background image

WATER

FLOW

GAL/MIN

PRESSURE DROP IN PSI PER 100 FT OF HOSE

WITH TYPICAL WATER FLOW RATES

(HOSE INSIDE DIAMETERS, INCHES)

1/4

5/16

3/8

1/2

5/8

3/4

1”

0.5

16

5

2

1

54

20

7

2

2

180

60

25

6

2

3

380

120

50

13

4

2

4

220

90

24

7

3

5

320

130

34

10

4

6

220

52

16

7

1

8

300

80

25

10

2

10

120

38

14

3

15

250

80

30

7

20

121

50

12

25

200

76

19

40

410

162

42

60

370

93

servicing unloader valves. The valve should be mounted

as close to the pump outlet as possible; do not use any 

hose between the pump and the unloader.

Pressure  Relief  Valve

- A safety  device which when

installed  and  set-up  according  to  the  manufacturer’s

specifications  will  open  and  dump  to  atmosphere  a

quantity of water if the system becomes overpressurized

due to a failure of system components.

Pulsation  Dampener

-  Pulsation  Dampeners  are 

installed in systems either to smooth out the pulsations

caused by the pump itself or to absorb pressure spikes

when the gun is shut off. A duplex pump may require a

pulsation  dampener  because  of    the  pulsation  not 

experienced with a triplex pump. When there are long

runs of pipe, a pulsation dampener may be required to

soften the hammer effect when a gun is shut off.

Pressure  Gauge

- Allows  the  equipment  operator  to

monitor the system for peak performance. A worn spray 

tip will be evident with a decrease in system pressure. 

High pressure may indicate a partially plugged spray tip

or other restriction, or a defect in the unloader valve.

Important factors in gauge selection:

• Liquid filled - to absorb the pressure fluctuations

in the system.

• Restriction orifice installed to avoid damage from

pressure “spikes”.

• Select a gauge so that normal system operating

pressure  is  in  the  middle  of  the  gauge’s  range.

Downstream Injector

- Introduces a cleaning chemical

into the water stream after or downstream of the pump.

Care must be taken to size the injector to the system

volume or GPM. Check with manufacturer’s literature.

Too small of an injector causes a large pressure drop

across the injector and injects a very high concentration 

of chemical. Too large of an injector 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 Pressure Hose

- A required component of your 

system. Be sure that the hose that you select to use is

compatible  with  all  chemicals  that  will  be  introduced

into  the  system,  is  rated  at  least  50%  greater

than  the  system  operating  pressure,  has

good  quality  Permanite  couplings  on  each  end  (do

not  use  hose  clamps),  and  is  as  short  as 

possible  to  avoid  pressure  accumulation  when

releasing  trigger,  and  to  minimize  operating

pressure loss in hose.

7

If quick disconnect couplings are used on the ends of

the  high  pressure  hose,  be  sure  that  they  are  of  the

“straight through” design. Air type quick couplers with 

internal  “shut-offs”  are  not  acceptable  because 

pylsations in the water flow will destroy the moving parts

and lodge them in the gun and/or spray tip.

Spray Gun

- Must be selected to withstand pressure,

volume, temperature and chemicals in the system. Guns

must be durable to withstand the kind of abuse typical in 

pressure wash applications. Consider comfort to reduce

operator fatigue. Ease if servicability is also important.

There are many types and styles of guns available. Be

sure to “shop around” and select one that most closely

fits your needs.

INSTALLING YOUR

COMPONENTS

Refer  to  manufacturer’s  printed  literature  and  install

all  components  according  to  manufacturer’s

recommendations  to  avoid  serious  bodily  injury  or

property  damage  and  to  insure  proper  system 

operation.

All plumbing and component parts must be of the same

size or larger than is on the inlet and outlet of your pump.

The  thread  sizes  are  a  guide  to  the  required

sizes of plumbing for proper water flow both in and out 

of the pump.

All  plumbing  and  component  parts  must  have  an 

operating  pressure  rating  of  at  least  50%  above  the

maximum rated output pressure of the pump, and should

have an actual burst pressure of 3-5 times the normal

system working pressure.

HOSE FRICTION LOSS

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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