5DX, 6DX, 66DX PLUNGER PUMP SERVICE MANUAL
Contents
1. NOTE The Seal Case may stay in the manifold or on the 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 will 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 the O Ring off each Seal Case CAUTION Exercise caution as the screwdriver may score O Ring sealing surface Remove V Packing and Male Adapter from each seal chamber by hand or with a reverse pliers V Packing and Lo Pressure Seal Components Reassembly of V Packings Reassembly 1 10 11 13 Examine the manifold chamber walls for scale buildup or damage Examine 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 and outer surfaces or 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 Lubricate and install Male Adapter with notch side down Lubricate and install new V Packing by hand into seal chamber with grooved side down Lubricate and inst2. sories 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 pressurization 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 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 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 opera tions 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 l
3. Remove brass Adjusting Cap by turning in a counter clockwise direction 3 Remove exposed Coil Spring and flat Spring Retainer 4 Using a wrench remove Piston Retainer by turning in a counterclockwise direction NOTE The Piston Stem and Valve Assembly may fall out when the piston retainer is removed If so proceed to step 7 If not continue with step 5 5 Use a needle nose pliers to remove Piston Stem and Valve Assembly 6 Separate Piston Stem from Valve Ball Assembly by securing the Valve Ball Assembly near the Spacer Insert a screwdriver into slotted head of Piston Stem and unthread from Valve Ball Assembly CAUTION Exercise extreme caution to avoid contact and damage to the tapered surface of Valve Ball Assembly 7 Examine Seat at the bottom of the unloader chamber for grooves pitting or wear replace only as needed CAUTION Seat will be damaged when removed 9 On the 5DX model remove Discharge Fitting with O Ring On the 6DX and 66DX models remove Chemical Injector with O Ring Remove Spring and Check Valve with O Ring Reassembly 10 11 12 13 14 15 16 NOTE All O Rings are available in an O Ring Kit Other components sold separately If seat is worn or damaged press new seat into unloader chamber until squarely seated Examine Piston Stem Washer Spacer and Valve Ball Assembly for grooves pitting or wear and replace as needed Examine O Rings and Back up Ring f
4. 870 72 5 98 Rear Cover Screws M10 Hex 25082 50 40 54 Bearing Cover Screws 5DX 6DX M13 Hex 25324 115 958 13 66DX M10 Hex 25082 50 40 54 Bubble Oil Gauge M28 Oil Gauge Tool 44050 45 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 Plunger Pump LPS and HPS Servicing All Plunger Models 055 Removing Pumps from Gas or Electric Motor 2SF 2SFX 2X 2DX 3DX 3SP 4SF 4HP 5DX 6DX 66DX 060 Baffle Assembly 34170 071 Plunger Rod Change HP Pumps 4HP 5DX 074 Torque Chart All Models 083 Winterizing a Pump All Models 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 T Open inlet shut off valve and turn on water supply to avoid starving the pump DO NOT RUN PUMP DRY C1 Temperatures above 130 F are permissible Add 1 2 PSI inlet pressure per each degree F over 130
5. F Elastomer or RPM changes may be required See Tech Bulletin 002 or call CAT PUMPS for recommendations 4 Avoid closed loop systems especially with high temperature ultra high pressure or large volumes Conditions vary with regulating unloader valve C1 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 of 6 10 times the GPM however a combination of system fac tors 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 Cj 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 T The line MUST be a FLEXIBLE hose NOT a rigid pipe and reinforced on SUCTION systems to avoid collapsing C1 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 CI Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of the pump m Acceleration loss of liquids may be increa
6. to exposed threaded end of Plunger Retainer Install Ceramic Plunger with Plunger Retainer Seal Washer and Barrier Slinger over each Plunger Rod shoulder and thread hand tight Torque to specifications per chart Slide Seal Retainer over each Ceramic Plunger with the openings to the top and bottom Press into 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 sup porting it from the underside to avoid damage to the plungers or seals Press the Manifold Head flush with the Crankcase Thread HSH screws in hand tight Torque in sequence to specifications in torque chart TORQUE SEQUENCE 7 ees ae 5 ae 2s SERVICING THE CRANKCASE SECTION 1 While Manifold Plungers and Seal Retainers are removed examine Crankcase Oil Seals for leaking and wear 2 Check for any signs of leaking at Bearing Covers Rear Cover Drain Plug or Bubble Gauge 3 Check oil level and for evidence of water in oil Change crankcase oil on a regular schedule See Preventative Maintenance Check List 4 Rotate Crankshaft by hand to feel for smooth bearing movement 5 Examine Crankshaft Oil Seals externally for drying cracking or leaking 6 Contact CAT PUMPS or your local distributor if crankcase service is evidenced SERVICING THE UNLOADER CHEMICAL INJECTOR Disassembly 1 Remove black Adjusting Handle 2
7. 2 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 Supply Line Bypass Line from regulator or unloader T Dia of pipe X_D i 4 1 5 x D Min Level Sensing Device 7A S Flexible Hose to Pump Bypass Line p from regulator or h unloader FILTER Minimum Two Baffles MIN 4 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 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 _ Standard 85 Horsepower Required 1460 Mech Efficiency Q What size motor pulley should I use Pump RPM Motor Engine RPM Q How do I c
8. 49 6126 9303 33 B e mail catpumps t online de www catpumps de PN 30004 Rev E 5510 Removal of Valve Assemblies Valve Assembly Components Separation of Manifold Head from Crankcase CAUTION Before commencing with service shut off drive electric motor gas or diesel engine and turn off water supply to pump Relieve all discharge line pressure by triggering gun or opening valve in discharge line Inspect and service all system accessories on the same schedule as your pump 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 SERVICING THE VALVES Disassembly Reassembly 1 Using an M24 hex tool remove the top discharge and 1 Examine Spring Retainers for internal wear or breaks in bottom inlet Valve Plugs the structure and replace as needed 2 Using a pliers grasp the Spring Retainer by the tab at 2 Examine Springs for fatigue or breaks and replace as the top and remove from the valve chamber needed 3 If the Valve assembly separates during removal remove 3 Examine Valves and Seats for grooves pitting or wear the Spring and Valve with a needle nose pliers Then and replace as needed with a reverse pliers remove the Valve Seat from the 4 Examine Seat and Valve Plug O Rings for cuts or wear valve chamber and replace as neede
9. 5DX 6DX 66DX PLUNGER PUMP SERVICE MANUAL NAF 5DX MODELS 6DX MODELS 66DX MODELS 5DX30G1 5DX35G1 5DX40G1 5DX50G1 6DX35G1I 6DX40G1I 66DX30G1I 66DX35G11 66DX40G11 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 5DX 22 65 oz 6DX 18 6 oz 66DX 18 0 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 a 1 gas shaft The 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 maximum pressure at the pump Consult the manufacturer of gas or diesel engine for selection of the proper engine MOUNTING All DX models are direct d
10. alculate the torque for my hydraulic drive system A Torque ft Ibs 3 6 Consult A Pump Pulley Outer Diameter x Engine Mfr cem 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 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 Air Leaks in Plumbing Check 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 Verify viscosity against pump specifications before operation e Elevate liquid temperature e
11. all O Ring on each Seal Case Press small end of Seal Case into each seal chamber Lubricate and press new Lo Pressure Seal into each Seal Case with the garter spring down Examine Ceramic Plungers for scoring scale buildup chips or cracks and replace as needed Slide Seal Retainer over each Ceramic Plunger with the openings to the top and bottom 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 sup porting it from the underside to avoid damage to the plungers or seals Press the Manifold Head flush with the Crankcase Thread HSH screws in hand tight Torque in sequence to specifications in torque chart Removal of Plunger Retainer SERVICING THE PLUNGERS Disassembly NOTE Refer to Tech Bulletin 071 old 4HP Plunger Rod Change for additional information on Ceramic Plungers Disconnect all plumbing from the manifold head Remove unloader by using a M22 wrench to remove the top unloader Flow Thru screw and a M27 wrench to remove the bottom unloader Flow Thru screw Using an M6 Allen Tool remove the eight HSH screws from the face of the Manifold head Insert flat head screwdrivers on each side between the Crankcase and Manifold Head and gently apply pres sure to the head to begin separation Support the Manifold Head from the underside and pull the Manif
12. d NOTE Inlet and Discharge Valve Assemblies are interchangeable Two Valve Kits are needed for a complete valve change 4 To separate the Valve assembly insert a screwdriver into the side of the Retainer and press on the back side of the Valve until Seat separates from the Spring Retainer 5 Remove O Ring from each Seat and Valve Plug 5 Lubricate and install new O Ring onto outside diameter of Seat 6 Place Seat on work surface with small diameter side up 7 Place Valve onto Seat with concave side down 8 Place Spring on Valve 9 Install Spring Retainer with deep stepped end over Spring and snap onto Seat 10 Press complete Valve assembly into each valve cham ber until completely seated 11 Lubricate and install new O Ring onto each Valve Plug 12 Apply Loctite 242 to threads of each Valve Plug and thread in hand tight Torque to specifications per chart Removal of Seal Case and Lo Pressure Seal SERVICING THE SEALS Disassembly 1 Using an M6 allen wrench remove the eight 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
13. ical Injector and hand thread into unloader by turning in a clockwise direction and then tighten with wrench Loctite and 242 are registered trademarks of the Henkel Corporation PREVENTATIVE MAINTENANCE CHECK LIST Fone aly Wee Sor ora 00 a ooo ma x _ Te a loiter eee ma x _ Pees Puley _ x _ co x _ iia ou Ghange __ x _ rorGhange __ _ Seal Ghangs vane changs _ 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 perfor mance 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 TORQUE CHART Torque Pump Model Thread Tool Size P N in lbs ftllbs Nm Plunger Retainer M6 M10 Hex 25082 55 46 6 2 Flow Thru Screws Inlet 1 2 NPT Discharge 3 8 NPT M27 Hex 360 M22 Hex 384 30 40 32 44 Manifold Head Screws M6 Allen 30941 132 11 0 15 Valve Plugs M24 Hex 44046
14. iquids 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 A 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 catpumps com International Inquiries E FAX 763 785 4329 e mail intlsales catpumps com L MNF 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 2550 Kontich Belgium Phone 32 3 450 71 50 Fax 32 3 450 71 51 e mail cpi catpumps be www catpumps be CAT PUMPS DEUTSCHLAND GmbH Buchwiese 2 D 65510 Idstein Germany Phone 49 6126 9303 0 Fax
15. kcase Knocking noise Inlet supply Bearing Oil leak eCrankcase oil seals Crankshaft oil seals and o rings Drain plug Bubble gauge Rear cover Filler cap Pump runs extremely rough eInlet conditions Pump valves Pump seals Premature seal failure PROBABLE CAUSE Worn nozzle 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 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 eLoose filler cap or excessive oil in crankcase 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 Ab
16. nough 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 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 cran
17. old Head away from the crankcase CAUTION Keep the Manifold Head properly aligned with the Ceramic Plungers when removing to avoid damage to the plungers or seals 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 Remove the Barrier Slinger Ceramic Plunger and Seal Washer from each Plunger Retainer Ceramic Plunger and Retainer Components Reassembly 1 10 11 12 Visually inspect the Crankcase Oil Seals for deteriora tion or leaks Contact CAT PUMPS for assistance with replacement See SERVICING THE CRANKCASE SECTION Examine Seal Washers and Barrier Slingers for cuts for wear and replace as needed Examine Plunger Retainers for damaged threads and replace as needed Examine the Ceramic Plungers for scoring scale buildup chips or cracks and replace as needed The Ceramic Plungers typically do not need to be replaced with every seal servicing Install new Seal Washer onto each Plunger Retainer Slide Plunger Retainer with Seal Washer into flat end of Ceramic Plunger Install Barrier Slinger on Plunger Retainer NOTE Ceramic Plungers can only be installed in one direction Slotted end of Ceramic Plunger should face toward crankcase Apply Loctite 242
18. or cuts or wear and replace as needed Lubricate and install O Ring over slotted head of Piston Stem then position Back up Ring on top of O Ring Lubricate and install O Rings on Spacer Install Washer and then Spacer with O Rings onto Piston Stem Apply Loctite 242 to threads of Piston Stem and screw Valve Ball Assembly onto Piston Stem Lower complete Piston Stem and Valve Assembly into unloader chamber with Valve Ball Assembly facing downward Examine Piston Retainer for damaged threads or wear and replace as needed Examine O Ring for cuts or wear and replace as needed Apply Loctite 242 to Piston Retainer threads and then hand thread Piston Retainer into unloader by turning in a clockwise direction and then tighten with wrench Examine Spring Retainer and Coil Spring for fatigue or breaks and replace as needed Place Spring Retainer into Piston Retainer followed by Coil Spring Thread brass Adjusting Cap onto Piston Retainer by turning in a clockwise direction On the 66DX models slide black Adjusting Handle over brass Adjusting Cap On the 6DX and 66DX models examine Chemical Injector Check Valve and Spring for fatigue or wear and replace as needed Examine O Ring for cuts or wear and replace as needed Install Spring into inlet port of Chemical Injector Lubricate and install Check Valve with O Ring into inlet port of Chemical Injector with O Ring facing out Apply Loctite 242 to threads of Chem
19. r 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
20. rasive 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 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 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 rear cover or replace o ring Tighten filler cap Fill crankcase to specified capacity Correct inlet size plumbing Check fo
21. ring the by pass mode No addi tional plumbing is required m It is critical that a Thermo Valve be installed to protect the pump during prolonged by pass The Thermo Valve may be installed on the opposite side of the Manifold Head or by replacing the Flow Thru Screw with the Flow Thru Direct Mount Thermo Valve PN 33920 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 14 12 1 4 3 8 1 2 3 4 1 1 4 1 2 1 4 3 8 1 2 5 8 3 4 7 8 120 13 400 45 94 150 36 3 9 0 2 2 230 50 17 330 86 21 5 2 1 6 500 120 40 520 130 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 37 52 210 107 Nominal Equivalent Length of Standard Pipe in Feet Pipe Inside 180 Tee Tee Size 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 6
22. rive and come with a flange adapter that mounts to a gas engine Before mounting pump to gas engine apply PN 6106 antiseize lubricant to pump shaft Refer to Technical Bulletin 055 for instructions on removing pump from 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 without proper ventilation Liquid 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 OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure 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 acces
23. sed by high RPM high temperatures low vapor pressures or high viscosity and may require a pressurized inlet to maintain adequate inlet supply T 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 Q 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 pressuriza tion control inlet flow contamination or temperature and provide ease of servicing 1 A shut off valve is recommended to facilitate maintenance 1A stand pipe can be used in some applications to help maintain a positive head at the pump inlet line 1 Inspect and clean inlet filters on a regular schedule to avoid flow restriction 1 A pressure transducer is necessary to accurately read inlet pressure Short term intermittent cavitation will not register on a standard gauge m All accessories should be sized to avoid restricting the inlet flow 4 All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction BY PASS TO INLET 1 The standard 5DX 6DX and 66DX pump comes with a Regulating Unloader This Regulating Unloader has a built in by pass channel which routes liquid back to the inlet du
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