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.

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)

+ 23 hidden pages