JetStream Manual

OWNER’S MANUAL
OASIS CAR WASH SYSTEMS

800-892-3537 · www.oasiscarwashsystems.com
Installation Revised 04/01/08 1.3
REVERSE OSMOSIS OPERATION
Once your Oasis RO System is on-line, the day to day operation is very simple.
You should check the salt level in the brine tank daily and add salt as required. Once per week test to ensure the
water is free of chlorine. This can be checked from the test cock located on top of the carbon filter. You should
also check the water for hardness to ensure the proper operation of the water softener. Water must be at zero grains
hardness. During normal operation, the system will operate automatically and does not require any further
attention.
The Oasis RO System is basically two systems in one. The first system produces pure water. The other system
delivers the pure water to the wash bays.
RO MEMBRANE SYSTEM
The RO Membrane is nothing more than a very fine filter. This filter (membrane) is so fine that it simply removes
the minerals from the water and allows only the pure water to pass (permeate) through the membrane.
Since the membrane is so fine, a pump must be used to pressurize the water to approximately 200 PSI to force the
water through the membrane. As with any filter, after time the membrane could become clogged (fouled) with
minerals, grease or dirt and not allow any further passage of the pure water through the membrane and into the
holding tank. Since the membranes are very fine and fouling can occur, a water softener is used to soften the
incoming water and the carbon filter is used to remove the chlorine. Chlorine will damage the membrane, and
prolonged exposure can cause permanent damage.
To keep fouling from happening, a certain amount of water must be used to flush past the surface of the membrane
and rinse the build-up of minerals from the membrane surface. This water is then recirculated through the
membrane pump system and used over. After several passes by the membrane, the recirculating water becomes
very saturated with minerals. It must therefore be discarded. To ensure smooth continuous operation, an orifice is
located in the recirculation system and a controlled amount of water is rejected from the system to drain (reject
water) on a continuous basis as long as the membrane pump is running. The amount of reject water is controlled by
the orifice located in the plumbing in the lower portion of panel. See schematic for its location. The amount of
reject water is set at the factory and should only be changed after consultation with the factory. The amount of
water going to drain can be monitored in the REJECT WATER FLOW METER.
The pure water (PRODUCT WATER) that permeates through the membrane is then stored in the stainless steel
product water holding tank. As the water level reaches the top of the tank a float switch will shut off the membrane
pump, thus stopping the production of pure water. Once the water level is reduced a sufficient amount, the float
switch will start the membrane pump and once again fill the tank with pure water.
If you operate the Oasis system 24 hours per day you will find that the water softener will regenerate at
approximately 2 o'clock AM. The system will receive city water to the Oasis system during the time that the water
softener regeneration takes place. This should be avoided. Do not allow the storage system to run at this time, as
it will cause membrane damage. The normal regeneration time is about 2 hours. You may wish to check the
softener manual for more detailed information concerning the operation of the water softener.
DELIVERY SYSTEM OPERATION
The Delivery System consists of a pump capable of producing pressure up to approximately 150 PSI using the water
from the pure water holding tank. The electric control panel and wash bay switches control the pump.
Should the water level fall below the low water level switch in the water holding tank, the delivery pump shuts off
until the water level is restored.
INSTALLATION & OPERATION INSTRUCTIONS

This Oasis RO system is pre-plumbed and wired for easy installation and start-up. Once this system is on-line, very
little preventative maintenance is required.
1. Chlorine test weekly. The chlorine level should remain at zero to prevent permanent damage to the RO
Membranes.
2. Water hardness test weekly. The water hardness should remain at zero, to prevent premature fouling of the RO
Membranes.
3. Sediment filter checked weekly (visual inspection).
INSTALLATION
1. Select a location where the required utilities are easily accessible.
2. Check the incoming water pressure prior to installing the RO System. Should the water pressure be less than 40
PSI, a booster pump may be required (consult factory). If the incoming water pressure exceeds 100 PSI it will be
necessary to install a pressure-reducing valve.
3. Normal electrical requirements for this system are 240/480 volt 3-phase 10/20-amp service. Controls are located
in the main electrical enclosure.
4. Make the drain line connection (1/2 inch) to a floor drain near the RO system. Should a drain not be available in
close proximity to the RO system, you can run the drain line overhead to a drain located elsewhere in the building
(Max height 8' above base). Please refer to sketch for the location of this connection.
5. The final connection to make is the pure water connection from each wash bay to the RO manifold located on the
upper right end of JETSTREAM MODULE.
START UP INSTRUCTIONS
1. Charging the system with water is the first step in starting up the RO system. Check to be sure that the
manual service valve is in the off position (customer supplied).
2. Make sure the power is turned off.
3. Install a temporary jumper wire between terminal number 5 and number 76 (solenoid valve).
4. Remove sediment filter and housing, being careful to not lose the o-ring.
5. Turn off the 3-phase contactor for RO storage pump.
6. Turn on the power to control panel.
7. Partially open the service valve to flush the dust out of the charcoal tank. If this step is skipped, you may
cause the sediment filter to foul prematurely.
8. Allow charcoal filter to flush slowly for approximately fifteen minutes.
9. Close the service valve therefore shutting off the water supply, turn off control power and then remove the
jumper between terminal number 5 and number 76.
10. Reinstall the sediment filter and housing.
11. Turn on control power.
12. Caution! Make sure water softeners have been regenerated before charging system (water should test 0
grains hardness).
13. Make sure the ½” permeate pure water hose is connected to the bottom plumbing of the pure water holding
tank.
14. Turn off the RO 3-Phase contactor. This will enable the storage pump and allow water to flow and expel
all air from the system (air bubbles can be seen through flow meters on front door).
15. The upper float switch in the pure water holding tank must be in the down position.
16. Turn on the service valve slowly, checking for air bubble again in flow meters.
17. Now check pump for correct rotation by watching shaft (may seen at about mid position of storage
pump), while someone else bumps RO pump contactor momentarily.
18. See pump for correct rotation. CAUTION! Do not run pump for more than 5 seconds in the event rotation
is wrong, as this can cause sever damage to the pump. When the rotation is correct, the PUMP
CONTACTOR can now be turned to run position. The high-level float switch must be in the down position
for the pump to run. There is about an 8 second delay before the pump will start.
19. Once the system is producing water, adjust the pressure to about 200 PSI. See Schematic for pressure
regulator location.
20. Water should begin to fill the pure water holding tank
21. Make sure the high-level float switch will shut the system down automatically. Manually raise this switch
by hand, which should shut down the system. Again lower the high-level float switch and the system will
restart after the 8-second delay.
22. While the storage tank is filling, use the water test kits. Take a sample of water from the water sample
valve and check for chlorine and hardness. It is extremely important that the RO membrane(s) be supplied
with chlorine-free, soft water. Both of the readings should be zero. If they are not, discard the water in the
storage tank until the water becomes pure.
23. After the storage tank has filled with pure water, make sure the hand valve in the supply line to the delivery
pump from the storage tank is fully open.
24. The RO System is now in full automatic operation.
TROUBLE SHOOTING GUIDE
1) Product flow is less than normal, pressure normal and water with water temperature at
approximately 78 deg F
* CAUSE: RO membrane(s) fouled.
* SOLUTION: Membrane(s) should be cleaned. CONSULT FACTORY.
2) Product flow higher than normal and pressure normal with water temperature at
approximately 78 deg F
* CAUSE: Membrane(s) damaged.
* SOLUTION: Repair or replace. The membrane life is approximately three to five years depending on service
duty.
3) Storage pump will not start.

* CAUSE: a) Control panel circuit breaker has tripped.
b) Motor overload has tripped.
c) Float switch is stuck or defective.
d) Motor has become defective.
e) High-level float switch is stuck or defective.
* SOLUTION: a) Reset circuit breaker.

b) Reset motor overload.
c) Repair or replace.
d) Repair or replace.
e) Repair or replace.
5) Delivery pump will not start.

* CAUSE: a) Control panel circuit breaker has tripped.
b) Motor overload has tripped.
c) Motor has become defective.
d) Pressure switch is not working.
e) Low water level in holding tank.
f) Low-water switch is defective.
* SOLUTION: a) Reset circuit breaker.

b) Reset motor overload.
c) Repair or replace.
e) Repair or replace.
6) No delivery pressure.
* CAUSE: a) See step number 5.
b) Insufficient amount of water in storage tank.
c) Delivery pump is damaged.
d) Pump is running in the wrong direction.
* SOLUTION: a) See step number 5.

b) Allow time for tank to fill.
c) Repair or replace pump.
d) Change motor rotation if required, at time
of installation only.
7) No storage pressure.
* CAUSE: a) Low incoming water pressure.
b) Float switch is defective.
c) Lost power to pump.
d) Pump is running in the wrong direction.
e) Motor has become defective.
f) System water leaks.
* SOLUTION: a) Incoming water pressure should be between 40 and 100 PSI.

b) Repair or replace.
c) Replace fuse or reset overload.
d) Change motor rotation if required at time of installation only.
f) Repair or replace.
g) Repair or replace failed plumbing.
8) Storage pump short cycles on and off.

* CAUSE: a) Sediment filter dirty.
b) Insufficient water flow/pressure.
* SOLUTION: a) Replace.
b) Check incoming water supply (40-100 PSI required).
DLA9, DLA12, DLA16, DLA26
Operating instructions Combination contactor - motor circuit-breaker
FPTC 407714 P0001-07/97
ABB Control Inc. 23

AC 1000.6 – 7/98
15 lb.in.
9 lb.in.
9 lb.in.
Warning ! The operation, installation and servicing of this appliance must be carried out by a qualified electrician applying the relevant rules of the art, installation standards and safety regulations. Before operating
the contactors, check that control voltage complies with the data on the coil mounting bracket. Connection to other control voltage can destroy the coil. Do not touch live parts. Danger !.
24 ABB Control Inc.

AC 1000.6 – 7/98
®
5CP Plunger Pump

Models 5CP2120W
5CP2140WCS
5CP2150W
SPECIFICATIONS U.S. Measure Metric Measure
MODEL 5CP2120W
Flow ...............................................................4.0 GPM (15 L/M)
Pressure Range......................................100-2500 PSI (7-175 BAR)
RPM ..............................................................950 RPM (950 RPM)
FEATURES Bore....................................................................0.787" (20 mm)
Stroke .................................................................0.709" (18 mm)
Superior Design Weight ...........................................................19.14 lbs. (8.7 kg)
● Triplex plunger design gives smoother liquid flow. MODEL 5CP2140WCS
● Hi-Pressure Seals are completely lubricated and cooled by Flow ...............................................................4.0 GPM (15 L/M)
the liquids being pumped. Pressure Range......................................100-2500 PSI (7-175 BAR)
● Inlet and discharge valve assemblies interchange for easier RPM ............................................................1725 RPM (1725 RPM)
maintenance. Bore....................................................................0.787" (20 mm)
● Lubricated Lo-Pressure Seals provides double protection against Stroke .................................................................0.394" (10 mm)
external leakage. Weight ...........................................................19.14 lbs. (8.7 kg)
● Oil bath crankcase assures optimum lubrication. MODEL 5CP2150W
● Close tolerance concentricity of the ceramic plunger maximizes Flow ...............................................................5.0 GPM (19 L/M)
seal life. Pressure Range.......................................100-2000 PSI (7-140 BAR)
RPM ............................................................1725 RPM (1725 RPM)
Quality Materials Bore....................................................................0.787" (20 mm)
● Precision design 304 stainless steel valves and seats are hardened Stroke .................................................................0.472" (12 mm)
and polished for ultimate seating and extended valve life. Weight ...........................................................19.14 lbs. (8.7 kg)
● Forged brass manifolds for strength and corrosion resistance.
● Special blend W770 manifold offers washout and freeze protection COMMON SPECIFICATIONS
Inlet Pressure Range (950 RPM) .............– 5 to 60 PSI (– 0.35 to 4 BAR)
for car wash applications.
Inlet Pressure Range (1725 RPM) ...Flooded to 60 PSI (Flooded to 4 BAR)
● Special concentric, high-density, polished, solid ceramic plungers
Crankcase Capacity ............................................17 oz. (0.51 L)
provide a true wear surface and extended seal life. Max. Liquid Temperature ....................................160°F (71°C)
● Specially formulated, CAT PUMP exclusive, Hi-Pressure Seals offer Above 130°F call CAT PUMPS for inlet conditions and elastomer recommendations.
unmatched performance and seal life. Inlet Ports (2)................................................1/2" NPTF (1/2" NPTF)
● Die cast aluminum crankcase provides high strength, minimum Discharge Ports (2) ......................................3/8" NPTF (3/8" NPTF)
weight and precision tolerance control. Shaft Diameter....................................................0.787" (20 mm)
● Chrome-moly crankshaft gives unmatched strength and surface Dimensions ....................................10.35 x 10.0 x 5.78" (263 x 254 x 147 mm)
hardness.
● Oversized crankshaft bearings with greater loading capacity mean ELECTRIC HORSEPOWER REQUIREMENTS
longer bearing life. MODEL FLOW PRESSURE MOTOR PULLEY SIZE
Easy Maintenance PSI PSI PSI PSI Using 1725 RPM Motor
● Convenient “press-in” style seal case for ease in servicing. 1200 1500 2000 2500 & 8" Std. Pump Pulley
● Wet-end is easily serviced without entering crankcase, requiring less U.S. BAR BAR BAR BAR RPM Pulley
time and effort. GPM L/M 85 105 140 175 O.D.
● Valve assemblies are accessible without disturbing piping, for quick 2120W 4.0 15 3.3 4.1 5.5 6.9 950 4.3
service. Alternate 5.0 19 4.1 5.1 6.9 N/A 1188 5.5
● Preset packings mean no packing gland adjustment is necessary, 2140WCS 4.0 15 3.3 4.1 5.5 6.9 1725 Direct
reducing maintenance costs. 2150W 5.0 19 4.1 5.1 6.9 N/A 1725 Direct
DETERMINING Rated G.P. M. = “Desired” G.P. M.
THE PUMP R.P.M. Rated R.P. M. “Desired” R.P. M.
DETERMINING GPM x PSI = Electric Brake
WARNING THE REQUIRED H.P. 1460 H. P. Required
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 DETERMINING Motor Pulley O.D. = Pump Pulley O.D.
install such relief devices could result in personal injury or damage to the pump or to MOTOR PULLEY SIZE Pump R.P.M. Motor R.P.M.
system components. CAT PUMPS does not assume any liability or responsibility for the
See complete Drive Packages [Inclds: Pulleys, Belts, Hubs, Key] Tech Bulletin 003.
operation of a customer’s high pressure system.
Refer to pump Service Manual for repair procedure, additional technical information and pump warranty.
“Customer confidence is our greatest asset”

PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
5CP2120W MATL 5CP2140WCS MATL 5CP2150W MATL
2 30057 STL 30057 STL 30057 STL Key (M6x6x25) 1
5 96031 STZP 96031 STZP 96031 STZP Screw, Sems HHC (M8x16) 8
126542 STCP R 126542 STCP R 126542 STCP R Screw, Sems HHC (M8x16) 8
8 46910 AL 46910 AL 46910 AL Cover, Bearing 2/1
10 14028 NBR 14028 NBR 14028 NBR O-Ring, Bearing Cover - 70D 2
11 43222 NBR 43222 NBR 43222 NBR Seal, Oil, Crankshaft 2
15 14480 STL 14480 STL 14480 STL Bearing, Ball 2
20 48742 TNM 48742 TNM 48742 TNM Rod, Connecting Assy [10/01] 3
25 46928 FCM — — 46982 FCM Crankshaft, Dual End 1
— — 48203 FCM — — Crankshaft, Single End 1
30 — — 48224 AL — — Cover, Bearing Blind 1
32 46798 — 46798 — 46798 — Cap, Oil Filler, Domed 1
33 14179 NBR 14179 NBR 14179 NBR O-Ring, Oil Filler Cap - 70D 1
37 92241 — 92241 — 92241 — Gauge, Oil, Bubble w/Gasket - 80D 1
38 44428 NBR 44428 NBR 44428 NBR Gasket, Flat, Oil Gauge - 80D 1
40 92519 STZP 92519 STZP 92519 STZP Screw, Sems HHC (M6x16) 4
125824 STCP R 125824 STCP R 125824 STCP R Screw, Sems HHC (M6x16) 4
48 25625 STCP 25625 STCP 25625 STCP Plug, Drain (1/4"x19BSP) 1
49 23170 NBR 23170 NBR 23170 NBR O-Ring, Drain Plug - 70D 1
50 46940 AL 46940 AL 46940 AL Cover, Rear 1
51 14044 NBR 14044 NBR 14044 NBR O-Ring, Rear Cover 1
53 48617 AL 48617 AL 48617 AL Crankcase 1
64 46746 CM 46746 CM 46746 CM Pin, Crosshead 3
65 48458 BBNP 48458 BBNP 48458 BBNP Rod, Plunger 3
70 46838 NBR 46838 NBR 46838 NBR Seal, Oil, Crankcase - 70D 3
75 43328 S 43328 S 43328 S Slinger, Barrier 3
88 45697 S 45697 S 45697 S Washer, Keyhole (M18) 3
90 46841 CC 46841 CC 46841 CC Plunger (M20x50) 3
98 46730 NBR 46730 NBR 46730 NBR Washer, Seal - 90D 3
48394 FPM 48394 FPM 48394 FPM Washer, Seal - 90D 3
◆ 48432 EPDM ◆ 48432 EPDM ◆ 48432 EPDM Washer, Seal 3
99 ✝ 48201 SSL ✝ 48201 SSL ✝ 48201 SSL Retainer, Plunger w/Stud (M6) 3
100 46749 PVDF 46749 PVDF 46749 PVDF Retainer, Seal 3
106 43305 NBR 43305 NBR 43305 NBR Seal, LPS w/S-Spg 3
45153 FPM 45153 FPM 45153 FPM Seal, LPS w/SS-Spg 3
◆ 48429 EPDM ◆ 48429 EPDM ◆ 48429 EPDM Seal, LPS w/SS-Spg 3
120 46843 BB 46843 BB 46843 BB Case, Seal (Press-in-style) 3
121 13978 NBR 13978 NBR 13978 NBR O-Ring, Seal Case - 70D 3
14329 FPM 14329 FPM 14329 FPM O-Ring, Seal Case 3
◆ 48904 EPDM ◆ 48904 EPDM ◆ 48904 EPDM O-Ring, Seal Case 3
125 43307 SNG 43307 SNG 43307 SNG Seal, HPS w/S 3
44936 FPM 44936 FPM 44936 FPM Seal, HPS w/SS 3
46667 HT 46667 HT 46667 HT Seal, HPS 2-Pc w/S-Support 3
139 22179 BBCP 22179 BBCP 22179 BBCP Plug, Inlet (1/2"NPT) 1
162 48361 D 48361 D 48361 D Back-up-Ring, Seat 6
163 43358 NBR 43358 NBR 43358 NBR O-Ring, Seat - 70D 6
44938 FPM 44938 FPM 44938 FPM O-Ring, Seat - 70D 6
◆ 48908 EPDM ◆ 48908 EPDM ◆ 48908 EPDM O-Ring, Seat 6
164 43725 S 43725 S 43725 S Seat 6
166 43723 S 43723 S 43723 S Valve 6
167 43750 S 43750 S 43750 S Spring 6
168 44565 PVDF 44565 PVDF 44565 PVDF Retainer, Spring 6
172 17615 NBR 17615 NBR 17615 NBR O-Ring, Valve Plug - 75D 6
15855 FPM 15855 FPM 15855 FPM O-Ring, Valve Plug - 70D 6
◆ 48431 EPDM ◆ 48431 EPDM ◆ 48431 EPDM O-Ring, Valve Plug - 75D 6
174 43849 BBCP 43849 BBCP 43849 BBCP Plug, Valve 6
185 48245 W770 48245 W770 48245 W770 Manifold, Head - W770 1
188 87872 STZP 87872 STZP 87872 STZP Screw, HSH (M8x70) 8
126513 STCP R 126513 STCP R 126513 STCP R Screw, HSH (M8x70) 8
196 22187 BBCP 22187 BBCP 22187 BBCP Plug, Discharge (3/8"NPT) 1
250 118672 STCP 118672 STCP 118672 STCP Protector, Shaft 1
255 30243 STZP 30243 STZP 30243 STZP Mount, Direct 1
260 30611 STZP 30611 STZP 30611 STZP Assembly, Angle Rail - B 1
(Inclds: 28499, 30900, 30910, 30920) (Belt Drive Only)
30637 STZP 30637 STZP 30637 STZP Mount, Angle Assy-Retro Fit 1
265 30659 — 30659 — 30659 — Kit, Complete Mounting 1
(Inclds: 30611, 30633, 118672) (Belt Drive Only)
275 30944 STL 30944 STL 30944 STL Hub & Key Assy (M20 w/M6 Keyway) 1
[See Drive Packages, Tech Bulletin 003]
283 34334 — 34334 — 34334 — Kit, Oil Drain 1
298 34970 STZP 34970 STZP 34970 STZP Clutch, Assy, Single Groove, 20mm, 12VDC 1
34980 STZP 34980 STZP 34980 STZP Clutch, Assy, Dual Groove, 20mm, 12VDC 1
299 816650 W770 816650 W770 816650 W770 Head, Complete 1
300 33628 NBR 33628 NBR 33628 NBR Kit, Seal (Inclds: 98, 106, 121, 125) 1
31628 FPM 31628 FPM 31628 FPM Kit, Seal (Inclds: 98, 106, 121, 125) 1
◆ 31648 EPDM* ◆ 31648 EPDM* ◆ 31648 EPDM* Kit, Seal (Inclds: 98, 106, 121, 125) 1
31638 HT 31638 HT 31638 HT Kit, Seal (Inclds: 98, 106, 121, 125) 1
EXPLODED VIEW
Models
5CP2120W, 5CP2140WCS, 5CP2150W
October 2006
5CP2120W MATL 5CP2140WCS MATL 5CP2150W MATL
310 30821 NBR 30821 NBR 30821 NBR Kit, Valve (Inclds: 162,163,164,166,167,168,172) 2
31821 FPM 31821 FPM 31821 FPM Kit, Valve (Inclds: 162,163,164,166,167,168,172) 2
◆ 31162 EPDM ◆ 31162 EPDM ◆ 31162 EPDM Kit, Valve (Inclds: 162,163,164,166,167,168,172) 2
350 30696 STZP 30696 STZP 30696 STZP Plier, Reverse 1
400 7850 BB 7850 BB 7850 BB Modular Unloader (See Individual Data Sheet) 1
— — — 8026ES-8042ES — 8026ES-8042ES — BD Motors (See Individual Data Sheet) 1
— 6107 — 6107 — 6107 — Oil, Bottle (21 oz) ISO 68 Multi-viscosity Hydraulic 1
(Fill to specified crankcase capacity prior to start-up)
Bold print part numbers are unique to a particular pump model. Italics are optional items. ◆ Silicone oil/grease required. ✝ Production parts are different than repair parts.
R Components comply with RoHS Directive. [ ] Date of latest production change. W770 effective with 97 production.
*Review material codes for individual items (HT generally may be used as alternate).
See Tech Bulletins 002, 003, 024, 036, 043, 053, 060, 061, 064, 073, 074, 077, 078 and 083 for additional information.
MATERIAL CODES (Not Part of Part Number): AL=Aluminum BB=Brass BBCP=Brass/Chrome Plated BBNP=Brass/Nickel Plated CC=Ceramic CM=Chrome-moly
D=Acetal EPDM=Ethylene Propylene Diene Monamer FBB=Forged Brass FCM=Forged Chrome-moly FPM=Fluorocarbon HS=High Strength
HT=Hi-Temp (EPDM Alternative) NBR=Medium Nitrile (Buna-N) PVDF=Polyvinylidene Fluoride S=304SS SNG=Special Blend (Buna) SSL=316SS/Low Carbon STL=Steel
W770=Special Alloy STCP=Steel/Chrome Plated STZP=Steel/Zinc Plated TNM=Special High Strength
Models 5CP2120W, 5CP2140WCS, 5CP2150W
10
1
9 11
3
4
5 6 7
12 8
2
10
1 Die cast aluminum crankcase means 6 The stainless steel slinger provides 10 Stainless steel valves, seats and springs
high strength, lightweight, and excellent back-up protection for the crankcase provide corrosion-resistance, ultimate
tolerance control. seal, keeping pumped liquids out of the seating and extended life.
2 Oversized crankshaft bearings provide ex- crankcase. 11 Specially formulated, CAT PUMP exclu-
tended bearing life and pump performance. 7 Special concentric, high-density, polished, sive, Hi-Pressure Seals offer unmatched
3 Chrome-moly crankshaft provides solid ceramic plungers provide a true performance and seal life.
unmatched strength and surface hard- wear surface and extended seal life. 12 Press-in style seal case offers alignment
ness for long life. 8 Manifolds are a high tensile strength and support for seals and “no tools”
4 Matched high strength connecting rods forged W770 alloy for long term, continuous servicing.
noted for strength and superior bearing duty.
quality. 9 100% wet seal design adds to service life
5 The plunger rods with hardened surfaces by allowing pumped liquids to cool and
offer wear resistance and Zamak cross- lubricate on both sides.
heads for high load capacity.
Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580
World Headquarters CAT PUMPS (U.K.) LTD.

1 Fleet Business Park, Sandy Lane, Church Crookham
CAT PUMPS FLEET, Hampshire, GU52 8BF, England
1681 - 94th Lane N.E. Minneapolis, MN 55449 - 4324 Phone Fleet 44 1252-622031 — Fax 44 1252-626655
e-mail: [email protected]
Phone (763) 780-5440 — FAX (763) 780-2958 N.V. CAT PUMPS INTERNATIONAL S. A.
e-mail: [email protected] Heiveldekens 6A, B-2550 Kontich, Belgium
www.catpumps.com The Pumps with Nine Lives Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51
e-mail: [email protected] www.catpumps.be
International Inquiries CAT PUMPS DEUTSCHLAND GmbH
FAX (763) 785-4329 Buchwiese 2, D-65510 Idstein, Germany
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
e-mail: [email protected] e-mail: [email protected] www.catpumps.de
PN 993100 Rev D 9618

CP PLUNGER PUMP SERVICE MANUAL
3CP MODELS: 3CP1120, 3CP1130, 3CP1140

5CP MODELS: 5CP2120W, 5CP2140WCS, 5CP2150W, 5CP3120, 5CP3120G1, 5CP3130G1,
5CP5120, 5CP5150G1, 5CP6120, 5CP6120G1, 5CP6140, 5CP6150
7CP MODELS: 7CP6170
INSTALLATION AND START-UP INFORMATION
Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only
with the proper selection, installation of plumbing, and operation of the pump and accessories.
SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to
implied that all maximums can be performed simultaneously. If more than one avoid deadhead overpressure condition and severe damage to the pump or system.
maximum is considered, check with your CAT PUMPS supplier to confirm the
Install a Pulsation Dampener on the discharge head or in the discharge line as
proper performance and pump selection. Refer to individual pump Data Sheet for
close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) is
complete specifications, parts list and exploded view.
properly precharged for the system pressure (see individual Data Sheet).
LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications
A reliable Pressure Gauge should be installed near the discharge outlet of the high
(3CP-10 oz., 5CP-17 oz., 7CP-38 oz.). DO NOT RUN PUMP WITHOUT OIL IN
pressure manifold. This is extremely important for adjusting pressure regulating
CRANKCASE. Change initial fill after 50 hours running period. Thereafter, change
devices and also for proper sizing of the nozzle or restricting orifice. The pump is
oil every 3 months or 500 hour intervals. Additional lubrication may be required
rated for a maximum pressure; this is the pressure which would be read at the
with increased hours of operation and temperature.
discharge manifold of the pump, NOT AT THE GUN OR NOZZLE.
PUMP ROTATION: Pump was designed for forward rotation to allow optimum
Use PTFE thread tape or pipe thread sealant (sparingly) to connect accessories or
lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil
plumbing. Exercise caution not to wrap tape beyond the last thread to avoid
level is increased slightly above center dot to assure adequate lubrication.
tape from becoming lodged in the pump or accessories. This condition will cause a
PULLEY SELECTION: Select size of motor pulley required to deliver the desired malfunction of the pump or system.
flow from Horsepower Requirement and Pulley Selection Chart (refer to Tech
PRESSURE REGULATION: All systems require both a primary pressure regulating
Bulletin 003 or individual Data Sheet).
device (i.e., regulator, unloader) and a secondary pressure safety relief device
DRIVE SELECTION: The motor or engine driving the pump must be of adequate (i.e., pop-off valve, safety valve). The primary pressure device must be installed on
horsepower to maintain full RPM when the pump is under load. Select the electric the discharge side of the pump. The function of the primary pressure regulating
motor from the Horsepower Requirement Chart according to required pump device is to protect the pump from over pressurization, which can be caused by a
discharge flow, maximum pressure at the pump and drive losses of approximately plugged or closed off discharge line. Over pressurization can severely damage the
3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper pump, other system components and can cause bodily harm. The secondary safety
engine size. 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
MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit system if the primary regulating device fails. Failure to install such a safely device
drainage of crankcase oil. An uneven mounting surface will cause extensive will void the warranty on the pump.
damage to the pump base. To minimize piping stress, use appropriate flexible
hose to inlet and discharge ports. Use the correct belt; make sure pulleys are When the high pressure system is left running with the trigger gun off, the by-pass
aligned. Excessive belt tension may be harmful to the bearings. Hand rotate pump liquid can be routed to drain or to the pump inlet. If routed to the pump inlet, the
before starting to be certain shaft and bearings are free moving. by-pass liquid can quickly develop excessive heat and result in damage to the
pump. A THERMO VALVE installed in the by-pass line is recommended to protect
LOCATION: If the pump is used in extremely dirty or humid conditions, it is the pump. An AUTO SHUT-OFF ASSEMBLY may also be used.
recommended pump be enclosed. Do not store or operate in excessively high
temperature areas or without proper ventilation. 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
INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual 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 PUMPED LIQUIDS: Some liquids may require a flush between operations or before
130°F. Elastomer or RPM changes may be required. See Tech Bulletin 002 or call storing. For pumping liquids other than water, contact your CAT PUMPS supplier.
CAT PUMPS for recommendations.
STORING: For extended storing or between use in cold climates, drain all pumped
C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in liquids from pump and flush with antifreeze solution to prevent freezing and
applications with stressful inlet conditions such as high temperatures, booster pump damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech
feed, long inlet lines or quick closing valves. 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.

Phone (763) 780-5440 — FAX (763) 780-2958 ®
N.V. CAT PUMPS INTERNATIONAL S. A.
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
PN 33009 Rev J 7709

All Models 3CP1120, 5CP2120W, 7CP6170 5CP3120, 5CP5120, 5CP5150
Removal of Valve Plugs Valve Plug and O-Ring Valve Plug, O-Ring and Back-up Ring
CAUTION: Before commencing with service, shut off drive (electric motor, gas or diesel engine) and turn off water supply to
pump. Relieve all discharge line pressure by triggering gun or opening valve in discharge line.
After servicing is completed, turn on water supply to pump, start drive, reset pressure regulating device and secondary valve, read
system pressure on the gauge at the pump head. Check for any leaks, vibration or pressure fluctuations and resume operation.
SERVICING THE VALVES
1. Remove the hex Valve Plugs (top discharge, bottom inlet). 4. Examine all valve parts for pitting, gouges or wear and
2. Examine the O-Ring under the plug for cuts or distortion. replace with preassembled Valve Assembly. Service
Replace if worn. Lubricate new O-Rings before installing. kit contains Spring Retainers, Springs, Valves, Seats,
Back-up Rings and O-Rings.
NOTE: The 5CP3120, 5CP5120 and 5CP5150 have
both an O-Ring and Back-up Ring on the Valve Plug. NOTE: Inlet and discharge valve parts are inter-
changeable. Two Valve Kits are needed for complete
3. Grasp Spring Retainer by the tab at the top with a valve change.
pliers and remove from each valve chamber. Usually
the valve assembly will remain together while being 5. Grasp new Valve Assembly by the tab at the top with a
removed. To separate the valve assembly, insert a pliers, immerse in oil and push into each valve cham-
screw-driver into the side of the Spring Retainer and ber. Be certain valve assembly is completely seated in
press on the back side of the Valve to begin separa- valve chamber.
tion, then between the Spring Retainer and Seat to NOTE: For certain applications apply liquid gasket
separate completely. If the valve assembly separates to the o-ring crevices and seal surfaces. See Tech
during removal, remove the Spring and Valve with a Bulletin 053 for model identification.
needle nose pliers. With a reverse pliers, remove the NOTE: EPDM elastomers require Silicone-base
Seat from each valve chamber. Then, with a small lubricant.
screwdriver, carefully remove the O-Ring at the bottom
of the valve chamber. 6. Apply Loctite® 242® to the threads of each Valve Plug,
thread into valve port and torque per chart.
NOTE: The 5CP2120W, 5CP6120 and 7CP6170
have an O-Ring and Back-up Ring on each Seat.
3CP1120, 5CP2120W, 7CP6170 5CP3120, 5CP5120, 5CP5150 All Models

Removal of Valve Assembly Removal of Valve Assembly Removal of Valve Seat O-Ring
3CP1120, 5CP3120, 5CP5120 5CP2120W, 5CP6120, 7CP6170 All Models
Complete Valve Assembly Complete Valve Assembly Removal of Socket Head Screws
SERVICING THE PUMPING SECTION
Disassembly Reassembly
1. Using an allen wrench, remove the Socket Head 1. Generally Plungers do not need to be replaced. Clean
Screws from the Manifold Head. plungers and remove any foreign material with a non-
2. Rotate Crankshaft by hand to start separation of abrasive cleaner.
Manifold Head from Crankcase. 2. Install Seal Retainer over Plungers with small tab facing
3. Insert two flat head screwdrivers on opposite sides to down and holes facing forward towards manifold head.
further separate Manifold Head from Crankcase. 3. Rotate the crankshaft so the two outside plungers are
Support the underside of the Manifold Head and tap extended the same distance.
lightly with a mallet on the backside of the Manifold 4. Lightly lubricate the Plungers and carefully slide the
Head. Manifold Head onto the Plungers supporting from the
CAUTION: KEEP MANIFOLD PROPERLY ALIGNED underside. On the high pressure V-Packing models or
WITH CERAMIC PLUNGERS WHEN REMOVING TO larger manifolds, it may be necessary to gently tap
AVOID DAMAGE TO THE PLUNGERS. with a soft mallet until the Manifold Head is flush with
4. Remove the Seal Retainer from each plunger rod and the Crankcase.
examine for wear. 5. Replace Socket Head Screws and torque per chart.
5. Examine Ceramic Plunger for cracks or scoring. Refer
to SERVICING THE PLUNGERS if replacement is
needed.
3CP1120, 5CP2120W, 5CP6120 5CP3120, 5CP5120, 5CP5150, 7CP6170 All Models except 7CP6170
Seal Arrangement Seal Arrangement Plunger Arrangement
SERVICING THE PLUNGERS
Disassembly
1. To service the plungers, it is necessary to remove the 7. All other models, lubricate and install Seal Washer
manifold head. Follow disassembly procedure for onto Plunger Retainer.
SERVICING THE PUMPING SECTION. 8. On the model 7CP6170 apply Loctite® 242® to one end
2. Remove the Seal Retainer from each plunger rod. of threaded Plunger Retainer Stud and secure to
3. Using a wrench, loosen the Plunger Retainer about Plunger Retainer.
three to four turns. 9. Examine Ceramic Plungers for scoring, scale build-up,
4. Push the Ceramic Plunger back towards the chips or cracks and replace as needed. Generally the
crankcase to separate from the Plunger Retainer and ceramic plungers do not need to be replaced.
proceed with unthreading the Plunger Retainer by 10. Slide Plunger Retainer Assembly into flat end of
hand. Ceramic Plunger.
5. Remove the Plunger Retainer, Seal Washer, Ceramic 11. Apply Loctite ® 242 ® to exposed threaded end of
Plunger, Keyhole Washer and Barrier Slinger from Plunger Retainer.
each Plunger Rod. 12. Install Ceramic Plunger with Plunger Retainer onto
6. On the model 7CP6170 remove the Plunger Retainer, each Plunger Rod shoulder and thread Plunger Rod.
Stud, Gasket, O-Ring, Back-up Ring, Ceramic Plunger Torque to specifications per chart.
and Barrier Slinger from each Plunger Rod. NOTE: Ceramic Plungers can only be installed in
one direction. Counterbore end of Ceramic
Reassembly Plunger to fit over Plunger Rod shoulder.
1. Visually inspect Crankcase Oil Seals for deterioration 13. Install Seal Retainers with small tabs facing down and
or leaks and contact factory for assistance with holes facing forward towards manifold head.
replacement. 14. Proceed with servicing the seals or remounting of
2. Replace Barrier Slinger if damaged and slide onto Manifold Head as described.
Plunger Rod with concave side away from
Crankcase.
3. Examine Seal Washer for cuts or wear and replace as
needed.
4. On the model 7CP6170 examine Gaskets, O-Rings
and Back-up Rings for cuts or wear and replace as
needed.
5. Examine Plunger Retainers and Studs for wear or
damaged threads and replace as needed.
6. On the model 7CP6170 install Gaskets first, then
O-Rings and Back-up Rings onto the Plunger
Retainer.
NOTE: Lubricate O-Rings and Back-up Rings for
ease in installation and to reduce possible damage.
SERVICING THE SEALS AND V-PACKINGS
Disassembly V-Packing Models:

1. Remove the Manifold Head as described in SERVICING 1. Lubricate each seal chamber in manifold head.
THE PUMPING SECTION. NOTE: For certain applications apply liquid gasket
2. Place the Crankcase side of manifold facing up and to the O-Ring crevices and seal surfaces. See Tech
with a reverse pliers, remove the Lo-Pressure Seal Bulletin 053 for model identification.
from the Seal Case. NOTE: EPDM elastomers require silicone-base
3. Using a reverse pliers, remove the press-in style Seal lubricant.
Case from the Manifold Head. 2. Insert Male Adapter with notches down and “v” side
4. Remove the O-Ring from O.D. of Seal Case. up and press completely into each seal chamber by
Hi-Pressure Seal hand.
Models 3CP1120, 3CP1130, 3CP1140, 3. Lubricate V-Packings and install one at a time with
5CP2120W, 5CP2140WCS, 5CP2150W, grooved side down into each seal chamber.
5CP6120, 5CP6120GI 4. Examine Seal Case O-Ring and replace if worn.
The Hi-Pressure Seal is generally easily removed from Lubricate new O-Rings before installing.
the manifold without any tools. If extremely worn, a re- 5. Press Seal Case into each seal chamber until completely
verse pliers may be used. seated.
V-Packing Lo-Pressure Seal-All Models:
Models 5CP3120, 5CP3120G1, 5CP3130G1,
5CP5120, 5CP5150G1, 7CP6170 1. Examine Lo-Pressure Seals for wear to the internal
ridges, outer surfaces or for broken springs and re-
The V-Packings and Male Adapter are easily removed place as needed.
from the manifold without any tools.If extremely worn,
a reverse pliers may be used. 2. Install Lo-Pressure Seal into Seal Case with garter
spring down.
3. All Models: Install Seal Retainer over Plungers with
Reassembly small tabs facing down and holes facing forward
NOTE: If your pump has been built with special towards manifold head.
seals and O-Rings, service with same type. Refer 4. Replace Manifold Head onto pump as described under
to pump Data Sheet for correct parts or kits. SERVICING THE PUMPING SECTION and torque per
Hi-Pressure Seal Models: chart.
1. Lubricate each seal chamber in manifold head.
NOTE: For certain applications apply liquid gasket SERVICING THE CRANKCASE SECTION
to the O-Ring crevices and seal surfaces. See Tech
Bulletin 053 for model identification. 1. While Manifold Head, Plungers and Seal Retainers are
removed, examine Crankcase Oil Seals for leaking
NOTE: EPDM elastomers require silicone-base
and wear.
lubricant.
2. Check for any signs of leaking at Rear Cover, Drain
2. Carefully square Hi-Pressure Seal into position by
Plug, Bubble Gauge and Dipstick (7CP6170).
hand with the grooved side down (metal back facing
out) and press into each seal chamber until completely 3. Check oil level and for evidence of water in oil.
seated. Change crankcase oil on a regular schedule. See
Preventative Maintenance Check-List.
3. Examine Seal Case O-Rings and replace if worn.
Lubricate new O-Ring before installing. 4. Rotate Crankshaft by hand to feel for smooth bearing
movement.
4. Press the Seal Case into each seal chamber until
completely seated. 5. Examine Crankshaft Oil Seal externally for drying,
cracking or leaking.
6. Contact CAT PUMPS or your local distributor if
crankcase service is evidenced.
Loctite and 242 are registered trademarks of the Henkel Corporation.

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
Clean Filters x 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
Oil Level/Quality x 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
Water Leaks x assure 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
Initial Oil Change x
Bulletin 002 or call 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.
Valve Change x to maintain adequate inlet supply.
❏ Higher viscosity liquids require a positive head and a C. A.T. to assure adequate
Accessories x inlet supply.
❏ Higher temperature liquids tend to vaporize and require positive heads and
* If other than CAT PUMPS special cutstom-blend multi-viscosity ISO68 C. A.T. to assure adequate inlet supply.
hydraulic oil is used, change cycle should be every 300 hours. ❏ When using an inlet supply reservoir, size it to provide adequate liquid to
accommodate the maximum output of the pump, generally a minimum of 6-10
** Each system’s maintenance cycle will be exclusive. If system perfor- times the GPM (however, a combination of system factors can change this
mance decreases, check immediately. If no wear at 1500 hours, check requirement); provide adequate baffling in the tank to eliminate air bubbles and
again at 2000 hours and each 500 hours until wear is observed. Valves turbulence; install diffusers on all return lines to the tank.
typically require 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 ❏ Line size must be a minimum of one size larger than the pump inlet fitting. Avoid
conditions all effect the life of pump wear parts and service cycle. tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of
** Remember to service the regulator/unloader at each seal servicing flow restriction and cavitation.
and check all system accessories and connections before resuming ❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on SUCTION
operation. systems to avoid collapsing.
❏ The simpler the inlet plumbing the less the potential for problems. Keep the
Refer to service DVD for additional assistance. 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.

TORQUE CHART ❏ Acceleration loss of liquids may be increased by high RPM, high temperatures,
low vapor pressures or high viscosity and may require pressurized inlet
Pump Item Torque and C. A.T. to maintain adequate inlet supply. DO NOT USE C.A.T. WITH
SUCTION INLET.
Pump Model Thread Tool Size [P/N] in. lbs. ft. lbs. Nm
❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure
Plunger Retainer M6 M10 Hex [25082] 55 4.6 6.2 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).
Manifold Screw M8 M6 Allen [30941] 115 9.58 13 ❏ 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
Valve Plugs pump and measure flow.
3CP, 5CP M22 M24 Hex [44046] 870 72.5 98
INLET ACCESSORIES are offered to protect against over pressurization,
7CP M26 M27 Hex [44045] 870 72.5 98 contamination or temperature and control flow.
❏ A shut-off valve is recommended to facilitate maintenance.
Bearing Cover Screws ❏ Installation of a C. A.T. is essential in applications with stressful conditions such
3CP M6 M10 Hex./Phil. [25082] 50 4.0 5.4 as high temperatures, booster pump feed or long inlet lines. Do not use C. A.T.
5CP, 7CP M8 M13 Hex [25324] 115 9.58 13 with negative inlet pressure.
❏ A stand pipe can be used in some applications to help maintain a positive head
Rear Cover Screws M6 M10 Hex./Phil. [25082] 50 4.0 5.4 at the pump inlet line.
❏ Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
Connecting Rod Screws M7 M10 Hex [25082} 95 8.0 11 ❏ A pressure transducer is necessary to accurately read inlet pressure. Short
term, intermittent cavitation will not register on a standard gauge.
Bubble Oil Gauge M28 Oil Gauge Tool [44050] 45 3.8 5 ❏ All accessories should be sized to avoid restricting the inlet flow.
❏ All accessories should be compatible with the solution being pumped to prevent
Direct Mount Bolts M8 M13 Hex [25324] 115 9.58 13 premature failure or malfunction.
❏ Optional inlet protection can be achieved by installing a pressure cut off switch
between the inlet filter and the pump to shut off pump when there is no positive
inlet pressure.
BY-PASS TO INLET Care should be exercised when deciding the method of by-pass
TECHNICAL BULLETIN REFERENCE CHART from control valves.
No. Subject Models ❏ 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.
002 Inlet Pressure VS Liquid Temperature All Models ❏ Although not recommended, by-pass liquid may be returned to the inlet line
003 Power Unit Drive Packages 3PFR - 68PFR, 10FR - 60FR of the pump if the system is properly designed to protect your pump. When a
pulsation dampener is used, a PRESSURE REDUCING VALVE must be
024 Lubrication of Lo-Pressure Seals All Models installed on the inlet line (BETWEEN THE BY-PASS CONNECTION AND THE
036 Cylinder and Plunger Reference Chart All Models INLET TO THE PUMP) to avoid excessive pressure to the inlet of the pump. It is
also recommended that a THERMO VALVE be used in the by-pass line to moni-
043 LPS and HPS Servicing All Plunger Models tor the temperature build-up in the by-pass loop to avoid premature seal failure.
060 Baffle Assembly 34170 ❏ A reinforced, flexible, low pressure hose rated up to 300 PSI should be used for
routing by-pass back to the pump inlet.
064 By-Pass Hose Sizing All Unloaders/Regulators
❏ Caution should be exercised not to undersize the by-pass hose diameter and
074 Torque Chart Piston and Plunger Pumps length. Refer to Technical Bulletin 064 for additional information on the size and
077 Oil Drain Kit All Models (except 2SF/4SF) length of the by-pass line.
❏ Check the pressure in the by-pass line to avoid over pressurizing the inlet.
078 Field Retrofit Mounting 5CP ❏ The by-pass line should be connected to the pump inlet line at a gentle angle of
083 Winterizing a Pump All Models 45° or less and no closer than 10 times the pump inlet port diameter e.g. 1-1/2"
port size = 15" distance from pump inlet port.
HOSE FRICTION LOSS Handy Formulas to Help You
PRESSURE DROP IN PSI PER 100 FT OF HOSE
WITH TYPICAL WATER FLOW RATES Q. How can I find the RPM needed to get specific GPM
Water* Hose Inside Diameters, Inches
Flow (Gallons Per Minute) I want?
Gal/Min 1/4 5/16 3/8 1/2 5/8 3/4 1"
Rated RPM
0.5 16 5 2 A. Desired RPM = Desired GPM x
1 54 20 7 2 Rated GPM
2 180 60 25 6 2
3 380 120 50 13 4 2 Q. I have to run my pump at a certain RPM. How do I figure
4 220 90 24 7 3 the GPM I’ll get?
5 320 130 34 10 4 Rated GPM
6 220 52 16 7 1 A. Desired GPM = Desired RPM x
8 300 80 25 10 2 Rated RPM
10 450 120 38 14 3
15 900 250 80 30 7 Q. Is there a simple way to find the approximate horsepower
20 1600 400 121 50 12 I’ll need to run the pump?
25 650 200 76 19
30 250 96 24 A. Electric Brake GPM x PSI (Standard 85%
40 410 162 42 =
Horsepower Required 1460 Mech. Efficiency)
50 600 235 62
60 370 93
*At a fixed flow rate with a given size hose, the pressure drop across a given hose length
Q. What size motor pulley should I use?
will be directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100 Pump RPM (Consult
ft. hose. Above values shown are valid at all pressure levels.
A. Pump Pulley (Outer Diameter) x Engine Mfr.)
Motor/Engine RPM
Q. How do I calculate the torque for my hydraulic drive
WATER LINE PRESSURE LOSS system?
Water
PRESSURE DROP IN PSI PER 100 FEET
Steel Pipe—Nominal Dia. Brass Pipe—Nominal Dia. Copper Tubing O.D. Type L
A. Torque (ft. lbs.) = 3.6 (
GPM x PSI
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 13 2.9 1.0
400 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 28 9.0 2.2 230 50 17 6.1 3.0

8 330 86 28 6.7 1.9 220 62 21 5.2 1.6 500 120 40 15 6.5
10 520 130 43 10 3.0 320 90 30 7.8 2.4 180 56 22 10
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
60 37 17 23 11
80 52 29 40 19
100 210 107 48 61 28
RESISTANCE OF VALVES AND FITTINGS One or several of the conditions shown in the chart below may
Nominal Equivalent Length of Standard Pipe in Feet contribute to cavitation in a system resulting in premature wear,
Pipe Inside 180˚ Tee Tee system downtime and unnecessary operating costs.
Size Diameter Gate Globe Angle 45˚ 90˚ Close Thru Thru
Inches Inches Valve Valve Valve Elbow Elbow Ret Run Branch
CONDITION SOLUTION
1/2 0.622 0.41 18.5 9.3 0.78 1.67 3.71 0.93 3.33 Inadequate inlet ● Increase line size to the inlet port or one size
3/4 0.824 0.54 24.5 12.3 1.03 2.21 4.90 1.23 4.41 line size larger
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
Water hammering ● Install C.A.T. Tube
11/2 1.610 1.05 48.0 24.0 2.15 4.31 9.59 2.40 8.63
liquid acceleration/ ● Move pump closer to liquid supply
deacceleration
2 2.067 1.35 61.5 30.8 2.59 5.55 12.30 3.08 11.60
2 1/2 2.469 1.62 73.5 36.8 3.09 6.61 14.70 3.68 13.20
Rigid Inlet Plumbing ● Use flexible wire reinforced hose to absorb
3 3.068 2.01 91.5 45.8 3.84 8.23 18.20 4.57 16.40
pulsation and pressure spikes
4 4.026 2.64 120.0 60.0 5.03 10.80 23.90 6.00 21.60 Excessive Elbows in ● Keep elbows to a minimum and less than 90°
Arriving at a total line pressure loss, consideration should then be given to

Inlet Plumbing
pressure loss created by valves, fittings and elevation of lines. Excessive Liquid ●Use Thermo Valve in bypass line
If a sufficient number of valves and fittings are incorporated in the system to Temperature ●Do not exceed pump temperature specifications
materially affect the total line loss, add to the total line length, the equivalent ● Substitute closed loop with baffled holding tank
length 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
Supply Line Agitation in Supply ● Size tank according to pump output —

Bypass Line
(from regulator or unloader) Tank Minimum 6-10 times system GPM
→
T (Dia of pipe) ● Baffle tank to purge air from liquid and

Level Sensing
Device X D separate inlet from discharge
→
→
→
High Viscosity Liquids ● Verify viscosity against pump specifications

→
MIN. 4"
before operation
→
1.5 x D (Min.)
● Elevate liquid temperature enough to reduce
→
viscosity
● Lower RPM of pump
Flexible Hose Minimum
to Pump ● Pressure feed pump
Liquid Bypass Line
Level (from regulator or ● Increase inlet line size
FILTER unloader)
→
Clogged Filters ● Perform regular maintenance or use clean
filters to monitor build up

→
● Use adequate mesh size for liquid and pump

Minimum Two Baffles
MIN. 4" Sealed at Bottom 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, Hi-Pressure 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, Hi-Pressure 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.
®
7 Frame
Plunger Pump
Models 530
550
SPECIFICATIONS U.S. Measure Metric Measure
MODEL 530
Flow ...........................................................5.0 GPM (19 L/M)
Pressure Range.............................100 to 2500 PSI (7 to 175 BAR)
FEATURES RPM .......................................................1100 RPM (1100 RPM)
Bore..............................................................0.708" (18 mm)
Superior Design Stroke...........................................................0.945" (24 mm)
● Triplex plunger design gives smoother liquid flow. MODEL 550
● Hi-Pressure Seals or V-Packings are completely lubricated and Flow ...........................................................5.0 GPM (19 L/M)
cooled by the liquid being pumped. Pressure Range.............................100 to 3000 PSI (7 to 210 BAR)
● Inlet and discharge valve assemblies interchange for easier RPM .......................................................1415 RPM (1415 RPM)
maintenance. Bore..............................................................0.630" (16 mm)
● Lubricated Lo-Pressure Seals provide double protection against Stroke...........................................................0.945" (24 mm)
external leakage.
● Oil bath crankcase assures optimum lubrication. COMMON SPECIFICATIONS
● Close tolerance concentricity of the ceramic plunger maximizes Inlet Pressure Range ..................Flooded to 60 PSI (Flooded to 4 BAR)
seal life. Crankcase Capacity ......................................25 oz. (0.75 L)
Maximum Liquid Temperature .......................160°F (71°C)
Quality Materials For temperatures above 130°F call CAT PUMPS for inlet conditions and elastomer recommendations.
● Precision design 304 stainless steel valves and seats are hardened Inlet Ports (2) ..........................................1/2" NPTF (1/2" NPTF)
and polished for ultimate seating and extended valve life. Discharge Ports (2).................................3/8" NPTF (3/8" NPTF)
● Forged brass manifold is strong and corrosion resistant. Shaft Diameter ..............................................0.945" (24 mm)
● Special concentric, high-density, polished, solid ceramic plungers Weight........................................................25.5 lbs. (11.5 kg)
provide a true wear surface and extended seal life. Dimensions................................13.6 x 9.61 x 6.41" (346 x 244 x 163 mm)
● Specially formulated, CAT PUMP exclusive, Hi-Pressure Seals or
V-Packings offer unmatched performance and seal life. ELECTRIC HORSEPOWER REQUIREMENTS
● Die cast aluminum crankcase provides high strength, minimum
weight and precision tolerance control. MODEL FLOW PRESSURE MOTOR PULLEY SIZE
● Chrome-moly crankshaft gives unmatched strength and surface PSI PSI PSI PSI Using 1725 RPM Motor
hardness. 1800 2150 2500 3000 & Std. 10" Pulley O.D.
● Oversized crankshaft bearings with greater capacity mean longer U.S. BAR BAR BAR BAR RPM Pulley
bearing life. GPM L/M 125 150 175 210 O.D.
Easy Maintenance 530 5.0 19.0 6.2 7.4 8.6 N/A 1100 6.3
4.5 17.0 5.6 6.6 7.7 N/A 990 5.6
● Wet end is easily serviced without entering crankcase, requiring less 4.0 15.0 5.0 5.9 6.9 N/A 880 5.0
time and effort.
● Valve assemblies are accessible without disturbing piping, for quick 550 5.0 19.0 6.2 7.4 8.6 10.3 1415 8.0
service. 4.0 15.0 5.0 5.9 6.9 8.3 1130 6.4
● Preset packings mean no packing gland adjustment is necessary, 3.0 11.4 3.7 4.4 5.2 6.2 850 5.0
reducing maintenance costs.
DETERMINING Rated G.P. M. = “Desired” G.P. M.
THE PUMP R.P.M. Rated R.P. M. “Desired” R.P. M.
DETERMINING GPM x PSI = Electric Brake
WARNING
All systems require both a primary pressure regulating device (i.e., regulator, unloader) and THE REQUIRED H.P. 1460 H. P. Required
a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to DETERMINING Motor Pulley O.D. = Pump Pulley O.D.
install such relief devices could result in personal injury or damage to the pump or to MOTOR PULLEY SIZE Pump R.P.M. Motor R.P.M.
system components. CAT PUMPS does not assume any liability or responsibility for the
operation of a customer’s high pressure system. See complete Drive Packages [Inclds: Pulleys, Belts, Hubs, Key] Tech Bulletin 003.
Refer to pump Service Manual for repair procedure, additional technical information and pump warranty.
“Customer confidence is our greatest asset”

PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
530 MATL 550 MATL
2 30067 STL 30067 STL Key (M8x7.5x25) 1
5 92519 STZP 92519 STZP Screw, HHC Sems (M6x16) 8
8 43223 AL 43223 AL Cover, Bearing 2
9 815280 FBR 815280 FBR Shim, Bearing Cover (2-pc) 1
10 12393 NBR 12393 NBR O-Ring, Bearing Cover 2
11 43222 NBR 43222 NBR Seal, Oil 2
15 43221 STL 43221 STL Bearing, Roller 2
20 48863 TNM 48863 TNM Rod, Assy, Connecting [6/02] 3
25 43220 FCM 43220 FCM Crankshaft, Dual End 1
31 828710 — 828710 — Protector, Oil Cap w/Gasket 1
32 43211 ABS 43211 ABS Cap, Oil Filler 1
33 14177 NBR 14177 NBR O-Ring, Filler Cap - 70D 1
37 92241 — 92241 — Gauge, Oil, Bubble w/Gasket - 80D 1
38 44428 NBR 44428 NBR Gasket, Flat, Oil Gauge - 80D 1
40 92520 STZP 92520 STZP Screw, HHC Sems (M6x20) 4
48 25625 STCP 25625 STCP Plug, Drain (1/4"x19BSP) 1
49 23170 NBR 23170 NBR O-Ring, Drain Plug - 70D 1
50 43217 AL 43217 AL Cover, Rear 1
51 44836 NBR 44836 NBR O-Ring, Rear Cover - 70D 1
53 45056 AL 45056 AL Crankcase (M10) 1
56 43240 POP 43240 POP Pan, Oil 1
64 43237 CM 43237 CM Pin, Crosshead 3
65 43229 ZZCP 43229 ZZCP Rod, Plunger 3
69 43227 STZP 43227 STZP Washer, Oil Seal 3
70 43228 NBR 43228 NBR Seal, Oil, Crankcase 3
75 43328 S 43328 S Slinger, Barrier 3
88 45697 S 45697 S Washer, Keyhole (M18) 3
90 43232 CC 43311 CC Plunger (M18x77 and M16x77) 3
96 43235 PTFE 43235 PTFE Back-up-Ring, Plunger Retainer 3
97 17399 NBR 17399 NBR O-Ring, Plunger Retainer - 80D 3
14160 FPM 14160 FPM O-Ring, Plunger Retainer - 70D 3
98 45891 CU 45891 CU Gasket, Plunger Retainer 3
99 104360 S 104360 S Retainer, Plunger w/Stud 3
100 45686 PVDF 45686 PVDF Retainer, Seal, Rear 3
45687 PVDF 45687 PVDF Retainer, Seal, Adapter, Front 3
101 43239 — 43313 — Wick, Long Tab 3
106 43243 NBR 43316 NBR Seal, LPS w/S-Spg 3
44926 FPM — — Seal, LPS w/SS-Spg 3
— — 106660 FPM Seal, LPS w/S-Spg 3
120 45683 BB 45684 BB Case, Seal 3
121 20285 NBR 20285 NBR O-Ring, Seal Case - 70D 3
11693 FPM 11693 FPM O-Ring, Seal Case 3
125 43245 SNG — — Seal, HPS w/S 3
44925 FPM — — Seal, HPS w/SS 3
126 — — 43320 BB Adapter, Female 3
127 — — 43319 PTFE V-Packing 6
— — 46287 HT V-Packing 6
128 — — 43318 BB Adapter, Male 3
139 22179 BBCP 22179 BBCP Plug (1/2" NPT) 1
162 43248 PTFE 43248 PTFE Back-up-Ring, Seat 6
163 43249 NBR 43249 NBR O-Ring, Seat - 80D 6
44383 FPM 44383 FPM O-Ring, Seat - 70D 6
164 43722 S 43722 S Seat, Q.V. 6
43825 S — — Seat, F.V. 6
166 43721 S 43721 S Valve, Q.V. 6
43824 S — — Valve, F.V. 6
167 43751 S 43751 S Spring, Q.V. 6
43823 S — — Spring, F.V. 6
168 44564 PVDF 44564 PVDF Retainer, Spring 6
172 17617 NBR 17617 NBR O-Ring, Valve Plug - 90D 6
11691 FPM 11691 FPM O-Ring, Valve Plug - 90D 6
174 43851 BBCP 43851 BBCP Plug, Valve 6
185 45417 BBCP 45547 BBCP Head, Manifold (M10F) 1
187 46868 S 46868 S Stud, Manifold (M10x35) 4
194 45550 STZP 45550 STZP Nut, Flanged (M10) 4
196 43633 BB 43633 BB Plug, Discharge (3/8" NPT) 1
250 43256 STCP 43256 STCP Protector, Shaft 1
255 30243 STZP 30243 STZP Kit, Direct Mounting 1
260 30645 STZP 30645 STZP Rail, Angle, Assy A-U.S. (Inclds: 30635 [2.09"], 31129, 990777, 30910, 30920) 1
30611 STZP 30611 STZP Rail, Angle, Assy B-U.S. (Inclds: 28499 [2.95"], 30900, 30910, 30920) 1
265 30660 — 30660 — Kit, Mounting (Inclds: 30645, 30206, 33000, 30067, 43256) 1
269 30206 F 30206 F Pulley (10") [See Drive Packages, Tech Bulletin 003] 1
274 33000 STL 33000 STL Hub “H”, M24 (Keyway M8) [See Drive Packages, Tech Bulletin 003] 1
283 34334 — 34334 — Kit, Oil Drain 1
298 34628 STZP 34628 STZP Clutch Assy, Single Groove, 24mm, 12VDC 1
34630 STZP 34630 STZP Clutch Assy, Dual Groove, 24mm, 12VDC 1
34959 STZP 34959 STZP Clutch Assy, Eight Groove Poly L, 24mm, 12VDC 1
299 812183 BBCP 812184 BBCP Head, Complete 1
300 30488 NBR 30610 NBR Kit, Seal (Inclds: 97, 101, 106, 121, 125 or 127) 1
— — 31610 HT Kit, Seal, HT (Inclds: 97. 101, 106, 121, 125) 1
310 30820 NBR 30820 NBR Kit, Valve , Q.V. (Inclds: 162-164, 166, 167, 168, 172) 2
31820 NBR 31820 NBR Kit, Valve , F.V. (Inclds: 162-164, 166, 167, 168, 172) 2
350 30696 STZP 30696 STZP Plier, Reverse 1
351 43257 STZP 43257 STZP Tool, Seal Case Removal 1
352 44050 STZP 44050 STZP Tool, Oil Gauge Removal 1
— 6575 — 6575 — Plunger Pump Service DVD 1
— 6107 — 6107 — Oil, Bottle (21 oz.) ISO 68 Multi-Viscosity Hydraulic 1
(Fill to specified crankcase capacity prior to start-up)
Bold print part numbers are unique to a particular pump model. Italics are optional items. [ ] Date of latest production change.
Refer to Tech Bulletins 002, 003, 008, 024, 027, 035, 036,0 43, 045, 051, 053, 054, 067, 074, 077 and 083 for additional information.
MATERIAL CODES (Not Part of Part Number): AL=Aluminum ABS=ABS Plastic BB=Brass BBCP=Brass/Chrome Plated CC=Ceramic CM=Chrome-Moly
CU=Copper F=Cast Iron FBR=Fiber FCM=Forged Chrome-moly FPM=Fluorocarbon HT=Hi-Temp NBR=Medium Nitrile (Buna-N)
POP=Polypropylene PTFE=Pure Polytetrafluoroethylene PVDF=Polyvinylidene Fluoride S=304SS SNG=Special Blend (Buna) STCP=Steel/Chrome Plated STL=Steel
STZP=Steel/Zinc Plated TNM=Special High Strength ZZCP=Zamak/Chrome Plated
EXPLODED VIEW
Models
530, 550
May 2006
Models 530, 550
8
10
1
11 9
2
7 6 5 12 4 3
8 10
Model 530 shown
1 Die cast aluminum crankcase means 5 Special high strength plunger rods life by allowing pumped liquids to cool
high strength, lightweight, and excellent with Zamak crossheads for longevity and and lubricate on both sides.
tolerance control. corrosion resistance. 10 Stainless steel valves, seats and springs
2 Oversized crankshaft bearings provide ex- 6 The stainless steel slinger provides provide corrosion-resistance, ultimate
tended bearing life and pump performance. back-up protection for the crankcase seating and extended life.
3 Chrome-moly crankshaft provides seal, keeping pumped Liquids out of the 11 Specially formulated, CAT PUMP exclu-
unmatched strength and surface hard- crankcase. sive, Hi-Pressure Seals/V-Packings
ness for long life. 7 Special concentric, high-density, pol- offer unmatched performance and seal
4 Matched high strength connecting rods ished, solid ceramic plungers provide a life.
are for superior strength and bearing true wear surface and extended seal life. 12 Crossheads are 360° supported for
quality. 8 Manifolds are a high tensile strength uncompromising alignment.
forged brass for long term, continuous duty.
9 100% wet seal design adds to service

Phone 49 6126-9303 0 — Fax 49 6126-9303 33
PN 993112 Rev C 5608

5, 7, 15PFR PLUNGER PUMP SERVICE MANUAL
5 FRAME: 310, 340, 350, 311, 341, 351, 317, 347, 357 7 FRAME: 530, 550
5 FRAME OEM: 30, 31, 34, 35, 42HS, 43HS, 45 7 FRAME OEM: 51, 53, 55, 56, 57, 58, 59, 60, 70
15 FRAME: 650, 651, 660, 661,1050, 1051, 1057
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 DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to
implied that all maximums can be performed simultaneously. If more than one avoid deadhead overpressure condition and severe damage to the pump or system.
maximum is considered, check with your CAT PUMPS supplier to confirm the Install a Pulsation Dampening device on the discharge head or in the discharge line
proper performance and pump selection. Refer to individual pump Data Sheets for as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator)
complete specifications, parts list and exploded view. is properly precharged for the system pressure (see individual Data Sheet).
LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications A reliable Pressure Gauge should be installed near the discharge outlet of the high
[5PFR-18 oz., 7PFR-25 oz., 15PFR-42oz.]. DO NOT RUN PUMP WITHOUT OIL IN pressure manifold. This is extremely important for adjusting pressure regulating
CRANKCASE. Change initial fill after 50 hours running period. Thereafter, change devices and also for proper sizing of the nozzle or restricting orifice. The pump is
oil every 3 months or 500 hour intervals, whichever comes first. rated for a maximum pressure; this is the pressure that is read at the discharge
PUMP ROTATION: Pump was designed for forward rotation to allow optimum manifold of the pump, NOT AT THE GUN OR NOZZLE.
lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil Use PTFE thread tape or pipe thread sealant (sparingly) connect accessories or
level is increased slightly above center dot to assure adequate lubrication. plumbing. Exercise caution not to wrap tape beyond the last thread to avoid tape
PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow from becoming lodged in the pump or accessories. This condition will cause a mal-
from Horsepower Requirement and Pulley Selection Chart (refer to Tech Bulletin function of the pump or system.
003 or individual Data Sheet). PRESSURE REGULATION: All systems require both a primary pressure regulating
DRIVE SELECTION: The motor or engine driving the pump must be of adequate device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e.,
horsepower to maintain full RPM when the pump is under load. Select the electric pop-off valve, safety valve). The primary pressure device must be installed on the
motor from the Horsepower Requirement Chart according to required pump discharge side of the pump. The function of the primary pressure regulating device
discharge flow, maximum pressure at the pump and drive losses of approximately is to protect the pump from over pressurization, which can be caused by a plugged
3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper or closed off discharge line. Over pressurization can severely damage the pump,
engine size. other system components and can cause bodily harm. The secondary safety relief
MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit device must be installed between the primary device and pump. This will ensure
drainage of crankcase oil. An uneven mounting surface will cause extensive damage pressure relief of the system if the primary regulating device fails. Failure to install
to the pump base. To minimize piping stress, use appropriate flexible hose to such a safely device will void the warranty on the pump.
inlet and discharge ports. Use the correct belt; make sure pulleys are aligned. When the high pressure system is left running with the trigger gun off, the by-pass
Excessive belt tension may be harmful to the bearings. Hand rotate pump before liquid can be routed to drain or to the pump inlet. If routed to the pump inlet, the
starting to be certain shaft and bearings are free moving. by-pass liquid can quickly develop excessive heat and result in damage to the
LOCATION: If the pump is used in extremely dirty or humid conditions, it is recom- pump. A THERMO VALVE installed in the by-pass line is recommended to protect
mended pump be enclosed. Do not store or operate in excessively high temperature the pump. An AUTO SHUT-OFF ASSEMBLY may also be used.
areas or without proper ventilation. NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure
INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual regulating device to compensate. Replace nozzle and reset regulating device to
before starting system. DO NOT STARVE THE PUMP OR RUN DRY. Temperatures system pressure.
above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over PUMPED LIQUIDS: Some Liquids may require a flush between operations or
130°F. Elastomer or RPM changes may be required. See Tech Bulletin 002 or call before storing. For pumping liquids other than water, contact your CAT PUMPS
CAT PUMPS for recommendations. supplier.
C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in ap- STORING: For extended storing or between use in cold climates, drain all pumped
plications with stressful inlet conditions such as high temperatures, booster pump liquids from pump and flush with antifreeze solution to prevent freezing and
feed, long inlet lines or quick closing valves. 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.

1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet
CAT PUMPS Hampshire GU52 8BF, England
e-mail: [email protected] Heiveldekens 6A, 2550 Kontich, Belgium
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
PN 30002 Rev K 7311

Removal of Valve Plugs Examination of O-Ring and Back-up-Ring on Valve Plug Removal of Valve Assembly
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

NOTE: Usually the valve assembly will remain together 1. Examine Spring Retainers for internal wear or breaks in
while being removed. the structure and replace as needed.
1. Remove the hex Valve Plugs (top discharge, bottom inlet). 2. Examine Springs for fatigue or breaks and replace as needed.
2. Examine the O-Ring under the Valve Plug for cuts or dis- 3. Examine Valves and Seats for grooves, pitting or wear and
tortion and replace if worn. Lubricate new O-Rings before replace as needed.
installing. 4. Examine Seat and Valve Plug O-Rings for cuts or wear
NOTE: On Models 43HS, 45, 56, 57, 59, 60, 70 there is an and replace as needed. Lubricate and install new O-Ring
extended Valve Plug with O-Ring and Back-up-Ring. onto outside diameter of Seat and Valve Plugs.
Install the Back-up-Ring, then the O-Ring into the groove NOTE: Inlet and discharge valve parts are interchangeable.
at the end of the Valve Plug (refer to Tech Bulletin 058). Two Valve Kits are needed for complete valve change.
3. Grasp Spring Retainer by tab at the top with pliers and re- 5. Grasp new Valve Assembly by tab at top with pliers and
move from valve chamber. push into valve chamber. Be certain Valve Assembly is
4. To separate the valve assembly, insert a screwdriver into completely seated in valve chamber.
the side of the Retainer and press on the back side of the NOTE: For certain applications apply liquid gasket to
Valve to begin separation, then between the Retainer and the O-Ring crevices and seal surfaces (refer to Tech
Valve Seat to separate completely. Bulletin 053).
5. If the valve assembly separates during removal, remove NOTE: For Corrosion Resistant Models remember to
the Spring and Valve with a needle nose pliers. install the Coil Spring between the Valve Plug
6. Using a reverse pliers, remove the Valve Seat from the and Retainer (refer to Tech Bulletin 046).
manifold chamber. 6. Apply Loctite 242 to the threads of the Valve Plug, thread
into manifold port and torque per chart.
Y
X
Order of parts in Valve Assembly Removal of Seal Cases from Manifold Head Removal of High Pressure Seals
V-P Models
Y
X
H.P.S. Models
X
Seal and V-Packing Arrangement Installation of Male Adapter Order of Packings [MA, VP, FA]
SERVICING THE SEALS

1. Remove the Manifold Head as described in SERVICING V-Packing Models:
THE PLUNGERS section. 1. Lubricate seal chamber in the manifold.
2. Place Manifold Head on work surface with crankcase NOTE: For certain applications apply liquid gasket to
side up. the O-Ring crevices and seal surfaces (refer to Tech
3. On 5PFR and 7PFR plunger pumps prior to May of 1989, Bulletin 053).
remove Snap Ring and Lo-Pressure Seal from each Seal 2. Insert Male Adapter with notches down and “v” side up
Case. Discard Snap Rings (refer to Tech Bulletin 054). and press completely into chamber by hand.
4. On 5PFR and 7PFR plunger pumps after May of 1989, re- 3. Lubricate V-Packings and install one at a time with
move Lo-Pressure Seal from each Seal Case. grooved side down.
5. On 15PFR plunger pumps, remove Snap Ring and 4. Install Female Adapter with grooved side down.
Lo-Pressure Seal from each Seal Case.
5. Examine Seal Case O-Ring and replace if worn. Lubricate
6. Remove Seal Case from each seal chamber. Remove new O-Rings before installing.
O-Ring from outside diameter of Seal Case.
6. Thread Seal Case into manifold and tighten with special
7. Hi-Pressure Seal Models: The Hi-Pressure Seal is gener- seal case tool. Torque per chart.
ally easily removed from the manifold without any tools. If
extremely worn a reverse pliers may be used.
8. V-Packing Models: The Female Adapter, V-Packings and
Male Adapter are easily removed from manifold without
any tools. If extremely worn a reverse pliers may be used.
Separating Manifold Head from Crankcase Removal of Manifold Head from Crankcase Removal of Seal Retainers and Wicks
Ceramic Plunger and Retainer Arrangement Proper Alignment of Ceramic Plungers for reassembly
Hi-Pressure Seal Models: SERVICING THE PLUNGERS

1. Lubricate seal chamber in manifold. Disassembly
NOTE: For certain applications apply liquid gasket to 1. Using an M8 allen wrench on the 5PFR pumps, a M14 hex
the O-Ring crevices and seal surfaces (refer to Tech tool on the 7PFR pumps, or a M17 hex tool on the 15PFR
Bulletin 053). pumps, remove the two (2) Socket Head Screws, and two
2. Carefully square Hi-Pressure Seal into position by hand (2) Lockwashers or four (4) Flanged Nuts.
with the grooved side down (metal back facing out). 2. Rotate Crankshaft by hand to start separation of Manifold
NOTE: When alternate materials, the fit of the head from Crankcase.
special materials may be snug and require gently driv- 3. Insert two flat head screwdrivers on opposite sides to further
ing the LPS into position with a cylinder of the same separate Manifold Head from Crankcase or support the
diameter to assure a square seating and no damage to underside of the Manifold Head and tap lightly with a mallet
the LPS. on the backside of the Manifold Head.
3. Examine Seal Case O-Ring and replace if worn. Lubricate CAUTION: KEEP MANIFOLD PROPERLY ALIGNED
new O-Ring before installing. WITH CERAMIC PLUNGERS WHEN REMOVING TO
4. Secure Hi-Pressure Seal into position by threading Seal AVOID DAMAGE TO EITHER PLUNGERS OR SEALS.
Case into manifold. Tighten Seal Case with special seal 4. Remove Oil Pan and slide out Seal Retainer with Wick.
case tool. Torque per chart.
5. Using an M12 hex tool on the 5, 7 and 15PFR pumps, or
Lo-Pressure Seal - All Models: an M11 hex tool on the OEM 5, and 7PFR pumps, loosen
1. Examine Lo-Pressure Seals for wear or broken springs the Plunger Retainer about three to four turns.
and replace if necessary. 6. Push the Ceramic Plunger back towards the Crankcase to
2. Install Lo-Pressure Seal into each seal case with garter separate it from the Plunger Retainer and proceed with un-
spring down. threading the Plunger Retainer by hand.
3. On 5PFR and 7PFR plunger pumps do not use Snap Ring 7. Remove the Plunger Retainer, O-Ring, Back-up-Ring and
(refer to Tech Bulletin 054). Gasket. Stud may stay on Plunger Rod or come off with
Plunger Retainers.
4. On 15PFR plunger pumps install Snap Ring into each
Seal Case. 8. Remove the Ceramic Plunger, Keyhole Washer and
Barrier Slinger from Plunger Rod.
5. Install the Seal Retainer with new Wick onto each plunger
rod with tab down and wick out. Reassembly
6. Rotate Crankshaft by hand so the two outside plungers 1. Visually inspect Crankcase Oil Seals for deterioration or
are extended equally. leaks. Contact CAT PUMPS for assistance with replace-
ment. See SERVICING THE CRANKCASE section.
7. Lightly lubricate the Ceramic Plunger, then carefully slide
the Manifold Head over the Ceramic Plunger, supporting it 2. Examine Barrier Slingers and Keyhole Washers for dam-
from the underside to avoid damage to the plungers or age. Slide onto Plunger Rod with concave side away
seals. Press the Manifold Head into the Crankcase until from Crankcase.
flush. 3. Examine Ceramic Plunger for scoring, scale build-up, chips
8. Replace two (2) Lockwashers, two (2) Socket Head or cracks and replace as needed.
Screws for (4) Flange Nuts and torque per chart. 4. Slide Ceramic Plunger over each Plunger Rod.
NOTE: Ceramic Plunger can only be installed in one
direction (front to back). Do not force onto rod.
5. Examine O-Ring and Back-up-Ring on Plunger Retainer
and replace if cut or worn. Lubricate O-Rings for ease of
installation and to avoid damage to the O-Rings.
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 performance
6. Install new Gasket, then O-Ring, then Back-up-Ring onto decreases, check immediately. If no wear at 1500 hours, check again at
2000 hours and each 500 hours until wear is observed. Valves typically
each Plunger Retainer. require changing every other seal change.
NOTE: OEM models have a longer Plunger Retainer Stud. Duty cycle, temperature, quality of pumped liquid and inlet feed conditions all
effect the life of pump wear parts and service cycle.
7. Apply Loctite 242 to exposed threads of Stud and thread ** Remember to service the regulator/unloader at each seal servicing and check
Plunger Retainer onto Plunger Rod. Torque per chart. all system accessories and connections before resuming operation.
Refer to video for additional assistance.
8. Install the seal Retainer with NEW Wick onto each rod with
tab down and wick out.
NOTE: Do not lubricate wicks at initial start-up. TECHNICAL BULLETIN REFERENCE CHART
Operate for 10 to 15 minutes to allow grease from No. Subject Models
LPS to penetrate the plunger surface, then lubricate 003 Power Unit Drive Packages 3PFR - 68PFR, 10FR - 60FR
as needed.
024 Lubrication of Lo-Pressure Seals All Models
9. Rotate Crankshaft by hand so the two outside plungers 027 Spring Retainer 5PFR, 7PFR, 15PFR
are extended equally. 032 Shaft Extension and Manifold Port 310, 317, 323, 530, 550
10.Lightly lubricate the Ceramic Plungers, then carefully slide 035 Servicing Crankcase Section 7PFR - 60PFR
the Manifold Head over the Ceramic Plungers supporting it 036 Cylinder and Plunger Reference Chart All Models
from the underside to avoid damage to the Ceramic 043 LPS and HPS Servicing All Plunger Models
Plungers or Seals. On the high pressure V-Packing models 045 One-Piece S.S. Plunger Retainer w/Stud 5PFR, 7PFR, 15PFR
or larger manifolds, it may be necessary to gently tap with a 046 Valve Plug with Coil Spring 317, 347, 357, 1057
soft mallet until the manifold is flush with the crankcase. 047 Blind Bearing Shaft Cover Gearbox Plunger Pumps
11.Replace two (2) Lockwashers, two (2) Socket Head 048 Extended Valve Plug 7PFR and 15PFR
Screws or four (4) Flanged Nuts and torque per chart. 049 Stainless Steel Hardware 3PFR7, 5PFR7, 15PFR7
051 M10 Manifold and Crankcase 7PFR and OEM
052 Plunger Rod and Stud 3PFR, 5PFR, 15PFR, 35PFR, 60PFR
SERVICING THE CRANKCASE SECTION 053 Liquid Gasket All Plunger NAB-S.S. Models
054 2 Piece Seal Retainer 5PFR and 7PFR
1. While Manifold, Plungers and Seal Retainers are
058 Forged Manifold and Extended Valve Plugs 56, 57, 59, 60
removed, examine Crankcase Oil Seals for leaking and
060 Baffle Assembly 34170
wear.
061 Installation and Adjustment Procedure 8100
2. Check for any signs of leaking at Bearing Covers, Rear 062 Manifold and Seal Case 650 and 651
Cover, Drain Plug or Bubble Gauge.
064 By-Pass Hose Sizing All Unloaders/Regulators
3. Check oil level and for evidence of water in oil. 067 S.S. Plunger Retainer 3PFR, 5PFR, 7PFR
4. Rotate Crankshaft by hand to feel for smooth bearing 072 Manifold Head and V-Packing 1050, 1051, 1057
movement. 073 Hi-Temp HPS 3PFR, 5PFR, 2SF
074 Torque Chart Piston and Plunger Pumps
5. Examine Crankshaft Oil Seals externally for drying, crack-
077 Oil Drain Kit All Models (except 2SF/4SF)
ing or leaking.
083 Winterizing a Pump All Models
6. Consult CAT PUMPS or your local distributor if crankcase
service is evidenced.
See Section I of the Plunger Pump Service Video for addi-
tional information.
INLET CONDITION CHECK-LIST
TORQUE CHART Review Before Start-Up
Pump Item Torque
Inadequate inlet conditions can cause serious malfunctions in the best designed
Pump Model Thread Tool Size [P/N] in. lbs. ft. lbs. Nm 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
PLUNGER RETAINER 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
OEM Models ....................................M6 M11 Hex [44044] 55 4.4 6 carefully considered.
All Standard Models.........................M6 M12 Hex 55 4.4 6
INLET SUPPLY should exceed the maximum flow being delivered by the pump to
assure proper performance.
MANIFOLD HEAD BOLTS ❏ Open inlet shut-off valve and turn on water supply to avoid starving the pump.
DO NOT RUN PUMP DRY.
5PFR 30, 31, 34, 35....................M10 M8 Allen [25052] 220 18.1 25
❏ Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each
310, 340, 350
degree F over 130°F. Elastomer or RPM changes may be required. See Tech
311, 341, 351 Bulletin 002 or call CAT PUMPS for recommendations.
317, 347, 357 ❏ Avoid closed loop systems especially with high temperature, ultra-high pressure
or large volumes. Conditions vary with regulating/unloader valve.
5PFR 42HS, 43HS, 45................M10 M8 Allen [33046] 220 18.1 25
❏ Low vapor pressure liquids, such as solvents, require a booster pump and C. A.T.
7PFR 510, 530, 550....................M10 M14 Hex [25053] 220 18.1 25 to maintain adequate inlet supply.
❏ Higher viscosity liquids require a positive head and a C. A.T. to assure adequate
56, 57, 58, 59, 60, 70
inlet supply.
15PFR 650, 651, 660, 661............M10 M17 Hex [25083] 220 18.1 25 ❏ Higher temperature liquids tend to vaporize and require positive heads and
1050, 1051, 1057 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
VALVE PLUGS GPM (however, a combination of system factors can change this requirement);
provide adequate baffling in the tank to eliminate air bubbles and turbulence; install
5PFR 30, 31, 34, 35....................M22 M24 Hex [44046] 870 72.3 98
diffusers on all return lines to the tank.
310, 311, 317
340, 341, 347 INLET LINE SIZE should be adequate to avoid starving the pump.
350, 351, 357 ❏ Line size must be a minimum of one size larger than the pump inlet fitting. Avoid
42HS tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of
flow restriction and cavitation.
5PFR 43HS, 45...........................M25 M24 Hex [44046] 520 43.4 59 ❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on
SUCTION systems to avoid collapsing.
7PFR 530, 550 ........................3/4" SPT M27 Hex [44045] 870 72.3 98
❏ The simpler the inlet plumbing the less the potential for problems. Keep the
51, 55, 56, 57, 58 length to a minimum, the number of elbows and joints to a minimum (ideally no
59, 60, 70 elbows) and the inlet accessories to a minimum.
❏ Use pipe sealant to assure air-tight, positive sealing pipe joints.
15PFR 650, 651, 660, 661 ........3/4" SPT M27 Hex [44045] 870 72.3 98
1050, 1051, 1057 INLET PRESSURE should fall within the specifications of the pump.
❏ Acceleration loss of liquids may be increased by high RPM, high temperatures,
CRANKCASE COVER / BEARING COVER SCREWS low vapor pressures or high viscosity and may require pressurized inlet and
C. A.T. to maintain adequate inlet supply. DO NOT USE C. A.T. WITH SUCTION
5PFR 30, 31, 34, 35.....................M6 M10 Hex/Phil. [25082] 50 4.0 6 INLET.
310, 340, 350 ❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet
317, 347, 357 pressure and a C. A.T. for certain applications. With adequate inlet plumbing,
311, 341, 351 most pumps will perform with flooded suction. Maximum inlet pressure is 60 PSI
(4 BAR).
5PFR 42HS, 43HS, 45.................M6 M10 Hex/Phil. [25082] 50 4.0 6 ❏ After prolonged storage, pump should be rotated by hand and purged of air to
...........................................M8 M13 Hex [25324] 115 9.4 13 facilitate priming. Disconnect the discharge port and allow liquid to pass through
pump and measure flow.
7PFR 51, 53, 55, 56, 57,..............M6 M10 Hex [25082] 115 9.4 13
59, 60, 70 INLET ACCESSORIES are designed to protect against overpressurization,
control inlet flow, contamination or temperature and provide ease of servicing.
15PFR 650, 1050...........................M6 M10 Hex [25082] 50 4.0 5.7 ❏ A shut-off valve is recommended to facilitate maintenance.
❏ Installation of a C. A.T. is essential in applications with stressful conditions such
SEAL CASE as high temperatures, booster pump feed or long inlet lines. Do not use C. A.T.
with negative inlet pressure.
5PFR 30, 31, 34, 35 ....................N/A 1/2" Soc. Drive [33004] 354 29.5 40 ❏ A stand pipe can be used in some applications to help maintain a positive head
310, 311, 317 at the pump inlet.
340, 341, 347 ❏ Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
❏ A pressure transducer is necessary to accurately read inlet pressure. (Short
350, 351, 357
term, intermittent cavitation will not register on a standard gauge.)
42HS, 43HS, 45 ................N/A 1/2" Soc. Drive [33005] 354 29.5 40
❏ All accessories should be sized to avoid restricting the inlet flow.
7PFR 51, 53, 55, 56, ...................N/A 1/2" Soc. Drive [33005] 354 29.5 40 ❏ All accessories should be compatible with the solution being pumped to
prevent premature failure or malfunction.
57, 58, 59, 60, 70
❏ Optional inlet protection can be achieved by installing a pressure cutoff switch
530, 550
between the inlet filter and the pump to shut off pump when there is no positive
15PFR 650, 651, 660, 661 ............N/A 1/2" Soc. Drive [33006] 346 28.8 39 inlet pressure.
1050, 1051, 1057 ..............N/A 1/2" Soc. Drive [33006] 390 32.5 44
BY-PASS TO INLET Care should be exercised when deciding the method of
by-pass from control valves.
BUBBLE OIL GAUGE ❏ 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.
All Models .......................................M28 Oil Gauge Tool [44050] 45 3.6 5
❏ 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
MOUNTING BOLTS REDUCING VALVE must be installed on the inlet line (BETWEEN THE
BY-PASS CONNECTION AND THE INLET TO THE PUMP) to avoid excessive
5PFR, 7PFR ....................................M8 M13 Hex [25324] 115 9.4 13 pressure to the inlet of the pump. It is also recommended that a THERMO
15PFR ..........................................M10 M17 Hex [25083] 240 19.7 29 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 low-pressure, flexible cloth braid (not metal braid) hose should be used from
the by-pass connection to the inlet of the pump.
❏ 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.
HOSE FRICTION LOSS Handy Formulas to Help You
PRESSURE DROP IN PSI PER 100 FT OF HOSE
WITH TYPICAL WATER FLOW RATES Q. How can I find the RPM needed to get specific GPM
Water* Hose Inside Diameters, Inches
Flow (Gallons Per Minute) I want?
Gal/Min 1/4 5/16 3/8 1/2 5/8 3/4 1"
Rated RPM
0.5 16 5 2 A. Desired RPM = Desired GPM x
1 54 20 7 2 Rated GPM
2 180 60 25 6 2
3 380 120 50 13 4 2 Q. I have to run my pump at a certain RPM. How do I figure
4 220 90 24 7 3 the GPM I’ll get?
5 320 130 34 10 4 Rated GPM
6 220 52 16 7 1 A. Desired GPM = Desired RPM x
8 300 80 25 10 2 Rated RPM
10 450 120 38 14 3
15 900 250 80 30 7 Q. Is there a simple way to find the approximate horsepower
20 1600 400 121 50 12 I’ll need to run the pump?
25 650 200 76 19
30 250 96 24 A. Electric Brake GPM x PSI (Standard 85%
40 410 162 42 =
Horsepower Required 1460 Mech. Efficiency)
50 600 235 62
60 370 93
*At a fixed flow rate with a given size hose, the pressure drop across a given hose length
Q. What size motor pulley should I use?
will be directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100 Pump RPM (Consult
ft. hose. Above values shown are valid at all pressure levels.
A. Pump Pulley (Outer Diameter) x Engine Mfr.)
Motor/Engine RPM
Q. How do I calculate the torque for my hydraulic drive
WATER LINE PRESSURE LOSS system?
Water
PRESSURE DROP IN PSI PER 100 FEET
Steel Pipe—Nominal Dia. Brass Pipe—Nominal Dia. Copper Tubing O.D. Type L
A. Torque (ft. lbs.) = 3.6 (
GPM x PSI
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 13 2.9 1.0
400 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 28 9.0 2.2 230 50 17 6.1 3.0

8 330 86 28 6.7 1.9 220 62 21 5.2 1.6 500 120 40 15 6.5
10 520 130 43 10 3.0 320 90 30 7.8 2.4 180 56 22 10
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
60 37 17 23 11
80 52 29 40 19
100 210 107 48 61 28
RESISTANCE OF VALVES AND FITTINGS One or several of the conditions shown in the chart below may
Nominal Equivalent Length of Standard Pipe in Feet contribute to cavitation in a system resulting in premature wear,
Pipe Inside 180˚ Tee Tee system downtime and unnecessary operating costs.
Size Diameter Gate Globe Angle 45˚ 90˚ Close Thru Thru
Inches Inches Valve Valve Valve Elbow Elbow Ret Run Branch
CONDITION SOLUTION
1/2 0.622 0.41 18.5 9.3 0.78 1.67 3.71 0.93 3.33 Inadequate inlet ● Increase line size to the inlet port or one size
3/4 0.824 0.54 24.5 12.3 1.03 2.21 4.90 1.23 4.41 line size larger
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
Water hammering ● Install C.A.T. Tube
11/2 1.610 1.05 48.0 24.0 2.15 4.31 9.59 2.40 8.63
liquid acceleration/ ● Move pump closer to liquid supply
deacceleration
2 2.067 1.35 61.5 30.8 2.59 5.55 12.30 3.08 11.60
2 1/2 2.469 1.62 73.5 36.8 3.09 6.61 14.70 3.68 13.20
Rigid Inlet Plumbing ● Use flexible wire reinforced hose to absorb
3 3.068 2.01 91.5 45.8 3.84 8.23 18.20 4.57 16.40
pulsation and pressure spikes
4 4.026 2.64 120.0 60.0 5.03 10.80 23.90 6.00 21.60 Excessive Elbows in ● Keep elbows to a minimum and less than 90°
Arriving at a total line pressure loss, consideration should then be given to

Inlet Plumbing
pressure loss created by valves, fittings and elevation of lines. Excessive liquid ●Use Thermo Valve in bypass line
If a sufficient number of valves and fittings are incorporated in the system to Temperature ●Do not exceed pump temperature specifications
materially affect the total line loss, add to the total line length, the equivalent ● Substitute closed loop with baffled holding tank
length 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
Supply Line Agitation in Supply ● Size tank according to pump output —

Bypass Line
(from regulator or unloader) Tank Minimum 6-10 times system GPM
→
T (Dia of pipe) ● Baffle tank to purge air from liquid and

Level Sensing
Device X D separate inlet from discharge
→
→
→
High Viscosity Liquids ● Verify viscosity against pump specifications

→
MIN. 4"
before operation
→
1.5 x D (Min.)
● Elevate liquid temperature enough to reduce
→
viscosity
● Lower RPM of pump
Flexible Hose Minimum
to Pump ● Pressure feed pump
Liquid Bypass Line
Level (from regulator or ● Increase inlet line size
FILTER unloader)
→
Clogged Filters ● Perform regular maintenance or use clean
filters to monitor build up

→
● Use adequate mesh size for liquid and pump

Minimum Two Baffles
MIN. 4" Sealed at Bottom 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, Hi-Pressure 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, Hi-Pressure 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.
OWNER’S MANUAL
INSTALLATION AND OPERATING INSTRUCTIONS
REPAIR PARTS LIST
Signature 2000
High Pressure Booster Pump
60 Hz. 1/2 through 3 HP
1218 0894 NC
STA-RITE INDUSTRIES, DELAVAN, WISCONSIN 53115
© 2006, Sta-Rite Industries S327 (Rev. 1/8/07)

READ AND FOLLOW
SAFETY INSTRUCTIONS!
This is the safety alert symbol. When you see this
symbol on your pump or in this manual, look for one of
the following signal words and be alert to the potential
for personal injury:
DANGER warns about hazards that will cause serious
personal injury, death or major property damage if
ignored.
WARNING warns about hazards that can cause serious
personal injury, death or major property damage if
ignored.
CAUTION warns about hazards that will or can cause
minor personal injury or property damage if ignored.
The word NOTICE indicates special instructions which
are important but not related to hazards.
ELECTRICAL SAFETY GENERAL SAFETY

Some models of To avoid risk of serious bodily injury and property
WARNING pump are supplied damage, read safety instructions carefully before
installing pump.
with 3-connector
grounding type cord. Do not allow pump or any system component to freeze.
Connect only to properly To do so may damage system and will void warranty.
grounded, GFCI protected
outlet. Do not lift pump by Risk of electric shock. To avoid fatal
electrical cord. shocks, proceed as follows if pump needs servicing.
A. Disconnect power to pump outlet box before pul-
Pump is non- ling pump cord plug. After plug is pulled, let pump
submersible. Keep cool for 20 minutes before attempting to work on it.
motor dry at all times. Do B. Take extreme care when changing fuses. To re-
Hazardous voltage. not wash motor. Do not duced chance of fatal electrical shocks, DO NOT
Can shock, burn, or immerse. Protect motor stand in water or put your finger in the fuse socket.
cause death. from wet weather. C. Ground electrical outlet box.
Ground pump before D. Use only Ground Fault Circuit Interrupter (GFCI)
connecting to power If using extension
supply.
protected grounded outlet for cord plug.
cord, use only UL
approved indoor/outdoor, Never run pump dry. Running pump dry can damage
3-wire, grounding type cord. Do not allow any part internal parts, overheat pump (which can cause burns to
of cord or receptacle ends to sit in water or damp people handling or servicing pump), and will void
locations. warranty.
Do not pump chemicals or corrosive liquids with pump.
Unplug pump before servicing.
Hazardous Pressure.
Burn Hazard. Do not touch an oper- A. Use high pressure reinforced type discharge
ating motor. Modern motors can operate at high hose ONLY. See parts list for available hose, nozzle
temperatures. To avoid burns when servicing pump, and fittings. A high pressure relief valve is
allow it to cool for 20 minutes after shut-down before recom-mended.
handling. B. DO NOT use garden hose with High Pressure
Booster pump. Garden hose will not stand the
Follow local and/or national plumbing and electrical discharge pressure produced and will fail.
codes when installing. C. High pressure discharge stream is dangerous. To
avoid injury, DO NOT aim the discharge stream at
Hazardous Pressure. DO NOT run the any person or animal.
pump with discharge shutoff, as hose may burst or D. BE SURE that the pump suction pipe pressure
pump may be damaged due to high temperatures. plus the pump discharge pressure does not
exceed the pressure rating of hose and fittings.
See Table I for pump discharge pressure ratings.
2
INSPECT THE SHIPMENT INSTALLATION
The high pressure booster pump has been carefully The pump is designed to boost city water pressure or
inspected and packaged to assure safe delivery. water pressure from a private water system. Use this
Inspect the pump and fittings and report to the carrier high pressure stream to wash down milk parlors, barns,
any items which are damaged or missing. garages and driveways, or for fire protection.
The pump is portable with a convenient carrying handle.
If an existing pressure water system is to be used as a
TABLE I - DISCHARGE PRESSURE water supply, it can be connected with available fittings
and 3/4" or 1" high pressure hose to the pump inlet. A
Discharge Discharge
Pressure Pressure
special heavy duty 3/4" or 1" suction hose with fittings is
No. of PSI at PSI at available as an accessory. If pump is permanently
GPM HP Stages Rated Flow No Flow mounted on wall, use a 3/4" or 1" pipe or heavy-duty
7 1/2 9 90 130
hose for suction line. 20 GPM models require one-inch
discharge hose to reduce friction losses and 30 GPM
7 3/4 12 123 173
models require 1-1/4".
7 1 16 162 229
10 1/2 6 74 113
Hazardous pressure. Pump body may
10 3/4 8 97 147
explode if pressures exceed rated limits. Maximum
10 1 10 134 188 inlet pressure is 80 PSI. Maximum discharge pressure is
10 1 11 146 202 315 PSI. Warranty is void if these pressure limits are
10 1-1/2 14 173 206 exceeded.
10 2 16 197 260
20 1 7 75 110 HIGH PRESSURE BOOSTER PUMP
20 1-1/2 9 97 143 INSTALLATION INSTRUCTIONS
20 2 11 123 175 These instructions cover high pressure booster pump
20 3 15 195 250 installations as shown below:
30 1 5 59 75
From pressurized
30 1-1/2 6 71 91 house service
30 2 7 81 106
30 3 11 129 167
*For total discharge pressure, add this pressure to suction pipe Suction
pressure. For example, an HP7C pump taking suction from a 100 Discharge
psi water service line will produce 130 + 100 = 230 psi total discharge
pressure at 0 GPM flow. If suction pressure drops to 50 psi,
discharge pressure will drop to 180 psi.
NOTE: Model numbers that include an “S” (HPS7C, HPS10D, etc)
1208 0894
have a stainless steel suction, discharge assembly, and capscrews.
Model numbers ending in “3” (HP7C3, HPS10C3, etc) have 3-phase
motors. Models numbers ending in “T” have TEFC motors.
Figure 1 – Connection to house service.
Water tank
or reservoir
Suction
Discharge
1207 0894
Figure 2 – Connection to water reservoir.
3
Priming Plug Size the inlet according to the chart below:
Tee
90 Elbow
Recommended Recommended
Male Pipe to Male Hose Adapter Ave. Threaded Inlet Discharge
GPM Inlet Size Line Size Line Size
7 3/4" NPT 1" 1"
10 3/4" NPT 1" 1"
Female Hose Connection 20 1" NPT 1-1/4" 1-1/4"
30 1-1/4" NPT 1-1/2" 1-1/2"
High Pressure
15 Feet Hose
Maximum An inlet strainer will prevent suspended debris from
Male Hose clogging pump.
Connection
The internal running surfaces of the pump and seals
Water Supply require water lubrication for good, consistent operation.
Allowing pump to run dry will severely damage
pump and seals.
Gun Nozzle
Weeping Type ONLY
Install a pressure gauge in pump inlet line. Keep at
least two pounds per square inch pressure (2 PSI) in
inlet line whenever pump is operating. If this is not
Foot Valve
possible, consult customer service representative.
1210 0894
LUBRICATION
Figure 3 – Cistern or shallow well installation.
It is not necessary to lubricate pump or motor. The
motor is equipped with sealed ball bearings, lubricated
for the life of the bearing. The mechanical shaft seal in
the pump is self-lubricating and requires no adjust-
Service Line ment. Disassemble pump to replace seal (See “Main-
To Power
tenance”, Pages 8 to 9).
Gate Valve or Hose Bibb
Male Pipe to Male Hose Adapter
OPERATION
High Pressure Hose with two
NOTICE: Observe the following precautions when
Female Connections operating the pump:
1. Keep the motor dry! Do not direct stream from
pump discharge onto the motor!
2. Hazardous pressure. Do not run the
pump with discharge shutoff, as hose may burst or
Male Pipe to Male Hose Adapter pump may be damaged due to high temperatures.
(Suction)
3. Do not use a standard trigger gun with this pump.
Gun Nozzle
Use only trigger guns with an automatic weeping
Weeping Type ONLY feature. These are available as accessories and are
provided with three nozzles. The smallest nozzle
restricts the flow, allowing use of a smaller water
Male Pipe to Male Hose Adapter
(Discharge) source. The two larger nozzles are used if the water
source will supply the pump’s full capacity.
Female Hose Connection
4. Do not run pump dry; to do so may damage the
seal.
5. To avoid internal damage to pump, Do not operate
High Pressure Hose with water temperature above 175 degrees F.
1209 0894
Figure 4 – Wall mounted to pressurized

service line.
To reduce friction losses to a minimum, inlet (suction)

line should be short and have as few elbows as
possible.
4
Disconnect power before working on pump, motor, pressure switch, or wiring.
Single Phase, ODP Motor 3. Move and attach the plug at the 115 volt position.
The plug will now cover 2 metal tabs. The arrow on
MOTOR SWITCH SETTINGS the plug will point to 115V.
Dual-voltage motors (motors that can operate at either 4. Attach the power lead wires to the power lead
115 or 230 volts), are set at the factory to 230 volts. Do terminals. Make sure the wires are secure.
not change motor voltage setting if line voltage is 230 5. Attach the ground wire to the green ground screw
volts, or if you have a single voltage motor.* 6. Reinstall the Motor end cover
NOTE: Never wire a 115 volt motor to a 230 volt line. Go to Wiring Connections below.
REMOVE MOTOR END COVER DIAL TYPE VOLTAGE SELECTOR

If you have a dual-voltage motor, and will connect it to
115 volts, follow the procedure below.
Ground
Screw
End Cover Screws
Voltage Power
Change Lead
Dial Terminals
Motor
End Cover
Figure 5 – Removing Motor End Cover

Figure 7 – Voltage set to 230 volts, Dial Type
You will need to remove the motor end cover to
change the voltage setting.
To change to 115 volts:
Your motor terminal board (located under the motor
1. Make sure power is off.
end cover) should look like one of those below.
2. Turn the dial counter-clockwise until 115 shows in
the dial window.
PLUG TYPE VOLTAGE SELECTOR 3. Attach the power lead wires to the power lead
Ground terminals. Make sure the wires are secure.
Screw 4. Attach the ground wire to the green ground screw
5. Reinstall the Motor end cover
Voltage Go to Wiring Connections below.
Change
Plug
Power
Lead
Terminals
Figure 6 – Voltage set to 230 volts, Plug Type
To change to 115 volts:

1. Make sure power is off.
2. Pull the plug straight up.
*Models with power cords are pre-wired for 115 volts.
This includes models HP7D-02 and HP7C-02.
5
ELECTRICAL WIRING CONNECTIONS
Ground motor before connecting to electrical 1. Install, ground, wire and maintain this pump in
power supply. compliance with the National Electrical Code (NEC)
or the Canadian Electrical Code (CEC) and with all
Failure to ground motor can cause severe or local codes and ordinances that apply. Consult your
fatal electrical shock hazard. local building inspector for local information.
Explosion hazard. Do not ground to a gas 2. Make sure that the voltage, frequency and phase
supply line. (single phase or three phase) of the power supply
agree with that stamped on the motor nameplate. If
To avoid dangerous or fatal electrical shock, in doubt, check with the power company.
turn OFF power to motor before working on
electrical connections. 3. Some models are equipped with three phase
motors. Three phase motors require magnetic
Supply voltage must be within ±10% of starters and can run in either direction, depending
nameplate voltage. Incorrect voltage can on how they are connected to the power supply.
cause fire or serious damage to motor and voids
NOTICE: Dual voltage motors without cords are factory
warranty. If in doubt consult a licensed electrician.
wired for 230 volts. If necessary, reconnect the motor for
Use wire size specified in Wiring Chart (Table II, 115 volts, as shown. All cord connected motors are
Page 7). If possible, connect pump to a separate wired for 115 volts (See Page 5). Do not alter the wiring
branch circuit with no other appliances on it. in single voltage motors.
Wire motor according to diagram on motor Install, ground, wire, and maintain your pump in
nameplate. If nameplate diagram differs from comliance with the National Electrical Code (NEC) or
diagrams above, follow nameplate diagram. the Canadian Electrical Code (CEC), as applicable,
and with all local codes and ordinances that apply.
Consult your local building inspector for code
For All 3-phase and TEFC Motors: Follow information.
the wiring diagram on the motor junction box NOTICE: Clamp the power cable to prevent strain on
or on the motor nameplate. the terminal screws.
NOTICE: Your Motor Terminal Board (under the
motor end cover) looks like one of those shown
above. Do not change motor wiring if line voltage
is 230 volts. Connect power supply as shown for
your supply voltage.
NOTICE: Some models are equipped with three phase
motors. Three phase motors require magnetic starters
and can run in either direction, depending on how they
are connected to the power supply.
6
To Check For Proper Rotation – 3 Phase Motors Models without cord and plug:
Risk of electrical shock. 1. Connect ground wire first. Connect the ground first,
1. Be sure power is disconnected to motor when then to green grounding terminal provided under
working on electrical connections. motor canopy (see Figures 6 and 7) identified as
GRD. Make ground connection to this terminal. Do
2. Remove the motor end cover, exposing motor shaft. not connect motor to electrical power supply until
Momentarily start pump. If hookup is correct, the unit is permanently grounded; otherwise serious or
shaft will rotate clockwise. fatal electrical shock hazard may be caused.
3. If rotation is not clockwise, reverse any two leads to 2. For best ground connection, connect to a grounded
the starter. The rotation will now be correct. lead in the service panel or to a metal underground
GROUNDING THE MOTOR water pipe or well casing at least 10 ft. long. If
plastic pipe or insulated fittings are used, run ground
Ground the pump permanently using a wire of size and wire directly to the metal well casing or use ground
type specified by local or National Electrical Code. electrode furnished by the power company.
Models (HP7C and HP7D Series Only) with factory
installed cord and plug:
Risk of electric shock. This equipment is
only for use on 115V and is equipped with an approved
3-conductor cord and 3-prong, grounding-type plug. To
reduce the risk of electric shock, be certain that it is
connected to a properly grounded, grounding-type
receptacle. Do not modify or remove plug. Make sure
pump circuit meets National Electrical Code. To avoid
dangerous electrical shock hazard, keep cord dry at all
times.
TABLE II - RECOMMENDED FUSING AND WIRING

Branch
Max. Fuse Wire Length
Motor Motor Volts/ Load Rating 0’-100’ 101-200’ 201-300’
Type H.P. Phase Amps Amps AWG Wire Size
ODP 1/2 115/230/1 12.4/ 6.2 20/15 12/14 10/14 8/14
ODP 1/2 230/460/3 3.1/1.55 15/15 14/14 14/14 14/14
ODP 3/4 115/230/1 14.8/7.4 20/15 12/14 8/14 6/14
ODP 3/4 230/460/3 3.6/1.8 15/15 14/14 14/14 14/14
ODP 1 115/230/1 19.2/9.6 25/15 10/14 8/14 6/12
ODP 1 230/460/3 4.7/2.35 15/15 14/14 14/14 14/14
ODP 1-1/2 115/230/1 24/12 30/15 10/14 6/12 6/12
ODP 1-1/2 230/1 12.0 15 14 14 12
ODP 1-1/2 230/460/3 6.8/3.4 15/15 14/14 14/14 14/14
ODP 2 115/230/1 26/13 35/20 8/12 6/12 4/10
ODP 2 230/1 10.4 15 14 14 14
ODP 2 230/460/3 6.0/3.0 15/15 14/14 14/14 14/14
ODP 3 208-230/1 15.0 20 12 12 10
ODP 3 200-230/460/3 11.5/5.8 15/15 14/14 14/14 12/14
TEFC 1 115/230/1 18/9 25/15 10/14 8/14 8/12
TEFC 1 208-230/460/3 4.8/2.4 15/15 14/14 14/14 14/14
TEFC 1-1/2 230/1 10.4 15 14 14 12
TEFC 1-1/2 208-230/460/3 6.0/3.0 15/15 14/14 14/14 14/14
TEFC 2 230/1 11.7 15 14 10 8
TEFC 2 208-230/460/3 7.0/3.5 15/15 14/14 14/14 14/14
TEFC 3 230/1
TEFC 3 208-230/460/3 7.0/3.5 15/15 14/14 14/14 14/14
7
MAINTENANCE screwdriver by the handle and short capacitor term-
Pump Disassembly inals together. Do not touch metal screwdriver blade
or capacitor terminals.
Hazardous voltage. Can shock, burn or 3. Unscrew the overload and move it aside. Do not
cause death. Disconnect power to pump before disconnect wires. Slide 7/16" open end wrench in
servicing. behind spring loaded centrifugal switch as shown.
Tools required: Place on motor shaft flats to hold shaft stationary.
1. 7/16" open end wrench (2 required). 4. With one 7/16" wrench in place on motor shaft,
2. Flat blade screwdriver with insulated handle. place second wrench on shaft hex at pump end and
3. Work bench with vise recommended. unscrew impeller stack by turning counter-clockwise.
4. Pliers or similar tool. 5. Once loose from motor shaft, hold shaft by snap ring
5. Pipe wrench. using a pliers or similar tool, and pull stack from
Impeller Stack Changeout (See Figure 8) shell. You may have to apply a back and forth
motion to break stack loose from shell.
Remove pump from service and mount vertically in
vise (if available) motor side down. Hold at center of To assemble with replacement impeller stack, keep
motor. It may be desirable to wrap motor with a shop pump in the vertical position, motor down, and reverse
rag to protect outside surface. instructions 1 through 5.
Proceed as follows: Assembly hints:
A. Apply a soapy water solution to suction and
1. Attach pipe wrench to flats on discharge connection
dischage O-Rings to ease seating of shell.
and turn clockwise to remove (left hand threads).
B. Make sure mechanical shaft seal spring is in
2. Remove screws holding motor canopy and remove
proper position on motor shaft.
canopy. Pull straight off as shown. Leave switch
wires attached (if present). C. On three-phase models, apply Loctite No. 271 to
motor shaft threads before reinstalling stack.
Capacitor voltage may be hazard-
ous. To discharge capacitor, hold insulated handle
Remove with
clockwise
Discharge rotation.
1 Connection
Remove with
4 Counter-clockwise
rotation.
Torque discharge Snap
connection to 80 - 100 ft-lbs Ring 5
at reassembly
Impeller
Stack
7/16" Open 3
End Wrench
Overload screw
(remove)
Overload Protector
7 / 16
(Moved for access)
Capacitor
Centrifugal
Switch
View A-A
See View A-A
Motor end view with
canopy removed
3 Disconnect from
power source.
A
1211 0605
2 Motor Canopy
Figure 8 – Impeller stack changeout.
8
Mechanical Seal Changeout polished face of seat and press into seal cavity
(refer to Figures 8 and 9) using a 3/4" socket or a piece of 3/4" standard
This procedure is best completed with the pump held in pipe.
a vertical position, motor down. D. Be sure polished surface of seat is free of dirt
First complete “Disassembly” instructions 1 through 5 and has not been damaged by insertion. Re-
under “Impeller Stack Changeout.” (see Figure 8). move excess soapy water. Dispose of card-
6. Remove 4 capscrews holding pump body to motor. board washer.
Pump handle will come off with top capscrews. 12. Installation of rotating half and spring:
7. Unscrew pump shell from pump body, turning A. Reinstall pump body on motor using extreme
clockwise (left hand threads). caution not to hit ceramic portion of seal on
8. Remove mechanical shaft seal spring and rotating motor shaft. Reattach pump body to motor using
half from motor shaft. Use care not to scratch motor capscrews. Be sure to reinstall pump handle at
shaft when removing rotating half. this time.
9. Remove pump body from motor and place on flat B. Inspect shaft to make sure that it is clean.
surface, face down. Again, use care not to scratch C. Clean face of rotating half of seal with a clean
motor shaft. cloth.
10. Use a screwdriver to push ceramic seat out from D. Lubricate inside diameter of rotating half with
seal cavity as shown. soapy water and slide onto motor shaft (sealing
11. Installation of ceramic seat: face first).
A. Turn pump body over so seal cavity is up; clean E. Place spring over motor shaft so it rests on
cavity thoroughly. rotating half.
B. Clean polished surface of ceramic seat with a 13. To complete reassembly from this point, reverse
clean cloth. instructions 1 through 5 under “Impeller Stack
Changeout.”
C. Lubricate outside rubber surface of seat with
soapy water. Place cardboard washer over NOTICE: Lubricate suction and discharge O-Rings
with soapy water for easier installation of shell.
7 Remove shell;
turn clockwise.
10
Push ceramic
seat out of
pump body
8
Rotating Half
of Mechanical Rotating
Seal Half
9 12
Remove
Pump Body
11
3/4" pipe or
3/4" socket Cardboard
with extender washer (supplied
w/seal)
Polished
Face
6
Ceramic Seat Torque bolts to

15 - 27 Ft-lbs
during
reassembly. 1212 0605
Figure 9 – Mechanical seal changeout.

9
1
2
3
4
5
6
10 7
THE FOLLOWING ACCESSORIES
MAY BE ORDERED FOR HIGH
PRESSURE BOOSTER PUMPS
Hose 6’-3/4" w/Female Ends
(150 PSI Rating) PKG 83
7A
Hose 25’-3/4" w/Male & Female Ends
Adapter 3/4" NPT x 3/4" Hose PKG 85
Nozzle - High Pressure PKG 86
Suction Vacuum Relief Valve PKG 96
8
1206 0605 NCBSW/NB
5
9
Figure 9 – Exploded view.
REPAIR PARTS LIST

HP7E-02
HP7C-02 HP7D-02 HP7E3-02
HP7C3-02 HP7D3-02 HP10E-02 SHP10G3-02
HP10C-02 HP10D-02 HP10E3-02 HP10F-02 HP10G-02
Key HP10C3-02 HP10D3-02 HP10E311-02 HP10F3-02 HP10G3-02
No. Description Qty. 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP
1 Motor - 115/230 Volt, 1 Phase 1 J218-590PKG J218-596PKG J218-601PKG J218-883APKG J218-628APKG
1 Motor - 230/460 Volt, 3 Phase 1 AP100CH AP100DL2 AP100EH AP100FH AP100GH
2 Handle (†) 1 C54-21 C54-21 C54-21 – –
3 Water Slinger 1 17351-0009 17351-0009 17351-0009 17351-0009 17351-0009
4 Pump Body 1 C2-85 C2-85 C2-85 C2-85 C2-85
5 O-Ring 2 U9-430 U9-430 U9-430 U9-430 U9-430
6 Shaft Seal Assembly 1 U109-118 U109-118 U109-118 U109-118 U109-118
7 Pump Stack (7 GPM Pump) 1 P325-422 P325-423 P325-424 – –
7 Pump Stack (10 GPM Pump)†† 1 P325-425 P325-426 P325-439 P325-428 P325-429
7A Nylatron Bearing
(included with Key No. 9) 1 W31112 W31112 W31112 W31112 W31112
8 Pump Shell (7 GPM Pump) 1 P56-430SSL P56-431SSL P56-432SSL – –
8 Pump Shell (10 GPM Pump)††† 1 P56-460SSL P56-461SSL P56-469SSL P56-452SSL P56-432SSL
9 Discharge Assembly 1 C152-3 C152-3 C152-3 C152-3 C152-4
10 Capscrew - 3/8 x 16 x 1-1/2" 4 U30-982ZP U30-982ZP U30-982ZP U30-982ZP U30-982ZP
# Cord Connector** 1 U71-7 U71-7 – – –
# Cord** 1 U17-402 U17-1238 – – –
# Not Illustrated.
** Included with Model Numbers HP7C-01 and the HP7D Series Model Numbers.
† Handle comes with HP7 series and HP10E series.
†† Model HP10E311-02 uses Part Number P325-362.
††† Model HP10E311-02 uses Part Number P56-404SSL.
10
1
2
3
4
5
9 6
Hose 6’-3/4" w/Female Ends 6A
7
1206 0605 NHW/NB
4
8
REPAIR PARTS LIST

HPS7C-01 HPS7D-01 HPS7E-01
HPS7C3-01 HPS7D3-01 HPS7E3-01
HPS10C-01 HPS10D-01 HPS10E-01 HPS10F-01 HPS10G-01
Key HPS10C3-01 HPS10D3-01 HPS10E3-01 HPS10F3-01 HPS10G3-01
No. Description Qty. 1/2 HP 3/4 HP 1HP 1-1/2 HP 2 HP
1 Motor - 115/230 Volt, 1 Phase 1 J218-590PKG J218-596PKG J218-601PKG J218-883APKG J218-628APKG

1 Motor - 230/460, 3 Phase 1 AP100CH AP100DL2 AP100EH AP100FH AP100GH
2 Water Slinger 1 17351-0009 17351-0009 17351-0009 17351-0009 17351-0009
3 Pump Body 1 C2-86SS C2-86SS C2-86SS C2-86SS C2-86SS
4 O-Ring 2 U9-430 U9-430 U9-430 U9-430 U9-430
5 Shaft Seal Assembly 1 U109-118 U109-118 U109-118 U109-118 U109-118
6 Pump Stack (7 GPM) 1 P325-422R P325-423R P325-424R – –
6 Pump Stack (10 GPM) 1 P325-425R P325-426R P325-439R P325-428R P325-429R
6A Nylatron Bearing
(included with Key No. 9) 1 W31112 W31112 W31112 W31112 W31112
7 Pump Shell (7GPM) 1 P56-430SSL P56-431SSL P56-432SSL – –
7 Pump Shell (10GPM) 1 P56-460SSL P56-461SSL P56-469SSL P56-452SSL P56-432SSL
8 Discharge Assembly 1 C152-4 C152-4 C152-4 C152-4 C152-4
9 Capscrew
3/8 x 16 x 1-1/2", S.S. 4 S25983 S25983 S25983 S25983 S25983
11
1
2
3
4
5
6
10 7
Hose 6’-3/4" w/Female Ends
7A
Suction Vacuum Relief Valve PKG 96 8
1206 0605 NCBSW/NB
5
9
REPAIR PARTS LIST

HP20H-01
HP20H3-01
HP20E-02 HP20F-02 HP20G-02 HP20HT-02
Key HP20E3-02 HP20F3-02 HP20G3-02 HP20H3T-02
No. Description Qty. 1 HP 1-1/2 HP 2 HP 3 HP
1 Motor - 115/230 Volt, 1 Phase 1 J218-601PKG J218-883APKG J218-628APKG –
1 Motor - 230 Volt, 1 Phase 1 – – A100GSL AE100HLL
1 Motor - 230/460 Volt, 3 Phase 1 AP100EH AP100FH AP100GH AP100HL
1 Motor - 230 Volt, 1 Phase,
TEFC 1 – – – J218-1035
1 Motor - 208-230/460 Volt,
3 Phase, TEFC 1 – – – J218-1036
2 Handle 1 C54-21 C54-21 C54-21 C54-21
3 Water Slinger 1 17351-0009 17351-0009 17351-0009 17351-0009
4 Pump Body 1 C2-85A C2-85A C2-85A C2-85A
5 O-Ring 2 U9-430 U9-430 U9-430 U9-430
6 Shaft Seal Assembly 1 U109-118 U109-118 U109-118 U109-118
7 Pump Stack 1 P325-602R P325-431R P325-432R P325-718R
7A Nylatron Bearing
(included with Key No. 9) 1 W31112 W31112 W31112 W31112
8 Pump Shell 1 P56-433SSL P56-434SSL P56-452SSL P56-620SSL
9 Discharge Assembly 1 C152-3A C152-3A C152-3A C152-3A
10 Capscrew - 3/8 x 16 x 1-1/2" 4 U30-982ZP U30-982ZP U30-982ZP U30-982ZP
12
1
2
3
4
5
9 6
7
1206 0605 NHW/NB
4
8
REPAIR PARTS LIST

HPS20H-01
HPS20H3-0
HPS20E-01 HPS20F-01 HPS20G-01 HPS20HT-01
Key HPS20E3-01 HPS20F3-01 HPS20G3-01 HPS20H3T-01
No. Description Qty. 1HP 1-1/2 HP 2 HP 3 HP
1 Motor - 230/460 Volt, 3 Phase 1 AP100EL2 AP100FH AP100GH AP100HL
TEFC 1 – – – J218-1035
1 Motor - 208-230/460 Volt,
3 Phase, TEFC 1 – – – J218-1036
2 Water Slinger 1 17351-0009 17351-0009 17351-0009 17351-0009
3 Pump Body 1 C2-86SSA C2-86SSA C2-86SSA C2-86SSA
4 O-Ring 2 U9-430 U9-430 U9-430 U9-430
6A Nylatron Bearing
8 Discharge Assembly 1 C152-4A C152-4A C152-4A C152-4A
9 Capscrew 3/8 x 16 x 1-1/2" 4 S25983 S25983 S25983 S25983
13
1
2
3
4
5
6
10 7

Nozzle - High Pressure PKG 86 8
1206 0605 NCBSW/NB
5
9
REPAIR PARTS LIST

HP30E-02 HP30F-02 HP30G-02 HP30H-02
HP30E3-02 HP30F3-02 HP30G3-02 HP30H3-02
HP30ET-02 HP30FT-02 HP30GT-02 HP30HT-02
Key HP30E3T-02 HP30F3T-02 HP30G3T-02 HP30H3T-02
No. Description Qty. 1 HP 1-1/2 HP 2 HP 3 HP
1 Motor - 230/460 Volt, 3 Phase 1 AP100EH AP100FH AP100GH AP100HL
TEFC 1 A100FL-T AE100GL-T AE100G5L-T J218-1035
1 Motor - 208-230/460 Volt,
3 Phase, TEFC 1 AP100FL-T AP100GL-T AP100G5L-T J218-1036
2 Handle 1 C54-21 C54-21 C54-21 C54-21
3 Water Slinger 1 17351-0009 17351-0009 17351-0009 17351-0009
4 Pump Body 1 C2-85B C2-85B C2-85B C2-85B
5 O-Ring 2 U9-430 U9-430 U9-430 U9-430
7 Pump Stack 1 P325-719R P325-720R P325-721R P325-722
7A Nylatron Bearing
9 Discharge Assembly 1 C152-3B C152-3B C152-3B C152-3B
10 Capscrew - 3/8 x 16 x 1-1/2" 4 U30-982ZP U30-982ZP U30-982ZP U30-982ZP
14
1
2
3
4
5
9 6
7
1206 0605 NHW/NB
4
8
REPAIR PARTS LIST

HPS30E-01 HPS30F-01 HPS30G-01 HPS30H-01
HPS30E3-0 HPS30F3-01 HPS30G3-01 HPS30H3-01
HPS30ET-01 HPS30FT-01 HPS30GT-01 HPS30HT-01
Key HPS30E3T-01 HPS30F3T-01 HPS30G3T-01 HPS30H3T-01
No. Description Qty. 1HP 1-1/2 HP 2 HP 3 HP
1 Motor - 230/460 Volt, 3 Phase 1 AP100EH AP100FH AP100GH AP100H
TEFC 1 A100FL-T AE100GL-T AE100G5L-T J218-1035
1 Motor - 208230/460 Volt,
3 Phase, TEFC 1 AP100FL-T AP100GL-T AP100G5L-T J218-1036
2 Water Slinger 1 17351-0009 17351-0009 17351-0009 17351-0009
3 Pump Body 1 C2-86SSB C2-86SSB C2-86SSB C2-86SSB
4 O-Ring 2 U9-430 U9-430 U9-430 U9-430
6A Nylatron Bearing
8 Discharge Assembly 1 C152-4B C152-4B C152-4B C152-4B
9 Capscrew 3/8 x 16 x 1-1/2" 4 S25983 S25983 S25983 S25983
15
LIMITED WARRANTY
Sta-Rite Industries, warrants to the original consumer of the products listed below, that they will be free from defects in material and
workmanship for the Warranty Period from the date of original installation or manufacture as noted.
Product Warranty Period
Water Systems Products – jet pumps, whichever occurs first:

small centrifugal pumps, submersible pumps 1 year from date of original installation, or
and related accessories 2 years from date of manufacture
Hydro-Flow Filters 1 year from date of purchase
Signature 2000® Fibrewound Tanks 5 years from date of original installation
Pro-SourceTM Steel Pressure Tanks 5 years from date of original installation
Pro-SourceTM Epoxy-Lined Tanks 3 years from date of original installation
Sump/Sewage/Effluent Products 1 year from date of original installation, or

2 years from date of manufacture
Our warranty will not apply to any product that has been subject to negligence, misapplication, improper installation or maintenance. In the
event a three phase submersible motor is operated with single phase power through a phase converter, or if three-leg ambient
compensated, extra-quick trip overload relays of recommended size are not used, our warranty is void.
Buyer’s only remedy and Sta-Rite Industries’ only duty is to repair or replace defective products (at Sta-Rite Industries’ choice). Buyer
agrees to pay all labor and shipping charges associated with this warranty and to request warranty service through the installing dealer as
soon as a problem is discovered. If warranty service is requested more than 30 days after the Warranty Period has ended, it will not be
honored.
STA-RITE INDUSTRIES SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES
WHATSOEVER.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES,
INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, SHALL NOT EXTEND BEYOND THE WARRANTY PERIOD PROVIDED HEREIN.
Certain states do not permit the exclusion or limitation of incidental or consequential damages or the placing of limitations on the duration
of an implied warranty, therefore, the limitations or exclusions herein may not apply. This warranty sets forth specific legal rights and
obligations, however, additional rights may exist, which may vary from state to state.
Supersedes all previous publications.
Sta-Rite Industries, 293 Wright St., Delavan, WI 53115

HydroMinder Model 506
Package Contains:
1. Proportioner with U-clamp for mounting
2. Float with chain
3. Suction tube with foot valve -- 9 ft.
4. Discharge tube -- 2 ft.
5. Metering tip kit (14 tips)
6. Production information sheet
THANK YOU FOR YOUR INTEREST IN OUR PRODUCTS

Please use this equipment carefully and observe all warnings and cautions.
******************************************************************** NOTE ***********************************************************************
WEAR protective clothing and eyewear when dispensing chemicals or other materials.
ALWAYS observe safety and handling instructions of the chemical manufacturers.
ALWAYS direct discharge away from you or other persons or into approved containers.
ALWAYS dispense cleaners and chemicals in accordance with manufacturer's instructions. Exercise CAUTION
when maintaining your equipment.
KEEP equipment clean for proper operation.
WEAR protective clothing and eyewear when working in the vicinity of all chemicals, filling or emptying equip-
ment or changing metering tips.
ALWAYS re-assemble equipment according to instruction procedures. Be sure all components are firmly screwed
or latched into position.
ATTACH only to tap water outlets (85 PSI maximum).

Through proper care and maintenance, this equipment will serve your toughest cleaning jobs.
Installation:
1. Select a metering tip (see next three sections) and insert it into the suction stub on the eductor body.
2. Attach the end of the discharge tube with the clamp and flooding ring to the discharge barb on the eductor. Since the
HydroMinder 506 does not have a siphon breaker, you may want to drill a small hole (1/8" or 1/4" ID) in the discharge
tube, above the highest solution level and below the discharge end of the eductor. This will allow the discharge tube
to drain after each cycle.
3. Mount the unit in a level position on the side of the reservoir. The U-clamp may be repositioned or removed as necessary.
4. Insert the foot valve end of the suction tube into the concentrate container. (The level of the concentrate must be below
the level of the eductor, or the proportioner will continue to siphon concentrate after it is turned "off".)
5. Slide the open end of the suction tube over the suction stub.
6. Adjust the bead chain length to position the float at the desired level of solution. To prevent foaming, be certain that
the solution level will always be above the point of discharge. Be sure float mechanism is not hampered by water
turbulence caused by discharging solution. It may be necessary to baffle the float from the discharge in order for the
unit to work properly.
7. Install a minimum 1/2-inch ID water hose between the inlet threads and the water spigot. Minimum water pressure re-
quired to properly operate the proportioner is 25 PSI (flowing).
Measurement of Concentration:
You can determine the dispensed water-to-product ratio for any metering tip size and product viscosity. All that is required
is to operate the primed dispenser for a minute or so and note two things: the amount of dispensed water/product mixture,
and the amount of concentrate used in preparation of the solution dispensed. The water-to-product ratio is then calculated
as follows:
Dilution (X) = Amount of Mixed Solution — Amount of Concentrate Drawn
Amount of Concentrate Drawn
Dilution ratio, then, equals X parts water to one part concentrate (X:1). If the test does not yield the desired ratio, choose
a different tip and repeat the test. Alternative methods to this test are 1) pH (using litmus paper), and 2) titration. Contact
your concentrate supplier for further information on these alternative methods and the materials required to perform them.
Metering
Metering TipTip Selection:
Selection:
APPROXIMATE DILUTIONS CONVERSION CHART:
AT 40 PSI FOR WATER-THIN PRODUCTS (1.0 CP) TheThe final
final concentration
concentration ofthe
ofRatiothedispensed
dispensed
Equivalents
liquid is
liquid
toopen- is
related to both the size
related to both the size of Standard of the metering
the metering tiptip
opening
Measures
Orifice (Std. Drill ing (orifice)
(orifice) and the andviscosity
the viscosityof the of liquid
the liquid
being being si-
Tip Color Size Number) Ratio siphoned. If product
phoned. If product viscosity viscosity is noticeably
Oz./Gal.is noticeably
Ratio greater
greater
%
than
than thatthat of water,
of water, consult the procedure
consult for
No Tip .187 (3/16) 4:1 Measurement 128the procedure
of Concentration
for
50.0Mea-
1:1the first
on page
Grey .128 (30) 5:1 surement of Concentration on the
64 water-to-product
2:1 first 33.3 to
page
to achieve
achieve your your
desireddesired
water-to-product ratio.ratio.
For
Black .098 (40) 6:1 For water-thin products, 32 use the4:1 at20.0
water-thin products, use the chartchartat right right
asas a
Beige .070 (50) 8:1 21 factors
a guideline.
guideline. BecauseBecause
such such
factors as 6:1 aswater
inlet 14.3
inlet water
pres-
Red .052 (55) 17:1 pressure
sure and temperature
and temperature can 16affectcan 8:1affect
dilution dilution
11.1
ratios, the
White .043 (57) 23:1 ratios, the figures listed14 below are
9:1
figures listed below are only approximate. Test the only approxi-
10.0
Blue .040 (60) 25:1 mate.
actual Test you
dilution the are
actual dilution
8
achieving you
16:1are
using the achieving
5.9
Measure-
Tan .035 (65) 36:1 using
ment the Measurement
of Concentration 6of Concentration
procedure 24:1 proce-
4.0
for best results.
Green .028 (70) 48:1 Twodure for best results.
undrilled, clear tips Two4areundrilled,
32:1 clear
supplied for tips are
drilling
3.0
Orange .025 (72) 64:1
supplied for
sizes not listed. drilling sizes
3
not listed.
48:1 2.0
Brown .023 (74) 75:1 2 64:1 1.5
Yellow .020 (76) 90:1 1 128:1 0.8
Purple .014 (79) 120:1 1/2 256:1 0.4
Pink .010 (87) 240:1 1/4 512:1 0.2
Operation:
Open the water supply ball valve. When the solution in the reservoir reaches the level set by the float, the valve will close.
This will stop the water flow and siphoning of concentrate. When withdrawal of solution from the reservoir causes the level
to drop more than 1-1/2 inches, the valve will open, and the reservoir will be refilled to the previous, pre-set level. This cycle
will be repeated automatically until the supply of concentrate is depleted. The ball valve should be fully closed when
changing metering tips or concentrate container, when reservoir is drained, or when the unit is not in use.
Troubleshooting:
Problem Probable Cause Remedy
1. No discharge a. No water a. Open water inlet

b. Defective magnetic b. Replace assembly
valve assembly
c. Excessive water pressure c. Install regulator if pressure exceeds 85 PSI
2. No concentrate a. Clogged foot valve a. Clean or replace foot valve

draw b. Metering tip or eductor b. Clean* or replace
clogged
c. Low water pressure c. Minimum 25 PSI flowing required
d. Discharge tube or d. Check position: Replace discharge tube if
flooding ring not in place flooding ring is missing.
3. Failure of unit to a. Valve parts dirty or a. Clean or replace

turn off defective
b. Magnet spring too short b. Replace
c. Clogged valve orifice c. Clean or replace
4. Backflow into a. Diluted solution being a. Replace or repair foot valve

concentrate siphoned into container
b. Water being siphoned b. Replace eductor
into container
* In hard water areas, scale may form at the discharge of the eductor. This scale may be removed by
soaking the eductor in a descaling solution or by running the descaling solution through the system. If
descaling solution is educted through the system, flush the unit by educting water only before returning
the system to regular use.
HydroMinder Model 506 Parts Diagram/List
a
b KEY PART NO. DESCRIPTION
1 238100 strainer washer
c 2 506500 hose swivel
4 3 502000 ball valve
4 10080500 magnet parts kit: a. screw,
b. washer, c. magnet cover,
d d. Magnet cap, e. magnet assembly,
f. magnet spring,g. magnet
yoke
e 5 5030-K mounting bracket kit (specify
model 506): includes Z Bracket,
U clamp, lockwashers, screws and
f thumbscrews
6 6655-P valve parts kit: h.valve guide
("bonnet"), k. armature spring,
m. armature, n. diaphram
h 7 520000 water valve body
8 505600 street elbow
6 9 440121 eductor assembly
10 690015 metering tip (kit)
k 11 5057-A discharge tube assembly
12 5058-9A suction tube assembly
m (includes 13 & 14)
1 2 3 18
13 10076301 foot valve, Viton
n 14 250006 ceramic weight
15 519000 nipple
7 16 5043-A float assembly (includes #17 chain)
17 507200 bead chain
18 360900 nipple
5 8 15 8
9 10
4g
12
17 14 13
16
11
MILLENIUM
INSTALLATION MANUAL
NTR 735 B/E
Simple Automation Control Module (MAS)

MAS NTR 735 B
INSTALLATION MANUAL
Table of contents
1. INTRODUCTION 1
2. HARDWARE DESCRIPTION 2
3. INSTALLATION 6
4. CONNECTION 7
5. USER SAFETY AND PROTECTION OF EQUIPMENT 10
1. Introduction
The MILLENIUM series has been designed for use in domestic, office and industrial applications. Each module
can be used to manage all the sensors and actuators in the installation. A display on the front panel can be used
to check the state of your system at any time.
The MILLENIUM series is characterised by :
• Ease of programming and parameter entry

• WINDOWS-based programming software
• Compact size
• EEPROM module backup
• Realtime clock as standard
• Output with high breaking capacity
The MILLENIUM series has been designed for simple automation control modules (examples : lighting, air
conditioning, irrigation, doors, barriers, simple safety systems, greenhouses, ventilation). The realtime clock
allows equipment to be programmed in hours or minutes.

ntr_735b_e_mas_installation_manual.doc 02/2000 - 1/10
MAS NTR 735 B
INSTALLATION MANUAL
2. Hardware description
2.1 Part numbers
Codes Part numbers Power supply Inputs Outputs Dimensions Weight

Type No. Type No. mm kg
89 750 001 MAS 6 RCA 100 - 240V AC 100 - 240V AC 4 RELAY 2
89 750 002 MAS 10 RCA 6 RELAY 4 71.2 x 90 x 55 0.2
89 750 003 MAS 10 RCD 24V DC 24V DC 6 RELAY 4
89 750 013 MAS 10 TCD 6 TRANSISTOR 6
89 750 004 MAS 20 RCA 100 - 240V AC 100 - 240V AC 12 RELAY 8
89 750 005 MAS 20 RCD 24V DC 24V DC 12 RELAY 8 124.6 x 90 x 55 0.32*
89 750 015 MAS 20 TCD 12 TRANSISTOR 8
2.2 Description of power supplies
Description Code Specification

Power supply MAS x RCA 100 - 240V AC, +10% -15%, 50/60 Hz
MAS x xCD 24V DC, +20% -15%
Micro-cuts MAS x RCA 10ms
MAS x xCD 5ms
Current peak 240V AC ≤ 1.5 A t < 0.3 ms
24 V DC ≤ 7 A t < 0.2 ms
MAS 6 RCA, 264V AC 3 VA
MAS 10 RCA, 264V AC 4 VA
MAS 10 RCD, 28,8V DC 3W
Maximum consumption MAS 10 TCD, 28,8V DC 2W
*MAS 20 RCA, 264V AC 8 VA
*MAS 20 RCD, 28,8V DC 7W
*MAS 20 TCD, 28,8V DC 5W
MAS 6 RCA, 240V AC Active I/O : 2.5 VA Deactivated I/O : 1.5 VA
MAS 6 RCA, 120V AC Active I/O : 2 VA Deactivated I/O : 1.2 VA
MAS 10 RCA, 240V AC Active I/O : 3 VA Deactivated I/O : 1.5 VA
Typical consumption MAS 10 RCA, 120V AC Active I/O : 2.5 VA Deactivated I/O : 1.2 VA
MAS 10 RCD, 24V DC Active I/O : 2 W Deactivated I/O : 0.3 W
MAS 10 TCD, 28,8V DC Active I/O : 2 W Deactivated I/O : 0.3 W
*MAS 20 RCA, 240V AC Active I/O : 5 VA Deactivated I/O : 1.5 VA
*MAS 20 RCA, 120V AC Active I/O : 4 VA Deactivated I/O : 1.2 VA
*MAS 20 RCD, 24V DC Active I/O : 5 W Deactivated I/O : 0.3 W
*MAS 20 TCD, 24V DC Active I/O : 5 W Deactivated I/O : 0.3 W
* Without special connection modules.

MAS NTR 735 B
INSTALLATION MANUAL
2.3 Description of inputs
Description Description of AC inputs

Input voltage 100 - 240V AC, +10% -15%, 50/60 Hz
Input impedance ≥ 800 k Ohms
Level 0 ≤ 40V AC
Level 1 ≥ 80V AC
Response time 25 ms min, 130 ms max.
Galvanic isolation No
Status indication LCD display
Description Description of DC inputs

Input voltage 24V DC +20% -15%
Current consumption 5 mA
Level 0 ≤ 4V
Level 1 ≥ 18V
Response time 15 ms ± 5 ms (I 01 – I 08)
30 ms ± 10 ms (I 09 – I 12)
Galvanic isolation No
Description Description of analogue inputs

MAS 10 RCD 6 Inputs: I 01 – I 06
MAS 20 RCD 8 Inputs: I 01 – I 08
Number of bits 8
Resolution (10000 / 250) mV
Conversion time 15 ± 5ms
Input voltage 0 – 10V DC
Input impedance 150 k Ohms max.
Precision ± 5%
Default Offset/ Gain Offset = 0
Gain = 1
These values can be changed by the program
Temp. dependent derating ± 3 LSB on the authorised range

MAS NTR 735 B
INSTALLATION MANUAL
2.4 Description of relay outputs
Description Description of relay outputs

Max. operating voltage 250V AC, 30V DC
Max. operating current 8A / point
Minimum load 10mA at 5V DC
Response time ≤ 10ms
Type of contact Gold-plated silver
Category Max. operating Power consumption Durability Max. ops /

of use voltage in steady state (number of operations) hour
AC15 (electromagnet) 250V AC 450 VA 100 000 600
DC13 (electromagnet) 30V DC 10 W 100 000 360
(L/R = 150 ms)
AC14 (electromagnet) 250V AC 750 VA 100 000 600
AC12 (resistive) 250V AC / 110V AC 2000 VA / 1100 VA 100 000 / 30 000 1800
DC12 (resistive) 30V DC 192 W 100 000 1800
2.5 Description of transistor outputs
Description Description of transistor outputs

Operating voltage 5-24V DC (+ 20 % - 5 %)
Rating current / terminals 1 A / terminal (8-24V DC)
0.1A / terminal (5-8V DC)
Minimum load 1.0 mA
Max. inductive load 1 A / 24V DC (24 W)
Resistive load 0.125 A / 24V DC (3.0 W)
Response time Ton/Toff, Toff/Ton ≤ 1 ms
Open circuit current leakage ≤ 0.1 mA / 24 V DC
Isolation circuit None

MAS NTR 735 B
INSTALLATION MANUAL
2.6 General description
Description Specification
Programming Logic block or function block
Program capacity 64 blocks or 1500 bytes
Program backup Via internal EEPROM or optional external EEPROM module
Data backup 20 days at 25° C (via capacitor)
Clock backup 20 days at 25° C (via capacitor)
LCD display Display unit with 4 lines of 10 characters.
Real time clock accuracy 5 seconds / day
Climatic conditions :
Type Standard Amplitude

Operating temperature 0/55 °C
Storage temperature -30/70 °C
Humidity 35 - 85% relative humidity, without condensation
Degree of protection IP 20
Environment No corrosive gases. Minimum dust
Mechanical protection :
Type IEC Standard Amplitude

Resistance to vibrations 10- 57 Hz: 0.15 mm Constant amplitude
Direct mounting 60068-2-6 Acceleration 57- 150 Hz 19.6 m/ s²
X, Y, Z : 10 times (80 minutes in each direction)
Resistance to vibrations 10- 57 Hz: 0.075 mm Constant amplitude
Mounted on DIN rail 60068-2-6 Acceleration 57- 150 Hz: 9.8 m/s²
X, Y, Z : 10 times (80 minutes in each direction)
Resistance to shocks 60068-2-27 Acceleration : 147m/s², duration: 11 ms
X, Y, Z : 3 times in each direction
Type Standard Amplitude

Dielectric strength EN 60730-1 3750V AC > 1 min between the following points :
Power supply terminals / input / output terminals
Between the relay outputs
Between the terminals and the DIN 43880 control box or
equivalent
Insulation resistance EN 60730-1 7 Mohm at 500V DC between the following points :
Power supply terminals / input / output terminals
Between the relay outputs
Between the terminals and the DIN 43880 control box or
equivalent
Safety class II
Certifications CE Low Voltage directive 73/23/EEC
EMC directive 89/336/EEC
UL/ cUL
Conformity UL 508
EN60730- 1
EN61010- 1
EN50081- 1
EN50082- 1
EN50082- 2

MAS NTR 735 B
INSTALLATION MANUAL
3. Installation
IN
L N NC NC 1 2 3 4 5 6
Ref. Description of front panel
POWER AC INPUT 1 Programming port
AC 100/240V
EEPROM backup module
ESC 2 Fixing holes, ∅ : 4.2 mm
3 Power supply terminals
4 Input terminals
OK
5 LCD display
MAS 10 RCA
6 Menu keys
RELAY OUTPUT
7 Output terminals
8 DIN rail mounting
3.1 DIN rail mounting
The modules can be mounted on a 35 mm DIN rail (DIN EN 50022).
3.2 Panel mounting
Recommended diameter of fixing screws : M4.
3.3 Screw terminal connection
The end of the wire should be fitted with a ferrule.
3.4 Mounting instructions
The MILLENIUM series can be installed anywhere, but the following points should be taken
!
into consideration.
Do not install if : the atmosphere is excessively dusty, conductive, corrosive, gas-laden,
damp, wet or inflammable, or subject to excessive heat*, excessive shocks or vibrations.
Do not install the module in water or near any possible leaks.
Protect the module from external debris during installation.
Separate the cables and power equipment as far as possible. The MILLENIUM series module should be installed
in cabinets which adhere to standard DIN 43880.
• For sufficient module ventilation, allow a space of 10 mm between the front of the module and the cabinet
door, and likewise between the base of the cabinet and the bottom of the module.
4 6
10 10
IN IN
L N NC NC 1 2 3 4 5 6 (A) (B) 1 2 3 4 5 6 7 8 9 10 11 12
POWER AC INPUT POWER DC INPUT

AC 100/240V DC 24V
MADE IN JAPAN
SERIAL :
REF :
MODEL :
CROUZET AUTOMATISMES
ESC
89 750 015
CROUZET AUTOMATISMES
MAS 20 TCD
MAS 10 RCA
90
89 750 002
MADE IN JAPAN
MODEL :
SERIAL :
OK OK
REF :
MAS 10 RCA MAS 20 TCD
RELAY OUTPUT TRANSISTOR OUTPUT

4
10 6 10
55 71 124.6 55

MAS NTR 735 B
INSTALLATION MANUAL
4. Connection
4.1 Connection instructions
The MILLENIUM series has been designed with ease of connection in mind. A technician or
!
engineer with experience of national and local electrical standards should be able to connect
MILLENIUM series modules to the sensors and actuators without difficulty.
• The input and output cables should not be in the same wiring harness.
• Keep the input/output wiring harnesses well away from the power wiring harnesses.
• Use cables which are suitable for the application.
4.2 Conductor cross-section
For the inputs / outputs use conductors : 0.13 mm² - 3.31 mm² (26 - 12 AWG).
Strip back the conductor by 7 ± 0.5 mm.
! Undo the terminal screw to its maximum before inserting a conductor.

To be sure of correct connection, insert the wire fully in the terminal and tighten the screws.
Maximum tightening torque 0.5 Nm (5kgfcm).

Do not coat the conductor ends with tin to prevent them breaking.
4.3 Power supply
For an AC power supply, the phase should be connected to the L terminal and the
Neutral to the N terminal. Never connect the phase to the N terminal, as the user could
receive a dangerous electric shock.
For a DC power supply, the positive conductor should be connected to the ‘+’ terminal
and the negative conductor to the ‘-’ terminal.
The power supply terminals should not be connected to the other module terminals.

MAS NTR 735 B
INSTALLATION MANUAL
4.4 Wiring diagram, MAS 6-10
POWER : AC INPUT : AC FR Les bornes “L“ et “N“ ne sont pas réversibles.

L N
GB “L“ and “N“ terminals are not reversible.
100-240 VAC 50/60 Hz D “L“ und “N“ - Anschlüße sind nich tauschbar.
IT I morsetti “L“ e “N“ non sono invertibili.
SP Los bornes “L“ y “N“ no están reversibles.
1,0 A
Ambient External NL De klemmen “L“ en “N“ zijn niet omkeerbaar.
temperature : contact
0 + 55 °C only
L N NC NC 1 2 3 4 5 6
INPUTS
POWER : DC INPUT : DC NPN

_
+
24 VDC + 20 % - 15 % +
Ambient External 1,0 A

0 + 55 °C only
+ - (A) (B) 1 2 3 4 5 6 _
INPUTS
POWER : DC INPUT : DC _ PNP
24 VDC + 20 % - 15 % ANA
1,0 A
Ambient External
0 + 55 °C only
+ - (A) (B) 1 2 3 4 5 6
INPUTS
OUTPUT : RELAY
Resistive load : 7 mm
8 A 250 VAC 30 VDC OUT1 OUT2 OUT3 OUT4
Inductive load :
125 VAC : 245 VA (1/3 hp) 10 A
250 VAC : 367 VA (1/2 hp)
+ 26-12 AWG
or
0.13-3.31 mm²
OUTPUT : TRANSISTOR Resistive load : 1A / 8-24 Vcc ; 0,1A / 5-8 Vcc Inductive load : 1A / 24 Vcc (24W)
FR Le 0V est à relier à la borne “-“ de l’alimentation du Millenium.
GB Connect the 0V to “-“ terminal of Millenium power supply. +5VDC
to OUT1 OUT2 OUT3 OUT4
D Der Nulleiter ist mit der “-“ Klemme der Millenium-
Stromversorgung zu verbinden. +24VDC
IT Lo 0V deve essere collegato al morsetto “-“ dell’
alimentazione del Millenium. 5V ≤ 0,3A
SP El 0V se ha de conectar al borne “-“ de alimentación 12/24V ≤ 2A
del Millenium.
NL De 0V is verbonden aan de “-“ klem van de voeding.
0V

MAS NTR 735 B
INSTALLATION MANUAL
4.5 Wiring diagram, MAS 20
POWER : AC INPUT : AC FR Les bornes “L“ et “N“ ne sont pas réversibles.

GB “L“ and “N“ terminals are not reversible.
100-240 VAC 50/60 Hz L N D “L“ und “N“ - Anschlüße sind nich tauschbar.
IT I morsetti “L“ e “N“ non sono invertibili.
SP Los bornes “L“ y “N“ no están reversibles.
Ambient External 1,0 A NL De klemmen “L“ en “N“ zijn niet omkeerbaar.
0 + 55 °C only
L N NC NC 1 2 3 4 5 6 7 8 9 10 11 12
INPUTS
POWER : DC INPUT : DC NPN

+
_ +
24 VDC + 20 % - 15 %
Ambient External 1,0 A

0 + 55 °C only _
+ - (A) (B) 1 2 3 4 5 6 7 8 9 10 11 12
INPUTS
POWER : DC INPUT : DC PNP TOR ANA

_
24 VDC + 20 % - 15 %
TOR + ANA TOR
1,0 A
Ambient External
0 + 55 °C only
+ - (A) (B) 1 2 3 4 5 6 7 8 9 10 11 12
INPUTS
OUTPUT : RELAY Resistive load : 8 A 250 VAC 30 VDC Inductive load : 125 VAC : 245 VA (1/3 hp)
250 VAC : 367 VA (1/2 hp)
7 mm
OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 OUT8
10 A 10 A
+ +
or or
26-12 AWG
0.13-3.31 mm²
OUTPUT : TRANSISTOR Resistive load : 1A / 8-24 Vcc ; 0,1A / 5-8 Vcc Inductive load : 1A / 24 Vcc (24W)
FR Le 0V est à relier à la borne “-“ de l’alimentation du Millenium.
GB Connect the 0V to “-“ terminal of Millenium power supply.
D Der Nulleiter ist mit der “-“ Klemme der Millenium-Stromversorgung zu verbinden.
IT Lo 0V deve essere collegato
+5VDC
al morsetto “-“ dell’ to
OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 OUT8
alimentazione del Millenium. +24VDC

SP El 0V se ha de conectar al
borne “-“ de alimentación 5V ≤ 0,3A
del Millenium. 12/24V ≤ 2A
NL De 0V is verbonden aan
de “-“ klem van de voeding. 0V

MAS NTR 735 B
INSTALLATION MANUAL
5. User safety and protection of equipment

• This manual contains all the diagrams and explanations which will guide the user in installing and using
MILLENIUM products correctly. This manual should be read and understood prior to use or installation.
• If you have any doubts while installing MILLENIUM products or require any further information, consult your
Crouzet distributor.
• This manual may be amended without prior notification.
This manual is intended for use by competent personnel trained in installation of this equipment as defined in the
following European directives :
Machinery (98/37/EEC)
Low voltage (73/23/EEC)
EMC (89/336/EEC).
Installation and electrical connections must be performed by a qualified technician.
This manual uses the symbols below to highlight information relating to the safety of personnel and the protection
of equipment. Where these symbols appear, the associated comments should be read and understood.
The symbols are :
The identified danger will cause material damage.
! The identified danger is liable to cause material damage.
• In no circumstances can Crouzet Limited be held responsible for damage arising as a result of installing or
using this equipment.
• All examples and diagrams in this manual are intended to aid comprehension. Their application is entirely the
responsibility of the user. Crouzet Limited will not accept any responsibility for actual use of this product based on
these examples.
• It is up to the user to assess the suitability of this product for his applications.
• In the event of product malfunction, the integral safety features should prevent dangerous situations.
• Never modify or repair MILLENIUM products.
• Check that MILLENIUM products comply with existing national and local standards.

DIGITAL I/O MODULE MOUNTING BOARDS
FOR “M” SERIES MINIATURE MODULES
NOTES:
DIMENSIONS: INCHES (MILLIMETERS)
TOLERANCE: +0.020 (+.50)
PB24MD
SCREW TERMINAL
LOGIC SUPPLY BARRIER STRIP
REPLACEABLE 1A
2.200˝ (55.88) LOGIC SUPPLY FUSE POWER BARRIER STRIP
WIRE INSERTION SIDE
0.750˝ (19.05) 0.400˝ (10.16)
1 2 3 4 5 6 7 8
8.000˝ (203.19)
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
2
1.700˝ (43.18)
1
R1
RESISTOR NETWORK
3-32 NYLON STANDOFF
HOLD-DOWN BAR
6.000˝ (152.40)
2.600˝ (66.04)
1
R3
1 2 3 4 5 6 7 8 9 10 11 12
24 23 22 21 20 19 18 17 16 15 14 13 LED STATUS INDICATOR

(24 PLCS)
R2
REPLACEABLE 5A LINE FUSE
1
Y AC INPUT (24 PLCS)
W DC INPUT
SWAGED STANDOFF B AC OUTPUT
0.15 (3.8) DIA R DC OUTPUT
CROUZET
PB-24MD
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
0.294˝ (7.46)
0.250˝ (6.35)
SIGNAL INPUT/OUTPUT 50 TRACE

NOTES: (0.1˝ CENTERS) MALE CARD EDGE.
DIMENSIONS: INCHES 9MILLIMETERS)

TOLERANCE: +0.020 (+.50)
NOTES: 1) MATING CONNECTOR IS BERG66317-150 OR EQUIVALENT. SPECIFY SUFFIX ‘C’ FOR OPTIONAL 65823-093 OR EQUIVALENT
MALE PIN CONNECTOR FOR PARALLEL-TO-THE-BOARD CABLE CONNECTION. SPECIFY SUFFIX ‘V’ FOR OPTIONAL CIRCUIT
ASSEMBLY CA-50H-2B-SR OR EQUIVALENT MALE PIN CONNECTOR FOR PERPENDICULAR-TO-THE-BOARD CABLE CONNECTION.
2) 4-40 TERMINAL STRIPS ACCEPT WIRE SIZES FROM 26 TO 14 AWG .
3) OPTIONAL JUMPERS ARE AVAILABLE TO INTERCONNECT BARRIER STRIP ORDER “JM8”
4) PHOENIX MKD51.5 5.08mm SERIES (OR EQUIVALENT) SCREW TERMINAL BLOCKS STANDARD. SPECIFY SUFFIX “A” FOR
BOARD-MOUNTED PHOENIX MSTBVA 1.5/16-G-5.08 (OR EQUIVALENT) MALE CONNECTOR. SPECIFY SUFFIX “B” FOR
BOARD-MOUNTED PHOENIX MSTBVA 1.5/16-G-5.08 (OR EQUIVALENT) MALE CONNECTOR AND MATING PHOENIX
MSTBVA 1.5/16-ST-5.08 (OR EQUIVALENT) FEMALE. SCREW-TERMINAL PLUG-IN CONNECTOR.
5) LITTLE FUSE 251001 OR EQUIVALENT.
6) LITTLE FUSE 251005 OR EQUIVALENT.
POWER BARRIER STRIP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
+ -
LOGIC SUPPLY 1 1 1 1 1 1 1 1 1 1 1 1
TERMINAL STRIP
2 2 2 2 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3 3 3 3 3
4 4 4 4 4 4 4 4 4 4 4 4
5 5 5 5 5 5 5 5 5 5 5 5
25
27
29
31
33
50 PIN 35
37
CONNECTOR 39
41
43
45
47
49
ALL EVEN
PINS 2-50
1
3
5
7
9
50 PIN 11
CONNECTOR 13
15
17
19
21
23
5 5 5 5 5 5 5 5 5 5 5 5
4 4 4 4 4 4 4 4 4 4 4 4
3 3 3 3 3 3 3 3 3 3 3 3
2 2 2 2 2 2 2 2 2 2 2 2
1 1 1 1 1 1 1 1 1 1 1 1
48 47 46 45 4 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
POWER BARRIER STRIP
Products and specifications subject to change without notice.

Consult factory for application assistance.
204 Airline Drive, Suite 300, Coppell, Texas 75019 / Tel: (800) 677-5311 / FAX: (800) 677-3865 / www.crouzet-usa.com
2-47
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Keyword or Part #
Water Safety & Backflow Water Quality Drainage Brass & Control Potable PEX Quick-Connect Marine OEM
Flow Control Prevention Products Products Tubular Valves Plumbing Solutions Products Division
HOME > Search > N55B
N55B
Water Pressure Reducing Valves
Size(s) : 1/2 to 1 in. (15 to 25mm)
Description:
Series N55B Water Pressure Reducing Valves are used in commercial and residential
applications to reduce incoming water pressure for protection of plumbing system
components and to reduce water consumption. It consists of a bronze body
construction integral stainless steel strainer, thermoplastic seat, bronze sealed spring
cage for waterworks pit installations and thermal expansion bypass. The N55B is
available with either threaded, solder, PEX or CPVC end connections. Maximum
Working Pressure: 400psi (27.6 bar), Adjustable Reduced Pressure Range: 25 to 75psi
(172 to 517 kPa), Standard Pressure Setting: 50psi (345 kPa).
Model/UPC Code
UPC Part # Description
098268204728 0008235 3/4 N55B G M1
ES-N55B
For Residential and Commercial Applications
Job Name ––––––––––––––––––––––––––––––––––––––––––– Contractor ––––––––––––––––––––––––––––––––––––––––––––
Job Location ––––––––––––––––––––––––––––––––––––––––– Approval –––––––––––––––––––––––––––––––––––––––––––––

Engineer ––––––––––––––––––––––––––––––––––––––––––––– Contractor’s P.O. No. –––––––––––––––––––––––––––––––––––
Approval ––––––––––––––––––––––––––––––––––––––––––––– Representative ––––––––––––––––––––––––––––––––––––––––
Series N55B-M1
Water Pressure Reducing Valves* N55BU-M1
Sizes: 1/2" – 1" (15 – 25mm)
Series N55B-M1 Water Pressure Reducing Valves are designed to reduce
incoming water pressure to a sensible level to protect plumbing system
components and reduce water consumption. This series is suitable for water
supply pressures up to 400psi (27.6 bar) and may be adjusted from 25 to
75psi (172 – 517kPa). The standard setting is 50psi (345kPa). All parts are
quickly and easily serviceable without removing the valve from the line. The
standard bypass feature permits the flow of water back through the valve
into the main when pressures, due to thermal expansion on the outlet side
of the valve, exceed the pressure in the main.
Features
• Double union inlet & outlet connections (option DU)
• Integral stainless steel strainer
• Thermoplastic seat
• Bronze body construction
Reinforced
• Serviceable in line Diaphragm
• Bypass feature controls thermal expansion pressure**
• Sealed spring cage on all models for waterworks pit installations
Models
Threaded, solder,
N55B-M1 NPT threaded female inlet x NPT female outlet PEX or CPVC ends Integral Stainless
Steel Strainer
N55BU-M1 NPT threaded union inlet x NPT female outlet
N55BU-S-M1 Solder union inlet x NPT female outlet
N55BDU-M1 Double Union – NPT threaded union female
inlet and outlet
N55BDU-S-M1 Double Union – Solder union inlet and outlet
N55BDU-PEX-M1 Double Union – PEX union inlet and outlet
N55BDU-CPVC-M1 Double Union – CPVC union inlet and outlet Thermal Expansion Thermoplastic Seat
Bypass
Specifications
Standard Specifications: A Water Pressure Reducing Valve with integral Lead Free Specifications: A Water Pressure Reducing Valve with integral
strainer shall be installed in the water service pipe near its entrance strainer shall be installed in the water service pipe near its entrance to the
to the building where supply main pressure exceeds 60psi (413 kPa) to building where supply main pressure exceeds 60psi (413 kPa) to reduce it
reduce it to 50psi (345 kPa) or lower. The valve shall feature a bronze body to 50psi (345 kPa) or lower. The valve shall feature a bronze body where
suitable for water supply pressures up to 400psi (27.6 bar). Provision shall suitable for water supply pressures up to 400psi (27.6 bar). The combined
be made to permit the bypass flow of water around the valve back into the metal components of the valve contacted by potable water shall contain
main when pressures, due to thermal expansion on the outlet side of the less than one half of one percent (0.5%) lead by weight. Provision shall
valve, exceed the pressure in the main. Water Pressure Reducing Valve be made to permit the bypass flow of water around the valve back into
with built-in bypass check valves will be acceptable. Approved valve shall the main when pressures, due to thermal expansion on the outlet side of
be listed to ASSE 1003 and IAPMO and certified to CSA B356. Valve shall the valve, exceed the pressure in the main. Water Pressure Reducing Valve
be a Watts Regulator Company Series N55B-M1. with built-in bypass check valves will be acceptable. Approved valve
* A water saving test program concluded that reducing the supply pressure shall be listed to ASSE 1003 and IAPMO and certified to NSF 61-8 and
from 80 – 50psi (551 – 346kPa) resulted in a water savings of 30%. CSA B356. Valve shall be a Watts Regulator Company Series LF N55B-M1.
** Bypass will not work if inlet pressure is above 150psi (10.34 bar).
Watts product specifications in U.S. customary units and metric are approximate and are provided for reference only. For precise measurements,
please contact Watts Technical Service. Watts reserves the right to change or modify product design, construction, specifications, or materials with-
out prior notice and without incurring any obligation to make such changes and modifications on Watts products previously or subsequently sold.
Materials Capacity
Body: Bronze kPa psi
Seat: Thermoplastic
0 0
Cage: Bronze
Integral Strainer: Stainless steel
Diaphragm: Reinforced EPDM 34.5 5
Valve Disc: Elastomer
Pressure Drop
68.9 10
Pressure — Temperature
Temperature Range: 33°F – 180°F (5°C – 82°C)
103.4 15
Maximum Working Pressure: 400psi (27.6 bar)
Adjustable Reduced Pressure Range: 25 – 75psi (172 – 517kPa) 1"
3
137.8 20 ⁄4 " 25mm
Standard Reduced Pressure Setting: 50psi (345kPa) 20mm
1
⁄2"
Standards 172.3 25
15mm
Meets requirements of ASSE Standard 1003; (ANSI A112.26.2)

and CSA Standard B356. Certified by NSF to ANSI/NSF Standard 61-8 0 10 20 30 40 gpm
(LF N55B-M1 Models only). Listed by IAPMO and City of Los Angeles. 0 37.3 75.7 113.6 151.4 lpm
Flow
Options
Add Suffix
G Gauge tapping
GG Gauge tapping and 160psi (11 bar) gauge FNPT
LP Low Pressure Range 10-35psi (69-241kPa)
Add Preffix
LF Lead Free† construction
†The combined metal components of this product contacted by potable water
contain less than one half of one percent (0.5%) of lead by weight. ENPT
Dimensions – Weights FSWEAT
ESWEAT
FPEX
C
FEMALE NPT THREAD
BOTH ENDS OF BODY
EPEX
FCPVC
D
A
A+E G ECPVC
A+E+E
ABOVE VALVE SHOWN WITH SINGLE NPT UNION CONNECTION ON INLET
VALVES MAY BE ORDERED WITH 0,1,OR 2 UNION CONNECTIONS USING ANY
COMBINATION OF NPT, SOLDER, PEX OR CPVC CONNECTIONS REQUIRED
“F” DIMENTIONS ARE APPROXIMATE ENGAGEMENT LENGTHS.
SIZE (DN) DIMENSIONS WEIGHT

A C D ENPT ESWEAT EPEX ECPVC FNPT FSWEAT FPEX FCPVC G
in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm lbs kg
12
⁄ 15 3 / 7 16
88 4 ⁄ 116 1 ⁄ 9 16
43 11 16 58
⁄ 16 5 8
/ 15 13 16
/ 21 / 9 16
15 1 2
/ 13 1 2
/ 13 5 8
/ 16 ⁄12 14
13 2 ⁄ 57 1.5 .68
34
⁄ 20 37/16 88 49⁄16 116 111⁄16 43 5 8
/ 16 7 8
/ 21 15 16
/ 24 13 16
/ 21 9 16
/ 14 3 4
/ 19 5 8
/ 16 ⁄34 18 21⁄4 57 1.5 .68
1 25 41/8 105 49⁄16 116 111⁄16 43 3 4
/ 20 1 26 11⁄8 29 11/16 26 11/16 17 15/16 23 13/16 21 15⁄16 23 21⁄4 57 1.75 .79
Water Safety & Flow Control Products USA: 815 Chestnut St., No. Andover, MA 01845-6098; www.watts.com
Canada: 5435 North Service Rd., Burlington, ONT. L7L 5H7; www.wattscanada.ca
ES-N55B 0608 © Watts Regulator Company, 2006

IS-N55B-M1
Watts
1
Series N55B-M1
⁄2" - 1" (15-25mm)
Installation Instructions
1. The valve should be installed by a licensed contractor in accordance with local
codes and ordinances. This valve should be installed where it is accessible with
sufficient clearance for cleaning, service, or adjustment.
2. Before installing the valve, be sure that the pipe ends are reamed and threads are
cut to size. For valves with Quick-Connect tailpieces refer to "Quick-Connect
Installation" instructions below.
3. Flush the lines to remove all loose scale, dirt and other foreign matter that can
damage or clog the valve. N55BU-M1
4. Install the regulator with the arrow on the body pointing in the direction of the flow.
5. Regulator may be installed vertically or horizontally (upright or inverted).
6. Start Up — Open cold water supply then hot water supply. Inspect for leaks.
Note: The valve should be inspected annually to assure maximum life and
performance.
N55BDU-QC-M1
Typical Installation Quick-Connect Installation

To Connect
TO SILL COCK
WATTS
PRESSURE GAUGE 11/2 in. (38.1mm)
(2 PLACES)
1
/2 in.Pipe (12.7mm)
WATER 3
METER 1 /4 in. (44.45mm)
SUPPLY WATTS WATTS WATTS TO FIXTURES
SHUTOFF VALVE BACKFLOW PRESSURE
3
(2 PLACES) PREVENTER REGULATOR /4 in.Pipe (19.05mm)
17/8 in. (47.63mm)

Series Installation 1 in.Pipe (25.4mm)
Series installations are recommended where very high
supply pressure must be reduced to a very low down- 1. Mark pipe as shown. 2. Clean pipe end.
stream pressure. Reducing the pressure in stages elimi- This is pipe insertion depth.
nates whistling and noise.
PEX tubing only
Collet clip
TO SILL COCK
WATTS
PRESSURE GAUGE
(2 PLACES)
WATER
METER
SHUTOFF VALVE BACKFLOW PRESSURE
(2 PLACES) PREVENTER REGULATORS
(2 PLACES)
Mark
Pipe Stiffener
Parallel Installation Tail Piece
Parallel installations are recommended where high flow 3. If using PEX tubing, insert pipe 4. Push tubing into tailpiece up to mark.
stiffener (provided) into end of pipe.
or low flow demand is intermittent/occasional. They are 5. Insert collet clip.
also used for installations where service cannot be inter- To Disconnect
rupted.
TO SILL COCK
WATTS
PRESSURE GAUGE
( 2 PLACES )
WATER
METER
SHUT-OFF VALVE BACKFLOW PRESSURE
( 6 PLACES ) PREVENTER REGULATOR
( 2 PLACES )
Collet depressed
1. Remove collet clip. 2. Depress collet.

3. Pull tubing from tailpiece.
Maintenance Instructions SEAT/STEM MODULE
• To clean strainer or replace seat/stem
module shut off supply, loosen Locknut Stem Nut
and Lock Seal and back off Adjusting Screw.
• Remove Spring Cage, Spring, Washer and Adjusting
Slip Ring. Grasp Stem Nut with fingers or Screw
pliers and lift module from body. Lock Nut
Strainer Lock Seal
• Replace module and reassemble valve.
• Readjust pressure setting. Spring Washer
Adjustment Spring
Regulator is factory preset to 50psi (344 kPa). To adjust pres- Spring Cage
sure setting, loosen the lock nut and turn the adjusting bolt
Stem Nut
clockwise to increase pressure, counter clockwise to decrease
pressure. Slip Ring
Note: Use a pressure gauge downstream to adjust and verify

the pressure setting. Seat/Stem
Module
By-Pass Feature*
Strainer
This regulator has a built-in thermal expansion by-pass feature.
This feature prevents downstream pressure from rising to more
than 10psi above the supply pressure.
* By-Pass will not work if inlet pressure is above 150psi (10.3 bar).
Troubleshooting
High System Pressure Repair Kit
If the downstream system pressure is higher than the set KIT NO. SIZE ORDERING KIT
pressure under no flow conditions, the cause could be thermal in. mm CODE INCLUDES
expansion, pressure creep or dirt/debris on the seat. 1 1
⁄2 – 1 ⁄2, 3⁄4, 1 15, 20, 25 0007723 Seat/Stem
Thermal expansion occurs whenever water is heated in a N55B-RK Module
closed system. The system is closed when supply pressure
exceeds 150psi, or a check valve or backflow preventer is
installed in the supply piping.
You must make provisions for pressure relief protection of your
plumbing system and components. The use of a
relief valve such as the Watts 530C, BRV,
Governor 80, or 3L or potable water expansion
tank such as the Watts DET, PLT or DETA may be
required.
To determine if this is the result of thermal
expansion, try briefly opening the cold water
tap. If the increased pressure is caused by
thermal expansion, the pressure will immedi-
ately be relieved and the system will return
to the set pressure. Watts offers a pressure
test gauge, model 276H300 to assist you in
determining if you have high water pressure.
Watts 276H300 The 276H300 when attached to a hose bibb
registers the highest pressure reading over
the period of time it is left on the system.
Limited Warranty: Watts Regulator Company warrants each product to be free from defects in material and workmanship under normal usage for a period of one year from the date of original ship-
ment. In the event of such defects within the warranty period, the Company will, at its option, replace or recondition the product without charge. This shall constitute the sole and exclusive remedy for
breach of warranty, and the Company shall not be responsible for any incidental, special or consequential damages, including without limitation, lost profits or the cost of repairing or replacing other
property which is damaged if this product does not work properly, other costs resulting from labor charges, delays, vandalism, negligence, fouling caused by foreign material, damage from adverse water
conditions, chemical, or any other circumstances over which the Company has no control. This warranty shall be invalidated by any abuse, misuse, misapplication or improper installation of the prod-
uct. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Any implied warranties that are imposed by law are limited in duration to one year.
Some States do not allow limitations on how long an implied warranty lasts, and some States do not allow the exclusion or limitation of incidental or consequential damages. Therefore the above limi-
tations may not apply to you. This Limited Warranty gives you specific legal rights, and you may have other rights that vary from State to State. You should consult applicable state laws to determine
your rights.
Water Safety & Flow Control Products USA: 815 Chestnut St., No. Andover, MA 01845-6098; www.watts.com
Canada: 5435 North Service Rd., Burlington, ONT. L7L 5H7; www.wattscanada.ca
IS-N55B-M1 0730 EDP# 1915391 ©Watts Regulator Co., 2007

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OWNER’S MANUAL

OASIS CAR WASH SYSTEMS

INSTALLATION & OPERATION INSTRUCTIONS

3. Sediment filter checked weekly (visual inspection).

* SOLUTION: Membrane(s) should be cleaned. CONSULT FACTORY.

3) Storage pump will not start.

* SOLUTION: a) Reset circuit breaker.

5) Delivery pump will not start.

* SOLUTION: a) Reset circuit breaker.

* SOLUTION: a) See step number 5.

* SOLUTION: a) Incoming water pressure should be between 40 and 100 PSI.

8) Storage pump short cycles on and off.

Operating instructions Combination contactor - motor circuit-breaker

FPTC 407714 P0001-07/97

ABB Control Inc. 23

24 ABB Control Inc.

5CP Plunger Pump

“Customer confidence is our greatest asset”

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

PN 993100 Rev D 9618

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

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

PN 33009 Rev J 7709

SERVICING THE VALVES

3CP1120, 5CP2120W, 7CP6170 5CP3120, 5CP5120, 5CP5150 All Models

SERVICING THE PUMPING SECTION

Disassembly V-Packing Models:

Loctite and 242 are registered trademarks of the Henkel Corporation.

INLET PRESSURE should fall within the specifications of the pump.

5 150 36 12 2.8 100 28 9.0 2.2 230 50 17 6.1 3.0

15 270 90 21 6.2 1.6 190 62 16 5.0 1.5 120 44 20

Arriving at a total line pressure loss, consideration should then be given to

TYPICAL RESERVOIR TANK ● Properly ventilate cabinets and rooms

Supply Line Agitation in Supply ● Size tank according to pump output —

T (Dia of pipe) ● Baffle tank to purge air from liquid and

High Viscosity Liquids ● Verify viscosity against pump specifications

Clogged Filters ● Perform regular maintenance or use clean

filters to monitor build up

● Use adequate mesh size for liquid and pump

PROBLEM PROBABLE CAUSE SOLUTION

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

Pump runs extremely rough

Premature seal failure •Scored plungers. •Replace plungers.

“Customer confidence is our greatest asset”

Model 530 shown

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

PN 993112 Rev C 5608

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

PN 30002 Rev K 7311

SERVICING THE VALVES

SERVICING THE SEALS

Hi-Pressure Seal Models: SERVICING THE PLUNGERS

5 150 36 12 2.8 100 28 9.0 2.2 230 50 17 6.1 3.0

15 270 90 21 6.2 1.6 190 62 16 5.0 1.5 120 44 20

Arriving at a total line pressure loss, consideration should then be given to

TYPICAL RESERVOIR TANK ● Properly ventilate cabinets and rooms

Supply Line Agitation in Supply ● Size tank according to pump output —

T (Dia of pipe) ● Baffle tank to purge air from liquid and

High Viscosity Liquids ● Verify viscosity against pump specifications