Den-Sin Merlion Plus E500 User Manual & Spare Parts Manual
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Den-Sin Merlion Plus E500 User Manual & Spare Parts Manual

Electrical powered heavy duty cold water high high pressure cleaner
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Merlion Plus
E500
Electrical Powered
Heavy Duty Cold Water High
HIGH PRESSURE CLEANER
USER GUIDE & SPARE PARTS MANUAL
Original Instruction
www.densin.com

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Summary of Contents for Den-Sin Merlion Plus E500

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

  • Page 2: Introduction

    INTRODUCTION 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 DEN-SIN.

  • Page 3: Table Of Contents

    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.
  • Page 4 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.

  • Page 5: Operational Information

    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.

  • Page 6: Machine Dimension

    Getting Acquainted with your Heavy Duty Pressure Washer 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 Power Supply 380~415V 440~460V 220V~230V Freq. 50Hz 60Hz 60Hz Motor Type 25HP 25HP...

  • Page 7: High Pressure Machine Schematic Diagram

    Getting Acquainted with your Heavy Duty Pressure Washer 1.3 High Pressure Machine Schematic Diagram Symbol Description Symbol Description Filter 1-Incomming Main Pump Float Valve Unloader Level Sensor Pressure Gauge High Pressure Safety Valve Trigger Gun (Dry Shut Type) Water Water Tank Dump Back Signal Out PG 2...

  • Page 8: Marking & Indication

    Getting Acquainted with your Heavy Duty Pressure Washer 1.4 Marking & Indication Hose Type: 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.

  • Page 9: Machine Highlights

    Getting Acquainted with your Heavy Duty Pressure Washer 1.5 Machine Highlights Powder Coated Frame Galvanizing Electrical Box Stainless Steel Cover Filter Castor Wheels Crawl Coupling Safety Valve Unloader Valve Pressure Gauge Solid Wheels MERLION PLUS - E500 STD04 Page 8 of 50...

  • Page 10: High Pressure Machine Lockout/Tagout Procedure

    Getting Acquainted with your Heavy Duty Pressure Washer 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.
  • Page 11 Getting Acquainted with your Heavy Duty Pressure Washer Unloader/Safety Valve Protection Machine’s unloader Valve /Safety Valve are factory pre- set. Purpose of the Unloader is to regulate the machine pressure according to nozzle size. Safety valve is to prevent the machine from over pressure.
  • Page 12 Getting Acquainted with your Heavy Duty Pressure Washer 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”...
  • Page 13 Getting Acquainted with your Heavy Duty Pressure Washer 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).

  • Page 14: Safety And Protection Information

    2. Safety and protection information 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, L (ref.20 uPa), in decibels Uncertainty K , in decibels...

  • Page 15: Warning

    Inform the doctor of the cause of the injury. Show this card to the doctor. 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 MEDICAL ALERT...

  • Page 16: Safety Devices

    2. Safety and protection information 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.

  • Page 17: Transporting The Machine

    2. Safety and protection information 2.3 Transporting the machine Lifting Direction *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.

  • Page 18: Safety Ppe

    2. Safety and protection information 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.

  • Page 19: Operations

    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.

  • Page 20: Maintenance And Troubleshooting

    3. Maintenance and troubleshooting 3. Maintenance and troubleshooting 3.1 Maintenance Schedule Regular Service Each 50hrs Every month / When Procedure / Remarks Period as indicated Every 500hrs needed Check pump oil • Top up if necessary. level Change pump oil Renewal of oil: •...
  • Page 21 3. Maintenance and troubleshooting Machine Do`s and Don`ts Do’ Don’t Action Cause Spray directly onto the machine with high Electrical shock may occurs pressure water Operate the machine with damaged or removed Motor will be overheated and malfunction fan cover Operate/keep machine with frost built up Flush pump with antifreeze fluids before use.

  • Page 22: Troubleshooting

    3. Maintenance and troubleshooting 3.2 Troubleshooting Symptom Rectification Main switch is turned on the High Pressure • Check power supply connection for faulty components . Cleaner will not run. • Make sure the socket is inserted correctly • Check if fuse is blown, replace if necessary. •...

  • Page 23: Pump Service Instructions

    3. Maintenance and troubleshooting 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...
  • Page 24 3. Maintenance and troubleshooting 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...

  • Page 25: Torque Specification

    3. Maintenance and troubleshooting -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 &...

  • Page 26: Machine Spare Parts Lists

    4. Machine Spare Parts Lists 4. Machine Spare Parts Lists Pos: Part no.: Qty.: Description: 700520831 MERLION PLUS FRAME ASSY 2016 700520791 TOP PLATE SS MERLION 700510220 BOLT M6 X 20 HEX 700510023 WASHER FLAT M6 700560188 WING NUT M6 700520871 OUTLET PLATE MERLION PLUS 2016 700510023...

  • Page 27: Motor/Pump Assembly Spare-Parts List

    4. Machine Spare Parts Lists Motor/Pump Assembly Spare-Parts List Motor/Pump Assembly Spare-Parts List Pos: Part no.: Qty.: Description: 700530487 MOTOR 380~480V/24HP/50-60HZ 700530714 MOTOR 220V/24HP/50-60HZ 700951509 1.6m CABLE 7G 2.5MMSQ 380-440V 700951520 1.6m CABLE 7G 6MMSQ 220V 700510201 BOLT M12X45 HEX 700510131 WASHER M14 700510067...

  • Page 28: Water Tank Assembly Spare-Parts List

    4. Machine Spare Parts Lists Water Tank Assembly Spare-Parts List Pos: Part no.: Qty.: Description: 700520863 WATER TANK 39L W/COVER BLUE 3817582 LEVEL SENSOR 700540999 TANK OUTLET G1 W/GASKET 700541000 HOSETAIL FLAT SEAT G1 700541001 NUT FLY G1 700541002 FLAT GASKET G1 700540771 ELBOW 1/2"...

  • Page 29: Filter Assembly Spare-Parts List

    4. Machine Spare Parts Lists Filter Assembly Spare-Parts List Filter Assembly Spare-Parts List Pos: Part no.: Qty.: Description: 700540986 COUPLING CRAWL HOSE END 3/4 700540987 COUPLING CRAWL 1/2 F END 700540056 DOWTY SEAL 1/2" 700540057 NIPPLE 1/2 NPT - 1/2 BSPM 700540056 DOWTY SEAL 1/2"...

  • Page 30: E500 Pump Assembly Spare-Parts List

    4. Machine Spare Parts Lists E500 Pump Assembly Spare-Parts List E500 Pump Assembly Spare-Parts List Pos: Part no.: Qty.: Description: 700505284 PUMP E500 50HZ 700505285 PUMP E500 60HZ 700540323 ELBOW 3/4 BSPT M-F 700540102 HOSE NIPPLE 1- 3/4 BSPT 700540264 HOSE CLIP 1"...
  • Page 31 SAFETY VALVE 500BAR 1/2 700540276 T-JOINT ½”M H.P Optional E500 Auto SS Kit Pos: Part no.: Qty.: Description: 700530844 MERLION PLUS E500 AUTO SS KIT 700530514 TIMER 700530471 PRESSURE SW 3/8” 700540100 Nipple 1/2” MERLION PLUS - E500 STD04 Page 30 of 50...
  • Page 32 4. Machine Spare Parts Lists 4E ii. E500 Pump Spare Parts / Repair Kit List MERLION PLUS - E500 STD04 Page 31 of 50...
  • Page 33 4. Machine Spare Parts Lists E500 Pump Spare Parts / Repair Kit List Pos: Part no.: Qty.: Description: 700505287 CRANKCASE 700505289 PLUNGER ROD SEAL Kit 87 / Kit 88 O-RING Kit 87 PRESSURE RING Ø15 Kit 88 LOW PRESSURE SEAL Ø15 Kit 87 BACK RING Ø15 Kit 88...
  • Page 34 4. Machine Spare Parts Lists E500 Pump Spare Parts / Repair Kit List Pos: Part no.: Qty.: Description: 700505085 CRANKSHAFT 50HZ 700505115 CRANKSHAFT 60HZ 700505265 BACK COVER GASKET 700505288 BACK COVER CH PUMP 700505238 SIGHT GLASS OIL PLUG G1/2 700505141 PLUG GASKET 700505051 PLUG 3/8"...
  • Page 35 4. Machine Spare Parts Lists E500 Un-loader Assembly MERLION PLUS - E500 STD04 Page 34 of 50...
  • Page 36 4. Machine Spare Parts Lists E500 Un-loader Assembly Pos: Part no.: Qty.: Description: Valve body ½’F O-ring 1.78x15.6 2062 NBR 90 NERO Valve Seat Shutter Seal O-ring 1.78x17.17 2068 NBR 90 NERO Piston Spacer Backup Washer 10 x 14.7 x T1.8 O-ring 2.62x9.92 112 NBR 90 NERO O-ring 1.78x20.35 2081 NBR 90 NERO Spacer Support...
  • Page 37 4. Machine Spare Parts Lists E500 Safety Valve Assembly Pos: Part no.: Qty.: Description: Valve Body G1/2F - G1/2F 700540995 Backup Ring 14.9x17.9x1.8 700540995 O-Ring 1.78x14 700540995 Seat 700540995 O-Ring 1.78x17.17 700540995 Backup Ring 17.9x21.0x2 Bushing Piston 700540995 Piston Pin 700540995 O-Ring 2.62x13.10 117 Backup Ring 13.5x18.2x2.5...

  • Page 38: E500 Trigger Gun / Lance & Hose Assembly

    4. Machine Spare Parts Lists E500 Trigger Gun / lance & hose assembly E500 Trigger Gun / lance & hose assembly Pos: Part no.: Qty.: Description: 700550051 Nozzle, straight jet 0003 50/60Hz 700550389 Nozzle, fan jet 1503 50/60Hz 700551229 Spring Holder 700551230 Back-up ring, PTFE 700551231...
  • Page 39 4. Machine Spare Parts Lists E500 Trigger Gun / lance & hose assembly Pos: Part no.: Qty.: Description: 700551240 Housing 700551241 Coupling, ½” BSP S.S. 700551242 Safety Latch, Red 700551243 Trigger, Black 700551244 Stop Pin, Ø8x7.1mm 700551245 Parallel Pin, Ø5x27.5mm 700551246 Casing Kit + Screw 700510216...

  • Page 40: Electrical Assembly

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

  • Page 41: Main Contactor Overload Setting

    4. Machine Spare Parts Lists 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) •...
  • Page 42 4. Machine Spare Parts Lists ELECTRICAL BOX – 380~440V El-box assembly spare-parts list (380~440V) Pos: Part no.: Qty.: Description: 700530913 Run Light, Green 700530519 POWER ON Light, White 700530520 ON Push button, Green 700530711 OFF Push button, Red Lock w/key 700530837 MCB 2A 1P 700530163...
  • Page 43 4. Machine Spare Parts Lists Continue’ 1-18 700530836 El-box complete mains: 380/415/440V 50/60Hz 1-18 700530851 El-box complete mains: 220V/50~60Hz 700951549 15 m Main cable mains: 380/415/440V 50/60Hz (not shown) 700951524 15 m Main cable mains : 220V / 50~60Hz (not shown) 700951509 1.6 m Cable Star/Delta...
  • Page 44 4. Machine Spare Parts Lists ELECTRICAL BOX – 220V~230V El-box assembly spare-parts list (220~230V) Pos: Part no.: Qty.: Description: 700530913 Run Light, Green 700530519 POWER ON Light, White 700530520 ON Push button, Green 700530711 OFF Push button, Red 700530522 Main isolator 40A Lock w/key 700530837 MCB 2A 1P...

  • Page 45: Optional Rotating Nozzle

    5. Optional Rotating Nozzle 5. Optional Rotating Nozzle Rotating Nozzle – Type 1 Pos: Part no.: Qty.: Description: 700540314 ¼” Dowty Seal 700540149 ¼” Nipple 700551312 Nozzle Repair Kit 0003 50/60 Hz 700551308 ROTATING NOZZLE W/SPRING 030(Complete) 50/60 Hz Note: Due to the natural of the design the rotating life span estimated to be about 50-100Hr depending on quality of the water.

  • Page 46: E500 Bar Rotating Nozzle - Type 3

    5. Optional Rotating Nozzle Operation & Use of Rotating Nozzle –E500 Point nozzle Depress trigger Start Blasting only downwards Allow nozzle to after the nozzle has start spinning started spanning Failure to follow proper start up procedure will shorten the lifespan of the rotating nozzle! CAUTION CAUTION...
  • Page 47 5. Optional Rotating Nozzle Rotating Nozzle – Type 2 Pos: Part no.: Qty.: Description: 700551140 Multi Jet Shield Bolt 700551141 Multi Jet Shield 700551183 Multi Jet Head 2ports 700551143 Multi Jet Back-Up Ring 700551144 Multi Jet O-Ring 700551145 Multi Jet Seal, Large 700551146 Multi Jet Bearing, Thrust 700551164...
  • Page 48 5. Optional Rotating Nozzle Recommended Nozzle Sizing for 500Bar (Type 3) 700551035 1 set 1) Rotating Head 22KPSI 700551037 2) Barracuda Rotating Nozzle 029 (1pc) 700551037 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...

  • Page 49: Operation & Use Of Rotating Nozzle -E500

    5. Optional Rotating Nozzle Operation & Use of Rotating Nozzle –E500 Point nozzle Depress trigger Start Blasting only downwards Allow nozzle to after the nozzle has start spinning started spanning Failure to follow proper start up procedure will shorten the lifespan of the rotating nozzle! CAUTION CAUTION...

  • Page 50: Optional Sand & Slurry Blasting Kit E500

    5. Optional Rotating Nozzle Optional sand & slurry blasting kit E500 Pos.: Items Parts. No. Sandblasting House Complete 700551524 (Items :8-15) Lance 700550141 High Pressure Hose 700550099 Sand Suction Hose 700550248 Hose clamps 700540200 Regulator Handle 700550866 Grit Container Complete 700550865 Finger Screw 700520063+700510051...

  • Page 51: Warranty

    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...

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