Hog Technologies Stripe Hog SH5000 User manual

Operations
Manual

2

3
WARNING
INCORRECT USEOF HIGHPRESSURE WATERBLASTING EQUIPMENTMAYCAUSE
SERIOUS INJURY OR EVEN DEATH.
INEXPERIENCED PERSONNEL ATTEMPTING TO USE THIS EQUIPMENT MAY
CAUSE EXTENSIVE DAMAGE TO CERTAIN COMPONENTS, BYSTANDERS, OR
PERIPHERAL PROPERTY
DO NOT USE THIS EQUIPMENT WITHOUT PROPER SUPERVISIONAND TRAINING.
ALL OPERATING AND MAINTENANCE PERSONNEL MUST BE THOROUGHLY
TRAINED IN SAFE OPERATION BYAHOG TECHNOLOGIES CERTIFIED TRAINER,
IN THE INSTALLATION AND MAINTENANCE OF THIS EQUIPMENT,AND PROVIDED
WITH ADEQUATE SUPERVISION.
BEFORE ATTEMPTING TO CONNECT, OPERATE, OR REPAIR THIS EQUIPMENT,
THOROUGHLY READ THESE INSTRUCTIONS AND ANY SAFETY WARNING OR
INSTRUCTION PAMPHLETS INCLUDED WITH YOUR SHIPMENT.
FOR ANY QUESTIONS CONCERNING SAFE OPERATIONS AND MAINTENANCE
PROCEDURES,CONTACT YOUR HOG TECHNOLOGIES REPRESENTATIVE PRIOR
TO USE.
[phone] OR [phone]
HOG TECHNOLOGIES
WWW.HOGTECHNOLOGIES.COM
COPYRIGHT
Hog Technologies. maintains and holds all rights and privileges to the
information contained in the manual. The contents herein cannot be
shared or reproduced in any way or by any method without prior express
written consent by an authorized representative. Copies of this manual
are available by calling [phone].
COPYRIGHT/GENERAL WARNING

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5
Welcome
Thank You for choosing the Stripe Hog® SH5000. We believe you have made a great
choice.
Hog Technologies prides itself on providing quality equipment and superior Customer
Service on a global scale. It is our pleasure to serve the needs of waterblasting
service providers through a variety of venues on every inhabited continent on the
planet. Each one of our customers provides a unique opportunity to learn, grow,
and develop our experience. As one of our customers, your relevant input is greatly
appreciated. We value your opinion and will work hard to implement positive change
at every opportunity.
Whether this is your rst purchase from us or another one of a series, we want you
to know that each and every person on the Hog Technologies team is committed to
providing you with the highest level of quality available. From design to assembly,
from sales to customer support, there couldn’t be a team more anxious to serve you
with enthusiasm and genuine concern. We are still human however, and sometimes
details get past us that have to be dealt with. On the rare occasion that this happens,
we will work diligently and quickly to keep your equipment operating and producing
results for you. Every team member is at your disposal at any moment throughout
the year to resolve any and all issues that would hinder your machine from produc-
tion. The long and prosperous life of the equipment you purchase from us is our
number one priority. That is why we have prepared this operations manual for you.
Please take the time to read this operations manual before attempting to operate
your waterblasting system. This is an important aid in the operation and mainte-
nance of your new equipment. The information is intended as a guide and cannot
cover every question you may have about your Stripe Hog nor can itf cover every
operating situation. We encourage you to contact Hog Technologies for any additional
information you might need.
We provide rst class support to our customers for all of the equipment we sell. We
maintain a well-stocked inventory of parts and accessories in addition to technical
sta with the experience to satisfy all of your support questions. Please contact
us at [phone]-7393 or online at www.hogtechnologies.com. We have also
developed a website specically geared to customer service related issues www.
stripehogsupport.com.
Thank you again for being our valued customer.
Yours for a prosperous future,
The Hog Technologies Team

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7
DANGER
WARNING
CAUTION
Safety Warnings and Instructions
This manual has been written to include a number of safety instructions to assure the safe assembly,
operation and maintenance of your Waterblasting Equipment. These instructions are in the form of
DANGER, WARNING, and CAUTION statements. The following denitions apply:
All instructions given in this book are as seen from the rear looking forward. Common industry ter-
minology is used throughout the manual.
IMPORTANT NOTE: Your Waterblasting equipment uses internal combustion engines and am-
mable fuel. Every precaution has been taken by Hog Technologies to reduce the risks associated with
possible injury and damage from re or explosion, but your own precaution and good maintenance
procedures are necessary to ensure the safe operation of your equipment.
HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT
INMINOR PERSONALINJURYORPRODUCTANDPROPERTY
DAMAGE.
HAZARDSORUNSAFEPRACTICESWHICHCOULDRESULTIN
SEVERE PERSONAL INJURY OR DEATH.
IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE
PERSONAL INJURY OR DEATH.

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Table of Contents
Welcome ........................................................................................................................... 5
Safety Warnings and Instructions ......................................................................................... 7
Table of Contents................................................................................................................ 9
Getting Started .................................................................................................................11
SH5500 Specications........................................................................................................13
Section 1:
Safety Information .....................................................................................................................15
1.1General Safety .............................................................................................................15
1.2 Blasting Safety ............................................................................................................17
1.3 Nozzle Safety ..............................................................................................................18
1.4 Hose Safety ................................................................................................................18
1.5 High Pressure Fitting Safety..........................................................................................19
1.6 Dumping Safety..........................................................................................................19
Section 2:
Stripe Hog Systems ..................................................................................................................21
2.1 Truck Chassis ............................................................................................................21
2.2 Truck Power System and PTO........................................................................................23
2.3 Primary Drive Belts .....................................................................................................25
2.4 Truck Hydraulic Systems ..............................................................................................26
2.5 Fluid Cooler Placement.................................................................................................27
2.6 Hood Ventilation System..............................................................................................28
2.7 Truck Mounted Hog Head .............................................................................................30
2.8 Waterblast System......................................................................................................35
2.9 Vacuum System .........................................................................................................43
Section 3:
Waterblasting Hog Tools............................................................................................................51
3.1 Hog Tools (Optional)....................................................................................................51
3.2 Hog Tool Waterblast Systems........................................................................................52
3.3 Hog Tool Vacuum Systems............................................................................................52
Section 4:
Stripe Hog Operation.................................................................................................................53
4.1 Emergency Shutdown..................................................................................................53
4.2 SH5500 Start Up/Shutdown..........................................................................................53
4.3 Waterblasting Operations .............................................................................................56
4.4 Operating in Freezing Conditions...................................................................................57
Section 5:
General Maintenance................................................................................................................59
5.1 Lubrication.................................................................................................................59
5.2 Truck Maintenance ......................................................................................................59
5.4 High Pressure Blasting System & Charge Pump ..............................................................65
5.5 Hog Head & Hog Arm Maintenance ...............................................................................68
5.6 Hydraulic System Maintenance......................................................................................69

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Table of Contents
Section 5:
General Maintenance (Continued)
5.7 Vacuum System & Debris tank......................................................................................70
5.8 Lubrication Chart ........................................................................................................76
Section 6:
Component Repair ....................................................................................................................77
6.1 Thru-Shaft Motor Bearing Pre-Load................................................................................77
6.2 Caster Wheel Care – Hog Head Assembly ................................................................ 93
6.3 Shuto (Dump) Valve Repair ........................................................................................95
6.4 Manual Bypass Valve Repair .........................................................................................97
Appendix A:
Drawings and Supplies.......................................................................................................99
Fluid End Replacement Parts ...............................................................................................99
Appendix B:
Troubleshooting Guide......................................................................................................101
Appendix C:
SH5500 Specications......................................................................................................105
SH5500 Specications......................................................................................................105
Appendix D:
Checklists.......................................................................................................................107
Pre-Start Inspection.........................................................................................................107
Warm Weather Shutdown ................................................................................................108
Freezing Conditions Shutdown...........................................................................................109
Appendix E:
Spray Bar Conguration and Nozzles ..................................................................................111
Nozzle Calculation Sheet ..................................................................................................117
Appendix F:
Technical Support............................................................................................................119
Stripe Hog Support Web Page ...........................................................................................120

11
Getting Started
Caution and Warning Labels on High Pressure Pump
Water Filter Warning Label
Let’s start with Safety
High pressure, waterblasting equipment can cause
serious injury or even death if it is not operated
or maintained properly. Safety is the personal
responsibility of every individual in and around
the SH5500. This manual has been written to
include a number of safety instructions to help
assure the safe operation and maintenance of all
personnel and the SH5500 equipment. This is not
an exhaustive text nor is it meant to be. Rather it
is an aide to help you the reader form a basis to
consider what some of the safety issues are. You
must be responsible to constantly consider what
the safety issues are for you and those who are
within range of any and all safety risks regarding
its operations. We have incorporated a method
of highlighting notable safety instructions. These
instructions are in the form of a General Safety
Section as well as individual CAUTION, WARNING
and DANGER STATEMENTS. There are also CAU-
TION, WARNING AND DANGER LABELS located
on some Stripe Hog components. You should
read these warnings carefully and make sure you
understand the nature of the hazard, the precau-
tions and recommended procedures required to
ensure your safety as well as those around you.
Major Component Operation Manuals
The suppliers of some of the major components
such as truck chassis, tractors, engines, pumps,
and drive units, provide their own owner’s manuals
which have been included with your equipment.
You should read the information in this manual
and the manuals of other suppliers completely and
have a thorough understanding of all component
systems and their proper operation before operat-
ing your equipment.
REMEMBER - IT IS YOUR RESPONSIBILITY
TO ENSURE THAT YOUR EQUIPMENT IS SAFE
FOR YOU AND YOUR CREW. ALWAYS EXER-
CISE GOOD COMMON SENSE WHEN INSTALL-
ING OR REPAIRING EQUIPMENT AND WHILE
OPERATING THE SH5500.
Warranty
The Hog Technologies Limited Warranty Statement
is included with this manual. It has been written
to be clearly stated and easily understood. If you
have any questions after reading the warranty,
please contact the Customer Service Department.
Hog Technologies, the truck chassis manufacturer,
and the suppliers of major components maintain
their own manufacturer’s warranty and service fa-
cilities. Hog Technologies automatically validates
your warranty at the time of purchase and does
not require a warranty registration card. However,
the manufacturers of some major components
require a completed warranty registration card to
validate their warranty. It is important that you
properly complete any warranty registration cards
included with your Stripe Hog and mail them back
to the manufacturer to register your ownership.
This should be done within 15 days of the date of
purchase and before the unit is put into service.
PLEASE NOTE: All warranted parts will be
shipped via RMA to Hog Technologies for inspec-
tion before credits will be issued. If there is no

12
Getting Started
part available for Hog Technologies to inspect then
there will be no credit issued for the damaged part.
Other arrangements must be made in writing and
authorized by Hog Technologies prior to changing
the part in question.
IMPORTANT:
The terms and conditions of the Hog Technologies
Limited Warranty are outlined in the warranty
statement included with this manual. The manu-
facturer will automatically honor the warranty to
the original purchaser for 15 days from the date
of purchase. However, during that 15 day period,
owners must comply with the steps outlined in
the warranty statement to validate their warranty.
All manufacturers are required by the US Govern-
ment to notify rst time owners in the event any
defect is discovered “which creates a substantial
risk of personal injury to the public.” It is essen-
tial that we have your warranty registration card
complete with your name and mailing address in
our les so that we can comply with the law if it
should become necessary.
Hog Technologies Customer Service will assist you
in lling in the serial numbers and other data re-
quired on your registration card if you experience
diculty. Your Warranty Registration Card will be
added to our permanent les.
Product Changes
Hog Technologies is committed to the continu-
ous improvement of our products. As a result,
some of the equipment described in this manual
or pictured in the catalog may be changed or may
no longer be available.
All information, illustrations, and specications
contained in this manual are based on the lat-
est product information available at the time of
publication.
Hog Technologies reserves the right to make
changes at anytime, without notice, in colors,
materials, equipment, specications, and models.
If you have questions about the equipment on your
Stripe Hog, please contact the Customer Service
Department.
Service
All warranty repairs must be authorized by Hog
Technologies to be eligible for reimbursement.
Should a problem develop that is related to faulty
workmanship or materials, as stated in the Lim-
ited Warranty, you should contact the Customer
Service Department to arrange for assistance and
prior approval for the necessary repair.
It is the owner’s responsibility to contact Cus-
tomer Service for prior authorization for warranty
service. An RMA (Return Materials Authorization)
will be issued by Hog Technologies for the parts in
question. All warranty work, shipping and materi-
als will be initially invoiced to the customer until
Hog Technologies technicians determine the cause
of failure. In the event it is determined to be faulty
equipment and or workmanship an appropriate
credit will be issued against the charges. Note that
Hog Technologies will not issue a credit for parts
that are not made physically available for inspec-
tion by its technicians. No substitutes, such as but
not limited to, pictures, written descriptions, and
judgments made by personnel other than autho-
rized Hog Technologies Technicians are acceptable
in lieu of the physical parts. Faulty diagnosis and
repairs by unauthorized technicians or methods
will not be covered by warranty.
We are committed to providing the highest level of
support for all of the equipment we sell. We look
forward to a long and mutually rewarding relation-
ship with you. Please contact us with any questions
or concerns. Our Customer Service Department is
available by calling 011 772 223 7393

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LENGTH
(varies slightly depending on truck chassis) ................................................................ 27 ft / 8.223 m
WIDTH
(varies slightly depending on truck chassis) .................................................................. 8.5 Ft / 2.6 m
WIDTH
(mirrors folded in).......................................................................................................7.2 ft / 2.2 m
HEIGHT ................................................................................................................... 7.9 Ft / 2.5 m
EMPTY WEIGHT
(estimated w/ fuel, water & vacuum tanks empty) ..............................................17,700 lbs / 8,029 kg
WEIGHT LOADED
(estimated W/ fuel, water & vacuum tanks full).................................................22,700 lbs / 10,297 kg
VACUUM/DEBRIS TANK VOLUME............................................................................ 660 gal / 2,500 ltr
CLEAN WATER TANK............................................................................................. 600 gal / 2,271 ltr
BLOWER ....................................................................................................Dresser Roots U-RAI 59u
BLOWER CFM .....................................................................................................................718 cfm
MAXIMUM SYSTEM VACUUM..............................................................................................15 INHGV
UHP PUMP...............................................................................................................Jetstream 3600
UHP PUMP GPM.......................................................................................................... 6 gpm / 23 ltr
MAXIMUM UHP Pressure ................................................................................ 40,000 PSI / 2,722 bar
BLOWER DRIVE BELT......................................... Gates Poly Chain 14MGT - 1568-20 Part # 60209-001
BLOWER DRIVE BELT TENSION (new) ..............................................................................76 to 80 Hz
BLOWER DRIVE BELT TENSION
(used - over 20 hours)...................................................................................................65 TO 69 Hz
UHP PUMP DRIVE BELT .....................................Gates Poly Chain 14 MGT - 3850-90 Part # 60232-001
UHP PUMP DRIVE BELT TENSION (new)...........................................................................51 TO 54 Hz
UHP PUMP DRIVE BELT TENSION (used) ..........................................................................44 TO 47 Hz
SH5500 Specications

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15
Section 1:
Safety Information
1.1 General Safety
Safety and Operations Training
Only Hog Technologies Trained and Certied per-
sonnel should be allowed to setup, operate, or
maintain this equipment. All personnel working
with or around this equipment should be made
aware that the water jets or streams of water from
leaks can cause serious bodily injury. Ultra High
Pressure injection injuries can be life threaten-
ing and even simple injection injuries can cause
lifelong disabilities. Read and follow all Cautions,
Warnings, and Danger signs posted in all related
manuals and on the equipment. Do not operate
this equipment if you have not received full train-
ing in the safety, operations, and maintenance of
this equipment by a Hog Technologies Certied
Instructor and received a Certicate of Comple-
tion. A Certicate of Attendance is not an accept-
able substitute for certication. Stay up to date
with the latest technology and knowledge. Make
sure you are signed up for the Stripe Hog Support
website and your email address is on le to receive
bulletins and updates as they become available.
Advanced courses are available to increase your
skill, understanding, and production rates.
Know and Follow all OEM Maintenance
Procedures
Hog Technologies incorporates components manu-
factured by other vendors into the SH5500. This
manual is not meant to represent all of the OEM
(Original Equipment Manufacturer’s) operating
instructions or maintenance procedures. A copy
of each component’s Owners / Operations Manual
is made available with the delivery of each ma-
chine. Read each one and understand how to use
it before operating it. Copies will be made avail-
able upon request by one of the contact methods
included in the contact section of this manual.
Included in this SH5500 Operations and Training
Manual you will nd instructions and charts for the
proper maintenance and operations of the SH5500
at the time it was written. It is possible that an
individual OEM has changed their specications
and/or procedures and that update may not be
reected here.
Work Area Safety
Remember, safety is rst! Only set up to work
in areas properly protected from trac and other
hazards. Outt all operators with proper safety
gear such as Hard Hats, safety glasses, gloves,
ear protection with at least 29 db protection rat-
ing, etc..
Ultra High Pressure waterblasting systems gener-
ate noise levels above 90 db. Hearing protection
is required in accordance with OSHA Standards.
Mounting and Dismounting
There are ladders and hand holds provided for
safely mounting and dismounting the equipment.
Know where they are and Use Them. Face the
equipment and always maintain at least three
points of contact with the equipment. Never mount
or dismount facing away from the truck or equip-
ment. Never jump down from the equipment. If
necessary, use a ladder or other climbing device
suited for safely climbing onto or o of the equip-
ment and follow standard safety procedures.
Use Only Products Intended for Ultra
High Pressure Waterblasting equipment
Know the minimum burst rating of all equipment
being used and never exceed the rated operat-
ing pressure of the lowest rated component. This
system is designed at the time of sale to operate
at 40,000 psi (2750 bars). The original compo-
nents have a minimum burst rating of 60,000 psi
in compliance with OSHA Standards.
Never Alter a Hog Technologies Product
Do not alter any product without written consent
from the manufacturer. Any alterations will auto-
matically void all warranty and could have serious
consequences including bodily harm or death.
Water Supply
Use only clean water in any Ultra High Pressure
system. DO NOT accept water drawn from reten-
tion ponds, canals, or other non-potable sources.
Read and know the Instructions
Read and follow all manufacturers’ instructions
prior to using any Hog Technologies product. Con-
tact Hog Technologies should any questions arise.
Take the instructions seriously. If they are written
here they are important to follow.
Inspect the Equipment before using it
Inspect the condition of all components prior to
use. Do not use any item that is in questionable
condition. Use only components which are marked
with the recommended operating pressure. Never

16
Safety Information
exceed the operating pressure of the weakest
component in the system.
Check Connections
Check the condition of the connection threads
prior to connecting ttings or hoses. Use anti-seize
compound on all ttings and hoses to prevent
“galling”, as galling will destroy the threads and
essentially the ttings and or connecting ends.
Never attempt to tighten ttings while under
pressure.
Tightening Connections
Properly tighten all high pressure connections.
Snug plus 15% will properly seal all UHP ttings.
Purge System
Before attaching spray bars to the Hog Head as-
sembly, engage the pump at low speed and close
the Dump Valve to force all water to the Through
Shaft to ush out any debris or foreign materials.
Any dirt or debris in the system can clog nozzle
orices and cause system pressure to spike exces-
sively, cause accelerated wear or cause immedi-
ate damage of the orices. Damaged orices will
cause reduced pressure and poor performance
and may in turn damage the substrate.
Test System
With the Spray Bar installed and all nozzles prop-
erly matched and tightened, operate the system
at low pressure to check for nozzle cohesivity and
or leaks on the Spray Bar or nozzle seats. Should
any repairs or adjustments be necessary, disen-
gage the UHP Pump to relieve all pressure before
making any required repairs or adjustments.
Set System Pressure
With the system operating properly, set your
pressure according to the methods described by
the pump
Use the Minimum Pressure Required
Do not exceed the operating pressure of the sys-
tem’s lowest pressure-rated component. All equip-
ment pressure rating and warning tags should be
left intact.
Be Prepared
If the equipment malfunctions or a malfunction
is suspected, immediately stop all blasting activ-
ity and relieve all pressure in the system before
attempting repairs. Always follow manufacturer’s
repair instructions. Only use thoroughly trained
personnel to perform maintenance or repairs.
Low Pressure Test
Following Repairs and upon starting a cold system,
operate the system at low pressure for a test.
Bring the equipment up to operating pressure
slowly.
Freezing Conditions
Because the system uses water for operations
it is susceptible to freeze damage which can be
debilitating and costly. Make sure you properly
protect your equipment during freezing tempera-
tures. Warm the hydraulic oil and components to
60o Fahrenheit (16o Celsius) before attempting
to achieve full operating pressure or operating
the equipment. Proper protection measures can
be found on the Stripe Hog Support site at www.
stripehogsupport.com under the training tab or by
calling the Customer Service Dept at (772) 223-
7393 and in the procedures section of this manual.
Do not take short-cuts they can be very costly.
Store Components Properly
Protect all components from damage during stor-
age and travel. For example, Spray Bars should
be stored with the nozzles pointed up and should
never be allowed to be turned nozzles down in
order to prevent the nozzles from getting contami-
nated with dirt which can cause premature wear.
Injection Risk
Any Fluid under pressure poses the risk of injection
injury to personnel. Injection wounds can be very
dangerous even when the uid is clean. Injection
wounds must be treated immediately by a doctor
who is trained in dealing with these injuries. Never
check for leaks in hoses or connections with your
Hog Head

17
Safety Information
hands. Use a sheet of paper or other device to
locate a suspected leak. Never attempt to tighten
ttings while they are under pressure.
NEVER PLACE ANY PART OF YOUR BODY IN
FRONT OF OR IN CLOSE PROXIMITY TO HIGH
PRESSURE WATER STREAMS
1.2 Blasting Safety
Safety First – Always!
Be sure the work area is clear before engaging
the 40K Pump. Never operate the 40K Pump when
people are within 10’ of the Blast Head. Never
point the head at people or allow people to be
within 20’ in front of the head while o of the
ground and the 40 K Pump operating.
WARNING
INJURIES FROM ULTRAHIGH PRESSURE WATER INJECTION
CANBEVERYSERIOUSAND OFTENRESULT INAMPUTATION
OR DEATH. ALWAYS MAKE SURE ALL PERSONNEL ARE
A SAFE DISTANCE FROM THE WORK AREA BEFORE THE
PRESSURE PUMP IS ENGAGED. NEVER PUT HANDS, FEET
OR ANY PART OF YOUR BODY IN OR NEAR THE HIGH
PRESSURE STREAM. TURN OFF UHP IF ANYONE GETS
CLOSE TO THE HEAD.
Nozzle Flow Chart
Check Hog Head
Check the Hog Head for smooth and proper op-
eration before each shift. Ensure that the nozzles,
Spray Bars and hose ttings are not leaking at the
beginning of each shift and several times through-
out the shift. Make sure the Spray Bar covers are
in place and secured before each shift.
Check Stripe Hog Control Components
Check all switches and control panel devices to
ensure each is working properly before beginning
operations. Do not use equipment if any device is
malfunctioning.
WARNING
ULTRA HIGH PRESSURE BLASTING CAN CAUSE DEBRIS
TO BE PROJECTED UNEXPECTEDLY IN AND AROUND
THE WORK AREA THAT CAN CAUSE SEVERE EYE INJURY.
MAKE SURE ALL PERSONNEL STAY WELL CLEAR OF THE
BLASTING AREA AND USE HARD HATS, EYE AND EAR
PROTECTION.

18
Safety Information
Check the Pressure While Not Blasting
The pressure should drop below 500 psi (34 bars)
after the STOP switch is pressed. If it stays higher
you must check the Dump Valve Shut-O Cartridge.
Do not use the equipment until the repair is made.
Know Your Surroundings
Know your surroundings well – i.e. truck, hoses,
people, walls, moving vehicles, trac, live trac
lanes, etc.
Never Blast While Stopped
Always make sure to stop blasting before stopping
the truck. Blasting while the machine is stopped
will damage the road surface.
1.3 Nozzle Safety
Check Flow Rating
Know the ow rate of the UHP Pump. Because the
UHP Pump is a positive displacement pump it de-
velops a specic pressure at a specic ow rate.
A combination of nozzles must be used that does
not exceed the ow rate for a given pressure. Use
the above chart to calculate the ow rate of a given
combination of nozzles and make adjustments as
necessary to achieve the pressure you desire. Worn
out or “Blown” nozzles use more water and reduce
the possibility of achieving your desired pressure.
Check Pressure Rating
Use only nozzles with a manufacturer’s minimum
burst rating of 60,000 psi.
Check Nozzle Stream
After installing new nozzles and before installing the
Spray Bar Protectors you must check the nozzles
at operating pressure to make sure there are no
leaks and the streams are “Needle Sharp”. Refer
to the Nozzle Cohesivity Chart to decide if the new
nozzles should be replaced or not. It is common
to replace 10% of new nozzles due to undesired
nozzle streams.
Use Anti-seize
Use plenty of Anti-seize on each nozzle and make
sure they go into the Spray Bar easily. Never force
the nozzle into the socket as it will permanently
damage the threads. Never use power tools to
run the nozzles in or out. Always turn the nozzles
by nger as much as possible. If the threads gall
you should use a back and forth motion to slowly
extract it from the Spray Bar. Never use more than
20 ft lbs of torque.
Installing Nozzles
Insert the nozzle into the Spray Bar nger tight.
Using a 3/8” socket tighten the nozzle about 15%
more. Do not over-tighten. If the nozzle won’t seal
this way the seat may be damaged and must be
reconditioned.
Clogged Nozzles
The orices of the nozzles are so small that they
can be clogged by particles too small for the hu-
man eye to see. You must take great precaution
to keep the nozzles clean or they will be clogged
immediately upon starting the machine. Clogged
nozzles should be discarded and replaced. Trying
to unclog the orice usually results in damaging
or dislodging the sapphire and destroying the
nozzle. Clean, careful habits will save lots of time
and prevent clogged nozzles.
Remove a Nozzle from Service if:
A. Nozzle is split or damaged
B. Nozzle is clogged
C. Nozzle Stream is fanned
D. Nozzle cannot hold pressure or is suspected
to be weak
E. Nozzle Hex Head is rounded o
F. Nozzle Threads are damaged
1.4 Hose Safety
Check Pressure Rating
Use only hoses with a Minimum Burst Rating of
60,000 psi (4,136 bars)
Minimum Radius
Never bend the hose tighter than the minimum ra-
dius as given by the manufacturer. Smaller hoses
can be bent tighter than larger ones. If the mini-
mum radius is exceeded the hose will fail quickly
at that point. You should discard any hose that
has exceeded the minimum radius. When an Ultra
High Pressure Hose ruptures it can be extremely
dangerous to personnel in close proximity.
Leaking Fittings
Never tighten leaking hose ttings while they are
under pressure. There is a risk of injection injury.
Turn o the Pump then tighten the ttings before
continuing. Leaks in hose connections can destroy
the hose within minutes.

19
Safety Information
Hose care
Protect the hose from sharp objects, abrasive
surfaces, and wheel trac.
Retire a Hose from Service if:
A. Cover is damaged and reinforcing wire is ex-
posed
B. Cover is loose, has blisters, or bulges
C. Hose has been crushed or kinked
D. End Fittings show signs of damage, slippage,
or leakage
E. Hose has been exposed to pressures of 2 times
the operating pressure rating
F. Hose has been stressed or stretched
Check the Dump Valve Return Line
The hose used for the return line on the Dump
Valve must be of large enough diameter and
pressure rating to accept the full ow of the pres-
surized water released when the valve is opened
and facilitate an instantaneous pressure drop in
the system without bursting. Inspect this line
periodically to ensure it is in good condition. Re-
place when it becomes compromised in any way,
chaed, cut, dry-rotted, cracked or leaking.
1.5 High Pressure Fitting Safety
Fitting Ratings
Use high pressure ttings with a rating of 60,000
psi (4137 Bar.)
Check Fittings
Do not use ttings that have been cross threaded
or have damaged threads.
Fitting Connections
Use anti-seize compound on all hose and tting
connections to prevent galling. Do NOT use anti-
seize on the seating area of any connections.
1.6 Dumping Safety
A) Always dump on level ground, never uneven
or sloped ground.
B) Always choose solid ground, not soft sand or
wet soil.
C) Never allow personnel under raised tank with-
out safety supports in place.
D) Always be careful to avoid any pinch points
which could cause injury.
E) Always drain all the liquid from the debris
tank before dumping the solids.

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