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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. 

Continued

A. 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.

B. 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.

C. BY-PASS OPERATION HAZARD

Do not operate the pump in by-pass for extended lengths of time.  Operating the pump under this condition 

can quickly 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.

D. DRY OPERATION HAZARD

Do not operate the pump without water or liquid. Operating pump under these conditions could result in 

damage to the pump.
1.   Open all valves on inlet side of pump before starting operation to prevent starving the pump.
2.   Do not exceed inlet suction pressure limit specified in pump Data Sheet.
3.   Ensure inlet feed exceeds the maximum flow being delivered by the pump.
4.   Ensure all fittings, pipes and hoses are properly sized for the pump to avoid restricted flow.  
5.   Review and implement all other recommendations appropriate for your system from the Inlet Condition Check-List.

Содержание 1XP Series

Страница 1: ...1XP Series Plunger Pump Installation Operational and Repair Manual www catpumps com Product Quality Reliability and Support You Expect ...

Страница 2: ...t 8 Exploded view 9 Pump disassembly 10 12 Pump reassembly 13 16 DC Motor 8136 brush replacement 17 Stopping for long periods 17 i e long term and or winterization Restarting system 17 Torque specifications and repair tools 18 Preventative maintenance 18 Troubleshooting 18 i e problem cause solution Flow and Pressure 19 Cat Pumps Warranty 20 IMPORTANT SAFETY INSTRUCTIONS It is the responsibility o...

Страница 3: ...gger 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...

Страница 4: ...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 faste...

Страница 5: ...arings 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 C BY PASS OPERATION HAZARD Do not operate the pump in by pass for extended lengths of time Operating the pump under t...

Страница 6: ...25 03DCT 1XP150 1XP150 031 1XP150 051 1XP150 071 1XP150 101 1XP150 03DC 1XP150 03DC2 1XP150 03DCT 1XP180 1XP180 071 1XP180 101 1XP200 1XP200 031 1XP200 051 1XP200 071 1XP200 101 1XP200 03DC 1XP200 03DC2 1XP200 03DCT Stamped Cam ID number See Chart Pump and Motor Installation Technical Features Pump Models and Pump Motor Assemblies There are eight 8 cams available for the 1XP Series Pumps Each cam ...

Страница 7: ...ion 1 5 Install inlet water hose to center 3 8 NPT port on pump labeled INLET Inlet Port Electrical power connection 1 3 Connect to power source for AC induction motors 8133 8135 and 8147 115 208 230VAC 1 4 Connect to power source for DC permanent magnet motor 8136 8139 120 Volt rectified and 8138 240 Volt rectified Power Cord Connection NOTE Standard pump to motor mounting is shown in figure 1 5 ...

Страница 8: ...206 S Valve Discharge 2 26 76865 S Spring Valve 06 13 2 27 76069 PVDF Retainer Valve 2 28 76555 AL Assembly Plunger ConnectingRod Includes plungerrod connectingrod wristpin 2 29 76227 NY Kit InletValve Includes items16 17 18 19 20 1 30 76218 FPM Assembly DischargeValve Includes items23 24 25 26 27 1 31 76219 FPM Kit SealandO ring Includes items6 10 11 12 15 22 1 32 76127 Kit BrushReplacement 8136o...

Страница 9: ...9 13 14 22 22 21 19 17 26 24 30 15 1 15 27 25 23 14 20 28 18 16 13 7 3 4 5 6 9 11 8 10 12 ACMotor ThreadedShaft DCMotor KeyedShaft ACMotor KeyedShaft Exploded View ...

Страница 10: ...uipmentwhileenergized Electricitycancausepersonalinjury deathorpropertydamage 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 ToolsRequired 1 4mm M4 Allen Wren...

Страница 11: ...move and inspect shaft seal 10 from motor flange Do not scratch or damage motor shaft surface 5 10 Remove and inspect shaft seal 10 from motor flange Do not scratch or damage motor shaft surface 5 9 Insert two 2 flat tip screw drivers between flange and pry shaft seal away from motor 5 8 Unthread threaded cam from motor shaft For Threaded Shaft Units Ifoldshaftsealcannotbe removed itmayrequireremo...

Страница 12: ...re identical in both cylinder heads 5 18 Remove and inspect nut 16 washer 17 spacer 19 spring 18 and inlet valve 20 5 19 Remove and inspect ceramic plunger 21 and high pressure seal 22 from crankcase body 1 5 20 Remove and inspect connecting rod plunger rod and wrist pin assembly 5 15 Insert the short end of an allen wrench to remove discharge valve assembly 5 14 Use a 5mm allen wrench to remove f...

Страница 13: ...lange by sliding over motor shaft Center between shaft seal bore and back of the slinger seal bore 6 2 Lubricate and install motor flange o ring 12 onto the motor flange Loctite and 242 are registered trademarks of the Henkle Corporation 6 5 Hand thread cam 8 with stamped ID number and small holes facing pump clockwise 6 6 Use spanner wrench and 1 2 open wrench to tighten cam 8 NOTE Apply Loctite ...

Страница 14: ...o plunger 21 6 14 Lightly lubricate and install high pressure seal 22 with v groove facing up over ceramic plunger 21 6 13 Install ceramic plunger 21 with recessed face away from crankcase Pump Reassembly continued 6 10 Lubricate and install o ring 6 onto bearing cover 5 6 9 Install retaining ring 7 into snap ring groove on motor shaft to secure cam 8 Keyed Shaft only 6 7 Lubricate and install woo...

Страница 15: ...e over the spring 26 6 19 Apply Loctite 242 to M6 threads on plunger rod Thread nut 16 onto M6 threads of plunger rod and torque to 25 in lbs Loctite and 242 are registered trademarks of the Henkle Corporation 6 22 Place tapered side of seat 24 towards retainer 27 and snap into place 6 23 Lubricate and install o ring 23 to seat 24 Repeat for second valve assembly 6 24 Press discharge valve assembl...

Страница 16: ...mmwrenchtoinstalldrainplug 3 into bottom port of crankcase body 1 6 28 With bearing cover 5 removed position crankcase body 1 onto motor while lining up the connecting rods 28 with the cam 8 Note Make sure the connecting rods are loose on cam 1 3 4 5 2 6 29 Hand thread four 4 M6x75 button head screws 4 Use a 4mm allen wrench to torque to 48 in lbs in sequence as shown Note Lubricate o ring on bear...

Страница 17: ...er remove white retaining clip 7 3 Remove wire lead from small opening in motor housing 7 4 Blow out dust that may accumulate in opening of motor 7 5 Repeat steps 7 1 to 7 4 to remove second wire lead REASSEMBLY 7 6 Position wire lead into opening of motor with brush and attaching spring down into opening with brass end facing up 7 7 Place white retaining clip over wire lead and snap into place 7 ...

Страница 18: ... Pumps parts or kits when performing repairs Troubleshooting The troubleshooting table has been provided to assist in defining problems that may arise then giving probable causes to look for and finally providing possible solutions to the problem at hand Problem Probable Causes Solutions Low pressure Worn nozzle Replace with proper size nozzle Worn seals Install new seal kit Increase frequency of ...

Страница 19: ...CT 2 3 150 4 0 1XP200 03DC 1XP200 03DCT GPM Max PSI Pump Assembly SFA HP 0 40 600 1XP050 031 4 2 2 1 1 3 0 60 500 1XP075 031 0 70 500 1XP085 031 0 80 450 1XP100 031 1 400 1XP125 031 1 2 325 1XP150 031 1 70 250 1XP200 031 0 30 1000 1XP050 051 8 2 3 8 1 2 0 60 1000 1XP075 051 0 70 1000 1XP085 051 0 75 800 1XP100 051 1 800 1XP125 051 1 2 600 1XP150 051 1 70 450 1XP200 051 0 75 1000 1XP100 071 10 0 4 ...

Страница 20: ...Cat Pumps shall not be liable for defects or failures resulting from improper or lack of maintenance lack of proper crankcase lubrication failure to supply adequate liquid to pump pumping materials below 5 pH or above 9 pH above 500 cps general wear and tear or any malfunction damage or wear caused by faulty installation misapplication misuse accident excessive abrasion corrosion freezing or heat ...

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