2DX, 3DX, 3SP PLUNGER PUMP SERVICE MANUAL
Contents
1. 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 spring down Examine ceramic plunger for cracks or scale buildup and proceed to SERVICING THE PLUNGERS if worn On the models 2DX and 3DxX slide Seal Retainer over each Ceramic Plunger with the drain slots facing the Crankcase and the openings to the top and bottom Press into the Crankcase On the model 3SP 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 sup porting 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 2DX20ES 2DX27GS 2DX30GS 3DX25GSI 3DX30GSI Plunger Arrangement SERVICING THE PLUNGERS Disassembly ili 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 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 P2. 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 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 Us
3. 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 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 Level Sensing
4. 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 port size Pressurize and install C A T Replace manifold Check liquid compatibility
5. 2DX 3DX 3SP PLUNGER PUMP SERVICE MANUAL 2DX MODELS 2DX20ES 2DX27GS 2DX30GS 2DXO5ELS MIST 2DX10ES MIST 2DX15ES MIST 2DX20ES MIST 2DX27ES MIST 3DX MODELS 3DX25GSIl 3DX30GSI 3SP MODELS 3SP30G1I 3SP35GEI 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 2DX 3DX 8 5 oz 3SP 10 15 oz DO NOT RUN PUMP WITH OUT 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 models 3 4 hollow shaft on GEI and GS models 1 hollow shaft on Gil models The motor 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 maximum press
6. 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 49 6126 9303 33 e mail catpumps t online de www catpumps de PN 30263 Rev B 7322 2DX20ES 2DX27GS 2DX30GS 3DX25GSI 3DX30GSI 3SP30G1I 3SP35GEl Discharge and Inlet Valve Assembly Stacked Valve design 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 discharge 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 SERVICING THE VALVES Disassembly Reassembly NOTE The Discharge and Inlet Valve Assemblies 1 Examine Spring Retainers for internal wear or breaks in are stacked Follow these same procedure for both the structure and replace as needed inlet and discharge assemblies 2 Examine Springs for fatigue or breaks and replace as NOTE Discharge and Inlet Valve Assemblies may needed Stay together or separate du
7. ALS Reassembly steps 11 15 TORQUE SEQUENCE pera teal 6 2s SERVICING THE CRANKCASE SECTION 1 2 While Manifold Plungers and Retainers are removed examine Crankcase Oil Seals for leaking and wear Check for any signs of leaking at Bearing Cover Drain Plug or Bubble Gauge Check oil level and check for evidence of water in oil Rotate crankshaft by hand to feel for smooth bearing movement Examine Crankshaft Oil Seal externally for drying cracking or leaking Consult CAT PUMPS or local distributor if crankcase service is required SERVICING THE UNLOADER 2DX and 3DX Models Only 3SP Models refer to individual Unloader Data Sheet Disassembly 1 2 3 Remove brass Adjusting Cap by turning in a counter clockwise direction Remove exposed Coil Spring and flat Spring Retainer 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 6 If not continue with step 4 Use a needle nose pliers to remove Piston Stem and Valve Assembly Separate Piston Stem from Valve Secure the Valve near the Valve Retainer Insert a screwdriver into slot ted head of Piston Stem and unthread from Valve CAUTION Exercise extreme caution to avoid contact and damage to the tapered surface of valve Examine Seat at the bottom of the unloader chamber for grooves pitting or we
8. NE SIZE should be adequate to avoid starving the pump LI 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 1 The line MUST be a FLEXIBLE hose NOT a rigid pipe and reinforced on SUCTION systems to avoid collapsing 11 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 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 reco
9. ar replace only as needed CAUTION Seat will be damaged when removed Reassembly 1 2 10 11 If seat is worn or damaged press new seat into unloader chamber until squarely seated Examine Piston Stem Washer Valve Retainer and Valve for grooves pitting or wear and replace as needed Examine O Rings and Back up Ring for 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 Valve Retainer Install Washer and then Valve Retainer with O Rings onto Piston Stem Apply Loctite 242 to threads of Piston Stem and screw Valve onto Piston Stem Lower complete Piston Stem and Valve Assembly into unloader chamber with valve 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 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 PREVENTATIVE MAINTENANCE CHECK LIST Check Clean Filters Oil Level Quality Oil Leaks Water Leaks Plumbing Initial Oil Change Oil Change S
10. d 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 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
11. e 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 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 an
12. eal Change Valve Change Accessories 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 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 Manifold Head Screws M6 Valve Plugs M20 M10 Hex 25082 55 44 6 M5 Allen 55 44 6 M19 Hex 520 43 4 59 Bearing Cover Screws M6 Bubble Oil Gauge M28 Oil Gauge Tool 44050 45 36 5 M10 Hex 25082 50 40 6 TECHNICAL BULLETIN REFERENCE CHART No Subject Models 002 024 036 043 055 074 083 086 Inlet Pressure VS Liquid Temperature Lubrication of Lo Pressure Seals Cylinder and Plunger Reference Chart LPS and HPS Servicing Removing Pumps from Gas Engine or Electric Motor Torque Chart Winterizing a Pump Ceramic Plunger All Models All Models All Models All Plunger Models 2SF 2SFX 2DX 4SF 5DX 6DX Piston and Plunger Pumps All Mod
13. els 2DX 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 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 LI
14. emoval 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 On the models 2DX and 3DX the Hi Pressure Seals can be easily removed from each seal chamber by hand or with reverse pliers On the model 3SP remove V Packing and Male Adapter from each seal chamber by hand or with a reverse pliers 3SP30G1I 3SP35GEl Lo Pressure and Hi Pressure Seals with Seal Case Reassembly 1 2 10 11 12 14 15 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 On the models 2DX and 3DX lubricate and install new Hi Pressure Seal by hand into each seal chamber with the grooved side down On the model 3SP install Male Adapter with notch side down Lubricate and install new V Packing by hand into seal chamber with grooved side down
15. 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 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
16. lunger Retainer and proceed with unthreading the Plunger Retainer by hand On the models 2DX and 3DX remove the Ceramic Plunger and Seal Washer from each Plunger Retainer On the model 3SP remove the Ceramic Plunger and copper Retainer Gasket from each Plunger Retainer Reassembly 1 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 or Plunger Retainer Gaskets and replace if cut or worn Examine Plunger Retainers for damaged threads and replace as needed On the models 2DX and 3DX install new Seal Washer onto each Plunger Retainer On the model 3SP install the new copper Plunger Retainer Gasket 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 or Gasket into flat end of Ceramic Plunger Apply Loctite 242 to exposed threaded end of Plunger Retainer 3SP30G1I 3SP35GEl Plunger Arrangement 10 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 Plunger Rod shoulder See SERVICING THE SE
17. mmended 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 LI The 2DX and 3DX pumps come with a Regulating Unloader and built in by pass channel 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 additioal by pass hose is required 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 60 380 120 220 320 410 600 370 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
18. ortant 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 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 de
19. ring removal 3 Examine Valves and Seats for grooves pitting or wear NOTE Spring Retainer may also separate from the and replace as needed Seat during removal 4 Examine Seat and Valve Plug O Rings for cuts or wear 1 Using a Hex tool remove Valve Plugs at the top of the and replace as needed Manifold Head NOTE Inlet Valve Seat and O Ring are different 2 Use a reverse pliers to remove stacked valve assemblies from Discharge Valve Seat and O Ring One Valve from the valve chamber Kit required per pump 3 If the Discharge Valve Assembly separates from the 5 Lubricate and install new O Ring onto large outside Inlet Valve Assembly use a reverse pliers to remove it diameter of Seat from the valve chamber 6 On the model 3SP lubricate and install Back up Ring CAUTION Exercise caution as the reverse pliers and then O Ring onto large outside diameter of may damage the threads in valve chamber or Spring Discharge Seat Retainer 7 Place Seat on work surface with small diameter side 4 On the models 2DX and 3DX the Spring Retainer may up separate from the Seat Remove the Spring and Valve 8 place Valve onto Seat with concave side down from the valve chamber Thread an M8 screw into the Seat and remove from valve chamber 9 Place Spring on Valve 5 On the models 2DX and 3DX separate Valve Assembly 10 Install Spring Retainer with deep stepped end over by using the same M8 screw and thread into bottom of Spring and snap onto Seat Seat
20. until screw contacts bottom of Valve Continue 11 Snap Discharge Valve Assembly onto the Inlet Valve n in screw until Spring Retainer separates from Assembly and press into valve chamber until completely eat seated 6 On the model 3SP separate Valve Assembly by insert 12 Lubricate and install new O Ring onto each Valve Plug t oe deste Seal ha Ue the 13 Apply Loctite 242 to threads of each Valve Plug and arate OL UG Pen ce ee ena Nile ee thread in hand tight Torque to specifications per chart 7 Remove O Ring from each Seat and Valve Plug 2DX20ES 2DX27GS 2DX30GS 3DX25GSI 3DX30GSI Lo Pressure and Hi Pressure Seals with Seal Case SERVICING THE SEALS Disassembly 1 2 Using an 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 r
21. ure at the pump Consult the manufacturer of gas or diesel engine for proper selection MOUNTING 2DX 3DX and 3SP models are direct drive The 2DX and 3DX electric models can be mounted directly to a C Face motor the 3SP35GEIl model comes 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 OPEN 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 imp
22. vice 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 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
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