Castle 7900 User manual
INSTALLATION INSTRUCTIONS
61301604805 Rev. A
®
Castle
7900
FLOOR MOUNTED
CART WASHER
INSTALLATION
INSTRUCTIONS
®
Castle
7900 FLOOR LOADING
CART WASHER
Getinge/Castle, Inc.
1777 East Henrietta Road
Rochester, New Yor k 14623- 31 33
Phone: (800) 950-9912 USA
Facsimile: (800) 950-2570
INSTALLATION INSTRUCTIONS 61301604805
Rev. A (12/27/01)
Related Publication:
Operator Manual 61301604804
DESCRIPTION OF SYMBOLS AND NOTES IN MANUAL
The following symbols with related notes appear in this manual.
“Warning” notes alert the user to the possibility of personal injury.
WARNING
“Caution” notes alert the user to the possibility of damage to the equipment.
CAUTION
“Notes” alert the user to pertinent facts and conditions.
NOTE
NOTE
Castle
Copyright ©2001 by Getinge/Castle, Inc.
®
is a registered trademark.
This manual contains proprietary information of Getinge/Castle, Inc. It shall
not be reproduced in whole or in part without the written permission of
Getinge/Castle, Inc.
ii
Section 1 Installation Requirements
GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 1–1
MODEL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . 1–2
UTILITIES AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . 1–3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Hot Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Cold Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Overall Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
INSTALLATION ADVISORY . . . . . . . . . . . . . . . . . . . . . . . 1–4
WASHER OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Floor Mount vs. Pit Mount . . . . . . . . . . . . . . . . . . . . . . 1–4
Left Side vs. Right Side Controls. . . . . . . . . . . . . . . . . 1–4
Barrier Flanges and Service Enclosure . . . . . . . . . . . . 1–4
Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Seismic Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
SHIPPING CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . 1–5
TOOLS AND MATERIALS REQUIRED. . . . . . . . . . . . . . . 1–6
Table of Contents
Section 2 Installation
ASSEMBLE THE WASHER STRUCTURE . . . . . . . . . . . . 2–1
Install the Base/Sump Assembly . . . . . . . . . . . . . . . . . 2–1
Assemble the Washer Panels . . . . . . . . . . . . . . . . . . . 2–5
Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
Trim Panels (Non-Service Side) . . . . . . . . . . . . . . . . 2–12
INSTALL COMPONENTS ON TOP OF THE WASHER . 2–13
Dryer and Condenser Assemblies. . . . . . . . . . . . . . . 2–13
Power Floor Tilt Pulley System . . . . . . . . . . . . . . . . . 2–17
Transformer and Emergency Stop Switch
Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19
Rear Emergency Stop Switch . . . . . . . . . . . . . . . . . . 2–20
Plumbing Mounting Brackets. . . . . . . . . . . . . . . . . . . 2–21
61301604805 iii
INSTALL COMPONENTS ON THE OUTSIDE
OF THE WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Spray Manifold Drive Motor. . . . . . . . . . . . . . . . . . . . 2–23
Exhaust Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
Washer Light Assembly. . . . . . . . . . . . . . . . . . . . . . . 2–26
Front Dryer Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
Junction Box Assembly. . . . . . . . . . . . . . . . . . . . . . . 2–30
Dispenser Float Switch Junction Box . . . . . . . . . . . . 2–31
Front Emergency Stop Switch. . . . . . . . . . . . . . . . . . 2–32
Detergent and Rinse Aid Dispensers . . . . . . . . . . . . 2–33
Unload End Indicator Panel Box . . . . . . . . . . . . . . . . 2–34
Door Proximity Switches . . . . . . . . . . . . . . . . . . . . . . 2–35
Sump Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36
Return Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37
Circulation Tank Assembly . . . . . . . . . . . . . . . . . . . . 2–38
Wash Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
Tank Drain Valve, Tank Overflow, and Tank
Water Level Indicator . . . . . . . . . . . . . . . . . . . . . 2–40
Booster Heater Assembly . . . . . . . . . . . . . . . . . . . . . 2–41
Rinse Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43
Stainless Steel Plumbing. . . . . . . . . . . . . . . . . . . . . . 2–43
Black Iron (Steam) Plumbing. . . . . . . . . . . . . . . . . . . 2–44
Hot Water (Copper) Plumbing. . . . . . . . . . . . . . . . . . 2–44
Cold Water (Copper) Plumbing . . . . . . . . . . . . . . . . . 2–45
ELECTRICAL WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
INSTALL COMPONENTS ON THE INSIDE OF
THE WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49
Rear Dryer Ducts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49
Drive Chain Tension Idlers and Idler Bearings . . . . . 2–51
Chain Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . 2–52
Spray Manifold Supports and Manifold Assembly. . . 2–54
Manifold Cover and Spray Guard, Manifold Guard
Tubes, Wash Cart Tubes . . . . . . . . . . . . . . . . . . 2–56
Emergency Stop Switch Cables . . . . . . . . . . . . . . . . 2–58
FINAL INSTALLATION TASKS . . . . . . . . . . . . . . . . . . . . 2–60
Final Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2–61
Dispenser Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–62
Sanitary Barrier Flanges . . . . . . . . . . . . . . . . . . . . . . 2–64
Pit Covers (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 2–65
Service Area Enclosure (Option). . . . . . . . . . . . . . . . 2–66
Base Shrouds (Floor Mounted Option) . . . . . . . . . . . 2–67
Ramps (Floor Mounted Option). . . . . . . . . . . . . . . . . 2–68
iv
7900 Floor Loading Cart Washer
Exhaust Connection. . . . . . . . . . . . . . . . . . . . . . . . . . 2–68
Plumbing System Connections . . . . . . . . . . . . . . . . . 2–68
Electrical Supply Connection. . . . . . . . . . . . . . . . . . . 2–69
Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–69
61301604805 v
vi
General Description
Section 1 Installation Requirements
The Castle 7900 Floor Loading Cart Washer is a fully automatic, floor
loading, hydro-spray cart washer with dual side-by-side wash compartments
that is used to clean and decontaminate case carts, stands, utensils,
containers, tote boxes, and similar bulk items.
Processing cycles are set up using a programmable controller equipped
with a touch screen interface (touch control panel). Four cycle definitions
are possible. The operator needs only to select and start a cycle.
A standard cycle consists of the following sequential phases: wash, rinse,
exhaust, and drying. The length of a cycle’s phase can be adjusted at the
touch control panel.
The washer can be installed in a shallow pit or at floor level. When installed
in a pit, the floor of the washer’s chamber is level with the room floor, which
allows the direct loading and unloading of carts. When the washer is
installed at floor level, the floor is higher than the room floor. Ramps are then
provided as standard equipment to facilitate loading and unloading.
The washer is designed for pass-through operation. Items to be cleaned are
placed in the washer’s compartment through one of the load end doors.
After cleaning, the items are removed from the opposite end of the washer
through the unload end doors.
The washer is generally installed in a facility’s decontamination room with
the unload end doors opening out into a clean-preparation area. The unit is
110" (2794 mm) wide and 108" (2743 mm) high. The washer is currently
available in only one compartment size: 98" (2489 mm).
Figure 1–1. 7900 Floor Loading Cart Washer
HW-006
61301604805 1–1
Installation Requirements
Model Identification
The rating plate for a 7900 washer is affixed to the inside of the control box
door.
Record the model type and serial number (S/N) from the rating plate.
TYPE: _________________________________
SERIAL NO: ____________________________
Include the model type and serial number when communicating with
Getinge/Castle.
Figure 1–2. Rating Plate Location
1–2
Utilities and Specifications
7900 Floor Loading Cart Washer
Electrical
Hot Water
Cold Water
Steam
Condensate
208 V, 60 Hz, 3 phase, 100 A, 5-wire with neutral and ground
240 V, 60 Hz, 3 phase, 60 A, 4-wire with ground
380 V, 50 Hz, 3 phase, 60 A, 4-wire with ground
415 V, 50 Hz, 3 phase, 60 A, 4 wire with ground
480 V, 60 Hz, 3 phase, 30 A, 4-wire with ground
600 V, 60 Hz, 3 phase, 30 A, 4-wire with ground
1" IPS (25.4 mm)
40–60 PSI (276–414 kPa)
780 gal/hr (2953 l/hr) demand rate
12 gal/cycle (47 l/cycle) consumption
120° F min. (49° C)
3/4" IPS (19 mm)
40–60 PSI (276–414 kPa)
600 gal/hr (2271 l/hr) demand rate
10 gal/cycle (38 l/cycle) consumption
1-1/2" IPS
40–50 PSI (276–345 kPa)
1200 lb/hr demand rate
85 lb/cycle consumption
3/4" IPS (19 mm)
Drain
Exhaust
Weight
Overall Size
3" IPS (76. 1 mm) minimum
45 gal/cycle (170 l/cycle)
12" square flanged (304.8 mm)
3
/hr (22.7 m3/hr)
800 ft
1/4" static pressure
1800–2200 lb (811–991 kg) approximate
108" high x 110" wide x 106" long (2743 mm x 1321 mm x 1829 mm)
61301604805 1–3
Installation Requirements
Installation Advisor y
A 7900 washer is assembled at the factory, tested, then disassembled for
shipment. Extensive on-site reassembly is required. The installation
instructions in this manual are intended as the primary reference for
accomplishing this reassembly. Every effort has been made to make this
information as accurate as possible. No two washers are exactly alike,
however.
Each washer is uniquely configured to meet the demands of its operational
site. These demands most often necessitate variances in the location of a
washer's exterior components. These variances, in turn, impact the
configuration of related plumbing and electrical wiring assemblies.
For this reason, some instructions or illustrations carried here may not
reflect the actual location or configuration of selected component
assemblies for a specific site. Where applicable, installers should refer to
specifications contained in the product information documents, such as
Rough-In and Assembly drawings, that have been forwarded to local
Getinge/Castle product support personnel.
Wa sher Options
Floor Mount vs. Pit Mount
Left Side vs. Right Side
Controls
Barrier Flanges and Service
Enclosure
Electrical Service
Printer
There are a number of options that may be included with your washer.
These options affect the procedures that apply to your specific installation.
A floor mounted washer will require the installation of ramps to provide
access to the washer. The two options may have different plumbing
specifications.
The location of controls on your washer will also determine the location of
the service area, as well as the barriers flanges and service enclosure that
may be provided with your washer.
Your installation may have barrier walls at the load or unload end of the
washer, or both, as well as have a service enclosure. These structures will
be designed specifically for your site.
The electrical service at your facility determines the specific high voltage
devices (motors, pumps, etc.), transformer, and control box provided with
your washer.
If your washer has the printer option, the printer will already be mounted on
the control box.
Seismic Anchoring
1–4
Washers with the seismic anchoring option have base/sump assemblies
that are mounted differently.
Shipping Configuration
7900 Floor Loading Cart Washer
A disassembled 7900 washer is shipped on 4 to 8 pallets of various lengths.
The maximum size of any one pallet may be as large as 10' x 5'
(approximate). For stability during transit, selected pallets are often pegged
(with nails) to the floor of the truck.
Moving the disassembled washer from the truck to the installation site
requires the use of any available combination of the following:
• fork lift
• pallet jack
• dollies
• Johnson bars
A sufficient supply of commonly used fasteners (#10-32 and 1/4-20, for
example) is bagged for shipment. Speciality hardware and fasteners (door
latches and hinges, for example) are labeled and bagged separately for
shipment.
Many disassembled items, such as plumbing and panel sections, are
marked with handwritten numbers with black grease pen to identify their
location, orientation, or connection points. Take care not to inadvertently
smudge or erase these identifying marks.
61301604805 1–5
Installation Requirements
Tools and Materials Required
The following tables list the specific tools and materials required at the
installation site. Items marked with an asterisk * are supplied by Getinge/
Castle.
Table 1–1. Tools Required
Tool Quantity
Common hand tools Assorted
Bar clamp 2
C-clamp 2
Johnson bar 1
Pry/pinch bar 2
Caulking gun 1
1/4-20 tap, short 1
1/4-20 tap, long 1
10-32 tap, short 1
10-32 tap, long 1
#7 drill bit 2
#21 drill bit 2
Torpedo level 1
4’ level 1
Scratch awl 2
Table 1–2. Materials Required
Material Quantity
* Silicone adhesive 8 tubes
* Silicone primer 1 pt
* Thinner 1 pt
* Polish 1 container
* Stainless steel nuts, bolts,
washers, lock washers
Assorted
1–6
* Wire nuts, ti e wraps Assorted
* 3" x 6" stainless steel shims:
• 12 ga
• 14 ga
• 16 ga
• 18 ga
12
12
12
12
7900 Floor Loading Cart Washer
Material Quantity
1" x 4" x 6" wood block 2
2" x 4" x 52" wood block 4
The following items are recommended for use if a floor mounted washer is
to be assembled out-of-position, then moved to its intended operational site:
* 4’ x 8’ x 1/8" Masonite, smooth 2 to 3
Pipe, rigid 3/4" x 60" L 4
The Masonite protects the floor during assembly . The pipe is used to roll the
washer into position after assembly.
61301604805 1–7
Installation Requirements
1–8
Assemble the Washer Structure
This section contains procedures for assembling the basic structure of the
washer compartment. Refer to the following sections.
• “Install the Base/Sump Assembly” on page 2-1
• “Assemble the Washer Panels” on page 2-5
• “Door Assembly” on page 2-10
• “Trim Panels (Non-Service Side)” on page 2-12
Section 2 Installation
Install the Base/Sump
Assembly
NOTE
WARNING
General Instruction
The base/sump assembly is shipped in two halves that you must assemble
on the site. If the load or unload ends of the base are not marked, check the
configuration of the base’s sump against the rough-in drawing to determine
the correct orientation.
Some installation sites may have an existing wall in close proximity to the
non-service side of the washer that could interfere with the assembly of the
washer's side panels. If this situation exists, you will have to seat the base
temporarily out-of-position until the side, top, and non-service side trim
panels are assembled. You can then maneuver the unit to its operating
position, where you can level and anchor it, if required.
Installation
Silicone primer (orange) is extremely flammable, harmful if
swallowed or inhaled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eye wear when using this
product. Keep it away from heat, sparks, and flames. Store
upright in a cool place (less than 30°C (85°F). Keep the
container closed when not in use. Use only in a well-ventilated
area. Avoid breathing vapors.
Silicone Primer stains/discolors clothing, stainless steel surfaces, flooring,
CAUTION
etc. Avoid accidental spills. Avoid spreading this substance onto exterior
surfaces of the washer.
61301604805 2–1
Installation
1/4-20 FASTENERS
(4 PLACES EACH END)
REAR BASE HALF
FRONT BASE HALF
1. Clean all mating surf aces w here the tw o ha lv es of the base
meet with thinner, treat with silicone primer, and then apply
a generous amount of silicone sealant.
2. Move the two halves of the washer base together and
attach the halves together:
a. At each end , secure the front and rear halves together
with 1/4-20 fastene r s (four each 1/2" hex head bolts
and lock washers) as shown in Figure 2–1.
Figure 2–1. Attaching Ends of Base Assembly
2–2
WARNING
b. Use a fork lift to raise one end of the as sembly.
Make sure that the base/sump assembly is properly supported
and secured before getting underneath the assembly.
c. Underneath the sump, secure the halv es to ge the r wi th
5/16-18 fasteners (1-1/2" hex head bolts and lock
washers), two each at six places, as shown in Figure
2–2.
7900 Floor Loading Cart Washer
5/16-18 FASTENERS
(2 EACH AT 6 PLACES)
WOOD SUPPORT
FORK LIFT
Figure 2–2. Attaching Base Assembly Underneath
3. Move the base assembly into its final operating position.
4. Check the base for level.
Use the 4' level to check from all sides of the base and in
all directions. Adjust the level if necessary using the
stainless steel shims that are provided.
CAUTION
Failure to critically level the base will result in the misalignment of mounting
holes and will make assembly of the washer panels difficult.
If seismic anchoring is required, a 3" flange (with anchor bolt holes) is
welded to the bottom frame of the base for this purpose.
5. Drill holes for the anchors through the holes in the base
flanges.
Table 2–1. Drilling Specifications
Drill Bit Size
Embedment
Torque 50 ft.-lb.
1/2
1 1/4
"
to 3 1/2
"
"
6. Secure the base to the floor using the 1/2 x 4-1/2" stud
anchor bolts provided.
61301604805 2–3
Installation
FLOOR LIFT WELDMENTS
TRACK/FR AME ASSEMBLY
FLOOR GRATES (6)
CHANNEL FILLERS
THRESHOLD ASSEM BLI ES
(2 PLACES AT EACH END)
(2 PLACES AT EACH END)
7. Lay the two track/frame assemblies into the base so that
the floor lift weldments are to wa rd the center of the w asher ,
as shown in Figure 2–3. Base/Sump Components
Figure 2–3. Base/Sump Components
8. Lay the six floor grates in the tracks into the track/frame
9. Lay the masoni te sheets over the floor grates to protect
10. Position the four channel fillers (two on each end of the
11. Install the four threshold assemblies in the floor.
NOTE
There are two sizes: the longer threshold is installed on the rear (nonservice side) of the washer, one on each end. The shorter threshold is
installed on the front (service side) of each end.
assemblies.
from scratches while you complete the installation.
washer) in the floor and secure each with two #10 -32 x 3/8"
phillips head screws.
a. Position one threshold assembly in its appropriate
location with the gasket facing toward the inside of the
washer.
b. Secure the assembly to the washer base with two #10-
32 x 3/8" phillips head screws.
2–4
7900 Floor Loading Cart Washer
Assemble the Washer Panels
Objective
Assemble the door, side, and top panels. Install the required number of
interior side panel seam cover strips and the center mounting bracket.
There are six side panels and three top panels. Each of the end (door)
panels in turn consists of five panels: three vertical panels and two
horizontal panels (one over each door) that connect to the vertical panels.
Door panels and side panels are marked to indicate their location. Top
panels are not marked (check this). The unload end top panel has two
rectangular cutouts for the condenser mountings, a cutout for one of the rear
dryer ducts, and numerous threaded holes on its exterior surface for
mounting the dryer assemblies. The load end top panel one cutout for the
second rear dryer duct and has fewer mounting holes (for a transformer and
plumbing mounting plates). the middle panel has mounting brackets for the
floor tilt actuators. The width of a top panel is the width of the washer (92").
The side panels have 7/16" diameter holes that carry 3/8" thru bolts (five on
each side of the washer) to hold the panels together. The top panels have
holes to carry five thru bolts.
There is no established order to follow for panel assembly. You can start
from the load or the unload end. You can assemble all the vertical panels
first, followed by the top panels; or you can add individual top panels as you
erect the vertical panels. The method illustrated below starts from the load
end and progressively adds top panels as the vertical panels are erected.
NOTE
WARNING
You must clean all mating surfaces with thinner, then treat with silicone
primer, and then apply a generous amount of silicone sealant.
Installation
Refer to Figure 2–4. Assembling the Washer Panels for help to identifying
washer panels.
You must clean all mating surfaces with thinner, then treat with silicone
primer, and then apply a generous amount of silicone sealant.
Silicone primer (orange) is extremely flammable, harmful if
swallowed or in haled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eye wear when using this
product. Keep it away from heat, sparks, and flames. Store
upright in a cool place (less than 30°C (85°F). Keep the
container closed when not in use. Use only in a well-ventilated
area. Avoid breathing vapors.
61301604805 2–5
Installation
CAUTION
Silicone Primer stains/discolors clothing, stainless steel surfaces, flooring,
etc. Avoid accidental spills. Avoid spreading this substance onto exterior
surfaces of the washer.
Figure 2–4. Assembling the Washer Panels
1. Clean all mating surfaces with thinner, treat with silicone
primer, and then apply a generous bead of silicone sealant
wherever a wall panel is atta ched to the base or to ano the r
panel.
2. Attach the load end door panels to the base.
There are three vertical panels. The service side panel is
narrow and has thr ee mounting holes at the top to a ttach to
the horizontal panels. The middle panel is narrow and has
six mounting holes at the top. The non-service-side panel
is wide.
a. Position a vertic al panel.
b. Secure the bottom legs of the panel to the base frame
with 1/4-20 fasteners (1/2" hex head bolts, flat
washers, and lock washers).
c. Repeat steps a and b for the other vertical panels.
d. Secure each horizontal panel between two vertical
panels with 1/4-20 fasteners (six each 3/4" hex head
bolts and lock washers).
2–6
7900 Floor Loading Cart Washer
3. Attach the load end sid e panels to the bas e and to the l oad
end door.
a. Position one of the load end side panels.
b. Partially insert five 3/8" diameter thru rods through the
7/16" diameter holes to stabilize and align the side
panel with the door panel.
c. Use pipe clamps to draw the panels tight as shown in
Figure 2–5.
Figure 2–5. Installin g Washer Panels
d. Secure the bottoms o f the side p anel to the ba se frame
with 1/4-20 fasteners (1/2" hex head bolts and lock
washers).
e. Repeat steps a through d for the other load end side
panel.
4. Attach the middle side panels to the base and to the load
end panels.
a. Remove the pipe clamps.
b. Position one of the middle side panels.
c. Extend the five thru bolts to stabilize and align the
panels with the load end side panel.
d. Attach the pipe clamps to draw these pan els tight.
e. Secure the bottoms of the middle Side panel to the
base frame with 1/ 4-20 fasteners (1/2" hex head bolts
and lock washers).
61301604805 2–7
Installation
f. Repeat steps a through d for the other middle side
panel.
g. To ensure side panel alignment, attach C-clamps and
2x4" wooden blocks across the top edge of the
adjoining panels at the vertical seam.
5. Attach the load end top panel to the door panel and to the
load end side panels.
a. Position the load end top panel.
b. Secure the top panel to the door and load end side
panels with 1/4- 20 fast eners (1-3/4" hex hea d bolts, fl at
washers, and lock washers).
c. Partially i nsert the five remaining 3/8" diameter thru
bolts through the 7/16" diameter holes in the panel.
6. Attach the unload end side panels to the base and to the
middle (or load end) side panels.
a. Remove the pipe clamps.
b. Position one of the unload end side panels.
c. Extend the five thru bolts to stabilize and align this
panels with the previously erected panels.
d. Attach the pipe clamps to draw these panels tight.
e. Secure the bottom of the unload end side panel to the
base frame with 1/ 4-20 fasteners (1/2" hex head bolts
and lock washers).
f. Repeat steps a throug h d f or th e other u nload end si de
panel.
g. Move the C-clamp and 2" x 4" wooden block
assemblies to the vertical seams created by the
installation of t hese panels.
7. Attach the middle top panel to the load end top panel and
to the middle side panels.
a. Position the middle top panel.
b. Extend the two thru bolts.
c. Secure this panel to the mid dle side panel s with 1/4-20
fasteners ( 1-3/4" hex head bolts, flat washer s, an d loc k
washers).
2–8
7900 Floor Loading Cart Washer
8. Attach the unload end door panels to the base and to the
unload end side panels.
a. Remove the pipe clamps.
b. Position a vertical panel.
c. Secure the bottom legs of the panel to the base frame
with 1/4-20 fasteners (1/2" hex head bolts, flat
washers, and lock washers).
d. Repeat st eps a and b for the other vertical panels.
e. Secure each horizontal panel between two vertical
panels with 1/4-20 fasteners (six each 3/4" hex head
bolts and lock washers).
f. Extend the ten side thru bolts.
g. Attach the pipe clamps to draw the door panels tight.
h. Secure the thru bolts at both ends of the washer with
3/8" acorn nuts and flat washers.
9. Attach the unload end top panel to the unload end side
panels and to the unload end door panel.
a. Remove the C-clamp assemblies.
b. Position the unload end top panel.
c. Extend the five thru bolts.
d. Secure this panel to the unload end door panels and
side panels with 1/4-20 fasteners (1-3/4" hex head
bolts, flat washers, and lock washers).
e. Secure the thru bolts at both ends of the washer with
3/8" acorn nuts and flat washers.
10. Inside the washer, attach the four panel seam cover strips
over the vertical seams between adjoining side panels
using #10-32 screws and lock washers.
11. Attach the center mounting plate inside the washer, from
the load end to the unload end.
a. Align the holes in the mounting plate with the threaded
holes along the center of the washer.
b. Secure the mounting plate to the washer with six 1/4-
20 fasten ers ( 3/ 4" hex head cap screws, lock washers,
and flat washers). The mounting plate is attached to
the top panels in four places and once in each center
end panel.
61301604805 2–9
Installation
HINGE MOUNT
DOOR HINGE
(3 PER DOOR)
DOOR LATCH
RETAINERS
(2 PER DOOR)
DOOR HANDLE
DOOR LATCH
(2 PER DOOR)
(3 PER DOOR)
Door Assembly
Objective
Attach hardware to the doors and related door panels. Install two doors
each on both the load and unload ends of the washer. Plumb and square all
four doors.
Installation
Refer to Figure 2–52. Door Assembly.
Figure 2–6. Door Ass embly
2–10
WARNING
NOTE
A washer door is heavy and awkward to handle. Take care to
avoid crushing or strain injuries.
The washer may be shipped with all of the hardware (hinges, latches, striker
plates, etc.) already mounted on both the doors and the door panels. If so,
start with step 3 below.
7900 Floor Loading Cart Washer
1. Attach the following items to each door panel:
a. Attach three hinge m oun ts u s ing ni ne 1/ 4- 20 fasteners
(1" phillips head screws).
b. Attach two door latch retain er s, two door latch shims,
and two spacers using four 5/16-18 fasteners (2" hex
head cap screws and lock washers).
2. Attach the following items to each door:
a. Attach two door latches using four 5/16-18 fasteners
(1" hex head cap screws and lock washers).
b. Attach three hinges using twelve 1/4-20 fasteners
(1" phillips head screws).
c. Attach the door handle using four 5/16-18 fasteners
(1" hex head cap screws and lock washers).
3. Mount the door on the washer.
a. Raise and maneuver the door until its hinge posts are
in vertical alignment over the three hinge mounts
attached to the door panel.
NOTE
b. When aligned, lower the door and properly seat al l
three posts in their respective mounts.
4. Repeat steps 1 through 3 for the other door assemblies.
5. Check all door openings for plumb and square. If
necessary, use the shims that are provided.
After the plumb and square of all doors is checked and corrected, it may be
easier to lift the doors off their hinges and set them aside until the end of the
installation of the washer.
61301604805 2–11
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