CP SS PLUNGER PUMP SERVICE MANUAL - Three-Es
Contents
1. 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 Hi Pressure 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 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 compatibility2. 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 Liquid 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
3. M7 M10 Hex 25082 95 7 96 11 Bubble Oil Gauge M28 Oil Gauge Tool 44050 45 3 6 5 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 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 078 Field Retrofit Mounting 5CP 083 Winterizing a Pump All Models 088 6 Bolt S S Manifold 3CP and 5CP 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 l
4. 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 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 reinforced flexible low pressure hose rated up to 3000 PSI should be used for routing by pass back to the pump inlet 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 Check the pressure in the by pass line to avoid overpressurizing 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 times the pump inlet port diameter e g 1 1 2 port size 15 distance from pump inlet port 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
5. 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 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 pre
6. R 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 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 refer to 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 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 sy
7. S 5CP6251 Discharge Valve Assembly 3CP1221 3CP1231 3CP1241 Inlet 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 Reassembly Inlet 1 Examine Spring Retainers for internal wear or breaks in the structure and replace as needed 2 Examine Springs for fatigue or breaks and replace as needed 3 Examine Valves for grooves pitting or wear and replace as needed 4 Position Spring Retainer in each lower inlet valve chamber until they rest on the machined ridge in each chamber Insert Spring into Spring Retainer over the plastic center guide Place Valve over Spring with concave side down 5 Examine Seat O Rings for cuts or wear and replace as needed Place O Ring on lip of Spring Retainer Carefully square O Ring in each valve chamber to avoid cutting O Ring when Seat is installed 6 Examine Seats for grooves pitting or wear and replace as needed Install Seat with concave side down in each valve chamber so O Ring fits snugly into groove on Seat 7 Examine both front and rear O Ri
8. 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 CP SS PLUNGER PUMP SERVICE MANUAL PN 30075 Rev B 7313 3CP STAINLESS STEEL SPLIT MANIFOLD 3CP1221 3CP1231 3CP1241 5CP STAINLESS STEEL SPLIT MANIFOLD 5CP6221 5CP6241CS 5CP6251 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 3CP 10 oz 5CP 17 oz 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
9. case side up Remove Lo Pressure Seal LPS from each seal chamber using a screwdriver CAUTION Exercise caution as the screwdriver may damage sealing surface Reassembly NOTE For certain applications apply liquid gasket to O Ring crevices and seal Surfaces Refer to 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 LPS HPS Inlet Valve Adapter and Discharge Valve Adapter for ease of installation and to avoid damage 1 Examine Lo Pressure Seals for wear to the internal ridges outer surfaces or broken springs and replace as needed 2 Press Lo Pressure Seal into each seal chamber in the Inlet Manifold with garter spring down until completely seated 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 3 Examine Hi Pressure Seal for wear to the internal ridges or outer surfaces and replace as needed 4 Invert Inlet Manifold with crankcase side down Press Hi Pressure Seal into each seal chamber with metal backing down until completely seated 5 Rotate crankshaft by hand so the two outside Plungers are extended equally Lightly lubricate Ceramic Plungers to assist in installing the Inlet Manifold 6 Slide Inle
10. 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 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 Inc
11. et 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 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 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 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 ca
12. hes 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 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 p
13. hes 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 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 Inc
14. ife 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 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 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 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 Higher viscosity liquids require a positive head and a C A T to assure adequate inlet supply Higher temperature liquids tend to vaporize and
15. ischarge NOTE For certain applications apply liquid gasket to O Ring crevices and seal surfaces Refer to 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 for fatigue or breaks and replace as needed 3 Examine Valves for grooves pitting or wear and replace as needed 4 Position Spring Retainer in each upper discharge valve chamber until they rest on the machined ridge in each chamber Insert Spring into the Spring Retainer over the plastic center guide Place Valve over Spring with concave side down 5 Examine Seat O Rings for cuts or wear and replace as needed Place O Ring on lip of Spring Retainer Carefully square O Ring in each valve chamber to avoid cutting O Ring when Seat is installed 6 Examine Seats for grooves pitting or wear and replace as needed Install Seat with concave side down in each valve chamber so O Ring fits snugly into groove on Seat 7 Examine both front and rear O Rings on the Discharge Valve Adapter for cuts or wear and replace as needed Lubricate O Ring and fit into grooves on outside of each Adapter 8 Carefully press Discharge Valve Adapter into each upper valve chamber with small diameter side down until Adapter snaps tightly into position 3CP1221 3CP1231 3CP1241 Discharge Valve Assembly 5CP6221 5CP6241C
16. loosen Plunger Retainers approxi mately three to four turns 4 Push the Ceramic Plunger back towards crankcase to separate from the Plunger Retainers and proceed with unthreading the Plunger Retainers by hand 5 Remove Plunger Retainers and Seal Washers 6 Remove Ceramic Plungers Keyhole Washers and Barrier Slingers from each Plunger Rod Reassembly 1 Visually inspect Crankcase Oil Seals for deterioration or leaks and contact CAT PUMPS for assistance with replacement See SERVICING CRANKCASE SECTION 2 Examine Plunger Retainers Keyhole Washers and Barrier Slingers for wear and replace as needed 3 Examine Seal Washers for cuts or wear and replace as needed 4 Examine Ceramic Plungers for scoring scale build up chips or cracks and replace as needed Generally the Ceramic Plungers do not need to be replaced 5 Slide Seal Washer over each Plunger Retainer 6 Slide Plunger Retainer with Seal Washer into flat end of Ceramic Plunger NOTE Ceramic Plunger can only be installed in one direction Counterbore end of Ceramic Plunger fits over Plunger Rod shoulder 7 Slide Barrier Slinger over each Plunger Rod with con cave side away from crankcase 8 Slide Keyhole Washer over each Plunger Rod with split ends facing downward 9 Apply Loctite 242 to exposed threaded end of Plunger Retainer Thread into Plunger Rod and torque per chart 10 On the models 3CP1221 31 and 41 install Seal Retainers
17. ngs on the Inlet Valve Adapter for cuts or wear and replace as needed Lubricate O Ring and fit into grooves on outside of each adapter 8 Carefully press Inlet Valve Adapter into each lower valve chamber with small diameter side down until Adapter snaps tightly into position 9 Slide Discharge Manifold over Ceramic Plunger ends aligning exposed Discharge Valve Adapters with inlet valve chambers and press into position Tap with a soft mallet until Inlet and Discharge Manifolds are seated 10 Place Lockwasher on each HSH screw Apply anti seize to HSH screw threads and thread in hand tight Torque in sequence to specifications in torque chart 5CP6221 5CP6241CS 5CP6251 Inlet Valve Assembly All Models Seal Arrangement All Models Plunger Arrangement SERVICING THE SEALS Disassembly 1 To service the seals it is necessary to remove both the Discharge Manifold and the Inlet Manifold See SERVICING THE VALVES Disassembly steps 1 7 2 Remove HSH Screws from inlet manifolds 3 Rotate Crankshaft to loosen Inlet Manifold 4 Support Inlet Manifold from the underside and tap the backside of the manifold with a soft mallet to separate Inlet Manifold from Crankcase 5 Place Inlet Manifold on work surface with crankcase side down Remove Hi Pressure Seal HPS from each seal chamber using a screwdriver CAUTION Exercise caution as the screwdriver may damage sealing surface 6 Invert Inlet Manifold with crank
18. nlet 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 Hi Pressure or Lo Pressure Seals Install new seal kit Increase frequency of service Worn adapter spacer 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 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 Crankcase 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
19. 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 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 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 enclosed without proper ventilation INLET CONDITIONS Refer to complete Inlet Condition Check List in this manual before starting system DO NOT STARVE THE PUMP O
20. otential 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 clogged 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 i
21. ssure 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 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 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 cutoff switch between the inlet filter and the pump to shut off pump when there is no positive inlet pressure BY
22. stem 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 other system components and can cause bodily harm The secondary safety relief device must be installed in line between the primary device and the pump or on the opposite side of the manifold head This will ensure pressure relief of the sys tem 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 res
23. t Manifold over Ceramic Plungers Apply Loctite 242 to HSH screw threads and thread in hand tight Torque in sequence to specifications in torque chart 7 Examine Inlet and Discharge Valve Adapters for scale build up wear and replace as needed Examine O Rings on both the Discharge and Inlet Valve Adapters for cuts and deterioration and replace as needed 8 Carefully press Discharge Valve Adapter with O Rings into each upper Discharge Valve Chamber of Discharge Manifold with small diameter side down until Adapter snaps tightly into position 9 Carefully press Inlet Valve Adapter with O Rings into each lower Inlet Valve Chamber of Discharge Manifold with small diameter side down until Adapter snaps tightly into position 10 Slide Discharge Manifold over Ceramic Plunger ends aligning exposed Discharge Valve Adapters with inlet valve chambers and press into position Tap with a soft mallet until Inlet and Discharge Manifolds are seated 11 Place Lockwasher on each HSH screw Apply anti seize to HSH screw threads and thread in hand tight Torque in sequence to specifications in torque chart SERVICING THE PLUNGERS Disassembly 1 To service the plungers it is necessary to remove both the Discharge Manifold and Inlet Manifold See SERVICING THE VALVES Disassembly steps 1 7 2 Remove Seal Retainer from each Plunger Rod NOTE The 5CP models have a PVDF Oil Seal Washer behind the Seal Retainer 3 Using a wrench
24. tpumps com www catpumps com International Inquiries FAX 763 785 4329 e mail intlsales catpumps com The Pumps with Nine Lives SERVICING THE VALVES Disassembly 1 Remove the Hex Socket Head Screws HSH and Lockwashers from the Discharge Manifold 2 Support the Discharge Manifold from the underside and tap the backside of the Discharge Manifold with a soft mallet to gradually separate from the Inlet Manifold 3 Place Discharge Manifold on work surface with crankcase side up 4 Remove Inlet Valve Adapters with front and rear O Rings from the three small diameter lower inlet chambers These adapters are not held securely in position and may fall out as the Discharge Manifold is removed 5 Remove the Seats O Rings Valves Springs and Retainers from each inlet valve chamber 6 Remove Discharge Valve Adapters with front and rear O Rings from the three larger diameter upper discharge valve chambers These Adapters generally remain with the Discharge Manifold as it is removed When they remain in Discharge Manifold insert two screwdrivers under the lip on opposite sides of the Adapters and pry the Adapters from the valve chamber 7 Remove the Seats O Rings Valves Springs and Retainers from each discharge valve chamber NOTE The inlet and discharge use the same Retainers Springs Seats and Valves The O Rings and Valve Adapters are different Keep parts in order as they are removed Reassembly D
25. with the holes to the top and bottom and small tabs facing downward over each Plunger Rod 11 On the models 5CP6221 41CS and 51 install Oil Seal Washer first then the Seal Retainers with the holes to the top and bottom and small tabs facing downward over each Plunger Rod 12 Continue with reassembly See SERVICING THE SEALS Reassembly steps 5 11 TORQUE SEQUENCE SERVICING CRANKCASE SECTION 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 for proper level and for evidence of water or other contaminants in oil 4 Rotate Crankshaft by hand to feel for smooth bearing movement 5 Examine Crankshaft Oil Seal externally for drying cracking or leaking 6 Consult CAT PUMPS or your local distributor if crankcase service is required 1 3 5 6 4 2 TORQUE CHART Pump Item Torque Pump Model Thread Tool Size P N in lbs ft lbs Nm Plunger Retainer M6 M10 Hex 25082 55 4 4 6 Inlet Manifold Screws M8 M6 Allen 30941 115 9 4 13 Discharge Manifold Screws 3CP M10 M8 Allen 33046 140 12 16 5CP M12 M10 Allen 33047 260 22 30 Crankcase Cover Screws M6 M10 Hex Phil 25082 50 4 0 6 Bearing Cover Screws 3CP M6 M10 Hex Phil 25082 50 4 0 6 5CP M8 M13 Hex 25324 115 9 4 13 Connecting Rod Screws
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