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SERVICE MANUAL
4DNX, 4DX, 4SP, 4SPX SERIES PLUNGER PUMPS
FLOW
PUMP
MODEL
gpm
4DNX25GSI
2.5
4DNX27GSI
2.7
4DX03ELR
0.3
4DX10ER
1.0
4DX15ER
1.5
4DX20ER
2.0
4DX27ER
2.7
4DX30ER
3.0
4DX29GUIF
2.9
4SP21ELR
2.1
4SP29ELR
2.85
4SPX32G1I
3.2
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:
DANGER
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.
WARNING
CAUTION
indicates a hazardous situation which, if not avoided, could result in minor or moderate injury or property damage.
NOTICE
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.
SERVICING THE 4DNX, 4DX, 4SP and 4SPX SERIES PLUNGER PUMPS
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.
PRESSURE
lpm
psi
bar
9.5
3000
207
10.2
3000
207
1.14
2000
138
3.8
2000
138
5.7
2000
138
7.6
2000
138
10.2
2000
138
11.4
2000
138
11.0
2600
179
7.9
2000
138
10.8
1200
83
12.1
3000
207
RPM
TEMPERATURE
Pump
˚F
˚C
3450
140
60
3450
140
60
1750
140
60
3450
140
60
3450
140
60
3450
140
60
3450
140
60
3450
140
60
3450
140
60
1750
140
60
1725
140
60
3450
140
60
SHAFT DIA.
OIL CAPACITY
in
mm
oz
3/4
19
8.5
3/4
19
8.5
5/8
15.8
8.5
5/8
15.8
8.5
5/8
15.8
8.5
5/8
15.8
8.5
5/8
15.8
8.5
5/8
15.8
8.5
3/4
19
8.5
5/8
15.8
10.1
5/8
15.8
10.1
1
25.4
10.1
l
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.30
0.30
0.30
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Summary of Contents for CAT Pumps 4DNX Series
- Page 1 SERVICE MANUAL 4DNX, 4DX, 4SP, 4SPX SERIES PLUNGER PUMPS FLOW PRESSURE TEMPERATURE SHAFT DIA. OIL CAPACITY PUMP MODEL Pump ˚F ˚C 4DNX25GSI 3000 3450 0.25 4DNX27GSI 10.2 3000 3450 0.25 4DX03ELR 1.14 2000 1750 15.8 0.25 4DX10ER 2000 3450 15.8 0.25 4DX15ER 2000...
-
Page 2: Servicing The Valves
SERVICING THE VALVES Disassembly NOTE: All pump models require one (1) stacked valve kit to repair pump. NOTE: Discharge and inlet valve assemblies may stay together or separate during removal. Spring retainers may also separate from the seat during removal. Use a M19 hex tool to remove three (3) valve plugs (Model 4DX03ELR has [2] valve plugs). - Page 3 SERVICING THE SEALS Disassembly NOTE: All pump series require one (1) seal kit to repair pump. NOTE: Manifold must be removed to service the seals. Use a M5 allen wrench to remove hex socket head screws (HSH). NOTE: Pump series 4DNX and 4DX have six (6) HSH screws. NOTE: Pumps series 4SP and 4SPX have eight (8) HSH screws.
- Page 4 SERVICING THE PLUNGERS Disassembly NOTE: Remove manifold head as noted under SERVICING SEALS, Disassembly, steps 1 to 3. NOTE: Pump series 4SP and 4SPX crankcase style is different than the 4DNX and 4DX pump series. Use M10 hex tool to remove plunger retainer from each plunger rod. Remove seal washer from each plunger retainer.
- Page 5 SERVICING THE UNLOADER OR REGULATOR Disassembly Loosen and turn locking nut towards unloader body. Use a M21 hex tool or turn by hand to remove the brass adjusting cap. On pump series 4SPX, remove black nylon adjusting handle. Remove spring and flat spring retainer. Use a M19 hex tool to remove piston retainer.
- Page 6 Red Dot for Oil Level (Check for water contamination) Crankshaft Oil Seal (Leaking Oil) Drain Plug (Leaking Oil) Bearing Cover Crankcase Oil Seals (Leaking Oil) (Leaking Oil) Figure 19 Figure 20 Contact Cat Pumps or local distributor for servicing crankcase.
- Page 7 For equipment stored where the temperatures drop below freezing the pump can be damaged from water freezing in the manifold. Using Cat Pumps specially formulated Pump Protector (Part # 6108, 12 oz bottle) will help prevent any damage during storage.
-
Page 8: Preventive Maintenance Schedule
It is a good practice to replace both low and high pressure seals and inspect plungers when leaks are present. Cat Pumps recommends using our custom-blend premium grade hydraulic oil formulated to meet Cat Pumps specifications. For best results, perform an initial oil change after the first 50 hours of operation and every 500 hours thereafter. If other oil is used, oil change should be performed every 300 hours of operation. -
Page 9: General Safety Information And Symbols
GENERAL SAFETY INFORMATION AND SYMBOLS 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. - Page 10 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 (i.e., regulator or unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve, rupture disc) to assure proper pressure setting and overpressure protection.
- Page 11 1. Cat Pumps custom-blend oil is available worldwide in 21 oz. bottles, cases, or 5 gallon twin packs. Use of other oils may void the warranty.
-
Page 12: Diagnosis And Maintenance
A careful review of the necessary inlet conditions and protection devices required before the system is installed will eliminate many potential problems. Cat Pumps are very easy pumps to service and require far less frequent service than most pumps.
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