35PFR PLUNGER PUMP SERVICE MANUAL
Contents
1. 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 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 T Avoid closed loop systems especially with high temperature ultra high pressure or large volumes Conditions vary with regulating unloader valve O Low vapor pressure liquids such as solvents require a booster pump and C A T to maintain adequate inlet supply Q Higher viscosity liquids require a positive head and a C A T to assure adequate inlet supply 1 Higher temperature liquids tend to vaporize and require positive heads and C A T to assure adequate inlet supply m When using an inlet supply reservoir size it to provide adequate liquid to accommodate the maximum output of the pump ge2. models before threading into the valve chamber All models except 3560 Removal of Discharge Manifold Screws All models except 3560 Removal of Discharge Manifold Removal of Inlet Screws and Inlet Manifold Removal of Inlet Manifold O Rings Reassembly Model 3560 10 Place the Valve onto Inlet Seat with concave side down 12 13 11 14 15 16 17 NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 053 for model identification Examine the O Ring on the Inlet Seat and replace if cut or worn Examine Inlet Valves and Seats for grooves pitting or wear and replace as needed Examine Inlet Springs for fatigue or breaks and replace as needed Examine Inlet Spring Retainers for internal wear or breaks in the structure and replace as needed Examine the O Rings and Back up Rings on the Discharge Seat and replace if cut or worn Examine Discharge Valves and Seats for grooves pitting or wear and replace as needed Examine Discharge Springs for fatigue or breaks and replace as needed Examine Discharge Spring Retainers for internal wear or breaks in the structure and replace as needed NOTE Inlet Valve Seat and O Ring are different from the Discharge Valve Seat O Ring and Back up Ring One Valve Kit required per pump Lubricate and install new O Ring onto each Inlet Seat Place Inlet Seat on work surface with small diameter side up
3. Examine for broken or fatigued springs or scale build up or pitting and replace as needed 6 With a reverse pliers remove Male Adapter V Packings and Female Adapter NOTE Using the reverse pliers may damage V Packings or Female Adapter 7 Examine Female Adapter for worn I D and replace as needed Reassembly of the V Packings NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 053 for model identification 1 Lubricate outer surface of V Packing Cylinder and install new O Ring in groove 3520 3521 3527 Press V Packing Cylinder with O Ring end down into the manifold chamber until completely seated 2 Insert Female Adapter into V Packing Cylinder 3520 3521 3527 or manifold chamber 3535 3531 3537 3545 3541 3560 with the V groove up 3 Fit the new V Packings together lubricate outer surface of the pack ings and insert into V Packing Cylinder 3520 3521 3527 or mani fold chamber 3535 3531 3537 3545 3541 3560 with the V groove up 4 Install Male Adapter into V Packing Cylinder 3520 3521 3527 or manifold chamber 3535 3531 3537 3545 3541 3560 with the V groove down notches up 5 Lubricate outer surface of Spacer with Coil Springs and insert into V Packing Cylinder 3520 3521 3527 or manifold chamber 3535 3531 3537 3545 3541 with springs facing down See Tech Bulletin 050 when servicing old style pumps both the spa
4. Manifold onto Plungers and press into Crankcase Keep manifold aligned to avoid damaging Plungers 10 Replace four 4 HSH screws and torque per chart 11 Examine inlet port o rings at bottom of manifold and replace if cut or worn Wick lubrication Oiler setting for Wicks is three drops per hole twice per month for normal operation Oiler adjustment is vertical to start feed horizontal to stop feed 45 to flush bearing Additional lubrication may be required with increased hours of operation and temperature NOTE Do not lubricate wicks at initial start up Operate for 10 to 15 minutes to allow grease from LPS to penetrate the plunger surface then lubricate as needed Plunger Arrangement Lo Pressure Seal and Adapter Assembly 12 Lubricate outer surface of V Packing Spacer O Rings and valve chamber walls and carefully slip Discharge Manifold over V Packing Spacer 13 Hand tighten the two 2 HSH screws first Then hand tighten the remaining six 6 HSH screws Torque per chart and in this sequence 1 3 5 7 a a e 4 2 SERVICING THE CRANKCASE SECTION 1 2 3 4 5 6 While manifolds plungers and seal retainers are removed examine crankcase oil seals for leaking and wear Check for signs of leaking at Bearing Covers Rear Cover Drain Plug and Bubble Oil Gauge Check oil level and for evidence of water in oil Change crankcase oil on a regular schedule See Preventative Maintenance Check List R
5. Place Spring on Valve Install Inlet Spring Retainer with deep stepped end over Spring and snap onto Inlet seat Lubricate and install O Ring then Back up Ring onto the Discharge Seats Place Discharge Seat on a work surface with small diameter down Place Valve onto Discharge Seat with the concave side down Place Spring on Valve 3531 3535 3537 3541 3545 3650 Removal of V Packing Spacer from Inlet Manifold 18 19 20 21 22 3520 3521 3527 Removal of V Packing Cylinder Install Discharge Spring Retainer with deep stepped end over Spring and snap onto Discharge Seat Complete the stacked assembly by pressing the Discharge Valve Assembly into the Inlet Valve Assembly Place the complete stacked valve assembly into each Valve Chamber until completely seated Lubricate and install Back up Ring then O Ring onto each Valve Plug Press Valve Plug into each Valve Chamber Exercise caution to avoid damage from the valve plug threads Apply anti seize lubricant PN6119 to HSH screw threads and thread in hand tight Torque to specifications in torque chart REMOVING THE DISCHARGE MANIFOLD 1 2 3 Remove the eight 8 HSH screws Tap the back side of the Discharge Manifold with a soft mallet and gradually work head from pump Remove the O Rings from lower chambers of the face of the Inlet Manifold REMOVING THE INLET MANIFOLD 1 Using a hex allen wrench remove the four 4 HSH screws Rotate the
6. baffle between the by pass line and the inlet line to the pump O 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 monitor the temperature build up in the by pass loop to avoid premature seal failure T A reinforced flexible low pressure hose rated up to 300 PSI should be used for routing by pass back to the pump inlet O 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 O Check the pressure in the by pass line to avoid overpressurizing the inlet Q 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 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 lengt
7. 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 eUse PTFE thread tape or pipe thread sealant 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 and monitor build up e Use adequate mesh size for liquid and pump 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 ac
8. 35PFR PLUNGER PUMP SERVICE MANUAL 35 FRAME SPLIT MANIFOLD 3520 3521 and 3527 3535 3531 and 3537 3545 3541 3560 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 simultaneous y If more than one maximum is considered check with your CAT PUMP S 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 4 2 Qts 4 0 L 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 Oiler adjustment is vertical to start feed horizontal to stop feed dial to adjust flow rate Additional lubrication may be required with increased hours of operation and temperature PUMP ROTATION Pump was designed for forward rotation to allow optimum lubri cation 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 delive
9. APACITY x Supply Line Bypass Line from regulator or unloader Level Sensing T Dia of pipe Device X D lt 7A Flexible Hose to Pump aren 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 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
10. CAT PUMPS for recommendations C A T Installation of a C A T Captive Acceleration Tube is recommended in applications 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 Pressur e 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 pressur e which would be read at the discharg e 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 ie pop off v
11. Crankshaft to begin the separation of the Inlet Manifold from the Crankcase Tap the rear of the Inlet Manifold with a soft mallet and gradually work from pump NOTE Support from the underside and exercise caution to keep manifold aligned with Plungers to avoid damage to the Plungers as the manifold is removed NOTE Two screwdrivers on opposite sides of the manifold may be used to assist separation 3531 3535 3537 3541 3545 V Packing and Spacer Arrangement 3520 3521 3527 V Packing and Cylinder Arrangement 3560 V Packing Spacer Arrangement 3531 3535 3537 3541 3545 V Packing Spacer and Spacer with Coil Springs SERVICING THE SEALS Disassembly of the V Packings 1 Place the crankcase side of the Inlet Manifold down on the work surface 2 Remove the V Packing Spacer These may stay in either the Inlet or Discharge Manifold ports when the Discharge Manifold is removed If they are extremely dirty or dry remove the exposed O Ring and Back up Ring and insert two screwdrivers on opposite sides to pry out of chamber 3 Examine both front and rear O Rings and Back up Rings on the V Packing Spacer for cuts or wear and replace as needed NOTE The 3545 3541 do not have Back up Rings 4 Remove V Packing Cylinder 3520 3521 3527 by inserting two screwdrivers on opposite sides of the V Packing Cylinder and pry out Examine O Ring for wear and replace as needed 5 Remove Spacer with Coil Springs except 3560
12. Nm M21Hex 220 18 0 24 Mi4Hex 90 75 10 25053 M14 Mi2Allen 480 33048 M10 Allen 355 33047 Valve Plugs M45 M41 Hex 1305 109 148 Valve Plug Screws M14 M12 Allen 486 40 5 55 33048 M1i3Hex 115 25324 M17Hex 395 25083 M28 Oil Gauge Tool 45 3 6 5 44050 M14 M22 Hex 570 Plunger Retainer M10 Model 3560 Only M7 Inlet Manifold Screws 40 0 54 Discharge Manifold Screws M12 30 0 40 Rear Cover M8 Bearing Cover Screws 9 58 13 Connecting Rod Screws M10 33 0 45 Bubble Oil Gauge Direct Mount Screws 47 5 64 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 7CP 7PFR 68PFR 036 Cylinder and Plunger Reference Chart All Models 040 Manifold and Valve Part 3527 and 3537 041 Oil Gauge and Crankcase 3520 and 3535 043 LPS and HPS Servicing All Plunger Models 050 Spacer with Coil Springs 3520 3527 3535 3537 052 Plunger Rod and Stud 3PFR 5PFR 15PFR 35PFR 60PFR 053 Liquid Gasket All Plunger NAB S S Models 064 By Pass Hose Sizing All Unloaders Regulators 069 Forged Extended Manifolds 35PFR 074 Torque Chart Piston and Plunger Pumps 077 Oil Drain Kit Models except 2SF 4SF 083 Winterizing a Pump Models 087 Female Adapters 15PFR 35PFR 60PFR 095 Galling Preventative Stainless Steel Pumps
13. PUMP S 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 damage tothe pump DO NOT RUN PUMP WITH FROZEN LIQUID refer to Tech Bulletin 083 AX 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 PUMP S does not assume any liability or responsibility for the operation of a customer s high pressure system PIJTTERSEN Pijttersen B V Postbus 262 8500 AG Joure Transportwei 26 8501 ZP Joure The Netherlands Tel 31 0 513 414040 Fax 31 0 513 414066 E mail info pijttersen nl info catpumps nl Internet www pijttersen nl www catpumps nl CAT UMF The Pumps with Nine Lives All models except 3560 Removal of Discharge Valve Plug All models except 3560 Discharge Valve Assembly 3560 Stacked Inlet Discharge Valve Design 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 second
14. alve 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 other system components and can cause bodily harm The secondary safety relief device must be installed in line between the primary device and pump or on the opposite side of the manifold head 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 pressur e 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 temperature control device to shut the system down within the pump limits or multiple THERM O 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 befor e storing For pumping liquids other than water contact your CAT
15. ary 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 All models except 3560 1 2 Remove the six 6 M41 Hex Valve Plugs Remove the exposed Coil Spring from the top of the Spring Retainer Thread an M10 bolt into the top of the Spring Retainer The assembly will usually remain together To separate continue threading the bolt into the back side of the Valve Seat until it separates from the Spring Retainer In all models if the assembly separates during removal use a valve seat removal tool and lift the Seats from the chamber Disassembly Model 3560 NOTE The Discharge and Inlet Valve assemblies are a stacked design and are both accessible by removing the valve plugs Follow the same procedure for inlet and discharge assemblies NOTE The Discharge and Inlet Valve assemblies may stay together or separate during removal NOTE Spring Retainer may also separate from Valve Seat dur ing removal Using an M12 Allen wrench remove the 4 four hex socket head screws HSH from each valve plug Remove Valve Plugs with O Ring and Back up Ring from the Discharge Manifold chambers Using a reverse pliers pull the stacked valve assemblies from the valve chamber If the Inlet Valve Assembly stays in the manifold use a reverse pliers to remove it If the seat separates from the discharge or inlet assembly insert the
16. cer with coil springs and inlet manifold must be updated 6 Lubricate outer surface of V Packing Spacer install new O Rings and Back up Rings in both front and rear groove and press into V Packing Cylinder 3520 3521 3527 or manifold chamber 3535 3531 3537 3560 with small diameter down until completely seated NOTE The 3545 3541 do not have Back up Rings Removal of Lo Pressure Seal from Inlet Manifold 3531 3535 3537 3541 3545 Lo Pressure Seal and Washer Assembly Disassembly of the Lo Pressure Seal 1 With the Inlet Manifold on blocks and with the crankcase side down insert screwdriver into seal chamber and tap opposite sides of the Washer Spacer to drive out seal assembly NOTE Models 3535 3531 3537 3545 3541 include Spacer and Lo Pressure Seal Models 3520 3521 3527 include Washer Lo Pressure Seal Inlet Adapter and O Ring Model 3560 includes only LPS 2 Elevate Inlet Adapter with Lo Pressure Seal down and tap with screwdriver on opposite sides of seal to drive seal out of Inlet Adapter Models 3520 3521 3527 only Replace the Lo Pressure Seal and examine Inlet Adapter O Ring for wear and replace as needed Reassembly of the Lo Pressure Seal NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 053 for model identification Models 3535 3531 3537 1 With the crankcase side of Inlet Manifold up insert the LPS Spacer into the seal chamber 2 Ins
17. cessories 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 eInto the crankcase Knocking noise Inlet supply Bearing Pulley Oil leak Crankcase oil seals Crankshaft oil seals and o rings Drain plug Bubble gauge 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 Inadequat
18. e 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 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 or Lo Pressure seals Scored plungers Over pressure to inlet manifold Abrasive material in the liquid being pumped Excessive pressure and 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
19. h 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 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 C
20. 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 Check 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
21. nerally a minimum of 6 to 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 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 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 A 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 70 PSI 4 9 BAR O After prolonged storage pum
22. new Wick NOTE Model 3545 3541 do not have Wicks or front half of Seal Retainer 5 Replace Inner Collar on Seal Retainer 6 Loosen Plunger Retainer 4 to 5 turns Push Plunger towards Crankcase until Plunger Retainer pops out 7 Unscrew and remove Plunger Retainer Gasket O Ring Back up Ring and Ceramic Plunger Keyhole Washer and Barrier Slinger from each Plunger Rod Reassembly 1 With these plunger items removed examine the Crankcase Oil Seal for wear or deterioration and replace as needed 2 Replace Keyhole Washer on Plunger Rod 3 Carefully examine each Plunger for scoring or cracks and replace if worn NOTE Ceramic Plunger can only be installed one direction front to back Do not force onto rod 4 Examine Gasket O Ring and Back up Ring on Plunger Retainer and replace if cut or worn Lubricate O Ring for ease of installation and to avoid damaging O Rings NOTE First install Gasket then O Ring and Back up Ring 5 Apply loctite 242 to the threads of the Plunger Retainer and thread Plunger Retainer onto Plunger Rod Torque per specifications 6 Slip Seal Retainers over Plungers NOTE On Model 3545 3541 install LPS Spacer over plungers until flush with Seal Retainer Line up Wicks with the oil holes in the Crankcase and tabs in the Oil Pan 3520 3521 3527 3535 3531 3537 7 Rotate crankshaft by hand so the two outside Plungers are extended equally 8 Lubricate the Plungers 9 Carefully replace Inlet
23. otate Crankshaft by hand to feel for smooth bearing movement Examine Crankshaft Oil Seals externally for drying cracking or leaking Contact CAT PUMPS or your local distributor if crankcase service is required See Tech Bulletin 035 See section Ill of the Plunger Pump Service Video for additional information except 3560 PREVENTATIVE MAINTENANCE CHECK LIST Check Daily Weehly 50 nrs 500 hrs 1500 hrs 3000 hrs CleanFiters x Oil LeveliQuality x Oilleaks x WaterLeaks x T Belts Pulley x Plumbing x Initial Oil Change OilChange SealChange Vave Chane Accessories 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 perfor mance decreases check immediately If no wear at 1500 hours check again at 2000 hours and each 500 hours until wear is observed 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 service 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 TORQUE CHART Pump Item Thread Tool Size Torque Part No in lbs ft lbs
24. p 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 line 0 Inspect and clean inlet filters on a regular schedule to avoid flow restriction OA pressure transducer is necessary to accurately read inlet pressure Short term intermittent cavitation will not register on a standard gauge T All accessories should be sized to avoid restricting the inlet flow T All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction O 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 positive inlet pressure BY PASS TO INLET Care should be exercised when deciding the method of by pass from control valves q It is recommended the by pass be directed to a baffled reservoir tank with at least one
25. r the desired flow from Horsepower Requirement and Pulley Selection Chart refer to Tech Bulletin 003 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 discharg e 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 or call
26. reverse pliers into the I D of the seat and remove it Reassembly All models except 3560 NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 053 for model identification Examine the O Rings and Back up Rings on the Seat and replace if cut or worn Lubricate the O Ring before installing Examine the surface of the Valve and Seat for pitting grooves or wear and replace if necessary Assemble Valve Retainer Spring Valve and Seat by snapping togeth er securely Thread the M10 bolt into spring retainer for installation Lubricate outer O Ring and Back up Ring surface and walls of valve chamber and press Valve Assembly squarely into chamber Remove M10 bolt Place the washer over the top of the Spring Retainer and then the Coil Spring on top of the Washer Examine the O Ring and Back up Ring on the Valve Plug and replace if cut or worn Lubricate new O Ring and Back up Ring before installing onto Valve Plug Exercise caution to avoid damage from the valve plug threads NOTE The Back up Ring is installed first then the O Ring Slowly thread the Valve Plug into chamber Exercise caution to avoid extruding or cutting the Back up Ring or O Ring Then torque to specifications NOTE It is highly recommended that anti seize lubricant PN6119 be applied to the threads of all stainless steel components to prevent galling NOTE Apply Loctite 242 to the threads of the Valve Plug brass
27. tall Lo Pressure Seal into seal chamber with garter spring facing down and press squarely into position Models 3520 3521 3527 1 With the crankcase side of Inlet Manifold up insert the Washer into the seal chamber 2 Install Lo Pressure Seal into larger diameter of Inlet Adapter with spring up and press squarely into position 3 Lubricate outer surface of Inlet Adapter and install O Ring into the groove of the Inlet Adapter 4 Press Inlet Adapter with seal into seal chamber with garter spring facing down Models 3545 3541 1 With the crankcase side of the Inlet Manifold up insert the Lo Pressure Seal into the seal chamber with the garter spring facing down and press squarely into position NOTE Install the LPS Spacer onto the plunger in front of the Seal Retainer and not in the I M seal chamber Models 3560 1 With the crankcase side of the Inlet Manifold up insert the Lo Pressure Seal into the seal chamber with the garter spring facing down and press squarely into position 3560 Lo Pressure Seal 3520 3521 3527 SERVICING THE PLUNGERS Disassembly 1 To service the plungers it is necessary to remove the Discharge and Inlet Manifolds Follow the disassembly procedure found under REMOVING THE DISCHARGE MANIFOLD and REMOVING THE INLET MANIFOLD 2 Remove the Seal Retainers from the Ceramic Plungers 3 Remove the Inner Collar from the front of the seal retainer 4 Remove the used Wick and install
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