Den-Sin Merlion Plus E500 Guide

www.densin.com
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
MERLION PLUS - E500 STD04 Page 2 of 50
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 U
pdating. 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
MERLION PLUS - E500 STD04 Page 3 of 50
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

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 4 of 50
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 2
nd
operator is
to attend the pump unit keep close watch on the 1
st
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

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 5 of 50
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
440~4
60V
220V~230V
Freq. 50Hz 60Hz 60Hz
Motor Type 25HP 25HP 25HP
Motor Class
F
F
F
Motor Speed
1450rpm
1750rpm
1
75
0rpm
Power Req. 32A 32A 56A
Pump Specification
Working Pressure
500
Bar/
7250
psi
50
0Bar/
7250
psi
500
Bar/
7250
psi
Flow
-
Rate
16
l/min / 4.3gpm
16 l/min / 4.3g
pm
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

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 6 of 50
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.

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 7 of 50
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

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 8 of 50
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

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 9 of 50
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

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 10 of 50
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.
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

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 11 of 50
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

Getting Acquainted with your Heavy Duty Pressure Washer
MERLION PLUS - E500 STD04 Page 12 of 50
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
MERLION PLUS - E500 STD04 Page 13 of 50
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
pA
(ref.20 uPa), in decibels 75
Uncertainty K
pA
, in decibels 3
A-Weighted sound power level,L
WAd
(ref.1
pW
),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 Tri er 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.
Tri er Gun Vibration:
The declared vibration emission value a
hd
is 6.3 m/s
2
with an uncertainty K of 1.1 m/s
2
” . 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

2. Safety and protection information
MERLION PLUS - E500 STD04 Page 14 of 50
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: [phone] Fax: [phone]
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 (MgSO
4
) 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: [phone] Fax: [phone]
www.densin.com

2. Safety and protection information
MERLION PLUS - E500 STD04 Page 15 of 50
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. Safety and protection information
MERLION PLUS - E500 STD04 Page 16 of 50
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. Safety and protection information
MERLION PLUS - E500 STD04 Page 17 of 50
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. Safety and protection information
MERLION PLUS - E500 STD04 Page 18 of 50
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
MERLION PLUS - E500 STD04 Page 19 of 50
3. Maintenance and troubleshooting
3.1 Maintenance Schedule
Regular Service
Period as indicated
Each
use
1
st
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