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INSTALLATION

OPERATION

SERVICE

MANUAL

TABLE OF CONTENTS

Introduction..........................................................2

Selecting Remaining Components . . . . . . 6 - 7

Typical Operation & Requirements.......................2

Upstream or Inlet Side

Pressure.........................................................2

Components . . . . . . . . . . . . . . . . . . . 6

Flow................................................................2

Downstream or Outlet Side

Designing Your System ...................................3 - 5

Components . . . . . . . . . . . . . . . . 6 - 7

Pump Selection ..............................................3

Installing Your Components . . . . . . . . . . . 7 - 8

Motor/Engine Selection ..................................3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9

Determining Spray Tip Size............................5

Servicing Your Pump. . . . . . . . . . . . . . . 10 - 11

Drive System ...................................................5 - 6

Valve Assemblies. . . . . . . . . . . . . . . . . . 10

Pulley Selection..............................................5

Removing Manifold Head . . . . . . . . . . . 10

Belt Selection .................................................6

Replacing Plungers . . . . . . . . . . . . . . . . 11

Replacing Packings . . . . . . . . . . . . . . . . 11

Summary of Contents for Pressure Washer System

Page 1: ...tream or Inlet Side Pressure 2 Components 6 Flow 2 Downstream or Outlet Side Designing Your System 3 5 Components 6 7 Pump Selection 3 Installing Your Components 7 8 Motor Engine Selection 3 Troubleshooting 9 Determining Spray Tip Size 5 Servicing Your Pump 10 11 Drive System 5 6 Valve Assemblies 10 Pulley Selection 5 Removing Manifold Head 10 Belt Selection 6 Replacing Plungers 11 Replacing Packi...

Page 2: ... the spray gun is closed Without an unloading or regulating valve dangerously high pressures will be produced when the spray gun is closed because the water being forced out of the pump has no place to go Serious bodily injury or property damage could be caused by failure to properly utilize an appropriate un loader or regulator valve in your pressure washer system As a safety device at least one ...

Page 3: ...your work surface instead of cleaning it Never exceed the maximum pressures of ro tation speed as is stated on the Technical Data Sheet supplied with each pump Refer to the Pump Data Sheet to determine what pump RPM is needed to deliver your required GPM output MOTOR ENGINE SELECTION The size of the electric motor or gas engine required to drive your pump is determined by the pump GPM and PSI outp...

Page 4: ...5 5 060 55 87 1 40 1 90 2 10 2 30 2 50 2 8 3 0 3 4 3 8 4 4 4 8 5 2 5 5 6 062 60 95 1 50 2 10 2 30 2 50 2 70 3 0 3 2 3 7 4 2 4 8 5 2 5 6 6 0 6 5 064 65 1 00 1 70 2 30 2 50 2 70 2 90 3 3 3 6 4 0 4 6 5 2 5 7 6 0 6 5 7 067 70 1 10 1 80 2 50 2 70 2 90 3 10 3 5 3 8 4 3 5 0 5 6 6 1 6 6 7 0 7 5 707 75 1 20 1 90 2 70 2 90 3 20 3 40 3 8 4 1 4 6 5 3 6 0 6 5 7 0 7 5 8 072 80 1 30 2 00 2 80 3 10 3 40 3 60 4 0 ...

Page 5: ...performance using a tip that is sized too small will allow overpressurization of the pump and components You must know your output GPM and your desired output PSI to properly select a spray tip size To use the chart on page 4 find the desired PSI read down the column until you find the output GPM closest to your pump application Read to the far left to find the spray tip number and orifice diamete...

Page 6: ...low of water without restricion Thermal Relief Valve This is a temperature sensing valve that opens and dumps water to the atmosphere at a predetermined temperature Recirculating water through the by pass loop has a tendency to heat up to temperatures that can eventually damage internal pump parts A thermal relief valve is an inexpensive way to avoid costly repairs Upstream Injector A device which...

Page 7: ...njector will not draw any chemical Downstream injectors require low pressure generally about 200 PSI to activate the chemical flow A double nozzle holder rollover nozzle and a double lance are a few accessories that allow mounting a low pressure spray tip as well as the standard high pressure spray tip An adjustable nozzle allows a large orifice to be opened around the high pressure spray tip High...

Page 8: ... Mount the motor engine in relationship to the pump such that when running the rotation of the pump crankshaft is counterclockwise as you face the pump crankcase or pulley A gas engine has only one rotation direction which may vary between manufacturers Be sure you know the rotation direction before you begin assembly Most electric motors may be operated in either rotation direction by changing th...

Page 9: ...gs Oil leaking in the area of crankshaft Worn crankshaft seal or inproperly installed oil seal o ring Remove oil seal retainer and replace damaged o ring and or seals Bad bearing Replace bearing and any spacer or cover damaged by heat Excessive play in the end of the crankshaft pulley Worn main bearing from excessive tension on drive belt Replace crankcase bearing and or tension drive belt Water i...

Page 10: ...ed 7 Install new o rings in valve cavity 8 Insert assembly into valve cavity 9 Replace valve cap and torque to specifications REMOVING MANIFOLD HEAD Figure 2 1 Remove the fasteners retaining the head 2 Separate head from crankcase NOTE It may be necessary to tap head lightly with rawhide mallet to loosen CAUTION When sliding head from crankcase use caution not to damage plungers 3 The V packing as...

Page 11: ... this is replaced before new plunger is installed 3 Separate piston screw from plunger 4 Install new o ring and teflon backup ring on piston screw NOTE A film of grease on the outside of the o rings insures a better installation 5 Carefully press piston screw into plunger 6 Slide new plunger over the piston guide and torque to specifications 11 3 5 6 ...

Page 12: ...er until it will go no further using proper insertion tool Install rear head ring v packing and main seal retainer into cylinder in order shown and press firmly into cylinder 5 Repeat this sequence for each cylinder 6 Coat each plunger with grease and carefully remount manifold Torque head to specifications General Pump is a member of the Interpump Group G GE EN NE ER RA AL L P PU UM MP P 1174 Nor...

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