CAT Pumps 67102 User manual

SERVICE MANUAL

67102 PLUNGER PUMP

SERVICING THE 67102 PLUNGER PUMP SERIES

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.

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.

Indicates a potential personal injury hazard. Obey all safety messages that follow this symbol to avoid possible injury or death.

WARNING

CAUTION

NOTICE

DANGER

PUMP

MODEL

FLOW PRESSURE RPM TEMPERATURE SHAFT DIA. OIL CAPACITY

gpm lpm psi bar Pump Motor ˚F ˚C in mm oz l

67102 100.0 378.5 1,000 69 680 —140 60 1.772 45 320 9.46

67102C 100.0 378.5 1,000 69 680 —140 60 1.772 45 320 9.46

Servicing the Valves

DISASSEMBLY

NOTE: Two (2) valve kits are required to repair the pump (see data sheet PN 99DAT023).

NOTE: Discharge and inlet valve assemblies are identical (use procedure below for disassembly and reassembly of discharge and inlet valves).

1.0 Use a M14 socket wrench to remove the

eight (8) M16 x 30 Hex Socket Head (HSH)

screws from the valve plate.

1.1 Remove valve plate. 1.2 Insert two (2) at tip screw drivers into

grooves on opposite sides of valve plug

and pry upward to remove valve plug

with o-ring.

1.4 Remove spring washer.1.3 Remove coil spring.

1.6 To separate spring retainer from valve seat, insert a at tip screw driver between spring

retainer and top of valve and pry upward until there is small gap.

1.7 If spring retainer separates from valve seat, remove spring and valve. Use a reverse pliers to

remove valve seat.

1.8 Complete valve assembly.

NOTE: Examine valve seats, valves and springs for grooves, pitting or wear and replace with a new valve kit as needed.

NOTE: Examine o-rings for cuts or wear and replace with a new valve kit as needed.

1.5 Use one of the discharge manifold HSH

screws (M16 x 120) and hand thread into

threaded hole of spring retainer. Grasp

M16 screw and pull upward to remove

complete valve assembly.

1.15 Hand thread in eight (8) M16 x 30 HSH

screws.

1.16 Use a M14 socket wrench to torque all

eight (8) HSH screws to 1416 in/lbs, 118 ft/

lbs or 160 Nm in sequence show.

TORQUE SEQUENCE

NOTE: Lubricate o-rings on valve seats and valve plugs prior to reassembly.

REASSEMBLY

1.9 Place new preassembled valve assembly

into each valve chamber.

1.10 Install spring washer onto spring retainer

and then coil spring.

1.11 Install new o-ring onto valve plug.

1.12 Install valve plug by hand and then tap

with a rubber hammer to seat properly.

1.13 Place cover plate onto manifold.

1.14 Apply anti-seize (PN 6119) to threads of

HSH screws.

Servicing the Seals and Plungers

DISASSEMBLY FOR SEALS

NOTE: One (1) seal kit is required to repair pump (see data sheet PN 99DAT023).

NOTE: In order to replace seals, remove discharge and inlet manifolds.

CAUTION

Exercise extreme caution when

removing discharge manifold. Manifold

is very heavy and will require two (2)

individuals. The weight of manifold or

any twisting action can damage the

ceramic plungers.

2.2 Use a rubber hammer to tap back side

of discharge manifold to separate from

inlet manifold.

2.0 Use a M14 socket wrench to remove the

top outside two (2) M16 x 120 HSH screws

on the discharge manifold.

2.4 Insert two (2) at tip screws into the

groove on opposite sides of v-packing

spacer and pry upward.

2.3 Two (2) individuals are required to

safely remove the discharge manifold.

Place discharge manifold on work surface

with spacers facing upward.

2.1 Hand thread in two (2) M16 x 277 studs

(PN 88902). These studs will assist in

guiding the discharge manifold over the

plungers and evenly distribute the load.

2.5 Use a pick to remove o-rings from both

ends of the v-packing spacer.

2.7 Carefully insert two (2) at tip screws into

the groove on opposite sides of inlet

spacer and pry upward. Do not scratch

o-ring sealing area.

2.6 Use a pick to remove o-ring from top of

inlet spacer.

2.8 Use a pick to remove o-ring from the one

end of the inlet spacer.

2.9 Remove large coil spring positioned

around each plunger.

2.10 Use a M14 socket wrench to remove

the top outside two (2) M16 x 110 HSH

screws on the inlet manifold.

2.13 Use a crescent wrench to turn the

pump’s crankshaft to assist in separating

the inlet manifold from the crankcase.

CAUTION

Exercise extreme caution 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 in guiding the

inlet manifold over the plungers and evenly distribute the load.

2.12 Use a M14 socket wrench to remove the remaining six (6) M16 x 110 HSH screws on the

inlet manifold.

DISASSEMBLY FOR SEALS CONTINUED

2.16 Remove male adapter from each

seal chamber.

2.19 V-Packing 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 at tip screwdriver to remove low-pressure seal from each seal chamber.

2.18 Remove female adapter from each

seal chamber.

REASSEMBLY FOR SEALS

NOTE: Examine inlet and discharge manifolds, spacers, male and female adapters for grooves, pitting or wear and replace as needed.

NOTE: Examine o-rings, low-pressure seals and v-packings for cuts or wear and replace with a new seal kit as needed.

2.22 With crankcase side of inlet manifold facing upward, install low-pressure seals with coil spring facing down.

2.23 Turn inlet manifold over.

2.24 Install female adapter in each seal

chamber with at 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-rings on both

ends of inlet spacer.

2.30 Install inlet spacer in each seal chamber.

NOTE: The seal kit contains three (3)

plunger retainer o-rings and should

be replaced at this time prior to

re-installing manifolds.

2.34 Grasp ceramic plunger and turn

counterclockwise to remove plunger

from plunger rod.

2.38 Use a pick to remove o-ring, backup-

ring and gasket from plunger retainer.

2.35 Remove 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.

Loctite and 242 are registered trademarks of the Henkle Corporation

2.47 Hand thread ceramic plunger assembly

onto each plunger rod.

2.48 Use a M30 hex wrench to tighten the

plunger retainers. Torque to 588 in/lbs,

49 ft/lbs or 66 Nm.

2.49 Slide seal retainer assembly over each

plunger rod. Position wick downward.

REASSEMBLY OF PLUNGERS

NOTE: Lubricate 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 retainer.

2.42 Position backup-ring into groove on

top of o-ring of each plunger retainer.

2.43 Insert plunger retainer assembly into

ceramic plunger.

REASSEMBLY OF MANIFOLDS

2.50 Place inlet manifold onto two (2) M16 x 277 studs and slide up against crankcase.

2.58 Apply anti-seize (PN 6119) to six (6)

M16 x 120 HSH screws; insert screws into

discharge manifold and hand thighten.

2.59 Remove two (2) M16 x 277 studs.

2.60 Apply anti-seize (PN 6119) to remaining

two (2) M16 x 120 HSH screws and

install.

2.61 Use a M14 socket wrench to torque

all eight (8) HSH screws to 1416 in/lbs,

118 ft/lbs or 160 Nm in sequence shown.

2.55 Use a M14 socket wrench to torque all

eight (8) HSH screws to 1152 in/lbs,

96 ft/lbs or 130 Nm in sequence show.

2.56 Hand thread in two (2) M16 x 277 studs

(PN 88902) into upper outside holes of

inlet manifold. These 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

2.51 Install large coil spring over each ceramic plunger and press into place.

2.52 Apply Loctite®242® to six (6) M16 x 110 HSH screws; insert screws into inlet manifold and

hand thighten.

2.53 Remove two (2) M16 x 277 studs.

2.54 Apply Loctite®242® to remaining two (2) M16 x 110 HSH screws and install.

Loctite and 242 are registered trademarks of the Henkle Corporation

CAUTION

Exercise extreme caution when

reinstalling discharge manifold.

Manifold is very heavy and will require

two (2) individuals. The weight of

manifold or any twisting action can

damage the ceramic plungers.

This manual suits for next models

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