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All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility for the operation of a customers high pressure system.
WARNING
CAT PUMPS 1681 - 94th Lane N.E. Minneapolis, MN 55449 - 4324 Phone (763) 780-5440 FAX (763) 780-2958 e-mail: techsupport@catpumps.com www.catpumps.com
World Headquarters
1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet Hampshire GU52 8BF, England Phone Fleet 44 1252-622031 Fax 44 1252-626655 e-mail: sales@catpumps.co.uk
International Inquiries
FAX (763) 785-4329 e-mail: intlsales@catpumps.com
2. Remove the V-Packing Cylinder by inserting screwdrivers into the exposed grove on opposite sides and pry out of the chamber. 3. Using a reverse pliers remove the V-Packing Spacer from the center of the V-Packing Cylinder. The V-Packing Spacers may remain in the V-Packing Cylinder or Discharge Manifold. If in the Discharge Manifold, insert screwdrivers into groove on opposite sides of Spacer and pry out. 4. Remove the Male Adapter, V-Packings and Female Adapter from the V-Packing Cylinder.
Reassembly of V-Packings NOTE: For standard installation, apply a small amount of oil to the outside edge of the LPS, HPS, VP, MA, FA for ease of installation and to avoid damage. 1. Examine the exterior O-Rings on the V-Packing Cylinder and replace if cut or worn. 2. Inspect I.D. of V-Packing Cylinder for pitting or grooves and replace as needed. 3. Insert the new Female Adapter into the V-Packing Cylinder with the V side up. (see Tech Bulletin 053). 4. Assemble the three (3) V-Packings (Model 3507), two (2) V-Packings (Model 3517) and insert into the V-Packing Cylinder with V side up. 5. Insert Male Adapter into V-Packing Cylinder with notches up. 6. Examine O-Ring and Back-up-Ring on V-Packing Spacer and replace if cut or worn. 7. Insert smaller diameter end of V-Packing Spacer into V-Packing Cylinder. 8. Invert the Inlet Manifold with crankcase side down. Press the V-Packing Cylinder containing V-Packing Spacer and V-Packings into manifold chambers until completely seated.
Disassembly of Lo-Pressure Seal 1. Place the Inlet Manifold on blocks with crankcase side down. 2. Use a screwdriver or the head of the M10 x 100 bolt to drive out Lo-Pressure Seal and Inlet Adapter. 3. Separate stainless steel Washer from Inlet Adapter. 4. Place Inlet Adapter on V-Packing cylinder and drive out Lo-Pressure Seal using a socket sized to fit. Reassembly Lo-Pressure Seal NOTE: For certain applications apply liquid gasket to the o-ring crevices and seal surfaces. See Tech Bulletin 053 for model identification. 1. Place crankcase side of Inlet Manifold facing up, insert Washer into manifold chamber. 2. Examine O-Ring on Inlet Adapter and replace if cut or worn. 3. Place Inlet Adapter with o-ring side down and insert new pre-greased Lo-Pressure Seal into the Inlet Adapter with garter spring facing up. Press squarely into position (see Tech Bulletin 053). NOTE: When using alternate materials, the fit of the special materials may be snug and require gently driving the LPS into position with a cylinder of the same diameter to assure a square seating and no damage to the LPS. 4. Insert Inlet Adapter and Lo-Pressure Seal with garter spring facing down and press squarely into manifold chamber.
* If other than CAT PUMPS special multi-viscosity ISO68 oil is used, change cycle should be every 300 hours. ** Each systems 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.
TORQUE CHART
Pump Item Pump Model Plunger Retainer Model 3507 Plunger Retainer Model 3517 Inlet Manifold Screws All Models Thread M7 M10 M14 Tool Size [Part No.] M14 Hex [25053] M21 Hex M12 Allen [33048] M10 Allen [33047] M8 Allen [33046] M13 Hex [25324] M17 Hex [25083] Oil Gauge Tool [44050] M22 Torque in. lbs. ft. lbs. Nm 90 220 480 355 220 115 7.2 18.1 39.8 29.6 18.1 9.4 10 25 54 40 25 13
Discharge Manifold Screws M12 All Models Valve Plug Screws All Models Crankcase Cover/ Bearing Cover Screws All Models Connecting Rod Screws All Models Bubble Oil Gauge All Models Mounting Bolts All Models M10 M8
395 45 570
45 5 68
002 003 024 035 036 041 043 052 053 064 068 069 074 077 080 083
Inlet Pressure VS Liquid Temperature Power Unit Drive Packages Lubrication of Lo-Pressure Seals Servicing Crankcase Section Cylinder and Plunger Reference Chart Oil Gauge and Crankcase LPS and HPS Servicing Plunger Rod and Stud Liquid Gasket By-Pass Hose Sizing S.S. V-Packing Spacer and O-Rings Forged Extended Manifolds Torque Chart Oil Drain Kit Extended Discharge Manifold Winterizing a Pump
All Models 3PFR - 68PFR, 10FR - 60FR All Models 7PFR - 60PFR All Models 3520 and 3535 All Plunger Models 3PFR, 5PFR, 15PFR, 35PFR, 60PFR All Plunger NAB-S.S. Models All Unloaders/Regulators 3507 35PFR Piston and Plunger Pumps All Models (except 2SF/4SF) 3507 and 3517 All Models
1/4
5/16
3/8
1/2
5/8
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.
Q. How can I find the RPM needed to get specific GPM (Gallons Per Minute) I want? Rated RPM A. Desired RPM = Desired GPM x Rated GPM Q. I have to run my pump at a certain RPM. How do I figure the GPM Ill get? Rated GPM A. Desired GPM = Desired RPM x Rated RPM Q. Is there a simple way to find the approximate horsepower Ill need to run the pump? A. Electric Brake GPM x PSI = Horsepower Required 1460 (Standard 85% Mech. Efficiency)
Q. What size motor pulley should I use? Pump RPM A. Pump Pulley (Outer Diameter) x Motor/Engine RPM Q. How do I calculate the torque for my hydraulic drive system? GPM x PSI A. Torque (ft. lbs.) = 3.6 RPM
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
One or several of the conditions shown in the chart below may contribute to cavitation in a system resulting in premature wear, system downtime and unnecessary operating costs.
CONDITION Inadequate inlet line size Water hammering liquid acceleration/ deacceleration Rigid Inlet Plumbing Excessive Elbows in Inlet Plumbing Excessive Liquid Temperature SOLUTION Increase line size to the inlet port or one size larger q Install C.A.T. Tube q Move pump closer to liquid supply
q
2 1/2
3 4
Use flexible wire reinforced hose to absorb pulsation and pressure spikes q Keep elbows to a minimum and less than 90
q q q
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.
Supply Line
(Dia of pipe)
MIN. 4"
1.5 x D (Min.)
MIN. 4"
Use Thermo Valve in bypass line Do not exceed pump temperature specifications q Substitute closed loop with baffled holding tank q Adequately size tank for frequent or high volume bypass q Pressure feed high temperature liquids q Properly ventilate cabinets and rooms Air Leaks in Plumbing q Check all connections q Use PTFE thread tape or pipe thread sealant q Size tank according to pump output Agitation in Supply Tank minimum 6-10 times system GPM q Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids q Verify viscosity against pump specifications before operation q Elevate liquid temperature enough to reduce viscosity q Lower RPM of pump q Pressure feed pump q Increase inlet line size q Perform regular maintenance or use clean Clogged Filters filters to monitor build up q Use adequate mesh size for liquid and pump specifications
Low pressure
Worn nozzle. Belt slippage. Air leak in inlet plumbing. Pressure gauge inoperative or not registering accurately. Relief valve stuck, partially plugged or improperly adjusted. Inlet suction strainer (filter) clogged or improperly sized. Abrasives in pumped liquid. Leaky discharge hose. Inadequate liquid supply. Severe cavitation. Worn seals. Worn or dirty inlet/discharge valves.
Replace with properly sized nozzle. Tighten belt(s) or install new belt(s). Tighten fittings and hoses. Use PTFE liquid or tape. Check with new gauge. Replace worn or damaged gauge. Clean/adjust relief valve. Replace worn seats/valves and o-rings. Clean filter. Use adequate size filter. Check more frequently. Install proper filter. Replace discharge hose with proper rating for system. Pressurize inlet and install C.A.T. Check inlet conditions. Install new seal kit. Increase frequency of service. Clean inlet/discharge valves or install new valve kit.
Pulsation
Check precharge. If low, recharge, or install a new dampener. Clean inlet/discharge valves or install new valve kit.
Worn V-Packings or Lo-Pressure Seals. Worn adapter o-rings. Humid air condensing into water inside the crankcase. Excessive wear to seals and V-Packings.
Install new seal kit. Increase frequency of service. Install new o-rings. Install oil cap protector. Change oil every 3 months or 500 hours. Install new seal kit. Increase frequency of service.
Inadequate inlet liquid supply. Broken or worn bearing. Loose pulley on crankshaft
Check liquid supply. Increase line size, pressurize or install C.A.T. Replace bearing. Check key and tighten set screw.
Oil leak Crankcase oil seals. Crankshaft oil seals and o-rings. Drain plug Bubble gauge Rear cover Filler cap
Worn crankcase oil seals. Worn crankshaft oil seals or o-rings on bearing cover. Loose drain plug or worn drain plug o-ring. Loose bubble gauge or worn bubble gauge gasket. Loose rear cover or worn rear cover o-ring. Loose filler cap or excessive oil in crankcase.
Replace crankcase oil seals. Remove bearing cover and replace o-rings and/or oil seals. Tighten drain plug or replace o-ring. Tighten bubble gauge or replace gasket. Tighten rear cover or replace o-ring. Tighten filler cap. Fill crankcase to specified capacity.
Pump runs extremely rough Inlet conditions Pump valves Pump seals
Restricted inlet or air entering the inlet plumbing Stuck inlet/discharge valves. Leaking V-Packings or Lo-Pressure seals.
Correct inlet size plumbing. Check for air tight seal. Clean out foreign material or install new valve kit. Install new seal kit. Increase frequency of service.
Scored plungers. Over pressure to inlet manifold. Abrasive material in the liquid being pumped. Excessive pressure and/or temperature of pumped liquid. Running pump dry. Starving pump of adequate liquid. Eroded manifold.
Replace plungers. Reduce inlet pressure per specifications. Install proper filtration at pump inlet and clean regularly. Check pressure and inlet liquid temperature. DO NOT RUN PUMP WITHOUT LIQUID. Increase hose one size larger than inlet port size. Pressurize and install C.A.T. Replace manifold. Check liquid compatibility.