Operation Manual Trailer-mounted Hot Water High-Pressure Cleaner with Combustion Engine Power Trailer 330 von Oertzen GmbH Ferdinand-Harten-Str. 10 22949 Ammersbek Tel. +49 40 604110 Fax +49 40 6041149 www.oertzen-gmbh.de info@oertzen-gmbh.de
Table of Content 1. Introduction page 3 2. Safety Instructions page 4-5 3. General Arrangement/Illustrations page 6-8 4. Start-up/Shut-down/Operation/ page 9-13 Initial Start-up Instructions 5. Maintenance and Care page 14-16 6. Technical Data page 17 7. Trouble Shooting page 18-19 8. Electric Wiring Diagrams page 20-21 9. Declaration of Conformity page 22 PT330/708-AG 2
1. Introduction By buying the OERTZEN equipment you have purchased one of the most durable and reliable high pressure cleaners available on the market. Its balanced ratio of water flow (temperature) and working pressure perfectly meets all cleaning requirements. The OERTZEN high pressure cleaners and accessories conform to all European safety regulations which is guaranteed by the CE symbol on the type plate. A Declaration of Conformity is part of this manual. This manual to be made available to the operating personnel and to be read completely before start-up. We point out that we cannot be held responsible for any damage or malfunctions as a result of neglecting this manual. According to the Directive for Use of Liquid Blasters (ZH 1/406) the machine described in this manual to be inspected every year by qualified personnel. Inspection results to be recorded and to be made available to authorities their on request. OERTZEN offers qualified service personnel to carry out safety inspections at attractive prices. The packing materials (plastic foil, wood, cardboard boxes, nails etc.) are potentially dangerous, should be kept away from children and disposed according to environmental requirements. This symbol appears at all operating and safety instructions dealing with risks for personal entirety and life. This warning symbol appears in the operating manual at all operating safety instructions dealing with risks due to electric power. This symbol appears at all operating and safety instructions dealing with the fulfilment of rules, regulations and instructions for the proper operation and destruction of the machine. This manual is subject to technical alteration. All rights reserved. Any use in other than legally authorised cases requires the written approval of von Oertzen GmbH. 3
2. Safety Instructions The following instructions to be followed before, during and after work: This instruction manual to be read completely before initial start-up. If strictly followed, no danger should occur. This machine must only be run by qualified adult persons who are fully aware of possible danger. Directives ZH 1/406 and BGV D15, as well as relevant national safety rules to be followed. The machine is not suitable for unattended operation and must be operated according to specification and intended purpose. Protective clothing to be worn. The water jet emerging from the spray pistol has a dangerous cutting effect. Therefore the water jet must never be directed onto persons, animals or electrical installations. It must never be used for cleaning of clothes, footwear and the like. Be aware of torque and recoil. Ensure stable foothold. The max. allowed pressure which is stated on the type plate must not be exceeded. The safety/control valve opens, if the max. operating pressure is exceeded by more than 10 % and returns the water back into the suction side of the high pressure pump. The safety/control valve is workshop-set and sealed. Adjustment must not be changed. Machines driven by combustion engines must not be run indoors unless proper ventilation and exhaust gas evacuation are guaranteed. Exhaust gas is harmful, excessive concentration of carbon monoxide is lethal. Unsuitable respectively defective high pressure hoses often cause severe accidents during operation. Therefore high pressure hoses to be carefully inspected before start-up and replaced by original OERTZEN equipment in case of damage. Use of other than original OERTZEN equipment (hand nut marked with OERTZEN), results in expiry of the EC Declaration of Conformity, as well as product liability and warranty. Worn out or damaged high pressure hoses must never be repaired and reused but to be replaced by original OERTZEN equipment. Spray pistols with delayed closing mechanism must not be used because of risk of injuries. Lever in open position must never be blocked or fixed in any way. Use of spray wands of a length below 750 mm is prohibited. The machine must not be run in areas jeopardized by fire or explosions. During operation at filling stations Technical Rules for flammable Liquids (TfbF) to be observed. Consumables to be handled thoroughly according to technical rules and safety and environmental regulations to be observed. Do not start the machine in case cables, connections or switches are defective. 4
Before opening the machine in case of malfunction or emergency, switch off by means of the ON/OFF respectively the EMERGENCY STOP switch. Electric power can cause serious hazards. All symptoms of defective electrical components to be taken seriously and eliminated immediately. Repair works only to be carried out by qualified personnel. Make sure that the machine cannot move. If the unit is equipped with a parking brake, it must be set during working. During loading hoisting device to be fastened properly at jack rings. Ensure balanced load. The exhaust evacuation area is hot! Do not touch! Repair work in the high pressure section of the machine (pump, hoses, piping) only to be carried out by qualified personnel. After work the machine to be locked and secured against unauthorized/accidental operation by means of the safety lever. Use of equipment and/or consumables which is/are not delivered or expressively approved by OERTZEN results in expiry of the EC Declaration of Conformity, as well as product liability and warranty. 5
3. General Arrangement The PowerTrailer series mainly consists of a low speed inline plunger pump with safety shut-down system, which is driven by a water-cooled Diesel engine, and a boiler system which allows operation with one or two oil-fired stainless steel boilers and which fully meets relevant safety standards with respect to immission values. Power transmission between combustion engine and high pressure pump is effected by a low maintenance tooth belt. All components are arranged in a sturdy trailer with stainless steel structure and polyester cover and are easily accessible for operation and maintenance. Control instruments are installed on a panel in a lockable control cabinet. A sophisticated engine management provides safety shut-down in case of critical operating conditions as well as meeting emission limits. The high pressure pump sucks the feed water out of a 180 l storage tank and boosts it via the safety/control valve into the boiler system which heats it up. The sealed safety/control valve is arranged between high pressure pump and heating coil and opens in case the operating pressure is exceeded by more than 10 %. The water which cannot be taken by the nozzle is returned back into the suction line of the high pressure pump. The safety control valve also allows to continuously adjust working pressure and water flow as required. The boiler system is activated by means of the burner/temperature adjusting switch. Fuel is supplied from an in-situ 20 l fuel tank via a filter system. The fuel pump directs it through the oil nozzle into the burner chamber. A blower presses the oxygen needed for the burning process into the burner chamber, where atomisation and ignition of the fuel mixture is effected by ignition electrodes. The flame burns soot-free highly efficiently without touching the boiler shells. The infra-red radiation of the flame and hot exhaust gas allow economic heating of the water to the temperature adjusted at the thermostat. The hot water is directed from high pressure outlet into the high pressure hose and high pressure nozzle. The nozzle diameter determines the working pressure. The machine is protected against scaling by an anti-scalant device which continuously injects an anti-scalant liquid into the water tank. A safety/control device interrupts the fuel supply to the burner, if pistol is closed and the burner is switched off. If pistol is opened again and burner system activated, working pressure is generated immediately, so that the cleaning process can be continued without delay. The range of applications can be extended by a variety of accessories available. Contact your local distributor. 6
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4. Start-up/Shut-down Important Note for Transportation on Public Roads: The PowerTrailer to be registered as working trailer only; it must not be used for transport of materials. Initial Start-up Instructions After 50 km check and make sure that wheels are still properly fixed. Tighten nuts on wheels if needed. Check traffic and operating safety before start-up. When connecting trailer to a truck-tractor, make sure that coupling ball is properly engaged. Connect safety wire with coupling ball of truck-tractor. Check proper functioning of lighting set. Do not exceed max. tolerated weight and axle load. During transport machine cover to be closed and locked. Water storage tank to be empty. Road traffic act is applicable when operating the Power Trailer. For all compulsory services check with national authorities in charge. Make sure upon initial start-up of the machine: 1. Operation at reduced capacity during the first 50 operating hours as follows: the first 20 operating hours at max. 200 bar the following 30 operating hours at max. 280 bar after 50 operating hours at nominal capacity Regulation by means of a speed control lever. 2. After 20 operating hours check and tighten all connections. After 50 operating hours carry out oil change and change filter/fuel filter, combustion engine/high pressure pump: oil change. Oil to be dumped at operating temperature. Above work only to be carried out by qualified personnel. Use only consumables approved by OERTZEN (see chapter 5 Maintenance and Care). 9
Before Work Before every Start-up: Read and observe operation manual. In order to guarantee proper functioning and trouble-free operation, the following checks to be carried out before startup: General condition of the unit (connections, gaskets, etc.). Electric connections/cables. High pressure hoses, hose pipes, whether damaged. Air supply, fresh air grill must not be covered. Filling of consumables. Correct oil level of high pressure pump (sight glass/dip stick). Correct oil level of the reduction gear (sight glass/dip stick), correct oil level of combustion engine (dip stick). Only oil qualities approved by OERTZEN to be used. High pressure pump: special pump oil OERTZEN OSP, reduction gear: special pump oil OERTZEN OSP, combustion engine: OERTZEN special motor oil OSM. Check coolant/anti-freeze levels. Pump/pump connections whether leaking. Machine only to be run with absolutely clean water. Before connecting the water supply hose, rinse it thoroughly. Depending on feed water quality, regularly check water filter in short intervals, replace if needed. Machine only to be run horizontally (+/- 5 ). Never run machine without/with disconnected battery. In order to extend the lifetime of the combustion engine, engine to be warmed up for a few minutes during starting procedure and to run out during shut-down for cooling purposes. In order to guarantee proper function and trouble-free operation, the following checks to be carried out during working: Observe function of indicator lights/monitors. Observe pressure variations Observe leaks at high pressure pump, hose pipes, connections. Observe excessive exhaust formation/smoke development. In case of malfunctions immediately stop machine, eliminate cause according to chapter Trouble Shooting, call qualified service. 10
Connections Water Filter, water supply connection Connect water supply hose (min. " diam.) to water inlet (6) and to water mains. Flush hose before connecting it. Flow pressure minimum: 2 bar maximum: 8 bar Insufficient water supply will cause heavy damage on high pressure pump (cavitation). High Pressure Connection Connect high pressure hose to high pressure outlet (11) by means of the hand nut without using tools. Fuel Supply - Engine Diesel tank (37) to be filled with Diesel (min. 45 cetane). Properly lock tank. Diesel and its vapour are highly flammable and explosive. Fire and explosions may cause severe injuries or death. Diesel never to be handled near hot engines. Fuel Supply HOT BOX Fuel tank (36) to be filled with fuel oil. Properly lock tank. Fuel oil is highly flammable and explosive. Fire and explosions may cause severe injuries or death. Fuel oil never to be handled near hot engines. Fuel to be handled with care. Observe engine manufacturer s instructions. 11
Operation The PowerTrailers are equipped with an EMERGENCY STOP switch. In case of emergency press EMERGENCY STOP switch. After elimination of cause unlock EMERGENCY STOP switch by pulling it out, otherwise machine cannot be started. In order to guarantee proper functioning of the machine, particularly of the burner, carry out start procedure exactly as described below: Cold Water Mode Reel off the high pressure hose completely. Burner switch (23) to be in position 0 prior to starting the engine. Speed control lever (49) to be in position gas/start positions. Ignition key to be in position 1, pre-heat until control lamp goes out. Turn ignition key to position 2 until engine starts. Start attempt max. 10 seconds only. If engine does not start, eliminate cause. Speed control lever to be in idle running, heat up engine. Engine warm? If so, turn speed control lever to max. Pos. Open spray pistol/carry out job. Be aware of recoil/ensure stable foothold! If required, start heating module one after the other. Hot Water Mode HOT BOX Adjust engine speed > idle speed Adjust thermostat (23 a) to required temperature Turn burner switch (23) into position 1 Thermostat automatically controls adjusted working temperature. In case for one or the other job higher temperatures are needed, start heating module II as follows: In case of overheating the safety reset switch 0 of the respective heating module is being activated. Eliminate cause, remove reset switch cover, press reset button. Reinstall switch cover. If module does not start after several attempts, eliminate cause/call qualified service. 12
Pressure/Water Flow Rate Control Pressure/water volume are continuously adjustable by means of hand wheel of the safety/control valve (3). Clockwise: Continuous increase of pressure/water flow rate up to maximum capacity. Counter-clockwise: Continuous decrease of pressure/water flow rate to minimum capacity. The adjusted working temperature can be achieved earlier by decreasing the water flow rate, respectively it is so possible to work with overheated water (observe thermostat adjustment). For this procedure ensure correct temperature as needed for the job and as max. tolerated by materials. For safety and environmental reasons work should only be carried out with closed cover. Cover of operating panel to be kept closed as well. After Work Reduce engine speed to idle running by means of speed control lever (49) Turn thermostat of HOT BOX into position 0. Run the unit in cold water mode with open pistol until the water temperature dropped to approx. 25 C. Turn burner switch into position 0. Turn ignition and key switch (50) into position 0. De-pressurise spray equipment Lock spray equipment by means of the safety lever in order to avoid accidental or unauthorised activation Disconnect the unit from water source, remove and and store water filter and reel up water hose Check high pressure hose for damages and reel it up Ignition/starter key to be removed Cover of operating panel to be closed and locked. Unit and accessories to be stored in a dry, frost-protected place 13
5. Maintenance and Care Every machine is only as reliable as maintenance is carried out. In order to guarantee reliability and trouble free operation of the machine, it is of vital interest to follow the instructions below: If the required maintenance intervals are disregarded, warranty will expire. Before commencing maintenance unlock the cover and slowly push it up to final position. After work has been finished properly close and lock the cover. Daily checks before every start-up are stated on pages 9-11. Combustion Engine Maintenance and care to be carried out according to engine manufacturer s instructions. If instructions are disregarded, warranty will expire. For frequent maintenance and filter change there is a service kit available (fuel filter, oil filter, air filter and water filter). Maintenance intervals according to manufacturer's instructions. First motor oil change and filter change after 50 operating hours, all further oil changes after every 125 operating hours. For the combustion engine only OERTZEN OSM special motor oil to be used. Use of any other oils voids all warranty. OERTZEN OSM special motor oil is available at OERTZEN service point/head quarter. 14
High Pressure Pump First oil change after 50 operating hours, all further oil changes after every 500 operating hours or minimum every year. In case oil is becoming turbid by condensate, immediately shut off the unit and carry out oil change. In case this repeatedly happens, all seals and gaskets of the pump to be changed. For OERTZEN high pressure pumps only OERTZEN OSP special pump oil to be used, otherwise warranty will expire. OERTZEN OSP special pump oil is available at OERTZEN service point/head quarter. Water Filter In the water inlet (6) there is a strainer installed which must be checked and flushed/cleaned, if needed. Operation with polluted water or dirty water filters may cause severe damages on the pump and/or control units. Fuel Filter A fuel filter is arranged upstream of the fuel pump which must be checked and cleaned regularly. Anti-Scalant As a standard the Power Trailer is equipped with an anti-scalant device which avoids scaling to a great extent. Anti-scalant liquid to be refilled whenever necessary. Only use anti-scalant liquid OERTZEN ORM 30. Safety instructions for handling anti-scalant liquids (corrosive!) to be followed. 15
Frost Protection The cooling system of the water-cooled combustion engine is long-term frost protected down to temperatures of 25 C. Frost protection of the entire water system to be guaranteed even at moderate temperatures around freezing point during storage and transport, as frost may cause heavy damages and consequently dangers during operation. The best frost protection is the storage of unit and accessories in a permanently frost-proof place. If temperatures below 0 C are expected during storage and/or transport, carry out the following protection procedure: Open cover. Discharge water tank by opening discharge below tank. Disconnect intake hose from pump (knurled nut (66)) and connect suction hose instead. A bucket to be filled with 20 l of commercial anti-freeze. Put suction hose into the bucket. Open spray pistol. Start engine and keep it running until anti-freeze emerges from spray pistol. Open and close spray pistol 2 3 times. Collect anti-freeze in suitable vessel for re-use. (Caution: In case the anti-freeze contains too much water, the protection efficiency drops reasonably!) Stop engine (see 5 operating panel). Machine is now frost-protected. Anti-freeze never to be dumped but to be collected for re-use! 16
6. Technical Data Technical Data PowerTrailer 380 Water consumption max. 500 1320 l/h Unloading pressure max. 350 bar Working pressure (adjustable) 50 330 bar Water temperature (adjustable) 50 120 C Drive 18 kw Sound power level / sound pressure level*) 81/93 db(a) Volume of water tank for test runs 180 l Micro water filter mesh size 50 m Fuel oil tank volume 48 l Diesel tank volume 20 l Spray nozzle size 2338 Recoil 96 N Dimensions L x W x H 3550 x 1820 x 1700 mm Weight empty 800 kg Total weight allowed, max. 1300 kg Part No. 10.000.525 *) acc. to DIN EN ISO 3744 17
7. Trouble Shooting Electric power can cause severe injuries. Defective electrical components to be immediately replaced, possible causes for accidents to be eliminated without delay. Any repair work must only be carried out by qualified personnel. Only original equipment expressively approved by the manufacturer to be installed, as otherwise warranty and Declaration of Conformity will expire, health and safety standards are not guaranteed. During repair or maintenance work, unit to be disconnected from electrical network. Malfunction Cause Remedy Engine failures: Engine does not start Engine starts, but suddenly stops - Emergency Stop switch pressed/locked - Battery exhausted - Diesel tank empty - Air in fuel lines - Fuel filter clogged - Water storage tank empty - Motor protection switch activated due to low oil pressure. - Emergency Stop pressed. - Unlock/pull out Emergency Stop switch. - Charge battery - Refill tank - Bleed fuel lines - Clean/replace filter - Refill tank. - Refill oil, if needed - Unlock/pull Emergency Stop switch. - Refill tank - Low water level in tank. Engine smokes - Air filter/fuel filter blocked - Replace filter Engine suddenly stops during operation. Burner failures: Burner does not start - Fuel tank empty - Low oil pressure - Engine temperature high - Low water level in storage tank - Fuel tank empty - Fuel filter blocked - Refill/vent tank - Refill oil - Check level of cooling liquid - Check water supply - Clean water filter - Refill tank - Clean filter/call service. Burner does not achieve required temperature Burner trips - Incorrect start of boiler system. - Battery poor. - Incorrect temperature adjustment - Fuel oil filter blocked - Fuel oil tank empty - Filter blocked - Overheating - Restart, max. speed, then switch on heaters one after the other. - Charge battery. - Adjust correct temperature - Clean filter/call service - Refill tank - Clean filter/call service. - Push reset button 18
Malfunction Cause Remedy Burner malfunctions: (continued) Burner soots/smokes - Dirt in water/fuel oil tank - Clean tank/call service. Burner trips - Incorrect start procedure - Strictly follow instructions as described in chapter Hot Water Mode. Pump malfunctions: Pump splutters, - Filter blocked - Clean/replace filer. Capacity varies Insufficient pressure - Pump valves clogged - Spray nozzle/accessories worn out - Proportional control valve incorrectly adjusted - Call service. - Replace - Adjust correctly, call service. 19
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