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Karcher SHD-R 3000 User's Manual

1. Other cleaning liquids may only be used after being released by Karcher B4 5 956 486 A2005937 06 03 SHD R3000 B Types of system and operating information 2 System start up Emergency drill B Turn mains supply voltage of at system master switch m Turn off supply of cleaning liquid m f a handgun is being used release any remaining pressure in the system by pressing the lever on the handgun Working with the handgun A Danger The high pressure jet produces a recoil effect m You could lose your balance m You could fall over Therefore m Ensure that you have a firm footing m Keep a tight grip on the handgun m Do not wedge the handgun fast in the open position If the lever is wedged fast the recoil effect causes the high pressure hose to twist and turn in various directions which result in damage to other equipment or persons Starting up the system Mobile system m Place system on a horizontal solid surface B Lock wheel brakes 5 956 486 A2005937 06 03 English Mobile and static system m Turn on cleaning liquid supply m Switch system on at master switch m Commence cleaning with high pressure jet l Important In types LM SLA and SSR the stuffing boxes must be retightened after the initial startup The tension should be regulated one two four and 10 hours after initial start up For the running in phase of the seal
2. 5 956 486 A2005937 06 03 G3 English G Mounting kits and accessories SHD R 3000 Figure A 172 LM ARCHER A172 y ASGER Dimensional diagram SHD R 3000 F E Winnenden SSR Sheet 1 of 1 ABS electrical controls ABS float tank only for operation with water ABS dry run protection e ABS overpressure relief device M ABS filter monitoring system fj Electric motor 6 8 kW S 13 5 kW p e High pressure pump SHD R 3000 3000 I h 50 bar S 100 bar S 5 S lt e N x B A 4 eo Electrically conductive 3 el i l 4 Fixed castor Swivel castors y y 27 y E 77 T 177277 Cable 5x6mm without plug 7 5 m long external pre fusing 25A Approx 1400 Suction intake G 1 1 4 A ABS wire edge filter Approx 700 V belt protection P High pressure connection M 22x1 5 A ABS mounting kit optional only for ABS electrical controls Safety valve Manometer with switchover ABS suction side switchover Suction intake G 1 1 4 A Alfred K rcher GmbH amp Co KG Alfred K rcher Str 28 40 D 71364 Winnenden This sheet must not be reproduced nor may it be passed on to third parties without our prior written consent We reserve the right to exclusive utilisation of our intellectual property G4
3. B high voltages m detergents and solvents m Explosion hazard In order to avoid errors in operation or potentially dangerous situations read the following before starting the system up for the first time B all safety information in the enclosed brochure Safety information for high pressure cleaning units No 5 951 949 M these operating instructions B the legal requirements that are currently applicable in your country A1 SHD R 3000 All persons charged with the installation commissioning operation maintenance or service of the machine are required B to be appropriately qualified W to read and observe these operating instructions B to be aware of and observe associated regulations 2 Noise protection The sound level generated by the system is 80 dB A A noise hazard can occur if the water jet is directed at resonating components e g large metal panels In this case a hearing protection device must be worn 3 Authorized operators The operation of the system is restricted to persons over the age of 18 who have received proper instruction as to how this system is to be used For exceptions for trainees see BGV D15 Art 6 4 Personal protective equipment A Danger Health hazard due to cleaning fluids Wear the prescribed protective equipment for the cleaning liquid to be used e g W protective clothing overalls m protective goggles or face mask m watertight glo
4. Co KG Cleaning Systems Alfred K rcher Str 28 40 P O Box 160 D 71349 Winnenden Tel 49 71 95 14 0 Fax 49 71 95 14 22 12 5 957 383 01 02 Alfred K rcher Kommanditgesellschaft Registered offices Winnenden Register court Waiblingen HRA 169 Personally liable shareholder K rcher Reinigungstechnik GmbH Registered office Winnenden 2404 Waiblingen register court HRB Managing Directors Dr Bernhard Graf Hartmut Jenner Georg Metz J1 English EC Declaration of Conformity J Declaration of Conformity We herewith declare that the design and type of machine named in the following as well as the model marketed by us complies with the relevant fundamental health and safety requirements of the EC Directives This declaration becomes invalid if modifications are made to the machine which have not been previously agreed with us Product Type High pressure cleaner SHD R 3000 F LM SSR SLA Relevant EC Directives EC Machinery Directive 98 37 EC EC ATEX Directive 94 9 EC Harmonised standards used DIN EN 60 335 1 DIN EN 60 335 79 DIN EN 13463 1 2002 prEN 13463 5 2002 EN 1127 1 1997 National standards used No of nominated test institute 0123 Test report No 070039582 Type LM designation Ex Il 2 G ck TA Type SSR SLA designation Ex Il 2 G ck T3 Internal measures ensure that serial production units always comply with the requirements of th
5. 5 956 486 A2005937 06 03 SHD R 3000 G Mounting kits and accessories English Figure A 173 IOUT E A 173 le RCH ali Dimensional diagram SHD R 3000 FLM with crane Winnenden Sheet 1 of 1 GERS Mounting kit telescopic crane jib max liftable load 80kg Safety winch HKF 200 Be 7 SHD R 3000 FLM 800 450 min height 1900 max height 3070 y 1900 width 700 500 800 Alfred K rcher GmbH amp Co KG Alfred K rcher Str 28 40 D 71364 Winnenden This sheet must not be reproduced nor may it be passed on to third parties without our prior written consent We reserve the right to exclusive utilisation of our intellectual property 5 956 486 A2005937 06 03 G5 Figure A 161 rues A 161 MKARGHER i UKARCHER Dimensional diagram Circulation tank 600 I Winnenden Sheet 1 of 1 Push on cover DN 200 Return G 2 z Vent a EN 1 S X H X 1 o me Circulation part Clear rinse E
6. align it exactly E Install the unit in such a way as to ensure that it can be easily accessed for maintenance work B Secure in position with suitable materials For static and mobile systems Connecting hoses for supply of cleaning liquid Caution Vibrations generated by the system during operation could cause damage to the main water supply network therefore connect the system by means of flexible hoses B Connect the supply hose for cleaning liquid to the system Thread R 1 1 4 B Connect the high pressure hose for the cleaning liquid output to the system Thread M22 x 1 5 5 956 486 A2005937 06 03 L System installation English Check the oil level The level of oil in the reservoir on the high pressure pump should be between the MIN and MAX marks Fill up with oil if the level is below the MIN mark Electrical connections AN Danger Dangerous voltage The electrical installation should only be carried out by a qualified electrician in accordance with current local regulations B Connect the electric motor into the terminal strip m Switch on motor briefly and check direction of rotation mmm a Eum EHE oo mu mu EAS Ll i H 1 CO gmgmggNEmmEEMEE Boon Sloooptnoeoone FE EEGEN mmm a aja a a a ak cA c a egal N BEI CELL EET FEER El p mm mja n a n N r Boon Start up the system Switching off in an emerge
7. approx 4501 part approx 1501 e 2 3 3 Lo 77 l O H Fixed castors S o Swivel castors 8 ES t Electrically conductive 3 S Sludge drain E Wire edge filter z 2 3 Circulation clear rinse switchover z S Suction strainer E Slewable A 7 t t t i t T Strainer plate H Shut off ZS o valve e O 8 Ee CT 5 z Drain E E i V I I I H 3 1600 S gt E Alfred K rcher GmbH amp Co KG Alfred K rcher Str 28 40 D 71364 Winnenden E G6 5 956 486 A2005937 06 03 English G Mounting kits and accessories SHD R 3000 Figure A 154 A 154 n CHE X Winnenden N MRA Schematic diagram Solvent system mobile Sheet 1 of 1 goinus eunsseJdje o Xew d uonoejoJd uni p uiu d 4auMo eui Aq pepi oJd jeuJ93Xx3 sauleyuoo uess u jeuondo SseJeudsougne eAiso dxo ui esn JO Snyd jeu1ejxe pue uos Jejseui yez Buisnj eJd Ad N ZH0S OVE AOO0F Daat MA 8 9 Jeqog utuj OS WU 000 U AHS 13409 yous Ajejes gt 24 uiu 00 Jeq Zb die pesseJduio jeuondo Hun soueusjulew uy Jeu uogons pue Joules Ae pesseJdujoo duind winjoy ul ysnd sjojseo uy ejiqoui ped esuu pop UUM yue uone nojJit d002 3 H uiejs s Buuojuouu Jet w G9 esou eunsseJd uBiH Js ueH NV jeuondo Je f Dun e pesseJ
8. detergent reservoir Operator reservoir to empty detergent Accessory container kit Screech Incorrect V belt tension Tighten V belt see Maintenance Operator ing noise Tasks 5 956 486 A2005937 06 03 F2 English 1 Fault finding F Troubleshooting SHD R 3000 Component Possible cause Remedy By whom Knocking noise Leaking pressure switch Leaking pump System does not switch off although handgun is closed Float tank overflows F3 V belt V belt has snapped Detergent metering on suction side of pump Accessory kit Cleaning liquid High pressure pump High pressure pump Pulsation damper Accessory kit Pressure switch Accessory kit High pressure switch Pressure switch Volume control valve Accessory kit Float tank Accessory kit Float tank Accessory kit Pump is taking in air Cleaning liquid is too warm Broken valve spring Flange has come loose Defective pulsation damper Defective seal Too much free play in piston seal Wrongly adjusted pressure switch or volume control valve Wrongly adjusted closing force or maximum filling level Defective seal on float valve Replace V belt see Maintenance Tasks Fill up with cleaning liquid Check hoses to establish whether they are taking in air Check supply temperature of cleaning liquid Replace valve springs Tighten flange see Maintenance Tasks R
9. environment with waste oil is a criminal offence Oil type Oil 40 special Order no 6 288 003 3 x 1 litre pack Oil capacity per pump 3 L Oil change procedure m place drip pan under pump to collect waste oil M remove oil drain plug and collect waste oil in drip pan M wash out pump casing with diesel m allow diesel to drain thoroughly W fit new sealing ring A18 x 22 and refit oil drain plug B slowly fill up with fresh oil as far as MAX mark E deliver waste oil to an appropriate collection point E4 SHD R 3000 Tightening the piston seals il Important If the piston seal is held too tight by the gland it will be subjected to increased wear m Insert rod into gland and turn in direction indicated by arrow This increases the tension on the piston seal m Tighten all three piston seals uniformly by turning the glands until they are hand tight Relieving tension on piston seal B Insert rod into gland and turn in opposite direction to that indicated by arrow This relieves the tension on the piston seal B Relieve the tension on all three piston seals uniformly 5 956 486 A2005937 06 03 SHD R 3000 V belt aum B m E Dessmgmgmgmummumum EI enonnneeeeeeong Test tension of V belt and adjust as follows Switch off system and ensure that it cannot be switched back on again unintenti
10. in conjunction with fixed installation high pressure lines The mobile system m has been mounted onto a trolley B can be used in different locations 5 956 486 A2005937 06 03 B1 English Cleaning liquids Type of system Cleaning liquid see rating plate SHD R 3000 F Water VE water Water with K rcher RM Water VE water Water with K rcher RM SHD R 3000 F S Working pressure Pressure setting for safety valve bar 85 100 B Types of system and operating information SHD R 3000 Comments Standard version Standard version with increased working pressure SHD R 3000 F SVA Water VE water Water with K rcher RM Fully demineralised water 85 100 Pump parts that come into contact with the cleaning liquid are made from stainless steel Conditionally resistant use possible however Cu and Zn ions in the medium RM Alkali cleaning agent e g RM31 max 0 2 Acidic cleaning agent e g RM25 max 0 1 Max temperature 60 C Higher temperatures available on request precompression pump required F Mobile system Other cleaning liquids may only be used after being released by Karcher B2 5 956 486 A2005937 06 03 SHD R3000 B Types of system and operating information English Cleaning liquids Type of system Cleaning liquid Working Comments see rating plate pressure Pressure setting for safe
11. no pressure is built up and the load on the motor is reduced during the start up phase Detergent metering at the suction side of the pump Danger If the detergent reservoir is empty and the metering valve is open the pump takes in air This can lead to damage to the pump therefore m check detergent reservoir regularly B do not open metering valve until actual work commences E close metering valve as soon as work has ended Function m A diaphragm has been inserted into the pump intake connection B detergent is taken in from an external reservoir B the amount taken in is determined by a metering valve m metering is switched on or off by a solenoid valve G2 SHD R 3000 Detergent metering at the pressure side of the pump Function B Detergents are taken in from an external reservoir and fed to the output from the pump B an injector mixes the detergent with the high pressure jet double spray lance required for detergent metering m detergents can also be metered by means of a high pressure metering pump 2 Mounting kits hazardous area Please contact K rcher about mounting kits for hazardous potentially explosive atmosphere areas For representations please refer to figures A 170 1 A 172 A173 A 161 and A 154 3 Accessories Lubricants Oil for pump Oil 40 special Order no 6 288 003 1 litre pack Lubricating grease for SHD R 3000 F SHD R 3
12. of old units via suitable collection systems Cleaning liquids Please do not allow them to get into the environment Please protect the soil and dispose of waste oil in an environmentally friendly way Waste water containing mineral oil i e petrol etc Please do not allow this waste water to get into the ground bodies of water or the sewers Mineral oil in the high pressure pump Mineral oil is used to lubricate the high pressure pump The waste oil resulting from an oil change any oil and water mixture that may occur and rags that have been soaked in oil should be delivered to a proper collection point for disposal il Important Waste oil may only be disposed of by the operators of special collection points Please deposit your waste oil at one of these locations Polluting the environment with waste oil is a criminal offence Detergents K RCHER detergents possess demulsifying properties ASF This means that they do not interfere with the function of an oil se parator il Important These instructions contain descriptions of different types of system accessory kits and other supplementary components There are significant differences between the various parts so that you should not encounter any problems with identifying all the parts in your particular type of system SHD R 3000 o Jo mb WD P For your safety Safety information and instructions Noise protection Authorized oper
13. 000 F S SHD R 3000 F SVA 6 288 034 For normal use Order no 6 288 015 Tin with 1 kg The following grease is prescribed for food processing operations Order no 6 288 034 Tin with 1 kg High pressure hoses nozzles detergents Ask your dealer for further details about these or any other accessories or contact K rcher Plant Engineering 5 956 486 A2005937 06 03 Figure A 170 1 RAS A 170 1 UICABCHER Dimensional diagram SHD R 3000 LM Winnenden Sheet 1 of 1 ABS dry run protection ABS overpressure relief device ABS filter monitoring system Suction intake G 1 1 4 A Base approx 150 470 LM EX SE Rubber metal feet only if ordered separately 1106 Alfred K rcher GmbH amp Co KG Alfred K rcher Str 28 40 D 71364 Winnenden E 3 fe d Fi H Suction intake ABS wire 8 G 1 1 4 A 3 edge filter o ie A rice d TY xx Safety valve 3 HH 3 M Manometer E le shut off valve E g e o e RIO 5 Q K 3 5 LO x HESS RSR m ABS 8 switchover F i y Y N E I 5 2 y WS KC j y High pressure 5 connection M22x1 5 3 le Approx 1200 M 2 Base 1400 E r el E
14. 7 06 03 English Volume control valve Function If only a part of the pump delivery volume is required the remainder is fed back to the suction side of the pump via the volume control valve This item is required when the system is used with handguns Pressure switch AN Danger Danger due to high voltage The pressure switch has been pre set in the factory adjustments should only be made by a K rcher Customer Service engineer Function The pressure switch W switches the system off if the working pressure is exceeded B switches the system back on when the pressure drops again Pulsation damper Caution As the membrane in the pulsation damper is not suitable for solvents do not use the pulsation damper for operation with solvents Function The pulsation damper evens out variations or peaks in pressure while the system is in operation l Important Volume control valve pressure switch and pulsation damper are usually employed together as an automatic volume control system G1 English Pressure relief valve G Mounting kits and accessories Function m The pressure relief valve is an integrated solenoid valve m The pressure relief valve is only active during the start up phase when the system is configured for star delta starting m When the pressure relief valve is opened the liquid delivered by the pump flows back to the suction side As a result
15. KARCHER SHD R 3000 Betriebsanleitung NS cl yy cp T 0 Dy 7 M e JN S p WE e gt de N NS d KA 3m VI 5 956 486 A2005937 06 03 www karcher com Operating Instructions To be handed to the operator Read these instructions carefully before starting up the unit Retain for future reference Notes about these operating instructions Before starting up the interior cleaner for the first time please carefully read through these instructions In particular you should note all the safety information Store these instructions in a safe place for future use For whom are these instructions intended B All users Users are persons who have received instruction on how the system functions operators and trained specialists B Trained specialists Trained specialists are persons who are professionally qualified to install and commission this type of system Environmental protection Please dispose of the packaging in an environmentally friendly way The packaging materials are recyclable Please do not throw the packaging into the domestic waste but in the appropriate recyclable waste collection containers instead Please dispose of old units in an environmentally friendly way Old units contain valuable recyclable materials which should be reused You should never allow oil and similar materials to get into the environment Therefore please dispose
16. ators Personal protective equipment Emergency drill Safety devices Applicable regulations Using the system for its intended purpose Special conditions in hazardous area Schematic diagram of area classification Area classification Types of system and operating information Types of system System start up System shut down System functions Technical specifications 5 956 486 A2005937 06 03 Table of contents Tm c m Im on 0 English Care and maintenance General information Maintenance schedule Maintenance tasks Troubleshooting Fault finding Mounting kits and accessories Mounting kits non hazardous area Mounting kits hazardous area Accessories Warranty System installation Declaration of Conformity Test record English 1 Safety information and instructions A For your safety The following symbols are used throughout these Operating Instructions A 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 damage to property i Important Denotes operating hints and important information Errors in operation or misuse can result in danger to the operator or other persons due to W high water pressure B hot liquids
17. d to carry out maintenance tasks B Operator Tasks that are marked Operator may only be carried out by persons who have been instructed in the safe operation and maintenance of high pressure systems B Customer service Tasks that are marked Customer service may only be carried out by K rcher Customer Service engineers Maintenance agreement In order to ensure that the system functions reliably we recommend that you conclude a service agreement Please contact your local authorized K rcher Customer Service agent E1 English E Care and maintenance 2 Maintenance schedule SHD R 3000 Frequency Type of pump Procedure SHD R 3000 F 1 2 4 10 Regulate tension in See Maintenance Tasks hours after compression glands initial start up Once Check tension See Maintenance Tasks only after of V belt first 100 operating hours Oil change See Maintenance Tasks Check oil level Oil level must be between MIN or after and MAX marks If level below every 40 MIN fill up with oil operating Standard Check oil condition If oil is milky white change oil S SVA and tighten piston seal See SLA Maintenance Tasks SSR Check oil condition If oil has thinned out or is discoloured change oil and tighten piston seal See Maintenance Tasks Check high pressure Visual check of high pressure hoses hoses for signs of damage such as wear due to abrasion inner fabric is visible creases due to be
18. duio5 x S 0J UO9 291100 3 jun soueusjuley Jeu 1e pessoidwog SWE enImS sayoulm jenueyy w esou uonons V9 Jeu epo JIM ullu oor Jeq Z Y die pesseJduio Ul z esou unies jeuondo W14 000 Y AHS 01 peyoeye gif suelo ordooseje L Alfred K rcher GmbH amp Co KG Alfred K rcher Str 28 40 D 71364 Winnenden Auedoud jenjoaijeju no jo uonesi n eAisnjoxe oj JYBU y eaiese M 1uesuoo uayl m soud ano Jnoyyim Seed Du oj uo passed eq 1 eui Jou peonpoudei eq jou Jsnw Jeays SIUL G7 5 956 486 A2005937 06 03 English H Warranty The applicable warranty conditions in different countries are issued by the respective national distributor of KARCHER products In the event of a warranty claim please contact your original dealer or the nearest authorized customer service centre H1 SHD R 3000 5 956 486 A2005937 06 03 SHD R 3000 This system should only be installed by m K rcher Customer Service engineers m persons who have been specially authorized by K rcher Unpacking the system Unpack the system and deliver the packag ing materials to an appropriate collection point for recycling For static systems Preparing the installation site m A horizontal flat area or base of 1400 x 750 mm is required for installing the System m Place the system on the designated area or base and
19. e current EC Directives and the standards used The undersigned act on behalf of and with power of attorney issued by the Management eso P ride S Reiser H Jenner J2 SHD R 3000 Alfred K rcher GmbH amp Co KG Cleaning Systems Alfred K rcher Str 28 40 P O Box 160 D 71349 Winnenden Tel 49 71 95 14 0 Fax 49 71 95 14 22 12 5 957 384 06 03 Alfred K rcher Kommanditgesellschaft Registered office Winnenden Register court Waiblingen HRA 169 Personally liable shareholder K rcher Reinigungstechnik GmbH Registered office Winnenden 2404 Waiblingen register court HRB Managing Directors Dr Bernhard Graf Hartmut Jenner Georg Metz 5 956 486 A2005937 06 03 SHD R 3000 K Test record English Type no Factory no Commissioned on Tests carried out on Results Signature Tests carried out on Results Signature Tests carried out on Results Signature Tests carried out on Results Signature 5 956 486 A2005937 06 03 K1
20. eplace pulsation damper Replace seal Tighten piston seal see Maintenance Tasks Re adjust pressure switch and volume control valve Re adjust closing force and filling level see Chapter G1 Float tank Replace seal Operator Operator Operator Operator Operator Customer service Customer service Operator Customer service Operator Operator 5 956 486 A2005937 06 03 SHD R 3000 N Hazard The following mounting and accessory kits must not be used for operation with solvents or ina hazardous potentially explosive atmosphere area 1 Mounting kits non hazardous area G Mounting kits and accessories Float tank with float valve Function B The float valve fitted inside the float tank controls the level of liquid m The float tank serves as a service reservoir for the cleaning liquid W f water is used as the cleaning agent the float tank corresponds to mains disconnection according to EN 1717 B n the case of the mobile systems the float tank is fitted to the trolley L nn 4 amp mm Oo Settings Closing force Extending the length of L increases the amount of closing force i e even when the cleaning liquid is fed in at quite high pressure the float valve is able to shut off the supply Technical specification Capacity up to overflow 30 litres 5 956 486 A200593
21. ly explosive atmospheres exists constantly for long periods of time or frequently as a mixture of air and combustible gases vapours or mists Zone 1 is an area in which hazardous potentially explosive atmospheres consisting of a mixture of air and combustible gases vapours or mists can occasionally form during standard operation Zone 2 is an area in which hazardous potentially explosive atmospheres consisting of a mixture of air and combustible gases vapours or mists do not normally occur during standard operation or only for a short time Zone 20 is an area in which hazardous potentially explosive atmospheres in the form of a cloud of combustible dust contained in the air exist constantly frequently or for long periods of time A5 SHD R 3000 Zone 21 is an area in which hazardous potentially explosive atmospheres in the form of a cloud of combustible dust contained in the air can occasionally form during standard operation Zone 22 is an area in which hazardous potentially explosive atmospheres in the form of a cloud of combustible dust contained in the air do not form during standard operation or only for a short time 5 956 486 A2005937 06 03 SHD R3000 B Types of system and operating information English 1 Types of system Static or mobile systems The static system m is intended to be installed on a base m has been mounted onto a rigid steel frame m is most suitable for use
22. ncy see Chapter B Dimensional diagram Static system Mobile system approx 1100 700 Barth W dj E dm Sa l2 5 956 486 A2005937 06 03 SHD R 3000 EC Declaration of Conformity J Declaration of Conformity We herewith declare that the design and type of machine named in the following as well as the model marketed by us complies with the relevant fundamental health and safety requirements of the EC Directives This declaration becomes invalid if modifications are made to the machine which have not been previously agreed with us Product Type High pressure cleaner SHD R 3000 F S SVA Relevant EC Directives EC Machinery Directive 98 37 EC EC Low Voltage Directive 73 23 EEC amended by 93 68 EEC EC Electromagnetic Compatibility Directive 89 336 EEC amended by 91 263 EEC 92 31 EEC 93 68 EEC Harmonised standards used DIN EN 60 335 1 DIN EN 60 335 2 79 DIN EN 55 014 1 2000 A1 2001 DIN EN 55 014 2 1997 DIN EN 61 000 3 2 2000 DIN EN 61 000 3 3 1995 A1 2001 National standards used Internal measures ensure that serial production units always comply with the requirements of the current EC Directives and the standards used The undersigned act on behalf of and with power of attorney issued by the Management aL AI AA 45 Esx gees S Reiser H Jenner 5 956 486 A2005937 06 03 English Alfred K rcher GmbH amp
23. nding porous and split rubber Replace any damaged hoses E2 5 956 486 A2005937 06 03 2 Maintenance schedule Frequency Type of pump Action Procedure By whom SHD R 3000 F Monthly Standard Check pump for leaks If during operation more than Operator or after S SVA 5 droplets per minute leak from every 160 the pump tighten piston seal operating hours az Lubrication Lubricate with 2 pump strokes of Operator grease gun per nipple After Oil change See Maintenance Tasks Operator every 200 operating hours Six monthly Standard Oil change See Maintenance Tasks Operator or after S SVA every 500 SLA operating SSR hours After Check and clean valves on pump Customer every 1000 Check piston service operating Replace set of seals if required hours Oil change Check for correct functioning Annually Check tension of V belt See Maintenance Tasks Operator Formal test Inspection in accordance with Specialist Directive on Working With Liquid spraying Devices 5 956 486 A2005937 06 03 E3 English 3 Maintenance tasks E Care and maintenance Changing the oil AN Danger Burns hazard due to hot oil and hot system components Allow pump to cool down for 15 minutes before changing oil l Important Waste oil may only be disposed of by the operators of special collection points Please deposit your waste oil at one of these locations Polluting the
24. nt concentrates that are to be used with this system l Important According to the UVV accident prevention Guidelines BGV D15 Art 23 high pressure sprayers must be checked by an expert with the initial startup and at least every 12 months thereafter K rcher Customer Service engineers are qualified to carry out the prescribed tests on your system The results of the test procedures must be recorded in writing A form into which the test results can be entered is shown in Chapter K Test Record A2 English 8 Using the system for its intended purpose A For your safety This system is used for pumping a cleaning liquid at high pressure for the purpose of BW with the handgun attached cleaning containers boxes cases and equipment parts etc W with the interior cleaner attached cleaning enclosed containers drums barrels etc Cleaning the following is considered to be contrary to the intended purpose and is strictly forbidden m Persons and animals The high pressure jet represents a serious injury hazard B loose objects Such items could be catapulted away by the high pressure jet causing damage to property or injury to persons If water is used as the cleaning liquid the system must be protected against freezing temperatures Damage could be caused if water freezes inside the system 9 Special Conditions in a hazardous area 1 The pump may only be u
25. onally Remove guard over V belt B Test belt tension Press down on belt which should not move by more than 1 cm If necessary adjust as follows Slacken off mounting bolts 1 Tension V belt by adjusting bolts 2 Ensure that V belt runs in a straight line Tighten mounting bolts 1 Refit belt guard 5 956 486 A2005937 06 03 E Care and maintenance English Replacing the V belt Switch off system and ensure that it cannot be switched back on again uninten tionally m Remove guard over V belt Slacken off mounting bolts 1 Unscrew bolts 2 fully and push motor towards pump Replace V belt Tension belt by adjusting bolts 2 Ensure that V belt runs in a straight line Tighten mounting bolts 1 Refit belt guard E5 English AN Danger Injury hazard while working on the system Before commencing any work Turn mains supply voltage off at system master switch and ensure that it cannot be turned back on again unintentionally W Turn off supply of cleaning liquid m fahandgun is being used release any F1 remaining pressure in the system by pressing the lever on the handgun F Troubleshooting SHD R 3000 Who is permitted to repair faults on the system B Operator Tasks that are marked Operator may only be carried out by persons who have been instructed in the safe operation and maintenance of high pressure systems m Qualified electrician Persons who have a p
26. regulations and other national conditions 13 Hoses must be electrostatically conductive resistance R 1 M9 14 Only use cleaning liquids with a conductivity G 1000 pS m 15 All parts in contact with the media are to be connected to the earth connection system 16 The electric motor used must have a prescribed type testing certificate to 94 9 EC 5 956 486 A2005937 06 03 SHD R 3000 A For your safety 10 Schematic diagram of area classification English Zone 1 Telescopic jib Winch for telescopic jib Winch for moving the spray head High pressure spray head up and down Swivel device Zone 0 20 Rotating spray head Electrically conductive hose Circulation tank with filter device Push in strainer Suction strainer Fine filter Circulating medium 5 956 486 A2005937 06 03 A4 English 11 Area Classification A For your safety In the BetrSichV and EN 1127 1 hazardous potentially explosive areas are classified into zones according to the frequency and duration of the occurrence of hazardous potentially explosive atmospheres It is the responsibility of the owner operator to define these zones Notes on area classification are given in the BetrSichV EN 1127 1 BGR 104 Ex Guidelines of BG Chemie and in DIN EN 60 079 10 Zone 0 is an area in which hazardous potential
27. rive runs in an oil bath m Oil compartment for drive unit is separa ted from pressure chamber for cleaning liquid B Pump has three cylinders each with a pressure chamber and one suction chamber Drive for the high pressure pump W The high pressure pump is driven by an electric motor B V belts attached to the electric motor provide the actual drive to the high pressure pump 5 956 486 A2005937 06 03 C System functions English Safety valve AN Danger Injury hazard due to excessive pressure within system Do not adjust safety valve the safety valve has been pre set and sealed in the factory Adjustments should only be made by a K rcher Customer Service engineer The safety valve opens if the pressure exceeds the prescribed maximum level Cleaning liquid is allowed to escape thereby avoiding damage to the pump and high pressure hoses due to too much pressure in the system Pulsation damper The pulsation damper compensates for the variations or peaks in pressure This reduces the wear on pump components C2 English D Technical specifications SHD R 3000 F SHD R 3000 F S SHD R 3000 F SSR SHD R 3000 F SLA SHD R 3000 F SVA SHD R 3000 SHD R 3000 F LM Electrical connection Motor rating with Class of protection IP55 Class of protection IP55 Ex Mains fuse Direct starting Mains fuse Star delta starting Performance data Pump flow rate L h Working pre
28. rofessional quali fication in an electrical engineering discipline B Customer Service Tasks that are marked Customer Service should only be carried out by a K rcher Customer Service engineer 5 956 486 A2005937 06 03 SHD R 3000 F Troubleshooting English 1 Fault finding System Control No voltage supply to Check mains voltage Electrician does not circuitry System or control start up circuitry Control Fault on Electrician circuitry motor contactor fuses Control Bimetal relay has Wait for motor to cool down and Electrician circuitry switched off then re set relay Measure motor current If current consumption is too high relieve tension on piston seal see Maintenance Tasks Pressure Defective or wrongly Release pressure from system Customer switch adjusted pressure switch and check pressure valve service Accessory kit System No tension in V belt Tighten V belt see Maintenance Operator does not Tasks build up pressure Filter or Blocked filter or strainer Remove and clean filter or Operator strainer in supply line strainer Accessories Inlet hose Supply volume too small Test whether the correct amount Operator of cleaning liquid is being supplied to system High pressure Worn out valves or Replace defective part Operator pump broken valve spring High pressure Defective piston seal or Replace defective part Customer pump valve service Detergent Pump taking in air due Fill
29. s see E 3 Maintenance work 3 System shut down l Important Before carrying out the shut down procedures flush through without adding cleaning agents This prevents a crust forming on the seals or that they become stuck fast either of which would lead to premature wear During the recirculation operation with solvent the system must be rinsed through thoroughly using clean solvent before the shut down procedure takes place B Switch system off at master switch m Turn off cleaning liquid supply m If a handgun is being used release any remaining pressure in the system by pressing the lever on the handgun B5 English C System functions SHD R 3000 x pX 1 Transmission casing 2 Crankshaft with drive 3 Seal oil compartment 4 Gland 5 Seal grease compartment C1 6 Lubrication nipple or leakage pipe 7 Sealing pack high pressure 8 Piston 9 Suction valve 10 Pressure valve 5 956 486 A2005937 06 03 SHD R 3000 Operational sequence of the high pressure pump m Cleaning liquid is taken in by the piston m Suction valves 9 prevent cleaning liquid from flowing backwards m Action of piston pumps cleaning liquid onwards B Pressure valves 10 prevent cleaning liquid from flowing backwards m Action of piston takes in cleaning liquid again Features of the high pressure pump B Horizontal construction m D
30. sed in zones which correspond to the type of explosion protection given on the rating plate 2 The cleaning liquid must not contain more than 196 by weight of undissolved solids 3 The interior cleaner must be electrostatically grounded 4 The cleaning liquid pump may only be run if itis filled with liquid 5 The nominal pressure of the pump must not exceed 50 bar when used with solvents A3 SHD R 3000 6 The pump s flow rate must not exceed 50 l min when used with solvents 7 The operating temperature of the cleaning liquid made up of water with cleaning agent must not exceed 60 C 8 The operating temperature of the cleaning liquids must not exceed 20 C where solvents lyes alkali solutions and acids are used 9 The pump must be inspected after a reasonable operating time to ensure it has a faultless condition and function among other things bearings for wear pump for leaks tension in the V belt Repair if necessary 10 The pump may only be operated with cleaning liquids against which the materials from which the pump is made have adequate resistance 11 Cleaning liquids which contain combustible solvent fractions must correspond to the temperature classes IIA and IIB Solvents in the temperature class IIC must not be sprayed 12 The pump may only be operated in Zone 1 during cleaning Ensure compliance with the conditions applicable within the scope of the BetrSichV industrial safety
31. ssure bar 55 Pressure setting bar 65 Safety valve Max inlet temperature for water with detergents Max temperature for solvents alkalis acids Noise pressure level EN 60704 1 Dimensions and weight Width approx Weight approx Miscellaneous Ambient conditions temperature 2 40 Type of protection possible Il 2 G ck T3 Il 2 G ck T4 Oil capacity L 3 3 3 Type of oil Oil 40 Special Order no 6 288 003 3 x 1 litre pack Available as special version with 60 Hz Versions for other voltages available D1 5 956 486 A2005937 06 03 SHD R 3000 1 General information E Care and maintenance It is a fundamental requirement for ensuring that this system functions safely and reliably that maintenance is carried out regularly in accordance with the following schedule Use only original spare parts supplied by the manufacturer or recommended alterna tives for example B replacement and wearing parts B accessories m fuels lubricants etc B detergents A Danger Injury hazard while working on the system Before commencing any work m Turn mains supply voltage off at system master switch and ensure that it cannot be turned back on again unintentionally W Turn off supply of cleaning liquid m fahandgun is being used release any remaining pressure in the system by pressing the lever on the handgun 5 956 486 A2005937 06 03 English Who is permitte
32. ty valve bar SHD R 3000 F SSR Water 85 100 The pistons are made VE water from ceramic materials Water with other pump parts that K rcher RM come into contact with Acids acids are made from Alkali stainless steel amp solutions Ex versions possible VE Fully demineralised water RM RM Alkali cleaning agent e g RM31 max 0 2 Acidic cleaning agent e g RM25 max 0 1 Max temperature 60 C Higher temperatures available on request precompression pump required 1 Caution Increased material removal in hydrochloric and sulphuric acid therefore rinse neutralise immediately after use Reduced resistance against contaminated acids If necessary contact Karcher Acids max temperature 20 C Nitric acid max 10 Acetic acid max 10 Formic acid max 10 Phosphoric acid max 10 Citric acid max 10 Sulphuric acid max 0 5 Hydrochloric acid max 0 5 2 Sodium hydroxide solutions max 10 without hypochlorite fractions max temperature 20 C Potassium hydroxide max 10 without hypochlorite fractions max temperature 20 C F Mobile system Other cleaning liquids may only be used after being released by Karcher 5 956 486 A2005937 06 03 B3 English B Types of system and operating information SHD R 3000 Cleaning liquids Type of system Cleaning liquid Working Comments see rating plate pressure Pressure setting for safe
33. ty valve bar SHD R 3000 F SLA Water 85 100 Version with increased VE water working pressure Water with Leaked liquid is collected in K rcher RM a pipe leakage recycling Alkali solutions Ex versions possible Ex SHD R 3000 F LM Water 50 65 Explosion proof version VE water Leaked liquid is collected in Water with a pipe leakage recycling K rcher RM Additional pressure switch as Alkali safety device optional solutions Solvents VE Fully demineralised water Conditionally resistant use possible however Cu and Zn ions in the medium Acidic cleaning agent e g RM25 max 0 1 Max temperature 60 C Higher temperatures available on request precompression pump required Sodium hydroxide solutions max 1096 without hypochlorite fractions max temperature 20 C Potassium hydroxide max 10 without hypochlorite fractions max temperature 20 C Solvents max temperature 20 C 1 Hydrocarbons e g petroleum 2 Aromatic compounds e g benzene toluol 3 Ketones e g MEK methyl ethyl ketones acetone 4 Esters e g butyl acetate methyl acetate 5 Glycols e g butyl glycol 6 Mixed solvents e g butyl acetate 85 isobutyl acetate 85 85 85 butyl acetate 15 n butanol 7 Regenerates distillates made from various solvents which have already been used for cleaning purposes or similar F Mobile system
34. ves m watertight shoes 5 956 486 A2005937 06 03 SHD R 3000 5 Emergency drill A For your safety m Turn mains supply voltage off at system master switch m Turn off supply of cleaning liquid m f a handgun is being used release any remaining pressure in the system by pressing the lever on the handgun 6 Safety devices Safety valve AN Danger Injury hazard due to excessive pressure within system Do not adjust safety valve The safety valve has been preset and sealed in the factory Adjustments should only be made by a K rcher Customer Service engineer 7T Applicable regulations Accident prevent regulations m Working with liquid sprayers BGV D15 If water is used as the cleaning liquid m Observe local regulations for disposal of waste water m Waste water should be directed into the main drainage system in accordance with local regulations If the water to be used is drawn from the main supply network B install a mains disconnector to EN 1717 e g float tank with float valve m BetrSichV industrial safety regulations 5 956 486 A2005937 06 03 English If acids alkaline solutions or solvents are to be used B Observe the legal requirements that are currently applicable in your country In Germany the regulations of the industrial employer s liability insurance associations apply BGI 504 B Observe instruction leaflets provided by manufacturers of the deterge

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