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SERVICE MANUAL | 3CP Series Plunger Pumps

2

(763) 780-5440 | [email protected] | www.catpumps.com

Safety Symbols 

2

General Safety Information 

3

Seal & Valve Kits  

6

Service Intervals  

6

Seal & Valve Kit Pump Diagram  

7

Tools Needed 

7

Servicing the Seals 

8

Manifold and Seal Removal 

8

Seal Installation 

9

Plunger Removal 

10

Plunger Reassembly 

11

Manifold Reassembly 

12

Servicing the Valves 

13

Valve Removal 

13

Valve Disassembly 

14

Valve Reassembly 

15

Valve Installation 

16

Crankcase Component Inspection 

17

Reference Information 

18

Preventive Maintenance Schedule  

18

Torque Chart 

19

Manifold Screws Torque Sequence 

19

Technical Bulletin Reference Chart 

19

Diagnosis and Maintenance 

20

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.

Summary of Contents for 3CP Series

Page 1: ...ty Reliability and Support You Expect SERVICE MANUAL 3CP BRASS PLUNGER PUMPS PUMP MODELS INCLUDED 3CP1120 3CP1120G 3CP1130 3CP1140 See the 3CP1120 3CP1130 3CP1140 Valve and Seal Service Videos at www catpumps com 3cp service videos ...

Page 2: ...RTANT 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 Payspecialattentiontothefollowingsignalwords safetyalert symbolsandstatements Safety Symbols Indicates ...

Page 3: ...to Lock Out and Tag Out procedures for electrical equipment 2 Before commencing pump service turn power supply off turn water supply off squeeze trigger on gun to relieve system pressure 3 For mobile equipment be sure engines and hydraulics are turned off 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 sh...

Page 4: ...eslipperysurfaceonwhichapersonmayslipandfallcausingpersonalinjuryordeath 1 Wear suitable footwear to maintain a good grip on wet surfaces 2 Do not stand on ladders or scaffolding 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 Donotoperatethepumpwithimproperly connected sized worno...

Page 5: ...ATION DIRECTION HAZARD Donotrotatepumpcrankshaftinreversedirection Rotationofpumpcrankshaftinreversedirectionmaynotprovideproperlubrication andmayresultindamagetothedrive endcomponents 1 Forward rotation is the top of the crankshaft turning towards the manifold head of the pump 2 Ensure oil is filled to the center red dot on sight gauge for forward rotation 3 If reverse rotation is unavoidable ens...

Page 6: ...res are not due to the pump but fail because of other system components The Preventative Maintenance Check List on page 18 provides a summary of the various system maintenance concerns for all high pressure systems The seals on our pumps operating under normal conditions will perform for a minimum of 1500 hours with most lasting much longer The valves typically perform for 3000 hours with many las...

Page 7: ...NG HIGH PRESSURE SEAL Tools Needed 1 6 mm Hex Wrench 2 Flat Tip Screwdrivers 3 Pick 4 Needle Nose Pliers 5 Reverse Pliers PN 30696 6 Adjustable Wrench 7 10mmCombinationWrench 8 24mmSocketwithRatchet 9 Rubber Mallet 10 Oil Bubble Gauge Tool 11 Lubricating Oil 12 Liquid Thread Sealant Seal Valve Kit Pump Diagram SEAL KIT COMPONENTS PN 33983 Qty 1 VALVE KIT COMPONENTS PN 33062 Qty 2 1 9 4 3 2 7 5 11 ...

Page 8: ...iver to pry the low pressure seal upward and remove 1 05 Placethemanifoldonaflatsurfacewith low pressuresealsfacingup 1 01 Use a 6 mm hex wrench to remove the eight 8 hex socket head screws HSH 1 02 Rotate the crankshaft with an adjustable wrench to create separation between the manifold and crankcase 1 03 Insert two 2 flat tip screwdrivers on opposite sides to pry the manifold away from the crank...

Page 9: ...has a groove and spring Install groove side facing down and press into place 1 14 Remove seal case O ring with a pick or small flat tip screwdriver SEAL INSTALLATION 1 12 Apply a lubricant to the outside surface of the high pressure seals 1 15 Replace seal case O ring with new one from seal kit and apply a lubricant to outside surface 1 16 Install seal case with O ring side down into the manifold ...

Page 10: ...tothesurface Cleanwithawire wheel brush if necessary 1 22 Use a pick to remove keyhole washer and barrier slinger located behind the plunger Inspect for damage 1 18 Remove seal retainers from crankcase housing 1 19 Using a 10 mm combination wrench loosen and remove the plunger retainer and plunger 1 20 Remove and inspect plunger retainer gasket Servicing the Seals ...

Page 11: ... or 6 2 Nm 1 27 Insert plunger retainer with gasket into non stepped side of plunger 1 30 Install seal retainer with tabs facing down 1 28 Place a drop of Loctite 242 on the threaded end of the plunger rod PLUNGER REASSEMBLY 1 23 Install barrier slinger with dish side facing away from crankcase 1 24 Install keyhole washer The slot can face any direction 1 25 Replace plunger retainer gasket with ne...

Page 12: ...propriate cross pattern for even alignment Torque to 115 in lbs 9 58 ft lbs or 13 Nm See torque sequence below 1 34 Install eight 8 HSH screws by hand 1 36 Rotate crankshaft with adjustable wrench to ensure proper movement of plunger rod assemblies and that seals are not binding 1 32 Install manifold by hand ensuring even alignment 1 33 Use a rubber mallet to tap manifold on the rest of the way MA...

Page 13: ...NOTE Valve assemblies can be disassembled for inspection and servicing then reassembled If replacing complete valve kit assemblies skip to Valve Installation 2 18 2 02 Inspect valve plug O ring for cuts nicks or damage 2 01 Use a 24 mm socket with ratchet to remove the valve plug from pump manifold 2 03 Use a needle nosed pliers to grasp the sides of the spring retainer Twist while pulling away fr...

Page 14: ...eshooting 2 06 Placeflattipscrewdriveringapbetween valveseatandspringretainer andtwist tocompletelyseparate 2 05 Insertflattipscrewdriverthroughspring retainerjustabovevalve Twisttocreate asmallgapbetweenspringretainerand valveseat 2 07 Inspectspringretainerforcracks excessivewearordamage 2 08 Inspectspringforpropertensionorany damage 2 09 Inspecttaperedsurfaceofthevalvefor wear pittingordamage 2 ...

Page 15: ...O ringandapplya lubricanttooutsidesurface VALVE REASSEMBLY 2 12 Place valve seat on a flat surface with tapered surface facing up 2 13 Place valve onto valve seat with tapered surface facing down 2 14 Place spring onto concave side of valve 2 15 Place spring retainer onto valve seat 2 16 Usingarubbermallet lightlytapspring retainerintoplace ...

Page 16: ...O ring with a pick or small flat tip screwdriver 2 20 Replace valve plug O ring with new one from valve kit and apply a lubricant to outside surface 2 22 Install valve plug into manifold and thread by hand 2 23 Using a 24 mm socket with ratchet tighten valve plugs Torque to 870 in lbs 72 5 ft lbs or 98 Nm 2 18 Insertvalveassemblyintomanifoldand pressintoplace Loctite and 242 are registered tradema...

Page 17: ... the components in the drive end and will cause damage This damage can occur on the plunger rods or the crankshaft and connecting rods Also without a layer of oil on the drive end components oxidation and rust will form on the bearings and crankshaft If contamination is suspected inspect and replace the seals in the pump manifold then clean out the inside of the crankcase and change the oil Spot c...

Page 18: ...irst 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 ...

Page 19: ...irectMountScrews M8 13mmCombinationWrench 115 9 58 13 0 TECHNICAL BULLETIN REFERENCE CHART NO SUBJECT MODELS 002 Inlet Pressure vs Water Temperature All Models 034 Servicing Crankcase Section Ball Bearing Models 3FR 4FR 5FR 10FR 25FR 3CP 5CP 3PFR 5PFR 25PFR 28PFR 036 Identifying Your Pump All Models 043 Servicing the Low and High Pressure Seals All Plunger Models 061 Throttle Controller Installati...

Page 20: ...oise 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 wo...

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