CAT Pumps 6760 User manual

60PFR PLUNGER PUMP SERVICE MANUAL
60 FRAME SPLIT MANIFOLD 6747, 6760, 6761, 6767
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 Sheet for complete
specifications, parts list and exploded view.
LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications
[60FR-10 Qts.]. DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change ini-
tial fill after 50 hours running period. Thereafter, change oil every 3 months or 500
hour intervals. Additional lubrication may be required with increased hours of oper-
ation 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).
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 dam-
age 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 appli-
cations 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 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.
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 tem-
perature 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.
PN 30051 Rev F 7254
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.
Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580
CAT PUMPS (U.K.) LTD.
1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet
Hampshire GU52 8BF, England
Phone Fleet 44 1252-622031 — Fax [phone]
e-mail: [email protected]
N.V. CAT PUMPS INTERNATIONAL S.A.
Heiveldekens 6A, 2550 Kontich, Belgium
Phone [phone] — Fax [phone]
e-mail: [email protected] www.catpumps.be
CAT PUMPS DEUTSCHLAND GmbH
Buchwiese 2, D-65510 Idstein, Germany
Phone [phone] — Fax [phone]
e-mail: [email protected] www.catpumps.de
World Headquarters
CAT PUMPS
1681-94th Lane N.E. Minneapolis, MN 55449-4324
Phone [phone] — FAX [phone]
e-mail:[email protected]
www.catpumps.com
International Inquiries
FAX [phone]
e-mail:[email protected]
®
The Pumps with Nine Lives

SERVICING THE VALVES
Disassembly
1. On the models 6747, 6760 and 6767, remove six (6) M70
Hex Valve Plugs. On the model 6761, remove four (4)
Hex Socket Screws from each Valve Plug, then remove
Valve Plug.
2. Remove Coil Spring and Washer under Valve Plug.
3. Thread an M12 bolt into the top of the Spring Retainer
and pull out the Valve Assembly (including Retainer,
Spring, Valve Seat, O-Ring and Back-up-Ring) from the
valve chamber.
4. The valve assembly should remain together. If the valve
assembly separates, the parts can easily be removed
without any tools except for the Seat. Use a reverse pliers
or slip the head of a bolt under the edge of the Valve Seat
to remove.
Reassembly
NOTE: For certain applications apply liquid gasket to
the o-ring crevices and seal surfaces. See Tech
Bulletin 053 for model identification.
1. Examine the O-Rings on the Valve Seat and replace if cut
or worn. Lubricate the O-Rings before installing on the
Valve Seat.
2. Examine the surface of the Valve and Valve Seat for pit-
ting, grooves or wear and replace if necessary.
3. Examine the Spring for fatigue, scale or breaks and replace.
4. The Valve Assembly comes as one piece in the service
kit. Using individual parts, assemble Valve Retainer,
Spring, Valve and Seat (with O-Ring and Back-up-Ring)
and snap together securely.
5. Lubricate the O.D. of the Valve Assembly and the I.D. of
the valve chamber and press Valve Assembly squarely
into chamber until completely seated.
6. Replace Washer over top of Retainer, then Coil Spring.
7. Examine the O-Ring on the Valve Plug and replace if cut
or worn. Lubricate new O-Ring before installing on Valve
Plug. Exercise caution not to cut O-Ring on threads of
Valve Plug.
8. Lubricate O.D. of Valve Plug O-Ring and thread into valve
chamber. Exercise caution to avoid extruding O-Ring.
Torque to specifications in chart.
REMOVING THE DISCHARGE MANIFOLD
1. Remove eight (8) M16 Hex Socket Head Screws.
2. To assure alignment use two M16 Studs (PN 88902) as
guides while removing manifold. Tap the back side of the
Discharge Manifold with a soft mallet and gradually work
head from pump. Properly support Discharge Manifold to
avoid damage to the Ceramic Plungers.
REMOVING THE INLET MANIFOLD
1. Remove the center four (4) M16 Hex Head Screws and
the two (2) M16 Hex Nuts from the Studs.
2. Rotate Crankshaft to separate Inlet Manifold from the
Crankcase.
3. Tap the rear of the Inlet Manifold with a soft mallet and
gradually work from pump.
NOTE: Exercise caution and keep Manifold aligned
with Plungers to avoid damage to the Plungers as the
Inlet Manifold is removed.
Removing Valve Plug (6760) Complete Valve Assembly Removing screws from Discharge Manifold

SERVICING THE SEALS - ALL MODELS
Disassembly
1. To service the seals and packings, it is necessary to
remove both the Discharge Manifold and the Inlet
Manifold. Follow disassembly procedures for REMOVING
THE DISCHARGE MANIFOLD and REMOVING THE
INLET MANIFOLD.
NOTE: The V-Packing Spacer with Coil Springs and
V-Packing Cylinder (6747) or V-Packing Spacer (6760,
6761, 6767) Assemblies may stay in the Discharge
Manifold or Inlet Manifold.
2. If the V-Packing Spacer (6760, 6761, 6767) stays in either
the Discharge or Inlet Manifold, insert two screwdrivers on
opposite sides of the secondary groove and pry from the
valve chamber.
CAUTION: Exercise caution as the screwdrivers may
score o-ring sealing surface.
3. If the V-Packing Spacer with Coil Springs and V-Packing
Cylinder (6747) stays in either the Discharge or Inlet
Manifold, remove exposed O-Rings and Back-up-Rings
and insert two screwdrivers into the groove on opposite
sides and pry from valve chamber.
CAUTION: Exercise caution as the screwdrivers may
score o-ring sealing surface.
4. On the model 6747, separate V-Packing Spacer from
V-Packing Cylinder by inserting two screwdrivers on
opposite sides of the groove formed between components
and pry apart. Remove one Male Adapter, two V-Packings
and one Female Adapter from each V-Packing Cylinder.
5. On the models 6760, 6761,6767, remove one Spacer
w/Coil Spring, one Male Adapter, two V-Packings and one
Female Adapter from each seal chamber.
6. Place Inlet Manifold on the work surface crankcase side
up.
7. Using a screwdriver, remove LPS from each seal cham-
ber.
CAUTION: Exercise caution as the screwdriver may
damage sealing surface.
8. On the model 6747, place the Inlet Manifold on blocks
with crankcase side down using a screwdriver tap on op-
posite sides of the LPS Adapter to drive out LPS Adapter
and Lo-Pressure Seal from each chamber. Remove Lo-
Pressure Seals from backside of LPS Adapter.
CAUTION: Exercise caution as the screwdrivers may
damage sealing surface.
9. On the models 6760, 6761, 6767 remove Lo-Pressure
Seal from each seal chamber.
Gently working Discharge Manifold over plungers Gently removing Inlet Manifold over plungers Removing V-Packing Spacer from Inlet Manifold
Removing Inlet Spacer from Inlet Manifold Complete packing arrangement (6760-6767) Complete packing arrangement (6747)

SERVICING THE SEALS - ALL MODELS
Reassembly
NOTE: If your pump has been built with special seals
and O-Rings, service same type of special parts.
Refer to pump Data Sheet for correct parts and kits.
NOTE: For certain applications apply liquid gasket to
the O-Ring crevices and seal surfaces. See Tech
Bulletin 053 for model identification.
NOTE: EPDM elastomers require silicone-base lubricant.
1. Examine Lo-Pressure Seals for wear to the internal ridges
and outer surfaces, or for broken springs and replace as
needed.
2. Examine LPS Adapters for scale build up or wear and the
O-Rings for cuts or deterioration and replace as needed.
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.
3. On the model 6747, press new Lo-Pressure Seal into
each LPS Adapter with the garter spring up.
4. Place Inlet Manifold on flat work surface with crankcase
side up.
5. On the model 6747, press LPS Adapter Assembly into
each seal chamber of the Inlet Manifold with the garter
spring down.
6. On the models 6760, 6761, 6767, press Lo-Pressure Seal
into each seal chamber with the garter spring down.
7. Examine the V-Packing Cylinders, V-Packing Spacers
and V-Packing Spacer w/Coil Springs for scale build-up
and wear. Examine O-Rings and Back-up-Rings for cuts
or deterioration and replace as needed.
8. Examine Male Adapters and Female Adapters for wear
and replace as needed.
9. Examine Spacer w/Coil Springs for scale build-up, wear,
broken or fatigued Coil Springs and replace as needed.
10. Examine V-Packings for frayed edges or uneven wear
and replace as needed.
11. Place Inlet Manifold on flat work surface with crankcase
side down.
12. On the model 6747, install O-Ring on grooved end of
V-Packing Cylinder. Place V-Packing Cylinder with large
opening facing up on work surface.
13. Place Female Adapter with flat side down/“V” side up
inside each V-Packing Cylinder.
14.Insert two V-Packings with “V” side down into the
V-Packing Cylinder. The “V” will mate with “V” side of the
Female Adapter.
15.Place Male Adapter with “V” side down inside each
V-Packing Cylinder.
16. Press V-Packing Cylinder Assembly into each seal cham-
ber with V-Packings facing into the manifold chamber.
17. On the models 6760, 6761, 6767, place Female Adapter
with flat side down/
“ V” side up inside each seal chamber.
18. Insert two V-Packings with “V” side down into each seal
chamber. The “V” will mate with “V” side of the Female
Adapter.
19. Press Male Adapter with “V” side down into each seal
chamber.
20. Position Spacer w/Coil Springs so that the small springs
do not line up with grooves on top surface of Male
Adapter.
21.On the model 6747, install two O-Rings and two
Back-up-Rings on V-Packing Spacer w/Coil Springs with
O-Rings to the outside. Press V-Packing Spacer into each
V-Packing Cylinder.
22. On the models 6760, 6761, 6767, install O-Rings on each
end of V-Packing Spacer. Press Spacer into each seal
chamber.
23. Examine Inlet Spacer for scale build-up, wear and replace
as needed. Examine Inlet Spacer O-Rings for cuts and
deterioration and replace as needed.
24. Press Inlet Spacer into each lower manifold chamber.
Matching the spacer with coil springs and the Packings Removing the Lo-Pressure Seals from the Inlet Manifold Lo-Pressure Seals and Adapter arrangement (6747)

25. Support the Inlet Manifold from the under side and align
manifold with Crankcase Guide Pins. Keep manifold
aligned to avoid damaging Plungers. To assure alignment
use two M16 studs (PN 88902) as guides and remove
when manifolds are in place. Apply Loctite 242 to Hex
Head screw threads and thread in hand tight. Torque in
sequence to specification in torque chart.
26. Lubricate the exposed O-Rings on the V-Packing Spacer
and valve chamber walls.
27. Support the Discharge Manifold from the under side and
align with Inlet Manifold holes. Apply Loctite 242 to HSH
screw threads and thread in hand tight. Torque in se-
quence to specifications in torque chart.
SERVICING THE PLUNGERS
Disassembly
1. To secure the plungers, it is necessary to remove both the
Discharge and Inlet Manifolds. Follow disassembly proce-
dures for REMOVING THE DISCHARGE MANIFOLD and
REMOVING THE INLET MANIFOLD.
2. Remove the Seal Retainers from each Ceramic Plunger.
3. Remove the Adapter Front Seal Retainer from the Rear
Seal Retainer.
4. Remove the used Wick and install new wick.
5. Replace Front and Rear Seal Retainer.
6. Loosen Plunger Retainer 4 to 5 turns. Push Plunger to-
wards Crankcase until Plunger Retainer pops out.
7. Unscrew and remove Plunger Retainer, Gasket, O-Ring,
Back-up-Ring, Ceramic Plunger, Keyhole Washer and
Barrier Slinger.
Reassembly
1. Replace Barrier Slinger then Keyhole Washer on each
Plunger Rod.
2. Carefully examine each Plunger for scoring or cracks and
replace if worn.
NOTE: Ceramic Plunger can only be installed one di-
rection (front to back). Do not force onto rod.
3. Examine Gasket, O-Ring and Back-up-Ring on Plunger
Retainer and replace if cut or worn. Lubricate O-Ring for
ease of installation and to avoid damaging O-Rings. First
install Gasket, O-Ring then Back-up-Ring.
4. Apply a small amount of Loctite 242 to exposed threaded
end and thread Plunger Retainer onto Plunger Rod.
Torque per chart.
5. Slip Seal Retainers over Plungers. Insert smaller diameter first.
NOTE: Line up Wicks with the oil holes in the
Crankcase and tabs down towards the Oil Pan.
NOTE: No wick is used on 6747.
6. Rotate Crankshaft by hand so the two outside Plungers
are extended equally.
7. Carefully slide Inlet Manifold over Plungers and press
towards Crankcase. Keep manifold aligned to avoid dam-
aging Plungers. To assure alignment use two M16 studs
(PN 88902) as guides and remove when manifolds are in
place.
8. Replace four (4) Hex Head Screws and two (2) Hex Nuts
and torque per chart.
9. Lubricate the exposed O-Rings on the V-Packing Spacer
and valve chamber walls and carefully slip Discharge
Manifold over Plungers and snug up to the Inlet Manifold.
10. Hand tighten the outer top two (2) Hex Socket Head Screws
first. Then hand tighten the remaining six (6) Hex Socket
Head Screws. Torque in sequence to specifications in
torque chart.
TORQUE SEQUENCE
SERVICING THE CRANKCASE SECTION
1. While Manifolds, Plungers and Seal Retainers are re-
moved examine Crankcase Oil Seals for wear.
2. Check oil level and check for evidence of water in oil.
3. Rotate Crankshaft by hand to feel for smooth bearing
movement.
4. Check for any signs of leaking at Rear Cover, Drain Plug
and Bubble Gauge.
5. Examine Crankshaft Oil Seals externally for drying, crack-
ing or leaking.
6. Consult CAT PUMPS or your local distributor if Crankcase
service is required. Refer to Tech Bulletin 035.
See Section V of the Plunger Pump Service Video for
additional information.
51 37
00 00
00 00
84 26
Complete plunger arrangement

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 per-
formance decreases, check immediately. If no wear at 1500 hours,
check again at 2000 hours and each 500 hours until wear is ob-
served. 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 Thread Tool Size Torque
Pump Model [Part No.] in.lbs. ft.lbs. Nm
Plunger Retainer M14 M30 Hex 520 43.4 59
Inlet Manifold Screws M16 M24 Hex 565 47.0 64
[44046]
Discharge Manifold Screws M16 M14 Allen 565 47.0 64
[33049]
Valve Plugs M70 M41 Hex 1390 115.7 157
6747, 6760, 6767
Valve Plugs Screws M16 M14 Allen 250 21.0 28
6761 [33049]
Crankcase Cover/ M10 M17 Hex 220 18.1 25
Bearing Cover Screws [25083]
Connecting Rod Screws M10 M17 Hex 390 32.5 44
[25083]
Bubble Oil Gauge M28 Oil Gauge Tool 45 3.6 5
[44050]
TECHNICAL BULLETIN REFERENCE CHART
No. Subject Models
002 Inlet Temperature VS Liquid Temperature All Models
003 Drive Packages - Power Units 3FR - 68FR PFR
024 Lubrication of Lo-Pressure Seals All Models
036 Cylinder and Plunger Reference Chart All Models
043 Plunger Pump LPS and HPS Servicing All Plunger Models
052 Plunger Rod and Stud Change - CR Pumps 3PFR, 5PFR, 15PFR, 35PFR, 60PFR
053 Liquid Gasket All Plunger NAB-SS Models
074 Piston and Plunger Pump Torque Chart All Models
077 Oil Drain Kit All Models
082 Discharge Manifold 6761
083 Winterizing a Pump All Models
084 Crankcase Change - 60 Frame 60FR
087 Female Adapters 15PFR, 35PFR, 60PFR
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 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 liquid 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 50 PSI (3.5 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 over pressurization, 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 line.
❏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 cut off 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. When a pulsation
dampener is used, 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 recommend-
ed 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 064 for additional information on the size and
length of the by-pass line.
❏Check the pressure in the by-pass line to avoid over pressurizing 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.

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 I’ll get? Rated GPM
A. Desired GPM = Desired RPM x 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?
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
( )
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 ●Increase line size to the inlet port or one size
line size larger
Water hammering ●Install C.A.T. Tube
liquid acceleration/ ●Move pump closer to liquid supply
deacceleration
Rigid Inlet Plumbing ●Use flexible wire reinforced hose to absorb
pulsation and pressure spikes
Excessive Elbows in ●Keep elbows to a minimum and less than 90°
Inlet Plumbing
Excessive Liquid ●Use Thermo Valve in bypass line
Temperature ●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
Air Leaks in Plumbing ●Check all connections
●Use PTFE thread tape or pipe thread sealant
Agitation in Supply ●Size tank according to pump output —
Tank Minimum 6-10 times system GPM
●Baffle tank to purge air from liquid and
separate inlet from discharge
High Viscosity Liquids ●Verify viscosity against pump specifications
before operation
●Elevate liquid temperature enough to reduce
viscosity
●Lower RPM of pump
●Pressure feed pump
●Increase inlet line size
Clogged Filters ●Perform regular maintenance or use clean
filters to monitor build up
●Use adequate mesh size for liquid and pump
specifications
Handy Formulas to Help You
(Consult
Engine Mfr.)
TYPICAL RESERVOIR TANK
RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY
Avoid Cavitation Damage
1/4 5/16 3/8 1/2 5/8 3/4 1"
0.5 16 5 2
154 20 7 2
2180 60 25 6 2
3380 120 50 13 4 2
4220 90 24 7 3
5320 130 34 10 4
6220 52 16 7 1
8300 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.
PRESSURE DROP IN PSI PER 100 FT OF HOSE
WITH TYPICAL WATER FLOW RATES
Hose Inside Diameters, Inches
Water*
Flow
Gal/Min
HOSE FRICTION LOSS
Water
GPM
1
2
3
5
8
10
15
25
40
60
80
100
Steel Pipe—Nominal Dia.
1/4 3/8 1/2 3/4 1 11/411/2
8.5 1.9
30 7.0 2.1
60 14 4.5 1.1
150 36 12 2.8
330 86 28 6.7 1.9
520 130 43 10 3.0
270 90 21 6.2 1.6
670 240 56 16 4.2 2.0
66 17 8.0
37 17
52 29
210 107 48
Brass Pipe—Nominal Dia.
1/4 3/8 1/2 3/4 1 11/411/2
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
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
WATER LINE PRESSURE LOSS
PRESSURE DROP IN PSI PER 100 FEET
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
11/41.380 0.90 41.0 20.5 1.73 3.70 8.22 2.06 7.40
11/21.610 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
21/22.469 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
Nominal
Pipe
Size
Inches
Inside
Diameter
Inches
RESISTANCE OF VALVES AND FITTINGS
Gate
Valve Globe Valve Angle Valve 45˚ Elbow 90˚ Elbow
180˚
Close
Ret
Tee
Thru
Run
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.
Tee
Thru
Branch
Equivalent Length of Standard Pipe in Feet
Bypass Line
(from regulator or unloader)
Level Sensing
Device
Bypass Line
(from regulator or
unloader)
MIN. 4"
1.5 x D (Min.)
Minimum Two Baffles
Sealed at Bottom
Minimum
Liquid
Level
FILTER
MIN. 4"
Flexible Hose
to Pump
Supply Line
(Dia of pipe)
T
XD
→
→
→
→
→
→
→
→
→

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 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 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.