5,7,15PFR PLUNGER PUMP SERVICE MANUAL
Contents
1. em x PSI RPM Avoid Cavitation Damage One or several of the conditions shown in the chart below may contribute to cavitation in a system resulting in premature wear system downtime and unnecessary operating costs CONDITION SOLUTION Inadequate inlet e Increase line size to the inlet port or one size line size larger e Install C A T Tube e Move pump closer to liquid supply Water hammering liquid acceleration deacceleration Rigid Inlet Plumbing e Use flexible wire reinforced hose to absorb pulsation and pressure spikes Excessive Elbows in Keep elbows to a minimum and less than 90 Inlet Plumbing Excessive liquid e Use Thermo Valve in bypass line Temperature e Do not exceed pump temperature specifications e Substitute closed loop with baffled holding tank e Adequately size tank for frequent or high volume bypass e Pressure feed high temperature liquids e Properly ventilate cabinets and rooms e Check all connections e Use Teflon tape e Size tank according to pump output Minimum 6 10 times system GPM e Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids Verify viscosity against pump specifications before operation e Elevate liquid temperature enough to reduce viscosity e Lower RPM of pump e Pressure feed pump e Increase inlet line size e Perform regular maintenance or use clean filters to monitor build up e Use adequate mesh size for liquid and pum2. Removal of Valve Plugs Examination of O Ring and Back up Ring on Valve Plug Removal of Valve Assembly CAUTION Before commencing with service shut off drive electric motor gas or diesel engine and turn off water supply to pump Relieve all discharge line pressure by triggering gun or opening valve in discharge line After servicing is completed turn on water supply to pump start drive reset pressure regulating device and secondary valve read system pressure on the gauge at the pump head Check for any leaks vibration or pressure fluctuations and resume operation SERVICING THE VALVES Disassembly Reassembly NOTE Usually the valve assembly will remain together 1 Examine Spring Retainers for internal wear or breaks in while being removed the structure and replace as needed 1 Remove the hex Valve Plugs top discharge bottom inlet 2 Examine Springs for fatigue or breaks and replace as needed 2 Examine the O Ring under the Valve Plug for cuts or dis 3 Examine Valves and Seats for grooves pitting or wear and tortion and replace if worn Lubricate new O Rings before replace as needed installing 4 Examine Seat and Valve Plug O Rings for cuts or wear NOTE On Models 43HS 45 56 57 59 60 70 there is an and replace as needed Lubricate and install new O Ring extended Valve Plug with O Ring and Back up Ring onto outside diameter of Seat and Valve Plugs Install the Back up Ring then the O Ring into the groove NOTE Inlet and disc
3. The primary pressure device must be installed on the discharge side of the pump The function of the primary pressure regulating device is to protect the pump from over pressurization which can be caused by a plugged or closed off discharge line Over pressurization can severely damage the pump other system components and can cause bodily harm The secondary safety relief device must be installed between the primary device and pump This will ensure pressure relief of the system if the primary regulating device fails Failure to install such a safely device will void the warranty on the pump When the high pressure system is left running with the trigger gun off the by pass liquid can be routed to drain or to the pump inlet If routed to the pump inlet the by pass liquid can quickly develop excessive heat and result in damage to the pump A THERMO VALVE installed in the by pass line is recommended to protect the pump An AUTO SHUT OFF ASSEMBLY may also be used NOZZLES A worn nozzle will result in loss of pressure Do not adjust pressure regulating device to compensate Replace nozzle and reset regulating device to system pressure PUMPED LIQUIDS Some Liquids may require a flush between operations or before storing For pumping liquids other than water contact your CAT PUMPS supplier STORING For extended storing or between use in cold climates drain all pumped liquids from pump and flush with antifreeze solution to prevent freezing and
4. from Horsepower Requirement and Pulley Selection Chart refer to Tech Bulletin 003 or individual Data Sheet DRIVE SELECTION The motor or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load Select the electric motor from the Horsepower Requirement Chart according to required pump discharge flow maximum pressure at the pump and drive losses of approximately 3 5 Consult the manufacturer of gas or diesel engine for selection of the proper engine size MOUNTING Mount the pump on a rigid horizontal surface in a manner to permit drainage of crankcase oil An uneven mounting surface will cause extensive damage to the pump base To minimize piping stress use appropriate flexible hose to inlet and discharge ports Use the correct belt make sure pulleys are aligned Excessive belt tension may be harmful to the bearings Hand rotate pump before starting to be certain shaft and bearings are free moving LOCATION If the pump is used in extremely dirty or humid conditions it is recom mended pump be enclosed Do not store or operate in excessively high temperature areas or without proper ventilation INLET CONDITIONS Refer to complete Inlet Condition Check List in this manual before starting system DO NOT STARVE THE PUMP OR RUN DRY Temperatures above 130 F are permissible Add 1 2 PSI inlet pressure per each degree F over 130 F Elastomer or RPM changes may be required See Tech Bulletin 002
5. 20 4 57 16 40 4 026 2 64 120 01 60 0 5 03 10 80 23 90 6 00 21 60 Arriving at a total line pressure loss consideration should then be given to pressure loss created by valves fittings and elevation of lines If a sufficient number of valves and fittings are incorporated in the system to materially affect the total line loss add to the total line length the equivalent length of line of each valve or fitting TYPICAL RESERVOIR TANK RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY x Supply Line Bypass Line from regulator or unloader Level Sensing T Dia of pipe Device X D lt 7A Flexible Hose to Pump Bypass Line y from regulator or h unloader FILTER Minimum Two Baffles Sealed at Bottom Handy Formulas to Help You Q How can I find the RPM needed to get specific GPM Gallons Per Minute want A Desired RPM Desired GPM x Rated RPM Rated GPM Q Ihave to run my pump ata certain RPM How do figure the GPM I ll get A Desired GPM Desired RPM x Rated GPM Rated RPM Q Is there a simple way to find the approximate horsepower lIl need to run the pump A Electric Brake GPM x PSI 7 Standard 85 Horsepower Required 1460 Mech Efficiency Q What size motor pulley should use Pump RPM Motor Engine RPM Q How do calculate the torque for my hydraulic drive system A Torque ft lbs 3 6 Consult A Pump Pulley Outer Diameter x Engine Mfr
6. Rear cover Filler cap Pump runs extremely rough Inlet conditions Pump valves Pump seals Premature seal failure PROBABLE CAUSE Worn nozzle Belt slippage Air leak in inlet plumbing Pressure gauge inoperative or not registering accurately Relief valve stuck partially plugged or improperly adjusted Inlet suction strainer filter clogged or improperly sized Abrasives in pumped liquid Leaky discharge hose Inadequate liquid supply Severe cavitation Worn seals Worn or dirty inlet discharge valves Faulty Pulsation Dampener Foreign material trapped in inlet discharge valves Worn V Packings Hi Pressure or Lo Pressure Seals Worn adapter o rings Humid air condensing into water inside the crankcase Excessive wear to seals and V Packings Inadequate inlet liquid supply Broken or worn bearing Loose pulley on crankshaft Worn crankcase oil seals Worn crankshaft oil seals or o rings on bearing cover Loose drain plug or worn drain plug o ring Loose bubble gauge or worn bubble gauge gasket Loose rear cover or worn rear cover o ring Loose filler cap or excessive oil in crankcase Restricted inlet or air entering the inlet plumbing Stuck inlet discharge valves Leaking V Packings Hi Pressure or Lo Pressure seals Scored plungers Over pressure to inlet manifold Abrasive material in the liquid being pumped Excessive pressure and
7. Retainer and proceed with un threading the Plunger Retainer by hand Remove the Plunger Retainer O Ring Back up Ring and Gasket Stud may stay on Plunger Rod or come off with Plunger Retainers Remove the Ceramic Plunger Keyhole Washer and Barrier Slinger from Plunger Rod Reassembly 1 Visually inspect Crankcase Oil Seals for deterioration or leaks Contact CAT PUMPS for assistance with replace ment See SERVICING THE CRANKCASE section Examine Barrier Slingers and Keyhole Washers for dam age Slide onto Plunger Rod with concave side away from Crankcase Examine Ceramic Plunger for scoring scale build up chips or cracks and replace as needed Slide Ceramic Plunger over each Plunger Rod NOTE Ceramic Plunger can only be installed in one direction front to back Do not force onto rod Examine O Ring and Back up Ring on Plunger Retainer and replace if cut or worn Lubricate O Rings for ease of installation and to avoid damage to the O Rings PREVENTATIVE MAINTENANCE CHECK LIST Check Daily Weekly 50 hre 500 hrs 1500 hrs 9000 hrs Clean Fites x O Oil LeveQuaiity x Oil Leaks x Betts Puley x T T T Plumbing E e e ee e a mitiaoncnange x T T Oil Change OST T fs T sealChange J T T Txs vaveChange T xk Accessories 1 Tk If other than CAT PUMPS special multi viscosity ISO68 oil is used change cycle shou
8. damage to the pump DO NOT RUN PUMP WITH FROZEN LIQUID refer to Tech Bulletin 083 ZA WARNING All systems require both a primary pressure regulating device i e regulator unloader and a secondary pressure safety relief device i e pop off valve safety valve Failure to install such relief devices could result in personal injury or damage to the pump or to system components CAT PUMPS does not assume any liability or responsibility for the operation of a customer s high pressure system Products described hereon are covered by one or more of the following U S patents 3558244 3652188 3809508 3920356 3930756 and 5035580 World Headquarters CAT PUMPS 1681 94th Lane N E Minneapolis MN 55449 4324 Phone 763 780 5440 FAX 763 780 2958 e mail techsupport catpumps com www catpumps com International Inquiries E FAX 763 785 4329 e mail intlsales catpumps com L The Pumps with Nine Lives CAT PUMPS U K LTD 1 Fleet Business Park Sandy Lane Church Crookham Fleet Hampshire GU52 8BF England Phone Fleet 44 1252 622031 Fax 44 1252 626655 e mail sales catpumps co uk N V CAT PUMPS INTERNATIONAL S A Heiveldekens 6A 2550 Kontich Belgium Phone 32 3 450 71 50 Fax 32 3 450 71 51 7 e mail cpi catpumps be www catpumps be CAT PUMPS DEUTSCHLAND GmbH Buchwiese 2 D 65510 Idstein Germany Phone 49 6126 9303 0 Fax 49 6126 9303 33 J e mail catpumps t online de www catpumps de PN 30002 Rev K 7311
9. flow All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction Optional inlet protection can be achieved by installing a pressure cutoff switch between the inlet filter and the pump to shut off pump when there is no positive inlet pressure oO oc oe ovo BY PASS TO INLET Care should be exercised when deciding the method of by pass from control valves T It is recommended the by pass be directed to a baffled reservoir tank with at least one baffle between the by pass line and the inlet line to the pump Although not recommended by pass liquid may be returned to the inlet line of the pump if the system is properly designed to protect your pump A PRESSURE REDUCING VALVE must be installed on the inlet line BETWEEN THE BY PASS CONNECTION AND THE INLET TO THE PUMP to avoid excessive pressure to the inlet of the pump It is also recommended that a THERMO VALVE be used in the by pass line to monitor the temperature build up in the by pass loop to avoid premature seal failure A low pressure flexible cloth braid not metal braid hose should be used from the by pass connection to the inlet of the pump T Caution should be exercised not to undersize the by pass hose diameter and length Refer to Technical Bulletin 64 for additional information on the size and length of the by pass line T Check the pressure in the by pass line to avoid overpressurizing the inlet Q The by pass li
10. or temperature of pumped liquid Running pump dry Starving pump of adequate liquid Eroded manifold SOLUTION Replace with properly sized nozzle Tighten belt s or install new belt s Tighten fittings and hoses Use PTFE liquid or tape eCheck with new gauge Replace worn or damaged gauge Clean adjust relief valve Replace worn seats valves and o rings Clean filter Use adequate size filter Check more frequently Install proper filter Replace discharge hose with proper rating for system Pressurize inlet and install C A T eCheck inlet conditions Install new seal kit Increase frequency of service Clean inlet discharge valves or install new valve kit eCheck precharge If low recharge or install a new dampener Clean inlet discharge valves or install new valve kit Install new seal kit Increase frequency of service Install new o rings Install oil cap protector Change oil every 3 months or 500 hours Install new seal kit Increase frequency of service eCheck liquid supply Increase line size pressurize or install C A T Replace bearing eCheck key and tighten set screw Replace crankcase oil seals Remove bearing cover and replace o rings and or oil seals Tighten drain plug or replace o ring Tighten bubble gauge or replace gasket Tighten rear cover or replace o ring Tighten filler cap Fill crankcase to specified capacity Correct inlet size plumbing C
11. 5 4 15PFR PLUNGER PUMP SERVICE MANUAL 5 FRAME 310 340 350 311 341 351 317 347 357 5 FRAME OEM 30 31 34 35 42HS 43HS 45 7 FRAME 530 550 7 FRAME OEM 51 53 55 56 57 58 59 60 70 15 FRAME 650 651 660 661 1050 1051 1057 INSTALLATION AND START UP INFORMATION Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only with the proper selection installation of plumbing and operation of the pump and accessories SPECIFICATIONS Maximum specifications refer to individual attributes It is not implied that all maximums can be performed simultaneously If more than one maximum is considered check with your CAT PUMPS supplier to confirm the proper performance and pump selection Refer to individual pump Data Sheets for complete specifications parts list and exploded view LUBRICATION Fill crankcase with special CAT PUMP oil per pump specifications 5PFR 18 oz 7PFR 25 oz 15PFR 420z DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE Change initial fill after 50 hours running period Thereafter change oil every 3 months or 500 hour intervals whichever comes first PUMP ROTATION Pump was designed for forward rotation to allow optimum lubrication of the crosshead area Reverse rotation is acceptable if the crankcase oil level is increased slightly above center dot to assure adequate lubrication PULLEY SELECTION Select size of motor pulley required to deliver the desired flow
12. Rotate Crankshaft by hand so the two outside plungers are extended equally Lightly lubricate the Ceramic Plunger then carefully slide the Manifold Head over the Ceramic Plunger supporting it from the underside to avoid damage to the plungers or seals Press the Manifold Head into the Crankcase until flush Replace two 2 Lockwashers two 2 Socket Head Screws for 4 Flange Nuts and torque per chart Proper Alignment of Ceramic Plungers for reassembly SERVICING THE PLUNGERS Disassembly 1 Using an M8 allen wrench on the 5PFR pumps a M14 hex tool on the 7PFR pumps or a M17 hex tool on the 15PFR pumps remove the two 2 Socket Head Screws and two 2 Lockwashers or four 4 Flanged Nuts Rotate Crankshaft by hand to start separation of Manifold head from Crankcase Insert two flat head screwdrivers on opposite sides to further separate Manifold Head from Crankcase or support the underside of the Manifold Head and tap lightly with a mallet on the backside of the Manifold Head CAUTION KEEP MANIFOLD PROPERLY ALIGNED WITH CERAMIC PLUNGERS WHEN REMOVING TO AVOID DAMAGE TO EITHER PLUNGERS OR SEALS 4 Remove Oil Pan and slide out Seal Retainer with Wick Using an M12 hex tool on the 5 7 and 15PFR pumps or an M11 hex tool on the OEM 5 and 7PFR pumps loosen the Plunger Retainer about three to four turns Push the Ceramic Plunger back towards the Crankcase to separate it from the Plunger
13. S S Plunger Retainer 3PER 5PFR 7PFR Rotate Crankshaft by hand to feel for smooth bearing Manifold Head and V Packing 1050 1051 1057 movement Hi Temp HPS 3PFR 5PFR 2SF 5 Examine Crankshaft Oil Seals externally for drying crack iistgue Chart Piston and Elinger Pumps ing or leaking Oil Drain Kit All Models except 2SF 4SF ee i Winterizing a Pump All Models 6 Consult CAT PUMPS or your local distributor if crankcase service is evidenced See Section I of the Plunger Pump Service Video for addi tional information TORQUE CHART Pump Item Pump Model Torque Thread Tool Size P N in lbs ft lbs Nm PLUNGER RETAINER OEM Models All Standard Models M11 Hex 44044 M12 Hex MANIFOLD HEAD BOLTS 5PFR 30 31 34 35 310 340 350 311 341 351 317 347 357 M8 Allen 25052 42HS 43HS 45 M8 Allen 33046 510 530 550 56 57 58 59 60 70 M14 Hex 25053 650 651 660 661 1050 1051 1057 M17 Hex 25083 VALVE PLUGS 5PFR 30 31 34 35 310 311 317 340 341 347 350 351 357 42HS M24 Hex 44046 43HS 45 M24 Hex 44046 530 550 51 55 56 57 58 59 60 70 M27 Hex 44045 650 651 660 661 1050 1051 1057 3 4 SPT M27 Hex 44045 CRANKCASE COVER BEARING COVER SCREWS 5PFR 30 31 34 35 M6 310 340 350 317 347 357 311 341 351 M10 Hex Phil 25082 5PFR a M10 Hex Phil 25082 50 M13 Hex 25324 115 7PFR 51 53 55 56 57 59 60 70 M10 H
14. ex 25082 115 15PFR 650 1050 M10 Hex 25082 50 SEAL CASE 5PFR 30 31 34 35 310 311 317 340 341 347 350 351 357 42HS 43HS 45 1 2 Soc Drive 33004 1 2 Soc Drive 33005 51 53 55 56 57 58 59 60 70 530 550 1 2 Soc Drive 33005 650 651 660 661 1050 1051 1057 1 2 Soc Drive 33006 1 2 Soc Drive 33006 BUBBLE OIL GAUGE All Models Oil Gauge Tool 44050 MOUNTING BOLTS 5PFR 7PFR M13 Hex 25324 115 M17 Hex 25083 INLET CONDITION CHECK LIST Review Before Start Up Inadequate inlet conditions can cause serious malfunctions in the best designed pump Surprisingly the simplest of things can cause the most severe problems or go unnoticed to the unfamiliar or untrained eye REVIEW THIS CHECK LIST BEFORE OPERATION OF ANY SYSTEM Remember no two systems are alike so there can be no ONE best way to set up a system All factors must be carefully considered INLET SUPPLY should exceed the maximum flow being delivered by the pump to assure proper performance T Open inlet shut off valve and turn on water supply to avoid starving the pump DO NOT RUN PUMP DRY Temperatures above 130 F are permissible Add 1 2 PSI inlet pressure per each degree F over 130 F Elastomer or RPM changes may be required See Tech Bulletin 002 or call CAT PUMPS for recommendations Avoid closed loop systems especially with high temperature ultra high pressure or large volumes Conditi
15. harge valve parts are interchangeable at the end of the Valve Plug refer to Tech Bulletin 058 Two Valve Kits are needed for complete valve change 3 Grasp Spring Retainer by tab at the top with pliers and re 5 Grasp new Valve Assembly by tab at top with pliers and move from valve chamber push into valve chamber Be certain Valve Assembly is 4 To separate the valve assembly insert a screwdriver into completely seated in valve chamber the side of the Retainer and press on the back side of the NOTE For certain applications apply liquid gasket to Valve to begin separation then between the Retainer and the O Ring crevices and seal surfaces refer to Tech Valve Seat to separate completely Bulletin 053 5 If the valve assembly separates during removal remove NOTE For Corrosion Resistant Models remember to the Spring and Valve with a needle nose pliers install the Coil Spring between the Valve Plug 6 Using a reverse pliers remove the Valve Seat from the and Retainer refer to Tech Bulletin 046 manifold chamber 6 Apply Loctite 242 to the threads of the Valve Plug thread into manifold port and torque per chart Order of parts in Valve Assembly Removal of Seal Cases from Manifold Head Removal of High Pressure Seals Seal and V Packing Arrangement V P Models oog rs one H P S Models SERVICING THE SEALS Disassembly 1 Remove the Manifold Head as described in SERVICING THE PLUNGERS section Place Ma
16. heck for air tight seal Clean out foreign material or install new valve kit Install new seal kit Increase frequency of service Replace plungers Reduce inlet pressure per specifications Install proper filtration at pump inlet and clean regularly eCheck pressure and inlet liquid temperature DO NOT RUN PUMP WITHOUT LIQUID Increase hose one size larger than inlet port size Pressurize and install C A T Replace manifold Check liquid compatibility
17. ld be every 300 hours Each system s maintenance cycle will be exclusive If system performance 6 Install new Gasket then O Ring then Back up Ring onto decreases check immediately If no wear at 1500 hours check again at h PI Retai 2000 hours and each 500 hours until wear is observed Valves typically eac unger Retainer require changing every other seal change NOTE OEM models have a longer Plunger Retainer Stud Duty cycle temperature quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and service cycle 7 Apply Loctite 242 to exposed threads of Stud and thread Remember to service the regulator unloader at each seal servicing and check Plunger Retainer onto Plunger Rod Torque per chart all system accessories and connections before resuming operation i Refer to video for additional assistance 8 Install the seal Retainer with NEW Wick onto each rod with tab down and wick out NOTE Do not lubricate wicks at initial start up TECHNICAL BULLETIN REFERENCE CHART Operate for 10 to 15 minutes to allow grease from subject koak LPS e the plunger surface then lubricate Power Unit Drive Packages 3PFR 68PFR 10FR 60FR aS reece Lubrication of Lo Pressure Seals All Models 9 Rotate Crankshaft by hand so the two outside plungers Spring Retainer 5PFR 7PFR 15PFR are extended equally 10 Lightly lubricate the Ceramic Plungers then carefully slide the Manifold Head over the Ceramic Plunge
18. ne should be connected to the pump inlet line at a gentle angle of 45 or less and no closer than 10 times the pump inlet port diameter e g 1 1 2 port size 15 distance from pump inlet port HOSE FRICTION LOSS PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES Water Hose Inside Diameters Inches Flow Gal Min 0 5 1 162 235 370 At a fixed flow rate with a given size hose the pressure drop across a given hose length will be directly proportional A 50 ft hose will exhibit one half the pressure drop of a 100 ft hose Above values shown are valid at all pressure levels WATER LINE PRESSURE LOSS PRESSURE DROP IN PSI PER 100 FEET Water Steel Pipe Nominal Dia Brass Pipe Nominal Dia Copper Tubing O D Type L GPM 1 4 3 8 1 2 3 4 1 1 4 1 2 1 4 3 8 1 2 3 4 1 14 12 1 4 3 8 1 2 5 8 3 4 7 8 120 13 400 45 94 100 28 9 0 2 2 230 50 17 330 86 220 62 21 5 2 1 6 500 120 40 520 130 320 90 30 7 8 2 4 180 56 270 90 190 62 16 5 0 1 5 120 670 240 470 150 40 12 3 8 1 7 330 110 39 11 5 0 550 200 150 36 37 52 210 107 Nominal Equivalent Length of Standard Pipe in Feet Pipe Inside 180 Tee Tee Size Diameter 45 90 Close Thru Thru Inches Inches Elbow Elbow Ret Run Branch 2 067 1 35 61 5 30 8 2 59 5 55 12 30 3 08 11 60 2 469 1 62 73 5 36 8 3 09 6 61 14 70 3 68 13 20 3 068 2 01 91 5 45 8 3 84 8 23 18
19. nifold Head on work surface with crankcase side up On 5PFR and 7PFR plunger pumps prior to May of 1989 remove Snap Ring and Lo Pressure Seal from each Seal Case Discard Snap Rings refer to Tech Bulletin 054 On 5PFR and 7PFR plunger pumps after May of 1989 re move Lo Pressure Seal from each Seal Case On 15PFR plunger pumps remove Snap Ring and Lo Pressure Seal from each Seal Case Remove Seal Case from each seal chamber Remove O Ring from outside diameter of Seal Case Hi Pressure Seal Models The Hi Pressure Seal is gener ally easily removed from the manifold without any tools If extremely worn a reverse pliers may be used V Packing Models The Female Adapter V Packings and Male Adapter are easily removed from manifold without any tools If extremely worn a reverse pliers may be used Installation of Male Adapter Order of Packings MA VP FA Reassembly V Packing Models 1 Lubricate seal chamber in the manifold NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces refer to Tech Bulletin 053 Insert Male Adapter with notches down and v side up and press completely into chamber by hand Lubricate V Packings and install one at a time with grooved side down 4 Install Female Adapter with grooved side down Examine Seal Case O Ring and replace if worn Lubricate new O Rings before installing Thread Seal Ca
20. ons vary with regulating unloader valve Low vapor pressure liquids such as solvents require a booster pump and C A T to maintain adequate inlet supply Higher viscosity liquids require a positive head and a C A T to assure adequate inlet supply Higher temperature liquids tend to vaporize and require positive heads and C A T to assure adequate inlet supply When using an inlet supply reservoir size it to provide adequate liquids to accom modate the maximum output of the pump generally a minimum of 6 10 times the GPM however a combination of system factors can change this requirement provide adequate baffling in the tank to eliminate air bubbles and turbulence install diffusers on all return lines to the tank oO ovo D D B INLET LINE SIZE should be adequate to avoid starving the pump 4 Line size must be a minimum of one size larger than the pump inlet fitting Avoid tees 90 degree elbows or valves in the inlet line of the pump to reduce the risk of flow restriction and cavitation O The line MUST be a FLEXIBLE hose NOT a rigid pipe and reinforced on SUCTION systems to avoid collapsing The simpler the inlet plumbing the less the potential for problems Keep the length to a minimum the number of elbows and joints to a minimum ideally no elbows and the inlet accessories to a minimum 0 Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of
21. or call CAT PUMPS for recommendations C A T Installation of a C A T Captive Acceleration Tube is recommended in ap plications with stressful inlet conditions such as high temperatures booster pump feed long inlet lines or quick closing valves DISCHARGE CONDITIONS OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system Install a Pulsation Dampening device on the discharge head or in the discharge line as close to the head as possible Be certain the pulsation dampener Prrrrr o lator is properly precharged for the system pressure see individual Data Sheet A reliable Pressure Gauge should be installed near the discharge outlet of the high pressure manifold This is extremely important for adjusting pressure regulating devices and also for proper sizing of the nozzle or restricting orifice The pump is rated for a maximum pressure this is the pressure that is read at the discharge manifold of the pump NOT AT THE GUN OR NOZZLE Use PTFE liquid sparingly or tape to connect accessories or plumbing Exercise caution not to wrap tape beyond the last thread to avoid tape from becoming lodged in the pump or accessories This condition will cause a malfunction of the pump or system PRESSURE REGULATION All systems require both a primary pressure regulating device i e regulator unloader and a secondary pressure safety relief device i e pop off valve safety valve
22. p specifications Air Leaks in Plumbing Agitation in Supply Tank Clogged Filters 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 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 Typically only common tools are required making in field service convenient however there are a few custom tools special to certain models that do simplify the process This service manual is designed to assist you with the disassembly and reassembly of your pump The following guide will assist in determining the cause and remedy to various operating conditions You can also review our FAQ or SERVICE sections on our WEB SITE for more facts or contact CAT PUMPS directly PROBLEM Low pressure Pulsation Water leak Under the manifold Into the crankcase Knocking noise Inlet supply Bearing Pulley Oil leak eCrankcase oil seals Crankshaft oil seals and o rings Drain plug Bubble gauge
23. rs supporting it from the underside to avoid damage to the Ceramic Plungers or Seals On the high pressure V Packing models or larger manifolds it may be necessary to gently tap with a soft mallet until the manifold is flush with the crankcase 11 Replace two 2 Lockwashers two 2 Socket Head Screws or four 4 Flanged Nuts and torque per chart SERVICING THE CRANKCASE SECTION Shaft Extension and Manifold Port Servicing Crankcase Section Cylinder and Plunger Reference Chart LPS and HPS Servicing One Piece S S Plunger Retainer w Stud Valve Plug with Coil Spring Blind Bearing Shaft Cover Extended Valve Plug Stainless Steel Hardware M10 Manifold and Crankcase Plunger Rod and Stud Liquid Gasket 2 Piece Seal Retainer 310 317 323 530 550 7PFR 60PFR All Models All Plunger Models 5PFR 7PFR 15PFR 317 347 357 1057 Gearbox Plunger Pumps 7PFR and 15PFR 3PFR7 5PFR7 15PFR7 7PFR and OEM 3PFR 5PFR 15PFR 35PFR 60PFR All Plunger NAB S S Models 5PFR and 7PFR 1 While Manifold Plungers and Seal Retainers are removed examine Crankcase Oil Seals for leaking and Forged Manifold arid Extended valve Plugs 56 37 39 60 wear Baffle Assembly 34170 A Installation and Adjustment Procedure 8100 2 Check for any signs of leaking at Bearing Covers Rear E SsalGats 650 and 651 Cover Drain Plug or Bubble Gauge By Pass Hose Sizing All Unloaders Regulators 3 Check oil level and for evidence of water in oil
24. se into manifold and tighten with special seal case tool Torque per chart Separating Manifold Head from Crankcase Removal of Manifold Head from Crankcase Removal of Seal Retainers and Wicks Ceramic Plunger and Retainer Arrangement Hi Pressure Seal Models 1 Lubricate seal chamber in manifold NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces refer to Tech Bulletin 053 Carefully square Hi Pressure Seal into position by hand with the grooved side down metal back facing out NOTE When alternate materials the fit of the special materials may be snug and require gently driv ing the LPS into position with a cylinder of the same diameter to assure a square seating and no damage to the LPS Examine Seal Case O Ring and replace if worn Lubricate new O Ring before installing Secure Hi Pressure Seal into position by threading Seal Case into manifold Tighten Seal Case with special seal case tool Torque per chart Lo Pressure Seal All Models 1 Examine Lo Pressure Seals for wear or broken springs and replace if necessary Install Lo Pressure Seal into each seal case with garter spring down On 5PFR and 7PFR plunger pumps do not use Snap Ring refer to Tech Bulletin 054 On 15PFR plunger pumps install Snap Ring into each Seal Case Install the Seal Retainer with new Wick onto each plunger rod with tab down and wick out
25. the pump Acceleration loss of liquids may be increased by high RPM high temperatures low vapor pressures or high viscosity and may require pressurized inlet and C A T to maintain adequate inlet supply DO NOT USE C A T WITH SUCTION INLET T Optimum pump performance is obtained with 20 PSI 1 4 BAR inlet pressure and a C A T for certain applications With adequate inlet plumbing most pumps will perform with flooded suction Maximum inlet pressure is 60 PSI 4 BAR After prolonged storage pump should be rotated by hand and purged of air to facilitate priming Disconnect the discharge port and allow liquid to pass through pump and measure flow INLET ACCESSORIES are designed to protect against overpressurization control inlet flow contamination or temperature and provide ease of servicing T A shut off valve is recommended to facilitate maintenance g Installation of a C A T is essential in applications with stressful conditions such as high temperatures booster pump feed or long inlet lines Do not use C A T with negative inlet pressure A stand pipe can be used in some applications to help maintain a positive head at the pump inlet Inspect and clean inlet filters on a regular schedule to avoid flow restriction A pressure transducer is necessary to accurately read inlet pressure Short term intermittent cavitation will not register on a standard gauge All accessories should be sized to avoid restricting the inlet
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