SF PLUNGER PUMP SERVICE MANUAL
Contents
1. Oil Leaks x Water Leaks x Belts Pulley x Plumbing x Initial Oil Change x Oil Change x Seal Change x Valve Change x Accessories x 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 performance decreases check immediately If no wear at 1500 hours check again at 2000 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 Refer to video for additional assistance Q How can I find the RPM needed to get specific GPM Gallons Per Minute I want Rated RPM A Desired RPM Desired GPM x Rated GPM Q I have to run my pump at a certain RPM How do I figure the GPM I ll get Rated GPM A Desired GPM Desired RPM x Rated RPM Q Is there a simple way to find the approximate horsepower I ll need to run the pump A Electric Brake GPM x PSI Standard 85 Horsepower Required 1460 Mech Efficiency Q What size motor pulley should I use Pump RPM A Pump Pulley Outer Diameter x Motor Engine RPM Q How do I calculate the torque for my hydraulic drive2. Screw M6 M10 Hex Phil 50 4 0 6 25082 Inner Bearing Case Screw M6 M10 Hex Phil 50 4 0 6 25082 Manifold Screw M8 M6 Allen 115 9 4 13 30941 Plunger Rod Nut M6 M10 Hex 55 4 4 6 25082 Bubble Oil Gauge M28 Oil Gauge Tool 45 3 6 5 44050 Mounting 2SF Adapter Plate to Gas Engine 5 16 24 1 2 Hex 90 7 2 10 Pump to Adapter Plate 3 8 16 9 16 Hex 110 9 0 12 Pump to Electric Motor 3 8 16 9 16 Hex 110 9 0 12 Mounting 4SF Adapter Plate to Gas Engine 3 8 16 9 16 Hex 110 9 0 12 Pump to Adapter Plate 1 2 13 3 4 Hex 150 12 5 17 Pump to Electric Motor 1 2 13 3 4 Hex 150 12 5 17 TECHNICAL BULLETIN REFERENCE CHART No Subject Models 002 Inlet Pressure VS Liquid Temperature All Models 024 Lubrication of Lo Pressure Seals All Models 043 LPS and HPS Servicing All Plunger Models 055 Removing Pumps from Gas Engine or Electric Motor 2SF 2SFX 2DX 4SF 5DX 6DX 057 Set Screw and Hardened Key 4SF 064 By Pass Hose Sizing All Unloaders Regulators 065 Higher Performance Ratings 2SF and 4SF 070 Maximum Performance 2SF and 4SF 073 Hi Temp HPS 3PFR 5PFR 2SF 074 Torque Chart Piston and Plunger Pumps 075 Sleeved Plunger Rod 4SF S 083 Winterizing a Pump All Models 091 2SF Inlet Valve 2SF Models 092 Crankcase Changes All 2SF 2SFX INLET CONDITION CHECK LIST Review Before Start Up Inadequate inlet conditions can cause serious malfunction
3. can also review our FAQ or SERVICE sections on our WEB SITE for more facts or contact CAT PUMPS directly PROBLEM PROBABLE CAUSE SOLUTION Low pressure Worn nozzle Replace with properly sized nozzle Belt slippage Tighten belt s or install new belt s Air leak in inlet plumbing Tighten fittings and hoses Use PTFE liquid or tape Pressure gauge inoperative or not registering accurately Check with new gauge Replace worn or damaged gauge Relief valve stuck partially plugged or improperly adjusted Clean adjust relief valve Replace worn seats valves and o rings Inlet suction strainer filter clogged or improperly sized Clean filter Use adequate size filter Check more frequently Abrasives in pumped liquid Install proper filter Leaky discharge hose Replace discharge hose with proper rating for system Inadequate liquid supply Pressurize inlet and install C A T Severe cavitation Check inlet conditions Worn seals Install new seal kit Increase frequency of service Worn or dirty inlet discharge valves Clean inlet discharge valves or install new valve kit Pulsation Faulty Pulsation Dampener Check precharge If low recharge or install a new dampener Foreign material trapped in inlet discharge valves Clean inlet discharge valves or install new valve kit Water leak Under the manifold Worn V Packings Hi Pressure or Lo Pres
4. size plumbing Check for air tight seal Pump valves Stuck inlet discharge valves Clean out foreign material or install new valve kit Pump seals Leaking V Packings Hi Pressure or Lo Pressure seals Install new seal kit Increase frequency of service Premature seal failure Scored plungers Replace plungers Over pressure to inlet manifold Reduce inlet pressure per specifications Abrasive material in the liquid being pumped Install proper filtration at pump inlet and clean regularly Excessive pressure and or temperature of pumped liquid Check pressure and inlet liquid temperature Running pump dry DO NOT RUN PUMP WITHOUT LIQUID Starving pump of adequate liquid Increase hose one size larger than inlet port size Pressurize and install C A T Eroded manifold Replace manifold Check liquid compatibility
5. system GPM x PSI A Torque ft lbs 3 6 RPM 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 G Increase line size to the inlet port or one size line size larger Water hammering G Install C A T Tube liquid acceleration G Move pump closer to liquid supply deacceleration Rigid Inlet Plumbing G Use flexible wire reinforced hose to absorb pulsation and pressure spikes Excessive Elbows in G Keep elbows to a minimum and less than 90 Inlet Plumbing Excessive Liquid G Use Thermo Valve in bypass line Temperature G Do not exceed pump temperature specifications G Substitute closed loop with baffled holding tank G Adequately size tank for frequent or high volume bypass G Pressure feed high temperature liquids G Properly ventilate cabinets and rooms Air Leaks in Plumbing G Check all connections G Use PTFE thread tape or pipe thread sealant Agitation in Supply G Size tank according to pump output Tank Minimum 6 10 times system GPM G Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids G Verify viscosity against pump specifications before operation G Elevate liquid temperature enough to reduce viscosity G Lower RPM of pump G Pressure feed pump G Increase inlet line size Clogged Filters G Perform re
6. 2 220 62 21 5 2 1 6 320 90 30 7 8 2 4 190 62 16 5 0 1 5 470 150 40 12 3 8 1 7 39 11 5 0 23 11 40 19 61 28 Copper Tubing O D Type L 1 4 3 8 1 2 5 8 3 4 7 8 120 13 2 9 1 0 400 45 10 3 4 1 3 94 20 6 7 2 6 230 50 17 6 1 3 0 500 120 40 15 6 5 180 56 22 10 120 44 20 330 110 50 550 200 88 WATER LINE PRESSURE LOSS PRESSURE DROP IN PSI PER 100 FEET 1 2 0 622 0 41 18 5 9 3 0 78 1 67 3 71 0 93 3 33 3 4 0 824 0 54 24 5 12 3 1 03 2 21 4 90 1 23 4 41 1 1 049 0 69 31 2 15 6 1 31 2 81 6 25 1 56 5 62 11 4 1 380 0 90 41 0 20 5 1 73 3 70 8 22 2 06 7 40 11 2 1 610 1 05 48 0 24 0 2 15 4 31 9 59 2 40 8 63 2 2 067 1 35 61 5 30 8 2 59 5 55 12 30 3 08 11 60 21 2 2 469 1 62 73 5 36 8 3 09 6 61 14 70 3 68 13 20 3 3 068 2 01 91 5 45 8 3 84 8 23 18 20 4 57 16 40 4 4 026 2 64 120 0 60 0 5 03 10 80 23 90 6 00 21 60 Nominal Pipe Size Inches Inside Diameter Inches RESISTANCE OF VALVES AND FITTINGS Gate Valve Globe Valve Angle Valve 45 Elbow 90 Elbow 180 Close Ret Tee Thru Run 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 leng
7. Avoid thick walled fittings tees 90 degree elbows or valves in the inlet line of the pump to reduce the risk of flow restriction and cavitation 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 number of elbows and joints to a minimum ideally no elbows and the inlet accessories to a minimum Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of the pump 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 75 PSI 5 25 BAR After prolonged storage pump should be purged of air to facilitate priming Disconnect any discharge port and allow liquid to pass through pump INLET ACCESSORIES are designed to protect against over pressuriza tion control inlet flow contamination or temperature and provide ease of servicing A shut off valve is recommended to facilitate maintenance A stand pipe can be used in some applications to help maintain a positive head in the inlet line Inspect and clean inlet filters on a regular schedule A pressure gauge is recommended to monitor the inlet pressure and should be mounted AS CLOSE TO THE PUMP INLET as possible Short term in
8. SF PLUNGER PUMP SERVICE MANUAL 2SF 2SFX CEE SEEL MODELS 4SF MODELS S L E 0 5 F S 4 S L E 5 4 F S 4 S L E 0 4 F S 4 S L E 2 3 F S 4 2 2 F S 2 0 2 F S 2 0 1 F S 2 2SF25 2SF29 2SF30 2SF35 4SF30GS1 4SF35GS1 4SF40GS1 4SF45GS1 2SF05 10 15 25 29 35SEEL 4SF45GS118 4SF50GS1 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 pump Data Sheet for complete specifications parts list and exploded view LUBRICATION Fill crankcase with special CAT PUMP oil per pump specifications 2SF 2SFX prior 3 03 11 83 oz after 3 03 10 15 oz 4SF 23 66 oz DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE Change initial fill after 50 hours run ning period Thereafter change oil every 3 months or 500 hour intervals MOTOR SELECTION Identify the pump shaft size 2SF ES and ELS models have 5 8 electric shaft GES models have 3 4 electric shaft GS and GZ models have 3 4 gas shaft 4SF ELS models have 1 1 8 electric shaft GS models have a 1 gas shaft 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 Horse
9. ds and press into Inlet Manifold 9 Replace Socket Head Screws and torque per chart Use torque sequence chart 10 If oil was not changed be certain oil is to mark on Oil Gauge before resuming operation Removal of Inlet Manifold Removal of Lo Pressure Seal Plunger Seals and V Packing Arrangement Installation of Lo Pressure Seals V Packing Positioning Installation of V Packings 2SF 4SF SERVICING THE SEALS Disassembly of the Seal Assembly 1 Remove the Inlet Valve Assembly from the exposed plunger rod ends including Cotterpin Nut Washer Spring Spacer and Inlet Valve 2 Grasp the Inlet Manifold from the front and underside and pull to remove from Plunger Rods 3 Carefully examine back side of Lo Pressure Seal before removing from the Inlet Manifold as it will be damaged during removal If worn insert screwdriver into I D of seal and pry out from the backside of the I M Exercise caution to avoid damage to the Inlet Manifold 4 Press ceramic Plunger with thumb or soft tool from back side of Inlet Manifold On the Model 2SF the Hi Pressure Seal may stay with the plungers or remain in the Inlet Manifold If on the plungers slide off by hand If in the manifold use a re verse pliers to remove On the Model 4SF the V Packing and Female Adapters may stay with the plungers or remain in Inlet Manifold If on the plungers slide off by hand If in the manifold use a reverse pliers to remove 5 Remov
10. e Seal Retainers from Crankcase by grasping tab with pliers and pulling out 6 Examine Crankcase Oil Seal to determine if Crankcase servicing is needed 7 Examine Ceramic Plunger Lo Pressure Seals V Packings for scoring cracks and wear and replace NOTE The S versions of the 4SF pumps have a replaceable Sleeve 8 Examine the Sleeve for grooves for scale buildup and replace as needed Grasp the Sleeve by hand and pull from the Plunger Rod 9 Examine the O Ring and Back up Ring under the Sleeve for cuts or wear and replace 10 Examine the Barrier Slinger for wear and replace as needed Install the Barrier Slinger with the concave side facing away from the Crankcase Reassembly of Seal Assembly 1 With Inlet and Discharge Manifold removed examine Seal Retainers and replace if worn or damaged Install on Plunger Rod and press into Crankcase with tab out 2 Place Inlet Manifold on work surface with Crankcase side up 3 Lubricate new Lo Pressure Seals and press into posi tion with garter spring down Be certain the seal is seated squarely on the shoulder in the inlet manifold chamber 4 Place Inlet Manifold on work surface with Crankcase side down larger I D ports up 5 On the Model 4SF place new Female Adapter into Inlet Manifold chamber with v groove facing up 6 Carefully examine the Plungers for scoring or cracks and replace if worn 7 On the Model 2SF lubricate Ceramic Plungers and n
11. ew Hi Pressure Seals Press the plunger into the seal and position seal in middle of plunger NOTE Place the deeper recessed end of the plunger into the seal from the metal back side NOTE The Hi Temp 2SF models use a special Hi Pressure Seal and Hi Temp Seal Kit On the Model 4SF lubricate Ceramic Plungers and new V Packings Press Plunger into the V Packings and position in the middle of plunger NOTE The deeper recessed end of the plunger should face the same direction as the v groove on the V Packing 8 On the Model 4SF lubricate the Plunger Rod O Ring to avoid cutting during installation Install the Back up Ring first then the O Ring into the groove on the Plunger Rod 9 Install the Sleeve with the tapered end facing out Gently press towards the Plunger Rod shoulder until flush with the Barrier Slinger 10 Carefully install Inlet Manifold over Plunger Rod ends and slowly press into Crankcase 11 Install the Plungers onto the plunger rods Press into position using the larger I D end of Valve Spacer 12 Examine Inlet Valve and replace if worn Inlet valves cannot be reversed if worn The S S Inlet Valves may be lapped if not badly worn Install the S S Inlet valves with square edges towards the plungers round edges towards the discharge Install the Nylon Inlet Valve with ridged side towards the discharge NOTE The Hi Temp 2SF models use a Nylon Inlet Valve order individual parts not standa
12. gular maintenance or use clean filters to monitor buildup G Use adequate mesh size for liquid and pump specifications Handy Formulas to Help You Consult Engine Mfr TYPICAL RESERVOIR TANK RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Avoid Cavitation Damage 1 4 5 16 3 8 1 2 5 8 3 4 1 0 5 16 5 2 1 54 20 7 2 2 180 60 25 6 2 3 380 120 50 13 4 2 4 220 90 24 7 3 5 320 130 34 10 4 6 220 52 16 7 1 8 300 80 25 10 2 10 450 120 38 14 3 15 900 250 80 30 7 20 1600 400 121 50 12 25 650 200 76 19 30 250 96 24 40 410 162 42 50 600 235 62 60 370 93 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 PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES Hose Inside Diameters Inches Water Flow Gal Min HOSE FRICTION LOSS Water GPM 1 2 3 5 8 10 15 25 40 60 80 100 Steel Pipe Nominal Dia 1 4 3 8 1 2 3 4 1 11 4 11 2 8 5 1 9 30 7 0 2 1 60 14 4 5 1 1 150 36 12 2 8 330 86 28 6 7 1 9 520 130 43 10 3 0 270 90 21 6 2 1 6 670 240 56 16 4 2 2 0 66 17 8 0 37 17 52 29 210 107 48 Brass Pipe Nominal Dia 1 4 3 8 1 2 3 4 1 11 4 11 2 6 0 1 6 20 5 6 1 8 40 11 3 6 100 28 9 0 2
13. his 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 When the high pressure system is left running with the trigger gun off the by pass liquid can be routed to drain or to the pump inlet If routed to the pump inlet the by pass liquid can quickly develop excessive heat and result in damage to the pump A THERMO VALVE installed in the by pass line is recommended to protect the pump An AUTO SHUT OFF ASSEMBLY may also be used 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 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 PN 30036 Rev K 4364 WARNING All systems require both a primary pressure regulating device i e regulator
14. power Requirement Chart according to required pump dis charge flow and maximum pressure at the pump Consult the manufacturer of gas or diesel engine for selection of the proper engine MOUNTING All 2SF and 4SF are direct drive and do not need to be mounted to another surface Only the solid shaft 2SF22SLS with attachment brackets needs to be mounted to a rigid horizontal surface An uneven mounting surface will cause extensive damage to the pump base Use the correct belt make sure pulleys are aligned Excessive belt tension may be harmful to the bearings To minimize piping stress use appropriate flexible hose to inlet and discharge ports Before mounting pump to motor or gas engine apply PN 6106 antiseize lubricant to pump shaft Refer to Tech Bulletin 055 for instructions on removing pump from gas engine or electric motor 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 See Tech Bulletin 002 or call CAT PUMPS for recommendations DISCHARGE CONDITIONS OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overp
15. rd Inlet Valve Kit 13 Examine Spacers for wear and replace as needed Install Spacer on each Plunger Rod with smaller O D towards inlet valve 14 Examine Springs for damage or fatigue and replace as needed Place on Plunger Rods 15 Install Washers next with concave side towards Inlet Manifold 16 Install Nuts and torque per chart 17 On 2SF and 4SF models always install new Cotterpins and turn ends to secure in position NOTE X and S S Models do not use Cotterpins 18 Refer to steps 7 10 under Servicing Valves Reassembly to replace the Discharge Manifold 2SF Torque Sequence 4SF Torque Sequence Torque diagonally in order shown The outer four 4 screws then center screws all hand tight Then repeat series to specifications in torque chart SERVICING THE CRANKCASE SECTION 1 While Inlet Manifold Plungers and Seal Retainers are removed examine Crankcase Seals for wear 2 Check oil level and for evidence of water in oil 3 Rotate Crankshaft by hand to feel for smooth bearing movement 4 Examine Crankshaft Oil Seal externally for drying cracking or leaking 5 Consult CAT PUMPS or your local distributor if Crankcase service is required See section VIII of the Plunger Pump Service Video for additional information 3 6 1 2 5 4 7 6 1 4 2 3 5 8 TORQUE CHART Pump Item Thread Tool Size Torque Part No in lbs ft lbs Nm Outer Bearing Case
16. ressure condition and severe damage to the pump or system A reliable 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 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 All 2SF and 4SF Pumps come complete with a Pressure Regulating Unloader NOTE Except CEE and SEEL Models 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 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 T
17. s 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 be adequate to accommodate the maximum flow being delivered by the pump Open inlet shut off valve and turn on water supply to avoid cavitating pump DO NOT RUN PUMP 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 re quired See Tech Bulletin 002 or call CAT PUMPS for recommendations Avoid closed loop systems without a Thermo Valve high temperature protection Avoid low vapor pressure and high viscosity liquids Higher temperature liquids tend to vaporize and require positive heads When using an inlet supply reservoir size it to provide adequate liquid to accommodate 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 Line size must be a minimum of one size larger than the pump inlet fit ting
18. sure Seals Install new seal kit Increase frequency of service Worn adapter spacer o rings Install new o rings Into the crankcase Humid air condensing into water inside the crankcase Install oil cap protector Change oil every 3 months or 500 hours Excessive wear to seals and V Packings Install new seal kit Increase frequency of service Knocking noise Inlet supply Inadequate inlet liquid supply Check liquid supply Increase line size pressurize or install C A T Bearing Broken or worn bearing Replace bearing Pulley Loose pulley on crankshaft Check key and tighten set screw Oil leak Crankcase oil seals Worn crankcase oil seals Replace crankcase oil seals Crankshaft oil seals and o rings Worn crankshaft oil seals or o rings on bearing cover Remove bearing cover and replace o rings and or oil seals Drain plug Loose drain plug or worn drain plug o ring Tighten drain plug or replace o ring Bubble gauge Loose bubble gauge or worn bubble gauge gasket Tighten bubble gauge or replace gasket Rear cover Loose rear cover or worn rear cover o ring Tighten rear cover or replace o ring Filler cap Loose filler cap or excessive oil in crankcase Tighten filler cap Fill crankcase to specified capacity Pump runs extremely rough Inlet conditions Restricted inlet or air entering the inlet plumbing Correct inlet
19. termittent cavitation will not register on a standard gauge 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 BY PASS TO INLET Care should be exercised when deciding the method of by pass from control valves 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 The 2SF and 4SF come standard with a Regulating Unloader to handle by pass liquid directed to the inlet line of the pump If other than standard valve is used exercise caution to use proper flexible hose and adequate diameter A PRESSURE REDUCING VALVE may be needed 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 may also be necessary to use a THERMO VALVE in the by pass line to monitor the temperature build up in the by pass loop to avoid premature seal failure A low pressure FLEXIBLE CLOTH BRAID not metal braid hose should be used from the by pass connection to the inlet of the pump If standard unloader valve is not used check the pressure in the by pass line to avoid over pressurizing the inlet PREVENTATIVE MAINTENANCE CHECK LIST Check Daily Weekly 50 hrs 500 hrs 1500 hrs 3000 hrs Clean Filters x Oil Level Quality x
20. th of line of each valve or fitting Tee Thru Branch Equivalent Length of Standard Pipe in Feet Bypass Line from regulator or unloader Level Sensing Device Bypass Line from regulator or unloader MIN 4 1 5 x D Min Minimum Two Baffles Sealed at Bottom Minimum Liquid Level FILTER MIN 4 Flexible Hose to Pump Supply Line Dia of pipe T X D 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
21. 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 The Pumps with Nine Lives Available from Allparts Equipment and Accessories 1 877 475 5660 www allpartsinc com SERVICING THE VALVES Disassembly of the Discharge Valve Assembly 1 Disconnect all plumbing and remove unloader for ease in servicing NOTE CEE and SEEL models do not come with standard unloader 2 Inspect oil for proper level presence of water or discol oration and replace as needed 3 Using a standard M6 allen wrench remove the six 6 2SF or eight 8 4SF Socket Head Screws from the manifold Remove the outer screws first then the cen ter screws 4 Using a soft mallet tap the back side of the Discharge Manifold from alternate sides to maintain alignment and avoid damage to the plungers 5 Grasp the Discharge Manifold from the from underside and gradually lift manifold while you pull away from the Crankcase 6 The Adapter Spacers may stay with either the Discharge or Inlet Manifold By inserting two opposing screwdrivers between Spacer and manifold you can easily pry them out of the Discharge Manifold If they stay in the Inlet Manifold gently work them up and do
22. wn as you pull away from the Inlet Manifold 7 The valve assemblies are in the Discharge Manifold ports and will fall out when manifold is turned over A complete valve assembly includes Retainer Spring Valve and Seat NOTE On X models the Adapter and Seat are one piece NOTE The GZ models use the standard SF Valve Kit Removal of Discharge Manifold Removal of Adapter from Discharge Manifold Removal of Adapter from Inlet Manifold Discharge Valve Assembly 4SF Adapter and Discharge Valve Assembly 2SF Inlet Valve Assembly Reassembly of the Discharge Valve Assembly 1 Examine Adapter Spacer O Rings and replace if worn Lubricate and install O Rings and Back up Rings on both front and rear of the Adapter Spacer 2 Examine the Valve Retainers for scale buildup or wear and install into each Discharge Manifold port with tab down into the manifold chamber 3 Replace worn or damaged Springs and place into Retainers 4 Examine Valve and Seats for pitting grooves or wear and replace as needed 5 Place Valves over Springs with concave side down 6 Place Valve Seats on Valves with concave side down NOTE On X Models the Adapter and Seat are one piece 7 Lubricate O D of Adapter Spacer and insert smaller I D into Discharge Manifold ports Snap into posi tion Exercise caution not to cut or pinch o rings 8 Carefully guide Discharge Manifold with Spacers over Plunger Rod en
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