MERLION II

E250 E350 E500

Electrical Powered
Heavy Duty Cold Water High
HIGH PRESSURE CLEANER

USER GUIDE & SPARE PARTS MANUAL

www.densin.com
 Introduction
Introduction

Congratulations on your purchase of the DEN-SIN MERLION II E250, E350 & E500,
Heavy Duty Pressure Washer.

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 the first time.
This machine is a 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.
WARNING

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.
CAUTION

NOTE is used to highlight important information that may

assist the reader carrying out the procedure or understanding the
text.
NOTE

Version 26: May 2014

Revision History

Date Revision Rev.No.

Jan 13 Manual updating 23
Feb 13 Manual updating 24
Nov 13 Manual updating +Add in optional accessories+Pump Spares updating 25
May 14 Change of filter 26

MERLION II E250, E350, E500 R026 -1-

 Table of contents
Table of contents
Introduction .................................................................................................................................... 0
Table of contents............................................................................................................................. 2
1. Getting acquainted with your Heavy Duty Pressure Washer ................................................ 4
Applications ................................................................................................................................. 4
Unpacking .................................................................................................................................... 4
Key features ................................................................................................................................. 5
Installation ................................................................................................................................... 6
Operations .................................................................................................................................... 7
Technical specifications .............................................................................................................. 8
2. Safety and protection information ............................................................................................ 9
Safety device on the machine ...................................................................................................... 9
General safety & application guidelines .................................................................................... 10
Important medical information .................................................................................................. 11
WARNING .................................................................................................................................... 11
Safety precautions...................................................................................................................... 12
3. Maintenance and troubleshooting .......................................................................................... 13
Maintenance Schedule ............................................................................................................... 13
Machine Prevention ................................................................................................................... 13
Troubleshooting ......................................................................................................................... 14
Torque Specification.................................................................................................................. 19
4. Available Accessories ............................................................................................................... 20
5. Spare Parts Lists ....................................................................................................................... 21
Main Assembly .......................................................................................................................... 21
Main Assembly Spare-Parts List ............................................................................................... 22
Pump Connections E250 & E350 .............................................................................................. 23
Pump Connection Spare-Parts List E250 & E350 ..................................................................... 24
Pump Assembly E250 & E350 .................................................................................................. 25
Pump assembly spare-parts list E250 & E350........................................................................... 26
Pump spare-parts kit E250 & E350 Only .................................................................................. 28
Un-loader valve assembly spare-parts list E250 & E350 .......................................................... 29
Un-loader spare-parts kit E250 & E350 .................................................................................... 30
Safety valve & accumulator assembly E250 & E350................................................................ 31
Safety valve assembly spare-parts list E250 & E350 ................................................................ 32
Safety valve spare-parts kit E250 & E350................................................................................. 32
Accumulator assembly spare-parts list E250 & E350 ............................................................... 32
Trigger / gun & hose assembly E250 & E350 ........................................................................... 33
Trigger / gun & assembly spare-parts list E250 & E350 ........................................................... 33
Lance assembly E250 & E350................................................................................................... 34
Lance assembly spare-parts list E250 & E350 .......................................................................... 34
Pump Connections E500 ........................................................................................................... 35
Pump Connection Spare-Parts List E500 .................................................................................. 36
Pump assembly E500................................................................................................................. 37
Pump assembly spare-parts list E500 ........................................................................................ 38
Pump spare-parts kit E500 ......................................................................................................... 39
Un-loader valve assembly spare-parts list E500........................................................................ 40
Un-loader valve assembly spare-parts list E500........................................................................ 41
Un-loader spare-parts kit E500 .................................................................................................. 41
Safety valve assembly E500 ...................................................................................................... 42

MERLION II E250, E350, E500 R026 -2-

 Table of contents
Safety valve assembly spare-parts list E500.............................................................................. 42
Safety valve assembly spare-parts list E500.............................................................................. 43
Safety valve spare-parts kit E500 .............................................................................................. 43
Accumulator assembly E500 ..................................................................................................... 44
Accumulator assembly spare-parts list E500............................................................................. 44
Trigger / gun/ lance & hose assembly spare-parts list E500 ..................................................... 45
Lance, Complete with different length ...................................................................................... 46
6.OPTIONAL ................................................................................................................................ 47
Optional Rotating nozzle Type 1 ............................................................................................ 48
Rotating Nozzle E250, E350 & E500 ........................................................................................ 49
Operation & use of rotating nozzle............................................................................................ 49
Optional Rotating nozzle for 500bar Type 2 .......................................................................... 50
Operation & use of rotating nozzle............................................................................................ 54
Optional Rotating nozzle for 500bar Type 3 .......................................................................... 54
Safety valve assembly spare-parts list ....................................................................................... 55
After every 20-40 hrs, the rotating nozzle must be flushed or refilled with .............................. 56
Auto Transmission Fluid (ATF) ................................................................................................ 56
7. Electrical Assembly .................................................................................................................. 58
El-box assembly spare-parts list ................................................................................................ 58
Wiring diagram .......................................................................................................................... 59
7.1 Electrical Setting..................................................................................................................... 60
Main Contactor Overload Setting............................................................................................... 60
Timer Setting ................................................................................................................................ 60
8. Declaration and Warranty ...................................................................................................... 61
EU declaration of conformity .................................................................................................... 61
Warranty .................................................................................................................................... 61
9. Spare Parts Request Form....................................................................................................... 62
10. Maintenance Log Book .......................................................................................................... 63

The information contained in this user guide is subject to change without notice.

NOTE

MERLION II E250, E350, E500 R026 -3-

 1. Getting acquainted with your Heavy Duty Pressure Washer
1. Getting acquainted with your Heavy Duty Pressure Washer

The DEN-SIN MERLION II Series E250, E350 and E500 facilitate 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. The MERLION series
are designed for industrial and offshore use as well as for cleaning contractors. 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.
CAUTION

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:

The machine itself

Electrical cord (attached)
High-pressure hose
Trigger/gun
Spray lance
Water inlet male hose coupling
Optional accessories

MERLION II E250, E350, E500 R026 -4-

 1. Getting acquainted with your Heavy Duty Pressure Washer
Key features
This Heavy Duty Pressure Washer is mounted on a sturdy frame made of galvanized and powder coated
steel. For easy maneuvering, it is equipped with four big rubber wheels.
By using the latest technology, integrated automatic start/stop function and water filter, the machine has
been designed for optimum and long-lasting use in heavy industry.
1
4
1. Handle
2. Control panel
3. Model tag (Not Shown)
4. Lifting eyes

1. Handle
The handle can be flipped forward to reduce the transportation and storage size.

2. Control panel Control panel

1) Run indicator
2) Power indicator
3) Start button 1
4) Stop button 2
5) Main Isolator
3
4

3. Model tag/ID tag

The model tag provides the following information:
Model. Phase IP
Serial No. Amp Volt
HP/KW Cal/min L/min
RPM Max inlet Temp
BAR/PSI Noise
Nozzle Weight

MERLION II E250, E350, E500 R026 -5-

 1. Getting acquainted with your Heavy Duty Pressure Washer
4. Lifting eyes
The machine can also be elevated from the ground by putting the strap through the
lifting eyes and be lift off.

Lifting Indication
Installation
Prepare the water supply for the Heavy Duty Pressure Washer by attaching a hose to the supplied low-
pressure inlet male coupling. Connect the other end to a water supply. Open the tap and let the water
flush through the pump for min. 30 sec. Close the tap.

It is NOT allowed to connect this Heavy Duty Pressure Washer directly to a portable
water supply! If portable water supply is used, it is strictly necessary to include a water
break tank in accordance with European standard EN 1717 (Protection against pollution
WARNING of portable water in water installations)

High Pressure,
Water Outlet
Low Pressure,
Water Inlet

Connect the high-pressure hose by screwing the swivel onto the high-pressure fitting.
Attach the lance to the trigger/gun using its quick screw coupling.
Open the tap again, squeeze the trigger/gun and let the water flush through the pump, high-pressure hose
and spray-lance for min. 15 sec. Release the trigger/gun but leave the tap open.
Connect the main power wire to a 3-phase main power supply.

Make sure your local power supply specifications are in accordance with the motors
requirement. Refer to the Model tag on the machine. Do NOT run the Heavy Duty
Pressure Washer without sufficient water supply as it can cause cavitation and serious
CAUTION damage to internal pump parts.

The machine is now ready to start.

Turn on the power supply and main Isolator. Start the Heavy Duty Pressure Washer by pushing the green
start button. Check that there is NO leakage from the hose connections!
Get a firm grip with both hands on the trigger/gun and the lance. Press the trigger and start cleaning.

MERLION II E250, E350, E500 R026 -6-

 1. Getting acquainted with your Heavy Duty Pressure Washer
Operations

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.
WARNING

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.

MERLION II E250, E350, E500 R026 -7-

 1. Getting acquainted with your Heavy Duty Pressure Washer

Technical specifications
Model Type E250 E350 E500
380~415V, 50Hz 700995154 700995156 700995158
440V, 60Hz 700995155 700995157 700995159
220~230V, 50Hz - 700995207 700995193
220~230V, 60Hz - 700995231 700995225

Machine (50Hz)
Working pressure Bar / psi 250 / 3625 350 / 5075 500 / 7250
Water flow L/min 26 21 16
Water flow Gal/min 6.9 5.6 4.3
Recoil force N 96 92 84
Nozzle size 0.007 0.005 0.003

Machine (60Hz)
Working pressure Bar / psi 250 / 3625 320 / 4640 500 / 7250
Water flow L/min 31 25 16
Water flow Gal/min 8.2 6.7 4.3
Recoil force N 115 110 84
Nozzle size 0.0075 0.0055 0.003

Motor
Power consumption Hp / kW 20 / 14.7 20 / 14.7 20 / 14.7
Frequency Hz 50 / 60 50 / 60 50 / 60
Number of phases 3 3 3
Protection IP 55 55 55
Weight of motor Kg 140 140 140

Machine Dry Weight Kg 218 218 218

Noise emission declaration:

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, LpA (ref.20 uPa), in decibels 91
Uncertainty KpA, in decibels 3
A-Weighted sound power level,LWAd (ref.1pW),in decibels 110

MERLION II E250, E350, E500 R026 -8-

 2. Safety and protection information
2. Safety and protection information

Safety device on the machine

Automatic Start / Stop:

This Heavy Duty Pressure Washer comes with Automatic Start/ Stop function for extended life span of
the pump/motor. If the machine is running for more than 4 minutes without trigger/ gun being activated
then it will shut down automatically.

To restart the machine again, simply press the trigger/ gun and release. Wait for about 5-8sec, for the
motor to stablise then press the trigger/gun again to start using the machine.

Note : - the machine starts up in a two-step sequence and it takes about 5-8sec to obtain full pressure
(star/ delta sequence).

Important Notice:
Certain environments(e.g.when using long extension electrical-cables) may influence the start up
function. The user may experience, electrical-box trips due to very high start-up Amps. To avoid this,
simply squeeze the trigger/ gun until the machine starts and then immediately let go of the trigger. Allow
the machine to run for about 5-8sec and then the trigger/ gun can be activated for continuous use. The 5-
8sec is the time it takes for the machine to start up to full power mode (delta mode).

The timer is preset to 4 minutes - do NOT change the setting.

Thermal sensor and over load relay:

The thermal sensor and the overload relay protects the motor against over-loading. The relay resets
automatically after 5 minutes upon activation.

Notice: The overload relay is set to 14-16 Amp. The motor runs at 20 to 26 Amps depending on Hz and
model. The overload relay reacts on single phase current while the motor running Amp is at three phase.
The power difference is [3] and hence 16 Amp overload relay is equivalent to 28 Amp.

Unloader valve:
The high-pressure side of the pump is fitted with a bypass valve. This valve bypasses the water back to
the suction side when the trigger is released. The water will continue to circulate until the motor stops.

Safety valve:
The machine is fitted with a safety valve, which ensures the pressure in the system does not exceed the
permissible pressure (pressure indicated on model tag). The valve is adjusted and pre-set from the factory
and should never be adjusted.

MERLION II E250, E350, E500 R026 -9-

 2. Safety and protection information
Location of safety devices

Safety valve
Safety valve

Over load relay

(Inside el-box)

Pressure switches
for auto start/stop

Water escape! If the pressure exceeds

Un-loader Valve
the permissible pressure, water will
flush out from here.

General safety & 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 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 portable water supply.
8) If the machine is to be connected to portable water supply it is strictly necessary to fit the machine
with a water break tank, in accordance with EN1717.

MERLION II E250, E350, E500 R026 - 10 -

 2. Safety and protection information
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.

IMPORTANT
MEDICAL INFORMATION

This card is to be carried by

WARNING personnel working with high-
pressure water jetting equipment.
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.

DEN-SIN - a division of Nilfisk-Advance Pte

Ltd.
5 Tuas Ave 2, Singapore 639445
Tel: +65 6268 1006 Fax: +65 62684916
www.densin.com

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 (MgSO4) 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

DEN-SIN - a division of Nilfisk-Advance Pte

Ltd.
5 Tuas Ave 2, Singapore 639445
Tel: +65 6268 1006 Fax: +65 62684916
www.densin.com

MERLION II E250, E350, E500 R026 - 11 -

 2. Safety and protection information
Safety precautions
The following protective clothing and devices should be worn both by personnel
operating the Heavy Duty Pressure Washer and those working nearby:

WARNING

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
users 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
them selves or other personnel.

Hose protection- Protect user from high pressure water injuries incase
hose connection is loose.

MERLION II E250, E350, E500 R026 - 12 -

 3. Maintenance and troubleshooting
3. Maintenance and troubleshooting
Maintenance Schedule
Regular Service Each 1st Every When Procedure / Remarks
Period as use 50hrs month / needed
indicated Every
200hrs
Check pump oil Top up if necessary.
level
Change pump oil Renewal of oil:
Turn off High Pressure Cleaner.
Recommended Oil : Loosen bolt(Hex) at bottom of pump housing.
SAE 30 or
Drain oil into a waste oil-tray.
equivalent
Tighten bolt(Hex)
Usage : Add oil through pump inlet on top of the
Approx. 1.4kg of pump until the red point of the oil control
oil glass has been reached.

Notice: Do not dispose of used oil in drain.

Cleaning of Use damp cloth to wipe the cabinet and handle
machine bar.

Notice:
Do not use detergent cleaning chemicals
Cleaning of Clean the motor fan cover.
motor fan Clean the motor fan blade.
( to ensure sufficient
airflow ) Do NOT operate the machine with damaged or
removed fan cover.

Filter cleaning The pre-inlet filter cartridge is washable and

should be checked and cleaned regularly.
Clogged filters may inflict cavitation in the
high-pressure pump leading to severe damage
of the pump.
Unscrew the bottom of the black filter
housing. Clean the housing and filter
cartridge, replace filter if necessary.

Machine Prevention
Do Dont Action Cause
Spray directly onto the machine with high Electrical shock may occurs
pressure water
Operate the machine with damaged or removed Motor will be overheated and malfunction
fan cover
Operate/keep machine with frost built up Flush pump with antifreeze fluids before use.

Check hose and cord are not vehicle run over
by heavy or squeezed in door opening
Check electrical cord and high pressure hose
for wear and cracks
Ensure coupling parts free of dirt to ensure
long life of O-ring seals preventing water leaks.
May cause machine not function properly.
To prevent electrical shock and safety to the user
Extend life span of the pump seals and
maintaining correct pressure.

MERLION II E250, E350, E500 R026 - 13 -

 3. Maintenance and troubleshooting
Troubleshooting
Symptom
Main switch is turned on the High Pressure
Cleaner will not run.
Motor is humming & Pump does not give
pressure or low pressure
Pump pressure drops and the High Pressure
Cleaner works irregularly
Pump continuously stops and starts, when the
spray-gun trigger is activated.
High pressure cleaner does not reach the proper
working pressure when the spray-gun handle is
activated
High Pressure Cleaner only works with
approximately 2/3 of the maximum pressure,
and the high-pressure hose is vibrating.
Noisiness
Water in the oil
The High Pressure Cleaner does not suck
chemicals
For any further inconveniences, not mentioned in this user guide or any damages of the machine, we
strongly suggest you to make contact with your dealer for the repair or possible replacement of any original
spare-parts.
NOTE
MERLION II E250, E350, E500
Rectification
Check power supply connection for faulty components .
Make sure the socket is inserted correctly
Check if fuse is blown, replace if necessary.
Voltage is too low as compare to specification.(Check main voltage)
Motor phase is missing(For 3 phase application).
Check the connection box voltage with a meter
High-pressure pump is blocked
Strain filter is clogged.
Water supply from the tap is insufficient.
Clean the strain water filter
The high pressure nozzle is partly clogged.
Turn off the High Pressure Cleaner, dismantle the high-pressure nozzle
and remove the extraneous matter. Replace if damaged
The high-pressure nozzle is clogged.
Dirt in the by-pass valve.
The pump sucks air.
Turn off the High Pressure Cleaner. Clean the nozzle.
Inspect the low pressure supply, while spray-gun trigger is activated,
ON the machine on again.
Repeat the procedure again; now with the trigger released. If the
problem still occurs, by-pass valve should be dismantled and the
extraneous matter removed.
Valves are dirty
Remove the dirt and check to ensure the valve flaps are movable and
fits tightly.
The pump sucks air.
One or more valve springs are broken or down.
Extraneous matter in the valves.
Crankcase or motor bearings worn out.
Inspect the low-pressure supply. Replace springs.
Clean the valves. Replace the bearings.
The O-ring casing is worn out.
High moisture in the air (condensing inside the crankcase)
The seals are completely worn out.
Check or replace the O-ring.
Renewal of the crankcase oil more often.
Replace the seals.
The chemical container is empty.
The High Pressure Cleaner has not been set to low-pressure (on the
double barrel lance cock).
The low-pressure nozzle is clogged, or partly clogged.
The non-return valve of the chemical injector is stuck.
Ensure the chemical container contains sufficient fluid for proper
suction.
Set the spray-lance to low pressure by turning the cock on the lance
counterclockwise.
Clean or replace the low-pressure nozzle.
Clean, correct or replace the non-return valve of the chemical injector.
R026 - 14 -
 3. Maintenance and troubleshooting
Service Instructions
For E250 & E350, please refer to pump assembly page 27 unless otherwise stated
For E500, please refer to pump assembly page 37 unless otherwise stated.
(For detail E500 instructions please refer to Merlion Svc Manual.)

Disassembling of pump:

Turn out the screws that clamp head with

crankcase

Remove the head from plungers

Insert the drawer in the plungers seat

MERLION II E250, E350, E500 R026 - 15 -

 3. Maintenance and troubleshooting

Draw out the seals package

Unscrew the drawer and take out the seals

package

Assembling of pump:

Push the spacer in the plungers seat

MERLION II E250, E350, E500 R026 - 16 -

 3. Maintenance and troubleshooting

Insert the guide bushing in the plungers seat

Place the front seal ring (brown color) on the pad

Push the pad in the busing guide with the help of a

rubber-faced hammer

Insert the washer in the plungers seat

Insert the front brass ring in the plungers seat

MERLION II E250, E350, E500 R026 - 17 -

 3. Maintenance and troubleshooting

Slip the O-Ring on the back brass ring

Push the back seal ring (the black color) in the

back brass ring.

Push the back brass ring in the plungers seat

Assemble the head

Turn the screws in, beginning from the middle

ones and according to torque specifications stated
in page19

MERLION II E250, E350, E500 R026 - 18 -

 3. Maintenance and troubleshooting
Torque Specification

E250 E350 E500

Pos. Description
N.m/lb.ft N.m/lb.ft N.m/lb.ft
1 Head Bolts 50/37 50/37 50/37
2 Valve Caps 120/88 120/88 NA
3 Inlet Cap 140/103 140/103 140/103
4 Outlet Cap 80/60 80/60 80/60
5 Bearing Flange Bolts 25/19 25/19 25/19
6 Rear Cover Bolts 11/8 11/8 11/8
7 Connecting Rod Bolts 30/22 30/22 30/22
8 Plunger Bolts 20/15 20/15 15/11
9 Valve Cover Bolts NA NA 50/37

MERLION II E250, E350, E500 R026 - 19 -

 4. Available Accessories
4. Available Accessories
For various applications, accessories can be easily attached to the machine to speed up the work

Accessories
Rotating Nozzle
Industrial sandblaster kit with boron carbide nozzle
Container for sandblasting grid, including regulator

Notice:

Always state type of Water Blaster along with the part no. when ordering accessories or spare-parts.
Please refer to Model tag/ID tag for the machine model.

MERLION II E250, E350, E500 R026 - 20 -

 5. Spare Parts Lists
5. Spare Parts Lists
Main Assembly

MERLION II E250, E350, E500 R026 - 21 -

 5. Spare Parts Lists
Main Assembly Spare-Parts List
Pos: Part no.: Qty.: Description:
1 700520501 1 Frame complete
2 Standard 1 Wheel Shaft Dia 25mm
2A 700960178 2 Wheel Shaft Dia 20mm (Available upon request only E500,60hZ)
6 700510005 12 Washer M8
7 700510004 8 Lock nut M8
8 700520093 4 Star lock w/ cap
8A 700520007 4 Star lock Dia 20mm (Available upon request only E500,60hZ)
9 700520481 4 Pneumatic wheel
9A 700520626 4 Solid wheel Dia 20mm (Available upon request only E500,60hZ)
10 700510220 8 Bolt M6x20 HEX S.S
11 700510023 16 Washer M6
12 700510007 8 Lock nut M6
13 700520601 1 Filter support plate E250 / E350 / E500
14 700510009 4 Bolt M8x16 Allen Head
15 700530527 1 El-box complete (see assembly page 58)
16 700510034 4 Spring washer M8
- - - -
18 700530487 1 Motor 380/415/440V, 50/60 Hz
19 700510201 4 Bolt M12x50
20 700510067 8 Washer M12
21 700510059 4 Lock nut M12
22 700510104 4 Bolt M8x25 Allen Head
23 700510064 4 Bolt M8x40 HEX
24 700520502 1 Top cover
25 700520622 1 Water filter with 250um mesh
* 700520756 1 Water filter mesh 250um
* 700540934 1 Bushing -1/2 BSP
26 700540059 1 Nipple 1/2" 3/4"
27 700540034 1 Quick coupling 3/4"
28 700540323 1 Elbow BSPT
29 700540102 1 Hose Nipple 1-3/4 BSPT
30 700540264 1 Hose clip 1
31 700950014 1 Hose 1
32 700550004 1 Dowty Seal 3/8

MERLION II E250, E350, E500 R026 - 22 -

 5. Spare Parts Lists
Pump Connections E250 & E350

ASSEMBLY

MERLION II E250, E350, E500 R026 - 23 -

 5. Spare Parts Lists
Pump Connection Spare-Parts List E250 & E350

Pos: Part no.: Qty.: Description:

1 700530154 2 Pressure switch E250
1 700530471 1 Pressure switch E350
2 700540730 1 X-joint 3/8
700540731 T-joint 3/8
3 700540396 2 Nipple 3/8
4 700540330 1 Safety valve
5 700540113 1 Nipple 3/8
6 700540264 3 Hose clip 1
7 700540102 3 Hose nipple 1
8 700950021 0.75m Hose 1 (by-pass hose)
9 700505098 1 Pump E250
9 700505099 1 Pump E350
10 700540323 2 Elbow
11 700540679 1 Unloader valve
12 700550004 7 Dowty seal 3/8
13 700540003 1 Pressure gauge E250
13 700540055 1 Pressure gauge E350
14 700540721 1 Bushing
15 700540270 1 Hose nipple 1
16 700540749 2 Accumulator (see assembly page31)
17 700540249 2 Nipple 3/4"- 1/2"
18 700540060 1 Dowty seal 3/4"
19 700540059 1 Nipple 3/4" - 1/2"

MERLION II E250, E350, E500 R026 - 24 -

 5. Spare Parts Lists
Pump Assembly E250 & E350

MERLION II E250, E350, E500 R026 - 25 -

 5. Spare Parts Lists
Pump assembly spare-parts list E250 & E350

Pos: Part no.: Qty.: Description:

1 700505000 1 Crankcase
2 700505001 3 Bushing
3 700505002 3 Plunger rod seal
4 700505086 3 O-ring E250
4 700505087 3 O-ring E350
5 700505086 3 Pressure ring 22 E250
5 700505087 3 Pressure ring 20 E350
6 700505088 3 Support ring 22 E250
6 700505089 3 Support ring 20 E350
7 700505086 3 Back ring 22 E250
7 700505087 3 Back ring 20 E350
8 700505088 3 High-pressure seal kit 22 E250
8 700505089 3 High-pressure seal kit 20 E350
9 700505013 1 Aluminum gasket E250 & E350
10 700505014 1 Plug 3/8 E250 & E350
11 700505015 1 Plug 3/4
12 700505016 1 Aluminum gasket
13 700505017 3 Manifold plug M27 E250 & E350 (Option A : For Big Nut - Steel)
700505217 3 Manifold plug M27 E250 & E350 (Option B : For Small Nut - Brass)
14 700505018 3 O-ring E250
700505019 3 O-ring E350 (Option A : For Big Nut - Steel)
700505216 3 O-ring E350 (Option B : For Small Nut - Brass)
15 700505044 6 O-ring
16 700505021 8 M10x75 Bolt
17 700505022 8 M10 Washer
18 700505023 1 Manifold E250
700505024 1 Manifold E350 (Option A : With Big Nut - Steel)
700505215 1 Manifold E350 (Option B : With Small Nut - Brass)
(Continues)

MERLION II E250, E350, E500 R026 - 26 -

 5. Spare Parts Lists
(Continued)

Pos: Part no.: Qty.: Description:

19 700505090 3 Plunger nut E250
19 700505091 3 Plunger nut E350
20 700505090 3 Nylon washer E250
20 700505091 3 Nylon washer E350
21 700505090 3 O-ring E250
21 700505091 3 O-ring E350
22 700505090 3 Anti extrusion ring E250
22 700505091 3 Anti extrusion ring E350
23 700505033 3 Plunger ceramic 22 E250
23 700505034 3 Plunger ceramic 20 E350
24 700505090 3 Disc E250
24 700505091 3 Disc E350
25 700505037 3 Plunger rod E250
25 700505038 3 Plunger rod E350
26 700505039 3 Connection rod pin
27 700505040 3 Connection rod E250 & E350
28 700505041 8 Bolt M8x22
29 700505042 8 M8 Washer
31 700505044 2 O-ring
32 700505045 2 Roller bearing
33 700505046 1 Oil plug
34 700505047 1 Gasket, crankcase cover
35 700505048 1 Crankcase cover
36 700505049 4 Bolt M6x45
37 700505050 1 Oil plug gasket
38 700505051 1 Oil plug 3/8
39 700505052 1 Oil level glass 3/4
40 700505053 1 Crankshaft
41 700505054 1 Key, crankshaft
42 700505055 1 Shim
43 700505056 1 Flange, open
44 700505057 1 Seal for crankshaft
1-44 700505098 1 Pump E250 complete
1-44 700505099 1 Pump E350 complete

MERLION II E250, E350, E500 R026 - 27 -

 5. Spare Parts Lists
Pump spare-parts kit E250 & E350 Only

Kit - Part no.:/ Kit description Pos: Qty.: Individual components Part no.:
KIT 42 700505086 (1 SET) 4 3 O-ring
Support packing kit 22 5 3 Pressure ring
E250 7 3 Back ring
KIT 42 700505087 4 3 O-ring
Support packing kit 20 5 3 Pressure ring
E350 7 3 Back ring
KIT 9 700505088 (1 SET) 6 3 Support ring
Seal packing kit 22 8 3 High-pressure seal kit
E250
KIT 9 700505089 (1 SET) 6 3 Support ring
Seal packing kit 20 8 3 High-pressure seal kit
E350
19 3 Plunger nut
KIT 9 700505090 (1 SET) 20 3 Nylon washer
Plunger rod seal kit 22 21 3 O-ring
E250 22 3 Anti extrusion ring
24 3 Disc
19 3 Plunger nut
KIT 40 700505091 (1 SET) 20 3 Nylon washer
Plunger rod seal kit 20 21 3 O-ring
E350 22 3 Anti extrusion ring
24 3 Disc
KIT 41 700505092 (1 SET)
Valve kit 15 6 Valve Kit
E250
KIT 41 700505093 (1 SET)
Valve kit Steel 15 6 Valve Kit
(Option A: For Big Nut)
E350
KIT 63 700505214 (1 SET)
Valve kit Brass 15 6 Valve Kit
(Option A: For Small Nut)
E350

MERLION II E250, E350, E500 R026 - 28 -

 5. Spare Parts Lists
Un-loader valve assembly E250 & E350

Un-loader valve assembly spare-parts list E250 & E350

Pos: Part no.: Qty.: Description:
1 700540680 1 3/8 Outlet Adaptor
2 700540015 2 O-ring
3 700540216 1 Spring
4 700540419 1 Check Valve
5 700540179 1 O-Ring
6 700540681 1 Housing BPV
7 700540682 1 Seat
8 700540683 1 Shutter M8 SS
9 700540160 1 O-Ring
10 700540684 1 Spacer
11 700540685 1 Valve Piston Seal Rep. Kit
12 700540073 1 O-Ring
13 700540686 1 Piston Housing
14 700540211 1 M4 Dowel Screw
15 700540687 1 Lock Nut
16 700540688 1 Piston Seal Rep. Kit
17 700540851 1 Piston Set M8
18 700540162 1 Ball SS.
19 700540690 1 Spring Guide
20 700540691 1 Spring
21 700540692 1 Brass Cap
22 700540693 1 Adjusting Knob, Red
1-22 700540679 1 Un-loader Complete E250 & E350

MERLION II E250, E350, E500 R026 - 29 -

 5. Spare Parts Lists
Un-loader spare-parts kit E250 & E350

Part no.:/ Kit description Pos: Qty.: Individual components Part no.:
2 2 700540015
5 1 700540179
7 1 700540682
8 1 700540683
700540694 (1 Set)
9 1 700540160
Complete repair kit for Un-loader
11 1 700540685
12 1 700540073
16 1 700540688
18 1 700540162

MERLION II E250, E350, E500 R026 - 30 -

 5. Spare Parts Lists
Safety valve & accumulator assembly E250 & E350

MERLION II E250, E350, E500 R026 - 31 -

 5. Spare Parts Lists
Safety valve assembly spare-parts list E250 & E350

Pos: Part no.: Qty.: Description:

1 700540158 1 Hose nipple 5/8
2 700540449 1 By-pass fitting 3/8
3 700540120 1 O-ring
4 700540450 1 Seat SS
5 700550129 1 O-ring
6 700540452 1 Piston
7 700540172 2 Back-up ring
8 700540451 1 O-ring
9 700540453 1 Cap
10 700540455 1 Spring
11 700540456 1 Guide for spring
12 700540457 1 Ball
13 700540454 1 Contra nut
14 700540458 1 Body for safety valve
2-14 700540330 1 Safety valve complete

Safety valve spare-parts kit E250 & E350

Part no.:/ Kit description Pos: Qty.: Individual components Part no.:
3 1 700540120
700540460 (1 SET) 4 1 700540450
Complete repair kit for Safety
5 1 700550129
Valve
7 2 700540172
8 1 700540451

Accumulator assembly spare-parts list E250 & E350

Pos: Part no.: Qty.: Description:

15 700540742 1 Thrust screw
16 700540914 2 Spring
17 700540744 1 Piston
18 700540168 1 Back-up ring
19 700540169 1 O-ring
20 700540743 1 Accumulator housing
15-20 700540749 2 Accumulator complete E250
15-20 700540749 2 Accumulator complete E350

MERLION II E250, E350, E500 R026 - 32 -

 5. Spare Parts Lists
Trigger / gun & hose assembly E250 & E350

Trigger / gun & assembly spare-parts list E250 & E350

Pos: Part no.: Qty.: Description:
1 700551260 1 Gun Casing
2* 700551261 1 Back Up Ring
3 700551262 1 Washer
4* 700551263 1 Piston, Stainless Steel
5* 700551264 1 O-Ring +Seat
6 700551265 1 Spring, Stainless Steel
7 700551266 1 Spring, Plug
8* 700551267 1 O-Ring, 2.62x2.84
9* 700551268 1 Ball, Stainless Steel
10* 700551269 1 O-Ring, 1.5x10
11 700551270 1 Back tube
12 700551271 1 Gun Housing
13 700551272 1 Stop Pin
14 700551273 1 Front tube
15 700551274 1 Parallel pin
16 700551275 1 Safety Latch, Red Color
17 700551276 1 Trigger
18 700551277 7 Tapping Screw
1-18 700551257 1 Trigger/gun complete
19 700540314 1 Dowty Seal
20 700550696 1 Nipple -M22
21 700550004 1 Dowty Seal 3/8
22 700540099 1 Nipple -3/8
* 700551278 1 SET Repair Kit
- 700550097 - High-pressure Hose 15m E250/ E350 (Standard)
** 700550098 - High-pressure Hose 20m E250/ E350 (Optional)
** 700550099 - High-pressure Hose 30m E250/ E350 (Optional)
* Part for Repair Kit ; ** OPTIONAL

MERLION II E250, E350, E500 R026 - 33 -

 5. Spare Parts Lists
Lance assembly E250 & E350

Lance assembly spare-parts list E250 & E350

Pos: Part no.: Qty.: Description:
1 700550078 1 Nozzle guard
2 700550093 1 Nozzle straight 0007 E250 50Hz
2 700550142 1 Nozzle straight 00075 E250 60Hz
2 700550053 1 Nozzle straight 0005 E350 50Hz
2 700550054 1 Nozzle straight 00055 E350 60Hz
2 700550095 1 Nozzle fan jet 1507 E250 50Hz
2 700550144 1 Nozzle fan jet 15075 E250 60Hz
2 700550056 1 Nozzle fan jet 1505 E350 50Hz
2 700550057 1 Nozzle fan jet 15055 E350 60Hz
3 700550557 1 1/4 Bushing
4 700550699 1 Lance barrel
5 700550522 1 Lance guard complete L+R w/ Screws and Side handle support
6 700550073 1 Side handle
7 700550678 1 Insert Lance Nipple
8 700550030 1 Screw coupling female
9 700550008 1 O-ring / Backup-ring set
10 700550696 1 Screw coupling male S.S for trigger/gun connection (Not shown)
11 700060309 1 Copper washer for trigger/gun connection (Not shown)
1-11 700551060 1 Lance complete, Nozzle straight 0007 E250 50Hz
1-11 700551061 1 Lance complete, Nozzle straight 00075 E250 60Hz
1-11 700551064 1 Lance complete, Nozzle straight 0005 E350 50Hz
1-11 700551065 1 Lance complete, Nozzle straight 00055 E350 60Hz
1-11 700551062 1 Lance complete, Nozzle fan jet 1507 E250 50Hz
1-11 700551063 1 Lance complete, Nozzle fan jet 15075 E250 60Hz
1-11 700551066 1 Lance complete, Nozzle fan jet 1505 E350 50Hz
1-11 700551067 1 Lance complete, Nozzle fan jet 15055 E350 60Hz

MERLION II E250, E350, E500 R026 - 34 -

 5. Spare Parts Lists
Pump Connections E500

MERLION II E250, E350, E500 R026 - 35 -

 5. Spare Parts Lists
Pump Connection Spare-Parts List E500

Pos: Part no.: Qty.: Description:

1 700540549 1 Accumulator (see assembly page 44)
2 700540056 5 Dowty seal "
3 700540224 1 Adaptor M24 - 1/2"
4 700540083 1 Safety valve (see assembly page 42)
5 700540099 1 Nipple - 3/8 BSP
6 700550004 2 Dowty seal 3/8"
7 700505100 1 Pump E500 50 Hz (see assembly page 37)
7 700505101 1 Pump E500 60 Hz (see assembly page 37)
8 700540081 1 Unloader valve (see assembly page 40)
9 700540270 2 Hose nipple 1" - "
10 700540264 4 Hose clip 1
11 700540055 1 Pressure gauge
12 700540147 1 Bushing "M - "F
13 700540745 1 X-joint 1/2" BSP
14 700540100 2 Nipple 1/2" BSP-NPT
15 700530471 2 Pressure switch E500
16 700540138 2 Bushing 1/2" 3/8"
17 700950014 1.2m Hose 1"
18 700540102 2 Hose nipple 1" - 3/4"
19 700540323 2 Elbow 3/4"
20 700950014 0.35m Hose 1"
21 700540328 1 Elbow 1/2"

MERLION II E250, E350, E500 R026 - 36 -

 38
39
40
41 48
42 47
46
34 37 45
33 36 43
Pump assembly E500

KIT 4 32 49
35
30

MERLION II E250, E350, E500

29

26 28 44
55 20 31 2 50
515 3 51

R026
25 6
KIT 2
15 27 8 1 52
KIT 3 4 0
14 KIT 1 42
5
15
7 41
16 9
5. Spare Parts Lists

10 53
13 11 39
24 17 12 38
23 18
54
22 19
20
21

- 37 -
 5. Spare Parts Lists
Pump assembly spare-parts list E500
Pos: Part no.: Qty.: Description:
1 700505000 1 Crankcase
2 700505001 3 Bushing
3 700505002 3 Plunger rod seal
4 700505094 3 O-ring
5 700505094 3 Pressure ring 15
6 700505095 3 Low pressure seal kit 15
7 700505094 3 Back ring 15
8 700505095 3 High-pressure seal kit 15
9 700505063 1 Washer
10 700505015 1 Plug 3/4
11 700505064 1 Pump head
12 700505065 1 O-ring
13 700505066 3 VAM diffuser
14 700505096 3 Outlet valve kit
15 700505096 9 O-ring
16 700505096 6 Anti extrusion ring
17 700505020 3 O-ring
18 700505016 1 Aluminium gasket
19 700505014 1 Plug 3/8
20 700505022 16 Washer M10
21 700505070 8 Bolt M10x140
22 700505071 3 Bolt M6x10
23 700505072 3 Washer M6
24 700505073 1 Manifold
25 700505096 3 Inlet valve kit
26 700505075 3 Outlet valve cap
27 700505076 1 Outlet valve cover
28 700505077 8 Bolt M10x35
29 700505097 3 Plunger nut
30 700505097 3 Gasket
31 700505080 3 Plunger
32 700505097 3 O-ring
33 700505097 3 Anti extrusion ring
34 700505097 3 Disc
35 700505084 3 Plunger rod
36 700505039 3 Connection rod pin
37 700505040 3 Connection rod
38 700505041 8 Bolt M8x22
39 700505042 8 Washer M8
40 700505043 1 Flange, closed
41 700505044 2 O-ring
42 700505045 2 Roller bearing
43 700505046 1 Oil plug
(Continues)

MERLION II E250, E350, E500 R026 - 38 -

 5. Spare Parts Lists
(Continued)

Pos: Part no.: Qty.: Description:

44 700505047 1 Gasket, crankcase cover
45 700505048 1 Crankcase cover
46 700505049 4 Bolt M6x45
47 700505050 1 Oil plug gasket
48 700505051 1 Oil plug 3/8
49 700505052 1 Oil level glass 3/4
700505085 1 Crankshaft 50Hz
50
700505115 1 Crankshaft 60Hz
51 700505054 1 Key, crankshaft
52 700505055 1 Shim
53 700505056 1 Flange, open
54 700505057 1 Seal for crankshaft
55 700505127 3 O-Ring
1-55 700505100 1 Pump E500, 50 Hz complete
1-55 700505101 1 Pump E500, 60 Hz complete

Pump spare-parts kit E500

Kit - Part no.:/ Kit description Pos: Qty.: Individual components Part no.:
KIT 1 700505094 (1 SET) 4 3 O-ring
Support packing kit 15 5 3 Pressure ring 15
7 3 Back ring 15
KIT 2 700505095 (1 SET) 6 3 Low pressure seal kit 15
Seal packing 15 8 3 High-pressure seal kit 15
14 3 Outlet valve kit
KIT 3 700505096 (1 SET) 15 6 O-ring
Valve kit 15 16 3 Anti extrusion ring
25 3 Inlet valve kit
29 3 Plunger nut
KIT 4 700505097 (1 SET) 30 3 Gasket
Plunger rod seal kit 15 32 3 O-ring
33 3 Anti extrusion ring
34 3 Disc

MERLION II E250, E350, E500 R026 - 39 -

 5. Spare Parts Lists
Un-loader valve assembly E500

Un-loader valve assembly spare-parts list E500

Pos: Part no.: Qty.: Description:
1 700510015 2 Nut M10
2 700540061 1 Washer
3 700540062 1 Spring 8.5
4 700540063 1 Lock pin 3x18
5 700540064 1 Piston housing
6 700540065 2 Back-up ring 18x13.5
7 700540066 1 O-ring 2.62x13.1
8 700540067 1 Piston
9 700540068 1 Valve body
10 700540069 1 Seat
11 700540070 1 O-ring 1.78x12.42
12 700540071 1 Ball 13/32
13 700540072 1 Spring
14 700540073 3 O-ring 1.78x20.35
15 700540074 1 Inlet fitting 1/2

MERLION II E250, E350, E500 R026 - 40 -

 5. Spare Parts Lists
Un-loader valve assembly spare-parts list E500

Pos: Part no.: Qty.: Description:

16 700540075 1 Back-up ring 14.5x10
17 700540076 1 O-ring 2.62x9.93
18 700540077 1 O-ring 4x8
19 700540078 1 Check valve
20 700540079 1 Spring
21 700540080 1 Outlet fitting 1/2
1-21 700540081 1 Un-loader valve complete

Un-loader spare-parts kit E500

Part no.:/ Kit description Pos: Qty.: Individual components Part no.:
6 2 700540065
7 1 700540066
700540082 (1 SET) 10 1 700540069
Complete repair kit for Un-loader 11 1 700540070
12 1 700540071
14 3 700540073
16 1 700540075
17 1 700540076
18 1 700540077

MERLION II E250, E350, E500 R026 - 41 -

 5. Spare Parts Lists
Safety valve assembly E500

Safety valve assembly spare-parts list E500

Pos: Part no.: Qty.: Description:
1 700510015 2 Nut M10
2 700540061 1 Washer
3 700540062 1 Spring 8.5
4 700540063 1 Lock pin 3x18
5 700540064 1 Piston housing
6 700540065 2 Back-up ring 18x13.5
7 700540066 1 O-ring 2.62x13.1
8 700540067 1 Piston
9 700540068 1 Valve body
10 700540069 1 Seat

MERLION II E250, E350, E500 R026 - 42 -

 5. Spare Parts Lists
Safety valve assembly spare-parts list E500

Pos: Part no.: Qty.: Description:

11 700540070 1 O-ring 1.78x12.42
12 700540071 1 Ball 13/32
13 700540072 1 Spring
14 700540073 3 O-ring 1.78x20.35
15 700540074 1 Inlet fitting 1/2
16 700540075 1 Back-up ring 14.5x10
17 700540076 1 O-ring 2.62x9.93
18 700510012 2 Plug 1/2
1-18 700540083 1 Safety valve complete

Safety valve spare-parts kit E500

Part no.:/ Kit description Pos: Qty.: Individual components Part no.:
6 2 700540065
7 1 700540066
700540082 (1 SET) 10 1 700540069
Complete repair kit for Safety 11 1 700540070
Valve 12 1 700540071
14 3 700540073
16 1 700540075
17 1 700540076
* 1 700540077 (Not Shown)

MERLION II E250, E350, E500 R026 - 43 -

 5. Spare Parts Lists
Accumulator assembly E500

Accumulator assembly spare-parts list E500

Pos: Part no.: Qty.: Description:

1 700540553 1 Thrust screw
2 700540729 1 Spring
3 700540551 1 Piston
4 700540554 1 Backup-ring
5 700540555 1 O-ring
6 700540550 1 Accumulator body
1-6 700540549 1 Accumulator, Complete

MERLION II E250, E350, E500 R026 - 44 -

 5. Spare Parts Lists
Trigger / gun / lance & hose assembly E500

Trigger / gun/ lance & hose assembly spare-parts list E500

Pos: Part no.: Qty.: Description:

1 700550051 1 Nozzle, straight jet 0003 50/60Hz
1 700550389 1 Nozzle, fan jet 1503 50/60Hz
2 700551229 1 Spring Holder
3* 700551230 1 Back-up ring, PTFE
4* 700551231 1 O-ring, Ni85
5* 700551232 2 Stem Seal + O-ring
6 700551233 1 Brass Specer Ring
7* 700551234 1 Spring, S.S.
8* 700551235 1 Piston + seat
9* 700551236 1 O-ring, Ni85
10* 700551237 1 Back-up ring
11 700551238 1 Front Plug, M18x1.5
12 700551239 1 Parallel Pin, 6x25.8mm
(Continues)

MERLION II E250, E350, E500 R026 - 45 -

 5. Spare Parts Lists
(Continued)
Pos: Part no.: Qty.: Description:
13 700551240 1 Housing
14 700551241 1 Coupling, BSP S.S.
15 700551242 1 Safety Latch, Red
16 700551243 1 Trigger, Black
17 700551244 1 Stop Pin, 8x7.1mm
18 700551245 1 Parallel Pin, 5x27.5mm
19 700551246 1 Casing Kit + Screw
20 700510216 7 Self-tapping screw
21 700550126 1 Back pipe
22 700551182 1 Shoulder Rest (Optional)
23 700510217 2 Washer
24 700550108 1 Lance pipe 400mm Length (Optional)
24 700550109 1 Lance pipe 1000mm Length (Standard)
25 700550107 1 Bushing for Side Handle
26 700550106 1 Nozzle holder
27 700551247 1 Plug M BSP
28 700550073 1 Side Handle complete
29 700550116 1 Connection fitting 1/2BSPP-female
30 700540057 1 Nipple BSPP
31 700550097 1 High Pressure Hose 15m with BSPP Swivels (Standard)
31 700550098 1 High Pressure Hose 20m with BSPP Swivels (Optional)
31 700550099 1 High Pressure Hose 30m with BSPP Swivels (Optional)
32 700550136 1 Lance connection male 3/8 female BSPP
2-21 700551180 1 Trigger Complete (inclusive of item 27 & 29)
* 700551181 1 Set Trigger Gun Repair Kit
* Part for Trigger Repair Kit

Lance, Complete with different length

Description Pos: Qty.: Individual components Parts:

700550140, (1 SET) 24 1 Lance pipe 400mm Length (Optional)
Lance Length 400mm 25 1 Bushing for Side Handle
26 1 Nozzle holder
28 1 Side Handle complete
32 1 Lance connection male 3/8 female BSPP
700550141, (1 SET) 24 1 Lance pipe 1000mm Length (Standard)
Lance Length 1000mm 25 1 Bushing for Side Handle
(Standard) 26 1 Nozzle holder
28 1 Side Handle complete
32 1 Lance connection male 3/8 female BSPP

MERLION II E250, E350, E500 R026 - 46 -

 6.OPTIONAL
6.OPTIONAL
Stainless Steel Water Tank Assembly Kit

Water Tank Assembly Kit Spare Parts List

Pos: Part no.: Qty.: Description:

1 700520627 1 WATER TANK MERLION S.S
2 700950014 0.85m HOSE 1" SUCTION PLUTONE
3 700540264 2 HOSE CLIP 1" 31-34 (NORMA) SS
4 700520553 1 WATER TANK FILTER, 3/4 BSP
5 3817582 1 LEVEL SENSOR, LS103-12
6 700540291 1 HOSE NIPPLE 3/8"-1/4" BSPP BRASS
7 700510136 1 CONTRA NUT 3/8" BSPP BRASS
8 700950021 0.50m HOSE INLET 1" Rubber(18 Bar)- Black
0.65m
9 700540264 4 HOSE CLIP 1" 31-34 (NORMA) SS
10 700540261 2 ELBOW 1/2" NPT F-F BRASS
11 700540270 2 HOSE NIPPLE 1" - 1/2" BSPT BRASS
12 700950021 0.20m HOSE INLET 1" Rubber(18 Bar)- Black
13 700520638 1 FLOAT VALVE 1/2"
14 700540270 1 HOSE NIPPLE 1" - 1/2" BSPT BRASS
1-14 700520656 1 WATER TANK MERLION S.S COMPLETE

MERLION II E250, E350, E500 R026 - 47 -

 6.OPTIONAL
Optional Rotating nozzle Type 1

MERLION II E250, E350, E500 R026 - 48 -

 6.OPTIONAL
Rotating Nozzle E250, E350 & E500

Pos: Part no.: Qty.: Description:

1 700540314 2 Dowty Seal
2 700540149 1 Nipple
3 700551136 1 Nozzle Repair Kit 0007 E250 50 Hz
3 700551137 1 Nozzle Repair Kit 0008 E250 60 Hz
3 700551135 1 Nozzle Repair Kit 0005 E350 50 Hz
3 700551134 1 Nozzle Repair Kit 00055 E350 60 Hz
3 700551312 1 Nozzle Repair Kit 0003 E500 50/60 Hz

Note : Due to the natural of the design the rotating life span estimated to be about 50-80Hr.
It depend on quality of the water.

Machine: Rotating Nozzle Complete

Merlion II E250, 50Hz 700551120
Merlion II E250, 60Hz 700551121
Merlion II E350, 50Hz 700551119
Merlion II E350, 60Hz 700551118
Merlion II E500, 50/60Hz 700551308

Operation & use of rotating nozzle

Point nozzle Depress trigger Start Blasting only

1 2 3
downwards Allow nozzle to after the nozzle has
start spinning started spanning

Failure to follow proper start up procedure will shorten the lifespan of

CAUTION the rotating nozzle!

MERLION II E250, E350, E500 R026 - 49 -

 6.OPTIONAL

Optional Rotating nozzle for 500bar Type 2

Pos: Part no.: Qty.: Description:

A - 1 Front Cover
B - 1 Seat (Comes with Pos C)
C 700551453 1 Rep. Kit , rotor 1.10 (50Hz) c/w with seat (Pos B)
C 700551453 1 Rep. Kit , rotor 1.10 (60Hz) c/w with seat (Pos B)
D - 1 Housing
E 700551454 1 Driving Tube, 1.4 x 2 (50Hz)
E 700551454 1 Driving Tube, 1.4 x 2 (60Hz)
F - 1 Inlet Cover
A-F 700551452 1 Rotating Nozzle Complete for 500bar (50Hz)
A-F 700551452 1 Rotating Nozzle Complete for 500bar (60Hz)

Note : Due to the natural of the design the rotating life span estimated to be about 50-80Hr.
It depend on quality of the water.

MERLION II E250, E350, E500 R026 - 50 -

 6.OPTIONAL

MERLION II E250, E350, E500 R026 - 51 -

 6.OPTIONAL

MERLION II E250, E350, E500 R026 - 52 -

 6.OPTIONAL

MERLION II E250, E350, E500 R026 - 53 -

 6.OPTIONAL
Operation & use of rotating nozzle

Optional Rotating nozzle for 500bar Type 3

MERLION II E250, E350, E500 R026 - 54 -

 6.OPTIONAL
Safety valve assembly spare-parts list

Pos: Part no.: Qty.:

Description:
1 700551140 1
Multi Jet Shield Bolt
2 700551141 1
Multi Jet Shield
3 700551183 1
Multi Jet Head 2ports
4 700551143 1
Multi Jet Back-Up Ring
5 700551144 1
Multi Jet O-Ring
6 700551145 1
Multi Jet Seal, Large
7 700551146 1
Multi Jet Bearing, Thrust
8 700551164 1
Multi Jet Shaft
9 700551148 1
Multi Jet Inlet seat
10 700551147 1
Multi Jet O-ring
11 700551149 1
Multi Jet O-Ring
12 700551150 1
Multi Jet Seal Holder Carbide
13 700551151 1
Multi Jet HP Seal Assy
14 700551152 1
Multi Jet Carbide Seat Coated
15 700551153 1
Multi Jet O-Ring
16 700551154 1
Multi Jet Seal, Shaft Small
17 700551156 1
Multi Jet Washer
18 700551184 1
Multi Jet Garter Spring
19 700551142 1
Multi Jet Spring
1-19 700551035 1
Rotating Nozzle, Barracuda 22kpsi
A 700551165 1
Multi Jet Springe (Optional)
*To use 700551035 onto lance, take out (Nozzle Holder)700550106 and add in
Adaptor(700551107).

Recommended Nozzle Sizing for 500Bar

* 700551035 1 set 1) Rotating Head 22KPSI

700551108 2) Barracuda Rotating Nozzle 0042 (1pc)
700551108 3) Barracuda Rotating Nozzle 0042 (1pc)
(For Mermaid 50Hz only)

* 700551035 1 set 1) Rotating Head 22KPSI

700551108 2) Barracuda Rotating Nozzle 0042 (1pc)
700551497 3) Barracuda Rotating Nozzle 0038 (1pc)
(For Mermaid 60Hz only)

* Not Shown

MERLION II E250, E350, E500 R026 - 55 -

 6.OPTIONAL

After every 20-40 hrs, the rotating nozzle must be flushed or refilled with
Auto Transmission Fluid (ATF)

For Troubleshooting and Maintenance please refer to manual that comes with the Rotating Nozzle

MERLION II E250, E350, E500 R026 - 56 -

 6.OPTIONAL
Optional sand & slurry blasting kit E250, E350 & E500

Pos.: Items Parts. No.

1 Sandblasting House Complete Assembly (Items :8,9,10,11,12,13)
2 Lance 700550141
3 High Pressure Hose 700550099
4 Sand Suction Hose 700550248
5 Hose clamps 700540200
6 Regulator Handle 700550866
7 Grit Container Complete 700550865
8 Finger Screw 700520063+700510051
9 High Pressure Water Nozzle 700550318 E250/50HZ
9 High Pressure Water Nozzle 700550238 E250/60HZ
9 High Pressure Water Nozzle 700550235 E350/50HZ
9 High Pressure Water Nozzle 700550236 E350/60HZ
9 High Pressure Water Nozzle 700550614 E500/50HZ
9 High Pressure Water Nozzle 700550614 E500/60HZ
10 Nozzle Adaptor 700550242
11 Venturi Housing 700550232
12 O-Ring 700550295
13 Boron Carbide Nozzle 700550231

MERLION II E250, E350, E500 R026 - 57 -

 7. Electrical Assembly
7. Electrical Assembly

El-box assembly spare-parts list

Pos: Part no.: Qty.: Description:
1 700530518 1 Run Light, Orange
2 700530519 1 POWER ON Light, white
3 700530520 1 ON Push button, green
4 700530521 1 OFF Push button, red
5 700530522 1 Main isolator 40A
6 700530247 2 FUSE 500V-2A (10 X 38)
7 700530517 2 Fuse carrier
8 700530164 2 Contactor mains: 380/415/440V 50/60Hz
8 700530186 2 Coil 24V series 0-10 mains: 380/415/440V 50/60Hz
9 700530477 1 Overload relay mains: 380/415/440V 50/60Hz
10 700530475 1 Contactor mains: 380/415/440V 50/60Hz
10 700530186 1 Coil 24V series 0-10 mains: 380/415/440V 50/60Hz
11 700530514 1 Timer on delay
12 700530513 1 Timer auto start/stop
13 700530515 1 Relay
14 700530473 1 Transformer 380/400/440V 50/60Hz - 24 V DC
15 700530523 4 Cable terminal, incoming power
16 700530524 4 Cable terminal, auto start/stop
17 700530010 2 Cable gland PG13.5
18 700530101 2 Cable gland PG21
18A 700530099 1 Cable gland PG16 (Not Shown, for incoming cable)
19 700530602 1 Panel Box
1-19 700530527 1 El-box complete
N/A 700530099 1 Cable Gland PG16
N/A 700530026 15 m Main cable mains: 380/415/440V 50/60Hz (not shown)
N/A 700951509 0.8 m Cable Star/Delta mains: 380/415/440V 50/60Hz (not shown)
N/A 700951506 50m Main cable mains: 380/415/440V 50/60Hz (not shown)

MERLION II E250, E350, E500 R026 - 58 -

Wiring diagram

MERLION II E250, E350, E500 R026 - 59 -

 7.1 Electrical Setting
7.1 Electrical Setting
Main Contactor Overload Setting
The setting of the overload-LRD must be always
set at about 2x of the motor running current at
~26A.

Incorrect setting of the overload will burnt the

motor or creates unnecessary tripping of the
overload.

Timer Setting
Star- Delta Timer Setting :
Factory setting of the switching of the
motor from Star-Delta is set to 50ms.
While the time to switch over is 3s.

RANGE:-must be set to 1s as
shown.
TIME:-must be set to 3
MS:- must be set to 50

Auto Start-Stop Timer Setting :

Factory setting of the machine to auto shut
down when the trigger is not pressed after
4min. This function protect the pump and
motor life span.

FUNCTION:-must be set to Op
as shown.
TIME:-must be set to 4
RANGE:- must be set to 60s

MERLION II E250, E350, E500 R026 - 60 -

 8. Declaration and Warranty
8. Declaration and Warranty

EU declaration of conformity

EU Declaration of Conformity
Product:
Electric powered
heavy duty
cold water high-pressure cleaner
Type:
MERLION II E250 / E350 / E500
Description:
380V-440 0~, 50/60Hz, IP 54 250 / 350 /
500[bar]
The design of the unit corresponds to the following
EC Machine Directive 98/37/EEC
pertinent regulations:
EC Low Voltage Directive 72/23/EEC

Applied harmonized standards:

EN 292, EN 60335-2-79, EN 55014-1,
EN 55014-2, EN 61000-3-2
Applied national standards and technical specifications:
DIN EN60335-2-79

DEN-SIN a division Nilfisk-Advance Pte Ltd.

No 5 Tuas Ave 2
Singapore 639445
Tel: +65 62681006
Fax: +65 62684916

Singapore, February 2008

Warranty
DEN-SIN warrants all equipments of its manufacture furnished under this agreement to be free from
defect in workmanship and material for a period of one year from the date of invoice of the
equipment. This warranty does not cover normal wear and tear, consumable items, or part failures
caused by (i) accident, (ii) abuse, or (iii) failure to maintain the DEN-SIN system containing the
affected parts in accordance with DEN-SIN technical specification. All labour is the responsibility,
and the expense of the Buyer. The liability of Seller under this warranty is limited, at Seller's option,
solely to repair or replacement with equivalent articles. This warranty is condition upon (a) Seller
being notified in writing by Buyer within one week after discovery of defects;
(b) the return of defective articles to Seller, transportation charges prepaid by Buyer; and (c) Seller's
examination of such article disclosing to its satisfaction that such defects were not caused by
negligence, misuse, improper maintenance, improper installation, accident, or unauthorized repair or
alteration.
Accessories or equipment furnished by DEN-SIN but manufactured by others, shall carry the
warranty that its manufacturer has conveyed to DEN-SIN, and which may be passed on to the
purchaser. The original warranty period of any article, which has been repaired or replaced by
DEN-SIN, shall not thereby be extended.

MERLION II E250, E350, E500 R026 - 61 -

 9. Spare Parts Request Form
9. Spare Parts Request Form

Company Name:
Delivery Address:
Country: Postal Code:
Contact Name: Contact Number:
Fax Number: Mobile Number:
Email:

S/N Part Number Description QTY Machine Model

or Serial Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Special Instructions:

MERLION II E250, E350, E500 R026 - 62 -

 10. Maintenance Log Book
10. Maintenance Log Book
This maintenance logbook will assist you to keep track on the servicing of your equipment.
Please record after service your machine.

Purchase date of the machine:

S/N Service Description Date Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

MERLION II E250, E350, E500 R026 - 63 -