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INSTALLATION
OPERATION
SERVICE
MANUAL
TABLE OF CONTENTS
Introduction ..........................................................2
Typical Operation & Requirements .......................2
Pressure .........................................................2
Flow................................................................2
Designing Your System ...................................3 - 5
Pump Selection ..............................................3
Motor/Engine Selection ..................................3
Determining Spray Tip Size............................5
Drive System ...................................................5 - 6
Pulley Selection..............................................5
Belt Selection .................................................6
INTRODUCTION
or closed, therefore a device is needed to control the direction of flow, either 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 pressures.
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. Flow or
volume is measured in gallons per minute (GPM).
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
SPRAY GUN
UNLOADER OR
REGULATOR VALVE
HIGH
PRESSURE
HOSE
SPRAY TIP
WAND
PRESSURE
RELIEF VALVE
PRESSURE
GAUGE
PULSATION
DAMPENER
PUMP
CHEMICAL
INJECTOR
THERMAL
RELIEF
VALVE
FLUID
BY-PASS
HOSE
POWER SOURCE
(MOTOR/ENGINE)
INLET FILTER
DESIGNING
YOUR SYSTEM
Drive
System
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 manufacturers specifications.
PUMP SELECTION
The heart of any pressure washer system is the high
pressure pump. Size the pump 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 Pump Data Sheet to determine what pump
RPM is needed to deliver your required GPM output.
GPM
100 PSI
200 PSI
250 PSI
300 PSI
400 PSI
500 PSI
700 PSI
1.0
.07
.14
.18
.21
.28
.35
.52
.35
.42
.5
1.5
2.0
2.5
3.0
3.5
4.0
5.0
6.0
7.0
8.0
9.0
10.0
.04
.10
.14
.17
.21
.24
.28
.35
.42
.07
.09
.21
.26
.28
.34
.42
.48
1.40
NOTES:
1.75
1,
2.
1.03
1.29
1.29
1.72
2.15
1.12
1.40
1.26
1.68
1.47
.70
.77
.84
.72
.86
.96
1.20
1.40
2.60
3.12
2.45
3.64
2.80
2.48
2.10
2.08
2.10
2.24
1.86
1.80
1.75
1.96
1.68
1.55
.44
1.56
1.23
1.40
1.24
.35
1.05
1.05
1.12
.26
.84
.69
.63
.88
.56
.98
.52
.56
.51
.70
.70
.41
.18
1.04
.60
.56
.14
.70
.53
1.05
.62
.31
.43
.84
.49
.11
4.16
3.10
2.80
4.65
3.50
5.20
Orifice Dia.
(Inches)
40 PSI
.052
.40
4.5
5
5.5
6
6.5
7
7.5
8
8.5
9
9.5
10
12
15
20
30
40
.055
.057
.060
.062
.064
.067
.707
.072
.074
.076
.078
.20
.45
.55
2.80
3.50
4.20
4.90
5.60
6.18
7.00
1.40
2.58
3.09
4.12
.88
1.05
1.40
1.76
1.76
2.10
2.80
3.53
1.55
2.58
2.64
4.40
5.28
6.16
7.35
7.04
9.28
8.40
5.60
6.88
8.40
9.60
11.20
10.50
14.00
12.32
14.70
19.60
11.20
14.08
15.56
14.00
2.80
8.80
10.56
12.40
10.50
7.20
8.40
9.80
8.40
6.30
7.04
7.00
6.30
5.14
6.00
5.60
5.25
4.20
5.28
4.80
4.20
1.92
4.30
4.20
3.60
3.52
8.80
3.44
3.15
3.00
7.73
2.06
17.60
12.60
16.80
18.58
21.00
16.50
22.40
24.80
28.00
4.00
1.6
1.7
1.9
2.0
2.00
2.2
2.4
2.8
3.0
3.6
3.9
4.3
4.5
1.90
2.10
2.20
1.60
1.90
2.40
3.20
4.70
*
1.4
1.80
1.50
3.00
1.2
1.30
1.40
2.00
1.1
.79
1.30
1.20
1.0
1.80
1.30
.95
.89
1.70
1.20
.90
.80
1.60
.75
.85
.77
1.40
1.10
.80
.71
1.00
.95
.70
.50
.63
1.00
1.50
.156
.32
.65
.094
.141
2.40
1.10
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
.87
.60
1.00
.109
2.10
.88
.71
.50
.080
.087
1.40
.70
*Tip
Size
.034
.70
.53
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.
1000 PSI 1250 PSI 1500 PSI 2000 PSI 2500 PSI 3000 PSI 4000 PSI
6.30
1.10
1.40
1.50
1.70
1.80
1.90
2.00
2.20
2.30
2.40
2.50
3.00
3.80
5.00
7.50
10.00
1.50
1.90
2.10
2.30
2.50
2.70
2.80
3.00
3.20
3.40
3.50
4.20
5.30
7.10
10.60
14.20
1.70
2.10
2.30
2.50
2.70
2.90
3.10
3.30
3.50
3.70
3.90
4.60
5.80
7.80
11.60
15.60
1.90
2.30
2.50
2.70
2.90
3.20
3.40
3.60
3.80
4.00
4.20
5.00
6.40
8.40
12.80
16.80
2.50
2.70
2.90
3.10
3.40
3.60
3.80
4.00
4.30
4.50
5.40
6.80
9.00
13.60
18.00
2.0
2.5
2.8
3.0
3.3
3.5
3.8
4.0
4.3
4.5
4.8
5.0
6.0
7.5
10.0
15.00
20.00
2.2
2.8
3.0
3.2
3.6
3.8
4.1
4.4
4.6
5.0
5.2
5.4
6.4
8.2
10.8
16.40
21.60
2.5
3.1
3.4
3.7
4.0
4.3
4.6
5.0
5.3
5.5
5.8
6.1
7.3
2.8
3.6
3.8
4.2
4.6
5.0
5.3
5.6
6.0
6.4
6.8
7.0
8.4
4.0
4.4
4.8
5.2
5.6
6.0
6.2
6.7
7.1
7.6
8.0
21.2
24.0
28.4
5.2
5.7
6.1
6.5
7.0
7.4
7.8
8.3
8.7
32.0
3.8
4.7
5.2
5.6
6.0
6.6
7.0
7.5
8.0
8.5
9.0
4.0
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
9.4
10.0
12.9
14.0
15.0
26.0
28.0
17.4
18.40
24.40
4.8
16.0
12.0
14.2
4.4
10.4
10.6
12.2
35.
9.5
9.2
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.
3.1
34.8
11.2
18.8
37.6
12.0
20.0
30.0
40.0
PULLEY SELECTION
There are many types of belts and pulleys available,
the following is a basic guide. Manufacturers
representatives should be consulted concerning your
specific requirements.
To Transmit:
HORSEPOWER
Pump Pulley
Outside Diameter
(inches)
2-1/2
2-1/4
3
3-1/4
3-1/2
3-3/4
4
4-1/4
4-1/2
4-3/4
5
5-1/4
5-1/2
5-3/4
6
6-1/2
7
8
9
10
11
12
13
14
15
16
2 Belts
Double
Groove
Pulley
2-1/2 Dia
3-1/4
5-1/4
3
7-1/2
1 Belt
Single
Groove
Pulley
1-1/2
DRIVE SYSTEM
A SECTION BELT
B SECTION BELT
1 Belt
Single
Groove
Pulley
2 Belts
Double
Groove
Pulley
4-1/2 Dia
3-1/2 Dia
4-1/2
66
10
10
15
5-1/4
20
3 Dia
1 Belt
Single
Groove
Pulley
3-3/4
3-1/2
C SECTION BELT
8 Dia
10
2-1/2 2-3/4
1725
1574
1431
1310
1210
1125
1050
985
926
876
830
788
750
715
685
630
584
507
450
405
366
336
309
286
267
250
1725
1590
1460
1346
1250
1168
1094
1030
974
922
875
834
795
760
700
648
564
500
450
407
373
343
318
297
278
3
1725
1604
1480
1375
1283
1201
1131
1070
1013
963
917
875
937
771
713
620
550
495
448
410
378
350
326
306
1725
1615
1500
1400
1311
1235
1168
1105
1050
1000
955
913
840
778
676
600
540
488
446
412
382
358
333
1725
1625
1518
1420
1339
1285
1198
1137
1082
1032
990
910
843
734
650
585
530
485
447
414
386
361
1725
1634
1530
1440
1362
1290
1225
1167
1113
1065
980
907
789
700
630
570
522
480
445
415
389
1725
1640
1543
1460
1382
1312
1250
1192
1140
1050
973
845
750
675
610
560
515
477
445
416
1725
1650
1558
1473
1400
1333
1270
1217
1120
1039
902
800
720
652
596
549
509
475
445
1725
1652
1568
1487
1417
1350
1290
1190
1102
959
850
765
692
634
584
540
505
473
1725
1660
1575
1500
1430
1370
1260
1168
1016
900
810
733
671
618
573
534
500
1725
1662
1581
1510
1450
1330
1231
1072
950
855
774
708
652
605
564
528
1725
1646
1575
1509
1393
1294
1132
1006
906
823
755
697
647
604
566
1725
1650
1581
1460
1355
1186
1054
949
863
791
730
678
633
593
1725
1653
1526
1417
1240
1102
992
902
827
763
708
661
620
6-1/2
10
11
12
1725
1592
1500
1312
1166
1050
954
875
807
750
700
656
1725
1602
1421
1263
1137
1034
947
875
813
758
711
1725
1509
1342
1208
1098
1006
929
863
805
755
1725
1533
1380
1255
1150
1062
986
920
863
1725
1553
1411
1294
1194
1109
1035
970
1725
1568
1438
1327
1232
1150
1078
1725
1581
1460
1355
1265
1186
1725
1592
1479
1380
1294
13
14
1725
1602 1725
1495 1610
1402 1509`
Motor
Pulley
Diameter
Pump
Pulley
Diameter
Where:
L=
C=
D=
d=
SELECTING REMAINING
COMPONENTS
(D - d)2
4C
WATER
FLOW
GAL/MIN
0.5
1
2
3
4
5
6
8
10
15
20
25
40
60
1/4
16
54
180
380
5/16
5
20
60
120
220
320
3/8
2
7
25
50
90
130
220
300
1/2
2
6
13
24
34
52
80
120
250
5/8
2
4
7
10
16
25
38
80
121
200
410
3/4
2
3
4
7
10
14
30
50
76
162
370
1
2
3
7
12
19
42
93
INSTALLING YOUR
COMPONENTS
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 other
electrical components. Never allow a water spray or 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.
PROBLEM
Pulsation
TROUBLESHOOTING
CAUSE
REMEDY
Worn nozzle.
Belt slippage.
Cracked plunger.
Bad bearing.
Valve stuck open or shut, or not opening enough. Replace bad valve.
Scored, damaged or worn plunger.
Replace plungers.
Inlet suction strainer clogged or improperly sized. Clean. Use adequate size. Check more frequently.
Fouled or dirty inlet or discharge valves.
Abrasive material in the fluid being pumped. Install proper filtration on pump inlet plumbing.
Overpressure of pump.
Reduce pressure.
SERVICING YOUR
PUMP
1. Remove
the
fasteners
retaining
the
head.
10
piston
screw
and
11
8
PACKING ASSEMBLY
Head Ring
Restop
Ring
Low
Pressure
Seal
O-ring
High
Pressure
Seal
Intermediate
Ring
Packing
Retainer
10
General Pump
is a member of
the Interpump Group