Operating and maintenance manual

ECO II

Original instructions
Issue 12/01

Customer: National Water Company

Chassis: MAN TGS 18.400 4x2 BB
Serial-No: 100034
Built in: 2011

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KAISER AG Fahrzeugwerk • Vorarlbergerstrasse 220 • LI-9486 Schaanwald • Fürstentum Liechtenstein
Tel: +423 – 377 21 21 • Fax +423 – 377 21 10 • www.kaiser.li • [email protected]

Public Register Vaduz No. FL-1.024.757-9

Operating and maintenance manual
ECO II

Table of contents Page Table of contents Page

1 Product description ___________________ 5 5.2 Auxiliary drive...................................................... 28

1.1 Basic information ................................................... 5 5.2.1 Auxiliary drive (NA1) ........................................... 28
5.2.2 Gearing dependent auxiliary drive (NA2) ............ 28
1.2 Authorised utilisation ............................................. 5
5.3 Engine speed ...................................................... 29
2 Safety Instructions ____________________ 5
5.3.1 Diesel engine speed setting ................................ 29
2.1 Always abide by instructions of operating manual . 5 5.3.2 Diesel engine START / STOP............................. 29
2.2 Operator commitments .......................................... 5 5.4 General functions ................................................ 30
2.3 Personnel commitments ........................................ 5 5.4.1 Tank lid and clamping ring .................................. 30
5.4.2 Tipping the tank .................................................. 31
2.4 Dangerous situations may arise when working with 5.4.3 Underride guide .................................................. 33
the ECO II .................................................................... 6 5.4.4 Winch ................................................................. 33
2.5 Instructions covering the operation of the ECO II .. 6 5.4.5 Fold-down tube rack ........................................... 34

2.6 Hazardous goods regulations ................................ 6 5.5 Vacuum system .................................................. 35

2.7 Guarantee and Liability .......................................... 7 5.5.1 Filling the fresh water tank .................................. 35
5.5.2 Switching the vacuum pump on and off .............. 35
2.8 Symbol and instruction explanations ..................... 7 5.5.3 Switching between suction / pressure ................. 36
5.5.4 Running the vacuum pump ................................. 36
2.9 Safety measures.................................................... 7
2.9.1 Organisational measures ...................................... 7
5.6 Suction boom ...................................................... 37
2.9.2 Safety devices ...................................................... 7 5.7 KDU high pressure water system ........................ 38
2.9.3 Informal safety measures ...................................... 8
5.7.1 Filling the sludge tank ......................................... 38
2.9.4 Training the personnel .......................................... 8
5.7.2 Using the fresh water tank .................................. 39
2.9.5 Machinery control system ..................................... 8
5.7.3 Using the sludge tank ......................................... 39
2.9.6 Safety measures to be taken during normal
5.7.4 Filling pump ........................................................ 39
operation ....................................................................... 8
5.7.5 Switching the KDU on / Pump pressure .............. 39
2.9.7 Dangers caused by hydraulic power ..................... 8
5.7.6 Ventilating the KDU ............................................ 41
2.9.8 Risks through water energy .................................. 9
5.7.7 Draining the sludge tank ..................................... 42
2.9.9 Other dangerous situations ................................... 9
5.7.8 Water valve maintenance display fitted on KDU . 42
2.9.10 Noxious gases and vapours escaping ................. 9
2.9.11 Maintenance and repair work, troubleshooting .. 10 5.8 Pressure relief system ........................................ 42
2.9.12 Structural alterations made to the machine ....... 10
5.8.1 Checking the pressure relief system for leaks ..... 43
2.9.13 Cleaning the machine and disposal ................... 10
2.9.14 Noise emitted by the machine ........................... 11 5.9 Hose reel............................................................. 44
2.9.15 Declaration of conformity .................................. 12
5.9.1 Hose reel operation ............................................ 44
3 ECO-Combi design ___________________ 13 5.9.2 Water distributor ................................................. 46
5.9.3 Winding a new hose on ...................................... 47
3.1 Chassis ................................................................ 13 5.9.4 Hose metre counter ............................................ 48
3.2 Main dimensions.................................................. 13 5.10 Manual reel ....................................................... 50
3.3 Tank .................................................................... 13 5.11 Tank cleaning nozzle ........................................ 50
3.4 Modules ............................................................... 13 5.12 Water recycling Rotomax .................................. 52
4 Operating and display controls _________ 15 5.12.1 Switching the water recycling system on ........... 52
4.1 Key to the symbols on the superstructure............ 15 5.12.2 Switching the water recycling system off ........... 52
5.12.3 Cleaning the drum sieve (Rotomax) .................. 53
4.2 Pneumatic functions ............................................ 18 5.12.4 Rotomax backflushing unit (low pressure) ........ 53
4.2.1 Pneumatics Key .................................................. 18 5.12.5 Rotomax free rinsing unit (high pressure) ......... 54

4.3 Electrics ............................................................... 19 5.13 Antifreeze unit ................................................... 55

4.3.1 Control console ................................................... 19 5.13.1 Antifreeze circulation ........................................ 55

4.4 Hetronic remote control NOVA ............................ 22 5.14 Draining the water out of the superstructure ..... 56
4.4.1 Key to remote control: ......................................... 22 5.15 Nozzle tables .................................................... 57
4.4.2 Remote control operation logon .......................... 23 5.16 Hose pressure loss table................................... 58
4.5 Cab controls ........................................................ 24 6 Maintenance _________________________ 59
4.5.1 Cab key: ............................................................. 24
6.1 Daily .................................................................... 59
4.6 Tank operating controls ....................................... 25
6.2 Every 25 operating hours .................................... 59
4.6.1 Tank diagram key: .............................................. 25
6.3 After the first 100 running hours .......................... 60
5 Operation ___________________________ 27
6.4 Every 200 operating hours .................................. 60
5.1 Hydraulics system ............................................... 27
6.5 Every 1,000 running hours (or annually) ............. 60
5.1.1 Hydraulic oil temperature monitoring ................... 28
5.1.2 Hydraulic oil level monitoring............................... 28 6.6 Exchange of hydraulic hoses .............................. 60

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6.7 Maintenance and changing the valves ................ 61

6.8 Correct Rotomax rotary union lubrication ............ 63
7 Operating materials __________________ 65
7.1 Hydraulic oil ......................................................... 65
7.1.1 Oil analysis ......................................................... 65
7.2 Vacuum pump lubricating oil................................ 65
7.3 Lubricating grease ............................................... 65
8 Service / Repairs _____________________ 66
8.1 Extra hydraulic filter ............................................. 66
9 Spare parts __________________________ 67
10 Copyright __________________________ 67

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Illustration table Page

Figure 1 Pneumatics shut-off valve .............................. 18

Figure 2 Pneumatic valve unit ...................................... 18
Figure 3 Control panel .................................................. 19
Figure 4 Hetronicremote control NOVA ........................ 22
Figure 5 Cab operating controls ................................... 24
Figure 6 Tank operating diagram.................................. 25
Figure 7 Oil tank + KDU connection ............................. 27
Figure 8 TD control block, locking ring, Tipping ............ 30
Figure 9 Fold-down tube rack ....................................... 34
Figure 10 Vacuum system ............................................ 35
Figure 11 Ventilating the KDU ...................................... 41
Figure 12 Pressure relief system .................................. 42
Figure 13 Relief port on pressure relief system ............ 43
Figure 14 Hose reel control panel................................. 44
Figure 15 Water distributor ........................................... 46
Figure 16 Hose shut-off valve ....................................... 47
Figure 17 hose metre counter....................................... 48
Figure 18 lubricating nipplel rotomax ............................ 60

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1 Product description
1.1 Basic information
Our KAISER ECO II is a municple vehicle with optimum weight distribution that has been designed solely to
be used for vacuuming and rinsing with recycled water.

1.2 Authorised utilisation

Any other or additional use (as compared to the use described in Section 1.1) is classified as unauthorised..
KAISER does not accept any liability for any damage resulting from unauthorised use.

The following are also considered to be part of the authorised utilisation:

 Abiding by all of the instructions given in the operating manual
 Completing all of the inspection and maintenance work.

2 Safety Instructions
2.1 Always abide by instructions of operating manual
 · The basic requirement to ensure safe and correct operation of this ECO II vehicle is to know
the basic safety instructions and the accident prevention regulations.
 · This operating manual includes important instructions that will ensure that the ECO II is
operated safely and correctly.
 · This operating manual, especially the safety instructions, must be read by all of the
personnel who will be working with/on the ECO II.
 You must also abide by the local laws and accident prevention regulations.

2.2 Operator commitments

The operator is commited to only allowing personnel to work on the ECO II, who
 Are familiar with the basic operational safety and accident prevention regulations and have
been trained to operate the ECO II,
 Have read and understood the safety chapter and the warnings given in this operating manual.

The safety conscious work undertaken by the personnel must be checked at regular intervals.

2.3 Personnel commitments

All of the personnel who are authorised to work on the ECO II are commited, prior to starting work:
 To read the basic operational safety and accident prevention regulations and
 the safety chapter and the warnings given in this operating manual.

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2.4 Dangerous situations may arise when working with the ECO II
This ECO II vehicle has been designed using the most up-to-date technology and complies with the
recognised technical safety regulations. However, danger to life and limb for the operator or a third party
might arise and the machine or other valuable equipment might be damaged by incorrect use.

This ECO II vehicle is only to be used:

 As authorised
 When it is in the correct working state, i.e. free of any technical problems.
Any problems that might affect the safe operation of the vehicle must be eliminated immediately.

2.5 Instructions covering the operation of the ECO II

You are only allowed to fill the KAISER ECO II with media that are not considered to be hazardous goods in
accordance with the ADR.
The maximum permitted temperature of the media that the vehicle will be filled with is 50°C. This
temperature must never be exceeded.
The vapour pressure of the materials that will be used to fill the vehicle must never be more than 0.5-bar
above the normal atmospheric pressure (1013 mbar) at the maximum permitted temperature.

You must abide by the following general guidelines when using the vacuum pressure tank:
 You must always abide by all of the safety conditions. This applies in particular to the danger of fire,
protecting the groundwater and the environment as well as safeguarding the health and life of the
driver and passers-by.
 The operation of the vehicle and the fittings must be undertaken so that the surrounding area is not
endangered. In this case the vehicle must always be depressurised prior to opening the locking
caps, lids or flanges.
 Flanges, lids and locks are only to be opened when the vehicle is in a depressurised state.
 The fittings must be kept locked in place and cleaned so that none of the transported media residue
can escape.
 Safety devices must never be rendered inoperable. If you have to exchange or repair any of the
fittings you must always ensure that the materials that they are made from are resistant to the media
that has to be transported.
 You are not allowed to use the fresh water tank or the separating tank for transporting waste
materials.

Always check that equipment materials and tank coatings are resistant to the
substances to be transported! The following fundamental rules apply:
 The period of time that transported substances are left in the tank should be as
short as possible
 Clean the inside of the tank every day at the close of operations
 Once the tank has been emptied and cleaned, leave it overnight in tipped
position and with the tank cover slightly open (IMPORTANT: Make sure that
the tank is only tipped and the tank cover only opened by a minimal amount so
that no person can become trapped between the tank and/or tank cover!)

2.6 Hazardous goods regulations

The KAISER ECO II is not to be used for hazardous goods as classified by the ADR!

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2.7 Guarantee and Liability

Our general delivery and sales terms and conditions apply in general. These will be sent to the operator after
the order has been placed (at the latest). Any guarantee or liability claims lodged on behalf of your personnel
or for damage caused to other equipment will be dismissed if they can be traced back to one or more of the
following causes:
 Unauthorised use of the machine
 Incorrect ECO II assembly, commissioning, operation or maintenance.
 Operating the machine with defective safety devices or incorrectly fitted or any inoperative safety
and protective devices.
 ·Non-adherence with the instuctions listed in this operating manual regarding transport, storage,
assembly, commissioning, operation, maintenance and setting up of the vehicle body.
 ·Any in-house structural alterations made to the ECO II.
 ·Any in-house changes made to the working procedure (performance and rpms.
 Poor monitoring of machine parts that are subject to wear.
 Any repairs that were carried out incorrectly.
 Disastrous situations caused by foreign bodies or force majeure.

2.8 Symbol and instruction explanations

This symbol indicates that an imminently dangerous life and health threatening
situation exists for the personnel and/or the machine might be well be damaged.

Ignoring this instruction might well result in your health being severely effected and
even mortal injuries being inflicted. This might also cause a considerable number
of faults and the machine will continually breakdown!

This symbol indicates that this section contains important information regarding the
correct operation of the machine.

Ignoring these instructions might result in machine faults or problems for the
surrounding area occurring.

This symbol indicates that this section containsuser tips and particularly usefull
informationen.

The tips will help you to use all of the machine's functions more economically.

2.9 Safety measures

2.9.1 Organisational measures

The operator must provide the necessary personal protective equipment.

All of the safety devices must be inspected on a regular basis.

2.9.2 Safety devices

The operator must fit the safety devices in compliance with the regulations
whenever sub-components are delivered.

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2.9.3 Informal safety measures

This operating manual must always be kept at the site where the machine will be
used. Any supplements issued for this operating manual are universally valid and
they must be implemented and you must also abide by them as well as the local
accident prevention and environmental protection regulations.

All of the safety instructions and dangerous situation information displayed on the
machine must be maintained in a legible state.

2.9.4 Training the personnel

Only qualified personnel who have been trained on the machine are allowed to
work on it. The responsibilities of the personnel must be clearly defined for:
 Assembly
 Commissioning
 Operation
 Preparation
 Maintenance
 Repairs.
Trainees are only permitted to work on the vehicle under the supervision of an
experienced person.

2.9.5 Machinery control system

You are not permitted to modify the software program under any circumstances!
Only trained personnel are allowed to operate the controls.

2.9.6 Safety measures to be taken during normal operation

The machinery is only to be operated if all of the safety devices are working
correctly.
You must ensure that nobody will be endangered by the vehicle before you switch
it on.
You must inspect the vehicle for any visible signs of damage and also check that
the safety devices are working correctly at least once per shift.

2.9.7 Dangers caused by hydraulic power

Only personnel with specialist hydraulic knowledge and expertise are allowed to
work on the hydraulic units.
Any system sections and pressurised pipelines that have to be opened must
always be depressurised prior to starting the repair work.
The hydraulic pipes must be changed at regular intevals even if no safety relevant
problems are apparent.

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2.9.8 Risks through water energy

The tank may only be entered when the diesel engine is switched off
► Water pressure relieved by the pressure relief system. Kommentiert [rube1]: Nur für FRA (Druckentlastung mit
Druckregelventil)
If the nozzle is already in the channel then the high-pressure ball-valve is only to
be opened for working on the respective reel.
The respective valve is only to be opened if the relevant nozzle is aleady in the
channel.
Hand spray gun ► Danger from the recoil
A severe recoil might occur when the hand spray gun's trigger is squeezed due to
the fact that the water exits under high pressure. The spray gun might spring back
and hit you in the body if you are not prepared for this or else you might loose your
balance and fall down to the ground, which might result in you being severly
injured!

2.9.9 Other dangerous situations

The operator must always ensure that nobody is in the danger area before tipping
the tank and opening or closing the tank lid.
You must always ensure that a fully functioning compressed air supply is always
available. A defective or shut-off compressed air supply might result in the vehicle
being damaged when other functions, including non-compressed air dependent
functions, are switched on (e.g. tipping the tank)!
The operator must always ensure that nobody is in the danger area before
unwinding / rewinding and swivelling the hose reel.
The lid mechanism must be mechanically locked in place whenever maintenance
work has to be carried out with the lid open. A safe ladder must always be used
when inspecting the manhole.
You must always wear a safety helmet if you have to enter the tank.

2.9.10 Noxious gases and vapours escaping

Noxious gases and vapours can escape when the lid is open. You must ensure
that adequate ventilation or extraction occurs.
Special protective precautions must be taken in the case of dangerous media, e.g.
eye rinsers might be needed if handling caustic chemicals.
The operator must assume responsibility for the overall safety when working with
dangerous chemicals. You must always comply with the product regulations and
country-specific laws.

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2.9.11 Maintenance and repair work, troubleshooting

The stipulated adjustment, maintenance and inspection work must be carried out
on the due date.
The operating personnel must be informed before any maintenance or repair work
is started.
All of the machine's inline and downline system parts and operating media, such as
the compressed air and the hydraulics, must be locked in place against
unauthorised switching back on.
Power to the machine must be switched off before any maintenance, inspection or
repair work is undertaken and the main switch must be locked in place against
unauthorised switching back on.
Lock the main switch in place and remove the key.
Hang a warning sign on the switch that warns against switching back on.
The lifting equipment must be carefully attached and secured in place to any large
module that has to be changed.
Check that any screw connections that were undone have all been retightened.
Always test the safety devices after you have completed the maintenance work to
see that they work correctly.

2.9.12 Structural alterations made to the machine

You are not permitted to make any alterations, additions or machine conversions
without obtaining prior permission from the manufacturer. This also applies to
welding on additional parts.
Any conversions that you want to make require written approval from
KAISER.
Any machine parts that do not work correctly must be changed immediately.
Only original spare and consumable parts are allowed to be used. Nobody can
guarantee that spare parts obtained from a third-party have been designed and
manufactured correctly and safely.

2.9.13 Cleaning the machine and disposal

Any materials and substances that have been used must be handled and disposed
of correctly, especially if solvents were used when working on the lubricating
systems and devices.
When pressure-cleaning the vehicle be careful not to aim directly onto electrical
components and caution signs and labeling.
Aiming directly onto electrical equipment can cause failures and malfunctions of
the relevant component or even the whole machine.

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2.9.14 Noise emitted by the machine

The continuous noise level emitted in the workplace amounts to 84 dB(A). The
workplace is defined as the area behind the control console. The noise level was
measured in the free area at
1,400 revs/min.
A higher noise level that causes noise-induced hearing loss might be emitted, but
this will depend on the local conditions. In this case the operating personnel must
wear the relevant protective equipment ot take preventative measures.
Hearing protectors must always be worn if the noise level exceeds 85 dB(A).

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2.9.15 Declaration of conformity

EC - Declaration of Conformity
The manufacturer
KAISER AG, Fahrzeugwerk
Voralbergerstrasse 220
FL-9486 Schaanwald
Principality of Liechtenstein

declares that the sewer cleaning vehicle

Model: Kaiser ECO-Combi II

Serial number: 100034
Year of manufacture: 2011

corresponds to the respective regulations of the following directive:

2006/42/EC Machinery Directive

Applied harmonised standards:

EN ISO 12100 Safety of Machinery - Basic concepts, general principles for design

EN ISO 13857 Safety distances to prevent hazard zones being reached by upper and
lower limbs
EN ISO 13850 Emergency stop - Principles for design
EN 982 Safety requirements for fluid power systems and their components -
Hydraulics

Authorised person for the composition of the relevant technical files:

Häusle Viktor
Voralbergerstrasse 220
FL-9486 Schaanwald

Information about the authorised utilisation can be found in the operating manual.
If the sewer cleaning vehicle is not used as intended or if the construction is altered without any
written confirmation of the manufacturer, the declaration of conformity expires.

Schaanwald, 07.01.2011 Kaiser Markus,

General manager

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3 ECO-Combi design
3.1 Chassis
- Make MAN Kommentiert [b2]: Chassismarke eintragen

- Model TGS 26.400 6x4 BB Kommentiert [b3]: Typ eintragen

- Wheelbase 3900 mm + 1400 mm Kommentiert [b4]: Radstände eintragen

- Chassis-No. WMAHW2ZZ99M542138 Kommentiert [beru5]: Fahrgestell-Nr. eintragen

3.2 Main dimensions

- Length 9350 mm Kommentiert [b6]: Gesamtlänge eintragen

- Width 2530 mm Kommentiert [b7]: Aufbaubreite eintragen

- Height 3680 mm Kommentiert [b8]: Gesamthöhe eintragen

- Weight 16530 kg Kommentiert [b9]: Gesamtgewicht eintragen

3.3 Tank
- Diameter 1700 mm
- Casing length 4800 mm Kommentiert [b10]: Tanklänge eintragen:
2-Achser = 4000 mm
- Tank casing sheet quality 1.0425 (P265GH – HII) 1.4301 (V2A) 3-Achser = 4800 mm
Kommentiert [MSOffice11]: Nicht verwendete Materialien
- Tank lid sheet quality 1.0425 (P265GH – HII) löschen!
- Tank lid lock KAISER clamping ring lock
- Tank lid seal NBR
- Inside coating of the tank ALPOTECT 565 – EA64 L
(Fresh water tank, separator conductive 2 pack epoxy corrosion protection coating;
tank, tank cover …) earthing resistance is less than 106 ohm; not suitable for alcohols
(methanol), fuels and biofuels
Resistances (according to manufacturer’s instructions):
Industrial atmosphere +
Oceanic atmosphere +
Underwater use +
Use of condensation +
Hot water use -
Mechanical use +
Temperature use dry until 150°C
Acids +
Lies +
Oils and greases +
The resistances in the acid and alkaline range refer to a 28-day examination in 10%
hydrochloric acid and in 30% caustic soda. Differences in terms of duration,
concentration and nature of the medium have to be tested separately.

3.4 Modules
Kommentiert [b12]: Entsprechende Literleistung eintragen
- High-pressure water pump KAISER KDU148 with 320l/min
Kommentiert [MSOffice13]: Entsprechende KWP
- Vacuum pump KAISER KWP2000i eintragen!

- Suction boom KAISER Suction boom KSR10-125 Kommentiert [MSOffice14]: Entsprechenden KSR mit
Schlauchdimension eintragen!

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- Hose reel KAISER KSH ECO II with 120m 1" hose Kommentiert [beru15]: entsprechende Schlauchlänge und
Dimension eintragen
- Manual reel KAISER with 40m ½" hose
Kommentiert [beru16]: entsprechende Schlauchlänge
eintragen
- Water recycling KAISER Rotomax with backflushing unit
Kommentiert [b17]: Ohne ZA-189 löschen
- Tipping cylinder FLC 3 105 3153 CRN
- Remote control Hetronic NOVA Kommentiert [b18]: Ohne ZA-419 löschen

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4 Operating and display controls

4.1 Key to the symbols on the superstructure

CAUTION!
Empty if there is a danger of frost

CAUTION!
Empty if there is a danger of frost / dirt

CAUTION!
Do not operate manually / Danger of being crushed!

Maximum filling level

Minimum filling level

Shut-off valve open

Shut-off valve closed

Rinsing unit low pressure bar

Refill with SAE 15W40 engine oil

Read the instructions given in the operating manual!

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Refill with Panolin HLP Uni 46 hydraulic oil

Read the instructions given in the operating manual!

Maximum noise level

CAUTION!
The supports must always be used to secure the tipped tank when service
work is being carried out.

CAUTION!
The tank must always be depressurised before the tank lid is opened!

CAUTION!
All of the hoses must always be wound back on with water pressure applied.

CAUTION!
The chamber must always be depressurised before you open the door to the
fresh water chamber.

CAUTION!
A strong recoil might occur when the hand spray gun trigger is pressed
under certain cicumstances.

Hose reel

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Hand spray gun

Tank cleaning nozzle

Rinsing unit high pressure bar

Locking ring Tank lid Tank

öffnen / öffnen / tip /

schliessen schliessen lower

Rope winch
Speed
Swivel hose reel
adjustment rewind
unwind

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4.2 Pneumatic functions

The main shut-off valve that supplies the compressed air to the KAISER superstructure can be found on the
left at the font of the superstructure and it is mounted on the auxiliary chassis. This shut-off valve is used as
the shut-off device whenever the vehicle will not be used for a long time.

Figure 1 Pneumatics shut-off valve

The pneumatic valve is mounted on the top of the tank and is always electrically controlled.

P4

Figure 2 Pneumatic valve unit

4.2.1 Pneumatics Key

Only a specialist workshop is
P1 Pressure setting knob mounted on the superstructure.
allowed to readjust this setting
Pneumatic pressure manometer (display) mounted on the
P2
superstructure
Main switch / compressed air shut-off valve mounted on the
P3
superstructure
Only a specialist workshop is
P4 Pneumatics valve unit
allowed to readjust this setting

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4.3 Electrics
The control panel is mounted on the hose reel. The separate switches are marked with the relevant symbols
or names. Ein Illuminated control lamps indicate that the relevant funtions are active.

4.3.1 Control console

Figure 3 Control panel

4.3.1.1 Control console legend:

H302 Remote control display active

H303 Superstructure running hours counter

H304 KDU running hours counter

H305 KWP running hours counter

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S301 EMERGENCY STOP

S309 KWP suction pressure changeover switch

S310 Suction boom flap open / close

Suction boom up / down Swing suction boom left/righ

S311
(KSR10, KSR22) (KSR10, KSR20, KSR22)

Suction boom telescopic arm Kommentiert [beru19]: je nach Saugrüssel => Funktionen
Unwind/rewind suction hose
S312 out/in löschen
(KSR20, KSR22)
(KSR10, KSR20, KSR22)

S313 Select rinsing rell ball-valve

S314 Unwind/rewind hose reel

S317 Start diesel engine and increase revs

S318 Stop diesel engine

S319 Decrease diesel engine rpms

S320 KDU high pressure pump on/off

S321 KDU maintenance display / Reset

S322 Water recycling on/off and ventilate KDU

S329 Not used (reserve)

S331 Not used (reserve)

S332 Not used (reserve)

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S335 Move underride guide out/in

S336 KWP vacuum pump on/off

R304 Set pump pressure – KDU (water pressure)

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4.4 Hetronic remote control NOVA

Figure 4 Hetronicremote control NOVA

4.4.1 Key to remote control:

F1 Transmitter on switch (key-switch)

F2 Switch on transmitter

KWP suction / pressure

F3 suction boom flap open/closed
Suction boom telescopic arm out/in

Suction boom up/down (KSR10;KSR22)

Kommentiert [beru20]: je nach Saugrüssel => Funktionen
F4 Unwind/rewind suction hose (KSR20) löschen

Swing suction boom left/right (KSR10, KSR20,KSR22)

KDU on/off
F5
KWP on / off

F6 Unwind/rewind hose reel

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F7 Stop diesel engine

Start diesel engine and increase revs

F8
Decrease diesel engine rpms

F9 EMERGENCY STOP

F10 Operating indicator light / Battery status

4.4.2 Remote control operation logon

 Check to see whether the emergency stop on the remote control has been
unlocked
 Turn the F1 key-switch on the control to Position 1
 Switch F2-key to Position 1 and hold it there for approx. 3 seconds
 Indicator light H302 will light up on the control panel if the logon was successful
 Repeat Steps 1 - 3 if you have not managed to logon

Never activate any of the functions during the logon process. Otherwise the
function will be activated and movement will start straight after you have logged on!
If you finished your work with the remote control you have to deactivate it and turn
off the key switch (F1)!

The remote control transmitter must be stored in a non-vibrating location (e,g, in

the driving cab) and always be kept close to hand. Vibrations can damage the
electronic components over a long period of time.
Therefore the transmitter must never be kept in one of the side boxes when
driving!

The emergency stop (F9) must be unlocked when you logon.

If the remote control is subject to external interference (other radio equipment, etc.)
and inoperable you can change the frequency by switching on and off (F1).

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4.5 Cab controls

K3 K2 K5 K1 K4

Figure 5 Cab operating controls

4.5.1 Cab key:

K1 Structure main switch on/off (electrics)

K2 NA1 (KDU) on/off

K3 NA2 (KWP) on/off

K4 KDU antifreeze circulation on/off

K5 Rotating warning beacon on/off

K6 Floodlight on/off

During driving the structure main switch must be turned off!

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4.6 Tank operating controls

Figure 6 Tank operating diagram

4.6.1 Tank diagram key:

s800 Hose reel water supply

s810 Manual reel water supply

S331 Sludge tank suction outlet

s333 Sludge tank drainage

S341 Separator tank outlet

s361 Fresh water tank outlet

s375 Water supply from fresh water tank

s390 Water supply from sludge tank (water recycling)

s392 Backflush unit water supply (low pressure bar)

s890 Tank cleaning nozzle water supply

s891 Free-rinsing water supply (high pressure bar)

x360 Free inlet

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y320 Vacuum pump suction / pressure change over switch

y325 Suction boom flap

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5 Operation
5.1 Hydraulics system
You must check the hydraulic oil level every day before starting the complete superstructure. The inspection
glass is fitted on the hydraulic oil tank on the left side of the vehicle. The level must come up to the lower
mark on the inspection glass if the oil is cold. The oil level will climb up into the upper part of the oil tank
when the oil is warm.

The tank must never be tipped when you check the hydraulic oil level.

oil filter refilling oil

inspection glass

oil level (cold)

oil level sensor

temperature sensor
oil cooling system

cleaning lid
heat exchanger

oil drainage

ventilation valve KDU

Figure 7 Oil tank + KDU connection

You are not allowed to alter the pressure setting for the overall hydraulic system.

When the working temperature has been reached you should only work using the
maximum diesel rpms in order to prevent the hydraulic system from being
damaged, i.e. the KDU and the vacuum pump must never be run at maximum
power if the oil is cold.

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5.1.1 Hydraulic oil temperature monitoring

The diesel revs will drop automatically to idle speed if the hydraulic oil temperature
climbs above 80°C. You will not be able to increase the revs using control panel
switch S317 or the F8 key on the remote control until the hydraulic oil has cooled
down to 60°C.

Dieser Zustand wird angezeigt indem die Kontrolllampe im Taster S319 (Drehzahl
senken) aufleuchtet

5.1.2 Hydraulic oil level monitoring

The diesel enginge will be switched off automatically if the level in the oil tank
drops below the float switch in the bottom half of the inspection glass.

This status is indicated by the “red“ light illuminating in the diesel engine stop
button S318 on the control panel.

5.2 Auxiliary drive

The auxiliary drive is switched on from the cab. You must always ensure that sufficient air pressure is
available (7-bar min). The auxiliary drive will also be switched off if the vehicle engine has been switched off
for a long period.

The auxiliary drive should only be switched on when running at idle speed and with
all the consumers in the superstructure switched off!

5.2.1 Auxiliary drive (NA1)

This auxiliary drive is used to drive the hydraulic pumps that drive the KDU, the reel drive and for the
additional consumers.
NA1 can be switched on when the engine is running and without having to declutch.

5.2.2 Gearing dependent auxiliary drive (NA2)

One of the hydraulic pumps is driven by this auxiliary drive. This supplies oil to the vacuum pump drive and
the suction boom drive.
You must always ensure that the vacuum pump and the suction boom are switched off before you switch on.
Disengage the coupling and then wait 5 - 6 seconds before you switch the auxiliary drive on. This auxiliary
drive must be switched on before driving off.

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5.3 Engine speed

The maximum diesel engine revs with the auxiliary drives switched on must never
exceed 1XXX revs/min nicht überschreiten. Higher rpms might irrepairably Kommentiert [MSOffice21]: Maximale Arbeitsdrehzahl
damage the pumps and the units! eingeben

A rpms limit at this speed has been programmed into the vehicle and this will
prevent the speed from being exceeded when the AD is switched on.
The programming must never be modified!

5.3.1 Diesel engine speed setting

The engine speed can be linearly adjusted from idle speed up to maximum engine
speed using the speed switch.
The revs switch is mounted on the hose reel control panel, as well as the remote
control.

Increasing the diesel engine speed:

 Press button S317 on the control panel or
 Press the F8 key upwards of the remote control

Decreasing the diesel motor speed:

 Press button S319 on the control panel or
 Press the F8 key downwards on the remote control

5.3.2 Diesel engine START / STOP

The diesel engine can be switched on and off from the operating box.

Starting the diesel engine:

 Press button S317 on the control panel or
 Press the F8 key upwards of the remote control

Stopping the diesel engine:

 Press button S318 on the control panel or
 Press the F7 key downwards on the remote control

The buttons only have to be pressed briefly to start or stop the diesel engine.
All of the consumers must be switched off before you stop the engine.

You are only allowed to start the diesel engine if all of the consumers are switched
off!

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5.4 General functions

The display and operating controls for the various hydraulic functions are fitted on the hose reel and by the
water distributer
Auxiliary drive NA1 provides the oil supply via the hydraulic pump and it is switched on from the cab (switch
K2).

5.4.1 Tank lid and clamping ring

The tank lid is opened by a hydraulic cylinder fitted inside the tank. The cylinder is fitted with a hose burst
safety device .

H2 H3 H1

Figure 8 TD control block, locking ring, Tipping

5.4.1.1 TD control block, locking ring, tipping key:

H1 Tip / lower tank

H2 Open / close locking ring

H3 Open / close tank lid

Unlocking the clamping ring and opening the tank lid:

1. Check the internal tank pressure, ventilate the tank (using the suction
boom flap)
2. Use hydraulic valve to open the locking ring (move leverl H2 upwards)
3. Use hydraulic valve to open the tank lid (move lever H3 upwards)
Closing the tank lid and locking the clamping ring:
4. Use hydraulic valve to close the tank lid (move lever H3 downwards)
5. Use hydraulic valve to lock the locking ring (move lever H2 downwards)
6. Shut all of the tank flaps

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The fastening parts must be opened right up to the stop before you open the lid.
You must always ensure that the fastening parts are closed first before closing the
tank lid that is lying on the tank. You must also ensure that the mechanical locking
system is latched in place.

The suction boom must always be swung into the park position before
opening the tank lid
Der Tank lid is only to be opened after the reel has been swung in otherwise
the tank lid bearing might be twisted and this might result in the tank lid no longer
being sealed correctly.

The tank lid lock and the tank lid are only to be openned after the tank has been
depressurised!

The tank lid seal and the sealing surfaces must be cleaned before the tank lid is
closed.

5.4.2 Tipping the tank

Tipping the tank upwards:
1. Unlock the clamping ring and open the tank lid
2. Use the hydraulic valve (move lever H1 upwards) to tip the tank
Lowering the tank:
1. Use the hydraulic valve (move the lever H1 downwards) to lower the tank
2. Close the lid and lock the clamping ring

The tank lid must be opened before the tank is tipped upwards, otherwise the tank
lid lock will be against the chassis.
Take care that the rear underrun protection is closed!

The tank must always be locked in place when maintenance work is undertaken
and when somebody has to go below the raised tank!

You are only allowed to tip the tank up if the vehicle is parked on a flat and strong
surfaced!

The tank must not be filled when it is tipped up!

The vehicle must not be moved forward or backward with fully extended tipping
ram! The resulting pressure peaks can lead to serious damage or even buckling of
the tipping ram.
If it is required to loosen debris in the sludge tank by moving the vehicle, this must
only be carried out with the first stage of the tipping ram extended.

Caution! Buckling or collapsing of the tipping ram can result to serious

accidents!

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5.4.3 Underride guide

The underride guard is moved in and out by a pneumatic cylinder integrated in the underride guard.
The underride guard is activated by two hydraulic cylinders integrated in the underride guard. Kommentiert [b22]: Nur bei hydraulischem Unterfahrschutz
=> Satz vom pneumatischen Unterfahrschutz muss dann
gelöscht werden.
Moving the underride guard out:
 Turn rotary switch S335 to the left, to move it out

Moving the underride guard in:

 Turn rotary switch S335 to the right, to retract it

The underride guard must be moved out before driving on public roads

Nobody should be in the dangerous area when the underride guard is moved out /
in

You must read through the manual provided by the manufacturer in order to ensure
that the underride guard is used safely and abide by the relevant safety instructions
given in it. Kommentiert [b23]: Nur bei hydraulischem Unterfahrschutz

5.4.4 Winch Kommentiert [b24]: Ohne Seilwinde kpl. Absatz löschen

The winch is hydraulically driven and mounted at the frame of the hose reel. Using the valve block of the
hose reel for the operation of the winch
The maximum tractive force is approx. 130 kg and is hydraulically limited.

H4 H6

5.4.4.1 Winch legend:

H4 Increase/decrease winch speed

H6 Unwind/rewind winch

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The winch must not be used to secure or to rescue people!

5.4.5 Fold-down tube rack

This vehicle is equipped with two fold-down tube racks, provided left and right of the tank. They can be fitted
with hoses or tubes in the right size.
Safety pin Light tubes/hoses
Heavy tubes/hoses

Figure 9 Fold-down tube rack

The tube racks are supported by two prestressed springs that are preset.
They support the operator when opening up or folding down the tube rack.
The maximum load is 55 kg per side.

You have to pay attention that the safety pin in the middle of the tube
racks is always in an interlocked position when the tube racks are tipped
up.
The maximum weight of 55 kg per fold-down tube rack must not be
exceeded; otherwise there is a great risk of injury for the operator when
folding it down.

In order to not exceed the maximum weight, the tubes / hoses should be
cleaned thoroughly after usage.
Furthermore, heavier tubes / hoses should always be positioned on the inside
and lighter and shorter tubes / hoses on the outside.

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5.5 Vacuum system

This vehicle is fitted with a water-ring vacuum pump, which is fitted in the fresh water tank. The drive system
is hydraulic. The fresh water is also the vacuum pump's operating liquid. This means that the pump must
always be submerged in the water. Never run the pump without water as the shaft seal will no longer be
reliable due to the danger of overheating.

The fresh water tank must always be filled with clean water.
This will improve the performance and the service life of the water-ring vacuum
pump!

change-over head

oil check

fresh water tank

fresh water level max.

dirt drain valve

drain valve

fresh water level min.

drain valve

dirt drain valve

fresh water supply pipe

Figure 10 Vacuum system

5.5.1 Filling the fresh water tank

Always switch the vacuum pump off before refilling the fresh water tank. Refill with water only up to the
maximum mark on the inspection glass!

Refilling using the free inlet:

 Pres the button S336 to switch the vacuum pump off
 Press button S309 to switch the change-over head to the “Suction“ position
 Refill the tank from a hydrant using the fresh water tank filling connection

5.5.2 Switching the vacuum pump on and off

 Switch on the auxiliary drive and superstructure main switch in the driving
cab
 Press button S336 to switch the vacuum pump on or off
In order to obtain the full power of the vacuum pump, the NA2 in the large splitter
group must be operated.
The water-ring vacuum pump will only work if sufficient fresh water is available.
This means that the pump must always be submerged in water (note the minimum
mark on the inspection glass).

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Never run without water due to the danger of the shaft seal overheating!

The vacuum pump should never be switched on or off at full working speed in
order to protect the system.

5.5.3 Switching between suction / pressure

The vacuum pump can be switched between suction and pressure
The prevailing working pressure inside the sludge tank can be read from the manometer on the control
panel.

Press button S309 on the control panel or push toggle F3 on the remote control
upwards to switch between suction and pressure mode

5.5.4 Running the vacuum pump

The vacuum pump is protected against excessive suction by a drainage slow-down chamber. The slow-down
chamber will be automatically emptied into the sludge tank whenever the vacuum pump is switched over to
pressure.
The slow-down chamber must be fully emptied and cleaned after the work has been completed by using the
drainage tap fitted on the left side of vehicle.

The pump must be cleaned internally after every 4 - 5 running hours. This is
realised by briefly opening the dirt drainage valves (6 x) on the outside of the tank
when the pump is switched off.
The water must be drained out of the pump after the work has been completed,
especially if the danger of frost exists. This is realised by fully emptying the fresh
water tank and draining the pump by opening the drainage valves and the dirt
drainage valves. The valves are fitted on the left, outside the fresh water tank (6 x).
If the suction work goes on for a long time you should replace the heated water
with cold water as the suction performance drops off as the fresh water
temperature increases. The fresh water cannot overheat.
The vacuum pump's bearing runs in an oil bath, which is connected to the oil tank
on the outside of the tank. A rising or falling oil level indicates that the shaft seals
leak.

The fresh water tank is also pressurised when the vacuum pump works under
pressure. Therefore the snap-connection on the opening door must be carefully
locked in place!
The maximum overpressure allowed in the fresh water tank is 0.5-bar!
You must never exceed the maximum permitted working speed in order to prevent
the vacuum pump from running at an excessive speed (this is limited by the vehicle
programming).

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5.6 Suction boom

The suction boom functions can be operated from the hose reel control panel or the remote control.

Available functions:
Swinging the suction boom:
 Use joystick S311to move left/right
 or F4 on the remote control to move left/right
Telescoping the suction boom:
 Use joystick S312 to move left/right
 or F3 on the remote control to move left/right
Raising / lowering the suction boom:
 Use joystick S311 to move up/down
 or F4 on the remote control to move up/down
Unwinding / rewinding the suction hose:
 Use joystick S312 to move up/down
 or F4 on the remote control to move up/down
Suction boom flap open / close:
 Press button S310
 or F3 downwards on the remote control
Switching vacuum pump between suction/pressure:
 Press button S309
 or F3 upwards on the remote control
In order to prevent unwanted remote control operation there will be a 2 second
delay before a suction boom function starts.
A new suction boom operation must be instigated within one minute of the previous
SB movement being completed to ensure that the new operation starts without any
delay.
A 2 second delay will occur if there is a gap of more than one minute between the
operations.

Nobody is allowed to be in the danger area when the suction boom is being
operated. Special attention must be paid when the suction boom is being swung
around.

The suction boom must be swung into the relevant park position before
driving on the roads

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5.7 KDU high pressure water system

You must ensure that the water supply to the KDU is switched on before starting. The fresh water tank or the
entire sludge tank (water recycling) can be used as the water tank.

If the sludge tank is is to be used as a fresh water storage tank then it must be
thoroughly cleaned prior to being filled. Water to be used for the cleaning can be
taken from the fresh water tank. The tank be filled from a hydrants or via the fresh
water tank.
You must use a strainer when using the vacuum to refil from water courses.

5.7.1 Filling the sludge tank

 Open manually operated flap s375 in the line going to the KDU
 Open manually operated flap s390 on the sludge tank
 Open suction boom flap y325
 TIp the tank slightly (by approx. 30 cm)
 Use free inlet x360 to fill the sludge tank

You should only fill the sludge tank after it has been ventilated as otherwise the
tank will be damaged by the very high pressure.
Open suction boom flap y325 to ventilate the tank.

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5.7.2 Using the fresh water tank

1. Refilling the fresh water tank
2. Check to ensure that flap s390 on the sludge tank has been closed
3. Open manually operated flap s375 in th line going to the KDU
 Operate the KDU as per the instructions

Flap s375 for the fresh water tank must always be closed after it has been used in
order to ensure that the dirty water in the sludge tank cannot be mixed with the
clean water in the fresh water tank.

If your vehicle is fitted with water recycling and a backflushing unit you must always
ensure that the water recycling system is switched off before the KDU supply
(s375) is opened, as otherwise water from the fresh water tank will be fed into the
sludge tank via the backflushing unit.

Overpressure can occur in the sludge tank as a result of incorrect operation (WRS
switched on)! Therefore you must always switch the water recycling unit off or open
the tank ventilation (suction boom flap y325).

5.7.3 Using the sludge tank

1. Filling the sludge tank
2. Check that flap s375 on the fresh water tank is closed
3. Open manually operated flap s390 in the line going to the KDU
4. Use suction boom flap y325 to ventilate the tank
5. Operate the KDU as per the instructions

5.7.4 Filling pump

A filling pump has been fitted in the KDU pipeline so that the KDU can be supplied with water. The filling
pump is hydraulically driven and it is switched on automatically when the KDU is switched on. A filling
pressure monitoring switch has been fitted after the filling pump. The KDU will be switched off if the filling
pressure switch is activated and the filling pressure is too low.

5.7.5 Switching the KDU on / Pump pressure

Switching the KDU on:
 Use button S320 on the control panel
 or press F5 on the remote control upwards
The filling pressure monitoring switch is activated in this mode.

Switching the KDU off:

 Press button S320 on the control panel once again
 Push button F5 on the remote control upwards once again

Depending on the position of the selector switch for the jetting hose reel S313, the
KDU function is either locking or non-locking:
 Turn rotary switch S313 on the control panel to the left
► KDU function is locking (for use of the hand reel)

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Turn rotary switch S313 on the control panel to the right

► KDU function is non-locking (for use of the jetting hose) Kommentiert [rube25]: Nur für FRAU (Druckentlastung)

Setting the pump pressure / KDU pressure:

 The maximum water pressure can be set up linearly on the control panel
using rotary control R304. This can be used when the pump is switched on
or off.
The pressure setting can be read from the manometer by the control panel.
Before starting to work with the KDU you must always ensure that the consumers
connected to the KDU have been shut off correctly or moved into their working
positions,
i.e. the high pressure ball-valve on the hose reel has been opened (opens
automatically if the reel has already been selected) for rinsing work and the hose
guide has been selected so that the reel hose runs over the guide towards the
shaft without any kinks in it. You can use the hose connection at the bottom of the
shaft. Now screw the correctly fitted out drain rinsing nozzle on (see nozzle table)
and check that it is on tightly. Run the hose out so that it is approx. 1 m inside the
drain. Increase the diesel speed slightly and then switch on the pressure intensifier
as described above.

The user is responsible for the correct fitting of suitable sized jetting nozzles! At the
end of this manual there are tables to help choosing the correct nozzles.
Generally, the operator has to adhere to the recommendations, standards,
guidelines and data sheets of nozzle manufacturers and local municipal authorities.

Before working with rotating sewer cleaning equipment (i.e. rotating nozzles, etc.) a
thorough cleaning of the respective water supply tank has to be carried out.
Working with rotating nozzles is generally only allowed with clean freshwater, as
impurities (sand, sedimentary deposits, etc.) can cause clogging and failure of the
nozzles!
To avoid impurities getting into the tank when filling water from a hydrant, it is
recommended to use a pre-filter.

It is inevitably to use special tools (jetting nozzles) which guarantee the highest
possible security during jetting work! (E.g. to prevent an accidental reversal of the
jetting nozzle in the sewer pipe.)

If you press the KDU button and hold it down for longer than 400 ms then the KDU
will be switched on immediately and the filling pressure switch will be linked out for
this period. The KDU will be switched off immediately as soon as you release the
button. This function is used to drain the hose (pump until empty).

Maximum pressure at the pressure intensifier (KDU high pressure pump)

is 200-bar!

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5.7.6 Ventilating the KDU

Proceed as follows to the operate the KDU after filling with water or after draining the tank:
 Ensure that water is being supplied (KDU supply pipeline) to the KDU (as
described above).
 Use rotary switch s322 to switch the filling pump on (turn to the left) – the
filling pump will now supply water for the next 2 minutes.
 Open the ventilation valve fitted on the right side of the heat exchanger
(leave the valve open until it is just water flowing out of the heat
exchanger). Use the vacuum pump to generate pressure if the water level
is below the level in the heat exchanger!

Ventilation valve
heat exchanger

Figure 11 Ventilating the KDU

If the filling pump switches off during the ventilation process you can restart it by
pressing the switch once again.

There might still be air in the KDU, the water pipes and in the reel hose. This air
must also be bleed off in order to prevent the water valve in the KDU, the pivot
joint, the drain rinsing nozzle or even the entire system from being damaged. This
is realised by unscrewing the drain rinsing nozzle from the rinsing hose and then
switching the KDU on.
Leave the KDU to run until it is only water that flows out of the hose. The
manometer must not “jump“ above 30-bar after the drain rinsing nozzle has been
unscrewed. If the pointer remains above 30-bar then there is still air left in the
pipeline.
Ventilating the KDU, the heat exchanger and the pipeline system should be carried
out after a long working pause (lunch break, emptying the sludge tank, etc.) and
always after the WRS drum sieve has been blocked (both suction valves or both
pressure valves).

The water pressure must be as low as possible, i.e. potentiometer R304 must be
turned back. You must also ensure that water is being supplied to the KDU.

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5.7.7 Draining the sludge tank

A half height drainage point s333 with hose coupling is fitted on the tank lid. A hose can be attached to this
and any excessive water that flows out of the sludge tank can be returned to the the drain.
The tank must be ventilated using section boom flap y325 for this task.

5.7.8 Water valve maintenance display fitted on KDU

Button S321 on the control will start to flash when 400'000 double strokes (= valve
operations) is reached.
The maintenance counter can be reset to yero by pressing button S321 (5
seconds) after the valves have been successfully inspected with the diesel engine
stopped.
This maintenance disply should indicate when the KDU valve inspection is
required. If the valves shown signs of wear then the pair of valves must be
replaced (both suction valves or both pressure valves) – see Section 6.7.

5.8 Pressure relief system

When the EMERGENCY STOP is pressed, the high-pressure water system (KDU) is immediately
depressurised by means of a pneumatically actuated overflow valve. When the KDU is switched off normally,
the pressure relief system is activated after a time delay in order to depressurise the high-pressure water
system.

Figure 12 Pressure relief system

When the KDU is switched off or if the EMERGENCY STOP is activated, the water
pressure is discharged into the tank.
The tank may only be entered if the diesel engine is switched off.

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5.8.1 Checking the pressure relief system for leaks

To check the pressure relief system for leaks, the following steps must be performed in the stated order:
1. Open the tank cover just far enough so that the relief port of the pressure relief system is visible
2. Close all ball valves on the water distributor
3. Reduce KDU pressure to minimum
4. Switch on KDU and, while constantly increasing the KDU pressure, check whether any water is
escaping at the relief port of the pressure relief system (see Figure 13 ).
5. Switch off KDU

When the KDU is switched off, the water pressure is discharged into the tank after
a time delay. (This is the case because all the ball valves on the water distributor
are closed.)
Only check for leaks when the tank is empty.
No entry to the tank is permitted when checking for leaks.

Figure 13 Relief port on pressure relief system

Kommentiert [beru26]: nur für FRA

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5.9 Hose reel

The hose reel is driven hydraulically and it is mounted on the tank lid.
The maximum reel capacity is 120 m 1 ¼“ reel hose or 200 m 1“reel hose.
Furthermore, the complete reel can be swivelled 180° in the vertical axis in order to move the reel into the
correct working position.

5.9.1 Hose reel operation

Control panel operation enables the hose reel to be swung out as well as increasing / decreasing the
working speed.
Unwinding / rewinding is controlled via the control panel.

H4 H5
Figure 14 Hose reel control panel

5.9.1.1 Hose reel control panel key:

H4 Increase / decrease working speed

H5 Swing reel in / out

Unwinding the hose reel:

 Push joystick S314 on the control panel upwards
 or push F6 upwards on the remote control

Rewinding the hose reel:

 Push joystick S314 on the control panel downwards
 or push F6 downwards on the remote control
Depending on the position of the selector switch for the jetting hose reel S313, the
winding of the reel is either activated or deactivated:

 Turn rotary switch S313 on the control panel to the left

► The functions for winding the reel are deactivated

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 Turn rotary switch S313 on the control panel to the right

► The functions for winding the reel are activated
► As long as the reel function is actuated, the KDU function (if switched
on) also remains activated Kommentiert [beru27]: nur für FRA

The operator must ensure that nobody is in the hose reel danger area (rotating
part) before unwinding/rewinding as well as swinging the hose reel in and out.

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5.9.2 Water distributor

The hose reel ball-valve s800 on the water distributor must be opened so that water is supplied to the hose
reel. Proceed as follows to realise this:
Select hose reel ball-valve:
 Turn rotary switch S313 on the control panel to the right
A blue light in the rotary switch will start to flash: The KDU is now switched on and
ball-valve s800 l then opens automatically and the light in the rotary switch
becomes a continuous blue light.
Ball-valve s800 will shut automatically when the KDU is switched off and the blue
light in the rotary switch will start to flash again. Kommentiert [beru28]: wenn FRA dann löschen

s800

s810

s890

s891

Figure 15 Water distributor

5.9.2.1 Water distributor key:

s800 Water supply ball-valve Hose reel

s810 Water supply ball-valve Manual reel

s890 Water sypply ball-valve Tank cleaning nozzle

s891 Free rinsing unit water supply ball-valve (HD-bar)

120 m of 1" hose is wound up on the hose reel. The pressure loss inside the hose
will be much greater if a longer or thinner hose is used, which means that much of
the pumping power mightl be lost. It is therefore advisable to throttle up the litre
power and increase the pressure if a longer hose has to be used. This can be
realised easily using the pressure controlled hydraulic pump fitted in the ECO-
Combi.

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When the hose have been used several times or if it’s wind up bad, please rewind
the whole hose and put it under pressure. Then you should wind up the hose
carefully again.

For a longer service life of the high pressure cleaning hose it is recommended to
keep one or two revolutions of the hose on the reel when unreeling completely.
This helps to transfer the force not only via the hose fitting but via the hose reel
directly to the hose.

The hose must always be rewound when it is pressurised. If you want to wind on a
new rinsing hose you must shut the installed fitting (ball-valve) so that the hose is
pressurised. - (see Section 5.9.3)

Rewinding without the water pressure being applied and then applying the
pressure afterwards might well result in the reel being damaged.

The reel must always be swung in before driving on public roads!

200-bar is the maximum working pressure that the reel can take.

5.9.3 Winding a new hose on

The following tasks must be completed in the listed sequence when winding on a new hose with pressure
applied:
1. Connect the new rinsing hose to the reel
2. Scew the supplied shut-off fitting - (see Figure 16) onto the free end
3. IMPORTANT!: Open the ball-valve
4. Turn the KDU pressure controller to position 5 (approx. 100-bar)
5. Switch on the KDU (keep hold of the free end of the hose )
6. Shut the ball-valve off as soon as water starts to flow out of the hose
7. Wind the hose on
8. Switch the KDU off
9. Depressurise the hose by slowly opening the ball-valve

Figure 16 Hose shut-off valve

You must always leave the ball-valve open until the water starts to flow out of the
hose when switching the KDU on!

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The ball-valve must always be opened slowly as a severe recoil force will
build up if it is opened quickly.

5.9.4 Hose metre counter

The electronic hose metre counter is built onto the cover plate of the jetting hose reel.

Figure 17 hose metre counter

5.9.4.1 Legend to metre counter:

F1 Display of length of hose unwound in metres [m]

F2 Display of hose speed [m/min]

Display of total counter &

F3 [m]
daily counter for length of hose unwound in metres

F6 Counter reset (to 0 m) Reset

The other push buttons have no assigned functions

Length of hose unwound in metres

Counter reset

Hose speed

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Total length of hose unwound in metres since start-up (cannot be reset)

Length of hose unwound up to individual reset
Daily counter reset

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5.10 Manual reel

In order to operate the hand reel, the ball valve for the hand reel s810 on the water distributor must be
opened. The hand gun can then be used.

When the hose have been used several times or if it’s wind up bad, please rewind
the whole hose and put it under pressure. Then you should wind up the hose
carefully again.

Do not use the hand spray gun when working with water recycling as the ball-valve
in the reel pipeline s810 has to remain in the closed position and this will cause
premature wear to the hand spray gun.
The high pressure system must be rinsed out using fresh water after working with
the water recycling system, before you start to use the hand spray gun. In this case
you must first change the high pressure system's water supply over to fresh water
and then rinse out the KDU using the tank nozzle afterwards (cleaned in approx. 1
minute).

If you have to change the hand spray gun you must ensure that the new one is
certified for use with this working pressure.
The maximum manual reel and hand spray gun working pressure is 200-bar!
A strong recoil might occur when the hand spray gun is used under certain
cicumstances!
Therefore the water pump's maximum pressure must be reduced to a lower setting
before you can work using the hand spray gun (automatically or by using the
potentiometer, - (see 5.7.5)!
The hand spray pistol will have a recoil force of 250 N when the maximum
pressure is reached and the maximum number of nozzles are fitted (Ø 3 mm
nozzles). Larger nozzles (or eroded nozzles) will create a considerably higher
recoil force! Therefore the nozzles must be continually checked for wear!

5.11 Tank cleaning nozzle

This superstructure is fitted with tank cleaning nozzles, which make cleaning the tank considerably easier.
Water is taken from the fresh water tank to run the tank cleaning nozzles.
Switching on the tank cleaning nozzle:
 Open flap s375 (water supply from FWK)
 Open suction boom flap y325 or tank lid
 Open ball-valve s890 for the tank cleaning nozzle
 Switch the KDU on

Switching the tank cleaning nozzle off:

 Switch the KDU off
 Shut ball-valve s890 for the tank cleaning nozzle
 Depending on the work: shut flap s375 or y325

The tank cleaning nozzles should only be used with fresh water and not recycled
water in order to keep wear down to a minimum.

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You must always ventilate the tank, without fail, before you switch the tank
cleaning nozzles on, otherwise it might be irrepairably damaged by very high
pressure.
The tank will be ventilated if you open suction boom flapy325 or the tank lid.

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5.12 Water recycling Rotomax

This superstructure is equipped with a continuously operating water recycling system. Therefore it is possible
to rinse drains for a longer time without having to refill with water.

When the recycling system is switched on the drum sieve in the sludge tank will start to rotate and the
circulation pump will then supply water to the KDU.

However, the following tasks must be completed in order to be able to work with the water recycling system:
 Fill the sludge tank with water so that it is approx. 2/3 full - (see Section
5.7.1)
 Shut off the manual slding valve for the fresh water tank s375 (line going to
the filling pump)
 Open the water recycling outlet s390 on the sludge tank
The KDU filling pressure is monitored in order to prevent the water pump from
running dry for a long time. The KDU will be switched off automatically if the filling
pressure fails (due to a blocked water filter or the pipeline being shut-off).

5.12.1 Switching the water recycling system on

 Set up the water supply going to the KDU correctly as described above
 Turn rotary switch s322 (locking function) to the right and this will select
water recyling and the WRG will also be switched on.
i,e, the KDU will now be switched on and the drum sieve will rotate in
alternate directions. The filling pump will also be switched on automatically
when the KDU runs.

The indicator light inside switch s322 always flashes at the same rate as the
alternating drum sieve. This will tell you if the drum sieve is being controlled
correctly.

5.12.2 Switching the water recycling system off

The high pressure system must be rinsed out using fresh water after you have finished rinsing with recycled
water or before the vehicle is switched off for a long time (lunch break, emptying the sludge tank at the depot
or at night).

Proceed as follows:
1. Shut off the water supply from the sludge tank (s390).
2. Now switch over the high pressure water supply over to fresh water
3. The KDU must now be rinsed out for approx. 1 minute using fresh water
(water consumption will be approx. 200 litres). This action will prevent
damage being caused to the KDU, the filling pump and the entire system
by the build up of deposits.
All of the consumers must be quickly rinsed out whenever possible, so that any
dirt deposits will be rinsed out of all of the water pipelines.

Only a correctly rinsed out system will ensure that the water recycling system runs
correctly.

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5.12.3 Cleaning the drum sieve (Rotomax)

The drum sieve rotating movement can be switched on so that optimum cleaning of
the drum sieve can be realised. The drum sieve can be rinsed out correctly using
the hand spray gun or, if fitted, the free rinsing unit - (see Section 5.12.5).

 Turn rotary switch s322 to the left (drainage mode) to switch the rotating
on
 Draining mode will be switched off automatically after 2 minutes in order to
prevent the pumps from running dry. Turn rotary switch s322 to the left
once again to swich drainage mode back on if the drum sieve is still dirty.
Prevent the filling pump and the KDU from running dry!
Open flap s375 in the pipeline from the fresh water tank to prevent the water pump
from running dry.
There must be sufficient water in the fresh water tank.
The drum sieve (Rotomax) might become blocked if there are too many solid
particles in the sludge tank. This means that the water will no longer flow from the
filling pump to the KDU.

5.12.4 Rotomax backflushing unit (low pressure)

Working with recycled water can be considerably if you use continuous backflushing (recycling some
of the water through a spray bar in the sludge tank). Proceed as follows to use backflushing:
 Open the water supply to low pressure bar s392
 Start the Rotomax water recycling system - (see Section 5.12.1)
The consumption of fresh water can be reduced by switching the water recycling
system and the backflushing unit off whenever water is being taken from the fresh
water tank (e.g. for cleaning work).

If the water for operating the backflushing unit is not taken from the sludge tank
(e.g. for cleaning work), then the tank must be ventilated, as otherwise the
pressure inside the tank will be too high.
This is realised by opening suction boom flap y325.

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5.12.5 Rotomax free rinsing unit (high pressure)

If the Rotomax (drum sieve) flow drops due to a progressive build up of solid particles in the sludge
tank then the filling pump pressure will drop below 0-bar. This means that KDU will receive
insufficient water and this will be indicated by the pressure manometer's pointer making a severe
"jump“.
The blockage can be eliminated by using the free rinsing unit and you should proceed as follows:
 Switch off the KDU and WRG - (see Sections 5.7.5 and 5.12.1)
 Dectivate the hose reel ball-valve s800 selection
 Shut flap s390 (sludge tank water supply)
 Open flap s375 (fresh water tank water supply)
 Shut ball-valve s392 (backflush unit)
 Open free rinsing unit ball-valve s891
 Put the suction boom hose in the channel and then open suction boom flap
y325
 Switch the WRG on
 Switch the KDU on for approx. 10 seconds
 reset all of the ball=valves and sliding valves to the start positions  for
water recycling mode
The interrupted work can be restarted after the rinsing process has been
completed.
The free rinsing unit can also be used to ensure better cleaning of the tanks and
the Rotomax sieve (drum sieve).
You must absolutely ensure that the tank has been ventilated!

If the free rinsing process does not clean the drum sieve then the solid particles
inside the sludge tank are too big. The sludge tank must then be emptied and the
system must be cleaned!

You are only to use the free rinsing unit in ventilated tanks, otherwise the very high
pressure might irreparably damage the tank.
Suction boom flap y325 must be opened to ventilate the tank.

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5.13 Antifreeze unit

5.13.1 Antifreeze circulation
To start up anti-freeze circulation, the jetting hoses are connected to the distributor on the tank cover. The
water supply for the KDU is taken from the fresh water tank.
The auxiliary drive for the high-pressure system and the KDU must also be switched on when the vehicle is
in motion.

When the auxiliary drive is switched on, the maximum rpm of the diesel engine is
automatically limited and cannot be overridden with the accelerator pedal.
The pump pressure should be reduced to minimum on the manual regulator in
order to ensure that as little power as possible is used for the anti-freeze
circulation.

a850.1 a850.2

Figure 14 Distributor antifreeze circulation

5.13.1.1 Distributor antifreeze circulation:

a850.1 Connector ½”

a850.2 Connector 1”

5.13.1.2 Switch on antifreeze circulation

 Set the water supply to the KDU correctly as described above

 Switch on master switch K1 and switch K2 (NA1)
+

 Press switch K4 in the driver's cab to switch on the KDU

The control lamp in the switch lights up when the antifreeze circulation is switched
on.

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The selector switch for the jetting hose reel S313 on the control panel must be
actuated

5.14 Draining the water out of the superstructure

You must carry out all of the tasks listed here and in this sequence!
The KDU should only be allowed to run dry for as short a time as possible in order to prevent the piston
seals from overheating.

1. Empty and clean the sludge tank; leave the tank lid open
2. Drain the fresh water tank (FWK) by using the drainage tap (s361) fitted at the front of the tank on
the left side and then open the fresh water tank door
3. Drain the discharge tank by opening the drainage tap (s341) fitted at the front of the tank on the left
4. Draian the water-ring pump by emptying the dirt out of the fresh water tank at thefront on the right (6
x).
5. Open the drainage tap on the left alongside the KDU
6. Enpty the KDU water supply using the drainage tap fitted at the back on the right
7. Drain the filling pump and the associated water pipes by opening all of the slider valves, flaps and
drainage taps fitted in the pipes.
Slightly tipping the tank can be a great help here.
8. Open the heat exchanger’s lid on the right
9. Unscrew the spray nozzle on the big drain rinsing hose and then switch the KDU on with ball-valve
s800 open until no more water flows out of the hose then shut ball-valve s800 once again.
10. Open the manual nozzle ball-valve s810, activate the hand spray gun and leave the KDU switched
on until water starts to flow out of the hand spray gun.
11. Open the tank nozzle (s890) and switch the KDU on until no more water flows out of the tank nozzle.
12. Empty the circulation pipelines on the ball-valve
13. Open all of the blind plugs on the inlet side and briefly open the associated slide valve.
14. Tip the tank briefly and then close the tank lid.

Shut all of the slider valves again after you have completed the draining and this
will prevent the water from escaping when you refill the tank.

The KDU must always be switched on for the procedures listed in Sections 9 –
11. However, this must be carried out at the slowest speed possible, i.e. the
auxiliary drive must be switched on, the diesel engine must be idling and the
pressure adjustment potentiometer R304 must be reset to 0.

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5.15 Nozzle tables

Kaiser AG due4sa
Fahrzeugwerk
FL-9486 Schaanwald

Nozzle table for Saphir nozzles

Quantity discharged from round-jet nozzles in l/min
Nozzle diameter in mm
bar 0.8 1.2 1.4 1.5 1.6 1.8 2.2 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.5 3.6 3.7 3.8 3.9 4.0 4.2 4.5
50 1.9 4.2 5.7 6.6 7.5 9.5 14.2 18.3 19.8 21.3 23.0 24.6 26.3 28.1 30.0 31.9 35.9 37.9 40.1 42.3 44.5 46.8 51.6 59.3
60 2.1 4.6 6.3 7.2 8.2 10.4 15.5 20.0 21.7 23.4 25.1 27.0 28.9 30.8 32.8 34.9 39.3 41.6 43.9 46.3 48.8 51.3 56.6 64.9
70 2.2 5.0 6.8 7.8 8.9 11.2 16.8 21.6 23.4 25.3 27.2 29.1 31.2 33.3 35.5 37.7 42.4 44.9 47.4 50.0 52.7 55.4 61.1 70.1
80 2.4 5.3 7.3 8.3 9.5 12.0 17.9 23.1 25.0 27.0 29.0 31.1 33.3 35.6 37.9 40.3 45.4 48.0 50.7 53.5 56.3 59.2 65.3 75.0
90 2.5 5.7 7.7 8.8 10.1 12.7 19.0 24.5 26.6 28.6 30.8 33.0 35.3 37.7 40.2 42.8 48.1 50.9 53.8 56.7 59.7 62.8 69.3 79.5
100 2.6 6.0 8.1 9.3 10.6 13.4 20.0 25.9 28.0 30.2 32.5 34.8 37.3 39.8 42.4 45.1 50.7 53.7 56.7 59.8 63.0 66.2 73.0 83.8
110 2.8 6.3 8.5 9.8 11.1 14.1 21.0 27.1 29.4 31.7 34.0 36.5 39.1 41.7 44.5 47.3 53.2 56.3 59.4 62.7 66.0 69.5 76.6 87.9
120 2.9 6.5 8.9 10.2 11.6 14.7 22.0 28.3 30.7 33.1 35.6 38.1 40.8 43.6 46.4 49.4 55.6 58.8 62.1 65.5 69.0 72.6 80.0 91.8
130 3.0 6.8 9.3 10.6 12.1 15.3 22.8 29.5 31.9 34.4 37.0 39.7 42.5 45.4 48.3 51.4 57.8 61.2 64.6 68.2 71.8 75.5 83.3 95.6
140 3.1 7.1 9.6 11.0 12.5 15.9 23.7 30.6 33.1 35.7 38.4 41.2 44.1 47.1 50.2 53.3 60.0 63.5 67.1 70.7 74.5 78.4 86.4 99.2
150 3.2 7.3 9.9 11.4 13.0 16.4 24.5 31.7 34.3 37.0 39.8 42.6 45.6 48.7 51.9 55.2 62.1 65.7 69.4 73.2 77.1 81.1 89.4 102.7
160 3.4 7.5 10.3 11.8 13.4 17.0 25.3 32.7 35.4 38.2 41.1 44.0 47.1 50.3 53.6 57.0 64.1 67.9 71.7 75.6 79.7 83.8 92.4 106.0
170 3.5 7.8 10.6 12.1 13.8 17.5 26.1 33.7 36.5 39.4 42.3 45.4 48.6 51.9 55.3 58.8 66.1 70.0 73.9 77.9 82.1 86.4 95.2 109.3
180 3.6 8.0 10.9 12.5 14.2 18.0 26.9 34.7 37.5 40.5 43.5 46.7 50.0 53.4 56.9 60.5 68.0 72.0 76.0 80.2 84.5 88.9 98.0 112.5
190 3.7 8.2 11.2 12.8 14.6 18.5 27.6 35.7 38.6 41.6 44.7 48.0 51.4 54.8 58.4 62.1 69.9 74.0 78.1 82.4 86.8 91.3 100.7 115.6
200 3.7 8.4 11.5 13.2 15.0 19.0 28.3 36.6 39.6 42.7 45.9 49.2 52.7 56.3 60.0 63.8 71.7 75.9 80.2 84.5 89.1 93.7 103.3 118.6
210 3.8 8.6 11.8 13.5 15.4 19.4 29.0 37.5 40.6 43.7 47.0 50.5 54.0 57.7 61.4 65.3 73.5 77.8 82.1 86.6 91.3 96.0 105.8 121.5
220 3.9 8.8 12.0 13.8 15.7 19.9 29.7 38.4 41.5 44.8 48.1 51.6 55.3 59.0 62.9 66.9 75.2 79.6 84.1 88.7 93.4 98.2 108.3 124.3
230 4.0 9.0 12.3 14.1 16.1 20.3 30.4 39.2 42.4 45.8 49.2 52.8 56.5 60.3 64.3 68.4 76.9 81.4 86.0 90.7 95.5 100.5 110.8 127.1
240 4.1 9.2 12.6 14.4 16.4 20.8 31.0 40.1 43.4 46.8 50.3 53.9 57.7 61.6 65.7 69.8 78.6 83.1 87.8 92.6 97.6 102.6 113.1 129.9
250 4.2 9.4 12.8 14.7 16.8 21.2 31.7 40.9 44.3 47.7 51.3 55.1 58.9 62.9 67.0 71.3 80.2 84.8 89.6 94.5 99.6 104.7 115.5 132.6
Example:
Drain rinsing nozzle with 6 x 2.5 mm diameter Saphir inserts
Nozzle pressure: 100-bar
6 x 25.9 = 155 litres/min

Kaiser AG due4ke
Fahrzeugwerk
FL-9486 Schaanwald

Nozzle table for ceramic nozzles

Quantity discharged from round-jet nozzles in l/min

Nozzle diameter in mm
bar 0.8 1.2 1.4 1.5 1.6 1.8 2.2 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.5 3.6 3.7 3.8 3.9 4.0 4.2 4.5
50 2.6 5.9 8.0 9.2 10.5 13.3 19.8 25.6 27.7 29.9 32.2 34.5 36.9 39.4 42.0 44.7 50.2 53.2 56.1 59.2 62.4 65.6 72.3 83.0
60 2.9 6.5 8.8 10.1 11.5 14.6 21.7 28.1 30.4 32.8 35.2 37.8 40.4 43.2 46.0 48.9 55.0 58.2 61.5 64.9 68.3 71.9 79.3 91.0
70 3.1 7.0 9.5 10.9 12.4 15.7 23.5 30.3 32.8 35.4 38.0 40.8 43.7 46.6 49.7 52.8 59.4 62.9 66.4 70.1 73.8 77.6 85.6 98.3
80 3.3 7.5 10.2 11.7 13.3 16.8 25.1 32.4 35.1 37.8 40.7 43.6 46.7 49.9 53.1 56.5 63.5 67.2 71.0 74.9 78.9 83.0 91.5 105.1
90 3.5 7.9 10.8 12.4 14.1 17.8 26.6 34.4 37.2 40.1 43.1 46.3 49.5 52.9 56.3 59.9 67.4 71.3 75.3 79.5 83.7 88.0 97.1 111.4
100 3.7 8.4 11.4 13.1 14.8 18.8 28.1 36.3 39.2 42.3 45.5 48.8 52.2 55.7 59.4 63.2 71.1 75.2 79.4 83.8 88.2 92.8 102.3 117.5
110 3.9 8.8 11.9 13.7 15.6 19.7 29.4 38.0 41.1 44.3 47.7 51.2 54.7 58.5 62.3 66.2 74.5 78.8 83.3 87.8 92.5 97.3 107.3 123.2
120 4.1 9.1 12.5 14.3 16.3 20.6 30.8 39.7 43.0 46.3 49.8 53.4 57.2 61.1 65.1 69.2 77.8 82.3 87.0 91.7 96.6 101.7 112.1 128.7
130 4.2 9.5 13.0 14.9 16.9 21.4 32.0 41.3 44.7 48.2 51.8 55.6 59.5 63.6 67.7 72.0 81.0 85.7 90.5 95.5 100.6 105.8 116.7 133.9
140 4.4 9.9 13.5 15.4 17.6 22.2 33.2 42.9 46.4 50.0 53.8 57.7 61.8 66.0 70.3 74.7 84.1 88.9 93.9 99.1 104.4 109.8 121.1 139.0
150 4.5 10.2 13.9 16.0 18.2 23.0 34.4 44.4 48.0 51.8 55.7 59.7 63.9 68.3 72.7 77.4 87.0 92.1 97.2 102.6 108.0 113.7 125.3 143.8
160 4.7 10.6 14.4 16.5 18.8 23.8 35.5 45.9 49.6 53.5 57.5 61.7 66.0 70.5 75.1 79.9 89.9 95.1 100.4 105.9 111.6 117.4 129.4 148.6
170 4.8 10.9 14.8 17.0 19.4 24.5 36.6 47.3 51.1 55.1 59.3 63.6 68.1 72.7 77.4 82.4 92.6 98.0 103.5 109.2 115.0 121.0 133.4 153.1
180 5.0 11.2 15.3 17.5 19.9 25.2 37.7 48.6 52.6 56.7 61.0 65.4 70.0 74.8 79.7 84.7 95.3 100.8 106.5 112.4 118.4 124.5 137.3 157.6
190 5.1 11.5 15.7 18.0 20.5 25.9 38.7 50.0 54.0 58.3 62.7 67.2 72.0 76.8 81.9 87.1 97.9 103.6 109.4 115.4 121.6 127.9 141.0 161.9
200 5.2 11.8 16.1 18.5 21.0 26.6 39.7 51.3 55.4 59.8 64.3 69.0 73.8 78.8 84.0 89.3 100.5 106.3 112.3 118.4 124.8 131.2 144.7 166.1
210 5.4 12.1 16.5 18.9 21.5 27.2 40.7 52.5 56.8 61.3 65.9 70.7 75.6 80.8 86.1 91.5 103.0 108.9 115.1 121.4 127.8 134.5 148.3 170.2
220 5.5 12.4 16.9 19.4 22.0 27.9 41.6 53.8 58.2 62.7 67.4 72.3 77.4 82.7 88.1 93.7 105.4 111.5 117.8 124.2 130.8 137.6 151.8 174.2
230 5.6 12.7 17.2 19.8 22.5 28.5 42.6 55.0 59.5 64.1 69.0 74.0 79.2 84.5 90.1 95.8 107.8 114.0 120.4 127.0 133.8 140.7 155.2 178.1
240 5.8 12.9 17.6 20.2 23.0 29.1 43.5 56.2 60.7 65.5 70.4 75.6 80.9 86.3 92.0 97.9 110.1 116.4 123.0 129.7 136.7 143.8 158.5 182.0
250 5.9 13.2 18.0 20.6 23.5 29.7 44.4 57.3 62.0 66.9 71.9 77.1 82.5 88.1 93.9 99.9 112.3 118.9 125.5 132.4 139.5 146.7 161.8 185.7
Example:
Drain cleaning nozzle with 6 x 2.5 mm diameter ceramic inserts
Nozzle pressure: 100-bar
6 x 36.3 = 218 litres/min

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5.16 Hose pressure loss table

Kaiser AG SCHL01
Fahrzeugwerk
FL-9486 Schaanwald

Pressure loss table

For rubber drain rinsing hoses
Theoretical pressure loss in bar per 10 m hose lengths
Internal hose diameter (mm)
L/min 12 15 19 25 32 38
50 3.85 1.26 0.39 0.10 0.03 0.01
60 5.54 1.81 0.56 0.14 0.04 0.02
70 7.54 2.47 0.76 0.19 0.06 0.02
80 9.84 3.23 0.99 0.25 0.07 0.03
90 12.46 4.08 1.25 0.32 0.09 0.04
100 15.38 5.04 1.55 0.39 0.11 0.05
110 18.61 6.10 1.87 0.47 0.14 0.06
120 22.15 7.26 2.23 0.56 0.16 0.07
130 26.00 8.52 2.61 0.66 0.19 0.08
140 30.15 9.88 3.03 0.77 0.22 0.09
150 34.61 11.34 3.48 0.88 0.26 0.11
160 39.38 12.90 3.96 1.00 0.29 0.12
170 44.46 14.57 4.47 1.13 0.33 0.14
180 49.84 16.33 5.01 1.27 0.37 0.16
190 55.53 18.20 5.58 1.41 0.41 0.17
200 61.53 20.16 6.18 1.57 0.46 0.19
210 67.84 22.23 6.82 1.73 0.50 0.21
220 74.45 24.40 7.48 1.90 0.55 0.23
230 81.37 26.66 8.18 2.07 0.60 0.26
240 88.60 29.03 8.90 2.26 0.66 0.28
250 96.14 31.50 9.66 2.45 0.71 0.30
260 103.99 34.07 10.45 2.65 0.77 0.33
270 112.14 36.75 11.27 2.86 0.83 0.35
280 120.60 39.52 12.12 3.07 0.89 0.38
290 129.37 42.39 13.00 3.30 0.96 0.41
300 138.44 45.37 13.91 3.53 1.03 0.43
310 147.83 48.44 14.86 3.77 1.10 0.46
320 157.52 51.62 15.83 4.01 1.17 0.49
330 167.52 54.89 16.83 4.27 1.24 0.53
340 177.82 58.27 17.87 4.53 1.32 0.56
350 188.44 61.75 18.94 4.80 1.40 0.59
360 199.36 65.33 20.03 5.08 1.48 0.63
370 210.59 69.01 21.16 5.37 1.56 0.66
380 222.13 72.79 22.32 5.66 1.65 0.70
390 233.97 76.67 23.51 5.96 1.74 0.73
400 246.12 80.65 24.73 6.27 1.83 0.77
410 258.58 84.73 25.99 6.59 1.92 0.81
420 271.35 88.92 27.27 6.91 2.01 0.85
430 284.42 93.20 28.58 7.25 2.11 0.89
440 297.81 97.59 29.93 7.59 2.21 0.94
450 311.50 102.07 31.30 7.94 2.31 0.98
460 325.50 106.66 32.71 8.29 2.41 1.02
470 339.80 111.35 34.15 8.66 2.52 1.07
480 354.42 116.13 35.62 9.03 2.63 1.11
490 369.34 121.02 37.12 9.41 2.74 1.16
500 384.57 126.01 38.65 9.80 2.85 1.21
510 400.10 131.11 40.21 10.19 2.97 1.26
520 415.95 136.30 41.80 10.60 3.08 1.31
530 432.10 141.59 43.42 11.01 3.20 1.36
540 448.56 146.98 45.08 11.43 3.33 1.41
550 465.32 152.48 46.76 11.86 3.45 1.46
560 482.40 158.07 48.48 12.29 3.58 1.51
570 499.78 163.77 50.22 12.73 3.71 1.57
580 517.47 169.57 52.00 13.19 3.84 1.63
590 535.47 175.46 53.81 13.64 3.97 1.68
600 553.77 181.46 55.65 14.11 4.11 1.74
Example:
120 m long drain rinsing hose; 25 mm internal diameter (1")
Flow rate = 300 litres of water per minute
Theoretical pressure loss: 3.53 x 12 = 42-bar

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Operating and maintenance manual
ECO II

6 Maintenance
6.1 Daily
(or when the work has been completed)
 Inspect and clean the shut-off valve in the tank
 Clean the system using fresh water after you have finisihed the rinsing work using recycled water -
(see Section 5.12.2)
 Empty the separating tank
 Check the hydraulic oil level – (see Figure 7
 Check the vacuum pump bearing inspection glass oil level - (see Figure 10)
 Briefly open the vacuum pump's dirt trap emptying valve every 4 running hours with the pump
running and drain off the dirty water - (see Figure 10)

6.2 Every 25 operating hours

 Clean the fresh water tank
 Inspect the hydraulic system for leaks and eliminate any leaks that are found.
 Clean the filter in the separating tank dome
 Check for leaks on the pressure relief system (see Punkt Fehler! Verweisquelle konnte nicht gefunden
werden. ) Kommentiert [b29]: Ohne ZA-645 löschen
 Lubricate the superstructure (lubricating points):
 Drive shaft at NA1 - 2 lubricating nipples (2 x joints)
 Underride guide bolts - 6 lubricating nipples
 Tank lid cylinder (inside tank) - 2 lubricating nipples (2 x bottom of bearing eyes)
 Clamping ring fastening pieces, lightly grease the cone surfaces
 Rear tank tipping bearing - 2 lubricating nipples
 Bottom tank tipping cylinder bearing - 2 lubricating nipples
 Top tank tipping bearing - 2 lubricating nipples
 Hose reel bolts (turning point) - 1 lubricating nipple

 Lubricate the hose reel (lubricating points):

 Hose reel swivelling motor - 2 lubricating nipples
 Bearing block (lower turning point) - 1 lubricating nipple
 Bearing block (Rotary joint) - 1 lubricating nipple
 Bearing block (forced winder) - 2 lubricating nipplesl
 Forced winder travelling nut - 1 lubricating nipplel Kommentiert [b30]: ohneZA-431 löschen

 Lubricate the KSR10 suction boom (lubricating points):

 Grease the suction boom turning drive teeth
 Grease the suction boom turning drive teeth
 Lifting cylinder lug on rod end - 1 x lubricating nipple
 Lifting cylinder lug at ground end - 1 x lubricating nipple
 Lifting cylinder removable bolts at rod end - 1 x lubricating nipple
 Hose guide clamp on top of tank - 1 x lubricating nipple Kommentiert [j31]: ohne KSR-10 ganzen Absatz löschen!

 Lubricate the KSR20 suction boom (lubricating points):

 Grease the inner suction boom turning drive teeth - 2 x lubricating nipples
 Grease the external suction boom turning drive teeth - 2 x lubricating nipples
 Grease the suction boom turning drive teeth

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Operating and maintenance manual
ECO II

1. Rotomax rotary union lubrication (external):

1. Empty sludge tank
2. Use the S322 rotary switch (key function) to turn the Rotomax to the left and switch it on
3. Use the lubrication nipple F1 to fill the rotary union with grease
(Press grease gun about 3 to 4 times)

F1

Figure 18 lubricating nipplel rotomax

6.3 After the first 100 running hours

 Change the hydraulic oil return filter - (see Figure 7 )
 Inspect the screw-on connections or retighten, e.g. Universal shaft flange, auxiliary chassis
securings, hydraulic pump mountings, etc.

6.4 Every 200 operating hours

 Inspect the KDU water valves (4 x) for signs of wear and replace whenever necessary. - (see Section
6.7)
 Check the hydraulic oil return filter: The contamination indicator in the head of the filter must not be
visible when the auxiliary drive is switched on or at working revs.

6.5 Every 1,000 running hours (or annually)

 Change all of the hydraulic oil filters
 Change filler-/breather filter (integrated in filler neck, see Figure 7 Oiltank + KDU frame) annually.
 Change the vacuum pump bearing lubricating oil
 Check the hydraulic oil for signs of ageing and dirt (send an oil sample to your
oil supplier), - (see Section 7.1.1)

6.6 Exchange of hydraulic hoses

As defined by EC machinery directive RL 98/37/EG the following maintainance intervals are to be followed:
 Hydraulic hoses have to be changed at least every six years.
 Hydraulic hoses mounted inside the tank (sludge tank, freshwater compartment) have to be changed
at least every three years.

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Operating and maintenance manual
ECO II

6.7 Maintenance and changing the valves

Step 1:

Unscrew the plates on both sides of the valve

housing.
Remove the valve, O-ring, support ring and
locking ring. Clean the parts and inspect for
wear. Replace any part whenever necessary.

Step 2:

If the valve plate and/or the sealing ring in the

valve is worn then the you must only use the
relevant removal tool to dismantle the valve and
remove the two segments.

Suction valve:

Extraction tool No. 0.608.880

Pressure valve:

Extraction tool No. 0.608.870

Suction valve
8 Pressure valve
2
7 Item Art. No. Art. No. Name
- 0.608.860 0.608.840 Valve complete
4
1 0.608.862 0.608.846 Housing
2 0.608.864 0.608.844 Housing
5 3 0.608.866 0.608.848 Ring
4 0.608.830 0.608.850 Valve plate

3 5 0.607.232 0.608.691 Compression

spring
6 6 2.010.310 6.730.480 O-ring
1 7 6.730.815 0.501.630 O-ring
8 0.606.623 0.606.624 Support ring, axial

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Operating and maintenance manual
ECO II

Reassemble in reverse order.

The housing sections segments must interlink.

Valve plate
Correct

Anti-wear ring Wrong

Step 3:

Lightly oil the valve, O-ring, support ring and

Mark locking ring and reposition them.
Take note of the slide in direction when fitting the
new valve!
The marks on the valves must be aligned with
the marks in the valve housing!

Mark

Step 4:

Reposition the locking rings in the plate.

0.600.357

0.600.355

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Operating and maintenance manual
ECO II

Step 5:
5 8
Coat the bolts with copper compound.
2 Position all of the bolts and tighten up so that
they are finger-tight (approx. 70 Nm) before
using a torque wrench to fully tighten them.
4 7 10
The bolt torque is 135 Nm.
1
Always abide by this sequence.

11

3
6 9

The valves must always be replaced in pairs (i.e. both suction valves or both pressure valves).
Prevent the delicate valve segments from being hit during the removal and refitting procedures.

6.8 Correct Rotomax rotary union lubrication

1. Unscrew the locking bolt (Item 20).
2. Use the lubrication nipple (Item 10) to fill the rotary union with grease.
 Squirt in grease during the initial filling process until the grease escapes on the opposite side.
Now run the Rotomax for approx. 30 seconds and then squirt grease in once again. This will
ensure that the rotary union is uniformly filled with grease.
 When you are relubricating with grease you should always squirt the grease in until it is just
clean grease that escapes on the other side.
3. Run the Rotomax for approx. 30 seconds with the locking bolt unscrewed.
4. Screw the locking bolt back in.
5. Check to see that you can rotate the Rotomax drum sieve manually. If you cannot, then:
 You did not unscrew the locking bolt prior to lubricating the union. Overpressure built up inside
the rotary union when grease was squirted in and the shaft seal (Item 30) has been pressed up
against the support (Item 40) causing excessive friction.
 The Rotomax would not run after the lubrication was completed even with the locking bolt
unscrewed (minor overpressure built up inside the rotary joint during the lubrication despite the
bolt being unscrewed).

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Operating and maintenance manual
ECO II

Kommentiert [as32]:

Item 20
Item 30
Sealing plug
Shaft seal

Item 10
Lubrication
nipple
Item 40
Support

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Operating and maintenance manual
ECO II

7 Operating materials
7.1 Hydraulic oil
The quality of the used hydraulic oil, which must not contain pollutions, is of vital importance for the
performance and life cycle of the machine. It is not allowed to mix different lubricants and oils.
Hydraulic oil PANOLIN HLP UNI 46 (ISO VG 46) should be used for the initial filling.

Attention: Other hydraulic oils may only be used when agreed beforehand with the
manufacturer. In this case, a written guarantee as well as an acceptance of the
warranty must be existent from the oil supplier.
It must never be mixed with biological degradable hydraulic oil!

Content: approx. 250 litres

7.1.1 Oil analysis

Regular hydraulic oil changes have been dispensed with in order to reduce running and maintenance costs.
However, it is necessary to send a hydraulic oil sample to your hydraulic oil supplier's laboratory for regular
status analysis in order to protect the operting safety and the guarantee obligations.

An oil analysis must be carried out immediately if you suspect that the hydraulic oil has aged, if it is visibily
dirty or if a major repair has been carried out on the hydraulic system.

Taking an oil sample:

The hydraulic oil sample (approx. 0.5 litre) must be taken from the pressure intensifier's measuring
connection when the system is running at its normal working temperature. Special containers for shiping the
sample to the oil supplier can be ordered for this purpose.

Measures:
The test report issued by the oil supplier will include the state of the hydraulic oil and any necessary
measures that have to be taken (e.g. fine filtering, adding additives, hydraulic oil change, etc.). These
measures must be implemented immediately.

The test report and the measures that have to be implemented must be documented together with the date
and running hours details.

7.2 Vacuum pump lubricating oil

Only mineral engine oil SAE 15W40 is to be used for oil changes or refilling.

Content: approx. 5 litres

7.3 Lubricating grease

A Super Longtime EP grease with a synthetic base oil component as per DIN 51825, Partl 3 KP 2 G-30 is to
be used as the lubricating grease. Mixing with Li-grease is permitted.
Super Longtime Autol TOP 2000 grease must be used for the initial filling.

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Operating and maintenance manual
ECO II

8 Service / Repairs
The tipped tank must always be locked in place when service and repair work
is being carried out!
Maintenance and repair work must only be carried out when the system is
switched off and the vehicle has been unloaded!
The maximum excess pressure tank pressure of 0.5-bar must never be
exceeded!

All of the electronic units (KDU electronics, etc.) must be disconnected before any
electro-welding is carried out on the vehicle and the starter batteries must also be
disconnected. The welding equipment's earthing clamp must be attached as close
as possible to the welding spot.
The same applies to a reversing camera when one is fitted.

8.1 Extra hydraulic filter

The hydraulic system is fitted with a leak filter system . This will prevent the system from being
contaminated if any of the hydraulic components are damaged. The filter insert in this filter must be changed
every 1,000 running hours or once a year.

The hydraulic oil and all of the filters must be replaced if repairs caused by damage were carried out on the
hydraulic system. The leak filter is mounted inside the auxiliary chassis behind the hydraulic pumps.

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Operating and maintenance manual
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9 Spare parts
An important note:

In order to be abve to process your spare parts order as quickly as possible it is

absolutely essential that you always provide us with the following data whenever
you place an order:
 Serial number and year that the vehicle was built: This
data can be found on the nameplate fitted on the side of
the tank or on the first page of this operating manual.
 Part name, nominal size, dimensions
 Part item number as shown in the spare
parts drawing
Article number given in the spare parts list

10 Copyright
The copyright of this operating manual remains the propery of KAISER. This operating manual has
been provided soley for use by the operator and his personnel. It contains instructions and
regulations that must neither be fully nor partially copied, distruted or passed on in any way.
Infringments might result in legal proceedings being taken against you.

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