CAT Pumps 67102, Service Manual

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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.
PN 99MAN002 Rev A 5/17
PROBLEM PROBABLE CAUSE SOLUTION
Low pressure
• Worn nozzle. • Replace with proper size nozzle.
• Belt slippage • Tighten belt(s) or install new belt(s).
• Air leak in inlet plumbing. • Tighten fittings and hoses. Use PTFE liquid or tape.
• Pressure gauge inoperative or not registering accurately. • Check with new gauge. Replace worn or damaged gauge.
• Relief valve stuck, partially plugged or improperly
adjusted.
• Clean/adjust relief valve. Replace worn seats/valves
and o-rings.
• Inlet suction strainer (filter) clogged or improperly sized. • Clean filter. Use adequate size filter. Check more frequently.
• Abrasives in pumped liquid. • Install proper filter.
• Leaky discharge hose. • Replace discharge hose with proper rating for system.
• Inadequate liquid supply. • Pressurize inlet or install inlet stabilizer.
• Severe cavitation. • Check inlet conditions.
• Worn seals. • Install new seal kit. Increase frequency of service.
• Worn or dirty inlet/discharge valves. • Clean inlet/discharge valves or install new valve kit.
Pulsation
• Faulty Pulsation Dampener. • Check precharge. If low, recharge, or install a new dampener.
• Foreign material trapped in inlet/discharge valves. • Clean inlet/discharge valves or install new valve kit.
Water leak
• Under the manifold
• Worn V-Packings or Lo-Pressure Seals. • Install new seal kit. Increase frequency of service.
• Worn adapter o-rings. • Install new o-rings.
• Into the crankcase • Humid air condensing into water inside the crankcase. • Install new oil cap protector. Change oil every 3 months
or 500 hours.
• Excessive wear to V-Packings and Lo-Pressure seals. • Install new seal kit. Increase frequency of service.
Knocking noise
• Inlet supply
• Inadequate inlet liquid supply. • Check liquid supply. Increase line size or pressurize or install
inlet stabilizer.
• Bearing • Broken or worn bearing. • Replace bearing.
• Pulley • Loose pulley on crankshaft. • Check key and tighten set screw.
Oil leak
• Crankcase oil seal
• Worn crankcase oil seal. • Replace crankcase oil seals.
• Crankshaft oil seal and o-ring • Worn crankshaft oil seal or o-ring on bearing cover. • Remove bearing cover 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 specified capacity.
Pump runs extremely rough
• Inlet conditions
• Restricted inlet or air entering the inlet plumbing. • Correct inlet size plumbing. Check for air tight seal.
• Pump valves • Stuck inlet/discharge valves. • Clean out foreign material or install new valve kit.
• Pump seals • Leaking V-Packings or Lo-Pressure seals. • Install new seal kit. Increase frequency of service.
Premature seal failure
• Scored plunger. • Replace plungers.
• Over pressure to inlet manifold. • Reduce inlet pressure per specifications.
• Abrasive material in the liquid being pumped. • Install proper filtration at pump inlet and clean regularly.
• Excessive pressure and/or temperature of pumped liquid. • Check pressure and inlet liquid temperature.
• Running pump dry.
• DO NOT RUN PUMP WITHOUT LIQUID.
• Starving pump of adequate liquid. • Increase hose one size larger than inlet port size. Pressurize
or install inlet stabilizer.
• Eroded manifold. • Replace manifold. Check liquid compatibility.
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.