CAT Pumps 7001 User manual

Pressure Regulator
Standard Models
7001-7033
Lower Body SS
7001.100-7033.100
SPECIFICATIONS
U.S. Measure Metric Measure
MODELS 7001, 7002, 7003 AND .100
Flow Range ......................................................0.5-5.0 GPM (1.9-19 l/m)
Pressure Range (7001) ...........................100-1000 PSI (7-70 bar)
(7002) ...........................500-2000 PSI (35-140 bar)
(7003) ........................ 1500-3000 PSI (105-210 bar)
Max. Temperature ......................................................240°F (116°C)
Inlet/Outlet Port .................................................3/8” NPTF (3/8” NPTF)
By-Pass Port .........................................................1/2” NPTF (1/2” NPTF)
Weight .......................................................................2.25 lbs. (1.02 kg)
Dimensions ......................................................... 6.25 x 1.5” (159 x 38 mm)
MODELS 7011, 7012, 7013, 7014 AND .100
Flow Range ................................................... 1.0-10.0 GPM (3.8-38 l/m)
Pressure Range (7011) ...........................100-1000 PSI (7-70 bar)
(7012) ...........................500-2000 PSI (35-140 bar)
(7013) ........................ 1500-3000 PSI (105-210 bar)
(7014) ........................ 2000-4000 PSI (140-275 bar)
Max. Temperature ......................................................240°F (116°C)
Inlet/Outlet Port .................................................1/2” NPTF (1/2” NPTF)
By-Pass Port .........................................................3/4” NPTF (3/4” NPTF)
Weight .......................................................................3.75 lbs. (1.70 kg)
Dimensions ......................................................... 7.5 x 1.88” (191 x 48 mm)
MODELS 7021, 7022, 7023, 7024 AND .100
Flow Range ................................................... 2.5-25.0 GPM (9.5-95 l/m)
Pressure Range (7021) ...........................100-1000 PSI (7-70 bar)
(7022) ...........................500-2000 PSI (35-140 bar)
(7023) ........................ 1500-3000 PSI (105-210 bar)
(7024) ........................ 2000-4000 PSI (140-275 bar)
Max. Temperature ......................................................240°F (116°C)
Inlet/Outlet Port .................................................3/4” NPTF (3/4” NPTF)
By-Pass Port ............................................................. 1” NPTF (1” NPTF)
Weight .........................................................................5.0 lbs. (2.40 kg)
Dimensions ......................................................... 8.5 x 2.25” (216 x 57 mm)
MODELS 7031*, 7032, 7033 AND .100
Flow Range .......................................................3.5-35 GPM (13.2-133 l/m)
Pressure Range (7031) ...........................250-1000 PSI (18-70 bar)
(7032) ........................ 1000-2000 PSI (70-140 bar)
(7033) ........................ 1500-3000 PSI (105-210 bar)
Max. Temperature ......................................................240°F (116°C)
Inlet/Outlet Port .................................................3/4” NPTF (3/4” NPTF)
By-Pass Port ............................................................. 1” NPTF (1” NPTF)
Weight .........................................................................5.5 lbs. (2.50 kg)
Dimensions ......................................................... 8.5 x 2.25” (216 x 57 mm)
* Model 7031 replaces model 7028.
FEATURES
l Conical piston and seat provide a consistently smooth flow
that reduces wear and compensates for pressure spikes for
extended valve life.
l Lightweight flow-through design for easy installation.
l Unique high velocity design assures consistent pressure for
multiple pump or shut-off gun installations.
l Maintains full pressure while running in idle for quick return
to system pressure.
l Piston retainer and lower body are 316SS for added
compatibility on the .100 models.
l Standard FPM elastomers for compatibility with many
liquids and temperatures up to 240°F.
l Adjusting nut allows easy calibrated pressure adjustment.
l Multiple regulators can be installed in parallel to handle
larger volumes.
7021-7033
7001-7003
7011-7014
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.

SELECTION
This pressure regulator is designed for systems with single or multiple
pumps, solenoid (gate) valves, nozzles, and standard or “weep” guns.
Note: For multiple pump systems, it is best to use a pressure regulator
not a pressure sensitive regulating unloader.
This regulator 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 regulator causes the
regulator to cycle or chatter. Operation above the maximum flows of
the regulator causes premature regulator wear, regulator cycling and
prevents attaining desired system pressure.
INSTALLATION
This regulator operates properly when mounted in any direction;
however, it is preferred to keep the plumbing to a minimum and the
pressure adjusting nut easily accessible. The best mounting location
is directly on the pump discharge manifold head. Flexible, high
pressure hose (minimum single wire braid) should be at least the size
of the regulator ports when plumbing to and from the regulator.
Since this is a flow through design regulator, the inlet and discharge
connections are interchangeable and are located on the sides. An
arrow on the label indicates liquid flow in either direction. Port size
varies with each size of regulator (see specifications). Plumb into
one side for inlet flow from pump and plumb opposite side to the
discharge line with spray guns, solenoid (gate) valves or nozzles.
The by-pass connection of this regulator is located on the bottom. An
arrow on the label indicates the direction of flow. Port size varies with
each size of regulator (see specifications). By-pass liquid is directed out
this port and can be routed to a reservoir (preferred method), or to a
drain or back to the pump inlet.
OPERATION
This pressure regulator maintains established system pressure in
the discharge line and at the pump head 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 allows for a quick return to established
system pressure without delay.
PRESSURE ADJUSTMENT
1. Setting and adjusting the regulator pressure must be done
with the system “on”.
2. Start the system with regulator 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 brass
adjusting nut one quarter turn in clockwise direction.
5. Squeeze the trigger and read the pressure.
6. Repeat this process until desired system pressure is attained.
7. Once the desired system pressure is reached, stop turning the
brass adjusting nut.
NOTICE: A minimum by-pass flow of 5% of the regulator rated
flow capacity is required for proper regulator performance. If the
entire output is directed through the regulator (zero by-pass) the
“cushioning” feature of the by-pass liquid is eliminated and the
regulator can malfunction or wear prematurely.
8. If desired system pressure cannot be reached, review
TROUBLESHOOTING chart.
9. When servicing existing systems, back off adjusting nut.
10. Follow adjustment procedures as stated above.
Note: Do not adjust regulators 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 safety relief device (i.e. pop-off valve,
safety valve) should be used along with this pressure regulator. Final
adjustment for the relief valve should relieve at 200 psi above the
system operating pressure.
TYPICAL REGULATOR INSTALLATION
1 Pressure Gauge
2 Relief Valve
Shown as a secondary safety relief valve
3 Pulsation Dampener
4 Pressure Regulator
5 Triplex Plunger Pump
2
DISCHARGE
1
4
3
5
INLET
BY-PASS
Read all CAUTIONS and WARNINGS before commencing
service or operation of any high-pressure system

SERVICING
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.
Disassembly
1. Disconnect by-pass, discharge and inlet plumbing from regulator.
2. Remove regulator from pump.
3. Secure lower body of regulator in a vise with brass adjusting nut
facing up.
4. Remove upper body by unthreading from lower body.
5. Grasp top of piston stem and separate from conical piston.
6. Remove piston stem with stack of spring washers, flat washers
and anti-rotating washer and place on flat surface.
7. Remove conical piston with reverse pliers by making contact on
the inside diameter of conical piston.
NOTICE: Exercise extreme caution to avoid contact and damage to
outside diameter and sharp tip of conical piston.
8. Remove piston retainer from lower body of regulator.
NOTICE: Exercise extreme caution to avoid contact and damage to
the inside diameter of the piston retainer.
9. Remove conical seat from lower body of regulator.
NOTICE: Exercise extreme caution to avoid contact and damage to
outside diameter and the tapered surface of the seat.
Note: With the regulator completely disassembled, inspect lower
body sealing areas where the conical seat and piston retainer makes
contact for grooves, pitting and wear. If damage is found, replace
with new lower body or complete new regulator. If not, proceed with
reassembly.
Reassembly
Note: Conical piston and seat should be changed as a matched set
when upgrading from the old tapered piston and seat. See Tech
Bulletin 097.
Note: Spring washers and flat washers should be changed as a
spring set. See Tech Bulletin 102.
1. Place lower regulator body with by-pass port facing down into a
vise.
2. Lubricate and install o-ring onto outside diameter of conical seat.
Press conical seat down into lower regulator body with small hole
facing up.
3. Lubricate and install o-ring onto piston retainer. Press piston
retainer with raised surface facing up.
4. Lubricate and install back-up-ring, then o-ring onto outside
diameter of conical piston. Press conical piston with sharp point
down into piston retainer.
5. Replace piston stem with stack of spring washers and flat washers
into hole of conical piston.
6. Place anti-rotating washer on top of spring set. Align tabs on
washer with slots on the upper body.
Note: The number of flat washers varies with each spring set. Place
the first flat washer between the anti-rotating washer and spring stack.
Place second washer (if required) between spring stack and retaining
ring. Place all remaining washers with first washer.
7. Thread upper body into lower body.
8. Re-install regulator onto pump.
9. Reconnect by-pass, discharge and inlet plumbing to regulator.
10. Proceed to PRESSURE ADJUSTMENT.
Read all CAUTIONS and WARNINGS before commencing
service or operation of any high-pressure system
TROUBLESHOOTING
Cycling /Chattering l Too little flow for valve specifications.
l Air in system, poor connections.
l Inlet seals in pump worn.
l O-ring in gun worn.
System will not l Nozzle worn.
build up to pressure l Improper nozzle size for system specs.
l Foreign material trapped in seat.
Pressure drop l Nozzles worn.
l Piston and seat in regulator worn.
l Air in system, poor connections.
l Insufficient flow to pump.
l Filter clogged. Check and clean regularly.
l Fatigued or broken spring washers.
Pressure spikes l Minimum by-pass of 5% not present.
while in by-pass l Excessive pressure adjustment made for worn
nozzle. REPLACE NOZZLE. Reset system pressure.
Leakage from l O-ring around piston worn. Service with O-ring Kit.
regulator vent hole l Piston Retainer scored. Service with O-ring kit and
or top slots replace retainer.
l Fatigued or broken spring washers.
Approximate Gauge Gauge
Pressure Reading Between Between
at Gauge Pump/Unloader Unloader/Gun-Nozzle-Valve
System in operation system pressure system pressure
(gun open)
System in by-pass 200-300 PSI above 200-300 PSI above
(gun closed) system pressure system pressure
PRESSURE READING

CUTAWAY
EXPLODED VIEW
(Models 7001, 7002, 7003 shown)
Standard
FPM
O-Rings for
maximum
durability and
compatibility.
Convenient
top adjusting
nut for setting
and adjusting
system
pressure.
Convenient inline
mounting for
compact easy
installation.
External leaking
from weep hole
signals worn
O-Rings
and needed
maintenance.
Hardened
316SS seat
and piston for
long life and
thousands of
cycles.
Item Description MATL 7001 7002 7003 7011 7012 7013 7014 7021 7022 7023 7024 7031 7032 7033
401 Nut, Adjusting BB 30758 30758 30758 30759 30759 30759 30759 30760 30760 30760 30760 30760 30760 30760
405 Washer, Anti-Rot STL 34491 34491 34491 34492 34492 34492 34492 34493 34493 34493 34493 34493 34493 34493
406 Body, Upper STNP — — — — — — — — — — — — — —
408 Spring Set STL 76201 76202 76202 76211 76212 76213 76214 76221 76222 76223 76224 76221 76222 76223
410 Retainer, Piston SSS 30873 30873 30874 30875 30875 30876 30876 30877 30877 30878 30878 30877 30877 30878
Retainer, Piston (.100 Option) SS 33885 33885 33886 31635 31635 31666 31666 33877 33877 31878 31878 33877 33877 30878
418 Piston, Conical SSB 31733 31733 31734 31738 31738 31739 31739 31743 31743 31744 31744 — — —
Piston, Conical SSSS R — — — — — — — — — — — 31749 31749 31750
421 Ring, Retainer STL R 30585 30585 30885 30886 30886 30886 30886 30887 30887 30887 30887 30887 30887 30887
435 Stem, Piston STL 30588 30588 30888 30889 30889 30889 30889 30892 30892 30892 30892 30892 30892 30892
436 Seat, Conical SSB 31732 31732 31732 31736 31736 31736 31736 31742 31742 31742 31742 — — —
Seat, Conical SSSS R — — — — — — — — — — — 31748 31748 31748
440 Body, Lower STNP R — — — — — — — — — — — — — —
Body, Lower (.100 Option) SS — — — — — — — — — — — — — —
468 Kit, O-Ring, Hex Body Style FPM 30771 30771 30775 30777 30777 30781 30781 30783 30783 30787 30787 30783 30783 30787
For EPDM O-Ring Kits add .0220 to the FPM kit part numbers (i.e. , 30771.0220)
It is recommended to replace spring washers and flat washers as a set.
Italics are optional items. See Tech Bulletins 022, 044, 097 and 102 for additional information.
R components comply with RoHS Directive. Material Codes (Not Part of Part Number):
BB=Brass FPM=Fluorocarbon SS=316SS SSB=316SS Condition B SSS=416SS SSSS=440SS STNP=Steel/Nickel Plated STL=Steel
Contact Cat Pumps for optional NBR or EPDM O-Ring Kits.
PARTS LIST
CAT PUMPS
1681 - 94TH LANE N.E. MINNEAPOLIS, MN 55449-4324
PHONE [phone] — FAX [phone]
e-mail: [e-mail]
www.catpumps.com
For International Inquiries go to www.catpumps.com and navigate to the “Contact Us” link. PN 993155 Rev F 10/11 101116