OWNER'S MANUAL

SPARE PARTS &

MAINTENANCE
ACCESSORIES

Caretech HPC 500

Water Blas}."rl=500 Bar

MARINE frCARE
Technical data
Model Caretech HPC 500-ll
Code No 705060
Voltage & frequency 3x440V I 6OHz
Motor power ratinq 18.skw
Operating Pressure 150-500 bar
Ad missi ble overpressure 550 bar
Water flow (maximum) 18 lpm
Maximum water input temperature 60 0c
Min. / max. water inlet pressure 2-8 bar
3/q"
Minimum inlet hose size
Nozzle size 034
Pump oil quantity 0.9Ko (1 litre)
Oil orade SAE 15W40
Dimension 95x70x80
Weight 165Ks

Machine's l.D.

Serial Number: .. []*'*ra..:fl:ffi

Powrr rupply: ?x4/oY I 6OHt
Mrx. work, prcr.: 500 brr
Mrx.Watorllow:18lpm C (
Wrtor lnlat trmp: 50 oC
Oll: Synih. 15W10
srrrrlNo.: MC02lg543g

lmportant
Change the oil of the pump after the first 50 operating hours!
Use fully synthetic oil, grade SAE 15W40, quantity 1 liter.

Page 1 of31
Contents

Technical data......... ....... 1

Machine's 1.D......,.,... .......'........... 1

lmportant '.........'..'....'. 1
lntroduction .............. ......4
Safety precautions.....,........ ............ 5

Standard equipment, quick overview .............6

Operating the machine............ -......7
Check points before start-up ......7

Water in1et......... ......7

High pressure water outlet,.... ...........-.-....7
Electric power...... ...................-7
Working with the machine ..........8
Auto shut-off ........... ............'...' .....................8
Shut down after works.............. '.................. 8
lnspection and Maintenance ...'......9
Maintenance schedu1e,............. ........,.........' I
Troubleshooting ..:.... 10

High Pressure Pump ........'..'.........'.............'. 13

High pressure pump - Spare parts list ........... ....-.-.14
UnloaderValve ...........i................. 16
Spray Gun ........ .......-...17
Spraying equipment, standard ....'i....,..... .'.. 18
Motor/pump assembly flexible coupling.. .'.'. 18
Electrical circuit diagram '......'...... 19
Optional accessories.............. ;......,......... '.....2O
Turbonozzle Quick Release attachment package .....20
Turbonozzle 500/35 ..........'......20
How to operate properly the Turbonozzle ....'....-.-.21
Sandblasting QR attachment package -.-.21

Accessories Quick List,.,....... .......22

Declaration of conformity .............24
Notes ...........25

Page 2 of 31
USER'S MANUAL
CARETECH HPC 5OO

Page 3 of 31
lntroduction

Thank you for purchasing the Caretech HPC 500 high pressure unit!

This manual or part of it should not be reproduced without the written approval
of the manufacturer.

Every effort has been made to ensure that the information in this manual is
both accurate and current. However, we reserve the right to change, alter or
otherwise improve the product and its documentation at any time without prior
notice.

Manufacturer's warranty is limited to repair or replacement of faulty parts at the

time of manufacture.

Warning
Please read carefully this manual before starting the machine for the first
time and keep this manual in a safe place. We cannot be held responsible
for damages or malfunctions due to not reading this manual.

Safety symbols
The below symbols used in this manual indicate actions that should not be
ignored, as they may result in human injuries or damages to the machine.

Risk for persons -Risk for the product

Risk due to electric lmpoftant helpful

power information

Page 4 of 31
Safety precautions
This machine should be operated by qualified adult people only.
Never let children or people who are not trained for its use, to
run the machine.
The machine should be used according to relevant national
safety rules.

Always check and ensure that the machine and its accessories

m (hoses, cable, fittings, gun, nozzle etc.) are in good working

condition before start-up.
lf during operation you observe any leakage, abnormal noise or

AI
I cnu,o* |
any other malfunction, stop the machine and get it serviced.
You should not attempt to repair and reuse damaged high
pressure hoses, Replace with original hoses only.

Never direct the spray jet at yourself, other people or animals, at

the machine itself and never attempt to clean your clothes or
footwear with the machine.
Keep bystanders away from the working area.
Always use eye protection, ear protection, adequate protective
clothing and footwear.

Use the correct type of electric plug to a corresponding socket

with ground earth wiring.
Ensure you connect the machine to the correct main supply
voltage, as specified by the manufacturer.
Use only watertight cable, plugs and sockets. Any electrical
installation should be made only by a qualified electrician.

Always ensure the machine is placed in a stable position and

cannot move.

m
Do not operate the machine without water or with insufficient
quantity of water.
y

E
Do not make modifications and service regularly the machine as
described in this manual.
Use only original spare parts for maintaining the machine.
l cAUfloN I
Repairs should be done only by qualified personnel,
After works, the machine should be stored and secured against
unauthorised use.

Page 5 of 31
Standard equipment, quick overview

The machine comprises of the following standard equipment:

. Stainless steel frame with Stainless Steel top cover and handle
o 1Omtr watertight cable H07RN-F, oil resistant
. 20mtr re outlet hose, with

Electric motor 31 duty, class F with thermal

protection

High pressure pump with nickel plated

head

Unloader valve, adjustable 150-500 bar

*
Water inlet filter, washable
IE
1

ia
Electric control panel complete dl (l .
'i 3lo
rra I
,ra I

Water inlet quick coupling with barb hose

rcxr
Waterless cut-off protection switch l\
Working hours counter

Pressure gauge 1000 bar

o
Thermo-protection valve F
Spray gun with safety latch

Overpressure bursting disc

u
1000mm single lance with nozzle quick
coupling
High turbo nozzle / rotating nozzle

Page 6 of 31
Operating the machine

Check points before start-uP

o Electrical mains voltage/frequency should be the same with the
electrical data of the machine
, General condition of the machine and accessories (cable, power &
water connectors, hoses, gun, lance, nozzle etc.)
. Water mains supply should be sufficient (pressure 2-B bar, min. flow 25
lpm)
. Machine is placed horizontally; it is stable and cannot move
o The oil level in the pump is correct and oil is not milky

Connections
Water inlet
. Use a clean hose of 3/4" (minimum) diameter and rinse it thoroughly
before connecting it to the machine. Attach -using a clip- the provided
hose plug (barb) to the hose and then fit it to the inlet quick coupling of
the machine. You should not use a very long water inlet hose (maximum
1 0mt0.

ln case you connect the machine to potable water mains supply,

you should use a prevention backflow valve, as per EN 1717.

lnsufficient water supply can cause heavy damage to the pump

and/or electric com ponents.
ln case the feed water is quite dirty, we recommend the use of
an additional water filter.

High pressure water outlet

. Connect the high pressure hose to the outlet of the machine. You should
not use tools to tighten the couplings.
. Connect the Spray gun with the lance, equipped with a nozzle.

Electric power
o lnstall a corresponding to your installation electric plug (3+1 x 32Amps
or 3+ 1 x 634) at the end of the power supply cable. The machine comes
with 3phases + earth cable.

Use the correct dimension of electric cable wire in case you

connect an extension cable. For cable extension lengths up to
50mtr, the cross section of the wire to be used is 6mm2.

Page 7 of 31
Working with the machine
. Open the feed water and press the trigger of the gun for minimum 30
seconds (subject to water hose inlet and hose length) to release air from
the circuit.
. Connect the electric cable plug to the power source socket (should be
an earth wired one), after which the POWER indicator on the control
panel will lit.
o Twist slightly clockwise to unlock the EMERGENGY STOP button.
. Push the START button on the control panel and the motor will now
start.
. Release the safety latch of the spray gun, and you are now ready to
work.

m Be aware of torque and recoil. Ensure stable foothold before

pressing the trigger of the gun.

A]
lcaunoru I
Make sure the feed water pressure is constantly over 1.5 bar, as
otherwise the machine will trip and the corresponding indicator
(TRIP) on the control panel will lit.

When the trigger of the gun is released, the water will circulate in

EI
lqaqe!]
by-pass mode inside the pump. After some time in this working
condition, if the water temperature exceeds 60
0C the thermo-
protection valve will open releasing hot water. Do not leave the
machine running in idle mode for more than 5 minutes..
During operation observe for eventual leaks at the pump, hoses,
connections and other components of the hydraulic circuit.
Also observe if there are any pressure variations or any abnormal
noise from the motor or PumP.
ln such cases, you should stop the machine and eliminate the
cause. Consult Troubleshooting guide (see page'1 1).

Auto shut-off
The machine is equipped with automatic shut off sensor. lf the machine works
in by-pass mode continuously for more than 3 minutes, then the machine will
automatically stop. You would need to press the START button at the control
panelfor re-starting the machine. '
In case there are leakages at the high pressure circuit (i.e. at
fittings, hoses, gun etc) then the auto shut-off sensor will not
work properly and therefore the machine will not stop
automatically.

Shut down after works

o Press the STOP button, and then press the EMERGENCY STOP button
as well.
. Disconnect the machine's electric cable from the electric power source.

Page 8 of 31
 o Press the trigger of the gun to de-pressurize the high pressure circuit
and then lock the safety latch of the trigger.
. Close the feed water tap and disconnect the inlet hose from the
machine.
o Release remained water at the high pressure hoses, reel up and store
carefully.
' Store the machine and its accessories in a safe, frost protected and dry
area.

lnspection and Maintenance

Maintenance schedule
Every time, After the first 50 Every 200 hours
before the use of hours ol of operation, or,
the machine ooeration every six months

Water Filter
(subject to water quality)
(

Oil level at the pump ./

Visual inspection of the

machine and its
equipment/accessories
(hoses, gun, lance, ,/
fittings, electrica!
components, other
eouipment)

lnspection for proper air

ventilation from the back ./
of the motor

Oil renewal of the PumP

crankcase ./
(SAE 75W90, fully
./
synthetic)

Unloader valve lubrication ./

Paoe 9 of 31
 Disposal of the oil of the pump crankcase, disposal of any parts
and components of the machine should be done according to
regulations

Oil of pump crankcase: Fully synthetic, SAE 15W40

Quantity: -0.9K9 (1 ltr)
Flexible coupling connecting the pump with the motor should
be checked annually

Troubleshooti
Malfunction Possible cause Repair
The machine is not
Check the installation and
connected to the mains connections
power supply
Replace.
Burn fuse lf the fuses keep burning, ask
The machine for an electrician
does not start Activated waterless cut-off
Confirm adequate quantity of
switch
water
ffRlP indicator should lit)
Activated Thermal overload
Press the RESET button of
relay inside the control Panel
the thermal overload relay
(TRIP indicator should lit)
Check the installation is
Phase is missing
correct
The machine
Low oil level in the pumP
makes abnormal Fill in
crankcase
noise
Motor bearings or pump Replace
bearinqs worn
Gaskets to be checked and
Pump sucks air
replaced
lnsufficient water flow Eliminate
Cloqqed water filter Clean or replace
Nozzle worn or wronq size Replace
Pressure drop
Worn gaskets on Unloader
Replace
valve
Air inside the pipinq Eliminate
Leakages on the hydraulic
Eliminate
svstem
I nsuff icient water flow Eliminate
Pressure Clean or replace
Nozzle clogged
fluctuates, or,
Dirt on pump valves Clean or replace
hose vibrates
Dirl on Unloader valve Clean or repair

Page 10 of 31
SPARE PARTS LIST
Pos Part Description Pos Part Description
No No
1 301430 Disc 33 301486 Screw
2 301431 Rins 34 301148 Washer
3 301432 O-ring 35 301423 Flanqe
4 301433 Gasket 36 301421 O-rinq
5 301434 Nut 37 30141 0 Bearing
6 301405 Plunger 3B 301 731 Rod assy
7 301722 Valve pluq 39 301493 Pin
I 301715 Back up ring 40 301732 Connectinq rod
9 301716 O-rinq 42 301 733 Water seal LP
10 301723 Discharoe valve 43 301734 Water seal HP
11 301716 O-rinq 44 301459 Washer
12 301724 Rinq 45 600061 Hex screw
13 301725 Suction valve 46 301148 Washer
14 301176 O-rinq 47 301 735 Pluq
15 301498 Rino 48 301736 Crankcase
16 301727 Manifold 49 301 146 Plus
17 301427 Washer 50 301 537 Gasket
18 301428 Screw 51 301 41 I Oil dipstick
19 301413 O-ring 52 301418 Gasket
20 301416 Hex screw 53 301820 Back cover
21 301462 Washer 54 600062 Hex screw
22 Pluq (not installed) 55 301420 Back cover qasket
Gasket (not 56 301 738 Shaft
23
installed)
24 301456 Spacer 57 301 531 Key
25 301429 O-ring 5B 301 41 0 Bearinq
26 301146 Plug 59 301421 O-rinq
27 101 1 05 Bonded washer 60 301 530 Shim
28 301728 Head 61 301422 Flanoe
29 301729 Ring 62 301417 Oilseal
30 301 730 Rinq 63 301436 Screw
31141 301443 O-rinq 64 301 148 Washer
32 301425 Oilseal
7A 301657 I Valve plug threaded for manomeler (not illustrated)

Page 11 of31
Main assembly

T
w
€--tr
fr
[tr
oc
op0

#
Pos. Code Description Pos. Code Description
1 1 01 280 Electrical control panel 11 1 01 266 Water filter
2 1 01 661 Motor 12 1 01 200 Quick coupling
3 101126 Auto shut off switch control 13 101172 Hose barb
4 1 01 352 Tee sst 14 101 1 10 Unloader valve
5 1 01 286 Burstino disc assembly 15 101297 Reducing outlet niPPle
6 1 01 351 Niople 16 1 01 298 Reducino nioole
7 1 625
01 Pressure qauoe 1000bar 17 101196 Y-Fittinq
8 1 01 765 HP Pump 18 101129 Thermo-valve
9 1 01 268 Reducino nipple, 3 wav 19 101249 Nipple
10 101287 Dry running protection 20 1 01 261 By-pass hose
switch
21 101272 Adaptor

Miscellaneous parts

(,@
Code Description Qtv
101014 Mos washer % 1

101105 Mos washer 3/8 2

101109 Mos washer % 2
30'1 161 O-rinq for hiqh pressure hoses 2
101244 Wheel, solid rubber with cover 4

Page 12 of 31
High Pressure Pump
_33
I --3s
(t- ^@[6, 44
45-
-------{ 49
50
i&
lz-.-.-...-.'.'-_l 46- ,l
-34 qt-
"o1:_____ll
:.-
^64- OE
ll
I i-_--_--l -.-116
!{o_ro aru P-
52
53
54

55
,---€
8-
56
57

o-- 58
59
sr't 32
so!o 60
2e)
28
27
26

25
24

il;w-11
4-';
REPAIR KITS

Repair Kit Pos Part No Description

'1
301 430 Disc
2 301 431 Ring
A) Plunger Kit
3 301432 O-ring
#301404
4 301 433 Gasket
5 301 434 Nut
10 301723 Discharqe valve
11 301 71 6 O-ring
B) Valves Kit 12 301724 Ring
#301629 13 301725 Suction valve
14 301 1 76 )-rino
15 301 498 Ring
31141 301 443 O-ring
C) Water seals Kit
42 301 733 Water seal LP
#301414
43 301734 Water seal HP
29 301729 Ring
D) Back up rings Kit
30 301 730 Ring
#301403
31141 301443 O-ring
38 301 731 Rod assennblv
E) Connecting rod Kit
39 301 493 Pin
#301637
40 301732 Connectinq rod

Page 13 of 31
 hl$gh Fressure purmp

44 -*--$
l1 45.*_____]
t2 46- .--, .,(
^j+ 47-,aW''
$E
r.5 ,$i.)9
d,t6 * i. | .... ** s,

'i 41 . .. .. . ... f\.trt......-.,

: "ti3;raee-B$"11\:'
aYl..5u-q*l-Y,,,,: liii i-*** 6{)

,W*::
,l

27

"-*- ------ 25

$".$
list
Pos Part No Description Pos Part Description
No
1 301 430 Disc 33 301486 Screw
2 30143-l Bing
.
- 34 301 148 Washer
J 301 432 O-ring 35 30142s Fln nnp
4 JUl 433 Gasket 36 301421 n
5 301 434 Nut 37 301 41 0 Bearino
g. 301 405 Jlq!ger 3B 301 731 Rod assy
7 301722 Valve f:luct 39 301493 Pin
8 301 715 Back up ring 4A 301 732 Connantir
I 30'1716 Q-ring 42 301 733 Wator soal I P
10 301 723 Discharcle valve 4e 301 734 Waler eeal l-lF
11 301 71 6 0-rino 44 301 459 Washer
12 301724 r{[19 45 600061 Flex screw
IJ 301 725 Suction valve z+b 301148 Washer
14 301 1 76 u-nr"lg 47 301 735 Plug
IJ 301 498 48
-tsus 301 736 Crankcase
to 301727 Manifold 49 301'146 lLlrs
tt 301427 Washer 50 Geqkpt
301 537
to
19
301 428 Screw 51 301 41 I Oil dr'pstick
301 41 3 9-llns 5?- 301 41 B Gasket
20 30'1416 Hex screw 53 30'1820 Back cover
21 301 462 Washer 54 600062 Hex screw
22 JiUU(lot instalect) 55 301 420 Back cover gasket
23 Gasket (notirrstalled) 56 301 738 Shaft
24 301 456 Spacer 57 30 1 531 Key
zc 301 429 ..-Q:tttLl 5B 301 41 0 Bearing
26 301 '146 59 301421
-Plus 0-ring
27 101105 Bonded washer 60 301 530 Shim
28 301 728 Head 6'l 301422 ll-alge-_
29 301 729 Ring 62 301417 Oil seal
30 301 730 63
-tstns 301 436 Screw
31141 301 443 64 301 1 48 Washer
32 -9-l!e_ -
30'1425 Oilseal
7A 301 657 Valve ph:o threadecl
ty-qanometer (not illustrated)

Page 14 of 31
MAntNH/tlCARE
Paoe 15 of 31
Unloader Valve (code #101110)

,r'1

@*=--_

Pos. Code Description Qtv KIT Kl

1 301127 Shutter coupl. '1i2F Bsp Sst 1

2 301 96
1 O-rinq 1 .78x17.17mm Ni 85 2 I
3 301 28
1 Sprino Sst 1

4 301 1 29 Shutter pin Sst 1

5 301 1 97 O-rinq 1 T
'l
6 301 208 Sst body
7 301172 O-rinq 1 r
8 301 209 Seat Sst 1 T
9 301223 Shutter pin Sst 1 T
10 301 01 2 Spacer rinq Sst 1

11 301224 Back-up rinq 1 I

12 301225 O-ring 1 T
't
13 301226 O-ring I
14 301 1 30 Spacer rinq Sst 1

15 301227 Stem seal + O-rinq 1 I

16 301 311 Piston Sst 1

17 301 1 32 Piston holder 1

18 301 013 BallSst 1

19 301 1 33 SprinO rest pin 1

20 301 01 1 Sprinq Zpl 1

21 301 1 34 Set screw 1

22 301 01 0 Rinq nut, brass 1

23 301 059 Valve regulating ring nut, brass 1

K1 | sotot+ Spares Kit,9xl

Page 16 of 31
Spray Gun (code #11O7O1)

Pos. Code Description Qtv KIT Kl

1 301228 Pluq, plastic black 1

2 1 01 081 Sprino holder 1

3 301 1 73 Back-up ring 1 t

T
4 301229 O-ring 1

Stem seal + O-ring 2 I

5 301174
6 1 01 080 Spacer ring 1

7 1 01 093 Sprinq Sst 1 r

Piston + seat 1 T
8 301 330
I
I 301',172 O-rinq 1

Back-up rinq 1 T
10 301 1 75
1'1 1 01 082 Front plug 1

12 1 01 083 Parallel pin, brass 1

I
13 1 01 089 Housino. brass 1

14 1 01 084 Couolino Stt 1

15 1 085
01 Safety latch 1

16 1 01 086 Triooer. black 1

17 1 087
01 Stop pin 1

18 1 01 088 Parallel pin, brass 1

19 301 096 Casinq kit + screws 1

20 301 331 S/tappinq screw Sst 7

21 1 01 090 Black tube Sst 1

22 1 01 092 Couolino Sst 1

Paoe 17 of 31
 Spraying equipment, standard

Pos. Code Description

w Qty
1 101175 Hioh pressure hose 1Omtr 1

2 101297 Nipple 1

3 11 0701 Spray gun 1

4 110751 Hand orio 1

5 'l 10991 Lance 1000mm 1

6 101246 Quick release couplinq 1

7 101247 Quick release oluo 1

8 101189 Hiqh pressure flat fan nozzle 1

Motor/pump assembly flexible coupling

Type E flexible coupling - Code #301099

a, 1ffi\
#r-J
-f
:EGF+.:

0..
'

Flexible coupling (1 - motor side,2 - Pump side)

Pos. Code Description'

3 301 332 Elastic bushing replacement set E

Pos. Gode Description

1 101512 Elastic spider replacement set N

Page 18 of 31
Electrical circuit diagram

f
J
I

E >,1

>
T
o
I
I
a
lx
UT
S=
k
l=

+.F
k
F
'-i,16

-l=

?i
+H
i iix i ii-
ll.-
Hi= | *ii !i,E
xi9
lt-;-l

Page 19 of 31
Optional accessories
Turbonozzle Quick Release attachment package (code #201 106)

Gryy
It lttoegs lTurbonozzle600/35 |

-----]

Turbonozzle 600135 (code #1 10995)

Position Part No Description

1 301 650 Sst couplinq
2 301 651 Back-up ring
3 301226 O-rino
4 301 508 Washer
5 301 1 40 Turbine
7 301 652 Seal
I 301 141 Repair Kit
11 301 1 97 O-rino
13 301 653 Sst housing

Page 20 of 31
How to operate properly the Turbonozzle

When starting to spray, keep the gun in upright position with nozzle
facing down. Press the trigger and the nozzle will start rotating.
You can now start moving to horizontal position at area to be blasted.

lf you do not follow the above-described procedure then your

Turbonozzle might get damaged or wear out prematurely.

Sandblasting QR attachment package (code #2O11O7)

Pos. Code Description

1 201107 Sandblastino QR head, complete
2 1 1 0904 Sand suction probe

Page 21 of 31
Accessories Quick List

Part No Description

101'.t77
HP EXTENSION HOSE 2OMTR,
(Stock
WITH SST FITTINGS
part)

101178
CONNECTION NIPPLE FOR HP
(Stock
EXTENSION HOSE
part)

201128
(Stock
TURBONOZZLE QR PACK 600/35
part)

CO
201107 SANDBLASTING QR PACK 5OO .ts

110702 SHOULDER REST FOR SPRAY GUN

11 0804 DOUBLE LANCE 5OO BAR

'1
10994 LANCE SHORT 500mm

11 0993 I-ANCE LONG 2000mm

GEASE FOR SEALS SOmI, WATER

1 01 054
RESISTANT

Page 22 of 31
Part No Description

201102
EXTENSION CABLE sOMTR,
(Stock
part)
WCONNECTORS IP67

101 357
WATER INLET HOSE 3/+",25MFR
(Stock
COIL
part)

1 01 359 HOSE CLIPS %''

HOSE REEL 500 BAR, for 50MTR

201152
hose

PIPE CLEANING HOSE 2OMTR

201113
w/MICRONOZZLE

11 0990 FLOOR CLEANER (MAX 280 BAR)

Page 23 of 31
Declaration of conformity

DECLARATION OF CON FORM ITY C(

Distributor Marine Care BV

Oude Maasweg 35
3197 KJ Botlek - Rotterdam
Address The Netherlands
Tel : +31(0)10 2950342
E-mail : [email protected]

Declares that the product

Product HIGH PRESSURE CLEANING MACHINE

name (ELECTRIC OPERATED, COLD WATER)

Model &
Caretech HPC 500, 3X400V/50H2 & 3X400V/60H2
Type

conforms to the essential requirements of the

directive 20061421EC
based on the followina specifications:
EN ISO 13857:2008
Safety distances to prevent hazard zones being reached by
upper and lower limbs

EN ISO 12100-2:2003
STANDARDS Safety of machinery. General principles for deqign. Risk
assessment and risk reduction

EN 349/93 + 41:2008
Safety of machinery - Minimum gaps to avoid crushing of
parts to the human bodv

Date July 2016

Page 24 of 31