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
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

2
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.

3
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
7
5
1
3
4
2
6
8
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.

4
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.

5
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.

6
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.

7
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.

8
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.

9
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.

10
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
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) 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.