OPERATION MANUAL
Bareshaft Pump
ii
Visual Safety System
Bareshaft Pump
iii
This manual is copyrighted with all rights reserved. Under copyright laws, this manual may not be copied
in whole or in part or reproduced in any other media without the express written permission of Jetstream
of Houston, LLP or its authorized agent. Permitted copies must carry the same proprietary and copyright
notices as were afxed to the original. Under the law, copying includes translations, whole or in part, into
another language.
Every reasonable effort has been made to ensure that the data given in this document is accurate, however,
the information, gures, illustrations, tables, specications, and schematics contained herein are subject to
change without notice. Jetstream
® reserves the right to change any term, condition or process represented
in this document without notice and at Jetstream’s sole discretion.
©2018 Jetstream of Houston, LLP.
Published in USA
P/N 65179
Revision F
Jetstream of Houston, LLP
5905 Thomas Road, Houston, TX 77041
(832) 590-1300 • (800) 231-8192
www.waterblast.com
Jetstream® is a registered trademark of Federal Signal Corp.
Operation Manual
iv
WARRANTY
Limited Warranty - Each Waterblast Unit, Bareshaft Pump, and Fluid End manufactured by Jetstream is warranted against de-
fects in material and workmanship for a period of 12 months or 1,000 hours, provided it is used in a normal and reasonable manner and in accordance with all operating instructions. If sold to an end user, the applicable warranty period commences from the
date of delivery to the end user. If used for rental purposes, the applicable warranty period commences from the date of delivery to
the party holding the equipment available for rent. This limited warranty may be enforced by any subsequent transferee during the
warranty period. This limited warranty is the sole and exclusive warranty given by Jetstream.
Exclusive Remedy - Should any warranted product fail during the warranty period, Jetstream will cause to be repaired or
replaced, as Jetstream may elect, any part or parts of such Waterblast Unit, Bareshaft Pump, or Fluid End that the examination
discloses in Jetstream’s sole judgment to be defective in material or factory workmanship. Repairs or replacements are to be
made at Jetstream in Houston, Jetstream FS Solutions Rental Center, the customer’s location, or at other locations approved by
Jetstream. Labor is furnished only when the unit or part is returned to the factory or when travel and expenses are paid by the
purchaser. Freight, travel and expenses incurred in connection with repair or warranty are excluded from this warranty
and shall be paid by the purchaser. The foregoing remedies shall be the sole and exclusive remedies of any party making a
valid warranty claim.
The Jetstream Limited Warranty shall NOT apply to (and Jetstream shall NOT be responsible for):
1. Major components or trade accessories that have a separate warranty from their original manufacturer, such as, but not
limited to: diesel engines, electric motors, electronic soft starter and/or across the line starter panels, axles, PTO’s, clutch
packs, high pressure gauges, high pressure hoses, ex lances, etc.
2. Normal adjustments and maintenance services.
3. Normal wear parts such as, but not limited to: oil, clutches, belts, lters, packing, cartridges, univalves, face seals, diffusers,
gland nut bushings, plungers, nozzles, rupture disks, etc.
4. Failures resulting from the machine being operated in a manner or for a purpose not recommended by Jetstream including
failures or malfunctions resulting from corrosion, misapplication, overpressurization, inadequate pump suction conditions,
improper water quality, improper maintenance, or misuse.
5. Repairs, modications or alterations which in Jetstream’s sole judgment, have adversely affected the machine’s stability,
operation or reliability as originally designed and manufactured.
6. Items subject to misuse, negligence, accident or improper maintenance.
NOTE - The use of any part other than those approved by Jetstream may invalidate this warranty. Jetstream reserves the right
to determine, at its sole discretion, if the use of non-approved parts invalidates the warranty. Nothing contained in this warranty
shall make Jetstream liable for loss, injury, or damage of any kind to any person or entity resulting from any defect or failure in
the machine or part.
THIS WARRANTY IS, AND SHALL BE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
WITHOUT LIMITATION, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE,
ALL OF WHICH ARE DISCLAIMED. THIS DISCLAIMER AND EXCLUSION SHALL APPLY EVEN IF ANY WARRANTY
POSSIBLY ASSERTED FAILS OF ITS ESSENTIAL PURPOSE.
This warranty is in lieu of all other obligations or liabilities, contractual and otherwise, on the part of Jetstream. For the avoid-
ance of doubt, Jetstream shall not be liable for any indirect, special, incidental or consequential damages, including,
but not limited to, loss of use or lost prots. Jetstream makes no representation that the unit has the capacity to perform any
functions other than as contained in Jetstream’s written literature, catalogs or specications accompanying delivery of the machine. No person or afliated company representative is authorized to alter the terms
of this warranty, to give any other warranties or to assume any other liability on behalf
of Jetstream in connection with the sale, servicing or repair of any machine manufactured by Jetstream. Any legal action based hereon must be commenced within
eighteen (18) months of the event or facts giving rise to such action.
Jetstream reserves the right to make design changes or improvements in its products
without imposing any obligation upon itself to change or improve previously manufactured products.
5905 Thomas Rd.
Houston, TX 77041
800-231-8192
832-590-1300
Bareshaft Pump
v
Table of Contents
Visual Safety System .......................................................................................................................................................ii
WATERBLAST SAFETY
....................................................................................................................................................... 1
Recognizing Safety Information.......................................................................................................................................1
Understanding Signal Words
......................................................................................................................................1
Waterblast Safety Manual
...............................................................................................................................................1
General Safety Precautions.............................................................................................................................................2
Read Instructions
.......................................................................................................................................................2
Inspect Equipment......................................................................................................................................................2
Check Pressure Ratings.............................................................................................................................................2
Rupture Discs
.............................................................................................................................................................2
Check Connections
....................................................................................................................................................2
Tighten Connections
..................................................................................................................................................2
Use Two Operators
....................................................................................................................................................2
Purge the System
.......................................................................................................................................................3
Test the System
..........................................................................................................................................................3
Slowly Increase Pressure
...........................................................................................................................................3
Use the Minimum Pressure Required
........................................................................................................................3
Be Prepared
...............................................................................................................................................................3
Performing Maintenance or Repairs...........................................................................................................................3
Freezing Conditions
...................................................................................................................................................3
Store Components Properly
.......................................................................................................................................3
COMPONENT IDENTIFICATION
......................................................................................................................................... 5
UN
x Pump ..................................................................................................................................................................5
Manifold
......................................................................................................................................................................5
Manifold Drain Valve
..................................................................................................................................................5
Water Lubrication System
..........................................................................................................................................5
Pressure Gauge
.........................................................................................................................................................5
Rupture Discs
.............................................................................................................................................................6
Bypass Valve
..............................................................................................................................................................6
Regulator Valve (Not Shown)
.....................................................................................................................................6
Discharge Fitting
........................................................................................................................................................6
Supply Couplings
.......................................................................................................................................................7
Secondary Filter (40K Units)
......................................................................................................................................7
Fluid End Identification
...............................................................................................................................................7
Jetstream 3000/3600/4200
Bareshaft Pump Installation
Guidelines........................................................................................................................................................................8
Models
........................................................................................................................................................................8
Water Supply
..............................................................................................................................................................8
Pulsation.....................................................................................................................................................................8
Lubrication
..................................................................................................................................................................8
Jetstream 6000
Bareshaft Pump Installation Guidelines...........................................................................................................................9
Water Supply
..............................................................................................................................................................9
Lubrication
..................................................................................................................................................................9
Technical Notes
.............................................................................................................................................................10
Operation Manual
vi
OPERATION ....................................................................................................................................................................... 11
Recommended Equipment
............................................................................................................................................ 11
Hose and Water Supply Requirements
.........................................................................................................................11
Start-up Preparation
......................................................................................................................................................12
Flushing the System
......................................................................................................................................................13
Checking the Water Lubrication System
.......................................................................................................................14
Raising System Pressure
..............................................................................................................................................15
Breaking in New Packing...............................................................................................................................................16
Monitoring Weep Holes
.................................................................................................................................................17
MAINTENANCE
.................................................................................................................................................................. 19
Daily
...............................................................................................................................................................................19
50 Hours
...................................................................................................................................................................19
100 Hours
.................................................................................................................................................................19
500 Hours
.................................................................................................................................................................19
1000 Hours
...............................................................................................................................................................19
Winterizing The Pump
...................................................................................................................................................20
WATER
................................................................................................................................................................................ 21
Water Quality Requirements
.........................................................................................................................................21
Fluid Compatibility with
Jetstream Pumps...........................................................................................................................................................21
Secondary Filter (40k Operation Only)
..........................................................................................................................22
Filter Cartridge Replacement
...................................................................................................................................23
Switch Adjustment
...................................................................................................................................................23
Uni-Valve Life
...........................................................................................................................................................23
PRESSURE CONVERSION
............................................................................................................................................... 25
Converting a Pump
........................................................................................................................................................25
40K Hose Connections ............................................................................................................................................32
SERVICE
............................................................................................................................................................................ 33
Fluid End
.......................................................................................................................................................................33
Checking Manifold Bolt Torque
.................................................................................................................................33
Rupture Disc Inspection
...........................................................................................................................................34
Packing Replacement
..............................................................................................................................................34
Uni-Valve Service
.....................................................................................................................................................40
40K Face Seal Replacement....................................................................................................................................41
15K, 20K Uni-Valve Service
.....................................................................................................................................43
40K Uni-Valve Service
..............................................................................................................................................47
Bypass Valve Cartridge Replacement
......................................................................................................................51
Power End
.....................................................................................................................................................................52
Checking Power End Oil Level
.................................................................................................................................52
Changing the Power End Oil
....................................................................................................................................53
Crosshead Pony Rod Seals
.....................................................................................................................................54
Rod Journal Bearings
...............................................................................................................................................57
Crosshead and Connecting Rod Assembly
..............................................................................................................61
UNx Pump
................................................................................................................................................................63
Crankshaft
...............................................................................................................................................................65
Bareshaft Pump
vii
TROUBLESHOOTING ........................................................................................................................................................ 69
TRAINING
........................................................................................................................................................................... 71
Safety Training...............................................................................................................................................................71
New Start-up Training
....................................................................................................................................................71
FS Solutions Training
....................................................................................................................................................71
Additional Training Opportunities...................................................................................................................................71
INDEX
............................................................................................................................................................................IND-1
Operation Manual
viii
Bareshaft Pump
1
WATERBLAST SAFETY
Recognizing Safety Information
One of Jetstream’s ongoing endeavors is to minimize or elminate the risk of injury to the product
user. Jetstream has taken every effort to alert the
user to potential safety risks through the use of cautionary statements within the operator manual and
safety decals on its products. Be sure to take the
time to identify and understand these notications
wherever they may be.
Always follow recommended precautions and safe
operating practices.
Understanding Signal Words
This is the safety-alert symbol. When you see
this symbol on your unit or in this manual, be alert
to the potential for personal injury. The safety-alert
symbol is often used in conjunction with signal
words.
A signal word – DANGER, WARNING, or CAUTION –
is
used with the safety-alert symbol. DANGER identies
the most serious hazards.
This symbol and these signal words appear on the
unit and in this manual. Read and understand the
following denitions of the signal words before operating or working on the unit.
Danger is used to indicate the presence of a hazard
which WILL cause severe physical injury or death if
proper precautions are not taken.
Warning is used to indicate the presence of a hazard
which MAY cause serious physical injury or death,
and can result in serious property damange if proper
precautions are not taken.
Caution is used to indicate the presence of a hazard
which MAY cause some physical injury or property
damage if proper precautions are not taken.
Attention indicates installation, operation, or maintenance information which is important but is not
considered a hazard.
!
DANGER
!
WARNING
!
!
CAUTION
ATTENTION
Waterblast Safety Manual
A safety manual is shipped with each
unit. It provides guidelines and instructions for maintaining a safe work environment while using and maintaining waterblast equipment.
All operators and maintenance person-
nel should read and understand the content of this
manual to help maintain a safe work environment.
Contact Jetstream for additional copies of the safety
manual.
ATTENTION
The Waterblast safety manual should be kept
with the unit at all times
Operation Manual
2
General Safety Precautions
Read Instructions
Read and follow all the manufacturer’s instructions prior
to using any
waterblast product. Contact the manu-
facturer if unsure of any details.
Further instructions for safe operation are located
in the Jetstream Safety Manual. Read this manual
before operating the equipment.
Inspect Equipment
Inspect the condition of all components prior to use.
Do not use any item that is in suspect condition. If
unsure about the condition of a component, ask a
supervisor or maintenance personnel for instructions. Use only components that are marked with a
recommended operating pressure. Never exceed the
operating pressure of the weakest component in the
system.
Check Pressure Ratings
All components in the
system must be properly
rated for the intended
operating pressure. Refer to
the Safety Manual for more
information on pressure
ratings.
Rupture Discs
Installation of two rupture discs is necessary to protect the pump and operators.
• Rupture disc ratings: one at 120% of operating
pressure, one at 140% of operating pressure
Check Connections
Check the condition of the connection threads prior
to making any high pressure connection. For 15,000
psi (1000 bar) and lower pressures use at least four
wraps of Teon tape on male pipe (NPT) threads for
sealing purposes. Do not allow any tape to overlap
the end of the tting. Tape fragments may enter the
system’s water stream and clog the nozzle’s orices.
Apply a coat of anti-seize compound over the Teon
sealant to prevent “galling” or seizing of threads.
For “Jetstream® 20K”; “type M”; “MP (20K)” and “HP
(40K)” connections use anti-seize compound on the
threads and the male cone.
Tighten Connections
Properly tighten all high pressure connections.
Hand-tighten pipe (NPT) ttings and then tighten
with a wrench another 1-1/2 to 2 full revolutions. Do
not exceed two revolutions on NPT threaded connections. \
Use caution when using a pipe wrench. Pipe
wrenches can cause deep scoring leading to weakened components.
Refer to the Technical sections in the 15K, 20K and
40K catalogs or at the following web page for more
information and torque specications for the various
ttings used on these units.
http://www.waterblast.com/Service_and_Support/
Resources/Download_Literature.aspx
Use Two Operators
Use at least two operators when waterblasting. The
primary operator handling the cleaning device must
maintain control of the water discharge at all times.
The secondary operator controlling the waterblast
unit must be positioned a safe distance of at least 12
ft. (3.7 m) from the blast operation.
Bareshaft Pump
3
Purge the System
Before attaching a nozzle to the control gun or tube
cleaning lance, operate the pump at low speed to
purge dirt and debris from the system. Dirt and
debris can clog nozzle orice(s) and cause excessive system pressures.
Test the System
With the nozzle installed, operate the pump at low
speed (low pressure) to test the system. Should
system repairs or adjustments be necessary, stop
the pump and relieve all pressure before performing
any required repairs or adjustments.
Slowly Increase Pressure
Visually inspect all ttings for leaks at 1000 psi (69
bar), and then again once the system reaches full
pressure. Do not use your hand to nd leaks. If leaks
are evident, turn the system off and relieve the pres-
sure. Remove the leaking tting, clean and inspect.
If the tting looks undamaged, re-install the tting.
If the leak persists, the tting must be replaced.
Leaking ttings can cause tting damage and very
dangerous injection wounds.
With the system operating properly, slowly increase
pump speed until operating pressure is reached.
Use the Minimum Pressure Required
Do not exceed the operating pressure of the system’s lowest pressure-rated component. Use of lower pressure-rated components in a system should
be avoided if possible. Components with a lower
pressure rating can be overlooked and explode if
vigilance is not maintained. Keep equipment pressure rating and warning tags intact.
Be Prepared
If equipment malfunctions or a malfunction is suspected, immediately stop the cleaning activity and relieve
the pressure in the system before attempting any repair. Always follow manufacturer’s repair instructions.
Performing Maintenance or Repairs
Because of the hazards involved with water blasting,
maintenance or repairs may only be performed by
service personnel that are properly trained to maintain this equipment. Training is available through
Jetstream® and can be requested from the Jetstream
website (www.waterblast.com) or FS Solutions rental
centers.
Following repairs or maintenance, operate the system at low pressure to test the system. Adjust the
pressure slowly during operation.
Freezing Conditions
After shutting down in freezing conditions, even for
brief periods, drain the water from all components.
Prior to starting the equipment after a freeze, the
operation of all equipment components must be
checked carefully to ensure they are not frozen, or
cracked, and are still in safe operating condition.
Refer to”Winterizing the Pump” on page 19” for
details.
Store Components Properly
Properly store components to protect from damage
when not in use. Ensure all warning tags and markers remain intact for the next usage.
Operation Manual
4
Bareshaft Pump
5
COMPONENT IDENTIFICATION
Before operating the unit it is necessary to fully understand each component and how it functions. Following is a
brief description of the unit’s main components.
UNx Pump
The UNx pump uses the power from the engine
to pressurize the source water into high pressure
output. The pump is separated into two sections, the
power end and the uid end.
The power end contains the components that drive
the pump. It is also referred to as the “crank end”
because it contains a crankshaft.
The uid end contains the components that determine
the output pressure of the pump. The operator may
change the output pressure and ow of the pump
by changing the components in the uid end. The
uid end is also referred to as the “wet” end as this is
where the water travels in and out of the pump.
Refer to the pressure specic catalogs (15K, 20K
and 40K) for detailed exploded views and component part numbers for the uid and power ends. The
catalogs are available at the following website:
http://www.waterblast.com/Service_and_Support/Resources/Download_Literature.aspx
Manifold
The manifold houses many of the components that
make up the uid end of the pump including the
uni-valves. The three uni-valves each consist of
a suction and discharge valve combined into one
assembly. The valves convert low pressure water to
high pressure water.
Manifold Drain Valve
The manifold drain valve allows the manifold to be
ushed of contaminants prior to pump usage. It is
also used to purge air during operation start up.
Water Lubrication System
The water lubrication system provides water to the
packing in the pump. The water lubricates and cools
for optimum operation of the pump. The system
includes a manifold and three water lines. Needle
valves are present on manifolds that are pressure
fed (all 40K units). The needle valves control the
amount of ow to each stufng box and must be
properly adjusted during operation. Manifolds that
are not pressure fed have a xed ow.
Pressure Gauge
The liquid lled pressure gauge allows the operator
controlling the pump to monitor the pressure of the
system.
Figure 1: Bareshaft Pump.
Operation Manual
6
Rupture Discs
Two rupture discs are used in the system. The rupture discs provide protection from excess pressure
in the system. If system pressure were to exceed the
rated pressure of the discs, the discs would burst.
If a disc bursts, water will ow through the ruptured
disc to provide relief for the system and protect
components from excess pressure. Check the discs
before operating the pump. Keep a supply of rupture
discs on hand for use. If a rupture disc should burst,
there is no way to build pressure until the disc is
replaced. Use only genuine Jetstream rupture discs
properly rated for the intended operating pressure.
Bypass Valve
The bypass valve controls the pump pressure by
bleeding off excess water and diffusing it to low pressure. Turning the knob allows the operator to adjust
pressure during operation and relieve pressure when
not waterblasting.
The bypass valve controls pressure by allowing
water to bypass though the valve. A discharge hose
is attached to the bypass valve. The hose extends
to the other side of the unit where it is attached to a
drain elbow. Water that bypasses the valve will drain
from the bypass drain throughout operation.
The proper use of the bypass valve is to install the
correct size nozzle in the system so that the bypass
valve can be closed during operation. A combination
of plunger size, engine rpm, and nozzle will allow the
bypass valve to close at almost all ow rates.
Note: For pumps employing a shut in
system, a regulator valve is substituted
for a bypass valve.
Regulator Valve (Not Shown)
For shut-in systems (where no low pressure water
dumps from the gun), the bypass valve is replaced
with a regulator valve. The regulator maintains
constant system pressure when operating one or
more shut-in devices. When a gun or other device
is disengaged, the regulator automatically adjusts
to shift the excess ow to a low pressure outlet
while maintaining system pressure. Because shutin systems maintain constant system pressure, the
hydro-throttle does not function in these applications.
Discharge Fitting
The discharge tting allows the connection of a
high pressure hose. High pressure water exits from
this tting. On 15K manifolds, a quick disconnect is
recommended to prevent galling of pipe threads and
damage to the manifold.
Pressure Gauge
Hydro-Throttle
Switch
Water
Lubrication
System
Manifold Drain Valve
Manifold
Rupture Discs
Figure 2: Pump Components.
Bareshaft Pump
7
Supply Couplings
The supply couplings provide a quick method for
attaching the supply hose to the manifold.
Secondary Filter (40K Units)
A secondary lter (Figure 4) is mounted on top of the
pump for use when operating at “40K”. The lter is
not connected during 15K or 20K operation.
A pressure gauge is mounted on the lter to monitor
pressure in the lter.
A differential pressure switch is mounted in the lter
circuit to monitor proper ow through the lter. If the
lter becomes plugged and ow is insufcient, the
switch will cause the engine to shut off. “Emergency
Stop” will be displayed on the control panel.
A drain valve is located on the lter cover that allows
the operator to purge air from the lter at startup.
Fluid End Identication
A plate (Figure 5) is attached to all uid end manifolds. The plate is stamped with the uid end model
number. In addition, the plate is stamped with plunger size and output pressure related to that plunger
size. Refer to this plate before operating the pump.
Discharge Fitting
Supply
Couplings
Bypass Valve
Figure 3: Pump Components (Continued).
Figure 4: Secondary Filter.
Rating Plate
Figure 5: Fluid End Rating Plate.
Operation Manual
8
Jetstream 3000/3600/4200
Bareshaft Pump Installation
Guidelines
Models
The Jetstream UNx bareshaft pump is available in
three horsepower ranges and three pressure ranges
– 15,000 psi, 20,000 psi, or 40,000 psi and can be
supplied with an optional geardrive. The geardrive is
available in four different gear ratios to support diesel engine or electric motor input speeds. Both styles
can be supplied left hand drive or right hand drive
(as viewed from FE) and the geardrive model’s input
shaft can also be clocked to five different locations.
The geardrive unit requires inline drive with flexible
coupling***. The standard unit can be inline or belt
driven via pulleys exerting a side load on the crankshaft. All Jetstream powerends have a preferred
rotation direction (top of crankshaft towards the fluid
end) that is marked on the casting. However reverse
rotation operation is allowed with the addition of
optional reverse rotation oil scrapers. The geardrive
requires a clockwise input rotation direction.
3000 series 150 hp max 600 rpm max
3600 series 175 hp max 550 rpm max
4200 series 325 hp max 518 rpm max
Water Supply
The 15K and 20K versions can be gravity fed (water
level 3’ minimum above the manifold suction inlet).
The 40K version requires 40 psi minimum supply
pressure at full pump speed to operate. All fluid ends
have a maximum inlet supply pressure of 75 psi.****
The supply water should be clean and cold. The
maximum allowed inlet water temperature is 125°F.
Ideally the water should be filtered to 25 micron (3
micron for 40K) and 40-80°F for maximum packing
life. Severly reduced packing life will be encountered
with warmer water. The inlet supply hose should be
3” ID if gravity fed and 2” ID if pressure fed. Jet-
stream recommends oilfield suction hose as it has
proven to be durable with a relatively small bend
radius. The hose should be as short and straight as
possible with no additional fittings (elbows) - especially important with gravity fed setup. If bends are
required it is best to bend the hose without the use
of elbows.
The plunger packing is lubricated with the supply
water and is not adjustable on normal gravity fed
15K/20K systems. On 40K and pressure fed systems, the lube harness needs to be equipped with
needle valves to allow adjustment of the lube water
flow. The cooling water should exit the rear of the
gland nuts with a steady stream (more than a drip)
but not enough to be splashed onto the pony rod
during operation.
Pulsation
Positive displacement pumps create pulsation in
the high pressure discharge line. For this reason,
it is extremely important to utilize flexible hoses
(ie rubber, thermoplastic) in lieu of rigid piping to
minimize water hammer and vibration. If rigid piping
is necessary, it should not be installed at the pump
discharge. A 25’ or 50’ section of hose should be
installed at the pump discharge. This length can be
coiled and hung for space savings. A high pressure
pulsation damper may be beneficial in some cases.
Short on/off cycles at high pressure will create the
largest spikes of pressure and require care to dampen. Flow controls or other means to slow the abrupt
change of pressure will smooth these pulsations.
Lubrication
The powerend is lubricated via 80W90 gear oil (non
detergent only) in the sump of the housing. The
journal bearings, crossheads, and connecting rod
bushings are supplied oil via gravity from a collection
trough above the crossheads. The powerend has a
level requirement to ensure oil lubricates the crankshaft tapered roller bearings and stays in contact
with the crankshaft. Front to back level specification
is 7° and side to side level is 10°. Both a low oil level
shutdown and a high oil temperature shutdown are
available as options.
The powerend oil has a recommended maximum
temperature of 190°F and can be comfortably run
in most environments. Extremely hot or cold environments (i.e. Middle East, Canada) may require oil
cooler or synthetic oil. Contact Jetstream Engineering for assistance.
Bareshaft Pump
9
Jetstream 6000
Bareshaft Pump Installation
Guidelines
All of the previous requirements are the same for
6000 except as noted below:
The 6000 powerend is internally geared and requires
inline drive with flexible coupling ***. It is available in
four different gear ratios to support diesel engine or
electric motor input speeds. It can be supplied left or
right hand drive but must be driven with input shaft
rotating top towards rear (i.e. LH requires CCW and
RH requires CW at input shaft).
6000 series 600 hp max 457 rpm max
Water Supply
The 6000 pump cannot be gravity fed and requires
40-50 psi suction water pressure at full pump speed
to operate. As such it is supplied with lube water flow
control valves mounted on the suction manifold. All
fluid ends have a maximum inlet supply pressure of
75 psi.****
Lubrication
The powerend is lubricated with 12 gallons of ISO
320 gear oil. Only the following brands are allowed:
• Aral Motanol HP 320
• Mobil DTE. Oil AA 320
• BP Energol CS 320
• Shell Vitrea 320
• Castrol Alpha ZN 320
• Valvoline IRF 320
• Dea Oursa OEL P 320
• Elf Polytelis 320
• Esso Nuto 320
The 6000 powerend is equipped with an oil temperature shutdown gauge and the maximum allowed oil
temperature is 190°F (normal range is 160-170°F).
An integrated oil cooler (dual loop) is located inside
the powerend sump and uses 3-5 gpm (15-20 lpm)
of suction water to cool the oil. The warm water
outlet of this cooler will need to be plumbed back
into the cold water supply tank or routed to an appropriate drain. The oil is pumped via external oil pump
through external filter and routed inside powerend to
critical points. It is supplied with an oil pressure shutdown gauge and requires 30 psi minimum (normal
operating range is 60-70 psi). The filter should be
changed every 500 hours.
Operation Manual
10
Technical Notes
*** Driver selection and coupling selection requires
engineering analysis of torsional loads and vibrations (TVA). Jetstream can supply the mass- elastic
data for the pump but it is customer’s responsibility to perform TVA of the system. Coupling failure,
engine damage, and powerend damage can result
from incorrect coupling selection.
****All pumps have a minimum inlet pressure necessary to prevent cavitation.
Additionally, Jetstream (and many other) pumps
have a maximum allowable inlet pressure. Excessive
inlet pressure will not affect the operation or life of
the fluid end, but can negatively affect the power
end.
The connecting rods are equipped with plain bearings where they contact the crankshaft. These bearings require lubrication to survive. When the crankshaft rotates and pulls the crosshead backwards
through the suction stroke, the force between the
connecting rod journal bearing and the crankshaft
decreases greatly. This reduction in force and the
rotation of the crankshaft causes oil to be drawn into
the small space between the connecting rod journal
bearing and the crankshaft. As there is no oil pump
in the 3000/3600/4200 series, this is the only mechanism that lubricates the journal bearings.
High pressure on the plungers during the suction
stroke can prevent oil from being drawn into the
space between the connecting rod journal bearing and the crankshaft. The lack of lubrication can
cause journal bearings to fail in only a few hours.
This problem is worse with large plungers, high inlet
pressure, and low speeds.
Following Jetstream’s maximum allowable fluid end
inlet pressure of 75 psi and minimum pump speeds
of 200 rpm for the 3000, 183 rpm for the 3600, 173
rpm for the 4200, and 100 rpm for the 6000 series
will prevent this type of failure.
Bareshaft Pump
11
OPERATION
Recommended Equipment
Jetstream equips the waterblast units with the components they recommend for safe operation. Those
components include:
• Pressure Gauge
• Two Rupture Disc Assemblies
• Bypass Valve or Regulator Valve
• Discharge Quick Disconnect Coupling.
ATTENTION
Installation of two rupture discs is required by
Jetstream for warranty coverage on this pump.
One rupture disc must be rated at 120% of the
uid end stamped pressure rating. The other
disc must be rated at 140% of the uid end
stamped pressure rating.
Keep a supply of rupture discs on hand for operation at different pressures and for replacement
in the event of a rupture.
WARNING
!
Do not operate the engine without water in the
system. Damage to the charge pump will occur.
ATTENTION
A quick disconnect coupling is an important
means of protecting the manifold from wear at
the high pressure discharge hose connection
port. If the internal threads on the manifold
become worn or damaged the cost to repair
them is far greater than replacing a coupling.
The manifold would need to be shipped back
to Jetstream for repair or replacement.
Hose and Water Supply
Requirements
– The water supply hose inside diameter must
be large enough to supply 150% of the unit’s
maximum ow requirements.
– The inside diameter of the high pressure
discharge hose will be determined by the
necessary length of hose and the amount of
ow passing through the hose length. Contact
your Jetstream representative for proper hose
sizing.
– Supply pressure must be no greater than 150
psi (10.3 bar) into the waer tank. If pressure
exceeds 150 psi (10.3 bar), install a pressure
regulator large enough to meet ow requirements. Regulators are available from Jetstream.
– Water temperature 125°F maximum.
Operation Manual
12
Start-up Preparation
1. Inspect the lter bags. Inspect the secondary
lter cartridge if operating at 40K.
2. Check the tightness of the gland nuts on each
stufng box.
3. Inspect all equipment. Ensure that every piece
of equipment in the pressure circuit is properly
rated for the intended operating pressure. Replace any component that is not properly rated.
4. Connect the supply hose and verify the drain
valve is closed.
5. Open the water supply valve and allow the tank
to ll. Any valves between the water tank and
the pump must be open.
6. Install the discharge hose onto the tting on the
manifold along with a hose safety check.
7. Open the bypass valve by turning the knob
fully counter-clockwise until the O-ring is visible
(where the knob enters the valve body) or four
full turns counter-clockwise from the closed
position. This allows the engine to start without
a load from the pump.
WARNING
!
Anytime the system has been opened, the
system must be purged.
When the high pressure hose is rst connected
to the unit or when extra hose lengths are added
to the hose string, the hose must be purged of all
dirt and debris. Do not connect the control gun or
tool to the high pressure hose until the hose has
been purged of dirt and debris with water ow
from the pump. Failure to purge debris inside
a hose may result in clogging of the cleaning
nozzle and excess pressure in the system.
Bareshaft Pump
13
Flushing the System
With the engine at idle, warming to operating tem-
perature, ush the system of any debris. Flushing the
system prevents any debris from clogging the cleaning nozzles and valves which will cause excessive
pressure in the system. Nozzles must be removed
from all equipment during ushing.
1. If operating at 40K, rst open the bleed valve
(“Figure 6: Secondary Filter Bleed Valve.” on
page 13) and allow any air to purge from the
secondary lter. Once a steady ow of water
exits the lter, close the valve.
2. Open the manifold drain valve. Allow water to
drain from the valve for approximately 5-10
seconds. (“Figure 7: Flushing the Manifold.” on
page 13).
3. Hold the discharge hose stationary (Figure 8).
4. With the manifold free of debris, the engine at nor-
mal operating temperature (160°F (71°C) - 185°F
(85°C)) and at idle speed, engage the clutch.
5. Turn the bypass valve clockwise just enough
to obtain a generous ow of water through the
discharge hose. Allow the hose to ush for
about 30 seconds.
Note: A substantial amount of thrust may occur
at the discharge end while ushing.
6. Decrease ow to the hose by fully opening
(counter-clockwise) the bypass valve. Some
water will continue to ow from the hose.
7. With the engine at idle speed, shift the trans-
mission to Neutral.
8. Connect the control gun (or other equipment
being used) to the discharge hose.
9. With the hose secure and equipment controlled
by another operator, engage the clutch.
10. Turn the bypass valve clockwise to increase
ow through the discharge device(s). Allow the
control gun to ush for about 30 seconds.
11. Reduce the discharge ow by fully opening the
bypass valve.
12. With the engine at idle speed, disengage the
clutch.
WARNING
!
Two operators are required to ush the
discharge hose and equipment. One operator
must be stationed at the unit and the other at
the discharge device.
13. The nozzles can now be installed on the discharge device(s).
14. Before waterblasting, adjust the lubrication line
needle valves, if equipped. Refer to “Checknig
the Water Lubrication System” on page 14 .
Figure 8: Flushing the Discharge Hose.
Figure 6: Secondary Filter Bleed Valve.
Bleed
Valve
Figure 7: Flushing the Manifold.
Drain
valve
Operation Manual
14
Lubrication Line Stuffing Box
Figure 9: Checking Lubrication.
Lubrication
Line
Needle Valve
Figure 10: Needle Valve Adjustment (40K).
Checking the Water Lubrication System
1. Lift the rod box cover to view the water lubrication system.
2. Look into the rod box and verify that lubrication
water is owing from the small holes in the bottom of the gland nut wrench holes. (Figure 9).
3. Next, check the stufng box temperature by
very carefully placing your nger tips on the top
of the stufng box. The temperature should be
cool to warm but still cool enough that you can
keep your ngers on it for 10 seconds.
If there is no water ow, or the temperature is
too hot, or if steam is visible, the needle valves
need to be adjusted.
4. Adjust the needle valves (Figure 10) to in-
crease the water ow. The water should not
overow the top-most hole. If it does, excessive
splashing will occur, which could cause water
to be drawn into the power end, contaminating
the oil. Adjust the needle valves to prevent
excessive lubrication water ow. Re-check
the lubrication water ow periodically during
operation.
5. Once properly adjusted, system pressure can
be raised for waterblasting.
WARNING
!
There are moving parts inside the rod box that
can cause serious injury. Use extreme caution. Keep all tools out of the rod box while the
pump is running.
Bareshaft Pump
15
Raising System Pressure
WARNING
!
Before building pressure, contain the high
pressure discharge hose. Failure to contain and
control the high pressure water can result in
death or serious injury. The water is considered
“contained” if it is allowed to discharge from the
system through a “manned” control gun or a
“manned” lance inserted in a tube. Control guns
can produce a tremendous amount of reverse
thrust based on ow and pressure.
Discharge must be in an enclosed space
where no one can get injected and the end of
the hose is restrained from moving.
Never use open lengths of high pressure hose
for anything but purging at low pump speed.
Install whip checks at all hose connections.
!
CAUTION
When operating in cold temperatures, allow
ample time for the pump oil to warm before
raising system pressure.
ATTENTION
If new packing was installed or if operating the
pump for the rst time, the pump packing must
be broken in properly. Refer to “Breaking In
New Packing” for instructions.
ATTENTION
Always blast with the bypass valve fully
closed. This will ensure the most efcient operation with all water being utilized. If less water
volume is required, reduce the engine rpm to
control the ow amount. If bypassing ow is
necessary, the bypass valve cartridge and the
bypass valve diffuser will wear and these parts
may need replacing regularly. Bypassing water
also wastes water and wastes fuel as this is
lost horsepower.
WARNING
!
Do not operate the pump under a load at en-
gine speeds below 1400 rpm. This will lug the
engine and cause excessive vibration leading
to engine damage and cracked brackets,
guards and ttings.
Operation Manual
16
Breaking in New Packing
1. Adjust the engine speed to 1400 rpm.
2. Adjust the discharge pressure to 3,000 psi (200
bar) by slowly closing the bypass valve (all
dump valves closed).
3. When the coolant temperature reaches 120°F
(49°C), increase engine speed to 2100 rpm.
4. Continue to bring the discharge pressure up
to full operating pressure in about three equal
steps while operating 1 minute for each step.
Check the lubrication water and carefully feel
the stufng boxes for excess temperatures.
Stufng boxes and gland nuts should only be
slightly warm to the touch when the pump is
running at the rated operating pressure. Hot
stufng boxes and gland nuts may be caused
by insufcient water lubrication or tight tting
packing. If insufcient lubrication water ow
cannot be corrected by readjusting the needle
valves, stop the pump and correct the problem.
ATTENTION
This procedure is only applicable for 15K and
20K molded packing. It is not required for
plastic packing.
New packing must be broken in to prevent
damage and ensure optimal performance.
Break-in should occur in three to four pressure
increases over a 5 minute period.
Bareshaft Pump
17
Monitoring Weep Holes
Weep holes are manufactured into the manifold to alert
the operator when seals have failed. If a seal fails, the
water will leak from its associated leakage hole.
There are two types of weep holes, the high pressure
face seal weep holes that are rectangular slots (Figure
11) and the low pressure uni-valve seal weep holes
that are round. There are three of each type located
along the top of the manifold.
If water is leaking from one of the rectangular weep
holes, the seal that seals the uni-valve to the stufng
box has failed. On 15K and 20K manifolds, the O-ring
(Figure 13) on the valve makes that seal. On 40K
manifolds, there is no O-ring on the valve to seal the
manifold. The stufng box contains a face seal to seal
this connection.
If water is leaking from the round weep holes (Figure
11), the outer O-rings (Figure 13) on the valves have
failed.
Note: The larger O-ring will leak to the rect-
angular weep hole.
Monitor the manifold for leakage during operation. If
leakage occurs, immediately replace all of the seals on
the leaking valve.
Inspect the valve seats during seal replacement and
lap the valves if necessary. Refer to “Valve Lapping”
for instructions.
Monitor the manifold for leakage during operation. If
leakage occurs, immediately replace all of the seals
on the leaking valve.
ATTENTION
On 20K manifolds, the rectangular weep holes
also communicates with the top pressure ports.
If water is observed at the rectangular weep
holes, rst check the corresponding 20K port
connection. The 20K seal pill may need reposi-
tioning or replacing.
WARNING
!
If leaks are allowed to continue, expensive damage to the valves or manifold block could occur.
Figure 13: Outer O-rings.
O-rings
Figure 12: Uni-valve to Stufng Box Seals.
15K, 20K 40K
Leak Path
O-Ring
Face Seal
Uni-valve
weep hole
Face Seal weep hole
Figure 11: Weep Holes
Operation Manual
18
Bareshaft Pump
19
MAINTENANCE
Daily
1. Check Power End Oil Level - Add oil as
necessary. Refer to “Checking Power End Oil
Level” on page 52 for instructions.
2. Check Gland Nut Torque - Ensure the gland
nuts are properly tightened for operation.
Refer to “Checking Gland Nut Torque” on page
33 for instructions.
3. Adjust Water Lubrication System - Ensure
the water is properly adjusted on pressure fed
manifolds equipped with needle valves. Refer
to “Checking the Water Lubrication System” on
page 14.
4. Inspect Rupture Discs - Ensure the rupture
discs are installed and inspect for damage.
Refer to “Rupture Disc Inspection” on page
34. Verify extra replacement discs are on
hand in case of a rupture.
50 Hours
1. Uni-Valve Inspection - Inspect the seals for
damage and the valve seats for deposits, jetting or other damage. Refer to “Valve Inspection” on page 50 .
2. Inspect Pump Breather - Remove the breather and inspect for dirt and debris. Clean or
replace as necessary.
100 Hours
1. Initial Power End Oil Change - After the rst
100 hours of operation on a new unit, change
the power end oil. Refer to “Changing the
Power End Oil” on page 53.
2. Initial Stufng Box Lubrication Check - Re-
move stufng boxes, clean powerframe bore,
lubricate with anti-seize or petroleum jelly, and
replace stufng boxes.
500 Hours
1. Regular Power End Oil Change - Change
the power end oil. Refer to “Changing the
Power End Oil” on page 53.
2. Regular Stufng Box Lubrication Check
- Remove stufng boxes, clean powerframe
bore, lubricate with anti-seize or petroleum
jelly, and replace stufng boxes.
1000 Hours
1. Journal Bearing Inspection - Replace as
necessary.
Operation Manual
20
Winterizing The Pump
Severe damage can result if the waterblast unit is
not protected from freezing conditions. The stufng
boxes hold water that can freeze, causing damage
to the stufng boxes, uni-valves, plungers and manifold. To prevent freezing, drain the water from all
hoses, charge pump and tanks, and add anti-freeze
to the stufng boxes.
If the unit is to be idle for any period of time that
would allow freezing in the pump or piping, utilize the
following procedure:
1. Drain the water from the tank.
2. Disconnect the water supply suction line and
high pressure discharge hose from the manifold.
3. Drain the manifold of water and close the drain.
4. Assemble pipe ttings into a funnel assembly
as shown in (Figure 14).
5. Install the assembly on the suction side of the
manifold.
6. Pour a glycol based anti-freeze solution into
the funnel (Figure 15). Approximately 0.5 gal.
(2 L) of anti-freeze is required.
7. Before starting the engine, check the area in
the path of the discharge tting on the manifold. Ensure the area is clear. Anti-freeze will
be discharged from the discharge tting during
this procedure.
8. Start the engine.
9. With the engine idling, gently feather the
clutch by applying light pressure to the clutch
handle in the engagement direction. Watch
the plungers move back and forth slowly until
anti-freeze is discharged from the manifold
port as shown in (Figure 16).
10. Once anti-freeze has been discharged from
the discharge port, disengage the clutch and
shut off the engine.
11. Remove the funnel assembly from the suction
port and reconnect the suction hose.
12. Disconnect the water lubrication lines from the
stufng boxes and drain the lines.
Funnel
Assembly
Figure 14: Funnel Assembly Installation.
Figure 15: Adding Anti-Freeze.
Figure 16: Draining the Anti-Freeze.
Bareshaft Pump
21
WATER
Water Quality Requirements
The quality of water that is supplied to your Jetstream pump can have a direct impact on performance. Items like dissolved solids and pH values out
of the allowable range can, either by themselves, or
together with other properties of the water, lead to
premature failure (such as cracking) of pump components and related accessories.
Suspended gasses (tiny bubbles) in the water can
also lead to premature component failure. These
gases can sometimes be detected visually by inspecting the water in the inlet tank for tiny bubbles or
a milky appearance.
As part of the installation and or operating procedures of this pump, an expert that specializes in
water quality must perform a water quality test. If
your water is found to exceed any of the allowable
measurements in the chart below, consult a special-
ist in water purication and conditioning.
Recommended water quality levels:
Substance
Maximum Allowed
(mg/L)
Silica 1.0
Calcium 0.5
Magnesium 0.5
Iron 0.1
Manganese 0.1
Chloride 5.0
Sulfate 25.0
Nitrate 25.0
Carbon Dioxide 0
Total Dissolved Solids 50.0
pH 6.8 – 7.5
Specic Conductivity 50 micro-mhos/cm
Note: Boiler water additives with either
ammonia or amines are not allowed.
Note: If water that has been treated by either
reverse osmosis or deionization is to
be used in your pump, it is important
that it does not have a total dissolved
solids (TDS) reading of less than 0.5
ppm. Water with a TDS reading of 0.5
ppm or less has been known to attack
carbide components such as plungers
and back-up rings.
Fluid Compatibility with
Jetstream Pumps
Jetstream pumps are designed and built primarily for pumping water at various pressure ratings.
Jetstream does not have a compatible fluids list at
this time. The use of any fluids other than water void
warranty.
There are special considerations for seawater ap-
plications. Please consult the factory for a specic
application.
There are instances where fluids besides water to be
pumped are considered for use in Jetstream pumps.
Jetstream does not approve the suitability of their
pumps for use with any other fluid besides water, for
the following primary reasons:
• Safety and Environmental: Water leakages in
the high pressure system, pump, waste water,
bypass water, etc., are normally quite easily contained (if necessary) and/or produce zero-risk to
low-risk situations.
• Corrosion Resistant Pump Components: The
stainless steel components in the fluid handling
portion of the Jetstream pump offer good corrosion resistance to water.
• Operational Characteristics: The plunger sealing elements are designed to be compatible with
and exhibit long operational lifetimes when using
clean cold water. Other fluids can signicantly
shorten the life of the packing material through
any number of failure mechanisms, including
chemical reactions or dissolving the packing
material, or offering inadequate lubrication to the
packing. High temperature water is also problematic, as the packing can only tolerate approximately 125°F water. At elevated temperatures
the packing life decreases substantially.
Suggestion: To understand the effects of a fluid on
pump internals and fluid conductors, it is suggested
to put a univalve part, an o-ring from the valve, a
packing set and a piece of high pressure hose into a
jar of this fluid and observe the effect over time.
Operation Manual
22
Secondary Filter (40k Operation Only)
The secondary lter, or polishing lter, is used for
40K operation only. When operating at 40K, monitor
the lter pressure gauge (Figure 17) for an indication
of lter condition. During normal operation, the
pressure gauge should be within the 30 to 40 psi (2
to 2.75 bar) range. When differential pressure inside
the lter housing between the clean side and the
dirty side drops approximately 7 to 10 psi (0.48 to
0.69 bar), the pressure switch on the lter housing
will trip and the engine will shut off to protect the unit
from damage. Replace the dirty lter cartridge if this
occurs.
ATTENTION
Extended operation with a dirty lter will lead
to lter failure and allow debris to reach the
valves, causing damage to the valves.
It is important to know the condition of your
lter cartridge. Standard units come with a
pressure gauge on the lter. In order to monitor the condition of the lter it is important to
note the engine operating speed and housing
pressure when the lter is rst changed. Refer
to “Filter Cartridge Replacement” on page
23 for more information.
Figure 17: Secondary Filter Assembly.
Pressure Gauge
Pressure Switch
Bareshaft Pump
23
Filter Cartridge Replacement
1. Relieve pressure from the housing using the
bleed valve then loosen the three eye-nuts
(Figure 18) on the lter cover.
2. Slowly open the cover and capture the spring
(Figure 19) and spring keeper.
3. Remove the lter cartridge.
4. Install the new lter cartridge onto the guide
rod. Ensure the guide rod is correctly seated
into the bottom of the housing.
5. Inspect the O-ring and install a new one if
necessary.
6. Place the spring keeper and spring into place
on the end of the lter cartridge.
7. Move the lter cover into position and tighten
the eye-nuts.
8. Prepare the pump for operation and start the
unit. Start a typical blast operation and record
the following:
• Engine rpm
• Gauge pressure on the secondary lter
9. Save this record for monitoring the status
of the secondary lter. Monitor the pressure
gauge as more hours of operation are ac-
cumulated on the lter cartridge. When the
pressure on the lter gauge has dropped ap-
proximately 7 to 10 psi (0.48 to 0.69 bar) (with
the unit operating at the same rpm as earlier
recorded), the lter must be replaced.
Switch Adjustment
The differential pressure switch will shut down the
unit when the pressure drop across the lter is
approximately 7 to 10 psi (0.48 to 0.69 bar). If the
switch doesn’t close within the 7 to 10 psi (0.48 to
0.69 bar) range, it may need to be adjusted. Contact
Jetstream for switch adjustment instructions.
Uni-Valve Life
The uni-valve seats can be damaged by dirty water.
It is important to change lters regularly to improve
pump performance and prolong valve life. (Nozzles
and bypass cartridges are also adversely affected by
dirty water).
Inspect uni-valve seats regularly to monitor condition
and lap the valve seats when necessary. Refer to
“Valve Lapping” on page 50 for lapping instructions.
Figure 18: Filter Cover.
Eye Nut
Bleed Valve
Eye Nuts
Cover
Figure 19: Cartridge Removal.
Spring
Keeper
Filter
O-Ring
Operation Manual
24
Bareshaft Pump
25
PRESSURE CONVERSION
The versatility of the Jetstream waterblast pump
allows operators to modify the pump to change to
different operating pressure ranges when necessary.
There are three ranges of pressure usually referred
to as 15K, 20K, and 40K. These are abbreviated
names to easily denote the maximum operating
pressure.
• The 15K uid end can operate up to 15,000 psi
(1034 bar).
• The 20K uid end can operate up to 20,000 psi
(1379 bar).
• The 40K uid end can operate up to 40,000 psi
(2758 bar).
When converting a uid end to a different pressure,
it is necessary to exchange the stufng boxes and
manifold with the proper components for the new
operating pressure.
Converting a Pump
Use the following procedure to convert a pump to a
different pressure.
1. Relieve pressure from the pump, shut off the
engine, and disengage the clutch.
2. Turn off the water supply, drain the water tank.
3. Remove the two bolts that secure the hydro-throttle switch aluminum housing (Figure
20) to the brass cartridge in the manifold.
Remove the switch and housing and set aside.
4. Disconnect the bypass drain hose and the
supply coupling from the manifold (Figure 21).
5. Open the rod box cover and disconnect the
lubrication lines from the stufng box ttings
(Figure 22).
WARNING
!
When switching to higher operating pressures, it
is necessary that all equipment be properly pressure rated. Refer to the Jetstream Safety Manual
for specic guidelines for hoses, ttings, etc.
Hydro-Throttle
Switch
Figure 20: Hydro-Throttle Switch.
Bypass Hose
Supply Coupling
Figure 21: Line Removal.
Cover
Lubrication
Lines
Figure 22: Disconnecting Lubrication Lines.
Operation Manual
26
6. Remove the cotter pin (Figure 23) from the
hinge rod and remove the rod.
7. Remove the top manifold bolts (Figure 24) at
each corner.
Note: The pump wrench can be used with a
hammer to remove the manifold bolts.
8. Install manifold mounting studs (Figure 25)
into the two open holes to allow for easier
installation of the new manifold.
Note: Manifold mounting studs can be pur-
chased from Jetstream.
4200 / 3600 - p/n 54261
3000 - p/n 56742
9. Continue removing the remaining manifold
bolts.
Manifold
Bolts
Figure 24: Manifold Bolt Removal.
Manifold
Mounting Studs
Figure 25: Manifold Mounting Stud Installation.
Figure 23: Hinge Rod, Trunnions, and Cotter Pin.
Hinge Rod
Cotter Pin
Trunnions
Bareshaft Pump
27
10. Once all of the bolts are removed, lift the
manifold off the pump (Figure 26).
Note: The weight of the manifold is approxi-
mately:
• 3000 Series: 90 lb. (41 kg)
• 3600/4200 Series: 165 lb. (75 kg)
11. Remove the water lubrication tting (Figure
27) from each stufng box.
12. Remove the two bolts that secure each plunger coupling (Figure 28) to the plungers and
remove the three couplings.
Note: The coupling halves are matched and
must be kept together.
!
CAUTION
Use two people to lift the manifold. The manifold is heavy and failure to use two people may
cause serious injury.
Figure 26: Manifold Removal.
Figure 27: Lubrication Fittings.
Lubrication Fitting
Stuffing Box
Figure 28: Plunger Coupling Removal.
Plunger
Plunger Coupling
Operation Manual
28
13. Pull each stufng box from the pump case
(Figure 29).
14. Clean the stufng box bore thoroughly and
apply petroleum jelly or Anti-Seize to the
bores.
15. Install the new stufng boxes into the pump
case. Orient the stufng boxes so the at face
on the outer diameter matches the at face in
each case bore.
16. Extend the plunger from each stufng box until
it mates with the opposing crosshead pony
rods. Install the plunger coupling (Figure 30)
on each plunger and secure with the two bolts.
Tighten the bolts to 20 ft.-lb.(27 N·m).
17. Ensure the gland nuts are tight. Use the pump
wrench and a 5 lb. (2 kg) hammer to tighten
the gland nuts to approximately 250 ft.-lb.(338
N·m) (Figure 31). Hit the wrench about three
times using moderate power. This should sup-
ply sufcient torque on the nut.
ATTENTION
Apply petroleum jelly or Anti-Seize to each
stufng box bore when installing stufng boxes
to help prevent corrosion and extend pump life.
Figure 29: Stufng Box Removal.
Figure 30: Plunger Coupling Installation.
Plunger Coupling
Figure 31: Tightening the Gland Nuts.
Bareshaft Pump
29
18. Apply Teon tape to the threads of the lubrica-
tion line ttings (Figure 32). Install the ttings
onto the stufng boxes.
19. Apply a light coating of petroleum jelly or
Anti-Seize to the mounting face of the power
end. This will greatly reduce the buildup of
corrosion.
20. Lift the new manifold onto the manifold
mounting studs (Figure 33).
21. Install and adjust the trunnion rod as follows:
Manifold Trunnion Adjustment
The trunnions in the manifold must be adjusted
such that the hinge rod supports the manifold to
allow the capscrews to be screwed in or out by
hand. The manifold holes need to be centered over
the tapped holes in the powerframe (or adapter
plate). This conguration will put the hinge rod in
a substantial bind and it will be bent down slightly
at the ends since it will be supporting the weight of
the manifold block. This centered position of the
manifold will also ensure proper operation of the
valves and seals at all pressures.
a. Remove two manifold bolts and install two
manifold mounting studs. Remove remaining
manifold bolts.
4200 / 3600 - p/n 54261
3000 - p/n 56742
b. Slide the manifold away from the powerframe
(or adapter plate) a few inches (Figure 34,
A). This will allow room to adjust the threaded
trunnions in the bottom of the manifold.
c. Screw both manifold trunnions (Figure 34, B)
in completely and then back them out approximately 2-1/2 turns. Slide the manifold back
against the powerframe (or adapter plate).
!
CAUTION
Use two people to lift the manifold. The manifold is heavy and failure to use two people may
cause serious injury.
Lubrication Fitting
Stuffing Box
Figure 32: Lubrication Line Fittings.
Figure 33: Lift the New Manifold onto the Mounting Studs.
Manifold
Mounting Studs
Figure 34: Manifold in Adjustment Position.
A
B
Operation Manual
30
d. To install the hinge rod (Figure 35), it will be
necessary to either lift the manifold or use a
screwdriver to ex the rod while simultaneously tapping the end with a hammer to get
the rod through the second set of trunnions.
Check for correct alignment and free rotation
of the manifold bolts.
e. Repeat as necessary making half turn adjust-
ments to both trunnions up or down until the
manifold bolts thread in and out easily.
22. Install the manifold bolts (Figure 36) in the
open holes and hand-tighten.
23. Remove the manifold mounting studs (Figure
36).
24. Install the remaining two bolts. Tighten all of
the bolts in a crisscross sequence (Figure 37).
Proper torque is 350 ft.-lb. (470 N·m).
!
CAUTION
Use two people to lift the manifold. The manifold is heavy and failure to use two people may
cause serious injury.
Figure 35: Hinge Rod Installation.
Figure 36: New Manifold Installation.
Mounting Studs
Manifold Bolt
Figure 37: Tightening Sequence.
Bareshaft Pump
31
25. Connect the water lubrication lines (Figure 38)
to the ttings on the stufng boxes.
26. Connect the supply coupling (Figure 39) and
the bypass hose to the manifold.
27. Place the hydro-throttle switch and housing
(Figure 40) into position and install the two
bolts that secure it.
28. Verify all connections, glands and bolts were
properly tightened.
29. Ensure the water lubrication system is properly adjusted, if equipped, before waterblasting. Refer to “Checking the Water Lubrication
System” on page 14 for instructions.
30. If new packing was installed, break in the
packing as outlined in “Breaking in New Packing” on page 16.
ATTENTION
If converting to a 40K uid end, the secondary
lter must be plumbed for operation. Refer to
“40K Hose Connections”.
When converting to 40K, a charge pump is required to force the water through the second-
ary lter. If the 40K manifold is not pressurized,
the univalves will be damaged. If your unit is
not equipped with a charge pump, it cannot be
converted to a 40K uid end. Units equipped
with a charge pump are plumbed so that the
charge pump feeds the manifold at all times
with the clutch engaged. The charge pump is
belt driven by the PTO.
Cover
Lubrication
Lines
Figure 38: Connecting the Water Lubrication Lines.
Figure 40: Hydro-Throttle Switch and Housing Installation.
Hydro-Throttle
Switch
Figure 39: Connecting Bypass Hose and Supply Coupling.
Bypass Hose
Supply Coupling
Operation Manual
32
40K Hose Connections
1. Remove the supply hose (Figure 41) (supply
from charge pump) from the suction elbow
tting on the 15K/20K manifold.
2. Install the 40K manifold as outlined earlier in
this chapter.
3. Remove the plug from the lter outlet hose
(Figure 42). Connect the hose to the elbow on
the 40K manifold.
4. Remove the cap from the secondary lter inlet
coupling (Figure 43).
5. Install the charge pump supply hose on the
secondary lter inlet coupling.
!
CAUTION
When ushing the system before operation,
purge the secondary lter of air. Failure to do so
could cause pump cavitation and damage. Use
the bleed valve (Figure 43) on the lter to purge
the air from the lter.
Bleed Valve
Figure 43: Secondary Filter Bleed Valve.
Figure 41: Supply Hose from Charge Pump.
Elbow
Supply from
Charge Pump
Figure 42: Plumbing.
Elbow
Filter Outlet
Hose
Supply from
Charge Pump
Secondary
Filter
Filter Inlet
Bareshaft Pump
33
SERVICE
Fluid End
Checking Manifold Bolt Torque
Verify the head bolts are properly tightened. Check
the bolt torque in a crisscross sequence starting with
the center bolts (Figure 44). Proper torque is 350
ft.-lb. (470 N·m) which can be achieved with a few
hammer strikes on the pump wrench.
Checking Gland Nut Torque
1. Open the rod box cover.
2. Place the long end of the pump wrench in one
of the gland nut holes.
3. Use a 5 lb. (2 kg) hammer to hit the wrench in
the direction to tighten the gland nuts. Hit the
wrench about three times using moderate force.
This will supply sufcient torque on the nut.
4. Repeat for the remaining nuts.
5. Close the rod box cover.
ATTENTION
It is helpful to mark gland nuts once they are
conrmed to be operating correctly. A permanent marker can be used to mark a line across
the top of the gland nut and stufng box. This
will allow easy visual conrmation that the
gland nuts are properly torqued.
Figure 44: Tightening Sequence.
Figure 45: Tightening the Gland Nut.
Operation Manual
34
Rupture Disc Inspection
1. Use an adjustable wrench to remove the cap
(Figure 46) from the rupture disc assembly.
2. Remove the rupture disc from the base and
inspect.
3. Verify a disc is installed and has not been
damaged. Replace as necessary.
4. Install the upper housing back onto the assembly.
5. Repeat for the remaining rupture disc.
Packing Replacement
Removal
1. Relieve pressure from the pump, shut off the
engine and disengage the clutch.
2. Turn off the water supply and drain the water
tank.
3. Open the rod box cover.
4. Disconnect the water lubrication lines, if
equipped.
5. Position the plunger to be serviced so that it is
at bottom dead center (pony rod is fully
retracted towards crankshaft). Pull the drive
belts to rotate the pump (Figure 48)
ATTENTION
Installation of rupture discs with a burst
pressure no greater than 1.4 times the working
pressure is required by Jetstream for warranty
coverage on this pump.
WARNING
!
Use caution when rotating the pump as this
can be a pinch hazard.
Figure 47: Disc Removal.
Rupture Disc
Figure 46: Housing/Cap Removal (15K Manifold Shown).
Cap
Figure 48: Rotating the Belt Drive.
Bareshaft Pump
35
6. Insert the rounded end of the pump wrench
(Figure 49) into one of the holes in the gland
nut and tap the top of the wrench sharply with a
heavy hammer to loosen. When loose, unscrew
the gland nut from the stufng box by hand.
7. Remove the two bolts that secure the plunger coupling (Figure 50) to the plunger and
remove the coupling. Push the plunger into the
stufng box for clearance.
8. Remove the gland nut and plunger from the
stufng box. It may require effort to wiggle the
packing out by moving the plunger from side
to side and up and down.
9. Remove the packing set (Figure 51).
Figure 49: Loosening the Gland Nut.
Figure 50: Plunger Coupling Removal.
Plunger Coupling
Plunger
Figure 51: Packing Removal.
Plunger
Packing Set
Gland Nut
Operation Manual
36
10. Remove the plunger and guide bushing (Figure 52) from the gland nut and inspect.
Note: The guide bushing may be stuck and
require some force to remove. Use a
tool in the cutout (Figure 53) to push
the bushing out. Use caution to avoid
damaging the gland nut.
Figure 52: Guide Bushing Removal (15K/20K Gland Nuts).
Guide
Bushing
O-Ring
Figure 53: Stuck Bushing.
Guide
Bushing
Cutout
Bareshaft Pump
37
Note: On 40K uid ends, the brass sleeve
(Figure 54) inside the stufng box does
not need to be removed unless the
plunger shows evidence of rubbing on
the sleeve.
11. Remove the O-ring (Figure 56) from the gland
nut.
12. Repeat the previous steps for the remaining
stufng boxes if packing is to be replaced.
Inspection
1. Inspect the plunger for scratched or deep
scores. Discard damaged plungers.
2. On 40K units, measure the diameter of the
guide bushing (Figure 56, A). If the diameter
exceeds the Dimension A specication listed in
the “40K Guide Bushing Replacement Table”
below, replace the bushing. If the bushing
shows scoring or if the edge is chipped, replace the bushing.
40K Guide Bushing Replacement Diameter
Fluid End Plunger Size Dimension A
3040 # 5 0.533 in. (13.54 mm)
3640 # 6 0.603 in. (15.32 mm)
4240 # 7 0.673 in. (17.09 mm)
4240 # 8 0.733 in. (18.62 mm)
1
2
3
4
5
6
7
1. Plunger
2. Gland Nut
3. O-Ring
4. Guide Bushing
5. Packing
6. Stufng Box
7. Uni-Valve
Figure 54: 40K Fluid End (Some Components Not Shown).
Figure 56: Guide Bushing Check (40K Only).
This side into
gland nut
A
Figure 55: 15K/20K Fluid End (Some Components Not Shown).
1
8
7
6
5
4
3
2
1. Plunger
2. Gland Nut
3. Guide Bushing
4. Packing
5.
6. Stufng Box
7. Face Seal
8. Uni-Valve
Brass Sleeve w/ O-ring
Operation Manual
38
Installation
1. Install a new O-ring (Figure 56) onto the gland
nut.
2. Install the guide bushing (Figure 57) and
plunger into the gland nut.
3. Place the new packing and guide bushing onto
the plunger. Orient the packing as shown in
(Figure 54) for 15K/20K and (Figure 55) for
40K.
4. Lubricate the gland nut with anti-seize compound. Apply the compound to the threads
and on the small face that contacts the inside
of the stufng box (Figure 58). Place the assembly into the stufng box. Hand-tighten the
gland.
Figure 58: Applying Anti-Seize.
Figure 57: Guide Bushing Installation.
Guide
Bushing
O-Ring
Anti-Seize
Anti-Seize
Bareshaft Pump
39
Figure 59: Gland Installation.
Plunger Coupling
Plunger
Figure 60: Plunger Coupling Installation.
Figure 61: Tightening the Gland.
5. Pull the plunger (Figure 59) back to meet the
crosshead pony rod. If the packing is too tight
to move the plunger by hand, the pump can be
rotated by hand (via the belts) to move the pony
rod to meet the plunger.
6. Place the plunger coupling into position and
install the coupling bolts (Figure 60). Tighten
the bolts to 20 ft.-lb.(27 N·m).
7. Use the pump wrench and a 5 lb. (2 kg) hammer to tighten the gland nuts to approximately
250 ft.-lb.(338 N·m). Hit the wrench about
three times using moderate force (Figure 61).
This will supply sufcient torque on the nut.
8. Repeat the previous steps for the remaining
stufng boxes.
9. Connect the water lubrication lines and close
the rod box cover.
10. It is necessary to break-in new packing properly to ensure optimal performance and a proper
seal. Refer to “Breaking in New Packing” on
page 16 for the proper break-in procedure.
Operation Manual
40
Uni-Valve Service
Removal
1. Relieve pressure from the pump, shut off the
engine, and disengage the clutch.
2. Turn off the water supply and drain the water
tank.
3. Disconnect the bypass drain hose and the
supply coupling from the manifold (Figure 62).
4. Open the rod box cover (Figure 63) and dis-
connect the lubrication lines from the stufng
box ttings.
5. Remove the manifold bolts (Figure 64).
Ensure the hinge rod (Figure 65) is installed
before removing the bolts.
Note: The pump wrench can be used with a
hammer to remove the manifold bolts.
WARNING
!
If the hinge rod is missing, the manifold can fall
and cause serious injury.
Bypass Hose
Supply Coupling
Figure 62: Line Removal.
Cover
Lubrication
Lines
Figure 63: Disconnecting the Lubrication Lines.
Manifold
Bolts
Figure 64: Removing the Manifold Bolts.
Hinge Rod
Trunnions
Figure 65: Hinge Rod and Trunnions.
Bareshaft Pump
41
6. Slowly swing the manifold downward to the
manifold support rest. The weight of the manifold is approximately:
• 3600/4200 Series: 165 lb. (75 kg)
• 3000 Series: 90 lb. (41 kg)
7. Use two small pry bars (Jetstream p/n 70179)
to pry the valve out of the manifold as shown
(Figure 66).
8. Remove the remaining valves. Refer to the
topics on valve service later in this chapter for
disassembly and maintenance instructions.
40K Face Seal Replacement
Because the valves on 40K manifolds do not have
exterior O-rings that seal the manifold to the pump
frame, the stufng boxes contain a face seal to seal
the two surfaces. Perform the following to replace.
1. Press slightly behind the face seal using your
nger and gently pull the seal out (Figure 67).
2. Wipe the seal retaining area and inspect.
3. Apply O-ring lubricant to the entire area of the
new seal.
4. With the sealing lip facing away from the stuffing box, press the new seal into place by hand
until seated.
5. Ensure the seal stays in place until the manifold is in place and tightened.
!
CAUTION
Jetstream uni-valves must be lapped regularly to minimize damage to the seating surfaces
and maximize valve life. Service intervals depend on many variables including water quality,
lter maintenance, and hourly usage. Refer to
“Valve Lapping” on page 50 for instructions.
!
CAUTION
Do not use hard metal tools such as screw-
drivers or picks to remove the face seal. Doing
so may cause damage to the stufng box and
sealing surface to the point where the box must
be discarded.
STUFFING
BOX
FACE SEAL
Figure 66: Valve Removal.
Valves
Figure 67: Face Seal Removal.
Operation Manual
42
Installation
1. Place the valve into position on the manifold.
Using the palms of your hands, press the
valve into the manifold as shown (Figure 68).
2. Install the remaining valves.
3. Swing the manifold upward to install the bolts.
4. Install the manifold bolts and tighten in a crisscross sequence starting with the center bolts
(Figure 69). Proper torque is 350 ft.-lb. (470
N·m).
5. Connect the water lubrication lines (Figure 70)
to the stufng boxes and close the rod box
cover.
6. Connect the supply coupling (Figure 71) and
the bypass hose to the manifold.
Figure 69: Tightening Sequence.
Cover
Lubrication
Lines
Figure 70: Connecting the Water Lubrication Lines.
Bypass Hose
Supply Coupling
Figure 71: Hose Connections.
Figure 68: Installing the Valves.
Valve
Bareshaft Pump
43
15K, 20K Uni-Valve Service
Disassembly
1. Remove the O-ring at each end of the valve
(Figure 72). Discard the O-rings.
2. Locate the slits in the two white backup rings
and carefully remove the rings. Remove the
companion O-rings, as well (Figure 73). Discard the O-rings and backup rings.
Note: Note the orientation of the seals for
installation.
3. Use a small screwdriver to depress the spring
retainer. Use another screwdriver to remove
the retaining ring. Insert the blade under the
slit and rotate the ring out of the groove. Use
caution to prevent bending or distorting the
ring (Figure 74).
O-Ring
Figure 72: O-Ring Removal.
Figure 73: Backup Ring and O-Ring Removal.
O-Ring
Backup Ring
Figure 74: Removing the Retaining Ring.
Retaining Ring
Spring Retainer
Operation Manual
44
4. Remove the valve spring retainer and valve
spring (Figure 75).
5. Lift the assembly off of the suction valve and
set the suction valve aside.
6. Insert a small screwdriver under the discharge spring (Figure 76). Carefully rotate the
screwdriver until the spring releases from the
groove.
Note: 3015 valves are equipped with a
retaining ring to secure the discharge
spring (Figure 77).
7. Remove the discharge valve and discharge
spring.
8. Inspect the valves. Refer to “Valve Inspection”
on page 50 for inspection criteria.
Figure 75: Retaining Ring and Spring Removal.
Spring Retainer
Spring
Suction Valve
Retaining Ring
Figure 76: Discharge Spring and Valve Removal.
Discharge
Spring
Discharge
Valve
Bareshaft Pump
45
1
2
3
4
5
6
7
8
9
10
11*
12
13
14
1. O-Ring
2. Backup Ring
3. O-Ring
4. Suction Valve
5. Discharge Valve Body
6. O-Ring
7. Backup Ring
8. O-Ring
9. Discharge Valve
10. Discharge Valve Spring
11. Retaining Ring (3015 Valves
Only)
12. Suction Valve Spring
13. Spring Retainer
14. Retaining Ring
Figure 77: 15/20K Uni-Valve Exploded View.
Operation Manual
46
Assembly
1. Install the discharge valve onto the valve body.
The shiny mating surface faces the holes on
the valve body. Place the discharge spring into
position on the valve (Figure 78).
2. Lock the spring in its retaining groove. Use a
screwdriver to push the spring in place. Start
at the base of the spring and follow along the
coils to the top of the spring until it locks in its
retaining groove.
3. Position the suction valve in the valve body
(Figure 79).
4. Insert the suction valve spring and spring
retainer into the valve body. Ensure the ledge
the retaining ring sits on is positioned properly
(Figure 80).
5. Press the spring retainer downward and install
the retaining ring onto the suction valve.
6. Install the new O-rings and backup rings into
their respective positions on the assembly
(Figure 77).
Figure 78: Discharge Installation.
Discharge
Spring
Discharge
Valve
Spring Retainer
Spring
Suction Valve
Retaining Ring
Figure 79: Suction Valve Installation.
Figure 80: Spring and Retainer Installation.
Ledge
Spring Retainer
Spring
Bareshaft Pump
47
40K Uni-Valve Service
Disassembly
1. Use a small screwdriver to remove the two
black O-rings from the valve (Figure 81).
2. Use the screwdriver to remove the seal retaining ring. Insert the blade under the slit and
rotate the ring out of the groove (Figure 82).
Use caution to prevent bending or distorting
the ring.
3. Use the screwdriver to remove the ring seal
(Figure 83) and seal support ring.
4. Turn the valve over.
Figure 81: O-Ring Removal.
O-Rings
Figure 82: Retaining Ring Removal.
Retaining Ring
Cup Seal
Figure 83: Cup Seal Removal.
Backup Ring
Operation Manual
48
5. Press down on the valve spring retainer and
slide the spring keepers out from the assembly
(Figure 84).
6. Remove the valve spring and valve spring
retainer.
7. Remove the suction and discharge valves
(Figure 85).
8. Inspect the valves. Refer to “Valve Inspection”
on page 50 for inspection criteria.
Figure 84: Spring Retainer Removal.
Keeper
Spring
Spring
Retainer
Suction
Valve
Discharge
Valve
Figure 85: Valve Removal.
Bareshaft Pump
49
Assembly
1. Install the discharge valve into the valve body
(Figure 86).
2. Position the valve spring and valve spring
retainer into place on the suction valve. Press
down on the spring retainer to insert the keepers
(Figure 87).
3. Place the backup ring (Figure 88) onto the
assembly. Note the chamfer on the inside
diameter of the backup ring. Orient the backup ring so the chamfer faces the valve body
and the at side of the ring faces the cup seal.
Install the cup seal and the retaining ring.
4. Install the two O-rings (Figure 89).
Figure 86: Valve Installation.
Spring
Spring
Retainer
Suction Valve
Discharge Valve
Keepers
Figure 87: Installing the Keepers.
O-Rings
Figure 89: Install the O-Rings.
Figure 88: Install the Seal Ring.
Backup Ring
Cup Seal
Retaining Ring
Operation Manual
50
Valve Inspection
1. Inspect all seals and discard as necessary.
2. Inspect the valve components. Discard excessively pitted or otherwise damaged components (Figure 90).
3. For valves with minor wear or corrosion, recondition the valves as outlined in Valve Lapping.
Valve Lapping
Lapping is a polishing process in which two
surfaces are rubbed together with an abrasive
between them. Lapping the valves at regular
intervals ensures a tight t between the valves
and valve seat for proper sealing. Regularly
lapping the valves allows the pump to operate
efciently and helps increase valve life.
1. Disassemble the valve.
2. Apply lapping compound to the mating surface
on the suction valve (Figure 91).
3. Place the valve into position on the valve body.
Rotate the valve and valve body in opposite
directions with a light pressure for approximately 30 seconds.
4. Pause lapping momentarily by disengaging surfaces. Rotate the parts in the opposite direction
approximately 90 degrees. Do this a few times
during lapping. This will ensure that the lapping
compound distributes evenly along the valve
and valve seat interface.
Repeat for approximately 2-5 minutes, until an
even dull grey circular ring can be seen without
any remaining pits or surface imperfections.
5. Clean off the excess lapping compound with a
clean dry cloth. Inspect the contact surfaces for
uniform, dull gray sealing rings (Figure 92).
6. Continue the lapping process until the desired
sealing surface is achieved.
7. Repeat the lapping process for the discharge
valve.
8. When completed, clean all metal parts by submerging in a mineral spirits solution for a few
minutes. Remove and air dry thoroughly with
compressed air. Ensure that no compound or
solution remains in the cross holes.
ATTENTION
Use silicon carbide lapping compound, 220 grit
medium ne.
Figure 90: Valve Pitting.
Excessive Pitting
Figure 91: Typical Example of Lapping Compound Application.
Lapping Compound
on Valve Seats
Figure 92: Properly Lapped Valve Seats.
Bareshaft Pump
51
Bypass Valve Cartridge Replacement
1. Remove the dump hose (Figure 93) from the
bypass valve.
2. Using an adjustable wrench, remove the cartridge housing (Figure 94) from the valve.
3. Pull the cartridge (Figure 95) from the housing.
4. Inspect the diffuser (Figure 96) for jetting damage. Replace if damage is extensive.
5. Push the new cartridge into the housing until it
snaps into place.
6. Install the cartridge housing back onto the
bypass valve.
7. Install the dump hose onto the bypass valve.
Figure 93: Dump Hose Removal.
Dump
Hose
Figure 94: Cartridge Housing Removal.
Cartridge
Housing
Cartridge
Figure 95: Cartridge Removal.
Figure 96: Seating Surface Inspection.
Diffuser
Operation Manual
52
Power End
Checking Power End Oil Level
The most accurate method to check the oil is when
the unit is on level ground and has not been in use
for 5 to 8 hours. If the pump has been in use and the
oil needs to be checked refer to the alternate methods as outlined in “Alternate Oil Check Methods”
following this procedure.
Note: Because of varying factors such as tem-
perature, the oil in the pump will completely settle between 5 and 8 hours.
1. Locate the sight gauge (Figure 97) on the back
of the power end case. With the pump off (for 5
to 8 hours), the oil should be at the Full level.
2. If the reservoir is low, add 80W/90 detergent
free gear oil while the engine is off. Remove
the ll plug and add oil through the port in the
back plate.
Alternate Oil Check Methods
Method 1: If the pump is at or near operating
temperature and needs to be stopped during
operation for purposes of checking the oil, stop
the pump, wait 1-2 minutes and check the sight
gauge. As long as oil is visible in the gauge, the
oil level is acceptable. If oil needs to be added,
add 80W/90 detergent free gear oil while the
engine is off. Remove the ll plug and add oil
through the port.
Method 2: If the pump has been run recently,
but it is not known how long it has been standing
idle, the oil level can still be reliably checked. With
the unit on level ground and the engine running
at slow speed, engage the PTO so the pump
turns over slowly for 10-15 seconds. Disengage
the PTO. Check the oil-level at the site gauge. If
the oil level is still visible in the gauge, there is
sufcient oil in the crankcase to run the pump.
Optimally, the level should be halfway between
the bottom of the site glass and the ADD line.
!
CAUTION
Under no circumstances should you operate
the pump if there is no oil visible in the sight
gauge at rest no matter what method is used to
check the oil level.
Figure 97: Oil Check and Change.
Breather
Fill Plug
Sight Gauge
Drain Plug
Drain Valve
Bareshaft Pump
53
The typical oil level for a pump that has been operating and then brought to a stop is shown in (Figure
98). The oil level will be at or near the full mark only
after the pump has been at rest for 5 to 8 hours.
Changing the Power End Oil
1. With the engine off, remove the drain plug
(Figure 97) from the oil drain valve located on
the back of the power end case.
2. Place a container below the valve large
enough to capture the oil. Refer to the oil capacities listed below.
3. Install an extension hose/pipe to extend the
drain past the trailer frame, if desired.
4. Open the ball valve to drain the oil.
5. After the oil has drained from the case, close
the ball valve and install the plug.
6. Remove the back cover plate and inspect
the magnets at the bottom of the pump for
metal shavings or lings. Clean the magnet.
If excessive shavings or lings were present,
inspect the crankshaft journal bearings.
7. Install the back cover plate.
8. Add 80W/90 gear oil through the ll plug.
• 3000 Series Pumps: 5 gal. (22 L)
• 3600/4200 Series Pumps: 9 gal. (34 L)
9. Install the ll plug when done lling.
Figure 98: Typical Oil Level for Recently Operated Pumps.
Operation Manual
54
Crosshead Pony Rod Seals
Removal
1. Relieve pressure from the pump, shut off the
engine, and disengage the clutch.
2. Turn off the water supply and drain the water
tank.
3. Drain the oil from the crankcase. Refer to
“Changing the Power End Oil” on page 53
for instructions.
4. Open the rod box cover.
5. Disconnect the water lubrication lines if desired for easier access.
6. Position the pony rod to be serviced so that it
is at top dead center (plunger fully extended
towards the crankshaft). Pull on the drive belts
to rotate the pump (Figure 99).
7. Remove the two capscrews that secure the
plunger coupling (Figure 100) to the plunger
and remove the coupling. Rotate the pump
until the pony rod is fully retracted.
Note: The coupling halves are a machined
pair. Keep the two halves together.
8. Slide the rubber deector (Figure 100) off of
the pony rod.
9. Remove the three capscrews and washers
that secure the rod box cover to the frame.
Remove the cover. Remove the rubber washers that sit below the mounting plate.
10. Using a 1/4” hex driver, loosen the set screw
inside the bolt hole 2-3 full revolutions (Figure
101).
WARNING
!
Use caution when rotating the pump as this
can be a pinch hazard.
Figure 99: Rotating the Belt Drive.
Figure 100: Plunger Coupling Removal.
Deflector
Plunger Coupling
Plunger
Figure 101: Set Screw Access.
Hex Driver
Bareshaft Pump
55
11. Install two 1/2”-13 UNC capscrews (Figure
102) into the seal plate.
12. It may be necessary to use a long pry bar with
the power frame as a lever to pry the back of
the bolts. The seal plate should pop out from
its bore. Remove the plate (Figure 103).
13. Remove the O-ring and press the seals from
the plate. Discard the O-ring and seals.
14. Repeat for the remaining crosshead seals, if
necessary.
Installation
1. Place the seal plate in a hydraulic or arbor
press with the inboard side facing up. Place
the red outboard seal into position and orient
the seal (Figure 104).
2. Use the press to press the seal into the plate
until it is ush with the face of the plate. Use
caution to avoid damaging the seal.
Figure 104: Pressing the Seal.
Figure 102: Seal Plate Removal.
Pry Bar
Capscrew
and Washer
Figure 103: Outboard Seal Installation.
Outboard Seal
Seal Plate
Operation Manual
56
3. Place the green inboard seal into position on
top of the outboard seal and orient the seal
(Figure 105). Press the seal into the plate
until it is ush with the face of the plate. Use
caution to avoid damaging the seal.
4. Install a new O-ring (Figure 106) onto the seal
plate. Lubricate the O-ring with O-ring lubricant.
5. Lubricate the inner seals with clean oil.
6. Repeat the prior steps for the remaining seal
plates, if necessary.
7. Clean the seal plate bore and chamfer with
emery cloth. Smooth any rough edges that
can cut or damage the O-ring.
8. Carefully install the seal plate onto the pony
rod and into the bore using hand pressure
only. Do not hammer the plate into place. The
plates must be ush with the frame.
9. Using a 1/4” hex drive, tighten the set screw
that secures the plate to 15 in.-lb. (1694
mN·m) inside the access holes.
10. Install the deector (Figure 107) onto the pony
rod.
11. Extend the plunger from the stufng box to
meet the pony rod.
12. Place the plunger coupling into position and
install the capscrews that secure the plunger.
Tighten to 20 ft.-lb.(27 N·m).
13. Place the rubber washers into position on the
frame and then place the cover into position.
Install the three capscrews and washers that
secure the cover.
14. Add oil to the crankcase as outlined in “Changing the Power End Oil” on page 53.
Figure 105: Inboard Seal Installation.
Inboard Seal
Figure 106: O-Ring Installation.
O-Ring
Deflector
Plunger Coupling
Plunger
Figure 107: Plunger Connection.
Bareshaft Pump
57
Rod Journal Bearings
Removal
1. Drain the oil from the power end as outlined in
“Changing the Power End Oil” on page 53.
2. Once drained, remove the capscrews, washers and lockwashers from the back plate
(Figure 108). Remove the plate, belt guard
and gasket. If the gasket is stuck to the frame,
it can remain.
3. Remove the rod cap capscrews (Figure 109)
from each rod journal. Rotate the pump by
pulling on the belts (Figure 110), to gain
access to the capscrews as needed.
4. Once the capscrews are removed, remove
each rod cap from the crankshaft. Observe the
stamp marks on the top of the cap and rod for
correct assembly.
5. To check the bearing life, proceed to Inspection. If the bearings are known to be worn,
continue to the following step.
WARNING
!
Use caution when rotating the pump as this
can be a pinch hazard.
Figure 108: Back Plate Removal.
Belt Guard
Back Plate
Capscrew
Figure 110: Rotating the Pump.
Figure 109: Rod Cap Removal.
Back Plate
Rod Cap
Capscrew
Crankshaft
Operation Manual
58
6. Remove the journal bearing from the rod cap
and discard (Figure 111).
7. To access the inner journal bearing (Figure
112), push the connecting rod away from the
crankshaft. Slide the bearing from the rod.
Inspection
1. Wipe the excess oil from the end cap bearings.
2. Install a small strip of plasti-gauge onto the
end cap bearing (Figure 113).
3. Position the end cap with capscrews back
onto the matching connecting rod.
4. Screw in the capscrews by hand and then
tighten to the proper torque:
• 3000 Series Pumps: 45 ft.lb (61 N·m)
• 3600/4200 Series Pumps: 80 ft.lb (108
N·m)
5. Remove the end cap.
Figure 111: Bearing Removal.
Rod Cap
Journal Bearing
Figure 112: Inner Bearing Removal.
Connecting Rod
Journal Bearing
Crankshaft
Figure 113: Plasti-Gauge Installation.
Plasti-Gauge
Bareshaft Pump
59
6. Measure the attened plasti-gauge using the
gauge wrapper (Figure 114).
7. If the thickness of the plasti-gauge exceeds
0.012 in. (0.31 mm), replace the bearings. If
the bearings do not exceed the criteria, the
bearings can be reused.
Note: New part clearances are as follows:
• Series 3000: 0.001 in. (0.025 mm) - 0.005
in. (0.13 mm)
• Series 3600/4200: 0.002 in. (.05 mm) -
0.005 in. (0.13 mm)
Installation
1. Apply clean new oil to the new connecting rod
journal bearing (inner diameter only) (Figure
115).
2. Slide the bearing (Figure 116) into the connecting rod from below the crankshaft journal.
3. Apply oil to the inner surface of the cap end
bearing.
4. Properly orient the grooves and install the
bearing in the rod cap.
5. Place the two capscrews into the rod cap.
ATTENTION
The journal bearings have tabs that match the
inner diameter of the connecting rods. Ensure
the bearings are properly oriented in the tabs
when installing (Figure 117).
Figure 114: Plasti-Guage Measurement.
Figure 115: Lubricating the Bearing.
Figure 116: Rod Bearing Installation.
Journal Bearing
Crankshaft
Figure 117: Bearing Grooves.
Bearing Grooves
Operation Manual
60
6. Pull the connecting rod (Figure 118) onto the
crankshaft and place the rod cap into position
aligned with the connecting rod. Ensure the
stampings (Figure 119) on the cap and rod
match.
7. Screw in the capscrews by hand and then
tighten to the proper torque:
• 3000 Series Pumps: 45 ft.lb (61 N·m)
• 3600/4200 Series Pumps: 80 ft.lb (108 N·m)
8. With the rst rod connected, rotate the pump
by pulling the belts. Allow the crankshaft to
turn a few revolutions to ensure the rod was
properly installed.
If the crankshaft spins freely, the bearings were
properly installed.
If the crankshaft does not spin freely, remove the
journal bearings and replace with another set.
9. Repeat the previous steps for installation of
the remaining journal bearings.
10. Place the back plate (Figure 120), belt guard
and gasket into position on the frame.
11. Install the capscrews, lock washers and at
washers. Tighten the capscrews to the proper
torque.
• 3000 Series Pumps: 20 ft.lb (27 N·m)
• 3600/4200 Series Pumps: 35 ft.lb (47 N·m)
12. Fill the power end with oil as outlined in
“Changing the Power End Oil” on page 53.
Figure 118: Rod Cap Installation.
Rod Cap & Bearing
Connecting Rod
Figure 119: Matched Parts Stampings.
Rod Cap & Bearing
Belt Guard
Back Plate
Capscrew
Figure 120: Cover Plate Installation.
Bareshaft Pump
61
Crosshead and Connecting Rod
Assembly
Removal
1. Remove the crankshaft from the pump as
outlined in “Crankshaft” on page 65.
2. Use two people to lift the crosshead/connecting rod assemblies from the crankcase. The
weight and location of the assemblies make it
difcult for one person to remove on their own.
Disassembly
1. Remove the two set screws from the crosshead (Figure 121). The set screws are installed on top of one another in the same hole.
2. Slide the pin out from the assembly (Figure
122).
3. Remove the connecting rod from the crosshead.
4. Keep the components for each assembly
together.
5. Disassemble the remaining assemblies.
Bushing Inspection
1. Use a micrometer to measure the outer diameter of the pin in three places and record the
measurements.
2. Add the three measurements and divide by 3
to get the average diameter.
3. Use an inside micrometer to measure the
bushing in the connecting rod in three places
and record the measurements.
4. Add the three measurements and divide by 3
to get the average diameter.
5. Subtract the diameter of the pin from the inside
diameter of the bushing. If the remainder is
greater than 0.008 in. (0.2 mm), the bushing
must be replaced. Note the new bushing will require honing after installation into the connecting rod to achieve the clearance listed below.
Note: New part clearances are as follows:
• Series 3000: 0.0030 in. (0.08 mm) - 0.0037
in. (0.09 mm)
• Series 3600/4200: 0.0040 in. (0.1 mm) -
0.0047 in. (0.12 mm)
6. Repeat for the remaining assemblies.
Figure 121: Set Screw Removal.
Figure 122: Pin Removal.
Pin
Crosshead
Operation Manual
62
Crosshead Inspection
1. Use a micrometer to measure the outer diameter of the crosshead in three places and
record the measurements.
2. Add the three measurements and divide by 3
to get the average diameter.
3. Use an inside micrometer to measure the
crosshead bore in the power frame in three
places and record the measurements.
4. Add the three measurements and divide by 3
to get the average diameter.
5. Subtract the diameter of the crosshead from
the inside diameter of the crosshead bore. If
the remainder is greater than 0.012 in. (0.31
mm), the crosshead must be replaced.
Note: New part clearances are as follows:
• Series 3000: 0.004 in. (0.1 mm) - 0.007
in.(0.2 mm)
• Series 3600/4200: 0.006 in. (0.15 mm) -
0.009 in. (0.23 mm)
6. Repeat for the remaining assemblies.
Assembly
1. Clean all surfaces of the crossheads, pins,
and connecting rods using brake cleaner.
2. Inspect all surfaces of the crossheads, pins,
and connecting rods for any signs of damage.
Replace any suspect or damaged parts.
3. Inspect the long bore oil passage through the
length of the connecting rod. Use a wire or a
long handle brush to clear passage if necessary.
4. Insert the connecting rod into the bottom of the
crosshead and line up the bores.
5. Lubricate the pin (Figure 123) with clean oil
and insert the pin into the hole in the side of
the crosshead.
6. Align the hole in the connecting rod with the
pin as it is slipped in.
7. Thread the rst set screw into the crosshead
hole until it touches the pin, then back off a
1/4 turn. Slide the pin into position and tighten
the set screw ensuring the screw is engaged
in the counterbore of the pin. Tighten the set
screw to 30 ft lb (41 N·m).
8. Apply Loctite Red-271© onto the threads of the
second backup set screw.
9. Install the second set screw on top of the rst set
screw. Tighten to 36 ft lb (49 N·m) (Figure 124).
10. The crosshead is now ready for installation in
the pump.
Figure 123: Pin Placement.
Figure 124: Second Set Screw Installation.
Pin
Crosshead
Bareshaft Pump
63
Installation
1. Place the crosshead/connecting rod assemblies into position inside of the crankcase.
2. Install the crankshaft as outlined in “Installation” on page 66.
UNx Pump
Removal
1. Drain the water tank.
2. Remove the bypass hose and supply hose
(Figure 125). If the supply hose is connected
to the secondary lter, disconnect it from the
lter.
3. Remove the two screws that secure the hydro-throttle switch housing to the cartridge and
disconnect the switch.
4. If equipped, the secondary lter switch must
be disconnected. Remove the two screws that
secure the switch cover (Figure 126) and dis-
connect the wiring. Unscrew the conduit tting
from the switch housing and lay the conduit and
wiring aside.
5. Remove the belts.
6. Use a marker to mark the location of the pump
footings for easier installation.
7. Remove the four pump mounting capscrews
and nuts.
8. Attach a hoist and lifting apparatus to the
pump as shown (Figure 127). The weight of
the pump is approximately:
• 3000 Series: 1200 lb. (544 kg)
• 3600/4200 Series: 2200 lb. (998 kg)
9. Lift the pump from the unit and place in a suitable location for servicing.
10. If shims were under the pump, keep the shims
together and note their proper location.
Figure 127: Lifting the Pump.
Figure 125: Pump Removal Preparation.
Throttle Switch
Bypass Hose
Supply Hose
Figure 126: 40K Switch Wiring.
Conduit Fitting
Switch Cover
Operation Manual
64
Installation
1. If shims were under the pump, place the shims
in their proper location.
2. Apply an anti-seize compound to the four
pump mount channels (Figure 128).
3. Attach a hoist and lifting apparatus to the
pump as shown (Figure 129). The weight of
the pump is approximately:
• 3000 Series: 1200 lb. (544 kg)
• 3600/4200 Series: 2200 lb. (998 kg)
4. Place the pump into position on the unit and
position the pump near the position markings
that were made during removal. Once in position, remove the lifting apparatus.
5. Loosely install the pump hardware.
6. Install the belts onto the pulleys. Adjust the
belt tension per manufacturer specications.
7. Install the belt guard.
8. If equipped with a secondary lter, insert the
switch wiring into the switch housing and
connect the conduit tting (Figure 130) to the
housing. Connect the wires and install the
switch cover.
9. Place the hydro-throttle switch (Figure 131)
in place on the hydro-throttle cartridge. Install
the two screws that secure the hydro-throttle
switch to the cartridge.
10. Install the bypass hose (Figure 131) and supply hose.
Figure 128: Apply Anti-Seize to the Pump Channels.
Figure 129: Lifting the Pump.
Conduit Fitting
Switch Cover
Figure 130: 40K Switch Wiring.
Throttle Switch
Bypass Hose
Supply Hose
Figure 131: Connect the Switch and Hoses.
Bareshaft Pump
65
Crankshaft
Removal
1. Remove the pump from the unit. Refer to “UNx
Pump” on page 63.
2. Open the rod box cover and remove the two
capscrews that secure the plunger coupling
(Figure 132) to the plunger and remove the
coupling.
Note: The coupling halves are a machined
pair. Keep the two halves together.
3. Remove the connecting rod end caps as outlined in “Rod Journal Bearings” on page 57.
4. Remove the 12 capscrews and washers that
secure the top cover (Figure 133) to the power
frame. Remove the cover and the gasket.
5. Remove the 12 capscrews and washers that
secure the rear cover (Figure 133) and belt
guard to the power frame. Remove the cover,
guard and gasket.
6. Pull the three connecting rod/crosshead
assemblies towards the uid end as far as
possible.
7. Remove the eight capscrews and washers
that secure the inboard side plate (Figure 133)
to the power frame.
8. Remove the side plate and shims. Keep the
shims together.
9. Remove the eight capscrews and washers
that secure the outboard side plate (Figure
133) to the power frame.
Plunger Coupling
Plunger
Figure 132: Plunger Coupling Removal.
8
9
4
3
1
7
5
6
2
10
11
12
1. Top Cover
2. Gasket
3. Outboard Side Plate
4. O-ring
5. Shim Pack
6. Shim Pack
7. Inboard Side Plate
8. Oil seal
9. O-Ring
10. Gasket
11. Rear Cover
12. Belt Guard
Figure 133: Power End Covers.
Operation Manual
66
10. Remove the side plate and shims while supporting the crankshaft. Keep the shims together.
11. Using a wood block and a hammer, hit either
end of the crankshaft to unseat it from its
bearing bores.
12. Install two threaded rods (1 in.-8NC x 8 in.) into
the ends of the crankshaft to aid in removal.
13. Using two people, lift the crankshaft from the
power frame. The weight of the crankshaft is
approximately:
• 3000 Series: 125 lb. (57 kg)
• 3600/4200 Series: 325 lb. (147 kg)
14. Remove the bearings from the crankshaft. Contact Jetstream for assistance with this task.
Installation
1. Heat the crankshaft bearings in a 250°F
(121°C) oven for 20 minutes. Check the
bearing color as they are heated. If the bearings turn blue or black they are overheated.
2. When ready, slide the bearings onto each end
of the crankshaft until they are fully seated
(Figure 134).
3. Verify that the bearing turns on the shaft.
4. Allow the crankshaft assembly to cool.
5. Install the outer bearing race (Figure 135) onto
the inboard bearing.
6. Install the outer bearing race (Figure 136) into
the power frame using a rubber mallet. Install
the race so it is ush with the face of the case.
WARNING
!
Use caution when unseating the crankshaft.
The crankshaft will fall approximately 1 in. (25
mm) as it slides out of the tapered race and
can cause bodily harm.
!
CAUTION
Temperatures in excess of 250°F (121°C) will
damage the bearing. If the bearings have been
heated over the limit, discard the bearings.
Figure 134: Bearing Installation.
Figure 135: Outer Race Installation.
Outer Race
Figure 136: Bearing Race Installation.
Bearing Race
Bareshaft Pump
67
7. Place the three crosshead/connecting rod
assemblies into place (Figure 137). Allow
clearance for the crankshaft by pushing them
towards the uid end.
8. Install two threaded rods (1 in.-8NC x 8 in.) into
the ends of the crankshaft to aid in installation.
9. Using two people, lift the crankshaft into the
power frame. The weight of the crankshaft is
approximately:
• 3000 Series: 125 lb. (57 kg)
• 3600/4200 Series: 325 lb. (147 kg)
10. Using a wood block and a hammer, hit either
end of the crankshaft to seat it in the bearing
bore. Ensure the outer bearing race (Figure
138) is inside the power frame case.
11. Tap in the bearing race on the opposite end of
the crankshaft if not already installed.
12. Install a new oil seal and O-ring onto the
inboard side plate. Install the outboard and inboard side plates with the original shim packs.
Ensure the thickness of each shim pack is
equal on both ends. Install four equally spaced
side plate capscrews and tighten to 50 ft.lb (68
N·m) (Figure 139).
Figure 137: Connecting Rod Installation.
Connecting Rod
Figure 139: Side Plate Installation.
Bearing Race
Power Frame
Figure 138: Crankshaft Seating.
Operation Manual
68
13. Mount a magnetic base dial indicator on the
crankshaft with the indicator pin on the inside
edge of the rear opening, as shown.
14. With a rm, slow, but not sudden pull in both
directions the total end play should read within
0.001 inch (0.03 mm) - 0.004 inch (0.10 mm)
tolerances.
15. Use a prybar (approx. 3 ft. (91 cm)) to move
the crankshaft back and forth from left to right.
Use rm, but not hard pressure. Record the
movement of the indicator while prying in
both directions. Add the measurements. Total
indicator reading (sum of movement in both
directions) should be 0.001 in. (0.0254 mm)
- 0.004 in. (0.1016 mm). Check several times
for consistency.
16. Add or remove shims as necessary to bring
the endplay within the specied range. Keep
the shim packs within 0.010 in. (0.254 mm) of
each other.
17. Install the remaining capscrews onto the
inboard and outboard side plates. Tighten the
capscrews to 50 ft.lb (68 N·m).
18. Oil the bearings and install the connecting
rods onto the crankshaft and install the crankcase cover as outlined in “Rod Journal Bearings” on page 57.
19. Install the three plunger couplings, connecting
the plungers to the pony rods.
20. Place the top cover and gasket into place.
Install the 12 capscrews and washers that secure the top cover to the power frame. Tighten
the capscrews to 50 ft.lb (68 N·m).
21. Position the rear cover, belt guard and gasket into place. Install the 12 capscrews and
washers that secure the components to the
power frame. Tighten the capscrews to 50 ft.lb
(68 N·m).
22. Add oil to the crankcase. Refer to “Changing
the Power End Oil” on page 53.
Figure 141: Plunger Coupling Installation.
Plunger Coupling
Plunger
Figure 140: Dial Indicator Mounting.
Dial Indicator
Pry Bar
Bareshaft Pump
69
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE REMEDY
High discharge
pressure
Nozzle too small Replace nozzle
Restriction in hose or lance Test hose/lance without nozzle
Inaccurate pressure gauge Replace gauge
Low discharge
pressure
Nozzle too large Replace nozzle
Nozzle worn Replace nozzle
Insufcient water tank level Fill tank, unplug vent
Inaccurate pressure gauge Replace gauge
Belts slipping Increase belt tension
Leaking or sticking pump valves Service or replace valves
Worn pump plunger packing Replace packing
Leaking control gun, hose, tting Repair or replace
Dirty lter bag Replace lter bag
Excessive pulsation in pump discharge
Low water tank level Fill tank, unplug vent
Leaking pump valves Repair or replace valves
Broken pump valve springs Replace springs
Worn pump plunger packing Replace packing
Belts slipping Increase belt tension
Dirty lter bag Replace lter bag
Vibration in unit Pump pulsating excessively See Excessive pulsation above
High pump packing
gland temperature
Insufcient packing lube water ow
Increase lube hose pressure
Clean guide bushing holes
Water too hot 125°F max
Pump noise
Low lubricant level Fill with lubricant
Pump cavitation
See “Excessive pulsation in pump
discharge” above
Loose plunger clamps Tighten plunger clamps
Worn bearings Replace bearings
Worn crosshead(s)
Replace crosshead(s)/repair
crosshead
Excessive crankshaft end play Adjust endplay
Leakage from
pump manifold
leakage holes
Damaged valve seal Replace seal
Leakage from
hydraulic throttle
control
Damaged piston seal Replace seal
Operation Manual
70
PROBLEM POSSIBLE CAUSE REMEDY
Insufcient water
lubrication
Needle valves not properly adjusted Adjust the needle valves
Air in the system
Open the manifold drain with
pump on
Plugged lines
Remove debris from lubrication
lines
Leakage from
pump
manifold uni-valve
leakage holes
Damaged valve seal Replace seals
Leakage from
discharge tting
leakage holes
Damaged ttings or seals Replace the ttings and/or seals
Pump oil leaking
from breather
Check oil level Add oill as necessary
Verify use of proper oil type
See “Oil Specications” on page
62
Water in pump oil
Cross head oil seal leak Replace seal
Cold oil
Continue to run until oil temp increases to adequate temperature
Engine will not
return to idle when
control gun dumping
Excessive hose back pressure Reduce hose string length
Throttle control piston sticking Repair throttle control unit
Engine will not
increase in speed
when control gun
rst closes
Engine idle speed too low Increase idle speed
Large gun nozzle Decrease nozzle size
Insufcient water
lubrication
Needle valves not properly adjusted Adjust the needle valves
Air in the system
Open the manifold drain with
pump on
Plugged lines
Remove debris from lubrication
lines
Poor packing life
Hot water 125°F max
Insufcient water ow Adjust water ow
Dirty water Clean/replace lter
Scored/pitted plunger Replace plunger
Gland nut loose Tighten nut
Bareshaft Pump
71
TRAINING
Safety Training
Only trained personnel may setup, operate, or maintain this equipment.
Waterblast operators must be aware of the dangers
that exist while using water blasting equipment. The
cleaning nozzle’s discharge jet(s) can inict serious
bodily injury. Jetstream® recommends demonstrating
to new operators the potential damage of the discharge jet(s). This can be done by showing the effect
of a waterjet from a straight tip nozzle cutting a scrap
piece of 2 in. x 4 in. (50 mm x 100 mm) wood.
A safety training DVD is available from Jetstream® at
their website (www.waterblast.com).
Training materials are also available from the Water
Jet Technology Association (WJTA) (www.wjta.org).
New Start-up Training
In order to ensure
customer satisfaction,
Jetstream has
developed the Right
Start program, a four-step plan designed to provide
the owners and operators of new Jetstream waterblast
units with the knowledge and support needed to feel
familiar, condent and satised with Jetstream equipment and personnel.
1. Transportation
Once a new waterblaster is built
and thoroughly tested, the Shipping
Manager contacts the new owner to
arrange for the unit’s arrival to the right
place at the right time.
2. Training
All new waterblasters include personal
training by the Right Start Technician.
Training involves both classroom and
“hands-on” instruction to make sure that
each operator is thoroughly familiar with
the design and function of the unit and
accessories, enabling him to safely put
the new equipment to optimal use.
3. Follow-up
Within thirty days of delivery, and again
within sixty days, the Solutions Provider
will call to answer any questions and
ensure complete satisfaction.
4. Trust
If any questions or problems arise,
the Jetstream team is available and
committed to providing prompt answers
and solutions.
FS Solutions Training
FS Solutions training begins where Right Start training
stops. Our certied training covers all skill levels and
incorporates: safety, application, troubleshooting, and
eld maintenance training.
For more information contact Jetstream.
Additional Training Opportunities
Jetstream offers multiple certied training classes
designed to promote safe, effecient, and protable
operation.
For more information on any of the other available Jetstream training opportunities please contact Jetstream
at 1-800-231-8192 or visit us at www.waterblast.com.
Operation Manual
72
Bareshaft Pump
Ind-1
INDEX
C
COMPONENT IDENTIFICATION 5, 8
Bypass Valve 6
Discharge Fitting 6
Fluid End and Unit Identication 7
Manifold 5
Manifold Drain Valve 5
Pressure Gauge 5
Regulator Valve 6
Rupture Discs 6
Secondary Filter (40K Units) 7
Supply Couplings 7
UNx Pump 5
Water Lubrication System 5
Water Tank and Filters 5
M
MAINTENANCE 19
Unit Maintenance 19
50 Hours 19
100 Hours 19
500 Hours 19
Winterizing the Unit 19
O
OPERATION 11
Breaking in New Packing 16
Checking The Water Lubrication System 14
Flushing The System 13
Hose and Water Supply Requirements 11
Monitoring Weep Holes 17
Preparing the Unit 11
Raising System Pressure 14
Recommended Equipment 11
Starting the Unit 12
Start-up Preparation 11
Using the Hydro-Throttle (Dump System Only) 16
P
PRESSURE CONVERSION 25
40K Hose Connections 32
Converting a Pump 25
Manifold Trunnion Adjustment 29
S
SERVICE 33
Fluid End 33
15K, 20K Uni-Valve Service 43
Assembly 46
Disassembly 43
40K Face Seal Replacement 41
Installation 42
40K Uni-Valve Service 47
Assembly 49
Disassembly 47
Valve Inspection 50
Valve Lapping 50
Bypass Valve Cartridge Replacement 51
Checking Gland Nut Torque 33
Checking Manifold Bolt Torque 33
Packing Replacement 34
Inspection 37
Installation 38
Removal 34
Rupture Disc Inspection 34
Uni-Valve Service 40
Removal 40
Power End 52
Changing the Power End Oil 53
Checking Power End Oil Level 52
Alternate Oil Check Methods 52
Checking PTO Oil Level 54
Crankshaft 65
Installation 66
Removal 65
Crosshead and Connecting Rod Assembly 61
Assembly 62
Bushing Inspection 61
Crosshead Inspection 62
Disassembly 61
Installation 63
Removal 61
Crosshead Pony Rod Seals 54
Installation 55
Removal 54
Rod Journal Bearings 57
Inspection 58
Installation 59
Removal 57
UNx Pump 63
Installation 64
Operation Manual
Ind-2
Removal 63
T
TRAINING 71
Additional Training Opportunities 71
FS Solutions Training 71
New Start-up Training 71
Safety Training 71
TROUBLESHOOTING 69
W
WATERBLAST SAFETY 1
General Safety Precautions 2
Be prepared 3
Check Connections 2
Check Pressure Ratings 2
Freezing Conditions 3
Inspect Equipment 2
Performing Maintenance Or Repairs 3
Purge The System 3
Read Instructions 2
Rupture Discs 2
Slowly Increase pressure 3
Store Components Properly 3
Test The system 3
Tighten Connections 2
Use The minimum Pressure Required 3
Use Two Operators 2
Recognizing Safety Information 1
Understanding Signal Words 1
Waterblast Safety Manual 1
WATER TANK AND FILTRATION 21
Water Quality Requirements 21
Water Tank With Filters 21
Filter Cartridge Replacement 23
Secondary Filter (40K Operation Only) 21
Switch Adjustment 23
Uni-Valve Life 23
To order Jetstream parts and accessories, call 1-800-231-8192
or visit www.waterblast.com
www.waterblast.com
(832) 590-1300 • (800) 231-8192
P/N 65179-F ©2018 Jetstream of Houston. Jetstream® is a registered trademark of Federal Signal Corp.
The Worldwide Leader in
TOTAL Solutions for
Challenging Waterblasting
Applications.
®
Gonzales, LA
(225) 647-0660
Highland, IN
(219) 924-3180
Lakewood, WA
(253) 584-0653
Long Beach, CA
(866) 515-9891
New Brunswick, NJ
(732) 448-7830
Midland, TX
(432) 563-4450
Streator, IL
(815) 672-6028
LaPorte, TX
(281) 674-8668
Williston, ND
(701) 572-7421
Leeds, AL
(800) 822-8785
Lexington, SC
(803) 996-0741
Prairieville, LA
(225) 372-7678
Jetstream products are also serviced by FS Solutions, with
13 convenient locations across the United States. FS Solutions provides
high-performance parts, accessories, Jetstream rentals, repair, rebuild
and safety training.
Toledo, OH
(888) 415-7368
Loading...