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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

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 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 recom-

mended 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 ap-

plications 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

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 mal-

function 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 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).

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.

INSTALLATION AND START-UP INFORMATION

PN 30002 Rev K 7311

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.

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