installation operation service manual
Contents
1. Pressure Washer System GENERAL PUMP T e M es p LLATION PERATION SERVICE MANUAL ad wu V7 EEE CX E Tm Phorm pur A em JA L I T T TABLE OF CONTENTS Introduction IA EA 2 Selecting Remaining Components 6 7 Typical Operation amp Requirements 2 Upstream or Inlet Side Pressure IAEA 2 Components s as aaeaa aaea 6 OW 2S xp Rie oh E E ec E AE 2 Downstream or Outlet Side Designing Your System 3 5 Components anaana aana 6 7 Pump Selection 3 Installing Your Components 8 Motor Engine Selection 3 Troubleshooting 9 Determining Spray Tip Size 5 Drive System 000 R Ra R nissa 5 6 Pulley Selection 5 Belt Selection 6 INTRODUCTION memm Thank you for purchasing a GENERAL PUMP pressure washer pump With proper installation and maintenance it will provide you with many years of dependable trouble free service This manual was developed as a basic guide to understanding the operation and requirements installation and servicing of GENERAL PUMP positive displacement pumps Pressure cleaning equipment is potentially hazardous and could cause personal injury or property damage if installed repaired or operated in an unsafe manner or in a manner which is not consistent with the manufacturer s recommendations or requirements2. There are many manufacturers of pressure washer pumps and complementary components Be sure that the required components that you choose to use are consistent with the high quality standards of GENERAL PUMP GENERAL PUMP does not assume liability or responsibility for the design or operation of a customer s high pressure system TYPICAL OPERATION AND REQUIREMENTS mm PRESSURE The pressure produced in a pressure washer system is the result of forcing a known volume or flow of water through a known size orifice spray tip Pressure is measured in pounds per square inch PSI FLOW The flow or volume produced in a pressure washer system is determined by the speed that the pump shaft is rotated RPM The faster the shaft is rotated the higher the output volume The flow or volume is measured in gallons per minute GPM The pump which is driven by an electric motor or a gas engine draws or accepts filtered water in through a series of inlet check valves as the plungers move back As the plungers move forward the inlet valves close forcing the water to travel through a series of outlet check valves and to the outbound side of the pump After the water exits the pump its flow direction must be controlled with an unloading or regulating valve A positive displacement pump is always delivering a certain volume of water whether the spray gun is open or closed therefore a device is needed to control the direction of flow either
3. allowing the flow to go through the open spray gun or redirecting by passing the flow back to the inbound side of the pump when 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 unloader or regulator valve in your pressure washer system As a safety device at least one pressure relief valve should be installed in the outbound side of the pump to guard against failure of component parts and the development of dangerously high pressure Cleaning chemicals or detergents may be introduced into the flow of water either inbound or outbound of the pump An inbound or upstream type of chemical injector simply uses the pumps ability to draw or suck fluid in to introduce a chemical into the stream of water Care must be taken to avoid introducing any chemicals which are not compatible with the materials in the pump and downstream components An upstream injector does allow chemicals to be applied to the work surface at the normal high working pressure of the system An outbound or downstream type of chemical injector uses a venturi very similar to that used in an automobile carburetor to draw a chemical into the water stream A downstream injector requires low pressure to activate chemical fl
4. nm pm poe pe pou oe pem pe pm pem om pem pm oem nm pm NOTES 1 A gasoline engine should be sized 1 8 times the electric horsepower requirement Always select a motor engine with a horsepower rating above the minimum requirements shown above Example 5 0 GPM 1250 PSI is 4 40 minimum electric horsepower requirement use a 5 horsepower electric motor If you wish to direct drive your pump from an electric motor you may want to use a C face motor Check with your motor supplier for technical information SPRAY TIP SELECTION CHART ap onec OUTPUT VOLUME GPM AT VARIOUS PRESSURES PSI SIZE DIA 40 PSI 100 PSI 250 PSI 500 PSI 600 PSI 700 PSI 800 PSI 1000 PSI 1200 PSI 1500 PSI 2000 PSI 2500 PSI 3000 PSI 3500 PSI 4000 PSI 2 70 A commonly used standard for tip size is the nozzle number which is equivalent to the nozzle capacity in GPM at 4000 PSI Spray angle does not affect nozzle volume 4 DETERMINING SPRAY TIP SIZE As stated earlier in this manual the output pressure is determined by forcing the output volume of water through a certain size orifice or spray tip Stray tip size is a very important factor of proper pressure washer 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 output PSI to properly select a spray tip size To use the chart on Page 4 find the desired PSI read down the col
5. E To Transmit 1 Belt 2 Belts 1 Belt HORSEPOWER Single Double Single Groove Groove Groove 2 Belts 1 Belt Double Single Groove Groove Pulley Pulley Pulley Pulley Pulley 3 ex e a GS oo fe SE NN O E am fe 1 s ss o 9 eo s ee eg TU TE ee ee ee ee es ee TH Pe fs DDR NN To determine pump pulley size based on a 1725 RPM motor find the motor pulley size on the chart below follow the column down untif you find your required pump RPM to meet your requirements or the next higher RPM Follow the column to the left to find pump pulley diameter MOTOR PULLEY OUTSIDE DIAMETER INCHES eg esa s e eve ea e alasan s lea Sie saa s Jere 7 ef o sto om 8 meer EXEC ae E998 E eee n e ag DENEN EE E ERUNT ERE ERR E EE UR ERST ERES ERR ERE EE ERR ERES ERE RET RE IIT RET RET ERI pue BESSER EE ES TT T ET EE fla aS NES f T T EIE EIE NIC ESSET RR ES a a Wai aa ENG ST 25w pempwepeepeepwep q n yp p Jy Tp ovr copo qm wd v p T sw ea ofso fees frs 3 T T p T T pp v qm op qq p Es per ps pas pes pes per 99 MA KA KAA KAA G H H O 9 9 9 H J peperere ue eee LLL OTT ee KI SS ee a eS SEE E SS ae ee SS me qe qe Ere ERES EST 7 SC e RSS TERES E qe qe T S s pee per pos es sen pon e pem m pom 8 H LL H G G 9 G Ege Eee Ee RESET SEE EE ESSE RES RES E Resp 99 oes voe nee KA 1250 1383 1417 1500 vor we vs T J T T p
6. ance between centers of pulleys in inches D Outside diameter of pump pulley in inches d Outside diameter of motor engine pulley in inches d D do zi Always install a safety cover or guard over belt and pulleys to avoid serious bodily injury or property damage SELECTING REMAINING COMPONENTS Sma UPSTREAM OR INLET SIDE COMPONENTS Inlet Filter A very important component to increase system life and avoid operating problems A 60 120 mesh screen filter is necessary to stop foreign matter from entering the system and possibly holding valves open clogging orifices scratching plungers tearing packing and causing unnecessary wear on all components By Pass Provision As mentioned earlier in this manual the unloader or regulator valve by passes or recirculates pumped water when the gun trigger is released A provision must be made in the inlet plumbing or inlet water holding tank to accept this flow of water without restrictions Thermal Relief Valve This is a temperature sensing valve that opens and dumps water to 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 colstly repairs Upstream Injector A device which uses the pumps ability to draw or suck fluid to introduce a cleaning chemical into the water stream This ty
7. ange oil intervals Use any high grade automotive 30 weight nondetergent oil Worn packing and or piston rod sleeve o rings on plunger retainer worn Replace packing Replace o rings Replace seals Damaged crankcase rear cover o ring drain plug Replace cover o ring drain plug o ring or sight glass o ring or sight glass o ring o ring Excessive pressure and or temperature of fluid being pumped Running pump dry Do not run pump without water Worn crankcase piston rod seals Pulley loose on crankshaft Check pressures and fluid inlet temperature be sure they are within specified range
8. 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 developed 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 l
9. dp ae s es ers ess wee ims 192 1272 1380 1430 s10 1575 teso f sf en ee ee H sse pe per pe T pss pae nr a p a ML ELLE E pe pr por pee no res rose ao p so so ove ao e pese a a LLL E pepe e pe pe eer e pe pee pee s T o n pr po pese p LLL E 3 ps pe pee pre pes se e ps pos rs ree nes ao ore peer p est 1114 pss se se e oso os e pro ase o oso se se vce pes ss e s a H pe pepe pee pe pem pe p pre p pes ps p e e poo prr se e s p 1 WA WA E pee perpe es po es ps pese one p ree aes con ome one e ne ss em pe 5 7 150 a o peperere a e eT pe 99 T T Te n o pr p pn s BR slol elel Sl Q N aj N o D If your motor engine will be operated at a speed other than 1725 RPM the pump pulley diameter can be calculated using the following formula Motor Pump E X Puley X Pulley Diameter Diameter Example Using a 1200 RPM motor and a pump that you want to turn at 850 RPM for your desired GPM output and you have chosen a 4 1 2 diameter motor pulley 1200 850 1 412 RPM Ratio 1 412 x 4 5 6 39 actual pump pulley diameter There may not be a pulley available in the exact size as calculated Simply use the closest one BELT SELECTION Be sure to use the same section belts A B or C as the pulleys were sized for Use the following formula to calculate belt length L 2 C 1 57 D d D 9 4C Where L Effective outside length of belt s in inches C Dist
10. eal and reassemble Clean adjust relief valve check for worn and dirty valve seats Kit available Relief valve studk partially plugged or improperly adjusted valve seat worn Inlet suction strainer clogged or improperly sized Clean Use adequate size Check more frequently Worn packing Abrasives in pumped fluid or severe cavitation Inadequate water Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies Worn inlet discharge valve block or dirty Replace worn valves valve seats and or discharge hose Leaky discharge hose Restricted inlet or air entering the inlet plumbing Proper size inlet plumbing check for air tight seal Replace worn cup or cups clean out foreign material replace worn valves Install proper filter Suction at inlet manifold must be limited to lifting less than 20 feet of water or 8 5 PSI vacuum Inlet restrictions and or air leaks Stuck inlet or discharge valve Worn packing Install new packing Worn crankcase piston rod seals o rings on plunger retainer worn Replace crankcase piston rod seals Replace o rings Worn crankshaft seal or improperly installed oil Remove oil seal reatiner and replace damaged o ring seal o ring and or seals Bad bearing Replace bearing Worn main bearing from excessive tension on Replace crankshaft bearing and or tension drive drive belt belt May be caused by humid air condensing into water inside the crankcase Ch
11. fatigue Ease of serviceability 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 Sma 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 Avoid bends and restrictions in the inlet and outlet plumbing They force the motor engine to work harder to drive the pump reduction of efficiency and create turbulence in the water flow which can cause cavitation on the inlet side and premature wear in the pump and in the outlet plumbing Bends and restrictions will cause a reduction in outlet pressure and increase amp draws with an electric motor Use a thread sealant on all plumbing connections and tighten all connections securely to avoid air entering the system Avoid using hoses which are secured with hose clamps
12. other electrical components Never allow a water spray or a leak to come in contact with any electrical components to avoid serious bodily injury or property damage If you are not sure about your electrical requirements component selection or hook up seek the advice of a professional electrician Always install a guard over belts and pulleys which meets OSHA standards to protect personnel from injury due to contact with moving parts Any moving part must be covered to guard against serious bodily injury and property damage Do not introduce acids or other caustic materials or any abrasives into your pressure washer system or warranties will be void and components in the system will be damaged Protect the pump system from a freezing condition TROUBLESHOOTING memm PROBLEM CAUSE REMEDY Faulty pulsation dampener Check precharge if low recharge it or install a new one Low Pressure Pump runs extremely rough pressure very low Water leakage from under manifold Slight leakage Oil leak between crankcase and pumping section Oil leaking in the area of the crankshaft Excessive play in the end of the crankshaft pulley Water in crankcase Oil leaking from underside of crankcase Oil leaking at the rear portion of the crankcase Loud knocking noise in pump Frequent or premature failure of the packing Belt slippage Tighten or replace use correct belt Air leak in inlet plumbing Disassemble res
13. ow Low pressure is achieved by changing to a large sized spray tip or opening up a large orifice at the outlet end of the spray gun using an adjustable nozzle or a double lance There are several advantages to using a downstream injector over using an upstream type 1 Fewer component parts are exposed to the cleaning chemicals extending system life 2 The operator can control the flow of chemical on and off by changing the system pressure at the nozzle 3 Applying chemical at low pressure is more economical because less chemical bounces off the work surface Heated pressure washers and steam cleaners increase the ability of a high pressure flow of water to break down dirt and grease They also increase the action of most cleaning chemicals These systems are very complex and add more potential for personal injury and property damage hazards Design of these systems requires many more additional components as well as experienced design personnel with knowledge of fuels heat transfers electronics etc TYPICAL PRESSURE WASHER SYSTEM SPRAY TN fap HL TIP eea Zer HIGH L PRESSURE ES HOSE ur UNLOADER OR PRESSURE 5 REGULATOR VALVE RELIEF VALVE PULSATION DAMPENER PRESSURE GAUGE CHEMICAL INJECTOR 9 0 Hf ji come E aM LN EE CL E aa aa in EK mu rj INLET aw 2 DESIGNING YOUR SYSTEM mmm PUMP SELECTION The heart of any pressure washer system is the high pressure pump Size the p
14. ow 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 PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES FLOW HOSE INSIDE DIAMETER INCHES GAL MIN WATER 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 pulsations 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
15. pe of injector is recommended for very mild chemicals only as the entire system especially the pump is exposed to the corrosive tendencies of the cleaning chemicals Pressure Reducing Valve If the water supply entering the pump is above maximum inlet pressure rating called out on the Pump Data Sheet A pressure reducing valve must be installed for proper pumpoperation Back Flow Preventer When using cleaning chemicals care must be taken to avoid these chemicals from being back flushed and contaminating the city water supply Check your local plumbing codes An alternative option to a back flow preventer is the use of a water holding tank If a holding tank is used be sure not to exceed the negative pressure rating of the pump DOWNSTREAM OR OUTLET SIDE COMPONENTS Unloader or Regulator Valve As mentioned earlier this device is required to direct the constant flow of water either through the spray tip when the gun is open or by pass the flow back to the inlet side of the pump when the gun is closed Be sure to adhere to manufacturer s requirements when selecting installing setting up and 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
16. they are very susceptible to air leaks and will not retain very high pressures Permanently coupled hoses with appropriately sized pipe threads installed are the best way to connect hose to hard plumbing Air leaks in the inlet plumbing will cause a reduction of outlet pressure noisy pump operation and excessive wear and tear on the pump When mounting the pulleys on the pump and motor engine install them as close as possible to the crankcase and crankcase bearing to avoid an excessive side load on the rotating parts Be sure that the pulleys are properly aligned to avoid excessive belt and pulley wear and belt noise Do not overtighten the belts to avoid an excessive side load on the rotating parts 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 crankshaft or pump pulley A gas engine has only one rotation direction which may vary between manufacturers Be sure you know the dotation direction before you begin assembly Most electric motors may be operated in either rotation direction by changing the wiring Check the manufacturer s specifications of your motor to determine the proper rotation direction for your application Water and electricity can be a very dangerous combination Use extreme caution when installing or working on electrical components Always use watertight conduit connections boxes motors switches and
17. umn until you find the output GPM closest to your pump application Read to the far left to find the spray tip number and orifice diameter Example 1000 PSI at 4 0 GPM needs a number 8 spray tip Spray tips are available in various spray angles It is advisable to have different spray angle tips in the same size for different cleaning applications Some spray tips or nozzles are available with an adjustable spray angle DRIVE SYSTEM Em There are three common methods of driving or connecting the pump and motor engine Direct drive and gear reduction drive require special components that are matched to the pump and to the motor engine as well as other technical considerations A belt and pulley system is the recommended method of driving the pump because it allows easy reduction of the motor engine RPM to your required pump RPM as well as absorbing shocks produced by both the engine and the pump PUMP PULLEY OUTSIDE DIAMETER INCHES PULLEY SELECTION There are many typed of belts and pulleys available the following is a basic guide Manufacturer s representatives should be consulted concerning your specific requirements From the MOTOR Pulley Guide below determine the pulley size A B or C section and number and size A B or C section of belt required The larger in size and or number of belts used will increase the life of belts Be sure to consider space limitations of your finished assembly MOTOR PULLEY GUID
18. ump according to your cleaning needs Higher than required pressure and volume will cause needless wear of all components in the system and could actually damage your work surface instead of cleaning it Never exceed the maximum pressures of rotation speed as is stated on the Technical Data Sheet supplied with each pump Refer to the Technical Data Sheet to determine what pump RPM is needed to deliver your required GPM output RELIEF FLUID BY PASS HOSE REEF KE j ic VALVE DRIVE SYSTEM POWER SOURCE MOTOR ENGINE 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 output desired Refer to the Technical Data Sheet supplied with each pump or the following chart Both charts are based on electric horsepower requirements for gas engines multiply by 1 8 Gas engine output horsepower varies with running RPM Be sure to run a gas engine fast enough to supply required horsepower but do not exceed manufacturer s specifications ELECTRIC MOTOR HORSEPOWER REQUIRED TO DRIVE A PUMP rper E REDEEM H e efe Pe a ee Pe fe fe fe fe oe pw e f e URE EECEECEE EE ERE EETE EIMEUNR a f e e e j e e fe oe f ee ee ee ee e Peso ae Pa Pe oe oe im fo oe om om oe om S o or o9 o e Dm m m p 9 D Le oe p poe oa po pee ae pum m pem pm om mm um Ls Tow Tom To o 9 Tm im e 9 Tm Tm Tom m Lx pom pue poe oe pem pm pem pum pre m pnm oem
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