CAT PUMPS 8 and 28PFR Plunger Pump Owner’s Manual

CAT PUMPS 8 and 28PFR Plunger Pump

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 [8PFR 25 0z., 28PFR 84 oz.]. DO NOT RUN PUMP WITHOUT OIL IN

• CRANKCASE. Change initial fill after 50 hours running period. Thereafter, change oil every 3 months or 500 hour intervals.

• PUMP ROTATION : Pump was designed for forward rotation to allow optimum lubri- cation 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 adequatehorsepower 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 enclosed 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 ap plications with stressful inlet conditions such as high temperatures, b0oster 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 on the discharge head or in the discharge line as close to the head as possible. Be certain the pulsation dampener (Prrr-o-lator) is properly precharged for the system pressure (refer to individual Data Sheet).

• 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 enclosed 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 ap plications with stressful inlet conditions such as high temperatures, b0oster 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 on the discharge head or in the discharge line as close to the head as possible. Be certain the pulsation dampener (Prrr-o-lator) is properly precharged for the system pressure (refer to individual Data Sheet).

• PUMPED LIQUIDS : Some liquids may require a flush between operations opr before storing. For pumping liquids other than water, contact your CAT PUMPS Supplier.

• SPECIAL “K” MODELS: Standard pumps have internal weep holes between the V-Packings and Lo-Pressure Seals allowing the pumped liquid to cool the back side of the packings. The “K° models do not have internal weep holes and do not Connect to the inlet Side. Ihey have speCial ports on both sides of the inlet manifold that can be fitted to an external flushing system to provide cooling and flushing.

• STORING: For extended storing or between use in cold climates, drain all pumped liquids from the pump and flush with an 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.

CAUTION : Before commencing with service, shut off drive (electric motor, gas or diesel engine) and turn off the water supply to the pump. Relieve all dis-charge line pressure by triggering gun or opening valve in the discharge line.
After servicing is completed, turn on the water supply to the pump, start the drive, reset the pressure regulating device and secondary valve, and read system pressure on the gauge at the pump head. Check for any leaks, vibration or pressure fluctuations and resume operation. Inspect and service all system accessories on the same schedule as your pump.

SERVICING THE VALVES

(Discharge and Inlet Valves)

Disassembly

NOTE : Both the standard and the “K” versions are serviced in the same manner.

1. To service the Discharge or Inlet Valve Assemblies, it is nec essary to remove the Valve Block Manifold (VBM).

2. Using an allen wrench, remove the Hex Socket Head screws (HSH) from the VBM.

3. On the model 781, insert two M8 x 114 metric threaded bolts into the upper left and lower right intermediate holes on the VBM face. Thread in bolts until they make contact with InletManifold/Discharge Manifold (IMDM) drilled holes. Continue threading until manifolds begin to separate. Support under- side of VBM to avoid possible damage to ceramic plungers or plunger rods
   NOTE : The Valve Assemblies may stay with either the VBM or the IMDM.

4. If the Inlet Valve Assemblies (lower chamber) stay in the IMDM or the Discharge Valve Assemblies (upper chamber) stay in the VBM, then grasp Spring Retainer tabs and pull assemblies from valve chambers.
   NOTE : The model 2831 has Valve Adapters with O-Rings and Back-up-Rings that may remain with inlet or Discharge Valve Assemblies when removed.

5. If the Inlet Valve Assemblies (lower chamber) stay in the VBM or the Discharge Valve Assemblies (upper chamber) stay in the IMDM, then remove exposed O-Rings (781).
   Insert two screwdrivers into the groove on opposite sides of the Seat (781) or secondary groove on the Valve Adapter (2831) and pry from valve chamber
   CAUTION: Exercise caution as the screwdrivers may score o-ring sealing area.

6. To separate Valve Assemblies, insert screwdriver into Spring Retainer and press the backside of Valve until Seat separates from the Spring Retainer. Each assembly consists of a Retainer Washer, Spring Retainer, Spring, Valve, Seat, O-Ring and Back-up-Ring.
   On the model 2831, remove Seat from the Valve Adapter by inserting reverse pliers through Seat opening and gently pull Out.
   CAUTION : Exercise caution as the reverse pliers may score sealing areas.

Reassembly

NOTE : For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces. Refer to Tech Bulletin 053 for model identification.

1. Examine Retainer Washers for fatigue or wear and replace as needed.

2. Examine Spring Retainers for internal wear or breaks in the structure and replace as needed.

3. Examine Springs for fatigue or breaks and replace as needed. Examine Valves and Seats for grooves, piting or wear and replace as needed.

4. Examine Seat 0-Rings and Back-up-Rings for cuts or wear and replace as needed.

5. On the model 2831, examine Valve Adapter for external sur- face scoring or wear and replace as needed. Examine Valve Adapter O-Rings for cuts or wear and replace as needed.
   Install Back-up-Ring, then O-Ring into large groove.
   NOTE: A new Valve Assembly will come pre-assembled in the Valve kit. Continue with steps 11 through 13. If servicing from individual parts, follow steps 7 through 13.

6. Place VBM on work surface with IMDM side up.

7. On the model 781, install Back-up-Rings and O-Rings onto both the front and rear of the seat with the O-Rings to the outside. On the model 2831, install Back-up-Ring and O-Ring on the Seat with the O-Rings facing to the inside.

8. On model 781, place the Seat with O-Rings and Back-up- Rings on the work surface with dish side up. Then place the Valve onto the Seat with dish side down/Spring tab up. On model 2831, place Valve Adapter on the work surface with Back-up-Ring and 0 ring facing up. Press the O-Ring side of the Seat into the Valve Adapter. Then place the valve onto the seat with the dish side down.

9. Place Spring on Valve and snap Spring Retainer onto Seat.

10. On model 781, insert the Retainer Washer into the valve chamber with a curved side down. On model 2831, place flat Retainer Washer into valve chamber. Press Valve Assembly into the valve chamber until completely seated.

11. On model 2831, insert O-Rings into the groove at bottom of the Valve Adapters.

12. Support the VBM from the underside and align the manifold with IMDM. Apply anti-seize to HSH screw threads and thread in hand tight. Torque in sequence to specifications in torque chart.

Disassembly

NOTE : Both the standard and the “K” versions are serviced in the same manner. All parts necessary for servicing are included in the Seat Kit.
CAUTION : Exercise caution as the reverse pliers may score sealing areas.

1. To service the seals, it is necessary to remove both the VBM and IMDM. Follow the disassembly procedure found under SERVICING THE VALVES.
   NOTE : The V-Packing Cylinder (781) or Hi-Pressure Seal Spacers (HPS) (2831) may stay in the VBM or IMDM.

2. Remove the exposed O-Rings and insert two screwdrivers into the grooves on opposite sides of the V-Packing Cylinder (781) or into the secondary groove on the HPS Spacer (2831) and pry from the chamber.
   CAUTION : Exercise caution as the screwdriver may score o-ring sealing area.

3. On the model 781, remove Female Adapters from each chamber.

4. On the model 781, use reverse pliers to remove three V-Packings and one Male Adapter from each V-Packing Cylinder.

5. On the model 2831, use reverse pliers to remove one Hi-Pressure Seal from each IMDM chamber.

6. Invert IMDM and place on flat work surface with crankcase side up.

7. On the model 781, use reverse pliers to remove three lnlet Adapter ASsemblies by grasping the Inlet Adapter.

8. Use reverse pliers to remove Lo-Pressure Seals from back- side of Inlet Adapter (781) or the IMDM chamber (2831).

Reassembly

NOTE : For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces. Refer to Tech Bulletin 053 for model identification.
NOTE : For standard installation, apply a small amount of oil to the outside edge of the LPS, HPS, VP, MA, FA for ease of installation and to avoid damage. Models 781 and 781K

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

2. Examine Inlet Adapters for scale build up or wear, and the Inlet Adapter O-Rings for cuts or deterioration and replace as needed.
   NOTE: When using alternate materials, the fit of the spe cial materials may be snug and require gently driving the LPS into position with a cylinder of the same diameter to assure a square seating and no damage to the LPS.

3. Press new Lo-Pressure Seals into the Inlet Adapters with the garter spring up.
   Press Inlet Adapter Assembly into each chamber of the IMDM with the garter spring down.

4. Invert IMDM and place on flat work surface with crankcase side down.

5. Examine the V-Packing Cylinder for scale build-up, wear and replace as needed. Examine V-Packing Cylinder O-Rings and Back-up-Rings for cuts or deterioration and replace as needed.

6. Examine Male and Female Adapters for wear and replace as needed.

7. Examine V-Packings for frayed edges or wear and replace as needed.

8. Place the Male Adapters into the V-Packing Cylinder with flat side down.

9. Insert three new V-Packings into each V-Packing Cylinder with “V” groove down. The “V will mate with “V side” of the Male Adapter.

10. Position Female Adapter into the IMDM with “V” groove up.

11. Press V-Packing Cylinder Assembly into IMDM center chambers with V-Packings facing into the manifold chamber.

12. Support the IMDM from the under side and align the manifold bolt holes with crankcase holes. Apply Loctite 242 to HSH screw threads and thread in hand tight. Torque in sequence to specifications in torque chat.

13. Support the VBM from the under side and align manifold with IMDM. Apply anti-seize to HSH screw threads and thread in hand tight. Torque in sequence to specifications in torque chart.

TORQUE SEQUENCE

Models 2831 and 2831K

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

2. Press new Lo-Pressure Seals into IMDM with the garter spring down.
   NOTE: When using alternate materials, the fit of the spe cial materials may be snug and require gently driving the LPS into position with a cylinder of the same diameter to are seating and no damage to the LPS. assure

3. Invert IMDM and place on flat work surface with crankcase side down.

4. Examine HPS Spacer for scale build-up, wear and replace as needed. Examine HPS Spacer O-Rings for cuts or deteriora- tion and replace as needed.

5. Examine Hi-Pressure Seals for frayed edges or wear and replace as needed.

6. Press Hi-Pressure Seal into each IMDM center chamber with metal backing facing down into the manifold chamber.

7. Press HPS Spacer into each center manifold chamber with secondary groove facing out.
   Support the IMDM from the under side and align the manifold bolt holes with crankcase holes. Apply Loctite” 242 to HSH Screw threads and thread in hand tight. Torque in sequence to specifications in torque chart.

8. Support the VBM from the under side and align manifold with IMDM. Apply anti-seize to HSH screw threads and thread in hand tight. Torque in sequence to specifications in torque chart.

Disassembly

NOTE : Both the standard and the “K” versions are serviced in the same manner.

1. To service the plungers, it is necessary to remove both the VBM and IMDM. Follow the disassembly procedure found under SERVICING THE VALVES.

2. Remove the one piece Seal Retainer from each Plunger Rod.

3. Using a Hex tool, loosen the Plunger Retainers about three to four turns.

4. Push the Ceramic Plungers back towards the crankcase to separate from the Plunger Retainers and proceed with un- threading the Plunger Retainers by hand.

5. Remove Plunger Retainers, O-Rings, Back-up-Rings and Gaskets.
   NOTE: Plunger Retainer Studs may stay on Plunger Rods or come off with Plunger Retainers.

6. Remove Ceramic Plungers, Keyhole Washers and Barier Slingers.

Reassembly

1. Visually inspect Crankcase Oil Seals for deterioration or leaks and contact CAT PUMPS for assistance with replacement.

2. See SERVICING THE CRANKCASE section.

3. Examine Plunger Retainers, Studs, Barrier Slingers and Keyhole Washers for wear and replace as needed.
   Slide Barrier Slingers over Plunger Retainer Studs with con- cave side away from the crankcase. Slide Keyhole Washers over Plunger Retainer Studs with split ends facing downward.

4. Examine Ceramic Plungers for scoring. scale build-up, chips or cracks and replace as needed.

5. Slide Ceramic Plungers over Plunger Retainer Studs.
   NOTE : Plunger can only be installed in one direction. Do not force onto Plunger Rod.

6. Examine Gaskets, O-Rings and Back-up-Rings for cuts or wear and replace as needed.

7. Instal Gaskets first, then O-Rings and Back-up-Rings onto Plunger Retainers.
   NOTE : Lubricate O-Rings and Back-up-Rings for ease in installation and to reduce possible damage.

8. Apply Loctite 242 to exposed threaded end of Plunger Retainer Studs. Thread on Plunger Retainer and torque per chart.

9. On the model 781, install Seal Retainers with drain slots facing the crankcase with openings to the top and bottom. On the model 2831 the drain openings must face the manifold.

10. Support the IMDM from the under side and align manifold bolt holes with crankcase holes. Apply Loctite 242° to HSH screws threads and thread in hand tight. Torque in sequence to specifications in torque chart

11. Support the VBM from the under side and align manifold with IMDM. Apply anti-seize to HSH screw threads and thread in hand tight. Torque in sequence to specifications in torque chart.

NOTE : Both the standard and the “K” versions are serviced in the same manner.

1. While manifolds, plungers and seal retainers are removed ex- amine crankcase oil seals for leaking and wear.
2. Check for any signs of leaking at Rear Cover, Drain Plug. and Bubble Oil Gauge (781) or Rear Cover, Drain Plug, and Dipstick (2831).
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. Examine crankshaft oil seals externally for drying, cracking or leaking.
5. Contact CAT PUMPS or your local distributor if crankcase service is required. Refer to Tech Bulletin 035.

Loctite and 242 are registered trademarks of the Henkel Corporation.

INLET CONDITION CHECKLIST

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 CHECKLIST BEFORE THE 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 accom- modate 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 pumpP.

• 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 pressurizedinlet and C.A.T. to maintain adequate inlet supply.
• 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 pertorm with tlooded suction. Maximum inlet pressure Is 0 PSI(4.9 BAR).
• After prolonged storage, pump should be rotated by hand and purged of air to Tacilitate priming. Disconnect the discharge port and allow liquid to pass through pump and measure flow
• “K” versions are suitable for high inlet pressures. Consult CAT PUMPS.

INLET ACCESSORIES

• Are designed to protect against over-pressurization, control inlet flow, contamination or temperature and provide ease Or servicing.
• A shut-oft valve IS recommended to facilitate maintenance.
• Installation of a C.A. T. is essential in applications vwith 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. acessories should be sized to avoid restricting the inlet flow.
• AIl 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 iniet pressure.
• D”K versions are suitable for high temperatures and containment of harmful liquids. Consult CAT PUMPS for optional flushing and cooling accessory.

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 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 or ten pumps it 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- ed that a THERMO VALVE be used in the by-pass line to monitor the temperature build-up in the by-pass loop to avoid premature seal failure.
• 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.

TYPICAL RESERVOIR TANK

RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY

Handy Formulas to Help You

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.

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.

References

• Authorized Cat Pumps Distributor - CatPumps.nl
• Leverancier van hogedrukpompen & onderdelen - Pijttersen

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