Pump Manual

ManualsBrandsSimpson ManualsOutdoors3800-PSI at 3.5 GPM Pressure Washer Trailer System

SERVICE MANUAL

4DNX, 4DX, 4SPX SERIES PLUNGER PUMPS

SERVICING THE 4DNX, 4DX, 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 2850 196 3450 140 60 3/4 19 8.5 0.25

4DNX27GSI 2.7 10.2 2850 196 3450 140 60 3/4 19 8.5 0.25

4DX10ER 1.0 3.8 2000 140 3450 140 60 5/8 15.8 8.5 0.25

4DX15ER 1.5 5.7 2000 140 3450 140 60 5/8 15.8 8.5 0.25

4DX20ER 2.0 7. 6 2000 140 3450 140 60 5/8 15.8 8.5 0.25

4DX27ER 2.7 10.2 2000 140 3450 140 60 5/8 15.8 8.5 0.25

4DX30ER 3.0 11.4 2000 140 3450 140 60 5/8 15.8 8.5 0.25

4SPX32G1I 3.2 12.1 3000 210 3450 140 60 1 25.4 10.15 0.3

Summary of content (12 pages)

PAGE 1
SERVICE MANUAL 4DNX, 4DX, 4SPX SERIES PLUNGER PUMPS PUMP MODEL 4DNX25GSI 4DNX27GSI 4DX10ER 4DX15ER 4DX20ER 4DX27ER 4DX30ER 4SPX32G1I FLOW gpm lpm 2.5 2.7 1.0 1.5 2.0 2.7 3.0 3.2 9.5 10.2 3.8 5.7 7.6 10.2 11.4 12.1 PRESSURE psi bar 2850 2850 2000 2000 2000 2000 2000 3000 196 196 140 140 140 140 140 210 RPM Pump 3450 3450 3450 3450 3450 3450 3450 3450 TEMPERATURE ˚F ˚C 140 140 140 140 140 140 140 140 60 60 60 60 60 60 60 60 SHAFT DIA. in mm OIL CAPACITY oz l 3/4 3/4 5/8 5/8 5/8 5/8 5/8 1 8.5 8.
PAGE 2
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. 1. Use a M19 hex tool to remove three (3) valve plugs. 2. Use a pick tool to remove o-ring from each valve plug. 3. Use a reverse pliers to remove stacked valve assembly from each valve chamber (See Figure 1).
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. 1. 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 4SPX have eight (8) HSH screws. 2. Use two (2) flat tip screwdrivers to create a separation between manifold and crankcase, then remove manifold by hand.
PAGE 4
SERVICING THE PLUNGERS Disassembly NOTE: R emove manifold head as noted under SERVICING SEALS, Disassembly, steps 1 to 3. NOTE: Pump series 4SPX crankcase style is different than the 4DNX and 4DX pump series. 1. 2. 3. 4. Use M10 hex tool to remove plunger retainer from each plunger rod. Remove seal washer from each plunger retainer. Remove ceramic plunger from each plunger rod. Remove seal retainers from crankcase.
PAGE 5
SERVICING THE UNLOADER OR REGULATOR Disassembly 1. 2. 3. 4. 5. 6. On pump series 4SPX, remove black nylon adjusting handle. On pump series 4SPX, use a M3 allen wrench to loosen set screw on locking nut. Loosen and turn locking nut towards unloader body. Use a M21 hex tool or turn by hand to remove the brass adjusting cap. Remove spring and flat spring retainer. Use a M19 hex tool to remove piston retainer.
PAGE 6
SERVICING THE CHEMICAL INJECTOR Disassembly NOTE: T o remove barb - do not remove chemical injector from pump. NOTE: Remove chemical hose from barb. 1. 2. 3. 4. 5. Use a M12 hex tool to remove barb. Use a pick tool to remove o-ring from within barb. Remove ball and spring from chemical injector body. Use a M22 hex tool to remove chemical injector from unloader/manifold body (See Figure 18). Use a flat tip screwdriver to remove orifice from chemical injector body.
PAGE 7
During long term or season storage of three months or longer, the residual fluid left in the pump can cause corrosion, sticking valves and mineral deposits. 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. STEPS TO STORE AND PROTECT YOUR PUMP 1. Turn engine/motor to Off position. 2. Disconnect all hoses.
PAGE 8
PREVENTATIVE MAINTENANCE SCHEDULE This schedule is intended as a guide only. Each system/application is different and should be evaluated/serviced according to its own custom maintenance schedule. Check Daily Clean Filters • Oil Level/Quality • Oil Leaks • Water Leaks • Plumbing Initial Oil Change Oil Change Weekly 50 Hrs. 500 Hrs.* 1500 Hrs.+ • • • Seal Change • Accessories • Valve Change 3000 Hrs.
PAGE 9
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. 1.
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. 2.
PAGE 11
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. 1. Lifting eyes installed on the pump must be used only to lift the pump. 2. Special lifting eyes should be installed on the base for lifting the pumping system (i.e. base, drive and accessories) 3.
PAGE 12
DIAGNOSIS AND MAINTENANCE One of the most important steps in a high pressure system is to establish a regular maintenance program. This will vary slightly with each system and is determined by various elements such as the duty cycle, the liquid being pumped, the actual specifications vs rated specifications of the pump, the ambient conditions, the inlet conditions and the accessories in the system.