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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.

  5.    Do not remove Flammable Liquids Product Suitability Hang Tag to assure proper safety.
  6.    Follow ATEX guidelines for potentially explosive atmospheres.

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 “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.

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.
  2.     Before commencing pump service, turn power supply off, turn water supply off, squeeze trigger on gun to relieve system pressure. 
  3.     For mobile equipment, be sure engines and hydraulics are turned off and secured to avoid accidental start.
  4.    Do not operate with safety guards removed.
  5.    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 performing 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 Safety Data Sheet (SDS) and take appropriate safety measures for the liquid being handled.

General Safety Information and Symbols

WARNING

DANGER

Summary of Contents for 67102

Page 1: ...mage personal injury or death GeneralSafetyInformationandSymbols 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 res...

Page 2: ...g witho ring 1 4 Removespringwasher 1 3 Removecoilspring 1 6 Toseparatespringretainerfromvalveseat insertaflattipscrewdriverbetweenspring retainerandtopofvalveandpryupwarduntilthereissmallgap 1 7 Ifspringretainerseparatesfromvalveseat removespringandvalve Useareversepliersto removevalveseat 1 8 Completevalveassembly NOTE Examine valve seats valves and springs for grooves pitting or wear and replac...

Page 3: ...icate o rings on valve seats and valve plugs prior to reassembly REASSEMBLY 1 9 Placenewpreassembledvalveassembly intoeachvalvechamber 1 10 Installspringwasherontospringretainer andthencoilspring 1 11 Installnewo ringontovalveplug 1 12 Installvalveplugbyhandandthentap witharubberhammertoseatproperly 1 13 Placecoverplateontomanifold 1 14 Applyanti seize PN6119 tothreadsof HSHscrews ...

Page 4: ...emovethe topoutsidetwo 2 M16x120HSHscrews onthedischargemanifold 2 4 Insert two 2 flat tip screws into the groove on opposite sides of v packing spacer and pry upward 2 3 Two 2 individualsarerequiredto safelyremovethedischargemanifold Placedischargemanifoldonworksurface withspacersfacingupward 2 1 Hand thread in two 2 M16 x 277 studs PN 88902 These studs will assist in guiding the discharge manifo...

Page 5: ...aution when removing inlet manifold Manifold is very heavy The weight of manifold or any twisting action can damage the ceramic plungers 2 14 Use a rubber hammer to tap back side of inlet manifold to further assist in separation from the crankcase 2 15 Remove inlet manifold and place on work surface with crankcase side down 2 11 Hand thread in two 2 M16 x 277 studs PN 88902 These studs will assist...

Page 6: ...king assembly arrangement 2 17 Remove the pair of white v packings from each seal chamber 2 20 Turn inlet manifold over so crankcase side is facing upward 2 21 Use a large flat tip screwdriver to remove low pressure seal from each seal chamber 2 18 Remove female adapter from each seal chamber ...

Page 7: ...4 Install female adapter in each seal chamber with flat surface facing down 2 25 Install the pair of v packings in each seal chamber with v shape facing down 2 26 Install male adapter in each seal chamber with v shape facing down 2 27 Install and lubricate o rings on both ends of v packing spacer 2 28 Install v packing spacer in each seal chamber of discharge manifold 2 29 Install and lubricate o ...

Page 8: ...e keyhole washer 2 39 Ceramic plunger assembly 2 36 Remove barrier slinger 2 37 Remove plunger retainer from ceramic plunger NOTE Examine o rings and backup rings for cuts or wear and replace with new parts as found in the seal kit as needed DISASSEMBLY FOR PLUNGERS 2 31 Remove seal retainers 2 32 Seal retainer assembly 2 33 Use a M30 hex wrench to loosen the plunger retainers ...

Page 9: ...ricate o rings and backup rings on plunger retainers prior to reassembly 2 44 Slide barrier slinger over plunger rod and position against step on plunger rod 2 45 Slide keyhole washer over plunger rod and position against barrier slinger 2 46 Place a drop of Loctite 242 on the end of each plunger rod 2 40 Install gasket onto each plunger retainer 2 41 Position o ring into groove of each plunger re...

Page 10: ...hese studs will assist in guiding the discharge manifold over the plungers and evenly distribute the load NOTE Ensure guide pins are in place 2 57 Line up holes on discharge manifold with studs and slide over ceramic plungers and press against inlet manifold TORQUE SEQUENCE 7 5 1 3 4 2 6 8 2 51 Install large coil spring over each ceramic plunger and press into place 2 52 Apply Loctite 242 to six 6...

Page 11: ... a similar condition It is a good practice to replace both low and high pressure seals and inspect plungers when leaks are present Cat Pumps recommends using our custom blend premium grade hydraulic oil formulated to meet Cat Pumps specifications For best results perform an initial oil change after the first 50 hours of operation and every 500 hours thereafter If other oil is used oil change shoul...

Page 12: ...vice turn power supply off turn water supply off squeeze trigger on gun to relieve system pressure 3 For mobile equipment be sure engines and hydraulics are turned off and secured to avoid accidental start 4 Do not operate with safety guards removed 5 Always use safety guards on all belt drives couplings and shafts C HOTSURFACEHAZARD Donottouchpump accessoriesordrivesystemwhileoperatinganduntilcoo...

Page 13: ...OPERUSEOFFITTINGSHAZARD Donotoperatethepumpwithimproperlyconnected sized wornorloosefittings pipesorhoses Operatingthepumpunderthese conditionscouldresultinpersonalinjuryandpropertydamage 1 Ensure all fittings pipes and hoses are properly rated for the maximum pressure rating and flow of the pump 2 Check all fittings and pipes for cracks or damaged threads 3 Check all hoses for cuts wear leaks kin...

Page 14: ...otation 3 Ensure oil is filled to slightly above center red dot on sight gauge for reverse rotation C BELTTENSIONHAZARD Donotoperatepumpwithexcessivebelttension Excessivebelttensionmaydamagethepumpsbearingsorreducehorsepower 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 horsepo...

Page 15: ...15 ...

Page 16: ...r and replace o ring and or oil seal Drain plug Loose drain plug or worn drain plug o ring Tighten drain plug or replace o ring Dipstick Loose dipstick or worn flat gasket Tighten dipstick or replace flat gasket Rear cover Loose rear cover or worn rear cover o ring Tighten rear cover or replace o ring Filler cap Loose filler cap or excessive oil in crankcase Tighten filler cap Fill crankcase to sp...

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