CAT Pumps 1570 Bedienungsanleitung

SERVICE MANUAL

1570 PLUNGER PUMP

SERVICING THE 1570 PLUNGER PUMP SERIES

WARNING

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

1570 6.0 22.7 6,000 414 1350 —120 48 1.181 30 42 1.26

E-mail : [email protected] / [email protected]

Internet: www.pijttersen.nl / www.catpumps.nl

Servicing the Valves

DISASSEMBLY (DISCHARGE VALVES ONLY)

NOTE: One (1) valve kit is required to repair pump.

NOTE: The discharge seat has a smaller diameter than the inlet seat.

1.0 Use a M10 Allen Wrench to remove the

eight (8) Hex Socket Head (HSH) screws

from valve cover on IMDM.

1.1 Remove valve cover. 1.2 Use a at tip screwdriver to remove

valve plugs from each valve chamber.

1.4 Remove coil spring and then washer

from each valve chamber.

1.3 Use a pick tool to remove backup-ring

and o-ring from each valve plug.

1.6 Disassemble discharge valve assembly

and inspect all parts per NOTES

NOTE: Examine seats, valves and springs for grooves, pitting or wear and replace with a

new valve kit as needed.

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

as needed.

1.5 Use a needle nose pliers to grab the tip

end of the spring retainer and pull valve

assembly from each valve chamber.

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

1.7 Place new assemblied discharge valve

assembly into each valve chamber.

1.8 Place washer over tip of spring retainer

and then coil spring.

1.9 Press in valve plug into each valve

chamber.

1.11 Apply anti-sieze lubricant (PN 6119) to

threads of all eight (8) HSH screws and

hand tighten.

1.10 Place valve cover on top of IMDM and

align with threaded holes.

REASSEMBLY

1.12 Use a M10 Allen Wrench to torque all

eight (8) HSH screws to 398 in lbs, 33 ft

lbs or 45 Nm in sequence show.

TORQUE SEQUENCE

Servicing the Valves

DISASSEMBLY (INLET VALVES ONLY)

NOTE: One (1) valve kit is required to repair pump.

NOTE: In order to remove inlet valve assembly, remove IMDM and housing block.

NOTICE

Exercise extreme caution when

removing head assembly. The weight of

the head assembly or any twisting action

can damage the ceramic plungers.

2.2 Pull complete head assembly carefully

over ceramic plungers and place on a

at surface with the housing block side

facing upwards.

2.0 Use a M8 Allen Wrench to remove the four

(4) Hex Socket Head Screws (HSH) that

secure the housing block to the crankcase.

2.4 Pull housing block away from IMDM.2.3 Use a M10 Allen Wrench to remove the

eight (8) HSH screws that secure the

housing block to the IMDM.

2.1 Postion two at tip screwdrivers on

either side of housing block and pry the

housing block from the crankcase.

2.5 Remove outer cylinders with seal case

assembly from IMDM.

2.7 Use a reverse pliers to grasp spring

retainer and pull inlet valve assembly

from each valve chamber.

2.6 Remove V-Packing (V/P) cylinder

assembly from each IMDM valve

chamber.

2.8 Disassemble inlet valve assembly and

inspect all parts per NOTES

NOTE: Examine seats, valves and springs for grooves, pitting or wear and replace with a

new valve kit as needed.

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

as needed.

REASSEMBLY

2.11 Slide outer cylinder with seal case

assembly and hand press into place.

2.9 Place new assembled inlet valve

assembly into each valve chamber.

2.10 Position V/P cylinder assembly into

IMDM and hand press into place.

2.12 Position housing block with counter-

bore surfaces facing downward over

outer cylinders.

NOTE: Apply anti-sieze lubricant (PN 6119) to threaded ends of all eight (8) HSH screws and hand

thread into position.

NOTE: Lubricate o-rings and backup-rings on valve seats and V/P cylinders and o-rings on outer cylinder prior to reassembly.

TORQUE SEQUENCE

2.15 Use a M8 Allen Wrench to torque all four

(4) HSH screws to 531 in lbs, 44 ft lbs or

60 Nm in sequence show.

NOTE: Apply Loctite®242® to threaded ends

of all four (4) HSH screws and hand

thread into position.

TORQUE SEQUENCE

NOTICE

Exercise extreme caution when installing

head assembly. The weight of the head

assembly or any twisting action can

damage the ceramic plungers.

Rotate crankshaft by hand so the two

outside plungers are extended equally.

2.13 Use a M10 Allen Wrench to torque all

eight (8) HSH screws to 398 in lbs, 33 ft

lbs or 45 Nm in sequence show.

2.14 Slide complete head assembly carefully

over ceramic plungers until ush against

crankcase.

Loctite and 242 are registered trademarks of the Henkle Corporation

REASSEMBLY CONTINUED

Servicing the Seals

DISASSEMBLY

NOTE: One (1) seal kit is required to repair pump.

NOTE: In order to replace seals, remove IMDM and housing block.

NOTICE

Exercise extreme caution when removing

head assembly. The weight of the head

assembly or any twisting action can

damage the ceramic plungers.

3.2 Pull complete head assembly carefully

over ceramic plungers and place on a at

surface with the housing block side facing

upwards.

3.0 Use a M8 Allen Wrench to remove the four

(4) Hex Socket Head Screws (HSH) that

secure the housing block to the crankcase.

3.4 Pull housing block away from IMDM.3.3 Use a M10 Allen Wrench to remove the

eight (8) HSH screws that secure the

housing block to the IMDM.

3.1 Postion two at tip screwdrivers on either

side of housing block and pry the housing

block from the crankcase.

3.5 Remove outer cylinder with seal case

assembly from IMDM.

3.6 Remove low pressure seals and o-rings

from each seal case.

3.7 Remove seal case assembly from each

outer cylinder.

3.9 Remove female adapter from each

V/P cylinder.

3.10 Remove v-packings (qty 3) from each

V/P cylinder.

3.11 Remove male adapter from each

V/P cylinder.

NOTE: Remove o-ring and backup-rings

from each V/P cylinder.

3.8 Remove V/P cylinders from IMDM.

DISASSEMBLY CONTINUED

NOTE: Examine low pressure seals and v-packings for wear and replace with a new seal kit

as needed.

NOTE: Examine o-rings, backup-rings and wicks for cuts or wear and replace with a new

seal kit as needed.

NOTE: Examine collars for wear or damage and replace individually as needed.

NOTE: Examine female adapters for grooves, pitting or wear and replace with a new seal kit

as needed.

NOTE: Examine male adapters for grooves, pitting or wear and replace individually

as needed.

NOTE: Examine seal case, outer cylinder and V/P cylinders for wear or damage and replace

individually as needed.

3.13 Inspect all parts per NOTES

3.12 Remove collars and wicks from

crankcase side of housing block.

REASSEMBLY

3.16 Install female adapter with v-grooved

side facing down into each V/P cylinder.

3.14 Install brass male adapter with at

surface down into each V/P cylinder.

3.19 Lubricate outside diameter of each

low pressure seal and inside diameter

of each seal case. Install low pressue seal

with spring side down into each seal

case.

3.20 Lubricate seal case o-ring and inside

diameter of each outer cylinder. Hand

press each seal case assembly with

low pressure seal facing outwards into

outer cylinder.

3.15 Lubricate and install v-packings with

v-grooved side down into each V/P

cylinder. Each cylinder requires three (3)

v-packings.

3.17 Lubricate and install backup-ring and

then o-ring onto small end of each V/P

cylinder. Position small end of each

V/P cylinder into the IMDM and press

into place.

3.18 Lubricate and install o-ring into groove of each outer cylinder. Slide outer cylinder over

each V/P cylinder and hand press into IMDM.

REASSEMBLY CONTINUED

3.21 Install wicks and then collars into

crankcase side of housing block.

3.22 Position housing block with counter-

bore surfaces facing downward over

outer cylinders.

NOTE: Apply anti-sieze lubricant (PN 6119)

to threaded ends of all eight (8) HSH

screws and hand thread into position.

TORQUE SEQUENCE

3.25 Use a M8 Allen Wrench to torque all four

(4) HSH screws to 531 in lbs, 44 ft lbs or

60 Nm in sequence show.

NOTE: Apply Loctite®242® to threaded ends

of all four (4) HSH screws and hand

thread into position.

TORQUE SEQUENCE

NOTICE

Exercise extreme caution when installing

head assembly. The weight of the head

assembly or any twisting action can

damage the ceramic plungers.

Rotate crankshaft by hand so the two

outside plungers are extended equally.

3.23 Use a M10 Allen Wrench to torque all

eight (8) HSH screws to 398 in lbs, 33 ft

lbs or 45 Nm in sequence show.

3.24 Slide complete head assembly carefully

over ceramic plungers until ush

against crankcase.

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