Kärcher HDS 796 CW User manual

HDS 796 CW
www.karcher.com 5.959 - 421 (09/99)
1.173...

HDS 796 CW
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HDS 796 CW
Operating Instructions 3
Spare Parts List 14
Prior to initial startup, operating manual and safety
instructions no. 5.951-949 must be consulted

English HDS 796 CW 3
CONTENTS
Important Safety Instructions 4
Environmental protection 4
Overview 5
Commissioning 5
Checking oil level 5
Filling with fuel 5
Fill with cleaning agent 5
Mounting handgun 5
Water connection 5
Drawing in water from tank 6
Mains connection 6
Operation 6
Switching on unit 6
Setting cleaning temperature 6
Measuring out cleaning
agents 6
Intended use 7
Cleaning 7
Operation with cold water 7
Operation with hot water 7
After every operation 7
Shutting down 7
Frost protection 8
Maintenance 8
Maintenance intervals 8
Maintenance work 8
Clean strainer in water
connection 8
Clean strainer in low water
protection 9
Clean filter at cleaning-agent
suction hose 9
Change oil 9
Faults 10
Warranty 12
General notes 12
Technical data 13

English HDS 796 CW 4
IMPORTANT SAFETY
INSTRUCTIONS
WARNING
WHEN USING THIS PRODUCT
BASIC PRECAUTIONS SHOULD
ALWAYS BE FOLLOWED,
INCLUDING THE FOLLOWING:
*DO NOT USE WITH FLAMMABLE
LIQUIDS AND TOXIC
CHEMICALS.
*INJECATION HAZARD:
EQUIPMENT CAN CAUSE
SERIOUSE INJURY IF THE
SPRAY PENETRATES THE
SKIN. DO NOT POINT THE GUN
AT ANYONE OR ANY PART OF
THE BODY. IN CASE OF
PENETRATION SEEK MEDICAL
AID IMMIDIATELY.
*THIS SYSTEM IS CAPABLE OF
PRODUCING 12000KPA.TO
AVOID RUPTURE AND INJURY,
DO NOT OPERATE THIS PUMP
WITH COMPONENTS RATED
LESS THAN 12000KPA
WORKING PRESSURE
(INCLUDING BUT NOT LIMITED
TO SPRAY GUNS, HOSE AND
HOSE CONNECTIONS).
*BEFORE SERVICING,
CLEANING OR REMOVAL ANY
PARTS, SHUT OFF POWER AND
RELIEVE PRESSURE.
*DO NOT USE GASOLINE,
CRANCASE DRAININGS, OR OIL
CONTAINING GASOLINE OR
SOLVENTS.
*WARNING: RISK OF INJECTION
OR SEVERE INJURY. KEEP
CLEAR OF NOZZLE. DO NOT
DIRECT DIRECT DISCHARGE
STREAM AT PERSONS. THIS
EQUIPMENT IS TO BE USED
ONLY BY TRAINED
OPERATORS.
*Read all the instructions before
using the product.
*To reduce the risk of injury, close
supervision is necessary when a
product is used near children.
*Know how to stop the product and
bleed pressure quickly. Be
thoroghly familiar with the controls.
*Stay alert watch what you are
doing.
*Do not operate the product when
fatigued or under the influence of
alcohol or drugs.
*Keep operating area clear of all
persons.
*Do not overreach or stand on
unstable support. Keep good
footing and balance all times.
*Follow te maintenance instructions
specified in the manual.
*This product must connected to a
power supply receptacle protected
by a GFCI (ground fault circuit
interrupter). „If Replacement Of
The Plug Or Cord Is Needed, Use
Only Identical Replacement
Parts.“
*WARNING Risk of injection or
injury-Do Not Direct Discharge
Stream At Persons.
Grounding Instructions
*This Product must be grounded. If
it should malfunction or
breakdown, grounding provides at
a path of least resistance for
electric current to reduce the risk
of electric shock. This product is
equipped with a cord having an
equipment-grounding conductor
and a rounding plug. The plug
must be plugged into an
appropriate outlet that is properly
installed and grounded in
accordance with all local codes
and ordinances.
*DANGER - Improper connection of
the equipment grounding
conductor can result in a risk of
electrocution. Check with a
qualified electrician or service
personel if you are in doubt as to
wether the outlet is properly
grounded. Do not modify the plug
provided with the product - if it will
not fit the outlet, have a proper
outlet installed by a qualified
electrician. Do not use any type of
adaptor with te product.
SAVE THESE INSTRUCTIONS
Prior to initial startup, operating
manual and safety instructions
no.. 5.951949 must be consulted!
Inform retailer immediately of any
transportation damage.
ENVIRONMENTAL PROTECTION
Items used when working, such as
fuel, oil, cleaning agent and
contaminated maintenance
materials, are to be deposited at a
special collection point.
Packaging materials, metal and
plastic containers are to be set aside
for recycling as appropriate.

English HDS 796 CW 5
OVERVIEW
Fig. 1
1 Swivel caster with parking brake
2 Connection for high-pressure hose
3 Fuel tank inlet
4 High-pressure hose
5 Cover latch
6 Handgun
7 Pressure gauge
8 Filler opening for cleaning agent
and metering equipment
9 Water connection 1 with strainer
Fig. 2
1 Selector switch ON/OFF and
temperature
Indicator lamps
2 Fuel low
3 Ready for operation
Fig. 3
Press down cover latch with
screwdriver or coin and turn counter-
clockwise to open.
Turn clockwise to close.
Fig. 4
Compartment for accessories
beneath cover
10 Steam nozzle (4.766-023)
optional
COMMISSIONING
–Unit, piping, high-pressure hose
and connections must be in
perfect working order!
–Lock the hand brake.
Checking oil level
Fig. 5
Oil reservoir
Prior to initial startup, cut off tip of oil
reservoir cap
Contact KÄRCHER AFTER-SALES
SERVICE immediately if oil is
opaque!
If oil level is approaching MIN mark,
fill up with oil as far as MAX mark.
Seal oil filler inlet.
Refer to technical data for oil grade.
Filling with fuel
–Never operate unit with fuel tank
empty! Fuel pump would
otherwise be destroyed!
Fig. 6
Only fill with Kerosin.
Close tank cap
Wipe off excess fuel
Fill with cleaning agent
*Only use KÄRCHER products.
*Never pour in solvent (petrol,
acetone, thinner etc.)!
*Avoid contact with eyes and skin
*Pay attention to cleaning-agent
manufacturer's instructions on
safety and handling
KÄRCHER can provide an
individual range of cleaning and
treatment agents.
Your dealer will be pleased to advise
you.
Fig. 8
Fill with cleaning agent
Mounting handgun
–Connect spray lance to handgun
–Insert high-pressure nozzle in
union nut
–Mount and tighten unit nut
–Mount high-pressure hose at high-
pressure connection Fig. 1 Item 2
Water connection
For connected loads, refer to
Technical Data.
Mount supply hose at water
connection of unit.
Fig. 1 Item 9
(supply hose is not part of scope of
delivery)

English HDS 796 CW 6
Drawing in water from tank
The following conversion work is
necessary if water is to be drawn in
from an external tank.
Lift off scale inhibitor reservoir.
Remove upper supply hose to water
reservoir and route to pump head.
Detach water connection at pump
head and swivel aside.
Connect supply hose to pump head.
For drawing in, use 3/4 hose with
suction filter.
Max. suction height 0,5 m.
Mains connection
Refer to technical data and rating
plate for connected loads.
Fitting power plug
Have power plug fitted by
KÄRCHER AFTER-SALES
SERVICE or an authorised
electrician.
Set selector switch to "0"
Insert power plug
Whenever socket is changed,
check direction of rotation of
motor.
If direction of rotation is correct,
powerful jet of air will be felt at
exhaust-gas opening of burner. In
the event of incorrect direction of
rotation, refer to Faults "Burner not
ignited".
If an extension cable is used, this
should always be fully uncoiled and
have an adequate cross-section.
(10 m min. 1,5 mm2, 30 m
min. 2.5 mm2)
OPERATION
*Never operate unit with fuel tank
empty! Fuel pump would
otherwise be destroyed!
Switching on unit
Fig. 2
Set selector switch (1) to "I"
Indicator lamp (3) lights
*If indicator lamp (2)come on
during operation, switch off unit
immediately. Eliminate fault, refer
to Faults.
Unit starts up briefly and is switched
off as soon as operating pressure is
reached.
Fig. 7
Release handgun
Actuation of handgun switches unit
back on again.
Bleed pump if no water emerges
from high-pressure nozzle. Refer to
Faults "No build-up of pressure by
unit"
Setting cleaning temperature
Set selector switch (1) to desired
temperature
30°C 90°C
Hot water cleaning
Measuring out cleaning agents
*Use cleaning agents sparingly to
protect the environment
*The cleaning agent must be
suitable for the surface to be
cleaned.
Fig. 9
Set cleaning-agent concentration as
specified by manufacturer
0 =Working without cleaning agent
Metering setting Concentration
10,25%
21,00%
31,25%
41,50%
51,75%
62,00%
Approximate values at maximum
operating pressure

English HDS 796 CW 7
Intended use
Cleaning of: Machines, vehicles,
structures, tools, facades, terraces,
garden implements, etc.
*Engine cleaning is only to be
performed in areas provided with
oil separator.
*Heed appropriate safety
regulations for use at petrol
stations or in other hazardous
environments.
Working with high-pressure
nozzle
Spray angle is crucial to efficiency of
high-pressure jet.
Use is normally made of 25°fan jet
nozzle (included).
Recommended nozzles, available as
accessories
–For stubborn dirt 0°full jet nozzle
–For delicate surfaces and slight
contamination 40°fan jet nozzle
–For thick layers of stubborn dirt dirt
blaster
–Nozzle with variable spray angle,
for adaptation to various cleaning
tasks variable-angle nozzle
Cleaning
*Set pressure/temperature and
cleaning-agent concentration in
line with surface to be cleaned
*Always start by directing high-
pressure jet from a good distance
at object to be cleaned to avoid
damage caused by excessive
pressure.
Recommended cleaning method
Loosen up dirt:
Spray on cleaning agent sparingly
and allow to react for 1...5 min (do
not allow to dry on).
Remove dirt:
Spray off loosened-up dirt with high-
pressure jet.
Operation with cold water
Removal of slight contamination and
rinsing
e.g.: Garden implements, terrace,
tools, etc.
Set operating pressure as required
Set selector switch to "I"
Operation with hot water
*Danger of scalding
We recommend the following
cleaning temperatures
–Slight contamination 86-122°F
–Protein soiling, e.g. in foodstuffs
industry max. 140°F
–Motor vehicle cleaning, machine
cleaning 140-194°F
Set selector switch to desired
temperature
AFTER EVERY OPERATION
Following operation with cleaning
agent
–Set cleaning-agent regulator to "0"
–Set mode selector switch to "I"
–Actuate handgun and flush unit for
approx. 1 min
Stopping machine
–Set mode selector switch to "0"
–Shut off water supply
–Briefly switch on pump with
selector switch (approx. 5 sec.)
–Make sure hands are dry when
pulling power plug out of socket
–Detach water connection
–Actuate handgun to depressurise
unit
–Secure handgun (Fig. 7)
–Engage spray lance in cover
holder
–Roll up high-pressure hose and
cable and place in compartment
*Take care not to kink high-
pressure hose and cable!
Frost will destroy unit if water is not
drained off completely!
Store unit in a frost-free location
Take unit out of service if frost-free
storage is not possible.
SHUTTING DOWN
In the event of lengthy periods of
non-use or if frost-free storage is not
possible:
–Drain unit or flush with anti-freeze
–Drain cleaning fluid tank
Draining unit
–Unscrew water supply hose and
high-pressure hose
–Unscrew supply line at boiler base
and allow heating coil to drain
–Run unit for max. 1 min until pump
and lines are empty
Flushing unit with anti-freeze
–Use commercial grade antifreeze
–Observe handling instructions of
antifreeze manufacturer
–By this means, a certain degree of
corrosion protection is achieved.

English HDS 796 CW 8
FROST PROTECTION
The unit has a frost protection
feature, which avoids freezing of the
watersystem down to -30 °C.
The frost protection will be activated
as follows.
1. Unscrew the water inlet hose of
the unit. (Fig.1)
2. Unscrew the high pressure hose
with handgun, store in freeze
protected room. (Fig.1)
3. Connect waterinlet - and high
pressure connection with the
enclosed hose. (Fig.10)
4. Fasten the lever to open the float
valve. (Fig.11)
5. Set the frost protection switch on
the instrument panel to the
symbol frost protection (penguin).
(Fig.12)
Caution:
The unit may not be separated from
the electric circuit.
To get the ready of separated, do
the following points:
1. Set the frost protection on the
instrument panel on the symbol
spray lance. (Fig.12)
2. Unfasten the lever of the float
valve. (Fig.11)
3. Disconnect hose between water
inlet and high pressure
connection. (Fig. 10)
4. Connect high pressure hose with
handgun. (Fig.1)
5. Connect water inlet hose. (Fig.1)
MAINTENANCE
*Disconnect unit from mains before
carrying out any maintenance or
repair work.
*Always use genuine spare parts
Shut off unit before performing any
work, refer to AFTER USE.
Set mode selector switch to "0"
Pull power plug out of socket
Shut off water supply
Actuate handgun to depressurise
unit.
Detach water connection
Allow unit to cool down
Please consult your KÄRCHER
dealer for details of regular safety
inspection/maintenance
agreement
Maintenance intervals
Once a week
–Clean strainer in water connection
–Check oil level
Contact KÄRCHER AFTER-SALES
SERVICE immediately if oil is
opaque!
Once a month
–Clean strainer in low water
protection
–Clean filter at cleaning-agent
suction hose
After 500 hours of operation, at
least once a year
–Change oil
MAINTENANCE WORK
Clean strainer in water
connection
–Remove strainer
–Clean in water and re-insert

English HDS 796 CW 9
Clean strainer in low water
protection
–Unfasten union nut and detach
hose
–Take out strainer
If necessary, screw in bolt M8
approx. 5mm to pull out strainer.
–Clean strainer in water
–Slide in strainer
–Mount hose
–Tighten union nut
Clean filter at cleaning-agent
suction hose
–Pull out cleaning-agent suction
hose
–Clean filter in water and re-insert
Change oil
–Provide a collecting container for
approx. 1 litres of oil
–Place drainage spout in position
–Loosen starting screw
KÄRCHER tip
*Cut open RM 110 bottle and use
as drainage spout
–Drain off oil via drainage spout into
collector
*Dispose of used oil in appropriate
manner or hand in at a collection
point.
–Tighten drain plug again
–Slowly fill with oil as far as MAX
mark
Air bubbles must be able to escape.
Refer to technical data for oil grade
and quantity to be used.

English HDS 796 CW 10
FAULTS
Fault
FUEL indicator lamp on
READY FOR OPERATION
indicator lamp off
Unit does not run
Unit does not build up pressure
Cause
–Fuel tank empty
–Motor overloaded/overheated
–No mains voltage
–Air in system
–Pressure set to MIN
–Strainer in water connection dirty
–Insufficient water supply
Remedy
Fill up
Set selector switch to "0" and allow
motor to cool down for at
least 5 min.
Have unit checked by After-Sales
Service if this does not remedy fault.
Check mains connection/power cord
Bleed pump:
–Set cleaning-agent metering to "0"
–With handgun open, use selector
switch to switch unit on and off
several times.
Fill up cleaning-agent tank if empty.
Check connections and lines
Set pressure to MAX
Clean strainer
Check water supply volume (refer to
technical data)
If fault cannot be rectified, have
unit checked by After-Sales
Service.

English HDS 796 CW 11
Fault
Unit leaking, water dripping out at
bottom
Unit constantly switched on and
off with handgun closed
Unit does not draw in cleaning
agent
Burner not ignited
Set temperature not attained
when working with hot water
Cause
–Pump leaking
–Leak in high-pressure system
–Filter in cleaning-agent suction
hose dirty
–Non-return valve gummed up
–Fuel tank empty
–Lack of water
–Fuel filter dirty
–Incorrect direction of rotation. If
direction of rotation is correct,
powerful jet of air will be felt at
exhaust-gas opening of burner.
–No ignition spark
–Soot deposits on heating coil
Remedy
3 droplets/min are permitted.
In the event of a major leak, have
unit checked by After-Sales Service.
Check high-pressure system and
connections for leaks
Clean filter
Pull off cleaning-agent hose and use
blunt object to release non-return
valve (see Fig.).
Fill up
Check water connection, check
supply lines, clean low water
protection.
Replace fuel filter.
Check direction of rotation. If
necessary, have connection
replaced by a qualified electrician.
Have unit checked by After-Sales
Service if no ignition spark is visible
through inspection glass during
operation.
Have After-Sales Service remove
soot deposits from unit
If fault cannot be rectified, have
unit checked by After-Sales
Service.

English HDS 796 CW 12
WARRANTY
The warranty terms and conditions
issued by our responsible sales
company apply in every country.
Within the warranty period, any
faults in the unit will be rectified free
of charge provided that the problem
was caused by a material defect or
manufacturing error.
The warranty only applies if the
dealer fills in, stamps and signs the
enclosed reply card when the unit is
sold and the purchaser then returns
it to the appropriate local distributor.
In the event of a warranty claim,
please contact your dealer or the
nearest authorised After-Sales
Service office and produce both
accessories and proof of purchase.
GENERAL NOTES
Safety features
*Overflow valve with two pressure
switches
Reducing the water volume at the
pump head or with the servopress
control opens the overflow valve and
some of the water runs back to the
pump suction end.
If the handgun is closed thus
causing all the water to return to the
pump suction end, the pressure
switch at the overflow valve shuts off
the pump.
Reopening the handgun causes the
pressure switch at the cylinder head
to switch the pump back on again.
The overflow valve is set at the
factory and sealed. Adjustment can
only be made by After-Sales
Service.
*Safety valve
The safety valve opens if the
overflow valve or pressure switch is
defective. The safety valve is set at
the factory and sealed. Adjustment
can only be made by After-Sales
Service.
*Low water protection
The low water protection stops the
burner being switched on in the
event of a lack of water. A strainer
stops the protection feature
becoming dirty and requires regular
cleaning.
*Motor protection switch
The motor protection switch
interrupts the circuit should
overloading occur.
Guidelines for liquid spraying
equipment
*The accident prevention regulation
(VBG 87) "Working with liquid
spraying equipment" applies. In
accordance with these guidelines,
high-pressure spraying equipment
must be checked at least every 12
months by an expert and the
results of the inspection recorded
in writing.
Order governing boilers
*Test pressure and design of unit
comply with Order governing
boilers as per TRD. The water
content of the heating coil is less
than 10 litres. The boiler section of
the unit is thus not subject to
installation regulations. Local
building regulations are to be
heeded.

English HDS 796 CW 13
TECHNICAL DATA
Type HDS 796 CW-50 (1.173-114) HDS 796 CW-60 (1.173-115)
Mains connection 200 V
3~ 50 Hz 120 V 1~ 60Hz
Connected load 3.0 kW 3.1 HP
Engine output 2.2 kW
Fuse (slow blow) 13 A 20 A
Water connection
Supply temperature max. 30 °C max. 30 °C
Supply volume min. 900 l/h min. 900 l/h
Suction height when drawn
from open tank 0.5 m 0.5 m
Performance data
Flow rate: cold/hot water 750 l/h 750 l/h
Operating pressure: cold/hot water
(with standard nozzle supplied) 100 MPa (100 bar) 100 MPa (100 bar)
Operating temperature
- Hot water max. 80 °C max. 80 °C
- Steam -- --
Cleaning-agent intake 0 – 12 l 0 – 12 l
Burner output 40 kW 40 kW
Recoil force of
handgun max. 30 N max. 30 N
Sound level as per
DIN 45635 T36 76 dB(A) 76 dB(A)
Fuels
Fuel Kerosene Kerosene
Oil quantity 0.5 l 0.5 l
Oil grade Hypoid SAE90 (6.288-016) Hypoid SAE90 (6.288-016)
Dimensions and weights
Length x Width x Height 940x600x740 mm 940x600x740 mm
Weight not incl. accessories 94 kg 94 kg
Fuel tank 16 l 16 l
Cleaning-agent tank 8 l 8 l

HDS 796 CW 14