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Installation, Operations, and Maintenance Manual

The MART Corporation

Standard Turntable Power Washer v. 4.0

Safety/Precautions

Before you take any corrective action or attempt to repair the power washer, read and
follow these recommended safety/precaution instructions:

WARNING!   NEVER get inside the washer cabinet when the
main power supply is ON.  This could result in severe injury or
death.

WARNING!   Be sure that people who perform repairs are
qualified and trained for the task.

What You Will Learn In This Chapter

In this chapter you will learn about troubleshooting the following:

·

  Startup 

·

Ineffective cleaning

·

Wash pump system

·

Heating system

·

Turntable drive

·

Nozzles

·

Foaming

·

Power blast manifold (PBM)

·

Solution-level control system

·

Door limit switch

·

Rinse system

·

Automatic steam exhaust (ASE)

·

Electrical control system

Summary of Contents for Cyclone 30 Series

Page 1: ...atents 4 741 351 4 143 669 4 213 475 5 529 080 5 524 653 5 427 128 5 540 246 This manual is an unpublished copyrighted work by The MART Corporation The information and drawings in this manual are the...

Page 2: ...res Figures 1 Welcome and Introduction Welcome 1 Purpose of Manual Welcome 1 Audience Welcome 2 How the Manual Is Organized Welcome 2 How to Use This Manual Welcome 3 MART Technical Services Welcome 3...

Page 3: ...m And Grit Blasting 1 7 3 1 2 Temperature 1 8 3 1 3 Chemical 1 8 Removal of Soils 1 9 Applications 1 9 Usage 1 10 3 1 4 Time 1 10 3 1 5 General Information and Conclusion 1 11 3 2 Operating Principles...

Page 4: ...ce 2 15 Electric Heat Source 2 20 Steam Heat Source 2 20 5 2 2 Water Input 2 21 5 2 3 Compressed Air Input 2 22 5 2 4 Electricity Input 2 23 Earthgrounding to Prevent Corrosion 2 23 5 3 Connection Pro...

Page 5: ...tting the Rinse Cycle optional 3 11 2 9 Starting the Washer 3 12 2 10 Verifying Proper Function 3 12 2 11 Opening the Door after a Cycle 3 13 2 12 Unloading Parts 3 13 3 Continuous Operation 3 14 4 Ad...

Page 6: ...Washer Adjustments 5 4 2 1 Pumps and Power Blast Manifold PBM Assembly 5 4 2 1 1 Wash Pump Intake Filter Inspect Clean 5 4 2 1 2 PBM Swivel Joint Grease 5 5 2 1 3 PBM Nozzles Inspect Monitor 5 6 2 1...

Page 7: ...e Clean Out and Heat Exchanger Suction Tube Clean 5 24 3 3 Heating Elements Clean electric only 5 24 4 Maintenance of Options 5 25 6 Troubleshooting 6 1 Purpose 6 1 Prerequisites 6 1 Safety Precaution...

Page 8: ...s 7 13 2 3 1 Clean Machine Operation Frequency 7 14 2 3 2 Clean Machine Chemical Management 7 14 2 4 Maintenance 7 15 2 5 Troubleshooting 7 16 3 Center Manifold 7 18 3 1 Theory of Operation 7 18 3 2 I...

Page 9: ...cy Drive 7 42 8 1 Theory of Operation 7 42 8 2 Installation 7 42 8 3 Operations 7 43 8 4 Maintenance 7 43 8 5 Troubleshooting 7 44 9 Hot Air Blow Off HABO 7 45 9 1 Theory of Operation 7 45 Steam Exhau...

Page 10: ...68 14 3 Operations 7 68 14 4 Maintenance 7 68 14 5 Troubleshooting 7 69 15 Rack and Fixture Set or Small Parts Basket 7 70 15 1 Theory of Operation 7 70 15 2 Installation 7 70 15 3 Operations 7 72 15...

Page 11: ...and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 19 Short High Manifold SHIM System 7 84 19 1 Theory of Operation 7 84 19 2 Operations 7 84 19 3 Maintenance 7 85 19 4...

Page 12: ...ox Wiring 2 18 Fig 2 6 Steam Solenoid and Steam Trap Installation 2 20 Fig 2 7 Water Connection Location 2 21 Fig 2 8 Compressed Air Connection 2 22 Fig 2 9 General Layout of the Electrical Control Pa...

Page 13: ...4 21 Fig 5 1 Service Schedule 5 3 Fig 5 2 Cleaning the Pump Intake Filter Box 5 5 Fig 5 3 Lubrication Chart 5 6 Fig 5 4 Cleaning and Replacing the PBM Nozzles 5 7 Fig 5 5 Swivel Jam Nut Non adjustable...

Page 14: ...Troubleshooting Oil Skimmer Tank Overflows into Cyclone Separator Tank 7 17 Fig 7 7 Troubleshooting Skimmer Wheel Drain Trough Backs Up 7 17 Fig 7 8 Center Manifold Mechanism and Superstructure 7 20...

Page 15: ...ting Skimmer Wheel Does Not Skim 7 62 Fig 7 33 Troubleshooting Power Assist Does Not Activate 7 65 Fig 7 34 Troubleshooting Pump Pressure Gauge Does Not Work 7 67 Fig 7 35 Troubleshooting Pump Pressur...

Page 16: ...ions and Warnings contains general warnings and cautions that are meant to be observed at all times when you work with the washer Personnel training is required to work with the power washer Be sure a...

Page 17: ...mes when you work with the washer Be sure all operators read and heed the instructions in that section Chapter 1 Overview presents an overview of the MART Standard Turntable Power Washer including a t...

Page 18: ...y use the Table of Contents List of Figures and Index to refer to information as you need it MART Technical Services MART s technical services department is available to provide you with the extra sup...

Page 19: ...cuments for additional details on installation operations and maintenance Startup A MART factory trained technician is optionally available to perform startup and customer training Call MART technical...

Page 20: ...ake Ovens EPA OSHA and Hazardous Waste Disposal How MART Power Washers Work Printed Material Hazardous waste lab reports Procedure for sludge disposal Message to financial management Ins outs of leasi...

Page 21: ...AND WARNINGS IN THIS SECTION GENERAL SAFETY INSTRUCTIONS FOR OPERATING THIS PRODUCT 1 Read all safety and operating instructions procedures before installing operating maintaining repairing or troubl...

Page 22: ...result causing loss of life personal injury or damage to property WARNING VENTING OF EXHAUST GASES Do NOT vent exhaust gases into a wall a ceiling or a concealed space of a building Refer to the instr...

Page 23: ...d for the task WARNING Set up your power washer installation to conform to all local code requirements WARNING The standard power washer is designed to be installed inside a building not outside WARNI...

Page 24: ...l panel open when the power is ON CAUTION You must turn the main power supply OFF before performing many maintenance procedures BE SURE to turn the main power supply back ON after you perform maintena...

Page 25: ...your power washer before you attempt to install operate or maintain the washer Prerequisites You will find it helpful to have read the introductory material especially Welcome so that you understand...

Page 26: ...nd manufacturing information This section also shows you a diagram of the washer with principal parts labeled 1 1 Getting Acquainted MART Power Washers are non solvent based cleaning systems They are...

Page 27: ...ew 1 3 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 1 1 Standard Turntable Power Washer View 1 Power Blast Manifold Door Mounted Turntable Water and Compressed Air Electrical Control...

Page 28: ...aintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 1 2 Standard Turntable Power Washer View 2 Skimmer Box Ttbl Drive Sprocket Enclosed Turntable Drive Gearmotor Lifting E...

Page 29: ...d valves outside the electrical control panel and all electrical devices for example timers relays motor starters inside the electrical control panel are clearly labeled Separate temperature compensat...

Page 30: ...on of the factors must be determined for your application based on the types of soils to be removed the degree of cleanliness required the cycle time required the types of parts to be cleaned and so o...

Page 31: ...that most directly affects how quickly and effectively the soils are removed The impact per square inch of a given nozzle depends on the following Flow and pressure produced by the pump Type of nozzl...

Page 32: ...does not rely primarily on chemical concentration This is because your MART sales technician worked with you to determine your cleaning needs such as Required degree of cleanliness Nature of the soil...

Page 33: ...emoved as sludge A key feature of this type of cleaner is that you only have to dispose of the contaminants as waste the washer can recycle the liquid until the saturation point As the wash solution i...

Page 34: ...fresh water to flash dry parts without rusting 4 If you need to dry the parts quickly MART can provide an air or heated drying phase 5 All parts and materials washed in a MART Power Washer are clean...

Page 35: ...as to overpower the soils Cleanliness is proportional to the combination of the following factors Power Temperature Chemical Time The exact combination of these factors is variable and depends on you...

Page 36: ...the pump inlet Finally the solution leaves the pump under pressure and travels through piping to the power blast manifold PBM The pump is capable of handling hot alkaline cleaners and can pass solids...

Page 37: ...means cleaner parts Nozzles Nozzle placement evenly distributes blasted solution throughout the wash cabinet From the bottom up across the cabinet and from the top downward This ensures that each por...

Page 38: ...om the power washer cabinet during the wash cycle and the optional automatic rinse cycle ARC and for a timed period after the rinse cycle The ASE serves two purposes 1 It reduces the amount of steam t...

Page 39: ...osion resistant materials Rinse time is controlled by two factors The amount of water that can be made up due to water loss through steam exhaust evaporation or drag out or The rinse timer inside the...

Page 40: ...am First let s look at general operating principles that apply to all the systems Following that we ll take a closer look at principles specific to each system Note The discussions of heating system o...

Page 41: ...LOW neither the heating system nor the wash pumps will function The water fill valve will be open to provide water fill LOW This is the minimum safe operating condition The heat exchanger should be fu...

Page 42: ...up Overnight This allows longer rinses than would be possible with a simple single set point water fill and rinse system With the single set point system only water evaporated or discharged from the...

Page 43: ...he electrical control panel to the left side of the door Major system controls are housed inside the electrical panel A number of system features are logically interdependent in order to help ensure s...

Page 44: ...art Run Light Press the START button all the way to begin the wash cycle The green run light illuminates indicating cycle running Note The start circuit is interlocked with the door closed limit switc...

Page 45: ...controls include Timers and relays that control the cycle logic 7 day clock A programmable device that allows the operator to preset the days of the week and time of day for the washer to heat up The...

Page 46: ...begins the wash cycle When the 0 30 minute wash cycle timer times out the wash pump starter and power blast manifold PBM stop operating This ends the wash cycle Rinse System optional The rinse solenoi...

Page 47: ...pump comes on How this works depends on whether you have a single pump or a duplex pump system Single Pump System All 20 30 and 40 horse power systems have an APE Automatic Pressure Equalization unit...

Page 48: ...lation Here are some tips Inspect For Entire cabinet including the top dents or scrapes Electrical wire conduits breakage Cabinet door dents or scrapes Misalignment Water hoses and pipes breaks or cra...

Page 49: ...ern To ensure that you have a valid warranty Prerequisites Before you begin to install the power washer be sure you have followed the recommendations in this section q Information Read the entire manu...

Page 50: ...om the cabinet doorframe m Operations Access Leave adequate room to work with the washer during normal operations Allow sufficient room for loading and unloading the washer with the door in a half ope...

Page 51: ...en exhaust and makeup air in the plant Refer to the latest issue of the National Fuel Gas Code American National Standard ANSI Z223 1 for details In general it specifies that a permanent opening or op...

Page 52: ...ding provides a path of least resistance for electric current thus reducing the risk of electric shock during maintenance troubleshooting or repair CAUTION GROUNDING INSTRUCTIONS The washer must be co...

Page 53: ...ING Do NOT add water chemical or turn on the power during installation These steps are part of the startup procedure Wait until Startup Procedure at the end of this chapter to add water chemical or tu...

Page 54: ...e lifting eyes located on the top left and top right sides of the cabinet as shown in FIG 2 1 WARNING Use lifting equipment rated for the weight of your power washer To find out the weight refer to th...

Page 55: ...on 2 7 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 2 1 Raising the Power Washer by the Lifting Eyes Lifting Eyes Steam Vent Pipe Attachment Flange Flue Pipe Attachment For Gas Heate...

Page 56: ...installation location place it according to your plan Watch the overhead and side areas around the washer as you place it Walk around the washer and verify clearances Refer to section Prerequisites Pl...

Page 57: ...r slowly and carefully Note Some items secured to turntable may have shifted during shipment 3 Remove the cartons strapped to the turntable 4 Check all standard items accessories and documentation aga...

Page 58: ...sure correct installation as you follow the steps in the next several sections Use the Field Startup Procedure FSP form in this way 1 As you install the washer fill in the Field Startup Procedure FSP...

Page 59: ...Concrete pad Steel structure 4 1 Leveling Follow this procedure 1 Find the leveling and anchoring feet at each corner of the washer at floor level 2 Find the leveling bolt nut and the anchor hole on e...

Page 60: ...his will interfere with the leveling bolts Shim under the frame of the washer only 5 When the washer is level and the shims are in place back off the tension of the screws on the leveling bolts so tha...

Page 61: ...cause corrosion When placing grout follow the manufacturer s detailed instructions to the letter This will help prevent voids and other grout repair problems later In general use only non shrink grout...

Page 62: ...Placement Planning at the beginning of this chapter Your plan and the SBO tell you which of the following utility connections and options installations you must make Use this manual to locate the con...

Page 63: ...ctions in this manual for information on making the necessary connections 5 2 1 Heat Source Depending on the washer s configuration and options it will use one of the following heat sources Gas natura...

Page 64: ...ious figure 1 Attach Heat exchanger flange A Burner gasket B Burner locking collar C to the heat exchanger opening located on the right side of the washer Use the mounting bolts provided 2 Insert the...

Page 65: ...pe gasket supplied with the burner Wind it in a spiral on the face of the burner flange inside the bolthole circle in a single layer Cut off the excess rope NOTE The rope may be held in place by maski...

Page 66: ...the green ground screw in burner junction box For Gordon Piatt burners the orange wire connects to 1 the white wire connects to 2 and the green wire connects to the green ground screw in the junction...

Page 67: ...ngs and joints including all connections on the burner and all piping installed to the burner To do this smear a solution of soap and water around all fittings and look for bubbles If you see bubbles...

Page 68: ...and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 3 Make connections to your in plant steam power system according to plant and other local codes Fig 2 6 Steam Solenoid...

Page 69: ...eater than 125 PSI 862 kilopascals The regulator should regulate water pressure to 100 125 PSI 690 862 kilopascals NOTE The water regulator is not provided by MART 2 Connect a 1 2 inch diameter 13 mm...

Page 70: ...IZED fitting If you do NOT have a galvanized fitting you may not need a compressed air line Follow this procedure 1 Install a 1 2 inch diameter 13 mm compressed air line to the washer The incoming pre...

Page 71: ...system OR an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the washer Earthgrounding to Prevent Corrosion The washe...

Page 72: ...er supply to the washer following NEC methods Use proper size wires in the conduit and make watertight connections to the electrical control panel 5 Attach the feeder wires to the power distribution b...

Page 73: ...erequisites PVC Kit at the beginning of this chapter MART washers are set up for using PVC pipe for the steam exhaust Your washer and ASE auto steam exhaust blower unit arrive equipped for using PVC f...

Page 74: ...st pipe connection must be independent of any other pipe connection It can not share a steam vent pipe with any other equipment Steam Exhaust Pipe Refer to the following figure for the location of the...

Page 75: ...blower Note Install venturi such that fan motor shaft is horizontal Use a twist transition supplied from MART if required Fig 2 11 Auto Steam Exhaust ASE Piping and Blower Installation Configurations...

Page 76: ...calculating pipe length each 90 angle bend equals 10 feet 3 m of straight pipe CAUTION You must mount the ASE assembly in line with the steam exhaust pipe and as far away from the washer as possible a...

Page 77: ...Installation 2 29 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 2 13 Auto Steam Exhaust ASE Piping and Blower Assembly...

Page 78: ...efer to your machine s panel layout drawing on the inside of the enclosure door for the exact location Splice the other end of the red wire to one of the black wires on the ASE motor 3 Attach one end...

Page 79: ...lation Your MART Power Washer is capable of producing exhaust gas temperatures up to 1000 degrees F The gas burner flue installation must comply with all applicable local and or national gas codes for...

Page 80: ...a minimum of 1 4 inch 6 mm per pipe foot per 30 5 cm of pipe 3 Be sure the exhaust vent ends in a vertical position The vent termination point must be above the roof peak by the required height as st...

Page 81: ...rntable Power Washer v 4 0 The MART Corporation 5 4 Installation of Options If you have purchased any options with your washer such as a Clean Machine refer to chapter Options later in this manual for...

Page 82: ...nsure that all connections have been properly made During this inspection you will inspect the following items and document your inspection results on the FSP Visual inspection Leveling Anchoring Phys...

Page 83: ...Power up Procedure Preliminary checks Supply Voltage Water Fill Water Level Control Control Voltage Heat Gas Electric Steam Oil Pump s Rotation Direction Temperature Control Voltage Readings Amp Readi...

Page 84: ...l panel to be sure they are seated in their sockets Close the electrical control panel door 6 2 Lubrication Procedure Your power washer was pre lubricated at the factory If you install the washer with...

Page 85: ...wer supply to the Power Washer 3 Turn electrical disconnect located on the MART Washer Control Enclosure door to the OFF position 4 Open electrical enclosure door 3 Measure and record incoming voltage...

Page 86: ...inutes 7 After about two hours check the washer reservoir to verify or adjust the set point water level While the reservoir fills you can continue with the power up procedure Water Level Control The w...

Page 87: ...lower the water level When the washer has completed filling to the set point water level the cam and float limit switches should appear as shown in the following figure Fig 2 17 Float Cam at SET POINT...

Page 88: ...rect skip to step 6 4 Mark the current location of the cam on the float rod with a marker or a piece of tape before making any adjustments If the water level measurement you made is higher than the in...

Page 89: ...correct set point water level after operations have started you must allow the washer to fill to the set point You can check this by observing the position of the float cam relative to the limit switc...

Page 90: ...rned ON 2 Verify that the incoming pressure is within the range specified in the table below Lower gas pressures can reduce the burner firing rate and increase the time it takes for the machine to hea...

Page 91: ...ue to various installation variables it may be necessary to adjust operating parameters to obtain consistent burner performance Maximum Actual Operating Temperature Altitude in Feet Temperature F 0 20...

Page 92: ...efficiency 70 or more Stack temperature 350 F to 1000 F 177 C to 371 C Carbon monoxide 200 PPM or less 8 Record the water temperature and time of day for reference Refer to the following figure for g...

Page 93: ...rol unit to 220 degrees F 2 Allow the burner to operate until the water temperature reaches 200 degrees F 3 Measure and record the exhaust stack temperature 4 Adjust the Hi Limit controller 100 degree...

Page 94: ...s Be sure the people performing this task are qualified and trained for the task 4 Turn the electrical disconnect on the control enclosure door OFF Open electrical enclosure door With door open turn t...

Page 95: ...air entering a hot enclosure When the pump system comes on this cool air is rapidly heated by the hot water solution which results in a rapid expansion in excess of the normal exhaust system capacity...

Page 96: ...hemical Charging Procedure If you have successfully completed the startup procedure to this point you are ready to charge the washer with chemical When you charge the washer with chemical always follo...

Page 97: ...e main power supply OFF 2 Pump out the amount of water that is to be replaced by liquid chemical 3 Pump the liquid chemical SLOWLY from drums onto the false floor or over the doorframe CAUTION Use ext...

Page 98: ...ave to do is open a chemical barrel place the strainer tube in the bottom of the barrel and prime the injector pump To prime the injector pump follow these guidelines 1 Shut off the incoming water sup...

Page 99: ...anel 10 To set the rinse timer and injector pump speed control refer to chapter Advanced Operations Process Control 6 7 Startup Problems If you have any problems during the startup procedure do the fo...

Page 100: ...owing thoroughly Important Safety Instructions and Warnings in the front material Chapter 1 Overview This chapter Basic Operations assumes that appropriate operating parameters have been established f...

Page 101: ...due remain on part surfaces and in recesses Before you remove a part from the washer cabinet be sure to drain back into the washer any solution that remains on a part surface or in recesses What You W...

Page 102: ...the turntable for easier loading unloading Start Run Light Press the START button all the way to begin the wash cycle The green run light illuminates indicating cycle running Note The start circuit is...

Page 103: ...orporation Standard Turntable Power Washer v 4 0 FIG 3 1 Standard Turntable Power Washer Control Panel HOUR METER SKIMMER ON OFF AUTO OPTIONAL CLOCK OVERRIDE TURNTABLE JOG START CYCLE LIGHT WASH STOP...

Page 104: ...gure for the gauge s location WARNING Do NOT operate the washer unless it has reached minimum operating temperature Scheduled Shift During a scheduled shift check the temperature gauge about every 15...

Page 105: ...internal temperature control unit is to be considered normal operation of the system To increase the average wash temperature increase the set point temperature on the control unit inside of the elect...

Page 106: ...oration 2 3 Opening the Door Door Latch Pull the latch handle away from the washer cabinet to release the latch Refer to the following figure Swing the latch hook away from the door handle Pull the do...

Page 107: ...door back slowly 3 Release the position lock 4 Continue pushing the door until it locks in place The position lock handle is located at the bottom of the door The two position locks hold the door open...

Page 108: ...loaded exactly at the center of the turntable Guideline Assume that every nozzle hits every part with 15 lbs 6 8 kg of force Recommendations Wrap securing devices tightly around all fixtures and part...

Page 109: ...tom of the door Refer to Fig 3 4 Door Latch Swing the latch hook toward the door handle Push the latch handle toward the washer cabinet to close and lock the latch Refer to Fig 3 3 2 6 Verifying Wash...

Page 110: ...NOTE In general most cleaning cycles can be completed in less than 15 minutes 2 8 Setting the Rinse Cycle optional If you have the optional Automatic Rinse Cycle ARC setting the rinse off auto switch...

Page 111: ...en to the pump does it sound normal Is the turntable drive motor jackshaft rotating Cycle Completion At the end of the cleaning cycle the following things should happen START button light turns off Tu...

Page 112: ...Fig 3 4 Securing the Door Always be sure that the open door is locked in position Visually check the position lock Or Try to pull or push the door 2 12 Unloading Parts Press the TURNTABLE JOG button t...

Page 113: ...about the following to help get the best cleaning results and optimize energy usage while minimizing chemical usage and problems Managing chemical concentration Setting rinse cycle time optional ARC...

Page 114: ...tion instructions WARNING Never get inside the washer cabinet when the main power supply is ON This could result in severe injury or death What You Will Learn In This Chapter In this chapter you will...

Page 115: ...t as necessary this is important not only for cleaning results but it will also reduce cleaning time and other chemical related problems such as foaming You must also use some chemical during the clea...

Page 116: ...potassium hydroxide will blacken the surface of the parts being cleaned and if exposed for five minutes or more can etch the surface Type of Soils A wide of range of compounds is available to remove s...

Page 117: ...cal to add Divided by 128 fluid ozs Gal You must test and adjust the variables in your application to determine an effective chemical type and concentration Chemical concentration depends on Your clea...

Page 118: ...all the variables in your application in order to give you the best cleaning results while using the least amount of chemical possible For help in developing a chemical concentration monitoring sched...

Page 119: ...y a light chemical charge you may need to add a booster charge of de foamer if foaming is a problem Consider adding a defoaming agent rather than more chemical given the following conditions Your clea...

Page 120: ...condition is called supersaturation of solution To correct this problem you must remove greases and oils from the solution Allow solution to cool and oils to rise to surface then Manually skim greases...

Page 121: ...s a Power Kleen product specifically designed for your particular cleaning applications In all cases Power Kleen products provide the highest degree of efficient effective cleaning Power Kleen product...

Page 122: ...insability factor with no conductive residue Power Kleen IV Aerospace Specially formulated Power Washer detergent for removing carbon grease and dirt from Aerospace Metals Aircraft Parts and chemicall...

Page 123: ...ting Temperature Altitude in Feet Temperature F 0 2000 190 F 88 C 2000 4000 185 F 85 C 4000 5000 180 F 82 C 5000 and above call MART WARNING Do NOT exceed recommended settings or serious damage can oc...

Page 124: ...temperature increases greases and oil become more fluid Since grease is the primary binder that holds and contains the soils on the parts heat melts the binder generally producing better cleaning resu...

Page 125: ...up water needed due to water loss through evaporation or drag out Automatic rinse system ARC timer In controlling rinse cycle time water loss takes priority The amount of makeup water required determi...

Page 126: ...emical supplier for the appropriate inhibitor chemical and for instructions on using it NOTE Monitor inhibitor chemical usage visually Replace drums as needed to ensure that inhibitor chemical is appl...

Page 127: ...rations find the correct rinse regulator pressure line on the graph NOTE There are five rinse regulator pressures represented on each graph Refer to the key code box under the graph to select the corr...

Page 128: ...0 10 20 30 40 50 60 70 80 90 100 Injector Pump Output Setting 0 00 0 50 1 00 1 50 2 00 Mix Ratio OZ GAL 10 PSI 20 PSI 30 PSI 40PSI 50 PSI Chemical Injection Mix Ratio 3 Nozzle Rinse System Rinse Regu...

Page 129: ...T Corporation Fig 4 6 Injector Pump Output Setting 5 Nozzle Rinse System 0 10 20 30 40 50 60 70 80 90 100 Injector Pump Output Setting 0 00 0 50 1 00 1 50 2 00 Mix Ratio OZ GAL 10 PSI 20 PSI 30 PSI 40...

Page 130: ...tor is factory pre set Adjust it to achieve rinse characteristics that meet your requirements To Get This Adjust the Regulator for Smaller drops more volume Higher gauge reading Larger drops less volu...

Page 131: ...wn off mode Program run times for optional devices The clock is located on the face of the electrical control panel as shown in the following figure Circuit 1 controls the heating and water fill times...

Page 132: ...switch controls some optional devices such as the Clean Machine and the Oil Skimmer and circuit 2 of the 7 day dual circuit clock located on the face of the electrical control panel In order for these...

Page 133: ...e automatic steam exhaust ASE cycle removes steam from the washer cabinet During the wash cycle During the optional automatic rinse cycle ARC For the ASE timer set period of time after the automatic r...

Page 134: ...e ASE cycle 3 Check to see if any steam remains in the cabinet after the ASE cycle has completed 4 Increase or decrease the ASE timer by one minute increments Generally if steam remains in the cabinet...

Page 135: ...ter monitoring and indicate if any maintenance procedures need to be performed Refer to chapter Maintenance for maintenance procedures 6 1 Monitoring Lubrication Monitoring lubrication of the followin...

Page 136: ...udge when there is about 4 inches 10 16 cm of it on the bottom of the front reservoir Pump Intake Filter Monitor daily Clean the pump intake filter every 8 hours of operation to remove sludge and othe...

Page 137: ...nd long economical life of the washer Prerequisites Before you read this chapter we recommend that you read the following thoroughly Important Safety Instructions and Warnings in the front material Ch...

Page 138: ...k manual be sure to re set the 7 day clock located inside the electrical control panel WARNING Do NOT OVERLOAD the false floor or other horizontal surfaces The false floor is intended as a chemical so...

Page 139: ...Sludge Level monitor __________ _________ 40 Hours Weekly PBM Nozzles inspect monitor __________ _________ Chemical Concentration test __________ _________ Slip Clutch Torque Limiter inspect ________...

Page 140: ...swivel joint grease Lubriplate 1444 PBM nozzles inspect monitor PBM swivel jam nut inspect adjust Amperage draw at wash pump measure Upper manifold bearing grease Mobilith AW2 Wash pump and pump moto...

Page 141: ...The MART Corporation Fig 5 2 Cleaning the Pump Intake Filter Box 2 1 2 PBM Swivel Joint Grease Grease the PBM Swivel Joint with Lubriplate 1444 Refer to the following figure NOTE It is imperative that...

Page 142: ...hich gives you the best cleaning results When you check for clogging be sure to check that all nozzles are correctly aligned as indicated in the following figure Monitor the amperage draw at the main...

Page 143: ...ain power supply OFF 2 Remove the nozzle with a 9 16 inch 14 mm wrench 3 Remove any debris 4 Apply 6 7 turns of teflon tape to the threads 5 Re install the old nozzle or install a new one Thread nozzl...

Page 144: ...ou need to adjust the jam nut The jam nut is located on the swivel at the bottom of the PBM manifold The swivel assembly allows for take up of the packing after it wears 5 Swivels with Jam Nuts only A...

Page 145: ...on tag The tag indicates two things 1 Full load amperage draw at your specified voltage and 2 The service factor which is either 1 15 or 1 25 times the full load amperage depending on motor size and i...

Page 146: ...of premature motor failure If you apply too much grease it is eventually forced out of the bearing housing and begins dripping on the motor windings The grease then attacks and destroys the insulatio...

Page 147: ...each bearing 6 Replace the fittings and plugs 7 Turn the main power supply ON Fig 5 6 Wash Pump and Pump Motor s To grease the pump motor s follow this procedure refer to the previous figure 1 Turn th...

Page 148: ...mp Couplings Inspect Inspect the wash pump s couplings for the following Wear Separation Misalignment Refer to Fig 5 6 as you inspect couplings for the following Wear If couplings are worn replace the...

Page 149: ...lean the air intake on the burner blower motor natural gas L P gas or fuel oil fired burners only with a compressed air blower or a soft brush in order to remove dust and dirt Refer to the following f...

Page 150: ...r replace 2 3 1 Float Assembly Inspect Clean Inspect Clean Inspect the float assembly periodically The single ball float system normally requires little or no cleaning however under some operating con...

Page 151: ...urement you made is higher than the indicator you will need to move the cam up the float rod by the difference between the indicator and the measured value If the measurement is lower than the indicat...

Page 152: ...at cam relative to the limit switches in the float box Refer to Fig 1 3 Float Level Mechanics If the cam is higher than the set point you will have to remove solution from the washer and allow the was...

Page 153: ...als Cyclone 30 s and Tornado 40 s Turntable roller bearings only Cyclone 30 s and Tornado 40 s have extended life bearings that require lubrication every 1100 hours of operation To lubricate the turnt...

Page 154: ...bottom sprocket support plate Use a nut that is appropriate for your torque wrench 2 Use a torque wrench with 50 foot pound 6 9 kg m capability 3 Loosen the set screws on the large hexagon torque adju...

Page 155: ...use phenolphthalen indicator P as a reactant and an acid hydrochloric or phosphoric as a neutralizer The indicator P turns red or pink or blue when added to a sample of the solution By counting the d...

Page 156: ...proved testing accuracy 1 Prepare a control sample using fresh city water and chemical to the desired concentration 2 Titrate this control sample 3 Compare titrations of the wash solution to the resul...

Page 157: ...Voltage at Power Distribution Block Measure Measure and record the incoming voltage to the washer with wash pump s running CAUTION Be sure that ONLY a qualified electrician performs this maintenance...

Page 158: ...n than sludge clean out or cleaning of the heat exchanger and suction tube WARNING Do not stand or walk on the false floor inside the cabinet or on the reservoir cover 3 1 Sludge Monitoring To monitor...

Page 159: ...ds by an approved waste disposal method 6 Pump the solution into holding barrels CAUTION Do NOT pump out the SLUDGE 7 Move the door position lock to allow the washer cabinet door to open to a 180 angl...

Page 160: ...plies to electrically heated power washers only NOTE Maintenance of heating elements may need to be done more often than sludge clean out or cleaning of the heat exchanger and suction tube Follow this...

Page 161: ...lse floor 8 Turn the main power supply ON 9 Allow solution to heat up to operating temperature before running a wash cycle Fig 5 11 Cleaning the Heating Elements 4 Maintenance of Options For instructi...

Page 162: ...d correct the problem In many cases you can use procedures in chapters Installation Advanced Operations Process Control or Maintenance to correct a problem after you have diagnosed it In other instanc...

Page 163: ...abinet when the main power supply is ON This could result in severe injury or death WARNING Be sure that people who perform repairs are qualified and trained for the task What You Will Learn In This C...

Page 164: ...not start Check This Probable Cause s APE pressure switch Misadjusted Insufficient compressed air supply Clock override Set to OFF must be ON 7 day clock Not programmed program 1 must be ON Compressed...

Page 165: ...rol or Maintenance to correct a problem after you have diagnosed it Or refer to your vendor supplied manuals or cut sheets for instructions on correcting problems Problem Ineffective cleaning of parts...

Page 166: ...er solution Wash pump motor trips overload high amperage reading Seal leakage at wash pump mounting plate Wash pump or motor vibrates or is noisy Problem Wash pump motor won t start Check This Probabl...

Page 167: ...le Cause s Pump or motor Mechanical defects rotate pump shaft by hand to verify if one of the following is causing the problem Bent shaft Loose impeller Pump casing unbolted Throttle bushing failure S...

Page 168: ...Wash pump or motor vibrates or is noisy Check This Probable Cause s Pump or motor Bearings Need lubrication Need to be replaced Damaged Pump Throttle bushing failure Pump motor Coupling Loose dropped...

Page 169: ...at specified pressures Blower motor not running Check for fan obstruction No ignition blower motor must be running Flameproving rods Corroded replace Igniter rods Corroded replace Burner controller d...

Page 170: ...rect setting Fig 6 10 Troubleshooting Water Does Not Heat Steam Problem Water does not heat electric Check This Probable Cause s Electric heaters Defective element Replace Defective wires loose burned...

Page 171: ...s This section contains tables on the following problems Turntable does not rotate Problem Turntable does not rotate Check This Probable Cause s Drive gear motor Not operating Fuse overload Blown trip...

Page 172: ...supplied manuals or cut sheets for instructions on correcting problems This section contains tables on the following problems Nozzles ineffective cleaning Problem Nozzles Ineffective cleaning Check T...

Page 173: ...er you have diagnosed it Or refer to your vendor supplied manuals or cut sheets for instructions on correcting problems Problem Foaming Check This Probable Cause s Operating temperature Too low raise...

Page 174: ...cut sheets for instructions on correcting problems This section contains tables on the following problems PBM not oscillating Problem PBM not oscillating Check This Probable Cause s Linkage Not conne...

Page 175: ...ctions on correcting problems This section contains tables on the following problems Water not filling reservoir Water overflowing reservoir System not heating Problem Water not filling reservoir Wate...

Page 176: ...on contains tables on the following problems Washer will not start Problem Washer will not start Check This Probable Cause s Door limit switch Door not closed does not activate Loose bolts switch has...

Page 177: ...tion contains tables on the following problems No rinse cycle Problem No rinse cycle Check This Probable Cause s Rinse timer Not set above 0 Steam exhaust fan Not operating Rinse solenoid Not energizi...

Page 178: ...will not operate ASE leaks liquid Problem ASE will not operate Check This Probable Cause s Wires Not tight enough Fuses Blown Blower fan Wheel off shaft Corroded ASE motor Not operating overload tripp...

Page 179: ...power supply OFF before working on the electrical control system NOTE Use your electrical schematics to work on the electrical control system NOTE If a part or assembly on the power washer will not wo...

Page 180: ...ore you read this chapter we recommend that you read the following thoroughly Important Safety Instructions and Warnings in the front material Chapter 1 Overview Safety Precautions Before you install...

Page 181: ...nce Manual The MART Corporation Standard Turntable Power Washer v 4 0 What You Will Learn In This Chapter In this chapter you will learn the following about each option Theory of operation Installatio...

Page 182: ...every set number of wash cycles 1 1 Theory of Operation The automatic lubrication system consists of the following refer to the following figure Grease reservoir Pneumatically driven grease pump Grea...

Page 183: ...able upper and lower bearings PBM swivel bearings An electronic programmable controller inside the control panel mounted next to the grease pump controls the automatic lubrication system A counter in...

Page 184: ...output Step 8 0 Idle mode no lube on power up Step 9 1 Normally energized fault relay goes off during power loss Step 10 1 Places controller in the operating mode These settings set the controller fo...

Page 185: ...o that a lubrication cycle is run every washer cleaning cycle Check the system for proper operation See the Operations section for instructions on changing the controller program Automatic Operation T...

Page 186: ...s ON your Auto lube system is not providing grease to the bearings Discontinue washer operations until the problem is corrected Refer to section Troubleshooting NOTE Use Lubriplate 1444 grease ONLY Ev...

Page 187: ...er Time set too short program Fig 7 2 Troubleshooting Automatic Lubrication System Fault Light Is ON NOTE Bearing Lubrication Bearing lubrication is critical Before making any changes to the lubricati...

Page 188: ...settling and building up Two processes are used in the Clean Machine to separate oils greases and particulate matter from the cleaning solution A hydrocyclone removes heavy particles and entrains air...

Page 189: ...n Machine 2 Level the separator tank if necessary Refer to chapter Installation Leveling 3 Anchor the separator using 5 8 18 bolts through the welded nuts on the feet of the tank Refer to chapter Inst...

Page 190: ...11 Standard Turntable Power Washer v 4 0 The MART Corporation NOTE Use a minimum of elbows and bends in the piping configuration Refer to chapter Installation for more information Fig 7 3 Clean Machi...

Page 191: ...container at the outlet of the skimmer assembly to collect waste and tramp oils WARNING Fill the Clean Machine s separator tank BEFORE you turn on the heat 7 Set the temperature controller aquastat lo...

Page 192: ...of the 7 day clock NOTE You must program the 7 day clock s circuit 2 for ON OFF times and set the Clean Machine s selector switch to auto 2 After you activate the Clean Machine verify the following Th...

Page 193: ...ght Soils Operate the Clean Machine every other day NOTE If sludge builds up on the front floor of the washer reservoir operate the Clean Machine more often 2 3 2 Clean Machine Chemical Management Use...

Page 194: ...of the particle the actual particle size and the pressure at the cyclone entrance The hydrocyclone expels sludge from its apex into the sludge chamber underneath Because the hydrocyclone also discharg...

Page 195: ...tank Skimmer wheel drain trough backs up Problem Clean machine does not heat Check This Probable Cause s Aquastat Incorrect temperature set controller to 170 F 77 C Amperage Low draw Wires may be loos...

Page 196: ...Fig 7 6 Troubleshooting Oil Skimmer Tank Overflows into Cyclone Separator Tank Problem Skimmer wheel drain trough backs up Check This Probable Cause s Drain trough Clogged Blades Not contacting wheel...

Page 197: ...f the cabinet roof Optionally an extra tube may be attached to the vertical manifold tube for carrying rinse water to a pair of rinse nozzles on the lower end of the manifold Flexible tubing is connec...

Page 198: ...this procedure refer to the following figure 1 Place beads of sealant around the roof opening 2 Place the superstructure frame and mechanism on the pad support on the roof 3 Connect the superstructure...

Page 199: ...7 20 Installation Operations and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 7 8 Center Manifold Mechanism and Superstructure...

Page 200: ...h the center manifold WARNING Be sure the part is centered properly so that the center manifold does not hit the part 3 Set the center manifold mode selector switch located on the washer s control pan...

Page 201: ...is up near the top of the cabinet roof in the Home position 3 Inspect the lift chain lift pin and bushings for wear and looseness 4 If loose tighten the lift chain by using the adjuster located near...

Page 202: ...d replace Loose tighten Rinse pipefittings Broken tubing replace Loose fittings tighten Fig 7 9 Troubleshooting Water Leaks Onto Cabinet Roof Problem Center manifold assembly does not work Check This...

Page 203: ...d Turntable Power Washer v 4 0 Problem Center manifold light does not illuminate Check This Probable Cause s Selector switch Not set to auto or manual manifold at home position Switch light bulb Burne...

Page 204: ...electric current All aqueous solutions conduct electricity to some degree The addition of electrolytes increases conductivity Since conductive liquids consist of ionic compounds electrolytes dissolve...

Page 205: ...uctivity has fallen below the set point you have selected it closes a relay If the relay closes while the wash pump is operating the peristaltic pump activates and pumps concentrated chemical solution...

Page 206: ...the conductivity of the solution in the washer These compounds include iron oxide rust and carbon both commonly found in most washing applications This means that while conductivity measuring systems...

Page 207: ...al and the actual chemical concentration of the solution Use this compensation factor to know how to adjust chemical concentration based on conductivity readings Conclusion After you have developed a...

Page 208: ...plier or developed through process control testing refer to chapter Advanced Operations Process Control 2 Adjust the LO set point to this reading NOTE Refer to the controller vendor supplied manual fo...

Page 209: ...the actual solution conductivity 2 Run a wash cycle 3 Verify that the pump is pumping chemical into the reservoir 4 Re set the LO set point to your control set point Peristaltic Pump and Tubing The pu...

Page 210: ...ntinuity Overloads Not all of them are re set Probe Dirty clean Set point Too high set below readout level Pump motor Defective replace Fig 7 13 Troubleshooting Peristaltic Pump Does Not Pump Problem...

Page 211: ...al reservoir cover is steel sheet supported by angles welded to the cabinet walls above the wash solution reservoir and below the turntable It funnels all liquid back through an expanded metal screen...

Page 212: ...panded metal screen or the optional chip baskets becomes clogged the pump s may flood the false floor resulting in cleaning solution or rinse water pouring over the doorframe into the front reservoir...

Page 213: ...s no longer directly coupled to the pump This option uses a V belt drive to recover the loss in rpm and turn the pump at the same rpm it would turn at 60 Hz The bigger sheave pulley is on the pump mot...

Page 214: ...ows To verify sheave alignment follow this procedure 1 Remove the belt guard 2 Adjust belt tension 3 Use a level to verify that the motor shaft and the pump shaft are parallel This prevents excessive...

Page 215: ...system Poor cleaning results or abnormal pump noise duplex pump system Problem 50 Hz electrical power Squealing sounds from pump area Check This Probable Cause s Belt s Slippage tighten Worn and fray...

Page 216: ...lectrical power Poor cleaning results or abnormal pump noise duplex pump system Check This Probable Cause s Main pump belt s Broken replace Booster pump belt s Broken replace Fig 7 18 Troubleshooting...

Page 217: ...filter housing affecting pump pressure and flow rate 7 1 Theory of Operation The two filter types are Bag Cartridge Filter Types Bag filters are generally recommended for 50 100 microns although they...

Page 218: ...arisons NOTE The lower limit of visibility to the naked human eye is 40 microns Filtering System Configurations There are two filtering system configurations The following diagram shows solution flow...

Page 219: ...standard 5 hour timer is numbered 1 10 each number represents a 1 2 hour increment The timer controls the length of time the filter pump operates in auto mode if you set the selector switch to auto i...

Page 220: ...l pressure differential gauge replace the filter when the pressure differential has increased by 10 PSI 142 kg cm2 or more 7 5 Troubleshooting This section contains tables on the following problems Wa...

Page 221: ...ed on the washer cabinet or in another more convenient location If the unit is remote mounted the power lines run from the washer s control panel to the Frequency Drive and then to the pump motor Refe...

Page 222: ...ure and flow The following figure shows frequency drive results One benefit of reduced pressure is the ability to clean delicate parts 0 10 20 30 40 50 60 70 80 90 100 Pressure or Flow 0 10 20 30 40 5...

Page 223: ...g This section contains tables on the following problems Pump motor does not run Problem Pump motor does not run Check This Probable Cause s Power Not ON Frequency drive LED power indicator not lit ch...

Page 224: ...e the washer cabinet by the fan and blown through the electric heating coils The air picks up heat as it passes around the heating coils Finally the heated air is accelerated to high velocity as it tr...

Page 225: ...g system works in conjunction with a high level shutdown system to de activate the HABO system if the heating element should overheat Refer to section Troubleshooting 9 2 Installation If you have a HA...

Page 226: ...aulk Tip Seal all joints with a 100 pure silicone caulking compound to prevent dripping and leaking from the steam in the exhaust Tip If at all possible install the ASE fan outside to eliminate many o...

Page 227: ...7 48 Installation Operations and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 7 24 HABO ASE Fan Installation...

Page 228: ...ocouples and the heating element is shipped installed on smaller washers You must install the outside plenum on larger washers To install the outside plenum on larger washers follow this procedure 1 T...

Page 229: ...7 50 Installation Operations and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 7 26 Hot Air Blow Off HABO Inside Plenum...

Page 230: ...r is located inside the electrical control panel WARNING Do NOT set the HABO temperature controller above a maximum set point of 200 F 93 C Exceeding 200 F 93 C may burn out the electric element or tr...

Page 231: ...exhaust wastes energy and raises operating costs Initially set the ASE speed control to the lowest setting that will satisfactorily keep steam in the washer during operation If this setting does not...

Page 232: ...gins to overheat Check This Probable Cause s Fan Not activating check HABO selector switch fuses Fan motor Burned out Blown fuse Fuses Blown pull out of electrical control panel to check and Be sure t...

Page 233: ...g jib boom about a column located in the rear center of the washer A roller on the jib boom rides on a support over the top of the doorframe Stops at each end of the support limit the arc travel of th...

Page 234: ...urntable Power Washer v 4 0 The MART Corporation 6 Mount the center brace on the column and the boom track 7 Bolt the center brace to the column and the beam 8 Tighten the boom track bolts Fig 7 28 Ji...

Page 235: ...in the angle 10 Fit the bronze washer onto the top of the boom shaft 11 Fit the top support angle onto the shaft and the washer Verify that there is a bronze bushing in the angle 12 Bolt the angle to...

Page 236: ...ORE using the Jib Crane DO NOT OPERATE the Jib Crane if you have not anchored the washer to the floor the washer could tip over and severely injure or kill the operator WARNING Be sure the washer rese...

Page 237: ...part To unload a part from the washer using the Jib Crane follow this procedure 1 Pull the door open slowly until it locks in the first position 90 angle from cabinet frame 2 Use the jog button locate...

Page 238: ...nd parts for tightness Check the jib boom wheel located at the top front of the cabinet above the door to be sure that the shaft pin is actually all the way through the wheel and held in place by the...

Page 239: ...the side of the power washer cabinet Refer to the following figure Skimmer Assembly The skimmer is electrically connected to the washer by a standard 120V 3 prong grounded plug It is operated by a sin...

Page 240: ...ol panel to one of the following Manual Activates the skimmer It will run continuously Off Turns the skimmer off Auto Automatically activates and runs the skimmer according to the program set for circ...

Page 241: ...move the skimmer assembly and box cover to clean sludge out of the box Refer to chapter Maintenance for more information on sludge clean out 11 5 Troubleshooting This section contains tables on the fo...

Page 242: ...the cabinet can be adjusted to regulate the general range of opening and closing speed You can fine tune your control of the speed at which the door opens and closes by raising and lowering the posit...

Page 243: ...switch located on the front of the door 2 Unlatch the door if it is latched 3 Lift and hold the position lock handle up to keep the power assist activated 4 Release the handle to stop the power assis...

Page 244: ...ur vendor supplied cutsheet for instructions 12 5 Troubleshooting This section contains tables on the following problems Power assist does not activate Problem Power assist does not activate Check Thi...

Page 245: ...sure remains exactly as adjusted NOTE When the control valve is fully closed the water line still carries the minimum water flow necessary to avoid damage to the pump A coupling welded into piping bet...

Page 246: ...re 1 Unscrew the diaphragm seal and gauge together 2 Clean the gauge pipe out 3 If the problem persists replace the gauge and diaphragm seal assembly 13 5 Troubleshooting This section contains tables...

Page 247: ...out The pressure gauge assembly includes a diaphragm seal that prevents solution from entering the gauge Pressure on the diaphragm is transmitted through the glycerin inside the gauge to the reading...

Page 248: ...eal assembly 14 5 Troubleshooting This section contains tables on the following problems Pump pressure gauge does not work Problem Pump pressure gauge does not work Check This Probable Cause s Gauge p...

Page 249: ...ecuring Parts for information on using securing devices 15 1 Theory of Operation The rack and fixture set and small parts basket are optionally available from MART Refer to the following two figures Y...

Page 250: ...Options 7 71 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 7 36 Rack and Fixture Set...

Page 251: ...p of the centering vertical post facing the center of the turntable 4 Load the part vertically inside the head rack or fixture 5 Attach securing devices as described in chapter Basic Operations Loadin...

Page 252: ...tion Fig 7 37 Small Parts Basket 15 4 Maintenance Clean racks fixtures and baskets as required 15 5 Troubleshooting If you properly secure all parts using racks fixtures small parts baskets and approp...

Page 253: ...turntable or the Power Blast Manifold PBM swivel bearings It improves accessibility reducing maintenance time This option is available for any bearing in the washer 16 2 Installation The optional Rem...

Page 254: ...ed nozzle Since water from spray is normally returned to the water reservoir a solenoid valve connected to the solution level control system disallows spray wand use whenever the solution level is at...

Page 255: ...r is not heated It will not flash dry as quickly as rinse water in the washer Wand water returns to the reservoir and uses part of the rinse bank rinse bank is the available volume for rinse water The...

Page 256: ...g This section contains tables on the following problems No hand rinse Problem No hand rinse Check This Probable Cause s Light on control panel Solution level at HIGH HIGH maximum mark Solenoid Failed...

Page 257: ...ervoir Part of the assembly extends as a chute behind the washer at a 45 degree angle When the Sludge Scraper is operating angle scrapers move across the bottom of the reservoir collecting sludge and...

Page 258: ...Options 7 79 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 7 39 Sludge Scraper External View 18 2 Installation The Sludge Scraper is factory installed...

Page 259: ...The timer controls the length of time the scraper operates in auto mode if you set the selector switch to auto in the following step 2 Set the scraper s selector switch located on the washer s contro...

Page 260: ...ive sprocket moves back and up Adjust both sides of the chain Adjust the drive chain from the motor to the torque limiter by sliding the motor Follow the manufacturer s recommendations for adjusting t...

Page 261: ...7 82 Installation Operations and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 7 40 Sludge Scraper Diagram of Parts...

Page 262: ...e Check This Probable Cause s Chain Caught on something Use reverse jog Broken Drive sprocket too loose adjust tension tighten Sprockets Chain is not on sprockets Torque limiter Not adjusted correctly...

Page 263: ...zzles so that the nozzles in the SHIM are packed more tightly together The nozzles in the standard Manifold have a 25 degree blast pattern while the SHIM has narrower15 degree pattern nozzles thus mor...

Page 264: ...nce Lubricate Fold down Arm Swivel every 8 hours of operation or as required Replace worn nozzles in both manifolds as required to prevent overloading of pumping system SHIM Selector Valve Upper SHIM...

Page 265: ...d manuals or cut sheets for instructions on correcting problems This section contains tables on the following problems PBM not oscillating Problem PBM not oscillating Check This Probable Cause s Linka...

Page 266: ...g power washer 2 13 APE Timer 1 22 cycling test in power up 2 45 startup 1 23 Applications cleaning 1 9 Aqueous Alkaline Cleaner 1 8 ARC and ASE 4 19 overview 1 15 ASE and ARC 4 19 blower motor 1 22 m...

Page 267: ...th chemical 4 9 Chemical charging power washer 4 9 cleaning results 1 8 concentration 4 5 and foaming 4 7 and supersaturation 4 8 maintenance 5 21 conductivity test 4 6 corrosion prevention 4 3 genera...

Page 268: ...2 45 D Devices securing parts 3 9 Diaphragm Seal pump pressure gauge assembly 7 66 7 68 Documentation unpacking 2 9 Door closing 3 10 latch 3 7 3 10 3 13 limit switch problems 6 15 locking 3 10 openi...

Page 269: ...on monoxide 2 31 configurations 2 31 connection 2 31 construction of 2 31 oxygen 2 31 placement planning 2 2 roof clearance 2 2 termination location 2 32 Foaming chemical 4 7 problems 6 12 troubleshoo...

Page 270: ...on connections 2 34 electrical connections 2 36 power washer 1 24 J Jib Crane maintenance bronze washer 7 59 yearly inspection list 7 59 option 7 54 Jog button 3 13 L Latch door 3 7 3 10 3 13 Leveling...

Page 271: ...Controls power washer 1 20 Options 50 hertz electrical power 7 34 7 day dual circuit clock 4 18 and 7 day clock 4 18 automatic turntable swivel bearings lubrication 7 3 center manifold 7 18 chemical c...

Page 272: ...rol components 1 21 operator controls 1 20 placement 2 8 power up installation 2 37 sequence of operation 1 22 starting 3 12 startup procedure 2 35 unpacking 2 9 verifying correct function 3 12 Power...

Page 273: ...3 13 parts 3 9 parts with fixtures 3 9 Sequence of Operation power washer 1 22 Sequestrant 1 9 Service Access placement planning 2 2 Service Schedule 5 3 and monitoring 4 21 Services By Others SBO ins...

Page 274: ...for operations 3 5 cleaning results 1 8 controller 4 10 4 12 guidelines 4 11 power up procedure 2 45 verifying wash t 3 10 Time actual wash time 3 11 cleaning results 1 10 Timer ape single pump 1 22 1...

Page 275: ...ntenance 5 10 problems 6 5 troubleshooting 6 5 Wash Pump Intake Filter maintenance 5 4 Wash Pump Motor maintenance 5 10 Wash Rinse Relay 1 22 Wash Cycle Timer setting 3 11 Wash Delay Timer 1 22 startu...

Page 276: ...t morning You want to turn ON an output at 10 00 on Monday and turn it OFF at 17 00 on Friday Multiple day operation is recommended You want the Time Switch to turn outputs ON OFF at the same interval...

Page 277: ...rcuit number indicators FROM TO indicators COPY indicator HOLIDAY indicator AM PM indicator Summer time DST indicator Main display Pulse width unit indicator Total value alarm indicator Sub display AM...

Page 278: ...lue Pressing decrements the value of the Key that was last pressed Note On first power up or after a reset Section 8 the time adjustment display appears on the screen Adjust the time by following the...

Page 279: ...o confirm the settings P1 P2 RUN SUN MON TUE WED THU FRI SAT 8 30 17 15 8 30 17 15 8 30 17 15 8 30 17 15 8 30 17 15 Number of remaining steps The color indicates flashing SUN MON TUE WED THU FRI SAT S...

Page 280: ...y pressing in program setting mode When the Mode Switch is set to P1 or P2 to PRGM for 4 channel type the Time Switch stop automatic operation To forcibly turn ON or OFF the output use the OUT ON OFF...

Page 281: ...on the bar at the Friday position Set the OFF time with and 2 MON MON FRI SUN MON TUE WED THU FRI SAT The color indicates flashing Set the Mode Switch to P1 or P2 1 See Section 4 5 for 4 channel type...

Page 282: ...THU FRI SAT P1 P2 RUN PULSE TIMER The color indicates flashing SUN MON TUE WED THU FRI SAT SUN MON TUE WED THU FRI SAT SUN MON TUE WED THU FRI SAT h m Press Press to turn off the bar at the Monday po...

Page 283: ...g SUN MON TUE WED THU FRI SAT SUN MON TUE WED THU FRI SAT SUN MON TUE WED THU FRI SAT Set the Mode Switch to P1 or P2 1 See Section 4 5 for 4 channel type P1 P2 RUN PULSE TIMER Press the DAY Keys to t...

Page 284: ...d by pressing in program setting mode When the Mode Switch is set to P1 or P2 to PRGM for 4 channel type the Time Switch stops automatic operation To forcibly turn ON or OFF the output use the OUT ON...

Page 285: ...ircuit 1 or circuit 2 ON for 5 minutes and OFF for 1 hour 55 minutes repeatedly from 8 00 to 19 00 on Sunday Press to turn on the bar at the Sunday position Set the start time to 8 00 with and 2 4 4 C...

Page 286: ...ons in individual circuits The set data will be cleared if the OUTPUT setting switch is moved between the TIMER and PULSE positions after the data has been set SUN MON TUE WED THU FRI SAT SUN MON TUE...

Page 287: ...ncelled Each operation clears the following combination of settings Timer operation weekly Both the ON OFF times Pulse output operation weekly Both the ON time and pulse width Cyclic operation weekly...

Page 288: ...mode holiday settings or day override settings cannot be cleared in the same manner Yearly programs are also cleared with the yearly types The color indicates flashing SUN MON TUE WED THU FRI SAT Set...

Page 289: ...s not turned ON or OFF according to displays in program check mode but according to settings and the current time Program check mode can be entered from run mode only Holiday settings Section 5 1 day...

Page 290: ...omatically returns to run mode Note This mode can be entered from run mode only Output is not turned ON or OFF according to displays but according to settings and the current time Holiday settings Sec...

Page 291: ...le in run mode only If summer time adjustment Section 6 6 6 is set to automatic for the yearly types manual adjustment is disabled The settings are not changed by summer time adjustment 5 5 SummerTime...

Page 292: ...y 4 chnls 5 7 Display Switching Current time Current month and day Factory setting Current time Next operation Total time hour Total count cnt Weekly 2 chnls Yearly 2 chnls Yearly 4 chnls 5 7 Display...

Page 293: ...Key for 1 s or more Except for slide switches and DIP switches A next operation is not displayed during the power off Override and automatic return operation is not available Weekly 2 chnls Yearly 2 c...

Page 294: ...de and automatic return operation Isn t the Time Switch set for day override operation Weekly type only Isn t the Time Switch set for yearly operation Yearly types only Are banks weekly type only or s...

Page 295: ...MART REVISION 06 06 06 Revision 03 OWNER S MANUAL for MART VERTICAL POWER WASHER PUMP...

Page 296: ...mp 3 C Stopping the Pump 4 VI MAINTENANCE 4 A Backhead 4 B Bearing Temperature 4 C Bearing Lubrication 4 VII TROUBLESHOOTING 4 VIII DISASSEMBLY AND REASSEMBLY 6 A Disassembly 6 B Parts Inspection 8 C...

Page 297: ...ber on the lines below Pump Serial Number ___________________________________ Model Number ________________________________________ D SAFETY PRECAUTIONS This manual contains descriptions and instructi...

Page 298: ...y depending on climatic environment length of storage and equipment For storage periods of three months or longer contact a representative from Carver Pump Company for specific instructions Improper s...

Page 299: ...pecially the following instructions 2 Before starting the pump rotate shaft by hand to assure all moving parts are free 3 Before starting the pump install closed guards around all exposed rotating par...

Page 300: ...bearings C BEARING LUBRICATION Lubrication frequency depends on operating conditions Normal duty calls for relubrication every 1000 hours of operation Bearings are lubricated at Carver Pump Company wi...

Page 301: ...Check inspect replace 10 Worn swivel joint 10 Check inspect replace Pump surges 1 Liquid level in tank too low 1 Add liquid to system 2 Solution is too hot 2 Lower solution temperature 3 Solution is t...

Page 302: ...screen or reduce operating temperature if problem persists disassemble pump and inspect Rapid wear of coupling spider 1 Misalignment 1 Align pump and motor as outlined in section IV Alignment 2 Bent s...

Page 303: ...1 from casing 2 and inserting lifting eyes into pipe plug holes 12 Remove capscrews 10 and washers 38 securing backhead 6 to casing 2 Remove casing 2 from pumping unit 13 Remove capscrews 35 and washe...

Page 304: ...meter of impeller 1 wear surface exceeds double the maximum clearances given in Table 2 replace suction head 3 and impeller 1 5 On bearing column 30 measure the inside diameter at the lower bearing G3...

Page 305: ...pe wrench or try to jam the impeller with a screw driver while tightening Holding the impeller by the vanes may break it NOTE Use Loctite 262 Red when installing capscrew 15 Install new suction head g...

Page 306: ...me type is on your pump There are two frames for MART pumping systems 12V or 1530 Use one of the ways below to determine which pump frame type you have 1 Count the bolt holes on the upper pump frame b...

Page 307: ...Page 18 For 1530 See Page 20 for 12V Main Pump See Page 12 for 1530 with Hardened Steel Bushing See Page 14 for 1530 with Composite Bushing See Page 16 for 12V Main Pump See Page 12 for 1530 with Hard...

Page 308: ...12 Fig 1 Main Pump Cut Away 1530 Frame Hardened Steel Throttle Bushing...

Page 309: ...column base 60 Baseplate 61 52395 Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermediate 65 Hex head bolt motor i...

Page 310: ...14 Fig 2 Main Pump Cut Away 1530 Frame Composite Throttle Bushing...

Page 311: ...Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermediate 65 Hex head bolt motor intermediate 70 72556 71919 Coupli...

Page 312: ...16 Fig 3 Main Pump Cut Away 12V Frame Composite Throttle Bushing...

Page 313: ...r column base 42 Lockwasher column base 60 Baseplate 61 52395 Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermedi...

Page 314: ...18 Fig 4 Boost Pump Cut Away 1530 Frame Composite Throttle Bushing...

Page 315: ...1 52395 Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermediate 65 Hex head bolt motor intermediate 70 72555 Coupl...

Page 316: ...20 Fig 4 Boost Pump Cut Away 12V Frame Composite Throttle Bushing...

Page 317: ...n base 60 Baseplate 61 52395 Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermediate 65 Hex head bolt motor interm...

Page 318: ...Washer Torque Capscrew turn FIGURE 1 IMPELLER CAP SCREW TORQUE METHOD Follow these instructions for installation of the impeller cap screw 1 Install the flange head capscrew with washer into the shaft...

Page 319: ...1530 12V 30281 C Kit Main Pump 15 50 hp Oil Seal 1 Oil Seal 2 Radial Bearing 1 Thrust Bearing 1 Bearing Locking Nut 1 1530 51173 12V 30310 Main Pump 20 50 hp Stainless Steel Sleeve Shaft 1530 53203 15...

Page 320: ...otor Couplings for 1530 Frame with Leeson Motor Assy Pump Coupling 15 20hp 1 Coupling 1 3 8 1 Coupling 1 5 8 1 Insert 72555 Assy Pump Coupling 30hp Simplex 1 Coupling 1 3 8 1 Coupling 1 5 8 1 Insert 1...

Page 321: ...p Motor Couplings for 12V Frame with US Motor Assy Pump Coupling 15 20hp 1 Coupling 1 7 16 1 Coupling 1 5 8 1 Insert 71934 Assy Pump Coupling 30 40 50 hp 1 Coupling 1 7 16 1 Coupling 1 7 8 1 Insert 1...

Page 322: ...26 2450 Adie Road Suite 100 Maryland Heights MO 63043 Tele 1 800 543 6278 Fax 314 567 6318 Website www marttechservices com Copyright 2005 Arcus Corporation All Rights Reserved Made in the USA...

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