Cat CP Pump Service Manual 279KB Jul 20 2012
Contents
1. Reduce inlet pressure per instructions Install proper filtration on pump inlet plumbing Check pressure and inlet liquid temperature Be sure they are within specified range DO NOT RUN PUMP WITHOUT WATER Check for smooth surfaces on inlet and discharge valve seats Replace with kit if pitted or worn Check supply tank for contamination Install and regularly clean filter Do not pump abrasive liquids2. 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 sales catpumps com www catpumps com International Inquiries a FAX 763 785 4329 e mail intlsales catpumps com L The World s Most Dependable Pumps CAT PUMPS U K LTD 1 Fleet Business Park Sandy Lane Church Crookham Fleet Hampshire GU52 8BF England Phone Fleet 44 1252 622031 Fax 44 1252 626655 e mail sales catpumps co uk N V CAT PUMPS INTERNATIONAL S A Heiveldekens 6A 2550 Kontich Belgium Phone 32 3 450 71 50 Fax 32 3 450 71 51 7 e mail cpi catpumps be www catpumps be CAT PUMPS DEUTSCHLAND GmbH Buchwiese 2 D 65510 Idstein Germany Phone 49 6126 9303 0 Fax 49 6126 9303 33 _I e mail catpbumps t online de www catpumps de PN 33009 RevE 10111 All Models Removal of Valve Plugs 3CP1120 5CP3120 5CP5120 Complete Valve Assembly Valve Plug and O Ring SERVICING THE VALVES Remove the hex
3. 8 1 2 5 8 3 4 7 8 8 5 1 9 6 0 1 6 120 13 2 9 1 0 30 7 0 2 1 20 5 6 1 8 400 45 10 34 1 3 60 14 4 5 1 1 40 11 3 6 94 20 6 7 2 6 230 50 17 6 1 3 0 330 86 28 6 7 1 9 220 62 21 500 120 40 15 6 5 520 130 43 10 3 0 320 90 30 180 56 22 10 270 90 21 6 2 1 6 190 62 16 5 0 1 5 120 44 20 670 240 56 16 4 2 2 470 150 40 12 3 8 1 7 330 110 50 66 17 8 39 11 5 0 550 200 88 37 52 210 107 150 36 12 28 100 28 9 0 RESISTANCE OF VALVES AND FITTINGS Nominal Equivalent Length of Standard Pipe in Feet Pipe 180 Tee Tee Size i Gate Globe Angle 45 90 Close Thru Thru Inches Valve Valve Valve Elbow Elbow Ret Run Branch 1 2 3 33 3 4 4 41 i 5 62 1 4 7 40 1 2 8 63 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 0 60 0 5 03 10 80 1 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 Supply Line Bypass Line from regulator or unloader Level Sensing Dia of pipe Dev
4. 90 degree elbows or valves in the inlet line of the pump to reduce the risk of flow restriction and cavitation LJ The line MUST be a FLEXIBLE hose NOT a rigid pipe and reinforced on SUCTION systems to avoid collapsing _1 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 T Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of the pump T Acceleration loss of liquids may be increased by high RPM high temperatures low vapor pressures or high viscosity and may require pressurized inlet and C A T to maintain adequate inlet supply DO NOT USE C A T WITH SUCTION INLET T Optimum pump performance is obtained with 20 PSI 1 4 BAR inlet pressure and a C A T for certain applications With adequate inlet plumbing most pumps will perform with flooded suction Maximum inlet pressure is 60 PSI 4 BAR 11 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 LI A shut off valve is recommended to facilitate maintenance LJ Installation of a C A T is essential in applications with
5. fit over Plunger Rod shoulder NOTE If new plungers are installed operate for 24 hours to allow grease from LPS to penetrate plunger surface Install Seal Retainers with small tabs facing down and holes facing forward towards manifold head Proceed with servicing the seals or remounting of Manifold Head as described SERVICING THE SEALS AND V PACKINGS Disassembly 1 Remove the Manifold Head as described in SERVICING THE PUMPING SECTION 2 Place the Crankcase side of manifold facing up and with a reverse pliers remove the Lo Pressure Seal from the Seal Case 3 Using a reverse pliers remove the press in style Seal Case from the Manifold Head 4 Remove the O Ring from O D of Seal Case 5 Hi Pressure Seal Models The Hi Pressure Seal is generally easily removed from the manifold without any tools If extremely worn a reverse pliers may be used 6 V Packing Models The V Packings and Male Adapter are easily removed from the manifold without any tools If extremely worn a reverse pliers may be used Reassembly NOTE Prior to reassembly ensure Seals V Packing and O Rings are of the proper configuration to re pair original pump i e 0110 for FPM Viton 0220 for EPDM 3 for HT V Packing Models 1 Lubricate each seal chamber in manifold head NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces See Tech Bulletin 053 for model identification NOTE EPDM e
6. 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 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 liquid sparingly or tape to connect accessories or plumbing Exercise caution not to wrap tape beyond the last thread to avoid tape from becoming lodged in the pump or accessories This condition will cause a malfunction of the pump or system PRESSURE REGULATION All systems require both a primary pressure regulating device i e regulator unloader and a secondary pressure safety relief device i e pop off valve safety valve 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 ov
7. CP PLUNGER PUMP SERVICE MANUAL 3CP MODELS SCP MODELS 3CP1120 3CP1130 3CP1140 9CP2120W 5CP2140WCS 5CP2150W 5CP3120 5CP3120G1 5CP3130G1 9CP5120 5CP5150G1 5CP6120 5CP6120G1 5CP6140 5CP6150 7CP MODELS 7CP6170 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 Sheet for complete specifications parts list and exploded view LUBRICATION Fill crankcase with special CAT PUMP oil per pump specifications 8CP 10 oz 5CP 17 oz 7CP 38 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 oil level is increased slightly above center dot to assure adequate lubrication PULLEY SELECTION Select size of moto
8. G SECTION and torque per chart SERVICING THE CRANKCASE SECTION 1 While Manifold Head 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 Bubble Gauge and Dipstick 7CP6170 3 Check oil level and for evidence of water 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 factory or your local distributor if crankcase service is evidenced PREVENTATIVE MAINTENANCE CHECK LIST Check Daily Weekly 50 hrs 500 hrs 1500 hrs 3000 hrs Cean Fites x J T Oitevevauaiy x J T T nteas x J f To T Waterteas x J f T T Bets Pulley x T Pumb ins x f So S miiaroitChange fo Soo S cnanse J fx T Seaicnanse lx VavecChanse J Jx Accessories f d l Ixi 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 Rememb
9. Reassembly il Visually inspect Crankcase Oil Seals for deterioration or leaks and contact factory for assistance with replacement Replace Barrier Slinger if damaged and slide onto Plunger Rod with concave side away from Crankcase Examine Sealing Washer for cuts or wear and replace as needed On the model 7CP6170 examine Gaskets O Rings and Back up Rings for cuts or wear and replace as needed Examine Plunger Retainers and Studs for wear or damaged threads and replace as needed On the model 7CP6170 install Gaskets first then O Rings and Back up Rings onto the Plunger Retainer NOTE Lubricate O Rings and Back up Rings for ease in installation and to reduce possible damage 10 11 12 13 14 All other models lubricate and install Sealing Washer onto Plunger Retainer On the model 7CP6170 apply Loctite 242 to one end of threaded Plunger Retainer Stud and secure to Plunger Retainer 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 Slide Plunger Retainer Assembly into flat end of Ceramic Plunger Apply Loctite 242 to exposed threaded end of Plunger Retainer Install Ceramic Plunger with Plunger Retainer onto each Plunger Rod shoulder and thread Plunger Rod Torque to specifications per chart NOTE Ceramic Plungers can only be installed in one direction Counterbore end of Ceramic Plunger to
10. Valve Plugs top discharge bottom inlet Examine the O Ring under the plug for cuts or distortion Replace if worn Lubricate new O Rings before installing NOTE The 5CP3120 5CP5120 and 5CP5150 have both an O Ring and Back up Ring on the Valve Plug Grasp Spring Retainer by the tab at the top with a pliers and remove from each valve chamber Usually the valve assembly will remain together while being removed To separate the valve assembly insert a screw driver into the side of the Spring Retainer and press on the back side of the Valve to begin separa tion then between the Spring Retainer and Seat to separate completely If the valve assembly separates during removal remove the Spring and Valve with a needle nose pliers With a reverse pliers remove the Seat from each valve chamber Then with a small screwdriver carefully remove the O Ring at the bottom of the valve chamber NOTE The 5CP2120W 5CP6120 and 7CP6170 have an O Ring and Back up Ring on each Seat 3CP1120 5CP2120W 7CP6170 5 5CP3120 5CP5120 5CP5150 Valve Plug O Ring and Back up Ring Examine all valve parts for pitting gouges or wear and replace with preassembled Valve Assembly Service kit contains Spring Retainers Springs Valves Seats Back up Rings and O Rings NOTE Inlet and discharge valve parts are inter changeable Two Valve Kits are needed for complete valve change Grasp new Valve Assembly by the tab at the top with a pliers imme
11. 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 LJ A low pressure flexible cloth braid not metal braid hose should be used from the by pass connection to the inlet of the pump _1 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 1 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 A WITH TYPICAL WATER FLOW RATES Water Hose Inside Diameters Inches camin 14 one se w2 se 3a 1 16 5 2 54 20 180 60 380 120 220 320 410 600 370 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 1 4 1 2 1 4 3
12. e 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 LJ Open inlet shut off valve and turn on water supply to avoid starving pump DO NOT RUN PUMP DRY 1 Avoid closed loop systems especially with high temperature ultra high pressure or large volumes Conditions vary with regulating unloader valve _1 Low vapor pressure liquids such as solvents require a booster pump and C A T to maintain adequate inlet supply m Higher viscosity liquids require a positive head and a C A T to assure adequate inlet supply _I Higher temperature liquids tend to vaporize and require positive heads and C A T to assure adequate inlet supply _1 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 T Line size must be a minimum of one size larger than the pump inlet fitting Avoid tees
13. er pressurization which can be caused by a plugged or closed off discharge line Over pressurization can severely damage the pump other system components and can cause bodily harm The secondary safety relief device must be installed between the primary device and pump This will ensure pressure relief of the system if the primary regulating device fails Failure to install such a safely device will void the warranty on the pump When the high pressure system is left running with the trigger gun off the by pass liquid can be routed to drain or to the pump inlet If routed to the pump inlet the by pass liquid can quickly develop excessive heat and result in damage to the pump A THERMO VALVE installed in the by pass line is recommended to protect the pump An AUTO SHUT OFF ASSEMBLY may also be used NOZZLES A worn nozzle will result in loss of pressure Do not adjust pressure regulating device to compensate Replace nozzle and reset regulating device to system pressure PUMPED LIQUIDS Some liquids may require a flush between operations or before storing For pumping liquids other than water contact your CAT PUMPS supplier STORING For extended storing or between use in cold climates drain all pumped liquids from pump and flush with antifreeze solution to prevent freezing and damage to the pump DO NOT RUN PUMP WITH FROZEN LIQUID refer to Tech Bulletin 083 Z WARNING All systems require both a primary pressure regulating device i e
14. er to service the regulator unloader at each seal servicing and check all system accessories and connections before resuming operation Refer to Service Manual and video for additional assistance TORQUE CHART Pump ltem Torque Pump Model Thread Tool Size P N in lbs ft lbs Nm Plunger Retainer M6 M10 Hex 25082 55 44 6 Manifold Screw M8 M6 Allen 30941 115 94 13 Valve Plugs 3CP 5CP M24 Hex 44046 7CP M27 Hex 44045 870 72 3 98 870 72 3 98 Bearing Cover Screws 3CP M6 SCP 7CP M8 M10 Hex Phil 25082 50 40 6 M13 Hex 25324 115 94 13 Crankcase Cover M10 Hex Phil 25082 40 6 Bubble Oil Gauge Oil Gauge Tool 44050 45 3 6 5 Direct Mount Bolts M8 M13 Hex 25324 115 9 4 M10 M17 Hex 25083 240 19 7 gt TECHNICAL BULLETIN REFERENCE CHART Models All Models 3PFR 68PFR 10FR 60FR All Models Cylinder and Plunger Reference Chart All Models LPS and HPS Servicing All Plunger Models Baffle Assembly 34170 By Pass Hose Sizing No Subject Inlet Pressure VS Liquid Temperature Power Unit Drive Packages Lubrication of Lo Pressure Seals All Unloaders Regulators Torque Chart Piston and Plunger Pumps Oil Drain Kit All Models except 2SF 4SF Field Retrofit Mounting 5CP Winterizing a Pump All Models 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 th
15. gers and remove any foreign material with a non abrasive cleaner Install Seal Retainer over Plungers with small tab facing down and holes facing forward towards manifold head Rotate the crankshaft so the two outside plungers are extended the same distance Lightly lubricate the Plungers and carefully slide the Manifold Head onto the Plungers supporting from the underside On the high pressure V Packing models or larger manifolds it may be necessary to gently tap with a soft mallet until the Manifold Head is flush with the Crankcase Replace Socket Head Screws and torque per chart 3CP1120 5CP2120W 5CP6120 Seal Arrangement Seal Arrangement 5CP3120 5CP5120 5CP5150 7CP6170 All Models except 7CP6170 Plunger Arrangement SERVICING THE PLUNGERS Disassembly 1 To service the plungers it is necessary to remove the manifold head Follow disassembly procedure for SERVICING THE PUMPING SECTION Remove the Seal Retainer from each plunger rod Using a wrench loosen the Plunger Retainer about three to four turns Push the Ceramic Plunger back towards the crankcase to separate from the Plunger Retainer and proceed with unthreading the Plunger Retainer by hand Remove the Plunger Retainer Ceramic Plunger Keyhole Washer and Barrier Slinger from each Plunger Rod On the model 7CP6170 remove the Plunger Retainer Stud Gasket O Ring Back up Ring Ceramic Plunger and Barrier Slinger from each Plunger Rod
16. ice Flexible Hose ini a toPump Ye me iquid Bypass Line from regulator or unloader FILTER T O A ae e a a Za Minimum Two Baffles MIN 4 Sealed at Bottom Handy Formulas to Help You Q How can find the RPM needed to get specific GPM Gallons Per Minute want A Desired RPM Desired GPM x Rated RPM Rated GPM Q have to run my pump at a certain RPM How do figure the GPM FII 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 B Standard 85 Horsepower Required 1460 Mech Efficiency Q What size motor pulley should I use Pump RPM Consult Motor Engine RPM Engine Mfr Q How do I calculate the torque for my hydraulic drive system A Torque ft Ibs 3 6 ePm x Pst RPM A Pump Pulley Outer Diameter x 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 Exces
17. lastomers require silicone base lubricant 2 Insert Male Adapter with notches down and v side up and press completely into each seal chamber by hand 3 Lubricate V Packings and install one at a time with grooved side down into each seal chamber 4 Examine Seal Case O Ring and replace if worn Lubricate new O Rings before installing 5 Press Seal Case into each seal chamber until com pletely seated Hi Pressure Seal Models 1 Lubricate each seal chamber in manifold head NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces See Tech Bulletin 053 for model identification NOTE EPDM elastomers require silicone base lubricant 2 Carefully square Hi Pressure Seal into position by hand with the grooved side down metal back facing out and press into each seal chamber until completely seated 3 Examine Seal Case O Rings and replace if worn Lubricate new O Ring before installing 4 Press the Seal Case into each seal chamber until completely seated Lo Pressure Seal All Models 1 Examine Lo Pressure Seals for wear to the internal ridges outer surfaces or for broken springs and re place as needed 2 Install Lo Pressure Seal into Seal Case with garter spring down 3 All Models Install Seal Retainer over Plungers with small tabs facing down and holes facing forward towards manifold head 4 Replace Manifold Head onto pump as described under SERVICING THE PUMPIN
18. nd replace as needed Clean and reset relief valve to system pressure and correct by pass Check supply tank for contamination Clean or replace with Valve Kit Use adequate size for inlet pump connection and liquid being pumped Clean frequently Install and maintain proper filter check line size and flow available to pump Install a C A T Clean inlet and discharge valve assemblies Replace with Valve Kit Replace hose Check connections Check precharge should be 30 50 of system pressure or replace as needed Check filters and clean as needed Check fittings and use PTFE liquid or tape for airtight connection Clean or replace valve Check supply tank for contamination Replace with Seal Kit Check inlet pressure and system temperature Use Thermo Valve in by pass line Use inlet pressure regulator in inlet line Replace crankcase seals Replace damaged seals Replace bearing Replace bearing Change oil every 3 months or 500 hour intervals using special CAT PUMP Premium Grade Oil PN 6100 Case 6107 Bottle other approved oil every month or 300 hours Replace seals Follow proper installation procedure Contact CAT PUMPS supplier for crankcase servicing Replace oil gauge crankcase cover or drain plug O ring Thread in oil gauge and drain plug hand tight to avoid extruding o ring Check key and tighten set screw Consult CAT PUMPS supplier for crankcase servicing Install C A T Replace plungers
19. pressure DIAGNOSIS AND MAINTENANCE 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 Worn seat or valves Inlet suction strainer clogged or improperly sized Worn seals Abrasives in pumped liquid severe cavitation inadequate water supply stressful inlet conditions Fouled or dirty inlet or discharge valves Worn inlet or discharge valves Leaky discharge hose Faulty Pulsation Dampener Restricted inlet or air entering inlet plumbing Stuck inlet or discharge valve Worn Lo Pressure Hi Pressure seals or V packings Worn crankcase seals Worn crankshaft seal Bad bearing Worn bearing Humid air condensing into water inside of the crankcase Leaking of crankcase seals or seals installed backward Damaged or improperly installed oil gauge crankcase cover or drain plug O ring Pulley loose on crankshaft Worn bearing connecting rod or crankshaft Stressful inlet conditions Scored plungers Over pressure to inlet manifold Abrasive material in the liquid being pumped Excessive pressure and or temperature of liquid being pumped Running pump dry Foreign particles in the inlet or discharge valve or worn inlet and or discharge valves SOLUTION Replace nozzle of proper size Tighten or replace use correct belt Use PTFE liquid or tape Check pressure with new gauge a
20. r 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 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 C A T Installation of a C A T Captive Acceleration Tube is recommended in applications with stressful inlet conditions
21. rse in oil and push into each valve cham ber Be certain valve assembly is completely seated in valve chamber NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 053 for model identification NOTE EPDM elastomers require Silicone base lubricant Apply Loctite 242 to the threads of each Valve Plug thread into valve port and torque per chart 5CP2120W 5CP6120 7CP6170 Complete Valve Assembly All Models Removal of Socket Head Screws 3CP1120 5CP2120W 7CP6170 Removal of Valve Assembly SERVICING THE PUMPING SECTION Disassembly 1 Using an allen wrench remove the Socket Head Screws from the Manifold Head Rotate Crankshaft by hand to start separation of Manifold Head from Crankcase Insert two flat head screwdrivers on opposite sides to further separate Manifold Head from Crankcase Support the underside of the Manifold Head and tap lightly with a mallet on the backside of the Manifold Head CAUTION KEEP MANIFOLD PROPERLY ALIGNED WITH CERAMIC PLUNGERS WHEN REMOVING TO AVOID DAMAGE TO THE PLUNGERS Remove the Seal Retainer from each plunger rod and examine for wear Examine Ceramic Plunger for cracks or scoring Refer to SERVICING THE PLUNGERS if replacement is needed 5CP3120 5CP5120 5CP5150 Removal of Valve Assembly All Models Removal of Valve Seat O Ring Reassembly 1 Generally Plungers do not need to be replaced Clean plun
22. sive Elbows in eKeep elbows to a minimum and less than 90 Inlet Plumbing Excessive Liquid Temperature e Use Thermo Valve in bypass line 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 Air Leaks in Plumbing eCheck all connections e Use Teflon tape Agitation in Supply e Size tank according to pump output Tank Minimum 6 10 times system GPM e Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids e Verify viscosity against pump specifications before operation e Elevate liquid temperature enough to reduce viscosity e Lower RPM of pump e Pressure feed pump e Increase inlet line size e Perform regular maintenance or use clean filters to monitor build up e Use adequate mesh size for liquid and pump specifications Clogged Filters PROBLEM Low Pressure Pulsation pump runs extremely rough pressure low Water leakage from under the manifold Slight leakage Oil leak between crankcase and pumping section Oil leaking in the area of crankshaft Excessive play in the end of the crankshaft Water in crankcase Oil leaking at the rear portion of the crankcase Loud knocking noise in pump Frequent or premature failure of the packing Strong surging at the inlet and low
23. stressful conditions such as high temperatures booster pump feed or long inlet lines Do not use C A T with negative inlet pressure 1 A stand pipe can be used in some applications to help maintain a positive head at the pump inlet line _I Inspect and clean inlet filters on a regular schedule to avoid flow restriction _1 A pressure transducer is necessary to accurately read inlet pressure Short term intermittent cavitation will not register on a standard gauge LJ All accessories should be sized to avoid restricting the inlet flow LI All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction LJ 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 LJ 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 LJ 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
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