SERVICE MANUAL
Contents
1. a chemical injector use a M22 hex tool to remove chemical injector from unloader manifold body See Figure 15 Pump series 4DX without a chemical injector use a M22 hex tool to remove discharge fitting from regulator manifold body See Figure 16 11 On pump series 4DNX and 4DX remove spring check valve check valve seat and o ring from unloader manifold chamber Examine o rings and backup rings for cuts or deterioration and replace with a new o ring kit as needed Examine valve end of piston assembly for wear scoring and replace with a new repair kit as needed Examine spring check valve check valve seat and o ring for damage and replace with a new check valve kit as needed Reassembly 12 On pump series 4DNX 4DX and 4SPX with chemical injector lubricate and install o ring on check valve seat Insert with o ring towards manifold 13 Install check valve into check valve seat followed by spring 14 Lubricate and install o ring on chemical injector 15 Apply Loctite 242 to threads of chemical injector 15 On pump series 4DX without chemical injector apply Loctite 242 to threads of discharge fitting 17 Use a M22 hex tool to tighten chemical injector Ensure hose barb faces upward 18 Lubricate and install o ring on seat 19 Install seat with tapered inside diameter facing downward into unloader regulator chamber See Figure 17 20 Install complete piston assembly into unloader regulator chamber with2. pop off valve safety valve rupture disc to assure proper pressure setting and overpressure protection All high pressure systems require a pressure gauge to monitor pressure settings and avoid overpressure of equipment or personal harm Install primary pressure relief device on the discharge side of the pump Install secondary pressure relief device between the primary device and pump Install pressure gauge onto the discharge manifold or in the discharge line near the manifold Open all valves on discharge side of plumbing before operation OM AUN G OXYGEN HAZARD Do not charge Prrrrr O Lators Pulsation Dampeners with Oxygen Oxygen may cause an explosion causing personal injury death or property damage 1 Use Nitrogen only when charging pulsation dampeners DO NOT USE OXYGEN 2 Use proper charging tools to charge pulsation dampeners 3 Charge pulsation dampener within specifications stated on data sheet to assure proper pulsation dampening and prevent failure of bladder H FALL HAZARD Do not operate pressure washer while standing on slippery or unstable surface unless extraordinary safety precautions are observed Pressure washing may create slippery surface on which a person may slip and fall causing personal injury or death 1 Wear suitable footwear to maintain a good grip on wet surfaces 2 Do not stand on ladders or scaffolding 3 Do not over reach or stand on unstable supports 4 Keep good footing and ba
3. seats valves and o rings e Clean filter Use adequate size filter Check more frequently e Install proper filter e Replace discharge hose with proper rating for system e Pressurize inlet e Check inlet conditions e Install new seal kit Increase frequency of service e Clean inlet discharge valves or install new valve kit e Clean inlet discharge valves or install new valve kit e Install new seal kit Increase frequency of service e Install new oil cap protector Change oil every 3 months or 500 hours e Install new seal kit Increase frequency of service e Check liquid supply Increase line size or pressurize e Replace bearing e Replace crankcase oil seal e Remove bearing cover and replace o ring and or oil seal e Tighten drain plug or replace o ring e Tighten bubble gauge or replace gasket e Tighten bearing cover or replace o ring e Tighten filler cap Fill crankcase to specified capacity e Correct inlet size plumbing Check for air tight seal e Clean out foreign material or install new valve kit e Install new seal kit Increase frequency of service e Replace plunger e Reduce inlet pressure per specifications e Install proper filtration at pump inlet and clean regularly e Check pressure and inlet liquid temperature e DO NOT RUN PUMP WITHOUT LIQUID e Increase hose one size larger than inlet port size or pressurize e Replace manifold Check liquid compatibility PN 31378 Rev A
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5. Follow safety instructions as found in MSDS or SDS or on packaging of each liquid 2 Clean equipment in a well ventilated area 3 Disposal of solvents to be in accordance with local state and federal regulations D OPERATING BEYOND SPECIFICATIONS HAZARD Do not operate the pump outside the specifications of individual pump data sheet or service manual Operating the pump under these conditions could result in personal injury and property damage 1 Do not operate the pump faster than the maximum recommended rpm 2 Do not operate the pump at pressures higher than the maximum recommended pressure 3 Do not operate the pump at temperatures higher than the maximum recommended temperatures 4 Do not use accessories that are not compatible or rated for the pump E LIFTING DEVICE HAZARD Do not lift pump with unsuitable lifting devices Use of unsuitable lifting devices may cause pump to fall resulting in personal injury damage to pump and or pump with drive base plate 1 Lifting eyes installed on the pump must be used only to lift the pump 2 Special lifting eyes should be installed on the base for lifting the pumping system i e base drive and accessories 3 If slings or chains are used for lifting they must be safely and securely attached to properly balance the weight of the unit 4 Inspect slings and chains prior to use and replace worn and damaged slings and chains NOTICE A OILHAZARD Use only genuine Cat Pumps custom ble
6. Remove black protective 6 Screw bottle into garden 7 Squeeze bottle to inject 8 Gas Pressure Washers cap to expose male garden hose fitting on inlet pump protector fluid Pull starter cord until pump hose thread and internal of pump into pump protector fluid is discharged check valve from pump outlet DO NOT START ENGINE 9 Electric Pressure Washers 10 Remove bottle from Briefly turn pressure washer garden hose fitting on until pump protector Store or dispose of bottle fluid is discharged from properly pump outlet then turn unit Off PREVENTATIVE MAINTENANCE SCHEDULE This schedule is intended as a guide only Each system application is different and should be evaluated serviced according to its own custom maintenance schedule Check Daily Weekly 50 Hrs 500 Hrs 1500 Hrs 3000 Hrs Clean Filters aAa viy Oil Leaks Water Leaks Plumbing Initial Oil Change o Oil Change i Ea Accessories valve Chemee If alternate to Cat Pumps custom blend premium grade petroleum base hydraulic oil is used change cycle should be every 300 hours Each system s maintenance cycle will differ 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 t
7. SERVICE MANUAL rar ILL dD 4DNX 4DX 4SPX SERIES PLU NGER PUMPS The Pumps with Nine Lives PUMP FLOW PRESSURE RPM TEMPERATURE SHAFT DIA OIL CAPACITY MODEL gpm lpm psi bar Pump F C in mm oz l ADNX25GSI 25 9 5 2850 196 3450 140 60 3 4 19 8 5 0 25 4DNX27GSI 2 10 2 2850 196 3450 140 60 3 4 19 8 5 0 25 4DX10ER 1 0 3 8 2000 140 3450 140 60 5 8 15 8 8 5 0 25 4DX15ER 1 5 5 7 2000 140 3450 140 60 5 8 15 8 8 5 0 25 4DX20ER 2 0 7 6 2000 140 3450 140 60 5 8 15 8 8 5 0 25 4DX27ER 2 7 10 2 2000 140 3450 140 60 5 8 15 8 8 5 0 25 4DX30ER 3 0 11 4 2000 140 3450 140 60 5 8 15 8 8 5 0 25 4SPX32G11 3 2 12 1 3000 210 3450 140 60 1 25 4 10 15 0 3 IMPORTANT SAFETY INSTRUCTIONS It is the responsibility of the user to read and understand all instructions important safeguards and safety precautions before operating or servicing any pump Failure to do so may result in property damage personal injury or death General Safety Information and Symbols Pay special attention to the following signal words safety alert symbols and statements indicates a hazardous situation which if not avoided will result in death or serious injury indicates a hazardous situation which if not avoided could result in death or serious injury indicates a hazardous situation which if not avoided could result in minor or moderate injury or property damage indicates a hazardous situation which if not avoided could result in property damage A Indicates a potential perso
8. avitation e Worn seals e Worn or dirty inlet discharge valves e Foreign material trapped in inlet discharge valves e Worn High Pressure or Lo Pressure Seals e Humid air condensing into water inside the crankcase e Excessive wear to High Pressure and Lo Pressure seals e Inadequate inlet liquid supply e Broken or worn bearing e Worn crankcase oil seal e Worn crankshaft oil seal or o ring on bearing cover e Loose drain plug or worn drain plug o ring e Loose bubble gauge or worn bubble gauge gasket e Loose bearing cover or worn bearing cover o ring e Loose filler cap or excessive oil in crankcase e Restricted inlet or air entering the inlet plumbing e Stuck inlet discharge valves e Leaking High Pressure or Lo Pressure seals e Scored plunger e Over pressure to inlet manifold e Abrasive material in the liquid being pumped e Excessive pressure and or temperature of pumped liquid Running pump dry e Starving pump of adequate liquid e Eroded manifold 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 For International Inquiries go to www catpumps com and navigate to the Contact Us link SOLUTION e Replace with proper size nozzle e Tighten fittings and hoses Use PTFE liquid or tape e Check with new gauge Replace worn or damaged gauge e Clean adjust relief valve Replace worn
9. ck Out and Tag Out procedures for electrical equipment 2 Before commencing pump service turn power supply off 3 Keep water away from electrical outlets and electrical devices 4 Electrical components must be installed by a qualified electrician to avoid risk of electrocution B ROTATING PARTS HAZARD Do not service pump while energized Moving rotating or reciprocating parts can crush and cut causing personal injury death or property damage 1 Adhere to Lock Out and Tag Out procedures for electrical equipment Before commencing pump service turn power supply off turn water supply off squeeze trigger on gun to relieve system pressure For mobile equipment be sure engines and hydraulics are turned off and secured to avoid accidental start Do not operate with safety guards removed mB wh Always use safety guards on all belt drives couplings and shafts C HOT SURFACE HAZARD Do not touch pump accessories or drive system while operating and until cool down is complete Touching hot surface areas of the pump accessories or drive system can cause severe burns or personal injury D SKIN PUNCTURE HAZARD Do not allow spray to contact any part of the body or animals Pumped liquids under high pressure can pierce skin and underlying tissue or can deflect debris leading to serious personal injury or death 1 Relieve all line pressure in the inlet line to the pump and discharge line from the pump before per
10. ckly cause heat build up resulting in damage to the pump 1 Route by pass line to supply reservoir to dissipate heated by pass liquid into a large reservoir of cool water to reduce excessive temperature build up 2 Route by pass line to inlet of pump using a thermo valve in the by pass line or auto shut off assembly that will sense temperature rise and either by pass or shut down system before damage occurs E DRY OPERATION HAZARD Do not operate the pump without water or liquid Operating pump under these conditions could result in damage to the pump Open all valves on inlet side of pump before starting operation to prevent starving the pump Do not exceed inlet suction pressure limit specified in pump data sheet Ensure inlet feed exceeds the maximum flow being delivered by the pump Ensure all fittings pipes and hoses are properly sized for the pump to avoid restricted flow Review and implement all other recommendations appropriate for your system from the Inlet Condition Check List Mm A U N gt 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
11. forming any maintenance on the pump 2 When high pressure gun is not in use set safety trigger lock safety latch to avoid accidental high pressure operation and personal injury or property damage 3 Do not check for leaks with hand Use a piece of cardboard to check for leaks 4 Review cleaning procedures to minimize heavy back blasting 5 Wear adequate safety equipment and clothing when operating high pressure sprayer Never use high pressure spray with bare feet or exposed skin and always wear safety glasses E PUMPING LIQUIDS HAZARD Do not operate pump with hot water chemicals or other hazardous liquids unless extraordinary safety precautions are observed Pumping hot water chemicals or other hazardous liquids can expose personnel to serious injury 1 Provide guards or shields around equipment to protect personnel 2 Wear mask goggles or eye protection while operating high pressure equipment 3 Obtain a Material Safety Data Sheet MSDS or Safety Data Sheet SDS and take appropriate safety measures for the liquid being handled F OVER PRESSURIZATION HAZARD Do not operate high pressure pumping system unless extraordinary safety precautions are observed A high pressure pumping system can deadhead or over pressurize causing serious personal injury and property damage 1 All high pressure systems require a primary pressure regulating device i e regulator or unloader and a secondary pressure safety relief device i e
12. ger retainer 8 Install ceramic plunger with plunger retainer and seal washer over each plunger rod shoulder and thread hand tight See Figure 11 9 Use a M10 hex tool and torque to 55 in lbs 4 6 ft lbs or 6 2 Nm 10 On pump series 4DNX and 4DX slide white seal retainer with slotted openings to the top and bottom and facing the crankcase See Figure 12 11 On pump series 4SPX slide white seal retainer with flat end facing the crankcase See Figure 13 Pump Series 4SPX Only Figure 10 Figure 11 Figure 12 Figure 13 SERVICING THE UNLOADER OR REGULATOR Disassembly 1 Onpump series 4SPX remove black nylon adjusting handle 2 Onpump series 4SPX use a M3 allen wrench to loosen set screw on locking nut 3 Loosen and turn locking nut towards unloader body 4 Use a M21 hex tool or turn by hand to remove the brass adjusting cap 5 Remove spring and flat spring retainer NOTE NOTE NOTE NOTE NOTE NOTE 6 Use a M19 hex tool to remove piston retainer Complete piston assembly may stay in unloader regulator chamber or stay with piston retainer 7 Use a needle nose pliers to remove complete piston assembly 8 Secure valve end of piston assembly in vise use a screwdriver in slotted head of piston stem to separate 9 Use a modified reverse plier or nail head to remove seat w o ring See Figure 14 10 Use a pick tool to remove o ring from seat Pump series 4DNX 4DX and 4SPX with
13. he life of pump wear parts and service cycle Remember to service the regulator unloader relief valve at each seal servicing and check all system accessories and connections before resuming operation GENERAL SAFETY INFORMATION AND SYMBOLS 4 DANGER A FLAMMABLE OR EXPLOSIVE LIQUID HAZARD Do not operate pump with flammable or explosive liquids unless extraordinary safety precautions are observed Leaks of flammable or explosive liquids if exposed to elevated temperatures static electricity sparks or other hazards will result in flame or possible explosion causing serious personal injury death or property damage 1 Before operating pump with flammable or explosive liquids ensure proper maintenance has been performed 2 Do not operate pump with flammable or explosive liquids if leaks are detected 3 Only pump flammable or explosive liquids that are compatible with pump component materials 4 Do not operate pump with flammable or explosive liquids without safeguards or safety systems to detect leaks elevated temperatures spark prevention or any other hazards defined by the NFPA systems Do not remove Flammable Liquids Product Suitability Hang Tag to assure proper safety 6 Follow ATEX guidelines for potentially explosive atmospheres ZAWARNING A ELECTRICAL SHOCK HAZARD Do not service pump or electrical equipment while energized Electricity can cause personal injury death or property damage 1 Adhere to Lo
14. ightly lubricate ceramic plungers Carefully slide manifold over the ceramic plungers supporting it from the underside Press manifold up to crankcase until flush 7 Thread in manifold screws by hand 8 Use a M5 allen wrench and torque in sequence as shown to 55 in Ibs 4 6 ft Ibs or 6 2 Nm PUMP SERIES 4DNX AND 4DX TORQUE SEQUENCE Figure 4 Figure 8 Open Side High Pressure Low Pressure Seal Seal Figure 9 SERVICING THE PLUNGERS Disassembly NOTE Remove manifold head as noted under SERVICING SEALS Disassembly steps 1 to 3 NOTE Pump series 4SPX crankcase style is different than the 4DNX and 4DX pump series Use M10 hex tool to remove plunger retainer from each plunger rod Remove seal washer from each plunger retainer oe a Remove ceramic plunger from each plunger rod 4 Remove seal retainers from crankcase NOTE Pump series 4SPX seal retainer is different than the 4DNX and 4DX pump series See Figure 10 NOTE Examine seal washers for cuts or deterioration and replace with a new seal kit as needed NOTE Examine plunger retainer for damaged threads and replace individually as needed NOTE Examine ceramic plunger for scoring scale build up chips or cracks and replace individually as needed Reassembly 5 Install seal washer over each plunger retainer 6 Slide plunger retainer with seal washer onto flat end of each ceramic plunger 7 Apply Loctite 242 to exposed threaded end of each plun
15. 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 e Under the manifold e Into the crankcase Knocking noise e Inlet supply e Bearing Oil leak e Crankcase oil seal e Crankshaft oil seal and o ring e Drain plug e Bubble gauge e Bearing cover e Filler cap Pump runs extremely rough e Inlet conditions e Pump valves e Pump seals Premature seal failure a CAT MINA A The Pumps with Nine Lives PROBABLE CAUSE e Worn nozzle e Air leak in inlet plumbing e Pressure gauge inoperative or not registering accurately e Relief valve stuck partially plugged or improperly adjusted e Inlet suction strainer filter clogged or improperly sized e Abrasives in pumped liquid e Leaky discharge hose e Inadequate liquid supply e Severe c
16. lance and hold gun with both hands to control kick back A CAUTION A IMPROPER USE OF FITTINGS HAZARD Do not operate the pump with improperly connected sized worn or loose fittings pipes or hoses Operating the pump under these conditions could result in personal injury and property damage 1 Ensure all fittings pipes and hoses are properly rated for the maximum pressure rating and flow of the pump Check all fittings and pipes for cracks or damaged threads Check all hoses for cuts wear leaks kinks or collapse before each use Ensure all connections are tight and secure Mm A WU N Use PTFE thread tape or pipe thread sealant sparingly to reconnect plumbing Do not wrap tape beyond the last thread this will prevent tape from becoming lodged in the pump or accessories 6 Apply proper sealants to assure secure fit or easy disassembly when servicing B FROZEN LIQUID HAZARD Do not operate the pump with frozen liquid Operating the pump under this condition could over pressurize and jettison the manifold from the crankcase causing personal injury and property damage 1 Store pump or pumping system in an environmentally controlled room protected from freezing temperatures 2 Follow procedures in TECH BULLETIN 083 to winterize pump C CLEANING PUMP HAZARD Do not use solvents that are flammable and toxic to clean or degrease equipment Use of these solvents could result in personal injury and property damage 1
17. nal injury hazard Obey all safety messages that follow this symbol to avoid possible injury or death SERVICING THE 4DNX 4DX 4SPX SERIES PLUNGER PUMPS AWARNING Do not service pump or electrical equipment while energized Electricity can cause personal injury death or property damage 1 Adhere to Lock Out and Tag Out procedures for electrical equipment 2 Before commencing pump service turn power supply off 3 Keep water away from electrical outlets and electrical devices 4 Electrical components must be installed by a qualified electrician to avoid risk of electrocution SERVICING THE VALVES Disassembly NOTE All pump models require one 1 stacked valve kit to repair pump NOTE Discharge and inlet valve assemblies may stay together or separate during removal Spring retainers may also separate from the seat during removal 1 Use a M19 hex tool to remove three 3 valve plugs 2 Use a pick tool to remove o ring from each valve plug 3 Use a reverse pliers to remove stacked valve assembly from each valve chamber See Figure 1 NOTE Pump series 4DX if inlet seat or discharge seat remains in valve chamber use a M8 screw to thread into seat and pull out See Figure 2 4 Separate discharge valve assembly top from inlet valve assembly bottom See Figure 3 5 Disassemble discharge valve assembly and inspect all parts per NOTE NOTE Pump series 4DNX and 4SPX have o ring and backup ring no backup ring on pump
18. nd premium grade petroleum based hydraulic oil Use of other oil may not provide proper lubrication of drive end components and may result in damage to the crankcase of the pump 1 Cat Pumps custom blend oil is available worldwide in 21 oz bottles cases or 5 gallon twin packs Use of other oils may void the warranty 2 Fill pump crankcase to specific capacity indicated on data sheet or service manual prior to startup B ROTATION OF PUMP HAZARD Do not rotate pump crankshaft in reverse direction Rotation of pump crankshaft in reverse direction may not provide proper lubrication and may result in damage to the drive end components 1 Forward rotation is the top of the crankshaft turning towards the manifold head of the pump 2 Ensure oil is filled to the center red dot on sight gauge for forward rotation 3 Ensure oil is filled to slightly above center red dot on sight gauge for reverse rotation C BELT TENSION HAZARD Do not operate pump with excessive belt tension Excessive belt tension may damage the pumps bearings or reduce horsepower 1 Rotate pump crankshaft before starting to ensure shaft and bearings are moving freely 2 Ensure pulleys are properly sized 3 Periodically replace belts to assure full horsepower transmission 4 Ensure center distance dimensions between pulleys is correct D BY PASS OPERATION HAZARD Do not operate the pump in by pass for extended lengths of time Operating the pump under this condition can qui
19. nifold by hand NOTICE Keep the manifold head properly aligned with the ceramic plungers when removing to avoid damaging the plungers 3 Remove low pressure seals from either plungers or within seal cases 4 Use two 2 flat tip screwdrivers to remove seal cases from manifold See Figure 6 5 Use a pick tool to remove o ring from each seal case 6 Remove high pressure seal from each seal chamber See Figure 7 NOTE Pump series 4SPX remove ring support first then high pressure seal Pump series 4DNX and 4DX do not have this support ring See Figure 8 NOTE Examine low pressure seals for wear to internal surfaces outer surfaces and broken springs and replace with a new seal kit as needed NOTE Examine seal case o rings for cuts or deterioration and replace with a new seal kit as needed NOTE Examine high pressure seals for frayed edges or uneven wear and replace with a new seal kit as needed Reassembly 1 Place manifold on a flat surface with the crankcase side of manifold facing upwards 2 Install high pressure seal with open side down into each seal chamber See Figure 9 NOTE Pump series 4SPX place support ring on top of high pressure seal 3 Lubricate and install o ring onto each seal case 4 Install seal case into each seal chamber of manifold 5 Pump Series 4DX and 4SPX Install low pressure seal with spring facing down into seal case press into place until flush with seal case 6 L
20. of barb 11 Apply Loctite 242 to threaded end of barb 12 Hand thread barb into body of chemical injector 13 Use a M12 hex tool to tighten barb 14 Ensure check valve seat w o ring check valve and spring are installed in unloader manifold chamber 15 Lubricate and install o ring onto chemical injector 16 Apply Loctite 242 to threads of chemical injector 17 Hand thread chemical injector into unloader manifold chamber 18 Tighten with M22 hex tool INSPECTION OF CRANKCASE COMPONENTS Bubble Gauge Leaking Oil I Red Dot for Oil Level Check for water contamination Crankshaft Oil Seal Leaking Oil Drain Plug Leaking Oil Bearing Cover Crankcase Oil Seals Leaking Oil Leaking Oil Figure 19 Figure 20 Contact Cat Pumps or local distributor for servicing crankcase During long term or season storage of three months or longer the residual fluid left in the pump can cause corrosion sticking valves and mineral deposits For equipment stored where the temperatures drop below freezing the pump can be damaged from water freezing in the manifold Using Cat Pumps specially formulated Pump Protector Part 6108 12 oz bottle will help prevent any damage during storage STEPS TO STORE AND PROTECT YOUR PUMP oe ligase a 1 Turn engine motor to 2 Disconnect all hoses 3 Unscrew blue valve from 4 Thread blue valve back Off position bottle and remove white onto bottle internal seal 5
21. series 4DX See Figure 4 6 Disassemble inlet valve assembly and inspect all parts per NOTE NOTE Examine seats valves and springs for grooves pitting or wear and replace with a new valve kit as needed See Figure 5 NOTE Examine o rings and backup rings for cuts or wear and replace with a new valve kit as needed Reassembly NOTE New stacked valve assembly inlet discharge already assembled 7 Place new stacked valve assembly inlet discharge with inlet valve down into each valve chamber 8 Lubricate and install o ring onto each valve plug 9 Apply Loctite 242 to threads of each valve plug hand thread valve plug into each valve chamber 10 Use a M19 hex tool to torque each valve plug to 520 in lbs 43 ft lbs or 58 Nm Loctite and 242 are registered trademarks of Henkel Corporation Note difference between Discharge and Inlet Spring Retainer Valve Assembly Valve Assembly Inlet Discharge Figure 1 Figure 2 Figure 3 Pump Series Pump Series 4DNX and 4SPX 4DX Figure 4 Figure 5 SERVICING THE SEALS Disassembly NOTE All pump series require one 1 seal kit to repair pump NOTE Manifold must be removed to service the seals 1 Use a M5 allen wrench to remove hex socket head screws HSH NOTE Pump series 4DNX and 4DX have six 6 HSH screws NOTE Pumps series 4SPX have eight 8 HSH screws 2 Use two 2 flat tip screwdrivers to create a separation between manifold and crankcase then remove ma
22. valve facing downward 21 Apply Loctite 242 to threads of piston retainer Hand thread into unloader regulator chamber by turning in a clockwise direction tighten with M19 hex tool 22 Install flat spring retainer and then spring 23 Thread brass adjusting cap onto piston retainer threads 24 On pump series 4SPX install black nylon adjusting handle Figure 14 Figure 15 Figure 16 Tapered Surface facing down into Manifold Flat Surface facing up Figure 17 SERVICING THE CHEMICAL INJECTOR Disassembly NOTE To remove barb do not remove chemical injector from pump NOTE Remove chemical hose from barb Use a M12 hex tool to remove barb Use a pick tool to remove o ring from within barb Remove ball and spring from chemical injector body ee pS Use a M22 hex tool to remove chemical injector from unloader manifold body See Figure 18 5 Use a flat tip screwdriver to remove orifice from chemical injector body NOTE Examine barb and orifice for wear and damage and replace individually as needed Figure 18 Igu NOTE Examine spring ball and o ring for damage and replace with a new repair kit Reassembly 6 Apply Loctite 263 to threads of orifice 7 Thread in orifice to chemical injector body Torque to 53 in Ibs 4 4 ft Ibs or 6 Nm 8 Install spring with large diameter side down into barb hole 9 Install ball onto spring 10 Lubricate and install o ring into inside threaded end
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