CAT Pumps 67DX39G1I User manual

SERVICE MANUAL
67DX PLUNGER PUMP SERIES
PUMP MODEL FLOW GPM (L/M) PRESSURE PSI (BAR) PUMP RPM MOTOR RPM TEMPERATURE Far. (Cent) SHAFT DIA. INCH (MM) OIL CAP Oz. (l)
    —  
SERVICING THE 67DX SERIES PLUNGER PUMP
WARNING
Do not service pump or electrical equipment while energized.
Electricity can cause personal injury, death or property damage.
 
 
 
 

SERVICING THE VALVES
Disassembly
NOTE:
NOTE:

 
 
  
 
IMPORTANT SAFETY INSTRUCTIONS


General Safety Information and Symbols






WARNING
CAUTION
NOTICE
DANGER




 
 
 
 
 
 
Reassembly
NOTE:

  
 
 
 
 
NOTE:

 
 
 
 
 
 
NOTE:
 
 
 
 
 
SERVICING THE SEAL
Disassembly
NOTE:
 
 
 
 
 


 
 

  


  
NOTICE
NOTICE
NOTICE



 
 
Reassembly
 
 
 
 
 
 
 
 
 
 
 
  
 
 
 SERVICING THE PLUNGER
 
  
 
 
 
TORQUE SEQUENCE
SERVICING THE PLUNGER
Disassembly
 
SERVICING THE SEALS, Disassembly
 
  
 
  
 
Reassembly
  
 SERVICING THE CRANKCASE.
  
 
 
 
 
 
 
  
 
NOTE:

NOTICE
7 1 3 5
6 4
2 8


  
 
 
  
 
  
 
 
  
 
 
 
 
 
 
TORQUE SEQUENCE.
SERVICING THE CRANKCASE
 

 

 

 

 

 

SERVICING THE UNLOADER/CHEMICAL INJECTOR
Disassembly
 
 
 
 
  
 
 
 
  
 
NOTE: 

 
 
  
  
  
 


  
  
 

Reassembly
NOTE


  
  
  
 
  
 
  
 
  
 
  
 
  
 
 
  
 
  
 
  
  
 
  
  
 
 
 
  
 
  
  
 
  
 
  
 
NOTICE
NOTICE


DANGER
A. FLAMMABLE OR EXPLOSIVE LIQUID HAZARD
Do not operate pump with flammable or explosive liquids unless extraordinary safety precautions are observed. Leaks of flammable or
explosive liquids, if exposed to elevated temperatures, static electricity, sparks or other hazards, will result in flame or possible explosion,
causing serious personal injury, death or property damage.
 
 
 
 

 
 
WARNING
A. ELECTRICAL SHOCK HAZARD
Do not service pump or electrical equipment while energized. Electricity can cause personal injury, death or property damage.
 
 
 
 
PREVENATIVE MAINTENANCE CHECKLIST
 Daily Weekly 50 hrs. 500 hrs. * 1,000 hrs. **
 X
 X
 X
 X
 X
 X
 X
 X
 X
 X
* If other than Cat Pumps special custom blend, ISO 68 hydraulic oil is
used, change cycle should be every 300 hours.
** Each system’s maintenance cycle will be exclusive. If system
performance decreases, check immediately. If no wear at 1000 hours,
check again at 1500 hours and each 500 hours until wear is observed.
Valves typically require changing every other seal change.
Duty cycle, temperature, quality of pumped liquid and inlet feed
conditions all effect the life of pump wear parts and service cycle.
** Remember to service the regulator at each seal servicing and check all
system accessories and connections before resuming operation.
GENERAL SAFTEY INFORMATION AND SYMBOLS
NOTE:
 
 
 
 
 
 
 
 



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.
 
 
 
 
 
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 deflect debris leading to serious personal injury or death.
 
 

 
 
 

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.
 
 
 
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.
 

 
 
 
 
 
G. OXYGEN HAZARD
Do not charge Prrrrr-O-Lators (Pulsation Dampeners) with oxygen. Oxygen may cause an explosion
causing personal injury, death or property damage.
 
 
 
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.
 
 
 
 
CAUTION
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.
 
 
 
 
 

 


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.
 
 
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.
 
 
 
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.
 
 
 
 
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.
 
 
 
 
NOTICE
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.
 
 
B. 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.
 
 
 
C. BELT TENSION HAZARD
Do not operate pump with excessive belt tension. Excessive belt tension may damage the pumps bearings or reduce horsepower.
 
 
 
 
D. 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.
 

 

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.
 
 
 
 
 

PROBLEM PROBABLE CAUSE SOLUTION
Low pressure  
 












 
 
 
 
 
 
Pulsation  
Water leak
  
 






Knocking noise
  
  
Oil leak
  
  

  
  
  
  
Pump runs extremely rough
  
  
  
Premature seal failure  
 
 




 
 
 
DIAGNOSIS AND MAINTENANCE






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