CAT Pumps 4DNX25GSI - User Manual

SERVICE MANUAL
4DNX, 4DX, 4SP, 4SPX SERIES PLUNGER PUMPS
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.
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 ˚F ˚C in mm oz l
4DNX25GSI 2.5 9.5 3000 207 3450 140 60 3/4 19 8.5 0.25
4DNX27GSI 2.7 10.2 3000 207 3450 140 60 3/4 19 8.5 0.25
4DX03ELR 0.3 1.14 2000 138 1750 140 60 5/8 15.8 8.5 0.25
4DX10ER 1.0 3.8 2000 138 3450 140 60 5/8 15.8 8.5 0.25
4DX15ER 1.5 5.7 2000 138 3450 140 60 5/8 15.8 8.5 0.25
4DX20ER 2.0 7. 6 2000 138 3450 140 60 5/8 15.8 8.5 0.25
4DX27ER 2.7 10.2 2000 138 3450 140 60 5/8 15.8 8.5 0.25
4DX30ER 3.0 11. 4 2000 138 3450 140 60 5/8 15.8 8.5 0.25
4DX29GUIF 2.9 11.0 2600 179 3450 140 60 3/4 19 8.5 0.25
4SP21ELR 2.1 7.9 2000 138 1750 140 60 5/8 15.8 10.1 0.30
4SP29ELR 2.85 10.8 1200 83 1725 140 60 5/8 15.8 10.1 0.30
4SPX32G1I 3.2 12.1 3000 207 3450 140 60 1 25.4 10.1 0.30

Summary

General Safety Information and Symbols

Safety Signal Words Explained

Servicing Pump Valves

Valve Disassembly Procedure

Step-by-step guide for disassembling valve assemblies.

Valve Reassembly Procedure

Step-by-step guide for reassembling valve assemblies.

Servicing Pump Seals

Seal Disassembly and Reassembly

Procedures for removing and installing pump seals.

Torque Sequences for Pump Models

Servicing Pump Plungers

Plunger Disassembly and Reassembly

Procedures for disassembling and reassembling plunger components.

Servicing Unloader and Regulator

Unloader;Regulator Disassembly and Reassembly

Steps for taking apart and putting back the unloader or regulator.

Servicing Chemical Injector

Chemical Injector Disassembly and Reassembly

Procedures for removing and installing chemical injector parts.

General Safety Hazards and Precautions

Liquid, Electrical, and Mechanical Hazards

Thermal, Pressure, and Pumping Hazards

Additional Operational Safety Hazards

Pressurization, Oxygen, Fall, and Fitting Hazards

Freezing, Cleaning, and Specification Hazards

Specific Operational Hazards and Notices

Lifting, Oil, Rotation, and Belt Tension Hazards

By-Pass and Dry Operation Hazards

Troubleshooting and Maintenance Guide

Diagnosing Low Pressure, Pulsation, and Leaks

Resolving Noise, Oil Issues, and Rough Running

Addressing Premature Seal Failure

CAT Pumps 4DNX25GSI Specifications