Karcher HD 6000 C User's Manual
Contents
1. part no 6 288 061 Do NOT use alternate oil products Check unit for Entire water system Functional faults on valves or pumps Operator lime deposits may indicate calcification Use trained in procedures outlined on the following decalcificat pages procedures Tighten Control cabinet Tighten all terminal strips of Electrician terminal strips components master mains power circuit Annually Safety check Entire system Safety inspection pursuant to Expert guidelines covering liquid spraying Customer devices Refer to section A 12 service E5 5 956 648 A10369 06 98 HD 4000 C HD 6000 C 3 Removing the Cover E Maintenance Certain repair or service procedures may require the removal of the cover Proceed as follows m Remove cover A m Remove both cover retaining screws B m Slide off cover horizontally as indicated by the arrow 4 Decalcification A 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 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 de scaling acid with test mark may be used For scale removal in the hi2. Water Flow volume L h 3900 3900 3900 3900 Max supply temperature C 60 80 60 80 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 Suppi temperatur S S E Eo 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 5 956 648 A10369 06 98 D3 English 2 Connected Loads D Specifications HD 4000 C HD 6000 C HD 6000 C HD 6000 C 1 967 045 1 967 045 with hot water accessory kit 2 638 697 Mains power Power type 3 50 Hz 3 50 Hz Voltage V 400 400 with water temp of 20 C Kw 15 15 Power supply cable mm 4x10 4x10 Control cable mm 5x 1 5 5x 1 5 Motor starter type ASA A A External pre fusing A 50 50 slow Water Flow volume L h 5600 5600 Max supply temperature C 60 80 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 C approx 10 to 18 approx 10 to 18 Min flow pressure bar 2 2 Max flow pressure bar 8 8 Supply line nominal dia mm 15 15 D4 5 956 648 A10369 06 98 HD 4000 C HD 6000 C D Specifications English 3 Dimension Diagram 5 956 648 A10369 06 98 D5 English 1 Maintenance Contract E Maintenance Only a properly maintained system is really safe It is in you
3. exiting from the system must not be used as drinking water Switching the System ON LIE Open the water tap for water supply and cooling water N Turn the Emergency STOP master switch Q1 to the I ON MM Y U position 4 Press the unlock button S1 m 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 K Press the unlock button S1 4 Stopping the System B System Operation N Turn the system s Emergency S STOP 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 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 frost free 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 If a system is to be shut down during cold periods it must first be flushed wi
4. in accordance with the aforementioned regulations must be carried out by the Karcher 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 high pressure 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 Karcher A4 English B System Operation 1 Operating Controls HD 4000 C HD 6000 C Emergency STOP master switch Q1 Switches the system ON and OFF also serves as Emergency STOP switch alke Unlock button with operational indicator light starts the availability time of the pump by the press of the button serves for resetting after malfunctions is alight when the pump
5. is running and during the availability time Pressure gauge Indicates the pressure downstream of the pump also serves as function control Indicator lamp Motor Fault Illuminates when the motor protection switch has tripped switching off the motor motor fault amid Alea Indicator lamp General Fault is illuminated for 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 Elapsed hour meter Counts the total pump operating hours Warning Label Danger Danger of Death by electrical shock Control cabinet may be opened by trained personnel only Control cabinet closure Used for opening the control cabinet May be opened by trained personnel only LI all SSOSSSIBHBISS ai JLo Fault indication on the printed 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 2 Using Emergency STOP B System Operation switch to the 0 OFF position Turn the Emergency STOP master N m O
6. 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 m VDMA guideline standardised leaflet 24416 Fixed Installation High Pressure Cleaning Systems m VDE Regulations VDE Professional Association of German Electricians m 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 G1 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 netw
7. 10369 06 98 HD 4000 C HD 6000 C Handguns with different spray lances Dependent on the cleaning application different spray lance extensions are required ranging from 250 mm for one hand operation to 2040 mm for cleaning high objects H Accessories D e Spray lance with bypass valve Featuring two spray patterns and operation in conjunction with cleaning detergents length approx 1000 mm 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 Order no angle 6 415 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 25N The spraying device i e handgun is connected by means of an in line quick coupling 5 956 648 A10369 06 98 English System tap workstation Features injector for metering cleaning detergent into pressure side wall mounted container console and hose keeper remote release 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 i
8. 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 waste oil collection point e l 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 K rcher 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 For Your Safety System Operating Hazards Safety Information and Instructions Danger Sources Hazards posed by Accessor
9. ctrical connections in accordance with the Specifications contained in the Operating Instructions m Check the function of decalcifying component if required m Check water supply for required delivery volume and maximum allowable temperature m Check cold water cooling circulation Verify cooling water volume refer to Specifications and connection data Adjusting cooling water volume 2 on pressure regulator Locking screw E Install float reservoir overflow line m Check pump oil level Remove threaded plug from oil reservoir Threaded plug Z A f f 4 UL IA AUTHORISED PROFESSIONAL PERSONNEL ONLY 5 956 648 A10369 06 98 G2 English G System Installation HD 4000 C HD 6000 C AUTHORISED PROFESSIONAL PERSONNEL ONLY 6 Space Assignment Plan dm ca 1000 q_e Il L L g 1070 850 20 co ol ly A Pressure outlet M30x1 5 B Water inlet G 1 HD 4000 C G 1 HD 6000 C C Overflow O D 41 D Cooling water inlet G 3 4 c Ioanmn Cooling water supply Rp 1 Water outlet Mains supply Control line Control cabinet min 200 max 500 AUTHORISED PROFESSIONAL PERSONNEL ONLY G3 5 956 648 A
10. ed version PROSS Pprox PPOX PPOX upon request lower values can be set by customer service 5 956 648 A10369 06 98 D1 English 1 Equipment Features D Specifications HD 4000 C HD 6000 C HD 6000 C HD 6000 C 1 967 045 1 967 045 with hot water accessory kit 2 638 697 Supply volume L h 5600 5600 Operating pressure bar 60 60 Max operating pressure bar 90 90 safety valve Dimensions Length mm 1090 1090 Width mm 615 615 Height without pedestal mm 1070 1070 Weight empty kg 260 260 Capacity Float reservoir L 89 89 max capacity Pump housing motor oil order no 6 288 061 L 2x 1 8 2x1 8 1 Litre packaging Sound level dB A approx 80 approx 80 Sound level sound insulated version OBINI approx 0 approx 79 upon request lower values can be set by customer service D2 5 956 648 A10369 06 98 HD 4000 C HD 6000 C Specifications English 2 Connected Loads HD 4000 C HD 4000 CH HD 4000 C HD 4000 C 1 509 035 1 509 115 Scandinavia Scandinavia 1 509 515 1 509 515 with hot water accessory kit 2 638 689 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 ora S ss assise Power supply cable mm 4x10 4x10 4x16 4x16 Control cable mm 5x 1 5 5x 1 5 5x 1 5 5x 1 5 Motor starter type A A A A A A A A External pre fusing n 50 50 63 63 slow
11. ersons 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 m making the Operating Instructions available to the system operator E 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 m For protection against spray water water repellent protective clothing must be worn 9 Safety Measures on the Installation Site N 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 10 Protective Devices A For Your Safety N System operation is stopped by the S Emergency STOP master switch N located at the instrument panel E Inadvertent contact with all hot system compone
12. f the flow of cooling water falls below the prescribed rate see Technical specifica tions 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 E6 English F Trouble Shooting HD 4000 C HD 6000 C Problem Possible Cause Remedy by whom High pressure Leaking suction side tubing Check fastener and hose Operator pump fails to system connections come up to l pressure Water starvation Correct the cause Operator Defective valve in pump Replace valves Customer High pressure solenoid valve Service fails to close Pronounced pump Defective dashpot replace Operator knock pressure l l DA gauge pointer Pump is drawing air Check suction line Operator oscillates Defective valve seat or valve Replace as required Customer spring Service With hot water Defective or calcified Check precompression Operator accessory kit only precompression pump pump Overflow volume Blown hose between overflow __ replace Operator is blown outinto valve and float valve open and or an Defective overflow valve Repair or exchange Customer CAUTION For safety reaso
13. fective hose coupling Check hose coupling daily for tightness and absence of leakage A2 English A Danger m 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 m Poisoning hazard Chemical burn hazard Fire hazard Protect cleaning detergent storage against access by unauthorised persons Observe all safety instructions for cleaning detergents 5 Noise Protection A For Your Safety 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 noise polluted 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 A3 HD 4000 C HD 6000 C 7 Authorised Operators The operation of the system is restricted to p
14. gh pressure system the use of K RCHER 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 English 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 pre mixed in the float reservoir for shortterm system operation in circulation idle pressure mode Allow chemicals to activate and conclude by flushing the system Decalcifying the cooling coil for the pump motor I
15. he orifice of the spray lance nozzle When operating the spray lance keep in mind the following A Danger m 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 English A Danger m njury 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 m Accident hazard due to hidden damage Clean tires and valve stems from a minimum distance of 30 cm m njury hazard through exiting water jet of high pressure or high temperature water Only original Karcher 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 m njury 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 m njury hazard through de
16. ies Noise Protection Workplaces Authorised Operators Personal Protective Equipment Safety Measures on the Installation Site 10 Protective Devices 11 Emergency Drill 12 Guidelines and Regulations 13 Proper Use of the Equipment OMAN DOOD WDYD PB 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 C System Functions 1 Flow Diagram 2 Description of Functions 5 956 648 A10369 06 98 Table of Contents WN O Ro Pp Mm DARNO English Specifications Equipment Features Connected Loads Dimension Diagram Maintenance Maintenance Contract Maintenance Schedule Removing the Cover Decalcification Trouble Shooting System Installation Placement Connections High pressure Installation Hard water Treatment Preparations for Commissioning Space Assignment Plan Accessories Customer Service English 1 System Operating Hazards A For Your Safety HD 4000 C HD 6000 C 3 Danger Sources 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 ob
17. ine Cleaning and disinfecting RM 32 D liquid alkaline Disinfecting RM 735 D liquid alkaline Lime RM 25 liquid ASF strongly acidic EN RM 59 liquid ASF acidic mineral deposits foaming cleanser RM 25 liquid ASF strongly acidic Sanitar Lime basic cleaning y urinal deposits RM 59 liquid ASF acidic installations soaps etc foaming cleanser RM 68 liquid ASF acidic for short term use only Two step method Flush with clean water ASF abscheidefreundlich H2 5 956 648 A10369 06 98 HD 4000 C HD 6000 C J Customer Service English System Type Works No Commissioned date Inspected Results Comments Inspected Results Comments Inspected Results Comments Inspected Results Comments Signature 5 956 648 A10369 06 98 Ji
18. ligated m to be appropriately qualified m to diligently observe these Operating Instructions 2 Safety Instructions and Information Throughout the present Operating Instructions the following symbols are used 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 property damage e l Important Denotes operating hints and important information A1 Sections of the water volume contained in the system are under high pressure High pressure water jets may exit from damaged system components posing injury and or scalding hazards General Hazard Overview A Danger m njury 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 m 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 m njury 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 m Explosion hazard The use of
19. n 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 m njury 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 m njury 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 m 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 m Accident hazard due to hidden damage Clean tires and valve stems from a minimum distance of 30 cm m njury hazard through exiting water jet of high pressure or high temperature water Only original Karcher 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 A Danger m Health hazard through cleaning detergents Due to the possible adding of detergents to the system water the water
20. n 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 H1 H Accessories English HD 4000 C HD 6000 C Area of Contamination type Approx pH value application Application method Cleaning agent 1 solution Automotive RM 55 1000 liquid ASF slightly alkaline petrol stations Dust road grime mineral oils RM 22 80 powder ASF alkaline motor carriers on painted surfaces RM 81 liquid ASF alkaline vehicle fleets RM 803 liquid ASF alkaline RM 820 hot wax ASF neutral Vehicle protection RM 821 spray wax ASF neutral RM 824 Super Perlwachs ASF neutral RM 22 powder ASF alkaline Oils RM 55 liquid ASF slightly alkaline Metal workin greases RM 81 liquid ASF alkaline 9 dust RM 31 liquid ASF strongly alkaline industry vene er and similar heavy contamination contamination RM 39 liquid slightly alkaline with corrosion protection RM 55 liquid ASF slightly alkaline Light to medium RM 81 liquid ASF alkaline Food SERI rocessinh contamination y I greases oils RM 58 liquid ASF alkaline industry large surfaces foaming cleanser RM 31 liquid ASF strongly alkaline Smoky resin RM 33 liquid strongly alkal
21. nd Pressure controller clean strainers Check float Float reservoir Water level must stand 40 mm Operator valve below the overflow weir With float valve closed no water may exit For adjustment information refer to the Service Manual Check Pressure relief valve on When functioning correctly the Operator pressure relief pump motor must reach full RPM within valve 2 seconds If required clean the strainer upstream of the pressure release valve Prior to cleaning Shut OFF water set Emergency STOP master switch to OFF Check run on System control Close utiliser e g handgun Operator interval After the after running time approx 15 sec the pump must switch off Check Pressure switch The pump is stationary as no water Operator automatic is being drawn Open the handgun switching on When the pressure in the high pressure network drops below 25 bar the pump must switch on Tighten hose All hose clamps in on the Tighten hose clamps with torque Operator clamps unit wrench Torque 28 mm nominal diameter 2 Nm 29 mm nominal diameter 6 Nm 5 956 648 A10369 06 98 E4 E Maintenance English HD 4000 C HD 6000 C Interval Procedure Subject Assembly Activity By whom Semi Oil change All high pressure pumps CAUTION Operator annually Hot Oil Scalding Hazard or after Prior to oil change allow pump to 1000 cool for 15 minutes operating Drain oil and fill pump on each side hours with 1 8 L oil
22. ns overflow valve Service excess water is vented outdoors Shut down the system Water is returning System is calcified Decalcify system circuits Operator to float reservoir refer to Maintenance despite full volume section m Defective spray lances and or Check spray lances Operator nozzles Defective overflow valve Check overflow valve Cust Service Overflow valve Leak in high pressure system Repair leak Operator cycles ON and defective spray gun Oli GESDIIE zar Leaking non return valve or Repair overflow valve Customer usage control piston seal in overflow Service valve Pump does not Blocked strainer upstream of Clean strainer Operator reach working solenoid valve ith A P T Defective pressure relief Replace solenoid valve Customer or A starter f solenoid valve Service F1 5 956 648 A10369 06 98 HD 4000 C HD 6000 C F Trouble Shooting English Problem Possible cause Remedy by whom ee Insufficient water in Check site water supply Operator si float tank General fault and Water supply fault LED light up on printed circuit board Temperature of the water Reduce inlet temperature Operator inlet too high ua Cooling water quantity too low cu sia ang Strainer in pressure reduction Clean strainer Operator temperature fault valve contaminated LED light up on Mains water pressure too low Raise pressure Operator rin
23. nts is prevented by the protective housing 11 Emergency Drill Disable the system by activating o the Emergency STOP master N switch m 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 Karcher customer service engineers qualify as certified professionals and are authorised to carry out the aforementioned inspection 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 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
24. ock button activated Pressure switch replace Customer operational indicator light defective Service illuminates system does not start up While activating the HD Flow switch does not check flow switch Customer pistols the unit switches function Service itself off Electrician Unlock button activated operational indicator switch Emergency STOP Customer system starts up light defective master switch Q1 to Service operational indicator light position 0 open control Electrician does not illuminate cabinet and verify or replace components System does not switch on Flow switch S2 replace upper part of flow Customer defective switch Service Electrician Remote start button does Systemina eliminate the cause and Operator not function malfunction state press unlock button 5 956 648 A10369 06 98 F4 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 ac cess In the absence of sufficient space the elastic feet can be used by themselves 2 Connections The
25. ork 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 high pressure lines as low as possible the following recommendations should be used as mandatory guidelines Delivery Tubing line Hose size 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 5 956 648 A10369 06 98 HD 4000 C HD 6000 C G System Installation English AUTHORISED PROFESSIONAL PERSONNEL ONLY 4 Hard water Treatment Excessive water hardness gt 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 m Thoroughly rinse entire HD system HD 4000 6000 C also Check entire HD system for correct assembly and lack of leaks m Complete ele
26. pen the handgun until the water pressure has dissipated m 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 N Danger m njury 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 m 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 A Danger m 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 English A Danger m njury 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 m Bur
27. r 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 Karcher 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 m Spare parts and wearing consumable parts m Accessory parts m Operating media m Cleaning media E1 HD 4000 C HD 6000 C A Danger m Accident hazard through improper maintenance procedures Without exception maintenance work and service repairs must be performed by personnel or by the Karcher customer service m njury 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 m Electric shock hazard Switch OFF and secure master switch before commencing work on the system 5 956 648 A10369 06 98 HD 4000 C HD 6000 C E Maintenance English Safety valve Pump side Pressure controller Solenoid valve cooling water Drip pan Pressure relief valve Cooling coil Float reservoir with float valve Overflow valve pres
28. remedy the cause see also the section on Trouble Shooting Check hose Hose quick couplings Pump must be running Operator quick coupling between system tap and Check for leakage in tandem and high pressure hose to individual operation handgun Connect clutch and check clutch locking function Customer Replace defective clutches Service Check Dashpot on each pump side A defective dashpot is readily Operator dashpot identifiable through increased pump vibration Customer Replace defective dashpot Service E3 5 956 648 A10369 06 98 E Maintenance HD 4000 C HD 6000 C English Interval Procedure Subject Assembly Activity By whom monthly or Check Overflow valve Dependent on the number of Operator after 200 overflow valve high pressure handguns used the operating pressure reading fluctuates between hrs 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 Customer service Check Float switch in float For about 5 seconds press down the Trained low water reservoir float of the low water protection operator sensor facility and check the fault indication authorised on the printed circuit board If to open necessary remove any deposits control cabinet Clean Dirt trap upstream of float Switch OFF unit turn OFF water Operator strainers reservoir release pressure Disassemble a
29. sure switch Flow monitor Oil level sight glass Dashpot 3 _s_ se o a00 9 5 956 648 A10369 06 98 E2 E Maintenance English HD 4000 C HD 6000 C Interval Procedure Subject Assembly Activity By whom Daily Check All handguns Check whether handgun closes Operator handgun properly Check function of safeguard against inadvertent operation Replace defective handguns Check Outlet lines amp hoses leading Check hoses for damage Replace Operator high pressure to workstations defective hoses immediately hoses Accident Hazard Weekly or Check system Entire system Check pump overflow valve and Operator after 40 for leaks tubing installation for leaks If oilis Customer operating present in the drip pan under pump Service hours of if a leak exceeds 10 drops of water per minute call customer service immediately Keep weep holes unblocked Check oil level Both pump sides Check pump oil level MIN level Operator Centre of oil sight glass MAX level up to mark in housing If required top up with oil part no 6 288 061 Check oil Both pump sides If the oil appears milky it must be Operator quality changed In this case it is Customer recommended to change the pump __ Service oil seal also Customer service Check Pressure gauge in control Check system water pressure Operator working panel pressure gauge If pressure is too pressure high or too low investigate and
30. ted circuit board an a sere Cooling coil calcified Decalcify Operator solenoid valve defective replace solenoid valve Oil level too low Check oil level Customer Service Oil change not made owing Check pump parts Customer to which there is oil carbon replace as necessary Service under the piston guide shoes Make an oil change piston seizing Gi Rotation direction of Change rotation direction Electrician precompression pump wrong General fault and Admission pressure of hot water pump too low LED light up Only with ABS Pressure switch Replace pressure switch Customer hot water precompression hot water Service pump in the ABS hot water defective Sit Too many utilisers Close down some utilisers Operator simultaneously opened General fault and Drop in system pressure LED light ce ii Pipe burst in the Turn off installation and Customer without pressure high pressure network repair pipeline Service longer than Pressure switch defective Replace pressure switch Customer 15 seconds Service 5 956 648 A10369 06 98 F2 HD 4000 C HD 6000 C F Trouble Shooting English Motor protection switch Check voltage of the three Customer Q1 or Q2 has triggered phases Service Motor fault lights up owing to overcurrent or Electrician drop out of one phase of power supply system Motor protection switch Set in accordance with Customer falsely set circuit diagram Service Electrician Press
31. ter approx 6 hours E after six attempts at leakage compensation m after the switching off of the supply voltage After expiry of the availability time the system can only be restarted with the unlock button 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 D Specifications English 1 Equipment Features HD 4000 C HD 4000 CH HD 4000 C HD 4000 C 1 509 035 1 509 115 Scandinavia Scandinavia 1 509 515 1 509 515 with hot water accessory kit 2 638 689 Supply volume L h 3900 3900 3900 3900 Operating pressure bar 100 100 100 100 Max operating pressure ban 130 130 130 130 safety valve Dimensions Length mm 1090 1090 1090 1090 Width mm 615 615 615 615 Height without pedestal mm 1070 1070 1070 1070 Weight empty kg 245 245 245 245 Capacity Float reservoir L 63 63 63 63 max capacity Pump housing motor oil order no 6 288 061 L 2x 1 8 2x 1 8 2x 1 8 2x 1 8 1 Litre packaging Sound level dB A approx 80 approx 80 approx 80 approx 80 ound lave dB A approx 70 approx 70 approx 70 approx 70 sound insulat
32. th an antifreeze solution As a rule antifreeze products also contain corrosion inhibitors 5 956 648 A10369 06 98 HD 4000 C HD 6000 C C System Function English 1 Flow Diagram 1 High pressure pumps 9 Flow monitor 2 Float valve 10 Safety valve 3 Dirt trap 11 Solenoid valve cooling water 4 Overflow 12 Pressure controller 5 Low water sensor 13 Dashpot 6 Pressure relief valve 14 Precompression pump 7 Filter with hot water attachment unit only 8 Overflow valve 15 Pressure switch 5 956 648 A10369 06 98 C1 English 2 Description of Functions C System Function 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 i
33. this system in enclosed indoor areas is prohibited m 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 m 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 A 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 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 E manufacturer approved customer service depots E trained professional personnel A Danger m njury 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 m Electric shock hazard Switch OFF and secure master switch before commencing work on the system 4 Hazards posed by Accessories A For Your Safety A sharp and powerful waterjet exits from t
34. ts 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 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 C2 HD 4000 C HD 6000 C 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 E af
35. ure at pump Check pressure adjust as Customer outlet too high necessary Service Available time is less than Site high pressure Seal it off Operator 6 hours network is leaky Pressure switch Replace Kundendienst defective System does not start up Site power supply switch on Operator when unlock button is interrupted pressad pounaleaten ont Emergency STOP switch on Operator illuminates master switch off Motor protection switch check Customer for control system and Service precompression pump Electrician has been triggered Control circuit fuse on replace check cause Customer transformer defective Service Electrician Printed circuit board replace check Customer defective green LED Service does not blink EPROM loose install again check cause Customer Service Electrician F3 5 956 648 A10369 06 98 HD 4000 C HD 6000 C F Trouble Shooting English System runs for about 15 Admission pressure of check pump rotation Customer sec after pressing the hot water too low direction check water Service unlock button and then intake switches off General fault and Admission pressure Pressure switch replace Customer of hot water pump too low precompression Service LED light up hot water pump or cable in ABS hot water defective Pump starts during Pressure switch or replace Customer available time but not by cable to pressure Service opening the handgun switch defective Unl
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