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Summary of Contents for CAT Pumps 3CP1211CS
- Page 1 SERVICE MANUAL 3CP STAINLESS STEEL PLUNGER PUMPS PUMP MODELS INCLUDED 3CP1211CS 3CP1211G 3CP1221 3CP1231 3CP1241 3CP1241G Product Quality, Reliability and Support You Expect www.catpumps.com...
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Page 2: Table Of Contents
Table of Contents Safety Symbols IMPORTANT SAFETY INSTRUCTIONS Safety Symbols It is the responsibility of the user to read and understand all General Safety Information instructions, important safeguards and safety precautions before Seal & Valve Kits operating or servicing any pump. Failure to do so may result in Service Intervals property damage, personal injury or death. -
Page 3: General Safety Information
General Safety Information A. FLAMMABLE OR EXPLOSIVE LIQUID HAZARD Do not operate pump with flammable or explosive liquids unless extraordinary safety precautions are observed. Leaks of flammable or explosive liquids, if exposed to elevated temperatures, static electricity, sparks or other hazards, will result in flame or possible explosion, causing serious personal injury, death or property damage. - Page 4 General Safety Information and Symbols F. OVER PRESSURIZATION HAZARD CONTINUED Do not operate high-pressure pumping system unless extraordinary safety precautions are observed. A high-pressure pumping system can deadhead or over pressurize causing serious personal injury and property damage. 1. All high-pressure systems require a primary pressure regulating device (e.g., regulator or unloader) and a secondary pressure safety relief device (e.g., pop-off valve, safety valve, rupture disc) to assure proper pressure setting and overpressure protection.
- Page 5 1. Fill pump crankcase to specific capacity indicated on data sheet or service manual prior to startup. 2. Cat Pumps premium custom-blend oil is available worldwide in 21-ounce bottles, (single and 12-pack cases), 2.5 gallon jugs (single and 2-pack) or 30 gallon drums. Use of other oils may void the warranty.
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Page 6: Seal & Valve Kits
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 lasting much longer. Cat Pumps always recommends replacing these items as a kit since components usually wear at about the same rate. -
Page 7: Seal & Valve Kit Pump Diagram
Seal & Valve Kit Pump Diagram SEAL KIT COMPONENTS PN 33985 | Qty 1 VALVE KIT COMPONENTS PN 30982 | Qty 1 PLUNGER RETAINER GASKET LOW-PRESSURE SEAL O-RING O-RING VALVE KIT HIGH-PRESSURE SEAL ASSEMBLY 30982 O-RING O-RING VALVE KIT ASSEMBLY 30982 Tools Needed 1. -
Page 8: Servicing The Seals
Servicing the Seals MANIFOLD AND SEAL REMOVAL NOTE: One (1) seal kit is required to repair the pump (see data sheets PN 993104 or 99DAT019). 1.01 Use an 8 mm hex bit socket with 1.02 Support the discharge manifold from 1.03 Place the discharge manifold on a flat ratchet to remove the six (6) hex socket underneath. - Page 9 Servicing the Seals MANIFOLD AND SEAL REMOVAL 1.10 Inspect the inside diameter of the low- 1.11 Flip the inlet manifold over so the high- 1.12 Use a flat tip screwdriver to pry the pressure seals for wear or damage. pressure seals are facing upwards. high-pressure seals upward and remove.
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Page 10: Plunger Removal
Servicing the Seals PLUNGER REMOVAL 1.19 Remove seal retainer from crankcase 1.20 Using a 10 mm combination wrench, 1.21 Remove and inspect plunger retainer housing. loosen and remove the plunger retainer gasket. and plunger. 1.22 Inspect ceramic plunger for cracks and 1.23 Use a pick to remove keyhole washer scoring to the surface. -
Page 11: Plunger Reassembly
Servicing the Seals PLUNGER REASSEMBLY 1.24 Install barrier slinger with dish side 1.25 Install keyhole washer. The slot can face 1.26 Replace plunger retainer gasket with facing away from crankcase. any direction. new one from seal kit and apply a lubricant to the outside surface. -
Page 12: Manifold And Seal Installation
Servicing the Seals MANIFOLD AND SEAL INSTALLATION NOTICE: Examine manifold for grooves, pitting or wear and replace as needed. 1.33 Apply a lubricant to the outside surface 1.34 One side of the low-pressure seal has a 1.32 Place inlet manifold on a flat surface with of the low-pressure seals. - Page 13 Servicing the Seals MANIFOLD AND SEAL INSTALLATION NOTICE: Examine manifold for grooves, pitting or wear and replace as needed. NOTE: If replacing valve kit assemblies, continue to Valve Installation 2.20, then proceed to Discharge Manifold Installation. TORQUE PATTERN 1.42 Using a 6 mm hex socket bit, tighten 1.41 Install four (4) HSH screws by hand.
- Page 14 Servicing the Seals MANIFOLD AND SEAL INSTALLATION 1.50 Use a rubber mallet to tap manifold on 1.51 Apply anti-seize to the six (6) HSH 1.49 Install discharge manifold by hand, the rest of the way. screws. ensuring even alignment. 1.52 Install six (6) HSH screws by hand. 1.53 Using an 8 mm hex socket bit, tighten 1.54 Rotate crankshaft with adjustable hex head screws using appropriate...
- Page 15 (763) 780-5440 | techsupport@catpumps.com | www.catpumps.com SERVICE MANUAL | 3CP Stainless Steel Series Plunger Pumps...
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Page 16: Servicing The Valves
Servicing the Valves VALVE REMOVAL NOTE: One (1) valve kit is required to repair the pump (see data sheets PN 993104 or 99DAT019). NOTE: Discharge and inlet valve assemblies are identical (use procedure below for disassembly and reassembly of discharge and inlet valves). 2.01 Use an 8 mm hex bit socket with 2.02 Support the discharge manifold from 2.03 Place the discharge manifold on a flat... - Page 17 Servicing the Valves VALVE REMOVAL NOTICE: Pitting on the valve seat or valve is an indication of cavitation. Review our Cavitation Troubleshooting Support Document for assistance. www.catpumps.com/cavitation-troubleshooting 2.10 Remove the discharge spring retainer. 2.11 Using a reverse pliers, grasp the inside 2.12 Remove the front inlet valve adapter Inspect for cracks, excessive wear or diameter of the inlet valve adapter.
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Page 18: Valve Installation
Servicing the Valves VALVE INSTALLATION 2.20 Lubricate and install valve seat O-ring 2.21 Place the spring onto the guide in the 2.19 Install spring retainer with white notch into the inlet valve bore. spring retainer. facing down into the inlet valve bore. 2.22 Place the valve onto the spring with 2.23 Place the valve seat onto the valve with 2.24 Replace rear inlet valve adapter O-ring... - Page 19 Servicing the Valves VALVE INSTALLATION 2.29 Place the spring onto the guide in the 2.30 Place the valve onto the spring with 2.28 Lubricate and install valve seat O-ring spring retainer. concave side facing down. into the discharge valve bore. 2.31 Place the valve seat onto the valve with 2.32 Replace front discharge valve adapter 2.33 With smaller side facing down, install...
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Page 20: Discharge Manifold Installation
Servicing the Valves DISCHARGE MANIFOLD INSTALLATION 2.35 Use a rubber mallet to tap manifold on 2.36 Apply anti-seize to the six (6) HSH 2.34 Install discharge manifold by hand, the rest of the way. screws. ensuring even alignment. 2.38 Using an 8 mm hex socket bit, tighten 2.39 Rotate crankshaft with adjustable 2.37 Install six (6) HSH screws by hand. -
Page 21: Crankcase Component Inspection
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-check the following areas for signs of leaks and contact Cat Pumps or a local distributor for servicing crankcase if needed. Crankshaft Oil Seals... -
Page 22: Reference Information
Cat Pumps recommends using our custom-blend premium grade hydraulic oil formulated to meet Cat Pumps specifications. For best results, perform an initial oil change after the first 50 hours of operation and every 500 hours thereafter. -
Page 23: Torque Chart
Reference Information TORQUE CHART PUMP ITEM THREAD TOOL SIZE TOOL PART NUMBER TORQUE IN-LBS FT-LBS Plunger Retainers 10 mm Combination Wrench — Inlet Manifold Screws 6 mm Hex Bit Socket with Ratchet 9.58 Discharge Manifold Screws 8 mm Hex Bit Socket with Ratchet —... -
Page 24: Diagnosis And Maintenance
For International Inquiries go to www.catpumps.com and navigate to the “Contact” link. ©2021 Cat Pumps. All written and visual data contained in this document reflects the latest product information available at the time of publication. Cat Pumps reserves the right to make changes at any time without notice.
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