Kärcher SHD-R 3000 User manual

5.956-486 A2005937 (06/03)
SHD-R 3000
Betriebsanleitung
!
www.karcher.com

Operating Instructions
To be handed to the operator
Read these instructions carefully before starting up the unit
Retain for future reference
Notes about these operating
instructions
Before starting up the interior cleaner for the
first time, please carefully read through
these instructions. In particular, you should
note all the safety information. Store these
instructions in a safe place for future use.
For whom are these instructions
intended
All users
Users are persons who have received
instruction on how the system functions,
operators and trained specialists.
Trained specialists
Trained specialists are persons who are
professionally qualified to install and
commission this type of system.
Environmental protection
Please dispose of the packaging in an
environmentally friendly way.
The packaging materials are recyclable.
Please do not throw the packaging into the
domestic waste but in the appropriate
recyclable waste collection containers
instead.
Please dispose of old units in an
environmentally friendly way
Old units contain valuable recyclable
materials, which should be reused. You
should never allow oil and similar materials
to get into the environment. Therefore,
please dispose of old units via suitable
collection systems.
Cleaning liquids
Please do not allow them to get into the
environment. Please protect the soil and
dispose of waste oil in an environmentally
friendly way.
Waste water containing mineral oil (i.e.
petrol, etc.)
Please do not allow this waste water to get
into the ground, bodies of water or the
sewers.
Mineral oil in the high-pressure pump
Mineral oil is used to lubricate the high-
pressure pump. The waste oil resulting from
an oil change, any oil and water mixture that
may occur, and rags that have been soaked
in oil should be delivered to a proper
collection point for disposal.
i
Important!
Waste oil may only be disposed of by the
operators of special collection points.
Please deposit your waste oil at one of
these locations. Polluting the environment
with waste oil is a criminal offence.
Detergents
KÄRCHER detergents possess demulsifying
properties (ASF). This means that they do
not interfere with the function of an oil se-
parator.
i
Important
These instructions contain descriptions of
different types of system, accessory kits
and other supplementary components.
There are significant differences between
the various parts so that you should not
encounter any problems with identifying all
the parts in your particular type of system.

English
SHD-R 3000
5.956-486 A2005937 (06/03)
A. For your safety
1. Safety information and instructions
2. Noise protection
3. Authorized operators
4. Personal protective equipment
5. Emergency drill
6. Safety devices
7. Applicable regulations
8. Using the system for its intended
purpose
9. Special conditions in hazardous area
10. Schematic diagram of area
classification
11. Area classification
B. Types of system, and operating
information
1. Types of system
2. System start-up
3. System shut-down
C. System functions
D. Technical specifications
E. Care and maintenance
1. General information
2. Maintenance schedule
3. Maintenance tasks
F. Troubleshooting
1. Fault-finding
G. Mounting kits and accessories
1. Mounting kits (non-hazardous area)
2. Mounting kits (hazardous area)
3. Accessories
H. Warranty
I. System installation
J. Declaration of Conformity
K. Test record
Table of contents
1

SHD-R 3000
English
5.956-486 A2005937 (06/03)
1. Safety information
and instructions
The following symbols are used throughout
these Operating Instructions:
!
Danger!
Denotes an immediate and present danger.
Failure to observe this notice could lead to
severe injury or death.
Caution!
Denotes a potentially hazardous situation.
Failure to observe this notice could lead to
minor injuries or damage to property.
i
Important!
Denotes operating hints and important
information.
Errors in operation or misuse can result in
danger to the operator or other persons
due to:
high water pressure,
hot liquids,
high voltages,
detergents and solvents,
Explosion hazard.
In order to avoid errors in operation or
potentially dangerous situations, read the
following before starting the system up for
the first time:
all safety information in the enclosed
brochure "Safety information for high-
pressure cleaning units" No. 5.951-949,
these operating instructions,
the legal requirements that are currently
applicable in your country.
A. For your safety
All persons charged with the installation,
commissioning, operation, maintenance or
service of the machine are required:
to be appropriately qualified,
to read and observe these operating
instructions,
to be aware of and observe associated
regulations.
2. Noise protection
The sound level generated by the system is
80 dB(A).
A noise hazard can occur if the water jet is
directed at resonating components (e.g.
large metal panels). In this case a hearing
protection device must be worn.
3. Authorized operators
The operation of the system is restricted to
persons over the age of 18 who have
received proper instruction as to how this
system is to be used (For exceptions for
trainees see BGV D15 Art. 6).
4. Personal protective equipment
!
Danger!
Health hazard due to cleaning fluids.
Wear the prescribed protective equipment
for the cleaning liquid to be used, e.g.
protective clothing/overalls,
protective goggles or face mask,
watertight gloves,
watertight shoes.
A1

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5.956-486 A2005937 (06/03) A2
A. For your safety
5. Emergency drill
Turn mains supply voltage off at system
master switch.
Turn off supply of cleaning liquid.
If a handgun is being used, release any
remaining pressure in the system by
pressing the lever on the handgun.
6. Safety devices
Safety valve
!
Danger!
Injury hazard due to excessive pressure
within system. Do not adjust safety valve.
The safety valve has been preset and
sealed in the factory. Adjustments should
only be made by a Kärcher Customer
Service engineer.
7. Applicable regulations
Accident prevent regulations
Working with liquid sprayers BGV D15.
If water is used as the cleaning liquid:
Observe local regulations for disposal of
waste water.
Waste water should be directed into the
main drainage system in accordance with
local regulations.
If the water to be used is drawn from the
main supply network:
Install a mains disconnector to EN 1717
(e.g. float tank with float valve),
BetrSichV (industrial safety regulations).
If acids, alkaline solutions or solvents are to
be used:
Observe the legal requirements that are
currently applicable in your country. In
Germany the regulations of the industrial
employer's liability insurance
associations apply (BGI 504).
Observe instruction leaflets provided by
manufacturers of the detergent
concentrates that are to be used with this
system.
i
Important!
According to the UVV (accident prevention)
Guidelines (BGV D15, Art. 23), high-
pressure sprayers must be checked by an
expert with the initial startup and at least
every 12 months thereafter. Kärcher
Customer Service engineers are qualified to
carry out the prescribed tests on your
system.
The results of the test procedures must be
recorded in writing. A form into which the
test results can be entered is shown in
Chapter K: Test Record.

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A3
8. Using the system for its
intended purpose
This system is used for pumping a cleaning
liquid at high-pressure, for the purpose of:
with the handgun attached – cleaning
containers, boxes, cases and equipment
parts, etc.
with the interior cleaner attached –
cleaning enclosed containers, drums,
barrels, etc.
Cleaning the following is considered to be
contrary to the intended purpose, and is
strictly forbidden:
Persons and animals
The high-pressure jet represents a serious
injury hazard.
Loose objects
Such items could be catapulted away by
the high-pressure jet, causing damage to
property or injury to persons.
If water is used as the cleaning liquid, the
system must be protected against freezing
temperatures. Damage could be caused if
water freezes inside the system.
9. Special Conditions in a
hazardous area
1. The pump may only be used in zones
which correspond to the type of explosion
protection given on the rating plate.
2. The cleaning liquid must not contain more
than 1% by weight of undissolved solids.
3. The interior cleaner must be
electrostatically grounded.
4. The cleaning liquid pump may only be run
if it is filled with liquid.
5. The nominal pressure of the pump must
not exceed 50 bar when used with solvents.
A. For your safety
6. The pump's flow rate must not exceed
50 l/min when used with solvents.
7. The operating temperature of the cleaning
liquid, made up of water with cleaning agent,
must not exceed 60 °C.
8. The operating temperature of the cleaning
liquids must not exceed 20 °C where
solvents, lyes (alkali solutions) and acids
are used.
9. The pump must be inspected after a
reasonable operating time to ensure it has a
faultless condition and function (among
other things, bearings for wear, pump for
leaks, tension in the V-belt). Repair if
necessary.
10. The pump may only be operated with
cleaning liquids against which the materials
from which the pump is made have
adequate resistance.
11. Cleaning liquids, which contain
combustible solvent fractions, must
correspond to the temperature classes IIA
and IIB. Solvents in the temperature class
IIC must not be sprayed.
12. The pump may only be operated in Zone
1 during cleaning. Ensure compliance with
the conditions applicable within the scope of
the BetrSichV (industrial safety regulations)
and other national conditions.
13. Hoses must be electrostatically
conductive (resistance R < 1 MΩ).
14. Only use cleaning liquids with a
conductivity G > 1000 pS/m.
15. All parts in contact with the media are to
be connected to the earth connection
system.
16. The electric motor used must have a
prescribed type testing certificate to
94/9/EC.

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SHD-R 3000
5.956-486 A2005937 (06/03) A4
A. For your safety
10. Schematic diagram of area classification

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A5
A. For your safety
11. Area Classification
In the BetrSichV and EN 1127-1, hazardous
(potentially explosive) areas are classified
into zones according to the frequency and
duration of the occurrence of hazardous,
potentially explosive atmospheres.
It is the responsibility of the owner/
operator to define these zones.
Notes on area classification are given in the
BetrSichV, EN 1127-1, BGR 104 - Ex-
Guidelines of BG Chemie and in
DIN EN 60 079-10.
Zone 0
is an area in which hazardous, potentially
explosive atmospheres exists constantly,
for long periods of time or frequently as a
mixture of air and combustible gases,
vapours or mists.
Zone 1
is an area in which hazardous, potentially
explosive atmospheres consisting of a
mixture of air and combustible gases,
vapours or mists can occasionally form
during standard operation.
Zone 2
is an area in which hazardous, potentially
explosive atmospheres consisting of a
mixture of air and combustible gases,
vapours or mists do not normally occur
during standard operation or only for a short
time.
Zone 20
is an area in which hazardous, potentially
explosive atmospheres in the form of a
cloud of combustible dust contained in the
air exist constantly, frequently or for long
periods of time.
Zone 21
is an area in which hazardous, potentially
explosive atmospheres in the form of a
cloud of combustible dust contained in the
air can occasionally form during standard
operation.
Zone 22
is an area in which hazardous, potentially
explosive atmospheres in the form of a
cloud of combustible dust contained in the
air do not form during standard operation or
only for a short time.

English
SHD-R 3000
5.956-486 A2005937 (06/03)
1. Types of system
Static or mobile systems
The static system
is intended to be installed on a base,
has been mounted onto a rigid steel
frame,
is most suitable for use in conjunction
with fixed-installation high-pressure lines.
B.Types of system, and operating information
The mobile system
has been mounted onto a trolley,
can be used in different locations.
B1

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B2
B.Types of system, and operating information
Cleaning liquids
Type of system
(see rating plate) Cleaning liquid Working
pressure/
Pressure
setting for
safety valve
[bar]
Comments
SHD-R 3000 (F)
- Water
- VE -water *
- Water with
Kärcher-RM
50/65 Standard version
SHD-R 3000 (F) S
- Water
- VE -water *
- Water with
Kärcher-RM
85/100 Standard version with
increased working pressure
SHD-R 3000 (F) SVA
- Water
- VE -water *
- Water with
Kärcher-RM
85/100 Pump parts that come into
contact with the cleaning liquid
are made from stainless steel.
VE Fully demineralised water
* Conditionally resistant, use possible, however Cu and Zn ions in the medium
RM
RM Alkali cleaning agent: e.g. RM31 (max. 0 - 2%)
Acidic cleaning agent: e.g. RM25 (max. 0 - 1%)
Max. temperature + 60˚C
(Higher temperatures available on request - precompression pump required!)
(F) Mobile system
Other cleaning liquids may only be used after being released by Kärcher!

English
SHD-R 3000
5.956-486 A2005937 (06/03) B3
B.Types of system, and operating information
Cleaning liquids
Type of system
(see rating plate) Cleaning liquid Working
pressure/
Pressure
setting for
safety valve
[bar]
Comments
SHD-R 3000 (F)
SSR -
Water
- VE -water
-
Water with
Kärcher-RM
- Acids 1)
- Alkali
solutions 2)
85/100 - The pistons are made
from ceramic materials,
other pump parts that
come into contact with
acids are made from
stainless steel.
- Ex-versions possible.
VE Fully demineralised water
RM
RM Alkali cleaning agent: e.g. RM31 (max. 0 - 2%)
Acidic cleaning agent: e.g. RM25 (max. 0 - 1%)
Max. temperature + 60 ˚C
(Higher temperatures available on request - precompression pump required!)
1)
Caution!
Increased material removal in hydrochloric and sulphuric acid, therefore rinse/neutralise
immediately after use!
Reduced resistance against contaminated acids!
If necessary contact Kärcher!
Acids (max. temperature +
20 ˚C)
Nitric acid max. 10%
Acetic acid max. 10%
Formic acid max. 10%
Phosphoric acid max. 10%
Citric acid max. 10%
Sulphuric acid max. 0.5%
Hydrochloric acid max. 0.5%
2)
Sodium hydroxide solutions max. 10%, without hypochlorite fractions (max. temperature
+ 20 ˚C)
Potassium hydroxide max. 10%, without hypochlorite fractions (max. temperature + 20 ˚C
)
(F) Mobile system
Other cleaning liquids may only be used after being released by Kärcher!

SHD-R 3000
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5.956-486 A2005937 (06/03)
B.Types of system, and operating information
B4
Cleaning liquids
Type of system
(see rating plate) Cleaning liquid Working pressure/
Pressure
setting for
safety valve
[bar]
Comments
SHD-R 3000 (F) SLA
– Water
–
VE water*
– Water with
Kärcher-RM
– Alkali
solutions
2)
85/100 –
–
–
Version with increased
working pressure.
Leaked liquid is collected in
a pipe (leakage recycling).
Ex-versions possible.
SHD-R 3000 (F) LM
– Water
–
VE water*
– Water with
Kärcher-RM
– Alkali
solutions
2)
– Solvents
3)
50/65 –
–
–
Explosion-proof version.
Leaked liquid is collected in
a pipe (leakage recycling).
Additional pressure switch as
safety device (optional).
VE
Fully demineralised water
*
Conditionally resistant, use possible, however Cu and Zn ions in the medium
RM
Acidic cleaning agent: e.g. RM25 (max. 0 - 1%)
Max. temperature + 60
˚C
(Higher temperatures available on request - precompression pump required!)
2) Sodium hydroxide solutions max. 10%, without hypochlorite fractions
(max. temperature + 20 ˚C)
Potassium hydroxide max. 10%, without hypochlorite fractions (max. temperature + 20 ˚C)
3)
Solvents (max. temperature + 20 ˚C)
1. Hydrocarbons, e.g.: petroleum
2. Aromatic compounds, e.g.: benzene, toluol
3. Ketones, e.g.: MEK (methyl ethyl ketones), acetone
4. Esters, e.g.: butyl acetate, methyl acetate
5. Glycols, e.g.: butyl glycol
6. Mixed solvents, e.g.: butyl acetate 85, isobutyl acetate 85
(85=85% butyl acetate + 15% n-butanol)
7. Regenerates, distillates made from various solvents which have already been used
f or cleaning purposes or similar.
(F) Mobile system
Other cleaning liquids may only be used after being released by Kärcher!

English
SHD-R 3000
5.956-486 A2005937 (06/03) B5
B.Types of system, and operating information
2. System start-up
Emergency drill
Turn mains supply voltage of at system
master switch.
Turn off supply of cleaning liquid.
If a handgun is being used, release any
remaining pressure in the system by
pressing the lever on the handgun.
Working with the handgun
Mobile and static system
Turn on cleaning liquid supply.
Switch system on at master switch.
Commence cleaning with high-pressure
jet.
i
Important !
In types LM, SLA and SSR the stuffing
boxes must be retightened after the initial
startup. The tension should be regulated
one, two, four and 10 hours after initial start-
up. (For the running-in phase of the seals,
see E.3 Maintenance work).
3. System shut-down
i
Important!
Before carrying out the shut-down
procedures, flush through without adding
cleaning agents. This prevents a crust
forming on the seals or that they become
stuck fast, either of which would lead to
premature wear.
During the recirculation operation with
solvent, the system must be rinsed through
thoroughly using clean solvent before the
shut-down procedure takes place.
Switch system off at master switch.
Turn off cleaning liquid supply.
If a handgun is being used, release any
remaining pressure in the system by
pressing the lever on the handgun.
!
!
Danger!
The high-pressure jet produces a recoil
effect.
You could lose your balance.
You could fall over.
Therefore:
Ensure that you have a firm footing.
Keep a tight grip on the handgun.
Do not wedge the handgun fast in the
open position.
If the lever is wedged fast, the recoil effect
causes the high-pressure hose to twist and
turn in various directions, which result in
damage to other equipment or persons.
Starting up the system
Mobile system
Place system on a horizontal, solid
surface.
Lock wheel brakes.

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C1
C. System functions
1Transmission casing
2Crankshaft with drive
3Seal (oil compartment)
4Gland
5Seal (grease compartment)
6Lubrication nipple or leakage pipe
7Sealing pack (high-pressure)
8Piston
9Suction valve
10 Pressure valve

English
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5.956-486 A2005937 (06/03) C2
C. System functions
Operational sequence of the high-
pressure pump
Cleaning liquid is taken in by the piston.
Suction valves (9) prevent cleaning liquid
from flowing backwards.
Action of piston pumps cleaning liquid
onwards.
Pressure valves (10) prevent cleaning
liquid from flowing backwards.
Action of piston takes in cleaning liquid
again.
Features of the high-pressure pump
Horizontal construction.
Drive runs in an oil bath.
Oil compartment for drive unit is separa-
ted from pressure chamber for cleaning
liquid.
Pump has three cylinders, each with a
pressure chamber, and one suction
chamber.
Drive for the high-pressure pump
The high-pressure pump is driven by an
electric motor.
V-belts attached to the electric motor
provide the actual drive to the high-
pressure pump.
Safety valve
!
Danger!
Injury hazard due to excessive pressure
within system. Do not adjust safety valve.
the safety valve has been pre-set and
sealed in the factory. Adjustments should
only be made by a Kärcher Customer
Service engineer.
The safety valve opens if the pressure
exceeds the prescribed maximum level.
Cleaning liquid is allowed to escape,
thereby avoiding damage to the pump and
high-pressure hoses due to too much
pressure in the system.
Pulsation damper
The pulsation damper compensates for the
variations or peaks in pressure. This
reduces the wear on pump components.

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D1
D. Technical specifications
Unit SHD-R 3000 (F) SHD-R 3000 (F) S
SHD-R 3000 (F) SSR 1)
SHD-R 3000 (F) SLA 1)
SHD-R 3000 (F) SVA
SHD-R 3000 (F) LM
Electrical connection
Type of current
Frequency Hz 3~ 50* 3~ 50* 3~ 50*
Voltage V 400** 400** 400**
Motor rating with
Class of protection IP55
Class of protection IP55 Ex kW kW 5.5 –11 13.5 – 6.8
Mains fuse
Direct starting A25 35 25
Mains fuse
Star-delta starting A16 35 16
Performance data
Pump flow rate L/h 3000 3000 3000
Working pressure bar 55 85 50
Pressure setting
Safety valve bar 65 100 65
Max. inlet temperature for
water with detergents ˚C 60 60 60
Max. temperature for solvents,
alkalis, acids ˚C – 20 20
Noise pressure level
(EN 60704-1) dB(A) 80 80 80
Dimensions and weight
Length approx. mm 1200 1200 1200
Width approx. mm 600 600 600
Height approx. mm 500 500 500
Weight approx. kg 125 165 135
Miscellaneous
Ambient conditions,
temperature ˚C +2 ... +40 +2 ... +40 +2 ... +40
Type of protection – 1) possible
II 2 G ck T3 II 2 G ck T4
Oil capacity L 3 3 3
Type of oil Oil 40 Special Order no. 6.288-003 (3 x 1 litre pack)
* Available as special version with 60 Hz
** Versions for other voltages available

English
SHD-R 3000
5.956-486 A2005937 (06/03) E1
E. Care and maintenance
1. General information
It is a fundamental requirement for ensuring
that this system functions safely and reliably
that maintenance is carried out regularly in
accordance with the following schedule.
Use only original spare parts supplied by
the manufacturer or recommended alterna-
tives, for example:
replacement and wearing parts
accessories
fuels, lubricants, etc.
detergents.
!
Danger!
Injury hazard while working on the system.
Before commencing any work:
Turn mains supply voltage off at system
master switch, and ensure that it cannot
be turned back on again unintentionally.
Turn off supply of cleaning liquid.
If a handgun is being used, release any
remaining pressure in the system by
pressing the lever on the handgun.
Who is permitted to carry out maintenance
tasks?
Operator
Tasks that are marked “Operator” may
only be carried out by persons who have
been instructed in the safe operation and
maintenance of high-pressure systems.
Customer service
Tasks that are marked “Customer service”
may only be carried out by Kärcher
Customer Service engineers.
Maintenance agreement
In order to ensure that the system functions
reliably, we recommend that you conclude
a service agreement. Please contact your
local authorized Kärcher Customer Service
agent.

SHD-R 3000
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E2
E. Care and maintenance
2. Maintenance schedule
Frequency Type of pump
SHD-R 3000
(F)
Action Procedure By whom?
1, 2, 4, 10
hours after
initial start-
up.
LM
SLA
SSR
Regulate tension in
compression glands See Maintenance Tasks Operator
Once
only after
first 100
operating
hours
all Check tension
of V-belt See Maintenance Tasks Operator
all Oil change See Maintenance Tasks Operator
Weekly
or after
every 40
operating
hours
all Check oil level Oil level must be between MIN
and MAX marks. If level below
MIN, fill up with oil.
Operator
Standard
S / SVA
SLA
SSR
Check oil condition If oil is milky-white, change oil
and tighten piston seal (See
Maintenance Tasks)
Operator
LM Check oil condition If oil has thinned out or is
discoloured, change oil and
tighten piston seal (See
Maintenance Tasks)
Operator
all Check high-pressure
hoses Visual check of high-pressure hoses for signs of damage such
as
– wear due to abrasion
– inner fabric is visible
– creases due to bending
– porous and split rubber
Replace any damaged hoses
Operator

English
SHD-R 3000
5.956-486 A2005937 (06/03) E3
E. Care and maintenance
2. Maintenance schedule
Frequency Type of pump
SHD-R 3000
(F)
Action Procedure By whom?
Monthly
or after
every 160
operating
hours
Standard
S / SVA Check pump for leaks If during operation more than 5 droplets per minute leak from
the pump, tighten piston seal
Operator
Standard
SLubrication Lubricate with 2 pump strokes of grease gun per nipple Operator
After
every 200
operating
hours
LM Oil change See Maintenance Tasks Operator
Six-monthly
or after
every 500
operating
hours
Standard
S / SVA
SLA
SSR
Oil change See Maintenance Tasks Operator
After
every 1000
operating
hours
all – Check and clean valves on pump
– Check piston
– Replace set of seals if required
– Oil change
– Check for correct functioning
Customer
service
Annually all Check tension of V-belt See Maintenance Tasks Operator
all Formal test Inspection in accordance with
Directive on "Working With
Liquid-spraying Devices"
Specialist

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E4
E. Care and maintenance
3. Maintenance tasks
Changing the oil
!
Danger!
Burns hazard due to hot oil and hot system
components. Allow pump to cool down for
15 minutes before changing oil.
i
Important!
Waste oil may only be disposed of by the
operators of special collection points.
Please deposit your waste oil at one of
these locations. Polluting the environment
with waste oil is a criminal offence.
Oil type: Oil 40 special
Order no. 6.288-003 (3 x 1 litre pack)
Oil capacity per pump: 3 L
Tightening the piston seals
i
Important!
If the piston seal is held too tight by the
gland, it will be subjected to increased wear.
Insert rod into gland and turn in direction
indicated by arrow. This increases the
tension on the piston seal.
Tighten all three piston seals uniformly,
by turning the glands until they are hand-
tight.
Relieving tension on piston seal:
Insert rod into gland and turn in opposite
direction to that indicated by arrow.
This relieves the tension on the piston
seal.
Relieve the tension on all three piston
seals uniformly.
Oil change procedure:
place drip pan under pump to collect
waste oil
remove oil drain plug, and collect waste
oil in drip pan
wash out pump casing with diesel
allow diesel to drain thoroughly
fit new sealing ring (A18 x 22), and refit
oil drain plug
slowly fill up with fresh oil as far as MAX
mark
deliver waste oil to an appropriate
collection point.