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I don't know if either would have saved the pump in my picture. The pop-off would not have done anything because the pressure it would have been set for would not have been reached. The bay had a weep gun and the tip wasn't clogged. I don't know if a thermal valve would have helped because...

It's not all that aggressive. I have yet to see it eat away brass. I've seen a lot of cast iron booster pumps used in spot-free delivery and last over 20 years. I've used it on a car a couple times a week for many years and it didn't rust away. The first pump you pictured is a hydraulic pump...

It must not be or you'd have been having lots of problems with tanks overflowing. Mark VII is one SS manufacturer's equipment with which I'm not familiar.

Melted pump from washdown switch left on (No plugged tip): The low-pressure seals are melted to the seal retainers. The melted black stuff is the plastic cages of the valves. The grayish plastic bits were the valve backup rings. It takes a long time for it to get that hot, but it does happen.

My bank wants $35 for a box of 500 dollar coins. If this happened to me even once I'd be opening them in the bank and asking for replacements. I wonder if OP ever got his answer.

Then if he's in that area he definitely should use something to protect the pump. I've only seen it happen once, from someone prying mud from his fenders, and it didn't even completely plug the tip.

What does?

The Procon goes onto an electric motor.

It could be a swing check valve, they look very similar, and they don't usually do a good job of preventing backflow. I use these: https://www.kleen-ritecorp.com/p-3259-kleen-rite-944-430-brass-inline-check-valve-1-2in-f-x-f.aspx

I'd stay away from Dosatrons. It's a good theory, but you're limited to your water pressure for output to the bays, and I like good pressure on presoak. The Dosatrons are expensive and not very reliable. I'd recommend using a Procon at 100 PSI and build your own, there's not a lot to it. Use...

If you use the soapy water method to apply it, just about anyone can do it and get it smooth on a flat surface. The hardest part will be getting the vinyl off the backing without stretching it.

That indicates a problem with the bay pump. It should hold back reverse flow. There may be a check valve on the inlet side of the pump, which will also be bad.

The vinyl won't stick to a dirty surface so you'll need to clean it anyway. Since you're going to wrap it, a wire cup on a grinder will do the job and the wrap will hide the damage.

Rather than try to spot-weld it (If your welder is really, really good at welding stainless it might work out okay), take the extension to a muffler shop and have them expand it so it will slip over the existing boom by a few inches, then either clamp it or spot-it on.

I thought they had gone out of business. FWIW, I quit using them because they can't cut a round hole, and their work area must be a mess because every meter door decal has debris under the laminate. They also stopped offering the matte clear Lexan, and I don't like the shiny stuff. Their...

What exactly are they offering to do?

I'd go with the 300-1500 if I HAD TO use a pressure relief, but I never use them and never see them on car washes (I've worked on about 500 different car washes all across Texas), and when there are relief valves I often end up removing them because they're leaking. IMO if you plumb everything...

If you can't see which one is leaking, you may just have to change them all. If you don't have one, you might want to get a spare plunger. It's very unlikely that it's cracked, but I have seen it happen on a 310. 30W non-detergent works fine, but if the oil looks milky at all change the oil...

You might want to try a different brand of hose. Kleen-Rite's brand vac hose pulls apart very easily. Smooth-Bor is better but the last couple of boxes seems to be getting soft and weak very fast. I've seen a rainbow vac hose that is very durable, but I don't know if they make it long enough...

Have you looked at the price of it lately? It's gone up about 800% in the last 20 years.