Product Brochure - Tommy Car Wash Systems Store
Contents
1. TAF The Pumps with Nine Lives Car Wash Reclaim Systems Cat Pumps are found worldwide operating with reclaimed water while continuing to meet the life requirements and provide satisfactory performance for the operator With decades of proven field experience and internal testing Cat Pumps is expanding car wash reclaim rating from 10 micron up to 50 micron Car wash reclaim systems typically operate in the 5 50 micron range with the majority running 5 25 micron range The water quality and type of particulate does have a direct effect on pump life As particle sizes increase there is a potential decrease in pump life Consequently we do recommend the specifications below for optimum performance and maximum life Particle Size Not to exceed 50 Micron TSS Not to exceed 50 PPM pH Maintained between 5 and 9 Sediment pits Cleaned regularly Reclaim Filtration System Must be operated and maintained according to requirements provided by manufacturer of reclaim system It s also important to consider reclaim water quality and the effects it may have on finish of vehicle being washed For reclaim use outside of car wash applications contact Cat Pumps Technical Sales SA RECLAIM TANK FILTRATION SYSTEM 1681 94th Lane N E Mpls MN 55449 4324 P 763 780 5440 F 763 780 2958 E techsupport catpumps com 993411 Rev C 4 Model 3CP1120 Shown Rails and shaft protector sold separately FEAT2. Remove by pass fitting with o ring from bottom port Remove seat with o ring from the male threaded side of by pass fitting Examine seat for scale build up scoring and wear and replace as needed Examine o ring for cuts or wear and replace as needed Removal of piston stem and valve ball assembly requires the use of a small hex socket and screwdriver Insert screwdriver from the top and place in slotted head of piston stem Insert small hex socket into bottom port and secure valve ball assembly Unthread by turning in a counterclockwise direction Examine piston stem and valve ball assembly for scale build up scoring pitting and wear and replace as needed Examine o rings and backup ring for cuts or wear and replace as needed Remove piston retainer with o rings and backup rings by turning in a counterclockwise direction TROUBLESHOOTING Check for leak downstream of unloader e Worn O ring or check valve Air in system poor connection O ring in gun worn Insufficient flow through unloader Unloader cycles Liquid leaking from bottom fitting O ring for fitting cut or worn O ring for seat cut or worn Liquid leaking from middle Unloader will not come up to pressure O ring for piston worn or cut O rings for piston stem worn or cut Not properly sized for system pressure Foreign material in unloader Clean filter Piston stem O rings worn Nozzle worn Insufficient flow to pump Extreme press
3. 174 Models 3CP1120 3CP1120G 3CP1130 3CP1140 February 2011 a 911 231 6 87 174 5 gt 5 64 143 5 8 78 223 4 88 124 DISCHARGE eakenknaj S 7 a ae B o s i OOOO ji B 16 5 218 Tim aip N ES ER o OECC T IA ANAVAA I e A DOO WA d SARS d 1 57 40 2 1 2 14 NPTF INLET 1 96 50 3 15 80 4 17 106 gt 4 88 124 me a r No c F NOO al A 1 37 35 0 79 20 3 94 100 4 88 124 i 6 02 153 1 Models 3CP1120 3CP1120G 3CP1130 3CP1140 100 wet seal design adds to service life Special concentric high density polished 3 solid ceramic plungers provide a true wear surface and extended seal life Manifolds are a high tensile strength forged brass for long term continuous duty by allowing pumped liquids to cool and lubricate on both sides of the seals Stainless steel valves seats and springs provide corrosion resistance ultimate a li a PILL The Pumps with Nine Lives seating and extended life CAT PUMPS 1681 94TH LANE N E MINNEAPOLIS MN 55449 4324 PHONE 763 780 5440 FAX 763 780 2958 e mail techsupport catpumps com www catpumps com For International Inquiries go to www catpumps com and navigate to the Contact Us link J l 5 Specially formulated Cat Pump exclusive Hi Pressure Seal
4. 8 78 223 4 88 124 DISCHARGE eakenknaj S 7 a ae B o s i OOOO ji B 16 5 218 Tim aip N ES ER o OECC T IA ANAVAA I e A DOO WA d SARS d 1 57 40 2 1 2 14 NPTF INLET 1 96 50 3 15 80 4 17 106 gt 4 88 124 me a r No c F NOO al A 1 37 35 0 79 20 3 94 100 4 88 124 i 6 02 153 1 Models 3CP1120 3CP1120G 3CP1130 3CP1140 100 wet seal design adds to service life Special concentric high density polished 3 solid ceramic plungers provide a true wear surface and extended seal life Manifolds are a high tensile strength forged brass for long term continuous duty by allowing pumped liquids to cool and lubricate on both sides of the seals Stainless steel valves seats and springs provide corrosion resistance ultimate a li a PILL The Pumps with Nine Lives seating and extended life CAT PUMPS 1681 94TH LANE N E MINNEAPOLIS MN 55449 4324 PHONE 763 780 5440 FAX 763 780 2958 e mail techsupport catpumps com www catpumps com For International Inquiries go to www catpumps com and navigate to the Contact Us link J l 5 Specially formulated Cat Pump exclusive Hi Pressure Seals offer unmatched per formance and seal life PN 993101 Rev G 2 11 11145 Model 7600S Model 7500S FEATURES e Maintains full system pressure while running in by pass without
5. Fitting By Pass 3 8 NPTF 1 446 13969 NBR O Ring Discharge Fitting 70D 1 460 107681 BB Fitting Discharge 3 8 NPTM 1 14320 FPM O Ring Discharge Fitting 70D 1 468 32098 NBR Kit O Ring Inclds 414 415 428 429 430 437 441 442 446 1 455 45695 BB Fitting By Pass 8 8 NPTF 1 Italics are optional items 460 107681 BB Fitting Discharge 8 8 NPTM 1 MATERIAL CODES Not Part of Part Number 468 32097 NBR Kit O Ring Inclds 414 415 428 430 437 442 446 1 BB Brass NBR Medium Nitrile Buna N PTFE Pure Polytetrafluoroethylene 31627 FPM Kit O Ring Inclds 414 415 428 430 437 442 446 1 S 304SS ZP Zinc Plated Italics are optional items R Components comply with RoHS Directive MATERIAL CODES Not Part of Part Number BB Brass FPM Fluorocarbon NBR Medium Nitrile Buna N PTFE Pure Polytetrafluoroethylene S 304SS STZP Steel Zinc Plated CAT PUMPS U K LTD World Headquarters 1 Fleet Business Park si ae Crookham CAT PUMPS FLEET Hampshire GU52 8BF England Ph Fleet 44 1252 622031 Fax 44 1252 626655 sc ate ese ee yaa Sie Ge pune our jy ee oak e mail techsupport catpumps com N V CAT PUMPS INTERNATIONAL S A Heiveldekens 6A B 2550 Kontich Belgium www catoumps com The Pumps with Nine Lives Phone 32 3 4071 D a 32 3 450 7151 E 7 cp pumps be www catpumps be International Inquiries CAT PUMPS DEUTSCHLAND GmbH Buchwiese 2 D 65510 Idstein G aa Oa OI Ra Phone 49 6126 9303 0 Fax 49 6126 93
6. Kit Seal Inclds 98 106 121 125 1 31983 HT Kit Seal Inclds 98 106 121 125 1 76526 STHT Kit Seal Inclds 98 106 120 121 125 Prior to 4 10 1 76983 STHT Kit Seal Inclds 98 106 121 125 After 4 10 1 310 33062 NBR Kit Valve Inclds 163 164 166 167 168 172 2 33258 FPM Kit Valve Inclds 163 164 166 167 168 172 2 350 30696 STZP Plier Reverse 1 500 8075 Gearbox See Individual Data Sheet 1 6107 Oil Bottle 21 oz ISO 68 Hydraulic 1 PARTS LIST Fill to specified crankcase capacity prior to start up Bold print part numbers are unique to a particular pump model talics are optional items Date of latest production change t Production parts are different than repair parts R Components comply with RoHS Directive View Tech Bulletins 002 003 024 036 064 073 074 077 083 and 110 for additional information For motorized versions see BD motor data sheet For Gearbox version see 8075 data sheet MATERIAL CODES Not Part of Part Number AL Aluminum BB Brass BBCP Brass Chrome Plated BBNP Brass Nickel Plated CC Ceramic CM Chrome moly FBB Forged Brass FCM Forged Chrome Moly FPM Fluorocarbon HT Hi Temp EPDM Alternative NBR Medium Nitrile Buna N PVDF Polyvinylidene Fluoride RTP Reinforced Composite S 304SS SNG Special Blend Buna ST Polyetheretherketon STHT Special PTFE High Temp STL Steel STCP Steel Chrome Plated STZP Steel Zinc Plated TNM Special High Strength EXPLODED VIEW DA OU 172
7. Weight sirara i 21 6 oz 0 61 kg DIMENSIONS 00ccceeeeeeeeees 3 25 x 1 0 x 5 0 82 x 25x 127 mm COMMON SPECIFICATIONS Max Temperature ccccseceeeeeeees 180 F 82 C Inlet POM saewcsnscteccantcesvacnaleseneswetienss 3 8 NPTM 3 8 NPTM By Pass Port c cccssceeceseeeeeeees 3 8 NPTF 3 8 NPTF Ou tlet POM scmssesssisisesinniaennesis 3 8 NPTM 3 8 NPTM For Relief Valve version add 100 to unloader model number Read all CAUTIONS and WARNINGS before commencing service or operation of any high pressure system SELECTION These are pressure sensitive regulating unloaders designed for systems with single or multiple pumps solenoid gate valves nozzles standard or weep guns Note For multiple pump systems it is best to use a pressure regulator not a pressure sensitive regulating unloader These pressure sensitive regulating unloaders should meet both the desired system flow combined nozzle flow rate requirement and the desired system pressure Note Operation below the minimum flow of the unloader causes the unloader to cycle Operation above the maximum flow of the unloader Causes premature unloader wear cycling and prevents attaining desired system pressure INSTALLATION These unloaders operate properly when mounted in any direction however it is preferred to keep the plumbing to a minimum and the hex adjusting cap easily accessible The best mounting loca
8. a 32 3 450 7151 E 7 cp pumps be www catpumps be International Inquiries CAT PUMPS DEUTSCHLAND GmbH Buchwiese 2 D 65510 Idstein G aa Oa OI Ra Phone 49 6126 9303 0 Fax 49 6126 9303 33 e mail intlsales catpumps com L _ e mail catpumps t online de www catpumps de Original Instructions PN 993307 Rev A 01 10 5901 ITEM P N MATL DESCRIPTION QTY 2 30047 STL Key M5x5x24 1 5 92519 STZP Screw HHC Sems M6x16 8 125824 STCPR Screw HHC Sems M6x16 8 8 46901 AL Cover Bearing 2 48259 AL Cover Blind 3CP1120G 1 10 14028 NBR O Ring Bearing Cover 70D 2 11 43222 NBR Seal Oil Crankshaft 70D 1 2 15 14480 STL Bearing Ball 2 20 48730 TNM Rod Connecting Assembly 5 01 3 25 46927 FCM Crankshaft Dual End 3CP1120 M12 7 1 46994 FCM Crankshaft Dual End 3CP1130 M7 1 46991 FCM Crankshaft Dual End 3CP1140 M11 1 48484 FCM Crankshaft Single End 3CP1140CS M11 1 48257 FCM Crankshaft Single End 3CP1120G M12 7 1 32 46798 RTP Cap Oil Filler 1 33 14179 NBR O Ring Oil Filler Cap 70D 1 37 92241 Gauge Oil Bubble w Gasket 1 38 44428 NBR Gasket Flat Oil Gauge 80D 1 40 92519 STZP Screw HHC Sems M6x16 4 125824 STCPR Screw HHC Sems M6x16 4 48 25625 STCP Plug Drain 1 4 x19BSP 1 49 23170 NBR O Ring Drain Plug 70D 1 50 46939 AL Cover Rear 1 51 14041 NBR O Ring Rear Cover 70D 1 53 48644 AL Crankcase 1 64 46615 CM Pin Crosshead 3 65 48459 BBNP Rod Plunger 3 70 46839 NBR Seal Oil Crank
9. along with this pressure sensitive regulating unloader Final adjustment for the relief valve should relieve at 200 psi above the system operating pressure DISCHARGE BY PASS Read all CAUTIONS and WARNINGS before commencing service or operation of any high pressure system SERVICING Disassembly 1 2 3 4 Disconnect by pass discharge and inlet plumbing from unloader Remove unloader from pump Secure body of unloader in a vise with hex adjusting cap facing up Model 7500S Remove discharge fitting and o ring spring check valve and o ring Model 7600S Remove discharge fitting and o ring spring check valve and o ring collar check valve seat and o ring Note Seat for check valve will remain in the unloader Exercise caution in removing to avoid damage to unloader walls and seat 5 Examine check valve check valve seat collar and discharge fitting for wear spring for wear or fatigue and o rings for cuts or wear and replace as needed Note While the discharge fitting is removed inspect sealing area where the check valve makes contact within the internal body of the unloader for grooves pitting and wear If damage is found stop the repair and replace with complete new unloader If not proceed with disassembly 6 Ts 8 g9 10 11 12 13 14 To If supplied with a lock nut the lock nut does not need to be removed Turn lock nut down towards unloader body Remove
10. full load on pump e Offers pump protection against pressure fluctuations and system changes e Minimum pressure fluctuations with alternating use of multiple guns e Adjusting cap permits easy adjustments of pressure A CAUTIONS AND WARNINGS All High Pressure Systems require a primary pressure regulating device i e regulator unloader and a secondary pressure relief device i e pop off valve relief valve Failure to install such relief devices could result in personal injury or damage to pump or property CAT PUMPS does not assume any liability or responsibility for the operation of a customer s high pressure system Read all CAUTIONS and WARNINGS before commencing service or operation of any high pressure system The CAUTIONS and WARNINGS are included in each service manual and with each Data sheet CAUTIONS and WARNINGS can also be viewed online at www catpumps com cautions warnings or can be requested directly from CAT PUMPS WARRANTY View the Limited Warranty on line at www catpumps com warranty Customer confidence is our greatest asset MNF Pressure Sensitive Regulating Unloader 7500S 7600S Models SPECIFICATIONS U S Measure Metric Measure MODEL 7500S Flow Range c eccccceeeeeeeeeeeees 0 5 6 0 GPM 1 89 23 0 L M Pressure RAnge cccsecceeseees 100 2000 PSI 7 140 BAR Weight 0ccccceseccsseeceseeeeeseeeseeeeseues 14 4 oz 0 41 kg DIMENSIONS 0cccee
11. hex adjusting cap by turning in a counterclockwise direction Remove spring and spring retainer Examine spring and spring retainer for scale build up fatigue or wear and replace as needed Remove by pass fitting with o ring from bottom port Remove seat with o ring from the male threaded side of by pass fitting Examine seat for scale build up scoring and wear and replace as needed Examine o ring for cuts or wear and replace as needed Removal of piston stem and valve ball assembly requires the use of a small hex socket and screwdriver Insert screwdriver from the top and place in slotted head of piston stem Insert small hex socket into bottom port and secure valve ball assembly Unthread by turning in a counterclockwise direction Examine piston stem and valve ball assembly for scale build up scoring pitting and wear and replace as needed Examine o rings and backup ring for cuts or wear and replace as needed Remove piston retainer with o rings and backup rings by turning in a counterclockwise direction TROUBLESHOOTING Check for leak downstream of unloader e Worn O ring or check valve Air in system poor connection O ring in gun worn Insufficient flow through unloader Unloader cycles Liquid leaking from bottom fitting O ring for fitting cut or worn O ring for seat cut or worn Liquid leaking from middle Unloader will not come up to pressure O ring for piston worn or cut O rings for pi
12. install o ring onto seat Press seat into by pass fitting Hand thread by pass fitting into lower port of unloader body and tighten with wrench Lubricate and install o ring on discharge fitting Model 7500S Insert spring into discharge filling then insert check valve with small step end into spring Hand thread into unloader body and tighten with wrench Model 7600S Lubricate and install o ring onto check valve seat Insert check valve seat with o ring into unloader body Install collar with notches facing in towards check valve seat Insert spring into discharge fitting then insert check valve with small step end into spring Hand thread into unloader body and tighten with wrench Place spring retainer on top of piston stem Place spring on to spring retainer Thread hex adjusting cap onto piston retainer Remove unloader from vise Re install unloader onto pump Reconnect by pass discharge and inlet plumbing to unloader Proceed to PRESSURE ADJUSTMENT Loctite and 242 are registered trademarks of the Henkel Corporation PRESSURE READING all guns valves closed Approximate Pressure Reading at Gauge Gauge Between Pump Unloader Gauge Between Unloader Gun Nozzle Valve System in operation gun open system pressure system pressure System in by pass low pressure 0 150 PSI system pressure 200 PSI EXPLODED VIEW EXPLODED VIEW 7500S Unloader 7600S Unloader 402 D
13. unloader backed off to the lowest pressure setting counterclockwise direction 3 Squeeze the trigger and read the pressure on the gauge at the pump Note Do not read the pressure at the gun or nozzle 4 If more pressure is desired release the trigger turn hex adjusting Cap one quarter turn in clockwise direction Squeeze the trigger and read the pressure Repeat this process until desired system pressure is attained Once the desired system pressure is reached stop turning the hex adjusting cap Note Pressure is not set at the factory Caution A minimum by pass flow of 5 of the unloader rated flow Capacity is required for proper unloader performance If the entire out is directed through the nozzle zero by pass the cushioning feature of the by pass liquid is eliminated and the unloader can malfunction or wear prematurely 8 If desired system pressure cannot be reached review TROUBLESHOOTING chart 9 When servicing existing systems follow adjustment procedures as stated above for new unloaders Note Do not adjust unloader pressure setting to compensate for a worn nozzle Check the nozzle as part of the regular maintenance and replace if worn Note A secondary pressure relief device i e pop off valve should be used along with this pressure sensitive regulating unloader Final adjustment for the relief valve should relieve at 200 psi above the system operating pressure DISCHARGE BY PASS Read all CA
14. 03 33 e mail intlsales catpumps com L _ e mail catpumps t online de www catpumps de Original Instructions PN 993307 Rev A 01 10 5901 ITEM P N MATL DESCRIPTION QTY 2 30047 STL Key M5x5x24 1 5 92519 STZP Screw HHC Sems M6x16 8 125824 STCPR Screw HHC Sems M6x16 8 8 46901 AL Cover Bearing 2 48259 AL Cover Blind 3CP1120G 1 10 14028 NBR O Ring Bearing Cover 70D 2 11 43222 NBR Seal Oil Crankshaft 70D 1 2 15 14480 STL Bearing Ball 2 20 48730 TNM Rod Connecting Assembly 5 01 3 25 46927 FCM Crankshaft Dual End 3CP1120 M12 7 1 46994 FCM Crankshaft Dual End 3CP1130 M7 1 46991 FCM Crankshaft Dual End 3CP1140 M11 1 48484 FCM Crankshaft Single End 3CP1140CS M11 1 48257 FCM Crankshaft Single End 3CP1120G M12 7 1 32 46798 RTP Cap Oil Filler 1 33 14179 NBR O Ring Oil Filler Cap 70D 1 37 92241 Gauge Oil Bubble w Gasket 1 38 44428 NBR Gasket Flat Oil Gauge 80D 1 40 92519 STZP Screw HHC Sems M6x16 4 125824 STCPR Screw HHC Sems M6x16 4 48 25625 STCP Plug Drain 1 4 x19BSP 1 49 23170 NBR O Ring Drain Plug 70D 1 50 46939 AL Cover Rear 1 51 14041 NBR O Ring Rear Cover 70D 1 53 48644 AL Crankcase 1 64 46615 CM Pin Crosshead 3 65 48459 BBNP Rod Plunger 3 70 46839 NBR Seal Oil Crankcase 3 75 43900 S Slinger Barrier 3 88 45697 S Washer Keyhole M18 x 10 3 90 46976 CC Plunger M18x43 3 98 46730 NBR Washer Seal 90D 3 48394 FPM Washer Seal 90D 3 99 48201 SS Retai
15. 06 121 125 After 4 10 1 310 33062 NBR Kit Valve Inclds 163 164 166 167 168 172 2 33258 FPM Kit Valve Inclds 163 164 166 167 168 172 2 350 30696 STZP Plier Reverse 1 500 8075 Gearbox See Individual Data Sheet 1 6107 Oil Bottle 21 oz ISO 68 Hydraulic 1 PARTS LIST Fill to specified crankcase capacity prior to start up Bold print part numbers are unique to a particular pump model talics are optional items Date of latest production change t Production parts are different than repair parts R Components comply with RoHS Directive View Tech Bulletins 002 003 024 036 064 073 074 077 083 and 110 for additional information For motorized versions see BD motor data sheet For Gearbox version see 8075 data sheet MATERIAL CODES Not Part of Part Number AL Aluminum BB Brass BBCP Brass Chrome Plated BBNP Brass Nickel Plated CC Ceramic CM Chrome moly FBB Forged Brass FCM Forged Chrome Moly FPM Fluorocarbon HT Hi Temp EPDM Alternative NBR Medium Nitrile Buna N PVDF Polyvinylidene Fluoride RTP Reinforced Composite S 304SS SNG Special Blend Buna ST Polyetheretherketon STHT Special PTFE High Temp STL Steel STCP Steel Chrome Plated STZP Steel Zinc Plated TNM Special High Strength EXPLODED VIEW DA OU 172 174 Models 3CP1120 3CP1120G 3CP1130 3CP1140 February 2011 a 911 231 6 87 174 5 gt 5 64 143 5
16. 3 31047 BB Nut Lock M18 x 1 1 404 45201 BB Nut Lock M25x1 1 408 32094 STZPR Spring Pressure 1 408 45198 ZP Spring Pressure 1 410 107672 BB Retainer Spring 1 410 45199 BB Retainer Spring 1 412 45694 S Stem Piston M5 1 412 45694 S Stem Piston M5 1 414 20184 PTFE Back up Ring Piston Stem 1 414 20184 PTFE Back up Ring Piston Stem 1 415 14190 NBR O Ring Piston Stem 70D 1 415 14190 NBR O Ring Piston Stem 70D 1 14161 FPM O Ring Piston Stem 70D 1 425 45200 BB Retainer Piston 1 425 107673 BB Retainer Piston 1 428 26133 NBR O Ring Piston Guide 80D 1 428 13969 NBR O Ring Piston Retainer 70D 1 429 14759 NBR O Ring Body 1 14320 FPM O Ring Piston Retainer 70D 1 430 107675 PTFE Back up Ring Body 1 429 14759 NBR O Ring Body 1 435 45716 S Valve and Ball Assembly M5 1 14160 FPM O Ring Body 80D 1 436 107680 S Seat 1 430 107675 PTFE Back up Ring Body 1 437 26127 NBR O Ring Seat 1 435 45696 BB Valve and Ball Assembly M5 1 438 45206 S Seat C Valve 1 436 107680 S Seat 1 439 45205 BB Collar 1 437 13963 NBR O Ring Seat 70D 1 440 BB Body 1 14303 FPM O Ring Seat 70D 1 441 13963 NBR O Ring Seat 70D 1 440 BB Body 1 442 26133 NBR O Ring Adapter 80D 1 442 13969 NBR O Ring By Pass Fitting 70D 1 443 35203 BB Valve Check w O Ring 1 14320 FPM O Ring By Pass Fitting 70D 1 444 45924 S Spring 1 443 541060 BB Valve Check w O Ring 1 446 26133 NBR O Ring Discharge Fitting 80D 1 444 45924 S Spring 1 455 45695 BB
17. ISCHARGE DISCHARGE BY PASS BY PASS PARTS LIST PARTS LIST ITEM P N MATL DESCRIPTION QTY ITEM P N MATL DESCRIPTION QTY 402 540081 BB Cap Hex Adjusting 1 402 45197 BB Cap Hex Adjusting 1 403 31047 BB Nut Lock M18 x 1 1 404 45201 BB Nut Lock M25x1 1 408 32094 STZPR Spring Pressure 1 408 45198 ZP Spring Pressure 1 410 107672 BB Retainer Spring 1 410 45199 BB Retainer Spring 1 412 45694 S Stem Piston M5 1 412 45694 S Stem Piston M5 1 414 20184 PTFE Back up Ring Piston Stem 1 414 20184 PTFE Back up Ring Piston Stem 1 415 14190 NBR O Ring Piston Stem 70D 1 415 14190 NBR O Ring Piston Stem 70D 1 14161 FPM O Ring Piston Stem 70D 1 425 45200 BB Retainer Piston 1 425 107673 BB Retainer Piston 1 428 26133 NBR O Ring Piston Guide 80D 1 428 13969 NBR O Ring Piston Retainer 70D 1 429 14759 NBR O Ring Body 1 14320 FPM O Ring Piston Retainer 70D 1 430 107675 PTFE Back up Ring Body 1 429 14759 NBR O Ring Body 1 435 45716 S Valve and Ball Assembly M5 1 14160 FPM O Ring Body 80D 1 436 107680 S Seat 1 430 107675 PTFE Back up Ring Body 1 437 26127 NBR O Ring Seat 1 435 45696 BB Valve and Ball Assembly M5 1 438 45206 S Seat C Valve 1 436 107680 S Seat 1 439 45205 BB Collar 1 437 13963 NBR O Ring Seat 70D 1 440 BB Body 1 14303 FPM O Ring Seat 70D 1 441 13963 NBR O Ring Seat 70D 1 440 BB Body 1 442 26133 NBR O Ring Adapter 80D 1 442 13969 NBR O Ring By Pass Fitting 70D 1 443 35203 BB Valve Chec
18. ON These unloaders operate properly when mounted in any direction however it is preferred to keep the plumbing to a minimum and the hex adjusting cap easily accessible The best mounting location is directly onto the pump discharge manifold head The inlet connection is a 3 8 NPTM sized port located on the back side of the unloader An arrow is cast into the body indicating the direction of flow through the valve Liquid from the discharge of the pump goes through this connection The discharge connection is a 3 8 NPTM sized port located on the front side hex end An arrow and the word OUT is cast into the body indicating the direction of flow Plumbing for spray guns solenoid gate valves or nozzles is connected here The by pass connection is a 3 8 NPTF sized port located on the bottom By Pass liquid is directed out of this port and can be routed to a reservoir preferred method or to a drain or to the pump inlet OPERATION These pressure sensitive regulating unloaders hold established system pressure in the discharge line when the trigger gun is closed or solenoid gate valve is closed or the nozzle is clogged thus by passing all unrequired flow Squeezing the trigger gun or opening the solenoid gate valve will close off the by pass and return to established system pressure without delay TYPICAL UNLOADER INSTALLATION Pressure Gauge Relief Valve Shown as a secondary relief valve Pulsation Dampener Pres
19. URES Triplex design offers high efficiency and low pulsation Durable high pressure seals are lubricated and cooled by pumped liquid Pre set Lo Pressure Seals provide secondary protection against external leaks and require no packing adjustment Special high density polished concentric plungers provide a true wear surface and extended seal life Specially formulated seals offer unmatched performance and extended life Optional STHT FPM and EPDM elastomers for compatibility with many liquids and temperaturesup to 200 F Convenient press in style seal case and interchangeable inlet and discharge valves for easy servicing Wet end easily serviced without entering crankcase COMMON SPECIFICATIONS Inlet Pressure RangGG sseeeee Flooded to 70 PSI Flooded to 4 9 BAR BONO aiaa a EEA 0 709 18 mm Crankcase Capacity sss ssseesesessseesseesssessseressess 12 oz 0 35 L Standard Liquid Temperature eseseseees 160 F 71 C Above 130 F call CAT PUMPS for inlet conditions and elastomer rec ommendations inlet a0 aia 2 lemeenenrneeeereeee ener caren eee 1 2 NPTF 1 2 NPTF Discharge Ports 2 sssesssessseesssesssessssessseee 3 8 NPTF 3 8 NPTF Pulley Mounting ssessessssessseesssessseesseesssessss Either Side Either Side Shaft Diameter sss essseessseeesssesosseesssecsssseesssseesssee 0 650 16 5 mm IN IN ra a 14 84 Ibs 6 7 kg DIMENSIONS sssesisrissiaiiasis
20. UTIONS and WARNINGS before commencing service or operation of any high pressure system SERVICING Disassembly 1 2 3 4 Disconnect by pass discharge and inlet plumbing from unloader Remove unloader from pump Secure body of unloader in a vise with hex adjusting cap facing up Model 7500S Remove discharge fitting and o ring spring check valve and o ring Model 7600S Remove discharge fitting and o ring spring check valve and o ring collar check valve seat and o ring Note Seat for check valve will remain in the unloader Exercise caution in removing to avoid damage to unloader walls and seat 5 Examine check valve check valve seat collar and discharge fitting for wear spring for wear or fatigue and o rings for cuts or wear and replace as needed Note While the discharge fitting is removed inspect sealing area where the check valve makes contact within the internal body of the unloader for grooves pitting and wear If damage is found stop the repair and replace with complete new unloader If not proceed with disassembly 6 Ts 8 g9 10 11 12 13 14 To If supplied with a lock nut the lock nut does not need to be removed Turn lock nut down towards unloader body Remove hex adjusting cap by turning in a counterclockwise direction Remove spring and spring retainer Examine spring and spring retainer for scale build up fatigue or wear and replace as needed
21. case 3 75 43900 S Slinger Barrier 3 88 45697 S Washer Keyhole M18 x 10 3 90 46976 CC Plunger M18x43 3 98 46730 NBR Washer Seal 90D 3 48394 FPM Washer Seal 90D 3 99 48201 SS Retainer Plunger w Stud M6 3 100 46541 PVDF Retainer Seal 3 106 43243 NBR Seal LPS w S Spg 3 44926 FPM Seal LPS w SS Spg 3 76243 ST Seal LPS w S Spg 3 120 46625 BB Case Seal See Tech Bulletin 110 3 121 13976 NBR O Ring Seal Case 70D 3 48522 FPM O Ring Seal Case 3 125 43245 SNG Seal HPS w S 3 44925 FPM Seal HPS w SS 3 46652 HT Seal HPS Hi Temp 2 Pc w S Support 3 139 43448 BB Plug Inlet 1 2 NPT 1 163 17547 NBR O Ring Seat 85D 6 11685 FPM O Ring Seat 85D 6 164 45790 S Seat 6 166 43723 S Valve 6 167 43750 S Spring 6 168 44565 PVDF Retainer Spring 6 172 17615 NBR O Ring Valve Plug 75D 6 15855 FPM O Ring Valve Plug 70D 6 174 46756 BB Plug Valve 6 185 46616 FBB Manifold Head 1 188 126512 STCPR Screw HSH M8x65 8 196 22187 BBCP Plug Discharge 3 8 NPT 1 250 118672 STCP Protector Shaft 1 260 30612 STZP Mount Rail Assy 1 265 30641 Mount Assy Inclds 30612 30032 30047 118672 1 270 30246 STL Assy Pulley amp Key Inclds 30032 30047 See Tech Bulletin 003 1 283 34334 Kit Oil Drain 3 8 x 24 See individual Data Sheet 1 76334 Kit Oil Indicator 3 8 x 24 See individual Data Sheet 1 299 814841 FBB Head Complete 1 300 33983 NBR Kit Seal Inclds 98 106 121 125 1 33257 FPM
22. d cooled by pumped liquid Pre set Lo Pressure Seals provide secondary protection against external leaks and require no packing adjustment Special high density polished concentric plungers provide a true wear surface and extended seal life Specially formulated seals offer unmatched performance and extended life Optional STHT FPM and EPDM elastomers for compatibility with many liquids and temperaturesup to 200 F Convenient press in style seal case and interchangeable inlet and discharge valves for easy servicing Wet end easily serviced without entering crankcase COMMON SPECIFICATIONS Inlet Pressure RangGG sseeeee Flooded to 70 PSI Flooded to 4 9 BAR BONO aiaa a EEA 0 709 18 mm Crankcase Capacity sss ssseesesessseesseesssessseressess 12 oz 0 35 L Standard Liquid Temperature eseseseees 160 F 71 C Above 130 F call CAT PUMPS for inlet conditions and elastomer rec ommendations inlet a0 aia 2 lemeenenrneeeereeee ener caren eee 1 2 NPTF 1 2 NPTF Discharge Ports 2 sssesssessseesssesssessssessseee 3 8 NPTF 3 8 NPTF Pulley Mounting ssessessssessseesssessseesseesssessss Either Side Either Side Shaft Diameter sss essseessseeesssesosseesssecsssseesssseesssee 0 650 16 5 mm IN IN ra a 14 84 Ibs 6 7 kg DIMENSIONS sssesisrissiaiiasissivsieisiseaniie 9 1 x 8 78 x 5 47 231 x 223 x139 mm A CAUTIONS AND WARNINGS All High Pressure Systems re
23. e RPM ssesssesserssesseosseossesseosseossrossesseees 3600 rpm 3600 rpm GUOKO ces cepa atari atic pects etnetiiemaane 0 500 12 7 mm MODEL 3CP 1130 pirEcT DRIVE ENO Vie EE E EEE EAEE E 2 4 gpm 9 lpm Pressure RANGE sscsssecscecesssseeseecees 100 to 2200 psi 7 to 155 bar E aira E E A 1725 rom 1725 rom OKE ar A eens 0 276 7 mm MODEL 3CP 1140 pirEcT DRIVE TE A E E 3 6 gpm 13 6 lpm Pressure Range s ssesserssesssessersseess 100 to 2200 psi 7 to 155 bar FPP IW O E E A E 1725 rom 1725 rom SORO aiin R TE 0 433 11 mm ELECTRIC HORSEPOWER REQUIREMENTS MODELS PRESSURE MOTOR PULLEY SIZE e e a aaa Using 1750 rpm Motor 1200 1500 2000 2200 rpm 5 0 Pump Pulley O D eleo E gpm Ipm 85 105 140 155 O D Bea senmo 24 o io 24 32 36 1725 DiecDive 3CP1120 DETERMINING Rated gom Desired gpm THE PUMP R P M Rated rom Desired rom DETERMINING gpm x psi Electric Brake THE REQUIRED H P 1460 H P Required DETERMINING Motor Pulley O D Pump Pulley O D MOTOR PULLEY SIZE Pump rpm Motor rom See complete Drive Packages Inclds Pulleys Belts Hubs Key Tech Bulletin 003 Refer to pump Service Manual for repair procedure and additional technical information 4 Model 3CP1120 Shown Rails and shaft protector sold separately FEATURES Triplex design offers high efficiency and low pulsation Durable high pressure seals are lubricated an
24. eeeeeeees 3 0 x 1 0 x 4 25 76 x 25x 108 mm MODEL 7600S Flow Range seccceeeeeeeeeeeeeees 2 0 5 0 GPM 7 6 19 0 L M Pressure RANnge ccceeceeeseees 700 3500 PSI 48 245 BAR Weight sirara i 21 6 oz 0 61 kg DIMENSIONS 00ccceeeeeeeeees 3 25 x 1 0 x 5 0 82 x 25x 127 mm COMMON SPECIFICATIONS Max Temperature ccccseceeeeeeees 180 F 82 C Inlet POM saewcsnscteccantcesvacnaleseneswetienss 3 8 NPTM 3 8 NPTM By Pass Port c cccssceeceseeeeeeees 3 8 NPTF 3 8 NPTF Ou tlet POM scmssesssisisesinniaennesis 3 8 NPTM 3 8 NPTM For Relief Valve version add 100 to unloader model number Read all CAUTIONS and WARNINGS before commencing service or operation of any high pressure system SELECTION These are pressure sensitive regulating unloaders designed for systems with single or multiple pumps solenoid gate valves nozzles standard or weep guns Note For multiple pump systems it is best to use a pressure regulator not a pressure sensitive regulating unloader These pressure sensitive regulating unloaders should meet both the desired system flow combined nozzle flow rate requirement and the desired system pressure Note Operation below the minimum flow of the unloader causes the unloader to cycle Operation above the maximum flow of the unloader Causes premature unloader wear cycling and prevents attaining desired system pressure INSTALLATI
25. iemaane 0 500 12 7 mm MODEL 3CP 1130 pirEcT DRIVE ENO Vie EE E EEE EAEE E 2 4 gpm 9 lpm Pressure RANGE sscsssecscecesssseeseecees 100 to 2200 psi 7 to 155 bar E aira E E A 1725 rom 1725 rom OKE ar A eens 0 276 7 mm MODEL 3CP 1140 pirEcT DRIVE TE A E E 3 6 gpm 13 6 lpm Pressure Range s ssesserssesssessersseess 100 to 2200 psi 7 to 155 bar FPP IW O E E A E 1725 rom 1725 rom SORO aiin R TE 0 433 11 mm ELECTRIC HORSEPOWER REQUIREMENTS MODELS PRESSURE MOTOR PULLEY SIZE e e a aaa Using 1750 rpm Motor 1200 1500 2000 2200 rpm 5 0 Pump Pulley O D eleo E gpm Ipm 85 105 140 155 O D Bea senmo 24 o io 24 32 36 1725 DiecDive 3CP1120 DETERMINING Rated gom Desired gpm THE PUMP R P M Rated rom Desired rom DETERMINING gpm x psi Electric Brake THE REQUIRED H P 1460 H P Required DETERMINING Motor Pulley O D Pump Pulley O D MOTOR PULLEY SIZE Pump rpm Motor rom See complete Drive Packages Inclds Pulleys Belts Hubs Key Tech Bulletin 003 Refer to pump Service Manual for repair procedure and additional technical information Model 7600S Model 7500S FEATURES e Maintains full system pressure while running in by pass without full load on pump e Offers pump protection against pressure fluctuations and system changes e Minimum pressure fluctuations with alternating use of multiple guns e Adjusting cap permi
26. k w O Ring 1 14320 FPM O Ring By Pass Fitting 70D 1 444 45924 S Spring 1 443 541060 BB Valve Check w O Ring 1 446 26133 NBR O Ring Discharge Fitting 80D 1 444 45924 S Spring 1 455 45695 BB Fitting By Pass 3 8 NPTF 1 446 13969 NBR O Ring Discharge Fitting 70D 1 460 107681 BB Fitting Discharge 3 8 NPTM 1 14320 FPM O Ring Discharge Fitting 70D 1 468 32098 NBR Kit O Ring Inclds 414 415 428 429 430 437 441 442 446 1 455 45695 BB Fitting By Pass 8 8 NPTF 1 Italics are optional items 460 107681 BB Fitting Discharge 8 8 NPTM 1 MATERIAL CODES Not Part of Part Number 468 32097 NBR Kit O Ring Inclds 414 415 428 430 437 442 446 1 BB Brass NBR Medium Nitrile Buna N PTFE Pure Polytetrafluoroethylene 31627 FPM Kit O Ring Inclds 414 415 428 430 437 442 446 1 S 304SS ZP Zinc Plated Italics are optional items R Components comply with RoHS Directive MATERIAL CODES Not Part of Part Number BB Brass FPM Fluorocarbon NBR Medium Nitrile Buna N PTFE Pure Polytetrafluoroethylene S 304SS STZP Steel Zinc Plated CAT PUMPS U K LTD World Headquarters 1 Fleet Business Park si ae Crookham CAT PUMPS FLEET Hampshire GU52 8BF England Ph Fleet 44 1252 622031 Fax 44 1252 626655 sc ate ese ee yaa Sie Ge pune our jy ee oak e mail techsupport catpumps com N V CAT PUMPS INTERNATIONAL S A Heiveldekens 6A B 2550 Kontich Belgium www catoumps com The Pumps with Nine Lives Phone 32 3 4071 D
27. ner Plunger w Stud M6 3 100 46541 PVDF Retainer Seal 3 106 43243 NBR Seal LPS w S Spg 3 44926 FPM Seal LPS w SS Spg 3 76243 ST Seal LPS w S Spg 3 120 46625 BB Case Seal See Tech Bulletin 110 3 121 13976 NBR O Ring Seal Case 70D 3 48522 FPM O Ring Seal Case 3 125 43245 SNG Seal HPS w S 3 44925 FPM Seal HPS w SS 3 46652 HT Seal HPS Hi Temp 2 Pc w S Support 3 139 43448 BB Plug Inlet 1 2 NPT 1 163 17547 NBR O Ring Seat 85D 6 11685 FPM O Ring Seat 85D 6 164 45790 S Seat 6 166 43723 S Valve 6 167 43750 S Spring 6 168 44565 PVDF Retainer Spring 6 172 17615 NBR O Ring Valve Plug 75D 6 15855 FPM O Ring Valve Plug 70D 6 174 46756 BB Plug Valve 6 185 46616 FBB Manifold Head 1 188 126512 STCPR Screw HSH M8x65 8 196 22187 BBCP Plug Discharge 3 8 NPT 1 250 118672 STCP Protector Shaft 1 260 30612 STZP Mount Rail Assy 1 265 30641 Mount Assy Inclds 30612 30032 30047 118672 1 270 30246 STL Assy Pulley amp Key Inclds 30032 30047 See Tech Bulletin 003 1 283 34334 Kit Oil Drain 3 8 x 24 See individual Data Sheet 1 76334 Kit Oil Indicator 3 8 x 24 See individual Data Sheet 1 299 814841 FBB Head Complete 1 300 33983 NBR Kit Seal Inclds 98 106 121 125 1 33257 FPM Kit Seal Inclds 98 106 121 125 1 31983 HT Kit Seal Inclds 98 106 121 125 1 76526 STHT Kit Seal Inclds 98 106 120 121 125 Prior to 4 10 1 76983 STHT Kit Seal Inclds 98 1
28. ng Model 7500S Insert spring into discharge filling then insert check valve with small step end into spring Hand thread into unloader body and tighten with wrench Model 7600S Lubricate and install o ring onto check valve seat Insert check valve seat with o ring into unloader body Install collar with notches facing in towards check valve seat Insert spring into discharge fitting then insert check valve with small step end into spring Hand thread into unloader body and tighten with wrench Place spring retainer on top of piston stem Place spring on to spring retainer Thread hex adjusting cap onto piston retainer Remove unloader from vise Re install unloader onto pump Reconnect by pass discharge and inlet plumbing to unloader Proceed to PRESSURE ADJUSTMENT Loctite and 242 are registered trademarks of the Henkel Corporation PRESSURE READING all guns valves closed Approximate Pressure Reading at Gauge Gauge Between Pump Unloader Gauge Between Unloader Gun Nozzle Valve System in operation gun open system pressure system pressure System in by pass low pressure 0 150 PSI system pressure 200 PSI EXPLODED VIEW EXPLODED VIEW 7500S Unloader 7600S Unloader 402 DISCHARGE DISCHARGE BY PASS BY PASS PARTS LIST PARTS LIST ITEM P N MATL DESCRIPTION QTY ITEM P N MATL DESCRIPTION QTY 402 540081 BB Cap Hex Adjusting 1 402 45197 BB Cap Hex Adjusting 1 40
29. quire a primary pressure regulating device i e regulator unloader and a secondary pressure relief device i e pop off valve relief valve Failure to install such relief devices could result in personal injury or damage to pump or property CAT PUMPS does not assume any liability or responsibility for the operation of a customer s high pressure system Read all CAUTIONS and WARNINGS before commencing service or operation of any high pressure system The CAUTIONS and WARNINGS are included in each service manual and with each Accessory Data sheet CAUTIONS and WARNINGS can also be viewed online at www catpumps com cautions warnings or can be requested directly from CAT PUMPS WARRANTY View the Limited Warranty on line at www catpumps com warranty 3CP Plunger Pump Standard odes 3CP1120 3CP1130 3CP1140 Gearbox ia 3CP1120G SPECIFICATIONS U S Measure Metric Measure MODEL 3CP 1120 pirEcT DRIVE POW E 4 2 gpm 16 lpm Pressure Range s ssesserssesssessersseess 100 to 2200 psi 7 to 155 bar FUP O E E AA 1725 rom 1725 rom SLES SRE E E AEE TA 0 500 12 7 mm MODEL 3 CP 1 120G GEARBOX 2 55 1 RATIO FONTS PE A TA E 3 5 gpm 13 2 lpm Pressure RANGE csssssscsccessssecscecees 100 to 2200 psi 7 to 155 bar Pump RPM ssicsessessvsnsvssonsessieoonssaveivcsntsseshansssanns 1420 rom 1420 rom Engine RPM ssesssesserssesseosseossesseosseossrossesseees 3600 rpm 3600 rpm GUOKO ces cepa atari atic pects etneti
30. s offer unmatched per formance and seal life PN 993101 Rev G 2 11 11145
31. sivsieisiseaniie 9 1 x 8 78 x 5 47 231 x 223 x139 mm A CAUTIONS AND WARNINGS All High Pressure Systems require a primary pressure regulating device i e regulator unloader and a secondary pressure relief device i e pop off valve relief valve Failure to install such relief devices could result in personal injury or damage to pump or property CAT PUMPS does not assume any liability or responsibility for the operation of a customer s high pressure system Read all CAUTIONS and WARNINGS before commencing service or operation of any high pressure system The CAUTIONS and WARNINGS are included in each service manual and with each Accessory Data sheet CAUTIONS and WARNINGS can also be viewed online at www catpumps com cautions warnings or can be requested directly from CAT PUMPS WARRANTY View the Limited Warranty on line at www catpumps com warranty 3CP Plunger Pump Standard odes 3CP1120 3CP1130 3CP1140 Gearbox ia 3CP1120G SPECIFICATIONS U S Measure Metric Measure MODEL 3CP 1120 pirEcT DRIVE POW E 4 2 gpm 16 lpm Pressure Range s ssesserssesssessersseess 100 to 2200 psi 7 to 155 bar FUP O E E AA 1725 rom 1725 rom SLES SRE E E AEE TA 0 500 12 7 mm MODEL 3 CP 1 120G GEARBOX 2 55 1 RATIO FONTS PE A TA E 3 5 gpm 13 2 lpm Pressure RANGE csssssscsccessssecscecees 100 to 2200 psi 7 to 155 bar Pump RPM ssicsessessvsnsvssonsessieoonssaveivcsntsseshansssanns 1420 rom 1420 rom Engin
32. ston stem worn or cut Not properly sized for system pressure Foreign material in unloader Clean filter Piston stem O rings worn Nozzle worn Insufficient flow to pump Extreme pressure spikes Adjusting nut turned completely into unloader Restricted by pass or no by pass System flow exceeds unloader rating Filtration Clean filter on regular schedule to avoid cavitation 16 Examine piston retainer for wear Examine o rings and back up ring for cuts or wear and replace as needed Reassembly iF 2 3 Oo 10 11 12 13 14 15 16 17 18 Lubricate and install small body back up ring and then body o ring into unloader body Lubricate and install o ring over threads of piston retainer Carefully hand thread piston retainer with small diameter hole facing down into unloader body and tighten with a wrench Lubricate and install o ring over piston stem head and then backup ring into groove of piston stem Apply Loctite 242 to the last few threads of the piston stem Insert piston stem from the top through the piston retainer until seated Using the same tools in removing the piston stem and valve ball assembly place valve ball assembly into hex socket tool with ball surface facing down into socket Place screwdriver tip into piston stem slotted head Thread piston stem into valve ball assembly Place by pass fitting on flat surface with male threads facing up Lubricate and
33. sure Sensitive Regulating Unloader Triplex Plunger Pump PRESSURE ADJUSTMENT 1 Setting and adjusting the unloader pressure must be done with the system on 2 Start the system with unloader backed off to the lowest pressure setting counterclockwise direction 3 Squeeze the trigger and read the pressure on the gauge at the pump Note Do not read the pressure at the gun or nozzle 4 If more pressure is desired release the trigger turn hex adjusting Cap one quarter turn in clockwise direction Squeeze the trigger and read the pressure Repeat this process until desired system pressure is attained Once the desired system pressure is reached stop turning the hex adjusting cap Note Pressure is not set at the factory Caution A minimum by pass flow of 5 of the unloader rated flow Capacity is required for proper unloader performance If the entire out is directed through the nozzle zero by pass the cushioning feature of the by pass liquid is eliminated and the unloader can malfunction or wear prematurely 8 If desired system pressure cannot be reached review TROUBLESHOOTING chart 9 When servicing existing systems follow adjustment procedures as stated above for new unloaders Note Do not adjust unloader pressure setting to compensate for a worn nozzle Check the nozzle as part of the regular maintenance and replace if worn Note A secondary pressure relief device i e pop off valve should be used
34. tion is directly onto the pump discharge manifold head The inlet connection is a 3 8 NPTM sized port located on the back side of the unloader An arrow is cast into the body indicating the direction of flow through the valve Liquid from the discharge of the pump goes through this connection The discharge connection is a 3 8 NPTM sized port located on the front side hex end An arrow and the word OUT is cast into the body indicating the direction of flow Plumbing for spray guns solenoid gate valves or nozzles is connected here The by pass connection is a 3 8 NPTF sized port located on the bottom By Pass liquid is directed out of this port and can be routed to a reservoir preferred method or to a drain or to the pump inlet OPERATION These pressure sensitive regulating unloaders hold established system pressure in the discharge line when the trigger gun is closed or solenoid gate valve is closed or the nozzle is clogged thus by passing all unrequired flow Squeezing the trigger gun or opening the solenoid gate valve will close off the by pass and return to established system pressure without delay TYPICAL UNLOADER INSTALLATION Pressure Gauge Relief Valve Shown as a secondary relief valve Pulsation Dampener Pressure Sensitive Regulating Unloader Triplex Plunger Pump PRESSURE ADJUSTMENT 1 Setting and adjusting the unloader pressure must be done with the system on 2 Start the system with
35. ts easy adjustments of pressure A CAUTIONS AND WARNINGS All High Pressure Systems require a primary pressure regulating device i e regulator unloader and a secondary pressure relief device i e pop off valve relief valve Failure to install such relief devices could result in personal injury or damage to pump or property CAT PUMPS does not assume any liability or responsibility for the operation of a customer s high pressure system Read all CAUTIONS and WARNINGS before commencing service or operation of any high pressure system The CAUTIONS and WARNINGS are included in each service manual and with each Data sheet CAUTIONS and WARNINGS can also be viewed online at www catpumps com cautions warnings or can be requested directly from CAT PUMPS WARRANTY View the Limited Warranty on line at www catpumps com warranty Customer confidence is our greatest asset MNF Pressure Sensitive Regulating Unloader 7500S 7600S Models SPECIFICATIONS U S Measure Metric Measure MODEL 7500S Flow Range c eccccceeeeeeeeeeeees 0 5 6 0 GPM 1 89 23 0 L M Pressure RAnge cccsecceeseees 100 2000 PSI 7 140 BAR Weight 0ccccceseccsseeceseeeeeseeeseeeeseues 14 4 oz 0 41 kg DIMENSIONS 0ccceeeeeeeeees 3 0 x 1 0 x 4 25 76 x 25x 108 mm MODEL 7600S Flow Range seccceeeeeeeeeeeeeees 2 0 5 0 GPM 7 6 19 0 L M Pressure RANnge ccceeceeeseees 700 3500 PSI 48 245 BAR
36. ure spikes Adjusting nut turned completely into unloader Restricted by pass or no by pass System flow exceeds unloader rating Filtration Clean filter on regular schedule to avoid cavitation 16 Examine piston retainer for wear Examine o rings and back up ring for cuts or wear and replace as needed Reassembly iF 2 3 Oo 10 11 12 13 14 15 16 17 18 Lubricate and install small body back up ring and then body o ring into unloader body Lubricate and install o ring over threads of piston retainer Carefully hand thread piston retainer with small diameter hole facing down into unloader body and tighten with a wrench Lubricate and install o ring over piston stem head and then backup ring into groove of piston stem Apply Loctite 242 to the last few threads of the piston stem Insert piston stem from the top through the piston retainer until seated Using the same tools in removing the piston stem and valve ball assembly place valve ball assembly into hex socket tool with ball surface facing down into socket Place screwdriver tip into piston stem slotted head Thread piston stem into valve ball assembly Place by pass fitting on flat surface with male threads facing up Lubricate and install o ring onto seat Press seat into by pass fitting Hand thread by pass fitting into lower port of unloader body and tighten with wrench Lubricate and install o ring on discharge fitti
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