CAT Pumps 1530 User manual

www.catpumps.com
Product Quality, Reliability and Support You Expect
SERVICE MANUAL
15 & 25 FRAME PLUNGER PUMPS
PUMP MODELS INCLUDED
1530 1531 1540 1540E 1560 1580
2510 2511

SERVICE MANUAL | 15 & 25 Frame Plunger Pumps2(763) 780-5440 | [email protected] | www.catpumps.com
Safety Symbols 2
General Safety Information 3
Servicing the Seals 6
Discharge Manifold Removal 6
Inlet Manifold Removal 6
Seal Disassembly 6
Seal Reassembly 6
Servicing the Plungers 7
Plunger Disassembly 7
Plunger Reassembly 7
Servicing the Valves 8
Valves Disassembly 8
Valves Reassembly 8
Servicing the Crankcase 9
Reference Information 10
Torque Chart 10
Technical Bulletin Reference Chart 10
Torque Sequences 10
Preventive Maintenance Schedule 11
Diagnosis and Maintenance 12
Table of Contents
IMPORTANT SAFETY INSTRUCTIONS
It is the responsibility of the user to read and understand all
instructions, important safeguards and safety precautions before
operating or servicing any pump. Failure to do so may result in
property damage, personal injury or death.
GENERAL SAFETY INFORMATION AND SYMBOLS
Pay special attention to the following signal words, safety alert
symbols and statements:
Safety Symbols
Indicates a potential personal injury hazard.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury or property damage.
Indicates a hazardous situation which, if not
avoided, could result in property damage.
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.

SERVICE MANUAL | 15 & 25 Frame Plunger Pumps 3(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information
A. FLAMMABLE OR EXPLOSIVE LIQUID HAZARD
Do not operate pump with ammable or explosive liquids unless extraordinary safety precautions are observed. Leaks of ammable or explosive
liquids, if exposed to elevated temperatures, static electricity, sparks or other hazards, will result in ame or possible explosion, causing serious
personal injury, death or property damage.
1. Before operating pump with ammable or explosive liquids, ensure proper maintenance has been performed.
2. Do not operate pump with ammable or explosive liquids if leaks are detected.
3. Only pump ammable or explosive liquids that are compatible with pump component materials.
4. Do not operate pump with ammable or explosive liquids without safeguards or safety systems to detect leaks, elevated temperatures,
spark prevention or any other hazards dened by the NFPA systems.
5. Do not remove Flammable Liquids Product Suitability Hang Tag to assure proper safety.
6. Follow ATEX guidelines for potentially-explosive atmospheres.
A. ELECTRICAL SHOCK HAZARD
Do not service pump or electrical equipment while energized. Electricity can cause personal injury, death or property damage.
1. Adhere to “Lock Out” and “Tag Out” procedures for electrical equipment.
2. Before commencing pump service, turn power supply o.
3. Keep water away from electrical outlets and electrical devices.
4. Electrical components must be installed by a qualied electrician to avoid risk of electrocution.
B. ROTATING PARTS HAZARD
Do not service pump while energized. Moving, rotating or reciprocating parts can crush and cut, causing personal injury, death
or property damage.
1. Adhere to “Lock Out” and “Tag Out” procedures for electrical equipment.
2. Before commencing pump service, turn power supply o, turn water supply o, squeeze trigger on gun to relieve system pressure.
3. For mobile equipment, be sure engines and hydraulics are turned o and secured to avoid accidental start.
4. Do not operate with safety guards removed.
5. Always use safety guards on all belt drives, couplings and shafts.
C. HOT SURFACE HAZARD
Do not touch pump, accessories or drive system while operating and until cool down is complete. Touching hot surface areas of the pump,
accessories or drive system can cause severe burns or personal injury.
D. SKIN PUNCTURE HAZARD
Do not allow spray to contact any part of the body or animals. Pumped liquids under high pressure can pierce skin and underlying tissue
or can deect debris leading to serious personal injury or death.
1. Relieve all line pressure in the inlet line to the pump and discharge line from the pump before performing any maintenance on the pump.
2. When a high-pressure gun is not in use, set safety trigger lock (safety latch) to avoid accidental high-pressure operation and personal injury
or property damage.
3. Do not check for leaks with hand. Use a piece of cardboard to check for leaks.
4. Review cleaning procedures to minimize heavy back blasting.
5. Wear adequate safety equipment and clothing when operating a high-pressure
sprayer. Never use high-pressure spray with bare feet or exposed skin, and always wear safety glasses.
E. PUMPING LIQUIDS HAZARD
Do not operate pump with hot water, chemicals or other hazardous liquids unless extraordinary safety precautions are observed.
Pumping hot water, chemicals or other hazardous liquids can expose personnel to serious injury.
1. Provide guards or shields around equipment to protect personnel.
2. Wear mask, goggles or eye protection while operating high-pressure equipment.
3. Obtain a Safety Data Sheet (SDS) and take appropriate safety measures for the liquid being handled.

SERVICE MANUAL | 15 & 25 Frame Plunger Pumps4(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information and Symbols
F. OVER PRESSURIZATION HAZARD
Do not operate high-pressure pumping system unless extraordinary safety precautions are observed. A high-pressure pumping system can
deadhead or over pressurize causing serious personal injury and property damage.
1. All high-pressure systems require a primary pressure regulating device (e.g., regulator or unloader) and a secondary pressure safety relief device
(e.g., pop-o valve, safety valve, rupture disc) to assure proper pressure setting and overpressure protection.
2. All high-pressure systems require a pressure gauge to monitor pressure settings and avoid overpressure of equipment or personal harm.
3. Install primary pressure relief device on the discharge side of the pump.
4. Install secondary pressure relief device between the primary device and pump.
5. Install pressure gauge onto the discharge manifold or in the discharge line near the manifold.
6. Open all valves on discharge side of plumbing before operation.
G. OXYGEN HAZARD
Do not charge pulsation dampeners with oxygen. Oxygen may cause an explosion causing personal injury, death or property damage.
1. Use nitrogen only when charging pulsation dampeners, DO NOT USE OXYGEN.
2. Use proper charging tools to charge pulsation dampeners.
3. Charge pulsation dampener within specications stated on data sheet to assure proper pulsation dampening and prevent failure of bladder.
H. FALL HAZARD
Do not operate pressure washer while standing on slippery or unstable surface unless extraordinary safety precautions are observed.
Pressure washing may create slippery surface on which a person may slip and fall causing personal injury or death.
1. Wear suitable footwear to maintain a good grip on wet surfaces.
2. Do not stand on ladders or scaolding.
3. Do not over reach or stand on unstable supports.
4. Keep good footing and balance and hold gun with both hands to control kick back.
A. IMPROPER USE OF FITTINGS HAZARD
Do not operate the pump with improperly-connected, sized, worn or loose ttings, pipes or hoses. Operating the pump under these conditions
could result in personal injury and property damage.
1. Ensure all ttings, pipes and hoses are properly rated for the maximum pressure rating and ow of the pump.
2. Check all ttings and pipes for cracks or damaged threads.
3. Check all hoses for cuts, wear, leaks, kinks or collapse before each use.
4. Ensure all connections are tight and secure.
5. Use PTFE thread tape or pipe thread sealant (sparingly) to reconnect plumbing. Do not wrap tape beyond the last thread, this will prevent loose
tape from becoming lodged in the pump or accessories.
6. Apply proper sealants to assure secure t or easy disassembly when servicing.
B. FROZEN LIQUID HAZARD
Do not operate the pump with frozen liquid. Operating the pump under this condition could over pressurize and jettison the manifold from
the crankcase causing personal injury and property damage.
1. Store pump or pumping system in an environmentally-controlled room protected from freezing temperatures.
2. Follow procedures in TECH BULLETIN 083 to winterize pump.
C. CLEANING PUMP HAZARD
Do not use solvents that are ammable and toxic to clean or degrease equipment. Use of these solvents could result in personal injury
and property damage.
1. Follow safety instructions as found in SDS or on packaging of each liquid.
2. Clean equipment in a well-ventilated area.
3. Disposal of solvents to be in accordance with local, state and federal regulations.
D. OPERATING BEYOND SPECIFICATIONS HAZARD
Do not operate the pump outside the specications of individual pump data sheet or service manual. Operating the pump under these
conditions could result in personal injury and property damage.
1. Do not operate the pump faster than the maximum recommended RPM.
2. Do not operate the pump at pressures higher than the maximum recommended pressure.
3. Do not operate the pump at temperatures higher than the maximum recommended temperatures.
4. Do not use accessories that are not compatible or rated for the pump.
CONTINUED

SERVICE MANUAL | 15 & 25 Frame Plunger Pumps 5(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information and Symbols
E. LIFTING DEVICE HAZARD
Do not lift pump with unsuitable lifting devices. Use of unsuitable lifting devices may cause pump to fall, resulting in personal injury, damage
to pump and/or pump with drive/base plate.
1. Lifting eyes installed on the pump must be used only to lift the pump.
2. Special lifting eyes should be installed on the base for lifting the pumping system (e.g. base, drive and accessories)
3. If slings or chains are used for lifting, they must be safely and securely attached to properly balance the weight of the unit.
4. Inspect slings and chains prior to use and replace worn and damaged slings and chains.
A. OIL HAZARD
Use only genuine Cat Pumps custom-blend, premium-grade, petroleum-based hydraulic oil. Use of other oil may not provide proper
lubrication of drive-end components and may result in damage to the crankcase of the pump.
1. Fill pump crankcase to specic capacity indicated on data sheet or service manual prior to startup.
2. Cat Pumps premium custom-blend oil is available worldwide in 21-ounce bottles, (single and 12-pack cases), 2.5 gallon jugs (single and 2-pack)
or 30 gallon drums. Use of other oils may void the warranty.
B. PUMP ROTATION DIRECTION HAZARD
Do not rotate pump crankshaft in reverse direction. Rotation of pump crankshaft in reverse direction may not provide proper lubrication
and may result in damage to the drive-end components.
1. Forward rotation is the top of the crankshaft turning towards the manifold head of the pump.
2. Ensure oil is lled to the center red dot on sight gauge for forward rotation.
3. If reverse rotation is unavoidable, ensure oil is lled to slightly above center red dot on sight gauge.
C. BELT TENSION HAZARD
Do not operate pump with excessive belt tension. Excessive belt tension may damage the pump’s bearings or reduce horsepower.
1. Rotate pump crankshaft before starting to ensure shaft and bearings are moving freely.
2. Ensure pulleys are properly sized.
3. Periodically replace belts to assure full horsepower transmission.
4. Ensure center distance dimensions between pulleys is correct.
D. BYPASS OPERATION HAZARD
Do not operate the pump in bypass for extended lengths of time. Operating the pump under this condition can quickly cause heat build-up
resulting in damage to the pump.
1. Route bypass line to supply reservoir to dissipate heated bypass liquid into a large reservoir of cool water to reduce excessive temperature build-
up.
2. Route bypass line to inlet of pump using a thermo valve in the bypass line or auto shut-o assembly that will sense temperature rise
and either bypass or shut down system before damage occurs.
E. DRY OPERATION HAZARD
Do not operate the pump without water or liquid. Operating pump under these conditions could result in damage to the pump.
1. Open all valves on inlet side of pump before starting operation to prevent starving the pump.
2. Do not exceed inlet suction pressure limit specied in pump data sheet.
3. Ensure inlet feed exceeds the maximum ow being delivered by the pump.
4. Ensure all ttings, pipes and hoses are properly-sized for the pump to avoid restricted ow.
5. Review and implement all other recommendations appropriate for your system from the Inlet Condition Check-List.
CONTINUED
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.
Inspect and service all system accessories on the same schedule as your pump.

SERVICE MANUAL | 15 & 25 Frame Plunger Pumps6(763) 780-5440 | [email protected] | www.catpumps.com
Servicing the Seals
MANIFOLD AND SEAL REMOVAL
1540, 1540E
High-Pressure Seal Arrangement
1530, 1531
V-Packing Arrangement
REMOVING THE DISCHARGE MANIFOLD
1. Remove the hex head (HSH) screws.
2. Support the manifold from the underside and tap the backside of the
discharge manifold with a soft mallet to gradually work manifold from
pump.
3. Remove the O-rings from lower chambers of the face of the inlet manifold.
REMOVING THE INLET MANIFOLD
1. Remove the HSH Screws. Use a adjustable wrench to rotate the crankshaft
to begin the separation of the inlet manifold from the crankcase.
2. Support the manifold from the underside and tap the rear of the inlet
manifold with a soft mallet to gradually remove from pump.
NOTE: Two screwdrivers on opposite sides of the manifold may be used
to assist separation.
SERVICING THE SEALS
Disassembly
1. To service the seals and packings, it is necessary to remove both the
discharge and inlet manifolds. Follow disassembly procedures for
REMOVING THE DISCHARGE MANIFOLD and REMOVING THE INLET
MANIFOLD.
NOTE: On models 1530, 1531, 2510, 2511, the spacer with coil springs may
stay in the discharge manifold or inlet manifold. On models 1540, 1540E,
the high-pressure seal spacer will generally stay in the inlet manifold.
2. Models 1530, 1531, 2510, 2511: Remove the spacer with coil springs from
either manifold and exposed O-rings and backup rings from the spacer.
Models 1540, 1540E, 1560, 1580: Remove the exposed O-ring. Insert two (2)
screwdrivers into the grooves on opposite sides of the spacer and pry from
the chamber.
NOTICE:Exercise caution as the screwdrivers may score O-ring sealing
surface.
3. Models 1530, 1531, 2510, 2511: Remove male adapter, two (2) V-Packings
and female adapter from each seal chamber.
Models 1540, 1540E: Remove high-pressure seal from each seal chamber.
Models1560, 1580: Remove three (3) V-Packings (1560), two (2) V-Packings
(1580) and female adapter from each seal chamber.
4. Place the inlet manifold on the work surface with crankcase side up.
5. Models 1530, 1531, 1540, 1540E, 1560, 1580: Use a screwdriver to remove
low-pressure seal from backside of manifold.
Models 2510, 2511: Use a screwdriver to remove washer and
low-pressure seal from backside of manifold.
NOTICE:Exercise caution as the screwdriver may score O-ring sealing
surface.
Reassembly
NOTE: For certain applications apply liquid gasket to the O-ring crevices
and seal surfaces. Refer to Tech Bulletin 053 for model identification.
NOTE: EPDM elastomers require silicone-basedlubricant.
NOTE: For standard applications, apply a small amount of oil to the
outside edge of the LPS, HPS, VP, MA, FA and O-rings for ease of
installation and to avoid damage.
1. Examine low-pressure seals for wear to the internal ridges, outer surfaces
or for broken springs. Replace as needed.
2. Press low-pressure seal into each seal chamber of the Inlet Manifold with
the garter spring down.
Models 2510, 2511: Install washers into each seal chamber.
NOTE: When using alternate materials, the fit of the special materials
may be snug and require gently driving the low-pressure seal into
position with a cylinder of the same diameter to ensure a square
seating and no damage to the low-pressure seal.
3. Models 1530, 1531, 2510, 2511: Examine the spacer with coil springs
for scale build-up, wear, broken or fatigued coil springs. Replace
as needed. Examine both front and rear O-rings and backup
rings for cuts or deterioration, replace as needed.
Models 1540, 1540E: Examine the high-pressure seal spacer for scale
build-up or wear and replace as needed. Examine the front and rear
O-rings for cuts or deterioration and replace as needed.
4. Models 1530, 1531, 2510, 2511: Examine male and female adapters
for wear. Replace as needed.
Models1560 1580: Examine female adapter and spacer. Replace
as needed.
5. Models 1530, 1531, 1560, 2510, 2511: Examine V-Packings for frayed
edges or uneven wear. Replace as needed.
Models 1540, 1540E: Examine high-pressure seals for frayed edges
or uneven wear. Replace as needed.
2510, 2511
V-Packing Arrangement

SERVICE MANUAL | 15 & 25 Frame Plunger Pumps 7(763) 780-5440 | [email protected] | www.catpumps.com
Reassembly (Continued)
6. Place the inlet manifold on work surface with crankcase side down.
7. Models 1530, 1531, 1560, 1580, 2510, 2511: Place the female adapter with
flat side down, “V” side up,into each seal chamber.
8. Models 1530, 1531, 1580, 2510, 2511: Fit two (2) new V-Packings together.
Model 1560: Fit three (3) new V-Packings together.
Lubricate the outer surface of the packings and insert into seal chamber
with the “V” side down. The “V” will mate with “V” side of the female
adapter.
9. Models 1530, 1531, 1560, 1580, 2510, 2511: Place male adapter with “V”
side down inside each seal chamber.
10. Models 1530, 1531, 2510, 2511: Lubricate outer surface of spacer with coil
springs and insert into seal chamber until completely seated.
11. Models 1540, 1540E: Lubricate outer surfaces of high-pressure seals
and position into seal chamber with metal side down, grooved side up.
Lubricate the outer O-rings on the high-pressure seal spacer and press
into inlet manifold seal chamber.
12. Model 1540E ONLY: Apply liquid gasket ThreeBond 1207D®to the face
of the crankcase and inlet manifold to maintain a moisture-free seal.
Refer to Tech Bulletin 100.
13. Support the inlet manifold from the under side and slide over plungers.
Apply Loctite®242®to HSH screw threads and thread in hand tight.
Torque in sequence to specifications in torque chart.
14. Install new O-rings at bottom face of inlet manifold.
15. Support the discharge manifold from the under side and press
discharge manifold into inlet manifold. Thread HSH screws in hand
tight. Torque in sequence to specifications in torque chart
NOTE: It is highly recommended that antiseize lubricant (PN 6119) be
applied to the threads on all stainless steel components to prevent
galling.
Loctite and 242 are registered trademarks of the Henkel Corporation.
ThreeBond is a registered trademark of ThreeBond Co., LTD.
DISASSEMBLY AND REASSEMBLY
Servicing the Plungers
SERVICING THE PLUNGERS
Disassembly
1. To service the plungers, it is necessary to remove the discharge and inlet
manifolds. Follow disassembly procedures for REMOVING THE DISCHARGE
MANIFOLD and REMOVING THE INLET MANIFOLD.
2. Models 1530, 1531, 1560, 1580: Remove the two-piece seal retainer and
wick from each plunger rod.
Models 2510, 2511: Remove the one-piece seal retainer and wick from each
plunger rod.
Model 1540, 1540E: Remove the one-piece seal retainer from each plunger rod.
3. Using a wrench, loosen the plunger retainers about three to four turns.
4. Push the ceramic plungers back towards the crankcase to separate from
the plunger retainers and proceed with unthreading the plunger retainers
by hand.
5. Remove plunger retainers, O-rings, backup rings and gaskets.
NOTE: On Models 1531, 2510, 2511, the plunger retainer studs may stay
on plunger rods or come off with plunger retainers.
6. Models 1530, 1531, 1540, 1540E: Remove ceramic plungers and barrier
slingers.
Models 1560, 1580, 2510, 2511: Remove ceramic plungers, keyhole washers
and barrier slingers.
Reassembly
1. Visually inspect crankcase oil seals for deterioration or leaks and contact
Cat Pumps for assistance with replacement.
2. Examine plunger retainers, studs, barrier slingers and keyhole washers
for wear and replace as needed.
3. Models 1530, 1531, 1540, 1540E: Slide barrier slingers over plunger rods
with concave side away from crankcase.
Models 1560, 1580, 2510, 2511: Slide keyhole washer over plunger rods
with split ends facing downward.
4. Examine ceramic plungers for scoring, scale build-up, chips or cracks
and replace as needed. Generally,the ceramic plungers do not need
to be replaced.
5. Slide ceramic plungers over plunger rods.
NOTE: Ceramic plunger can only be installed in one direction. Do not
force onto plunger rod.
NOTE: Do not lubricate wicks at initial start-up. Operate for 10 to 15
minutes to allow grease from low-pressure seal to penetrate the plunger
surface, then lubricate as needed.
6. Examine gaskets, O-rings and backup rings for cuts or wear and replace
as needed.
7. Models 1530, 1531, 1560, 1580, 2510, 2511: Install gaskets first, then O-rings
and backup rings onto plunger retainers.
NOTE: Lubricate O-rings and backup rings for ease in installation and
to reduce possible damage.
Models 1540, 1540E: Install gasket onto plunger retainers.
1530, 1531
Low-Pressure Seal
1540, 1540E
Low-Pressure Seal
2510, 2511
Low-Pressure Seal

SERVICE MANUAL | 25 Frame Plunger Pumps8(763) 780-5440 | [email protected] | www.catpumps.com
Servicing the Valves
VALVE REMOVAL
SERVICING THE VALVES
Disassembly
1. Models 1530 1531, 1540, 1540E, 2510, 2511: Remove the hex valve
plugs with O-ring.
Models1560, 1580: Remove the eight (8) hex socket head (HSH) screws
and valve cover. Remove valve plugs with O-ring and backup ring.
2. Models 1530 1531, 2510, 2511: Remove the exposed coil spring and
washer from the top of the spring retainer.
Models 1540 and 1540E: Remove washer from the top of the spring
retainer.
3. Models 1530, 1531, 1540, 1540E, 2510 and 2511: Usea pliers to grasp
the spring retainer by the tab at the top and remove from valve
chamber. Normally the valve assembly will remain together. If the
assembly separates during removal, use a reverse pliers and lift the
seat from the chamber.
Models1560, 1580: Use a reverse pliers to grasp the spring retainer
and remove the stacked valve assemblies.
4. To separate valve assemblies, insert screwdriver into spring retainer
and use a twisting motion on the backside of valve until seat separates
from the spring retainer. Each assembly consists of a spring retainer,
spring, valve, seat, O-ring and backup ring.
Models 1540, 1540E ONLY: The discharge manifold must be removed
in order to remove the inlet valve assemblies. Follow disassembly
procedure for REMOVING THE DISCHARGE MANIFOLD.
Reassembly
NOTE: For certain applications apply liquid gasket to the O-ring
crevices and seal surfaces. Refer to Tech Bulletin 053 for model
identification.
NOTE: EPDM elastomers require silicone-basedlubricant.
1. Examine spring retainers for internal wear or breaks in the structure
and replace as needed.
2. Examine springs and coil 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 O-rings and backup rings for cuts or wear and replace as
needed.
5. Models 1530, 1531, 2510, 2511: Install O-ring, then backup ring onto
seat.
Models 1540, 1540E: Install O-ring onto seat.
6. Place the valve onto the seat with dish side down.
7. Place spring on valve and snap the spring retainer onto seat.
8. Models 1560, 1580: Install O-ring onto small diameter inlet seat.
9. Place the valve onto the seat with dish side down.
Reassembly (Continued)
8. Apply Loctite®242®to exposed threads on the plunger retainer
and torque per chart.
9. Rotate the crankshaft so the two outside plungers are extended
the same distance.
10. Models 1530, 1531, 1560, 1580, 2510, 2511: Install seal retainer onto
the plunger rod with new wicks, long tab down.
Models 1530, 1531, 1560, 1580: The drain slots should face the
crankcase with openings to the top and bottom.
Models 1540, 1540E, 2510, 2511: The seal retainer openings should
be at top and bottom. Press completely into crankcase.
11. Lightly lubricate ceramic plungers to assist in installing into the
manifold.
12. Support the inlet manifold from the under side and slide over
plungers. Press completely into crankcase. Apply Loctite®242®
to HSH screw threads and thread in hand tight. Torque in sequence
to specifications in torque chart.
13. Install new O-rings at bottom inlet ports of inlet manifold.
14. Support the discharge manifold from the under side and align
with inlet manifold. Thread in hand tight. Torque in sequence
to specifications in torque chart.
NOTE: It is highly recommended that antiseize lubricant (PN 6119)
be applied to the threads on all stainless steel components to prevent
galling.
Loctite and 242 are registered trademarks of the Henkel Corporation.
1540, 1540E
Plunger Arrangement
1530, 1541
Plunger Arrangement
1530, 1541
Plunger Arrangement

SERVICE MANUAL | 25 Frame Plunger Pumps 9(763) 780-5440 | [email protected] | www.catpumps.com
Servicing the Crankcase
SERVICING THE CRANKCASE SECTION
1. While manifolds, plungers and seal retainers are removed
examine crankcase oil seals for leaking and wear.
2. Check for any signs of leaking at rear cover, drain plug, bubble gauge
and dipstick (2510, 2511).
Model 1540E ONLY: When servicing the crankshaft seal, bearing cover
or rear cover, apply liquid gasket ThreeBond 1207Dto the face of the
crankcase, inlet manifold, bearing covers and rear cover O-ring groove
to maintain a moisture-free seal. Refer to Tech Bulletin 100.
3. Check oil level and check for evidence of water in oil. Change
crankcase oil on a regular schedule. See Preventative Maintenance
Check-List.
4. Rotate crankshaft by hand to feel for smooth bearing movement.
5. Examine crankshaft oil seals externally for drying, cracking or leaking.
6. Contact Cat Pumps or your local distributor if crankcase service is
required. Refer to Tech Bulletin 035.
SERVICING THE CRANKCASE
1530, 1531
Complete Inlet/Discharge Valve Assembly
1540, 1540E
Complete Inlet/Discharge Valve Assembly
2510, 2511
Complete Inlet/Discharge Valve Assembly
Reassembly (Continued)
10. Place spring on valve and snap longer spring retainer with large
opening onto seat.
11. Install O-ring, then backup ring onto discharge seat. Snap discharge
seat onto inlet spring retainer.
12. Place valve onto seat with dish side down.
13. Place spring on valve and snap smaller spring retainer onto discharge
seat.
14. Lubricate outer O-ring and backup ring surface and walls of valve
chamber. Press valve assembly squarely into valve chamber until
completely seated.
15. Models 1530, 1531, 2510, 2511: Place washer, then coil spring on top of
the spring retainer.
Models 1540, 1540E: Place washer on top of the spring retainer.
16. Models 1540, 1540E (inlet valve assemblies): Place washer into valve
chamber on back side of manifold. Lubricate outer O-ring and press
valve assembly into valve chamber, retainer first, until completely
seated.
17. Examine the O-ring on the valve plug and replace if cut or worn.
Lubricate new O-ring before installing on valve plug to avoid
damaging as they are worked over the plug threads.
NOTE: It is highly recommended that antiseize lubricant (PN 6119)
be applied to the threads on all stainless steel components to
prevent galling.
18. Models1530, 1531, 1540E, 2510, 2511: Slowly thread the valve plug
into chamber. Exercise caution to avoid extruding or cutting the
O-ring. Torque to specifications in torque chart.
19. Models1560, 1580: Place valve cover over valve plugs. Thread HSH
screws in hand tight. Torque to specifications in torque chart.
20. Install new O-rings at bottom inlet ports of inlet manifold. Support
the discharge manifold from the under side and press discharge
manifold into inlet manifold. Thread HSH screws in hand tight. Torque
in sequence to specifications in torque chart.

SERVICE MANUAL | 15 & 25 Frame Plunger Pumps10 [phone] | [email protected] | www.catpumps.com
Reference Information
TORQUE CHART
PUMP ITEM THREAD TOOL SIZE TOOL TORQUE
PART NUMBER IN-LBS FT-LBS Nm
Plunger Retainers 15PFR M6 12mm Combination Wrench —55 4.6 6.2
25PFR M7 14mm Combination Wrench —108 9.0 12.2
Inlet Manifold Screws 15PFR M10 8mm Hex Bit Socket with Ratchet —222 18.5 25.0
25PFR M12 10mm Hex Bit Socket with Ratchet —355 30.0 40.0
Discharge Manifold Screws 1540, 1540E M10 8mm Hex Bit Socket with Ratchet —250 21.0 28
1530, 1531, 1560 M12 10mm Hex Bit Socket with Ratchet —355 30.0 40.0
1580, 2510, 2511
Valve Plugs 15PFR M36 32mm Socket with Ratchet —1060 88 119
25PFR M42 36mm Socket with Ratchet —1680 140 190
Valve Plug Cover Screws 1560, 1580 M12 10mm Hex Bit Socket w!ith Ratchet —250 21.0 28
Rear Cover Screws and
Bearing Cover Screws
15PFR M6 10mm Combination Wrench —50 4.0 5.4
25PFR M8 13mm Combination Wrench —115 9.58 13
Connecting Rod Screws 15PFR, 25PFR M8 13mm Combination Wrench —216 18 24
Bubble Oil Gauge 15PFR Only M28 Oil Gauge Tool 44050 45 3.8 5.0
TECHNICAL BULLETIN REFERENCE CHART
NO. SUBJECT MODELS
002 Inlet Pressure vs. Liquid Temperature All Models
003 Power Unit Drive Packages 3PFR–68PFR, 10PFR–60PFR
024 Lubrication of Low-Pressure Seals All Models
035 Servicing Crankcase Section 7CP, 7PFR–68PFR
036 Cylinder and Plunger Reference Chart All Models
043 Servicing the Low and High- Pressure Seals All Plunger Models
053 Liquid Gasket All Plunger NAB Stainless Steel Models
064 Bypass Hose Sizing All Unloaders/Regulators
074 Torque Chart Piston and Plunger Pumps
083 Winterizing a Pump All Models
085 M8 Keyway 25FR, 25PFR, 28PFR
095 Galling Preventative All Stainless Steel Models
100 Crankcase and Model Number Change 1540 to 1540E
TORQUE SEQUENCES
Models: 1530, 1531, 1560, 1580, 2510, 2511 Models: 1540, 1540E

SERVICE MANUAL | 15 & 25 Frame Plunger Pumps 11(763) 780-5440 | [email protected] | www.catpumps.com
Reference Information
PREVENTIVE MAINTENANCE SCHEDULE
Many application factors determine proper pump maintenance intervals. Variation in duty cycle, operating performance, fluid temperature, fluid
type, inlet conditions and application environment can affect maintenance schedules. Every application should be evaluated and serviced based on
its own requirements. The following checklist is intended as a reference guide only.
CHECK DAILY WEEKLY 50 HRS. 500 HRS. 1500 HRS. 3000 HRS.
Filters •or •
Oil Level/Quality •or •
Water Leaks •or •
Oil Leaks •
Plumbing •
Belts, Pulley •
Accessories •
Seals
Valves
1 1
2
3
Cat Pumps recommends using our custom-blend premium grade hydraulic oil formulated to meet Cat Pumps specifications. For best results,
perform an initial oil change after the first 50 hours of operation and every 500 hours thereafter.
Every system operates under different conditions. Past performance and maintenance history are the best indicators of future performance.
If system performance degrades or changes, check seals and valves immediately. Service as required to restore system performance.
Depending upon operating conditions, maintenance intervals for seals kits range between 1,500 and 8,000 hours.
Pump valves typically require changing every other seal change. If system performance degrades or changes, check valves immediately.
Depending upon operating conditions, maintenance intervals for valve kits range between 3,000 and 16,000 hours.
1
2
3
Cat Pumps custom blend crankcase oil is exclusively designed, tested and proven to maximize the life of your pump.
This special formulated premium-grade, petroleum-based, ISO 68 hydraulic oil contains the most advanced additive
package to protect against wear, oxidation, rust and corrosion.
Cat Pumps premium custom-blend oil is available worldwide in 21-ounce bottles, (single and 12-pack cases), 2.5 gallon jugs
(single and 2-pack) or 30 gallon drums. Use of other oils may void the warranty.
Water leaks or loss of system performance can be an indicator of seal wear. Seal wear has many causes, including contaminated liquid or high-
temperature/run dry operation. If the low-pressure seals show wear, the high-pressure seals most likely are in a similar condition. It is a good
practice to replace both low and high-pressure seals and inspect plungers when leaks are present.

PROBLEM PROBABLE CAUSE SOLUTION
Low pressure • Worn nozzle. • Replace with proper size nozzle.
• 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.
• 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 • Foreign material trapped in inlet/discharge valves. • Clean inlet/discharge valves or install new valve kit.
Water leak
• Under the manifold • Worn high-pressure or low-pressure seals. • Install new seal kit. Increase frequency of service.
• Into the crankcase • Humid air condensing into water inside the crankcase. • Install new oil cap protector. Change oil every 3 months
or 500 hours.
• Excessive wear to high-pressure or low-pressure seals. • Install new seal kit. Increase frequency of service.
Knocking noise
• Inlet supply • Inadequate inlet liquid supply. • Check liquid supply. Increase line size or pressurize.
• Bearing • Broken or worn bearing. • Replace bearing.
Oil leak
• Crankcase oil seal • Worn crankcase oil seal. • Replace crankcase oil seal.
• Crankshaft oil seal and O-ring • Worn crankshaft oil seal or O-ring on bearing cover. • Remove bearing cover and replace O-ring and/or oil seal.
• 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.
• Bearing cover • Loose bearing cover or worn bearing cover O-ring. • Tighten bearing 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 high-pressure or low-pressure seals. • Install new seal kit. Increase frequency of service.
Premature seal failure • Scored plunger. • Replace plunger.
• 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. Fill pump with oil.
• Starving pump of adequate liquid. • Increase hose one size larger than inlet port size
or pressurize.
• Eroded manifold. • Replace manifold. Check liquid compatibility.
Diagnosis and Maintenance
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 & TRAINING sections on our WEB SITE for
more facts or contact Cat Pumps directly.
PN 30000 Rev E 21080 4/21
CAT PUMPS 1681 94th Lane N.E., Minneapolis, MN 55449-4324 P: [phone] F: [phone] E: [e-mail] www.catpumps.com
• CAUTIONS AND WARNINGS
All high-pressure systems require a primary pressure regulating device (i.e. regulator, unloader) and a secondary pressure relief device (i.e. pop-off valve, relief valve). Failure to install such
relief devices could result in personal injury or damage to pump or property. Cat Pumps does not assume any liability or responsibility for the operation of a customer’s high-pressure system.
Read all CAUTIONS and WARNINGS before commencing service or operation of any high-pressure system. The CAUTIONS and WARNINGS are included in each Service Manual and with each
Accessory Data sheet. CAUTIONS and WARNINGS can also be viewed online at www.catpumps.com/dynamic-literature/cautions-and-warnings or can be requested directly from Cat Pumps.
WARRANTY
View the Limited Warranty on-line at www.catpumps.com/literature/cat-pumps-limited-warranty
©2021 Cat Pumps Inc. All rights reserved. All data contained in this document are based on the latest product information available at the time of publication. Cat Pumps reserves the right to make changes at any time without notice.