CP PLUNGER PUMP SERVICE MANUAL

®

3CP MODELS: 3CP1120, 3CP1130, 3CP1140

5CP MODELS: 5CP2120W, 5CP2140WCS, 5CP2150W, 5CP3120, 5CP3120G1, 5CP3130G1,

5CP5120, 5CP5150G1, 5CP6120, 5CP6120G1, 5CP6140, 5CP6150

7CP MODELS: 7CP6170

INSTALLATION AND START-UP INFORMATION

Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only with the proper selection, installation of plumbing, and operation of the pump and accessories.

SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not implied that all maximums can be performed simultaneously. If more than one maximum is considered, check with your CAT PUMPS supplier to confirm the proper performance and pump selection. Refer to individual pump Data Sheet for complete specifications, parts list and exploded view.

LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications

(3CP-10 oz., 5CP-17 oz., 7CP-38 oz.). DO NOT RUN PUMP WITHOUT OIL IN

CRANKCASE. Change initial fill after 50 hours running period. Thereafter, change oil every 3 months or 500 hour intervals. Additional lubrication may be required with increased hours of operation and temperature.

PUMP ROTATION: Pump was designed for forward rotation to allow optimum lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil level is increased slightly above center dot to assure adequate lubrication.

PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow from Horsepower Requirement and Pulley Selection Chart (refer to Tech

Bulletin 003 or individual Data Sheet).

DRIVE SELECTION: The motor or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load. Select the electric motor from the Horsepower Requirement Chart according to required pump discharge flow, maximum pressure at the pump and drive losses of approximately

3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper engine size.

MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit drainage of crankcase oil. An uneven mounting surface will cause extensive damage to the pump base. To minimize piping stress, use appropriate flexible

hose to inlet and discharge ports. Use the correct belt; make sure pulleys are aligned. Excessive belt tension may be harmful to the bearings. Hand rotate pump before starting to be certain shaft and bearings are free moving.

LOCATION: If the pump is used in extremely dirty or humid conditions, it is recommended pump be enclosed. Do not store or operate in excessively high temperature areas or without proper ventilation.

INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual before starting system. DO NOT STARVE THE PUMP OR RUN DRY. 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.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in applications with stressful inlet conditions such as high temperatures, booster pump feed, long inlet lines or quick closing valves.

DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system.

Install a Pulsation Dampener 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 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 regulating device to compensate. Replace nozzle and reset regulating device to system pressure.

PUMPED LIQUIDS: Some liquids may require a flush between operations or before

storing. For pumping liquids other than water, contact your CAT PUMPS supplier.

STORING: For extended storing or between use in cold climates, drain all pumped liquids from pump and flush with antifreeze solution to prevent freezing and

damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech

Bulletin 083).

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: [email protected]

www.catpumps.com

International Inquiries

FAX (763) 785-4329 e-mail: [email protected]

®

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: [email protected]

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: [email protected] 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: [email protected] www.catpumps.de

PN 33009 Rev H 12432

All Models

Removal of Valve Plugs

3CP1120, 5CP2120W, 7CP6170

Valve Plug and O-Ring

5CP3120, 5CP5120, 5CP5150

Valve Plug, O-Ring and Back-up Ring

CAUTION: Before commencing with service, shut off drive (electric motor, gas or diesel engine) and turn off water supply to pump. Relieve all discharge line pressure by triggering gun or opening valve in discharge line.

After servicing is completed, turn on water supply to pump, start drive, reset pressure regulating device and secondary valve, read system pressure on the gauge at the pump head. Check for any leaks, vibration or pressure fluctuations and resume operation.

SERVICING THE VALVES

1.

Remove the hex Valve Plugs (top discharge, bottom inlet).

2.

Examine the O-Ring under the plug for cuts or distortion.

Replace if worn. Lubricate new O-Rings before installing.

NOTE: The 5CP3120, 5CP5120 and 5CP5150 have both an O-Ring and Back-up Ring on the Valve Plug.

3.

Grasp Spring Retainer by the tab at the top with a pliers and remove from each valve chamber. Usually the valve assembly will remain together while being removed. To separate the valve assembly, insert a screw-driver into the side of the Spring Retainer and press on the back side of the Valve to begin separation, then between the Spring Retainer and Seat to separate completely. If the valve assembly separates during removal, remove the Spring and Valve with a needle nose pliers. With a reverse pliers, remove the

Seat from each valve chamber. Then, with a small screwdriver, carefully remove the O-Ring at the bottom of the valve chamber.

NOTE: The 5CP2120W, 5CP6120 and 7CP6170 have an O-Ring and Back-up Ring on each Seat.

4. Examine all valve parts for pitting, gouges or wear and replace with preassembled Valve Assembly. Service kit contains Spring Retainers, Springs, Valves, Seats,

Back-up Rings and O-Rings.

NOTE: Inlet and discharge valve parts are interchangeable. Two Valve Kits are needed for complete valve change.

5.

Grasp new Valve Assembly by the tab at the top with a pliers, immerse in oil and push into each valve chamber. Be certain valve assembly is completely seated in valve chamber.

NOTE: For certain applications apply liquid gasket to the o-ring crevices and seal surfaces. See Tech

Bulletin 053 for model identification.

NOTE: EPDM elastomers require Silicone-base lubricant.

6.

Apply Loctite 242 to the threads of each Valve Plug, thread into valve port and torque per chart.

3CP1120, 5CP2120W, 7CP6170

Removal of Valve Assembly

5CP3120, 5CP5120, 5CP5150

Removal of Valve Assembly

All Models

Removal of Valve Seat O-Ring

3CP1120, 5CP3120, 5CP5120

Complete Valve Assembly

5CP2120W, 5CP6120, 7CP6170

Complete Valve Assembly

All Models

Removal of Socket Head Screws

SERVICING THE PUMPING SECTION

Disassembly

1.

Using an allen wrench, remove the Socket Head

Screws from the Manifold Head.

2.

Rotate Crankshaft by hand to start separation of

Manifold Head from Crankcase.

3.

Insert two flat head screwdrivers on opposite sides to further separate Manifold Head from Crankcase.

Support the underside of the Manifold Head and tap lightly with a mallet on the backside of the Manifold

Head.

CAUTION: KEEP MANIFOLD PROPERLY ALIGNED

WITH CERAMIC PLUNGERS WHEN REMOVING TO

AVOID DAMAGE TO THE PLUNGERS.

4.

Remove the Seal Retainer from each plunger rod and examine for wear.

5.

Examine Ceramic Plunger for cracks or scoring. Refer to SERVICING THE PLUNGERS if replacement is needed.

Reassembly

1.

Generally Plungers do not need to be replaced. Clean plungers and remove any foreign material with a nonabrasive cleaner.

2.

Install Seal Retainer over Plungers with small tab facing down and holes facing forward towards manifold head.

3.

Rotate the crankshaft so the two outside plungers are extended the same distance.

4.

Lightly lubricate the Plungers and carefully slide the

Manifold Head onto the Plungers supporting from the underside. On the high pressure V-Packing models or larger manifolds, it may be necessary to gently tap with a soft mallet until the Manifold Head is flush with the Crankcase.

5.

Replace Socket Head Screws and torque per chart.

3CP1120, 5CP2120W, 5CP6120

Seal Arrangement

5CP3120, 5CP5120, 5CP5150, 7CP6170

Seal Arrangement

All Models except 7CP6170

Plunger Arrangement

SERVICING THE PLUNGERS

Disassembly

1.

To service the plungers, it is necessary to remove the

2.

manifold head. Follow disassembly procedure for

SERVICING THE PUMPING SECTION.

Remove the Seal Retainer from each plunger rod.

3.

Using a wrench, loosen the Plunger Retainer about three to four turns.

4.

Push the Ceramic Plunger back towards the crankcase to separate from the Plunger Retainer and proceed with unthreading the Plunger Retainer by hand.

5.

Remove the Plunger Retainer, Seal Washer, Ceramic

Plunger, Keyhole Washer and Barrier Slinger from each Plunger Rod.

6.

On the model 7CP6170 remove the Plunger Retainer,

Stud, Gasket, O-Ring, Back-up Ring, Ceramic Plunger and Barrier Slinger from each Plunger Rod.

Reassembly

1.

Visually inspect Crankcase Oil Seals for deterioration or leaks and contact factory for assistance with replacement.

2.

Replace Barrier Slinger if damaged and slide onto

Plunger Rod with concave side away from

Crankcase.

3.

Examine Sealing Washer for cuts or wear and replace as needed.

4.

On the model 7CP6170 examine Gaskets, O-Rings and Back-up Rings for cuts or wear and replace as needed.

5.

Examine Plunger Retainers and Studs for wear or damaged threads and replace as needed.

6.

On the model 7CP6170 install Gaskets first, then

O-Rings and Back-up Rings onto the Plunger

Retainer.

NOTE: Lubricate O-Rings and Back-up Rings for ease in installation and to reduce possible damage.

7.

All other models, lubricate and install Sealing Washer onto Plunger Retainer.

8.

On the model 7CP6170 apply Loctite 242 to one end of threaded Plunger Retainer Stud and secure to

Plunger Retainer.

9.

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.

10. Slide Plunger Retainer Assembly into flat end of

Ceramic Plunger.

11. Apply Loctite 242 to exposed threaded end of Plunger

Retainer.

12. Install Ceramic Plunger with Plunger Retainer onto each Plunger Rod shoulder and thread Plunger Rod.

Torque to specifications per chart.

NOTE: Ceramic Plungers can only be installed in one direction. Counterbore end of Ceramic

Plunger to fit over Plunger Rod shoulder.

13. Install Seal Retainers with small tabs facing down and holes facing forward towards manifold head.

14. Proceed with servicing the seals or remounting of

Manifold Head as described.

SERVICING THE SEALS AND V-PACKINGS

Disassembly

1.

Remove the Manifold Head as described in SERVICING

THE PUMPING SECTION.

2.

Place the Crankcase side of manifold facing up and with a reverse pliers, remove the Lo-Pressure Seal from the Seal Case.

3.

Using a reverse pliers, remove the press-in style Seal

Case from the Manifold Head.

4.

Remove the O-Ring from O.D. of Seal Case.

5.

Hi-Pressure Seal Models: The Hi-Pressure Seal is generally easily removed from the manifold without any tools. If extremely worn, a reverse pliers may be used.

6.

V-Packing Models: The V-Packings and Male

Adapter are easily removed from the manifold without any tools.If extremely worn, a reverse pliers may be used.

Hi-Pressure Seal Models:

1.

Lubricate each seal chamber in manifold head.

NOTE: For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces. See Tech

Bulletin 053 for model identification.

NOTE: EPDM elastomers require silicone-base lubricant.

2.

Carefully square Hi-Pressure Seal into position by hand with the grooved side down (metal back facing out) and press into each seal chamber until completely seated.

3.

Examine Seal Case O-Rings and replace if worn.

Lubricate new O-Ring before installing.

4.

Press the Seal Case into each seal chamber until completely seated.

Reassembly

NOTE: If your pump has been built with special seals and O-Rings, service with same type. Refer to pump Data Sheet for correct parts or kits.

V-Packing Models:

1.

Lubricate each seal chamber in manifold head.

NOTE: For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces. See Tech

Bulletin 053 for model identification.

NOTE: EPDM elastomers require silicone-base lubricant.

2.

Insert Male Adapter with notches down and “v” side

up and press completely into each seal chamber by hand.

3.

Lubricate V-Packings and install one at a time with

grooved side down into each seal chamber.

4.

Examine Seal Case O-Ring and replace if worn.

Lubricate new O-Rings before installing.

5.

Press Seal Case into each seal chamber until completely seated.

Lo-Pressure Seal-All Models:

1.

Examine Lo-Pressure Seals for wear to the internal ridges, outer surfaces or for broken springs and replace as needed.

2.

Install Lo-Pressure Seal into Seal Case with garter

spring down.

3.

All Models: Install Seal Retainer over Plungers with small tabs facing down and holes facing forward towards manifold head.

4.

Replace Manifold Head onto pump as described under

SERVICING THE PUMPING SECTION and torque per chart.

SERVICING THE CRANKCASE SECTION

1.

While Manifold Head, Plungers and Seal Retainers are removed, examine Crankcase Oil Seals for leaking and wear.

2.

Check for any signs of leaking at Rear Cover, Drain

Plug, Bubble Gauge and Dipstick (7CP6170).

3.

Check oil level and for evidence of water in oil.

Change crankcase oil on a regular schedule. See

Preventative Maintenance Check-List.

4.

Rotate Crankshaft by hand to feel for smooth bearing movement.

5.

Examine Crankshaft Oil Seal externally for drying, cracking or leaking.

6.

Contact CAT PUMPS or your local distributor if crankcase service is evidenced.

PREVENTATIVE MAINTENANCE CHECK-LIST

Check

Clean Filters

Oil Level/Quality

Oil Leaks

Water Leaks

Belts, Pulley

Plumbing

Initial Oil Change

Oil Change

Seal Change

Valve Change

Accessories

Daily Weekly 50 hrs. 500 hrs.* 1500 hrs.** 3000 hrs.** x x x x x x x x x x 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 decreases, check immediately. If no wear at 1500 hours, check again at 2000 hours and each 500 hours until wear is observed. Valves typically require changing every other seal change.

Duty cycle, temperature, quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and service cycle.

** 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

Pump Item

Pump Model

Plunger Retainer

Manifold Screw

Thread

M6

M8

Tool Size [P/N]

M10 Hex [25082]

M6 Allen [30941]

Torque in. lbs. ft. lbs. Nm

55 4.4 6.2

115 9.58 13

Valve Plugs

3CP, 5CP

7CP

Bearing Cover Screws

3CP

5CP, 7CP

M22

M26

M24 Hex [44046]

M27 Hex [44045]

870

870

72.5 98

72.5 98

M6 M10 Hex./Phil. [25082] 50 4.0 5.4

M8 M13 Hex [25324] 115 9.58 13

Rear Cover Screws M6 M10 Hex./Phil. [25082] 50 4.0 5.4

Connecting Rod Screws M7 M10 Hex [25082} 95 8.0

11

Bubble Oil Gauge

Direct Mount Bolts

M28 Oil Gauge Tool [44050] 45 3.8

5

M8 M13 Hex [25324] 115 9.58 13

TECHNICAL BULLETIN REFERENCE CHART

No.

Subject

002 Inlet Pressure VS Liquid Temperature

003 Power Unit Drive Packages

024 Lubrication of Lo-Pressure Seals

036 Cylinder and Plunger Reference Chart

043 LPS and HPS Servicing

060 Baffle Assembly

064 By-Pass Hose Sizing

074 Torque Chart

077 Oil Drain Kit

078 Field Retrofit Mounting

083 Winterizing a Pump

Models

All Models

3PFR - 68PFR, 10FR - 60FR

All Models

All Models

All Plunger Models

34170

All Unloaders/Regulators

Piston and Plunger Pumps

All Models (except 2SF/4SF)

5CP

All Models

INLET CONDITION CHECK-LIST

Review Before Start-Up

Inadequate inlet conditions can cause serious malfunctions in the best designed pump. Surprisingly, the simplest of things can cause 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.

❏ 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.

❏ 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 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.

INLET LINE SIZE should be adequate to avoid starving the pump.

❏ 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.

❏ 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.

❏ 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.

❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure and a C. A.T. for certain applications. With adequate inlet plumbing, most pumps will perform with flooded suction. Maximum inlet pressure is 60 PSI (4 BAR).

❏ After prolonged storage, pump should be rotated by hand and purged of air to facilitate priming. Disconnect the discharge port and allow liquid to pass through pump and measure flow.

INLET ACCESSORIES are offered to protect against over pressurization, contamination or temperature and control flow.

❏ A shut-off valve is recommended to facilitate maintenance.

❏ 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 achieved by installing a pressure cut off switch between the inlet filter and the pump to shut off pump when there is no positive inlet pressure.

BY-PASS TO INLET Care should be exercised when deciding the method of by-pass from control valves.

❏ It is recommended the by-pass be directed to a baffled reservoir tank, with at least one baffle between the by-pass line and the inlet line to the pump.

❏ Although not recommended, by-pass liquid may be returned to the inlet line of the pump if the system is properly designed to protect your pump. When a pulsation dampener is used, a PRESSURE REDUCING VALVE must be installed on the inlet line (BETWEEN THE BY-PASS CONNECTION AND THE

INLET TO THE PUMP) to avoid excessive pressure to the inlet of the pump. It is also recommended that a THERMO VALVE be used in the by-pass line to monitor the temperature build-up in the by-pass loop to avoid premature seal failure.

❏ A reinforced, flexible, low pressure hose rated up to 300 PSI should be used for routing by-pass back to the pump inlet.

❏ 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.

❏ Check the pressure in the by-pass line to avoid over pressurizing the inlet.

❏ 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.

Water*

Flow

Gal/Min

HOSE FRICTION LOSS

PRESSURE DROP IN PSI PER 100 FT OF HOSE

WITH TYPICAL WATER FLOW RATES

Hose Inside Diameters, Inches

1/4 5/16 3/8 1/2 5/8 3/4 1"

20

25

30

40

6

8

10

15

50

60

4

5

2

3

0.5

1

16

54

180

380

5

20

60

120

220

320

25

50

90

130

2

7

220

300

450

900

1600

2

6

13

24

34

52

80

120

250

400

650

7

10

16

25

38

80

2

4

121

200

250

410

600

2

3

4

7

10

14

30

50

76

96

162

235

370

12

19

24

42

62

93

3

7

1

2

*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

GPM

15

25

40

60

80

100

5

8

10

1

2

3

Steel Pipe—Nominal Dia.

1/4 3/8 1/2 3/4 1 1 1 /

4

1 1 /

2

8.5 1.9

30 7.0 2.1

60 14 4.5 1.1

150 36 12 2.8

330 86 28 6.7 1.9

520 130 43 10 3.0

270 90 21 6.2 1.6

670 240 56 16 4.2 2.0

66 17 8.0

37 17

52 29

210 107 48

Brass Pipe—Nominal Dia.

1/4 3/8 1/2 3/4 1 1 1 /

4

1 1 /

2

6.0 1.6

20 5.6 1.8

40 11 3.6

100 28 9.0 2.2

220 62 21 5.2 1.6

320 90 30 7.8 2.4

190 62 16 5.0 1.5

470 150 40 12 3.8 1.7

39 11 5.0

23 11

40 19

61 28

Copper Tubing O.D. Type L

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

230 50 17 6.1 3.0

500 120 40 15 6.5

180 56 22 10

120 44 20

330 110 50

550 200 88

RESISTANCE OF VALVES AND FITTINGS

Nominal

Pipe

Size

Inches

Inside

Diameter

Inches

1/2

3/4

1

1 1 /

4

1 1 /

2

2

2 1 /

2

3

4

0.622

0.824

1.049

1.380

1.610

2.067

2.469

3.068

4.026

Gate

Valve

Equivalent Length of Standard Pipe in Feet

Globe

Valve

Angle

Valve

45˚

Elbow

90˚

Elbow

180˚

Close

Ret

Tee

Thru

Run

Tee

Thru

Branch

0.41

0.54

0.69

0.90

1.05

18.5

24.5

31.2

41.0

48.0

1.35

1.62

2.01

61.5

73.5

91.5

30.8

36.8

45.8

2.64

120.0

60.0

9.3

12.3

15.6

20.5

24.0

0.78

1.03

1.31

1.73

2.15

1.67

2.21

2.81

3.70

4.31

3.71

4.90

6.25

8.22

9.59

0.93

1.23

1.56

2.06

2.40

3.33

4.41

5.62

7.40

8.63

2.59

3.09

3.84

5.55

6.61

8.23

12.30

14.70

18.20

3.08

3.68

4.57

11.60

13.20

16.40

5.03

10.80

23.90

6.00

21.60

Arriving at a total line pressure loss, consideration should then be given to pressure loss created by valves, fittings and elevation of lines.

If a sufficient number of valves and fittings are incorporated in the system to materially affect the total line loss, add to the total line length, the equivalent length of line of each valve or fitting.

TYPICAL RESERVOIR TANK

RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY

Supply Line

Level Sensing

Device

Bypass Line

(from regulator or unloader)

MIN. 4"

T

X D

(Dia of pipe)

1.5 x D (Min.)

Flexible Hose to Pump

FILTER

MIN. 4"

Minimum

Liquid

Level

Bypass Line

(from regulator or unloader)

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) I want?

Rated RPM

A. Desired RPM = Desired GPM x

Rated GPM

Q. I have to run my pump at a certain RPM. How do I figure the GPM I’ll get?

Rated GPM

A. Desired GPM = Desired RPM x

Rated RPM

Q. Is there a simple way to find the approximate horsepower

I’ll need to run the pump?

A. Electric Brake

Horsepower Required

=

GPM x PSI

1460

(Standard 85%

Mech. Efficiency)

Q. What size motor pulley should I use?

Pump RPM

A. Pump Pulley (Outer Diameter) x

Motor/Engine RPM

Q. How do I calculate the torque for my hydraulic drive system?

(Consult

Engine Mfr.)

A. Torque (ft. lbs.) = 3.6

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

Inadequate inlet line size

SOLUTION

●

Increase line size to the inlet port or one size larger

Water hammering liquid acceleration/ deacceleration

●

●

Install C.A.T. Tube

Move pump closer to liquid supply

Rigid Inlet Plumbing

●

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

Temperature

●

Use Thermo Valve in bypass line

●

Do not exceed pump temperature specifications

●

Substitute closed loop with baffled holding tank

●

Adequately size tank for frequent or high volume bypass

●

Pressure feed high temperature liquids

●

Properly ventilate cabinets and rooms

Air Leaks in Plumbing

●

Check all connections

●

Use PTFE thread tape or pipe thread sealant

Agitation in Supply

Tank

●

Size tank according to pump output —

Minimum 6-10 times system GPM

●

Baffle tank to purge air from liquid and separate inlet from discharge

High Viscosity Liquids

●

Verify viscosity against pump specifications

● before operation

Elevate liquid temperature enough to reduce

● viscosity

Lower RPM of pump

●

Pressure feed pump

●

Increase inlet line size

Clogged Filters

●

Perform regular maintenance or use clean filters to monitor build up

●

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 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

PROBABLE CAUSE

•Worn nozzle.

•Belt slippage.

•Air leak in inlet plumbing.

•Pressure gauge inoperative or not registering accurately.

•Relief valve stuck, partially plugged or improperly adjusted.

•Inlet suction strainer (filter) clogged or improperly sized.

•Abrasives in pumped liquid.

•Leaky discharge hose.

•Inadequate liquid supply.

•Severe cavitation.

•Worn seals.

•Worn or dirty inlet/discharge valves.

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 o-rings.

•Clean filter. Use adequate size filter. Check more frequently.

•Install proper filter.

•Replace discharge hose with proper rating for system.

•Pressurize inlet and install C.A.T.

•Check inlet conditions.

•Install new seal kit. Increase frequency of service.

•Clean inlet/discharge valves or install new valve kit.

Pulsation •Faulty Pulsation Dampener.

•Foreign material trapped in inlet/discharge valves.

•Check precharge. If low, recharge, or install a new dampener.

•Clean inlet/discharge valves or install new valve kit.

Water leak

•Under the manifold

•Into the crankcase

•Worn V-Packings, Hi-Pressure or Lo-Pressure Seals.

•Worn adapter o-rings.

•Humid air condensing into water inside the crankcase.

•Excessive wear to seals and V-Packings.

•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.

Knocking noise

•Inlet supply

•Bearing

•Pulley

•Inadequate inlet liquid supply.

•Broken or worn bearing.

•Loose pulley on crankshaft

Oil leak

•Crankcase oil seals.

•Worn crankcase oil seals.

•Crankshaft oil seals and o-rings.

•Worn crankshaft oil seals or o-rings on bearing cover.

•Drain plug •Loose drain plug or worn drain plug o-ring.

•Bubble gauge

•Rear cover

•Filler cap

•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.

Pump runs extremely rough

•Inlet conditions

•Pump valves

•Pump seals

Premature seal failure

•Restricted inlet or air entering the inlet plumbing

•Stuck inlet/discharge valves.

•Leaking V-Packings, Hi-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.

•Check 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.

•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.

•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.

•Replace manifold. Check liquid compatibility.