DATA SHEET

DIRECT DRIVE PLUNGER PUMPS

Brass 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 6.9 - 275 bar
Stroke 0.339" 8.6 mm
Model 66DX35G1I
Flow 3.5 gpm 13.2 lpm
Pressure Range 100 to 4000 psi 6.9 - 275 bar
Stroke 0.394" 10.0 mm
Model 66DX40G1I
Flow 4.0 gpm 15.0 lpm
Pressure Range 100 to 4000 psi 6.9 - 275 bar
Stroke 0.449" 11.4 mm
COMMON SPECIFICATIONS
Pump RPM 3400 rpm 3400 rpm
Inlet Pressure Range Flooded to 75 psi Flooded to 5.2 bar
FEATURES
Max. Liquid Temperature 140° F 60° C
• Triplex plunger design provides a smooth liquid flow. Bore 0.551" 14 mm
• S pecial concentric, high-density, polished, solid ceramic plungers Crankcase Capacity 18.0 oz. 0.55 l
provide a true wear surface and extended seal life. Inlet Ports (2) 1/2" NPT(F) 1/2" NPT(F)
•C
 ompact flange mount permits easy, direct mounting to most Discharge Ports (2) 3/8" NPT(F) 3/8" NPT(F)
gas engines.* Shaft Diameter (Hollow) 1.0" 25.4 mm
• Modular regulating unloader with built-in by-pass is standard for Engine Mounting Face 6.5" 6.5"
safety and pressure setting.
Weight 26.15 lbs. 11.9 kg
• F ixed chemical injector is standard and mounts directly onto Dimensions (pump only) 11.73 x 10.51 x 8.15" 298 x 267 x 207 mm
unloader to provide cleaning flexibility.

*Gas Mounting Flange: SAE J609, Flange B, Extension 4 (1"Ø), Shaft

Length= 3 1/4", Pilot Ø= 5 3/4", BC. Ø= 6 1/2", Thread 3/8"-16 UNC Tap.

ELECTRIC HORSEPOWER REQUIREMENTS

MODELS FLOW PRESSURE RPM
psi psi psi
2500 3200 4000
bar bar bar
gpm lpm
172 220 275
66DX30G1I 3.0 11.4 5.1 6.6 8.2 3400
66DX35G1I 3.5 13.2 6.0 7.7 9.6 3400
66DX40G1I 4.0 15.0 6.9 8.8 11.0 3400

DETERMINING Rated gpm = “Desired” gpm

THE PUMP R.P.M. Rated rpm “Desired” rpm
DETERMINING Hp = gpm x psi
THE REQUIRED H.P. (Electric Brake) 1460
Refer to pump Service Manual for repair procedure and additional technical information.
 EXPLODED VIEW

31 40
37
32 50
33
33
48
49
5 38
8
10
27 255
51
65
70
75
90 53
98 64 20
99 20
100 172
400 20
174 25
167
168
164 106
166
Discharge 163
197 120
121 15
127 11
128
188 Discharge 13
Inlet
164
167 Inlet 251
172 252
163 185
166
168 249
174

PARTS LIST

ITEM P/N MATL DESCRIPTION QTY ITEM P/N MATL DESCRIPTION QTY
5 125824 STCP R Screw, HHC (M6x16) 4 98 46730 NBR Washer Seal, Plunger Retainer - 90D 3
8 48259 AL Cover, Bearing 1 99 † 48201 SS Retainer, Plunger 3
10 14028 NBR O-Ring, Bearing Cover - 70D 1 100 48755 NY Retainer, Seal 3
11 125351 NBR Seal, Oil, Crankshaft 1 106 45188 NBR Seal, LPS w/S-Spg 3
13 14037 NBR O-Ring, Bearing Cover 1 120 48759 BB Case, Seal 3
15 146421 STL Bearing, Ball - Inner 1 121 13980 NBR O-Ring, Seal Case - 70D 3
20 48843 TNM Rod, Connecting 3 127 48758 SNG V-Packing 3
25 48970 CM Crankshaft (8.6 mm) 30G1I 1 49201 STG V-Packing 3
48977 CM Crankshaft (10.0 mm) 35G1I 1 128 48757 NY Adapter, Male 3
48839 CM Crankshaft (11.4 mm) 40G1I 1 163 17547 NBR O-Ring, Seat - 85D 6
27 14480 STL Bearing, Ball - Outer 1 164 45790 S Seat 6
31 127409 — Cap, Vented w/ O-Ring (Rain Cap) 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 † 44565 PVDF 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 125824 STCP R Screw, HHC (M6x16) 4 185 48846 BB Head, Manifold 1
48 25625 STCP Plug, Drain (1/4"x19BSP) 1 188 126512 STCP R Screw, HSH (M8x65) 8
49 23170 NBR O-Ring, Drain Plug - 70D 1 197 941517 BB Assy, GH 1/2" NPT(F) 1
50 48862 AL Cover, Rear 1 249 48841 AL Flange, Adapter 1
51 14048 NBR O-Ring, Rear Cover 1 251 126746 STCP R Lockwasher, Conical (M8) 4
53 48830 AL Crankcase 1 252 46403 STL Screw, FH (M8x25) 4
64 46404 CM Pin, Crosshead 3 255 30510 STZP Assy, Bolt Mount 1
65 48845 BB Rod, Plunger 3 283 34334 — Kit, Oil Drain (3/8"x24") (Not Shown) 1
70 48911 NBR Seal, Oil, Crankcase 3 300 34262 NBR Kit, Seal (Inclds: 98,106,121,127,128) 1
75 48754 NBR Slinger, Barrier 3 310 34260 NBR Kit, Valve (Inclds: 163,164,166,167,168,172) 2
90 48752 CC Plunger (M14x47) 3 400 7860 BB Unloader Assy w/Fixed Injector (Eff. 04/07) 1

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, 036, 055, 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 
PVDF=Polyvinylidene Flouride   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
 MODEL 7860 UNLOADER WITH INJECTOR MODEL 7367 FIXED CHEMICAL INJECTOR
SPECIFICATIONS U.S. Metric SPECIFICATIONS U.S. Metric
Flow Range 3.0 - 5.0 gpm 7.6 - 19.0 lpm Flow Range 3.0 - 5.0 gpm 11.4 - 19.0 lpm
PSI Range 700 - 4000 psi 50 - 275 bar Nozzle Orifice 2.1 mm 2.1 mm
Inlet Port, Side 1/2" NPT(F) 1/2" NPT(F) Hose Barb - Extension 1/4" 1/4"
Discharge Port, Front 3/8" NPT(M) 3/8" NPT(M) 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 170 x 6.75" 118 x 43 x 171 mm Discharge Port 3/8" NPT(M) 3/8" NPT(M)
Weight 5.3 oz. 0.15 kg
Dimensions 2.0 x 1.0 x 1.75" 52 x 25 x 44 mm

425
472
401 476
428
414 477 483
415 Repair Kit
412
470 478
402 Repair Kit
426 418
Inlet
403 429 Complete 479
430 Piston
404 423 Assembly
408 424 Discharge
435 480
410 436 PARTS LIST
437
ITEM P/N MATL DESCRIPTION QTY
440 472 — BB Barb 1
442 442
471 476 — NBR O-Ring, Barb - 70D 1
462 Repair Kit 477 — S Ball 1
443
454 444 460 478 — S Spring 1
479 — S Orifice 1
456 446 480 — BB Body 1
464 464 Inlet 483 76176 NBR Kit, Repair ( Includes: 476, 477, 478) 1
463 469
Discharge MATERIAL CODES (Not Part of Part Number): 
Inlet BB=Brass  NBR=Medium Nitrile (Buna-N)  S=304SS

PARTS LIST CHEMICAL INJECTOR PERFORMANCE CHART

Desired Maximum Maximum Pressure Drop Across
ITEM P/N MATL DESCRIPTION QTY Pump Orifice Injecting Chemical Injector At System
401 49100 NY Handle, Adjusting (Black) 1 Size
Flow Pressure Draw Pressure (4000 psi)
402 49099 BB Cap, Adjusting 1 3.0 2.1 mm 190 psi 70.0 oz/min 136 psi
403 125521 BB Nut, Locking (M25x1) 1
404 88953 S Screw, Set (M4x4) 1 3.5 2.1 mm 260 psi 74.2 oz/min 245 psi
408 45198 ZP R Spring, Pressure 1 4.0 2.1 mm 358 psi 76.8 oz/min 288 psi
410 49101 STZP R Retainer, Spring 1 Optimum performance of chemical injector occurs with a 35 ft. high pressure hose
412 49103 S Stem, Piston 1 and a minimum 3/8" I.D. The type of hose, extended lengths, reduced I.D. and
414 129638 PTFE Back-up-Ring, Piston Stem 1
fittings may create back pressures in excess of the low pressure nozzle rating and
415 49104 NBR O-Ring, Piston Stem - 90D 1
prevent the injector from drawing chemical. Deduct hose friction loss from above
418 — BB Assy, Piston (Included in Repair Kit) 1
423 49105 BB Retainer, Valve 1 low psi nozzle. Contact Cat Pumps for assistance with other options.
424 49106 NBR O-Ring, Valve Retainer - 70D 1 Note: Deduct the pressure drop shown in the performance chart from your desired
425 49102 BB Retainer, Piston 1 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, Piston Retainer - 80D 1
429 22056 NBR O-Ring, Valve Retainer - 70D 1
430 49123 D Back-up-Ring, Valve Retainer 1 UNLOADER TYPE
435 49383 S Valve/Ball Assembly 1 A modular regulating unloader with chemical injector comes with each 66DX pump
436 49384 S Seat 1 to provide system pressure regulation, pump protection, and metered chemical
437 13965 NBR O-Ring, Seat - 70D 1 application.
440 — BB Valve Body 1
442
443
49121
49245
STL
BB
Washer, Seal (3/8”)
Valve, Check w/NBR O-Ring
2
1
OPERATION:
Purge pump of air before commencing operation by allowing liquid to flow through
444 117275 S Spring, Check Valve 1 the pump without discharge restriction. Removing trapped air will assure full system
446 26133 NBR O-Ring, Body - 80D 1 pressure can be obtained. Install a pressure gauge close to the manifold head of
454 11346 NBR O-Ring, Manifold - 70D 1 the pump to assist in setting system pressure and to periodically monitor system
456 — BB Manifold 1 pressure. Setting and adjusting the unloader pressure must be done with the system
460 126974 BB Fitting, Discharge [3/8” NPT(M)] 1 turned on. Start the system with the unloader backed off to the lowest pressure
462 49120 BB Screw, Flo-Thru [3/8” NPT(M)] 1 setting (counterclockwise direction). Squeeze the trigger and read the pressure on
463 49117 BB Screw, Flo-Thru [1/2” NPT(M)] 1 the gauge at the pump. Do not read pressure at the gun or nozzle. If more pressure
464 49118 STL Washer, Seal (1/2”) 2 is desired, release the trigger, turn adjusting cap one quarter turn in a clockwise
468 31708 NBR Kit, O-Ring 1 direction. Squeeze the trigger and read the pressure. Repeat this process until the
(Inclds: 414, 415, 424, 428-430, 437, 446, 454) desired system pressure is reached. Thread locking nut up to adjusting cap and
469 7367 BB Injector, Chemical Fixed 1 tighten set screw. All high pressure systems should have a secondary relief valve.
470 31556 NBR Kit, Repair 1 Set secondary relief valve 200-300 psi above the unloader setting.
(Inclds: 418, 425, 428, 436, 437) NOTE: Pressure is not set at the factory.
471 76185 NBR Kit, Check Valve (Inclds: 443, 444, 446) 1

Italics are optional items.  R Components comply with RoHS Directive. SERVICE:
MATERIAL CODES (Not Part of Part Number):  BB=Brass  D=Acetal The unloader should be serviced on the same schedule as the seals in the pump.
NBR=Medium Nitrile (Buna-N)  NY=Nylon  PTFE=Pure Polytetrafluoroethylene Refer to 66DX Service Manual for start-up, servicing of seals and valves, torque
S=304SS  STL=Steel  STZP=Steel/Zinc Plated  ZP=Zinc Plated requirements and Diagnosis/Maintenance chart.
 10.51 (267)

11.73 (298) 9.09 (231)

ø6
.5
(1 (2) 3/8" NPT(F)
65

3.70 (94)
)
DISCHARGE
3/8" NPT(M)
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" NPT(F) (35) 5.35 (136)
3
45 0
INLET
(4) ø.394 (10) 4.84 (123) 9.68 (246)
5.28 (134)
9.80 (249)

10.0 (254)

• CAUTIONS AND WARNINGS

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.

WARRANTY
View the Limited Warranty on-line at ww.catpumps.com/warranty.

CAT PUMPS
1681 - 94TH LANE N.E. MINNEAPOLIS, MN 55449-4324
PHONE (763) 780-5440 — FAX (763) 780-2958
e-mail: techsupport@catpumps.com
www.catpumps.com

For International Inquiries go to www.catpumps.com and navigate to the “Contact Us” link. PN 993259 Rev H 6/17