CAT Pumps Model 2510 service manual
Contents
1. 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 V Packings 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 Stuck inlet discharge valves Leaking V Packings 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 Chec2. Replace manifold Check liquid compatibility
3. 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 motor pulley should use Pump RPM Motor Engine RPM Q How do calculate the torque for my hydraulic drive system A Torque ft lbs 3 6 Consult A Pump Pulley Outer Diameter x Engine Mfr RPM Avoid Cavitation Damage One or several of the conditions shown in the chart below may contribute to cavitation in a system resulting in premature wear system downtime and unnecessary operating costs CONDITION SOLUTION Inadequate inlet e Increase line size to the inlet port or one size line size larger e Install C A T Tube e Move pump closer to liquid supply Water hammering liquid acceleration deacceleration Rigid
4. for broken springs and replace as needed 2 Press Lo Pressure seal into each seal chamber of the Inlet Manifold with the garter spring down Models 2510 2511 Install washers into each seal chamber 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 Models 1530 1531 2510 2511 Examine the spacer with coil springs for scale build up wear broken or fatigued coil springs and replace as needed Examine both front and rear o rings and back up rings for cuts or deterioration replace as needed Models 1540 1540E Examine the HPS spacer for scale build up or wear and replace as needed Examine the front and rear o rings for cuts or deterioration and replace as needed 4 Models 1530 1531 2510 2511 Examine male and female adapters for wear and replace as needed Model 1560 Examine female adapter and spacer and replace as needed 1530 1531 Lo Pressure Seal 10 11 12 13 14 15 16 1540 1540E Lo Pressure Seal Models 1530 1531 1560 2510 2511 Examine V Packings for frayed edges or uneven wear and replace as needed Models 1540 1540E Examine Hi Pressure seals for frayed edges or uneven wear and replace as needed Place the inlet manifold on work surface with crankcase side down Models 1530 1531 1560 2510 2511 Place th
5. 0 The drain slots should face the crankcase with openings to the top and bottom Models 1540 1540E 2510 2511 The seal retainer openings should be at top and bottom Press completely into crankcase 2510 2511 Plunger Arrangement 1540 1540E Plunger Arrangement 11 12 13 14 Lightly lubricate ceramic plungers to assist in installing into the manifold Support the inlet manifold from the under side and slide over plungers Press completely into crankcase Apply Loctite 242 to HSH screw threads and thread in hand tight Torque in sequence to specifications in torque chart Install new o rings at bottom inlet ports of inlet manifold Support the discharge manifold from the under side and align with inlet manifold Thread in hand tight Torque in sequence to specifications in torque chart NOTE It is highly recommended that antiseize lubricant PN6119 be applied to the threads on all stainless steel components to prevent galling SERVICING THE CRANKCASE SECTION 1 While manifolds plungers and seal retainers are removed examine crankcase oil seals for leaking and wear Check for any signs of leaking at rear cover drain plug bubble gauge and dipstick 2510 2511 Model 1540E ONLY When servicing the crankshaft seal bearing cover or rear cover apply liquid gasket ThreeBond 1207D to the face of the crankcase inlet manifold bearing covers and rear cover o ring groove to maintain a moisture free seal R
6. 15 amp 25PFR PLUNGER PUMP SERVICE MANUAL 15 FRAME SPLIT MANIFOLD 25 FRAME SPLIT MANIFOLD 1530 1531 1540 1540E 1560 2510 2511 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 special CAT PUMP oil per pump specifications 15PFR 42 oz 25PFR 84 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 lubrica tion of the crosshead area Reverse rotation is acceptable if the crankcase oil level is increased slightly above center dot to assure adequate lubrication PULLEY SELECTION Select size of motor pulley required to deliver the desired flow from Horsepower Requirement and Pulley Selection Char
7. 540 and 1540E Remove washer from the top of the discharge seat onto inlet spring retainer spring retainer 12 Place valve onto seat with dish side down 3 Models 1530 1531 1540 1540E 2510 and 2511 Using a 13 Place spring on valve and snap smaller spring retainer onto pliers to grasp the spring retainer by the tab at the top and re discharge seat move from valve chamber Normally the valve assembly will remain together If the assembly separates during removal 14 Lubricate outer o ring and back up ring surface and walls of use a reverse pliers and lift the seats from the chamber Mite colt and cay valve ere squarely into valve c ti t ted Model 1560 Use a reverse pliers to grasp the spring retainer Sp gaia aren tase Y SERE and remove the stacked valve assemblies 15 Models 1530 1531 2510 2511 Place washer then coil 4 To separate valve assemblies insert screwdriver into spring Spring on10p of the spring retainer retainer and press the backside of valve until seat separates Models 1540 1540E Place washer on top of the spring retainer from the spring retainer Each assembly consists of a spring 16 Models 1540 1540E inlet valve assemblies Place washer retainer spring valve seat o ring and back up ring into valve chamber on back side of manifold Lubricate outer Models 1540 1540E ONLY The discharge manifold must be o ring and press valve assembly into valve chamber retainer removed in order to remove the inlet va
8. 540E 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 QO Open inlet shut off valve and turn on water supply to avoid starving pump DO NOT RUN PUMP DRY Temperatures above 130 F are permissible Add 1 2 PSI inlet pressure per each degree F over 130 F Elastomer or RPM changes may be required See Tech Bulletin 002 or call CAT PUMPS for recommendations Avoid closed loop systems especially with high temperature ultra high pressure or large volumes Conditions vary with regulating unloader valve O Low vapor pressure liquids such as solvents require a booster pump and C A T to maintain adequate inlet supply Q Higher viscosity liquids require a positive head and a C A T to assure adequate inlet supply 1 Higher temperature liquids tend to vaporize and require positive heads and C A T to assure adequate inlet supply When using an inlet supply reservoir size it to provide adequate liquid to accom modate the maximum out
9. 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 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 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 conditio
10. allation 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 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 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 mal function 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
11. ation Refer to DVD for additional assistance TORQUE CHART Pump Item Pump Model Torque Thread Tool Size P N in lbs ft lbs Nm Plunger Retainer 15PFR M6 25PFR M7 Inlet Manifold Screws 15PFR 25PFR Discharge Manifold Screws 1530 1531 1560 2510 2511 1540 1540E Valve Plug Valve Cover Screws 1560 ONLY M12 15PFR M36 25PFR M42 Rear Cover Bearing Cover Screws 15PFR M6 25PFR M8 Connecting Rod Screws 15PFR 25PFR M8 Bubble Oil Gauge 15PFR Only M12 Hex 55 46 6 2 M14 Hex 25053 108 9 0 12 2 M8 Allen 33046 M10 Allen 33047 M10 Allen 33047 M8 Allen 33046 M10 Allen 33047 M32 Hex M36 Hex M10 Hex 25082 M13 Hex 25324 M13 Hex 25324 216 M28 Oil Gauge Tool 44050 45 3 8 TECHNICAL BULLETIN REFERENCE CHART No Subject Models 002 Inlet Pressure VS Liquid Temperature All Models 003 Power Unit Drive Packages 3PFR 68PFR 10FR 60FR 024 Lubrication of Lo Pressure Seals All Models 035 Servicing Crankcase Section 7CP 7PFR 68PFR 036 Cylinder and Plunger Reference Chart All Models 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 077 Oil Drain Kit All Models except 2SF 4SF 083 Winterizing a Pump All Models 085 M8 Keyway 25FR 25PFR 28PFR 095 Galling Preventative All Stainless Steel Pumps Crankcase and Model Number Change 1540 to 1
12. 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 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 regulat ing 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 antifree
13. e female adapter with flat side down V side up into each seal chamber Models 1530 1531 2510 2511 Fit two new V Packings together Model 1560 Fit three new V Packings together Lubricate the outer surface of the packings and insert into seal chamber with the V side down The V will mate with V side of the female adapter Models 1530 1531 2510 2511 Place male adapter with V side down inside each seal chamber Models 1530 1531 2510 2511 Lubricate outer surface of spacer with coil springs and insert into seal chamber until completely seated Models 1540 1540E Lubricate outer surfaces of Hi Pressure seals and position into seal chamber with metal back down grooved side up Lubricate the outer o rings on the HPS spacer and press into IM seal chamber Model 1540E ONLY Apply liquid gasket ThreeBond 1207D to the face of the crankcase and inlet manifold to maintain a moisture free seal Refer to Tech Bulletin 100 Support the inlet manifold from the under side and slide over plungers Apply Loctite 242 to HSH screw threads and thread in hand tight Torque in sequence to specifications in torque chart Install new o rings at bottom inlet ports of inlet manifold Support the discharge manifold from the under side and press discharge manifold into inlet manifold Thread HSH screws in hand tight Torque in sequence to specifications in torque chart NOTE It is highly recommended that antisei
14. ecifications in 5 Models 1530 1531 2510 2511 Install o ring then back up ring torque chart onto seat Models 1540 1540E Install o ring onto seat 6 Place the valve onto the seat with dish side down 1530 1531 V Packing Arrangement REMOVING THE DISCHARGE MANIFOLD l 2 3 Remove the HSH screws Support the manifold from the underside and tap the backside of the discharge manifold with a soft mallet to gradually work manifold from pump Remove the o rings from lower chambers of the face of the inlet manifold REMOVING THE INLET MANIFOLD 1 2 Remove the HSH Screws Rotate the crankshaft to begin the separation of the inlet manifold from the crankcase Support the manifold from the underside and tap the rear of the inlet manifold with a soft mallet to gradually work from pump NOTE Two screwdrivers on opposite sides of the manifold may be used to assist separation SERVICING THE SEALS Disassembly 1 To service the seals and packings it is necessary to remove both the discharge and inlet manifolds Follow disassembly procedures for REMOVING THE DISCHARGE MANIFOLD and REMOVING THE INLET MANIFOLD NOTE On models 1530 1531 2510 2511 the spacer with coil springs may stay in the discharge manifold or inlet mani fold On models 1540 1540E the HPS spacer will generally stay in the inlet manifold Models 1530 1531 2510 2511 Remove the spacer with coil springs from either manifold and exp
15. efer to Tech Bulletin 100 Check oil level and check for evidence of water in oil Change crankcase 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 Contact CAT PUMPS or your local distributor if crankcase service is required Refer to Tech Bulletin 035 Loctite and 242 are registered trademarks of the Henkel Corporation PREVENTATIVE MAINTENANCE CHECK LIST Fok ay Wes 0 ore 00s 00 Ws e x _ oa Dra fee e m x Peete Puy _ x coa x iia oH Ghange _ x __ O A _ _ Seal Changs rvahe Grange Paecessores _ If other than CAT PUMPS special custom blend multi viscosity ISO68 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 relief valve at each seal servicing and check all system accessories and connections before resuming oper
16. ger retainers studs barrier slingers and keyhole washers for wear and replace as needed Models 1530 1531 1540 1540E Slide barrier slingers over plunger rods with concave side away from crankcase Models 1560 2510 2511 Slide keyhole washer over plunger rods with split ends facing downward 1530 1531 Plunger Arrangement 10 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 ceramic plungers over plunger rods NOTE Ceramic plunger can only be installed in one direction Do not force onto 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 Examine gaskets o rings and back up rings for cuts or wear and replace as needed Models 1530 1531 1560 2510 2511 Install gaskets first then o rings and back up rings onto plunger retainers NOTE Lubricate o rings and back up rings for ease in instal lation and to reduce possible damage Models 1540 1540E Install gasket onto plunger retainers Apply Loctite 242 to exposed threads on the plunger retainer and torque per chart Rotate the crankshaft so the two outside plungers are extended the same distance Models 1530 1531 1560 2510 2511 Install seal retainer onto the plunger rod with new wicks long tab down Models 1530 1531 156
17. ir 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 recommend ed 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 OA reinforced flexible low pressure hose rated up to 300 PSI should be used for routing by pass back to the pump inlet QO 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 T Check the pressure in the by pass line to avoid over pressurizing the inlet m 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 pres
18. k 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 plug or replace o ring Tighten bubble gauge or replace gasket Tighten rear cover or replace o ring Tighten filler cap Fill crankcase to specified capacity Correct inlet size plumbing Check for air tight seal Clean out foreign material or install new valve kit Install new seal kit Increase frequency of service Replace plungers Reduce inlet pressure per specifications Install proper filtration at pump inlet and clean regularly eCheck pressure and inlet liquid temperature DO NOT RUN PUMP WITHOUT LIQUID Increase hose one size larger than inlet port size Pressurize and install C A T
19. lve assemblies Follow first until completely seated aD procedure for REMOVING THE DISCHARGE 17 Examine the o ring on the valve plug and replace if cut or worn Lubricate new o ring before installing on valve plug to Reassembly avoid damaging as they are worked over the plug threads NOTE For certain applications apply liquid gasket to the o ring NOTE It is highly recommended that antiseize lubricant crevices and seal surfaces Refer to Tech Bulletin 053 for PN6119 be applied to the threads on all stainless steel model identification a l components to prevent galling NOTE EPDM elastome rs require silicone Base lubricant 18 Slowly thread the valve plug into chamber Exercise caution 1 Examine spring retainers for internal wear or breaks in the to avoid extruding or cutting the o ring Torque to specifications structure and replace as needed in torque chart 2 Examine springs and coil springs for fatigue or breaks and 19 Model 1560 Place valve cover over valve plugs Thread HSH replace as needed screws in hand tight Torque to specifications in torque chart 3 Examine valves and seats for grooves pitting or wear and 20 Install new o rings at bottom inlet ports of inlet manifold replace as needed Support the discharge manifold from the under side and 4 Examine seat o rings and back up rings for cuts or wear and press discharge manifold into inlet manifold Thread HSH replace as needed screws in hand tight Torque in sequence to sp
20. ne de www catpumps de PN 30000 Rev D 10709 1530 1531 1540 1540E 2510 2511 Complete Inlet Discharge Valve Assembly Complete Inlet Discharge Valve Assembly Complete Inlet Discharge 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 dis charge 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 Inspect and service all system accessories on the same schedule as your pump SERVICING THE VALVES Disassembly 1 Models 1530 1531 1540 1540E 2510 2511 Remove the hex 7 Place spring on valve and snap the spring retainer onto seat valve plugs with o ring 8 Model 1560 Install o ring onto small diameter inlet seat Model 1560 Remove the eight 8 hex socket head HSH screws and valve cover Remove valve plugs with o ring and S23 dee the valve onto the seat with dishiSige down back up ring 10 Place spring on valve and snap longer spring retainer with large 2 Models 1530 1531 2510 2511 Remove the exposed coil opening onto seat spring and washer from the top of the spring retainer 11 Install o ring then back up ring onto discharge seat Snap Models 1
21. ns 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 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
22. olonged 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 over pressurization control inlet flow contamination or temperature and provide ease of servicing O 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 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 T 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 ou BY PASS TO INLET Care should be exercised when deciding the method of by pass from control valves q It is recommended the by pass be directed to a baffled reservo
23. osed o rings and back up rings from the spacer 2510 2511 V Packing Arrangement 1540 1540E Hi Pressure Seal Arrangement Models 1540 1540E 1560 Remove the exposed o ring Insert two screwdrivers into the grooves on opposite sides of the spacer and pry from the chamber CAUTION Exercise caution as the screwdrivers may score o ring sealing surface 3 Models 1530 1531 2510 2511 Remove male adapter two V Packings and female adapter from each seal chamber Models 1540 1540E Remove Hi Pressure seal HPS from each seal chamber Model 1560 Remove three V Packings and female adapter from each seal chamber 4 Place the inlet manifold on the work surface with crankcase side up 5 Models 1530 1531 1540 1540E 1560 Use a screwdriver to remove Lo Pressure seal LPS from backside of manifold Models 2510 2511 Use a screwdriver to remove washer and Lo Pressure seal from backside of manifold CAUTION Exercise caution as the screwdriver may score o ring sealing surface Reassembly NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces Refer to Tech Bulletin 053 for model identification NOTE EPDM elastomers require silicone base lubricant NOTE For standard applications apply a small amount of oil to the outside edge of the LPS HPS VP MA FA and o rings for ease of installation and to avoid damage 1 Examine Lo Pressure seals for wear to the internal ridges outer surfaces or
24. put 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 joints to a minimum ideally no elbows and the inlet accessories to a minimum 0 Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of the pump Acceleration loss of liquids may be increased by high RPM high temperatures low vapor pressures or high viscosity and may require pressurized inlet and C A T to maintain adequate inlet supply DO NOT USE C A T WITH SUCTION INLET 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 pr
25. sure 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 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
26. t 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 recommend ed pump be enclosed Do not store or operate in excessively high temperature areas or without proper ventilation INLET CONDITIONS Refer to complete Inlet Condition Check List in this manual before starting system DO NOT STARVE THE PUMP OR RUN DRY Temperatures above 130 F are permissible Add 1 2 PSI inlet pressure per each degree F over 130 F Elastomer or RPM changes may be required See Tech Bulletin 002 or call CAT PUMPS for recommendations C A T Inst
27. ze lubricant PN6119 be applied to the threads on all stainless steel components to prevent galling TORQUE SEQUENCE Models 1530 1531 1560 2510 2511 1 3 lt i 4 2 2510 2511 Lo Pressure Seal TORQUE SEQUENCE Models 1540 1540E SERVICING THE PLUNGERS Disassembly 1 To service the plungers it is necessary to remove the discharge and inlet manifolds Follow disassembly procedures for REMOVING THE DISCHARGE MANIFOLD and REMOVING THE INLET MANIFOLD Models 1530 1531 1560 Remove the two piece seal retainer and wick from each plunger rod Models 2510 2511 Remove the one piece seal retainer and wick from each plunger rod Model 1540 1540E Remove the one piece seal retainer from each plunger rod Using a wrench loosen the plunger retainers about three to four turns Push the ceramic plungers back towards the crankcase to separate from the plunger retainers and proceed with un threading the plunger retainers by hand Remove plunger retainers o rings back up rings and gaskets NOTE On Models 1531 2510 2511 the plunger retainer studs may stay on plunger rods or come off with plunger retainers Models 1530 1531 1540 1540E Remove ceramic plungers and barrier slingers Models 1560 2510 2511 Remove ceramic plungers keyhole washers and barrier slingers Reassembly 1 Visually inspect crankcase oil seals for deterioration or leaks and contact CAT PUMPS for assistance with replacement Examine plun
28. ze 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 B 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 B e mail catpumps t onli
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