Kärcher IP 120 Manual page 16

Maintenance instructions
The bases of a safe operating of the equip-
ment is thr regularly maintenance accord-
ing to the following maintenance plan.
Repair and maintenance works must be
carried out by authorized qualified person-
nel (Kärcher service or personnel trained by
the manufacturer).
Use exclusively original parts of the manu-
facturer or those parts recommended by
him like
– parts and wearing parts,
– accessories parts,
– operating materials,
– cleaning agents.
Danger!
Risk of accident while working on the appli-
ance. Carry out all the steps described in
the chapter "Shut down" before starting
anhy work on the device.
Danger
Risk of cold burns on account of dry ice or
cold parts of the machine. While working on
the machine, wear appropriate safety gear
for protection against cold or remove dry ice
and let the machine heat up.
Avoid bodily contact with dry ice.
Never put dry ice in your mouth.
Maintenance contract
In order to guarantee a reliable operation og
the equipment, we success, you signed a
maintenance agreement. Please refer to
you local Kärcher service department.
Maintenance schedule
Daily
Place the collection container under the
condensate drain and empty on a regu-
lar basis.
Weekly
Check oil level. The oil level indicator
must be filled with 3/4 with oil.
Visual inspection of oil cooler. The oil
cooler and the air inlet and outlet must
be clean. Clean or blow out with com-
pressed air if necessary.
Check ventilator function of oil cooler,
clean if required. The ventilator must
start up as soon as the oil temperature
reaches 45°C.
Visual check of the hydraulic motor ven-
tilator, clean if required.
Check the function of the valves EV2,
EV3 and EV4*. When the valve is open
you will hear streaming noises.
Check the carbon dioxide lines for tight-
ness, call customer service in case of
leaks.
* IP 220 only
Monthly
Check the hydraulic system for tight-
ness (hoses, piping, connections). Fix
the leaks.
Clean the inside and outside of the ma-
chine.
16 English
After the first 100 operating hours
Install new oil filter.
Check that screws and fittings are firmly
screwed in, tighten if necessary (tor-
ques are listed in the section "tightening
torques").
Every 1000 operating hours
Check the pistons for scratches and
grooves; contact customer service if
piston is damaged.
Every 2000 operating hours
Replace the hydraulic oil and oil filter
(see "Maintenance Procedures").
Tightening torques
M3 1.1 Nm
M4 2.5 Nm
M5 5.1 Nm
M6 8.8 Nm
M8 21.4 Nm
M10 44 Nm
M12 88 Nm
M14 119 Nm
M16 183 Nm
M20 224 Nm
Opening the device
Danger!
Risk of accident while working on the appli-
ance. Carry out all the steps described in
the chapter "Shut down" before starting
anhy work on the device.
– The front cover can be tilted outward
and removed after the two locks have
been released.
– The other covers can be removed once
the screws have been taken off.
Maintenance Works
Oil change with oil change system
Only change the oil while it is still warm.
Danger
Risk of burns due to hot oil!
Let the oil cool down to approx. 40 °C prior
to changing the oil.
Turn out the oil drain screw.
Connect the oil change system to the
locking valve.
Open locking tap.
Pump all the oil into a reservoir using
the oil change system.
Unscrew the lid from the oil filter hous-
ing.
Change the oil filter inlay.
Attach the lid to the oil filter housing.
Fill the machine with new oil using the
oil change system until the oil level indi-
cator shows 3/4 full.
For oil type refer to technical specifica-
tions.
Switch on the machine and check the oil
level indicator while the machine is run-
ning. If required, top up oil carefully.
Oil change without oil change system
Only change the oil while it is still warm.
Danger
Risk of burns due to hot oil!
Let the oil cool down to approx. 40 °C prior
to changing the oil.
Place a pan underneath the locking
valve to catch the oil.
Turn out the oil drain screw.
Open the locking valve and let all the oil
drain.
Close locking tap.
Fix in the oil drain screw and tighten it.
IP 120:
Unscrew the lid from the oil filter hous-
ing.
Change the oil filter inlay.
Attach the lid to the oil filter housing.
Unscrew the lid from the air filter hous-
ing.
Take out the air filter sieve.
Fill in new oil until the oil level indicator
shows 3/4 full.
For oil type refer to technical specifica-
tions.
Install the air filter insert.
Screw the lid onto the air filter housing.
Switch on the machine and check the oil
level indicator while the machine is run-
ning. If required, top up oil carefully.
IP 220:
Unscrew the lid from the oil filter hous-
ing.
Take out the oil filter insert.
Fill in new oil until the oil level indicator
shows 3/4 full.
For oil type refer to technical specifica-
tions.
Insert a new oil filter insert.
Screw the lid onto the oil filter housing.
Switch on the machine and check the oil
level indicator while the machine is run-
ning. If required, top up oil carefully.
Check piston
Remove the cover from the machine.
Set the key switch "M/0/A" to "M".
Press the key "Piston backwards".
The piston moves back into the rear-
most position.
Check the piston for scratches and
grooves.
Set the key switch "M/0/A" to "A". Re-
move the key and store so that it can
only be accessed by service personnel.