2x32 litre compressor washing rig complete with heaters(JMP/SHWR/D/0376/C1000)

April 2014 2x32 litre compressor washing rig with heaters page 1 of 6

A. T. JUNIPER (LIVERPOOL) Ltd.

As per the rigs JMP/SHWR/D/0376/C800BH but for the following removals and additions:

Side storage box removed and replaced with electrical control box tocontrol heating system.

Pressure relief valves removed and replaced with pressure relief valvescomplete with vent pipes.

Tank heating system complete with controls added

Combination delivery and bleed hose removed and replaced with a 1⁄2” bore x 15’ delivery hose terminating in a SM474 quick disconnect coupling

Twin hose assembly (JMP/CF6/A/4087) added

Storage box for twin hose assembly and electrical leads added to rear of rig

Drop leg removed and rear castors added for stability

New identification label and decal set added to highlight changes

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GENERAL OPERATING INSTRUCTIONS

Ensure panel mounted pressure regulator is fully closed (fully anti-clockwise).

Ensure nitrogen cylinder is fully charged to maximum stated on cylinder.NOTE: Minimum requirement for one engine wash is 1000 PSI. The pressure is indicated on the regulator gauge.

Ensure all ball valves on the rig are in the closed position (across the direction of flow).

Fill respective tanks with recommended fluids, ie. one tank with washing solution and the other withdemineralised water, or both tanks with demineralised water.

Close and tighten filler caps.

HEATING THE TANKS

Using the supplied leads, connect tank 1 and tank 2 to a 240V, single phase power supply. Red lights onthe electrical control box will illuminate indicating you have power. The temperature of the water in the tanksis indicated on the control box’s LED display. When the temperature in the tanks reaches 70ºC, the redlights will go out. Leave the rig connected to the power supply until you are ready to carry out the wash.NOTE: Thermostats fitted to the tanks control the temperature.

ENGINE PREPARATION

Fit the engine washing probes to the engine as per the fitment guide supplied with the probes.

WASHING THE ENGINE

Disconnect the electrical supply.

Site the rig in a suitable position away from the engine exhaust and connect the delivery hose of the rig tothe twin hose assembly.

REFER TO ENGINE MANUAL FOR FLOW RATE REQUIREMENT

OPERATING THE RIG

Turn on nitrogen supply from the cylinder (fully anti-clockwise).

Open tank nitrogen inlet ball valve (in line with direction of flow).

Rotate pressure regulator clockwise until desired pressure is reached on the tank’s pressure gauge.

THE RIG IS NOW PREPARED FOR COMPRESSOR WASHING. TO COMMENCE WASH:

Open solution tank outlet ball valve for desired wash period.

On completion of wash period, close tank outlet ball valve and close the nitrogen inlet ball valve to the tank.

Repeat operations 5.3 to 5.5 for the rinsing cycle using relevant tank and valves.

AFTER COMPLETING THE WASH AND RINSE CYCLE, CARRY OUT THE FOLLOWING:

Disconnect fluid delivery hose and twin hose assembly from the engine and re-stow them on the rig.

Remove engine probes and re-stow them in the trailer.

Turn of nitrogen cylinder.

Exhaust nitrogen from both tanks by operating the lever on the pressure relief valve.

1.

1.0

1.1

1.2

1.3

1.4

2.

2.0

3.

3.0

4.

4.0

4.1

5.

5.0

5.1

5.2

5.3

5.4

5.5

6.

6.0

6.1

6.2

6.3

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OPERATING THE RIG

Continued

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BACK UP PROCEDURE WHEN NO NITROGEN IS AVAILABLE

Ensure nitrogen cylinder is turned off.

Connect auxiliary air supply to Schrader ait inlet valve. Maximum allowable inlet pressure is 120 PSI.

Turn auxiliary air supply on and proceed as Para 5.2.

AFTER USE:

Turn off air supply and disconnect rig, then proceed as Para 7.0.

7.

7.0

7.1

7.2

8.

8.1

April 2014 2x32 litre compressor washing rig with heaters page 4 of 6

1

6

2

5

29 30

3

20

16

10

4

2524

34

17

35

36

9

26

PARTS LIST

11

Description

FrameFluid tank (front)Fluid tank (rear)Electrical control boxHose assembly 1⁄2” NB x 30’Cylinder clampInstruction sheet (laminated)Traffolyte panelPressure relief valvePressure relief valve nozzleRelief valve nozzle bracketImmersion heater Immersion heater thermostat Immersion heater conduitEqual elbow, 1⁄4” BSPAdaptor, 1⁄2” (f)BSP x 3⁄8” (m)BSPTwin hose assemblyAdaptor 1⁄4” x 1⁄4” BSPAdaptor 3⁄8” x 1⁄4” BSPHex Bolt, 8mm x 16mm1⁄2” Dowty seal3⁄4” Dowty sealSocket head screws, 8mm x 16mmPlain washer, 11⁄4” OD x 1⁄2” IDNut, 1⁄2” UNF ‘P’ typeBlanking plug, 3⁄8” BSPNyloc nut, 8mmPlain washer, 8mmNyloc nut, 5⁄16” BSWPlain washer, 5⁄16” BSWHex head set bolt, 8mm x 30mmPlain washer, 8mmNut, 8mm ‘P’ typePower leadsCastor backing plateCastorDecal set

* In the quantity column Indicates change in quantity (Part not illustrated).

11111111221222*221*5*22*10*4*142214422*10*12*102221

JMP/CF34/D/7049JMP/CF34/D/7037JMP/CF34/D/7038SM 945JMP/CF34/HL/6669JMP/CF34/D/7049/02JMP/CF34/A/7052JMP/CF34/A/7053SM 725JMP/CFM56/A/4827JMP/CF34/A/7051SM 944-1SM 944-3SM 944-4JMP/STD/A/5471JMP/STD/A/7054JMP/CF6/A/4087JMP/STD/A/5397JMP/STD/A/5352N/DN/DN/DN/DN/DN/DJMP/STD/A/5051/5N/DN/DN/DN/DN/DN/DN/DN/DJMP/CF34/D/7049/03SM 074SM 946

All welded assemblyStainless steelStainless steelcomplete with 2 power leadsFluid delivery hose

Cut to suit lengthsSupports front nozzle

Pressure reg valveSafety valvein storage box

Tank bracket under control boxSight glass and thermostatDrain valve adaptor and heaterTank bracketWheelWheelCharging manifoldControl boxControl boxCylinder clampCylinder clampFilter mountingFilter mountingFilter mountingFor control box (see item 4)

Qty

1 2345678910111213141516171819202122232425262728293031323334353637

Item Part number Remarks, finish etc.

NEW PARTS LIST (and changes to quantity for existing parts)

7

142728

1312

14

12 13

8

April 2014 2x32 litre compressor washing rig with heaters page 5 of 6

ELECTRICAL SCHEMATIC DIAGRAMS

Description

Enclosure 300 x 300 x 210mm16 Amp Residual current circuit breaker 16 Amp Residual current circuit breaker240V Mini contactor240V Mini contactorRed indicating lampRed indicating lampPanel mounted temperature controllerHeater terminals‘J’ Type thermocouple terminals5 Metre power lead

11111112422

SM945-1SM945-2SM945-3SM945-4SM945-5SM945-6SM945-7SM945-8SM945-9SM945-10SM945-11

Qty

E1RCBO1RCBO2K1K2H1H2Temperature controllerTerminalTerminalPower lead

RittalEatonEatonEatonEatonEatonEatonTecnologicWeidmullerWeidmullerMennekes

Item Part no.Manufacturer

April 2014 2x32 litre compressor washing rig with heaters page 6 of 6