Direct-Drive

Plunger Pump
Models 66DX30G1I
66DX35G1I
66DX40G1I
SPECIFICATIONS U.S. Measure Metric Measure

MODEL 66DX30G1I
Flow . .......................................................................... 3.0 gpm (11.4 lpm)
Pressure Range.......................................... 100 to 4000 psi (7 to 275 bar)
Stroke.............................................................................. 0.339” (8.6 mm)

MODEL 66DX35G1I
Flow . .......................................................................... 3.5 gpm (13.2 lpm)
Gas engine must be purchased separately. Pressure Range.......................................... 100 to 4000 psi (7 to 275 bar)
(Pump includes Unloader and Chemical Injector) Stroke.............................................................................. 0.394” (10 mm)

MODEL 66DX40G1I
Flow............................................................................. 4.0 gpm (15.0 lpm)
FEATURES Pressure Range.......................................... 100 to 4000 psi (7 to 275 bar)
Stroke.............................................................................. 0.449” (11.4 mm)
l Triplex plunger design provides a smooth liquid flow. COMMON PUMP SPECIFICATIONS
l Special
concentric, high-density, polished, solid ceramic Max. RPM................................................................ 3400 rpm (3400 rpm)
Engine Mounting Face.................................................. 6.5” (6.5”)
plungers provide a true wear surface and extended seal Inlet Pressure Range...........................Flooded to 75 psi (Flooded to 5.25 bar)
life. Bore................................................................................. 0.551” (14 mm)
Shaft Diameter (Hollow)...................................................1” (25.4 mm)
l Compact flange mount permits easy, direct mounting Max. Liquid Temperature..........................................140°F (60°C)
to most gas engines. Crankcase Capacity.....................................................18 oz. (0.55 l)
Inlet Ports (2).........................................................1/2” NPTF (1/2” NPTF)
l Modular Discharge Ports (2)..............................................3/8” NPTF (3/8” NPTF)
Regulating Unloader with built-in by-pass
Weight......................................................................26.15 lbs. (11.9 kg)
is standard for safety and pressure setting. Dimensions (Pump Only)............11.73 x 10.51 x 8.15” (298 x 267 x 207 mm)

l Fixed
Chemical Injector is standard and mounts directly
ELECTRIC HORSEPOWER REQUIREMENTS
onto Unloader to provide cleaning flexibility.
MODELS FLOW PRESSURE RPM
psi psi psi
2500 3200 4000
U.S. bar bar bar
gpm lpm 175 220 275
All High Pressure Systems require a primary pressure regulating device (i.e. regulator, 66DX30G1I 3.0 11.4 5.1 6.6 8.2 3400
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 66DX35G1I 3.5 13.2 6 7.7 9.6 3400
property. CAT PUMPS does not assume any liability or responsibility for the operation 66DX40G1I 4.0 15 6.9 8.8 11 3400
of a customer’s high pressure system.
DETERMINING Rated gpm = “Desired” gpm
Read all CAUTIONS and WARNINGS before commencing service or operation of any
high pressure system. The CAUTIONS and WARNINGS are included in each service
THE PUMP R.P.M. Rated rpm “Desired” rpm
manual and with each Accessory Data sheet. CAUTIONS and WARNINGS can also be DETERMINING gpm x psi = Electric Brake
viewed online at www.catpumps.com/cautions-warnings or can be requested directly THE REQUIRED H.P. 1460 H. P. Required
from CAT PUMPS.
DETERMINING Motor Pulley O.D. = Pump Pulley O.D.
MOTOR PULLEY SIZE Pump rpm Motor rpm

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

Refer to pump Service Manual for repair procedure and additional technical information.
 EXPLODED VIEW 66DX PLUNGER PUMPS
April 2011 66DX30G1I, 66DX35G1I, 66DX40G1I

PARTS LIST
ITEM P/N MATL DESCRIPTION QTY ITEM P/N MATL DESCRIPTION QTY
5 92519 STZP Screw, HHC (M6x16) 4 98 46730 NBR Washer Seal, Plunger Retainer - 90D 3
125824 STCP R Screw, HHC (M6x16) 4 99 = 48201 SS Retainer, Plunger 3
8 48259 AL Cover, Bearing 1 100 48755 NY Retainer, Seal 3
10 14028 NBR O-Ring, Bearing Cover - 70D 1 106 45188 NBR Seal, LPS w/S-Spg 3
11 125351 NBR Seal, Oil, Crankshaft - 70D 1 120 48759 BB Case, Seal 3
13 14037 NBR O-Ring, Bearing Cover 1 121 13980 NBR O-Ring, Seal Case - 70D 3
15 146421 STL Bearing, Ball - Inner 1 127 48758 SNG V-Packing 3
20 48843 TNM Rod, Connecting 3 49201 STG V-Packing 3
25 48970 CM Crankshaft (8.6 mm) 30G1I 1 128 48757 NY Adapter, Male 3
48977 CM Crankshaft (10.0 mm) 35G1I 1 163 17547 NBR O-Ring, Seat - 85D 6
48839 CM Crankshaft (11.4 mm) 40G1I 1 164 45790 S Seat 6
27 14480 STL Bearing, Ball - Outer 1 166 46429 S Valve 6
32 46798 — Cap, Domed, Oil Filler 1 167 43750 S Spring 6
33 14179 NBR O-Ring, Filler Cap - 70D 1 168 46583 NY Retainer, Spring 6
37 92241 — Gauge, Oil Bubble w/Gasket - 80D 1 172 17616 NBR O-Ring, Valve Plug - 80D 6
38 44428 NBR Gasket, Flat, Oil Gauge - 80D 1 174 48760 BB Plug, Valve w/O-Ring 6
40 92519 STZP Screw, HHC (M6x16) 4 185 48846 BB Head, Manifold 1
125824 STCP R Screw, HHC (M6x16) 4 188 126512 STCP R Screw, HSH (M8x65) 8
48 25625 STCP Plug, Drain (1/4”x19BSP) 1 196 46690 BB Plug, Discharge HSH 3/8” NPTM (Not Shown) 1
49 23170 NBR O-Ring, Drain Plug - 70D 1 249 48841 AL Flange, Adapter 1
50 48862 AL Cover, Rear 1 251 126746 STCP R Lockwasher, Conical (M8) 4
51 14048 NBR O-Ring, Rear Cover 1 252 46403 STZP Screw, FH (M8x25) 4
53 48830 AL Crankcase 1 255 30510 STZP Assy, Bolt Mount 1
64 46404 CM Pin, Crosshead 3 283 34334 — Kit, Oil Drain (3/8”x24”) (Not Shown) 1
65 48845 BB Rod, Plunger 3 300 34262 NBR Kit, Seal (Inclds: 98,106,121,127,128) 1
70 48911 NBR Seal, Oil, Crankcase 3 310 34260 NBR Kit, Valve (Inclds: 163,164,166,167,168,172) 2
75 48754 NBR Slinger, Barrier 3 400 7860 BB Unloader Assy w/Fixed Injector (Eff. 04/07) 1
90 48752 CC Plunger (M14x47) 3
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
 7860 UNLOADER WITH INJECTOR 7367 FIXED CHEMICAL INJECTOR
Specifications U.S. Measure Metric Measure Specifications U.S. Measure Metric Measure
Flow.................................................. 3.0-5.0 gpm (7.6-19 lpm) Flow . ............................................... 3.0-5.0 gpm (11.4-19 lpm)
PSI Range........................................ 700-4000 psi (50-275 bar) Nozzle Orifice................................ 2.1 mm (2.1 mm)
Inlet Port, Side.............................. 1/2” NPTF (1/2” NPTF) Hose Barb - Ext............................. 1/4” (1/4”)
Discharge Port, Front................. M20 x 1 (M20 x 1) Tapped Barb.................................. 8/32” UNF (8/32” UNF)
Weight............................................. 35.2 oz. (1.0 kg) Inlet Port......................................... M20 x 1 (M20 x 1)
Dimensions.................................... 4.65 x 1.70 x 6.75” (118 x 43 x 171 mm) Discharge Port.............................. 3/8” NPTM (3/8” NPTM)
Weight............................................. 5.3 oz. (0.15 kg)
Dimensions.................................... 2.0 x 1.0 x 1.75” (52 x 25 x 45 mm)

401 414

415

412

402 418
426
429
430
403 423

404 424

408 435

436

410 437

440
425
442
442

462
428 443
444
454

456
Inlet 460
464 464
446
463

Inlet 469 Discharge

PARTS LIST CHEMICAL INJECTOR PERFORMANCE CHART

ITEM P/N MATL DESCRIPTION QTY. Desired Maximum Maximum Pressure Drop Across
401 49100 NY Handle, Adjusting (Black) 1 Pump Orifice Injecting Chemical Injector at System
402 49099 BB Cap, Adjusting 1 Flow Size Pressure Draw Pressure (4000 PSI)
403 125521 BB Nut, Locking (M25X1) 1 3.0 2.1 mm 190 psi 70.0 oz/min 136 psi
404 88953 S Screw, Set 1 3.5 2.1 mm 260 psi 74.2 oz/min 245 psi
408 45198 ZP R Spring 1 4.0 2.1 mm 358 psi 76.8 oz/min 288 psi
410 49101 STZP R Retainer, Spring 1
412 49103 S Stem, Piston 1 Optimum performance of chemical injector occurs with a 35 ft. high pressure hose
418 811529 BB Assy, Piston 1 and a minimum 3/8 I.D. The type of hose, extended lengths, reduced I.D. and
(Inclds: 412,414,415,423,424,426,429,430,435) fittings may create back pressure in excess of the low pressure nozzle rating and pre-
414 129638 PTFE Back-up-Ring, Piston Stem 1 vent the injector from drawing chemical. Deduct hose friction loss from the above
415 49104 NBR O-Ring, Piston Stem - 90D 1 PSI nozzle. Consult CAT PUMPS for assistance with other options.
423 49105 BB Retainer, Valve 1
424 49106 NBR O-Ring, Valve Retainer - 70D 1 CAUTION: Deduct the pressure drop shown in the performance chart from your
425 49102 BB Retainer, Piston 1 desired system pressure to arrive at the maximum high pressure nozzle rating. This is
426 49107 S Washer 1 essential to avoid over-pressurizing the pump.
428 26133 NBR O-Ring, Retainer - 80D 1
429 22056 NBR O-Ring, Valve Retainer - 70D 1
430 49123 D Back-up-Ring, Valve Retainer 1
435 49383 S Valve/Ball Assembly 1
436 49384 S Seat 1
437 13965 NBR O-Ring, Seat - 70D 1
440 — BB Valve Body 1
442 49121 STL Washer, Seal (3/8”) 2
443 49245 BB Valve, Check w/NBR O-Ring 1
444 117275 S Spring, Check Valve 1
446 26133 NBR O-Ring, Body - 80D 1
454 11346 NBR O-Ring, Manifold - 70D 1
456 — BB Manifold 1
460 126974 BB Fitting, Discharge (3/8” NPTM) 1
462 49120 BB Screw, Flo-thru (3/8” NPTM) 1
463 49117 BB Screw, Flo-thru (1/2” NPTM) 1
464 49118 STL Washer, Seal (1/2”) 2
468 31708 NBR Kit, O-Ring, (Inclds: 414,415,424,428,429,430,437,446,454) 1
31556 NBR Kit Repair, (Inclds: 412,414,415,423-426,428-430,435-437) 1
469 7367 BB Injector, Fixed 1
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
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
A modular regulating unloader with chemical injector comes with each
the unloader setting.
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 The unloader should be serviced on the same schedule as the
to flow through the pump without discharge restriction. Removing seals in the pump. Refer to 66DX Service Manual for start-up,
trapped air will assure full system pressure can be obtained. 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) 9.09 (231)

ø6
.5
(1 (2) 3/8" NPTF
65
3.70 (94)

) DISCHARGE
3/8" NPTM
DISCHARGE
6.38 (162)

1.26
(32)

2.56 (65)
1.30
(33)
3.19 (81)

.4
(1 3
1)
1.38
(2) 1/2" NPTF (35) 5.35 (136)
3
45ϒ 0ϒ
INLET
(4) ø.394 (10) 4.84 (123) 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