35PFR PLUNGER PUMP SERVICE MANUAL

35 FRAME SPLIT MANIFOLD: 3520, 3521 and 3527

3535, 3531 and 3537
3545, 3541
3560
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 DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM
maximum is considered, check with your CAT PUMPS supplier to confirm the proper to avoid deadhead overpressure condition and severe damage to the pump or system.
performance and pump selection. Refer to individual pump Data Sheets for complete Install a Pulsation Dampening device on the discharge head or in the discharge line as
specifications, parts list and exploded view. close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) is properly
LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications (4.2 precharged for the system pressure (see individual Data Sheet).
Qts. - 4.0 L). DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change A reliable Pressure Gauge should be installed near the discharge outlet of the high
initial fill after 50 hours running period. Thereafter, change oil every 3 months or 500 pressure manifold. This is extremely important for adjusting pressure regulating devices and
hour intervals. Oiler adjustment is vertical to start feed, horizontal to stop feed, dial to also for proper sizing of the nozzle or restricting orifice. The pump is rated for a maximum
adjust flow rate. Additional lubrication may be required with increased hours of operation pressure; this is the pressure which would be read at the discharge manifold of the
and temperature. pump, NOT AT THE GUN OR NOZZLE.
PUMP ROTATION: Pump was designed for forward rotation to allow optimum lubri- Use PTFE thread tape or pipe thread sealant (sparingly) to connect accessories or plumbing.
cation of the crosshead area. Reverse rotation is acceptable if the crankcase oil level is Exercise caution not to wrap tape beyond the last thread to avoid tape from becoming lodged
increased slightly above center dot to assure adequate lubrication. in the pump or accessories. This condition will cause a malfunction of the pump or system.
PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow PRESSURE REGULATION: All systems require both a primary pressure regulating
from Horsepower Requirement and Pulley Selection Chart (refer to Tech Bulletin 003). device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off
DRIVE SELECTION: The motor or engine driving the pump must be of adequate valve, safety valve). The primary pressure device must be installed on the discharge side of
horsepower to maintain full RPM when the pump is under load. Select the electric motor the pump. The function of the primary pressure regulating device is to protect the pump
from the Horsepower Requirement Chart according to required pump discharge flow, from over pressurization, which can be caused by a plugged or closed off discharge line.
maximum pressure at the pump and drive losses of approximately 3-5%. Consult the Over pressurization can severely damage the pump, other system components and can cause
manufacturer of gas or diesel engine for selection of the proper engine size. bodily harm. The secondary safety relief device must be installed in-line between the
primary device and pump or on the opposite side of the manifold head. This will
MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit drainage ensure pressure relief of the system if the primary regulating device fails. Failure to install
of crankcase oil. An uneven mounting surface will cause extensive damage to the pump such a safely device will void the warranty on 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 If a large portion of the pumped liquid is by-passed (not used) when the high pressure
tension may be harmful to the bearings. Hand rotate pump before starting to be certain shaft system is running, this by-pass liquid should be routed to an adequately sized, baffled supply
and bearings are free moving. 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 temperature control device to
LOCATION: If the pump is used in extremely dirty or humid conditions, it is recom- shut the system down within the pump limits or multiple THERMO VALVES must be
mended pump be enclosed. Do not store or operate in excessively high temperature areas or installed in the by-pass line to protect the pump.
without proper ventilation.
NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure regulating
INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual device to compensate. Replace nozzle and reset regulating device to system pressure.
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. PUMPED LIQUIDS: Some liquids may require a flush between operations or before
Elastomer or RPM changes may be required. See Tech Bulletin 002 or call CAT PUMPS for storing. For pumping liquids other than water, contact your CAT PUMPS supplier.
recommendations. STORING: For extended storing or between use in cold climates, drain all pumped liquids
C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in from pump and flush with antifreeze solution to prevent freezing and damage to
applications with stressful inlet conditions such as high temperatures, booster pump feed, the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech Bulletin 083).
long inlet lines or quick closing valves.

WARNING
All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve).
Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or
responsibility for the operation of a customer’s high pressure system.

World Headquarters CAT PUMPS (U.K.) LTD.

1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet
CAT PUMPS Hampshire GU52 8BF, England
1681 - 94th Lane N.E. Minneapolis, MN 55449 - Phone Fleet 44 1252-622031 — Fax 44 1252-626655
4324 Phone (763) 780-5440 — FAX (763) 780-2958 e-mail: [email protected]
®
e-mail: [email protected] www.catpumps.com N.V. CAT PUMPS INTERNATIONAL S. A.
Heiveldekens 6A, 2550 Kontich, Belgium Phone
International Inquiries The Pumps with Nine 32- 3- 450.71.50 — Fax 32-3- 450.71.51
FAX (763) 785-4329 Lives e-mail: [email protected] www.catpumps.be

e-mail: [email protected]
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 30009 Rev J 8405

All models except 3560 All models except 3560 3560
Removal of Discharge Valve Plug Discharge Valve Assembly Stacked Inlet/Discharge Valve Design

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 Reassembly (All models except 3560)

Disassembly (All models except 3560) NOTE: For certain applications apply liquid gasket to the o-ring
1. Remove the six (6) M41 Hex Valve Plugs. crevices and seal surfaces. See Tech Bulletin 053 for model
2. Remove the exposed Coil Spring from the top of the Spring Retainer. Thread identification.
an M10 bolt into the top of the Spring Retainer. The assembly will usually 1. Examine the O-Rings and Back-up-Rings on the Seat and replace if cut or
remain together. To separate, continue threading the bolt into the back side worn. Lubricate the O-Ring before installing.
of the Valve Seat until it separates from the Spring Retainer. In all models if 2. Examine the surface of the Valve and Seat for pitting, grooves or wear
the assembly separates during removal, use a valve seat removal tool and lift and replace if necessary.
the Seats from the chamber.
3. Assemble Valve Retainer, Spring, Valve and Seat by snapping togeth- er
Disassembly (Model 3560) securely. Thread the M10 bolt into spring retainer for installation.
NOTE: The Discharge and Inlet Valve assemblies are a stacked 4. Lubricate outer O-Ring and Back-up-Ring surface and walls of valve
design and are both accessible by removing the valve plugs. chamber and press Valve Assembly squarely into chamber. Remove M10
Follow the same procedure for inlet and discharge assemblies. bolt. Place the washer over the top of the Spring Retainer and then the Coil
NOTE: The Discharge and Inlet Valve assemblies may stay Spring on top of the Washer.
together or separate during removal. 5. Examine the O-Ring and Back-up-Ring on the Valve Plug and replace if cut
NOTE: Spring Retainer may also separate from Valve Seat dur- or worn. Lubricate new O-Ring and Back-up-Ring before installing onto
ing removal. Valve Plug. Exercise caution to avoid damage from the valve plug threads.
1. Using an M12 Allen wrench remove the (4) four hex socket head screws NOTE: The Back-up-Ring is installed first, then the O-Ring.
(HSH) from each valve plug. Remove Valve Plugs with O-Ring and Back- 6. Slowly thread the Valve Plug into chamber. Exercise caution to avoid
up-Ring from the Discharge Manifold chambers. extruding or cutting the Back-up-Ring or O-Ring. Then torque to
2. Using a reverse pliers, pull the stacked valve assemblies from the valve specifications.
chamber. NOTE: It is highly recommended that anti-seize lubricant
3. If the Inlet Valve Assembly stays in the manifold, use a reverse pliers to (PN6119) be applied to the threads of all stainless steel
remove it. components to prevent galling.
4. If the seat separates from the discharge or inlet assembly, insert the reverse NOTE: Apply Loctite 242 to the threads of the Valve Plug (brass
pliers into the I.D. of the seat and remove it. models) before threading into the valve chamber.

All models except 3560 All models except 3560 Removal of Inlet Screws and Inlet Manifold
Removal of Discharge Manifold Screws Removal of Discharge Manifold
Removal of Inlet Manifold O-Rings 3531, 3535, 3537, 3541, 3545, 3650 3520, 3521, 3527
Removal of V-Packing Spacer from Inlet Manifold Removal of V-Packing Cylinder

Reassembly (Model 3560)

18. Install Discharge Spring Retainer with deep stepped end over Spring and
NOTE: For certain applications apply liquid gasket to the o-ring snap onto Discharge Seat.
crevices and seal surfaces. See Tech Bulletin 053 for model
19. Complete the stacked assembly by pressing the Discharge Valve Assembly
identification.
into the Inlet Valve Assembly.
1. Examine the O-Ring on the Inlet Seat and replace if cut or worn.
20. Place the complete stacked valve assembly into each Valve Chamber until
2. Examine Inlet Valves and Seats for grooves, pitting or wear and replace as completely seated.
needed.
21. Lubricate and install Back-up-Ring, then O-Ring onto each Valve Plug.
3. Examine Inlet Springs for fatigue or breaks and replace as needed. Press Valve Plug into each Valve Chamber. Exercise caution to avoid
4. Examine Inlet Spring Retainers for internal wear or breaks in the damage from the valve plug threads.
structure and replace as needed. 22. Apply anti-seize lubricant (PN6119) to HSH screw threads and thread in
5. Examine the O-Rings and Back-up-Rings on the Discharge Seat and replace hand tight. Torque to specifications in torque chart.
if cut or worn.
6. Examine Discharge Valves and Seats for grooves, pitting or wear and REMOVING THE DISCHARGE MANIFOLD
replace as needed.
1. Remove the eight (8) HSH screws.
7. Examine Discharge Springs for fatigue or breaks and replace as needed.
2. Tap the back side of the Discharge Manifold with a soft mallet and
8. Examine Discharge Spring Retainers for internal wear or breaks in the gradually work head from pump.
structure and replace as needed.
3. Remove the O-Rings from lower chambers of the face of the Inlet
NOTE: Inlet Valve Seat and O-Ring are different from the Manifold.
Discharge Valve Seat, O-Ring and Back-up-Ring.
One Valve Kit required per pump. REMOVING THE INLET MANIFOLD
9. Lubricate and install new O-Ring onto each Inlet Seat. 1. Using a hex allen wrench, remove the four (4) HSH screws. Rotate the
10. Place Inlet Seat on work surface with small diameter side up. Crankshaft to begin the separation of the Inlet Manifold from the Crankcase.
11. Place the Valve onto Inlet Seat with concave side down. 2. Tap the rear of the Inlet Manifold with a soft mallet and gradually work from
pump.
12. Place Spring on Valve.
NOTE: Support from the underside and exercise caution to keep
13. Install Inlet Spring Retainer with deep stepped end over Spring and manifold aligned with Plungers to avoid damage to the Plungers
snap onto Inlet seat. as the manifold is removed.
14. Lubricate and install O-Ring, then Back-up-Ring onto the Discharge Seats. NOTE: Two screwdrivers on opposite sides of the manifold may
15. Place Discharge Seat on a work surface with small diameter down. be used to assist separation.
16. Place Valve onto Discharge Seat with the concave side down.
17. Place Spring on Valve.

3531, 3535, 3537, 3541, 3545 3520, 3521, 3527 3560

V-Packing and Spacer Arrangement V-Packing and Cylinder Arrangement V-Packing-Spacer Arrangement
3531, 3535, 3537, 3541, 3545 Removal of Lo-Pressure Seal from Inlet Manifold 3531, 3535, 3537, 3541, 3545
V-Packing Spacer and Spacer with Coil Springs Lo-Pressure Seal and Washer Assembly

SERVICING THE SEALS Disassembly of the Lo-Pressure Seal

Disassembly of the V-Packings 1. With the Inlet Manifold on blocks and with the crankcase side down,
1. Place the crankcase side of the Inlet Manifold down on the work insert screwdriver into seal chamber and tap opposite sides of the Washer
surface. Spacer to drive out seal assembly.
2. Remove the V-Packing Spacer. These may stay in either the Inlet or NOTE: Models 3535, 3531, 3537, 3545, 3541 include Spacer and
Discharge Manifold ports when the Discharge Manifold is removed. If they Lo-Pressure Seal. Models 3520, 3521, 3527 include Washer, Lo-
are extremely dirty or dry, remove the exposed O-Ring and Back-up-Ring Pressure Seal, Inlet Adapter and O-Ring. Model 3560 includes
and insert two screwdrivers on opposite sides to pry out of chamber. only LPS.
3. Examine both front and rear O-Rings and Back-up-Rings on the V-Packing 2. Elevate Inlet Adapter with Lo-Pressure Seal down and tap with
Spacer for cuts or wear and replace as needed. screwdriver on opposite sides of seal to drive seal out of Inlet Adapter
NOTE: The 3545, 3541 do not have Back-up-Rings. (Models 3520, 3521, 3527 only). Replace the Lo-Pressure Seal and examine
4. Remove V-Packing Cylinder (3520, 3521, 3527), by inserting two Inlet Adapter O-Ring for wear and replace as needed.
screwdrivers on opposite sides of the V-Packing Cylinder and pry out. Reassembly of the Lo-Pressure Seal
Examine O-Ring for wear and replace as needed. NOTE: For certain applications apply liquid gasket to the o-ring
5. Remove Spacer with Coil Springs (except 3560). Examine for broken or crevices and seal surfaces. See Tech Bulletin 053 for model
fatigued springs or scale build up or pitting and replace as needed. identification.
6. With a reverse pliers remove Male Adapter, V-Packings and Female Models 3535, 3531, 3537
Adapter. 1. With the crankcase side of Inlet Manifold up insert the LPS Spacer
NOTE: Using the reverse pliers may damage V-Packings or into the seal chamber.
Female Adapter. 2. Install Lo-Pressure Seal into seal chamber with garter spring facing
7. Examine Female Adapter for worn I.D. and replace as needed. down and press squarely into position.
Reassembly of the V-Packings Models 3520, 3521, 3527
NOTE: For certain applications apply liquid gasket to the o-ring 1. With the crankcase side of Inlet Manifold up insert the Washer into
crevices and seal surfaces. See Tech Bulletin 053 for model the seal chamber.
identification. 2. Install Lo-Pressure Seal into larger diameter of Inlet Adapter with
1. Lubricate outer surface of V-Packing Cylinder and install new O-Ring in spring up and press squarely into position.
groove (3520, 3521, 3527). Press V-Packing Cylinder with O-Ring end 3. Lubricate outer surface of Inlet Adapter and install O-Ring into the
down into the manifold chamber until completely seated. groove of the Inlet Adapter.
2. Insert Female Adapter into V-Packing Cylinder (3520, 3521, 3527) or 4. Press Inlet Adapter with seal into seal chamber with garter spring
manifold chamber (3535, 3531, 3537, 3545, 3541, 3560) with the “V” facing down.
groove up. Models 3545, 3541
3. Fit the new V-Packings together, lubricate outer surface of the pack- ings 1. With the crankcase side of the Inlet Manifold up insert the Lo- Pressure
and insert into V-Packing Cylinder (3520, 3521, 3527) or mani- fold Seal into the seal chamber with the garter spring facing down and press
chamber (3535, 3531, 3537, 3545, 3541, 3560) with the “V” groove up. squarely into position.
4. Install Male Adapter into V-Packing Cylinder (3520, 3521, 3527) or NOTE: Install the LPS Spacer onto the plunger in front of the
manifold chamber (3535, 3531, 3537, 3545, 3541, 3560) with the “V” Seal Retainer and not in the I.M. seal chamber.
groove down (notches up).
Models 3560
5. Lubricate outer surface of Spacer with Coil Springs and insert into V-
1. With the crankcase side of the Inlet Manifold up insert the Lo-
Packing Cylinder (3520, 3521, 3527) or manifold chamber (3535, 3531,
3537, 3545, 3541) with springs facing down. See Tech Bulletin 050 Pressure Seal into the seal chamber with the garter spring facing down
when servicing old style pumps; both the spacer with coil springs and inlet and press squarely into position.
manifold must be updated.
6. Lubricate outer surface of V-Packing Spacer, install new O-Rings and Back-
up- Rings in both front and rear groove and press into V-Packing Cylinder
(3520, 3521, 3527) or manifold chamber (3535, 3531, 3537, 3560) with
small diameter down until completely seated.
NOTE: The 3545, 3541 do not have Back-up-Rings.
3560 3520, 3521, 3527 Plunger Arrangement
Lo-Pressure Seal Lo-Pressure Seal and Adapter Assembly

SERVICING THE PLUNGERS 12. Lubricate outer surface of V-Packing Spacer, O-Rings and valve chamber
Disassembly walls and carefully slip Discharge Manifold over V-Packing Spacer.
1. To service the plungers it is necessary to remove the Discharge and Inlet 13. Hand tighten the two (2) HSH screws first. Then hand tighten the remaining
Manifolds. Follow the disassembly procedure found under REMOVING six (6) HSH screws. Torque per chart and in this sequence.
THE DISCHARGE MANIFOLD and REMOVING THE INLET
MANIFOLD. 1 3
2. Remove the Seal Retainers from the Ceramic Plungers.
5 7
3. Remove the Inner Collar from the front of the seal retainer.
4. Remove the used Wick and install new Wick. 8 6
NOTE: Model 3545, 3541 do not have Wicks or front half of Seal 4 2
Retainer.
5. Replace Inner Collar on Seal Retainer.
6. Loosen Plunger Retainer 4 to 5 turns. Push Plunger towards Crankcase until
Plunger Retainer pops out.
7. Unscrew and remove Plunger Retainer, Gasket, O-Ring, Back-up- Ring and SERVICING THE CRANKCASE SECTION
Ceramic Plunger, Keyhole Washer and Barrier Slinger from each Plunger 1. While manifolds, plungers and seal retainers are removed examine
Rod. crankcase oil seals for leaking and wear.
Reassembly 2. Check for signs of leaking at Bearing Covers, Rear Cover, Drain Plug, and
1. With these plunger items removed, examine the Crankcase Oil Seal for Bubble Oil Gauge.
wear or deterioration and replace as needed. 3. Check oil level and for evidence of water in oil. Change crankcase oil on a
2. Replace Keyhole Washer on Plunger Rod. regular schedule. See Preventative Maintenance Check-List.
3. Carefully examine each Plunger for scoring or cracks and replace if worn. 4. Rotate Crankshaft by hand to feel for smooth bearing movement.
NOTE: Ceramic Plunger can only be installed one direction (front 5. Examine Crankshaft Oil Seals externally for drying, cracking or leaking.
to back). Do not force onto rod. 6. Contact CAT PUMPS or your local distributor if crankcase service is
4. Examine Gasket, O-Ring and Back-up-Ring on Plunger Retainer and replace required. See Tech Bulletin 035.
if cut or worn. Lubricate O-Ring for ease of installation and to avoid See section III of the Plunger Pump Service Video for additional
damaging O-Rings. information (except 3560).
NOTE: First install Gasket, then O-Ring and Back-up-Ring.
5. Apply loctite 242 to the threads of the Plunger Retainer and thread
Plunger Retainer onto Plunger Rod. Torque per specifications.
6. Slip Seal Retainers over Plungers.
NOTE: On Model 3545, 3541 install LPS Spacer over plungers
until flush with Seal Retainer. Line up Wicks with the oil holes in
the Crankcase and tabs in the Oil Pan (3520, 3521, 3527, 3535,
3531, 3537).
7. Rotate crankshaft by hand so the two outside Plungers are extended equally.
8. Lubricate the Plungers.
9. Carefully replace Inlet Manifold onto Plungers and press into
Crankcase. Keep manifold aligned to avoid damaging Plungers.
10. Replace four (4) HSH screws and torque per chart.
11. Examine inlet port o-rings at bottom of manifold and replace if cut or worn.
Wick lubrication: Oiler setting for Wicks is three drops per hole, twice per
month for normal operation. Oiler adjustment is vertical to start feed,
horizontal to stop feed, 45° to flush bearing. Additional lubrication may be
required with increased hours of operation and temperature.
NOTE: Do not lubricate wicks at initial start-up. Operate for 10 to
15 minutes to allow grease from LPS to penetrate the plunger
surface, then lubricate as needed.
 INLET CONDITION CHECK-LIST
PREVENTATIVE MAINTENANCE CHECK-LIST
Review Before Start-Up
Check Daily Weekly 50 hrs. 500 hrs.* 1500 hrs.** 3000 hrs.** 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
Clean Filters x the unfamiliar or untrained eye. REVIEW THIS CHECK-LIST BEFORE OPERATION OF
Oil Level/Quality x 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.
Oil Leaks x
INLET SUPPLY should exceed the maximum flow being delivered by the pump to assure
Water Leaks x proper performance.
Belts, Pulley x ❏ Open inlet shut-off valve and turn on water supply to avoid starving pump.
DO NOT RUN PUMP DRY.
Plumbing x ❏ 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
Initial Oil Change x CAT PUMPS for recommendations.
Oil Change x ❏ Avoid closed loop systems especially with high temperature, ultra-high pressure or
large volumes. Conditions vary with regulating/unloader valve.
Seal Change x ❏ Low vapor pressure liquids, such as solvents, require a booster pump and C. A.T. to
maintain adequate inlet supply.
Valve Change x ❏ Higher viscosity liquids require a positive head and a C. A.T. to assure adequate inlet
supply.
Accessories x
❏ Higher temperature liquids tend to vaporize and require positive heads and
C. A.T. to assure adequate inlet supply.
* If other than CAT PUMPS special multi-viscosity ISO68 oil is used, change
❏ When using an inlet supply reservoir, size it to provide adequate liquid to accommodate
cycle should be every 300 hours. the maximum output of the pump, generally a minimum of 6 to 10 times the
** Each system’s maintenance cycle will be exclusive. If system perfor- mance GPM (however, a combination of system factors can change this requirement); provide
decreases, check immediately. If no wear at 1500 hours, check again at 2000 adequate baffling in the tank to eliminate air bubbles and turbulence; install diffusers on
hours and each 500 hours until wear is observed. Valves typically require all return lines to the tank.
changing every other seal change.
INLET LINE SIZE should be adequate to avoid starving the pump.
Duty cycle, temperature, quality of pumped liquid and inlet feed conditions ❏ Line size must be a minimum of one size larger than the pump inlet fitting. Avoid tees,
all effect the life of pump wear parts and service cycle. 90 degree elbows or valves in the inlet line of the pump to reduce the risk of flow
** Remember to service the regulator/unloader at each seal servicing and restriction and cavitation.
check all system accessories and connections before resuming operation. ❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on SUCTION
systems to avoid collapsing.
❏ TheRefer to video
simpler for plumbing
the inlet additionaltheassistance.
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.
TORQUE CHART
❏ Use pipe sealant to assure air-tight, positive sealing pipe joints.
Pump Item Thread Tool Size Torque INLET PRESSURE should fall within the specifications of the pump.
[Part No.] in. lbs. ft. lbs. Nm ❏ 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
Plunger Retainer M10 M21 Hex 220 18.0 24 adequate inlet supply. DO NOT USE C.A.T WITH SUCTION INLET.
Model 3560 Only M7 M14 Hex 90 7.5 10 ❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure and a
[25053] C. A.T. for certain applications. With adequate inlet plumbing, most pumps will perform with
Inlet Manifold Screws M14 M12 Allen 480 40.0 54 flooded suction. Maximum inlet pressure is 70 PSI (4.9 BAR).
[33048] ❏ 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
Discharge Manifold Screws M12 M10 Allen 355 30.0 40 measure flow.
[33047]
Valve Plugs M45 M41 Hex 1305 109 148 INLET ACCESSORIES are designed to protect against overpressurization, control inlet
flow, contamination or temperature and provide ease of servicing.
Valve Plug Screws M14 M12 Allen 486 40.5 55
❏ A shut-off valve is recommended to facilitate maintenance.
[33048] ❏ Installation of a C. A.T. is essential in applications with stressful conditions such as
Rear Cover/ M8 M13 Hex 115 9.58 13 high temperatures, booster pump feed or long inlet lines. Do not use C. A.T. with
Bearing Cover Screws [25324] negative inlet pressure.
❏ A stand pipe can be used in some applications to help maintain a positive head at the
Connecting Rod Screws M10 M17 Hex 395 33.0 45
pump inlet line.
[25083] ❏ Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
Bubble Oil Gauge M28 Oil Gauge Tool 45 3.6 5 ❏ A pressure transducer is necessary to accurately read inlet pressure. Short term,
[44050] intermittent cavitation will not register on a standard gauge.
❏ All accessories should be sized to avoid restricting the inlet flow.
Direct Mount Screws M14 M22 Hex 570 47.5 64
❏ All accessories should be compatible with the solution being pumped to prevent
premature failure or malfunction.
TECHNICAL BULLETIN REFERENCE CHART ❏ 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.
No.SubjectModels
Inlet Pressure VS Liquid TemperatureAll Models BY-PASS TO INLET Care should be exercised when deciding the method of by-pass from
control valves.
Power Unit Drive Packages3PFR - 68PFR, 10FR - 60FR
❏ It is recommended the by-pass be directed to a baffled reservoir tank, with at least one
024 Lubrication of Lo-Pressure SealsAll Models baffle between the by-pass line and the inlet line to the pump.
Servicing Crankcase Section7CP, 7PFR - 68PFR ❏ Although not recommended, by-pass liquid may be returned to the inlet line of the pump
Cylinder and Plunger Reference ChartAll Models if the system is properly designed to protect your pump. When a pulsation dampener is
Manifold and Valve Part3527 and 3537 used, a PRESSURE REDUCING VALVE must be installed on the inlet line
(BETWEEN THE BY-PASS CONNECTION AND THE INLET TO
Oil Gauge and Crankcase3520 and 3535 THE PUMP) to avoid excessive pressure to the inlet of the pump. It is also recommended
043 LPS and HPS ServicingAll Plunger Models that a THERMO VALVE be used in the by-pass line to monitor the temperature
050 Spacer with Coil Springs3520, 3527, 3535, 3537 build-up in the by-pass loop to avoid premature seal failure.
Plunger Rod and Stud3PFR, 5PFR, 15PFR, 35PFR, 60PFR ❏ A reinforced, flexible, low pressure hose rated up to 300 PSI should be used for routing
Liquid GasketAll Plunger NAB-S.S. Models by-pass back to the pump inlet.
❏ Caution should be exercised not to undersize the by-pass hose diameter and length. Refer
064 By-Pass Hose SizingAll Unloaders/Regulators to Technical Bulletin 064 for additional information on the size and length of the by-pass
069 Forged Extended Manifolds35PFR line
074 Torque ChartPiston and Plunger Pumps ❏ Check the pressure in the by-pass line to avoid overpressurizing the inlet.
077 Oil Drain KitAll Models (except 2SF/4SF) ❏ 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"
083 Winterizing a PumpAll Models distance from pump inlet port.
087 Female Adapters15PFR, 35PFR, 60PFR
095 Galling PreventativeStainless Steel Pumps
 HOSE FRICTION LOSS Handy Formulas to Help You
PRESSURE DROP IN PSI PER 100 FT OF HOSE Q. How can I find the RPM needed to get specific GPM
WITH TYPICAL WATER FLOW RATES
Hose Inside Diameters, Inches (Gallons Per Minute) I want?
1/4 5/16 3/8 1/2 5/8 3/4 1" Rated RPM
Water* A. Desired RPM = Desired GPM x
Flow
Gal/Min Rated GPM
0.5 16 5 2
Q. I have to run my pump at a certain RPM. How do I figure
1 54 20 7 2 the GPM I’ll get?
2 180 60 25 6 2
Rated GPM
A. Desired GPM = Desired RPM x
3 380 120 50 13 4 2 Rated RPM
4 220 90 24 7 3 Q. Is there a simple way to find the approximate horsepower
5 320 130 34 10 4 I’ll need to run the pump?
6 220 52 16 7 1 A. Electric Brake
Horsepower Required GPM x PSI (Standard 85%
*At a8fixed flow rate with a given size hose,
300
the pressure80drop across25 10 length will
a given hose 2 be = 1460 Mech. Efficiency)
directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100 ft. hose.
10 450 120 38 14 3
Above values shown are valid at all pressure levels. Q. What size motor pulley should I use?
A. Pump Pulley (Outer Diameter) x Pump RPM (Consult
Engine Mfr.)
Motor/Engine RPM
Q. How do I calculate the torque for my hydraulic drive
WATER LINE PRESSURE LOSS system?

( )
GPM x PSI
PRESSURE DROP IN PSI PER 100 FEET A. Torque (ft. lbs.) = 3.6
Water Steel Pipe—Nominal Dia. Brass Pipe—Nominal Dia. Copper Tubing O.D. Type L
RPM
GPM 1/4 3/8 1/2 3/4 1 1 /4 1 /2
1 1
1/4 3/8 1/2 3/4 1 11/4 11/2 1/4 3/8 1/2 5/8 3/4 7/8
1
2
8.5 1.9

30 7.0 2.1
6.0 1.6

20 5.6 1.8
120

400
13 2.9 1.0

45 10 3.4 1.3
Avoid Cavitation Damage
3 60 14 4.5 1.1 40 11 3.6 94 20 6.7 2.6

5 150 36 12 2.8 100 2 9.0 2.2 230 50 17 6.1 3.0

8
8 330 86 28 6.7 1.9 220 6 21 5.2 1.6 500 120 40 15 6.5
2
10 520 130 43 10 3.0 320 9 30 7.8 2.4 180 56 22 10
0
15 270 90 21 6.2 1.6 190 62 16 5.0 1.5 120 44 20

25 670 240 56 16 4.2 2.0 470 150 40 12 3.8 1.7 330 110 50

40 66 17 8.0 39 11 5.0 550 200 88

RESISTANCE OF VALVES AND One or several of the conditions shown in the chart below may
FITTINGS Equivalent Length of Standard Pipe in Feet contribute to cavitation in a system resulting in premature wear, system
Nominal
Gate Globe Angle 45˚ 90˚
180˚
Close
Tee
Thru
Tee
Thru
downtime and unnecessary operating costs.
Pipe
Size Inside Valve Valve Valve Elbow Elbow Ret Run Branch
Inches Diameter CONDITION SOLUTION
Inches Inadequate inlet ● Increase line size to the inlet port or one size line
1/2 0.622 0.41 18.5 9.3 0.78 1.67 3.71 0.93 3.33 size larger
3/4 0.824 0.54 24.5 12.3 1.03 2.21 4.90 1.23 4.41
Water hammering ● Install C.A.T. Tube
1 1.049 0.69 31.2 15.6 1.31 2.81 6.25 1.56 5.62
liquid acceleration/ ● Move pump closer to liquid supply
11/4 1.380 0.90 41.0 20.5 1.73 3.70 8.22 2.06 7.40
deacceleration
11/2 1.610 1.05 48.0 24.0 2.15 4.31 9.59 2.40 8.63
Rigid Inlet Plumbing ● Use flexible wire reinforced hose to absorb
2 2.067 1.35 61.5 30.8 2.59 5.55 12.30 3.08 11.60
2 1/2
pulsation and pressure spikes
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 Excessive Elbows in ● Keep elbows to a minimum and less than 90°
Inlet Plumbing
Arriving at a total line pressure loss, consideration should then be given to pressure
loss created by valves, fittings and elevation of lines. Excessive Liquid Use Thermo Valve in bypass line Temperature
●

If a sufficient number of valves and fittings are incorporated in the system to Do not exceed pump temperature specifications
●

materially affect the total line loss, add to the total line length, the equivalent length Substitute closed loop with baffled holding tank
●

of line of each valve or fitting. Adequately size tank for frequent or high
●

volume bypass
Pressure feed high temperature liquids
●

TYPICAL RESERVOIR TANK Properly ventilate cabinets and rooms

●

RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Air Leaks in Plumbing ● Check all connections
Use PTFE thread tape or pipe thread sealant
●

Bypass Line
Supply Line Agitation in Supply ● Size tank according to pump output —
(from regulator or unloader) Tank minimum 6-10 times system GPM
→

Level Sensing
Device X D T
(Dia of pipe) ●
Baffle tank to purge air from liquid and
separate inlet from discharge
→
→

MIN. 4"
→

High Viscosity Liquids ● Verify viscosity against pump specifications before

→

1.5 x D (Min.)
operation
→

Elevate liquid temperature enough to reduce

→

viscosity
Flexible Hose to Minimum ●
Lower RPM of pump
Pump Liquid Bypass Line (from
Level regulator or
●
Pressure feed pump
FILTER unloader) ●
Increase inlet line size
→

Clogged Filters ● Perform regular maintenance or use clean

filters and monitor build up
→

Minimum Two Baffles

MIN. 4" Sealed at Bottom
●
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 PROBABLE CAUSE SOLUTION

Low pressure •Worn nozzle. •Replace with properly sized nozzle.

•Belt slippage. •Tighten belt(s) or install new belt(s).
•Air leak in inlet plumbing. •Tighten fittings and hoses. Use PTFE liquid or tape.
•Pressure gauge inoperative or not registering accurately. •Check with new gauge. Replace worn or damaged gauge.
•Relief valve stuck, partially plugged or improperly adjusted. •Clean/adjust relief valve. Replace worn seats/valves and o-rings.
•Inlet suction strainer (filter) clogged or improperly sized. •Clean filter. Use adequate size filter. Check more frequently.
•Abrasives in pumped liquid. •Install proper filter.
•Leaky discharge hose. •Replace discharge hose with proper rating for system.
•Inadequate liquid supply. •Pressurize inlet and install C.A.T.
•Severe cavitation. •Check inlet conditions.
•Worn seals. •Install new seal kit. Increase frequency of service.
•Worn or dirty inlet/discharge valves. •Clean inlet/discharge valves or install new valve kit.

Pulsation •Faulty Pulsation Dampener. •Check precharge. If low, recharge, or install a new dampener.
•Foreign material trapped in inlet/discharge valves. •Clean inlet/discharge valves or install new valve kit.

Water leak
•Under the manifold •Worn V-Packings or Lo-Pressure Seals. •Install new seal kit. Increase frequency of service.
•Worn adapter o-rings. •Install new o-rings.
•Into the crankcase •Humid air condensing into water inside the crankcase. •Install oil cap protector. Change oil every 3 months or 500 hours.
•Excessive wear to seals and V-Packings. •Install new seal kit. Increase frequency of service.

Knocking noise
•Inlet supply •Inadequate inlet liquid supply. •Check liquid supply. Increase line size, pressurize or install C.A.T.
•Bearing •Broken or worn bearing. •Replace bearing.
•Pulley •Loose pulley on crankshaft •Check key and tighten set screw.

Oil leak
•Crankcase oil seals. •Worn crankcase oil seals. •Replace crankcase oil seals.
•Crankshaft oil seals and o-rings. •Worn crankshaft oil seals or o-rings on bearing cover. •Remove bearing cover and replace o-rings and/or oil seals.
•Drain plug •Loose drain plug or worn drain plug o-ring. •Tighten drain plug or replace o-ring.
•Bubble gauge •Loose bubble gauge or worn bubble gauge gasket. •Tighten bubble gauge or replace gasket.
•Rear cover •Loose rear cover or worn rear cover o-ring. •Tighten rear cover or replace o-ring.
•Filler cap •Loose filler cap or excessive oil in crankcase. •Tighten filler cap. Fill crankcase to specified capacity.

Pump runs extremely rough

•Inlet conditions •Restricted inlet or air entering the inlet plumbing •Correct inlet size plumbing. Check for air tight seal.
•Pump valves •Stuck inlet/discharge valves. •Clean out foreign material or install new valve kit.
•Pump seals •Leaking V-Packings or Lo-Pressure seals. •Install new seal kit. Increase frequency of service.

Premature seal failure •Scored plungers. •Replace plungers.

•Over pressure to inlet manifold. •Reduce inlet pressure per specifications.
•Abrasive material in the liquid being pumped. •Install proper filtration at pump inlet and clean regularly.
•Excessive pressure and/or temperature of pumped liquid. •Check pressure and inlet liquid temperature.
•Running pump dry. •DO NOT RUN PUMP WITHOUT LIQUID.
•Starving pump of adequate liquid. •Increase hose one size larger than inlet port size. Pressurize and install
C.A.T.
•Eroded manifold. •Replace manifold. Check liquid compatibility.