1. Introduction and Safety Information
This instruction manual provides essential information for the safe and efficient installation, operation, and maintenance of your CAT Pumps 66DX40G1I high-pressure triplex plunger pump. Please read this manual thoroughly before operating the pump to ensure proper function and to prevent personal injury or equipment damage.
1.1 General Safety Precautions
- Always wear appropriate personal protective equipment (PPE) including eye protection, gloves, and hearing protection when operating or servicing the pump.
- Ensure all connections are secure and leak-free before starting the pump. High-pressure leaks can cause serious injury.
- Never operate the pump without adequate water supply. Dry running can cause severe damage to internal components.
- Do not exceed the maximum rated pressure or flow for this pump. Refer to the specifications section.
- Disconnect power to the motor or engine before performing any maintenance or adjustments.
- Keep children and unauthorized personnel away from the operating area.
2. Product Overview and Features
The CAT Pumps 66DX40G1I is a robust high-pressure triplex plunger pump designed for demanding applications. It features a durable construction and advanced engineering to provide reliable performance.
Image of the CAT Pumps 66DX40G1I high-pressure triplex plunger pump, showcasing its blue crankcase and brass pump head with multiple ports and a black pressure regulator knob.
2.1 Key Features
- Triplex Plunger Design: Provides a smooth and consistent liquid flow, reducing pulsation.
- Special Concentric, High-Density, Polished, Solid Ceramic Plungers: Offers a true wear surface, significantly extending seal life and overall pump durability.
- Compact Flange Mount: Allows for easy and direct mounting to most gas engines, simplifying installation.
- Modular Regulating Unloader with Built-in By-pass: Standard feature for safety and precise pressure setting, protecting the pump from over-pressurization.
- Fixed Chemical Injector: Standard and mounts directly onto the unloader, providing flexibility for chemical application.
3. Setup and Installation
Proper installation is crucial for the performance and longevity of your pump. Follow these guidelines carefully.
3.1 Mounting
- Mount the pump securely to a stable, level surface or directly to a compatible gas engine using the compact flange mount.
- Ensure adequate ventilation around the pump to prevent overheating.
3.2 Water Inlet Connection
- Connect a clean water supply to one of the 1/2" NPTF inlet ports. It is recommended to use a water filter to prevent debris from entering the pump.
- Ensure the inlet pressure is within the specified range of Flooded to 75 PSI. Insufficient inlet pressure can lead to cavitation and pump damage.
- Avoid kinks or restrictions in the inlet hose.
3.3 Discharge Connection
- Connect the high-pressure hose to one of the 3/8" NPTF discharge ports.
- Ensure all discharge fittings are rated for the maximum operating pressure of the pump.
3.4 Crankcase Oil
- Verify that the crankcase is filled with the recommended CAT Pumps crankcase oil to the proper level before initial startup. Refer to the maintenance section for oil specifications.
4. Operating Instructions
Follow these steps for safe and effective operation of your CAT Pumps 66DX40G1I.
- Check Fluid Levels: Ensure the crankcase oil is at the correct level and the water supply is connected and turned on.
- Purge Air: Before starting, open the trigger gun or discharge valve to allow water to flow through the pump and hoses, purging any trapped air. This prevents air pockets from damaging the pump.
- Start Engine/Motor: Start the engine or motor connected to the pump. Allow it to reach operating speed (up to 3400 RPM).
- Adjust Pressure: Slowly close the trigger gun or discharge valve. The modular regulating unloader will allow you to adjust the operating pressure within the range of 100 to 4000 PSI. Do not exceed 4000 PSI.
- Chemical Injection (Optional): If using the fixed chemical injector, ensure the chemical solution is prepared according to its instructions and the injector is properly connected.
- Shut Down: To stop operation, release the trigger gun or open the discharge valve to relieve pressure, then shut off the engine or motor. Turn off the water supply.
5. Maintenance
Regular maintenance is essential for extending the life and ensuring the optimal performance of your pump.
5.1 Crankcase Oil
- Check Oil Level: Check the oil level before each use. The oil should be visible in the sight glass or at the specified mark on the dipstick.
- Oil Change: Change the crankcase oil after the first 50 hours of operation, then every 3 months or 500 hours, whichever comes first. Use genuine CAT Pumps crankcase oil or an equivalent non-detergent oil. The crankcase capacity is 18 oz. (0.55 L).
5.2 Water Seals and Plungers
- Inspect water seals and ceramic plungers periodically for wear or damage. Replace as necessary. Signs of wear include consistent water leaks from the manifold.
5.3 Inlet Filter
- Clean or replace the inlet water filter regularly to prevent debris from entering the pump and causing damage.
5.4 General Inspection
- Regularly check all bolts, nuts, and fittings for tightness.
- Inspect hoses for wear, cuts, or leaks. Replace damaged hoses immediately.
6. Troubleshooting
This section provides solutions to common operational issues. For problems not listed here, contact CAT Pumps technical support.
| Problem | Possible Cause | Solution |
|---|---|---|
| No pressure or low pressure |
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| Pump making unusual noise (e.g., knocking) |
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| Water leaking from pump head |
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| Oil leaking from crankcase |
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7. Specifications
Detailed technical specifications for the CAT Pumps 66DX40G1I pump.
| Specification | Value |
|---|---|
| Model Number | 66DX40G1I |
| Flow Rate | 4.0 GPM (15.0 L/M) |
| Pressure Range | 100 to 4000 PSI (7 to 275 BAR) |
| Maximum RPM | 3400 RPM |
| Stroke | 0.449" (11.4 mm) |
| Engine Mounting Face | 6.5" |
| Inlet Pressure Range | Flooded to 75 PSI (Flooded to 5.25 BAR) |
| Bore | 0.551" (14 mm) |
| Shaft Diameter (Hollow) | 1" (25.4 mm) |
| Maximum Liquid Temperature | 140°F (60°C) |
| Crankcase Capacity | 18 oz. (0.55 L) |
| Inlet Ports | (2) 1/2" NPTF |
| Discharge Ports | (2) 3/8" NPTF |
| Weight | 26.15 lbs. (11.9 kg) |
| Dimensions (Pump Only) | 10.0 x 9.96 x 6.38" (254 x 253 x 162 mm) |
| Material | Metal |
| Color | Blue |
| UPC | 724373416670 |
8. Warranty and Support
For specific warranty information regarding your CAT Pumps 66DX40G1I, please refer to the documentation provided at the time of purchase or visit the official CAT Pumps website. Warranty terms typically cover manufacturing defects for a specified period.
For technical assistance, parts, or service, please contact CAT Pumps customer support directly. Ensure you have your pump model number (66DX40G1I) and serial number available when contacting support.
Manufacturer: CAT Pumps
