INSTALLATION OPERATION SERVICE MANUAL
Contents
1. GE Pressure Washer System GENERAL PUMP ne IN LLATION OP ERATION S ERVIGE MA UR Of TENCO Et ee A sio TARA I L 1 CH O P MCL TABLE OF CONTENTS MOC Lee ata 2 Selecting Remaining Components 6 7 Typical Operation amp Requirements 2 Upstream or Inlet Side ST 2 Components 6 FIN 2 Downstream or Outlet Side Designing Your System 3 5 Components 6 7 Pump Selection EN 3 Installing Your Components 7 8 Motor Engine Selection 3 Troubleshooting 0000 eee 9 Determining Spray Tip Size 5 Servicing YourPump 10 11 Drive System ssi 5 6 Valve Assemblies 10 PUIGYSEIECHON ani 5 Removing Manifold Head 10 Belt Selection WE 6 Replacing Plungers 11 Replacing Packings 11 INTRODUCTION mumm 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 repaired2. Phone 651 686 2199 e Fax 800 535 1745 e mail sales gpcompanies com e www generalpump com GENERAL PUMP
3. automotive carburetor to draw a chemical into the water stream A downstream injector requires low pressure to ac tivate chemical flow Low pressure is achieved by chang ing to a large sized spray tip or opening up a large orifice at the outlet end of the spray gun using an adjustable noz zle 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 comples and add more potential personal injury and property damage hazards Design of these systems requires many more additional components as well as experienced de sign personnel with knowledge of fuels heat transfers electronics etc TYPICAL PRESSURE WASHER SYSTEM SPRAY ON WAND SPRAY TIP C amp HIGH K UNLOADER OR PRESSURE PRESSURE ES REGULATOR VALVE RELIEF VALVE HOSE Si PULSATION DAMPENER PRESSURE GAUGE PUMP CHEMICAL is INJECTOR L fil g NIE RIS cells ES i INLET A DESIGNING Y
4. models 2 To service any valve remove valve cap and extract valve assembly 3 Examine o rings and replace if there is any evidence of cuts abrasions or distortion 4 Remove valve assembly retainer spring valve valve seat from valve cavity 5 Remove o ring from valve cavity 6 Only one valve kit is necessary to repair all the valves in the pump The kit included new o rings valve seat poppet spring and retainer all pre assembled 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 t 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 assemblies may come off with the head At this point examine plungers Plunger surfaces should be smooth and free from scoring or pitting if not replace 4 Reinstall manifold head and torque to specifications per sequence described below TORQUE SEQUENCE FOR TIGHTENING HEAD Figure 4 Install all head bolts fingertight Torque to 10 foot pounds in sequence as shown then retorque to specifications again in sequence shown 10 REPLACING PLUNGERS Figure 3 5 amp 6 1 Remove stainless steel piston screw and plunger from piston rod 2 If slinger washer co
5. 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 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 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 There are three common methods of driving or connecting the pump and motor engine Direct drive and gear reductions 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 PULLEY SELECTION There are many types 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 se
6. or operated in an unsafe manner or in a manner which is not consistent with the manufacturer s recommendations or requirements There are many manufacturers of pressure washer pumps and complementary components Be sure that the required components you choose to use are consistent with the high quality standards of GENERAL PUMP pumps GENERAL PUMP does not assume liability or responsibility for the design of a customer s high pressure system TYPICAL OPERATION AND REQUIREMENTS mmm 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 The pump which is driven by an electric motor or a gas engine draws or accepts filtered water in through a se ries 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 volu
7. oso eso eso om oe oo ae oe oe oe oe oe re wee ss so ao ow om om oo oe far e oe oe oe oo res e v0 ave eso om am ow ss ve oo ve oe or oo oe a e ro ae ee eso eso as ove ss ve ae so se on fe ro as o fas fed sso aro eso am ow oe a oe se 60 os e re e ere 0 ie ame 200 ovo sso om ao ve so se oe re 8 oo res om oso am 200 om am ow as ve os oo fo ve 00 os Pe ere so ae a so om om am as oo ss oe ni ve oe oo res om oso ow ae om am ow ss oe oe oe ve oe oo oe ro oso o ae eso sso ome am om oo se or re 00 ar 08 00 Cra oer a ae see eo 00 so sen oo oe ve ee os oe na 0 re om 20 ven sso oe eso om re ez a2 oe ao e oo a see eso a0 see rio ra seo ome 100 vom ea na oo a e m0 ae nei so ero re oso eo eo oe se wean so ara mo moo EEN eo tee eo ose 01 isan seo 680 000 2000 oven sso mee een sea oe 00 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 Spray tip size is a very important factor
8. OUR SYSTEM PUMP SELECTION The heart of any pressure washer system is the high pressure pump Size the pump according to your clean ing 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 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 THERMAL I RELIEF VALVE FLUID rie HOSE GH 6 BI uay POWER B di MOTOR ENGINE 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 manufacturer s specifications ELECTRIC MOTOR HORSEPOWER REQUIRED TO DRIVE A PUMP COCO DITO DOES DIE 14 18 20 EEE Ce EEE NEE IEEE EZRA e e oo om re ime ae a oe ee e ae ome ae om om ae e e re e EC o e san sso 260 ss s0 ss ie 0 a ae ase a se S Te e re e ow ow es re aa a e 20 ave azo sa eso o
9. 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 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 abrasive into your pressure washer system or warranties will be void and components in the system will be damaged Protect the pump and system from a freezing condition TROUBLESHOOTING GENERAL PUMP GENERAL PUMP PROBLEM CAUSE REMEDY Pulsation Check all valves remove foreign matter Check precharge if low rechargeit or install a new one Replace nozzle of proper size Tighten or replace use correct belt Disassemble reseal and reassemble Clean adjust relief valve check for worn and dirty improperly adjusted valve seat worn valve seats Kit available Low pressure Clean Use adequate size Check more frequently Worn packing Abrasives in pumped fluid Install proper filter Suction at inlet manifold
10. ction 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 GUIDE To Transmit 2 Belts 2 Belts Double i Double HORSEPOWER Groove Groove Pulley e e A ME DT e eq e ae ss SE RNA II IC SE NC fr To determine pump pulley size based on a 1725 RPM motor find the motor pulley size on the chart below follow the column down until 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 PUMP PULLEY GUIDE 1725 RPM Motor Pump Pulley MOTOR PULLEY OUTSIDE DIAMETER inches Outside Diameter inches 3 1 4 3 1 2 3 4 1 2 4 3 4 5 1 4 5 1 2 5 3 4 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 A Pulley A Pulley Ration 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
11. me of water whether the spray gun is open or closed therefore a device is needed to control the di rection 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 un loader 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 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 pump s 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 compo nents An upstream injector does allow chemicals to be ap plied 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
12. mes off with plunger be certain 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 REPLACING V PACKINGS Figure 7 8 9 amp 10 1 Remove manifold from crankcase 2 Insert proper extractor collet through main seal retainer Tighten collet and extract retainers v packings and head rings 3 Place proper insertion tool in cylinder and install front head ring v packing and long life ring and press firmly into cylinder until they will go no further using proper insertion tool 4 Insert intermediate seal retainer pressing it firmly into cylinder 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 PACKING ASSEMBLY Low Head Ring nang Gd O ring HI High lie Pal Pressure pe late i ing Seal ing etainer General Pump era is a member of ze the Interpump Group ce GENERAL PUMP 1174 Northland Drive e Mendota Heights MN 55120
13. must be limited or severe cavitation Inadequate water to lifting less than 20 feet of water or 8 5 PSI vacuum Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies Worn inlet discharge valve blocked or dirty l Replace worn 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 Pump runs extremely rough pressure very low Inlet restrictions and or air leaks Stuck Replace worn cup or cups clean out foreign material inlet or discharge valve replace worn valves Water leakage from under Worn packing Install new packing manifold Slight leakage Cracked plunger Replace plunger s Oil leak between crankcase Worn crankcase piston rod seals O rings Replace crankcase piston rod seals Replace and pumping section on plunger retainer worn O rings Worn crankshaft seal or inproperly Remove oil seal retainer and replace damaged Oil leaking in the area of installed oil seal o ring o ring and or seals crankshaft Replace bearing and any spacer or cover damaged Bad bearing by heat Excessive play in the end of Worn main bearing from excessive Replace crankcase bearing and or the crankshaft pulley tension on drive belt tension drive belt May be caused by humid air condensing Change oil intervals Use General Pump SAE 30 nto water inside the crankcase non detergent oil Water in cra
14. n all plumbing connections and tighten all connections securely to avoid air entering the system Avoid using hosed which are secured with hose clamps 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 re duction 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 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 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 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 combina tion
15. nkcase Worn packing and or piston rod sleeve Replace packing Replace o rings O rings on plunger retainer worn Cracked plunger Replace plunger s Oil leaking from underside Worn crankcase piston rod seals Replace seals of crankcase Scored piston rod Replace piston rod Oil leaking at the rear portion Damaged crankcase rear cover o ring Replace cover or ring drain plug o ring or sight of the crankcase drain plug o ring or sight glass o ring glass o ring Pulley loose on crankshaft Check key and tighten screw Loud knocking noise in pump Broken or worn bearing on rod s Replace bearing or rod s Valve stuck open or shut or not opening enough Replace bad valve Scored damaged or worn plunger Replace plungers Overpressure to inlet manifold Reduce inlet pressure Abrasive material in the fluid being pumped Install proper filtration on pump inlet plumbing Frequent or premature failure Excessive pressure and or temperature Check pressures and fluid inlet temperature be of the packing of fluid being pumped sure they are within specified range Overpressure of pump Reduce pressure Running pump dry Do not run pump without water Upstream chemical injection Use downstream chemical injection 9 SERVICING YOUR PUMP emm VALVE ASSEMBLIES Figure 1 1 All inlet and discharge valves can be serviced without disrupting the inlet or discharge plumbing The inlet and discharge valves are identical in all
16. oo rome sso e se sso sso rae ooo wu oa eso ae sso rm ea ra sos 256 sso sso ve re ome 0 rose om sso s ro san 080 se00 seo NOTES 1 Agasoline 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 a CECR ERR st om o oa ERR ZEEN 10 50 12 60 14 70 16 80 18 58 21 00 ro E NI iN CO CO NI N FS N CO NI oO N 00 Wu NI Wu N 88 PS 1 05 7 ER RS CR RR RR RR SS SOSS RS RS RES KR RS RS A 1 23 1 47 on 1 40 1 68 1 55 1 86 o O 1 75 2 10 O 00 N LS If you wish to direct drive your pump from an electric Check with your motor supplier for technicla motor you may want to use a C face motor information SPRAY TIP SELECTION CHART Tip Orifice Dia OUTPUT VOLUME GPM AT VARIOUS PRESSURES PSI are GRIT ATVARIOUSPRESRURESPS ists Tamara Psi Tono rs ws PS 100 ao Pa Paso rao rai no Paso POD Pa fm a e o n o e fe fe fe oe oe oe ie oo a ese eo fe ae ae oe om ow oe ae es ee Poe ee ao as os 6 ri ve eso ro vm om oe ee ee oe oe oe fe oe Pe pes fs fre om see om ae om es oe oe se oe fe oe oo es oe or vee
17. perature 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 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 increased amp draws with and electric motor Use a thread sealant o
18. pulleys were sized for Use the following formula to calculate belt length LAY L 2c 1 57 D d Sidi Where L Effective outside length of belt s in inches C Distance between centers of pulleys in inches D Outside diameter of pump pulley in inches d Outside diameter of motor engine in inches Always install a safety cover or guard over belt and pulleys to avoid serious bodily injury or property damage SELECTING REMAINING COMPONENTS mmm 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 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 repai
19. ross 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 HOSE FRICTION LOSS PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES HOSE INSIDE DIAMETERS INCHES 16 5 2 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 tem
20. rs Upstream Injector A device which uses the pumps ability to draw or suck fluid to introduce a cleaning chemical into the water stream This type 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 pump operation Back Flow Preventer When using cleaning chemicals care must be taken to avoid these chemicals fom 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 re quirements 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 safet
21. y 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 e Liquid filled to absorb the pressure fluctuations in the system e 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 ac
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