Kärcher HD 9000 E USA User manual

www.karcher.com
!
5.961-163 A 2006087 (09/03)
HD 9000 E USA
2.640-543.0
Operating instructions English

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03) I
IMPORTANT SAFETY INSTRUCTIONS
WARNING  When using this product basic precautions
should always be followed, including the following:
1. Read all the instructions before using the product.
. To reduce the risk of injury, close supervision is
necessary when a product is used near children.
3. Know how to stop the product and bleed pressures
quickly. Be thoroughly familiar with the controls.
4. Stay alert  watch what you are doing.
5. Do not operate the product when fatigued or under the
influence of alcohol or drugs.
6. Keep operating area clear of all persons.
7. Do not overreach or stand on unstable support. Keep
good footing and balance at all times.
8. Follow the maintenance instructions specified in the
manual.
This Product Shall Only Be Connected To A Power
Supply Receptacle Protected By A Ground Fault Circuit
Interrupter.
WARNING  Risk of Injection or Injury  Do Not Direct
Discharge Stream At Persons.
GROUNDING INSTRUCTIONS
This product must be grounded. If it should malfunction
or breakdown, grounding provides a path of least
resistance for electric current to reduce the risk of
electric shock. This product is equipped with a cord
having an equipment-grounding conductor and a
grounding plug. The plug must be plugged into an
appropriate outlet that is properly installed and
grounded in accordance with all local codes and
ordinances.
DANGER  Improper connection of the equipment-
grounding conductor can result in a risk of electrocution.
Check with a qualified electrician or service personnel if
you are in doubt as to whether the outlet is properly
grounded. Do not modify the plug provided with the
product  if it will not fit the outlet, have a proper outlet
installed by a qualified electrician. Do not use any type
of adaptor with this product.
GROUND FAULT CIRCUIT INTERRUP-
TER PROTECTION
To comply with the National Electrical Code (NFPA 70)
and to provide additional protection from the risk of
electric shock, this pressure washer should only be
connected to a receptacle that is protected by a ground
fault circuit interrupter (GFCI).
EXTENSION CORDS
Use only 3-wire extension cords that have 3-prong
grounding-type plugs and 3-pole cord connectors that
accept the plug from the product. Use only extension
cords that are intended for outdoor use. These extension
cords are identified by a marking Acceptable for use
with outdoor appliances: store indoors while not in use.
Use only extension cords having an electrical rating not
less than the rating of the product. Do not use damaged
extension cords. Examine extension cord before using
and replace if damaged. Do not abuse extension cord
and do not yank on any cord to disconnect. Keep cord
away from heat and sharp edges. Always disconnect the
extension cord from the receptacle before disconnecting
the product from the extension cord.
WARNING  To reduce the risk of electrocution, keep all
connections dry and off the ground. Do not touch plug
with wet hands.
WARNING  To reduce the risk of fire, electric shock or
injury:
Injection hazard: equipment can cause serious injury if
the spray penetrates the skin. Do not point the gun at
anyone or any part of the body. In case of penetration
seek medical aid immediately.
This system is capable of producing 0000 kPA. To
avoid rupture and injury, do not operate this pump with
components rated less than 0000 kPa working
pressure (including but not limited to spray guns, hose
and hose connections.)
Before servicing, cleaning, or removal of any part, shut
off power and relieve pressure.
High Pressure. Keep clear of nozzle.
Close cover before operating machine.
Warning: If connection is made to a potable water
system, the system shall be protected against backflow.
This appliance is intended for commercial use.
Do not spray electrical apparatus and wiring.
This machine has been designed for use with cleaning
chemicals supplied or recommended by the
manufacturer. The use of other cleaning chemicals may
affect the operation of the machine and void the
warranty.
SAVE THESE INSTRUCTIONS.

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
For our environment, disposal
II
Packaging
The system packaging is made from the problem free
materials wood and cardboard. Both materials can be
easily separated from each other and reused or recycled.
Operating materials
Motor oil
The high-pressure module contains motor oil. When
changing the oil, the waste oil must be handed in to a
waste oil collection point or a disposal company. The
same applies for oil or an oil and water mixture collected
in case of leaks.
Important!
Waste oil must only be disposed of at the collection
points provided. Please hand in all waste oil there. Conta-
minating the environment with waste oil is a punishable
offence.
Cleaning agent
Kärcher cleaning agents are separator friendly (ASF).
This means that they do not hinder the function of an
oilseparator. A list with recommended cleaning agentsis
given in the „Accessories“ section.
The warranty terms and conditions issued by our respon-
sible sales company in each country apply. In case of a
warranty claim, please contact your dealer or your nea-
rest authorised customer service agent.
Warranty
i

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03) III
Contents Forourenvironment,disposal
Warranty
Packaging
Operatingmaterials
A. For your safety
1. Hazards
2. Safety information and tips
3. Hazard sources
General hazards
Hazards while working on the high-pressure module
Electrical hazards
4. Accessory hazards
5. Noise protection
6. Intended use
7. Workplaces
8. Approved machine operators
9. Safety measures at the place of installation
10. Safety installations
11. Emergency procedures
12. Guidelines and regulations
B. Designandfunction
1. Design
2. Flow diagram of water cycle
3. Overall flow diagram
4. Flow diagram of compressed air distributors
5. Functional description
Waterinlet
High-pressure pumps
High-pressure side
Cooling
Chemicals pump
Osmotic/fresh water
Frost protection
Drying aid
Air distributor
C. Operation
1. Switching off in emergencies
2. Initial start up
3. Operation
4. Shut-down procedures
5. Metering pump settings
Set the metered quantity
Set the injectors
6. Frost protection
7. Shutdown

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
IV
D. Technical specifications
E. Maintenance
1. Maintenance instructions
Who is allowed to carry out maintenance work?
Maintenance contract
2. Manual controls
Manual controls/ water/ pumps
Manual controls/ water/ high-pressure valves
3. General maintenance schedule
4. Oil change
5. Descaling
Procedure
Descaling the high-pressure system:
Descaling the pump motor cooling coil
F. Troubleshooting
1. Who can remedy the faults?
2. Chemical pump faults
3. Faults in the mechanisms
G. Accessories
Cleaningagent
H. Systeminstallation
1. Installation
2. Connections
3. High-pressure installation
4. Water hardness
5. Preparations for the initial startup
6. Installation plan
I Customerservice
ONLYFORAUTHORISED
QUALIFIEDPERSONNEL

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03) A1
A. For your safety 1. Hazards
Incorrect operation or misuse can cause health hazards
and loss of life for the machine operator or third persons.
All persons involved in the installation, initial startup,
operation, servicing or maintenance of the high-pressure
module must:
nbe appropriately qualified.
nprecisely observe these operating instructions.
2. Safety information and tips
The following symbols are used in these operating in-
structions:
Hazard!
Denotes a directly impending hazard. Failure to observe
the information can lead to death or severe injuries.
Caution!
Denotes a possible hazardous situation. Failure to obser-
ve this information can lead to slight injuries or damage to
property.
Important!
Denotes tips for use and important information.
3. Hazard sources
The water in the high-pressure module is highly-pressuri-
sed in places. It can escape from damaged components.
This results in potential injury and possible burn hazards.
i
!

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
A2
General hazards
Hazard!
nInjury hazard due to escaping,
possibly hot waterjet.
Check the high pressure hose, pipes and fittings for
damage before each use.
Immediately renew any leaking components and
seal leaking connections.
Only original Kärcher high-pressure hoses are optimal-
ly designed for the system. We will not accept any
responsibility if other hoses are used.
Even after being switched off at the EMERGENCY
STOP button or master switch, the high-pressure
module is still highly pressurised. Release the pressu-
re at the end of operation.
nBurn hazards due to hot system parts.
Do not touch any non-insulated pipes and hose cou-
plings when running the system with hot water.
nInjury hazard due to parts flying off the system.
Fragments or objects flying off the system can cause
injuries to people or animals. Never direct the water jet
at fragile or loose objects.
nExplosion hazard.
This high-pressure module must not be run in potenti-
ally explosive rooms.
nExplosion hazard.
Do not process any liquids other than water with the
module, in particular no combustible or caustic liquids.
Do not use any cleaning agents containing explosive,
highly flammable or poisonous substances, e.g.:
– benzine
– heating oil and diesel fuel
– solvents
– liquids containing solvents
– undiluted acids
– acetone.
If you are uncertain ask the manufacturer.
Check the high-pressure hose, pipes with fittings and
spray lance for damage before each use.
A. For your safety
!

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03) A3
Hazards while working on the high-pressure module
Maintenance works may only be carried out by:
ncustomer service agents approved by the manufactur-
er.
nauthorised skilled persons.
Hazard!
nInjury hazard due to escaping, possibly hot water jet.
Release the pressure before carrying out any work on
the high-pressure module. When running the high-
pressure module with hot water, leave it to cool.
Wear safety goggles.
nElectric shock hazard.
Switch off and secure the master switch on the high-
pressure module before starting any work on it.
Electrical hazards
Hazard!
Electric shock hazard!
nNever touch electric cables, plug-in connections and
terminal boxes if your hands are wet.
nElectrical connection cables or extension cables must
not be damaged by driving over them, crushing, tea-
ring or similar. Protect cables against heat, oil and
sharp edges.
nThe water jet of mobile cleaning units (e.g. high-pres-
sure cleaners) must never be pointed at electrical units
or systems.
nAll parts within the working area that conduct electrici-
ty must be protected against water jets and sprays.
nSystems may only be connected to properly grounded
electricity sources.
nAny work on electrical parts of the facility may only be
carried out by a qualified electrician.
A. For your safety
!
!

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
A4
4. Hazards due to the accessories
The high-pressure module is the component of downst-
ream high-pressure cleaning equipment. Apart from the
safety information given here, you must also observe the
safety information for the high-pressure cleaning equip-
ment.
Hazard!
nPoisoning or caustic burns hazard caused by cleaning
agent.
Appropriate safety measures must be taken when
handling cleaning agent concentrates that contain
substances harmful to health. In particular, safety
goggles, protective gloves and protective clothing are
to be worn.
The information leaflets enclosed with the cleaning
agent and the local regulations must be observed.
Store the cleaning agent out of reach of unauthorized
persons.
nHealth hazard due to cleaning agent.
The water given off by the module is not drinking water
quality due to the cleaning agents added.
5. Noise protection
The noise level is approx. 80 dB (A).
Therefore it is not compulsory to wear ear protection at
the place of installation .
6. Intended use
This high-pressure module pumps water under high
pressure from an upstream storage tank to downstream
high-pressure cleaning equipment. The storage tank and
high-pressure cleaning equipment are not part of this
high-pressure module. The high-pressure module is
permanently installed in a dry, frost free room. This room
must have a water connection in accordance with the
information given in the technical specifications. The
place of installation must not be hotter than 40°C. This
high-pressure module is controlled by a central control
unit installed on site. This external central control unit is
not part of this high-pressure module. It also controls the
interaction between the system and upstream and down-
stream equipment. The high-pressure water is distributed
via a fixed-installation pipeline.
A. For your safety
!

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03) A5
Important!
Only use clean water as the high-pressure medium.
Soiling leads to premature wear or deposits.
Water quality requirements:
Above 15° dH, it may be necessary to take measures to
reduce the hardness.
7. Workplaces
The high-pressure module is installed in a cabinet (not
part of the supply). This cabinet usually has an EMER-
GENCY STOP button and a master switch for switching
the high-pressure module on and off. Otherwise, only
maintenance works are carried out on the high-pressure
module.
A. For your safety
i
eulavHp5.9…5.6
ytivitcudnoccirtcelEmc/Sµ0002nahtssel
sdiloselbaeltteS*l/gm5.0nahtssel
250.0nahtsseleziselcitrap(sdiloselbaretliF )mm l/gm02nahtssel
snobracordyHl/gm02nahtssel
edirolhCl/gm003nahtssel
muiclaCl/gm58nahtssel
ssendrahlatoT**Hd°51nahtssel **Hf°7.62nahtssel **He°57.81nahtssel **mpp762nahtssel **lag/g6.51nahtssel
norIl/gm5.0nahtssel
esenagnaMl/gm50.0nahtssel
reppoCl/gm20.0nahtssel
srododirtupmorfeerF
setunim03doirepnoitatnemides/l1emulovelpmas*
rehgiheraseulavehtfideriuqereraserusaemgnilacseD**

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
A6
A. For your safety 8. Approved machine operators
Only persons over 18 years of age who have received
relevant training, may operate the system.
An exception applies for young persons over the age of
16, if this is necessary for their training and they are
properly supervised while using the system (VBG 87).
Also comply with all additional local regulations.
The machine operator is responsible for third parties
within the working area.
The responsibilities for the various activities on the ma-
chine must be clearly specified and observed. Unclear
accountabilities are a safety risk.
The owner/operator must:
nprovide the machine operator with access to the ope-
rating instructions.
nensure that the machine operator has read and under-
stood them.
9. Safety measures at the place of installation
Hazard!
nThe high-pressure module must be installed in a stable
way on a level and firm ground.
10. Safety installations
nThe system is shutdown by the EMERGENCY STOP
switch or the master switch of the high-pressure cle-
aning equipment.
nOverpressure escapes via a pneumatically operated
ball valve.
11. Emergency procedures
nPress the emergency stop button
nSet the master switch to the „0“ position.
nShut off the water supply
nRelease pressure
!

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03)
12. Guidelines and regulations
nThe „Working with liquid sprayers“ guidelines apply for
operation of this high-pressure module in the Federal
Republic of Germany.
These are issued by the main association of the com-
mercial employers’ liability insurance associations.
The guidelines are available from: Carl Heymanns
Verlag KG, Luxemburger Straße 449, 50939 Köln.
– Among other things, according to these guidelines
the high-pressure module must be inspected at
least every 12 months by an expert.
The result of the inspection must be recorded in
writing.
– At the end of these operating instructions there is
an inspection sheet for entering the inspection
results.
– Kärcher customer service fitters are experts and
can carry out this inspection.
nComply with the Hazardous Materials Regulations
(Gef Stoff V) when handling cleaning agents.
nPlease also observe any local regulations concerning
electrical connections, water and wastewater connec-
tion. These regulations can be obtained from the utility
supply companies.
nConnection works may only be carried out by
Kärcher’s customer service personnel or authorised
skilled persons and compliance with these regulations.
A. For your safety
A7

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
B1
B. Design and function
Figure B.1 Front view
1 Bypass valve
2 Low-pressure hoses
3 Low-pressure inlet
4 Cooling water inlet
1. Design

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03) B2
B. Design and function
Figure B.2 Rear view
1 Terminal box
2 High-pressure pump 1
3 High-pressure pump 2
4 High pressure feed gantry
5 High pressure feed
underbody wash
6 Pulsation damper
7 Frost protection supply gantry (optional)
8 Frost protection supply
underbody wash (optional)
9.1 High-pressure solenoid valve
underbody wash (optional)
9.2 High-pressure solenoid valve gantry
10 High-pressure pump hoses
11 High-pressure water manometer
12 High-pressure pressure switch
13 Pushbutton for manually switching the
solenoid valve

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
B3
Figure B.3 Flow diagram of water cycle
1 „Motor cooling“ solenoid valve
2 Pressure regulator
3 Cooling water inlet
4 Water inlet (tank)
5 Overflow
6 „Water inlet“ float valve
7 Storage tank
8 Level probe
9 „Bypass“ solenoid valve
10 High-pressure non-return valve
11 High-pressure manometer
12 Pressure switch
13 High-pressure outlet
14 Vibration damper
15 Safety valve
16 High-pressure pump 1
17 High-pressure pump 2
B. Design and function 2. Flow diagram of water cycle

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03) B4
B. Design and function 3. Overall flow diagram
Non-return valve
V Shut-off valve
Y Solenoid valve
no normally open
nc normally closed
FW Water supply flow diagram
SV Float valve
Figure B.4 Overall flow diagram
1 High-pressure outlet
underbody wash
2 High-pressure outlet gantry
4 Frost protection inlet

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
B. Design and function 4. Flow diagram of compressed air supply
for pneumatic high-pressure solenoid valves
(gantry and underbody wash) on the
high-pressure module
Figure B.5 Flow diagram
1 Compressed air inlet (provided on site)
2 „Bypass“ solenoid valve
3 „High-pressure gantry“ solenoid valve
4 „High-pressure underbody wash“ solenoid valve
(optional)
B5
1
234

HD 9000 E USA Operating instructions English
5.961-163 A 2006087 (09/03) B6
5. Functional description
Water inlet
(see Figure B.3)
The storage tank (7) is filled with water via the „water
inlet“ float valve (6) (provided on site).
The water level is kept constant via this „water inlet“ float
valve (6). A float switch sends a signal to the pump
controls if there is a water supply shortage in the storage
tank (7).
The high-pressure pumps (16, 17) are then switched off,
in order to protect them against running dry.
In case of faults, which cause the storage tank (7) to
overflow, the water can flow away via the overflow (5).
The storage tank (7), including the equipment, is not
included in the standard extent of supply.
High-pressure pumps
(see Figure B.3)
Each high-pressure pump (16, 17) is driven by an electric
motor. The pumps pump the water to the pressure side
under high-pressure. When the motors are started up the
bypass valve (9) is open. This connects the pressure and
suction sides of the pumps and prevents the pressure
from falling. The motors can start up gently without load.
High-pressure side
(see Figure B.3 and B.4)
The high-pressure water is passed via non-return valves
(10, Figure B.3) to a high-pressure collector. The gantry
(2, Figure B.4) or underbody wash (1, Figure B.4) are
then supplied.
The vibration dampers (14, Figure B.3) smooth the
pulsating water pressure due to the piston strokes.
The pressure can be read off at the manometer (11,
Figure B.3). If the pressure exceeds the maximum opera-
ting pressure, the pressure switch (12, Figure B.3) swit-
ches off. The safety valves (15, Figure B.3) provide
additional safety.
B. Design and function

5.961-163 A 2006087 (09/03)
English Operating instructions HD 9000 E USA
B7
Cooling
(see Figure B.3)
While a pump is running the „motor cooling“ solenoid
valve (1) is open. This causes the cooling water to flow
via the pressure regulator (2) through the motors’ cooling
windings. The cooling water is then fed back into the
storage tank. The cooling water pressure is set at the
pressure regulator (2).
Frost protection
(see Figure B.3)
The high-pressure module must be installed in a room
protected against frost. The supply hoses to the washing
facility and the washing facility itself are protected against
frost damage by a device. Compressed air is fed to the
high-pressure circuits through the „frost protection inlet“
solenoid valve (Y1) .
The compressed air supply is installed on-site.
B. Design and function