Merlion PLUS 2016 E500 STD04densin.com/wp-content/uploads/2017/10/Merlion-PLUS-2016-E500-S… · MERLION PLUS - E500 STD04 Page 18 of 50 2.5 Operations 1) Treat the machine as a high-speed

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USER GUIDE & SPARE PARTS MANUAL

Electrical Powered Heavy Duty Cold Water High HIGH PRESSURE CLEANER

Original Instruction

Merlion Plus E500

INTRODUCTION

MERLION PLUS - E500 STD04 Page 1 of 50

Disclaimers Den-Sin reserves the right to change specifications and to improve our products without notice or obligation.

All Rights Reserved This document or part of it may not be photocopied, or in any other way reproduced, or translated to other

languages without the prior written consent of DEN-SIN.

Warning Read this user manual before you start up your Heavy Duty Pressure Washer for the first time. This Heavy Duty Pressure Washer producing water jet under high-pressure, which is why severe injuries can occur if the safety 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 if not followed correctly could result in personal injuries.

CAUTION is used to alert the reader of procedures or practice which if not followed correctly could result in damage to machine or other equipment.

NOTE is used to highlight important information that may assist the reader carrying out the procedure or understanding the text.

EAR PROTECTION is used to caution of high noise machine level. User must wear ear plug or ear muffler. High noise level will damage user hearing.

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.

WARNING

CAUTION

NOTE

INTRODUCTION


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 01

19/04/2017 Updating 220V components 02

05/06/2017 Pump and Component Changeover and removal of CE declaration 03

25/09/2017 Manual Content Updating. Cable and Water Tank P/N update. 04

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

Getting Acquainted with your Heavy Duty Pressure Washer


The DEN-SIN Merlion Plus E500 facilitates cleaning in less time at high performance. The compact

design enables the machines to be agile within tight/ narrow places, and the high performance gives you the opportunity to solve an array of cleaning tasks. With built in water tank, machine now works even more efficient and reliable. 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.

Applications These Heavy Duty Pressure Washers are capable of removing any kind of dirt:

• Algae off concrete constructions

• Paint 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 to reach places

• Rotating nozzle

This machine is only to be used for the purposes it is designed for. Any other use shall be considered improper and therefore potentially dangerous. The manufacturer is NOT to be held responsible for any damages caused by improper use.

Unpacking Remove the Heavy Duty Pressure Washer and its accessories from the packing material. For transport and packing reasons some accessories are supplied disassembled. Make sure all components are present:

Standard items:

CAUTION

Trigger Gun

Machine Manual

Nozzle

Machine

High Pressure Hose



1.1 OPERATIONAL INFORMATION High Pressure Machine has IP55 rating. Parking the machine outdoor will not pose any damage to the machine. Ensure that the ventilation to the motor must not be blocked. During operation, the machine must not park at an incline angle of 10deg. The machine will become unstable and may endanger user. When hose is pull up to a high, pressure will drop due to gravity. This machine is designed to deliver clean water or non-aggressive water. Using any other water source or sea water will damage the pump unless authorized in writing by Den-Sin. Prior to beginning work, all equipment must be inspected to ensure that it is in safe working condition. Inspection shall include 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 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 of holding the trigger gun for blasting due to the recoil force from the

trigger gun. � Understand how to operate the machine correctly. � Basic Maintenance and Troubleshooting.

** Den-Sin Training program is available upon request. Please contact us for more details **

IMPORTANT that user read the manual guide to understand the operation of the

machine before usage.

NOTE



1.2 MACHINE DIMENSION

MACHINE SPECIFICATION

Model Merlion Plus Model Type

Type E500 E500 E500

M/C no. 700995876 700995877 700995878

Pump Specification Power Phase 3 3 3

Power 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 1060x490x938 1060x490x938 1060x490x938

* Water inlet should not more than 40DegC



1.3 High Pressure Machine Schematic Diagram

Symbol Description Symbol Description F1 Filter 1-Incomming MP Main Pump

FV Float Valve UV Unloader

LS Level Sensor PG2 Pressure Gauge High Pressure

SV Safety Valve TG Trigger Gun (Dry Shut Type)

Remarks: • SV : - SV(Safety Valve) is set at factory about 20~30Bar more than PG 2(Pressure Gauge)

• TG: - TG(Trigger Gun –Dry) is normally close, pressurize when trigger is pressed.

• UV:- UV(Unloader) is normally open, pressurize when trigger is pressed.

SV- Safety Valve Operation Safety valve is a system to protect the machine from over pressure. Over pressure occurs when nozzle size is wrong or 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 system is factory set. Do not try to reset the setting. There should not be any water dump back from to the water tank if the nozzle is use correctly.

MP

F

Water IN

80L Water Tank

FV

LS

F 1

SV

Signal Out

Dump Back

UV

PG 2

TG 1

CAUTION

Machine is manufactured with factory preset settings for its Unloader and Safety valves. Please do not try to change these setting. Adjusting the setting will affect the machine performance or machine become unstable. A trained personal is required to change the settings if necessary.



1.4 Marking & Indication

Hose Type:

Machine ID Plate

v

v

Manufacturing Date: Quarter; Year

WP: 500 Bar

Hose Size: ID ½” or DN 12

Hose Fitting: ½”

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



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



1.6 HIGH PRESSURE MACHINE LOCKOUT/TAGOUT PROCEDURE This procedure establishes lockout on the high pressure machine that could cause injury to personnel. All operators shall comply with the procedure. Equipment shall be locked out to protect against accidental or inadvertent operation when such operation could cause injury to personnel. Do not attempt to operate any switch, valve, or other main switch bearing a lock.

Responsibility The responsibility for seeing that this procedure is followed is binding upon all operators. All operators shall be instructed in the safety significance of the lockout procedure by (designated individual). Each new or transferred affected operator shall be instructed by (designated individuals) in the purpose and use of the lockout procedure.

Sequence of Lockout Procedure

1. Notify all affected operators that a lockout is required and the reason therefor.

2. If high pressure machine is operating, shut it down by the pressing the stop button. Only turn off the booster pump switch 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. Lockout the trigger with a lock that is assigned individual lock. This is to prevent accidentally activate the trigger or sabotage. Possible way to lock the trigger gun as shown below.

After ensuring that no personnel are exposed and as a check on having disconnected the power sources,

operate the start push button and main switch to ensure the high pressure machine will not operate.

CAUTION: Return operating controls to neutral position after the test.

8. The equipment is now locked out

Restoring Equipment to Service 1. When the high pressure machine is to operate at is normal service, check the area around the machine

that no one is exposed. Barricade the area of working zone to prevent people entering the working zone.

2. When equipment is clear, remove all locks. Turn on the main switch, unlock the trigger gun lock and start the normal operating procedure to start using the high pressure machine.

Lock



Unloader/Safety Valve Protection

Machine’s unloader Valve /Safety Valve are factory preset. Purpose of the Unloader is to regulate the machine pressure according to nozzle size. Safety valve is to prevent the machine from over pressure. Therefore, it is not recommended to adjust the setting 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 unauthorized usage or sabotage, the electrical box & main switch is equipped with locks.

Tempered Proof Sealant

Unloader Valve: Tempered Proof

Sealant

Safety Valve: Tempered Proof Sealant

LOCK



Machine Installation / setup Make sure that the machine is operating on flat floor or inclined not more than 10Deg. The machine must be parked or securely tighten to structure. Mount the supplied ½” high-pressure hose onto the Water Blaster onto ½” high-pressure fitting on the HP Water Outlet as labelled. Prepare the water supply by attaching water hose to the supplied Low pressure Inlet (Crawl Coupling), as labelled. Turn on the water supply tap and fill the water tank with water. When water tank is full, the water will be cut off to prevent overflow.

Connect the main power cord to a grounded 3-phase main power supply. Turn on the power and the Water Blaster. Ensure the motor and pump turns anti-clockwise (view from motor fan end) indicated by the arrows on the coupling cover. When machine is power up, water will to start flowing out from the machine. This is to ensure pump is free from air pockets which would result in cavitation. Next, power off machine and mount the Trigger Gun with Lance to the other end of the ½” 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 handle and the lance. Press the trigger and start blasting. 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.

CAUTION

It is NOT allowed to connect this Heavy Duty Pressure washer directly to a portable water supply! If portable water is used, it is strictly necessary to include a water break tank in accordance to EU standards EN 1717

Make sure your local power supply specifications are in accordance with the motors specification Refer to the ID-plate located at the electrical box or frame. Do not let the machine recycle the water (running with Spray-gun trigger not activated) for more than 10 minutes; this can cause serious damage to the seals



Starting up Issues / Troubleshooting During initial start, machine and water supply is turn on however the pump does not produce any water due to the pump is not primed and is running dry because the valves are stuck. (i.e. Pump inactivity or prolong shipment). This would result in a phenomenon called “Sticky Valve”. Troubleshooting procedure as below:

Step 1

Fill up water tank with water till low-level switch is at OFF position.

Step 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 and water is not seen flowing from the outlet, manually inspect all valve by unfastening all valve plug. Ensure the spring of the valve is not jammed and apply small amount of liquid lubricant to prevent jamming. Refer to pump service instruction on valve removal and servicing.

OFF Position

Water Supply

Pump Inlet Port

NOTE

2. Safety and protection information



2.1 General safety

High Pressure Water Blaster, Merlion 2, 3Phase+PE Normal Operation

Declared Single-Number & Dual-Number Noise Emission Values

In accordance with ISO 4871 Normal Operation

A-weighted sound pressure level, LpA (ref.20 uPa), in decibels 75 Uncertainty KpA, in decibels 3 A-Weighted sound power level,LWAd (ref.1pW),in decibels 95

It is recommended to put on ear protection equipment, etc. ear plug or ear muffler to protect the user from pro-long under high noise environment.

Recoil Force of Trigger Gun:

Based on calculated value, there will be a recoil force of 85~110N acting on the trigger gun to the user. Recoil force is within recommended range of not more than 150N. Holding a trigger gun in a correct position 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 prevent user from hearing related injuries. Noise warning sticker can be found on the machine to warn high noise emission values

Optional Shoulder Rest

Trigger Gun Complete

CAUTION

Be more caution when using the trigger gun. Shoulder rest is for the user to rest its trigger gun on its own body weight to counter react to the recoil force created by the trigger gun. Release any residual pressure from the gun when the machine is shut down.

CAUTION

Caution must be observe when working with trigger gun . Do not work continuously without rest in between jobs. Release any residual pressure from the gun when the machine is shut down



IMPORTANT MEDICAL INFORMATION Immediate hospital attention should be given to personnel who sustain equipment related injuries while operating the system. In such cases, it is vital that medical personnel be apprised of all facts relevant to such injuries. Therefore, all operating personnel should be provided with waterproof emergency medical alert tags or cards, describing the nature of their work and the possibility of injury inherent in the use of water jetting equipment. The following is an example of a standard card that can be photo copied, laminated and used as medical alert tag.

WARNING

DEN-SIN - a division of Nilfisk Pte Ltd.

No.5 Tuas Ave 2, Singapore 639445

Tel: +65 6268 1006 Fax: +65 62684916

www.densin.com

Obtain medical treatment immediately for ANY high-pressure

water-jet injuries.

Inform the doctor of the cause of the injury.

Show this card to the doctor.

This card is to be carried by personnel working with high-

pressure water jetting equipment.

MEDICAL ALERT

NOTE TO PHYSICIAN

This patient may be suffering from a water jet injury. Evaluation and management 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 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. Bandages with a hygroscopic solution (MgSO4) and hyperbaric oxygen treatment have been used as adjunctive therapy to decrease pain, edema and subcutaneous emphysema. Unusual infections with uncommon organisms in immunocompetent patients have been seen; the source of the water is important in deciding on initial, empiric antibiotic treatment, and broad spectrum intravenous antibiotics should be administered. Cultures should be obtained

IMPORTANT

MEDICAL INFORMATION

DEN-SIN - a division of Nilfisk Pte Ltd.

No.5 Tuas Ave 2, Singapore 639445

Tel: +65 6268 1006 Fax: +65 62684916

www.densin.com



2.2 Safety devices The machine is equipped with the following safety devices: 1) Emergency stop Button : (Do not use during normal working conditions)

This machine is equipped with an Emergency stop on the control panel. It is not considered primary safeguarding devices because they do not prevent access to a hazard nor do they detect access to a hazard. It is initiated by a single user’s action. When executed, it will override all other functions and machine operating modes. The objective is to stop the high pressure machine as quickly as possible without creating additional hazards.

• To use the emergency stop function, user need to tap hard on the button. When activated, the high pressure machine 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 may void warranty for the machine. 4) Thermal sensor and overload relay. The thermal sensor and the overload relay protect the

motor against overloading. When overload trip, open up electrical box and reset the overload. 5) If there is leakage current occurs, the RCCB installed will tripped. To reset, switch the lever to

“ON” position. This device will protect the user from leakage current. 6) When the incoming source is overloaded, the 40A MCB will protect the machine from

damage. To reset, switch the lever to “ON” position.

Noise Warning

Main Switch

E-Stop

Start Stop

Lock/Key



2.3 Transporting the machine

*Lifting of machine above is for reference only*

When lifting of the machine, please ensure that the followings are observed:

1) Ensure suspension points and anchorages are adequate for the full imposed load. 2) Check the 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 lift the machine from the frame. Only trained personal is require to do the lifting. Make sure the load evenly distributed.



2.4 Safety PPE

Eye protection- Operators must wear visors and goggles to guard against spray and flying debris. A combination of both goggles and visor is advisable. And will protect the eyes and the face during both water-blasting as well as abrasive water-blasting Head protection- Helmets must be worn at all time by personnel within the work area. Helmet material must be able to withstand mechanical shock without fracturing. Hearing protection- Operators and other personnel exposed to noise levels of more than 90-dBa for more than 1 hour must wear suitable ear protection. Ear plugs or ear muffs are usually sufficient.

Hand protection- Shear proof gloves must be worn by the operator at all times. A glove combination of a cloth inner lining and a water tight outer 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 regular protective boots. Five clips ensure that gaiters securely stay in place. The entire area is protected. Very comfortable and light to wear.

Body protection- Waterproof garments protect the operator only from spray and flying debris. They do NOT deflect direct jet impact. Therefore, an operator must take care never to point a water-jet either at themselves or other personnel. Hose protection- Protect user from high pressure water injuries incase hose connection is loose.

The following protective clothing and devices should be worn both by personnel operating the water blaster system and equipment and by those working nearby.

WARNING



2.5 Operations

1) Treat the machine as a high-speed cutting tool. 2) Anyone under the age of 18 is NOT allowed to use the machine. 3) Always use a proper plug and socket specially designed with ground to earth wiring. Only connect

to an installation with earth wiring. A certified electrician shall make the installation. It is strongly recommended that the electric supply to the machine include a Residual Current Device/GFCI.

4) Always keep the Water Blaster and its accessories in good working condition. Check the machine for defects, especially the insulation on the electric cable. Do NOT start up the machine if there is any defect. Have the machine serviced.

5) When using the Water Blaster and its accessories, eye protection must be worn to protect against repelling or ricocheting matters causing eye damage.

6) Suitable clothing and footwear must be worn while using the equipment 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 beams 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 accessories always make sure the machine is

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 and nozzles specified by DEN-SIN. 15) IMPORTANT – Do not use the machine in a possible explosive environment in accordance with

EN-50014.

2.6 Application Guidelines 1) It is not allowed to clean asbestos containing surfaces with high-pressure, unless using special

equipment. 2) Persons under the influence of alcohol, drugs or medicine should not operate the machine. 3) Do not touch the electrical plug and socket with wet hands. 4) Always unplug power supply when cleaning and maintaining the machine. 5) Do not use the machine if important parts are damaged – i.e. safety devices, high-pressure hoses,

spray handle. 6) The user is obliged to observe all national working environment and working safety regulations

concerning “operation of high-pressure washers”. 7) It is not allowed to connect this machine directly to a potable water supply. 8) If the machine is to be connected to potable water supply it is strictly necessary to fit the machine

with a water break tank, in accordance with EN1717.

WARNING

To prevent accidents from happening, ensure the safety of the person(s) who uses the equipment and to protect bystanders and nearby placed inventory or machinery, a few safety precautions needs attention

3. Maintenance and troubleshooting



3.1 Maintenance Schedule Regular Service

Period as indicated

Each

use

1st 50hrs Every month /

Every 500hrs

When

needed

Procedure / Remarks

Check pump oil

level • Top up if necessary.

Change pump oil

Recommended Oil : SAE 15W40 or SAE 30

Usage : Approx. 0.4kg of oil

Renewal of oil:

• Turn off High Pressure Cleaner.

• Loosen bolt (Hex) at bottom of pump housing.

• Drain oil into a waste oil-tray.

• Tighten bolt(Hex)

• Add oil through pump inlet on top of the pump until the red point of the oil control glass has been reached.

Note:

Do not dispose used oil into drain. Always

pour the used 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

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 Preventive Maintenance Guide

No Part No. Description Quantity

required Service Hours

1 700505094 Support Packing Kit Ø15 1 500

2 700505095 Water Seal Kit Ø15 1 500

3 700505096 Valve Kit 1 500

4 700505097 Plunger Kit Ø15 1 500

5 700505289 Plunger rod seal 1 500

6 700505080 Plunger rod 3 1000

Unloader Valve

7 700540983 Repair kit 1 400

Safety Valve

7 700540995 Repair kit 1 400

Trigger Lance

8 700551181 Repair kit 1 400

Above guide is based on machine operating with fresh water of ambient temperature

not more than 30 degree Celsius.

NOTE



Machine Do`s and Don`ts Do’ 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 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

when the machine is shut down

To prevent injuries others if the trigger is accidentally

pressed.

Used oil must be properly disposed. Do not dispose used oil into the environment that

will cause pollution to the environment.

WARNING



3.2 Troubleshooting Symptom Rectification

Main switch is turned on the High Pressure

Cleaner will not run. • Check power supply connection for faulty components .

• Make sure the socket is inserted correctly

• Check if fuse is blown, replace if necessary.

Motor is humming & Pump does not give

pressure or low pressure

• Voltage is too low as compare to specification.(Check main voltage)

• Motor phase is missing (For 3 phase application). Check the connection box voltage with a meter

• High-pressure pump is blocked

Pump pressure drops and the High Pressure

Cleaner works irregularly

• Strain filter is clogged.

• Water supply from the tap is insufficient.

• Clean the strain water filter

Pump continuously stops and starts, when the

spray-gun trigger is activated.

• The high pressure nozzle is partly clogged. Turn off the High Pressure Cleaner, dismantle the high-pressure nozzle and remove the extraneous matter. Replace if damaged

High pressure cleaner does not reach the proper working pressure when the spray-gun handle is activated

• The high-pressure nozzle is clogged.

• Dirt in the by-pass valve.

• The pump sucks air.

• Turn off the High Pressure Cleaner. Clean the nozzle.

• Inspect the low pressure supply, while spray-gun trigger is activated, ON the machine on again.

• Repeat the procedure again; now with the trigger 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.

• Extraneous matter in the valves.

• Crankcase or motor bearings worn out.

• Inspect the low-pressure supply. Replace springs.

• Clean the valves. Replace the bearings.

Water in the oil • The O-ring casing is worn out.

• High moisture in the air (condensing inside the crankcase)

• The seals are completely worn out.

• Check or replace the O-ring.

• Renewal of the crankcase oil more often.

• Replace the seals.

The High Pressure Cleaner does not suck chemicals

• The chemical container is empty.

• The High Pressure Cleaner has not been set to low-pressure (on the double barrel lance cock).

• The low-pressure nozzle is clogged, or partly clogged.

• The non-return valve of the chemical injector is stuck.

• Ensure the chemical container contains sufficient fluid for proper suction.

• Set the spray-lance to low pressure by turning the cock on the lance counterclockwise.

• Clean or replace the low-pressure nozzle.

• Clean, correct or replace the non-return valve of the chemical injector.

NOTE

For any further inconveniences, not mentioned in this user guide or any damages of the machine, we strongly suggest you to make contact with your dealer for the repair or possible replacement of any original spare-parts



3.3 Pump Service Instructions Disassembling of E500 pump:

-Loosen the M10 bolts in a star configuration

-Remove the Outlet Valve Cover -Insert a M6 screw and pull out the Outlet Valve Cap

-Pull out the Valve using a plier The valve is made of plastic, take care not to break the

plastic valves

-Check the Valve for damages, replace if necessary - Use a sharp object to “fish” out the O-ring at the

bottom Take care not to scratch the interior 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 -Use a finger to remove the Diffuser

-Push out the Back Ring & Pressure Ring from the back

with a brass rod. Take care not to scratch the interior of the pump.

-Use a screwdriver or pliers to fish out the packing. Take care not to scratch the interior of the pump.

Once taken out, all packing must be changed.



Assembling of pump:

-Disassembling of Pump Head & Manifold completed

Replace damaged parts with Original DEN-SIN spares Apply waterproof silicone grease onto the surface of the

O-rings Apply grease onto the thread surface for easy removal in

the future Clean all component before assembling

-Assemble White & Black Packing and insert into pump

Insert the Brown Packing -Take note of the sequence white, black & brown 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

-Assemble the Pump Head, push the Pump Head in until there is no visible gap.

Take care not to drop the Pump Head on the Plungers

-Assemble the Manifold, ensure that the cooling holes

are not choke before assembling -Take note of the location of the cooling holes Hand tighten the M10 Bolts



-Insert the Valve and O-ring into the Pump Head

- Insert the Valve Cap Take note of the orientation, threaded hole facing up

- Assemble the the Outlet Valve Cover - Hand tighten the M10 Bolts - Torque all the M10 bolt to 37lb.ft using a torque wrench in a star configuration -Assembly of Pump Head & Manifold completed

3.4 Torque Specification

Pos. Description 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. If nozzle is verified, still no pressure improvement, next you can check isfor leaking from the pump.

NOTE

Torque the bolts according to the table provided above. Incorrect of the pump will damage the pump piston and seal.

4. Machine Spare Parts Lists



Pos: Part no.: Qty.: Description:

1 700520831 1 MERLION PLUS FRAME ASSY 2016

2 700520791 1 TOP PLATE SS MERLION

3 700510220 2 BOLT M6 X 20 HEX

4 700510023 2 WASHER FLAT M6

5 700560188 2 WING NUT M6

6 700520871 1 OUTLET PLATE MERLION PLUS 2016

7 700510023 4 WASHER FLAT M6

8 700510038 8 WASHER FLAT 1/4- 3/4

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 700530851 1 EL-BOX COMP STD 25HP/220V

19 700520121 WIRE CLAMP W/BRACKET GR3DIA 19

20 700510107 4 BOLT M8 X 20 HEX

21A 700540316 4 DOWTY SEAL M8

21B 700510005 8 WASHER FLAT M8

21C 700510057 4 NUT M8



Motor/Pump Assembly Spare-Parts List

Motor/Pump Assembly Spare-Parts List


22 700530487 1 MOTOR 380~480V/24HP/50-60HZ

22 700530714 1 MOTOR 220V/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 ALLEN S.S

33 700510034 4 WASHER SPRING M8



Water Tank Assembly Spare-Parts List


34 700520863 1 WATER TANK 39L W/COVER BLUE

35 3817582 1 LEVEL SENSOR

36 700540999 2 TANK OUTLET G1 W/GASKET

37 700541000 1 HOSETAIL FLAT SEAT G1

38 700541001 1 NUT FLY 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 1-1/2 BSPT

50 700540056 1 DOWTY SEAL 1/2"

51 700950031 0.1m HOSE ½” 20BAR PVC

52 700540056 1 DOWTY SEAL 1/2"



Filter Assembly Spare-Parts List

Filter Assembly Spare-Parts List


80 700540986 1 COUPLING CRAWL HOSE END 3/4

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" 34 – 37



E500 Pump Assembly Spare-Parts List



53* 700505284 1 PUMP E500 50HZ

700505285 1 PUMP E500 60HZ

54* 700540323 1 ELBOW 3/4 BSPT M-F

55* 700540102 1 HOSE NIPPLE 1- 3/4 BSPT

56* 700540264 1 HOSE CLIP 1" 31-34

57* 700950014 1m 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 BSPT

67* 700541026 1 HOSE CLIP 1" 34 – 37

68* 700950021 0.6m HOSE INLET 1 RUBBER (18 BAR)

69* 700541026 1 HOSE CLIP 1" 34 – 37

70* 700550004 2 DOWTY SEAL 3/8"




Optional E500 Auto SS Kit


71* 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 ½”

74* 700540055 1 GAUGE 1000BAR 1/4 BSPT

75* 700540985 1 SAFETY VALVE 500BAR 1/2

76* 700540276 1 T-JOINT ½”M H.P


K1 700530844 1 MERLION PLUS E500 AUTO SS KIT

700530514 1 TIMER

700530471 2 PRESSURE SW 3/8”

700540100 1 Nipple 1/2”



4E ii. E500 Pump Spare Parts / Repair Kit List



E500 Pump Spare Parts / Repair Kit List


1 700505287 1 CRANKCASE

2 700505289 3 PLUNGER ROD SEAL 3 Kit 87 / Kit 88 3 O-RING

4 Kit 87 3 PRESSURE RING Ø15 5 Kit 88 3 LOW PRESSURE SEAL Ø15

6 Kit 87 3 BACK RING Ø15 7 Kit 88 3 HIGH-PRESSURE SEAL Ø15

8 700550004 1 DOWTY SEAL 3/8”

9 700505051 1 PLUG 3/8" 10 - 1 PUMP HEAD

11 - 3 O-RING 12 700505066 3 VAM DIFFUSER

13

Kit 152

3 OUTLET VALVE 14 9 O-RING

15 6 ANTI-EXTRUSION RING

16 3 INLET VALVE 17 3 ANTI-EXTRUSION RING

18 - 3 PLUG 19 700505020 3 O-RING

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 DIA15

36 700505039 3 CONNECTION ROD PIN

37 700505040 3 CONNECTION ROD 38 700505155 6 SCHNORR WASHER DIA.8MM

39 700505045 2 BEARING, ROLLER D.30 40 700505044 2 O RING

41 700505043 1 FLANGE,CLOSED

42 700510005 8 WASHER FLAT M8 ZN 43 700510107 8 BOLT M8 X 20 HEX ZN

44 700505057 1 OIL SEAL FOR CRANKSHAFT 45 700505056 1 FLANGE, OPEN

46 700505055 1 SHIM 47 700505054 1 KEY, CRANKSHAFT



E500 Pump Spare Parts / Repair Kit List

E500 Pump spare-parts kit

Kit - Part no.:/ Kit description Pos: Qty.: Individual components Part no.:

KIT 87 – 700505094 Support Packing Kit Ø15

(1 SET)

3 3 O-RING

4 3 PRESSURE RING Ø15

6 3 BACK RING Ø15

KIT 88 – 700505095

Water Seal Kit Ø15 (1 SET)

3 3 O-RING

5 3 LOW PRESSURE SEAL Ø15

7 3 HIGH-PRESSURE SEAL Ø15

KIT 152 – 700505096 Valve Kit (1 SET)

13 3 OUTLET VALVE

14 9 O-RING


16 3 INLET VALVE


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


48 700505085

1 CRANKSHAFT 50HZ

700505115 CRANKSHAFT 60HZ

49 700505265 1 BACK COVER GASKET

50 700505288 1 BACK COVER CH PUMP

51 700505238 1 SIGHT GLASS OIL PLUG G1/2

52 700505141 1 PLUG GASKET

53 700505051 1 PLUG 3/8"

54 700505046 3 OIL PLUG G3/8

1-54 700505284

1 PUMP E500, 50 HZ COMPLETE

700505285 PUMP E500, 60 HZ COMPLETE



E500 Un-loader Assembly



E500 Un-loader Assembly


1 - 1 Valve body ½’F

2* - 1 O-ring 1.78x15.6 2062 NBR 90 NERO

3* - 1 Valve Seat

4* - 1 Shutter Seal

5* - 1 O-ring 1.78x17.17 2068 NBR 90 NERO

6 - 1 Piston Spacer

7* - 1 Backup Washer 10 x 14.7 x T1.8

8* - 1 O-ring 2.62x9.92 112 NBR 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 SPRING

24* - 1 Backup Washer 20.8 x 23.7 x T1.4

25 - 1 Fitting 1/2”

1-25 700540982 1 Un-loader Valve Complete

* 700540983 1 Complete Repair kit

* Repair Kit Only



E500 Safety Valve Assembly


1 - 1 Valve Body G1/2F - G1/2F

2* 700540995 1 Backup Ring 14.9x17.9x1.8

3* 700540995 1 O-Ring 1.78x14

4* 700540995 1 Seat

5* 700540995 1 O-Ring 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 VALVE 500BAR 1/2

* 700540995 1 REP KIT SAFETY VALVE 500BAR



E500 Trigger Gun / lance & hose assembly



1 700550051 1 Nozzle, straight 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





13 700551240 1 Housing

14 700551241 1 Coupling, ½” BSP S.S.

15 700551242 1 Safety Latch, Red

16 700551243 1 Trigger, Black

17 700551244 1 Stop Pin, Ø8x7.1mm

18 700551245 1 Parallel Pin, Ø5x27.5mm

19 700551246 1 Casing Kit + Screw

20 700510216 7 Self-tapping screw

21 700550126 1 Back pipe

22 700551182 1 Shoulder Rest (Optional)

23 700510217 2 Washer

24 700550108 1 Lance pipe 400mm Length (Optional)

24 700550109 1 Lance pipe 1000mm Length (Standard)

25 700550107 1 Bushing for Side Handle

26 700550106 1 Nozzle holder

27 700551247 1 Plug ¼” M BSP

28 700550073 1 Side Handle complete

29 700550116 1 Connection fitting 1/2”BSPP-female

30 700540057 1 Nipple ½” BSPP

31 700550097 1 High Pressure Hose 15m with ½” BSPP Swivels (Standard)

31 700550098 1 High Pressure Hose 20m with ½” BSPP Swivels (Optional)

31 700550099 1 High Pressure Hose 30m with ½” BSPP Swivels (Optional)

32 700550136 1 Lance connection ½” male – 3/8” female BSPP

2-21 700551180 1 Trigger Complete (inclusive of item 27 & 29)

* 700551181 1 Set Trigger Gun Repair Kit

* Part for Trigger Repair Kit

Lance, Complete with different length

Description Pos: Qty.: Individual components Parts:

700550140, (1 SET) 24 1 Lance pipe 400mm Length (Optional)

Lance Length 400mm 25 1 Bushing for Side Handle

26 1 Nozzle holder

28 1 Side Handle complete

32 1 Lance connection ½” male – 3/8” female BSPP

700550141, (1 SET) 24 1 Lance pipe 1000mm Length (Standard)

Lance Length 1000mm 25 1 Bushing for Side Handle

(Standard) 26 1 Nozzle holder

28 1 Side Handle complete

32 1 Lance connection ½” male – 3/8” female BSPP



4F. Electrical Assembly

Wiring diagram



Circuit Highlights:- Standard circuit w/o Auto SS (Normal Operation):-

• Terminal TB3&TB4(see Note 1) is shorted

• Terminal TB2 & TB6(see Note 2) is Not Connected

Auto S.S Kit = Circuit w/Auto SS function:-

• Disconnect bridging wire from Terminal TB3 & TB4 (see Note 1)

• Connect Terminal TB3 onto T1 (Timer-700530514) of Terminal 16.

• Connect Terminal TB4 onto T1, Terminal 15.

• Connect Terminal TB6 onto T1 of Terminal A2.

• Connect RED/RED Wires on the SW1 & SW2 onto TB2

• 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 burnt the motor or creates unnecessary tripping of the overload.

Motor Switch Timer Setting Star- Delta Timer Setting : Factory setting of the switching of the motor from Star-Delta is set to 50ms. While the time to switch over is 3s.

� � RANGE:-must be set to “1s” as shown. � TIME:-must be set to “3” � MS:- must be set to “50”



ELECTRICAL BOX – 380~440V

El-box assembly spare-parts list (380~440V)


1 700530913 1 Run Light, Green

2 700530519 1 POWER ON Light, White

3 700530520 1 ON Push button, Green

4 700530711 1 OFF Push button, Red

6 - 1 Lock w/key

7 700530837 3 MCB 2A 1P

8 700530163 2 Contactor 24V mains: 380/415/440V 50/60Hz

8 700530152 2 Contactor 24V mains: 220V/50~60Hz

9 700530477 1 Overload relay mains: 380/415/440V 50/60Hz

9 700530169 1 Overload relay mains: 220V/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 terminal, incoming power

16 700530521 1 Emergency Stop Button

17 700530522 1 Main Switch 32-40A mains: 380/415/440V 50/60Hz

17 700530469 1 Main Switch 80A mains: 220V 50/60Hz

18 700530602 1 Panel Box 360x320x200 IP55

* 700530917 1 Hour Meter 24V



Continue’

1-18 700530836 1 El-box complete mains: 380/415/440V 50/60Hz

1-18 700530851 1 El-box 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)



ELECTRICAL BOX – 220V~230V

El-box assembly spare-parts list (220~230V)


1 700530913 1 Run Light, Green

2 700530519 1 POWER ON Light, White

3 700530520 1 ON Push button, Green

4 700530711 1 OFF Push button, Red

5 700530522 1 Main isolator 40A

6 - 1 Lock w/key

7 700530837 3 MCB 2A 1P


9 700530477 1 Overload relay 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 360x320x200 IP55

1-18 700530836 1 El-box complete

N/A 700951550 15 m Main cable mains: 380/415/440V 50/60Hz (not shown)

N/A 700951509 0.8 m Cable Star/Delta mains: 380/415/440V 50/60Hz (not shown)

N/A 700951550 50m Main cable mains: 380/415/440V 50/60Hz (not shown)

5. Optional Rotating Nozzle



Rotating Nozzle – Type 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.


1 700540314 2 ¼” Dowty Seal

2 700540149 1 ¼” Nipple

3* 700551312 1 Nozzle Repair Kit 0003 50/60 Hz

1-3 700551308 1 ROTATING NOZZLE W/SPRING 030(Complete) 50/60 Hz



Operation & 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



Rotating Nozzle – Type 2


1 700551140 1 Multi Jet Shield Bolt

2 700551141 1 Multi Jet Shield

3 700551183 1 Multi Jet Head 2ports

4 700551143 1 Multi Jet Back-Up Ring

5 700551144 1 Multi Jet O-Ring

6 700551145 1 Multi Jet Seal, Large

7 700551146 1 Multi Jet Bearing, Thrust

8 700551164 1 Multi Jet Shaft

9 700551148 1 Multi Jet Inlet seat

10 700551147 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


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 Spring

1-19 700551035 1 Rotating Nozzle, Barracuda 22kpsi

A 700551165 1 Multi Jet Springe (Optional)

*To use 700551035 onto lance, take out (Nozzle Holder) 700550106 and add in Adaptor (700551107).



Recommended Nozzle Sizing for 500Bar (Type 3)

* 700551035

700551037 700551037

1 set 1) Rotating 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



Operation & 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



Optional sand & slurry blasting kit E500

Pos.: Items Parts. No. 1 Sandblasting House Complete 700551524 (Items :8-15) 2 Lance 700550141 3 High Pressure Hose 700550099 4 Sand 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 700540149

13 12 11 10 9

1

8 15 14

6. Warranty


6. Warranty DEN-SIN warrants all equipment of its manufacture furnished under this agreement to be free from defect in workmanship and material for a period of one year from the date of invoice of the equipment. This warranty does not cover normal wear and tear, consumable items, or part failures caused by (i) accident, (ii) abuse, or (iii) failure to maintain the DEN-SIN system containing the affected parts in accordance with DEN-SIN technical specification. All labour is the responsibility, and the expense of the Buyer. The liability of Seller under this warranty is 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 negligence, misuse, improper maintenance, improper installation, accident, or unauthorized repair or alteration. Accessories or equipment furnished by DEN-SIN but manufactured by others, shall carry the warranty that its manufacturer has conveyed to DEN-SIN, and which may be passed on to the purchaser. The original warranty period of any article, which has been repaired or replaced by DEN-SIN, shall not thereby be extended.

Documents

Merlion PLUS 2016 E500 STD04densin.com/wp-content/uploads/2017/10/Merlion-PLUS-2016-E500-S… · MERLION PLUS - E500 STD04 Page 18 of 50 2.5 Operations 1) Treat the machine as a high-speed