Wilhelmsen Ships AIRCLEAN 32 User manual

AIRCLEAN 32
High-pressure cleaner
USER MANUAL
Produced in Norway for:
Wilhelmsen Ships Service

Contents
E.1 IMPORTANT INFORMATION 3
E.1.1 Safety 3
E.1.2 Lubrication 3
E.1.3 Air operating pressure 3
E.1.4 Frost protection 3
E.1.5 Guarantee 3
E.2 DESCRIPTION AND OPERATION 4
E.2.1 Pump unit 4
E.2.2 Water inlet 4
E.2.3 Air inlet 4
E.2.4 Chemical dosing 4
E.2.5 Cleaning procedures 4
E.2.6 Accessories 5
E.3 MAINTENANCE 5
E.3.1 Preventive maintenance 5
E.3.2 Pump Unit Dismantling 5
E.3.3 Change of pump piston seal 6
E.3.4 Pump valves 6
E.3.5 Valve shuttle 6
E.3.6 Valve rod sealing 6
E.3.7 Fault diagnosis 7
E.4 ENCLOSURES 8
E1 Data sheet 8
E2 Dimensioning of water- and air supply 9
E3 Part list 10
E4 Pump drawing 11
Airclean32/TF/02.11.2007

IMPORTANT INFORMATIONE.1
SafetyE.1.1
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 tted withstands the pressure.
If the cleaning unit is to be used in a hazardous environment, earthing the equipment will eliminate
static electricity.
Airclean is CE-marked.
LubricationE.1.2
The air motor requires lubricated air. In order to ensure uninterrupted steady operation you must never
let the tted air lubricator run dry. The correct position of the adjustment screw is approx. 1/2-1 turn.
Air operating pressureE.1.3
Do not exceed maximum safe air operating pressure specied in data sheet, enclosure 1.
Frost protectionE.1.4
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.
GuaranteeE.1.5
The guarantee is not valid for damages caused by erroneous usage or if the unit has been disassembled
without written permission from the manufacturer.
3

DESCRIPTION AND OPERATIONE.2
Pump unitE.2.1
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.
Water inletE.2.2
The connection is marked “Water”. Use a water supply hose with minimum diameter as specied 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.
The 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.
Air inletE.2.3
The air connection is marked “Air”. Use air supply hose with minimum diameter as specied in enclo-
sure E.2 “Dimensioning of water- and air inlet”. Do not t valves, ttings etc. with less diameter than
specied in enclosure E.2. If regulation is required at the unit, it is recommended to t 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 airow.
Chemical dosingE.2.4
A high-pressure injector tted 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.
Cleaning proceduresE.2.5
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 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.-
4

AccessoriesE.2.6
The Airclean standard scope of supply is tailored to cater for ordinary cleaning tasks in an efcient 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 lters, water lters, couplings for water and air.-
Extension tubes and extra hoses.-
Airclean wheel lance. Complete lance system for efcient washing of high walls, ceilings etc.-
Hose drums.-
MAINTENANCEE.3
Preventive maintenanceE.3.1
Preventive maintenance is limited to lling 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 occur:
Pump Seala.
A leak pump piston seal will cause a ow of water out of the drain hole on the bottom
side of the pump cylinder.
Threadsb.
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.
High-pressure hose couplingsc.
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 lter should be tted. A water lter should
be tted if the water contains abrasive particles.
Pump Unit DismantlingE.3.2
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.
5

Change of pump piston sealE.3.3
Loosen the attaching bolts.a.
Pull the cylinder of the piston.b.
Check the cylinder for scratches to see if honing or a replacement is required.c.
Remove the lock pin for the front part of the piston and screw it off. Fit o-ring, pump seal andd.
front part of the piston.
Fit new slide rings.e.
Lubricate piston, seal and slide rings to ease reassemble and prevent damages at start up.f.
Reassemble sequence is opposite to dismantling, but note the following:
Tighten the attaching-bolts two and two opposite at a time. Sealing liquid should be applied tog.
the bolts.
Pump valvesE.3.4
The valve seats are xed and are not removable. Proceed as follows to inspect/renew balls or springs:
Undo attaching bolts and pull free the pump head to gain access to the inlet valve. The outleta.
reducer is tted with sealing liquid.
Clean and inspect parts. Remove loose scale etc. Replace worn parts.b.
Clean threads.c.
Fit parts according to drawing.d.
Use sealing uid on outlet reducer threads when assembling. Tighten opposite bolts to avoid e.
skewing.
Valve shuttleE.3.5
Unscrew threads end cover, remove dampening ring and pull out the valve shuttle.a.
Dismantle, clean, inspect and replace parts as required.b.
Re-assembly is done in reversed order. Screw in and end cover till it bottoms.c.
Valve rod sealingE.3.6
Split pump unit by pulling lock ring B (See drawing)N5.a.
Dismantle, clean, inspect and replace worn parts as required.b.
Lubricate all o-rings prior to re-assembly.c.
Re-assembly is done in reversed order.d.
6

Fault diagnosisE.3.7
Symptom Possible Cause and Solution
Low delivery/pressure1. Restricted air supply.a)
See E.2.3 “Air inlet”.
Clean lters in the air supply.
Open closed valves.
Inadequate air supply capacity.b)
Check compressor capacity.
(See data sheet).
Wrong nozzle bore. Change nozzle.
Worn out nozzle. Change nozzle.
Uneven operation2. Inadequate lubrication.a)
Insufcient air supplyb)
Pump failure to start3. Pressure gauge on unit shows there isa)
pressure: Clogged nozzle. Disconnect air
supply and check for ice plug.
Pressure gauge on unit shows no pressure:b)
Closed air supply.
Clogged air supply.
No pressure in the air system.
Pump runs without delivery or low deliv-4.
ery
Closed water supply.a)
Check any valves and lters in the supply.
To large suction head.b)
Undersized valves/ttings in the supply.c)
Blocked/restricted air supply.d)
Leaking pump piston seal.e)
Water/air leakages5. Defect pump piston seal or other sealsa)
Pump over-speeds with no or low delivery6. Lacking or no water supply.a)
Check valves and lters.
To high suction head.b)
Restrictions in water supply.c)
Leaking pump piston seal.d)
Pump runs after trigger is released7. Pump inlet valve is damaged or blockeda)
in open position.
Leaking pump piston seal.b)
Pulsating spray8. Leaking suction line.a)
Only 1 pump is workingb)
Air motor stops and blows air9. Damage to o-ring seal(s) on air motor.a)
Seals must be changed.
7

ENCLOSURESE.4
Data sheetE1
Airclean 32
Pressure ratio 32 : 1
No of cylinders 2 pcs
Air motor cylinder diameter 125 mm
Pump cylinder diameter 22 mm
Stroke 75 mm
Capacity 0-24 l/min
Air consumption (free air, 1 bar) 0-7.5 m3/min(125 l/s)
Recommended air pressure 5-11 bar
Pump pressure 0-350 bar
Maximum inlet water pressure 25 bar
Suction head up to 4 m
Maximum inlet water temperature 150 °C
Water inlet nozzle 3/4’’ BSP female
Air inlet nozzle 3/4’’ BSP male
High pressure outlet 3/8’’ BSP male
Length overall 720 mm
Width overall 520 mm
Height overall (pump cart) 980 (540) mm
High pressure hose 3/8’’x10 m
Weight complete incl. hose, gun and lance 55 kg
Extension tube lenght 700 mm
MATERIALS
Pump head Nickel and chrome plated st
Pump valve seats Stainless steel AISI 316
Pump valve springs Stainless steel AISI 301
Pump piston seal PTFE/Carbon
Piston rod Stainless steel AISI 303
Valve ball Stainless steel AISI 420B
Pump cylinder JM3 seawater resist. bronze
Air cylinder Nickel and chrome plated st
Valve rod Stainless steel AISI 303
Frame Nickel and chrome plated st
Tube parts Galvanized steel
Cover Vacuum formed ABS
Bolts Hot galvanized steel
Spray gun Bronze/plastic
Extension tube Nickel plated steel
High pressure nozzle Stainless steel AISI 316
The unit will be delivered complete with 10m high pressure hose with spray gun,
extension tube, spray nozzle, press. gauge,
air lubricator and exhaust air mufer.
Subject to be improved without notice
8

Dimensioning of water- and air supplyE2
RECOMMENDATIONS Airclean 32
HOSE DIMENSIONS
Water supply
Use minimum 3/4’’ hose. If the supply pressure is low or the hose is long, a 1’’ hose is recommended.
Air supply
Use minimum 1’’ hose.
Do not t valves or ttings with less inner diameter than 19 mm.
9

Part listE3
AIRCLEAN 32
PART NO U1200 PUMP UNIT
Part No Description Pos no Qty.
P1002 Pump head 1 1
P1037 Hex nut 2 1
P1003 Stud screw 3 1
P1204 Piston rod 4 1
P1157 Glide ring 5 1
P1106 Air piston 6 1
P1007 Valve ball 7 2
P1008 Hex screw 8 4
P1019 Reduser 9 1
P1010 Spring 10 1
P1239 Pump cylinder 11 1
P1012 Cylinder cover 12 1
P1005 Spring 13 1
P1249 Pump piston 14 1
P1255 Glide ring 15 2
P1119 Ring 16 2
P1035 End cap 17 1
P1256 Pump packing 18 1
P1257 O-ring 19 1
P1045 O-ring 20 1
P1024 O-ring 21 5
P1123 O-ring 22 2
P1026 O-ring 23 6
P1025 O-ring 24 6
P1159 O-ring 25 6
P1158 Liner 26 1
P1166 Sleeve 27 1
P1027 Air cylinder 28 1
P1134 Valve shuttle 29 1
P1267 Valve housing 30 1
P1016 Snap ring 31 2
P1164 Sleeve 32 1
P1236 Valve rod 34 1
P1168 O-ring 35 1
P1080 Elbow 36 3
P1081 Hose nipple 37 2
P1082 Return line 38 1
P1083 Hose clip 39 2
P1084 Adapter 40 1
10

Pump drawingE4
11