JETStream 55515 Instruction sheet

Product Instructions
Hand-Adjustable Pressure Regulator
Jetstream of Houston, LLP [phone]
4930 Cranswick [phone]
Houston, TX 77041 [phone] fax
www.waterblast.com
Contents
Introduction................ 2
Safety Information........ 3
Installation................. 3
Operation .................. 4
Maintenance .............. 5
Troubleshooting........... 6
Repair ...................... 7
Parts List................... 8
Important!
This document contains important safety information.
Read carefully and retain for future reference.
PI-095
Part Number Inlet Outlet Maximum Pressure
P/N 55515 ¾ inch NPT Male 1" NPT Female 15,000 psi (1000 Bar)
P/N 55570 20K Male 1" NPT Female 20,000 psi (1400 Bar)
P/N 55525 40K Male 1" NPT Female 40,000 psi (2750 Bar)

Jetstream Product Instructions l Pressure Regulator
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Jetstream of Houston, LLP
Phone: [phone] or 713-462-7000
www.waterblast.com
Copyright © 2005 Jetstream of Houston, LLP
PI-095
This product instruction provides installation,
operation, maintenance, and troubleshooting
information for the Hand-Adjustable Pressure
Regulator. Also included are an illustrated parts
list and applicable safety information.
1.1 Models Covered
There are three different models of the Hand-
Adjustable Pressure Regulator covered in this
Product Instruction:
•P/N 55515
•P/N 55570
•P/N 55525
The three models are identical in appearance and
operation.
1.2 General Description
The Hand-Adjustable Pressure Regulator features
a cartridge-based design. This allows all parts
subject to normal wear to be easily field replace-
able using simple hand tools.
The Hand-Adjustable Pressure Regulator is nor-
mally mounted on the pump’s fluid end. The
Pressure Regulator’s function is to control pump
output pressure. This is done by adjusting the
Pressure Regulator to obtain the desired output
pressure. The Pressure Regulator is easily
adjusted using the handle.
Excess water is captured and routed to a low
pressure drain via a hose, or back to a holding
tank.
The Pressure Regulator can also be mounted
remotely. A remote-mount configuration allows
the operator to adjust the output pressure at the
blast site, rather than at the pump. The Pressure
Regulator features an oil filled plunger cavity
inside the body, providing a smoother damped
response when flow requirements change and
reducing overall wear in the system.
1.3 Specifications
Specifications for the Hand-Adjustable Pressure
Regulator are shown in Table 1.
Section 1. Introduction
Table 1. Hand-Adjustable Pressure Regulator Specifications
P/N 55515
Maximum Pressure 15,000 psi (1,000 Bar)
Maximum Flow Rate 50 GPM (189 LPM)
Dimensions Length: 13 in (33 cm), Diameter: 3 in (7.6 cm)
Weight 14.5 lb (6.6 Kg)
P/N 55570
Maximum Pressure 20,000 psi (1,400 Bar)
Maximum Flow Rate 30 GPM (113 LPM)
Dimensions Length: 13 in (33 cm), Diameter: 3 in (7.6 cm)
Weight 14.5 lb (6.6 Kg)
P/N 55525
Maximum Pressure 40,000 psi (2,750 Bar)
Maximum Flow Rate 15 GPM (57 LPM)
Dimensions Length: 13 in (33 cm), Diameter: 3 in (7.6 cm)
Weight 14.5 lb (6.6 Kg)

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Jetstream of Houston, LLP
Phone: [phone] or 713-462-7000
Copyright © 2005 Jetstream of Houston, LLP
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WARNING !
Ensure that all operators are thoroughly trained in the
proper operation of all components in the waterblast
system before beginning use of any products.
Never operate a waterblast unit without properly
installed guards covering all moving components of the
drive system.
Never put hands near moving parts when the
waterblast unit is in use.
Always back regulator adjuster out fully before
stopping unit. Begin blasting at low pressure and
slowly increase until desired pressure is reached.
WARNING !
If routing the relief water back to the tank, check the
temperature from time to time to ensure the water
temperature does not exceed 120 degrees Fahrenheit.
This could cause pump cavitation and/or damage from
trapped vapor.
Do not attempt to connect a high pressure hose to the
1" NPT Female Outlet port on the body as this will
cause a burst failure of the assembly and/or severe
injury and death. Maximum outlet pressure is 125 psi.
Never operate the regulator at a pressure higher than
that of the lowest rated component in the system. This
can also result in a burst failure of the component
causing severe injury or death.
A rupture disc set at 1.4 times operating pressure must
be used as a secondary relief device.
3.1 Manifold Mounting
Follow the steps below to install the Hand-Adjust-
able Pressure Regulator on the pump manifold.
a. Apply anti-seize compound on all
threaded connections to prevent galling of
Stainless Steel components.
b. Wrap all tapered pipe threads with three
to four turns of Teflon tape, again to help
sealing and reduce galling.
c. Install Regulator as shown in the illustra-
tion.
d. Install hose barb or quick disconnect fit-
ting in 1" discharge port and tighten
securely.
NOTE:
The low pressure connection hose must be rated for a
minimum operating pressure 125 psi and be at least
¾ "(20mm) inside diameter. Maximum length for the
hose should be no longer than 10 ft (3 meters).
Recommended hose ID is 1" (25 mm) especially for
flows over 25 GPM.
Section 2. Safety Information
Section 3. Installation

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Jetstream of Houston, LLP
Phone: [phone] or 713-462-7000
www.waterblast.com
Copyright © 2005 Jetstream of Houston, LLP
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Figure 1. Manifold Installation
3.2 Remote Mounting
WARNING !
Installation of lower pressure rated components could
result in severe injury or death should one of them fail.
If desired, the Pressure Regulator can be
mounted some distance from the pump to allow
better operator access. Ensure that the proper
parts are used.
A high pressure tee, hose, and fittings can be
used to mount the Regulator remotely as shown
in the illustration.
l hoses and fittings used to mount the Pressure
Regulator should be pressure rated at least equal
to or higher than the Regulator itself. For most
remote installations, the relief water should be
dumped to a suitable drain.
Figure 2. Remote Installation
Consult operating instructions for the waterblast
unit for detailed operating procedures. Start out
by engaging the waterblast unit’s PTO and blast-
ing at low pressure. While observing pressure
gauge, slowly turn the hand crank clockwise to
increase pressure until desired blast pressure is
reached. Cycle waterblast guns and/or foot
valves on and off, and check for pressure fluctua-
tions or improper regulator operation causing
cycling or resonation inside the valve.
When finished blasting, turn Pressure Regulator
adjustment handle counter-clockwise to lower
system pressure to near zero.
In freezing conditions, protect unit and regulator
by draining water from system and flushing with
anti-freeze.
!
Remote
mounting
tee connection
(shown bolted to
mounting bracket)
Section 4. Operation

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Phone: [phone] or 713-462-7000
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Scheduled maintenance of the Hand-Adjustable
Pressure Regulator is shown in Table 2.
5.1 Inspection
Perform the following inspection daily.
WARNING !
Do NOT use your hand or fingers to check around
fittings while unit is at operating pressure as this may
cause severe bodily injury if a high pressure jet is
encountered.
a. Visually check for leaks at high pressure
joints.
b. Stand away from the area and visually
check all high pressure areas.
c. Stop and repair regulator if any leaks are
found.
d. Start unit at low pressure and slowly
increase operating pressure until desired
blast pressure is reached. Inspect all
joints for leaks.
Figure 3. Inspection Points
Section 5. Maintenance
Table 2. Maintenance Schedule
Task Frequency
Inspection Daily
Oil Change After every 1000 hours of use 1
2
3
4
5
Inspect these
five pointsfor
leaks.

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5.2 Oil Change
a. Unscrew high pressure base and cartridge
from regulator body.
b. Remove adjuster cap and lever assembly
from body by unscrewing counter-clock-
wise (See Figure 4).
Figure 4. Initial Disassembly
c. With a clean tray or tub to catch debris,
turn body upside down and push out
spring plunger and springs (See Figure 5).
There should be 20 disc springs in addi-
tion to the plunger that are removed.
Clean all components in solvent and blow
dry.
Figure 5. Spring Plunger & Spring Removal
d. Inspect plunger, seals, and body for wear
and damage (See Figure 6). Replace seals
if cuts, wear, or other damage is found.
Figure 6. Plunger & Seals Inspection
e. Insert spring plunger into body as shown
until plunger seals contact body (See Fig-
ure 7). Turn body upside down while sup-
porting spring plunger.

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Jetstream of Houston, LLP
Phone: [phone] or 713-462-7000
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Figure 7. Spring Plunger Installation
f. Retract plunger slightly so that a small
opening is created between the body and
plunger (See Figure 8).
Figure 8. Retracting the Plunger
g. Over a clean tub or pan, pour the recom-
mended 10W-40 oil into the opening until
the cavity is full and all air has been
purged. Push plunger upward to close the
opening and engage the plunger seals into
the bore (See Figure 9).
Figure 9. Fill With Oil
h. Flip the body over and continue to force
the spring plunger downward so that the
O-ring seals are fully engaged in the bore.
Most or all of the trapped air should be
now be evacuated (See Figure 10).
Figure 10. Force Plunger Down
A8-0039
A8-0040
A8-0041

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Copyright © 2005 Jetstream of Houston, LLP
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i. Reinstall the high pressure base and car-
tridge assembly and tighten securely.
Push spring plunger down with a suitable
device so that plunger contacts valve car-
tridge.
j. Begin stacking the disc springs in an
alternating fashion as shown with the
spring OD contacting the flange and cap
surfaces (See Figure 11).
Figure 11. Stacking Disc Springs
NOTE:
Overall length for the assembly should be 2.720" +/-
.030". Replace the springs if the dimensions fall
outside this range.
k. Fill cavity with 10W-40 oil until the last
spring is just totally covered (See Figure
12). Do not overfill as this will cause
problems with the regulating accuracy
and may result in over pressurization.
l. Install spring pusher with O-ring end last
and tighten adjuster cap and lever assem-
bly firmly.
m. The unit is now ready for operation.
Figure 12. Filling Cavity
Plunger
Disc Springs
stacked in
alternating
orientation
A8-0044

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Phone: [phone] or 713-462-7000
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.
Section 6. Troubleshooting
Symptom Probable Cause Corrective Action
Regulator does not reach
operating pressure. Valve seat cartridge worn out Replace cartridge
Spring discs worn or damaged Replace springs
Regulator makes chattering
or "screaming" noises Oil level too low Check oil level and refill as needed
Cartridge damaged Replace cartridge
Regulating pressure incon-
sistent Valve seat cartridge damaged Replace cartridge
Spring plunger binding Replace spring plunger
Bypass hose too small or too long Replace hose with 1" minimum I.D.
and proper length
Oil leaking from regulator O-ring seals damaged Replace O-rings where necessary

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Phone: [phone] or 713-462-7000
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Copyright © 2005 Jetstream of Houston, LLP
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7.1 Valve Cartridge Replacement
If operating pressure cannot be attained, replace
cartridge as follows:
a. Turn the adjustment lever counterclock-
wise to the low pressure position.
b. Unscrew high pressure base from body as
shown (See Figure 13).
c. Remove valve cartridge from high pressure
base. Inspect base for any erosion or
other high pressure water damage.
Figure 13. Removing Base
NOTE:
Different pressure range cartridges have different
diameter threads, and will not fit into a base with the
incorrect pressure rating.
d. Install new valve cartridge.
e. Assemble high pressure base into body
and tighten securely. The unit is now
ready for operation.
Figure 14. Installing Cartridge
Section 7. Repair
Unscrew cartridge and base
from regulator body.
A8-0048

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Phone: [phone] or 713-462-7000
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Figure 1-1. Hand-Adjustable Pressure Regulator Parts Diagram
Section 8. Parts List

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Phone: [phone] or 713-462-7000
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Copyright © 2005 Jetstream of Houston, LLP
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Table 3. Hand-Adjustable Pressure Regulator Parts List
Item Description Part Number Qty
1 SPRING, DISC, REGULATOR 70127 20
2 PLUNGER, SPRING, REGULATOR 55519 1
3 O-RING, SPRING PLUNGER 25740 1
4 RING, BU, SPRING PLUNGER 70125 2
5 BODY, REGULATOR 55521 1
6 O-RING, BASE 26416 1
7 CARTRIDGE ASSEMBLY, 15,000 PSI (1000 BAR) 55530 1
CARTRIDGE ASSEMBLY, 20,000 PSI (1400 BAR) 55540 1
CARTRIDGE ASSEMBLY, 40,000 PSI (2750 BAR) 55545 1
8 BASE, REGULATOR, 15,000 PSI (1000 BAR) 55516 1
BASE, REGULATOR, 20,000 PSI (1400 BAR) 55567 1
BASE, REGULATOR, 40,000 PSI (2750 BAR) 55518 1
9 NUT, JAM, REGULATOR, 20,000 PSI ONLY 51929 1
10 PUSHER, SPRING, REGULATOR 55522 1
11 O-RING, PUSHER, SPRING 25125 1
12 O-RING, END CAP, I.D. 25212 1
13 O-RING, END CAP, O.D. 25165 1
14 CAP, END, REGULATOR 55523 1
15 CAPSCREW, PIVOT HANDLE 27680 1
16 ADJUSTER, REGULATOR 55524 1
17 HANDLE, REGULATOR 55531 1
18 BALL 70130 1
OIL, SYNTHETIC, 10W-40 28682 0.25 QT
(0.237 liter)