Den-Sin Merlion Plus E500 User Manual & Spare Parts Manual Download Page 3

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INTRODUCTION

MERLION PLUS - E500

STD04

Page 2 of 50

INTRODUCTION

............................................................................................................................ 1

1. Getting acquainted with your Heavy Duty Pressure Washer ................................................ 2

OPERATIONAL INFORMATION

................................................................................................. 3

MACHINE DIMENSION

................................................................................................................ 5

High Pressure Machine Schematic Diagram

.................................................................................... 6

Marking & Indication

....................................................................................................................... 7

Machine Highlights

.......................................................................................................................... 8

HIGH PRESSURE MACHINE LOCKOUT/TAGOUT PROCEDURE

......................................... 8

2. Safety and protection information .......................................................................................... 13

General safety

................................................................................................................................. 13

WARNING

..................................................................................................................................... 14

Safety devices

................................................................................................................................. 15

Transporting the machine

............................................................................................................... 15

Safety PPE

...................................................................................................................................... 17

Operations

...................................................................................................................................... 18

Application Guidelines

................................................................................................................... 18

3. Maintenance and troubleshooting .......................................................................................... 19

Maintenance Schedule

.................................................................................................................... 19

Troubleshooting

.............................................................................................................................. 21

Pump Service Instructions

.............................................................................................................. 22

Torque Specification

...................................................................................................................... 24

4. Machine Spare Parts Lists ....................................................................................................... 25

Motor/Pump Assembly Spare-Parts List

........................................................................................ 26

Water Tank Assembly Spare-Parts List

......................................................................................... 27

Filter Assembly Spare-Parts List

.................................................................................................... 28

E500 Pump Assembly Spare-Parts List

.......................................................................................... 29

E500 Trigger Gun / lance & hose assembly

................................................................................... 37

4. Electrical Assembly .................................................................................................................. 39

Wiring diagram

............................................................................................................................... 39

Main Contactor Overload Setting

................................................................................................... 40

Motor Switch Timer Setting

........................................................................................................... 40

5.Optional Rotating Nozzle .......................................................................................................... 44

E500 Bar Rotating Nozzle – Type 3

.............................................................................................. 45

Operation & Use of Rotating Nozzle –E500

.................................................................................. 48

Optional sand & slurry blasting kit E500

....................................................................................... 49

6. Warranty ................................................................................................................................... 50

Revison History:-

1. Getting acquainted with your Heavy Duty Pressure Washer

Date

Revision

Rev. No.

03/08/2016

Added start-up issues and troubleshooting guide

19/04/2017

Updating 220V components

05/06/2017

Pump and Component Changeover and removal of CE declaration

25/09/2017

Manual Content Updating. Cable and Water Tank P/N update.

The information contained in this user guide is subject to change without notice.

Summary of Contents for Merlion Plus E500

Page 1: ...www densin com USER GUIDE SPARE PARTS MANUAL Electrical Powered Heavy Duty Cold Water High HIGH PRESSURE CLEANER Original Instruction Merlion Plus E500 ...

Page 2: ...event injuries to you objects and persons nearby Safety The following symbols are used in this manual to indicate procedures that if not followed may results in personal injuries or damage to equipment WARNING is used to alert the reader of procedures or practice which if not followed correctly could result in personal injuries CAUTION is used to alert the reader of procedures or practice which if...

Page 3: ...e Parts List 26 Water Tank Assembly Spare Parts List 27 Filter Assembly Spare Parts List 28 E500 Pump Assembly Spare Parts List 29 E500 Trigger Gun lance hose assembly 37 4 Electrical Assembly 39 Wiring diagram 39 Main Contactor Overload Setting 40 Motor Switch Timer Setting 40 5 Optional Rotating Nozzle 44 E500 Bar Rotating Nozzle Type 3 45 Operation Use of Rotating Nozzle E500 48 Optional sand s...

Page 4: ...t and graffiti off walls Dust dirt soil mud off floors Oil grease off engines and other mechanical parts Rust dirt salt scale and paint off ship decks The Heavy Duty Pressure Washer can also be used for tasks such as Surface preparation Concrete removal And with the option of using different accessories many more jobs can be dealt with Sandblasting Drain cleaning Extra long short lances for hard t...

Page 5: ...nclude verifying the integrity of hoses and connections tips lances Personal protective equipment must be worn Prior to commencing any water blasting work the area must be barricaded to restrict unauthorized access We recommend to practice to employ 2 operators blasting method The role of the 2nd operator is to attend the pump unit keep close watch on the 1st operator for tiredness Therefore the o...

Page 6: ... Supply 380 415V 440 460V 220V 230V Freq 50Hz 60Hz 60Hz Motor Type 25HP 25HP 25HP Motor Class F F F Motor Speed 1450rpm 1750rpm 1750rpm Power Req 32A 32A 56A Pump Specification Working Pressure 500Bar 7250psi 500Bar 7250psi 500Bar 7250psi Flow Rate 16 l min 4 3gpm 16 l min 4 3gpm 16 l min 4 3gpm Nozzle size 0003 0003 0003 Machine Dimensions Machine Mass 220kg 220kg 220kg Dimension LxWxH 1060x490x9...

Page 7: ...he nozzle is chocked Another possible cause is the unloader setting is wrongly set When machine is over pressurized the safety valve will start to open and excess water is dumped The setting of the safety valve system is factory set Do not try to reset them UV Unloader Valve Operation Unloader valve system is a system to regulate the pressure for the machine The setting of the unloader valve syste...

Page 8: ...late v v Manufacturing Date Quarter Year WP 500 Bar Hose Size ID or DN 12 Hose Fitting Do not bend the hose or squeeze between doors Replace the hose if the hose wire is exposed Read the WP allow on the hose before using the machine Always switch off and de pressurize the machine before attach or dettached the hose to the machine CAUTION ...

Page 9: ...ty Pressure Washer MERLION PLUS E500 STD04 Page 8 of 50 1 5 Machine Highlights Solid Wheels Unloader Valve Pressure Gauge Powder Coated Frame Stainless Steel Cover Filter Crawl Coupling Galvanizing Electrical Box Castor Wheels Safety Valve ...

Page 10: ...h when the motor has come to a stop 3 Turn the main isolator to the off position 4 Release residue pressure in the trigger gun 5 Lockout the main isolator with a lock assigned individual lock This is to disable the operation of the machine 6 Lock the electrical box and the keys are kept with an assigned individual lock to prevent any unauthorized modification to the machine control settings 7 Lock...

Page 11: ...g on these valves If setting is required a trained personal must performed the task Incorrect adjustment to the valve may results machine damage which will cause warranty void To prevent unauthorized adjustment to the valves these valves are applied with tempered proof sealant Once the sealant cracked it showed that unauthorized activities occur on the valves Electrical Components To prevent unaut...

Page 12: ... air pockets which would result in cavitation Next power off machine and mount the Trigger Gun with Lance to the other end of the high pressure hose Always use two wrenches when tightening the hoses Switch on the motor and allow it a few seconds for the star delta connection to switch over automatically The Water Blaster is now ready for operation Get a firm grip with both hands on the spray gun h...

Page 13: ...p 2 Direct the water supply into the pump inlet from the water tank Water pressure supplied to the inlet to be about min 1 2 bar Step 3 Turn on machine and water supply and let water flow into the inlet port for about 4 5 sec Once a smooth flow of water is observed from the pump outlet sticky valve issue resolved Turn off machine and reconnect H P hose and resume blasting If problem still exist an...

Page 14: ...sition will prevent any unnecessary injuries as shown Trigger Gun Vibration The declared vibration emission value ahd is 6 3 m s2 with an uncertainty K of 1 1 m s2 Pro long working with the trigger gun will cause tiredness to the user It is recommended to work with the trigger gun not more than 20min continuously EAR PROTECTOR EQUIPMENT must be worn at all time when using the machine This is to pr...

Page 15: ...ent should parallel that of a gunshot injury The external manifestations of the injury cannot be used to predict the extent of internal damage Initial management should include stabilization and a thorough neurovascular examination X rays can be used to access subcutaneous air and foreign bodies distant from the site of injury Injuries to the extremities can involve extensive nerve muscle vessel d...

Page 16: ...ine will immediately come to a total stop To reset the machine turn the button clockwise and release Machine will remain in its neutral state To start up the machine again user needs to press the start button again 2 Safety valve protecting against over pressure The safety valve will start to open and excess water is dumped The setting of the safety valve system is factory set 3 Incorrect setting ...

Page 17: ...e load chain wire rope is hanging freely and not twisted or knotted 3 Position the hook over the center of gravity of the load 4 Ensure the slings are secure and load is free to be lifted 5 Do not try to hook on the machine frame to life up the machine It is not designed to lift from the frame 6 Check the travel path is clear 7 Ensure load is evenly distributed Lifting Direction WARNING Do not lif...

Page 18: ...ter layer is preferred Foot protection Safety footwear with steel toecaps must be worn Basic safety footwear must also be equipped with metatarsal guards to protect the instep Safety boots are available in other designs than the illustration Gaiters This is an additional layer of protection to the user foot that are not protected by the steel top cap It is intended to be worn outside of the user s...

Page 19: ...s turned off and disconnected from the main power supply 11 Only allow instructed personnel to operate the machine 12 Activating the trigger gun can cause backward force therefore always hold spray lance with both hands 13 When pausing during operation stop the machine by turning the main switch to position 0 and ensures that the trigger gun is locked 14 Only use high pressure hoses connections an...

Page 20: ...ntact recycles company to collect the waste oil for proper dispose Always let the pump cool before service Cleaning of machine Use damp cloth to wipe the cabinet and handle bar Notice Do not use detergent cleaning chemicals Cleaning of motor fan to ensure sufficient airflow Clean the motor fan cover Clean the motor fan blade Do NOT operate the machine with damaged or removed fan cover General Prev...

Page 21: ...r by heavy or squeezed in door opening May cause machine not function properly Check electrical cord and high pressure hose for wear and cracks To prevent electrical shock and safety to the user Ensure coupling parts free of dirt to ensure long life of O ring seals preventing water leaks Extend life span of the pump seals and maintaining correct pressure Release any residual pressure from the gun ...

Page 22: ...released If the problem still occurs by pass valve should be dismantled and the extraneous matter removed High Pressure Cleaner only works with approximately 2 3 of the maximum pressure and the high pressure hose is vibrating Valves are dirty Remove the dirt and check to ensure the valve flaps are movable and fit tightly Noisiness The pump sucks air One or more valve springs are broken or down Ext...

Page 23: ...erior of the pump Loosen and remove the M10 Bolts in the front Remove all but 2 bolts to support the Manifold Pump Head Remove the remaining bolts and pull out the Manifold followed by the Pump Head Take care not to drop the Pump Head on the Plungers Push out the Valve from the front with a brass rod Take care not to scratch the interior of the pump Check the Valve for damages replace if necessary...

Page 24: ... Insert the Back Ring Insert the Low Pressure Seal into the Pressure Ring Take note of the orientation groove facing outwards Insert the Pressure Ring into the Pump Head knock a few time with a mallet to compress the packing below Turn the Pump Head over and insert the Diffuser Take note of the orientation when insert the Valve Apply waterproof silicone grease onto the surface of the Plunger Assem...

Page 25: ...on E500 N m lb ft 1 Head Bolts 50 37 2 Valve Caps NA 3 Inlet Cap 140 103 4 Outlet Cap 80 60 5 Bearing Flange Bolts 25 19 6 Rear Cover Bolts 11 8 7 Connecting Rod Bolts 30 22 8 Plunger Bolts 15 11 9 Valve Cover Bolts 50 37 NOTE It is not necessary to open up the pump once you notice the pressure does not build up 1st thing is to check nozzle for wear and tear which will contribute to pressure drop ...

Page 26: ... 4 9 700510007 4 LOCK NUT M6 10 700510220 4 BOLT M6 X 12 HEX 11 700520626 2 WHEEL SOLID ID20 12 700520092 2 STARLOCK WITH CAP DIA 20 13A 700520837 1 set AXIAL DIA20MM MERLION 2016 W SPACER 13B 700520837 4 WHEEL SPACER 14 700520641 2 CASTOR WHEEL 6 SWL T LOCK 15 700510107 8 BOLT M8 x 20 HEX 16 700510005 8 WASHER M8 FLAT 17 700510004 8 LOCK NUT M8 18 700530836 1 EL BOX COMP STD 25HP 380 440V 18 7005...

Page 27: ...24HP 50 60HZ 23 700951509 1 6m CABLE 7G 2 5MMSQ 380 440V 23 700951520 1 6m CABLE 7G 6MMSQ 220V 24 700510201 4 BOLT M12X45 HEX 25 700510131 4 WASHER M14 26 700510067 8 WASHER FLAT M12 27 700510068 4 LOCK NUT M12 28 700510064 4 BOLT M8 X 40 HEX 29 700510034 4 WASHER SPRING M8 30 700505284 1 PUMP E500 E500 50Hz 700505285 1 PUMP E500 E500 60Hz 31 700530111 1 GASKET PUMP 32 700510230 4 BOLT M8 X 30 ALL...

Page 28: ...G1 39 700541002 1 FLAT GASKET G1 40 700540771 1 ELBOW 1 2 BSPT M F 90Deg 41 700540270 1 HOSE NIPPLE 1 1 2 BSPT 42 700510025 1 CONTRA NUT 1 2 BRASS 43 700540998 1 ELBOW 90DEG G1 2 M F 44 700520638 1 FLOAT VALVE 1 2 PLASTIC 45 700540997 1 SOCKET G 1 2 F F BSP 46 700540934 1 BUSHING 1 2 BSPPF 1 2 BSPPM 47 700540056 2 DOWTY SEAL 1 2 48 700540771 1 ELBOW 1 2 BSPT M F 90Deg 49 700540270 1 HOSE NIPPLE 1 ...

Page 29: ... 81 700540987 1 COUPLING CRAWL 1 2 F END 82 700540056 1 DOWTY SEAL 1 2 83 700540057 1 NIPPLE 1 2 NPT 1 2 BSPM 84 700540056 1 DOWTY SEAL 1 2 85 700520622 1 FILTER 1 2 BSP w WENCH 86 700520756 1 FILTER 5 CARTRIDGE 250um 87 700540328 1 ELBOW 1 2 BSPT M F 88 700540270 1 HOSE NIPPLE 1 1 2 BSPT 89 700541026 1 HOSE CLIP 1 34 37 90 700950021 0 4m HOSE INLET 1 RUBBER 18 BAR BLK 91 700541026 1 HOSE CLIP 1 3...

Page 30: ...m HOSE 1 SPRING TRANSPARENT 58 700540264 1 HOSE CLIP 1 31 34 59 700550004 1 DOWTY SEAL 3 8 60 700540345 1 NIPPLE 1 2 NPTM 3 8 BSPM 61 700540982 1 UNLOADER VALVE 500BAR 1 2 62 700540056 1 DOWTY SEAL 1 2 63 700540996 1 NIPPLE 1 2 NPT F M 500BAR Not require for Auto SS function Kit and replace K1 76 64 700540057 2 NIPPLE 1 2 BSPPM M 65 700540328 1 ELBOW 1 2 BSPT M F 66 700540270 1 HOSE NIPPLE 1 1 2 B...

Page 31: ... 700541014 1 ADPATOR 3 8 BSPM 1 4 BSPTF 3 8 BSPF 1 2 BSPM 72 700540540 1 PLUG 3 8 BSPP 73 700540056 1 DOWTY SEAL 74 700540055 1 GAUGE 1000BAR 1 4 BSPT 75 700540985 1 SAFETY VALVE 500BAR 1 2 76 700540276 1 T JOINT M H P Pos Part no Qty Description K1 700530844 1 MERLION PLUS E500 AUTO SS KIT 700530514 1 TIMER 700530471 2 PRESSURE SW 3 8 700540100 1 Nipple 1 2 ...

Page 32: ...4 Machine Spare Parts Lists MERLION PLUS E500 STD04 Page 31 of 50 4E ii E500 Pump Spare Parts Repair Kit List ...

Page 33: ...NG 20 1 ALUMINIUM GASKET 21 1 PLUG 3 4 22 700505156 16 SCHNORR WASHER DIA 10MM 23 700505070 8 BOLT HEX M10X140 ZN 24 700505071 3 BOLT M6 X 10 HEX ZN 25 700510023 3 WASHER FLAT M6 26 1 MANIFOLD 27 1 MANIFOLD COVER 28 700505167 8 BOLT M10X30 29 Kit 85 3 PLUNGER NUT 30 3 GASKET 31 700505080 3 PLUNGER DIA 15MM 32 Kit 85 3 O RING 33 3 ANTI EXTRUSION RING 34 3 DISC 35 700505286 3 PISTON GUIDE CH PUMP DI...

Page 34: ...15 KIT 152 700505096 Valve Kit 1 SET 13 3 OUTLET VALVE 14 9 O RING 15 6 ANTI EXTRUSION RING 16 3 INLET VALVE 17 3 ANTI EXTRUSION RING KIT 85 700505097 Plunger Kit Ø15 1 SET 29 3 PLUNGER NUT 30 3 GASKET 32 3 O RING 33 3 ANTI EXTRUSION RING 34 3 DISC Pos Part no Qty Description 48 700505085 1 CRANKSHAFT 50HZ 700505115 CRANKSHAFT 60HZ 49 700505265 1 BACK COVER GASKET 50 700505288 1 BACK COVER CH PUMP...

Page 35: ...4 Machine Spare Parts Lists MERLION PLUS E500 STD04 Page 34 of 50 E500 Un loader Assembly ...

Page 36: ...9 2 O ring 1 78x20 35 2081 NBR 90 NERO 10 1 Spacer Support 11 1 Piston 12 1 O ring 2 62x13 95 3056 NBR 90 NERO 13 1 Backup Washer 14 x 18 7 x T1 8 14 1 Piston Fitting 15 1 S S Ball 16 1 Pin Holder 17 1 Spring 5 4x16 6x65 18 1 Lock Nut M27x1 25 19 1 Set Screw M4 20 1 Knob 21 1 O ring 3 53x7 52 4028 NBR 90 NERO 22 700540970 1 UNLOADER PRES SHUTTER 23 700540971 1 UNLOADER PRES SHUTTER SPRING 24 1 Bac...

Page 37: ... 1 78x17 17 6 700540995 1 Backup Ring 17 9x21 0x2 7 1 Bushing Piston 8 700540995 1 Piston Pin 9 700540995 1 O Ring 2 62x13 10 117 10 1 Backup Ring 13 5x18 2x2 5 11 700541006 1 Piston Guide Bushing 12 700540995 1 O Ring 1 78x26 7 13 700541007 1 Spring Guide 14 700541004 1 Spring 15 700541005 1 Spring Tightening Bolt 16 1 Valve Spring Body 17 1 Nut M20x1 5 18 1 Retaining Ring 1 18 700540985 1 SAFETY...

Page 38: ...traight jet 0003 50 60Hz 1 700550389 1 Nozzle fan jet 1503 50 60Hz 2 700551229 1 Spring Holder 3 700551230 1 Back up ring PTFE 4 700551231 1 O ring Ni85 5 700551232 2 Stem Seal O ring 6 700551233 1 Brass Spacer Ring 7 700551234 1 Spring S S 8 700551235 1 Piston seat 9 700551236 1 O ring Ni85 10 700551237 1 Back up ring 11 700551238 1 Front Plug M18x1 5 12 700551239 1 Parallel Pin Ø6x25 8mm ...

Page 39: ... Connection fitting 1 2 BSPP female 30 700540057 1 Nipple BSPP 31 700550097 1 High Pressure Hose 15m with BSPP Swivels Standard 31 700550098 1 High Pressure Hose 20m with BSPP Swivels Optional 31 700550099 1 High Pressure Hose 30m with BSPP Swivels Optional 32 700550136 1 Lance connection male 3 8 female BSPP 2 21 700551180 1 Trigger Complete inclusive of item 27 29 700551181 1 Set Trigger Gun Rep...

Page 40: ...4 Machine Spare Parts Lists MERLION PLUS E500 STD04 Page 39 of 50 4F Electrical Assembly Wiring diagram ...

Page 41: ... Connect Brown Wire of SW1 to Terminal TB3 Terminal of T1 A1 Y1 Connect Blue Wire of SW2 to Terminal TB5 Set on T1 S1 Function Op Set on T1 S2 Time 2s Set on T1 S3 Range 60s Machine will stop after 2mins without trigger is pressed Main Contactor Overload Setting The setting of the overload LRD must be always set at about 2x of the motor running current at 26A Incorrect setting of the overload will...

Page 42: ... 9 700530477 1 Overload relay mains 380 415 440V 50 60Hz 9 700530169 1 Overload relay mains 220V 50 60Hz 10 700530475 1 Contactor 24V mains 380 415 440V 50 60Hz 10 700530163 1 Contactor 24V mains 220V 50 60Hz 11 700530513 1 Star delta timer 700530514 1 Timer auto start stop For Auto S S Kit Only 13 700530515 1 Relay 14 700530473 1 Transformer 380 400 440V 50 60Hz 24 V DC 15 700530523 4 Cable termi...

Page 43: ... complete mains 220V 50 60Hz N A 700951549 15 m Main cable mains 380 415 440V 50 60Hz not shown N A 700951524 15 m Main cable mains 220V 50 60Hz not shown N A 700951509 1 6 m Cable Star Delta mains 380 415 440V 50 60Hz not shown N A 700991520 1 6 m Cable Star Delta mains 220V 50 60Hz not shown N A 700951550 50m Main cable mains 380 415 440V 50 60Hz not shown ...

Page 44: ...ay mains 380 415 440V 50 60Hz 10 700530475 1 Contactor 24V mains 380 415 440V 50 60Hz 11 700530513 1 Star delta timer 700530514 1 Timer auto start stop For Auto S S Kit Only 13 700530515 1 Relay 14 700530473 1 Transformer 380 400 440V 50 60Hz 24 V DC 15 700530523 4 Cable terminal incoming power 16 700530521 1 Emergency Stop Button 17 700530522 1 Main Switch 32 40A 18 700530602 1 Panel Box 360x320x...

Page 45: ...e 1 Note Due to the natural of the design the rotating life span estimated to be about 50 100Hr depending on quality of the water Pos Part no Qty Description 1 700540314 2 Dowty Seal 2 700540149 1 Nipple 3 700551312 1 Nozzle Repair Kit 0003 50 60 Hz 1 3 700551308 1 ROTATING NOZZLE W SPRING 030 Complete 50 60 Hz ...

Page 46: ...on Use of Rotating Nozzle E500 Failure to follow proper start up procedure will shorten the lifespan of the rotating nozzle CAUTION CAUTION Point nozzle downwards Depress trigger Allow nozzle to start spinning Start Blasting only after the nozzle has started spanning 3 2 1 ...

Page 47: ...aft 9 700551148 1 Multi Jet Inlet seat 10 700551147 1 Multi Jet O ring 11 700551149 1 Multi Jet O Ring 12 700551150 1 Multi Jet Seal Holder Carbide 13 700551151 1 Multi Jet HP Seal Assy 14 700551152 1 Multi Jet Carbide Seat Coated 15 700551153 1 Multi Jet O Ring 16 700551154 1 Multi Jet Seal Shaft Small 17 700551156 1 Multi Jet Washer 18 700551184 1 Multi Jet Garter Spring 19 700551142 1 Multi Jet...

Page 48: ...ing Head 22KPSI 2 Barracuda Rotating Nozzle 029 1pc 3 Barracuda Rotating Nozzle 029 1pc 700551036 SVC KIT FOR MULTI JET 22KPSI For 50Hz 60Hz only Not Shown After every 20 40 hrs the rotating nozzle must be flushed or refilled with Auto Transmission Fluid ATF For Troubleshooting and Maintenance please refer to manual that comes with the Rotating Nozzle ...

Page 49: ...on Use of Rotating Nozzle E500 Failure to follow proper start up procedure will shorten the lifespan of the rotating nozzle CAUTION CAUTION Point nozzle downwards Depress trigger Allow nozzle to start spinning Start Blasting only after the nozzle has started spanning 3 2 1 ...

Page 50: ...and Suction Hose 700550248 5 Hose clamps 700540200 6 Regulator Handle 700550866 7 Grit Container Complete 700550865 8 Finger Screw 700520063 700510051 9 High Pressure Water Nozzle 700550614 E500 50HZ 9 High Pressure Water Nozzle 700550614 E500 60HZ 10 Nozzle Adaptor 700550242 11 Venturi Housing 700550232 12 O Ring 700550295 13 14 15 Boron Carbide Nozzle Dowty Seal Nipple 700550231 700540314 700540...

Page 51: ...limited at Seller s option solely to repair or replacement with equivalent articles This warranty is condition upon a Seller being notified in writing by Buyer within one week after discovery of defects b the return of defective articles to Seller transportation charges prepaid by Buyer c Seller s examination of such article disclosing to its satisfaction that such defects were not caused by negli...

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