CP PLUNGER PUMP SERVICE MANUAL - Cat …

1 CP PLUNGER PUMP SERVICE MANUAL3CP MODELS:3CP1120, 3CP1130, 3CP114 05CP MODELS:5CP2120W, 5CP2140 WCS, 5CP2150W, 5CP3120, 5CP3120G1, 5CP3130G1,5CP5120, 5CP5150G1, 5CP6120, 5CP6120G1, 5CP6140, 5CP61507CP MODELS:7CP6170 SPECIFICATIONS:Maximum specifications refer to individual attributes. It is notimplied that all maximums can be performed simultaneously. If more than onemaximum is considered, check with your CAT pumps suppl ie r to conf ir m the proper performance and pump selection. Refer to individual pump Data Sheet forcomplete specifications, parts list and exploded :Fill crankcase with special CAT PUMP oil per pump specifications(3CP-10 oz.)

2 , 5CP-17 oz., 7CP-38 oz.). DO NOT RUN PUMP WITHOUT OIL INCRANKCASE. Change initial fill after 50 hours running period. Thereafter, changeoil every 3 months or 500 hour lubrication may be requiredwith increased hours of operation and ROTATION:Pump was designed for forward rotation to allow optimum lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oillevel is increased slightly above center dot to assure adequate SELECTION:Select size of motor pulley required to deliver the desiredflow from Horsepower Requirement and Pulley Selection Chart (refer to TechBulletin 003 or individual Data Sheet).

3 DRIVE SELECTION:The motor or engine driving the pump must be of adequatehorsepower to maintain full RPM when the pump is under load. Select the electricmotor from the Horsepower Requirement Chart according to required pump discharge flow, maximum pressure at the pumpand drive losses of approximately3-5%.Consult the manufacturer of gas or diesel engine for selection of the properengine :Mount the pumpon a rigid, horizontal surface in a manner to permitdrainage of crankcase oil. An uneven mounting surface will cause extensive damage to the pump base. To minimize piping stress, use appropriate flexiblehose to inlet and discharge ports.

4 Use the correct belt; make sure pulleys ar ealigned. Excessive belt tension may be harmful to the bearings. Hand rotate pumpbefore starting to be certain shaft and bearings are free :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 CONDITIONS:Refer to complete Inlet Condition Check-Listin this manualbefore starting system. DO NOT STARVE THE PUMP OR RUN DRY. Temperaturesabove 130 F are permissible. Add 1/2 PSI inlet pressure per each degree F over130 F. Elastomer or RPM changes may be required.

5 See Tech Bulletin 002 or callCAT pumps for :Installa ti on of a C. A. T. (Captiv e Acce lera ti on Tube) is recommended in applications with stressful inlet conditions such as high temperatures, booster pumpfeed, long inlet lines or quick closing CONDITIONS:OPEN ALL VALVES BEFORE STARTING SYSTEM toavoid deadhead overpressure condition and severe damage to the pump or a Pulsation Dampeneron the discharge head or in the discharge line asclose to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) isproperly precharged for the system pressure (see individual Data Sheet).Areliable PressureGaugeshould be installed near the discharge outlet of the highpressure manifold.

6 This is extremely important for adjusting pressure regulating devices and also for proper sizing of the nozzle or restricting orifice. The pump israted for a maximum pressure; this is the pressurewhich would be read at the discharge manifold of the pump, NOT AT THE GUN OR PTFE thread tape or pipe thread sealant (sparingly) to connect accessories orplumbin g. Exercise cauti on not to wrap tape beyond th e la st thr ead to avoid tape from becoming lodged in the pump or accessories. This condition will cause amalfunction of the pump or REGULATION:All systems require both a primary pressure regulatingdevice ( , regulator, unloader) and a secondary pressure safety relief device ( , pop-off valve, safety valve).

7 The primary pressure device must be installed onthe 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 aplugged or closed off discharge line. Over pressurization can severely damage thepump, other system components and can cause bodily harm. The secondary safetyrelief device must be installed in-linebetween the primary device and the pump oron the opposite side of the manifold head. This will ensure pressure relief of thesystem if the primary regulating device fails. Failure to install such a safely devicewill void the warranty on the the high pressure system is left running with the trigger gun off, the by-passliquid can be routed to drain or to the pump inlet.

8 If routed to the pump inlet, the by-pass liquid can quickly develop excessive heat and result in damage to THERMO VALVE installed in the by-pass line is recommended to protectthe pump. An AUTO SHUT-OFF ASSEMBLY may also be :A worn nozzle will result in loss of pressure. Do not adjust pressure regulating device to compensate. Replace nozzle and reset regulating device tosystem LIQUIDS:Some liquids may require a flush between operations or pumping liquids other than water, contact your CAT pumps :For extended storing or between use in cold climates, drain all pumpedliquids from pump and flush with antifreeze solution to prevent freezing anddamageto the pump.

9 DO NOT RUN PUMP WITH FROZEN LIQUID (refer to TechBulletin 083).INSTALLATION AND START-UP INFORMATIONO ptimum performance of the pump is dependent upon the entire liquid system and will be obtained onlywith the proper selection, installation of plumbing, and operation of the pump and 33009 Rev J 7709 WARNINGAll systems require both a primary pressure regulating device ( , regulator, unloader) and a secondary pressure safety relief device ( , 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 responsibilityfor the operation of a customer s high pressure pumps ( ) Fleet Business Park, Sandy Lane, Church CrookhamFLEET, Hampshire, GU52 8BF, EnglandPhone Fleet 44 1252-622031 Fax 44 1252-626655e-mail: CAT pumps INTERNATIONAL 6A, B-2550 Kontich, BelgiumPhone 32- 3- Fax 32-3- : pumps DEUTSCHLAND GmbHBuchwiese 2, D-65510 Idstein, GermanyPhone 49 6126-9303 0 Fax 49 6126-9303 33e-mail.

10 HeadquartersCAT PUMPS1681- 94th Lane Minneapolis, MN 55449- 4324 Phone (763) 780-5440 FAX (763) InquiriesFAX (763) The pumps with Nine Lives3CP1120, 5CP2120W, 7CP6170 Removal of Valve Assembly5CP3120, 5CP5120, 5CP5150 Removal of Valve AssemblyAll ModelsRemoval of Valve Seat O-RingSERVICING THE VALVES1. Remove the hex Valve Plugs (top discharge, bottom inlet).2. Examine the O-Ring under the plug for cuts or if worn. Lubricate new O-Rings before : The 5CP3120, 5CP5120 and 5CP5150 haveboth an O-Ring and Back-up Ring on the Valve Grasp Spring Retainer by the tab at the top with a pliers and remove from each valve chamber.