68PFR PLUNGER PUMP SERVICE MANUAL
Contents
1. 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 50 PSI 3 5 BAR I 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 T K versions are suitable for high inlet pressure Consult CAT PUMPS INLET ACCESSORIES are designed to protect against over pressurization 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 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 Optional inlet protection can be achiev2. 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 8 259 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 01 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 Device 2 e e a Wea A l FA MT a aea as ao al Flexible Hose cle ee toPump gr cf ee iqud g 0 Bypass Line B gt ME soo from regulator or FILTER gt o a Ss reese whe aA ee ee ae te ee ee unloader 8 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 I have to run my pump at a certain RPM How do I f
3. refer to Tech Bulletin 003 or individual Data Sheet DRIVE SELECTION The motor or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load Select the electric motor from the Horsepower Requirement Chart according to required pump discharge flow maximum pressure at the pump and drive losses of approximately 3 5 Consult the manufacturer of gas or diesel engine for selection of the proper engine size MOUNTING Mount the pump on a rigid horizontal surface in a manner to permit drainage of crankcase oil An uneven mounting surface will cause extensive dam age to the pump base To minimize piping stress use appropriate flexible hose to inlet and discharge ports Use the correct belt make sure pulleys are aligned Excessive belt tension may be harmful to the bearings Hand rotate pump before starting to be certain shaft and bearings are free moving LOCATION If the pump is used in extremely dirty or humid conditions it is recom mended pump be enclosed Do not store or operate in excessively high temperature areas or 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
4. Bolts to act as handles 4 Then grasp the manifold from the sides and below these screws and pull from the pump placing the manifold on the work surface with the crankcase side down NOTE The V Packing Cylinders may stay in the Discharge Manifold or the Inlet Manifold 5 Insert two screwdrivers on opposite sides and pry the V Packing Cylinders from the manifold 6 On the Model 6861 remove the Spacer with Coil Springs from the Inlet Manifold by hand Lo Pressure Seal Inlet Manifold 6861 Inlet Manifold and order of V Packings and Adapters 7 On the Model 6841 insert the two screwdrivers in opposite sides and carefully pry the V Packing Spacer with Coil Springs from the cylinder 8 Remove the Male Adapter V Packings and Female Adapter by hand or with a reverse pliers from the manifold 6861 from the cylinder 6841 9 Place the Inlet Manifold on blocks with the crankcase side down 10 Using a socket to fit the seal chamber drive out the washer and Lo Pressure Seal 6861 or Inlet Adapter and Lo Pressure Seal 6841 NOTE If socket is not available use a screwdriver and tap on alternate sides of Spacer to work free NOTE See Servicing Plungers and Servicing Crankcase before starting reassembly Reassembly For standard installation apply a small amount of oil to the out side edges of the LPS HPS VP MA FA for ease of installation and to avoid damage NOTE For certain applications apply liquid gasket to the O
5. 68PFR PLUNGER PUMP SERVICE MANUAL 68 FRAME BLOCK STYLE MANIFOLD a m MNF 6811 6821 6831 6841 6861 6811K 6821K 6831K 6841K 6861K 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 320 oz 10 Qts 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 opera tion and temperature PUMP ROTATION Pump was designed for forward rotation to allow optimum lubrication of the crosshead area Reverse rotation is acceptable if the crankcase oil level is increased slightly above center dot to assure adequate lubrication PULLEY SELECTION Select size of motor pulley required to deliver the desired flow from Horsepower Requirement and Pulley Selection Chart
6. 821 4 Place the Washer 6811 6821 or the Spacer 6831 into the Inlet Manifold chamber 5 Press the Inlet Adapter with O Ring and Lo Pressure Seal 6811 6821 or Lo Pressure Seal 6831 squarely into the manifold chamber with the garter spring down 6 Invert the Inlet Manifold and place it on the work surface with the crankcase side down 7 Examine the exterior O Rings on the V Packing Cylinder and replace if cut or worn 6811 6821 8 Press the V Packing Cylinder O Ring end first into the manifold chamber 6811 6821 9 Examine the Female Adapter for wear and replace as needed 10 Lubricate the interior walls of the V Packing Cylinder 6811 6821 or the Inlet Manifold Seal Chambers 6831 and insert the Female Adapter with the flat side down 11 Examine the V Packings for frayed edges wear and replace as needed 12 Insert the V Packing into the V Packing Cylinder 6811 6821 or into the Inlet Manifold 6831 with the V groove down The V will mate with the V side of the Female Adapter 13 Examine the Male Adapter for wear and replace as needed 14 Insert the Male Adapter into the V Packing Cylinder 6811 6821 or into the Inlet Manifold 6831 with the V side down 15 Examine the O Ring and Back up Ring on the V Packing Spacer and the spacer for wear and replace as needed 16 Press the V Packing spacer into the V Packing Cylinder NOTE Press the smaller diameter into the V Packing Cylin
7. Discharge Manifold insert two of the M16 hex socket head bolts into the two top outer holes to act as handles Then grasp the manifold from the sides and below these screws and pull from the pump placing the Discharge Manifold on the work surface with the crankcase side up REMOVING THE INLET MANIFOLD 1 2 Remove the Guide Pins from the face of the Inlet Manifold First remove the top two M16 Hex Socket Head Bolts NOTE As an aid in removing the Inlet Manifold insert two M16 x 280 studs PN 88902 in place of the removed screws These will support the manifold during removal Remove the remaining M16 Hex Socket Head Bolts NOTE For ease in handling the Inlet Manifold insert two of the M16 hex socket head bolts to act as handles Then grasp the manifold from the sides and below these screws and pull from the pump NOTE Two screwdrivers on opposite sides may be needed to assist in separating the manifold from the crankcase Remove the Inlet Manifold Disassembly 1 Place the Inlet Manifold on the work surface with the crankcase side down NOTE The V Packing Spacers may stay in either Discharge or Inlet Manifold 2 Remove the V Packing Spacers by hand or by using two screw drivers on opposite sides of exposed grooves from either the V Packing Cylinders 6811 6821 or from the Discharge Manifold if they stayed in these ports during separation all models 3 Next with a reverse pliers remove the Male Adapter V Pac
8. PTFE thread tape or pipe thread sealant 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 Clogged Filters e Perform regular maintenance or use clean filters to monitor build up e Use adequate mesh size for liquid and pump specifications DIAGNOSIS AND MAINTENANCE One of the most important steps in a high pressure system is to establish a regular maintenance program This will vary slightly with each system and is determined by various elements such as the duty cycle the liquid being pumped the actual specifications vs rated specifications of the pump the ambient conditions the inlet conditions and the accessories in the system A careful review of the necessary inlet conditions and protection devices required before the system is installed will eliminate many potential problems CAT PUMPS are very easy pumps to service and require far less frequent service than most pumps Typically only common tools are required making in field service convenient however there are a few custom tools special to certain models that do simplify the process This service manual is designed to assist you with the disassembly an
9. Ring crevices and seal surfaces See Tech Bulletin 053 for model identification NOTE EPDM elastomers require silicone base lubricant 1 Invert the Inlet Manifold with the crankcase side up 2 Place the washer 6861 into the Inlet Manifold 3 Examine the Lo Pressure Seal for wear to the internal ridges or broken spring and replace as needed 4 Press the Lo Pressure Seal into Inlet Manifold seal chamber with the garter spring down 6861 5 Examine the Inlet Adapter for scale build up or wear and the outer O Rings for cuts or deterioration and replace as needed 6841 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 6 Press the Lo Pressure Seal into the Inlet Adapter with the garter spring up then press the Adapter into the Inlet Manifold with the garter spring down 6841 7 Invert Inlet Manifold with crankcase side down 6811 6821 6831 Discharge Valve Plugs 6811 6821 6831 Inlet and Discharge Valve Assemblies 6811 6821 6831 Inlet Manifold and V Packing Spacers 6811 6821 6841 Inlet Manifold Inlet Adapter and Lo Pressure Seals On the Model 6841 examine the V Packing Cylinder O Ring and replace if cut or worn Insert the V Packing Cylinder into the Inlet Manifold chamber with the O Ring facing down Examine the Female Adapter for wear
10. ad an M12x65 bolt into the top of the Retainer until it comes into contact with the back of the valve and separates the Valve Seat from the Retainer Each assembly consists of Retainer Spring Valve Seat O Rings and Back up Rings Reassembly mam 6841 6861 Inlet Valve Assemblies and V Packing Spacers 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 Examine the Spring Retainer for internal wear or breaks in the structure and replace as needed Examine the Spring for fatigue or breaks and replace as needed Examine the Valve for grooves pitting or general wear and replace as needed Examine Valve Seat for grooves pitting or general wear and replace as needed Examine the O Ring and Back up Ring on the Valve Seat for cuts or wear and replace as needed 6831 6861 Discharge Valve Assemblies 6841 6861 V Packing Cylinder Upper D M Chamber Inlet Valve Assembly Lower D M Chamber The new Valve Assembly will come preassembled in the kit NOTE If servicing from individual parts place the new Valve Seat with O Rings and Back up Rings on the work surface with the dish side up Next place the Valve onto the Seat with dish side down spring tab up Place the Spring onto the Valve Then snap the Spring Retainer onto the Seat Press the Valve Assembly into the valve chamber of the Di
11. allation of a C A T Captive Acceleration Tube is recommended in ap plications with stressful inlet conditions such as high temperatures booster pump feed long inlet lines or quick closing valves DISCHARGE CONDITIONS OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system Install a Pulsation Dampening device on the discharge head or in the discharge line as close to the head as possible Be certain the pulsation dampener Prrrrr o lator is properly precharged for the system pressure see individual Data Sheet A reliable Pressure Gauge should be installed near the discharge outlet of the high pressure manifold This is extremely important for adjusting pressure regulating devices and also for proper sizing of the nozzle or restricting orifice The pump is rated for a maximum pressure this is the pressure which would be read at the discharge manifold of the pump NOT AT THE GUN OR NOZZLE Use PTFE thread tape or pipe thread sealant sparingly to connect accessories or plumbing Exercise caution not to wrap tape beyond the last thread to avoid tape from becoming lodged in the pump or accessories This condition will cause a malfunction of the pump or system PRESSURE REGULATION All systems require both a primary pressure regulating device i e regulator unloader and a secondary pressure safety relief device i e pop off valve safety valve The primary pressure device m
12. and replace as needed Insert the Female Adapter into manifold chamber 6861 or the V Packing Cylinder 6841 with the flat side down Examine the V Packings for frayed edges or wear and replace as needed Insert the V Packings into the inlet manifold chamber 6861 or the V Packing Cylinder 6841 with the V groove down The V will mate with the V side of the Female Adapter Examine the Male Adapter for wear and replace as needed Insert the Male Adapter into the manifold chamber 6861 or the V Packing Cylinder 6841 with the V side down Next examine the Spacer with Coil Springs for wear or spring fatigue and replace as needed Insert Spacer with Coil Springs into seal chamber 6861 or the V Packing Cylinder 6841 with the springs facing in towards the Male Adapter SERVICING THE VALVES 6811 6821 6831 Disassembly 1 2 3 Both the Inlet and Discharge Valve Assemblies can be serviced without removing the Discharge Manifold Using a standard M8 allen wrench remove the six hex socket head bolts on each of the valve plugs Lift the Valve Plugs with O Ring and Back up Ring from the valve chambers Remove the Coil Spring and washer from the top of each Spring Retainer Generally the Valve Assembly will remain together With a standard pliers grasp the Retainer by the top tab and remove each of the Valve Assemblies NOTE If the Valve Assembly separates when re
13. d 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 Into the crankcase Knocking noise Inlet supply Bearing Pulley Oil leak Crankcase oil seals Crankshaft oil seals and 0 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 eInlet suction strainer filter clogged or improperly sized Abrasives in pumped liquid Leaky discharge hose Inadequate liquid supply Severe cavitation Worn seals Worn or dirty inlet discharge valves Faulty Pulsation Dampener Foreign material trapped in inlet discharge valves Worn V Packings 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 seal
14. der on Model 6821 o_o SERVICING THE INLET SPACER 6811 6821 and 6831 Disassembly 1 After the Inlet Manifold is remounted onto the crankcase remove the Inlet Spacer from the lower Inlet Manifold chambers Examine for scale buildup or wear and replace as needed 2 Examine the front and rear O Ring and Back up Ring for wear and replace as needed Reassembly NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces See Tech Bulletin 053 for model identification 1 Lubricate and install new Back up Ring first then the O Ring on both front and rear of Inlet Spacer 2 Press Inlet Spacer into Inlet Manifold SERVICING THE PLUNGERS ALL MODELS Disassembly 1 Remove the Seal Retainers from the Ceramic Plungers 2 Loosen the Plunger Retainer four to five turns and push the plunger to wards the crankcase until the Plunger Retainer pops out Reassembly 1 Carefully examine the Ceramic Plungers for scoring or cracks and re place if worn The surface of the ceramic plunger can be cleaned with a scotchbrite pad 2 Examine Plunger Retainer with stud O Ring Back up Ring and Gasket for wear or damage and replace as needed It is recommended the O Ring be replaced on schedule with the Lo Pressure Seal 3 Lubricate O Ring for ease of installation Install Gasket O Ring and then Back up Ring onto the plunger retainer 4 Apply Locktite 242 to the exposed threads and thread the Plunger R
15. dy 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 _ e mail catpumps t online de www catpumps de PN 30014 Rev G 8222 6841 6861 Discharge Block 6841 6861 SERVICING THE VALVES 6861 and 6841 REMOVING THE DISCHARGE BLOCK Discharge Valves Disassembly 1 2 To service the Discharge Valve Assembly it is necessary to remove the Discharge Valve Block Using an allen wrench remove the 8 Hex Socket Head Bolts from the top of the Discharge Valve Block and remove the Block from the Discharge Manifold NOTE The valve assemblies may stay with either the Valve Block or the Discharge Manifold If they stay in the Discharge Manifold remove the Coil Spring and Washer from the top of the Spring Retainer Then thread an M12x65 bolt into the top of the Spring Retainer and remove from the valve chamber If the Valve Assemblies remain in the Valve Block remove the ex posed O Ring and Back up Ring Then insert two screwdrivers on opposite sides into the Valve Seat groove and pry from the valve chamber Generally the Valve Assembly will remain together To separate thre
16. ed 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 T K versions are suitable for high temperatures and containment of harmful liquids Consult CAT PUMPS for optional flushing and cooling accessory LU Uo U ou 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 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 LI 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 pres
17. etainer onto Plunger Rod by hand Torque to specifications in chart Exercise caution not to over torque 5 Models 6841 6861 Slip Seal Retainer over Plunger with the wick end forward NOTE The 6811 6821 and 6831 have no wicks REPLACING THE INLET MANIFOLD ALL MODELS 1 Rotate crankshaft and line up the two outside plungers 2 Screw two M16x280 studs into top outer holes of crankcase to sup port the weight of the Inlet Manifold during reassembly 3 Carefully replace Inlet Manifold over Ceramic Plungers and press into crankcase Keep manifold aligned to avoid damage to the Plungers 4 Replace the M16 hex socket bolts and hand tighten Remove the M16 studs and replace with the standard hex socket screws Torque in sequence to specifications in torque chart REPLACING THE DISCHARGE MANIFOLD ALL MODELS 1 Lubricate the Ceramic Plungers and valve chamber walls 3 Reinstall the two guide pins into the Inlet Manifold 4 To support the weight of the Discharge Manifold during reassembly screw two M16x 280 studs into the top outer holes of the Inlet Manifold 5 Slide the Discharge Manifold over the studs and carefully push the manifold over the guide pins up flush with the Inlet Manifold Exercise caution not to pinch or cut the exposed O Rings 6 Replace the M16 hex socket bolts and the lower M12 bolts on the 6811 6821 and 6831 into the Discharge Manifold and hand tighten Remove the two M16 studs and replace the remaining tw
18. ging every other seal change Duty cycle temperature quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and service cycle Remember to service the regulator unloader at each seal servicing and check all system accessories and connections before resuming operation Refer to video for additional assistance TORQUE CHART Pumpltem Torque Item Torque Pump Model Thread Tool Size P N in lbs ft lbs Nm Plunger Retainer 6811 6821 6831 6841 6861 M21 Hex 220 18 1 25 M30 Hex 520 43 4 59 Inlet Manifold Screws M16 Discharge Manifold Screws UPPER 6811 6821 6831 6841 6861 M16 Discharge Manifold Screws LOWER 6811 6821 6831 M12 M14 Allen 33049 620 51 6 70 M14 Allen 83049 660 55 0 75 M10 Allen 83047 355 29 6 40 Valve Plug Screws 6811 6821 6831 M10 M8 Allen 33046 250 21 0 28 Valve Block Screws 6841 6861 M16 M14 Allen 83049 660 55 0 75 Crankcase Cover Bearing Cover Screws M10 M17 Hex 25083 220 18 1 25 Connecting Rod Screws M10x1 25 390 32 5 44 Bubble Oil Gauge M17 Hex 25083 M28 Oil Gauge Tool 44050 45 36 5 TECHNICAL BULLETIN REFERENCE CHART No Subject Models 002 Inlet Pressure VS Liquid Temperature All Models 003 Power Unit Drive Packages 3PFR 68PFR 10FR 60FR 024 Lubrication of Lo Pressure Seals All Models 036 Cylinder and Plunger Reference Chart All Models All Plunger Models All Plunger NAB S S Models All Unloaders Regu
19. igure 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 _ GPMxPSI 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 lbs 3 6 A Pump Pulley Outer Diameter x sew x PSI 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 Water hammering e Install C A T Tube liquid acceleration e Move pump closer to liquid supply deacceleration Rigid Inlet Plumbing e Use flexible wire reinforced hose to absorb pulsation and pressure spikes Excessive Elbows in eKeep 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 Air Leaks in Plumbing eCheck all connections e Use
20. in the three lower chambers of the Inlet Manifold and the Coil Spring and Washer will remain in the Discharge Manifold 6811 6821 6841 Inlet Manifold and V Packing Cylinder 6861 6861 Inlet Manifold V Packings Spacer with Coil Spring Male Adapter Female Adapter Reassembly NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces See Tech Bulletin 053 for model identification 1 The same procedure for serving the Discharge Valves should be followed for the Inlet Valve Assemblies NOTE If servicing only the valves remount the Discharge Manifold and Discharge Valve Block or proceed to SERVICING THE SEALS SERVICING THE SEALS 6861 and 6841 Disassembly 1 To service the seals it is necessary to remove both the Inlet and Discharge Manifold Follow above procedure for removing the Discharge Manifold 2 Both the standard and the K versions are serviced in the same manner Inspect flushing system while servicing seals Removing the Inlet Manifold 1 Remove the guide pins from the face of the Inlet Manifold 2 Next remove the two top outer M16 Hex Socket Head Bolts NOTE As an aid in removing the Inlet Manifold insert two M16 x 280 studs PN 88902 in place of the removed screws These will support the manifold during removal 3 Remove the remaining M16 Hex Socket Head Bolts NOTE For ease in handling the Inlet Manifold insert two of the M16 Hex Socket Head
21. kings and Female Adapter from the V Packing Cylinder 6811 6821 or from the manifold chamber 6831 4 Insert two screwdrivers on opposite sides into the outer groove on the V Packing Cylinder and pry from the manifold chamber 6811 6821 5 Place the Inlet Manifold on blocks with the crankcase side down 6 Using a socket to fit drive out the Inlet Adapter with Lo Pressure Seal 6811 6821 or Spacer and Lo Pressure Seal 6831 NOTE If socket is not available use a screwdriver and tap on alternate sides to work free 7 Separate the Washer from the Inlet Adapter 6811 6821 8 Place the Inlet Adapter on the V Packing Cylinder and with a screw driver tap out the Lo Pressure Seal 6811 6821 NOTE See Servicing Plungers and Servicing Crankcase before starting reassembly Reassembly For standard installation apply a small amount of oil to the out side edges of the LPS HPS VP MA FA for ease of installation and to avoid damage 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 Invert the Inlet Manifold with the crankcase side up 2 Examine the exterior O Rings on the Inlet Adapter and replace if cut or worn 6811 6821 3 Lubricate the inside of the Adapter Using a socket to fit press in the new pre greased Lo Pressure Seal with the garter spring fac ing up 6811 6
22. lators Piston and Plunger Pumps All Models except 2SF 4SF All Models 60FR 60PFR 68PFR 043 LPS and HPS Servicing 053 Liquid Gasket 064 By Pass Hose Sizing 074 Torque Chart 077 Oil Drain Kit 083 Winterizing a Pump 084 Eye Bolt Relocation 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 LJ Open inlet shut off valve and turn on water supply to avoid starving pump DO NOT RUN PUMP DRY _1 Temperatures above 130 F are permissible Add 1 2 PSI inlet pressure per each degree F over 130 F Elastomer or RPM changes may be required See Tech Bulletin 002 or call CAT PUMPS for recommendations Avoid closed loop systems especially with high temperature ultra high pressure or large volumes Conditions vary with regulating unloader valve Low vapor pressure liquids such as solvents require a booster pump and C A T to maintain adequate inlet supply Higher viscosity liquids require a positive head and a C A T to assure adequate inlet
23. moved retainer comes out alone lift the Spring and Valve from the chamber by hand Insert the head of an M8x 100 bolt into the valve chamber and under the the Valve Seat and lift out This procedure will avoid damaging the surface of the Valve Seats NOTE To separate the valve assembly insert a screwdriver into the side of the spring retainer behind the valve and apply pres sure to the back of the valve Reassembly NOTE For certain applications apply liquid gasket to the O Ring crevices and seal surfaces See Tech Bulletin 053 for model identification NOTE EPDM elastomers require silicone base lubricant Examine the Spring Retainer for internal wear or breaks in the structure and replace as needed Examine the Spring for fatigue or breaks and replace as needed Examine the surfaces of the Valves for pitting grooves or general wear and replace as needed Examine the surfaces of the Valve Seats for pitting grooves or general wear and replace as needed Examine the O Rings and Back up Rings on the Valve Seat and replace if cut or worn Lubricate for ease in installing into valve seat groove 6811 6821 6831 6841 Inlet Manifold and order of Packings 10 Next place the Valve Seat on the work surface with the dish side up Place the Valve onto the Valve Seat with dish side down spring tap up Locate the Valve Spring onto the Valve and place the Spring Retainer over the Spring onto the Valve Seat Snap the Valve Seat and S
24. n the V Packings and Lo Pressure Seals allowing the pumped liquid to cool the back side of the packings The K flushed inlet manifold models do not have the internal weep holes and do not connect to the inlet side They have special holes on the sides of the inlet manifold that can be fitted to an external flush ing system to provide this cooling and flushing The flushed inlet manifold models can also withstand high inlet pressures Consult CAT PUMPS 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 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 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 FAX 763 785 4329 e mail intlsales catpumps com L The Pumps with Nine Lives CAT PUMPS U K LTD 1 Fleet Business Park San
25. o M16 hex socket bolts 7 Torque in sequence to the specifications in the torque chart 8 For Models 6841 6861 replace the Discharge Valve Block Replace the M16 hex socket Head Bolts and torque in sequence TORQUE SEQUENCE DN Da 6 SERVICING THE CRANKCASE SECTION ALL MODELS 1 While manifold plungers and seal retainers are removed examine crankcase seals for wear Check oil level and check 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 CAT PUMPS or your local distributor if crankcase service is required Ol Coe See Section VI and VII of the Plunger Pump Service Video for additional information PREVENTATIVE SA canoe oneek Pally Weel Sars 500 hrs 1800 hrs 3000 hs Clean Figs ef KA E E E E E T EE ET Oilleaks x Jo Joo To S Water Leaks x Jo To o To T Belts Pulley J x Jo o To T Plumbing x J o S Initial Oil Change o S x OilChange J Jo So S xx S SealChange J 1 l x Valve Change o J T T x Accessories T J l x If other than CAT PUMPS special multi viscosity ISO68 oil is used change cycle should be every 300 hours Each system s maintenance cycle will be exclusive If system performance de creases check immediately If no wear at 1500 hours check again at 2000 hours and each 500 hours until wear is observed Valves typically require chan
26. pring Retainer securely together Press the Valve Assembly squarely into the valve chamber Place the Washer and then the Coil Spring on top of the Spring Retainer Examine the O Ring and Back up Ring on the Valve Plug and re place if cut or worn Carefully press valve plug into the valve chamber Exercise caution not to cut the O Ring or Back up Ring Replace the six hex socket bolts on each valve plug and hand tighten using the A 2 torque sequence shown Then torque to specifications in chart If servicing the seals proceed to SERVICING THE SEALS 1 3 TORQUE SEQUENCE SERVICING THE SEALS 6811 6821 6831 REMOVING THE DISCHARGE MANIFOLD 1 Remove the outer two M16 Hex Socket Head Bolts NOTE As an aid in removing the Discharge Manifold insert two M16 x 280 studs PN 88902 in place of the removed screws These will support the manifold during removal Remove the remaining upper M16 and lower M12 Hex Socket Head Bolts Tap the rear side of the Discharge Manifold with a soft mallet to begin separation of the discharge manifold from the inlet manifold NOTE If Manifold blocks do not separate inset two M8 x60 rods into the two M10 holes located at the front of the Discharge Manifold on the pump center line Screw in two M10 screws until the two blocks are separate Insert two screwdrivers on opposite sides of the Discharge Manifold to start the separation from the Inlet Manifold NOTE For ease in handling the
27. rs Install new seal kit Increase frequency of service eCheck liquid supply Increase line size pressurize or install C A T Replace bearing Check 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 eTighten 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 eInstall proper filtration at pump inlet and clean regularly Check 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 eReplace manifold Check liquid compatibility
28. s 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 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 Check with new gauge Replace worn or damaged gauge Clean adjust relief valve Replace worn seats valves and 0 rings Clean filter Use adequate size filter Check more frequently eInstall 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 Check precharge If low recharge or install a new dampener Clean inlet discharge valves or install new valve kit eInstall new seal kit Increase frequency of service eInstall new o rings Install oil cap protector Change oil every 3 months or 500 hou
29. scharge Manifold NOTE If servicing only the discharge valve assemblies place the Coil Spring then the Washer into the Valve Chamber Then press the Valve Assembly into the Valve Chamber until completely seated Then mount the Discharge Valve Block onto the Discharge Manifold If also servicing the inlet valve assemblies set the block aside and proceed to REMOVING THE DISCHARGE MANIFOLD REMOVING THE DISCHARGE MANIFOLD Inlet Valves Disassembly 1 2 Inlet Manifold and Lo Pressure Seals To service the Inlet Valves it is necessary to remove the Discharge Manifold Remove the two outer center M16 Hex Socket Head Bolts NOTE As an aid in supporting the manifold replace these two bolts with two M16 x 280 studs PN 88902 Then remove the remaining M16 Hex Socket Head Bolts Insert two screwdrivers on opposite sides of the Discharge Manifold to begin separation from the Inlet Manifold NOTE For ease in handling the Discharge Manifold thread in two M16 screws in the top outer holes NOTE If manifold blocks do not separate insert two M8 x 60 rods into the two M10 holes located on the front face of the Discharge Manifold Screw in two M10 screws until the two blocks separate Then grasp the Discharge Manifold from the sides and under these two screws and pull manifold over the support studs Place the Discharge Manifold on the work surface with the crankcase side up The Inlet Valve Assemblies will usually remain
30. supply 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 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 LU U U O 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 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
31. surizing 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 12 1 4 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 6 150 36 12 2 8 100 28 9 0 230 50 17 6 1 330 86 28 6 7 1 9 220 62 21 500 120 40 15 520 130 43 10 3 0 320 90 30 180 56 22 270 90 21 6 2 1 6 190 62 16 5 0 1 5 120 44 670 240 56 16 4 2 2 470 150 40 12 3 8 1 7 330 110 66 17 8 39 11 5 0 550 200 37 52 210 107 RESISTANCE OF VALVES AND FITTINGS Nominal Equivalent Length of Standard Pipe in Feet Pipe 180 Tee Tee Size i Gate Globe Angle 45 90
32. ust 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 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 If a large portion of the pumped liquid is by passed not used when the high pressure system is running this by pass liquid should be routed to an adequately sized baffled supply tank or to drain If routed to the pump inlet the by pass liquid can quickly develop excessive heat and result in damage to the pump A tem perature control device to shut the system down within the pump limits or multiple THERMO VALVES must be installed in the by pass line to protect the pump NOZZLES A worn nozzle will result in loss of pressure Do not adjust pressure regulating device to compensate Replace nozzle and 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 SPECIAL FLUSHED INLET MANIFOLD MODELS Standard pumps have internal weep holes betwee
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