Karcher HD 4000 C, HD 6000 C User Manual

Download

HD 4000 C

1.509-035

1.509-515

HD 6000 C

1.967-045

Operating Instructions

5.956-648 A 10369 (06/00)

Operating Instructions

Please read before operating the unit,

and keep in a safe place for future reference.

Proper disposal – for the sake of our environment

Packaging materials

The packaging components used to ship the unit are composed of wood and cardboard, i.e., environment-friendly materials, both of which can be easily sorted out and collected for recycling.

Operating media

Engine oil

The equipment contains engine oil. Any waste oil collected during an oil change, as well as any oil-water mixture exiting from the machine in conjunction with a leak, must be collected and delivered to a wasteoil collection point.

Important!

Waste oil may be disposed of only at designated collection points. Please take used oil to these special installations. Remember: It is an offence to contaminate the environment with waste oil!

Cleaning detergents

All Kärcher cleaning detergents, as indicated by the ‘ASF’ designation, are designed to be separator-friendly. This means that they do not impede the function of oil separators. A listing of the recommended cleaning detergents is featured in the “Accessories” section.

HD 4000 C / HD 6000 C

Table of Contents

English

A. For Your Safety

1. System Operating Hazards

2. Safety Information and Instructions

3. Danger Sources

4. Hazards posed by Accessories

5. Noise Protection

6. Workplaces

7. Authorised Operators

8. Personal Protective Equipment

9. Safety Measures on the Installation Site

10. Protective Devices

11. Emergency Drill

12. Guidelines and Regulations

13. Proper Use of the Equipment

B. System Operation

1. Operating Controls

2. Using Emergency-STOP

3. Starting the System

4. Stopping the System

5. Frost Protection

6. System Shut-Down

D. Specifications

1. Equipment Features

2. Connected Loads

3. Dimension Diagram

E. Maintenance

1. Maintenance Contract

2. Maintenance Schedule

3. Removing the Cover

4. Decalcification

F. Trouble Shooting

G. System Installation

1. Placement

2. Connections

3. High-pressure Installation

4. Hard-water Treatment

5. Preparations for Commissioning

6. Space Assignment Plan

H. Accessories

C. System Functions

1. Flow Diagram

2. Description of Functions

J. Customer Service

5.956-648 A10369 (06/98)

English

A. For Your Safety

HD 4000 C / HD 6000 C

1. System Operating Hazards

This system is equipped with an overpressure protection feature which was subjected to a safety inspection. Improper operation or abuse of this feature constitutes an hazard to health and life of the operator and/or third persons.

Any persons charged with the installation, commissioning, operation, maintenance or service of the machine are obligated:

to be appropriately qualified

to diligently observe these Operating Instructions

2. Safety Instructions and Information

Throughout the present Operating Instructions the following symbols are used:

Danger!

Denotes an immediate and present danger. Failure to observe this notice could lead to severe injury or death.

Caution!

Denotes a potentially hazardous situation. Failure to observe this notice could lead to minor injuries or property damage.

3. Danger Sources

Sections of the water volume contained in the system are under high pressure. Highpressure water jets may exit from damaged system components, posing injury and/or scalding hazards.

General Hazard Overview

Danger!

Injury hazard through exiting water jet of high-pressure or high-temperature water. Even after the Emergency-STOP master switch has been activated, the system contains high pressure. After a system stop, release remaining system pressure by opening a high-pressure gun.

Burn injury hazard through hot system components. During hot-water operation, do not touch non-insulated pipe installations and hose couplings. Grasp the jet lance by the grip surfaces only.

Injury hazard through flying debris. Flying debris or objects can cause injury to persons or animals. Never aim the water jet at fragile or loose objects.

Explosion hazard The use of this system in enclosed indoor areas is prohibited.

Important!

Denotes operating hints and important information.

Explosion hazard Injury hazard arising from system damage. Beside water, no other liquid media may be used. This also precludes the introduction of flammable or corrosive liquids to the system.

Health hazard through cleaning detergents. Due to the possible adding of detergents to the system water, the water exiting from the system must not be used as drinking water.

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

Hazards posed by defective equipment

Danger!

Injury hazard through exiting water jet of high-pressure or high-temperature water. Before each system start, check highpressure hose, tubing, valves and highpressure lance for damages. Replace leaking components immediately, and correct any leaks in connections or couplings without delay.

Hazards during work on the system

Repair or service work may be carried out only by:

n manufacturer-approved customer service

depots

n trained professional personnel

Danger!

Injury hazard through exiting water jet of high-pressure or high-temperature water. Release system pressure before performing work on system components. In the case of hot-water operation, allow unit to cool before commencing work.

A. For Your Safety

English

Danger!

Injury hazard. Hazard of chemical burns caused by cleaning detergents. Scalding hazard through hot water. Do not aim waterjet at persons or animals. Strictly observe safety instructions on detergent labels.

Accident hazard due to hidden damage. Clean tires and valve stems from a minimum distance of 30 cm.

Injury hazard through exiting water jet of high-pressure or high-temperature water. Only original Kärcher high-pressure hoses are optimised for the demanding use in the system. No warranty claims are accepted in the event that other types of hoses are used.

The waterjet exiting from the spray lance causes a recoil force which is deflected upward by the downward angle of the spray lance nozzle.

Electric shock hazard. Switch OFF and secure master switch before commencing work on the system.

4. Hazards posed by Accessories

A sharp and powerful waterjet exits from the orifice of the spray lance nozzle. When operating the spray lance, keep in mind the following:

Danger!

Deadly electrical shock hazard. Do not aim the waterjet at

–

electrical devices and systems

–

at any parts of the system proper All live components within the working area must be spray-water protected.

Injury hazard through recoil action. The force of the recoil action may throw you off balance, and you may fall down. The spray lance may whip around and injure persons standing nearby. Select a secure foothold position and firmly grasp the handgun. Never wedge the handgun trigger in the open position.

Injury hazard through defective hose coupling. Check hose coupling daily for tightness and absence of leakage.

5.956-648 A10369 (06/98)

English

Danger!

Health hazard posed by toxic substances. Do not spray clean the following materials, because substances known to pose a risk to human health may be swirled up:

– Materials containing asbestos – Materials that could possibly contain

toxic substances hazardous to human health.

Poisoning hazard Chemical burn hazard Fire hazard Protect cleaning detergent storage against access by unauthorised persons. Observe all safety instructions for cleaning detergents.

A. For Your Safety

HD 4000 C / HD 6000 C

7. Authorised Operators

The operation of the system is restricted to persons over the age of 18 who have been properly instructed. An exception is made with youths over age 16 who need to operate the system as part of their training, and if such use of the system is duly supervised (Regulation VBG 87).

Additional local ordinances must be observed.

The system operator is responsible for third persons within the working area.

The areas of responsibility covering the various operator functions on the machine must be precisely delineated and stringently observed. Overlapping areas of competence present a safety risk.

The system owner is responsible for:

5. Noise Protection

The system generates a sound level of approximately 80 dB (A), with the use of sound dampening, this is reduced to 70 dB (A). Therefore, hearing protection at the system installation site is not mandatory.

However, at the workplace proper, (i.e., handgun) a noise hazard must be assumed to be present under normal circumstances (pursuant to Regulation VBG 87). Accordingly, suitable hearing protection must be worn while working in noisepolluted areas.

6. Work Stations

The operator’s work station is located at the instrument panel. Dependent on the system configuration, additional work stations are constituted by the accessories (spraying devices) that are connected to the system taps.

n making the Operating Instructions

available to the system operator

n ensuring that the operator has read and

understood the Operating Instructions

8. Personal Protective Equipment

When cleaning resonating components, hearing protection must be worn to prevent hearing loss.

n For protection against spray-water, water

repellent protective clothing must be worn.

9. Safety Measures on the Installation Site

Danger!

Danger of Death posed by system components toppling or falling over. To assure reliable footing, the system must be securely anchored on a level and firm base.

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

A. For Your Safety

English

10. Protective Devices

System operation is stopped by the Emergency-STOP master switch located at the instrument panel.

n Inadvertent contact with all hot system

components is prevented by the protective housing.

11. Emergency Drill

Disable the system by activating the Emergency-STOP master switch.

n Release water pressure by opening a

high-pressure spray gun.

12. Guidelines and Regulations

In the Federal Republic of Germany the operation of this system is subject to the Regulations for Liquid Spraying Devices (VBG ZH 1/406), published by the Principal Organisation of the Commercial Employers’ Liability Insurance Association. The guidelines may be ordered from Carl Heymann Verlag KG, Luxemburger Strasse 449, D-50939 Cologne, Germany.

Among other requirements, the Regulations foresee a system inspection by a certified professional in intervals of no more than 12 months. The results of the inspection must be documented in writing.

A testing log for entering the inspection results is located at the end of this manual.

Kärcher customer service engineers qualify as certified professionals, and are authorised to carry out the aforementioned inspection.

Please also observe local regulations concerning electrical connections, water supply and waste-water connections. The applicable regulations may be obtained from the respective utility companies.

Any connection and installation work in accordance with the aforementioned regulations must be carried out by the Kärcher customer service or authorised contractors.

13. Proper Use of the Equipment

This system conveys water under high pressure to high-pressure cleaning stations situated downstream of the system. The system is designed for stationary installation in a dry indoor environment. At the installation site, a water and mains power connection satisfying the criteria stated in the Specifications section of this manual must be provided. The environmental temperature at the installation site must not rise above 40 °C. The high-pressure water is distributed via a fixed-installation tubing network.

Only clean water may be used as a highpressure medium. Water contamination of any kind would cause premature component wear or lead to deposits within the system.

In the presence of water hardness exceeding 15°dH appropriate water treatment measures for lowering the hardness point.

The use of recycling water requires prior discussion with Kärcher.

Also applicable are the (German) Regulations governing liquid spraying devices, VBG 87, and the Ordinance on Hazardous Substances VBG ZH 1/220 (GefStoffV).

5.956-648 A10369 (06/98)

English

1. Operating Controls

3 8 6 7 1 4 5 2 9

B. System Operation

HD 4000 C / HD 6000 C

1 Emergency-STOP master switchQ1Switches the system ON and OFF; also serves as

Emergency-STOP switch.

2 Unlock button with operational

indicator light

3 Pressure gauge Indicates the pressure downstream of the pump; also

4 Indicator lamp – Motor Fault Illuminates when the motor protection switch has tripped,

5 Indicator lamp – General Fault is illuminated for:

6 Elapsed-hour meter Counts the total pump operating hours.

7 Warning Label Danger!

starts the availability time of the pump by the press of the button serves for resetting after malfunctions is alight when the pump is running and during the availability time

serves as function control.

switching off the motor (motor fault).

– motor malfunction – drop in system pressure (at high-pressure outlet) – water temperature too high – motor temperature or oil temperature too high insufficient water – admission pressure of hot-water pump too low.

Danger of Death by electrical shock! Control cabinet may be opened by trained personnel only

8 Control cabinet closure Used for opening the control cabinet

May be opened by trained personnel only

9 Fault indication on the printed

1 2 3 4

circuit board

indicates following malfunctions: 1 insufficient water, water temperature too high 2 motor or oil temperature too high 3 admission pressure of hot-water pump too low 4 drop in pressure at high-pressure outlet

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

B. System Operation

2. Using Emergency-STOP

Turn the Emergency-STOP master switch to the 0 (OFF) position.

Open the handgun until the water pressure has dissipated.

Using the locking feature, secure the handgun against being opened inadvertently.

3. Starting the System

Before commissioning this system it is essential that you read the Operating Instructions, and to be certain that you have understood all the information presented herein.

Danger!

Injury hazard through exiting water jet of high-pressure or high-temperature water. Before each system start, check high-pressure hose, tubing, valves and high-pressure lance for damages. Correct any leaks in connections or couplings without delay.

Poisoning hazard or chemical burn hazard through cleaning detergents. Observe all safety instructions on cleaning detergent labels. Protect cleaning detergent storage against access by unauthorised persons.

A sharp and powerful waterjet exits from the orifice of the spray lance nozzle. When operating the spray lance, keep in mind the following:

English

Danger!

Burn injury hazard through hot system components. During hot-water operation, do not touch non-insulated pipe installations and hose couplings. Grasp the jet lance by the grip surfaces only.

Injury hazard through flying debris. Flying debris or objects can cause injury to persons or animals. Never aim the water jet at fragile or loose objects.

Health hazard posed by toxic substances. Do not spray clean the following materials, because substances known to pose a risk to human health may be swirled up:

– Materials containing asbestos – Materials that could possibly contain

toxic substances hazardous to human health.

Accident hazard due to hidden damage!

Danger!

Deadly electrical shock hazard. Do not aim the waterjet at – electrical devices and systems – at any parts of the system proper

All live components within the working area must be spray-water protected.

5.956-648 A10369 (06/98)

Clean tires and valve stems from a minimum distance of 30 cm.

English

Danger!

Health hazard through cleaning detergents. Due to the possible adding of detergents to the system water, the water exiting from the system must not be used as drinking water.

Switching the System ON

Open the water tap for water supply and cooling water.

B. System Operation

HD 4000 C / HD 6000 C

5. Frost Protection

The water-bearing parts of the system must be protected from freezing, since they could otherwise be destroyed. If the system is to be operated also in freezing temperatures, it must be installed in a frostfree location. Outdoor water lines must be frost-protected (i.e., through insulation or line heaters, or by draining during freezing temperatures).

6. System Shut-Down

Turn the Emergency-STOP master switch (Q1) to the I (ON) position.

Press the unlock button (S1).

n Carry out the cleaning procedure. The

pump stops for a cleaning break of more than 15 seconds. At the same time the 6 hours of continuous availability time is started. Within the availability time the system starts automatically owing to the drop in pressure when opening a handgun.

Restoring Operational Readiness

Press the unlock button (S1).

4. Stopping the System

If a system is to be shut down during cold periods, it must first be flushed with an antifreeze solution. As a rule, antifreeze products also contain corrosion inhibitors.

Turn the system’s EmergencySTOP master switch to the 0 (OFF) position.

Shut OFF the water supply.

Open the handgun until the water pressure has dissipated.

Using the locking feature, secure the handgun against being opened accidentally.

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

1. Flow Diagram

C. System Function

English

1 High-pressure pumps 2 Float valve 3 Dirt trap 4 Overflow 5 Low-water sensor 6 Pressure relief valve 7 Filter 8 Overflow valve

9 Flow monitor 10 Safety valve 11 Solenoid valve (cooling water) 12 Pressure controller 13 Dashpot 14 Precompression pump

(with hot-water attachment unit only)

15 Pressure switch

5.956-648 A10369 (06/98)

English

C. System Function

HD 4000 C / HD 6000 C

2. Description of Functions

Water Inlet

The water is conveyed from the float reservoir to the intake side of the two pumps. The water level in the float reservoir is maintained by the float valve (2). The incoming water is cleaned in the dirt trap (3). In the case of a float valve failure, the water exits through the overflow (4). In the event of insufficient feed water volume or failed water supply the low-water sensor (5) sends a fault signal to system control.

Pumps

The electric motor drives both pump ends (1). The pumps convey the water under high pressure to the pressure side. The starting of the motor opens the pressure relief valve with its upstream filter (7). This action connects pressure and suction sides of the pumps, and no pressure is built up. The motor is able to start free of any load.

High-pressure side

System Control

The pump motor is started with the unlock button (S1). If the volume of water taken drops below 8 +2 litres per minute, then the after running time starts. This amounts to about 15 seconds. If the water consumption remains below the minimum quantity, then the pump stops after expiry of the after running time. Within the immediately following availability time the pump starts due to the drop in pressure caused by the opening of a handgun or by activation of the unlock button. If the water pressure drops due to leakages in the high-pressure network then the pump starts and executes leakage compensation. The availability time ends

n after approx. 6 hours, n after six attempts at leakage

compensation,

n after the switching off of the supply

voltage.

After expiry of the availability time the system can only be restarted with the unlock button.

The high-pressure water passes through the overflow valve (8) and the flow monitor (9) to the high-pressure outlet, and subsequently into the high-pressure tubing system installed by the system owner. The dashpot (13) dampens the water pressure pulsing through the piston sleeve.

Pressure Control

Unused water is returned from the overflow valve to the float reservoir. If all utilisers are inactive, the overflow valve switches to idle-pressure circulation. If the outlet pressure exceeds the maximum operating pressure regardless of the overflow valve, the safety valve (10) opens.

Cooling

During the operation of the pump the solenoid valve (11) is kept in the open position. This allows cooling water to flow through the pressure regulator (12) and circulate through the cooling coils of the motor. The flow of cooling water is set by means of the pressure controller. Once the cooling water has passed through the cooling coils it is returned to the float reservoir.

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

1. Equipment Features

D. Specifications

English

HD 4000 C

1.509-035

Supply volume L/h 3900 3900 3900 3900

Operating pressure* bar 100 100 100 100

Max. operating pressure (safety valve)

Dimensions:

Length mm 1090 1090 1090 1090

Width mm 615 615 615 615

Height (without pedestal) mm 1070 1070 1070 1070

bar 130 130 130 130

HD 4000 CH

1.509-115

HD 4000 C

Scandinavia

1.509-515

HD 4000 C

Scandinavia

1.509-515

with hot-water

accessory kit

2.638-689

Weight (empty) kg 245 245 245 245

Capacity:

Float reservoir (max. capacity)

Pump housing (motor oil, order no. 6.288-061 1-Litre packaging)

Sound level dB(A) approx. 80 approx. 80 approx. 80 approx. 80

Sound level (sound-insulated version)

* upon request, lower values can be set by customer service.

L 63 63 63 63

L 2 x 1.8 2 x 1.8 2 x 1.8 2 x 1.8

dB(A) approx. 70 approx. 70 approx. 70 approx. 70

5.956-648 A10369 (06/98)

English

1. Equipment Features

D. Specifications

HD 4000 C / HD 6000 C

HD 6000 C

1.967-045

Supply volume L/h 5600 5600

Operating pressure* bar 60 60

Max. operating pressure (safety valve)

Dimensions:

Length mm 1090 1090

Width mm 615 615

Height (without pedestal) mm 1070 1070

Weight (empty) kg 260 260

bar 90 90

HD 6000 C

1.967-045

with hot-water

accessory kit

2.638-697

Capacity:

Float reservoir (max. capacity)

Pump housing (motor oil, order no. 6.288-061 1-Litre packaging)

Sound level dB(A) approx. 80 approx. 80

Sound level (sound-insulated version)

* upon request, lower values can be set by customer service.

L 89 89

L 2 x 1.8 2 x 1.8

dB(A) approx. 70 approx. 70

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

2. Connected Loads

D. Specifications

English

HD 4000 C

1.509-035

Mains power: Power type 3 ~ 50 Hz 3 ~ 50 Hz 3 ~ 50 Hz 3 ~ 50 Hz Voltage V 400, IEC 38 400, IEC 38 220 to 240 220 to 240 Nominal load (max.)

with water temp. of 20 °C

Power supply cable mm² 4 x 10 4 x 10 4 x 16 4 x 16

Control cable mm² 5 x 1.5 5 x 1.5 5 x 1.5 5 x 1.5 Motor starter (type)

External pre-fusing

kW 15 15 15.5 15.5

A slow

HD 4000 CH

1.509-115

50 50 63 63

HD 4000 C

Scandinavia

1.509-515

HD 4000 C

Scandinavia

1.509-515

with hot-water

accessory kit

2.638-689

Water: Flow volume L/h 3900 3900 3900 3900 Max. supply temperature Min. flow pressure bar 2 2 2 2 Max. flow pressure bar 6 6 6 6 Supply line, nominal dia. mm 25 25 25 25 Cooling water: Flow volume L/h 200 to 220 200 to 220 200 to 220 200 to 220

Supply temperature

Min. flow pressure bar 2 2 2 2 Max. flow pressure bar 8 8 8 8 Supply line, nominal dia. mm 15 15 15 15

°C 60 80 60 80

°C approx. 10

to 18

approx. 10

to 18

approx. 10

to 18

approx. 10

to 18

5.956-648 A10369 (06/98)

English

2. Connected Loads

D. Specifications

HD 4000 C / HD 6000 C

HD 6000 C

1.967-045

Mains power: Power type 3 ~ 50 Hz 3 ~ 50 Hz Voltage V 400 400 Nominal load (max.)

with water temp. of 20°C

Power supply cable mm² 4 x 10 4 x 10

Control cable mm² 5 x 1.5 5 x 1.5 Motor starter (type)

External pre-fusing

Water:

kW 15 15

A slow

50 50

HD 6000 C

1.967-045

with hot-water

accessory kit

2.638-697

Flow volume L/h 5600 5600 Max. supply temperature Min. flow pressure bar 2 2 Max. flow pressure bar 6 6 Supply line, nominal dia. mm 40 40 Cooling water: Flow volume L/h 250 250 Supply temperature Min. flow pressure bar 2 2 Max. flow pressure bar 8 8 Supply line, nominal dia. mm 15 15

°C 60 80

°C approx. 10 to 18 approx. 10 to 18

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

3. Dimension Diagram

D. Specifications

English

5.956-648 A10369 (06/98)

English

E. Maintenance

1. Maintenance Contract

Only a properly maintained system is really safe. It is in your best interest to ensure that regular system maintenance procedures are carried out according to the maintenance schedule outlined below.

You may wish to enter into a maintenance contract with the authorised Kärcher customer service in your area. A maintenance contract is highly recommended.

2. Maintenance Schedule

In system maintenance, use only original parts supplied or recommended by the manufacturer. Observe all safety and operating instructions packaged with these spare parts. In particular, this applies to:

HD 4000 C / HD 6000 C

Danger!

Accident hazard through improper maintenance procedures! Without exception, maintenance work and service repairs must be performed by personnel or by the Kärcher customer service.

Electric shock hazard. Switch OFF and secure master switch before commencing work on the system.

n Spare parts and wearing (consumable)

parts

n Accessory parts n Operating media n Cleaning media.

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

E. Maintenance

English

a Safety valve b Pump side c Pressure controller d Solenoid valve (cooling water) e Drip pan

f Pressure relief valve g Cooling coil h Float reservoir with float valve

j Overflow valve, pressure switch k Flow monitor

l Oil level sight glass

m Dashpot

5.956-648 A10369 (06/98)

English

Interval Procedure Subject Assembly Activity By whom

E. Maintenance

HD 4000 C / HD 6000 C

Daily Check

handgun

Check high-pressure hoses

Weekly, or after 40 operating hours

Check system for leaks

Check oil level Both pump sides Check pump oil level. MIN level:

Check oil quality

All handguns Check whether handgun closes

properly. Check function of safeguard against inadvertent operation. Replace defective handguns.

Outlet lines & hoses leading to workstations

Entire system Check pump, overflow valve and

Both pump sides If the oil appears milky, it must be

Check hoses for damage. Replace defective hoses immediately. Accident Hazard!

tubing installation for leaks. If oil is present in the drip pan under pump, of if a leak exceeds 10 drops of water per minute, call customer service immediately. Keep weep holes unblocked.

Centre of oil sight glass. MAX level: up to mark in housing. If required, top up with oil (part no. 6.288-061).

changed. In this case it is recommended to change the pump oil seal also. (Customer service.)

Operator

Operator/ Customer Service

Operator

Operator/ Customer Service

Check working pressure

Check hose quick-coupling

Check dashpot

Pressure gauge in control panel

Hose quick-couplings between system tap and high-pressure hose to handgun.

Dashpot on each pump side A defective dashpot is readily

Check system water pressure (pressure gauge). If pressure is too high or too low, investigate and remedy the cause (see also the section on Trouble Shooting).

Pump must be running. Check for leakage in tandem and individual operation. Connect clutch and check clutch locking function. Replace defective clutches.

identifiable through increased pump vibration. Replace defective dashpot.

Operator

Customer Service

Operator Customer

Service

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

Interval Procedure Subject Assembly Activity By whom

E. Maintenance

English

monthly, or after 200 operating hrs.

Check overflow valve

Check low-water sensor

Clean strainers

Check float valve

Overflow valve Dependent on the number of

high-pressure handguns used, the pressure reading fluctuates between the preset value and approx. 15 bar below the same. On closing all handguns, the gauge will read approx. 0 bar. In the event of malfunction, call customer service.

Float switch in float reservoir

Dirt trap upstream of float reservoir, Pressure controller

Float reservoir Water level must stand 40 mm

For about 5 seconds press down the float of the low water protection facility and check the fault indication on the printed circuit board. If necessary remove any deposits.

Switch OFF unit, turn OFF water, release pressure. Disassemble and clean strainers.

below the overflow weir. With float valve closed, no water may exit. For adjustment information, refer to the Service Manual.

Operator

Customer service

Trained operator authorised to open control cabinet

Operator

Check pressure relief valve

Check run-on interval

Check automatic switching on

Tighten hose clamps

Pressure relief valve on pump

System control Close utiliser (e.g. handgun).

Pressure switch The pump is stationary as no water

All hose clamps in/on the unit

When functioning correctly, the motor must reach full RPM within 2 seconds. If required, clean the strainer upstream of the pressure release valve. Prior to cleaning: Shut OFF water, set EmergencySTOP master switch to OFF.

After the after running time (approx. 15 sec) the pump must switch off.

is being drawn. Open the handgun. When the pressure in the high-pressure network drops below 25 bar, the pump must switch on.

Tighten hose clamps with torque wrench. Torque: 28 mm nominal diameter: 2 Nm 29 mm nominal diameter: 6 Nm

Operator

5.956-648 A10369 (06/98)

English

Interval Procedure Subject Assembly Activity By whom

E. Maintenance

HD 4000 C / HD 6000 C

Semiannually, or after 1000 operating hours

Annually Safety check Entire system Safety inspection pursuant to

Oil change All high-pressure pumps CAUTION!

Hot Oil Scalding Hazard. Prior to oil change, allow pump to cool for 15 minutes. Drain oil and fill pump on each side with 1.8 L oil, part no. 6.288-061. Do NOT use alternate oil products!

Check unit for lime deposits

Tighten terminal strips

Entire water system Functional faults on valves or pumps

may indicate calcification. Use procedures outlined on the following pages.

Control cabinet Tighten all terminal strips of

components master mains power circuit.

guidelines covering liquid spraying devices. Refer to section A.12.

Operator

Operator trained in decalcificat procedures

Electrician

Expert/ Customer service

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

E. Maintenance

English

3. Removing the Cover

Certain repair or service procedures may require the removal of the cover. Proceed as follows:

n Remove cover, “A”. n Remove both cover retaining screws, “B”. n Slide off cover horizontally, as indicated

by the arrow.

4. Decalcification

Danger!

Explosion hazard through flammable gases! Smoking is prohibited when carrying out decalcification procedures. Ensure adequate ventilation.

Caution!

Acid hazard! Protective goggles and gloves must be worn.

These products are balanced for use in conjunction with the materials present throughout the system. After decalcification we recommend neutralising the remaining acid residues by flushing the system with an alkaline solution (pH value 7–8).

The instructions for use and accident prevention regulations (dilution according to label specifications), and in particular VBG1,

§ 4, 14, and 44–47 must be observed.

Proceed as follows:

Begin by decalcifying the float reservoir: Close water supply.

Remove cover as discussed in para. 3, above. Remove the float reservoir lid. Remove the hose connecting the pump suction side with the float reservoir, pump side. Block the free end of the hose. Pour in 7-percent de-scaling solution. After the conclusion of decalcification, remove all scale residues from the reservoir!

Decalcifying high-pressure system: Disconnect high-pressure hose from water

supply inlet and hang into float reservoir. Next, use the decalcifying acid solution premixed in the float reservoir for shortterm system operation in circulation (idle pressure) mode. Allow chemicals to activate, and conclude by flushing the system.

Lime deposits throughout the water lines of the high-pressure system create increased pipe-run resistance and may result in the failure of calcified components.

According to official regulations, only approved boiler scale dissolvants (descaling acid) with test mark may be used.

For scale removal in the high-pressure system, the use of KÄRCHER scale dissolvants should be given preference (RM 100 ASF, hydrochloric acid-free, part no. 6.287-008, or RM 101 ASF, containing hydrochloric acid, part no. 6.287-013).

5.956-648 A10369 (06/98)

Decalcifying the cooling coil for the pump motor:

If the flow of cooling water falls below the prescribed rate (see Technical specifications), in spite of sufficient input pressure and a clean strainer in the pressure reducer, then the cooling coil must be decalcified.

Close the cooling water supply. Remove, i.e., pull off, the water hose from the solenoid valve and hang into a catch container. Remove cooling water hose from float reservoir, position open end of hose at suitable height and fill with de-scaling solution. Allow to activate and conclude by flushing repeatedly.

English

Problem Possible Cause Remedy by whom

F . T rouble Shooting

HD 4000 C / HD 6000 C

High-pressure pump fails to come up to pressure

Pronounced pump knock, pressure gauge pointer oscillates

With hot-water accessory kit only

Overflow volume is blown out into open, and/or safety valve is activated

Leaking suction-side tubing system

Water starvation Correct the cause Operator Defective valve in pump

High-pressure solenoid valve fails to close

Defective dashpot replace Operator Pump is drawing air Check suction line Operator Defective valve seat or valve

spring Defective or calcified

precompression pump Blown hose between overflow

valve and float valve

Defective overflow valve CAUTION: For safety reasons, excess water is vented outdoors. Shut down the system!!

Check fastener and hose connections

Replace valves Customer

Replace as required Customer

Check precompression pump

replace Operator

Repair or exchange overflow valve

Operator

Service

Service Operator

Customer Service

Water is returning to float reservoir despite full-volume usage

Overflow valve cycles ON and OFF despite zero usage

Pump does not reach working RPM with and/ or - starter.

System is calcified Decalcify system circuits

(refer to Maintenance section)

Defective spray lances and/or nozzles.

Defective overflow valve Check overflow valve Cust. Service Leak in high-pressure system,

defective spray gun. Leaking non-return valve or

control piston seal in overflow valve

Blocked strainer upstream of solenoid valve

Defective pressure relief solenoid valve

Check spray lances Operator

Repair leak Operator

Repair overflow valve Customer

Clean strainer Operator

Replace solenoid valve Customer

Operator

Service

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

Problem Possible cause Remedy by whom

F . T rouble Shooting

English

General fault and “Water supply fault” LED light up on printed circuit board

General fault and “HD pump temperature fault” LED light up on printed circuit board

Insufficient water in float tank

Temperature of the water inlet too high

Cooling water quantity too low:

Strainer in pressure reduction valve contaminated

Mains water pressure too low Raise pressure Operator Cooling coil calcified,

solenoid valve defective Oil level too low Check oil level Customer

Oil change not made, owing to which there is oil carbon under the piston guide shoes, piston seizing.

Check site water supply Operator

Reduce inlet temperature Operator

Clean strainer Operator

Decalcify, replace solenoid valve

Check pump parts, replace as necessary. Make an oil change

Operator

Service Customer

Service

General fault and “Admission pressure of hot-water pump too low” LED light up. (Only with ABS hot water)

General fault and “Drop in system pressure” LED light up on the printed circuit board (flow without pressure longer than 15 seconds)

Rotation direction of precompression pump wrong

Pressure switch precompression hot-water pump in the ABS hot water defective

Too many utilisers simultaneously opened

Pipe burst in the high-pressure network

Pressure switch defective Replace pressure switch Customer

Change rotation direction Electrician

Replace pressure switch Customer

Service

Close down some utilisers Operator

Turn off installation and repair pipeline

Customer Service

Service

5.956-648 A10369 (06/98)

English

F . T rouble Shooting

HD 4000 C / HD 6000 C

Motor fault lights up

Available time is less than 6 hours

System does not start up when unlock button is pressed, no indicator light illuminates

Motor protection switch Q1 or Q2 has triggered owing to overcurrent or drop-out of one phase of power supply system

Motor protection switch falsely set

Pressure at pump outlet too high

Site high-pressure network is leaky

Pressure switch defective

Site power supply interrupted

Emergency-STOP master switch off

Check voltage of the three phases

Set in accordance with circuit diagram

Check pressure, adjust as necessary

Seal it off Operator

Replace Kundendienst

switch on Operator

Customer Service/ Electrician

Customer Service

Motor protection switch for control system and precompression pump has been triggered

Control-circuit fuse on transformer defective

Printed circuit board defective, green LED does not blink

EPROM loose install again, check cause Customer

check Customer

Service / Electrician

replace, check cause Customer

Service / Electrician

replace, check Customer

Service

Service / Electrician

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

F . T rouble Shooting

English

System runs for about 15 sec after pressing the unlock button and then switches off. General fault and “Admission pressure of hot-water pump too low” LED light up

Pump starts during available time but not by opening the handgun

Unlock button activated, “operational” indicator light illuminates, system does not start up

While activating the HD pistols the unit switches itself off

Admission pressure of hot water too low

Pressure switch precompression hot-water pump or cable in ABS hot water defective

Pressure switch or cable to pressure switch defective

Pressure switch defective

Flow switch does not function

check pump rotation direction, check water intake

replace Customer

check flow switch Customer

Customer Service

Service

Service/ Electrician

Unlock button activated, system starts up, “operational” indicator light does not illuminate

System does not switch on Flow switch S2

Remote start button does not function

“operational” indicator light defective

defective

System in a malfunction state

switch Emergency-STOP master switch Q1 to position 0, open control cabinet and verify or replace components

replace upper part of flow switch

eliminate the cause and press unlock button

Customer Service/ Electrician

Operator

5.956-648 A10369 (06/98)

English

G. System Installation

HD 4000 C / HD 6000 C

AUTHORISED PROFESSIONAL PERSONNEL ONLY

1. Placement

The system must be installed in dry indoor surroundings free from explosion hazard. The components shall be placed on firm and level ground, and the system must be easily accessible for the purpose of maintenance procedures. The room temperature must not exceed 40 °C.

Additional height-over-floor obtained through the use of the component feet (140 mm length) facilitates maintenance access. In the absence of sufficient space the elastic feet can be used by themselves.

2. Connections

The water and waste-water connections, as well as the connection with the electrical mains network may only be carried out by licensed and authorised professional contractors pursuant to local regulations. In the Federal Republic of Germany the following regulations apply:

n VDMA guideline, standardised leaflet

24416 “Fixed-Installation High-Pressure Cleaning Systems”

n VDE Regulations (VDE = Professional

Association of German Electricians)

In the event of excessive admission pressure or the occurrence of pressure peaks in the mains network, the installation of a pressure regulator upstream of the system is mandatory.

The motor cooling circuit within the system requires a separate cold-water connection.

A water drain must be present at the installation site.

3. High-pressure Installation

The link between the fixed-installation pipe network and the system must be executed in the form of a flexible high-pressure hose connection.

The permanent pipe network installation must consist of as many straight runs as possible. All high-pressure tubing must be installed pursuant to regulations, using vibration-dampened strain relief and fixed pipe or tubing clamps, while allowing for longitudinal expansion/contraction due to the effects of temperature and pressure.

To keep pressure losses in the highpressure lines as low as possible, the following recommendations should be used as mandatory guidelines:

n Regulations issued by local utility

companies

Both the required water supply and the electrical mains network connection must be configured for permanent operation. The specified connective load values are stated in the Specifications.

The water supply must be equipped with a shutoff valve, and must be connected with the high-pressure by means of a flexible high-pressure hose. Insufficient supply line cross section or insufficient admission pressure will result in water starvation. To prevent pump damage, a low-water condition will automatically result in system shut-down.

Delivery

volume

1000 L/h NW 10 (3/8") NW 8 2000 L/h NW 15 (1/2") NW 12 3000 L/h NW 15 (1/2") NW 12 4000 L/h NW 20 (3/4") NW 16 6000 L/h NW 25 (1") NW 20

It should be understood that the above guidelines still require additional allowances for the overall tubing length, the number of directional changes and armatures.

Tubing line Hose size

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

AUTHORISED PROFESSIONAL PERSONNEL ONLY

G. System Installation

English

4. Hard-water Treatment

Excessive water hardness (>15° dH) can lead to deposits and result in malfunctions. Contact the manufacturer in the event of unusually high degrees of water hardness.

5. Preparations for Commissioning

n Thoroughly rinse entire HD system

(HD 4000/6000 C also). Check entire HD system for correct assembly and lack of leaks.

n Complete electrical connections in

accordance with the Specifications contained in the Operating Instructions.

n Check the function of decalcifying

component (if required).

n Check water supply for required delivery

volume and maximum allowable temperature.

n Install float reservoir overflow line n Check pump oil level. Remove threaded

plug from oil reservoir.

Threaded plug

n Check cold-water cooling circulation:

Verify cooling water volume (refer to Specifications) and connection data.

Adjusting cooling water volume on pressure regulator.

Locking screw

AUTHORISED PROFESSIONAL PERSONNEL ONLY

5.956-648 A10369 (06/98)

English

AUTHORISED PROFESSIONAL PERSONNEL ONLY

6. Space Assignment Plan

G. System Installation

HD 4000 C / HD 6000 C

A : Pressure outlet M30x1.5 B : Water inlet G 1¼" HD 4000 C

G 1 ¾" HD 6000 C C : Overflow O.D. 41 D : Cooling water inlet G ¾"

AUTHORISED PROFESSIONAL PERSONNEL ONLY

D1: Cooling water supply Rp ½" E : Water outlet F : Mains supply G : Control line H : Control cabinet J : min. 200 / max. 500

5.956-648 A10369 (06/98)

HD 4000 C / HD 6000 C

H. Accessories

English

Handguns with different spray lances

Dependent on the cleaning application, different spray lance extensions are required, ranging from 250 mm for onehand operation to 2040 mm for cleaning high objects.

Spray lance with bypass valve

Featuring two spray patterns and operation in conjunction with cleaning detergents, length approx. 1000 mm.

System tap / workstation

Features injector for metering cleaning detergent into pressure side, wall-mounted container console and hose keeper, remote release.

Nozzles

Several nozzles with different spray angles are available for the system. The nozzles are mounted on the spray lance by means of a union nut, and are easily changed. Recommended nozzle size is size 07.

Designation Spraying

angle

1507 15° -305 2507 25° -287 4007 40° -288

Force of recoil from the handgun when using these nozzles:

HD 4000 C 100 bar 43 N HD 6000 C 60 bar 25 N

The spraying device (i.e., handgun) is connected by means of an in-line quickcoupling.

Order no.

6.415-

Hot-water accessory kit

This accessory kit permits an increase of the water supply temperature to a maximum of 80°C.

Cleaning detergents

Cleaning detergents facilitate any cleaning task. A selection of cleaning agents is listed in the table on the following page. When using detergents it is essential to observe the instructions supplied on the product labels.

The following types of cleaning detergents must not be used with this system:

Detergents containing nitric acid

•

Detergents containing active chlorine

•

Using these types of detergents will result in damage to unit components.

5.956-648 A10369 (06/98)

English

H. Accessories

HD 4000 C / HD 6000 C

Area of application

Automotive, petrol stations, motor carriers, vehicle fleets

Metal-working industry

Food processing industry

Contamination type Application method

Dust, road grime, mineral oils (on painted surfaces)

Vehicle protection

Oils, greases, dust and similar contamination

Light to medium contamination, greases/oils large surfaces

Cleaning agent

RM 55/1000-liquid ASF ** RM 22/80-powder ASF RM 81-liquid ASF RM 803-liquid ASF

RM 820-hot wax ASF RM 821-spray wax ASF RM 824-Super-Perlwachs ASF

RM 22-powder ASF RM 55-liquid ASF RM 81-liquid ASF RM 31-liquid ASF (heavy contamination) RM 39-liquid (with corrosion protection)

RM 55-liquid ASF RM 81-liquid ASF

RM 58-liquid ASF (foaming cleanser) RM 31-liquid ASF *

Approx. pH value

1 %-solution

slightly alkaline

alkaline alkaline alkaline

neutral neutral neutral

alkaline

slightly alkaline

alkaline

strongly alkaline

slightly alkaline

alkaline alkaline

strongly alkaline

Smoky resin RM 33-liquid * strongly alkaline

Cleaning and disinfecting RM 32-D-liquid alkaline

Disinfecting RM 735-D-liquid alkaline

Lime, mineral deposits

Sanitary installations

* = for short-term use only. Two-step method. Flush with clean water. ** = ASF = abscheidefreundlich

Lime, urinal deposits, soaps, etc.

RM 25-liquid ASF * RM 59-liquid ASF (foaming cleanser)

RM 25-liquid ASF (basic cleaning) RM 59-liquid ASF (foaming cleanser) RM 68-liquid ASF

strongly acidic

acidic

strongly acidic

acidic acidic

5.956-648 A10369 (06/98)H2

HD 4000 C / HD 6000 C

System Type: Works No. Commissioned: (date)

Inspected:

(date)......................................................................................................

Results/Comments:

Inspected:

(date)......................................................................................................

Results/Comments:

J. Customer Service

English

......................................

Signature

Inspected:

(date)......................................................................................................

Results/Comments:

Inspected:

(date)......................................................................................................

Results/Comments:

......................................

Signature

......................................

Signature

5.956-648 A10369 (06/98)

......................................

Signature

Karcher HD 4000 C, HD 6000 C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual