USER MANUAL
Contents
1. eliminate static electricity Airclean is CE marked E 1 2 Lubrication The air motor requires lubricated air In order to ensure uninterrupted steady operation you must never let the fitted air lubricator run dry The correct position of the adjustment screw is approx 1 2 1 turn E 1 3 Air operating pressure Do not exceed maximum safe air operating pressure specified in data sheet enclosure 1 E 1 4 Frost protection If frost is expected the waterside must be emptied to prevent damage by frost This is simple Discon nect the water supply and let the unit run some strokes until the pump hose spray gun and extension tube is empty Or change over the air supply to the water intake and blow the waterside dry E 1 5 Guarantee The guarantee is not valid for damages caused by erroneous usage or if the unit has been disassembled without written permission from the manufacturer E2 DESCRIPTION AND OPERATION 4 E 2 1 Pump unit The pump unit comprises a single acting pump powered by a double acting air motor An air shuttle valve that changes the air direction when the piston reaches the end positions controls the air motor E 2 2 Water inlet The connection is marked Water Use a water supply hose with minimum diameter as specified in enclosure 2 Dimensioning of water and air inlet It is recommended to connect a low pressure hose of minimum 3 meters length to the water inlet of the unit to prevent shock in the water system T2. 40 cm Leave the detergent to work approx 3 minutes or according to the manufacturer s instructions However do not let detergent dry on the surface Start cleaning from the bottom and move upward This prevents water to run down and dilute detergent below The spraying distance should be 10 30 cm When cleaning is completed wash down from the top to prevent stains Use water generously E 2 6 Accessories 3 The Airclean standard scope of supply is tailored to cater for ordinary cleaning tasks in an efficient and economic manner Special demands are met by made suit accessories which may be procured when needed Such accessories include Chemical injector Turbo nozzles and other nozzle types Sand blasting set for cleaning and de scaling rusty steel structures etc Nozzles for opening clogged tubes Foam set for soap disinfectants etc Air filters water filters couplings for water and air Extension tubes and extra hoses Airclean wheel lance Complete lance system for efficient washing of high walls ceilings etc Hose drums E3 MAINTENANCE E 3 Preventive maintenance Preventive maintenance is limited to filling of lubrication oil visual inspection and cleaning Particular attention should be paid to high pressure leaks and high pressure hose High pressure leaks should be repaired straight away as they may increase rapidly if left unattended The method of repair depends on where the leaks oc
3. AIRCLEAN 48 High pressure cleaner USER MANUAL Produced in Norway for Wilhelmsen Ships Service Contents E 1 E 1 1 E 1 2 E 1 3 E 1 4 E 1 5 E 2 E 2 1 E 2 2 E 2 3 E 2 4 E 2 5 E 2 6 E 3 E E 3 2 p 33 E 3 4 E 3 5 E 3 6 E 3 7 E 4 El E2 E3 E4 IMPORTANT INFORMATION Safety Lubrication Air operating pressure Frost protection Guarantee DESCRIPTION AND OPERATION Pump unit Water inlet Air inlet Chemical dosing Cleaning procedures Accessories MAINTENANCE Preventive maintenance Pump Unit Dismantling Change of pump piston seal Pump valves Valve shuttle Valve rod sealing Fault diagnosis ENCLOSURES Data sheet Dimensioning of water and air supply Part list Pump drawing Airclean48 TF 02 11 2007 ka OO MOM ING NGNN UHM mn IB RA PIP W v W W W G2 E 1 IMPORTANT INFORMATION E 1 1 Safety Never point the gun at yourself or anybody else and hold it with both hands when spraying A high pressure spray can penetrate the skin causing serious injury Before service work always disconnect the air supply When cleaning it is strongly advisable to use protective goggles wear protective gloves and protective clothing Never spray electrical equipment or cables unless you are sure that the installation stands high pressure cleaning Be sure that any part to be fitted withstands the pressure If the cleaning unit is to be used in a hazardous environment earthing the equipment will
4. cur a Pump Seal A leak pump piston seal will cause a flow of water out of the drain hole on the bottom side of the pump cylinder b Threads All threads are BSP standard The sole exception is the spray nozzle which is NPT All threads are assembled with sealing liquid and leaks will normally never occur How ever if leaks should occur the threads must be cleaned and reassembled using either a sealing liquid or thread tape c High pressure hose couplings The high pressure hose couplings have metal to metal seals To stop a leak tighten the nut until the leak stops If this does not work open the coupling and inspect the sealing surfaces High pressure cleaning is the best method for cleaning the unit If the plant air is contaminated for instance by rust an air filter should be fitted A water filter should be fitted if the water contains abrasive particles E 3 2 Pump Unit Dismantling The pump unit is assembled by means of lock rings and may be split at A or B Pump unit drawing For access to the pump piston seal undo the tie bolts E des of pump piston seal oce e f Loosen the attaching bolts Pull the cylinder of the piston Check the cylinder for scratches to see if honing or a replacement is required Remove the lock pin for the front part of the piston and screw it off Fit o ring pump seal and front part of the piston Fit new slide rings Lubricate piston seal and slide rings to ease reassemble and
5. he hose is long a 1 hose is recommended Air supply Use minimum 1 hose Do not fit valves or fittings with less inner diameter than 19 mm E3 Part list AIRCLEAN 48 PART NO U1200 PUMP UNIT Part No P1002 P1037 P1003 P1204 P1157 P1106 P1007 P1008 P1019 P1010 P1040 P1012 P1005 P1041 P1042 P1119 P1035 P1043 P1044 P1045 P1024 P1123 P1026 P1025 P1159 P1158 P1166 P1027 P1134 P1267 P1016 P1164 P1236 P1168 P1080 P1081 P1082 P1083 P1084 Description Pump head Hex nut Stud screw Piston rod Glide ring Air piston Valve ball Hex screw Reduser Spring Pump cylinder Cylinder cover Spring Pump piston Glide ring Ring End cap Pump packing O ring O ring O ring O ring O ring O ring O ring Liner Sleeve Air cylinder Valve shuttle Valve housing Snap ring Sleeve Valve rod O ring Elbow Hose nipple Return line Hose clip Adapter Pos no Qty 1 ON OO FW ND 11 12 13 14 15 16 M 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38 39 40 N NY WO a NM A A GGO A A NMN HS BS a M a a a a 10 11 E4 Pump drawing 00c 091 JH T LINQ dAfid
6. he suction head capacity of the pump is reduced with increasing temperatures Increased supply pres sure may therefore be required when pumping hot water The suction line must be free from leeks Claw couplings are not suitable for suction lines with pressures below atmospheric pressure E 2 3 Air inlet The air connection is marked Air Use air supply hose with minimum diameter as specified in enclo sure E 2 Dimensioning of water and air inlet Do not fit valves fittings etc with less diameter than specified in enclosure E 2 If regulation is required at the unit it is recommended to fit a full bore ball valve and use this for throttling the air supply If you are going to use an air pressure regulator it must be plentiful dimensioned for the airflow E 2 4 Chemical dosing A high pressure injector fitted between the high pressure pump outlet and the high pressure hose may dose chemicals You may need to turn down the water pressure by throttling the air motor to achieve that the injector will work properly We recommend to disconnect the injector when not in use because it steals pressure E 2 5 Cleaning procedures Hot water if available will always give the best result and reduces the need for chemicals The follow ing procedures are recommended to get the best result when working with detergents Apply the detergent with a wide angle spray Start at the bottom and move upwards The spray distance should be approximately
7. mum inlet water temperature Water inlet nozzle Air inlet nozzle High pressure outlet Length overall Width overall Height overall pump cart High pressure hose Weight complete incl hose gun and lance Extension tube lenght MATERIALS Pump head Pump valve seats Pump valve springs Pump piston seal Piston rod Valve ball Pump cylinder Air cylinder Valve rod Frame Tube parts Cover Bolts Spray gun Extension tube High pressure nozzle The unit will be delivered complete with Subject to be improved without notice 48 48 1 2 pcs 125 mm 18 mm 75 mm 0 19 l min 0 9 m3 min 150 l s 5 11 bar 0 480 bar 25 bar 4m 150 C 3 4 BSP female 3 4 BSP male 3 8 BSP male 720 mm 520 mm 980 540 mm 3 8 x10 m 59 kg 800 mm Nickel and chrome plated st Stainless steel AISI 316 Stainless steel AISI 301 PTFE Carbon Stainless steel AISI 303 Stainless steel AISI 420B Stainless st 582387 Hard Nickel and chrome plated st Stainless steel AISI 303 Nickel and chrome plated st Galvanized steel Vacuum formed ABS Hot galvanized steel Stainless steel plastic Stainless steel AISI 316 Stainless steel AISI 316 10m high pressure hose with spray gun extension tube spray nozzle press gauge air lubricator and exhaust air muffler E2 Dimensioning of water and air supply RECOMMENDATIONS Airclean 48 HOSE DIMENSIONS Water supply Use minimum 3 4 hose If the supply pressure is low or t
8. prevent damages at start up Reassemble sequence is opposite to dismantling but note the following g Tighten the attaching bolts two and two opposite at a time Sealing liquid should be applied to the bolts E 3 4 Pump valves The valve seats are fixed and are not removable Proceed as follows to inspect renew balls or springs a eae E 3 5 E 3 6 aoe Undo attaching bolts and pull free the pump head to gain access to the inlet valve The outlet reducer is fitted with sealing liquid Clean and inspect parts Remove loose scale etc Replace worn parts Clean threads Fit parts according to drawing Use sealing fluid on outlet reducer threads when assembling Tighten opposite bolts to avoid skewing Valve shuttle Unscrew threads end cover remove dampening ring and pull out the valve shuttle Dismantle clean inspect and replace parts as required Re assembly is done in reversed order Screw in and end cover till it bottoms Valve rod sealing Split pump unit by pulling lock ring B See drawing NS Dismantle clean inspect and replace worn parts as required Lubricate all o rings prior to re assembly Re assembly is done in reversed order E 3 7 Fault diagnosis Symptom Possible Cause and Solution 1 Low delivery pressure a Restricted air supply Uneven operation Pump failure to start Pump runs without delivery or low deliv ery Water air leakages 6 Pump over speeds with no or lo
9. w delivery Pump runs after trigger is released Pulsating spray Air motor stops and blows air See E 2 3 Air inlet Clean filters in the air supply Open closed valves Inadequate air supply capacity Check compressor capacity See data sheet Wrong nozzle bore Change nozzle Worn out nozzle Change nozzle Inadequate lubrication Insufficient air supply Pressure gauge on unit shows there is pressure Clogged nozzle Disconnect air supply and check for ice plug Pressure gauge on unit shows no pressure Closed air supply Clogged air supply No pressure in the air system Closed water supply Check any valves and filters in the supply To large suction head Undersized valves fittings in the supply Blocked restricted air supply Leaking pump piston seal Defect pump piston seal or other seals Lacking or no water supply Check valves and filters To high suction head Restrictions in water supply Leaking pump piston seal Pump inlet valve is damaged or blocked in open position Leaking pump piston seal Leaking suction line Only 1 pump is working Damage to o ring seal s on air motor Seals must be changed E 4 ENCLOSURES EI Data sheet Airclean Pressure ratio No of cylinders Air motor cylinder diameter Pump cylinder diameter Stroke Capacity Air consumption free air 1 bar Recommended air pressure Pump pressure Maximum inlet water pressure Suction head up to Maxi
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