Kärcher HD 4000 C User manual

5.956-648
A 10369
(06/00)
HD 4000 C
1.509-035
1.509-515
HD 6000 C
1.967-045
Operating Instructions

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.
i
Important!
Waste oil may be disposed of only at
designated collection points. Please take
used oil to these special installations.
Remember: It is an offence to contaminate
the environment with waste oil!
Cleaning detergents
All Kärcher cleaning detergents, as
indicated by the ‘ASF’ designation, are
designed to be separator-friendly. This
means that they do not impede the function
of oil separators. A listing of the
recommended cleaning detergents is
featured in the “Accessories” section.

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98) 1
Table of Contents
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
C. System Functions
1. Flow Diagram
2. Description of Functions
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
J. Customer Service

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
A1
A. ForYour Safety
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:
n
to be appropriately qualified
n to diligently observe these Operating
Instructions
2. Safety Instructions and
Information
Throughout the present Operating
Instructions the following symbols are used:
!
Danger!
Denotes an immediate and present danger.
Failure to observe this notice could lead to
severe injury or death.
Caution!
Denotes a potentially hazardous situation.
Failure to observe this notice could lead to
minor injuries or property damage.
i
Important!
Denotes operating hints and important
information.
3. Danger Sources
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
!
Danger!
n Injury hazard through exiting water jet of
high-pressure or high-temperature water.
Even after the Emergency-STOP master
switch has been activated, the system
contains high pressure. After a system
stop, release remaining system pressure
by opening a high-pressure gun.
n Burn injury hazard through hot system
components.
During hot-water operation, do not touch
non-insulated pipe installations and hose
couplings. Grasp the jet lance by the
grip surfaces only.
n Injury hazard through flying debris.
Flying debris or objects can cause injury
to persons or animals. Never aim the
water jet at fragile or loose objects.
n Explosion hazard
The use of this system in enclosed
indoor areas is prohibited.
n Explosion hazard
Injury hazard arising from system
damage.
Beside water, no other liquid media may
be used. This also precludes the
introduction of flammable or corrosive
liquids to the system.
n Health hazard through cleaning
detergents.
Due to the possible adding of detergents
to the system water, the water exiting
from the system must not be used as
drinking water.

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98)
A. ForYour Safety
!
Danger!
n Injury hazard.
Hazard of chemical burns caused by
cleaning detergents.
Scalding hazard through hot water.
Do not aim waterjet at persons or animals.
Strictly observe safety instructions on
detergent labels.
n Accident hazard due to hidden damage.
Clean tires and valve stems from a
minimum distance of 30 cm.
n Injury hazard through exiting water jet of
high-pressure or high-temperature water.
Only original Kärcher high-pressure
hoses are optimised for the demanding
use in the system.
No warranty claims are accepted in the
event that other types of hoses are used.
The waterjet exiting from the spray lance
causes a recoil force which is deflected
upward by the downward angle of the spray
lance nozzle.
!
n Injury hazard through recoil action.
The force of the recoil action may throw
you off balance, and you may fall down.
The spray lance may whip around and
injure persons standing nearby.
Select a secure foothold position and
firmly grasp the handgun.
Never wedge the handgun trigger in the
open position.
n Injury hazard through defective hose
coupling.
Check hose coupling daily for tightness
and absence of leakage.
Hazards posed by defective equipment
!
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:
nmanufacturer-approved customer service
depots
ntrained professional personnel
!
Danger!
n Injury hazard through exiting water jet of
high-pressure or high-temperature water.
Release system pressure before
performing work on system components.
In the case of hot-water operation, allow
unit to cool before commencing work.
n Electric shock hazard.
Switch OFF and secure master switch
before commencing work on the system.
4. Hazards posed by Accessories
A sharp and powerful waterjet exits from
the orifice of the spray lance nozzle. When
operating the spray lance, keep in mind the
following:
!
Danger!
n Deadly electrical shock hazard.
Do not aim the waterjet at
– electrical devices and systems
– at any parts of the system proper
All live components within the working
area must be spray-water protected.
A2

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
!
Danger!
n Health hazard posed by toxic
substances.
Do not spray clean the following
materials, because substances known to
pose a risk to human health may be
swirled up:
– Materials containing asbestos
– Materials that could possibly contain
toxic substances hazardous to human
health.
n Poisoning hazard
Chemical burn hazard
Fire hazard
Protect cleaning detergent storage
against access by unauthorised persons.
Observe all safety instructions for
cleaning detergents.
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 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.
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:
nmaking the Operating Instructions
available to the system operator
nensuring 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.
nFor 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.
A. ForYour Safety
A3

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98)
10. Protective Devices
System operation is stopped by the
Emergency-STOP master switch
located at the instrument panel.
nInadvertent 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.
nRelease 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.
Also applicable are the (German)
Regulations governing liquid spraying
devices, VBG 87, and the Ordinance on
Hazardous Substances VBG ZH 1/220
(GefStoffV).
A. ForYour Safety
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 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 Kärcher.
A4

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
1 2 3 4
1. Operating Controls
B. System Operation
B1
3 8 6 7 1 4 5 2 9
1Emergency-STOP master switch
Q1 Switches the system ON and OFF; also serves as Emergency-STOP switch.
2Unlock 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 is running and during the
availability time
3Pressure gauge Indicates the pressure downstream of the pump; also
serves as function control.
4Indicator lamp – Motor Fault Illuminates when the motor protection switch has tripped,
switching off the motor (motor fault).
5Indicator 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.
6Elapsed-hour meter Counts the total pump operating hours.
7Warning Label Danger!
Danger of Death by electrical shock!
Control cabinet may be opened by trained personnel only
8Control cabinet closure Used for opening the control cabinet
May be opened by trained personnel only
9Fault 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

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98)
2. Using Emergency-STOP
Turn the Emergency-STOP master
switch to the 0 (OFF) position.
n Open the handgun until the water
pressure has dissipated.
n Using the locking feature, secure the
handgun against being opened
inadvertently.
3. Starting the System
Before commissioning this system it is
essential that you read the Operating
Instructions, and to be certain that you
have understood all the information
presented herein.
!
Danger!
n Injury hazard through exiting water jet of
high-pressure or high-temperature
water. Before each system start, check
high-pressure hose, tubing, valves and
high-pressure lance for damages.
Correct any leaks in connections or
couplings without delay.
n Poisoning hazard or chemical burn
hazard through cleaning detergents.
Observe all safety instructions on
cleaning detergent labels. Protect
cleaning detergent storage against
access by unauthorised persons.
A sharp and powerful waterjet exits from
the orifice of the spray lance nozzle. When
operating the spray lance, keep in mind the
following:
!
Danger!
n Deadly electrical shock hazard.
Do not aim the waterjet at
– electrical devices and systems
– at any parts of the system proper
All live components within the working
area must be spray-water protected.
B. System Operation
B2
!
Danger!
n Injury hazard.
Hazard of chemical burns caused by
cleaning detergents.
Scalding hazard through hot water.
Do not aim waterjet at persons or
animals.
Strictly observe safety instructions on
detergent labels.
n Burn injury hazard through hot system
components.
During hot-water operation, do not touch
non-insulated pipe installations and hose
couplings. Grasp the jet lance by the
grip surfaces only.
n Injury hazard through recoil action.
The force of the recoil action may throw
you off balance, and you may fall down.
The spray lance may whip around and
injure persons standing nearby.
Select a secure foothold position and
firmly grasp the handgun.
Never wedge the handgun trigger in the
open position.
n Injury hazard through flying debris.
Flying debris or objects can cause injury
to persons or animals. Never aim the
water jet at fragile or loose objects.
n Health hazard posed by toxic substances.
Do not spray clean the following
materials, because substances known to
pose a risk to human health may be
swirled up:
– Materials containing asbestos
– Materials that could possibly contain
toxic substances hazardous to human
health.
n
Accident hazard due to hidden damage!
Clean tires and valve stems from a
minimum distance of 30 cm.
n Injury hazard through exiting water jet of
high-pressure or high-temperature water.
Only original Kärcher high-pressure
hoses are optimised for the demanding
use in the system.
No warranty claims are accepted in the
event that other types of hoses are used.

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
!
Danger!
n Health hazard through cleaning
detergents.
Due to the possible adding of
detergents to the system water, the
water exiting from the system must not
be used as drinking water.
Switching the System ON
Open the water tap for water
supply and cooling water.
Turn the Emergency-STOP
master switch (Q1) to the I(ON)
position.
Press the unlock button (S1).
nCarry 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
Turn the system’s Emergency-
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.
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 with an
antifreeze solution. As a rule, antifreeze
products also contain corrosion inhibitors.
B. System Operation
B3

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98)
1. Flow Diagram
C1
C. System Function
1High-pressure pumps
2Float valve
3Dirt trap
4Overflow
5Low-water sensor
6Pressure relief valve
7Filter
8Overflow valve
9Flow monitor
10 Safety valve
11 Solenoid valve (cooling water)
12 Pressure controller
13 Dashpot
14 Precompression pump
(with hot-water attachment unit only)
15 Pressure switch
15

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
2. Description of Functions
Water Inlet
The water is conveyed from the float
reservoir to the intake side of the two
pumps. The water level in the float
reservoir is maintained by the float valve
(2). The incoming water is cleaned in the
dirt trap (3). In the case of a float valve
failure, the water exits through the overflow
(4). In the event of insufficient feed water
volume or failed water supply the low-water
sensor (5) sends a fault signal to system
control.
Pumps
The electric motor drives both pump ends
(1). The pumps convey the water under
high pressure to the pressure side. The
starting of the motor opens the pressure
relief valve with its upstream filter (7). This
action connects pressure and suction sides
of the pumps, and no pressure is built up.
The motor is able to start free of any load.
High-pressure side
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.
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
nafter approx. 6 hours,
nafter six attempts at leakage
compensation,
nafter 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.
C2
C. System Function

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98)
1. Equipment Features
D. Specifications
D1
HD 4000 C
1.509-035 HD 4000 CH 1.509-115 HD 4000 C Scandinavia
1.509-515
HD 4000 C
Scandinavia
1.509-515
with hot-water
accessory kit
2.638-689
Supply volume L/h 3900 3900 3900 3900
Operating pressure* bar 100 100 100 100
Max. operating pressure
(safety valve) bar 130 130 130 130
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
(max. capacity) L63 63 63 63
Pump housing
(motor oil, order no. 6.288-061
1-Litre packaging) L 2 x 1.8 2 x 1.8 2 x 1.8 2 x 1.8
Sound level dB(A) approx. 80 approx. 80 approx. 80 approx. 80
Sound level
(sound-insulated version) dB(A) approx. 70 approx. 70 approx. 70 approx. 70
* upon request, lower values can be set by customer service.

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
1. Equipment Features
D. Specifications
D2
HD 6000 C
1.967-045 HD 6000 C 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
(safety valve) bar 90 90
Dimensions:
Length mm 1090 1090
Width mm 615 615
Height (without pedestal) mm 1070 1070
Weight (empty) kg 260 260
Capacity:
Float reservoir
(max. capacity) L89 89
Pump housing
(motor oil, order no. 6.288-061
1-Litre packaging) L 2 x 1.8 2 x 1.8
Sound level dB(A) approx. 80 approx. 80
Sound level
(sound-insulated version) dB(A) approx. 70 approx. 70
* upon request, lower values can be set by customer service.

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98)
2. Connected Loads
D. Specifications
D3
HD 4000 C
1.509-035 HD 4000 CH 1.509-115 HD 4000 C Scandinavia
1.509-515
HD 4000 C
Scandinavia
1.509-515
with hot-water
accessory kit
2.638-689
Mains power:
Power type 3 ~ 50 Hz 3 ~ 50 Hz 3 ~ 50 Hz 3 ~ 50 Hz
Voltage V400, IEC 38 400, IEC 38 220 to 240 220 to 240
Nominal load (max.)
with water temp. of 20 °C kW 15 15 15.5 15.5
Power supply cable mm² 4 x 10 4 x 10 4 x 16 4 x 16
Control cable mm² 5 x 1.5 5 x 1.5 5 x 1.5 5 x 1.5
Motor starter (type)
External pre-fusing A
slow 50 50 63 63
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
Supply temperature °C approx. 10
to 18 approx. 10 to 18 approx. 10 to 18 approx. 10 to 18
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

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
2. Connected Loads
D. Specifications
D4
HD 6000 C
1.967-045 HD 6000 C 1.967-045
with hot-water
accessory kit
2.638-697
Mains power:
Power type 3 ~ 50 Hz 3 ~ 50 Hz
Voltage V400 400
Nominal load (max.)
with water temp. of 20°C kW 15 15
Power supply cable mm² 4 x 10 4 x 10
Control cable mm² 5 x 1.5 5 x 1.5
Motor starter (type)
External pre-fusing A
slow 50 50
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

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98)
3. Dimension Diagram
D. Specifications
D5

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
1. Maintenance Contract
Only a properly maintained system is really
safe. It is in your best interest to ensure
that regular system maintenance
procedures are carried out according to the
maintenance schedule outlined below.
You may wish to enter into a maintenance
contract with the authorised Kärcher
customer service in your area.
A maintenance contract is highly
recommended.
2. Maintenance Schedule
In system maintenance, use only original
parts supplied or recommended by the
manufacturer. Observe all safety and
operating instructions packaged with these
spare parts. In particular, this applies to:
nSpare parts and wearing (consumable)
parts
nAccessory parts
nOperating media
nCleaning media.
E. Maintenance
!
Danger!
n Accident hazard through improper
maintenance procedures!
Without exception, maintenance work
and service repairs must be performed
by personnel or by the Kärcher customer
service.
n Injury hazard through exiting water jet of
high-pressure or high-temperature water.
Release system pressure before
performing work on system components.
In the case of hot-water operation, allow
unit to cool before commencing work.
n Electric shock hazard.
Switch OFF and secure master switch
before commencing work on the system.
E1

HD 4000 C / HD 6000 C English
5.956-648 A10369 (06/98)
E. Maintenance
E2
aSafety valve
bPump side
cPressure controller
dSolenoid valve (cooling water)
eDrip pan
fPressure relief valve
gCooling coil
hFloat reservoir with float valve
jOverflow valve, pressure switch
kFlow monitor
lOil level sight glass
mDashpot

HD 4000 C / HD 6000 C
English
5.956-648 A10369 (06/98)
E. Maintenance
E3
Interval Procedure Subject Assembly Activity By whom
Daily Check
handgun All handguns Check whether handgun closes properly. Check function of
safeguard against inadvertent
operation. Replace defective
handguns.
Operator
Check
high-pressure
hoses
Outlet lines & hoses leading
to workstations Check hoses for damage. Replace defective hoses immediately.
Accident Hazard!
Operator
Weekly, or
after 40
operating
hours
Check system
for leaks Entire system Check pump, overflow valve and tubing installation for leaks. If oil is
present in the drip pan under pump,
of if a leak exceeds 10 drops of
water per minute, call customer
service immediately.
Keep weep holes unblocked.
Operator/
Customer
Service
Check oil level Both pump sides Check pump oil level. MIN level:
Centre of oil sight glass. MAX level:
up to mark in housing. If required,
top up with oil (part no. 6.288-061).
Operator
Check oil
quality Both pump sides If the oil appears milky, it must be changed. In this case it is
recommended to change the pump
oil seal also.
(Customer service.)
Operator/
Customer
Service
Check
working
pressure
Pressure gauge in control
panel Check system water pressure (pressure gauge). If pressure is too
high or too low, investigate and
remedy the cause (see also the
section on Trouble Shooting).
Operator
Check hose
quick-coupling Hose quick-couplings between system tap and
high-pressure hose to
handgun.
Pump must be running.
Check for leakage in tandem and
individual operation.
Connect clutch and check clutch
locking function.
Replace defective clutches.
Operator
Customer
Service
Check
dashpot Dashpot on each pump side A defective dashpot is readily identifiable through increased pump
vibration.
Replace defective dashpot.
Operator
Customer
Service