CAT Pumps 2530 Service Manual Download Page 1

Page: 1 / 8

25PFR PLUNGER PUMP SERVICE MANUAL

25 FRAME SPLIT MANIFOLD:

2530, 2531, 2537

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 CAT PUMPS custom-blend, ISO-68 hydraulic

oil per pump specifications [84 oz., 2.5 L]. 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. Oiler adjustment is vertical to start feed,

horizontal to stop feed, dial to adjust flow rate. Additional lubrication may be re-

quired with increased hours of operation and temperature.
PUMP ROTATION: Pump was designed for forward rotation to allow optimum

lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil

level is increased slightly above center dot to assure adequate lubrication.
PULLEY SELECTION: Select size of motor pulley required to deliver the desired

flow from Horsepower Requirement and Pulley Selection Chart (refer to Tech

Bulletin 003 or individual Data Sheet).
MOTOR SELECTION: The motor or engine driving the pump must be of adequate

horsepower to maintain full RPM when the pump is under load. Select the electric

motor from the Horsepower Requirement Chart according to required pump

discharge flow, maximum

pressure at the pump and drive losses of approximately

3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper

engine size.
MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit

drainage of crankcase oil. An uneven mounting surface will cause extensive

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 be required. See Tech

Bulletin 002 or call CAT PUMPS for recommendations.
C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in

applications with stressful inlet conditions such as high temperatures, booster pump

feed, long inlet lines or quick closing valves.

DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to

avoid deadhead overpressure condition and severe damage to the pump or system.
Install a

Pulsation Dampening device on the discharge head or in the discharge line

as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) is

properly precharged for the system pressure (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 which would be read at the

discharge manifold of the pump, NOT AT THE GUN OR NOZZLE.
Use PTFE thread tape or pipe thread sealant (sparingly) to connect accessories or

plumbing. Exercise caution not to wrap tape beyond the last thread to avoid

tape from becoming lodged in the pump or accessories. This condition will cause a

malfunction of the pump or system.
PRESSURE REGULATION: All systems require both a primary pressure regulating

device (i.e., regulator, unloader) and a secondary pressure safety relief device

(i.e., pop-off valve, safety valve). The primary pressure device must be installed on

the discharge side of the pump. The function of the primary pressure regulating

device is to protect the pump from over pressurization, which can be caused by a

plugged or closed off discharge line. Over pressurization can severely damage the

pump, other system components and can cause bodily harm. The secondary safety

relief device must be installed in-line between the primary device and pump or on

the opposite side of the manifold. 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.
If a large portion of the pumped liquid is by-passed (not used) when the high

pressure system is running, this by-pass liquid should be routed to an adequately

sized, baffled supply tank or to drain. If routed to the pump inlet, the

by-pass liquid

can quickly develop excessive heat and result in damage to the pump. A

temperature control device to shut the system down within the pump limits or multiple

THERMO VALVES must be installed in the by-pass line to protect the pump.
NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure

regulating device to compensate. Replace nozzle and reset regulating device to

system pressure.
PUMPED LIQUIDS: Some liquids may require a flush between operations or before

storing. For pumping liquids other than water, contact your CAT PUMPS supplier.
STORING: For extended storing or between use in cold climates, drain all pumped

liquids from pump and

flush with antifreeze solution to prevent freezing and

damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech

Bulletin 083).

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.

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.

PN 30053 Rev H 1643

CAT PUMPS (U.K.) LTD.

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

Hampshire GU52 8BF, England

Phone Fleet 44 1252-622031 — Fax 44 1252-626655

e-mail: [email protected]

N.V. CAT PUMPS INTERNATIONAL S.A.

Heiveldekens 6A, 2550 Kontich, Belgium

Phone 32-3-450.71.50 — Fax 32-3-450.71.51

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

CAT PUMPS DEUTSCHLAND GmbH