CAT Pumps 2560 User manual

www.catpumps.com
Product Quality, Reliability and Support You Expect
SERVICE MANUAL
25 FRAME PLUNGER PUMPS
PUMP MODELS INCLUDED
2560 2565 2560BH 2565BH

SERVICE MANUAL | 25 Frame Plunger Pumps2(763) 780-5440 | [email protected] | www.catpumps.com
Safety Symbols 2
General Safety Information 3
Seal & Valve Kits 6
Service Intervals 6
Seal & Valve Kit Pump Diagram 7
Tools Needed 7
Servicing the Seals 8
Manifold and Seal Removal 8
Plunger Removal 11
Plunger Reassembly 12
Seal Installation 13
Manifold Reassembly 14
Servicing the Valves 15
Valve Removal 15
Valve Disassembly 16
Valve Reassembly 18
Valve Installation 20
Crankcase Component Inspection 21
Reference Information 22
Preventive Maintenance Schedule 22
Torque Chart 23
Discharge Manifold Torque Sequence 23
Valve Plug Cover Torque Sequence 23
Technical Bulletin Reference Chart 23
Diagnosis and Maintenance 24
Table of Contents
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:
Safety Symbols
Indicates a potential personal injury hazard.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
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 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.

SERVICE MANUAL | 25 Frame Plunger Pumps 3(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information
A. FLAMMABLE OR EXPLOSIVE LIQUID HAZARD
Do not operate pump with ammable or explosive liquids unless extraordinary safety precautions are observed. Leaks of ammable or explosive
liquids, if exposed to elevated temperatures, static electricity, sparks or other hazards, will result in ame or possible explosion, causing serious
personal injury, death or property damage.
1. Before operating pump with ammable or explosive liquids, ensure proper maintenance has been performed.
2. Do not operate pump with ammable or explosive liquids if leaks are detected.
3. Only pump ammable or explosive liquids that are compatible with pump component materials.
4. Do not operate pump with ammable or explosive liquids without safeguards or safety systems to detect leaks, elevated temperatures,
spark prevention or any other hazards dened 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 o.
3. Keep water away from electrical outlets and electrical devices.
4. Electrical components must be installed by a qualied 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 o, turn water supply o, squeeze trigger on gun to relieve system pressure.
3. For mobile equipment, be sure engines and hydraulics are turned o 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 deect 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 a 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 a 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.

SERVICE MANUAL | 25 Frame Plunger Pumps4(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information and Symbols
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 (e.g., regulator or unloader) and a secondary pressure safety relief device
(e.g., pop-o 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 specications 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 scaolding.
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 ttings, pipes or hoses. Operating the pump under these conditions
could result in personal injury and property damage.
1. Ensure all ttings, pipes and hoses are properly rated for the maximum pressure rating and ow of the pump.
2. Check all ttings 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 loose
tape from becoming lodged in the pump or accessories.
6. Apply proper sealants to assure secure t 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 ammable 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 specications 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.
CONTINUED

SERVICE MANUAL | 25 Frame Plunger Pumps 5(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information and Symbols
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 (e.g. 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.
A. OIL HAZARD
Use only genuine Cat Pumps custom-blend, premium-grade, petroleum-based hydraulic oil. Use of other oil may not provide proper
lubrication of drive-end components and may result in damage to the crankcase of the pump.
1. Fill pump crankcase to specic capacity indicated on data sheet or service manual prior to startup.
2. Cat Pumps premium custom-blend oil is available worldwide in 21-ounce bottles, (single and 12-pack cases), 2.5 gallon jugs (single and 2-pack)
or 30 gallon drums. Use of other oils may void the warranty.
B. PUMP ROTATION DIRECTION 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 lled to the center red dot on sight gauge for forward rotation.
3. If reverse rotation is unavoidable, ensure oil is lled to slightly above center red dot on sight gauge.
C. BELT TENSION HAZARD
Do not operate pump with excessive belt tension. Excessive belt tension may damage the pump’s 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.
D. BYPASS OPERATION HAZARD
Do not operate the pump in bypass 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 bypass line to supply reservoir to dissipate heated bypass liquid into a large reservoir of cool water to reduce excessive temperature build-
up.
2. Route bypass line to inlet of pump using a thermo valve in the bypass line or auto shut-o assembly that will sense temperature rise
and either bypass or shut down system before damage occurs.
E. 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 specied in pump data sheet.
3. Ensure inlet feed exceeds the maximum ow being delivered by the pump.
4. Ensure all ttings, pipes and hoses are properly-sized for the pump to avoid restricted ow.
5. Review and implement all other recommendations appropriate for your system from the Inlet Condition Check-List.
CONTINUED

SERVICE MANUAL | 25 Frame Plunger Pumps6(763) 780-5440 | [email protected] | www.catpumps.com
Seal & Valve Kits
SERVICE INTERVALS
Typically, plunger pumps require only a very basic standard maintenance procedure of regular oil changes and seal and valve replacement.
Seal and valve life are extremely dependent upon the type of pumped liquid, temperature, inlet conditions, system protective devices, ltration,
duty-cycle and maintenance-cycle. Most system failures are not due to the pump, but fail because of other system components.
The Preventative Maintenance Check-List (on page 22) provides a summary of the various system maintenance concerns for all high-pressure systems.
The seals on our pumps, operating under normal conditions, will perform for a minimum of 1500 hours, with most lasting much longer.
The valves typically perform for 3000 hours, with many lasting much longer. Cat Pumps always recommends replacing these items as a kit
since components usually wear at about the same rate.
SEAL KITS
2560, 2560BH: PN 76853 | Qty 1
VALVE KIT
PN 31292 | Qty 1
2565, 2565BH: PN 76854 | Qty 1

SERVICE MANUAL | 25 Frame Plunger Pumps 7(763) 780-5440 | [email protected] | www.catpumps.com
VALVE KIT
ASSEMBLY
31292
O-RING
BACKUP RING
O-RING O-RING
O-RING
V-PACKINGS
LOW-PRESSURE
SEAL
BACKUP RING
Tools Needed
1. 10 mm Hex Socket
2. Small Flat Tip Screwdriver
3. 2 x Large Flat Tip Screwdrivers
4. Pick
5. Reverse Pliers (PN 30696)
6. 14 mm Combination Wrench
7. Rubber Mallet
8. Oil Bubble Gauge Tool
9. Lubricating Oil
10. Liquid Thread Sealant
Seal & Valve Kit Pump Diagram
VALVE KITS
PN 31292 | Qty 1
2 3 4 65 10 97 81
SEAL KIT
2560, 2560BH: PN 76853 | Qty 1
2565, 2565BH: PN 76854 | Qty 1

SERVICE MANUAL | 25 Frame Plunger Pumps8(763) 780-5440 | [email protected] | www.catpumps.com
Servicing the Seals
MANIFOLD AND SEAL REMOVAL
1.04 If the V-packing spacers remain in the
discharge manifold, use two (2) flat tip
screwdrivers on opposite sides to pry the
spacers loose from the manifold and remove.
1.06 Inspect O-ring and backup ring for damage.
1.05 If the V-packing spacers remain in the
inlet manifold, remove by inserting two
screwdrivers on opposite sides to pry out
of chamber.
1.01 Use a 10 mm hex socket to remove the six
(6) hex socket head screws (HSH) from the
discharge manifold.
1.02 Support the manifold from underneath.
Using a rubber mallet, tap the manifold to
separate from the inlet manifold and remove
completely.
1.03 Place the discharge manifold on a flat surface
with the V-packing spacer bores facing up.
1.07 Using a pick, remove both sets of O-rings and
backup rings from V-packing spacers.
1.08 Use a small pick to remove inlet manifold
O-rings.
NOTICE: The discharge manifold is very heavy so
use caution. Be sure to properly support the bottom
of the manifold to avoid injury.
NOTE: One (1) seal kit is required to repair the pump (see data sheet PN 99DAT090).

SERVICE MANUAL | 25 Frame Plunger Pumps 9(763) 780-5440 | [email protected] | www.catpumps.com
Servicing the Seals
MANIFOLD AND SEAL REMOVAL
1.09 Use a 10 mm hex socket to remove the
four (4) HSH screws from the inlet manifold.
1.10 Using a rubber mallet, tap the manifold to
create a separation between the crankcase
and the manifold.
1.13 Use a flat tip screwdriver to pry the first
V-packing upward and remove.
NOTICE: Be careful not to score the inside of
the manifold.
1.16 Inspect the manifold bore to ensure sealing
surface is smooth and free from corrosion.
1.11 Insert two (2) flat tip screwdrivers on opposite
sides to pry the manifold away from the
crankcase.
1.14 Repeat for the second V-packing, inspect both
for wear or damage.
1.17 Flip the inlet manifold over so low-pressure
seals are facing upwards.
1.12 Remove inlet manifold by hand and place
on a flat surface with V-packing spacer bores
facing up.
1.15 Remove the female adapter and inspect for
wear or damage.

SERVICE MANUAL | 25 Frame Plunger Pumps10 [phone] | [email protected] | www.catpumps.com
1.19 Inspect the inside diameter of the low-
pressure seals for wear or damage.
Servicing the Seals
1.18 Use a flat tip screwdriver to pry the low-
pressure seal upward and remove.
MANIFOLD AND SEAL REMOVAL
NOTICE: Be careful not to score the inside
of the manifold.

SERVICE MANUAL | 25 Frame Plunger Pumps 11(763) 780-5440 | [email protected] | www.catpumps.com
PLUNGER REMOVAL
1.22 Seal retainer can be separated to remove and
inspect the wicks. Replace as needed (wicks
not included in the seal kit).
1.25 Remove the plunger retainer from the
plunger and inspect the O-ring and backup
ring for damage.
1.20 Remove seal retainers from crankcase
housing.
1.23 Using a 14 mm combination wrench, loosen
the plunger retainer.
1.21 Remove low-pressure seal washer.
1.24 Before completely removing the plunger
retainer, stop and push the plunger towards
the drive end to break loose from the retainer.
Remove the plunger and retainer.
Servicing the Seals
1.28 Use a pick to remove keyhole washer and
barrier slinger located behind the plunger.
Inspect for damage.
1.26 Using a pick, remove the plunger retainer
O-ring from plunger retainer.
1.27 Inspect ceramic plunger for cracks and
scoring to the surface. Clean with a wire-
wheel brush if necessary.

SERVICE MANUAL | 25 Frame Plunger Pumps12 [phone] | [email protected] | www.catpumps.com
1.38 Press low-pressure seal washer onto seal
retainer.
PLUNGER REASSEMBLY
1.29 Install barrier slinger with dish side facing
away from crankcase.
1.30 Install keyhole washer. The slot can face any
direction.
1.31 Replace plunger retainer O-ring with new one
from seal kit and apply a lubricant to outside
surface.
Servicing the Seals
1.32 Look for stepped side of plunger. This side
goes towards the pump crankcase.
1.35 Thread plunger assembly onto plunger rod
by hand.
1.33 Insert plunger retainer with O-ring and
backup ring into non-stepped side of plunger.
1.36 Using a 14 mm combination wrench, torque
to 108 in-lbs, 7.5 ft-lbs or 10 Nm.
1.34 Place a drop of Loctite® 242®on the threaded
end of the plunger rod.
1.37 Install seal retainer with wick tab facing down
towards the oil pan.
Loctite and 242 are registered trademarks of the Henkel Corporation.

SERVICE MANUAL | 25 Frame Plunger Pumps 13(763) 780-5440 | [email protected] | www.catpumps.com
Servicing the Seals
1.41 Flip inlet manifold over so that valve spacer
bores are facing up.
1.44 Install the second V-packing with the groove
side also facing up.
1.42 The female adapter has a flat side and a
grooved side. Install with the groove side
facing up.
1.45 Install backup rings, then O-rings onto the
V-packing spacers.
NOTICE: Backup rings go on the inside of the
grooves, and O-rings on the outside.
1.46 Apply a lubricant to the V-packing spacer
O-rings.
1.43 Install the first V-packing with the groove
side facing up.
1.39 Apply a lubricant to the outside surface of the
low-pressure seals.
1.40 One side of the low-pressure seal has a
groove. Install groove side facing down and
press into place.
Loctite and 242 are registered trademarks of the Henkel Corporation.
SEAL INSTALLATION
1.47 The V-packing spacer has two distinct steps.
Press the longer side with the groove into the
inlet manifold.
NOTICE: Examine manifolds, and male and female adapters for grooves, pitting or wear. Replace as needed.

SERVICE MANUAL | 25 Frame Plunger Pumps14 [phone] | [email protected] | www.catpumps.com
1.51 Using a 10 mm hex socket, tighten HSH
screws. Torque to 355 in-lbs, 30 ft-lbs, or 40
Nm.
1.50 Place a drop of Loctite® 242® on the threaded
end of the four (4) HSH screws and install by
hand.
1.53 Lift the discharge manifold into place against
the inlet manifold and V-packing spacers and
press into place.
1.52 Replace inlet manifold O-rings.
1.54 Install six (6) HSH screws by hand. Using a
10 MM hex socket, tighten screws using
appropriate cross-pattern for even alignment.
Torque to 355 in-lbs, 30 ft-lbs, or 40 Nm.
1.48 Rotate crankshaft so outside two plungers are
even at furthest distance from crankcase.
1.49 Install inlet manifold by hand, ensuring even
alignment. Press into place.
Servicing the Seals
MANIFOLD REASSEMBLY
TORQUE SEQUENCE
Loctite and 242 are registered trademarks of the Henkel Corporation.

SERVICE MANUAL | 25 Frame Plunger Pumps 15(763) 780-5440 | [email protected] | www.catpumps.com
Servicing the Valves
VALVE REMOVAL
2.02 Using a small flat tip screwdriver, tap between
the notched corner of the valve plug and the
manifold to create a gap and pry upwards.
2.01 Use a 10 mm hex socket to remove the four (4)
HSH screws from the valve plug.
2.03 Remove the valve plug by hand.
2.04 Inspect valve plug O-ring and backup ring for
cuts, nicks or damage.
2.07 The valve seat O-ring may remain in
the manifold. Use a pick or small flat tip
screwdriver to remove O-ring.
2.05 Using a pick, remove O-ring and backup ring
from valve plug.
NOTICE: Valve assembly can be disassembled
for inspection and servicing, then reassembled.
If replacing the complete valve kit assembly,
skip to Valve Installation 2.37.
2.06 Use a reverse pliers to grasp the center of the
valve spring retainer. Twist while pulling away
from manifold to remove valve assembly.
NOTE: One (1) valve kit is required to repair the pump (see data sheet PN 99DAT090).

SERVICE MANUAL | 25 Frame Plunger Pumps16 [phone] | [email protected] | www.catpumps.com
Servicing the Valves
VALVE DISASSEMBLY
2.10 Inspect discharge valve spring retainer for
cracks, excessive wear or damage.
2.11 Inspect spring for proper tension or any
damage.
2.09 Remove discharge spring retainer by hand.
2.12 Inspect tapered surface of discharge valve for
wear, pitting or damage.
2.15 Inspect discharge valve seat O-ring and
backup ring for cuts, nicks or damage.
2.16 Using a pick, remove O-ring and backup ring
from discharge valve seat.
2.13 Remove discharge valve seat by hand.
2.14 Inspect tapered surface of discharge valve
seat for wear, pitting or damage.
NOTICE: Pitting on the valve or valve seat is an
indication of cavitation.
2.17 Insert a flat tip screwdriver through inlet
spring retainer just above inlet valve. Twist
to create a small gap between inlet spring
retainer and inlet valve seat.
2.08 Insert a flat tip screwdriver through discharge
spring retainer just above discharge valve.
Twist to create a small gap between discharge
spring retainer and discharge valve seat.

SERVICE MANUAL | 25 Frame Plunger Pumps 17(763) 780-5440 | [email protected] | www.catpumps.com
VALVE DISASSEMBLY
2.18 Remove inlet spring retainer by hand. 2.19 Inspect inlet valve spring retainer for cracks,
excessive wear or damage.
2.20 Inspect spring for proper tension or any
damage.
Servicing the Valves
2.21 Inspect tapered surface of inlet valve for wear,
pitting or damage.
2.22 Inspect tapered surface of inlet valve seat for
wear, pitting or damage.
2.23 Inspect inlet valve seat O-ring for cuts, nicks or
damage and remove.

SERVICE MANUAL | 25 Frame Plunger Pumps18 [phone] | [email protected] | www.catpumps.com
Servicing the Valves
2.31 Install discharge valve seat onto inlet spring
retainer and push assembly together until it
snaps into place.
2.29 Push assembly together until it snaps into
place.
2.30 Replace discharge valve backup ring, then
O-ring onto discharge valve seat.
2.32 Place discharge valve onto discharge valve
seat with tapered surface facing down.
2.28 Place inlet valve spring retainer onto inlet
valve seat.
VALVE REASSEMBLY
2.27 Place spring onto stepped side of inlet valve.
2.25 Hold inlet valve seat with tapered surface
facing up.
2.24 Replace inlet valve O-ring. 2.26 Place inlet valve onto inlet valve seat with
tapered surface facing down.

SERVICE MANUAL | 25 Frame Plunger Pumps 19(763) 780-5440 | [email protected] | www.catpumps.com
Servicing the Valves
2.34 Place discharge valve spring retainer onto
discharge valve seat.
2.35 Push assembly together until it snaps into
place.
2.33 Place spring onto stepped side of discharge
valve.
2.36 Apply a lubricant to the outside surface of the
inlet valve seat O-ring.
VALVE REASSEMBLY

SERVICE MANUAL | 25 Frame Plunger Pumps20 [phone] | [email protected] | www.catpumps.com
2.40 Install valve plug into manifold and press into
place.
2.38 Insert valve assembly into manifold and press
into place.
2.39 Install valve plug backup ring, then O-ring,
and apply a lubricant to outside surface.
NOTICE: Valve plug O-ring faces down when
installed in the manifold.
2.41 Install four (4) HSH screws by hand. 2.42 Using a 10 mm hex socket, tighten HSH
screws using appropriate cross-pattern
for even alignment. Torque to 355 in-lbs,
30 ft-lbs, or 40 Nm.
2.37 Apply a lubricant to the outside surface of the
discharge valve seat O-ring.
VALVE INSTALLATION
TORQUE SEQUENCE
Servicing the Valves