R-SERIES PUMPS SERVICE MANUAL - Three-Es
Contents
1. Daily inspect the area under and around the pump for oil leakage or spots Oil change should occur when the pump s oil temperature has decreased to approximately 77 F 25 C PUMP LIQUID END Seal and valve kits can be installed without removing the manifold head Service frequency of wear parts will depend on operating pressure pump speed and duty cycle The degree of prefiltration minimum 5y cleanliness of the surroundings sand and dust penetration and dosification of chemicals pH 0 3 or 9 12 will influence the service frequency and may affect seal lifetime Pumps operated under cavitation conditions or with liquids containing high oxygen contents or gaseous waters will contribute to premature wear of pump components 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 CAT PUMPS U K LTD World Headquarters 1 Fleet Business Park Sandy Lane Church Crookham Fleet CAT PUMPS Hampshire GU52 8BF England 1681 94th2. Lane N E Minneapolis MN 55449 4324 Phone Fleet 44 1252 622031 Fax 44 1252 626655 Phone 763 780 5440 FAX 763 780 2958 e mail sales catpumps co uk N V CAT PUMPS INTERNATIONAL S A e mail techsupport catpumps com www catpbumps com Heiveldekens 6A B 2550 Kontich Belgium The Pumps with Nine Lives Phone 32 3 450 71 50 Fax 32 3 450 71 51 i l e mail cpi catpumps be www catpumps be nternational Inquiries CAT PUMPS DEUTSCHLAND GmbH FAX 763 785 4329 M SN Meera ay as ce one Fax e mail intisales catpumps com L _ e mail catpbumps t online de www catpumps de PN 993295 Rev A 5719 SERVICING THE VALVES Disassembly 1 Models 152R060 152RO080 152R100 Remove forty eight 48 hex socket head HSH screws from all six 6 valve plugs Model 157RO60 Remove seventy two 72 HSH screws from all six 6 valve plugs Lift valve plugs from valve chambers figures 1A and 1B Unscrew the valve guide stud and remove spring retainer spring and valve from each valve chamber figures 2A and 2B The valve seat will remain in the valve chamber To remove the valve seat a special extracting tool is required figure 3A NOTE The valve seat does not have to be replaced with every valve kit servicing Replace only if the valve surfaces are pitted grooved or worn See Data Sheets for valve kits Extracting Tool Support Place the extractor tool with the claws towards the chamber until the s
3. DEL SLEEVE PLUNGER PN 998803 PN 998804 PN 998805 PN 998806 PN 998807 PN 998808 V Packing Arrangement Seal Installation Plunger Tool ae Seal Housing Seal Installation Sleeve Tool 2 Lubricate outside diameter of appropriate sleeve tool and install tapered end into seal housing Place plunger tool with V Packing into large end of sleeve tool and press into place 3 Remove sleeve tool and then plunger tool 4 Carefully install the ceramic plunger in the manifold s cham ber figure 4A and then slide the spacer and packing spac er over the ceramic plunger figure 4B 5 Thread on the packing adjuster 2 or 3 turns but do not tight en it figure 5A 6 Install plunger rod figure 6A and connect it to the connecting rod Use a 50 mm wrench to tighten up Torque at 110 ft lbs 150 Nm figure 6B 7 Lubricate the outer rim of the oil seal carrier and place it in its chamber Install two 2 washers and two 2 HSH screws Torque at 11 ft lbs 15 Nm figure 7A 8 Turn the pulley to position the plunger rod in the most for ward position Pull the ceramic plunger backwards until both threads meet Tighten with a 50 mm wrench Torque at 90 ft lbs 120 Nm figure 8A 9 Tighten the packing adjuster using the Packing Tool figure 9A 10 Repeat the same steps for the other 2 plungers Reinstall the acrylic panel before beginning operation Loctite is a registered trademark of the Henkel Corporation PROBLEM
4. Low flow Pulsation Water leak Under the manifold Into the crankcase Knocking noise Inlet supply Bearing Connecting Rod or Crosshead Pins Pulley Manifold head Crankcase Oil leak Crankcase oil seals Crankshaft oil seals and o rings Drain plug Bubble gauge Rear cover Filler cap Pump runs extremely rough Inlet conditions Pump valves Pump seals Drive end Premature seal failure DIAGNOSIS AND MAINTENANCE This service manual is designed to assist you with the disassembly and reassembly of your pump The following guide will assist in defining the problem citing probable cause s and providing the solution s PROBABLE CAUSE eIncorrect RPM Belt slippage 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 NPSH Pump not filling 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 Excessive wear to seals and V Packings Inadequate inlet liquid supply Broken or worn bearing connecting rod or crosshead pins Loose pulley on crankshaft eAir e
5. R SERIES PUMPS SERVICE MANUAL Model 152R100 Shown PUMP DRIVE END Maintenance of the drive end is limited to regular oil changes to assure The surface temperature of the pump s drive end should regularly be optimum lubrication In case of a new pump a first oil change is required after about 20 operating hours Thereafter oil changes will only be necessary every 3000 hours or every 6 months Fill crankcase with special CAT PUMPS custom blend multi viscosity ISO100 petroleum based hydraulic oil 22 4 gallons 85 liters Use PN checked during the first 50 operating hours of the pump and thereafter once a day NOTE If the thermo pump stickers indicate higher temperatures than 150 F 65 C change oil or review installation Temperatures may vary according to the unit s surroundings operating pressure and pump speed 6116 16 gallons or PN 6116 5 gallons Oil level can visually be checked at the oil gauge A correct oil level is obtained when the oil gauge shows a 3 4 level with the pump stopped NOTE Overfilling with oil may lead to overheating the pump Check the oil level and the oil color daily A black oil color can indicate a strong reduction of the lubrication capacity of the oil overheating or the use of the wrong oil type A milky white oil color can be a sign of water penetrating the crankcase through the oil seals It is possible that due to temperature differences minor oil sweating may occur
6. ck 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 eInstall new seal kit Increase frequency of service Change oil eCheck liquid supply Increase line size pressurize Replace bearing connecting rod or crosshead pins Check key and tighten set screw Purge air from manifold head Refill oil level Inspect for damage if very low Replace crankcase oil seals Check for contaminated oil Remove bearing cover and replace o rings and or oil seals eTighten drain plug Tighten bubble gauge or replace gasket Install sealant and tighten rear cover Tighten filler cap Check for proper oil level 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 Tighten adjust or replace Replace plungers or plunger rods Reduce inlet pressure per specifications Install new seal kit eInstall proper filtration at pump inlet and clean regularly Check pressure and inlet liquid temperature are within limits DO NOT RUN PUMP WITHOUT LIQUID Increase line one size larger than inlet port size eInstall per instructions Select correct seal kit for plunger size
7. d ceramic plungers figure 16A as well as the stack of seals and spacers figure 16B and replace if damaged or worn SERVICING OIL SEALS V PACKINGS AND LO PRESSURE SEALS Disassembly Continued 17 Inspect the Lo Pressure seal located in the inner groove of the packing spacer figure 17A and replace as needed Also inspect the o ring located at the exterior of the pack ing spacer and replace as needed figure 17B 18 Models 152R060 152R080 152R100 If after removal of the ceramic plunger it still appears to be impossible to remove the V Packing or spacers they will have to be removed from the inlet valve side Remove all twenty four 24 HSH screws figure 18A Remove inlet valve plugs figure 18B 19 Remove the valve guide stud figure 19A spring retainer spring and valve from each inlet valve chamber figure 19B NOTE Do not remove the valve seat 20 Gently push the V Packings and or spacers out of the cylin der line with a fine metal bar Take care not to scratch or damage the inner cylinder walls in particular the valve seat s surface figure 20 17B Reassembly 1 Assemble a complete seal stack onto the appropriate seal installation plunger tool in the correct sequence figure 1A Slightly lubricate the outside diameter of the V Packing with glycerine to facilitate their installation in the chamber NOTE Use the appropriate seal installation tools for each pump model PUMP MO
8. e manifold s shoulder figures 2A and 2B 3 Models 152R060 152R080 152R100 Place valve spring spring retainer and valve guide stud onto the valve seat Torque at 55 ft lbs 75 Nm figures 3A and 3B Model 157RO060 Place threaded end of the valve through center hole of tapered surface of valve seat Slide spring over threaded end of valve Apply a small amount of Loctite 243 to threads of valve Hand thread nut onto threads of valve Torque at 60 ft lbs 80 Nm figure 3C Place valve assembly in each valve chamber Install valve assembly in a perpendicular position 4 Press each valve plug into the valve chamber Models 152R060 152R080 152R100 Torque HSH screws at 55 ft lbs 75 Nm figures 4A and 4B Model 157RO60 Torque HSH screws at 75 ft lbs 100 Nm SERVICING OIL SEALS V PACKINGS AND LO PRESSURE SEALS NOTE Prior to disassembly of packings and seals drain oil from crankcase to 1 2 capacity Disassembly 1 Remove acrylic cover on top of pump with an 8 mm allen wrench 2 Lift the packing tool mounted on the top of the pump from its holder and insert one end into one of the holes of the packing adjuster figures 2A and 2B 3 Disassembly and reassembly steps refer to one single plunger Accomplish them completely and repeat in the same order for the other 2 plungers 4 Loosen the packing adjuster by turning it counterclockwise 5 Turn the pump s pulley until the ceramic plunger is in it
9. ntrapped in manifold head eLow oil level Worn crankcase oil seals Worn crankshaft oil seals or o rings on bearing cover Loose drain plug Loose bubble gauge or worn bubble gauge gasket Loose rear cover 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 Loose piston rods bearings crosshead pins or connecting rod screws Scored plungers or plunger rods Over pressure to manifold head Abrasive material in the liquid being pumped Excessive pressure and or temperature of pumped liquid eRunning pump dry Starving pump of adequate liquid Improper installation of packings eImproper packing selection SOLUTION Change drive ratio or correct motor speed Tighten belt s or install new belt s Tighten fittings and hoses and purge air 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 eInstall proper filter Replace discharge hose with proper rating for system Increase inlet pressure or line size or minimize elbows Prime pump Increase inlet pressure eCheck inlet conditions eInstall new seal kit Increase frequency of service Clean inlet discharge valves or install new valve kit Che
10. s most forward position 6 Separate the plunger rod from the ceramic plunger by unscrewing the plunger nut with a 50 mm wrench figures 6A and 6B 7 Rotate the pulley in order to position the plunger rod in its most rear position Push the ceramic plunger toward the pump manifold 8 Unscrew and remove the packing adjuster figures 8A and 8B 9 Remove two 2 HSH screws and two 2 washers from the oil seal carrier figure 9A with a 6 mm hexagon key Carefully remove the oil seal carrier from its chamber by means of two screwdrivers figure 9B 10 Inspect the condition of the oil seal within the oil seal carrier The oil seal is located in the interior groove of the oil seal carrier figure 10A Also check the o ring on the exterior groove of the oil seal carrier figure 10B 10A 10B 11 Remove the oil seal and replace as needed figures 11A and 11B 12 Loosen the plunger rod by using a 50 mm wrench figure 12A and carefully remove it from its chamber figure 12B 13 Carefully remove ceramic plungers from the manifold figures 13A and 13B 14 Use Lantern Ring Puller PN 998809 to remove packing spacer and spacer figure 14A Ensure stainless steel pins engage with holes of spacer Lantern Ring Puller 15 Remove V Packings by hand NOTE Models 152R060 152R080 and 152R100 ONLY If V Packings and spacers cannot be removed proceed to disassembly steps 18 19 and 20 16 lnspect plunger rods an
11. upport s surface rests on the valve seat Turn the extractor 15 until the claws cling under the 3 inner studs of the valve seat figure 4A Pull the extractor upwards All 3 claws have to be engaged with the inner valve seat studs figure 4B Hold this position while positioning the extractor s face onto the upper face of the valve s chamber figure 4C Gradually tighten the nuts of the extractor tool figure 5A until the valve seat is pried out of its valve chamber figure 5B Clean the surfaces of the valve seat Lubricate new o ring for ease in installation figure 6A 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 Reassembly 1 Apply a small amount of Loctite 641 figure 1A onto the top rim of the valve seat 2 Models 152R060 152R080 152R100 Place valve seat in each valve chamber Install valve seat in a perpendicular position Tap the valve seat gently into its chamber by using a wooden or copper hammer until the upper rim contacts with th
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