3
Table of Contents
Machine Data Label . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . 4
Safety
Introduction & Safety Information . . . . . . . . . . . . . . . 5
Important Safety Information. . . . . . . . . . . . . . . . . . . 5
Propane Tank Safety Instructions. . . . . . . . . . . . . . 10
Operations
Component Identification - All Models . . . . . . . . . . 11
Installation HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30
12
Installation HDS 6.3/32, 8.0/32, 9.5/30 . . . . . . . . . . 13
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gas Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pipe Sizing Chart for Natural Gas. . . . . . . . . . . . . . 15
LP-Gas (Liquid petroleum gas or propane). . . . . . . 15
Filling the LP-Gas Container. . . . . . . . . . . . . . . . . . 15
Propane Tank Disposal. . . . . . . . . . . . . . . . . . . . . . 15
Room Vents for Combustion and Ventilation Air. . . 16
Water Source: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection and Testing Gas Piping: . . . . . . . . . . . . 17
Gas Valve Replacement: . . . . . . . . . . . . . . . . . . . . 18
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check List Before Starting: . . . . . . . . . . . . . . . . . . . 20
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . 21
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . 22
Applying Detergent & General
Operating Techniques. . . . . . . . . . . . . . . . . . . . . 23
Shutting Down & Cleanup. . . . . . . . . . . . . . . . . . . . 24
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance
Maintenance & Service . . . . . . . . . . . . . . . . . . . . . . 26
Spray Nozzles: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Unloader Valves:. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Low Pressure Diagnosis: . . . . . . . . . . . . . . . . . . . . 26
High Limit Hot Water Thermostat:. . . . . . . . . . . . . . 26
Pumps: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Heating Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gas Valve Regulator Adjustment . . . . . . . . . . . . . . 27
Propane Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General Safety Precautions . . . . . . . . . . . . . . . . . . 28
Burner Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Replace regulator adjustment screw cap.. . . . . . . . 28
Burner Basic Facts . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pressure Equivalents . . . . . . . . . . . . . . . . . . . . . . . 30
Oil Change Record . . . . . . . . . . . . . . . . . . . . . . . . . 30
Preventative Maintenance . . . . . . . . . . . . . . . . . . . 31
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . .31
Parts
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Frame 38
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Frame 40
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Burner 41
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Burner 42
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Coil . . 43
HDS 6.3/32, 8.0/32, 9.5/30 Frame . . . . . . . . . . . . 46
HDS 6.3/32, 8.0/32, 9.5/30 Frame . . . . . . . . . . . . 48
HDS 6.3/32, 8.0/32, 9.5/30 Burner . . . . . . . . . . . . 49
HDS 6.3/32, 8.0/32, 9.5/30 Coil . . . . . . . . . . . . . . 51
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Float Tank
53
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Float Tank
54
HDS 6.3/32, 8.0/32, 9.5/30 Float Tank . . . . . . . . . 55
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Pump . 57
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Pump . 58
HDS 6.3/32, 8.0/32, 9.5/30 Pump . . . . . . . . . . . . . 59
HDS 6.3/32, 8.0/32, 9.5/30 Pump . . . . . . . . . . . . . 60
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Tensioner
61
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Tensioner
62
HDS 6.3/32, 8.0/32, 9.5/30 Tensioner . . . . . . . . . 63
Tensioner Torque Specs & Assembly Parts . . . . . 65
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Electrical
Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
HDS 6.3/32, 8.0/32, 9.5/30 Electrical Box. . . . . . . 69
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Control
Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
HDS 6.3/32, 8.0/32, 9.5/30 Control Panel. . . . . . . 74
HDS 3.5/20, 4.0/22, 3.9/30, 5.0/23, 4.8/30 Panels &
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
HDS 6.3/32, 8.0/32, 9.5/30 Panels & Doors . . . . . 78
Hose & Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . 80
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
NG Burner Specifications . . . . . . . . . . . . . . . . . . . .81
LP Burner Specifications. . . . . . . . . . . . . . . . . . . . .81
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
VRT3 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
VRT100 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . 87
HDS 4.0/22, 3.9/30 M.3 Series Pump . . . . . . . . . . 89
HDS 5.0/23, 4.8/30, 6.3/32 KT.2 Series Pump . . . 91
HDS 8.0/32, 9.5/30 X.2 Series Pump . . . . . . . . . . 93
HDS 3.5/20 KB Series Pump . . . . . . . . . . . . . . . . 95
Karcher Liberty HDS Stationary Dealer’s Manual 9.801-508.0 - AY
Содержание HDS4.0/22
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