ࡱ> M  bjbj== ".WWlFF#L  I  I#$% 4'm#m#l#lll. l l.l  ˚F: #0# '|' l.$" The Pumps with Nine Lives 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, plumbing and operation of the pump and accessories. Specifications: Maximum specifications refer to individual attributes. It is not implied that all maximums [flow/pressure/rpm/temperature] 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. Certain liquids may require that the pump be oversized and run at a lower rpm. Lubrication: Fill crankcase with special CAT PUMP oil per pump specifications on individual Data Sheet. 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. Lack of proper lubrication will void the warranty. PUMP ROTATION:Pump was designed with a splash lubrication. Forward rotation [toward the manifold/head/liquid-end] is recommended to allow optimum lubrication of the crosshead area. Reverse rotation is acceptable, if the crankcase oil level is increased slightly above the center line dot on the oil gauge to assure adequate lubrication. Pulley Selection: Select size of motor pulley required to deliver the desired flow from the Horsepower Requirement and Pulley Selection Chart on the Data Sheet. Pre-selected Drive Packages are available for various performances for each pump. These include Pump Pulley, Drive Pulley, Hubs, Belts and key. [see Technical Bulletin 03] 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 on the Data Sheet according to meet the 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 misalignment of the pump and drive and extensive damage to the pump and/or base. To minimize piping stress, use appropriate reinforced, flexible hose at inlet and discharge ports. Use the correct belt[s] and center distance; make sure pulleys are aligned. Excessive belt tension may be harmful to the pump 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 the pump be enclosed. Do not store or operate in excessively high temperature areas or without proper ventilation. Pump cannot be submersed or directly sprayed on. Inlet Conditions: Do not starve the pump or run dry. Use a line size at least equal to or one size greater than pump inlet port size. Flooded or pressurized feeding provides optimum performance. OPEN ALL VALVES BEFORE STARTING SYSTEM. Refer to complete Inlet Condition Check-List in each Service Manual before starting system. 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. The C.A.T. should not be used with negative suction inlet. Discharge Plumbing: OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead, overpressure condition and severe damage to the pump or system. Use reinforced, flexible hose prior to connection to rigid plumbing. Review Typical Installation diagram or contact your CAT PUMPS supplier for assistance in placement of system accessories. CAT PUMPS recommends a Primary Pressure Regulator Valve [Unloader or Regulator] and a Secondary Pressure Relief Valve [Relief Valve Pop-Off valve, Safety Valve or Rupture Disc] on all high pressure systems to prevent over pressurizing the pump in the event the discharge or downstream plumbing becomes plugged or is turned off. Severe damage to the pump will result, if this condition occurs without a relief valve in the line. caution: Failure to install such a safety valves will void the warranty on the pump. Discharge regulating devices should be at minimum pressure setting at start-up and set at pressure increments until system pressure is reached. Secondary valve should be set with primary up to 200-300 PSI above Primary Valve. Start system with all valves open or in the low pressure setting. Install a Pulsation Dampening device mounted directly onto the discharge manifold [head] or in the discharge line near the head. Be certain the pulsation dampener [Prrrrr-o-lator] is properly sized for the system specification and pre-charged for the system pressure (see individual data sheet for proper pre-charge.) A reliable Pressure Gauge should be installed onto the discharge manifold [head] or in the discharge line near the head. This is extremely important for adjusting the 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 [head] of the pump, not at the gun or nozzle. A pressure gauge is your system monitor as fluctuating pressure or loss of pressure will signal system problems. By-pass: 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. The optimum installation is to route the by-pass back to the supply tank. Contact your CATPUMPS supplier for recommendations and assistance. FITTINGS: Keep fittings and 90 degree elbows to a minimum. Use PTFE liquid (sparingly) or tape to connect accessories or plumbing to assure airtight fit. 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. Nozzles: A worn nozzle will result in loss of pressure. Do not adjust pressure regulating device to compensate. Replace nozzle[s] and reset regulating device to system pressure and secondary relief valve approximately 200 PSI above primary valve. Pumped LIQUIDS: Some Liquids may require a flush between operations or before storing. Standard pH range for CAT PUMPS is 5-9. Standard viscosity is 500 CPS or 2500SSU. Hi-Temp or high vapor liquids may require special installation. Special K version of the Block-Style pumps offer ported inlet manifolds to permit flushing between the Lo- Pressure and Hi-Pressure seals. These models also permit high inlet pressures for low vapor liquids. 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. 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