Wash Bay Manual

Contents

About Us ................................................................................................................................................. 2
Wash Bay System.................................................................................................................................... 3
Unit Specification ................................................................................................................................... 4
Wash Bay ............................................................................................................................................ 4
Technical Information- wash bay .................................................................................................... 5
Installation............................................................................................................................................... 7
Method of Installation ......................................................................................................................... 7
Operation .............................................................................................................................................. 10
operating Philosophy ........................................................................................................................ 10
Power and Water ................................................................................................................................... 11
Power ................................................................................................................................................ 11
Water ................................................................................................................................................. 12
Cleaning and Maintenance ................................................................................................................... 13
Troubleshooting ................................................................................................................................ 15
Winter Maintenance .............................................................................................................................. 17
Disclaimer ............................................................................................................................................. 18
Contact .................................................................................................................................................. 19
Appendices............................................................................................................................................ 20
General arrangement.1 ..................................................................................................................... 20
General arrangement .2 .................................................................................................................... 21
General shipping plan ....................................................................................................................... 22
11kw wash pump data sheet .............................................................................................................. 23

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About Us

We do so much more than provide you with a highly energy efficient and environmentally
friendly wheel washing system.

We realise every customer is unique, so we take the time to understand precisely what you
need. This means you can be sure of getting the best advice, solutions, and service. We’ll look
at your specific site requirements, commercial parameters, and service needs before
recommending a solution we know will help you drive productivity, ensure safety, and
minimise environmental impact.

Our reputation is built upon putting customers at the heart of what we do, delivering on our
promises and designing, engineering, and supplying the highest quality products and services.
We’re very proud of everything we do; but for us, ‘good’ is never good enough. We know we
can always improve, and always strive to do so.

That’s why customers trust us to provide them with the right wheel wash solution every time.
Because with Wheelwash, you know you’re in safe hands.

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Wash Bay System

This bespoke wash bay has been designed to predominately was sections of mobile cranes.
The following pages give a detailed breakdown of the specification of the systems.

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Unit Specification

Wash Bay

The wash bay has been designed for washing mobile crane sections. The unit is supplied with
four wedged ramps which allow the sections to be raised so the underside can be cleaned. The
system is supplied with a jet was cabinet capable of high pressure washing up to 2465 psi. The
system also features a wash down pump to help maintain the efficiency of the unit as well as a
return pump to aid water retention and reusage.

The system is shown below.

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Technical Information- wash bay

Manufacturer Wheelwash Limited, UK

Date of Manufacture 2024 (current models)

Type of Installation Above ground (no civils work required see drawings)
64m2 of flat, level ground required

Power requirement 415 V Neutral + Earth / 50 hz connected by site

provided electrician upon installation. Connection will
be hardwired through a gland in the base of the panel.

40 amp supply on a D-type/ D-curve breaker

Water requirement ¾” mains water connection to be connected by site

upon install
% Water recycled Up to 90%

Expected Lifespan of Paint Signs of wear on ramps and internal grids expected
within year 1;
Paint should remain intact for 5 years on other parts of
the equipment, depending on the level of salt /
corrosive material in the atmosphere / going through
the wheel washing system. If damage to paint occurs it
should be treated

Sludge removal 2000 ltr capacity recycling tank, sludge requires

regular removal by valve, excavator by dredging or
vacuum truck.

Usage guidelines – Built for washing mobile crane sections as detailed by

the customer

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 Item Qty Weight
14m x 3.5m wide wash platform
suitable for mobile crane sections 1 6910 kg
Complete with:
5 x internal grids
GRP
16 brass nozzles – up to 2.0 bar at the nozzle

Side screens 3x1.5 13 1560 kg

Steel side sump 1 54 kg

2m x 1m x 1m Settlement Tank (2000 litres capacity)

Complete with: 1 500kg

Baffle and weir plates creating 2 individual chambers to
aid particulate settlement
With 4” Valves and Bauers for manual sludge removal

1.5m x 1m x 1m headerTank (1500 litres capacity) with

submersible washdown pump
305kg
Complete with: 1
With 4” Valve and Bauers for manual sludge removal
Electrical control panel fitted

Removable wedge pods 4 2700kg

Washdown cabinet 1
600kg

Push button mounted on a stand 1 10 kg

Recovery Pump 1 59 kg

TOTAL 12698 kg

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Installation

All Wheelwash employees and sub-contractors have a high standard of health & safety
awareness gained through training and experience. All are CSCS certified.
Our nominated haulier will be the sole provider of the Hiab vehicle, lifting equipment and
operator, all of which have current and appropriate certification. The Hiab Operator is fully
trained, experienced and qualified. Refer to the generic lift plan sent by Wheelwash

We will always adhere to the site-specific guidelines as advised.

Appropriate PPE will be worn at all times.
Lifting points of equipment accessible via step to back of wagon. Hiab operator FAFR
trained.

Method of Installation

1. The Wheel wash Engineer reports to the Site Responsible Person

2. They will receive a site induction / site safety instruction

3. All relevant emergency telephone numbers and the sites first-aiders will be noted on
arrival to site in the site induction.

4. They will only operate in a safe working area that has been cordoned off by the
Lifting Supervisor / Site Responsible Person

5. The Wheel wash Engineer will commence installation once the following items have
been completed by using the HIAB. Hiab operator to set up:

a. Attach chains to the lifting points on the header tank and lift into the agreed
position. Repeat with the settlement tank placing behind the header tank

b. Attach the chains to the jet wash cabinet and lift into place. Remove the chains

c. Attach the chains to the lifting points on each of the 4 pods (individually) and
lift to a suitable and safe place.

d. Using a suitable set of slings lift the braces off the wash platform and place by
the pods. Remove the straps and chains.

e. Attach the chains to the top side screen on its own and lift off to one side

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 f. Using two slings and two chains lift each of the side screen bundles (6 each) off
the base and onto the ground.

g. Attach the chains to the welded lifting points on the base and lift from the wagon
and put in place. The grids may have to be removed depending on Hiab
specification. Remove the chains.

h. Lift the sump into position and bolt

i. Using the Hiab lift each of the side screens into place and the Wheelwash
engineer secures the bottom bolts.

j. Lift each of the braces into position using the Hiab and secure to the screens
using the bolts provided. The engineer will need to use a step or access platform
for this and to remove the chains from the screens.

k. The pods can now be lifted into place on the base

l. Fold in crane and outriggers on vehicle. Vehicle can leave site via designated
route.

Please note the precise sequencing may vary depending on the driver and vehicle sent, as this
may affect the loading strategy.

6. Site engineer to connect mains water to the first tank (connected to the
pumphouse/pump box) and commence water fill. Make sure all the plugs and caps are
present on the tanks and they all have PTFE tape applied to the threads. A bulk fill is
recommended on commission for speed and effective testing.

7. Wheel wash engineer to connect feed and return hoses between the pumps and inlet
points.

8. Connect feed pipes (left and right) and flexible hoses between connections.

9. Conduct a visual inspection of pipe, pipework, unions, and bolts. Tighten as necessary.

10. Position the push button and plug into the panel

11. Customer-supplied electrician to gland-in and connect the supply cable to the panel and
jet wash cabinet

12. Wheelwash engineer to bolt down all side screen braces ensuring they are square

13. Once all the connections have been completed, the engineer will proceed to test the unit
operation to ensure all components function as designed.

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 14. Engineer to fix corner sheets in place using silicone and tec screws

15. Our engineer will train your nominated staff in the unit operation and maintenance
procedures.

16. Our engineer will obtain a signature on the delivery paperwork and leave site via
designated route.

For Risk assessments refer to the generic RAMS document supplied

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Operation

operating Philosophy

The system will only operate when the Settlement Tank is primed withwater.

1. The parts are to be lifted on to the system using onsite cranes. The jet wash
can then be used to wash down the system
2. When finished press the push button and the system will wash down for a
set time.
3. The recovery pump is float operated and will start when required

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Power and Water

Power

The mains power can be supplied either from mains or from a suitably sized generator. The
connection should be made by a site electrician or contractor. Wheelwash will NOT connect
mains power unless pre requested, in which an additional charge will be requested for an
electrical engineer.

Power requirement- 380-420v, 50HZ 3 phase supply on a minimum 40a D-type/D-curve

breaker
Generator size- 40kva dedicated (minimum)
Connection- Client to wire through a stuffing gland in the base of the panel and hardwire into
the isolator. And also to the jet wash unit

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Water

Every Unit requires a fresh supply of water, fed from a mains supply, or from a treated site
water source. {Recommendation pH 5 – 9 / ppm 100}

The tank has a ¾” mains water valve with protruding male thread for site to connect supplies
too. The mains connection is typically at the clean end of the tank closest to the pump. Refer
to the General arrangement for guidance.
The jet wash unit has a 1” mains water fitting attached to it

Every system has either an A-A or A-B rated air gap which complies with WRAS regulations.
The minimum flow and pressure required for a sufficient supply is around 15 Liters Per
minute. At around 1 bar pressure. This is typical in most homes.
The system is supplied with a low level float switch to prevent the main wash pump from
operating if there is no or insufficient water. In this event, the “Water Low Level” light on the
control panel will illuminate and the warning beacon on the top of the pump house will flash.

If a mains water connection isn’t available, then there may be issues with performance. The
system loses a percentage of the wash water per wash cycle. This amount depends on site
variables such as wind and driver behaviour. If the system runs low on water, then it will not
operate until the tank is sufficiently full. If a mains supply isn’t available. We recommend
regular checks and a bowser on standby when required.

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Cleaning and Maintenance

Cleaning and maintaining your system will ensure its optimum performance and prolong its
life. The frequency of the suggested cleaning and maintenance regime can be adapted to suit
local conditions. As part of the installation and commissioning process, the Installation
engineer will provide additional information and training on site to assist in this regard.
General Guidelines: Daily
• Visually inspect the wash platform for any debris that can be manually removed.

• Check all spray nozzles for blockages. To remove blockages, unscrew the nozzle,
clean, and replace. Note the orientation of the nozzle as this could affect the spray
pattern of the unit when in operation.

• Check all water levels are adequate (this will be self-maintaining if the unit is
connected to a central water supply).

• Inspect for damage through incorrect use such as, but not exclusively, bent
pipework, damage to grids or side screens.

• Check for silt accumulation around the recovery pump located in the sump.

Weekly
• Isolate the system then dry wipe the sensor clean with a soft cloth to ensure proper
activation. Ensure it is put back in the correct position.

Monthly
• Isolate the mains power and check all electrical cables for security of
attachment and condition.

• Check for damaged bumper bars and tighten any bolts as required.

• Check the wash platform for signs of large debris particles. These can be
removed by lifting the internal grids from the wash platform and removing the
debris manually.

Periodically, When Required

• Open the drain valve at the base of each chamber in the settlement tank to check the
viscosity of the discharged material. If the discharge is runny, shut off the valve. If
there is semi-solid material or nothing being discharged, the silt has accumulated to
the extent it requires removal by either:
o Using a vacuum tanker to remove the silt deposits in the tank using the
drains fitted.
o Manual removal by either hand or power tools

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 The table below details items that should be checked

Check Details
Wash A visual inspection is made for signs of damage to the steel work on the wash platformgenerally. This
Platform includes the condition of welds, condition of the deflector bars (if present), walkway and nozzles
Check all spray nozzles for blockages or damage

Check the unit has the correct number of nozzles, nozzle position and type
Remove all nozzles, entirely flush system and replace worn nozzles as required
Check all lifting points

Washdown Pressure test checking pump efficiency and impeller wear.

Pump Take pressure readings at the nozzle to prove the whole system is working efficiently.
Push button Check the operating performance, the waterproof connectors, condition of cable

Side Check all remaining steelwork on equipment directly associated with the wash platform for signs of
screens/ obvious damage and general weld condition
Sump
Clear sump of any obstructions
Waste Check condition of cable and check attachment is secured
Water
Recovery Check pump and ensure that impellor it is moving freely
Pump
Check efficiency of the pump and sump, removing any obstructions

Settlement Visually inspect steelwork for signs of damage and leaks, checking the condition of welds
Tank
The hoses and connections are checked internally and externally
Check operation of the discharge valves
Check attachment of hoses and cables to the recovery pump

Check for indications of frequency of cleaning

Electrical Check the main voltage supply

Testing Check connections are earthed/bonded
Check contactors/overloads for heat fusion and replace if necessary
Check equipment labels for visibility
Motor cables and terminals to be checked to ensure security
Check for corrosion on terminals
Check the control circuit voltage
Functional Check all control switches and push button functions are functioning correctly, checking operation of status
Test indication lamps
Change faulty lamps if necessary
Check the operation of the emergency stop function
Reset overload settings
Check operation of relays
Check MCBS
Check main control valves and assembly

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Troubleshooting

Your equipment has been factory tested mechanically and electrically prior to reaching you
on site.
Should you encounter any difficulties regarding its operation, however, please refer to the
guidelines below or call your local office for assistance.

Please be aware that opening and making physical changes to the control panel or pumps will
invalidate their warranty.

Common and easy-to-solve problems that may arise with your wheel washing equipment
should regular inspections and cleaning not take place.

The table below shows a selection of the most common reported issues along with a possible
solution. DO NOT attempt any repairs or alterations to the system if you are unqualified
and/or unequipped to do so. If the problem persists, call the Wheelwash head office and ask
to speak to a member of our customer service Team
Common Issue Description Things to check
The panel is without power • Check the electrical supply to the system (must
be done by a qualified electrician)
• Check the main rcd trip inside the panel (only
if trained and competent)
• Check the isolator is switched on, on the panel
facia.
• Check all emergency stops are pulled out
The low-level light is illuminated • Check the water level in the front
tank/chamber.
• Check the float inside the tank is free to move.
If not then clean inside the tank and try and
free the float
There is an alarm • Check for fault lights on the front of the panel
• Press the alarm mute and estop reset button,
this should cancel the alarm. If it resounds then
there may be a further issue
The wash pump is displaying fault • Check the mpcb trip inside the panel (only if
trained and competent). Reset the trip and retry
the pump. It may of just tripped due to a spike
in current draw
• Check the pump has a good supply of water
• Check the water in the tank is clean
• Check the pump is running the right way
• Check there is no obstruction to the outlet

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 The recovery pump is displaying • Check the mpcb trip inside the panel (only if
fault trained and competent). Reset the trip and retry
the pump. It may of just tripped due to a spike
in current draw
• Check the water in the tank is clean
• Check the pump is running the right way
• Check there is no obstruction to the outlet

The recovery pump is running but • The pump may be airlocked, remove the hose
not pumping from the tank and lay the hose on the floor, run
the recovery in hand/manual for a few seconds
to remove the lock. Reconnect the hose and test
• The pump may be running backwards
The washdown pump is running • With the extra and extreme systems fitted with
but there are no sprays hosereels check the switch on the front of the
panel is put into the sensor mode. If in hose
mode all water will be directed to the hosereel
• For all systems check all valves are open
between system and wash pump
• Check pump direction
Reduction in system pressure • Check there is sufficient water
• Check the water is clean
• Check whether the tanks need cleaning
• Check for obstructions to feed
• Check for damages to hoses and fittings
• If able check the direction of the wash pump
• Check that pipes are free from obstruction
(open the side pipe valves and flush)

If Problems persist or do not fall into the troubleshooting guide above please call our head
office and ask for a member of our customer service team

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Winter Maintenance

When temperatures are set to drop to near or below freezing and your system is going to be
sat idle. It is important to take various steps to ensure that the system remains operational.
Below is a selection of measure that must be taken to prevent costly issues arising. Some
steps may not be relevant to your equipment.
• Ensure the hoses are disconnected and the pipes are drained.
• Ensure the heater is on in the jet wash cabinet
• If a Mains water feed is fitted. Make sure it is protected against frost
• It may help to place a float in the tank, this can stop the surface water freezing

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Disclaimer

This equipment has been designed for the sole purpose of removing unwanted debris and
material from the mobile crane parts s and therefore must not be used for any other purpose
unless specifically authorised by Wheelwash or its agents.
Wheelwash will not accept liability for the misuse of this system.
This manual serves to act as a guide and all activities should only be carried out by people
who are trained and competent to do so

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Contact

Our Service Team is available to respond to any query or difficulty you may
encounter with your wheel washing system once installed on site. In our
experience, many issues can be resolved over the telephone.

Head Office Address

Wheelwash Limited
Units 1 and 2
Road Four
Winsford Industrial Estate
Winsford
Cheshire
CW7 3QN

Contact Information
Customer service

Tel: +44 1270214886

Email: [email protected]

Web: www.wheelwash.com

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Appendices

General arrangement.1

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General arrangement .2

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General shipping plan

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11kw wash pump data sheet

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