co uk N V CAT PUMPS INTERNATIONAL S A Heiveldekens 6A B 2550 Kontich Belgium Phone 32 3 450 71 50 Fax 32 3 450 71 51 e mail coi catpumps be www catpumps be CAT PUMPS DEUTSCHLAND GmbH Buchwiese 2 D 65510 Idstein Germany Phone 49 6126 9303 0 Fax 49 6126 9303 33 _I e mail catpbumps t online de www catpumps de PN 30263 Rev C 11709 All 1DX MIST 2DX 2DX MIST and 3DX Models Discharge and Inlet Valve Assembly Stacked Valve design 3SP30G1I 3SP35GEI 3SPX30G1I 3SPX35GEl Discharge and Inlet Valve Assembly Stacked Valve design CAUTION Before commencing with service shut off drive electric motor gas or diesel engine and turn off water supply to pump Relieve all dis charge line pressure by triggering gun or opening valve in discharge line After servicing is completed turn on water supply to pump start drive reset pressure regulating device and secondary valve read system pressure on the gauge at the pump head Check for any leaks vibration or pressure fluctuations and resume operation Inspect and service all system accessories on the same schedule as your pump SERVICING THE VALVES Disassembly Reassembly NO2. SERVICING THE SEALS Disassembly NOTE All pump models require one 1 seal kit to repair pump Models 2DX 2DX MIST 3DX 3DNX 3SP and 3SPX contain 3 high pressure seals 3 low pressure seals 3 seal washers and 3 o rings Whereas model 1DXO3ELS MIST contains 2 high pressure seals 2 low pressure seals 2 seal washers and 2 o rings The model 1DX015ELS MIST contains 1 high pressure seal 1 low pressure seal 1 seal washer and 1 o ring Using an M5 allen wrench remove the hex socket head HSH screws from the face of the manifold head Insert flat head screwdrivers on each side between the crankcase and manifold head Gently apply pressure to the head to begin separation Support the manifold head from the underside and pull the manifold head away from the crankcase CAUTION Keep the manifold head properly aligned with the ceramic plungers when removing to avoid damage to the plungers NOTE The seal case may stay in the manifold or on the ceramic plungers Place manifold head on work surface with crankcase side up Remove seal retainer from each plunger rod Use a screwdriver to pry out the Lo Pressure seal from each seal case CAUTION Screwdriver may damage seal during removal Use reverse pliers to remove seal case from each seal chamber NOTE Insert the reverse pliers into the second lip to avoid damage to the seal case Carefully insert a small screwdriver under the o ring and roll th
3. Worn nozzle eAir 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 Packing Hi Pressure or Lo Pressure Seals Worn adapter o rings Excessive wear to seals Inadequate inlet liquid supply Broken or worn bearing 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 bearing cover or worn bearing cover o ring Loose filler cap or excessive oil in crankcase Restricted inlet or air entering the inlet plumbing Stuck inlet discharge valves eLeaking V Packing Hi Pressure 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 eRunning pump dry Starving pump of adequate liquid Eroded manifold SOLUTION Replace with properly sized nozzle Tighten fittings and hoses Use PTFE liquid or tape Check with new gauge Replac
4. 320 410 600 370 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 1 4 12 1 4 3 8 1 2 5 8 3 4 7 8 8 5 1 9 120 13 2 9 1 0 30 7 0 2 1 400 45 10 34 1 3 60 14 4 5 1 1 94 20 6 7 2 6 150 36 12 2 8 330 86 28 6 7 1 9 520 130 43 10 3 0 270 90 21 6 2 1 6 190 16 5 0 1 5 670 240 56 16 4 2 40 12 3 8 1 7 66 17 8 39 5 0 37 52 210 107 230 50 17 6 1 500 120 40 15 180 56 22 120 44 330 110 550 200 Nominal Equivalent Length of Standard Pipe in Feet Pipe i 180 Tee Tee Size i Gate Globe Angle 45 90 Close Thru Thru Inches Valve Valve Valve Elbow Elbow Ret Run Branch 1 2 E 3 33 3 4 4 44 1 5 62 1 4 7 40 1 2 8 63 1 35 61 5 30 8 2 59 5 55 12 30 3 08 11 60 1 62 73 5 36 8 3 09 6 61 14 70 3 68 13 20 2 01 91 5 45 8 3 84 8 23 18 20 4 57 16 40 2 64 120 01 60 0 5 03 I 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 fitt
5. or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load Select the horsepower requirement according to required pump discharge flow and maxi mum pressure at the pump Consult the manufacturer of gas or diesel engine for proper selection MOUNTING 1DX 2DX 3DX 3DNX 3SP and 3SPX models are direct drive The 1DX MIST and 2DX MIST electric models can be mounted directly to a C Face motor the 3SP35GEI and 3SPX35GEI models come with an adapter plate to mount to a C Face motor The gas model comes with an adapter plate that mounts to a gas engine Before mounting pump to electric motor or gas engine apply PN 6106 antiseize lubricant to pump shaft Refer to Technical Bulletin 055 for instructions on removing pump from electric motor or gas engine To minimize piping stress use appropriate flexible hose to inlet and discharge ports LOCATION If the pump is used in extremely dirty or humid conditions it is recommended pump be enclosed Do not store or operate in excessively high temperature areas or enclosed without proper ventilation 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 See Tech Bulletin 002 or call CAT PUMPS for recommendations INLET CONDITIONS Refer to complete Inlet Condition Check List in this manual before starting system DO NOT STARVE THE PUMP OR RUN DRY DISCHARGE CONDITIONS OP
6. 1DX 2DX 3DX 3DNX 3SP 3SPX PLUNGER PUMP SERVICE MANUAL 1DX MODELS 2DX MODELS 1DX015ELS MIST 1DX03ELS MIST 2DX20ES 2DX27GS 2DX30GS 2DX05ELS MIST 2DX15ES MIST 2DX20ES MIST 2DX27ES MIST 2DX30ES MIST UNA 3DX MODELS 3DX25GSI 3DX27GSI 3DX29GSI 3DX30GSI 3DNX MODELS 3DNX25GSI 3DNX27GSI 3SP MODELS 3SP30G1I 3SP35GEl 3SPX MODELS 3SPX30G1I 3SPX35GEl 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 simultaneously If more than one maximum is considered check with your CAT PUMPS supplier to confirm the proper performance and pump selection Refer to individual Data Sheets for complete specifications parts list and exploded view LUBRICATION Fill crankcase with special CAT PUMP Hydraulic oil per pump specifications 1DX 2DX 3DX 3DNX 8 5 oz 3SP 3SPX 10 15 oz DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE Change initial fill after 50 hours running period Thereafter change oil every 3 months or 500 hour intervals DRIVE SELECTION The pump shaft size is 5 8 hollow shaft on ES and ELS models 3 4 hollow shaft on GEI and GS models 1 hollow shaft on G1l models The motor
7. EN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system Areliable Pressure 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 pressure that is 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 safety 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 pressur ization can severely damage the pump other system components and can cause bodily harm The secondary safety relief device must be installed in line between the primary device and pump or on the opposite side of the manifold head This will ens
8. TE All pump models require one 1 stacked valve kit to repair pump Models 2DX 2DX MIST 3DX 3DNX iv Examine spring retainers for internal wear or breaks in the structure and replace as needed 3SP and 3SPX contain three complete valve assemblies 2 Examine springs for fatigue or breaks and replace as needed inlet and discharge Whereas model 1DXO3ELS MIST 3 E d ts f itti d contains two complete valve assemblies and model i a xa pear SCAS 10L JrOOVES PING OL WEAN aN 1DX015ELS MIST contains one complete valve assembly TE sace NOTE Discharge and inlet valve assemblies may stay 4 sel seat oe plug o rings for cuts or wear and together or separate during removal Dae dS MEEUGG NOTE Spring retainer may also separate from the seat NOTE Inlet valve seat and o ring are different from dis during removal ste valve seat and o ring One valve kit required per Nox tool fo remove valve plugs on top of manifold gt 5 Models 1DX MIST 2DX 2DX MIST and 3DX Lubricate l and install new o ring onto large outside diameter of dis Models 3DNX 3SP and 3SPX Use a M24 Hex tool to charge seat pemove VANE P UOS ontop OMANO Models 3DNX 3SP and 3SPX Lubricate and install back Use a reverse pliers to remove stacked valve assemblies up ring and then o ring onto large outside diameter of dis from the valve chamber charge seat If the discharge valve assembly separates from the inlet 6 Place seat on work surface with small diameter side
9. 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 facts or contact CAT PUMPS directly PROBLEM Low pressure Pulsation Water leak Under the manifold Into the crankcase Knocking noise Inlet supply Bearing Oil leak Crankcase oil seals Crankshaft oil seals and o rings Drain plug Bubble gauge Bearing cover Filler cap Pump runs extremely rough Inlet conditions Pump valves Pump seals Premature seal failure PROBABLE CAUSE
10. allow liquid to pass through pump and measure flow INLET ACCESSORIES are designed to protect against over pressuriza tion control inlet flow contamination or temperature and provide ease of servicing T A shut off valve is recommended to facilitate maintenance L1 A stand pipe can be used in some applications to help maintain a positive head at the pump inlet line LI Inspect and clean inlet filters on a regular schedule to avoid flow restriction Ll A pressure transducer is necessary to accurately read inlet pressure Short term intermittent cavitation will not register on a standard gauge LI All accessories should be sized to avoid restricting the inlet flow LI All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction BY PASS TO INLET Care should be exercised when deciding the method of by pass from control valves T The 2DX 3DX 3DNX and 3SPX pumps come with a Integral Unloader with built in by pass to route by pass liquid back to the pump inlet The 3SP pumps come with a Regulating Unloader and reinforced flexible hose rated up to 300 PSI No additional by pass hose is required The 1DX MIST and 2DX MIST pumps come with a Integral Regulator HOSE FRICTION LOSS PRESSURE DROP IN PSI PER 100 FT OF HOSE A WITH TYPICAL WATER FLOW RATES Water Hose Inside Diameters Inches camin 14 one se 12 se 3a 1 16 5 2 54 20 180 60 380 120 220
11. any signs of leaking at bearing cover drain plug or bubble gauge Check oil level and for evidence of water in oil Change crankcase oil on a regular schedule See PREVENTATIVE MAINTENANCE CHECK LIST Rotate crankshaft by hand to feel for smooth bearing movement Examine crankshaft oil seal externally for drying cracking or leaking Contact CAT PUMPS or local distributor if crankcase service is required SERVICING THE UNLOADER AND REGULATOR 1DX015ELS MIST 1DXO3ELS MIST Integral Regulator 2DX 3DX 3DNX 3SPX Integral Unloader 2DX MIST Integral Regulator 3SP 7700 Modular Unloader refer to individual data sheet Disassembly Reassembly NOTE On models 3SP30G1I 3SP35G1I 3SPX30G1I and 3SPX35GEI remove black adjusting handle 1 If seat is worn or damaged press new seat into unloader chamber until squarely seated Remove brass adjusting cap by turning in a counterclock 2 Examine piston stem washer valve retainer and valve for wise direction grooves pitting or wear and replace as needed Examine l o rings and back up ring for cuts or wear and replace as Remove exposed coil spring and flat spring retainer naeded U ee sa ie ree piston retainer by turning 3 Lubricate and install o ring over slotted head of piston nee er re nee nyse ETE stem then position back up ring on top of o ring NOTE The piston stem and valve assembly may fall out 4 Lubricate and install o rings on valve retainer when the pist
12. ar 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 e Keep elbows to a minimum and less than 90 Inlet Plumbing Excessive liquid Temperature e Use Thermo Valve in bypass line 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 Air Leaks in Plumbing eCheck all connections e Use PTFE thread tape or pipe thread sealant Agitation in Supply e Size tank according to pump output Tank Minimum 6 10 times system GPM e Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids e Verify viscosity 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 Clogged Filters DIAGNOSIS AND MAINTENANCE One of the most important steps in
13. ceramic plunger and seal washer from each plunger retainer Model 3SP Remove the ceramic plunger and copper retainer gasket from each plunger retainer NOTE Copper plunger retainer gasket has been replaced by NBR seal washer Reassembly if Visually inspect the crankcase oil seals for deterioration or leaks Contact CAT PUMPS for assistance with replace ment See SERVICING THE CRANKCASE Examine seal washers and replace if cut or worn Examine plunger retainers for damaged threads and replace as needed Install new seal washer onto each plunger retainer Examine the ceramic plungers for scoring scale buildup chips or cracks and replace as needed The ceramic plungers do not need to be replaced with every seal servicing Slide plunger retainer with seal washer into flat end of ceramic plunger Apply Loctite 242 to exposed threaded end of plunger retainer Install ceramic plunger with plunger retainer and seal washer over each plunger rod shoulder and thread hand tight Torque to specifications per chart NOTE Ceramic Plungers can only be installed in one direction Counterbore end of ceramic plunger fits over lunger rod shoulder See SERVICING THE SEALS Reassembly steps 10 13 3SP30G1I1 3SP35GEl Plunger Arrangement TORQUE SEQUENCE ney 3 5 tet a ter 8 SERVICING THE CRANKCASE a While manifold plungers and retainers are removed examine crankcase oil seals for leaking and wear Check for
14. e o ring off each seal case CAUTION Exercise caution as the screwdriver may score o ring sealing surface Models 1DX MIST 2DX 2DX MIST and 3DX The Hi Pressure seals can be easily removed from each seal chamber by hand or with reverse pliers Models 3DNX 3SP and 3SPX Remove V Packing and male adapter from each seal chamber by hand or with a reverse pliers 3SP30G1I 3SP35GEI 3SPX30G1I 3SPX35G1I Lo Pressure Seal V Packing Male Adapter and Seal Case Reassembly 1 10 11 12 13 Examine the manifold chamber walls for scale buildup or damage Examine Hi Pressure seals or V Packings for frayed edges or uneven wear and replace as needed Examine seal case o rings for cuts or deterioration and replace as needed Examine Lo Pressure seals for wear to the internal ridges outer surfaces for broken springs and replace as needed NOTE Seals and o rings are available in seal kits Examine seal retainers for deformation and replace as needed Models 1DX MIST 2DX 2DX MIST and 3DX Lubricate and install new Hi Pressure seal by hand into each seal chamber with the grooved side down Models 3DNX 3SP and 3SPxX Install male adapter with notch side down Lubricate and install new V Packing by hand into seal chamber with grooved side down Lubricate and install o ring on each seal case Press small end of seal case into each seal chamber Press new Lo Pressure seal into each seal case with the garter s
15. e 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 eInstall new seal kit Increase frequency of service Clean inlet discharge valves or install new valve kit Check precharge If low recharge or install a new dampener Clean inlet discharge valves or install new valve kit eInstall new seal kit Increase frequency of service Install new o rings eInstall new seal kit Increase frequency of service Check liquid supply Increase line size pressurize or install C A T Replace bearing Replace crankcase oil seals Remove bearing cover and replace o rings and or oil seals Tighten drain plug or replace o ring Tighten bubble gauge or replace gasket Tighten bearing 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 eInstall new seal kit Increase frequency of service Replace plungers Reduce inlet pressure per specifications eInstall proper filtration at pump inlet and clean regularly Check pressure and inlet liquid temperature DO NOT RUN PUMP WITHOUT LIQUID Increase hose one size larger than inlet p
16. f 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 J 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 LI The line MUST be a FLEXIBLE hose NOT a rigid pipe and reinforced on SUCTION systems to avoid collapsing I The simpler the inlet plumbing the less the potential for problems Keep the length to a minimum the number of elbows and joints to a minimum ideally no elbows and the inlet accessories to a minimum LI Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of the pump Ll Acceleration loss of liquids may be increased by high RPM high temperatures low vapor pressures or high viscosity and may require a pressurized inlet to maintain adequate inlet supply LI Optimum pump performance is obtained with 20 PSI 1 4 BAR inlet pressure With adequate inlet plumbing most pumps will perform with flooded suction Maximum inlet pressure is 60 PSI 4 BAR Ll After prolonged storage pump should be rotated by hand and purged of air to facilitate priming Disconnect the discharge port and
17. ings 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 Supply Line Bypass Line from regulator or unloader Level Sensing Pia Ol pipe Device Flexible Hose to Pump Y f Y liquid Ko YO Bypass Line pe bese ok ce amp A bevel from regulator or RILTER Sig Ye Sake aha eR ee Nk aa ce ek N ne a unloader 2 8 a o Za 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 I have to run my pump at a certain RPM How do figure the GPM FII 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 Horsepower Required 1460 Standard 85 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 los 3 6 Consult A Pump Pulley Outer Diameter x Engine Mfr eem x PSI 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 we
18. m Gas Engine or Electric Motor 1DX 2SF 2SFX 2X 2DX 3DX 3DNX 3SP 3SPX 4SF 4HP 5DX 6DX 66DX Torque Chart Piston and Plunger Pumps Winterizing a Pump All Models Ceramic Plunger 2DX Modular Unloader Valve and Seat 2DX and 3DX 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 con sidered INLET SUPPLY should exceed the maximum flow being delivered by the pump to assure proper performance LJ Open inlet shut off valve and turn on water supply to avoid starving the pump DO NOT RUN PUMP DRY 11 Temperatures above 130 are permissible Add 1 2 PSI inlet pressure per each degree F over 130 F Elastomer or RPM changes may be required See Tech Bulletin 002 or call CAT PUMPS for recommendations Ll Avoid closed loop systems especially with high temperature or ultra high pressure Conditions vary with regulating unloader valve LI Higher temperature liquids tend to vaporize and require positive heads 1 When using an inlet supply reservoir size it to provide adequate liquid to accommodate the maximum output of the pump generally a minimum o
19. on retainer is removed If so proceed to step 6 if not continue with step 4 si Install washer and then valve retainer with o rings onto piston stem Apply Loctite 242 to threads of piston Use a needle nose pliers to remove piston stem and valve stem and screw valve onto piston stem assembly i 6 Lower complete piston stem and valve assembly into Separate piston stem from valve Secure the valve near unloader chamber with valve facing downward the valve retainer Insert a screwdriver into slotted head of piston stem and unthread from valve 7 ae eee for apna ea or wear sie replace as needed Examine o ring for cuts or wear an CAUTION Exercise extreme caution to avoid contact and Prices ds reeded g damage to the tapered surface of valve i E a ebat fth bader chamberi 8 Apply Loctite 242 to threads and then hand thread piston KATSE A E SOT OTE U A cae E ANORA retainer into unloader by turning in a clockwise direction grooves pitting or wear replace only as needed and then tighten with wrench CAUTION Seat will be damaged when removed 9 Examine spring retainer and coil spring for fatigue or breaks and replace as needed 10 Place spring retainer into piston retainer followed by coil 11 spring Thread brass adjusting cap onto piston retainer by turning in a clockwise direction Loctite and 242 are registered trademarks of Henkel Corporation PREVENTATIVE MAINTENANCE CHECK LIST Check Clean Filters Oil Level Q
20. ort size Pressurize and install C A T Replace manifold Check liquid compatibility
21. pring down Examine ceramic plunger for cracks or scale buildup and proceed to SERVICING THE PLUNGERS if worn Models 1DX MIST 2DX 2DX MIST and 3DxX Slide seal retainer over each ceramic plunger with the drain slots fac ing the crankcase and the openings to the top and bottom Press into the crankcase Models 3DNX 3SP and 3SPX Slide seal retainer over each ceramic plunger with the tabs facing out Press into the crankcase Rotate crankshaft by hand so the two outside plungers are extended equally Lightly lubricate ceramic plungers then carefully slide the manifold head over the ceramic plungers supporting it from the underside to avoid damage to the plungers or seals Press the manifold head up to the crankcase until flush Thread HSH screws in hand tight Torque in sequence to specifications in torque chart All 1DX MIST 2DX 2DX MIST 3DX 3DNX and 3SPX Models Plunger Arrangement SERVICING THE PLUNGERS Disassembly if To service the ceramic plungers it is necessary to remove the manifold head See SERVICING THE SEALS Disassembly steps 1 3 Remove seal retainer from each plunger rod Using a M10 Hex tool loosen the plunger retainer on each plunger rod approximately three to four turns Push the ceramic plunger back towards the crankcase to separate from the plunger retainer and proceed with unthreading the plunger retainer by hand Models 1DX MIST 2DX 2DX MIST 3DX 3DNX and 3SPX Remove the
22. uality Oil Leaks Water Leaks Plumbing Initial Oil Change Oil Change Seal Change Valve Change Accessories If other than CAT PUMPS special custom blend multi viscosity ISO68 hydraulic oil is used change cycle should be every 300 hours Each system s maintenance cycle will be exclusive If system performance decreases check immediately If no wear at 1000 hours check again at 1500 hours and each 500 hours until wear is observed 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 TORQUE CHART Torque Pump Item Thread Tool Size P N in lbs ft Ibs Nm Plunger Retainer M6 M10 Hex 25082 55 46 6 2 Manifold Head Screws M6 M5 Allen 55 46 6 2 Valve Plugs 1DX MIST 2DX 2DX MIST M20 M19 Hex 520 43 58 3DX 3DNX 3SP 3SPX M22 M24 Hex 44046 870 72 5 98 Bearing Cover Screws M6 Bubble Oil Gauge M10 Hex 25082 50 40 5 4 M28 Oil Gauge Tool 44050 45 36 5 TECHNICAL BULLETIN REFERENCE CHART No Subject Models 002 Inlet Pressure VS Liquid Temperature All Models 024 Lubrication of Lo Pressure Seals All Models 036 Cylinder and Plunger Reference Chart All Models 043 LPS and HPS Servicing All Plunger Models 055 Removing Pumps fro
23. up valve assembly use a reverse pliers to remove it from the 7 Pl t with ide d walve chamber ace valve onto seat with concave side down CAUTION Exercise caution as the reverse pliers may amp Place spring on valve damage the threads in valve chamber or spring retainer 9 Install spring retainer with deep stepped end over spring Models 1DX MIST 2DX 2DX MIST and 3DX The spring ang enepoMmosedt retainer may separate from the seat Remove the spring NOTE Repeat steps 6 9 for inlet valve assembly and valve from the valve chamber Thread an M8 screw 410 Snap discharge valve assembly onto the inlet valve into the seat and remove from valve chamber assembly and press into valve chamber until completely Models 1DX MIST 2DX 2DX MIST and 3DX Separate seated valve assembly by using the same M8 screw and thread 41 Lubricate and install new o ring onto each valve plug into bottom of seat until screw contacts bottom of valve l Continue threading in screw until spring retainer separates 12 Apply Loctite 242 to threads of each valve plug and from seat Models 3DNX 3SP and 3SPX Separate valve assembly by inserting screwdriver into spring retainer and press the backside of valve until seat separates from the spring retainer Remove o ring from each seat and valve plug thread in hand tight Torque to specifications per chart All 1DX MIST 2DX 2DX MIST and 3DX Models Lo Pressure and Hi Pressure Seals with Seal Case
24. ure 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 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 PUMPS supplier 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 Z 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 PUMPS does not assume any liability or responsibility for the operation of a customer s high pressure system Products described hereon are covered by one or more of the following U S patents 3558244 3652188 3809508 3920356 3930756 and 5035580 World Headquarters CAT PUMPS 1681 94th Lane N E Minneapolis MN 55449 4324 Phone 763 780 5440 FAX 763 780 2958 e mail techsupport catpumps com www catpbumps com
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