Karcher HD 4000 C, HD 6000 C User Manual

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.

i

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)

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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

n

n

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!

n

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.

n

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.

n

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.

n

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

n

i

Important!

Denotes operating hints and important
information.

A1

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.

n

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.

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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!

n

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!

n

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.

n

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

n

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.

!

n

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!

n

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.

n

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.

n

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

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A2

English

!

!

Danger!

n

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.

n

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.

A3

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).

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A4

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

B1

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.

n

Open the handgun until the water
pressure has dissipated.

n

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!

n

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.

n

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!

n

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.

n

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.

n

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.

n

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.

n

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!

n

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)

n

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

n

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.

B2

English

!

Danger!

n

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.

B3

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