CAT Pumps 340, 310, 350, 311, 341 Installation And Start-up Information

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
implied that all maximums can be performed simultaneously. If more than one
maximum is considered, check with your CAT PUMPS supplier to confirm the
proper performance and pump selection. Refer to individual pump Data Sheets for
complete specifications, parts list and exploded view.

LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications
[5PFR-18 oz., 7PFR-25 oz., 15PFR-42oz.]. DO NOT RUN PUMP WITHOUT OIL IN
CRANKCASE. Change initial fill after 50 hours running period. Thereafter, change
oil every 3 months or 500 hour intervals, whichever comes first.

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

PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow
from Horsepower Requirement and Pulley Selection Chart (refer to Tech Bulletin
003 or individual Data Sheet).

DRIVE SELECTION: The motor or engine driving the pump
horsepower to maintain full RPM when the pump is under load. Select the electric
mot or from the Horsepo wer Requ ireme nt Chart ac cordi ng to requi red pump
discharge flow, maximum pressure at the pump and drive losses of approximately
3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper
engine size.

MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit
drainage of crankcase oil. An uneven mounting surface will cause extensive damage
to the pump base. To minimize piping stress, use appropriate flexible hose to
inlet and discharge ports. Use the correct belt; make sure pulleys are aligned.
Excessive belt tension may be harmful to the bearings. Hand rotate pump before
starting to be certain shaft and bearings are free moving.

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

INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual
before starting system. DO NOT STARVE THE PUMP OR RUN DRY. Temperatures
above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over
130°F. Elastomer or RPM changes may
CAT PUMPS for recommendations.

C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in ap­plications with stressful inlet conditions such as high temperatures, booster pump
feed, long inlet lines or quick closing valves.

be required. See Tech Bulletin 002 or call

must be of adequate

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

Install a Pulsation Dampening device on the discharge head or in the discharge line
as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator)
is properly precharged for the system pressure (see individual Data Sheet).

A reliable Pressure Gauge should be installed near the discharge outlet of the high
pressure manifold. This is extremely important for adjusting pressure regulating
devices and also for proper sizing of the nozzle or restricting orifice. The pump is
rated for a maximum pressure; this is the pressure that is read at the discharge
manifold of the pump, NOT AT THE GUN OR NOZZLE.

Use PTFE thread tape or pipe thread sealant (sparingly) connect accessories or
plumbing. Exercise caution not to wrap tape beyond the last thread to avoid tape
from becoming lodged in the pump or accessories. This condition will cause a mal­function of the pump or system.

PRESSURE REGULATION: All systems require both a primary pressure regulating
device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e.,
pop-off valve, safety valve). The primary pressure device must be installed on the
discharge side of the pump. The function of
is to protect the pump from over pressurization, which can be caused by a plugged
or closed off discharge line. Over pressurization can severely damage the pump,
other system components and can cause bodily harm. The secondary safety relief
device must be installed between the primary device and pump. This will ensure
pressure relief of the system if the primary regulating device fails. Failure to install
such a safely device will void the warranty on the pump.

When the high pressure system is left running with the trigger gun off, the by-pass
liquid can be routed to drain or to the pump inlet. If routed to the pump inlet, the

by-pass liquid can quickly develop excessive heat and result in damage to the
pump. A THERMO VALVE installed in the by-pass line is recommended to protect

the pump. An AUTO SHUT-OFF ASSEMBLY may also be used.

NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure
regulating device to compensate. Replace nozzle and reset regulating device to
system pressure.

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

supplier.

STORING: For extended storing or between use in cold climates, drain all pumped
liquids from pump and flush with antifreeze solution to prevent freezing and
damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech
Bulletin 083).

the primary pressure regulating device

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

World Headquarters

CAT PUMPS

1681 - 94th Lane N.E. Minneapolis, MN 55449- 4324

Phone [phone] — FAX [phone]

e-mail: [e-mail]

www.catpumps.com

International Inquiries

FAX [phone]

e-mail: [e-mail]

WARNING

The Pumps with Nine Lives

CAT PUMPS (U.K.) LTD.

1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet

N.V. CAT PUMPS INTERNATIONAL S. A.

CAT PUMPS DEUTSCHLAND GmbH

Hampshire GU52 8BF, England

Phone Fleet 44 1252-622031 — Fax [phone]

e-mail: [e-mail]

Heiveldekens 6A, 2550 Kontich, Belgium

Phone [phone] — Fax [phone]

e-mail: [e-mail] www.catpumps.be

Buchwiese 2, D-65510 Idstein, Germany

Phone [phone] — Fax [phone]

e-mail: [e-mail] www.catpumps.de

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

Disassembly

NOTE: Usually the valve assembly will remain together
while being removed.

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

2. Examine the O-Ring under the Valve Plug for cuts or dis­tortion and replace if worn. Lubricate new O-Rings before
installing.

NOTE: On Models 43HS, 45, 56, 57, 59, 60, 70 there is an
extended Valve Plug with O-Ring and Back-up-Ring.
Install the Back-up-Ring, then the O-Ring into the groove
at the end of the Valve Plug (refer to Tech Bulletin 058).

3. Grasp Spring Retainer by tab at the top with pliers and re­move from valve chamber.

4. To separate the valve assembly, insert a screwdriver into
the side of the Retainer and press on the back side of the
Valve to begin separation, then between the Retainer and
Valve Seat to separate completely.

5. If the valve assembly separates during removal, remove
the Spring and Valve with a needle nose pliers.

6. Using a reverse pliers, remove the Valve Seat from the
manifold chamber.

Reassembly

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

2. Examine Springs for fatigue or breaks and replace as needed.

3. Examine Valves and Seats for grooves, pitting or wear and
replace as needed.

4. Examine Seat and Valve Plug O-Rings for cuts or wear
and replace as needed. Lubricate and install new O-Ring
onto outside diameter of Seat and Valve Plugs.

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

5. Grasp new Valve Assembly by tab at top with pliers and
push into valve chamber. Be certain Valve Assembly is
completely seated in valve chamber.

NOTE: For certain applications apply liquid gasket to
the O-Ring crevices and seal surfaces (refer to Tech
Bulletin 053).

NOTE: For Corrosion Resistant Models remember to
install the Coil Spring between the Valve Plug
and Retainer (refer to Tech Bulletin 046).

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

Order of parts in Valve Assembly Removal of Seal Cases from Manifold Head Removal of High Pressure Seals

Y

X

V-P Models

Y

X

H.P.S. Models

Seal and V-Packing Arrangement Installation of Male Adapter Order of Packings [MA, VP, FA]

X

SERVICING THE SEALS

Disassembly

1. Remove the Manifold Head as described in SERVICING
THE PLUNGERS section.

2. Place Manifold Head on work surface with crankcase
side up.

3. On 5PFR and 7PFR plunger pumps prior to May of 1989,
remove Snap Ring and Lo-Pressure Seal from each Seal
Case. Discard Snap Rings (refer to Tech Bulletin 054).

4. On 5PFR and 7PFR plunger pumps after May of 1989, re­move Lo-Pressure Seal from each Seal Case.

5. On 15PFR plunger pumps, remove Snap Ring and
Lo-Pressure Seal from each Seal Case.

6. Remove Seal Case from each seal chamber. Remove
O-Ring from outside diameter of Seal Case.

7. Hi-Pressure Seal Models: The Hi-Pressure Seal is gener-
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.

Reassembly
V-Packing Models:

1. Lubricate seal chamber in the manifold.

NOTE: For certain applications apply liquid gasket to
the O-Ring crevices and seal surfaces (refer to Tech
Bulletin 053).

2. Insert Male Adapter with notches down and “v” side up
and press completely into chamber by hand.

3. Lubricate V-Packings and install one at a time with
grooved side down.

4. Install Female Adapter with grooved side down.

5. Examine Seal Case O-Ring and replace if worn. Lubricate
new O-Rings before installing.

6. Thread Seal Case into manifold and tighten with special
seal case tool. Torque per chart.

C

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:

1. Lubricate seal chamber in manifold.

NOTE: For certain applications apply liquid gasket t o
the O-Ring crevices and seal surfaces (refer to Tech
Bulletin 053).

2. Carefully square Hi-Pressure Seal into position by hand
with the grooved side down (metal back facing out).

NOTE: When alternate materials, the fit of the
special materials may be snug and require gently driv­ing the LPS into position with a cylinder of the same
diameter to assure a square seating and no damage to
the LPS.

3. Examine Seal Case O-Ring and replace if worn. Lubricate
new O-Ring before installing.

4. Secure Hi-Pressure Seal into position by threading Seal
Case into manifold. Tighten Seal Case with special seal
case tool. Torque per chart.

Lo-Pressure Seal - All Models:

1. Examine Lo-Pressure Seals for wear or broken springs
and replace if necessary.

2. Install Lo-Pressure Seal into each seal case with garter
spring down.

3. On 5PFR and 7PFR plunger pumps do not use Snap Ring
(refer to Tech Bulletin 054).

4. On 15PFR plunger pumps install Snap Ring into each
Seal Case.

5. Install the Seal Retainer with new Wick onto each plunger
rod with tab down and wick out.

6. Rotate Crankshaft by hand so the two outside plungers
are extended equally.

7. Lightly lubricate the Ceramic Plunger, then carefully slide
the Manifold Head over the Ceramic Plunger, supporting it
from the underside to avoid damage to the plungers or
seals. Press the Manifold Head into the Crankcase until
flush.

8. Replace two (2) Lockwashers, two (2) Socket Head
Screws for (4) Flange Nuts and torque per chart.

SERVICING THE PLUNGERS

Disassembly

1. Using an M8 allen wrench on the 5PFR pumps, a M14 hex
tool on the 7PFR pumps, or a M17 hex tool on the 15PFR
pumps, remove the two (2) Socket Head Screws, and two
(2) Lockwashers or four (4) Flanged Nuts.

2. Rotate Crankshaft by hand to start separation of Manifold
head from Crankcase.

3. Insert two flat head screwdrivers on opposite sides to further
separate Manifold Head from Crankcase or support the
underside of the Manifold Head and tap lightly with a mallet
on the backside of the Manifold Head.

CAUTION: KEEP MANIFOLD PROPERLY ALIGNED
WITH CERAMIC PLUNGERS WHEN REMOVING TO
AVOID DAMAGE TO EITHER PLUNGERS OR SEALS.

4. Remove Oil Pan and slide out Seal Retainer with Wick.

5. Using an M12 hex tool on the 5, 7 and 15PFR pumps, or
an M11 hex tool on the OEM 5, and 7PFR pumps, loosen
the Plunger Retainer about three to four turns.

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

7. Remove the Plunger Retainer, O-Ring, Back-up-Ring and
Gasket. Stud may stay on Plunger Rod or come off with
Plunger Retainers.

8. Remove the Ceramic Plunger, Keyhole Washer and
Barrier Slinger from Plunger Rod.

Reassembly

1. Visually inspect Crankcase Oil Seals for deterioration or
leaks. Contact CAT PUMPS for assistance with replace­ment. See SERVICING THE CRANKCASE section.

2. Examine Barrier Slingers and Keyhole Washers for dam­age. Slide onto Plunger Rod with concave side away
from Crankcase.

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

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.

6. Install new Gasket, then O-Ring, then Back-up-Ring onto
each Plunger Retainer.

NOTE: OEM models have a longer Plunger Retainer Stud.

7. Apply Loctite 242 to exposed threads of Stud and thread
Plunger Retainer onto Plunger Rod. Torque per chart.

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.

Operate for 10 to 15 minutes to allow grease from
LPS to penetrate the plunger surface, then lubricate
as needed.

9. Rotate Crankshaft by hand so the two outside plungers
are extended equally.

10.Lightly lubricate the Ceramic Plungers, then carefully slide
the Manifold Head over the Ceramic Plungers supporting it
from the underside to avoid damage to the Ceramic
Plungers or Seals. On the high pressure V-Packing models
or larger manifolds, it may be necessary to gently tap with a
soft mallet until the manifold is flush with the crankcase.

11.Replace two (2) Lockwashers, two (2) Socket Head
Screws or four (4) Flanged Nuts and torque per chart.

SERVICING THE CRANKCASE SECTION

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

2. Check for any signs of leaking at Bearing Covers, Rear
Cover, Drain Plug or Bubble Gauge.

3. Check oil level and for evidence of water in oil.

4. Rotate Crankshaft by hand to feel for smooth bearing
movement.

5. Examine Crankshaft Oil Seals externally for drying, crack­ing or leaking.

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

See Section I of the Plunger Pump Service Video for addi­tional information.

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

decreases, check immediately. If no wear at 1500 hours, check again at
2000 hours and each 500 hours until wear is observed. Valves typically
require changing every other seal change.

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

**Remember to service the regulator/unloader at each seal servicing and check

all system accessories and connections before resuming operation.
Refer to video for additional assistance.

TECHNICAL BULLETIN REFERENCE CHART

No. Subject Models

003 Power Unit Drive Packages 3PFR - 68PFR, 10FR - 60FR
024 Lubrication of Lo-Pressure Seals All Models
027 Spring Retainer 5PFR, 7PFR, 15PFR
032 Shaft Extension and Manifold Port 310, 317, 323, 530, 550
035 Servicing Crankcase Section 7PFR - 60PFR
036 Cylinder and Plunger Reference Chart All Models
043 LPS and HPS Servicing All Plunger Models
045 One-Piece S.S. Plunger Retainer w/Stud 5PFR, 7PFR, 15PFR
046 Valve Plug with Coil Spring 317, 347, 357, 1057
047 Blind Bearing Shaft Cover Gearbox Plunger Pumps
048 Extended Valve Plug 7PFR and 15PFR
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
053 Liquid Gasket All Plunger NAB-S.S. Models
054 2 Piece Seal Retainer 5PFR and 7PFR
058 Forged Manifold and Extended Valve Plugs 56, 57, 59, 60
060 Baffle Assembly 34170
061 Installation and Adjustment Procedure 8100
062 Manifold and Seal Case 650 and 651
064 By-Pass Hose Sizing All Unloaders/Regulators
067 S.S. Plunger Retainer 3PFR, 5PFR, 7PFR
072 Manifold Head and V-Packing 1050, 1051, 1057
073 Hi-Temp HPS 3PFR, 5PFR, 2SF
074 Torque Chart Piston and Plunger Pumps
077 Oil Drain Kit All Models (except 2SF/4SF)
083 Winterizing a Pump All Models

TORQUE CHART

Pump Item Torque
Pump Model Thread Tool Size [P/N] in.lbs. ft.lbs. Nm

PLUNGER RETAINER

OEM Models....................................M6 M11 Hex [44044] 55 4.4 6

All Standard Models.........................M6 M12 Hex 55 4.4 6

MANIFOLD HEAD BOLTS

5PFR 30, 31, 34, 35....................M10 M8 Allen [25052] 220 18.1 25

310, 340, 350
311, 341, 351
317, 347, 357

5PFR 42HS, 43HS, 45................M10 M8 Allen [33046] 220 18.1 25

7PFR 510, 530, 550....................M10 M14 Hex [25053] 220 18.1 25

56, 57, 58, 59, 60, 70

15PFR 650, 651, 660, 661............M10 M17 Hex [25083] 220 18.1 25

1050, 1051, 1057

VALVE PLUGS

5PFR 30, 31, 34, 35....................M22 M24 Hex [44046] 870 72.3 98

310, 311, 317
340, 341, 347
350, 351, 357
42HS

5PFR 43HS, 45...........................M25 M24 Hex [44046] 520 43.4 59

7PFR 530, 550........................3/4" SPT M27 Hex [44045] 870 72.3 98

51, 55, 56, 57, 58
59, 60, 70

15PFR 650, 651, 660, 661 ........3/4" SPT M27 Hex [44045] 870 72.3 98

1050, 1051, 1057

CRANKCASE COVER/BEARING COVER SCREWS

5PFR 30, 31, 34, 35.....................M6 M10 Hex/Phil. [25082] 50 4.0 6

310, 340, 350
317, 347, 357
311, 341, 351

5PFR 42HS, 43HS, 45.................M6 M10 Hex/Phil. [25082] 50 4.0 6

...........................................M8 M13 Hex [25324] 115 9.4 13

7PFR 51, 53, 55, 56, 57,..............M6 M10 Hex [25082] 115 9.4 13

59, 60, 70

15PFR 650, 1050...........................M6 M10 Hex [25082] 50 4.0 5.7

SEAL CASE

5PFR 30, 31, 34, 35 ....................N/A 1/2" Soc. Drive [33004] 354 29.5 40

310, 311, 317
340, 341, 347
350, 351, 357

42HS, 43HS, 45 ................N/A 1/2" Soc. Drive [33005] 354 29.5 40

7PFR 51, 53, 55, 56, ...................N/A 1/2" Soc. Drive [33005] 354 29.5 40

57, 58, 59, 60, 70
530, 550

15PFR 650, 651, 660, 661 ............N/A 1/2" Soc. Drive [33006] 346 28.8 39

1050, 1051, 1057 ..............N/A 1/2" Soc. Drive [33006] 390 32.5 44

BUBBLE OIL GAUGE

All Models.......................................M28 Oil Gauge Tool [44050] 45 3.6 5

MOUNTING BOLTS

5PFR, 7PFR....................................M8 M13 Hex [25324] 115 9.4 13

15PFR ..........................................M10 M17 Hex [25083] 240 19.7 29

INLET CONDITION CHECK-LIST

Review Before Start-Up

Inadequate inlet conditions can cause serious malfunctions in the best designed
pump. Surprisingly, the simplest of things can cause the most severe problems
or go unnoticed to the unfamiliar or untrained eye. REVIEW THIS CHECK-LIST
BEFORE OPERATION OF ANY SYSTEM. Remember, no two systems are alike, so
there can be no ONE best way to set-up a system. All factors must be
carefully considered.

INLET SUPPLY should exceed the maximum flow being delivered by the pump to
assure proper performance.
❏ Open inlet shut-off valve and turn on water supply to avoid starving the pump.

DO NOT RUN PUMP DRY.

❏ Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each

degree F over 130°F. Elastomer or RPM changes may be required. See Tech
Bulletin 002 or call CAT PUMPS for recommendations.

❏ Avoid closed loop systems especially with high temperature, ultra-high pressure

or large volumes. Conditions vary with regulating/unloader valve.

❏ Low vapor pressure liquids, such as solvents, require a booster pump and C.A.T.

to maintain adequate inlet supply.

❏ Higher viscosity liquids require a positive head and a C.A.T. to assure adequate

inlet supply.

❏ Higher temperature liquids tend to vaporize and require positive heads and

C.A.T. to assure adequate inlet supply.

❏ When using an inlet supply reservoir, size it to provide adequate liquids to accom-

modate the maximum output of the pump, generally a minimum of 6-10 times the
GPM (however, a combination of system factors can change this requirement);
provide adequate baffling in the tank to eliminate air bubbles and turbulence; install
diffusers on all return lines to the tank.

INLET LINE SIZE should be adequate to avoid starving the pump.
❏ Line size must be a minimum of one size larger than the pump inlet fitting. Avoid

tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of
flow restriction and cavitation.

❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on

SUCTION systems to avoid collapsing.

❏ The simpler the inlet plumbing the less the potential for problems. Keep the

length to a minimum, the number of elbows and joints to a minimum (ideally no
elbows) and the inlet accessories to a minimum.

❏ Use pipe sealant to assure air-tight, positive sealing pipe joints.
INLET PRESSURE should fall within the specifications of the pump.

❏ Acceleration loss of liquids may be increased by high RPM, high temperatures,

low vapor pressures or high viscosity and may require pressurized inlet and
C.A.T. to maintain adequate inlet supply. DO NOT USE C. A.T. WITH SUCTION
INLET.

❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet

pressure and a C.A.T. for certain applications. With adequate inlet plumbing,
most pumps will perform with flooded suction. Maximum inlet pressure is 60 PSI
(4 BAR).

❏ After prolonged storage, pump should be rotated by hand and purged of air to

facilitate priming. Disconnect the discharge port and allow liquid to pass through
pump and measure flow.

INLET ACCESSORIES are designed to protect against overpressurization,
control inlet flow, contamination or temperature and provide ease of servicing.

❏ A shut-off valve is recommended to facilitate maintenance.
❏ Installation of a C.A.T. is essential in applications with stressful conditions such

as high temperatures, booster pump feed or long inlet lines. Do not use C.A.T.
with negative inlet pressure.

❏ A stand pipe can be used in some applications to help maintain a positive head

at the pump inlet.

❏ Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
❏ A pressure transducer is necessary to accurately read inlet pressure. (Short

term, intermittent cavitation will not register on a standard gauge.)

❏ All accessories should be sized to avoid restricting the inlet flow.
❏ All accessories should be compatible with the solution being pumped to

prevent premature failure or malfunction.

❏ Optional inlet protection can be achieved by installing a pressure cutoff switch

between the inlet filter and the pump to shut off pump when there is no positive
inlet pressure.

BY-PASS TO INLET Care should be exercised when deciding the method of
by-pass from control valves.
❏ It is recommended the by-pass be directed to a baffled reservoir tank, with at

least one baffle between the by-pass line and the inlet line to the pump.

❏ Although not recommended, by-pass liquid may be returned to the inlet line of

the pump if the system is properly designed to protect your pump. A PRESSURE
REDUCING VALVE must be installed on the inlet line (BETWEEN THE
BY-PASS CONNECTION AND THE INLET TO THE PUMP) to avoid excessive
pressure to the inlet of the pump. It is also recommended that a THERMO
VALVE be used in the by-pass line to monitor the temperature build-up in the
by-pass loop to avoid premature seal failure.

❏ A 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

PRESSURE DROP IN PSI PER 100 FT OF HOSE

Water*

Flow

Gal/Min

0.5 16 5 2
1 54 20 7 2
2 180 60 25 6 2
3 380 120 50 13 4 2
4 220 90 24 7 3
5 320 130 34 10 4
6 220 52 16 7 1
8 300 80 25 10 2
10 450 120 38 14 3
15 900 250 80 30 7
20 1600 400 121 50 12
25 650 200 76 19
30 250 96 24
40 410 162 42
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
will be directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100
ft. hose. Above values shown are valid at all pressure levels.

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

WITH TYPICAL WATER FLOW RATES

Hose Inside Diameters, Inches

WATER LINE PRESSURE LOSS

PRESSURE DROP IN PSI PER 100 FEET

Steel Pipe—Nominal Dia.

Water

GPM

1/4 3/8 1/2 3/4 1 11/4 11/2

8.5 1.9

1

30 7.0 2.1

2

60 14 4.5 1.1

3

150 36 12 2.8

5

330 86 28 6.7 1.9

8

520 130 43 10 3.0

10

270 90 21 6.2 1.6

15

670 240 56 16 4.2 2.0

25
40

60
80

100

66 17 8.0

210 107 48

Brass Pipe—Nominal Dia.

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

6.0 1.6
20 5.6 1.8
40 11 3.6

100 28 9.0 2.2
220 62 21 5.2 1.6
320 90 30 7.8 2.4

37 17
52 29

11/4 11/2

190 62 16 5.0 1.5
470 150 40 12 3.8 1.7

39 11 5.0

23 11
40 19
61 28

Copper Tubing O.D. Type L

1/4 3/8 1/2 5/8 3/4 7/8

120 13 2.9 1.0
400 45 10 3.4 1.3

94 20 6.7 2.6

230 50 17 6.1 3.0
500 120 40 15 6.5

180 56 22 10

120 44 20
330 110 50
550 200 88

Handy Formulas to Help You

Q. How can I find the RPM needed to get specific GPM

(Gallons Per Minute) I want?

A. Desired RPM = Desired GPM x

Rated RPM
Rated GPM

Q. I have to run my pump at a certain RPM. How do I figure

the GPM I’ll get?

A. Desired GPM = Desired RPM x

Rated GPM
Rated RPM

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

I’ll need to run the pump?

A. Electric Brake GPM x PSI (Standard 85%

Horsepower Required

=

1460 Mech. Efficiency)

Q. What size motor pulley should I use?
A. Pump Pulley (Outer Diameter) x

Pump RPM

Motor/Engine RPM

(Consult

Engine Mfr.)

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

system?

A. Torque (ft. lbs.) = 3.6

GPM x PSI

( )

RPM

Avoid Cavitation Damage

RESISTANCE OF VALVES AND FITTINGS

Nominal

Pipe

Inside

Size

Diameter

Inches

Inches

1/2 0.622 0.41 18.5 9.3 0.78 1.67 3.71 0.93 3.33
3/4 0.824 0.54 24.5 12.3 1.03 2.21 4.90 1.23 4.41

1 1.049 0.69 31.2 15.6 1.31 2.81 6.25 1.56 5.62

1

1

/4 1.380 0.90 41.0 20.5 1.73 3.70 8.22 2.06 7.40

1

1

/2 1.610 1.05 48.0 24.0 2.15 4.31 9.59 2.40 8.63

2 2.067 1.35 61.5 30.8 2.59 5.55 12.30 3.08 11.60

1

2

/2 2.469 1.62 73.5 36.8 3.09 6.61 14.70 3.68 13.20
3 3.068 2.01 91.5 45.8 3.84 8.23 18.20 4.57 16.40
4 4.026 2.64 120.0 60.0 5.03 10.80 23.90 6.00 21.60

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

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

Equivalent Length of Standard Pipe in Feet

Gate

Globe

Angle

Valve

Valve

Valve

45˚

Elbow

90˚

Elbow

180˚

Close

Ret

Tee

Thru

Run

Tee

Thru

Branch

TYPICAL RESERVOIR TANK

RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY

→

T

D

X

→

1.5 x D (Min.)

→

Supply Line

(Dia of pipe)

→

Level Sensing

Device

→

Bypass Line

(from regulator or unloader)

→

MIN. 4"

→

Flexible Hose
to Pump

FILTER

→

MIN. 4"

→

Minimum

Liquid

Level

Bypass Line

(from regulator or

unloader)

Minimum Two Baffles

Sealed at Bottom

One or several of the conditions shown in the chart below may
contribute to cavitation in a system resulting in premature wear,
system downtime and unnecessary operating costs.

CONDITION SOLUTION

Inadequate inlet
line size larger

Water hammering
liquid acceleration/
deacceleration

Rigid Inlet Plumbing●Use flexible wire reinforced hose to absorb

Excessive Elbows in●Keep elbows to a minimum and less than 90°
Inlet Plumbing

Excessive liquid
Temperature

Air Leaks in Plumbing●Check all connections

Agitation in Supply
Tank Minimum 6-10 times system GPM

High Viscosity Liquids●Verify viscosity against pump specifications

Clogged Filters

●

Increase line size to the inlet port or one size

●

Install C.A.T. Tube

●

Move pump closer to liquid supply

pulsation and pressure spikes

●

Use Thermo Valve in bypass line

●

Do not exceed pump temperature specifications

●

Substitute closed loop with baffled holding tank

●

Adequately size tank for frequent or high
volume bypass

●

Pressure feed high temperature liquids

●

Properly ventilate cabinets and rooms

●

Use PTFE thread tape or pipe thread sealant

●

Size tank according to pump output —

●

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

before operation

●

Elevate liquid temperature enough to reduce
viscosity

●

Lower RPM of pump

●

Pressure feed pump

●

Increase inlet line size

●

Perform regular maintenance or use clean
filters to monitor build up

●

Use adequate mesh size for liquid and pump
specifications

DIAGNOSIS AND MAINTENANCE

One of the most important steps in a high pressure system is to establish a regular maintenance program. This will vary slightly with each
system and is determined by various elements such as the duty cycle, the liquid being pumped, the actual specifications vs rated specifications
of the pump, the ambient conditions, the inlet conditions and the accessories in the system. A careful review of the necessary inlet conditions
and protection devices required before the system is installed will eliminate many potential problems.

CAT PUMPS are very easy pumps to service and require far less frequent service than most pumps. Typically, only common tools are required,
making in-field service convenient, however, there are a few custom tools, special to certain models, that do simplify the process. This service
manual is designed to assist you with the disassembly and reassembly of your pump. The following guide will assist in determining the cause
and remedy to various operating conditions. You can also review our FAQ or SERVICE sections on our WEB SITE for more facts or contact
CAT PUMPS directly.

PROBLEM 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.