38PFR PLUNGER PUMP SERVICE MANUAL
Contents
1. 4 Examine Seat O Rings and Back up Rings for cuts or wear and replace as needed 5 Examine Valve Plugs for external surface scoring or wear and replace as needed 6 Examine Valve Plug O Rings and Back up Rings for cuts or wear and replace as needed NOTE A new Valve Assembly will come pre assembled in the kit Continue with steps 10 through 16 If servicing from individual parts follow steps 7 through 16 7 Install O Ring first then Back up Ring onto the each Seat 8 Place the Valve onto the Seat with dish side down spring tab up 3801 3811 3821 Removal of V Packing Cylinder from Inlet Manifold 3801 3811 Complete Inlet Discharge Valve Assembly 3821 3831 3841 Complete Inlet Discharge Valve Assembly 3801 V Packing Arrangement 3811 3821 V Packing Arrangement 3831 V Packing and Spacer Arrangement 9 Place Spring on Valve and snap the Spring Retainer onto Seat 10 On the models 3821 3831 3841 thread in M10 screw into Spring Retainer Lower Valve Assembly into the valve chamber and press until completely seated Remove M10 screw 11 On the models 3801 3811 using a standard pliers grasp Spring Retainer tab and lower Valve Assembly into valve chamber and press until completely seated 12 Place Washer on top of the Spring Retainer and then the Coil Spring on top of Washer 13 Install Back up Ring first then O Ring on Valve Plugs 14 Press Valve Plugs in valve chambers CAUTION Exercise2. 13 Position Spacer w Coil Springs so that the small springs do not line up with grooves on top surface of Male Adapter 14 Examine V Packing Spacers for scale build up wear and replace as needed Examine V Packing Spacer O Rings and Back up Rings 3831 only for cuts or deterioration and replace as needed 15 On the model 3831 install two O Rings and two Back up Rings on V Packing Spacer with O Rings to the outside On the model 3841 install O Rings on each end of V Packing Spacer 16 Press V Packing Spacer into each seal chamber 17 Examine Inlet Spacers for scale build up wear and replace as needed Examine Inlet Spacer O Rings and Back up Rings for cuts and deterioration and replace as needed 18 Press Inlet Spacers into each lower manifold chamber 19 Support the Inlet Manifold from the under side and align manifold with Crankcase Guide Pins Apply Loctite 242 to HSH screw threads and thread in hand tight Torque in sequence to specifi cations in torque chart 20 Support the Discharge Manifold from the under side and align with Inlet Manifold holes Apply anti seize to HSH screws and thread in hand tight Torque in sequence to specifications in torque chart TORQUE SEQUENCE SERVICING THE PLUNGERS ALL MODELS Disassembly NOTE Both the standard and the K versions are serviced in the same manner 1 To service the plungers it is necessary to remove both the Discharge Manifold and Inlet Manifold Follo
3. fitted to an external flushing sys tem to provide this cooling and flushing The flushed inlet manifold models can also withstand high inlet pressures Consult CAT PUMPS 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 damage to the pump DO NOT RUN PUMP WITH FROZEN LIQUID refer to Tech Bulletin 083 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 PN 30142 Rev B 10229 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 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
4. 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 PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES Hose Inside Diameters Inches Water Flow Gal Min HOSE FRICTION LOSS Water GPM 1 2 3 5 8 10 15 25 40 60 80 100 Steel Pipe Nominal Dia 1 4 3 8 1 2 3 4 1 11 4 11 2 8 5 1 9 30 7 0 2 1 60 14 4 5 1 1 150 36 12 2 8 330 86 28 6 7 1 9 520 130 43 10 3 0 270 90 21 6 2 1 6 670 240 56 16 4 2 2 0 66 17 8 0 37 17 52 29 210 107 48 Brass Pipe Nominal Dia 1 4 3 8 1 2 3 4 1 11 4 11 2 6 0 1 6 20 5 6 1 8 40 11 3 6 100 28 9 0 2 2 220 62 21 5 2 1 6 320 90 30 7 8 2 4 190 62 16 5 0 1 5 470 150 40 12 3 8 1 7 39 11 5 0 23 11 40 19 61 28 Copper Tubing O D Type L 1 4 3 8 1 2 5 8 3 4 7 8 120 13 2 9 1 0 400 45 10 3 4 1 3 94 20 6 7 2 6 230 50 17 6 1 3 0 500 120 40 15 6 5 180 56 22 10 120 44 20 330 110 50 550 200 88 WATER LINE PRESSURE LOSS PRESSURE DROP IN PSI PER 100 FEET 1 2 0 622 0 41 18 5 9 3 0 78 1 67 3 71 0 93 3 33 3 4 0 824 0 54 24 5 12 3 1 03 2 21 4 90 1 23 4 41 1 1 049 0 69 31 2 15 6 1 31 2 81 6 25 1 56 5 62 11 4 1 380 0 90 41 0 20 5 1 73 3 70 8 22 2 06
5. 31 3841 remove one Spacer w Coil Spring one Male Adapter two V Packings and one Female Adapter from each seal chamber 6 Place Inlet Manifold on blocks with crankcase side down 7 Using reverse pliers remove Inlet Spacer from each seal chamber CAUTION Exercise caution as the reverse pliers may damage sealing surface 8 On the models 3801 3811 3821 insert screwdrivers into seal chamber and tap opposite sides of the Washer to drive out Inlet Adapter Assembly and Washer from each chamber Remove Lo Pressure Seals from backside of Inlet Adapter CAUTION Exercise caution as the screwdrivers may damage sealing surface 9 On the model 3831 remove Lo Pressure Seal and Washer from each seal chamber 10 On the model 3841 remove Spacer and Lo Pressure Seal from each seal chamber Reassembly NOTE If your pump has been built with special seals and O Rings service with same type of special parts Refer to pump Data Sheet for correct parts or kits NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces See Tech Bulletin 053 for model identification NOTE EPDM elastomers require silicone base lubricant NOTE For standard installation apply a small amount of oil to the outside edge of the LPS HPS VP MA FA for ease of installation and to avoid damage Models 3801 3811 and 3821 1 Examine Lo Pressure Seals for wear to the internal ridges and outer surfaces or for bro
6. 38PFR PLUNGER PUMP SERVICE MANUAL 38 FRAME BLOCK STYLE MANIFOLD 3801 3811 3821 3831 3841 3801K 3811K 3821K 3831K 3841K 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 Sheet for complete specifications parts list and exploded view LUBRICATION Fill crankcase with special CAT PUMP oil per pump specifications 134 4 oz 4 2 Qts 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 Additional lubrication may be required with increased hours of operation and temperature 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 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 acco
7. 7 40 11 2 1 610 1 05 48 0 24 0 2 15 4 31 9 59 2 40 8 63 2 2 067 1 35 61 5 30 8 2 59 5 55 12 30 3 08 11 60 21 2 2 469 1 62 73 5 36 8 3 09 6 61 14 70 3 68 13 20 3 3 068 2 01 91 5 45 8 3 84 8 23 18 20 4 57 16 40 4 4 026 2 64 120 0 60 0 5 03 10 80 23 90 6 00 21 60 Nominal Pipe Size Inches Inside Diameter Inches RESISTANCE OF VALVES AND FITTINGS Gate Valve Globe Valve Angle Valve 45 Elbow 90 Elbow 180 Close Ret Tee Thru Run 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 Tee Thru Branch Equivalent Length of Standard Pipe in Feet Bypass Line from regulator or unloader Level Sensing Device Bypass Line from regulator or unloader MIN 4 1 5 x D Min Minimum Two Baffles Sealed at Bottom Minimum Liquid Level FILTER MIN 4 Flexible Hose to Pump Supply Line Dia of pipe T X D 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 variou
8. 9 4 13 Bearing Cover Screws Connecting Rod Screws M10 M17 Hex 25083 390 32 5 44 Bubble Oil Gauge M28 Oil Gauge Tool 44050 45 3 6 5 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 Open inlet shut off valve and turn on water supply to avoid starving 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 Conditions 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 where compatible 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 a
9. CHARGE MANIFOLD and REMOVING THE INLET MANIFOLD NOTE The V Packing Cylinder 3801 3811 3821 or V Packing Spacer 3831 3841 Assemblies may stay in the Discharge Manifold or Inlet Manifold 2 If V Packing Cylinders 3801 3811 3821 or V Packing Spacers 3831 3841 stay in the Inlet Manifold insert two screwdrivers on opposite sides of the V Packing Cylinder 3801 3811 3821 secondary groove and pry from the chamber On the model 3831 3841 remove exposed O Rings and Back up Rings and in sert two screwdrivers into the groove on opposite sides and pry from valve chamber 3841 V Packing and Spacer Arrangement 3801 3811 3821 Lo Pressure Seal and Adapter 3831 Lo Pressure Seal and Washer 3841 Lo Pressure Seal 3801 3811 3821 3831 Plunger Arrangement 10 Examine V Packings for frayed edges or uneven wear and replace as needed 11 Place V Packing Cylinder with large opening facing up on work surface 12 Place Female Adapter with flat side down V side up inside each V Packing Cylinder 13 On the models 3811 3821 insert two V Packings and on the model 3801 insert three V Packings with V side down into the V Packing Cylinder The V will mate with V side of the Female Adapter 14 Place Male Adapter with V side down inside each V Packing Cylinder 15 Position Spacer w Coil Springs so that the small springs do not line up with grooves on top surface of Male Adapter 16 Exam
10. Kontich Belgium Phone 32 3 450 71 50 Fax 32 3 450 71 51 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 e mail catpumps t online de www catpumps de 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 FAX 763 785 4329 e mail intlsales catpumps com The Pumps with Nine Lives SERVICING THE VALVES ALL MODELS Disassembly discharge and inlet valves NOTE Both the standard and the K versions are serviced in the same manner 1 To service the Valve Assemblies it is necessary to remove the Valve Plugs 3801 3811 or Valve Covers 3821 3831 3841 2 Using an allen wrench remove the Hex Socket Head Screws HSH from the top surface of the Valve Plugs 3801 3811 or top surfaces of the Valve Cover 3821 3831 3841 3 On the models 3801 3811 remove Valve Plugs 4 On the models 3821 3831 3841 remove Valve Covers then in sert two M6 x 25 threaded screws into the two threaded holes on the top surface of the Valve Plug and gently pull out 5 Remove the exposed Coil Spring and Washer from the top of the Spring Retainer in each valve chamber 6 On the models 3801 3811 using a standard pliers grasp Spring Retainer tab and pull assemblies from valve chamber
11. WITHOUT LIQUID Starving pump of adequate liquid Increase hose one size larger than inlet port size Pressurize and install C A T Eroded manifold Replace manifold Check liquid compatibility
12. aced 6 Slide Ceramic Plunger over each Plunger Rod NOTE Ceramic Plunger can only be installed in one direction Do not force onto Plunger Rod 7 Examine Gaskets O Rings and Back up Rings for cuts or wear and replace as needed 8 Examine Plunger Retainers for wear and damaged threads and replace as needed 9 Install Gasket first then O Ring and Back up Ring onto each Plunger Retainer NOTE Lubricate O Rings and Back up Rings for ease in installation and to reduce possible damage 10 Clean old Loctite from Plunger Retainer Studs using wire brush and Plunger Retainers by twisting cloth into threaded area then blow out with air gun Apply Loctite 242 to exposed threaded end of Plunger Retainer Studs thread into Plunger Retainer Torque per chart 11 Rotate crankshaft by hand so the two outside plungers are extended equally 12 On the models 3801 3811 3821 3831 slide Seal Retainer with wick over each Plunger Rod 13 On the model 3841 slide Seal Retainer with drain holes facing up and down and with small diameter end towards Crankcase over each Plunger Rod Install LPS Spacer over end of each Seal Retainer 14 Lightly lubricate Ceramic Plungers to assist in installing the Inlet Manifold NOTE If new Ceramic Plungers are installed operate for 24 hours to allow grease from seals to penetrate plunger surface 15 Support the Inlet Manifold from the under side and align manifold with Crankcase Guide P
13. ain applications With adequate inlet plumbing most pumps will perform with flooded suction Maximum inlet pressure is 70 PSI 4 9 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 K versions are suitable for high inlet pressures Consult CAT PUMPS INLET ACCESSORIES are offered to protect against over pressurization contamination or temperature and control flow A shut off valve is recommended to facilitate maintenance 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 line 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 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 cut off switch between the inlet filter and the pump to shut off pump when there is no positi
14. caution to avoid extruding or cutting the Back up Rings or O Rings 15 On the models 3821 3831 3841 place Valve Covers over Valve Plugs 16 Apply anti seize to HSH screw threads and thread in hand tight Torque in sequence to specifications in torque chart REMOVING THE DISCHARGE MANIFOLD ALL MODELS 1 Using an allen wrench remove the HSH screws 2 Insert two screwdrivers on opposite sides of the Discharge Manifold and gently pry apart NOTE Support underside of manifold to avoid possible damage to Ceramic Plungers or Plunger Rods CAUTION Exercise caution as the screwdrivers may score O Ring sealing surface 3 Place the crankcase side of the Discharge Manifold up on work surface REMOVING THE INLET MANIFOLD ALL MODELS 1 Using an allen wrench remove the HSH screws 2 Rotate the Crankshaft by hand to begin separation of the Inlet Manifold from the Crankcase Insert two screwdrivers on opposite sides of manifold to assist in separation NOTE Support underside of manifold to avoid possible damage to Ceramic Plungers or Plunger Rods 3 Place the crankcase side of the Inlet Manifold down on work surface SERVICING THE SEALS ALL MODELS Disassembly NOTE Both the standard and the K versions are serviced in the same manner 1 To service the seals and packings it is necessary to remove both the Discharge Manifold and the Inlet Manifold Follow disas sembly procedures for REMOVING THE DIS
15. ce cycle Remember to service the regulator unloader at each seal servicing and check all system accessories and connections before resuming operation Refer to video for additional assistance Q How can I find the RPM needed to get specific GPM Gallons Per Minute I want Rated RPM A Desired RPM Desired GPM x Rated GPM Q I have to run my pump at a certain RPM How do I figure the GPM I ll get Rated GPM A Desired GPM Desired RPM x Rated RPM Q Is there a simple way to find the approximate horsepower I ll need to run the pump A Electric Brake GPM x PSI Standard 85 Horsepower Required 1460 Mech Efficiency Q What size motor pulley should I use Pump RPM A Pump Pulley Outer Diameter x Motor Engine RPM Q How do I calculate the torque for my hydraulic drive system GPM x PSI A Torque ft lbs 3 6 RPM 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 G Increase line size to the inlet port or one size line size larger Water hammering G Install C A T Tube liquid acceleration G Move pump closer to liquid supply deacceleration Rigid Inlet Plumbing G Use flexible wire reinforced hose to absorb pulsation and pressure spikes Excessive Elbows in G Keep elbows to a minimum and less than 90 Inlet Plumbing Excessive Liq
16. e with crankcase side up 4 On the model 3831 place Washer in each seal chamber of the Inlet Manifold 5 Press new Lo Pressure Seal into each seal chamber with the garter spring down NOTE When using alternate materials the fit of the special materials may be snug and require gently driving the LPS into position with a cylinder of the same diameter to assure a square seating and no damage to the LPS 6 Examine Male Adapters and Female Adapters for scale build up wear and replace as needed 7 Examine Spacer w Coil Springs for scale build up wear broken or fatigued Coil Springs and replace as needed 8 Examine V Packings for frayed edges or uneven wear and replace as needed CAUTION Exercise caution as the screwdrivers may score o ring sealing surface 3 If V Packing Cylinders 3801 3811 3821 or V Packing Spacers 3831 3841 stay in the Discharge Manifold remove exposed O Rings Insert two screwdrivers into the groove on opposite sides and pry from valve chamber CAUTION Exercise caution as the screwdrivers may score o ring sealing surface 4 On the models 3801 3811 3821 separate V Packing Spacer from V Packing Cylinder by inserting two screwdrivers on oppo site sides of the groove formed between components and pry apart Remove one Spacer w Coil Spring one Male Adapter two V Packings 3811 3821 or three V Packings 3801 and one Female Adapter from each V Packing Cylinder 5 On the models 38
17. gged or improperly sized Clean filter Use adequate size filter Check more frequently Abrasives in pumped liquid Install proper filter Leaky discharge hose Replace discharge hose with proper rating for system Inadequate liquid supply Pressurize inlet and install C A T Severe cavitation Check inlet conditions Worn seals Install new seal kit Increase frequency of service Worn or dirty inlet discharge valves Clean inlet discharge valves or install new valve kit Pulsation Faulty Pulsation Dampener Check precharge If low recharge or install a new dampener Foreign material trapped in inlet discharge valves Clean inlet discharge valves or install new valve kit Water leak Under the manifold Worn V Packings or Lo Pressure Seals Install new seal kit Increase frequency of service Worn adapter o rings Install new o rings Into the crankcase Humid air condensing into water inside the crankcase Install oil cap protector Change oil every 3 months or 500 hours Excessive wear to seals and V Packings Install new seal kit Increase frequency of service Knocking noise Inlet supply Inadequate inlet liquid supply Check liquid supply Increase line size pressurize or install C A T Bearing Broken or worn bearing Replace bearing Pulley Loose pulley on crankshaft Check key and tighten set screw Oil leak Cra
18. ine V Packing Spacers for scale build up wear and replace as needed Examine V Packing Spacer O Rings and Back up Rings for cuts or deterioration and replace as needed 17 Install two O Rings and two Back up Rings on V Packing Spacer with O Rings to the outside Press V Packing Spacer into each V Packing Cylinder 18 Place Inlet Manifold on flat work surface with crankcase side down 19 Press V Packing Cylinder Assembly into each seal chamber with V Packings facing into the manifold chamber 20 Examine Inlet Spacers for scale build up wear and replace as needed Examine Inlet Spacer O Rings and Back up Rings for cuts and deterioration and replace as needed 21 Press Inlet Spacer into each lower manifold chamber 22 Support the Inlet Manifold from the under side and align manifold with Crankcase Guide Pins Apply Loctite 242 to HSH screw threads and thread in hand tight Torque in sequence to specifi cations in torque chart 23 Support the Discharge Manifold from the under side and align with Inlet Manifold holes Apply anti seize to HSH screws and thread in hand tight Torque in sequence to specifications in torque chart TORQUE SEQUENCE Models 3831 and 3841 1 Examine Lo Pressure Seals for wear to the internal ridges and outer surfaces or for broken springs and replace as needed 2 On the model 3831 examine Washers for scale build up or wear and replace as needed 3 Place Inlet Manifold on flat work surfac
19. ins Apply Loctite 242 to HSH screw threads and thread in hand tight Torque in sequence to specifi cations in torque chart 16 Support the Discharge Manifold from the under side and align with Inlet Manifold holes Apply anti seize to HSH screws and thread in hand tight Torque in sequence to specifications in torque chart SERVICING THE CRANKCASE SECTION ALL MODELS NOTE Both the standard and the K versions are serviced in the same manner 1 While manifolds plungers and seal retainers are removed examine crankcase oil seals for leaking and wear 2 Check for any signs of leaking at Rear Cover Drain Plug and Bubble Gauge 3 Check oil level and check for evidence of water in oil 4 Rotate crankshaft by hand to feel for smooth bearing movement 5 Examine crankshaft oil seals externally for drying cracking or leaking 6 Consult CAT PUMPS or your local distributor if crankcase service is required See also Tech Bulletin 035 7 1 3 9 11 5 6 12 10 4 2 8 TORQUE CHART Pump Item Torque Pump Model Thread Tool Size P N in lbs ft lbs Nm Plunger Retainer 3801 3811 M7 M14 Hex 90 7 2 10 3821 3831 3841 M10 M21 Hex 220 12 1 25 Inlet Manifold Screws M14 M12 Allen 33048 500 41 6 56 Discharge Manifold Screws M12 M10 Allen 33047 355 29 6 40 Valve Plug M10 M8 Allen 33046 250 21 0 28 Valve Cover Screws Crankcase Cover M8 M13 Hex 25324 115
20. ken springs and replace as needed 2 Examine Inlet Adapters and Washers for scale build up or wear and the Inlet Adapter O Rings for cuts or deterioration and replace as needed 3 Press new Lo Pressure Seal into each Inlet Adapter with the garter spring up NOTE When using alternate materials the fit of the special materials may be snug and require gently driving the LPS into position with a cylinder of the same diameter to assure a square seating and no damage to the LPS 4 Place Inlet Manifold on flat work surface with crankcase side up 5 Place Washer in each seal chamber of the Inlet Manifold 6 Press Inlet Adapter Assembly into each seal chamber of the Inlet Manifold with the garter spring down 7 Examine the V Packing Cylinders for scale build up wear and O Rings for cuts or deterioration and replace as needed 8 Examine Male Adapters and Female Adapters for wear and replace as needed 9 Examine Spacer w Coil Springs for scale build up wear broken or fatigued Coil Springs and replace as needed 7 1 3 9 11 5 6 12 10 4 2 8 9 Place Inlet Manifold on flat work surface with crankcase side down 10 Place Female Adapter with flat side down V side up inside each seal chamber 11 Insert two V Packings with V side down into each seal chamber The V will mate with V side of the Female Adapter 12 Press Male Adapter with V side down into each seal chamber
21. mes the pump inlet port diameter e g 1 1 2 port size 15 distance from pump inlet port TECHNICAL BULLETIN REFERENCE CHART No Subject Models 002 Inlet Pressure VS Liquid Temperature All Models 003 Power Unit Drive Packages 3PFR 68PFR 10FR 60FR 024 Lubrication of Lo Pressure Seals All Models 035 Servicing Crankcase Section 7PFR 60PFR 036 Cylinder and Plunger Reference Chart All Models 043 LPS and HPS Servicing All Plunger Models 053 Liquid Gasket All Plunger NAB S S Models 074 Torque Chart Piston and Plunger Pumps 077 Oil Drain Kit All Models except 2SF 4SF 083 Winterizing a Pump All Models PREVENTATIVE MAINTENANCE CHECK LIST Check Daily Weekly 50 hrs 500 hrs 1500 hrs 3000 hrs Clean Filters x Oil Level Quality x Oil Leaks x Water Leaks x Belts Pulley x Plumbing x Initial Oil Change x Oil Change x Seal Change x Valve Change x Accessories x If other than CAT PUMPS special multi viscosity ISO68 oil is used change cycle should be every 300 hours Each system s maintenance cycle will be exclusive If system per formance decreases check immediately If no wear at 1500 hours check again at 2000 hours and each 500 hours until wear is ob served Valves typically require changing every other seal change Duty cycle temperature quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and servi
22. nd C A T to assure adequate inlet supply When using an inlet supply reservoir size it to provide adequate liquid to accommodate 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 INLET LINE SIZE should be adequate to avoid starving the pump 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 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 Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of 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 Optimum pump performance is obtained with 20 PSI 1 4 BAR inlet pressure and a C A T for cert
23. nkcase oil seals Worn crankcase oil seals Replace crankcase oil seals Crankshaft oil seals and o rings Worn crankshaft oil seals or o rings on bearing cover Remove bearing cover and replace o rings and or oil seals Drain plug Loose drain plug or worn drain plug o ring Tighten drain plug or replace o ring Bubble gauge Loose bubble gauge or worn bubble gauge gasket Tighten bubble gauge or replace gasket Rear cover Loose rear cover or worn rear cover o ring Tighten rear cover or replace o ring Filler cap Loose filler cap or excessive oil in crankcase Tighten filler cap Fill crankcase to specified capacity Pump runs extremely rough Inlet conditions Restricted inlet or air entering the inlet plumbing Correct inlet size plumbing Check for air tight seal Pump valves Stuck inlet discharge valves Clean out foreign material or install new valve kit Pump seals Leaking V Packings or Lo Pressure seals Install new seal kit Increase frequency of service Premature seal failure Scored plungers Replace plungers Over pressure to inlet manifold Reduce inlet pressure per specifications Abrasive material in the liquid being pumped Install proper filtration at pump inlet and clean regularly Excessive pressure and or temperature of pumped liquid Check pressure and inlet liquid temperature Running pump dry DO NOT RUN PUMP
24. oid 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 which would be read at the discharge manifold of the pump NOT AT THE GUN OR NOZZLE Use PTFE thread tape or pipe thread sealant sparingly 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 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 othe
25. r 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 If a large portion of the pumped liquid is by passed not used when the high pressure system is running this by pass liquid should be routed to an adequately sized baffled supply tank or to drain If routed to the pump inlet the by pass liquid can quickly develop excessive heat and result in damage to the pump A tem perature control device to shut the system down within the pump limits or multiple THERMO VALVES must be installed in the by pass line to protect the pump 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 SPECIAL FLUSHED INLET MANIFOLD MODELS Standard pumps have internal weep holes between the V Packings and Lo Pressure Seals allowing the pumped liquid to cool the back side of the packings The flushed inlet manifold models do not have the internal weep holes and do not connect to the inlet side They have special holes on the sides of the inlet manifold that can be
26. rding 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 dam age 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 or call CAT PUMPS for recommendations C A T Installation of a C A T Captive Acceleration Tube is recommended in appli cations 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 av
27. s 7 On the models 3821 3831 3841 thread an M10 screw the HSH screws from the Valve Cover can be used into the top of the Spring Retainer and pull valve assembly out of each valve chamber NOTE The valve assembly will usually remain together 8 If the Valve Assembly separates during removal use a reverse pliers to lift and remove Valve Seats CAUTION Exercise caution as the reverse pliers may score seating surface 9 On the models 3801 3811 to separate Valve Assemblies insert screwdriver into Spring Retainer and press the backside of Valve until Seat separates from the Spring Retainer Each assembly consists of a Spring Retainer Spring Valve Seat O Ring and Back up Ring 10 On the models 3821 3831 3841 to separate Valve Assemblies continue threading the M10 screw into the back side of the Valve until the Valve Seat separates from the Spring Retainer Each assembly consists of a Spring Retainer Spring Valve Seat O Ring and Back up Ring Reassembly NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces See Tech Bulletin 053 for model identification NOTE EPDM elastomers require silicone base lubricant 1 Examine Spring Retainers for internal wear or breaks in the structure and replace as needed 2 Examine Springs and Coil Springs for fatigue or breaks and replace as needed 3 Examine Valves and Seats for grooves pitting or wear and replace as needed
28. s 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 PROBABLE CAUSE SOLUTION Low pressure Worn nozzle Replace with properly sized nozzle Belt slippage Tighten belt s or install new belt s Air leak in inlet plumbing Tighten fittings and hoses Use PTFE liquid or tape Pressure gauge inoperative or not registering accurately Check with new gauge Replace worn or damaged gauge Relief valve stuck partially plugged or improperly adjusted Clean adjust relief valve Replace worn seats valves and o rings Inlet suction strainer filter clo
29. uid G Use Thermo Valve in bypass line Temperature G Do not exceed pump temperature specifications G Substitute closed loop with baffled holding tank G Adequately size tank for frequent or high volume bypass G Pressure feed high temperature liquids G Properly ventilate cabinets and rooms Air Leaks in Plumbing G Check all connections G Use PTFE thread tape or pipe thread sealant Agitation in Supply G Size tank according to pump output Tank Minimum 6 10 times system GPM G Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids G Verify viscosity against pump specifications before operation G Elevate liquid temperature enough to reduce viscosity G Lower RPM of pump G Pressure feed pump G Increase inlet line size Clogged Filters G Perform regular maintenance or use clean filters to monitor build up G Use adequate mesh size for liquid and pump specifications Handy Formulas to Help You Consult Engine Mfr TYPICAL RESERVOIR TANK RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Avoid Cavitation Damage 1 4 5 16 3 8 1 2 5 8 3 4 1 0 5 16 5 2 1 54 20 7 2 2 180 60 25 6 2 3 380 120 50 13 4 2 4 220 90 24 7 3 5 320 130 34 10 4 6 220 52 16 7 1 8 300 80 25 10 2 10 450 120 38 14 3 15 900 250 80 30 7 20 1600 400 121 50 12 25 650 200 76 19 30 250 96 24 40 410 162 42 50 600 235 62 60 370 93 At a fixed
30. ve inlet pressure K versions are suitable for high temperatures and containment of harmful liquids Consult CAT PUMPS for optional flushing and cooling accessory BY PASS TO INLET Care should be exercised when deciding the method of by pass from control valves 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 When a pulsation dampener is used 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 moni tor 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 Caution should be exercised not to undersize the by pass hose diameter and length Refer to Technical Bulletin 064 for additional information on the size and length of the by pass line Check the pressure in the by pass line to avoid over pressurizing the inlet The by pass line should be connected to the pump inlet line at a gentle angle of 45 or less and no closer than 10 ti
31. w disassembly procedures for REMOVING THE DISCHARGE MANIFOLD and REMOVING THE INLET MANIFOLD 2 On the models 3801 3811 3821 3831 remove the two piece Seal Retainer with wick from each Plunger Rod 3 On the model 3841 remove the one piece Seal Retainer and LPS Spacer from each Plunger Rod 4 Using a Hex tool loosen the Plunger Retainers about three to four turns 5 Push the Ceramic Plungers back towards the crankcase to sepa rate from the Plunger Retainers and proceed with unthreading the Plunger Retainers by hand If resistant slip M14 or M21 deep socket over Plunger Retainer and gently tap end to free Ceramic Plunger 6 Remove Plunger Retainers O Rings Back up Rings and Gaskets NOTE Plunger Retainer Studs may stay on Plunger Rods or come off with Plunger Retainers 7 Remove Ceramic Plungers Keyhole Washers and Barrier Slingers Reassembly 1 Visually inspect Crankcase Oil Seals for deterioration or leaks and contact CAT PUMPS for assistance with replacement 2 Examine Plunger Retainer Studs Barrier Slingers and Keyhole Washers for wear and replace as needed 3 Slide Barrier Slinger over each Plunger Retainer Stud with concave side away from crankcase 4 Slide Keyhole Washer over each Plunger Retainer Stud with split ends facing downward 5 Examine Ceramic Plungers for scoring scale build up chips or cracks and replace as needed Generally the Ceramic Plungers do not need to be repl
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