Pump Service Manual for 25 PFR Plunger Pumps
Contents
1. _ oa Dra fee e m x 1 PBets Puley _ x coa x __ iia oH Ghange o _ O A _ _ Seal Changs rvahe Grange Paccessores _ If other than CAT PUMPS custom blend multi viscosity ISO 68 hydraulic 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 service cycle Remember to service the regulator unloader at each seal servicing and check all system accessories and connections before resuming operation Refer to service DVD for additional assistance TORQUE CHART Tool Size Torque Thread Part No in lbs ft lbs Nm M7 M14Hex 108 25053 M12 M10 Allen 33047 M10 Allen 33047 M13 Hex 25324 M13Hex 216 25324 M28 Oil Gauge Tool 45 38 5 44050 Pump Item Plunger Retainer 9 0 12 2 Inlet Manifold Screws 355 30 0 40 Discharge Manifold Screws M12 355 30 0 40 Rear Cover M8 Bearing Cover Screws 115 9 58 13 Connecting Rod Screws M8 18 0 24 Bubble Oil Gauge TECHNICAL BULLETIN REFERENCE CHART No Subject Model2. 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 Inadequate liquid supply Severe cavitation Worn seals Worn or dirty inlet discharge valves Faulty Pulsation Dampener Foreign material trapped in inlet discharge valves Worn High Pressure or Lo Pressure Seals Worn adapter o rings Humid air condensing into water inside the crankcase Excessive wear to seals and V Packings Inadequate inlet liquid supply Broken or worn bearing Loose pulley on crankshaft Worn crankcase oil seals Worn crankshaft oil seals or o rings on bearing cover Loose drain plug or worn drain plug o ring Loose bubble gauge or worn bubble gauge gasket Loose rear cover or worn rear cover o ring Loose filler cap or excessive oil in crankcase Restricted inlet or air entering the inlet plumbing S
3. 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 CAPACITY x Supply Line Bypass Line from regulator or unloader Level Sensing T Dia of pipe Device X D lt 7A Flexible Hose to Pump 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 m
4. 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 1 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 length will be directly proportional A 50 ft hose will exhibit one half the pressure drop of a 100 ft hose Above values shown are valid at all pressure levels WATER LINE PRESSURE LOSS PRESSURE DROP IN PSI PER 100 FEET Water Steel Pipe Nominal Dia Brass Pipe Nominal Dia Copper Tubing O D Type L GPM 1 4 3 8 1 2 3 4 1 1 4 1 2 1 4 3 8 1 2 3 4 1 14 12 1 4 3 8 1 2 5 8 3 4 7 8 120 13 400 45 94 100 28 9 0 2 2 230 50 17 330 86 220 62 21 5 2 1 6 500 120 40 520 130 320 90 30 7 8 2 4 180 56 270 90 190 62 16 5 0 1 5 120 670 240 470 150 40 12 3 8 1 7 330 110 39 11 5 0 550 200 150 36 37 52 210 107 Nominal Equivalent Length of Standard Pipe in Feet Pipe Inside 180 Tee Tee Size Diameter 45 90 Close Thru Thru Inches Inches Elbow
5. 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 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 temperature 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 supplie
6. or damage and place on the Plunger Rod with the concave side facing out Examine the Keyhole Washer and place on the Plunger Rod with the slot down Examine the O Ring and Back up Ring on the Plunger Retainer and replace if worn or damaged First install the Gasket then the O Ring and Back up Ring Lubricate the Plunger Retainer O Ring to avoid cutting during installation If the Plunger Retainer unthreads from the stud during re moval thread the stud into the retainer Examine the Ceramic Plunger for scoring cracks or scale and replace if needed The Ceramic Plunger can be cleaned with a scotchbrite pad Slide the Ceramic Plunger onto the retainer and stud assembly with the shallower counterbore away from the retainer NOTE Plunger can only be installed one direction Do not force into Plunger Rod 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 Apply Loctite 242 to the threads of the Plunger Retainer Stud and thread onto the Plunger Rod Then torque to specifications in chart 7 Install new wicks in front half of seal retainer Press rear half of seal retainer into front half until ends are flush Holes should be to the top and bottom to line up with front retainer holes Slide Seal Retainers over plungers and press into crankcase chamber until flush with oil seal Rotate the Crankshaft to line up t
7. 25PFR PLUNGER PUMP SERVICE MANUAL 25 FRAME SPLIT MANIFOLD 2530 2531 2537 INSTALLATION AND START UP INFORMATION Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only with the proper selection installation of plumbing and operation of the pump and accessories SPECIFICATIONS Maximum specifications refer to individual attributes It is not implied that all maximums can be performed simultaneously If more than one maximum is considered check with your CAT PUMPS supplier to confirm the proper performance and pump selection Refer to individual pump Data Sheets for complete specifications parts list and exploded view LUBRICATION Fill crankcase with CAT PUMPS custom blend ISO 68 hydraulic oil per pump specifications 84 oz 2 5 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 re quired 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 H
8. AT 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 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
9. PM 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 O Low vapor pressure liquids such as solvents require a booster pump and C A T to maintain adequate inlet supply where compatible 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 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 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 joint
10. UTSCHLAND GmbH Buchwiese 2 D 65510 Idstein Germany Phone 49 6126 9303 0 Fax 49 6126 9303 33 B e mail catpumps t online de www catpumps de PN 30053 Rev H 1643 Removal of Discharge Socket Head Screws Separation of Discharge Manifold from Inlet Manifold Discharge Manifold with both Inlet Valve Adapters and Discharge Valve Spacers CAUTION Before commencing with service shut off drive electric motor gas or diesel engine and turn off water supply to pump Relieve all discharge line pressure by triggering gun or opening valve in discharge line After servicing is completed turn on water supply to pump start drive reset pressure regulating device and secondary valve read system pressure on the gauge at the pump head Check for any leaks vibration or pressure fluctuations and resume operation SERVICING THE VALVES Disassembly 1 Removal of Discharge Valve Spacers To service the Valves the Discharge Manifold must be re moved Using a M10 allen wrench remove the eight Socket Head Screws Support the underside of the Discharge Manifold and lightly tap the top back of the manifold with a soft mallet Two screwdrivers may be needed to further separate the Discharge Manifold from the Inlet Manifold Remove the Discharge Manifold and place it crankcase side up NOTE The Discharge Valve Assembly is secured in the upper chambers by the Discharge Valve Spacer while the Inlet Valve Assembly is secured in the
11. emperature enough to reduce viscosity e Lower RPM of pump e Pressure feed pump e Increase inlet line size e Perform regular maintenance or use clean filters to monitor build up e Use adequate mesh size for liquid and 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 accessories in the system A careful review of the necessary inlet conditions and protection devices required before the system is installed will eliminate many potential problems CAT PUMPS are very easy pumps to service and require far less frequent service than most pumps Typically only common tools are required making in field service convenient however there are a few custom tools special to certain models that do simplify the process This service manual is designed to assist you with the disassembly and reassembly of your pump The following guide will assist in determining the cause and remedy to various operating conditions You can also review our FAQ or SERVICE sections on our WEB SITE for more facts or contact CAT PUMPS directly PROBLEM Low pressure
12. essary 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 T It is recommended the by pass be directed to a baffled reservoir tank with at least one baffle between the by pass line and the inlet line to the pump Although not recommended by pass liquid may be returned to the inlet line of the pump if the system is properly designed to protect your pump 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 O A reinforced flexible low pressure hose rated up to 300 PSI should be used for routing by pass back to the pump inlet T Caution should be exercised not to undersize the by pass hose diameter and length
13. etainer 9 Remove and examine both O Rings on the Discharge 3 Examine the Valve for pitting or grooves and replace as Valve Spacer for wear or cuts and replace as needed ae ihe Valve Ontasthe spalig wilt ine concave 10 Fit the new O Rings into the groove on the outside of the j Discharge Valve Spacer Apply liquid gasket into the 4 Place the Seat into the valve chamber with the concave O Ring crevice and carefully press the Spacer completely side down Then apply liquid gasket to the O Ring and into the Discharge Manifold chamber with the smaller press squarely into the lip on the Spring Retainer diameter side down NOTE Effective with 6 95 mfg date the O Ring was 11 Replace Discharge Manifold over the Plunger Rods with moved to the back side of the Seat with the O Ring Discharge Valve Spacers to the top and Inlet Adapters to installed first onto the lip in the manifold chamber the bottom Tap with a soft mallet until completely seated then the Seat with the machined O Ring groove down in chambers NOTE Effective with 11 95 mfg date the Seat was 12 Reinstall the eight Socket Head Screws and torque in modified to a new thicker style still with the O Ring sequence to specifications in torque chart installed first onto the lip in the manifold chamber then the Seat with the machined O Ring groove down NOTE It is highly recommended that antiseize lubricant PN6119 be applied to the threads on all stainless 5 Examine the Seat for a
14. evices and seal surfaces See Tech Bulletin 053 for model identification NOTE EPDM elastomers require a silicone base lubricant Examine the Lo Pressure Seal for wear or spring fatigue and replace Apply liquid gasket to the outside of the new Lo Pressure Seal and carefully press it into the Inlet Manifold chamber with the 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 Invert the Inlet Manifold and place the crankcase side down Examine the Hi Pressure Seal for deformity or wear and replace Apply liquid gasket to the outside of the new Hi Pressure Seal and carefully press it into the Inlet Manifold chamber with the metal side down SERVICING THE PLUNGERS Disassembly NOTE The Ceramic Plungers and the Plunger Retainers should be examined on the same schedule as servicing the seals To service the Ceramic Plungers first remove the Seal Retainers Loosen the Plunger Retainer about three or four turns using a M14 hex tool Grasp the Ceramic Plunger and push toward the Crankcase until it separates from the Plunger Retainer Unthread the Plunger Retainer with Gasket O Ring Back up Ring and Ceramic Plunger Remove the Keyhole Washer and Barrier Slinger from the Plunger Rod Reassembly 1 Examine the Barrier Slinger for any wear
15. he outside Plungers Then lightly lubricate the Plungers with oil Carefully slide the Inlet Manifold over the Ceramic Plungers and press until flush with the Crankcase Reinstall the four Inlet Socket Head Screws and torque to specifications in chart The Hi Pressure Seals may shift while installing the Inlet Manifold Use one of the Discharge Valve Spacers to press the Seals back into position Carefully press the Discharge Manifold into the Inlet Manifold Use a soft mallet to tap into place and reinstall the eight Socket Head Screws Torque in sequence to specifications in torque chart TORQUE SEQUENCE ee ae asa 26 SERVICING THE CRANKCASE SECTION 1 While Inlet Manifold Plungers and Seal Retainers are removed examine Crankcase Oil Seals for leaking and wear Check for any signs of leaking at Rear Cover or Dipstick Check oil level and for evidence of water in oil Change oil on a regular schedule See Preventative Maintenance Check List Rotate Crankshaft by hand to feel for smooth bearing movement Examine Crankshaft Oil Seals externally for drying cracking or leaking Consult CAT PUMPS or your local distributor if Crankcase service is required See also Tech Bulletin 035 See Section Il of the Plunger Pump Service DVD for additional information Loctite and 242 are registered trademarks of Henkel Corporation PREVENTATIVE MAINTENANCE CHECK LIST Fok ay Wes 0 ore 00s 00 Ws e x
16. lower chambers by the Inlet Valve Adapter The Discharge Valve Spacers will remain in either the Inlet Manifold or the Discharge Manifold To remove the Spacer from the manifold insert two screwdrivers on opposite sides under the machined lip on the outside of the Spacer and pry out Removal of Inlet Valve Adapters 5 Use a reverse pliers to remove the Inlet Valve Adapters from the Discharge Manifold or insert two screwdrivers into the secondary groove on opposite sides of the adapter and pry from valve chamber Both the Inlet and Discharge use the same Valve Assembly With a flat head screwdriver carefully pry the Seat O Ring Valve Spring and Retainer from the manifold chamber CAUTION Exercise caution to avoid scoring the manifold chamber wall NOTE This Valve Assembly does not snap together 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 a silicone base lubricant Inspect the Spring Retainer for any scale buildup or wear and replace as needed Place the Spring Retainer into the valve chamber Discharge Valve Assembly Inlet Valve Assembly Removal of I M Socket Head Screws Rotate Crankshaft to position plungers 2 Examine the Spring for fatigue or breaks and replace as 8 Press the Inlet Adapter into the lower manifold chamber needed Rises ho Spring inte the R
17. ny grooves pitting or wear and steel components to prevent galling replace Place the new Seat onto the the O Ring with the IMPORTANT Follow the torque sequence to assure concave side down the proper alignment 6 Look for wear or damage to both the inner and outer O Rings on the Inlet Adapter and replace 7 Fit the O Rings into both the outer groove and face groove of the Inlet Adapter and apply liquid gasket into the O Ring crevice Removal of Inlet Manifold Removal of Hi Pressure Seals Removal of Lo Pressure Seals Plunger Arrangement SERVICING THE SEALS Disassembly 1 Remove the Discharge Manifold as described in SERVICING THE VALVES section To service the seals the Inlet Manifold must be removed use a M10 allen wrench to remove the 4 Socket Head Screws Support the Inlet Manifold and lightly tap the top back side with a soft mallet Remove the Inlet Manifold and place it crankcase side down Use a reverse pliers to remove the Hi Pressure Seals The Lo Pressure Seals may stay on the Plungers or in the Inlet Manifold Invert the Inlet Manifold with the crankcase side up Remove the Lo Pressure Seal using a reverse pliers or slide it off the Plunger by hand 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 cr
18. orsepower Requirement and Pulley Selection Chart refer to Tech Bulletin 003 or individual Data Sheet MOTOR SELECTION The motor or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load Select the electric motor from the Horsepower Requirement Chart according to required pump discharge flow maximum pressure at the pump and drive losses of approximately 3 5 Consult the manufacturer of gas or diesel engine for selection of the proper engine size MOUNTING Mount the pump on a rigid horizontal surface in a manner to permit drainage of crankcase oil An uneven mounting surface will cause extensive damage to the pump base To minimize piping stress use appropriate flexible hose to inlet and discharge ports Use the correct belt make sure pulleys are aligned Excessive belt tension may be harmful to the bearings Hand rotate pump before starting to be certain shaft and bearings are free moving LOCATION If the pump is used in extremely dirty or humid conditions it is recommended 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 C
19. otor 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 wire reinforced hose to absorb pulsation and pressure spikes Excessive Elbows in Keep elbows to a minimum and less than 90 Inlet Plumbing Excessive Liquid e Use Thermo Valve in bypass line Temperature e Do not exceed pump temperature specifications e Substitute closed loop with baffled holding tank e Adequately size tank for frequent or high volume bypass e Pressure feed high temperature liquids e Properly ventilate cabinets and rooms e Check all connections e Use 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 t
20. r 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 A WARNING All systems require both a primary pressure regulating device i e regulator unloader and a secondary pressure safety relief device i e pop off valve safety valve Failure to install such relief devices could result in personal injury or damage to the pump or to system components CAT PUMPS does not assume any liability or responsibility for the operation of a customer s high pressure system Products described hereon are covered by one or more of the following U S patents 3558244 3652188 3809508 3920356 3930756 and 5035580 World Headquarters CAT PUMPS 1681 94th Lane N E Minneapolis MN 55449 4324 Phone 763 780 5440 FAX 763 780 2958 e mail techsupport catpumps com www catpumps com International Inquiries E FAX 763 785 4329 e mail intlsales catpumps com L UNF The Pumps with Nine Lives CAT PUMPS U K LTD 1 Fleet Business Park Sandy Lane Church Crookham Fleet Hampshire GU52 8BF England Phone Fleet 44 1252 622031 Fax 44 1252 626655 e mail sales catpumps co uk N V CAT PUMPS INTERNATIONAL S A Heiveldekens 6A 2550 Kontich Belgium Phone 32 3 450 71 50 Fax 32 3 450 71 51 7 e mail cpi catpumps be www catpumps be CAT PUMPS DE
21. s 002 Inlet Pressure VS Liquid Temperature All Models 3 003 Power Unit Drive Packages PFR 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 064 By Pass Hose Sizing All Unloaders Regulators 074 Torque Chart Piston and Plunger Pumps 076 Valve Seat and O Ring 2530 and 2537 077 Oil Drain Kit All Models except 2SF 4SF 081 Seal Case and Wick 2530 and 2537 083 Winterizing a Pump All Models 085 M8 Keyway 25FR 25PFR 28PFR 095 Galling Preventative Stainless Steel Pumps 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 R
22. s 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 T Optimum pump performance is obtained with 20 PSI 1 4 BAR inlet pressure and a C A T for certain applications With adequate inlet plumbing most pumps will perform with flooded suction Maximum inlet pressure is 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 INLET ACCESSORIES are offered to protect against over pressurization contamination or temperature and control flow A 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 Inspect and clean inlet filters on a regular schedule to avoid flow restriction A pressure transducer is nec
23. tuck inlet discharge valves Leaking High Pressure 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 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 pl
24. ug 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
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