Direct-Drive

Plunger Pump

66DX30G1I
66DX35G1I
66DX40G1I

Models

SPECIFICATIONS
MODEL

U.S. Measure

Metric Measure

66DX30G1I

Flow . .......................................................................... 3.0 gpm

Pressure Range.......................................... 100 to 4000 psi
Stroke.............................................................................. 0.339

MODEL
Gas engine must be purchased separately.
(Pump includes Unloader and Chemical Injector)

(11.4 lpm)
(7 to 275 bar)
(8.6 mm)

66DX35G1I

Flow . .......................................................................... 3.5 gpm

Pressure Range.......................................... 100 to 4000 psi
Stroke.............................................................................. 0.394

MODEL

(13.2 lpm)
(7 to 275 bar)
(10 mm)

66DX40G1I

FEATURES

Flow............................................................................. 4.0 gpm

Pressure Range.......................................... 100 to 4000 psi
Stroke.............................................................................. 0.449

l Triplex

COMMON PUMP SPECIFICATIONS

plunger design provides a smooth liquid flow.

l Special

concentric, high-density, polished, solid ceramic

plungers provide a true wear surface and extended seal
life.

l Compact

flange mount permits easy, direct mounting

to most gas engines.

l Modular

Regulating Unloader with built-in by-pass

is standard for safety and pressure setting.

l Fixed

Chemical Injector is standard and mounts directly

onto Unloader to provide cleaning flexibility.

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 customers 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.

(15.0 lpm)
(7 to 275 bar)
(11.4 mm)

Max. RPM................................................................ 3400 rpm

Engine Mounting Face.................................................. 6.5
Inlet Pressure Range...........................Flooded to 75 psi
Bore................................................................................. 0.551
Shaft Diameter (Hollow)...................................................1
Max. Liquid Temperature..........................................140F
Crankcase Capacity.....................................................18 oz.
Inlet Ports (2).........................................................1/2 NPTF
Discharge Ports (2)..............................................3/8 NPTF
Weight......................................................................26.15 lbs.
Dimensions (Pump Only)............11.73x 10.51x8.15

(3400 rpm)
(6.5)
(Flooded to 5.25 bar)
(14 mm)
(25.4 mm)
(60C)
(0.55 l)
(1/2 NPTF)
(3/8 NPTF)
(11.9 kg)
(298x267x207 mm)

ELECTRIC HORSEPOWER REQUIREMENTS

MODELS

66DX30G1I
66DX35G1I
66DX40G1I

FLOW

U.S.
gpm
3.0
3.5
4.0

lpm
11.4
13.2
15

PRESSURE
psi
2500
bar
175
5.1
6
6.9

psi
3200
bar
220
6.6
7.7
8.8

RPM
psi
4000
bar
275
8.2
9.6
11

3400
3400
3400

DETERMINING
THE PUMP R.P.M.

Rated gpm
Rated rpm

Desired gpm
Desired rpm

DETERMINING
THE REQUIRED H.P.

gpm x psi
1460

Electric Brake
H. P. Required

Motor Pulley O.D.

Pump rpm

Pump Pulley O.D.

Motor rpm

DETERMINING
MOTOR PULLEY SIZE

Note: Consult engine manufacturer when using gas or diesel engine.

Refer to pump Service Manual for repair procedure and additional technical information.

EXPLODED VIEW
April 2011

66DX PLUNGER PUMPS

66DX30G1I, 66DX35G1I, 66DX40G1I

PARTS LIST
ITEM

5

8
10
11
13
15
20
25


27
32
33
37
38
40

48
49
50
51
53
64
65
70
75
90

P/N MATL
92519
125824
48259
14028
125351
14037
146421
48843
48970
48977
48839
14480
46798
14179
92241
44428
92519
125824
25625
23170
48862
14048
48830
46404
48845
48911
48754
48752

STZP
STCP R
AL
NBR
NBR
NBR
STL
TNM
CM
CM
CM
STL

NBR

NBR
STZP
STCP R
STCP
NBR
AL
NBR
AL
CM
BB
NBR
NBR
CC

DESCRIPTION
Screw, HHC (M6x16)
Screw, HHC (M6x16)
Cover, Bearing
O-Ring, Bearing Cover - 70D
Seal, Oil, Crankshaft - 70D
O-Ring, Bearing Cover
Bearing, Ball - Inner
Rod, Connecting
Crankshaft (8.6 mm) 30G1I
Crankshaft (10.0 mm) 35G1I
Crankshaft (11.4 mm) 40G1I
Bearing, Ball - Outer
Cap, Domed, Oil Filler
O-Ring, Filler Cap - 70D
Gauge, Oil Bubble w/Gasket - 80D
Gasket, Flat, Oil Gauge - 80D
Screw, HHC (M6x16)
Screw, HHC (M6x16)
Plug, Drain (1/4x19BSP)
O-Ring, Drain Plug - 70D
Cover, Rear
O-Ring, Rear Cover
Crankcase
Pin, Crosshead
Rod, Plunger
Seal, Oil, Crankcase
Slinger, Barrier
Plunger (M14x47)

QTY
4
4
1
1
1
1
1
3
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
3
3
3
3
3

ITEM

98
99
100
106
120
121
127

128
163
164
166
167
168
172
174
185
188
196
249
251
252
255
283
300
310
400

P/N MATL
46730
= 48201
48755
45188
48759
13980
48758
49201
48757
17547
45790
46429
43750
46583
17616
48760
48846
126512
46690
48841
126746
46403
30510
34334
34262
34260
7860

NBR
SS
NY
NBR
BB
NBR
SNG
STG
NY
NBR
S
S
S
NY
NBR
BB
BB
STCP R
BB
AL
STCP R
STZP
STZP

NBR
NBR
BB

DESCRIPTION
Washer Seal, Plunger Retainer - 90D
Retainer, Plunger
Retainer, Seal
Seal, LPS w/S-Spg
Case, Seal
O-Ring, Seal Case - 70D
V-Packing
V-Packing
Adapter, Male
O-Ring, Seat - 85D
Seat
Valve
Spring
Retainer, Spring
O-Ring, Valve Plug - 80D
Plug, Valve w/O-Ring
Head, Manifold
Screw, HSH (M8x65)
Plug, Discharge HSH 3/8 NPTM (Not Shown)
Flange, Adapter
Lockwasher, Conical (M8)
Screw, FH (M8x25)
Assy, Bolt Mount
Kit, Oil Drain (3/8x24) (Not Shown)
Kit, Seal (Inclds: 98,106,121,127,128)
Kit, Valve (Inclds: 163,164,166,167,168,172)
Unloader Assy w/Fixed Injector (Eff. 04/07)

Bold Part Numbers are unique to a particular pump model. Italics are optional items.
R Components comply with RoHS Directive. = Production parts different from service parts. View Tech Bulletins 024, 060, 074, 083, and 101 for additional information.
MATERIAL CODES (Not Part of Part Number): AL=Aluminum BB=Brass CC=Ceramic CM-Chrome-moly NBR=Medium Nitrile (Buna-N) NY=Nylon S=304SS
SNG=Special Blend (Buna) SS=316SS STCP=Steel/Chrome Plated STG=Special Blend PTFE White STL=Steel STZP=Steel/Zinc Plated TNM=Special High Strength

QTY
3
3
3
3
3
3
3
3
3
6
6
6
6
6
6
6
1
8
1
1
4
4
1
1
1
2
1

7860 UNLOADER WITH INJECTOR

Specifications
Flow..................................................
PSI Range........................................
Inlet Port, Side..............................
Discharge Port, Front.................
Weight.............................................
Dimensions....................................

7367 FIXED CHEMICAL INJECTOR

U.S. Measure

Metric Measure

3.0-5.0 gpm
700-4000 psi
1/2 NPTF
M20 x 1
35.2 oz.
4.65x1.70x6.75

(7.6-19 lpm)
(50-275 bar)
(1/2 NPTF)
(M20 x 1)
(1.0 kg)
(118x43x171 mm)

Specifications
Flow . ...............................................
Nozzle Orifice................................
Hose Barb - Ext.............................
Tapped Barb..................................
Inlet Port.........................................
Discharge Port..............................
Weight.............................................
Dimensions....................................

401

U.S. Measure

Metric Measure

3.0-5.0 gpm
2.1 mm
1/4
8/32 UNF
M20x1
3/8 NPTM
5.3 oz.
2.0x1.0x1.75

(11.4-19 lpm)
(2.1 mm)
(1/4)
(8/32 UNF)
(M20x1)
(3/8 NPTM)
(0.15 kg)
(52x25x45 mm)

414
415
412

402

418

426
429
430

403

423

404

424

408

435
436
437

410

440

425

442

442
462

428

443
444

454
456
464

463

446
469

Inlet

PARTS LIST
ITEM

401
402
403
404
408
410
412
418

414
415
423
424
425
426
428
429
430
435
436
437
440
442
443
444
446
454
456
460
462
463
464
468

469

P/N MATL DESCRIPTION

460

Inlet

464

Discharge

CHEMICAL INJECTOR PERFORMANCE CHART

QTY.

49100 NY
Handle, Adjusting (Black)
49099 BB
Cap, Adjusting
125521 BB
Nut, Locking (M25X1)
88953 S
Screw, Set
45198 ZP R
Spring
49101 STZP R Retainer, Spring
49103 S
Stem, Piston
811529 BB
Assy, Piston

(Inclds: 412,414,415,423,424,426,429,430,435)
129638 PTFE
Back-up-Ring, Piston Stem
49104 NBR
O-Ring, Piston Stem - 90D
49105 BB
Retainer, Valve
49106 NBR
O-Ring, Valve Retainer - 70D
49102 BB
Retainer, Piston
49107 S
Washer
26133 NBR
O-Ring, Retainer - 80D
22056 NBR
O-Ring, Valve Retainer - 70D
49123 D
Back-up-Ring, Valve Retainer
49383 S
Valve/Ball Assembly
49384 S
Seat
13965 NBR
O-Ring, Seat - 70D
BB
Valve Body
49121 STL
Washer, Seal (3/8)
49245 BB
Valve, Check w/NBR O-Ring
117275 S
Spring, Check Valve
26133 NBR
O-Ring, Body - 80D
11346 NBR
O-Ring, Manifold - 70D
BB
Manifold
126974 BB
Fitting, Discharge (3/8 NPTM)
49120 BB
Screw, Flo-thru (3/8 NPTM)
49117 BB
Screw, Flo-thru (1/2 NPTM)
49118 STL
Washer, Seal (1/2)
31708 NBR
Kit, O-Ring, (Inclds: 414,415,424,428,429,430,437,446,454)
31556 NBR
Kit Repair, (Inclds: 412,414,415,423-426,428-430,435-437)
7367 BB
Injector, Fixed
Italics are optional items. R Components comply with RoHS Directive.
MATERIAL CODES (Not Part of Part Number): BB=Brass D=Acetal
NBR=Medium Nitrile (Buna-N) NY=Nylon PTFE=Pure Polytetrafluoroethylene
S=304SS STL=Steel STZP=Steel/Zinc Plated ZP=Zinc Plated

1
1
1
1
1
1
1
1

1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1

Desired
Pump
Orifice
Flow
Size

3.0
3.5
4.0

2.1 mm
2.1 mm
2.1 mm

Maximum
Injecting
Pressure

Maximum
Chemical
Draw

Pressure Drop Across

Injector at System
Pressure (4000 PSI)

190 psi
260 psi
358 psi

70.0 oz/min
74.2 oz/min
76.8 oz/min

136 psi
245 psi
288 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 pressure in excess of the low pressure nozzle rating and prevent the injector from drawing chemical. Deduct hose friction loss from the above
PSI nozzle. Consult CAT PUMPS for assistance 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.

UNLOADER TYPE

ing cap and tighten set screw. All high pressure systems should have
a secondary relief valve. Set secondary relief valve 200-300 psi above
the unloader setting.

A modular regulating unloader with chemical injector comes with each

66DX pump to provide system pressure regulation, pump protection,
and metered chemical application.

NOTE: Pressure is not set at the factory.

OPERATION:

SERVICE:

Purge pump of air before commencing operation by allowing liquid

to flow through the pump without discharge restriction. Removing
trapped air will assure full system pressure can be obtained.

The unloader should be serviced on the same schedule as the

seals in the pump. Refer to 66DX Service Manual for start-up,
servicing of seals and valves, torque requirements and Diagnosis/
Maintenance chart.

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 adjust-

66DX DIMENSIONAL

10.51 (267)
11.73 (298)

(1

65

1.30
(33)

3.19 (81)

1.26
(32)

6.38 (162)

3/8" NPTM
DISCHARGE

(2) 3/8" NPTF

DISCHARGE

3.70 (94)

.5

2.56 (65)

9.09 (231)

.4
(1 3
1)

(4) .394 (10)

3
45 0

(2) 1/2" NPTF

INLET
4.84 (123)

1.38
(35)

5.35 (136)
9.68 (246)

5.28 (134)
9.80 (249)
10.0 (254)

CAT PUMPS
1681 - 94TH LANE N.E. MINNEAPOLIS, MN 55449-4324
PHONE (763) 780-5440 FAX (763) 780-2958
e-mail: [email protected]
www.catpumps.com
For International Inquiries go to www.catpumps.com and navigate to the Contact Us link.

PN 993259 Rev F 4/11 31117