Operation Manual

D 500-30

To be read carefully before start-up!

von Oertzen GmbH • Ferdinand-Harten-Str. 10 • 22949 Ammersbek • Tel. +49 40 604110 • Fax +49 40 6041149
www.oertzen-gmbh.de • [email protected]
 Table of Content

1. Introduction page 3

2. Safety Instructions pages 4 – 5

3. Configuration/Illustration pages 6 – 7

4. Start-up/Operation/Shut-down pages 8 – 12

5. Maintenance and Care pages 13 – 15

6. Technical Data page 16

7. Trouble-Shooting pages 17

8. Declaration of Conformity page 18

D500-30-07/06-AG

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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 ignoring 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 instructins 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.

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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 dangers. Directives ZH 1/406 and BGR 500, 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. Protective clothing to be worn.

Suitable ear protection to be worn.

The water jet emerging from the spray pistol has a dangerous cutting effect. There-
fore the water jet must never be directed onto persons, animals or electrical installa-
tions. 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 20 bar and returns the water 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.

Used 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.

4
Before opening the machine in case of malfunction or emergency, switch off by
means of the emergency switch.

Electric power is harmful. Any symptoms for faulty electrical components to be taken
seriously and cause to be eliminated immediately. For repair work machine to be
disconnected from power supply

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 expres-

sively approved by OERTZEN results in expiry of the EC Declaration of
Conformity, as well as product liability and warranty.

5
3. Configuration/Illustration

The machines of this series consist of a low speed, high pressure inline
plunger pump, driven by a low-emission water-cooled 4-stroke Diesel engine.
Power transmission between Diesel engine and high pressure pump is
effected by a low-maintenance tooth belt.

A sophisticated engine control system ensures that the machine is stopped in

case of critical operating conditions and that the emission limits are kept.

The feed water is directed with the required admission pressure via a pre-filter
to the high pressure pump which – in connection with the required spray
nozzle – boosts it to the stated/adjusted working pressure. In order to protect
the pump against cavitation due to poor water flow, a low water cut-out is
arranged which stops the machine as soon as the flow pressure drops below
1 bar.

Downstream of the high pressure pump a locked and sealed safety/control

valve is installed which opens as soon as the operating pressure is exceeded
by more than 20 bar and returns the water which cannot be taken by the
nozzle into the suction line of the pump.
It also allows to continuously adjust working pressure and water flow as
required.

The machine is equipped with a circulation shut-off system and additionally

with a thermo valve in order to protect the pump against overheating. After
closing the spray pistol the safety/control valve opens, and returns the
circulating water back into the suction line. If the the temperature of the
circulating water exceeds 60 °C, the thermo valve opens, releases small
amounts of hot water and allows cold water to enter. Re-starting and
immediate generation of required/adjusted working pressure is achieved by
opening the spray pistol again, allowing to continue the cleaning task without
delay.

The range of applications can be extended by a variety of accessories

available. Contact your local distributor.

6
7
. Start-up / Shut-down
Initial Start-up Instructions

Upon initial start-up, follow instructions below:

• During the first 50 operating hours machine to be run at reduced load

up to max. 300 bar.

• After 50 operating hours machine to be run within specified limits.

Speed can be adjusted by means of the speed control.

• After 20 hours all connections to be tightened. Check for leaks.

• After 50 operating hours oil change to be carried out on motor and high
pressure pump, filter/Diesel filter to be changed.

• Oil to be drained warm.

• Above works to be carried out by qualfied personnel only. Only spare parts
and consumables approved by OERTZEN to be used (see chapter
"Maintenance and Care").

8
Before Start-up:

Read and observe operation manual.

In order to guarantee proper function and trouble-free operation, the

following checks to be carried out before start-up:

• General condition of the unit (connections, gaskets, etc.).

• 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 Diesel 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,
Diesel engine: OERTZEN special motor oil OSM.
• 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°).
• In order to extend the lifetime of the Diesel 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.
• Observe abnormal noise.

In case of malfunctions immediately stop machine, eliminate cause

according to chapter „Trouble Shooting“, call qualified service.

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Connections
Water inlet (6) and high pressure water outlet (11) are protected
with sealing caps which must be removed before start-up. It is
recommended to protect water in- and outlet with those caps
during extended shut-down periods

Water Supply
Connect water inlet (6) of the machine to water source with a clean hose of
1
" diameter. Before connecting water supply hose, rinse it thoroughly. In
case of connection to the potable water distribution, observe DIN 1988 (for
momentary connections use a backflow preventer with non-return function and
ventilation).

Flow pressure Min. flow rate *

minimum: 2 bar
15 l/min " water supply hose
maximum: 8 bar
21 l/min 1" water supply hose

30 l/min 1
" water supply hose
* see Technical Data

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.

Diesel Supply
Diesel tank (37) to be filled with Diesel (min. 45 cetane). Properly lock tank.
Diesel and Diesel vapour are highly flammable and explosive. Fire and
explosions may cause severe injuries or death. Diesel never to be handled
near hot engines.

Fuel to be handled with care. Observe engine manufacturer’s

instructions.

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Operation

In case of emergency push in emergency switch (2a). After eleminating

cause release emergency switch by pulling it out. Machine can then be
re-started.

Observe engine manufacturer’s instructions.

Initial start-up instructions: During the first 50 operating hours machine

to be run at reduced load up to max. 300 bar.

Never disconnect starter battery when engine is running.

• Fully open water source.

Start Procedure:
• Turn speed control (49) into
position.
• Turn ignition key (50) clockwise into position 1 "pre-heating" until
control lamp goes out. Turn ignition key (50) further into position
2 until engine starts. Release ignition key. Actuate starter only for
max. 10 seconds. Too many successless start attempts may
damage the starter.
• Run engine at low speed for several minutes to warm it up.
When engine is warm, turn speed control in "max." position.
• Open spray pistol and carry out cleaning task.

Be aware of significant recoil. Ensure stable foothold.

Pressure/Flow Regulation
Pressure and flow rate can continuously be adjusted as required at the
adjusting knob of the safety control valve (3).
Counter-clockwise: continuous pressure and flow increase to maximum
capacity
Clockwise: continuous pressure and flow reduction to minimum
capacity

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After Work
Cool down engine by reducing speed.

• Close and lock spray pistol.

• Stop engine: Turn ignition key into position “0”.
• Remove key in case machine is not in operation or or
remains unattended.
• Thoroughly clean high pressure hose. In case of damage (cuts,
abrasions, kinks) replace high pressure hose for safety reasons.
• Only original OERTZEN high pressure hoses to be used.
Otherwise Declaration of Conformity and warranty will expire.
• Reel up high pressure hose properly without any loops.
• Store machine and accessories in a dry, frost-protected area.

Particularly note:
In case of malfunctions, eliminate cause according to chapter „Trouble
Shooting“, call qualified service.

In case frost is likely, frost protection to be carried out (see chapter

„Maintenance and Care“), otherwise severe damage will be the result.

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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:

Ignoring the required maintenance intervals voids all warranty.

Diesel Engine / Cooling System

Maintenance instructions of engine manufacturer to be strictly followed.

For regular maintenance and filter change a service kit is available, consisting of fuel
filter, oil filter, air filter and water filter.

Maintenance intervals according to engine manufacturer's instructions striclty to be

kept. First oil and filter change after 50 operating hours. Further oil changes after
every 125 operating hours.

Exclusively OERTZEN OSM motor oil to be used. Use of oil qualities not
approved by OERTZEN voids all warranty.

Cooling system regularly to be checked for leaks and correct coolant level.
Coolant to be changed every 2000 operating hours, respectively every 2
years. Observe proper frost protection. Commercial coolants according to
engine manufacturer's instructions to be used.

High Pressure Pump

First oil change after 50 operating hours, all further oil changes every 500 operating
hours, min. once a year. In case the oil is getting turbid, stop the machine and carry
out oil change. If oil is getting turbid again, call qualified service personnel

Exclusively OSP pump oil to be used. Use of oil qualities not approved by
OERTZEN voids all warranty.

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Battery
Maintenance work to be carried out according to manufacturer’s instructions.
Check acid level every week. Refill distilled water whenever needed.

Water Filter
The cartridge filter (5) is arranged in the water inlet (6) and must be inspected
prior to start up. Change filter cartridge, if needed.

Supply of polluted water or dirty strainer will cause severe damage on

the pump and safety/control valve.

Frost Protection
Proper frost protection of the machine during storage and transport is
essential, in order to avoid severe damages and consequently dangers
during operation..

The best frost protection is to store the unit in a permanently frost-free

area.

If there is a risk of frost during storage and/or transport, the machine to

be protected as follows:

• 2 l of a 1 : 1 water/frost protection liquid to be mixed in a clean

vessel, water connecting hose to be dipped into vessel, pump to be
started.
• Spray pistol to be opened and frost protection liquid to be returned
into the vessel, so circulating the liquid through the system.
• Spray pistol to be opened and closed several times, in order to also
fill the unloader valve with the liquid.
• High pressure pump to be stopped, all hoses to be disconnected.
• Machine is now protected against frost of approx. – 30 °C.

Ignoring the above instructions will cause severe damages on the

entire system.

In order to avoid pollution of the environment, frost protection

liquid must not be dumped, but collected and reused respectively
disposed as per relevant regulations.

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6. Technical Data

Technical Data D 500-30

Water consumption/adjustable 1000 – 1800 l/h
Unloading pressure 520 bar
Working pressure/adjustable 500 bar
Power rating 33 kW
Fuel consumption at full load 5,0 l/h
Tank volume 44 l
Low oil level cut-out standard
Starting device battery start
Dimensions (L x W x H mm) 1370 x 820 x 1080 mm
Weight (net) 408 kg
Nozzle 2038 HIP
Recoil 145 N
Noise level Lp/Lw acc. to DIN EN ISO 3744 94/111 dB(A)

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7. Trouble Shooting
Electric power can cause severe injuries. Defective electrical compo-
nents 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.

Faiure Cause Remedy

Engine does not start - Emergency switch pressed - Release switch by pulling it out.
- Poor water supply - Ensure proper water supply.
- Motor oil low level. - Fill up oil up to max. mark.
- Counter pressure high - Release safety/control valve
- Battery exhausted - Charge battery.
Engine suddenly stops - Poor water supply - Ensure proper water supply.
- Fuel tank empty - Fill tank
- Engine oil level low - Fill up oil up to max. mark
- Fuel filter blocked - Clean/replace filter.
Operating pressure not achieved/ - Air in unit - Bleed unit.
varies - Poor water supply - Ensure proper water supply.
- Nozzle worn - Replace nozzle.
- Incorrect nozzle - Install correct nozzle.
- Nozzle clogged - Remove/clean nozzle.
- Water strainer blocked - Clean strainer.
- Safety/control valve leaking - Call service.
- Suction valves sticking - Carefully loosen valves by
means of a screw driver, if
needed, remove and clean
valves.
Vibrations on high pressure hose - Air in unit - Open handle on pistol unless
and spray pistol continuous pressure is achieved
Heavy vibrations on unit - Plungers blocked - Stop unit immediately,
call service.

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