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Den-Sin MERMAID E500-S, User Manual & Spare Parts Manual

The Den-Sin MERMAID E500-S user manual and spare parts manual are essential resources for understanding and maintaining this exceptional product. Available for download free of charge, these manuals provide comprehensive instructions and can be found on our website. Enhance your user experience and keep your unit in peak condition with these valuable resources.

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3. Maintenance and troubleshooting 

MERMAID E500-S 

 

 

 

STD08 

 

 

 

          Page 24 of 52 

 

Service Instructions   

 

•

 

Checking or Replacement of Plunger 

 

 

•

 

Loosen the screws of the front head

 

 

•

 

Remove the piston nut and the gasket

 

 

•

 

By removing the screws please hold the 
suction manifold

 

 

•

 

Remove the plunger from the piston 
guide

 

 

•

 

Turn the shaft in order to move out the 
head easily

 

 

•

 

Fatten the thread inside the plunger

 

 

 

•

 

Remove the head from the plunger use a 
plastic hammer. Attention, head is heavy

 

 

•

 

Mount the new plunger on the piston 
guide. Attention! 

 

Do not damage the ring.

 

 
 

 
 
 
 

 
 

 

Summary of Contents for MERMAID E500-S

Page 1: ...www densin com USER GUIDE SPARE PARTS MANUAL E E5 50 00 0 S S Electrical Powered Heavy Duty Cold Water High HIGH PRESSURE CLEANER M ME ER RM MA AI ID D Original Instruction ...

Page 2: ... precautions are not observed Therefore a full understanding of the contents of this instruction manual is required in order to prevent 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 ...

Page 3: ...ecommend 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 operators can take turns to operate the machine Operators must be trained on how to operate the machine DENSIN and the basic blasting protocol before allow to use the machine How to prepare machine for usage Correct way ...

Page 4: ... Don ts 22 Troubleshooting 23 Service Instructions 24 4 Spare parts list 31 Main Chassis Assembly 31 Main Chassis Assembly spare parts list 32 Motor Pump Assembly 33 Motor Pump Assembly spare parts list 33 Filter Assembly 35 Filter Assembly spare parts list 35 Pump assembly 35 Pump assembly spare parts list 36 Pump Spares Kit List 38 Un loader valve assembly 39 Un loader valve assembly spare parts...

Page 5: ...he opportunity to solve an array of blasting tasks The Water blasters are designed for industrial and for offshore use All pump parts fittings and pipes in contact with water are made of non corrosive materials Together with the ceramic pistons long life seals and stainless steel valves it ensures long life and high durability Specifications Model Motor Motor Speed Working Pressure Flow Capacity P...

Page 6: ...Drain cleaning Unpacking Remove the Water Blaster and its accessories from the packing material if any For transport and packing reasons some accessories are supplied disassembled Standard items CAUTION High Pressure Machine Trigger Gun High Pressure Hose Manual Spares Parts Nozzle Water Coupling This machine is only to be used for the purposes it is designed for Any other use shall be considered ...

Page 7: ...the 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 syst...

Page 8: ... 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 depressurize the machine before attach or dettached the hose to the machine CAUTION NOTE The information contained in this user guide is subject to change without notice ...

Page 9: ... are HOT SURFACE is used to caution user of hot surface that may cause injuries Any maintenance work to be done after the surfaces had cool down HP Water Outlet Motor Pump Rotation Hot Surface Indication Min Pressure 480Bar Max Pressure 500Bar Pressure Gauge Water Dump Back Overflow Water Drain Water Inlet ...

Page 10: ...e 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 Lockout the t...

Page 11: ...use 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 Unloader Valve Safety Valve Tempered Proof Sealant Important The unloader valve is factory set Only trained authorized personal is qualified to perform any adjustment in the event the tempered sea...

Page 12: ...etting acquainted with your Water Blaster MERMAID E500 S STD08 Page 11 of 52 Electrical Components To prevent unauthorized usage or sabotage the electrical box main switch is equipped with locks Locks Lock ...

Page 13: ...tening the hoses It is important to use FRESH water Any other liquid or chemical will damage your pump Using recycle water please make sure that the impurity sand stone must be filtered It is recommended to use additional filter 130um to filter incoming water before going into the tank when using recycle water Please note that any recycle water not process properly will shorten its pump life span ...

Page 14: ...es to a complete stop Step 2 After shut down of the Water Blaster always release the pressure inside the high pressure hoses by pulling the trigger on the spray gun before dismantling the high pressure hoses Step 3 Dis connect the lance and hose s and carefully store them in a safe place CAUTION It is NOT allowed to connect this Heavy Duty Pressure washer directly to a portable water supply If por...

Page 15: ...f 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 prevent user from hearing related injuries Noise warning sticker can be found on the machine to warn high noise emission values Shoulder Rest Trigger Gun C...

Page 16: ...ve extensive nerve muscle vessel damage as well as cause a distal compartment syndrome Injuries to the torso can involve internal organ damage Surgical consultation should be obtained Aggressive irrigation and debridement is recommended Surgical decompression and exploration may also be necessary Angiographic irrigation studies are recommended pre operatively if arterial injury is suspected Bandag...

Page 17: ...tton 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 Incorrect setting may void warranty for the machine 3 Thermal sensor and overload relay The th...

Page 18: ...ng 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 50 25 Lifting hole dimension mm Possible type of ...

Page 19: ...uter 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 ...

Page 20: ...nt to protect the operator Do not try to clean clothes or footwear with the machine 7 Precautions must be made to keep bystanders away from the working range 8 DO NOT spray clean on yourself others or live animals The high pressure jets are capable of making severe injuries 9 DO NOT spray at electrical equipment OR the machine itself 10 While repairing or servicing the equipment and its accessorie...

Page 21: ...ard hat as well as certified jackets trousers and boots against high pressure jets Triggers must never be taped tied or otherwise altered so the equipment stays in the on position If the lance is dropped it will whip about wildly causing serious injuries The lance should be a minimum of One 1 metre length to keep the operator from pointing it at himself and reducing recoil Never point a lance at o...

Page 22: ...ed oil into recycle container or plastic bag with Waste oil labeled Contact recycles company to collect the waste oil for proper dispose Always let the pump cool before service Check water filter inside the water tank Clean or replace with new filter Check water inlet filter Clean or replace with new filter Check booster pump filter Clean or replace with new filter Check for air bubbles inside hos...

Page 23: ...o Don t Action Cause Spray directly onto the machine with high pressure water Electrical shock may occurs Operate the machine with damaged or removed fan cover Motor will be overheated and malfunction Operate keep machine with frost built up Flush pump with antifreeze fluids before use Check hose and cord are not vehicle run over by heavy or squeezed in door opening May cause machine not function ...

Page 24: ...pressure and the high pressure hose is vibrating Inlet water filters is clogged Service or replaced Water supply is in sufficient to accommodate pump Low inlet booster pressure Check booster pump Valves are dirty or worn Required service Remove the dirt and check to ensure the valve flaps are movable and fit tightly High pressure pump exceeds its rated pressure and safety discs burst or safety val...

Page 25: ... the piston nut and the gasket By removing the screws please hold the suction manifold Remove the plunger from the piston guide Turn the shaft in order to move out the head easily Fatten the thread inside the plunger Remove the head from the plunger use a plastic hammer Attention head is heavy Mount the new plunger on the piston guide Attention Do not damage the ring ...

Page 26: ... new gasket Insert 2 screws into manifold as shown Fatten with LOCTITE 270 the nut thread Fix the manifold onto the pump head Turn in the piston nut with a torque moment of 15 Nm Turn screws in 1st 4th in the middle with torque of 50Nm Fix the head pushing against the crankcase ...

Page 27: ...os 54 out Lastly remove the O ring pos 31 at the base of the pump head pos 45 with a screwdriver take extra caution not to scratch the inner wall of the pump head pos 45 Check sealing surfaces of the valve body and outlet valve plate Check outlet valve pos 54 s spring and O ring Replace where necessary Clean all the parts and replace the worn parts with the corresponding parts in the repair kit Re...

Page 28: ...spacer pos 17 and O ring pos 27 can be easily removed once the suction valve assembly pos 55 had been successfully removed Check sealing surfaces of the valve body and suction valve plate Check suction valve pos 55 s spring and O ring Replace where necessary Clean all the parts and replace the worn parts with the corresponding parts in the repair kit Reassemble the in reverse order and pay extra c...

Page 29: ...d use a punch to gently knock the brass ring pos 34 out of the pump head pos 45 Take extra caution not to knock on the step inside the pump head Check O ring and packing replace where necessary Clean all the parts and replace the worn parts with the corresponding parts in the repair kit Reassemble the in reverse order and pay extra care to the orientation of parts during assembly Step Knock Here 2...

Page 30: ...ly recommended to remove the assembly as a whole in order to prevent any intermediate components such as valves and spacers etc from dropping off and getting lost Unscrew M13 nut pos 16 to remove the gasket pos 20 ceramic piston pos 32 separator disk pos 15 Check plungers pos 32 for score marks replace if necessary Reassemble the in reverse order When reassembling the plungers ensuring all parts a...

Page 31: ... out or correct size refer to part list pg 42 ADJUSTMENT OF THE UNLOADER VALVE S MAXIMUM PRESSURE Acting on the adjustment knob increase the pressure until you reach the desired value with the gun opened Repeat some operations of closing and opening of the high pressure water spray gun and then check always with the gun opened that the set pressure is really the one wanted Once the pressure is reg...

Page 32: ...4 Spare parts list MERMAID E500 S STD08 Page 31 of 52 4 Spare parts list Main Chassis Assembly ...

Page 33: ...1 Lid Water Tank 18 700520548 1 Top Cover 19 700520561 1 Lock Clip 20 3817582 1 Level Sensor 21 700520638 700950031 1 0 3m Float Valve Hose 20Bar Water Inlet Flow 22 700540848 1 Apdator 22a 700540109 1 Elbow 3 8 x Plastic 22b 700950031 0 9m Hose 20Bar Water Over Flow 22c 700510136 1 Contra Nut 3 8 22d 700510025 1 Contra Nut 22e 700540147 1 Bushing M x F 23 700510094 1 Contra Nut 1 Tank Outlet 24 7...

Page 34: ...700520525 1 SET COUPLING COMPL OD35 55 41A 700520019 1 COUPLING HALF MOTOR 41B 700520562 1 TAPER BUSH MOTOR 41C 700520023 1 COUPLING RUBBER ELEMENT 41D 700520022 1 TAPER BUSH PUMP 41E 700520018 1 COUPLING HALF PUMP 42 700540319 1 NIPPLE 1 2 BSPP 43 700540056 1 DOWTY SEAL 1 2 44 700540982 1 UNLOADER ASSEMBLY 45 700540270 1 HOSE NIPPLE 46 700550004 1 DOWTY SEAL 3 8 47 700950014 1m HOSE 1 BLACK 48 70...

Page 35: ... 700540264 1 HOSE CLIP 1 31 34 NORMA 54 700950014 0 5m HOSE 1 SPRING TRANSPARENT 55 700540264 1 HOSE CLIP 1 31 34 NORMA 56 700530535 1 MOTOR 380 480V 40HP 50 60HZ 57 700530792 1 CABLE 7G 10mmsq BLK 1 3M 58 700510080 4 BOLT 5 8 X 2 1 2 HEX 59 700510081 8 WASHER FLAT 18 38 5X 60 700510082 4 WASHER SPRING 5 8 61 700510083 4 NUT 5 8 62 700540261 1 ELBOW 1 2 NPT F F 63 700510025 1 CONTRA BUT 64 7005407...

Page 36: ...s Part no Qty Description 66 700540848 1 ADAPTOR 1 2 M 1 2 F BSPP 67 700520506 1 1 2 FILTER c w 25 MESH 68 700520507 1 FILTER CARTRIDGE 1 2 5 69 700540100 1 NIPPLE 1 2 NPT 1 2 BSPM 70 71 700540056 1 DOWTY SEAL 1 2 72 700540987 1 Coupling Crawl F End 73 700540986 1 COUPLING Crawl Hose End 3 4 Pump assembly ...

Page 37: ...4 Spare parts list MERMAID E500 S STD08 Page 36 of 52 Pump assembly spare parts list ...

Page 38: ... Ring 23 KIT 155 5 High Pressure Seal Kit Dia 16 24 KIT 155 5 Low Pressure Seal Kit Dia 16 25 700505145 1 Key A10x8x70 26 700505146 2 O Ring 88x50 27 700505020 5 O Ring Dia 20 24x25 48x2 62 29 KIT 155 157 5 O Ring Dia 36 14x41 36x2 62 30 700505065 5 O Ring Dia 9 92x2 62 31 KIT 154 15 O Ring Dia 17 13x2 62 90shore 32 700505204 5 Piston Dia 16mm 33 1 Plate 34 KIT 157 5 Brass Ring 35 700505155 10 Was...

Page 39: ...l Components Description Kit 156 700505198 Piston Kit 15 5 Separate Disk 1 Kit for Complete Pump Repair 16 5 Piston Nut 20 5 Gasket Kit 154 700505178 7 10 Ring Valve Kit 22 5 O Ring 1 Kit for Complete Pump Repair 31 15 O Ring Dia 17 13x2 62 90shore 54 5 Outlet Valve Assy 55 5 Suction Valve Assy Kit 157 700505201 5 5 Upper Ring Brass O Ring Kit 29 5 O Ring Dia 36 14x41 36x2 62 1 Kit for Complete Pu...

Page 40: ...4 Spare parts list MERMAID E500 S STD08 Page 39 of 52 Un loader valve assembly ...

Page 41: ...BR 90 NERO 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 SPRI...

Page 42: ... RING15 9x19 0x2 7 N A 1 BUSHING PISTON 8 1 PISTON VALVE 9 1 O RING 2 62x11 91 10 1 BACKUP RING 12 0x16 8x2 11 N A 1 PISTON GUIDE 12 1 O RING 1 78x31 47 13 N A 1 SPRING GUIDE 14 700540974 1 SAFETY VALVE 720BAR SPRING RED 15 N A 1 SPRING TENSIONAL 16 N A 1 SPRING HOLDER 17 N A 1 LOCK NUT M22 18 N A 1 RETAINER RING 1 18 700540958 1 UNLOADER ASSEMBLY 720 Bar BLACK SPRING Safety valve assembly Repair ...

Page 43: ...3 1 Nozzle 0005 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 Part for Trigger Repair Kit ...

Page 44: ...onnection 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 N A 700551181 1 Set Trigger Gun R...

Page 45: ...age 44 of 52 Rotating Nozzle Type 2 Rotating Nozzle Spare parts list Pos Part no Qty Description 700551396 1 ROTATING NOZZLE 050 COMPLETE 60Hz Rotating Nozzle Repair Kit Pos Part no Qty Description 700551397 1 ROTATING NOZZLE REP KIT 050 60Hz ...

Page 46: ...ress on the trigger to bring up pressure with the lance assembly pointing in the downward direction 4 Check that no over pressure and no leaking on the fittings 5 Release the trigger and make any holding position adjustment 6 Start blasting by follow the procedure from 2 4 Note Do not point the lance at any person at any time Ensure the rotating nozzle is pointing down before starting to blast Thi...

Page 47: ...earing Thrust 8 700551164 1 Multi Jet Shaft 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 Je...

Page 48: ...otating Head 20KPSI 2 Barracuda Rotating Nozzle 042 1pc 3 Barracuda Rotating Nozzle 038 1pc For Mermaid 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: ...ion 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 700550235 60HZ 10 Nozzle Adaptor 700550242 11 Venturi Housing 700550232 12 O Ring 700550295 13 14 15 Boron Carbide Nozzle Dowty Seal Nipple 700550231 700540314 700540149 700550484 S BLAST G EQPT WB NOZ0005 COMPLETE 60Hz 13 12 11...

Page 50: ...80 415V 440V 480V 50 60Hz CAUTION When servicing the Electrical Components Only a qualified electrical trained personal to service or perform any troubleshooting on the electrical control box Improper connection may cause damage to the equipment or person using the machine ...

Page 51: ...A 9 700530913 1 Machine Run Indicator Light Green 10 700530519 1 Power On Indicator Light White 11 700530518 1 Service Indicator Light Orange 12 700530520 1 Start Push Button Green 13 700530521 1 Emergency 14 700530711 1 Stop Push Button Red 15 700530813 1 EL Box 450x400x200mm 16 2 Blank 17 700530709 1 Hour Counter 18 Terminal Blocks 700951506 15m Cable 4G10mm sq Grey 1 18 700530830 1 EL Box STD C...

Page 52: ...5 Wiring diagram 380 480V 50 60Hz MERMAID E500 S STD08 Page 51 of 52 5 Wiring diagram 380 480V 50 60Hz ...

Page 53: ...imited 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 neglig...

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