Mart Cyclone 30 Series User manual
MART Standard Turntable Power Washer
Installation, Operations, and Maintenance Manual
Version 4.0
JAN 2004
1st Printing
Copyright 1993,1994, 1995 1996, 1997,1998,1999,2000, 2002 and 2004
by The MART Corporation.
All rights reserved.
The MART Corporation
2450 Adie Road
Maryland Heights, MO 63043-9978 U.S.A.
Phone: 1-800-543-MART
Missouri Direct: (314) 567-7222
Fax: (314) 567-6551
e-mail: themart@martwash.com
Website: www.martwash.com
Power Blast Manifold (PBM), Auto Rinse Cycle, Rinse Bank, Single Ball Float Control,
Wet Grit Blasting feature, NPSH reduction system, Automatic Pressure Equalization
(APE), Fold-up Turntable and Clean Machine are protected by one or more of the
following U.S. Patents: 4,741,351; 4,143,669; 4,213,475, 5,529,080; 5,524.653;
5,427,128; 5,540,246.
This manual is an unpublished, copyrighted work by The MART Corporation.
The information and drawings in this manual are the property of The MART Corporation
and shall not be reproduced or copied or used in whole or in part in other media without
written permission.
MART has attempted to provide a Manual that is reliable and accurate. Note that the
information contained in this Manual is subject to change at any time without notification.
The information contained in this version of the Manual supersedes all previous versions,
while some information may not be accurate due to changes in the product or operating
system since this version of the Manual was completed. Please report any discrepancies
or omissions to MART. No liability is assumed with respect to the information contained
herein.
Table of Contents Contents - 1
Standard Turntable Power Washer v. 4.0 The MART Corporation
Table of Contents
Letter from MART's President
Title Page
Table of Contents.................................... Contents-1
List of Figures ............................................Figures-1
Welcome and Introduction .....................Welcome-1
Purpose of Manual ...................................................................Welcome-1
Audience ..................................................................................Welcome-2
How the Manual Is Organized ..................................................Welcome-2
How to Use This Manual ..........................................................Welcome-3
MART Technical Services ........................................................Welcome-3
Other Resources ......................................................................Welcome-4
Vendor-supplied Manuals .............................................Welcome-4
Startup..........................................................................Welcome-4
HELP ............................................................................Welcome-4
Other Product-Support Services ...................................Welcome-5
Important Safety Instructions and
Warnings.......................................................Safety-1
Contents - 2 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
1 Overview ........................................................... 1-1
Purpose..................................................................................... 1-1
Prerequisites ............................................................................. 1-1
What You Will Learn In This Chapter ........................................ 1-1
1. Your New MART Power Washer .....................................1-2
1.1. Getting Acquainted ........................................................................ 1-2
1.2. Major Components......................................................................... 1-2
2. Materials and Components .............................................1-5
2.1. Electrical Standards ....................................................................... 1-5
2.2. Cabinet Construction .....................................................................1-5
3. Theory Of Operation........................................................1-6
3.1. How The Power Washer Works.....................................................1-6
3.1.1. Power .............................................................................. 1-7
Pressure and Flow = Power ........................................ 1-7
Closed-Loop System And Grit-Blasting ....................... 1-7
3.1.2. Temperature.................................................................... 1-8
3.1.3. Chemical ......................................................................... 1-8
Removal of Soils ......................................................... 1-9
Applications................................................................. 1-9
Usage ....................................................................... 1-10
3.1.4. Time .............................................................................. 1-10
3.1.5. General Information and Conclusion ............................. 1-11
3.2. Operating Principles Of Key Features......................................... 1-12
3.2.1. Pumping System ........................................................... 1-12
3.2.2. Power Blast Manifold (PBM).......................................... 1-12
3.2.3. Door-Mounted Turntable ............................................... 1-13
3.2.4. Turntable Drive System ................................................. 1-14
3.2.5. Automatic Steam Exhaust (ASE)................................... 1-14
3.2.6. Automatic Rinse System (ARC)..................................... 1-14
3.2.7. Heating System .............................................................1-16
3.2.8. Water-Level Control System.......................................... 1-17
3.2.9. Power Washer Control System ..................................... 1-19
Operator Controls ..................................................... 1-20
Major Components.................................................... 1-21
Sequence of Washer Operation................................ 1-23
Interdependent System Features .............................. 1-23
Electrical Schematics ................................................ 1-23
4. Washer Inspection.........................................................1-24
Table of Contents Contents - 3
Standard Turntable Power Washer v. 4.0 The MART Corporation
2 Installation .........................................................2-1
Purpose .................................................................................... 2-1
Prerequisites............................................................................. 2-1
Results of Correct Installation ................................................... 2-4
Safety/Precautions.................................................................... 2-4
What You Will Learn In This Chapter........................................ 2-5
1. Lifting and Moving...........................................................2-6
2. Placement ........................................................................2-8
3. Unpacking ........................................................................2-9
4. Leveling and Anchoring ................................................2-11
4.1. Leveling........................................................................................2-11
4.2. Anchoring .....................................................................................2-12
5. Services and Connections ............................................2-14
5.1. Introduction ..................................................................................2-14
5.2. Connection Procedures - Input.....................................................2-15
5.2.1. Heat Source...................................................................2-15
Gas & Oil Heat Source ..............................................2-15
Electric Heat Source..................................................2-20
Steam Heat Source ...................................................2-20
5.2.2. Water (Input)..................................................................2-21
5.2.3. Compressed Air (Input)..................................................2-22
5.2.4. Electricity (Input) ............................................................2-23
Earthgrounding to Prevent Corrosion ........................2-23
5.3. Connection Procedures - Output ..................................................2-25
5.3.1. Steam Exhaust (Output) ................................................2-25
Steam-Exhaust Pipe..................................................2-26
Steam-Exhaust Fan...................................................2-28
5.3.2. Flue Pipe (Output) .........................................................2-31
5.3.3. Drain (Output) ................................................................2-33
5.4. Installation of Options...................................................................2-33
5.5. Inspection and Verification ...........................................................2-34
6. Startup Procedure .........................................................2-35
6.1. Electrical Connections Inspection.................................................2-36
6.2. Lubrication Procedure ..................................................................2-36
6.3. Power-up Procedure.....................................................................2-37
6.4. Chemical-Charging Procedure .....................................................2-48
6.5. 7-Day Dual-Circuit Clock Initialization...........................................2-50
6.6. Rinse System (optional) ...............................................................2-50
6.7. Startup Problems..........................................................................2-51
Contents - 4 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
3 Basic Operations.............................................. 3-1
Purpose..................................................................................... 3-1
Prerequisites ............................................................................. 3-1
Safety/Precautions .................................................................... 3-1
What You Will Learn In This Chapter ........................................ 3-2
1. Control Panel ...................................................................3-3
2. Standard Cleaning Cycle.................................................3-5
2.1. Checking Water Temperature........................................................ 3-5
2.2. Using the Clock-Override Switch.................................................... 3-6
2.3. Opening the Door .......................................................................... 3-7
2.4. Loading and Securing Parts........................................................... 3-9
2.5. Closing and Locking the Door ...................................................... 3-10
2.6. Verifying Wash Temperature ....................................................... 3-10
2.7. Setting the Wash-Cycle Timer ..................................................... 3-11
2.8. Setting the Rinse Cycle (optional) ................................................ 3-11
2.9. Starting the Washer ..................................................................... 3-12
2.10. Verifying Proper Function........................................................... 3-12
2.11. Opening the Door after a Cycle.................................................. 3-13
2.12. Unloading Parts ......................................................................... 3-13
3. Continuous Operation...................................................3-14
4 Advanced Operations: Process-Control ........ 4-1
Purpose..................................................................................... 4-1
Prerequisites ............................................................................. 4-1
Safety/Precautions .................................................................... 4-2
What You Will Learn In This Chapter ........................................ 4-2
1. Chemical-Concentration Management...........................4-3
1.1. Chemical: General ......................................................................... 4-3
1.2. Selecting the Right Chemical .........................................................4-4
1.3. Selecting the Right Concentration................................................. 4-5
1.4. Maintaining the Proper Chemical Charge....................................... 4-6
1.5. Problems........................................................................................ 4-7
1.5.1. Foaming Related to Chemical Concentration .................. 4-7
1.5.2. Supersaturation of Solution ............................................. 4-8
1.6. Charging the Power Washer with Chemical................................... 4-8
1.7 Corrosion Protection……………………………………..…………...…4-8
2. Temperature Adjustment ..............................................4-11
Table of Contents Contents - 5
Standard Turntable Power Washer v. 4.0 The MART Corporation
3. Rinse-System Control (optional ARC)..........................4-13
3.1. Setting the Rinse Timer................................................................4-13
3.2. Rinse Injector Pump .....................................................................4-14
3.3. Rinse Water-Flow Adjustment ......................................................4-18
4. Setting the 7-Day Dual-Circuit Clock............................4-19
4.1. 7-Day Dual-Circuit Clock and Optional Devices............................4-20
5. Steam-Exhaust Timer ....................................................4-21
5.1. Setting the ASE Timer..................................................................4-21
6. Monitoring......................................................................4-22
6.1. Monitoring Lubrication ..................................................................4-22
6.2. Other Monitoring...........................................................................4-23
5 Maintenance ......................................................5-1
Purpose .................................................................................... 5-1
Prerequisites............................................................................. 5-1
Safety/Precautions.................................................................... 5-1
What You Will Learn In This Chapter........................................ 5-2
1. Service Schedule.............................................................5-3
2. Performing Maintenance and Common
Washer Adjustments ......................................................5-4
2.1. Pumps and Power Blast Manifold (PBM) Assembly....................... 5-4
2.1.1. Wash Pump Intake Filter (Inspect/Clean) ....................... 5-4
2.1.2. PBM Swivel Joint (Grease) ............................................. 5-5
2.1.3. PBM Nozzles (Inspect/Monitor)....................................... 5-6
2.1.4. PBM Swivel (Inspect/Adjust) ........................................... 5-8
2.1.5. Amperage Draw at Wash Pump(s) (Measure) ................ 5-9
2.1.6. Upper Manifold Bearing (Grease) ................................... 5-9
2.1.7. Wash Pump and Pump Motor (Grease).........................5-10
2.1.8. Wash Pump Couplings (Inspect) ...................................5-12
2.2. Heating System............................................................................5-13
2.2.1. Air Intake - Burner Blower Motor (Clean) .......................5-13
2.2.2. Burner Blower Motor (Oil) ..............................................5-13
2.3. Water-Level Control System.........................................................5-14
2.3.1. Float Assembly (Inspect/Clean) .....................................5-14
2.3.2. Water Solenoid Valves (Clean or Replace)....................5-16
2.4. Turntable and Drive Assembly......................................................5-17
2.4.1. Turntable Bearings (Grease) .........................................5-17
2.4.2. Turntable Drive Bearings (Grease) ................................5-17
2.4.3. Slip Clutch/Torque Limiter (Inspect)...............................5-17
2.4.4. Door Bearings (Grease).................................................5-20
Contents - 6 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
2.5. Auto Steam Exhaust (ASE) Assembly.......................................... 5-20
2.5.1. ASE Blower Motor (Oil) ................................................. 5-20
2.6. Chemical Concentration............................................................... 5-20
2.7. Voltage ........................................................................................ 5-21
2.7.1. Voltage at Power Distribution Block (Measure).............. 5-21
3. Sludge Monitoring and Clean-Out ................................5-22
3.1. Sludge Monitoring ........................................................................ 5-24
3.2. Sludge Clean-Out and Heat Exchanger/Suction Tube (Clean)..... 5-24
3.3. Heating Elements (Clean - electric only) ...................................... 5-24
4. Maintenance of Options ................................................5-25
6 Troubleshooting .............................................. 6-1
Purpose..................................................................................... 6-1
Prerequisites ............................................................................. 6-1
Safety/Precautions .................................................................... 6-2
What You Will Learn In This Chapter ........................................ 6-2
1. Startup..............................................................................6-3
2. Ineffective Cleaning.........................................................6-4
3. Wash Pump System.........................................................6-5
4. Heating System................................................................6-8
5. Turntable Drive ..............................................................6-10
6. Nozzles ...........................................................................6-11
7. Foaming..........................................................................6-12
8. Power Blast Manifold (PBM) .........................................6-13
9. Solution-Level Control System.....................................6-14
10. Door Limit Switch ........................................................6-15
11. Rinse System ...............................................................6-16
12. Automatic Steam Exhaust (ASE) ................................6-17
13. Electrical Control System ...........................................6-18
Table of Contents Contents - 7
Standard Turntable Power Washer v. 4.0 The MART Corporation
7 Options...............................................................7-1
Purpose .................................................................................... 7-1
Prerequisites............................................................................. 7-1
Safety/Precautions.................................................................... 7-1
What You Will Learn In This Chapter........................................ 7-2
1. Automatic Turntable/Swivel Bearings Lubrication .......7-3
1.1. Theory of Operation ...................................................................... 7-3
1.2. Installation ..................................................................................... 7-4
1.3. Operations..................................................................................... 7-5
1.4. Maintenance.................................................................................. 7-7
1.5. Troubleshooting............................................................................. 7-8
2. Clean Machine .................................................................7-9
2.1 Theory of Operation ....................................................................... 7-9
2.2 Installation .....................................................................................7-10
2.3 Operations.....................................................................................7-13
2.3.1 Clean-Machine Operation: Frequency............................7-14
2.3.2 Clean Machine: Chemical Management.........................7-14
2.4 Maintenance..................................................................................7-15
2.5 Troubleshooting.............................................................................7-16
3. Center Manifold .............................................................7-18
3.1. Theory of Operation .....................................................................7-18
3.2. Installation ....................................................................................7-19
3.3. Operations....................................................................................7-21
3.4. Maintenance.................................................................................7-22
Every 40 Hours of Operation .....................................7-22
Every 250 Hours of Operation ...................................7-22
3.5. Troubleshooting............................................................................7-23
4. Chemical Concentration Controller..............................7-25
4.1. Theory of Operation .....................................................................7-25
4.2. Installation ....................................................................................7-28
4.3. Operations....................................................................................7-29
4.4. Maintenance.................................................................................7-30
4.5. Troubleshooting............................................................................7-31
5. False Floor .....................................................................7-32
5.1. Theory of Operation .....................................................................7-32
5.2. Installation ....................................................................................7-32
5.3. Operations....................................................................................7-32
5.4. Maintenance.................................................................................7-33
5.5. Troubleshooting............................................................................7-33
Contents - 8 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
6. 50 Hertz Electrical Power..............................................7-34
6.1. Theory of Operation ..................................................................... 7-34
6.2. Installation.................................................................................... 7-34
6.3. Operations ................................................................................... 7-34
6.4. Maintenance ................................................................................ 7-34
6.5. Troubleshooting ........................................................................... 7-36
7. Filters..............................................................................7-38
7.1. Theory of Operation ..................................................................... 7-38
7.2. Installation.................................................................................... 7-39
7.3. Operations ................................................................................... 7-40
7.4. Maintenance ................................................................................ 7-41
7.5. Troubleshooting ........................................................................... 7-41
8. Frequency Drive.............................................................7-42
8.1. Theory of Operation ..................................................................... 7-42
8.2. Installation.................................................................................... 7-42
8.3. Operations ................................................................................... 7-43
8.4. Maintenance ................................................................................ 7-43
8.5. Troubleshooting ........................................................................... 7-44
9. Hot-Air Blow-Off (HABO)...............................................7-45
9.1. Theory of Operation ..................................................................... 7-45
Steam-Exhaust Fan .................................................. 7-45
Controlling HABO Heat ............................................. 7-46
9.2. Installation.................................................................................... 7-46
9.3. Operations ................................................................................... 7-51
9.4. Maintenance ................................................................................ 7-52
9.5. Troubleshooting ........................................................................... 7-53
10. Jib Crane ......................................................................7-54
10.1. Theory of Operation ................................................................... 7-54
10.2. Installation.................................................................................. 7-54
10.3. Operations ................................................................................. 7-57
10.4. Maintenance .............................................................................. 7-59
10.5. Troubleshooting ......................................................................... 7-59
11. Oil Skimmer..................................................................7-60
11.1. Theory of Operation ................................................................... 7-60
11.2. Installation.................................................................................. 7-61
11.3. Operations ................................................................................. 7-61
11.4. Maintenance .............................................................................. 7-62
11.5. Troubleshooting ......................................................................... 7-62
Table of Contents Contents - 9
Standard Turntable Power Washer v. 4.0 The MART Corporation
12. Power-Assisted Door ..................................................7-63
12.1. Theory of Operation ...................................................................7-63
12.2. Installation ..................................................................................7-63
12.3. Operations..................................................................................7-63
12.4. Maintenance...............................................................................7-65
12.5. Troubleshooting..........................................................................7-65
13. Pump Pressure Control Valve and Gauge .................7-66
13.1. Theory of Operation ...................................................................7-66
13.2. Installation ..................................................................................7-66
13.3. Operations..................................................................................7-66
13.4. Maintenance...............................................................................7-67
13.5. Troubleshooting..........................................................................7-67
14. Pump Pressure Gauge ................................................7-68
14.1. Theory of Operation ...................................................................7-68
14.2. Installation ..................................................................................7-68
14.3. Operations..................................................................................7-68
14.4. Maintenance...............................................................................7-68
14.5. Troubleshooting..........................................................................7-69
15. Rack and Fixture Set, or Small-Parts Basket ............7-70
15.1. Theory of Operation ...................................................................7-70
15.2. Installation ..................................................................................7-70
15.3. Operations..................................................................................7-72
15.4. Maintenance...............................................................................7-73
15.5. Troubleshooting..........................................................................7-73
16. Remote Grease Fittings ..............................................7-74
16.1. Theory of Operation ...................................................................7-74
16.2. Installation ..................................................................................7-74
16.3. Operations..................................................................................7-74
16.4. Maintenance...............................................................................7-74
16.5. Troubleshooting..........................................................................7-74
17. Rinse Wand ..................................................................7-75
17.1. Theory of Operation ...................................................................7-75
17.2. Installation ..................................................................................7-75
17.3. Operations..................................................................................7-75
17.4. Maintenance...............................................................................7-76
17.5. Troubleshooting..........................................................................7-77
18. Sludge Scraper ............................................................7-78
18.1. Theory of Operation ...................................................................7-78
18.2. Installation ..................................................................................7-79
18.3. Operations..................................................................................7-80
18.4. Maintenance...............................................................................7-81
18.5. Troubleshooting..........................................................................7-83
Contents - 10 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
19. Short High Manifold (SHIM) System…….………….………..7-84
19.1. Theory of Operation………………………………………………………….7-84
19.2. Operations…………….……………………….……………………………...7-84
19.3. Maintenance…………………………………….…………………………….7-85
19.4. Troubleshooting………………………………….………...…………………7-86
Index............................................................... Index-1
List of Figures Figures - 1
Standard Turntable Power Washer v. 4.0 The MART Corporation
List of Figures
Chapter - Page
Fig. 1 - 1: Standard Turntable Power Washer, View 1.................................................1-3
Fig. 1 - 2: Standard Turntable Power Washer, View 2.................................................1-4
Fig. 1 - 3: Rinse System ..............................................................................................1-15
Fig. 1 - 4: Float-Level Mechanics.................................................................................1-18
Fig. 1 - 5: Water Level Differences At Four Positions ..................................................1-19
Fig. 1 - 6: Washer Inspection Before Installation .........................................................1-24
Fig. 2 - 1: Raising the Power Washer by the Lifting Eyes............................................2-7
Fig. 2 - 2: Leveling and Anchoring Feet.......................................................................2-11
Fig. 2 - 3: Mounting the Combustion Burner (Up to 180,000 BTU) ..............................2-16
Fig. 2 - 4: Mounting the Combustion Burner (Up to 400,000 and 800,000 BTU)..........2-17
Fig. 2 - 5: Burner Junction Box -- Wiring .....................................................................2-18
Fig. 2 - 6: Steam Solenoid and Steam Trap Installation...............................................2-20
Fig. 2 - 7: Water Connection Location .........................................................................2-21
Fig. 2 - 8: Compressed-Air Connection .......................................................................2-22
Fig. 2 - 9: General Layout of the Electrical Control Panel (Block Diagram)..................2-24
Fig. 2 - 10: Steam-Exhaust Vent Pipe and Flue Pipe Attachments ..............................2-26
Fig. 2 - 11: Auto Steam Exhaust (ASE) Piping and Blower Configurations ..................2-27
Fig. 2 - 12: Mounting the Venturi Tube ........................................................................2-28
Fig. 2 - 13: Auto Steam Exhaust (ASE) Piping and Blower Installation........................2-29
Fig. 2 - 14: Wiring the ASE Blower Assembly..............................................................2-30
Fig. 2 - 15: Services and Connections Inspection........................................................2-34
Fig. 2 - 16: Float Control Box.......................................................................................2-38
Fig. 2 - 17: Float Cam at SET-POINT Water Level......................................................2-39
Fig. 2 - 18: Water-Level Set-Point Dimensions and Measurement Location................2-40
Fig. 2 - 19: Initial Burner Settings ................................................................................2-42
Fig. 2 - 20: Maximum Operating Temperature.............................................................2-43
Fig. 2 - 21: Water Temperature Gauge Location .........................................................2-44
Figures - 2 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
Chapter - Page
Fig. 3 - 1: Standard Turntable Power Washer Control Panel ...................................... 3-4
Fig. 3 - 2: Water Temperature Gauge Location .......................................................... 3-5
Fig. 3 - 3: Cabinet Door Latch..................................................................................... 3-7
Fig. 3 - 4: Cabinet Door Position Lock......................................................................... 3-8
Fig. 4 - 1: Maximum Actual Operating Temperature ................................................... 4-11
Fig. 4 - 2: General Layout of the Electrical Control Panel (Block Diagram) ................. 4-11
Fig. 4 - 3: Automatic Rinse Cycle (ARC) Timer Increments ........................................ 4-13
Fig. 4 - 4: Injector Pump Output Setting: 3-Nozzle Rinse System ............................... 4-16
Fig. 4 - 5: Injector Pump Output Setting: 4-Nozzle Rinse System ............................... 4-16
Fig. 4 - 6: Injector Pump Output Setting: 5-Nozzle Rinse System ............................... 4-17
Fig. 4 - 7: Injector Pump Output Setting: 5-Nozzle Rinse System .............................. 4-18
Fig. 4 - 8: Standard Turntable Power Washer Control Panel ...................................... 4-19
Fig. 4 - 9: Automatic Steam Exhaust (ASE) Cycle Timer Increments.......................... 4-21
Fig. 5 - 1: Service Schedule ........................................................................................ 5-3
Fig. 5 - 2: Cleaning the Pump Intake Filter Box........................................................... 5-5
Fig. 5 - 3: Lubrication Chart ........................................................................................ 5-6
Fig. 5 - 4: Cleaning and Replacing the PBM Nozzles.................................................. 5-7
Fig. 5 - 5: Swivel Jam Nut Non-adjustable Swivel ....................................................... 5-8
Fig. 5 - 6: Wash Pump and Pump Motor(s)................................................................. 5-11
Fig. 5 - 7: Burner Blower Motor (180,000 BTU Burner Shown; Other
Sizes Similar).............................................................................................. 5-13
Fig. 5 - 8: Float Assembly ........................................................................................... 5-14
Fig. 5 - 9: Solenoid valves........................................................................................... 5-16
Fig. 5 - 10: Turntable Drive and Turntable: Slip Clutch/Torque Limiter........................ 5-18
Fig. 5 - 11: Cleaning the Heating Element .................................................................. 5-25
Fig. 6 - 1: Troubleshooting: Startup............................................................................. 6-3
Fig. 6 - 2: Troubleshooting: Ineffective Cleaning of Parts............................................ 6-4
Fig. 6 - 3: Troubleshooting: Wash Pump Motor Won't Start ........................................ 6-5
Fig. 6 - 4: Troubleshooting: Wash Pump Surges ........................................................ 6-5
Fig. 6 - 5: Troubleshooting: Wash Pump Fails to Deliver Solution............................... 6-6
Fig. 6 - 6: Troubleshooting: Wash Pump Motor Trips Overload -- High Amperage
Reading.......................................................................... 6-6
Fig. 6 - 7: Troubleshooting: Seal Leakage at Wash Pump Mounting Plate ................. 6-7
Fig. 6 - 8: Troubleshooting: Wash Pump or Motor Vibrates or Is Noisy....................... 6-7
Fig. 6 - 9: Troubleshooting: Water Does Not Heat (Gas/Oil Burner Does Not
Ignite)............................................................................. 6-8
List of Figures Figures - 3
Standard Turntable Power Washer v. 4.0 The MART Corporation
Chapter - Page
Fig. 6 - 10: Troubleshooting: Water Does Not Heat (Steam) .......................................6-9
Fig. 6 - 11: Troubleshooting: Water Does Not Heat (Electric)......................................6-9
Fig. 6 - 12: Troubleshooting: Turntable Does Not Rotate ............................................6-10
Fig. 6 - 13: Troubleshooting: Nozzles -- Ineffective Cleaning.......................................6-11
Fig. 6 - 14: Troubleshooting: Foaming.........................................................................6-12
Fig. 6 - 15: Troubleshooting: PBM Not Oscillating .......................................................6-13
Fig. 6 - 16: Troubleshooting: Water Not Filling Reservoir, or Water Overflowing
Reservoir, or System Not Heating .................................6-14
Fig. 6 - 17: Troubleshooting: Washer Will Not Start ....................................................6-15
Fig. 6 - 18: Troubleshooting: No Rinse Cycle ..............................................................6-16
Fig. 6 - 19: Troubleshooting: ASE Will Not Operate ....................................................6-17
Fig. 6 - 20: Troubleshooting: ASE Leaks Liquid...........................................................6-17
Fig. 6 - 21: Troubleshooting: Electrical Control System ...............................................6-18
Fig. 7 - 1: Automatic Lubrication System Block Diagram .............................................7-3
Fig. 7 - 2: Troubleshooting: Automatic Lubrication System Fault Light Is ON ..............7-8
Fig. 7 - 3: Clean Machine Piping..................................................................................7-11
Fig. 7 - 4: Troubleshooting: Clean Machine Does Not Heat.........................................7-16
Fig. 7 - 5: Troubleshooting: Hydrocyclone Does Not Achieve Cone Effect ..................7-16
Fig. 7 - 6: Troubleshooting: Oil Skimmer Tank Overflows into Cyclone
Separator Tank...............................................................7-17
Fig. 7 - 7: Troubleshooting: Skimmer-Wheel Drain Trough Backs Up .........................7-17
Fig. 7 - 8: Center Manifold Mechanism and Superstructure.........................................7-20
Fig. 7 - 9: Troubleshooting: Water Leaks Onto Cabinet Roof ......................................7-23
Fig. 7 - 10: Troubleshooting: Center Manifold Assembly Does Not Work ....................7-23
Fig. 7 - 11: Troubleshooting: Center Manifold Light Does Not Illuminate .....................7-24
Fig. 7 - 12: Chemical Concentration Conductivity Probe..............................................7-26
Fig. 7 - 13: Troubleshooting: Peristaltic Pump Does Not Pump ...................................7-31
Fig. 7 - 14: Troubleshooting: Concentration Cannot Be Maintained.............................7-31
Fig. 7 - 15: Troubleshooting: False Floor: Water Leaks Over Door Frame ..................7-33
Fig. 7 - 16: Troubleshooting: 50 Hz Electrical Power -- Squealing Sounds from
Pump Area ....................................................................7-36
Fig. 7 - 17: Troubleshooting: 50 Hz Electrical Power -- No Wash Cycle (No
Water Pumped): Simplex Pump System .......................7-36
Fig. 7 - 18: Troubleshooting: 50 Hz Electrical Power -- Poor Cleaning Results or
Abnormal Pump Noise: Duplex Pump System ..............7-37
Fig. 7 - 19: Micron Comparisons..................................................................................7-39
Fig. 7 - 20: Troubleshooting: Wash Load Not Clean....................................................7-41
Fig. 7 - 21: Troubleshooting: Solution Leaks from Filter Cover ....................................7-41
Fig. 7 - 22: Frequency Drive Results ...........................................................................7-43
Fig. 7 - 23: Troubleshooting: Pump Motor Does Not Run ............................................7-44
Fig. 7 - 24: HABO -- ASE Fan Installation....................................................................7-48
Fig. 7 - 25: HABO -- ASE Fan Installation....................................................................7-49
Figures - 4 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
Chapter - Page
Fig. 7 - 26: Hot-Air Blow-Off (HABO) Inside Plenum ................................................... 7-50
Fig. 7 - 27: Troubleshooting: HABO Heating Element Begins to Overheat.................. 7-53
Fig. 7 - 28: Jib Crane, Washer-mounted ..................................................................... 7-55
Fig. 7 - 29: Jib Boom: Bronze Bushing and Washer Locations ................................... 7-56
Fig. 7 - 30: Troubleshooting: Boom Does Not Swing Freely........................................ 7-59
Fig. 7 - 31: Oil Skimmer Assembly.............................................................................. 7-60
Fig. 7 - 32: Troubleshooting: Skimmer-Wheel Does Not Skim .................................... 7-62
Fig. 7 - 33: Troubleshooting: Power-Assist Does Not Activate .................................... 7-65
Fig. 7 - 34: Troubleshooting: Pump Pressure Gauge Does Not Work......................... 7-67
Fig. 7 - 35: Troubleshooting: Pump Pressure Gauge Does Not Work......................... 7-69
Fig. 7 - 36: Rack and Fixture Set ................................................................................ 7-71
Fig. 7 - 37: Small-Parts Basket ................................................................................... 7-73
Fig. 7 - 38: Troubleshooting: Rinse Wand: No Hand Rinse......................................... 7-77
Fig. 7 - 39: Sludge Scraper -- External View ............................................................... 7-79
Fig. 7 - 40: Sludge Scraper -- Diagram of Parts .......................................................... 7-82
Fig. 7 - 41: Troubleshooting: Sludge Scraper Drag Chain Does Not Move.................. 7-83
Fig. 7 - 42: SHIM Manifold Selector Valve Schematic……………………..................... 7-84
Fig. 7 - 43: SHIM Manifold System - Tornado 40HP………………………… ................ 7-85
Fig. 7 - 44: Troubleshooting: PBM not Oscillating………………. ................................. 7-86
Welcome and Introduction Welcome - 1
Standard Turntable Power Washer v. 4.0 The MART Corporation
Welcome and
Introduction
This section describes this manual and other resources that will help you get the most
out of your MART Power Washer. Before you use the washer, read the entire manual
to learn about installation, operations, maintenance, and troubleshooting.
Refer to chapter "Options" for descriptions of any options you have purchased.
Purpose of Manual
The MART Standard Turntable Power Washer manual is a comprehensive guide that
contains information and operating instructions/procedures you need to operate the
power washer as intended. Operating instructions are also referred to as "procedures"
in this manual.
The next section, Important Safety Instructions and Warnings, contains general
warnings and cautions that are meant to be observed at all times when you work with
the washer. Personnel training is required to work with the power washer. Be sure all
operators and maintenance personnel read and UNDERSTAND the instructions in this
section. In addition, operating instructions/procedures are preceded as necessary by
warnings and cautions that alert operators to reasonably foreseeable risks of injury to
people or damage to property.
IMPORTANT! Keep this manual and all safety and operating
instructions. Operators must refer to them to safely install,
operate, maintain, repair, troubleshoot, or work with the
washer in any way.
MART knows that its customers don't want washing machines ... they want clean
parts. The manual has been written with this objective in mind, and every chapter, from
"Installation" to "Troubleshooting" and "Options," provides guidelines and suggestions
for helping you achieve that goal ... safely.
Welcome - 2 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
Audience
This manual is intended for you, if you need to clean parts, whether you have already
bought a MART Power Washer system or are thinking about buying one. You will find
MART Power Washers in all types and sizes of shops and manufacturing facilities --
wherever there are tough industrial cleaning problems.
Those who will find this manual especially useful include the following:
·Maintenance supervisors
·Maintenance staff
·Manufacturing engineers
·Operators
·Shop supervisors
·Contractors
How the Manual Is Organized
Review the Table of Contents to get a feel for what is in the manual, and where it is
located. The List of Figures lists all graphics by figure number and title, and refers you
to the correct page.
Important Safety Instructions and Warnings contains general warnings and cautions that
are meant to be observed at all times when you work with the washer. Be sure all
operators read and heed the instructions in that section.
Chapter 1, "Overview," presents an overview of the MART Standard Turntable Power
Washer, including a theory of operation.
Chapter 2, "Installation," explains how to install the MART Power Washer. Pay special
attention to the prerequisites, particularly placement planning, and to the
safety/precaution information.
Chapter 3, "Basic Operations," provides step-by-step instructions on how to load and
wash parts.
Chapter 4, "Advanced Operations: Process-Control," describes how to establish
operating parameters to optimize the performance of your power washer.
Chapter 5, "Maintenance," discusses the maintenance of your power washer. Use the
information in this chapter to establish and follow a service schedule.
Chapter 6, "Troubleshooting," contains problem symptoms/probable causes for key
assemblies and components of your washer. Use this chapter to help diagnose and
correct a problem.
Chapter 7, "Options," contains installation, operations, maintenance, and
troubleshooting information on the Clean Machine and any other power washer options
you may have purchased from MART.
Welcome and Introduction Welcome - 3
Standard Turntable Power Washer v. 4.0 The MART Corporation
At the end of the manual you will find an Index. Use it to find information quickly.
How to Use This Manual
Read the entire manual before you attempt to install, operate, or maintain the power
washer. This will provide the foundation you need to understand how the washer works
and how to use it to your best advantage.
Staff members who are responsible for specific features or functions will benefit from
paying special attention to corresponding information in the manual.
After you have read the entire manual thoroughly, use the Table of Contents, List of
Figures, and Index to refer to information, as you need it.
MART Technical Services
MART's technical services department is available to provide you with the extra support
you might occasionally need.
If you have a question about the washer or its operation, first look in this manual and in
other printed product-support documentation. If you cannot find the answer, contact
MART Technical Services. Our phone number is on the title page near the beginning of
the manual, and in the following section, "Other Resources -- HELP."
Before your power washer is delivered, you will receive a courtesy call from MART
technical services. Our expert engineers and technicians will review your specifications
and answer questions about placement planning, installation, utility and service
requirements.
Welcome - 4 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
Other Resources
In addition to this manual and our technical service staff, MART offers the following
product support:
·Vendor-supplied manuals
·Startup
·HELP
·Other product-support services
Vendor-supplied Manuals
Your washer is delivered with vendor-supplied manuals and cutsheets for some
assemblies and parts. Refer to these documents for additional details on installation,
operations, and maintenance.
Startup
A MART factory-trained technician is optionally available to perform startup and
customer training. Call MART technical services to request this service.
As part of this service, the MART technician will fill in the Field Startup Procedure (FSP)
form to begin your one-year warranty coverage.
HELP
If you can't find the answer to your question in this manual, contact MART:
The MART Corporation
2450 Adie Road
Maryland Heights, MO 63043-9978 U.S.A.
Phone: 1-800-543-MART
Missouri Direct: (314) 567-7222
Fax: (314) 567-6551
E-mail: themart@martwash.com
Website: www.martwash.com
Welcome and Introduction Welcome - 5
Standard Turntable Power Washer v. 4.0 The MART Corporation
Other Product-Support Services
Contact MART to receive the following information:
Audio Cassettes:
"Shop Productivity and Profit"
"Bake Ovens, EPA, OSHA, and Hazardous Waste Disposal"
"How MART Power Washers Work"
Printed Material:
·Hazardous waste lab reports
·Procedure for sludge disposal
·Message to financial management
·Ins & outs of leasing
·Performance specifications for the power washer in which you are
interested
·List of users
·Testimonials
·MART parts cleaning cost analysis
Videos:
·All About Parts Washing
·EQ-1 Training Video
MART Website: www.martwash.com
This manual suits for next models
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