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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., pop-off valve, safety valve, rupture disc) to assure proper pressure setting and overpressure protection.

  2.   All high pressure systems require a pressure gauge to monitor pressure settings and avoid overpressure of equipment or personal harm.
  3.   Install primary pressure relief device on the discharge side of the pump.
  4.   Install secondary pressure relief device between the primary device and pump.
  5.   Install pressure gauge onto the discharge manifold or in the discharge line near the manifold.
  6.   Open all valves on discharge side of plumbing before operation.

G. OXYGEN HAZARD

Do not charge 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 balance and hold gun with both hands to control kick back.

 

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.
  2.   Check all fittings and pipes for cracks or damaged threads.
  3.   Check all hoses for cuts, wear, leaks, kinks or collapse before each use.
  4.   Ensure all connections are tight and secure.
  5.    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.   Follow safety instructions as found in 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.

CAUTION

Содержание 67102

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 15: ...15 ...

Страница 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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