2DX, 3DX, 3SP PLUNGER PUMP SERVICE MANUAL

2DX MODELS: 2DX20ES, 2DX27GS, 2DX30GS

2DX05ELS.MIST, 2DX10ES.MIST, 2DX15ES.MIST, 2DX20ES.MIST, 2DX27ES.MIST
3DX MODELS: 3DX25GSI, 3DX30GSI
3SP MODELS: 3SP30G1I, 3SP35GEI
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.

SPECIFICATIONS: Maximum specifications refer to individual attributes. It is DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING
not implied that all maximums can be performed simultaneously. If more SYSTEM to avoid deadhead overpressure condition and severe damage to the
than one maximum is considered, check with your CAT PUMPS supplier to pump or system.
confirm the proper performance and pump selection. Refer to individual Data
A reliable Pressure Gauge should be installed near the discharge outlet of the
Sheets for complete specifications, parts list and exploded view.
high pressure manifold. This is extremely important for adjusting pressure
LUBRICATION: Fill crankcase with special CAT PUMP Hydraulic oil per pump regulating devices and also for proper sizing of the nozzle or restricting orifice.
specifications [2DX, 3DX-8.5 oz., 3SP-10.15 oz.]. DO NOT RUN PUMP WITH- The pump is rated for a maximum pressure; this is the pressure that is read at
OUT OIL IN CRANKCASE. Change initial fill after 50 hours running period. the discharge manifold of the pump, NOT AT THE GUN OR NOZZLE.
Thereafter, change oil every 3 months or 500 hour intervals.
Use PTFE thread tape or pipe thread sealant (sparingly) to connect accessories
DRIVE SELECTION: The pump shaft size is 5/8" hollow shaft on “ES” models, or plumbing. Exercise caution not to wrap tape beyond the last thread to avoid
3/4" hollow shaft on “GEI” and “GS” models, 1" hollow shaft on “G1I” models. tape from becoming lodged in the pump or accessories. This condition will
The motor or engine driving the pump must be of adequate horsepower to cause a malfunction of the pump or system.
maintain full RPM when the pump is under load. Select the horsepower
PRESSURE REGULATION: All systems require both a primary pressure
requirement according to required pump discharge flow and maximum
regulating device (i.e., regulator, unloader) and a secondary pressure safety
pressure at the pump! Consult the manufacturer of gas or diesel engine for
relief device (i.e., pop-off valve, safety valve). The primary pressure device
proper selection.
must be installed on the discharge side of the pump. The function of the primary
MOUNTING: 2DX, 3DX and 3SP models are direct drive. The 2DX and 3DX pressure regulating device is to protect the pump from over pressurization,
electric models can be mounted directly to a C-Face motor; the 3SP35GEI which can be caused by a plugged or closed off discharge line. Over pressur-
model comes with an adapter plate to mount to a C-Face motor. The gas model ization can severely damage the pump, other system components and can
comes with an adapter plate that mounts to a gas engine. Before mounting cause bodily harm. The secondary safety relief device must be installed
pump to electric motor or gas engine, apply PN 6106 antiseize lubricant to in-line between the primary device and pump or on the opposite side of the
pump shaft. Refer to Technical Bulletin 055 for instructions on removing pump manifold head. This will ensure pressure relief of the system if the primary
from electric motor or gas engine. To minimize piping stress, use appropriate regulating device fails. Failure to install such a safely device will void the warranty
flexible hose to inlet and discharge ports. on the pump.
LOCATION: If the pump is used in extremely dirty or humid conditions, it is NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure
recommended pump be enclosed. Do not store or operate in excessively high regulating device to compensate. Replace nozzle and reset regulating device
temperature areas or enclosed without proper ventilation. Temperatures above to system pressure.
130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over
PUMPED LIQUIDS: Some liquids may require a flush between operations
130°F. Elastomer or RPM changes may be required. See Tech Bulletin 002 or
or before storing. For pumping liquids other than water, contact your CAT
call CAT PUMPS for recommendations.
PUMPS supplier.
INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this
STORING: For extended storing or between use in cold climates, drain all
manual before starting system. DO NOT STARVE THE PUMP OR RUN DRY.
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).

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

World Headquarters CAT PUMPS (U.K.) LTD.

1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet
CAT PUMPS Hampshire GU52 8BF, England
1681 - 94th Lane N.E. Minneapolis, MN 55449 - 4324 Phone Fleet 44 1252-622031 — Fax 44 1252-626655
e-mail: sales@catpumps.co.uk
Phone (763) 780-5440 — FAX (763) 780-2958 ®
N.V. CAT PUMPS INTERNATIONAL S. A.
e-mail: techsupport@catpumps.com Heiveldekens 6A, 2550 Kontich, Belgium
www.catpumps.com The Pumps with Nine Lives Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51
e-mail: cpi@catpumps.be www.catpumps.be
International Inquiries CAT PUMPS DEUTSCHLAND GmbH
FAX (763) 785-4329 Buchwiese 2, D-65510 Idstein, Germany
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
e-mail: intlsales@catpumps.com e-mail: catpumps@t-online.de www.catpumps.de

PN 30263 Rev B 7322

2DX20ES, 2DX27GS, 2DX30GS, 3DX25GSI, 3DX30GSI 3SP30G1I, 3SP35GEI
Discharge and Inlet Valve Assembly - Stacked Valve design Discharge and Inlet Valve Assembly - Stacked Valve design

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

SERVICING THE VALVES

Disassembly Reassembly
NOTE: The Discharge and Inlet Valve Assemblies 1. Examine Spring Retainers for internal wear or breaks in
are stacked. Follow these same procedure for both the structure and replace as needed.
inlet and discharge assemblies. 2. Examine Springs for fatigue or breaks and replace as
NOTE: Discharge and Inlet Valve Assemblies may needed.
stay together or separate during removal. 3. Examine Valves and Seats for grooves, pitting or wear
NOTE: Spring Retainer may also separate from the and replace as needed.
Seat during removal. 4. Examine Seat and Valve Plug O-Rings for cuts or wear
1. Using a Hex tool, remove Valve Plugs at the top of the and replace as needed.
Manifold Head. NOTE: Inlet Valve Seat and O-Ring are different
2. Use a reverse pliers to remove stacked valve assemblies from Discharge Valve Seat and O-Ring. One Valve
from the valve chamber. Kit required per pump.
3. If the Discharge Valve Assembly separates from the 5. Lubricate and install new O-Ring onto large outside
Inlet Valve Assembly, use a reverse pliers to remove it diameter of Seat.
from the valve chamber. 6. On the model 3SP, lubricate and install Back-up-Ring,
CAUTION: Exercise caution as the reverse pliers and then O-Ring onto large outside diameter of
may damage the threads in valve chamber or Spring Discharge Seat.
Retainer. 7. Place Seat on work surface with small diameter side
4. On the models 2DX and 3DX, the Spring Retainer may up.
separate from the Seat. Remove the Spring and Valve 8. Place Valve onto Seat with concave side down.
from the valve chamber. Thread an M8 screw into the
Seat and remove from valve chamber. 9. Place Spring on Valve.
5. On the models 2DX and 3DX, separate Valve Assembly 10. Install Spring Retainer with deep stepped end over
by using the same M8 screw and thread into bottom of Spring and snap onto Seat.
Seat until screw contacts bottom of Valve. Continue 11. Snap Discharge Valve Assembly onto the Inlet Valve
threading in screw until Spring Retainer separates from Assembly and press into valve chamber until completely
Seat. seated.
6. On the model 3SP, separate Valve Assembly by insert- 12. Lubricate and install new O-Ring onto each Valve Plug.
ing screwdriver into Spring Retainer and press the 13. Apply Loctite 242 to threads of each Valve Plug and
backside of valve until Seat separates from the Spring
thread in hand tight. Torque to specifications per chart.
Retainer.
7. Remove O-Ring from each Seat and Valve Plug.
2DX20ES, 2DX27GS, 2DX30GS, 3DX25GSI, 3DX30GSI 3SP30G1I, 3SP35GEI
Lo-Pressure and Hi-Pressure Seals with Seal Case Lo-Pressure and Hi-Pressure Seals with Seal Case

SERVICING THE SEALS

Disassembly Reassembly
1. Using an allen wrench, remove the Hex Socket Head 1. Examine the manifold chamber walls for scale buildup
(HSH) screws from the face of the Manifold Head. or damage.
2. Insert flat head screwdrivers on each side between the 2. Examine Hi-Pressure Seals or V-Packings for frayed
Crankcase and Manifold Head. Gently apply pressure to edges or uneven wear and replace as needed.
the head to begin separation. 3. Examine Seal Case O-Rings for cuts or deterioration
3. Support the Manifold Head from the underside and pull and replace as needed.
the Manifold Head away from the crankcase. 4. Examine Lo-Pressure Seals for wear to the internal
CAUTION: Keep the Manifold Head properly ridges, outer surfaces for broken springs and replace
aligned with the Ceramic Plungers when removing as needed.
to avoid damage to the plungers. NOTE: Seals and O-Rings are available in Seal Kits.
NOTE: The Seal Case may stay in the manifold or 5 Examine Seal Retainers for deformation and replace as
on the Ceramic Plungers. needed.
4. Place Manifold Head on work surface with crankcase 6. On the models 2DX and 3DX, lubricate and install new
side up. Hi-Pressure Seal by hand into each seal chamber with
5. Remove Seal Retainer from each Plunger Rod. the grooved side down.
6. Use a screwdriver to pry out the Lo-Pressure Seal from 7. On the model 3SP, install Male Adapter with notch
each Seal Case. side down. Lubricate and install new V-Packing by
CAUTION: Screwdriver may damage seal during hand into seal chamber with grooved side down.
removal. 8. Lubricate and install O-Ring on each Seal Case. Press
7. Use reverse pliers to remove Seal Case from each seal small end of Seal Case into each seal chamber.
chamber. 9. Press new Lo-Pressure Seal into each Seal Case with
NOTE: Insert the reverse pliers into the second lip the garter spring down.
to avoid damage to the Seal Case. 10. Examine ceramic plunger for cracks or scale buildup
8. Carefully insert a small screwdriver under the O-Ring and proceed to SERVICING THE PLUNGERS if worn.
and roll the O-Ring off each Seal Case. 11. On the models 2DX and 3DX, slide Seal Retainer over
CAUTION: Exercise caution as the screwdriver may each Ceramic Plunger with the drain slots facing the
score O-Ring sealing surface. Crankcase and the openings to the top and bottom.
Press into the Crankcase.
9. On the models 2DX and 3DX, the Hi-Pressure Seals
can be easily removed from each seal chamber by 12. On the model 3SP, slide Seal Retainer over each
hand or with reverse pliers. Ceramic Plunger with the tabs facing out. Press into
the crankcase.
10. On the model 3SP, remove V-Packing and Male Adapter
from each seal chamber by hand or with a reverse pliers. 13. Rotate crankshaft by hand so the two outside plungers
are extended equally.
14. Lightly lubricate Ceramic Plungers, then carefully slide
the Manifold Head over the Ceramic Plungers, sup-
porting it from the underside to avoid damage to the
plungers or seals. Press the Manifold Head up to the
Crankcase until flush.
15. Thread HSH screws in hand tight. Torque in sequence
to specifications in torque chart.
2DX20ES, 2DX27GS, 2DX30GS, 3DX25GSI, 3DX30GSI 3SP30G1I, 3SP35GEI
Plunger Arrangement Plunger Arrangement

SERVICING THE PLUNGERS

Disassembly 9. Install Ceramic Plunger with Plunger Retainer and Seal

1. To service the Ceramic Plungers, it is necessary to Washer over each Plunger Rod shoulder and thread
remove the Manifold Head. See SERVICING THE hand tight. Torque to specifications per chart.
SEALS, Disassembly, steps 1-3. NOTE: Ceramic Plungers can only be installed in
2. Remove Seal Retainer from each Plunger Rod. one direction. Counterbore end of Ceramic Plunger
fits over Plunger Rod shoulder.
3. Using a hex tool, loosen the Plunger Retainer on each
Plunger Rod approximately three to four turns. 10. See SERVICING THE SEALS, Reassembly, steps
11-15.
4. Push the Ceramic Plunger back towards the Crankcase
to separate from the Plunger Retainer and proceed with
unthreading the Plunger Retainer by hand.
TORQUE SEQUENCE
5. On the models 2DX and 3DX, remove the Ceramic
Plunger and Seal Washer from each Plunger Retainer. 7 1 3 5
6. On the model 3SP, remove the Ceramic Plunger and
copper Retainer Gasket from each Plunger Retainer.
6 4 2 8

Reassembly
1. Visually inspect the Crankcase Oil Seals for deteriora-
tion or leaks. Contact CAT PUMPS for assistance with SERVICING THE CRANKCASE SECTION
replacement. See SERVICING THE CRANKCASE
section. 1. While Manifold, Plungers and Retainers are removed
examine Crankcase Oil Seals for leaking and wear.
2. Examine Seal Washers or Plunger Retainer Gaskets
and replace if cut or worn. 2. Check for any signs of leaking at Bearing Cover, Drain
Plug or Bubble Gauge.
3. Examine Plunger Retainers for damaged threads and
replace as needed. 3. Check oil level and check for evidence of water in oil.
4. On the models 2DX and 3DX, install new Seal Washer 4. Rotate crankshaft by hand to feel for smooth bearing
onto each Plunger Retainer. movement.
5. On the model 3SP, install the new copper Plunger 5. Examine Crankshaft Oil Seal externally for drying,
Retainer Gasket onto each Plunger Retainer. cracking or leaking.
6. Examine the Ceramic Plungers for scoring, scale 6. Consult CAT PUMPS or local distributor if crankcase
buildup, chips or cracks and replace as needed. The service is required.
Ceramic Plungers do not need to be replaced with
every seal servicing.
7. Slide Plunger Retainer with Seal Washer or Gasket into
flat end of Ceramic Plunger.
8. Apply Loctite 242 to exposed threaded end of Plunger
Retainer.
SERVICING THE UNLOADER
2DX and 3DX Models Only
3SP Models refer to individual Unloader Data Sheet

Disassembly Reassembly
1. Remove brass Adjusting Cap by turning in a counter- 1. If seat is worn or damaged, press new seat into
clockwise direction. unloader chamber until squarely seated.
2. Remove exposed Coil Spring and flat Spring Retainer. 2. Examine Piston Stem, Washer, Valve Retainer and Valve
3. Using a wrench, remove Piston Retainer by turning in a for grooves, pitting or wear and replace as needed.
counterclockwise direction. Examine O-Rings and Back-up Ring for cuts or wear
and replace as needed.
NOTE: The Piston Stem and Valve Assembly
may fall out when the piston retainer is removed. If 3. Lubricate and install O-Ring over slotted head of Piston
so, proceed to step 6., If not, continue with step 4. Stem, then position Back-up Ring on top of O-Ring.
4. Use a needle nose pliers to remove Piston Stem and 4. Lubricate and install O-Rings on Valve Retainer.
Valve Assembly. 5. Install Washer and then Valve Retainer with O-Rings
5. Separate Piston Stem from Valve. Secure the Valve onto Piston Stem. Apply Loctite 242 to threads of Piston
near the Valve Retainer. Insert a screwdriver into slot- Stem and screw Valve onto Piston Stem.
ted head of Piston Stem and unthread from Valve. 6. Lower complete Piston Stem and Valve Assembly into
CAUTION: Exercise extreme caution to avoid contact unloader chamber with valve facing downward.
and damage to the tapered surface of valve. 7. Examine Piston Retainer for damaged threads or wear
6. Examine Seat at the bottom of the unloader chamber and replace as needed. Examine O-Ring for cuts or
for grooves, pitting or wear, replace only as needed. wear and replace as needed.
CAUTION: Seat will be damaged when removed. 8. Apply Loctite 242 to threads and then hand thread
Piston Retainer into unloader by turning in a clockwise
direction, and then tighten with wrench.
9. Examine Spring Retainer and Coil Spring for fatigue or
breaks and replace as needed.
10. Place Spring Retainer into Piston Retainer, followed by
Coil Spring.
11. Thread brass Adjusting Cap onto Piston Retainer by
turning in a clockwise direction.
 INLET CONDITION CHECK-LIST
PREVENTATIVE MAINTENANCE CHECK-LIST
Review Before Start-Up
Check Daily Weekly 50 hrs. 500 hrs.* 1000 hrs.**
Inadequate inlet conditions can cause serious malfunctions in the best
Clean Filters x designed pump. Surprisingly, the simplest of things can cause the
Oil Level/Quality x most severe problems or go unnoticed to the unfamiliar or untrained
Oil Leaks x eye. REVIEW THIS CHECK-LIST BEFORE OPERATION OF ANY
SYSTEM. Remember, no two systems are alike, so there can be no
Water Leaks x
ONE best way to set-up a system. All factors must be carefully con-
Plumbing x sidered.
Initial Oil Change x
INLET SUPPLY should exceed the maximum flow being delivered by the
Oil Change x pump to assure proper performance.
Seal Change x ❏ Open inlet shut-off valve and turn on water supply to avoid starving the
Valve Change x pump. DO NOT RUN PUMP DRY.
❏ Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per
Accessories x
each degree F over 130°F. Elastomer or RPM changes may be required.
* If other than CAT PUMPS special multi-viscosity ISO68 oil is used, change See Tech Bulletin 002 or call CAT PUMPS for recommendations.
cycle should be every 300 hours.
❏ Avoid closed loop systems especially with high temperature or ultra-high
** Each system’s maintenance cycle will be exclusive. If system performance pressure. Conditions vary with regulating/unloader valve.
decreases, check immediately. If no wear at 1000 hours, check again at
❏ Higher temperature liquids tend to vaporize and require positive heads.
1500 hours and each 500 hours until wear is observed. Valves typically
require changing every other seal change. ❏ When using an inlet supply reservoir, size it to provide adequate
Duty cycle, temperature, quality of pumped liquid and inlet feed conditions all
liquid to accommodate the maximum output of the pump, generally a
effect the life of pump wear parts and service cycle. minimum of 6-10 times the GPM (however, a combination of system
factors can change this requirement); provide adequate baffling in the
** Remember to service the regulator/unloader at each seal servicing and check tank to eliminate air bubbles and turbulence; install diffusers on all
all system accessories and connections before resuming operation.
return lines to the tank.

INLET LINE SIZE should be adequate to avoid starving the pump.

TORQUE CHART ❏ 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
Torque pump to reduce the risk of flow restriction and cavitation.
Pump Item Thread Tool Size [P/N] in. lbs. ft. lbs. Nm
❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced
Plunger Retainer M6 M10 Hex [25082] 55 4.4 6 on SUCTION systems to avoid collapsing.
❏ The simpler the inlet plumbing the less the potential for problems. Keep
Manifold Head Screws M6 M5 Allen 55 4.4 6 the length to a minimum, the number of elbows and joints to a minimum
Valve Plugs M20 M19 Hex 520 43.4 59 (ideally no elbows) and the inlet accessories to a minimum.
❏ Use pipe sealant to assure air-tight, positive sealing pipe joints.
Bearing Cover Screws M6 M10 Hex [25082] 50 4.0 6

Bubble Oil Gauge M28 Oil Gauge Tool [44050] 45 3.6 5 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 a
pressurized inlet to maintain adequate inlet supply.
TECHNICAL BULLETIN REFERENCE CHART ❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet
No. Subject Models pressure. With adequate inlet plumbing, most pumps will perform with
flooded suction. Maximum inlet pressure is 60 PSI (4 BAR).
002 Inlet Pressure VS Liquid Temperature All Models
❏ After prolonged storage, pump should be rotated by hand and purged
024 Lubrication of Lo-Pressure Seals All Models of air to facilitate priming. Disconnect the discharge port and allow liquid
036 Cylinder and Plunger Reference Chart All Models to pass through pump and measure flow.
043 LPS and HPS Servicing All Plunger Models
055 Removing Pumps from Gas Engine or Electric Motor 2SF, 2SFX, 2DX, 4SF, 5DX, 6DX INLET ACCESSORIES are designed to protect against over pressuriza-
074 Torque Chart Piston and Plunger Pumps tion, control inlet flow, contamination or temperature and provide ease of
servicing.
083 Winterizing a Pump All Models
❏ A shut-off valve is recommended to facilitate maintenance.
086 Ceramic Plunger 2DX
❏ 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.

BY-PASS TO INLET Care should be exercised when deciding the method

of by-pass from control valves.
❏ The 2DX and 3DX pumps come with a Regulating Unloader and built-in
by-pass channel to route by-pass liquid back to the pump inlet. The 3SP
pumps come with a Regulating Unloader and reinforced, flexible hose
rated up to 300 PSI. No additioal by-pass hose is required.
 HOSE FRICTION LOSS Handy Formulas to Help You
PRESSURE DROP IN PSI PER 100 FT OF HOSE
WITH TYPICAL WATER FLOW RATES Q. How can I find the RPM needed to get specific GPM
Water* Hose Inside Diameters, Inches
Flow (Gallons Per Minute) I want?
Gal/Min 1/4 5/16 3/8 1/2 5/8 3/4 1"
Rated RPM
0.5 16 5 2 A. Desired RPM = Desired GPM x
1 54 20 7 2 Rated GPM
2 180 60 25 6 2
3 380 120 50 13 4 2 Q. I have to run my pump at a certain RPM. How do I figure
4 220 90 24 7 3 the GPM I’ll get?
5 320 130 34 10 4 Rated GPM
6 220 52 16 7 1 A. Desired GPM = Desired RPM x
8 300 80 25 10 2 Rated RPM
10 450 120 38 14 3
15 900 250 80 30 7 Q. Is there a simple way to find the approximate horsepower
20 1600 400 121 50 12 I’ll need to run the pump?
25 650 200 76 19
30 250 96 24 A. Electric Brake GPM x PSI (Standard 85%
40 410 162 42 =
Horsepower Required 1460 Mech. Efficiency)
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
Q. What size motor pulley should I use?
will be directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100 ft. Pump RPM (Consult
hose. Above values shown are valid at all pressure levels.
A. Pump Pulley (Outer Diameter) x Engine Mfr.)
Motor/Engine RPM
Q. How do I calculate the torque for my hydraulic drive
WATER LINE PRESSURE LOSS system?

Water
PRESSURE DROP IN PSI PER 100 FEET
Steel Pipe—Nominal Dia. Brass Pipe—Nominal Dia. Copper Tubing O.D. Type L
A. Torque (ft. lbs.) = 3.6 (
GPM x PSI
RPM
)
GPM 1/4 3/8 1/2 3/4 1 1 /4 1 /2
1 1
1/4 3/8 1/2 3/4 1 11/4 11/2 1/4 3/8 1/2 5/8 3/4 7/8
1
2
8.5 1.9
30 7.0 2.1
6.0 1.6
20 5.6 1.8
120 13 2.9 1.0
400 45 10 3.4 1.3 Avoid Cavitation Damage
3 60 14 4.5 1.1 40 11 3.6 94 20 6.7 2.6

5 150 36 12 2.8 100 28 9.0 2.2 230 50 17 6.1 3.0

8 330 86 28 6.7 1.9 220 62 21 5.2 1.6 500 120 40 15 6.5
10 520 130 43 10 3.0 320 90 30 7.8 2.4 180 56 22 10

15 270 90 21 6.2 1.6 190 62 16 5.0 1.5 120 44 20

25 670 240 56 16 4.2 2.0 470 150 40 12 3.8 1.7 330 110 50
40 66 17 8.0 39 11 5.0 550 200 88

60 37 17 23 11
80 52 29 40 19
100 210 107 48 61 28

RESISTANCE OF VALVES AND FITTINGS One or several of the conditions shown in the chart below may
Nominal Equivalent Length of Standard Pipe in Feet contribute to cavitation in a system resulting in premature wear,
Pipe Inside 180˚ Tee Tee system downtime and unnecessary operating costs.
Size Diameter Gate Globe Angle 45˚ 90˚ Close Thru Thru
Inches Inches Valve Valve Valve Elbow Elbow Ret Run Branch
CONDITION SOLUTION
1/2 0.622 0.41 18.5 9.3 0.78 1.67 3.71 0.93 3.33 Inadequate inlet ● Increase line size to the inlet port or one size
3/4 0.824 0.54 24.5 12.3 1.03 2.21 4.90 1.23 4.41 line size larger
1 1.049 0.69 31.2 15.6 1.31 2.81 6.25 1.56 5.62
11/4 1.380 0.90 41.0 20.5 1.73 3.70 8.22 2.06 7.40
Water hammering ● Install C.A.T. Tube

11/2 1.610 1.05 48.0 24.0 2.15 4.31 9.59 2.40 8.63
liquid acceleration/ ● Move pump closer to liquid supply

deacceleration
2 2.067 1.35 61.5 30.8 2.59 5.55 12.30 3.08 11.60
2 1/2 2.469 1.62 73.5 36.8 3.09 6.61 14.70 3.68 13.20
Rigid Inlet Plumbing ● Use flexible wire reinforced hose to absorb
3 3.068 2.01 91.5 45.8 3.84 8.23 18.20 4.57 16.40
pulsation and pressure spikes
4 4.026 2.64 120.0 60.0 5.03 10.80 23.90 6.00 21.60 Excessive Elbows in ● Keep elbows to a minimum and less than 90°

Arriving at a total line pressure loss, consideration should then be given to

Inlet Plumbing
pressure loss created by valves, fittings and elevation of lines. Excessive liquid ●Use Thermo Valve in bypass line
If a sufficient number of valves and fittings are incorporated in the system to Temperature ●Do not exceed pump temperature specifications
materially affect the total line loss, add to the total line length, the equivalent ● Substitute closed loop with baffled holding tank

length of line of each valve or fitting. ● Adequately size tank for frequent or high

volume bypass
● Pressure feed high temperature liquids

TYPICAL RESERVOIR TANK ● Properly ventilate cabinets and rooms

RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Air Leaks in Plumbing ● Check all connections
● Use PTFE thread tape or pipe thread sealant

Supply Line Agitation in Supply ● Size tank according to pump output —

Bypass Line
(from regulator or unloader) Tank Minimum 6-10 times system GPM
→

T (Dia of pipe) ● Baffle tank to purge air from liquid and

Level Sensing
Device X D separate inlet from discharge
→

→
→

High Viscosity Liquids ● Verify viscosity against pump specifications

→

MIN. 4"
before operation
→

1.5 x D (Min.)
● Elevate liquid temperature enough to reduce
→

viscosity
● Lower RPM of pump
Flexible Hose Minimum
to Pump ● Pressure feed pump
Liquid Bypass Line
Level (from regulator or ● Increase inlet line size
FILTER unloader)
→

Clogged Filters ● Perform regular maintenance or use clean

filters to monitor build up

→

● Use adequate mesh size for liquid and pump

Minimum Two Baffles
MIN. 4" Sealed at Bottom specifications
 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.

•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-Packing, Hi-Pressure or Lo-Pressure Seals. •Install new seal kit. Increase frequency of service.
•Worn adapter o-rings. •Install new o-rings.
•Into the crankcase •Excessive wear to seals. •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.

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.
•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 V-Packing, Hi-Pressure 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.