CAT Pumps 3DX25GSI User manual

PUMP FEATURES
• Triplex plunger design provides a smooth liquid flow.
• Specially formulated Hi-Pressure Seals and concentric solid
ceramic plungers assure true wear surface and extended seal
life.
• Ultra-compact, hollow-shafted pump for direct mounting to
gas engine.
• Integral Regulating Unloader with built-in by-pass standard on
all units to assure system pressure control and pump protec-
tion.
• Fixed chemical injector standard on all units offers cleaning
flexibility.
• Stacked valve design for ease in servicing.
• Swivel garden hose fitting with filter screen for easy inlet
connection.
COMMON PUMP SPECIFICATIONS
Inlet Pressure Range .......................Flooded to 60 PSI (Flooded to 4 Bar)
Bore ................................................................... 0.630” (16 mm)
Max. Liquid Temperature ................................... 140°F (60°C)
Above 130°F call CAT PUMPS for inlet conditions and elastomer recommendations.
Crankcase Capacity .......................................... 8.5 oz. (0.25 L)
Inlet Port (1) ...................................................3/4” GHF (3/4” GHF)
Discharge Port (1) ...........................................M18x1.0 (M18x1.0)
Chemical Discharge Port (1) ......................3/8” NPTM (3/8” NPTM)
Chemical Injection Barb ..............................8/32” UNF (8/32” UNF)
Shaft Diameter ...................................................... 3/4” (19.0 mm)
Weight ............................................................ 10.7 lbs. (4.9 kg)
Dimensions ......................................7.99 x 7.75 x 6.29” (203 x 197 x 160 mm)
SPECIFICATIONS U.S. Measure Metric Measure
MODEL 3DX25GSI
Flow ........................................................... 2.5 GPM (9.5 L/M)
Max. Discharge Pressure ..........................2500 PSI (175 BAR)
Max. RPM ................................................3450 RPM (3450 RPM)
Stroke ............................................................ 0.204” (5.2 mm)
MODEL 3DX27GSI
Flow ........................................................... 2.7 GPM (10.2 L/M)
Max. Discharge Pressure ..........................2500 PSI (175 BAR)
Max. RPM ................................................3450 RPM (3450 RPM)
Stroke ............................................................ 0.220” (5.6 mm)
MODEL 3DX29GSI
Flow ........................................................... 2.9 GPM (10.9 L/M)
Max. Discharge Pressure ..........................2500 PSI (175 BAR)
Max. RPM ................................................3450 RPM (3450 RPM)
Stroke ............................................................ 0.232” (5.9 mm)
MODEL 3DX30GSI
Flow ........................................................... 3.0 GPM (11.4 L/M)
Max. Discharge Pressure ..........................2500 PSI (175 BAR)
Max. RPM ................................................3450 RPM (3450 RPM)
Stroke ............................................................ 0.244” (6.2 mm)
“Customer confidence is our greatest asset”
DETERMINING Rated G.P.M. = “Desired” G.P.M.
THE PUMP R.P.M. Rated R.P.M. “Desired” R.P.M.
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 R.P.M. Motor R.P.M.
Note: Consult engine manufacturer when using gas or diesel engine.
Refer to pump Service Manual for repair procedure and additional technical information.
Direct-Drive
Plunger Pump
Models
3DX25GSI Non-Production
3DX27GSI Non-Production
3DX29GSI See Current Data Sheet
3DX30GSI See Current Data Sheet
ELECTRIC HORSEPOWER REQUIREMENTS
MODEL FLOW PRESSURE RPM
PSI PSI PSI PSI PSI
1000 1200 1500 2000 2500
U.S. BAR BAR BAR BAR BAR
GPM L/M 70 85 105 140 175
3DX25GSI 2.5 9.5 1.7 2.0 2.6 3.4 4.3 3450
3DX27GSI 2.7 10.2 1.8 2.2 2.8 3.7 4.6 3450
3DX29GSI 2.9 10.9 1.9 2.4 3.0 4.0 5.0 3450
3DX30GSI 3.0 11.4 2.1 2.5 3.1 4.1 5.2 3450
Gas engine must be purchased separately.
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.

255
5
8
10
11
15
20
20
20
25
27
32
53
38
37
49
48
64
65
70
100
90
98
99
106
120
121
125
249
197
188
185
168
167
166
161
160
174
172
168
167
166
164
163
400
469
24
DISCHARGE
INLET
33
EXPLODED VIEW
July 2008
Center raised pilot guide on the Adapter Plate assures proper alignment of pump and engine. Before mounting pump onto engine inspect engine for recessed seal and
bearing guide to permit adapter to completely seat into recess and four bosses to be flush with engine face.
3DX PLUNGER PUMP MODEL
3DX25GSI, 3DX27GSI, 3DX29GSI, 3DX30GSI
PARTS LIST
ITEM PN MATL DESCRIPTION QTY
5 547161 STCP Screw, HHC Sems (M6x14) 3
549360 STCP R Screw, HHC Sems (M6x14) 3
8 547153 AL Cover, Bearing [4/05] 1
10 14041 NBR O-Ring, Bearing Cover - 70D 1
11 55337 NBR Seal, Oil - 70D 1
15 14488 STL Bearing, Ball 1
20 547048 TNM Rod, Connecting 3
24 76045 LDPE Plug, Oil Cap 1
25 547307 CM Crankshaft, 3450 RPM, 3/4”, 5.2 mm [01/04] 1
548195 CM Crankshaft, 3450 RPM, 3/4”, 5.6 mm [01/04] 1
547946 CM Crankshaft, 3450 RPM, 3/4”, 5.9 mm [01/04] 1
548196 CM Crankshaft, 3450 RPM, 3/4”, 6.2 mm [01/04] 1
27 56084 STL Bearing, Ball [11/03] 1
32 547961 RTP Cap, Oil Filler w/O-Ring [01/04] 1
33 14179 NBR O-Ring, Oil Filler Cap - 70D 1
37 92241 — Gauge, Bubble Oil w/Gasket 1
38 44428 NBR Gasket, Flat Flex, Oil Gauge - 80D 1
48 44842 NY Plug, Drain 1
49 14179 NBR O-Ring, Drain Plug - 70D 1
53 548062 AL Crankcase [02/05] 1
64 46229 CM Pin, Crosshead 3
65 542402 BBCP Rod, Plunger 3
70 47215 NBR Seal, Oil - 70D 3
90 542403 CC Plunger (M16x27) 3
98 46730 NBR Washer, Seal - 90D 3
99 542405 S Retainer, Plunger (M6x35) 3
100 46233 NY Retainer, Seal 3
106 48222 NBR Seal, LPS w/S-Spg 3
120 547357 BB Case, Seal 3
121 13976 NBR O-Ring, Seal Case - 70D 3
125 547157 SNG Seal, HPS w/S 3
160 13965 NBR O-Ring, Inlet Valve Seat - 70D 3
161 545177 S Seat, Inlet 3
163 19285 NBR O-Ring, Discharge Seat - 70D 3
ITEM PN MATL DESCRIPTION QTY
164 545178 S Seat, Discharge [1/04] 3
166 46764 S Valve 6
167 46865 S Spring 6
168 543988 PVDF Retainer, Spring 6
172 142807 NBR O-Ring, Plug - 90D 3
174 46759 BB Plug, Valve (M20x1.5) 3
35759 BB Plug, Valve w/1/4” NPT Port for Accessory 1
185 † 548592 BB Head, Manifold w/Integral Unloader Body 1
188 542406 STZP Screw, HSH (M6x60) 8
549357 STCP R Screw, HSH (M6x60) 8
197 941516 BB Assy, GH, 3/8” NPTM (Not Included on 3DX29GSI) 1
— — Nut, Swivel (3/4” FGH) 1
— — Fitting, (3/8” NPTM) 1
— — Screen, Inlet 1
— — Spring 1
249 30520 — Assy, Adapter Mount, Standard, GAS 1
46271 AL Flange 1
549351 STCP R Screw, HH (5/16”-24x20) 4
15845 STZP Lockwasher (M8) 4
126232 STCP R Lockwasher (M8) 4
126573 STCP R Washer, Flat (M8) 4
255 30516 STZP Assy, Bolt Mount, GAS 1
126543 STCP R Screw, HH (3/8”-16x1-3/8”) 4
127024 STZP R Washer, Flat (3/8”) 4
127025 STZP R Lockwasher (3/8”) 4
6106 — Lubricant, Antiseize 1
34050 STL Key (3/16x3/16x27 HD) 1
300 30530 NBR Kit, Seal (Inclds: 98,106,121,125) 1
310 33057 NBR Kit, Valve 1
(Inclds: 160,161,163,164,166,167,168,172)
400 — — Unloader, Modular (See Individual Parts) 1
469 7232 BB Injector, Chemical Fixed - 3DX25, 27, 30GSI 1
7242 BB Injector, Chemical Fixed - 3DX29GSI 1
Italics are optional items. [ ] Date of latest production change. † Production parts different than repair parts. R Components comply with RoHS Directive.
See Tech Bulletins 02, 024, 036, 043, 055, 074 and 083 for additional information.
MATERIAL CODES (Not Part of Part Number): AL=Aluminum BB=Brass BBCP=Brass/Chrome Plated CC=Ceramic CM-Chrome-moly LDPE=Low Density Polyethylene
NBR=Medium Nitrile (Buna-N) NY=Nylon PVDF=Polyvinylidene Fluoride RTP=Reinforced Composite S=304SS SNG=Special Blend (Buna) STL=Steel
STCP=Steel/Chrome Plated STZP=Steel/Zinc Plated TNM=Special High Strength
NOTE: Discard Key which may come standard with most engines and use only the key included in this kit.

INTEGRAL UNLOADER
SPECIFICATIONS U.S. Measure Metric Measure
Flow .......................................................... 3.0 GPM (11.4 L/M)
PSI Range ........................................ 100-2500 PSI (7-175 BAR)
Inlet Port ................................................. 3/4” GHF (3/4” GHF)
Discharge Port ........................................ M18x1.0 (M18x1.0)
402
401 408
410
425
428
418
414
415
412
426
429
423
424
435
436
437
444
443
438
439
469 460
446
Inlet
Discharge
PARTS LIST
ITEM PN MATL DESCRIPTION QTY.
401 32088 NY Handle, Adjusting 1
402 46570 BB Cap, Adjusting 1
403 45070 BB Nut, Lock (Not Shown) 3DX29GSI ONLY 1
408 33394 STZP R Spring, Pressure 1
410 549352 STCP R Retainer, Spring 1
412 46251 BB Stem, Piston 1
414 28338 PTFE Back-up-Ring, Piston Stem 1
415 22056 NBR O-Ring, Piston Stem - 70D 1
418 548230 BB Assy, Piston 1
(Inclds: 412,414,415,423,424,426,429,435)
423 46249 BB Retainer, Valve 1
424 13966 NBR O-Ring, Valve Retainer (Outer) - 70D 1
425 46248 BB Retainer, Piston 1
426 46250 S Washer 1
428 13969 NBR O-Ring, Piston Retainer - 70D 1
429 17399 NBR O-Ring, Valve Retainer (Inner) - 80D 1
435 547969 S Valve 1
436 548075 S Seat 1
437 13963 NBR O-Ring, Seat - 70D 1
438 46254 NY Seat, Check Valve 1
439 13963 NBR O-Ring, Check Valve Seat - 70D 1
443 541060 BB Valve, Check w/O-Ring 1
444 45924 S Spring 1
446 13969 NBR O-Ring, Body - 70D 1
460 107681 BB Fitting, Discharge (3/8” NPTM) 1
468 33099 NBR Kit, O-Ring (Inclds: 414,415,424,428,429,437) 1
— 30378 NBR Kit, Repair (Inclds: 418,428,436,437) 1
469 7232 BB Injector, Chemical Fixed, 3DX25,27,30GSI 1
7242 BB Injector, Chemical Fixed, 3DX29GSI 1
Italics are optional items. R Components comply with RoHS Directive.
MATERIAL CODES (Not Part of Part Number): BB=Brass
NBR=Medium Nitrile (Buna-N) NY=Nylon PTFE=Pure Polytetrafluoroethylene
S=304SS STCP=Steel/Chrome Plated STZP=Steel/Zinc Plated
CHEMICAL INJECTOR PERFORMANCE CHART
Maximum Maximum Pressure Drop Across
Orifice Injector Injecting Chemical Injector At System
Size Model Pressure Draw Pressure (2500 PSI)
2.1 mm 7232 250 PSI 37.2 oz/min 141 PSI
2.0 mm 7242 280 PSI 35.3 oz/min 148 PSI
Optimum performance of chemical injector occurs with a 35 ft. high pressure hose
and a minimum 3/8” I.D. The type of hose, extended lengths, reduced I.D. and fittings
may create back pressures in excess of the low pressure nozzle rating and prevent the
injector from drawing chemical. See Hose Friction Loss Chart in Service Manual.
Deduct hose friction loss from above low PSI Nozzle. Contact CAT PUMPS for assis-
tance with other options.
CAUTION: Deduct the pressure drop shown in the performance chart from your
desired system pressure to arrive at the maximum high pressure nozzle rating. This is
essential to avoid over-pressurizing the pump.
FIXED CHEMICAL INJECTOR
SPECIFICATIONS U.S. Measure Metric Measure
Model 7232
GPM ......................................................... 3.0 GPM (11.4 L/M)
Nozzle Orifice ............................................. 2.1 mm (2.1 mm)
Model 7242
GPM ......................................................... 2.9 GPM (10.9 L/M)
Nozzle Orifice ............................................. 2.0 mm (2.0 mm)
Common Specifications
Hose Barb ........................................................1/4” (1/4”)
Tapped Barb ......................................... 8/32” UNF (8/32” UNF)
Inlet Port ................................................... M18x1.0 (M18x1.0)
Discharge Port .....................................3/8” NPTM (3/8” NPTM)
Weight ..........................................................5.3 oz. (0.15 kg)
Dimensions ..........................................2 x 1 x 1.75” (52 x 25 x 45 mm)
UNLOADER TYPE
An integral unloader with built-in by-pass is part of the dis-
charge manifold to provide system pressure regulation and
pump protection. This pump also includes a fixed chemical
injector for chemical application.
OPERATION:
Pump should be purged of air before commencing with oper-
ation. Liquid must flow through the pump without discharge
restriction to assure full system pressure is reached
Install a pressure gauge close to the manifold head of the
pump to assist in setting system pressure and to periodically
monitor system pressure.
Setting and adjusting the unloader pressure must be done
with the system turned on. Start the system with the unloader
backed off to the lowest pressure setting (counterclockwise
direction). Squeeze the trigger and read the pressure on the
gauge at the pump. Do not read pressure at the gun or nozzle.
If more pressure is desired, release the trigger, turn adjusting
cap one quarter turn in a clockwise direction. Squeeze the
trigger and read the pressure. Repeat this process until the
desired system pressure is reached. Thread locking nut up to
adjusting cap (model 3DX29GSI only).
NOTE: Pressure is not set at the factory.
SERVICE:
The unloader should be serviced on the same schedule as
the seals in the pump. Refer to 3DX Service Manual for
start-up, servicing of seals and valves, torque requirements
and diagnosis and maintenance chart.

PN 993264 Rev D 5848_OB
Models 3DX25GSI, 3DX27GSI, 3DX29GSI, 3DX30GSI
1 Die cast flange-style aluminum crankcase
means high strength, lightweight, and
excellent tolerance control.
2 Heavy-duty dual crankshaft bearings
provide extended drive-end life.
3 Chrome-moly crankshaft provides un-
matched strength and surface hardness
for long life.
4 High strength connecting rods assure
durability and bearing quality.
5 Strong brass plunger rods with chrome-
moly crosshead pins.
6 Special, concentric, high-density, polished
solid ceramic plungers provide a true
wear surface and extended seal life.
7 High tensile strength, forged brass manifold
head with built-in integral unloader and eight
mounting screws for exceptional strength.
8 100% wet seal design adds to service life
by allowing pumped liquids to cool and
lubricate on both sides.
9 Stacked valve assemblies include stainless
steel valves, seats and springs to provide
corrosion-resistance, ultimate seating and
extended life.
10 Unique design and specially formulated
Hi-Pressure Seals offer unmatched perfor-
mance and seal life.
11 Crossheads are 360° supported for
uncompromising alignment.
2
9
9
1
3
456
7
8
10
11
CAT PUMPS (U.K.) LTD.
1 Fleet Business Park, Sandy Lane, Church Crookham
FLEET, Hampshire, GU52 8BF, England
Phone Fleet 44 1252-622031 — Fax [phone]
e-mail: [email protected] www.catpumps.co.uk
N.V. CAT PUMPS INTERNATIONAL S. A.
Heiveldekens 6A, B-2550 Kontich, Belgium
Phone [phone] — Fax [phone]
e-mail: [email protected] www.catpumps.be
CAT PUMPS DEUTSCHLAND GmbH
Buchwiese 2, D-65510 Idstein, Germany
Phone [phone] — Fax [phone]
e-mail: [email protected] www.catpumps.de
World Headquarters
CAT PUMPS
1681 - 94th Lane N.E. Minneapolis, MN 55449- 4324
Phone [phone] — FAX [phone]
e-mail: [email protected]
www.catpumps.com
International Inquiries
FAX [phone]
e-mail: [email protected]
The Pumps with Nine Lives
“Original Instructions”