CAT Pumps 66DX Series Service Manual

5DX, 6DX, 66DX PLUNGER PUMP SERVICE MANUAL
5DX MODELS:
6DX MODELS:
66DX MODELS:
Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only
with the proper selection, installation of plumbing, and operation of the pump and accessories.
SPECIFICATIONS: Maximum specifications refer to individual attributes.
It is not implied that all maximums can be performed simultaneously.
If more than one maximum is considered, check with your CAT PUMPS
supplier to confirm the proper performance and pump selection. Refer
to individual Data Sheets for complete specifications, parts list and
exploded view.
LUBRICATION: Fill crankcase with special CAT PUMP Hydraulic oil per
pump specifications [5DX-22.65 oz., 6DX-18.6 oz., 66DX-18.0 oz.]. DO
NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change initial fill after
50 hours running period. Thereafter, change oil every 3 months or 500
hour intervals.
DRIVE SELECTION: The pump shaft size is a 1" gas shaft. The engine
driving the pump must be of adequate horsepower to maintain full
RPM when the pump is under load. Select the horsepower requirement
according to required pump discharge flow and maximum pressure at the
pump! Consult the manufacturer of gas or diesel engine for selection of
the proper engine.
MOUNTING: All DX models are direct-drive and come with a flange adapter
that mounts to a gas engine. Before mounting pump to gas engine, apply
PN 6106 antiseize lubricant to pump shaft. Refer to Technical Bulletin 055
for instructions on removing pump from gas engine. To minimize piping
stress, use appropriate flexible hose to inlet and discharge ports.
LOCATION: If the pump is used in extremely dirty or humid conditions, it is
recommended pump be enclosed. Do not store or operate in excessively
high temperature areas or without proper ventilation. Liquid temperatures
above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree
F over 130°F. Elastomer or RPM changes may be required. See Tech
Bulletin 002 or call CAT PUMPS for recommendations.
INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this
manual before starting system. DO NOT STARVE THE PUMP OR RUN DRY.
DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING
SYSTEM to avoid deadhead overpressure condition and severe damage
to the pump or system.
All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve).
Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility
for the operation of a customer's high pressure system.
Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580
World Headquarters
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
International Inquiries
FAX (763) 785-4329
e-mail: intlsales@catpumps.com
®
5DX30G1, 5DX35G1, 5DX40G1, 5DX50G1
6DX35G1I, 6DX40G1I
66DX30G1I, 66DX35G1I, 66DX40G1I
INSTALLATION AND START-UP INFORMATION
®
The Pumps with Nine Lives
A reliable Pressure Gauge should be installed near the discharge outlet
of the high pressure manifold. This is extremely important for adjusting
pressure regulating devices and also for proper sizing of the nozzle or
restricting orifice. The pump is rated for a maximum pressure; this is the
pressure which would be read at the discharge manifold of the pump,
NOT AT THE GUN OR NOZZLE.
Use PTFE thread tape or pipe thread sealant (sparingly) to connect acces-
sories or plumbing. Exercise caution not to wrap tape beyond the last
thread to avoid tape from becoming lodged in the pump or accessories.
This condition will cause a malfunction of the pump or system.
PRESSURE REGULATION: All systems require both a primary pressure
regulating device (i.e., regulator, unloader) and a secondary pressure
safety relief device (i.e., pop-off valve, safety valve). The primary pressure
device must be installed on the discharge side of the pump. The function
of the primary pressure regulating device is to protect the pump from over
pressurization, which can be caused by a plugged or closed off discharge
line. Over pressurization can severely damage the pump, other system
components and can cause bodily harm. The secondary safety relief
device must be installed in-line between the primary device and pump or
on the opposite side of the manifold head. This will ensure pressure
relief of the system if the primary regulating device fails. Failure to install
such a safely device will void the warranty on the pump
NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust
pressure regulating device to compensate. Replace nozzle and reset
regulating device to system pressure.
PUMPED LIQUIDS: Some liquids may require a flush between opera-
tions or before storing. For pumping liquids other than water, contact
your CAT PUMPS supplier.
STORING: For extended storing or between use in cold climates, drain
all pumped liquids from pump and flush with antifreeze solution to
prevent freezing and damage to the pump. DO NOT RUN PUMP WITH
FROZEN LIQUID (refer to Tech Bulletin 083).
WARNING
CAT PUMPS (U.K.) LTD.
1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet
Hampshire GU52 8BF, England
Phone Fleet 44 1252-622031 — Fax 44 1252-626655
e-mail: sales@catpumps.co.uk
N.V. CAT PUMPS INTERNATIONAL S. A.
Heiveldekens 6A, 2550 Kontich, Belgium
Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51
e-mail: cpi@catpumps.be www.catpumps.be
CAT PUMPS DEUTSCHLAND GmbH
Buchwiese 2, D-65510 Idstein, Germany
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
e-mail: catpumps@t-online.de www.catpumps.de
PN 30004 Rev E 5510