HKF 200 - Kärcher

HKF 200
3.631-015 Deutsch
3.631-016 English
3.631-018 Français
3.631-023 Italiano
3.631-036 Nederlands
3.631-059 Español
3.631-060 Svenska
3.631-063 Русский
!
www.kaercher.com 5.956-515 2009800 (02/05)

Operating Instructions
Please issue to the operator,
ensure they read it before starting the initial operation and
store it in a safe place for future use.
About these operating instructions
Read these instructions through carefully before
the initial startup of the internal cleaner. Pay
particular attention to all safety information.
Store the instructions in a safe place for future
use.
These instructions are intended for
the following target groups
All users
Users are instructed labourers, owner/operators
and skilled persons.
Skilled persons
Skilled persons whose vocational training
enables them to set up and startup equipment
and systems.
Environmental protection
Please dispose of the packaging in an
environmentally friendly way
The packaging material can be recycled. Please
do not throw the packaging in the domestic waste
but place it in recycling containers.
Please dispose of used units in an
environmentally friendly way
Used units contain valuable recyclable materials,
which should be recycled. Batteries, oil and
similar materials must not be allowed to get into
the environment. Please therefore ensure that
you use suitable collection systems to dispose
of old units.
Cleaning liquids
Please do not allow them to get into the environment.
Protect the soil and dispose of waste oil in
an environmentally friendly way.
Wastewater containing mineral oil
Please do not allow it to get into the ground, bodies
of water or the sewers.

HKF 200
Contents
English
A. For your safety
1. Safety information and tips
2. Noise control
3. Approved operators
4. Personal protective equipment
5. What to do in emergencies
6. Proper intended use
7. Special conditions in Ex-areas
8. Schematic sketch of the area classification
9. Area classification
B. Function
C. Technical Specifications
1. Dimensional diagram HKF 200 E /
HKF 200 C
2. Dimensional diagram HKF 200 ET
3. Dimensional diagram HKF 200 C2
4. Dimensional diagram HKF 200 P
5. Dimensional diagram HKF 200 PT
6. Dimensional diagram HKF 200 PU
7. Installation example HKF 200 PU
8. Technical specifications
HKF 200 E / ET / P
9. Technical specifications
HKF 200 PT / PU / C / C2
10. Cleaning liquids
11. List of materials
12. Nozzle selection
D. Operation
1. Preparing for the initial startup
2. Initial operation switch ON
3. Shut-down procedure switch OFF
E. Maintenance
1. Maintenance instructions
2. Maintenance intervals
F. Troubleshooting
1. Fault information
2. Locating faults
G. Accessories
H. Guarantee
I. Declaration of conformity
5.956-515

A. For Your Safety
English HKF 200
1. Safety Information and Tips
The following symbols are used in these operating
instructions:
! Danger!
Denotes a direct, pending hazard. Failure to observe
this information can cause fatal or severe
injuries.
Caution!
Denotes a possibly hazardous situation. Failure
to observe this information can lead to slight injuries
or damage to property.
i Important!
Denotes user tips and important information.
Incorrect operation or misuse can cause dangers
for the operator and other persons due to:
high pressure,
high electric voltages (for electrical drive
units with 230 or 400 V),
Cleaning agents or used cleaning liquid,
hot parts of the system, if hot cleaning liquids
are used,
Explosion danger.
Please ensure you read the following before
operating the system for the first time to avoid
incorrect operations and hazards
All safety information in the attached brochure
"Safety information for high-pressure cleaning
systems" No. 5.951-949,
These operating instructions,
The respective national regulatory legislation,
The safety information enclosed with the cleaning
agents used (usually on the packaging
label).
To avoid hazards due to incorrect operation, the
system must only be operated by persons who
have been instructed in its use,
have proven their operating skills,
have been deployed to use the machine.
The operating instructions must be accessible
to each user.
! Danger!
There is a risk of injuries or possible risk to health
due to:
the drive unit of the internal cleaner (crushing
hazard). Only start up the drive unit of the internal
cleaner in closed containers.
The cleaner gives off a high-pressure spray,
therefore only start up the internal cleaner in
closed containers,
Residual materials in containers, which are
cleaned or from the cleaning liquid used.
Therefore follow the prescribed protective
measures,
Falling internal cleaner at a low submersion
depth. In this case you should additionally
secure the internal cleaner,
Falling containers, therefore additionally secure
the container and internal cleaner,
Hot hoses and hot frame when using hot cleaning
liquids.
When running the machine with hot cleaning
liquids, do not touch the frame and supply
line and wear appropriate protective clothing.
Accidental startup after interrupting the
mains voltage. Switch off the internal cleaner
and high-pressure pump drive units in case
of any faults.
A1
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HKF 200
A. For Your Safety
English
5. What to do in Emergencies
Risk of explosion and fire when using corresponding
cleaning agents and residual materials
in containers. In these cases contact
Kärcher to find out how these cleaning agents
are to be used.
Caution!
In order to prevent damage to the spray head,
ensure that it is freely positioned in the container.
The spray head must never bump against
the container wall.
2. Noise Control
The sound level of the internal cleaner with
compressed air motor and without a silencer is
max. 83 dB(A), see "Technical specifications". If
parts which amplify sound (e.g. large metal plates,
metal containers) are sprayed, a risk from
noise can occur. In this case ear protection must
be worn.
3. Approved Operators
Approved operators are persons who are 18
and over and qualified to use this system (exceptions
for trainees, see BGV D15 Art. 6).
4. Personal Protective Equipment
Depending on the concentration of and health
hazard caused by the cleaning liquid used, wear
liquid repellent protective clothing,
protective goggles or face protection,
impermeable gloves,
impermeable footwear.
Switch off the separate high-pressure pump,
Switch off the drive unit of the internal cleaner,
and at the same time
– if the drive unit is electrical unplug it or
switch off the power supply
– if the drive unit is run on compressed air
shut off the compressed air supply
Shut off the cleaning liquid supply.
6. Proper, Intended Use
HFK 200 internal cleaners are spraying devices
for cleaning barrels, containers and tank trucks.
The cleaning head of the HKF 200 E / ET / C /
P / PT is placed in the container through an opening
with a diameter of at least 200 mm.
HKF 200 ET / PT = min. 140 mm
HKF 200 C2 = min. 300 mm
The HKF 200 PU is intended for stationary operation.
To this end it must be installed vertically
upright, tightly fitting in a "dome" with flange.
The containers to be cleaned are placed over
the internal cleaner. (See the dimensional diagram
and installation example HKF 200 PU for
an illustration of the installation). A separate
high-pressure pump is connected to the internal
cleaner by a high-pressure hose.
i Important!
A list of approved cleaning liquids is given in
Chapter C. Technical Specifications.
It is not proper, intended use
outside closed containers,
with higher pressures and higher temperatures
than those given in the "Technical Specifications".
5.956-515
A2

A. For Your Safety
English HKF 200
7. Special Conditions in the Ex-Area
1. The internal cleaner may only be used in Area
0 of containers, if the containers do not exceed
3m diameter in size with a standard container
height or a comparable container size.
2. The cleaning liquid must not contain more
than 1% by weight of undissolved solids.
3. The internal 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 for use with solvents.
6 The pump's flow rate must not exceed 50 l/min
when used with solvents.
7. The compressed air motor or the electrical
gear motor may only be run if the cleaning liquid
is fed to the internal cleaner.
8. The speed in rpm of the spraying head must
not exceed 40 1/min.
9. The operating temperature of the cleaning liquid
must not exceed 95 °C if water with cleaning
agents added is used.
10. The operating temperature of the cleaning liquids
must not exceed 20° C where solvents,
lyes (alkaline solutions) and acids are used.
11. The internal cleaner is to be inspected after
a reasonable operating time to ensure it has a
perfect condition and function (including
checking that the drive motor is concentrically
located relative to the gland part, and checking
bearing bushes and drive seals for wear or
leaks). Repair if necessary.
12. The internal cleaner may only be operated
with cleaning liquids and used in media if the
materials it is made from have adequate resistance
against these.
13. 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.
14. The internal cleaner must not be permanently
placed in Area 0, only while the container
is being cleaned. The operating regulations applicable
within the scope of the BetrSichV (operating
safety regulations) and other national regulations
are to be complied with. It must be taken
into consideration that the connection between
the container and internal cleaner placed
in the container does not have a flame arrester.
15. Hoses must be electrostatically conductive
(resistance R < 1 MÙ)
16. Only cleaning liquids with a conductivity
G > 1000 pS/m may be used.
17. All parts in contact with the media are to be
connected to the earth connection system.
A3
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HKF 200
A. For Your Safety
English
8. Schematic Sketch of the Area Classification
Telescopic jib
Area 1
Winch for telescopic jib
Winch for lifting and lowering
the spraying head
High-pressure spray head
Slewing equipment
Area 0/20
Rotating
spray head
Area 1
Clear
medium
Circulation
medium
Electrically conductive
hose
Circulation container with
filter equipment
- push-in strainer
- suction basket (strainer)
- fine filter
5.956-515
A4

A. For Your Safety
English HKF 200
9. Area Classification
In the BetrSichV and EN 1127-1, hazardous
(potentially explosive) areas are classified in
areas according to the frequency and duration
of the occurrence of hazardous, potentially atmospheres.
It is the responsibility of the owner/operator
to defined these areas.
Information on area classification can be found
in the BetrSichV, EN 1127-1, BGR 104 - Ex-Guidelines
of BG Chemie and in DIN EN 60 079-10.
Area 0
is an area in which a hazardous, potentially explosive
atmosphere exists constantly, frequently
or for long periods of time as a mixture of air
and combustible gases, vapours or mists and
sprays.
Area 20
is an area in which a hazardous, potentially explosive
atmosphere in the form of a cloud of
combustible dust contained in the air exists constantly,
frequently or for long periods of time.
Area 21
is an area in which a hazardous, potentially explosive
atmosphere in the form of a cloud of
combustible dust contained in the air can occasionally
form during standard operation.
Area 22
is an area in which a hazardous, potentially explosive
atmosphere in the form of a cloud of
combustible dust contained in the air does not
form during standard operation or only for a
short time.
Area 1
is an area in which a hazardous, potentially explosive
atmosphere consisting of a mixture of
air and combustible gases, vapours or mists
and sprays can occasionally form during standard
operation.
Area 2
is an area in which a hazardous, potentially explosive
atmosphere consisting of a mixture of
air and combustible gases, vapours or mists
and sprays does not normally occur during standard
operation or only for a short time.
A5
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HKF 200
B. Function
English
Function
The internal cleaner consists of a drive parts,
the Carrier pipe and the cleaning head.
The nozzles in the cleaning head rotate about
two axes and therefore cover all areas of the
container.
An electrical or compressed air motor rotates
the cleaning head. The speed in rpm is therefore
independent of the pressure and quantity of
cleaning liquid. In electrical drive units the
speed is either constant or can be adjusted between
two stages, where pneumatic drives are
used the speed can be adjusted via the compressed
air.
5.956-515
B1

C. Technical Data
English HKF 200
1. Dimensional Diagram HKF 200 E / HKF 200 C
Cable entry for round cable
min. Ø 10mm 4x1,5mm²
Ø 30
Hanging bracket
Order-No. 4.034-126
Hole pattern of the
mounting flange
Ø 250
Ø 9
Ø 180
Ø 225
565
615
120°
3x120°
Delivery connection M22x1.5
Area 1
Category 2 respectively 3
Area 0/20
Category 1
Hole circle Ø225
Flange Ø250
Prescribed direction
of rotation
Standard length 800
300 - 1500 special design
X= Minimum inlet Ø180
XX= Rotational Ø200
x
xx
C1
5.956-515

HKF 200
C. Technical Data
English
2. Dimensional Diagram HKF 200 ET
Cable entry for round cable
min. Ø 10 mm, 4x1.5 mm²
Ø30
Hanging bracket
Order-No. 4.034-126
Hole pattern of the mounting flange
Delivery connection M 22x1.5
Area 1
Category 2 respectively 3
Area 0/20
Category 1
Hole circle Ø 225
Flange Ø 250
Prescribed direction of rotation
Standard length 500
X = Minimum inlet Ø 140
XX = Rotational Ø 142
5.956-515
C2

C. Technical Data
English HKF 200
3. Dimensional Diagram HKF 200 C2
Cable entry for round cable
min. Ø 10mm 4x1,5mm²
Ø 30
Hanging bracket
Order No. 4.034-126
Hole pattern of the
mounting flange
Ø 250
Ø 9
Ø 180
Ø 225
565
615
120°
3x120°
Delivery connection M22x1.5
Area 1
Category 2 respectively 3
Area 0/20
Category 1
Hole circle Ø225
Flange Ø250
2 special nozzles,
Nozzles can be
switched over manually
Prescribed direction
of rotation
Standard length 800
300 - 1500 special design
2 nozzles
X= Minimum inlet Ø300
XX= Rotational Ø320
x
xx
C3
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Ø 225
Ø 9
HKF 200
C. Technical Data
English
4. Dimensional Diagram HKF 200 P
Hole pattern of the mounting flange
Ø 250
Ø30
Ø 180
120°
3x120°
290
540
Area 1
Category 2 respectively 3
Delivery connection M22x1.5
Area 0/20
Category 1
EXH
1
2
Air outlet glands
(2 hoses DN 6,
at least 1.5mm)
Hole circle Ø225
Flange Ø250
Air requirement 300l/min
at 5 bar
Prescribed direction
of rotation
Standard length 800 (P) / 500 (PT)
300 - 1500 special design (P)
Air inlet glands
(1 hose DN 6)
X= Minimum inlet Ø180
XX= Rotational Ø200
x
xx
5.956-515
C4

C. Technical Data
English HKF 200
5. Dimensional Diagram HKF 200 PT
Hole pattern of the mounting flange
Hanging bracket
Order-No. 4.034-016
Area 1
Category 2 respectively 3
Delivery connection
M 22x1.5
Area 0/20
Category 1
Flange Ø 250
”X”
Air outlet glands
(2 hoses DN 6)
Hole circle Ø 225
Prescribed direction of rotation
Air requirement 300 l/min at 5 bar
Standard length 500
300-1500 special design
Air inlet glands (1 hose DN 6)
X = Minimum inlet Ø 140
XX = Rotational Ø 142
C5
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HKF 200
C. Technical Data
English
6. Dimensional Diagram HKF 200 PU
22,5°
Ø16
22,5°
Ø20
6x60°
60°
x
20°
Ø9
xx
Ø160
Ø225
Ø250
Compressed air 1/4"-Ø8
Air requirement
300l/min at 5 bar
Exhaust air 3/8"-Ø12
Delivery connection
M22x1.5
300
Area 0/20
Category 1
28
665
Area 1
Category 2 respectively 3
min. 400
300
(65)
X= Minimum inlet Ø180
XX= Rotational Ø200
Ø250
5.956-515
C6

C. Technical Data
English HKF 200
7. Installation Example HKF 200 PU
o I N
Ex
Maintenance unit
Compressed air filter
Compressed air
4-7 bar 300 l/h
1/2"
Exhaust air
1/4"
3/8"
Holding device
(Holding device with safety
switch = option)
HKF 200 PU
Grating
Compact circulation tank
LxBxH=2700x1500x650 mm
Push-in strainer
SHD- R 3000 LM
50 l/min-50 bar 6,8 kW
Option
Filter monitoring
P MIN PMAX P W
M
Wire plate filter
Exhaust air
Ø100
Suction filter
slewable
Clear rinsing
agent supply
customer-supplied
C7
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HKF 200
C. Technical Data
English
8. Technical Specifications
Units
HKF 200 E
(3x400V)
HKF 200 E
(3x42V)
HKF 200 ET HKF 200 P
Order No. 3.631-015 3.631-018 3.631-063 3.631-016
Throughput (MAX) l/h 10 000 10 000 10 000 10 000
Max. flow rate for use
with solvent
Max. temperature for water
with cleaning agents
Max. temperature for
solvents, lyes, acids
l/h
°C
°C
3000 3000 3000 3000
95 95 95 95
20 20 20 20
Max. operating pressure bar 200 200 200 200
Max. operating pressure
for use with solvents
bar
50 50 50 50
Voltage V 230/400 42 (D) 230/400 –
Type of current 3~ 3~ 3~ –
Frequency Hz 50 50 50 –
Rated power consumption W 120 120 120 –
Compressed air
bar
l/min
–
–
Functional speed drive 1/min 18,5 18,5 18,5 10–20
Sound level
(EN 60704-1)
High-pressure connection DN 15
M22x1.5
–
–
–
–
4–7
500
dB(A) 70 70 70 83
without
silencer
DN 15
M22x1.5
DN 15
M22x1.5
DN 15
M22x1.5
Min. container opening mm Ø 200 Ø 200 Ø 140 Ø 200
Length incl. bracket up to
middle of nozzle
mm 1415 1415 1115 1220
Standard immersed depth mm 800 800 500 800
Weight kg 40 40 38 30
Ambient conditions
temperature
Type of protection
°C +2....+40 +2....+40 +2....+40 +2....+40
II 1/2 G c T4 II 1/3 D c 120 °C
5.956-515
C8

C. Technical Data
English HKF 200
9. Technical Specifications
Units HKF 200 PT HKF 200
PU
HKF 200 C
HKF 200 C2
Order No. 3.631-036 3.631-023 3.631-059 3.631-060
Throughput (MAX) l/h 10 000 10 000 10 000 10 000
Max. flow rate for use
with solvent
Max. temperature for water
with cleaning agents
Max. temperature for
solvents, lyes, acids
l/h
°C
°C
3000 3000 3000 3000
95
95 95 95
20 20 20 20
Max. operating pressure bar 200 200 200 200
Max. operating pressure for
use with solvents
bar
50 50 50 50
Voltage V – – 400 400
Type of current – – 3~ 3~
Frequency Hz – – 50 50
Rated power consumption W – – 300 300
Compressed air
bar
l/min
4–7
500
4–7
594
Functional speed drive 1/min 10–20 10–20 10/20 10/20
Sound level
(EN 60704-1)
dB(A) 83
without
silencer
High-pressure connection DN 15
M22x1.5
83
without
silencer
DN 15
M22x1.5
–
–
–
–
70 70
DN 15
M22x1.5
DN 15
M22x1.5
Min. container opening mm Ø 140 Ø 200 Ø 200 Ø 300
Length incl. bracket up to
middle of nozzle
mm 920 700 1415 1415
Standard immersed depth mm 500 300 800 800
Weight kg 28 28 45 45
Ambient conditions -
temperature
Type of protection
°C +2....+40 +2....+40 +2....+40 +2....+40
II 1/2 G c T4 II 1/3 D c 120 °C
C9
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HKF 200
C. Technical Data
English
10. Cleaning Liquids
Solvents
Acids
! Danger!
The relevant special safety regulations must be
complied with when using the unit with solvents
or in hazardous, potentially explosive areas!
Maximum pressure for use with solvents: 50 bar
Maximum flow rate for use with solvents: 50 l/min
Caution!
When using solvents, the sealing materials have
a reduced durability, therefore you must always
rinse the unit immediately after use! Please contact
Kärcher if you have any questions!
1. Hydrocarbons
e.g.: Petroleum
2. Aromatic compounds (solvents)
e.g.: benzene, toluene
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. Regenerated substances, distillates made
from various solvents, which have already
been used for cleaning or similar purposes.
Lyes
Caution!
Increased material erosion if hydrochloric and
sulphuric acid are used, therefore rinse/neutralise
immediately after use! Reduced durability if
impure acids are used! Please contact Kärcher
if you have any questions!
1. Water with acidic cleaning agent
(max. 0 - 1%)
e.g.: Kärcher RM25 cleaning agent
2. Acids (max. temperature +20 °C)
Nitric acid max. 10%
Ethanoic 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%
Water
1. Water
2. Demineralised water
Other cleaning liquids
When using other cleaning liquids use the materials
list to check the durability!
These cleaning liquids may only be used after
they have been released by Kärcher!
1. Water with alkali cleaning agent
(max. 0 - 2%)
e.g.: Kärcher RM31 cleaning agent
2. Hydrated caustic soda max. 10%,
without hypochlorite fractions
3. Potassium hydroxide max. 10%,
without hypochlorite fractions
5.956-515
C10

C. Technical Data
English HKF 200
11. Materials List
Item Description Order No. Material Number Media
contact
1 Protective part 4.394-009 5.000-506 metal plate
1.4301
5.114-077 ring
1.4541
1 X
2 Protective part 4.394-011 1.4301 1 X
3 Circular lamination 5.005-174 1.4541 3 X
4 Housing 5.060-085 1.4305 1 X
5 Housing 5.060-114 1.4305 1 X
6 Shaft 5.100-043 1.4305 1 X
7 Shaft 5.100-044 1.4305 1 X
8 Washer 5.115-122 Teflon - bronze 2 X
9 Flange 5.122-059 1.4305 2 X
10 Flange 5.122-068 1.4305 1 X
11 Pin 5.314-037 1.4541 2 X
12 Bevel gear 5.354-003 1.4305 1 X
13 Bevel gear 5.354-004 1.4305 1 X
14 Coupler 5.471-031 1.4305 1 X
15 Ring 5.570-039 CuSn8F55 4 X
16 Cheese head screw M5x12 6.304-011 1.4571 20 X
17 Cheese head screw M5x16 6.304-012 1.4571 10 X
18 Cheese head screw M8x16 6.304-013 1.4571 1 X
19 Cheese head screw M5x30 6.304-112 A4-70 1
20 Lock washer 8.4 6.343-125 Nirosta X7 1 X
21 O-ring 23.47 x 2.62 6.362-219 EPDM 1 X
22 O-ring 18 x 2,5 6.362-431 FPM 1 X
23 O-ring 17.96 x 2,62 6.363-154 FPM 1 X
24 Lip seal D26 x D38 6.365-423 PTFE 4 X
25 Hexagonal screw M8x16 7.304-538 A4-70 1 X
26 Hexagonal nut M5 7.311-203 A4-70 2 X
27 Cap nut M5 7.311-385 A1-50 4 X
28 Sealing ring 22 7.362-011 Cu 1 X
29 VS screw 7.382-251 1.4571 1 X
30 Shaft 4.100-229 5.100-492 shaft 1.4305
VS screw 1.4571
1 X
C11
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HKF 200
C. Technical Data
English
12. Nozzle Selection
Throughout
l/h
Pressure
bar
Number
of
nozzles
Nozzle size
mm
Order No.
3000 50 4 1.8 4.765-007 o o – – –
3000 50 2 2.4 5.765-006 x x – – –
3000 60 4 1.65 5.765-082 o o – – –
3000 50 2 2.7 4.765-006 x x – – –
3000 50 1 3.8 4.765-008 o o – – –
3000 80 2 2.5 5.765-018 o o – – –
3800 50 2 2.9 5.765-025 o o – – –
3800 80 2 2.7 4.765-006 x x – – –
6000 50 2 3.8 4.765-008 o o – – –
6000 80 2 3.5 5.768-075 o o o – –
6000 80 1 5.0 of inquiry o o o – –
8000 80 2 3.8 4.765-008 – – x – –
3800 80 2 2,7 6.415-862 – – – x x
HKF 200 E
HKF 200 P
HKF 200 C
HKF 200 PT
HKF 200 ET
Remarks
The size of the nozzle is imprinted on the key
area of the nozzles.
o = possible
x = fitted as a standard
5.956-515
C12

D. Operation
English HKF 200
1. Preparation for the initial startup
Electrical drive unit
! Danger!
Risk of fatal injuries due to high electrical voltage.
The required electrical installations must
only be carried out by a qualified electrician.
The plug socket used must:
be fused with a residual current operated circuit-breaker
with a tripping current of 30 mA,
close to the workplace so that the mains plug
can be quickly removed in case of emergency.
Where the mains connection is fixed, a lockable
master switch must be installed for complete
disconnection from the electricity system.
Electrical drive units 42 V and 400 V
Connect wiring (4-cored) to the three-phase
a.c. motor,
connect the motor cable to the power supply
via a lockable master switch,
switch on spray head and check the direction
of rotation.
The spray head must rotate in the following direction
when in operation:
Pneumatic drive
Caution!
Install a maintenance unit in the compressed air
feed (Kärcher Order No. 6.610-020) in order to
avoid damage to the pneumatic drive due to
condensation and poor lubrication.
The maintenance unit must be designed for
An air throughput of 500 l/min,
Pressures up to 7 Bar.
The maintenance unit consists of:
Water separator,
Pressure regulator with manometer,
Proportional lubricator.
Fill proportional lubricator with suitable lubricating
oil. To do this unscrew the storage tank and
pour in the lubricating oil (See the "Maintenance"
section for oil type and grade).
D1
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HKF 200
D. Operation
English
Fit the compressed air hoses to the
compressed air motor
i Important!
If the silencers are too small, the exhaust air
backpressure created causes the pneumatic
drive to run unsafely. Install hoses at the exhaust
air openings.
2. Switch on for initial operation
! Danger!
Risk of injuries due to possibly hot high-pressure
jet given off by the unit. Therefore
only start up the internal cleaner in containers
closed on all sides,
only place the internal cleaner into the container
or change to another container if the
separate high-pressure pump and the unit's
own drive are switched off.
Place the internal cleaner on the container
and secure if necessary,
Connect the high-pressure pump with the internal
cleaner using a high-pressure hose,
Switch on the drive unit of the internal cleaner,
to do this
– Switch on the power supply to the
electrical drive unit
– Open the compressed air supply to the
pneumatic drive
Open the cleaning liquid inlet,
Switch on the separate high-pressure pump.
Install fresh air hose
Fresh air hose size DN 6,
Install exhaust air hoses to connection No. 2.
Install exhaust air hose
Hose length 1-2 m,
Hose size for exhaust air DN 6,
To connection No. 1 and EXH.
5.956-515
D2

D. Operation
English HKF 200
3. Shut-down procedure-switch OFF
i Important!
Before starting the shut-down procedure rinse
through the internal cleaner for 30 seconds without
adding cleaning agents. This way you prevent
incrustations and conglutination, and
therefore premature wear of the seals.
Switch off the separate high-pressure pump,
Shut off the cleaning liquid supply,
Switch off the drive unit of the internal cleaner
by
– removing the mains plug of the electrical
drive units or by switching off the power
supply,
– shutting off the compressed air supply to
the pneumatic drive,
Remove the internal cleaner from the container.
D3
5.956-515

HKF 200
E. Maintenance
English
1. Maintenance instructions
Regular maintenance is the basis for a safe
operating system (see table on page E2).
Only use original parts or parts recommended
by the manufacturer, such as
Spare and wearing parts,
Accessory parts,
Resources, fuel, etc,
Cleaning agents.
! Danger!
Risk of accidents when working on the system.
When carrying out any work
disconnect the high-pressure pump at the
master switch and secure,
shutoff the cleaning liquid supply,
switch off the drive unit des internal cleaner,
to do this
– remove the mains plug of electrical drive
units or switch off the power supply
– shutoff the compressed air supply to the
pneumatic drive
Who may carry out maintenance works?
Operator
Works marked "owner/operator" may only be
carried out by instructed persons who can
safely operate and service high-pressure
equipment and systems.
Service agreement
To guarantee reliable operation of the system,
we recommend that you take out a service
agreement. Please contact the Kärcher customer
service responsible for you.
5.956-515
E1

E. Maintenance
English HKF 200
2. Maintenance intervals
Time Activity Execution Who
Weekly or
every 40
operating
hours
Monthly or
every 160
operating
hours
Check
compressed
air
maintenance
unit
Check that all
screws are
tight
Caution!
Hazard due to compressed air. Shut off the compressed
air before carrying out any maintenance
work and allow any compressed air in the system
to flow out at the maintenance unit first.
Drain off the water in the water separator by
– opening the water drain plug
– drain water off
– close water drain plug
Fill the proportional lubricator with suitable
lubricating oil. To do this unscrew the storage tank
and pour in the lubricating oil. See table below for
lubricating oil types to be used.
Check that all screws are tight.
Operator
Operator
Lubricating oil for compressed air
maintenance unit
(for Order No. 3.631-016, 3.631-036)
Festo spezial
Aral Vitam GF 32
Esso Nuto H 32
Mobil DTE 24
BP Energol HLP 32
E2
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HKF 200
F. Troubleshooting
English
1. Fault information
! Danger!
Risk of accidents when working on the System.
Before carrying out any work
disconnect the high-pressure pump at the
master switch and secure,
shutoff the cleaning liquid supply,
switch off the drive unit des internal cleaner,
to do this
– remove the mains plug of electrical drive
units or switch off the power supply
– shutoff the compressed air supply to the
pneumatic drive
Who may correct faults?
Operator
Works marked "owner/operator" may only be
carried out by instructed persons who can
safely operate and service high-pressure
equipment and systems.
Qualified electricians
Work marked "qualified electrician" may only
be carried out by persons who have successfully
completed an electrical engineering
vocational course.
Customer service
Works marked "customer service" may only
be carried out by the fitters of Kärcher's customer
service.
5.956-515
F1

F. Troubleshooting
English HKF 200
2. Locating faults
Fault Possible cause Solution By whom
Motor wont rotate No voltage supply to motor Check fuses and cables Electrician
Motor rotates but
not the spray head
Spray head rotates
jerkily
Motor protection switch has
tripped
Residual current operated
circuit-breaker has tripped
No compressed air or
pressure too low
Air feed line bent
Mechanical defect in
- Coupling parts
- Drive shaft
- Gearing
Worn thrust rings lead to
increased bevel gear
clearance
Gear teeth of bevel gears
worn
Remove cause of the
overload, reset motor
protection switch
Remove cause and reset
the residual current
operated circuit-breaker
Check compressed air
Check compressed air
hoses
Check parts, replace
defective parts
Replace thrust ring
Replace bevel gears
Electrician
Electrician
Operator
Operator
Customer service
Customer service
Customer service
Uneven cleaning jet Spray nozzles blocked Clean spray nozzles Operator
Spray nozzles damaged Replace spray nozzles Operator
F2
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HKF 200
G. Accessories
English
Accessories
The HFK 200 internal cleaner can be supplemented with the following accessories:
Description
Order No.
Compressed air maintenance unit (only for compressed air operation) 6.610-020
Compressed air filter with automatic condensate drain
(only for compressed air operation)
6.414-154
Bracket (VA) HFK 200 P/PT 4.034-016
Bracket (VA) HFK 200 E/ET/C/C2 4.034-126
Domed cover (VA) Ø 560 mm 4.210-022
High pressure hose, NW 13 – 1.5 m* 1) 6.389-126
High pressure hose, NW 13 – 10 m* 1) 4.440-173
Coupling NW 13* 4.403-002
90° threaded connection NW 13* 4.408-023
Compressed air hose (sold by the metre) 6.388-192
Exhaust air silencer with oil separator
auf Anfrage
* Possible for max. 4000 l/h cleaning liquid flow rate. Please inform Kärcher if higher cleaning liquid
flow rates are required.
1) Hoses for use with solvents must be electrostatically conductive!
5.956-515
G1

H. Guarantee
English HKF 200
Guarantee
The guarantee terms and conditions issued by
our sales company in each country apply.
In case of guarantee claims, please contact
your dealer or your nearest authorised customer
service agent.
H1
5.956-515

HKF 200
I. Declaration of Conformity
English
EC Declaration of Conformity
We herewith declare that the design and type of
machine named in the following as well as the
model marketed by us complies with the relevant
fundamental health and safety requirements
of the EC Directives.
This declaration becomes invalid if modifications
are made to the machine which have not
been previously agreed with us.
Product: Internal cleaner
Type: HKF 200 P, HKF 200 PU,
HKF 200 PT
Relevant EC Directives:
EC Machine Directive (98/37/EC)
EC ATEX Directive (94/9/EC)
Harmonised standards used:
DIN EN 292 - 1
DIN EN 292 - 2
DIN EN 13463 - 1: 2002
prEN 13463 - 5: 2002
EN 1127 - 1: 1997
Alfred Kärcher GmbH & Co. KG
Cleaning Systems
Alfred-Kärcher-Str. 28-40
P.O. Box 160
D-71349 Winnenden
Phone: ++ 49 71 95 14-0
Fax: ++ 49 71 95 14-22 12
5.957-454 (06/03)
Alfred Kärcher Kommanditgesellschaft.
Registered office: Winnenden.
Register court: Waiblingen, HRA 169.
Personally liable shareholder:
Kärcher Reinigungstechnik GmbH.
Registered office: Winnenden, 2404 Waiblingen
register court, HRB
Managing Directors: Dr. Bernhard Graf,
Hartmut Jenner, Georg Metz
National standards used: -
No. of nominated test institute: 0123
Test report No. 70043569
Designation:
Ex II 1/2 G c T4
Ex II 1/3 D c 120 °C
Internal measures ensure that serial production
units always comply with the requirements of
the current EC Directives and the standards
used.
The undersigned act on behalf of and with power
of attorney issued by the management.
S. Reiser H. Jenner
5.956-515
I1

I. Declaration of Conformity
English HKF 200
EC Declaration of Conformity
We herewith declare that the design and type of
machine named in the following as well as the
model marketed by us complies with the relevant
fundamental health and safety requirements
of the EC Directives.
This declaration becomes invalid if modifications
are made to the machine which have not
been previously agreed with us.
Product: Internal cleaner
Type: HKF 200 E, HKF 200 ET,
HKF 200 C, HKF 200 C2
Relevant EC Directives:
EC Machine Directive (98/37/EC)
EC ATEX Directive (94/9/EC)
Harmonised standards used:
DIN EN 292 - 1
DIN EN 292 - 2
DIN EN 60 204 - 1
DIN EN 13463 - 1: 2002
prEN 13463 - 5: 2002
EN 1127 - 1: 1997
Alfred Kärcher GmbH & Co. KG
Cleaning Systems
Alfred-Kärcher-Str. 28-40
P.O. Box 160
D-71349 Winnenden
Phone: ++ 49 71 95 14-0
Fax: ++ 49 71 95 14-22 12
5.957-735 (06/03)
Alfred Kärcher Kommanditgesellschaft.
Registered office: Winnenden.
Register court: Waiblingen, HRA 169.
Personally liable shareholder:
Kärcher Reinigungstechnik GmbH.
Registered office: Winnenden, 2404 Waiblingen
register court, HRB
Managing Directors: Dr. Bernhard Graf,
Hartmut Jenner, Georg Metz
National standards used: -
No. of nominated test institute: 0123
Test report No. 70043569
Designation:
Ex II 1/2 G c T4
Ex II 1/3 D c 120 °C
Internal measures ensure that serial production
units always comply with the requirements of
the current EC Directives and the standards
used.
The undersigned act on behalf of and with power
of attorney issued by the management.
S. Reiser H. Jenner
I2
5.956-515

HKF 200
English
5.956-515