35FR PLUNGER PUMP SERVICE MANUAL - Three-Es
Contents
1. Pulsation Low Pressure Pump runs extremely rough pressure low Water leakage from under the manifold Oil leak between crankcase and pumping section Oil leaking in the area of crankshaft Excessive play in the end of the crankshaft pulley Water in crankcase Oil leaking from under side of crankcase Oil leakage from drain plug Loud knocking noise in pump Frequent or premature failure of the packing Strong surging at the inlet and low pressure on the discharge side DIAGNOSIS AND MAINTENANCE PROBABLE CAUSE Faulty Pulsation Dampener Material lodged in discharge valve Worn nozzle Belt slippage Air leak in inlet plumbing Pressure gauge inoperative or not registering accurately Relief valve stuck partially plugged or improperly adjusted valve seat worn Inlet suction strainer clogged or improper size Worn Packing Abrasives in pumped fluid or severe cavitation Inadequate water supply Fouled or dirty inlet or discharge valves Worn inlet or discharge valves Leaky discharge hose Restricted inlet or air entering the inlet plumbing Inlet restrictions and or air leaks Stuck inlet or discharge valve Leaking V Packings Cavitation Worn V Packings and Lo Pressure Seals Worn male and female adapter Excessive wear Operation beyond normal service cycle Worn crankcase piston rod seals Worn crankshaft seal or improperly installed oil seal retainer O ring Bad bearing Worn main bearing fro2. by pass fluid may be returned to the inlet line of the pump if the system is properly designed to protect your pump When using this method a PRESSURE REDUCING VALVE should 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 when a flow sensitive regulating device is used It is also recom mended 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 _J A low pressure flexible cloth braid not metal braid hose should be used from the by pass connection to the inlet of the pump J Caution should be exercised not to undersize the by pass hose diameter and length Refer to Technical Bulletin 64 for additional information on the size and length of the by pass line 1 Check the pressure in the by pass line to avoid overpressurizing the inlet _J 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 n WITH TYPICAL WATER FLOW RATES Water Hose Inside Diameters Inches camin 1a sne 38 12 se oa m 0 5 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
3. 3517 All Models All Models 35 Frame Forged Extended Manifolds Piston and Plunger Pump Torque Chart Oil Drain Kit 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 be adequate to accommodate the maximum flow being delivered by the pump 1 Open inlet shut off valve and turn on water supply to avoid cavitating 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 _J Low vapor pressure fluids such as solvents require a booster pump and C A T Captive Acceleration Tube to maintain adequate inlet supply 1 Higher viscosity fluids require a positive head and a C A T Captive Acceleration Tube to assure adequate inlet supply _J Higher temperature fluids tend to vaporize and require positive heads and C A T Captive Acceleration Tube to assure adequate inlet supply 1 When using an inlet supply reservoir size it to provide adequate fluid to accommodate the maximum output of the pump generally a min
4. contribute to cavitation in a system resulting in premature wear system downtime and unnecessary operating costs CONDITION Inadequate inlet line size Water hammering fluid acceleration deacceleration Rigid Inlet Plumbing Excessive Elbows in Inlet Plumbing Excessive Fluid Temperature Air Leaks in Plumbing Agitation in Supply Tank High Viscosity Fluids Clogged Filters SOLUTION e Increase line size to the inlet port or one size larger e Install C A T Tube e Move pump closer to fluid supply e Use flexible wire reinforced hose to absorb pulsation and pressure spikes e Keep elbows to a minimum and less than 90 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 fluids e Properly ventilate cabinets and rooms e Check all connections e Use Teflon tape e Size tank according to pump output Minimum 6 10 times system GPM e Baffle tank to purge air from fluid and separate inlet from discharge e Verify viscosity against pump specifications before operation e Elevate fluid 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 fluid and pump specifications PROBLEM
5. 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 Brass Pipe Nominal Dia Copper Tubing O D Type L 1 4 3 8 1 2 3 4 1 1 4 1 2 1 4 3 8 1 2 5 8 3 4 7 8 120 13 2 9 1 0 400 45 10 3 4 1 3 94 20 6 7 2 6 Water Steel Pipe Nominal Dia GPM 1 4 3 8 1 2 3 4 1 1 4 1 2 8 5 1 9 30 7 0 2 1 60 14 4 5 1 1 150 36 12 2 8 100 28 9 0 330 86 28 6 7 1 9 220 62 21 520 130 43 10 3 0 320 90 30 270 90 21 6 2 1 6 190 62 16 120 44 670 240 56 16 4 2 470 150 40 330 110 66 17 8 i 550 200 37 52 210 107 6 0 1 6 20 5 6 1 8 40 11 3 6 230 50 17 6 1 500 120 40 15 180 56 22 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 1 5 62 1 4 7 40 1 2 8 63 2 067 1 35 61 5 30 8 259 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 values fittings and elevation of lines If a sufficient number of values and
6. 35FR PLUNGER PUMP SERVICE MANUAL MNF SPLIT MANIFOLD PLUNGER PUMPS 35 FRAME 3507 and 3517 35 FRAME 3510 and 3515 CAUTION CAT PUMPS are positive displacement pumps Therefore a properly designed pressure RELIEF OR SAFETY VALVE MUST BE INSTALLED in the discharge piping Failure to install such a relief mechanism could result in personal injury or damage to the pump or system CAT PUMPS does not assume any liability or responsibility for the operation of a customer s high pressure system INSTALLATION AND START UP INFORMATION Optimum performance of the pump is dependent upon the entire fluid 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 LUBRICATION Fill crankcase with special CAT PUMP oil per pump specifications 4 2 Qts 4 0 L DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE Change initial fill after 50 hours running period Thereafter change oil every 3 months or 500 hour intervals Oiler adjustment is vertical to start feed dial to adjust flow rate Additional lubrication may be required with increased hours of operation and temperature PUMP ROTATION Pump was designed for f
7. Remember to service the regulator unloader at each seal servicing and check all system accessories and connections before resuming operation TORQUE CHART Pump Item Thread Pump Model Tool Size Torque Part No in lbs ft lbs Nm M7 M1i4Hex 90 7 2 10 25053 M21 Hex 220 18 1 25 Plunger Retainer Models 3507 3510 Plunger Retainer M10 Models 3515 3517 M14 M12 Allen 480 33048 M12 M10Allen 350 33047 M8 Allen 220 18 1 33046 Inlet Manifold Screws 39 8 55 All Models Discharge Manifold Screws 28 9 40 All Models Valve Plug Screws M10 All Models Crankcase Cover Bearing Cover Screws All Models M17 Hex 395 25083 Connecting Rod Screws M10 32 5 45 All Models Bubble Oil Gauge M28 Oil Gauge Tool 45 36 5 All Models 44050 Mounting Bolts M22 600 All Models 47 4 68 TECHNICAL BULLETIN REFERENCE CHART Subject Models Inlet Temperature vs Inlet Pressure All Models 5FR 68FR Drive Packages 5FR 68FR Plunger Models Lubrication of Lo Pressure Seals All Models Servicing Crankcase Section Plunger Pumps 5FR 7FR 15FR Cylinder and Plunger Reference Chart All Models Crankcase Changes 35FR All Plunger Models 3FR 5FR 15FR 35FR 60FR 5FR 7FR 15FR 35FR 60FR All Unloaders R egulators Plunger Pump LPS and HPS Servicing Plunger Rod and Stud Change CR Pumps Liquid Gasket By Pass Hose Length Discharge Valve Spacer and O Ring Change 3507 3520 3521 3921 3930 3531 3537 3507
8. Seal Retainers from the ceramic plungers Remove the used Wick Loosen Plunger Retainer 3 to 4 turns Push Ceramic Plunger towards Crankcase until Plunger Retainer pops out If resistant Slip M14 deep socket over Plunger Retainer and gently tap end to free Ceramic Plunger Unthread and remove Plunger Retainer Gasket O Ring and Back up Ring Remove Ceramic Plunger from Plunger Rod Barrier Slinger and Keyhole Washer will remain on the Plunger Rod Remove and examine for wear Reassembly 8 9 NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 53 for model identification With these plunger items removed examine the Crankcase Oil Seals for wear or deterioration and replace as needed Replace Barrier Slinger and Keyhole Washer on Plunger Rod Carefully examine each Plunger for scoring or cracks and replace if worn NOTE Ceramic Plunger can only be installed one direction larger I D out Examine O Ring and Back up Ring on Plunger Retainer and replace if cut or worn Lubricate O Ring for ease of installation and to avoid damaging O Rings NOTE First install O Ring then Back up Ring then Gasket Apply Loctite 242 to Plunger Retainer threaded end and thread onto Plunger Rod Torque per specifications Slip Seal Retainers over Plungers Insert smaller diameter first NOTE Line up Wicks with the oil holes in the Crankcase and tabs in the Oil Pan Rotate sha
9. ale Adapter into V Packing Cylinder with notches up Examine O Ring and Back up Ring on V Packing Spacer and replace if cut or worn Insert smaller diameter end of V Packing Spacer into V Packing Cylinder Invert the Inlet Manifold with crankcase side down Press the V Packing Cylinder containing V Packing Spacer and V Packings into manifold chambers until completely seated Disassembly of Lo Pressure Seal 1 2 3 4 Place the Inlet Manifold on blocks with crankcase side down Use a screwdriver or the head of the 5 16 x4 M8 x 100 bolt to drive out Lo Pressure Seal and Inlet Adapter Separate stainless steel Washer from Inlet Adapter Then place Inlet Adapter on V Packing cylinder and drive out Lo Pressure Seal using a socket sized to fit Reassembly Lo Pressure Seal NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 53 for model identification With crankcase side of Inlet Manifold facing up insert Washer into manifold chamber Examine O Ring on Inlet Adapter and replace if cut or worn Place Inlet Adapter with o ring side down and insert new pre greased Lo Pressure Seal into the Inlet Adapter with garter spring facing up Press squarely into position See Tech Bulletin 53 Next insert Inlet Adapter and Lo Pressure Seal with garter spring facing down and press squarely into manifold chamber SERVICING THE PLUNGERS Disassembly 1 ZA 3 Remove the
10. e Church Crookham Fleet Hampshire GU13 OBF England Phone Fleet 44 1252 622031 Fax 44 1252 626655 N V CAT PUMPS INTERNATIONAL S A Heiveldekens 6A 2550 Kontich Belgium Phone 32 3 450 71 50 Fax 32 3 450 71 51 e mail cpi catpumps be CAT PUMPS DEUTSCHLAND GmbH Buchwiese 2 D 65510 Idstein Germany Phone 49 6126 93030 Fax 49 6126 930333 e mail catpbumps t online de SERVICING THE VALVES Disassembly 1 Using a standard M8 allen wrench remove the six 6 M10 hex socket screws on each of the Valve Plugs and remove plugs Inlet and Discharge Valves may be serviced at different schedules 2 Remove the Coil Springs from the valve chambers 3 With a standard pliers grasp the Spring Retainer by the top tab and remove Valve Assembly The flat Washer will rest on top of the retainer NOTE Normally the Valve Assembly will remain together To separate the Valve Assembly place a screwdriver into the side of the Spring Retainer and press on the back of the Valve until the Spring Retainer and Seat separate If assembly separates lift Spring and Valve from chamber by hand using valve seat removal tool or the head of a 5 16 x 4 M8x100 bolt Insert under lip of the Valve Seat and lift out This procedure will avoid damaging the surface of the Valve Seat Reassembly NOTE For certain applications apply liquid gasket to the o ring crevices and seal surfaces See Tech Bulletin 53 for model identification 1 Examine
11. er 2000 PSI SECONDARY PROTECTION is recommended by installing a pop off valve safety valve or rupture disc START SYSTEM WITH ALL VALVES OPEN OR IN THE LOW PRESSURE SETTING 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 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 FLUIDS Some fluids may require a flush between operations or before storing For pumping fluids other than water contact your CAT PUMPS supplier STORING For extended storing or between use in cold climates drain all pumped fluids from pump and flush with antifreeze solution to prevent freezing and damage to the pump DO NOT RUN PUMP WITH FROZEN FLUID 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 612 780 5440 FAX 612 780 2958 e mail sales catpumps com www catpumps com International Inquiries FAX 612 785 4443 e mail intlsales catpumps com rar nA The Pump with Nine Lives CAT PUMPS U K LTD 1 Fleet Business Park Sandy Lan
12. 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 value or fitting TYPICAL RESERVOIR TANK RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Supply Line Bypass Line from regulator or unloader Level Sensing Device ji 1 5 x D Min Flexible Hose ass cs SSS toPump Y bY Fud 2 YoY Bypass Line a from regulator or FILTER O Y Y 72 unloader VR eg le ee oe ee Ma Soe er ees 7 t Minimum Two Baffles MIN 4 Sealed at Bottom T Dia of pipe XxX D lt 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 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 Pll need to run the pump A Electric Brake Horsepower Required Standard 85 Mech Efficiency GPM x PSI 1460 Q What size motor pulley should I use A Pump Pulley Outer Diameter x __Pump RPM Motor Engine RPM Consult Engine Mfr Q How do I calculate the torque for my hydraulic drive system A Torque ft lbs 3 6 cem X Psi RPM Avoid Cavitation Damage One or several of the conditions shown in th e chart below may
13. ft and line up two outside Plungers Carefully lubricate Plungers and slip Inlet Manifold onto Plungers and press into Crankcase Keep manifold aligned to avoid dam aging Plungers Press completely into Crankcase Reinstall four 4 M14 hex socket head screws and torque per chart Examine inlet port O Rings at bottom of manifold and replace if cut or worn 10 Carefully slip Discharge Manifold over V Packing Spacers See Tech Bulletin 53 11 Hand tighten the eight 8 M12 hex socket screws and torque per chart in this sequence Torque in order diagonally the center four 4 screws then the outer four 4 screws all hand tight then repeat series to specs ee te 34 26 SERVICING THE CRANKCASE SECTION 1 While manifold plungers and seal retainers are removed examine crankcase seals for wear Check oil level and for evidence of water in oil Rotate crankshaft by hand to feel for smooth bearing movement Examine crankshaft oil seal externally for drying cracking or leaking Consult factory or your local distributor if crankcase service is evidenced PREVENTATIVE MAINTENANCE CHECK LIST 1500 hrs o ON 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 performance decreases check immediately If no wear at 1500 hours check again at 2000 hours and each 500 hours until wear is observed
14. ifold with a soft mallet Support from underside and gradually work from the pump Exercise caution and keep manifold aligned with Plungers to avoid damaging them as the manifold is removed SERVICING THE PACKINGS Disassembly of the V Packings The V Packing Cylinder may remain in either the Inlet or Discharge Manifold and generally may be removed by hand or with a reverse pliers 1 Place the crankcase side of the Inlet Manifold down on the work surface 2 Remove the V Packing Cylinder by inserting screwdrivers into the exposed grove on opposite sides and pry out of the chamber 3 With valve seat removal tool or reverse pliers remove the V Packing Spacer from the center of the V Packing Cylinder The V Packing Spacers may remain in the V Packing Cylinder or Discharge Manifold If in the Discharge Manifold insert screwdrivers from opposite sides into groove on Spacer and pry out 4 Next remove the Male Adapter V Packings and Female Adapter from the V Packing Cylinder Reassembly of V Packings 1 Examine the exterior O Rings on the V Packing Cylinder and replace if cut or worn 2 Inspect I D of V Packing Cylinder for pitting or grooves and replace as needed 3 Insert the new Female Adapter into the V Packing Cylinder with the v side up See Tech Bulletin 53 Assemble the three 3 V Packings Model 3507 two 2 V Packings Model 3517 and insert into the V Packing Cylinder with v side up Next insert M
15. imum of 6 to 10 times the GPM however a combination of system factors can change this requirement provide adequate baffling in the tank to eliminate air bubbles and turbulence install diffusers on all return lines to the tank INLET LINE SIZE should be adequate to avoid starving the pump LI Line size must be a minimum of one size larger than the pump inlet fitting Avoid thick walled fittings tees 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 Ll Use pipe sealant to assure air tight positive sealing pipe joints INLET PRESSURE should fall within the specifications of the pump LI Acceleration loss of fluids may be increased by high RPM high temperatures low vapor pressures or high viscosity and may require pressurized inlet and C A T Captive Acceleration Tube to maintain adequate inlet supply DO NOT USE C A T Captive Acceleration Tube WITH SUCTION INLET 1 Optimum pump performance is obtained with 20 PSI 1 4 BAR inlet pressure and a C A T for certain applications With adequate inlet plumb ing most pumps will perform with flooded suction Maxi
16. m excessive tension on drive belt May be caused by humid air condensing into water inside the crankcase Worn and leaking V Packing Operating beyond normal service cycle Worn crankcase seals Loose drain plug or worn drain plug O ring Pulley loose on crankshaft Broken or worn bearing Stressful inlet conditions Scored plungers Over pressure to inlet manifold Abrasive material in the fluid being pumped Excessive pressure and or temperature of fluid being pumped Running pump dry cavitation Foreign particles in the inlet or discharge valve or worn inlet and or discharge valves Stressful inlet conditions SOLUTION Check precharge If low recharge it or install a new one Clean and replace damaged valve Replace nozzle of proper size Tighten or replace Use correct belt type and length Disassemble reseal and reassemble Check with new gauge replace worn or damaged gauge Clean and adjust relief valve check for worn or dirty valve seats Repair with Valve Kit Clean Use adequate size Check more frequently Install proper filter Check flow available to pump Clean inlet and discharge valve assemblies Replace worn valves valve seats and or discharge hose Check fitting or replace damaged hose Proper size inlet plumbing check for air tight seal Clean out foreign material replace worn valves Repair with Seal Kit Check water temperature and inlet conditions Repair with Seal Kit Install
17. mum inlet pressure is 70 PSI 5 BAR T After prolonged storage pump should be purged of air to facilitate priming Disconnect any discharge port and allow fluid to pass through pump INLET ACCESSORIES are designed to protect against overpressurization control inlet flow contamination or temperature and provide ease of servicing LI A shut off valve is recommended to facilitate maintenance LJ Installation of a C A T Captive Acceleration Tube is essential in applica tions with 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 in the inlet line _I Inspect and clean inlet filters on a regular schedule 1 A pressure gauge is recommended to monitor the inlet pressure and should be mounted AS CLOSE TO THE PUMP INLET as possible Short term intermittent cavitation will not register on a standard gauge J All accessories should be sized to avoid restricting the inlet flow LJ All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction 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
18. new male and female adapter Initiate more frequent service cycle Replace crankcase piston rod seals Remove oil seal retainer and replace damaged O ring and or seals Replace bearing Replace bearing Properly tension belt Use correct type and length Change oil every 3 months or 500 hour intervals using special CAT PUMP Premium Grade Oil PN 06100 Case 6107 Bottle other approved oil every month or 200 hours Repair with seal kit Initiate more frequent service cycle Replace seals Tighten drain plug or replace O ring Check key and tighten set screw Replace bearing Install C A T and or booster pump Replace plungers Reduce inlet pressure per instructions Install proper filtration on pump inlet plumbing Check pressure and inlet fluid temperature Be sure they are within specified range DO NOT RUN PUMP WITHOUT WATER Check for smooth lap surfaces on inlet and discharge valve seats Discharge valve seats and inlet valve seats may be lapped on a very fine oil stone Install C A T and or booster pump PN 30005 Rev D 5 98
19. orward 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 volume from Horsepower Requirement and Pulley Selection Chart 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 volume 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 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 befo
20. re 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 such as high temperatures booster pump feed long inlet lines or quick closing valves DISCHARGE PLUMBING OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system Install a Pulsation Dampening device mounted directly to the discharge line Be certain the pulsation dampener Prrrrr o lator is properly precharged for the system pressure see individual Prrrrr o lator 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 A Pressure Regulator or Unloader Valve must be installed to prevent over pressurizing the pump in the event the discharge or downstream plumbing becomes plugged or is turned off Severe damage to the pump will result if this condition occurs without a relief valve in the line CAUTION Failure to install such a safety valve will void the warranty on the pump Discharge regulating devices should be at minimum pressure setting at start up On systems ov
21. the O Rings and Back up Rings on the Seat and replace if cut or worn 2 Examine the surface of the Valve and Seat for pitting grooves or wear and replace if necessary 3 If servicing from individual parts place the Seat with O Ring and Back up Ring on work surface with o ring side down Place Valve onto Seat with the raised side up Place the Spring over the raised backside of the Valve Securely snap the Spring Retainer into the Seat The Valve Assemblies come preassembled in the valve kit NOTE Inlet and discharge valve parts are interchangeable Two valve kits are needed for complete valve change Press Valve Assembly squarely into chamber Place Washer and Coil Spring on top of Retainer Examine the O Ring and Back up Ring on Valve Plug and replace if cut or worn Press Valve Plug into valve chamber Exercise cau tion not to cut O Ring or Back up Ring 7 Reinstall six 6 M10 hex socket screws on each Valve Plug and hand tighten using torque 6 5 sequence Then torque all screws per chart D pi e 4 2 REMOVING DISCHARGE MANIFOLD 1 Remove the eight 8 M12 hex socket head screws 2 Tap the back side of the Discharge Manifold with a soft mallet and gradually work from pump 3 Remove the O Rings from lower Inlet Manifold chamber REMOVING THE INLET MANIFOLD 1 Remove the four 4 M14 hex socket head screws 2 Rotate Crankshaft to separate Inlet Manifold from the Crankcase 3 Tap the rear of the Inlet Man
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