CAT PUMPS 5CP6221 CP SS Plunger Pump Owner’s Manual

CP SS PLUNGER PUMP SERVICE MANUAL
3CP STAINLESS STEEL SPLIT MANIFOLD: 3CP1221, 3CP1231, 3CP1241
5CP STAINLESS STEEL SPLIT MANIFOLD: 5CP6221, 5CP6241CS, 5CP6251

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.]. 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 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 112 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, booster pump feed, long inlet lines or quick closing valves.
DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system. Install a Pulsation Dampening device on the discharge head or in the discharge line as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) is properly precharged for the system pressure (refer to individual Data Sheet). A reliable Pressure Gauge should be installed near the discharge outlet of the high pressure manifold. This is extremely important for adjusting pressure regulating devices and also for proper sizing of the nozzle or restricting orifice. The pump is rated for a maximum pressure; this is the pressure that is 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 sys-tem 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. 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 customers high pressure system.

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

Disassembly

1. Remove the Hex Socket Head Screws (HSH) and Lockwashers from the Discharge Manifold.
2. Support the Discharge Manifold from the underside and tap the backside of the Discharge Manifold with a soft mallet to gradually separate from the Inlet Manifold.
3. Place Discharge Manifold on work surface with crankcase side up.
4. Remove Inlet Valve Adapters with front and rear 0-Rings from the three small diameter lower inlet chambers. These adapters are not held securely in position and may fall out as the Discharge Manifold is removed.
5. Remove the Seats, 0-Rings, Valves, Springs and Retainers from each inlet valve chamber.
6. Remove Discharge Valve Adapters with front and rear 0-Rings from the three larger diameter upper discharge valve chambers. These Adapters generally remain with the Discharge Manifold as it is removed. When they remain in Discharge Manifold, insert two screwdrivers under the lip on opposite sides of the Adapters and pry the Adapters from the valve chamber.
7. Remove the Seats, 0-Rings, Valves, Springs and Retainers from each discharge valve chamber.

NOTE: The inlet and discharge use the same Retainers, Springs, Seats and Valves. The 0-Rings and Valve Adapters are different. Keep parts in order as they are removed.
Reassembly (Discharge)
NOTE: For certain applications apply liquid gasket to 0-Ring crevices and seal surfaces. Refer to Tech Bulletin 053 for model identification.
NOTE: EPDM elastomers require silicone-base lubricant.

1. Examine Spring Retainers for internal wear or breaks in the structure and replace as needed.
2. Examine Springs for fatigue or breaks and replace as needed.
3. Examine Valves for grooves, pitting or wear and replace as needed.
4. Position Spring Retainer in each upper discharge valve chamber until they rest on the machined ridge in each chamber. Insert Spring into the Spring Retainer over the plastic center guide. Place Valve over Spring with concave side down.
5. Examine Seat 0-Rings for cuts or wear and replace as needed. Place 0-Ring on lip of Spring Retainer. Carefully square 0-Ring in each valve chamber to avoid cutting 0-Ring when Seat is installed.
6. Examine Seats for grooves, pitting, or wear and replace as needed. Install Seat with concave side down in each valve chamber, so 0-Ring fits snugly into groove on Seat.
7. Examine both front and rear 0-Rings on the Discharge Valve Adapter for cuts or wear and replace as needed. Lubricate 0-Ring and fit into grooves on outside of each Adapter.
8. Carefully press Discharge Valve Adapter into each upper valve chamber with small diameter side down until Adapter snaps tightly into position.

Reassembly (Inlet)

1. Examine Spring Retainers for internal wear or breaks in the structure and replace as needed.
2. Examine Springs for fatigue or breaks and replace as needed.
3. Examine Valves for grooves, pitting or wear and replace as needed.
4. Position Spring Retainer in each lower inlet valve chamber until they rest on the machined ridge in each chamber. Insert Spring into Spring Retainer over the plastic center guide. Place Valve over Spring with concave side down.
5. Examine Seat 0-Rings for cuts or wear and replace as needed. Place 0-Ring on lip of Spring Retainer. Carefully square 0-Ring in each valve chamber to avoid cutting 0-Ring when Seat is installed.
6. Examine Seats for grooves, pitting, or wear and replace as needed. Install Seat with concave side down in each valve chamber, so 0-Ring fits snugly into groove on Seat.
7. Examine both front and rear 0-Rings on the Inlet Valve Adapter for cuts or wear and replace as needed. Lubricate 0-Ring and fit into grooves on outside of each adapter.
8. Carefully press Inlet Valve Adapter into each lower valve chamber with small diameter side down until Adapter snaps tightly into position.
9. Slide Discharge Manifold over Ceramic Plunger ends aligning exposed Discharge Valve Adapters with inlet valve chambers and press into position. Tap with a soft mallet until Inlet and Discharge Manifolds are seated.
10. Place Lockwasher on each HSH screw. Apply anti-seize to HSH screw threads and thread in hand tight. Torque in sequence to specifications in torque chart.

Disassembly

1. To service the seals. it is necessary to remove both the Discharge Manifold and the Inlet Manifold. See SERVICING THE VALVES, Disassembly, steps 1-7.

2. Remove HSH Screws from inlet manifolds.

3. Rotate Crankshaft to loosen Inlet Manifold.

4. Support Inlet Manifold from the underside and tap the backside of the manifold with a soft mallet to separate Inlet Manifold from Crankcase.

5. Place Inlet Manifold on work surface with crankcase side down. Remove Hi-Pressure Seal (HPS) from each seal chamber using a screwdriver.
   CAUTION: Exercise caution as the screwdriver may damage sealing surface.

6. Invert Inlet Manifold with crankcase side up. Remove Lo-Pressure Seal (LPS) from each seal chamber using a screwdriver.
   CAUTION: Exercise caution as the screwdriver may damage sealing surface.

Reassembly
NOTE: For certain applications apply liquid gasket to 0-Ring crevices and seal Surfaces. Refer to Tech Bulletin 053 for model identification.
NOTE: EPDM elastomers require silicone-base lubricant.
NOTE: For standard installation, apply a small amount of oil to the outside edge of LPS. HPS. Inlet Valve Adapter and Discharge Valve Adapter for ease of Installation and to avoid damage.

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

2. Press Lo-Pressure Seal into each seal chamber in the Inlet Manifold with garter spring down until completely seated.
   NOTE: When using alternate materials, the fit of the special materials may be snug and require gently driving the LPS into position with a cylinder of the same diameter to assure a square seating and no damage to the LPS.

3. Examine Hi-Pressure Seal for wear to the internal ridges or outer surfaces and replace as needed.

4. Invert Inlet Manifold with crankcase side down. Press Hi-Pressure Seal into each seal chamber with metal backing down until completely seated.

5. Rotate crankshaft by hand so the two outside Plungers are extended equally. Lightly lubricate Ceramic Plungers, to assist in installing the Inlet Manifold.

6. Slide Inlet Manifold over Ceramic Plungers. Apply Loctite-242 to HSH screw threads and thread in hand tight. Torque in sequence to specifications in torque chart.

7. Examine Inlet and Discharge Valve Adapters for scale bulld up. wear and replace as needed. Examine 0-Rings on both the Discharge and Inlet Valve Adapters for cuts and deterioration and replace as needed.

8. Carefully press Discharge Valve Adapter with 0-Rings into each upper Discharge Valve Chamber of Discharge Manifold with small diameter side down until Adapter snaps tightly into position.

9. Carefully press Inlet Valve Adapter with 0-Rings into each lower Inlet Valve Chamber of Discharge Manifold with small diameter side down until Adapter snaps tightly into position.

10. Slide Discharge Manifold over Ceramic Plunger ends aligning exposed Discharge Valve Adapters with inlet valve chambers and press into position. Tap with a soft mallet until Inlet and Discharge Manifolds are seated.

11. Place Lockwasher on each HSH screw. Apply anti-seize to HSH screw threads and thread in hand tight. Torque in sequence to specifications in torque chart.

Disassembly

1. To service the plungers. it is necessary to remove both the Discharge Manifold and Inlet Manifold. See SERVICING THE VALVES, Disassembly, steps 1-7.

2. Remove Seal Retainer from each Plunger Rod.
   NOTE: The 5CP models have a PVDF Oil Seal Washer behind the Seal Retainer.

3. Using a wrench, loosen Plunger Retainers approxi-mately three to four turns.

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

5. Remove Plunger Retainers and Seal Washers.

6. Remove Ceramic Plungers. Keyhole Washers and Barrier Slingers from each Plunger Rod.

Reassembly

1. Visually inspect Crankcase Oil Seals for deterioration or leaks and contact CAT PUMPS for assistance with replacement. See SERVICING CRANKCASE SECTION.
2. Examine Plunger Retainers. Keyhole Washers and Barrier Slingers for wear and replace as needed.
3. Examine Seal Washers for cuts or wear and replace as needed.
4. 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.
5. Slide Seal Washer over each Plunger Retainer.
6. Slide Plunger Retainer with Seal Washer into flat end of Ceramic Plunger. NOTE: Ceramic Plunger can only be installed in one direction. Counterbore end of Ceramic Plunger fits over Plunger Rod shoulder.
7. Slide Barrier Slinger over each Plunger Rod with con-cave side away from crankcase.
8. Slide Keyhole Washer over each Plunger Rod with split ends facing downward.
9. Apply Loctke-242 to exposed threaded end of Plunger Retainer. Thread into Plunger Rod and torque per chart.
10. On the models 3CP1221. 31 and 41. install Seal Retainers with the holes to the top and bottom. and small tabs facing downward over each Plunger Rod.
11. On the models 5CP6221.41CS and 51. install Oil Seal Washer first. then the Seal Retainers with the holes to the top and bottom, and small tabs facing downward over each Plunger Rod.
12. Continue with reassembly. See SERVICING THE SEALS, Reassembly. steps 5-11.

TORQUE SEQUENCE

SERVICING CRANKCASE SECTION

1. While Manifolds. Plungers and Seal Retainers are removed examine Crankcase Oil Seals for leaking and VOW.
2. Check for any signs of leaking at Rear Cover. Drain Plug and Bubble Gauge.
3. Check oil for proper level and for evidence of water or other contaminants in S.
4. Rotate Crankshaft by hand to feel for smooth bearing movement.
5. Examine Crankshaft Oil Seal externally for drying. cracking or leaking.
6. Consult CAT PUMPS or your local distributor if crankcase service is required.

PREVENTATIVE MAINTENANCE CHECK-LIST

Check| Daily| Weekly| 50 hrs.| 500 hrs.*| 1500 hrs.| 3000 hrs.
Clean Filters| x| | | | |
Oil Level/Quality| x| | | | |
Oil Leaks| x| | | | |
Water Leaks| x| | | | |
Belts, Pulley| | x| | | |
Plumbing| | x| | | |
Initial Oil Change| | | x| | |
Oil Change| | | | x| |
Seal Change| | | | | x|
Valve Change| | | | | | x
Accessories| | | | | 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 per- formance decreases, check immediately. If no wear at 1500 hours, check again at 2000 hours and each 500 hours until wear is ob- served. Valves typically require changing every other seal change.
  Duty cycle, temperature, quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and service cycle.
  Remember to service the regulator/unloader at each seal servicing and check all system accessories and connections before resuming operation.
  TORQUE CHART

  Pump Item Pump Model|

Thread

|

Tool Size [P/N]

| Torque in. lbs. ft. lbs.|

Nm

Plunger Retainer| M6| M10 Hex [25082]| 55| 4.4| 6
Inlet Manifold Screws| M8| M6 Allen [30941]| 115| 9.4| 13
Discharge Manifold Screws|

M10 M12

|

M8 Allen [33046]

M10 Allen [33047]

| | |
3CP

5CP

| 140

260

| 12

22

| 16

30

Crankcase Cover Screws| M6| M10 Hex./Phil. [25082]| 50| 4.0| 6
Bearing Cover Screws|

M6 M8

|

M10 Hex./Phil. [25082]

M13 Hex [25324]

| | |
3CP

5CP

| 50

115

| 4.0

9.4

| 6

13

Connecting Rod Screws| M7| M10 Hex [25082]| 95| 7.96| 11
Bubble Oil Gauge| M28| Oil Gauge Tool [44050]| 45| 3.6| 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
043| LPS and HPS Servicing| All Plunger Models
053| Liquid Gasket| All Plunger NAB-S.S. Models
074| Torque Chart| Piston and Plunger Pumps
077| Oil Drain Kit| All Models (except 2SF/4SF)
078| Field Retrofit Mounting| 5CP
083| Winterizing a Pump| All Models
088| 6 Bolt S.S. Manifold| 3CP and 5CP

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 the 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. LI 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 liquids 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 retum 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 CAT. 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 designed to protect against overpressurization, control inlet flow, contamination or temperature and provide ease of servicing.

• A shut-off valve is recommended to facilitate maintenance. U 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. U A stand pipe can be used in some applications to help maintain a positive head at the pump inlet.

• Inspect and clean inlet filters on a regular schedule to avoid flow restriction. U 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. U 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 cutoff 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. 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 3000 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 64 for additional information on the size and length of the by-pass line.

• Check the pressure in the by-pass line to avoid overpressurizing 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.

RESISTANCE OF VALVEA AND FITTINGS

Nominal Pipe Size Inches

|

Inside Diameter Inches

| Equivalent Length of Standard Pipe in Feet
---|---|---

Gate Valve

|

Globe Valve

|

Angle Valve

|

45˚ Elbow

|

90˚ Elbow

| 180˚

Close Ret

| Tee

Thru Run

| Tee

Thru Branch

1/2| 0.622| 0.41| 18.5| 9.3| 0.78| 1.67| 3.71| 0.93| 3.33
3/4| 0.824| 0.54| 24.5| 12.3| 1.03| 2.21| 4.90| 1.23| 4.41
1| 1.049| 0.69| 31.2| 15.6| 1.31| 2.81| 6.25| 1.56| 5.62
11/4| 1.380| 0.90| 41.0| 20.5| 1.73| 3.70| 8.22| 2.06| 7.40
11/2| 1.610| 1.05| 48.0| 24.0| 2.15| 4.31| 9.59| 2.40| 8.63
2| 2.067| 1.35| 61.5| 30.8| 2.59| 5.55| 12.30| 3.08| 11.60
21/2| 2.469| 1.62| 73.5| 36.8| 3.09| 6.61| 14.70| 3.68| 13.20
3| 3.068| 2.01| 91.5| 45.8| 3.84| 8.23| 18.20| 4.57| 16.40
4| 4.026| 2.64| 120.0| 60.0| 5.03| 10.80| 23.90| 6.00| 21.60

Arriving at a total line pressure loss, consideration should then be given to pressure loss created by valves, fittings and elevation of lines. If a sufficient number of valves and fittings are incorporated in the system to materially affect the total line loss, add to the total line length, the equivalent length of line of each valve or fitting.

TYPICAL RESERVOIR TANK

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.

CONDITION Inadequate inlet line size| SOLUTION
•Increase line size to the inlet port or one size larger
---|---
Water hammering liquid acceleration/ Jeacceleration| •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 Inlet Plumbing| •Keep elbows to a minimum and less than 90°
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.

•Ba sippage.
Ai leak in :get punting.
•Pressure gauge inoperatirem not remain° acctralety.
•Refeef vane stuck. Daily pugged or muropery activate
•lel seam stainer dad dogged or armeny med.
•besees in punted aud.
•eaydischage hose.
•hademale Mud simply.
•Severe anitalim.
•hism seals.
Aiken m dirty raldistarge valves.| •Replace wit Property sized nozz b.
•Tghten bats) cr motel new balls).
•T Olen Nags and hoses. Use PTFE Ma cr tape
Checkwit new gauge Replace wan cr damaged gauge.
•Ocereallust relef vane. Replace van seetstvaves and 0-rugs
•Ocen SW. Use adequate size ar. Check mere tecuenty.
•Instal mope fa.
•Replace Manage hose wit proper rattle br system
•Pressurize net and instal C.A.T.
Cluck innt cordibons.
•Instal new sea hat Increase hequancy of seruce.
Clan inleVeischarge valves or lista new vane lot
Pubalm| •Fauity Pubatcm Dampener.
•cream Weal tapped n aldischarge vanes.| Cteck precharge. If low, recharge. or instal a new danpener. Clean Inieldscharge valves or irisla new yaw lot
War teak
One( to mention
•Inta the aankcase| •Wan 11-Presstre a lo-Pressure Seas.
•Worn admanspacer Altos.
•H un kJ at condeag no water made tre aariccase.
•Excessree war to seals.| •Instal new Seta Ica Mcrease frequency d SOY ‘pot -Instal new onngs.
distal od cap protector. Change ote every 3 mod hs or 500 houes.
•Instal new sea hat Ire rease frequency of senme.
Knocking noise
•na stoney
•Bearing
•:bley| •Inadequale Net liquid amply. Broken swan bearirg.
•Loose pulley on owl:shaft| <beck aud simply. Increase Me sue, messuize a instal C A.T. ‘Replace beanie
Cheek key and !Oen set screw.
C41 lea
Carcase od sea Crankshaft ol seals and 0-fillg3 Can dug
•Utdde gauge
•Rea cover
‘Fa cap| •Wan crarkcase cal seas.
•Wan aarkstreft el seals or orings on bearng war. doom drab plug or wpm Oran pug O-tn
•Loose bubble gauge or wom bubble gauge gasket -Loose rear cover a marn rear cover o-itng.
•Loose far cap or excessive of in oradcase.| •Replace crankcase od seats.
•Remove bearing cover and replace (sags mdkr ml seas
•TgMen drab pug or enlace o-rig.
•Tghlen bubble gauge or recta gasket ‘Tighten rear cow Of replace actg.
•Trghten Mer cm. FA crarkcase to speeded camoly.
Pump runs extremely rough Mkt anthems
Atm vakes
•tm seas| •Restveted Net Of at canna be Net plumbing
•Stuck aneldschage valves
•Lealong li-Pressure or Lo-Press UT seas.| Cared tier size *rang. Check for at tight seal
•Oean od faegn material cr instal new valve let, sisal new seal kit Increase frequency d mance.
Praia= teal a lu re| •Scored clingers
Over pressure b dm marbted.
‘Alas tre material In hie Mud tag pumped.
‘Excessive pressure andtr temperature of aormal Isquil ‘Running turrp ay.
•Starving purrp of aquae Mud.
•Ercded manifold.| -Replace plungers.
‘Reduce Pet pressure pe speokatons.
‘Instal proper anal at pap mlet and dean remlady.
•Check pressure and inlet mid lerrperalure.
•DO NOT RUN PUMP WITHOUT LIOUO.
•Inaease hose one size auger tan at pal Sae. Pressurize and sal CAT.
•Replace manibki. Cheat bmii coupettrity.

PIJTTERSEN

Pijttersen B.V.
Beneluxweg 33
9636 HV  Zuidbroek
Tel.: +31(0)50-8200963| KvK 01013855
BIC RABONL2U
BTW NL002166811B01
IBAN NL24 RABO 0353 2970 97
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www.pijttersen.nl – info@pijttersen.nl | www.catpumps.nl – info@catpumps.nl

The Pumps with Nine Lives
PN 30075 Rev B 7313

References

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

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