HD 9000 E USA Operating Instructions English

HD 9000 E USA 2.640-543.0

Operating instructions English

! www.karcher.com 5.961-163 A 2006087 (09/03)

HD 9000 E USA Operating instructions English

IMPORTANT SAFETY INSTRUCTIONS EXTENSION CORDS

WARNING When using this product basic precautions Use only 3-wire extension cords that have 3-prong should always be followed, including the following: grounding-type plugs and 3-pole cord connectors that accept the plug from the product. Use only extension 1. Read all the instructions before using the product. cords that are intended for outdoor use. These extension cords are identified by a marking Acceptable for use 2. To reduce the risk of injury, close supervision is with outdoor appliances: store indoors while not in use. necessary when a product is used near children. Use only extension cords having an electrical rating not less than the rating of the product. Do not use damaged 3. Know how to stop the product and bleed pressures extension cords. Examine extension cord before using quickly. Be thoroughly familiar with the controls. and replace if damaged. Do not abuse extension cord and do not yank on any cord to disconnect. Keep cord 4. Stay alert watch what you are doing. away from heat and sharp edges. Always disconnect the extension cord from the receptacle before disconnecting 5. Do not operate the product when fatigued or under the the product from the extension cord. influence of alcohol or drugs.

6. Keep operating area clear of all persons. WARNING To reduce the risk of electrocution, keep all connections dry and off the ground. Do not touch plug 7. Do not overreach or stand on unstable support. Keep with wet hands. good footing and balance at all times.

8. Follow the maintenance instructions specified in the WARNING To reduce the risk of fire, electric shock or manual. injury:

Injection hazard: equipment can cause serious injury if This Product Shall Only Be Connected To A Power the spray penetrates the skin. Do not point the gun at Supply Receptacle Protected By A Ground Fault Circuit anyone or any part of the body. In case of penetration Interrupter. seek medical aid immediately.

This system is capable of producing 220000 kPA. To WARNING Risk of Injection or Injury Do Not Direct avoid rupture and injury, do not operate this pump with Discharge Stream At Persons. components rated less than 220000 kPa working pressure (including but not limited to spray guns, hose and hose connections.) GROUNDING INSTRUCTIONS Before servicing, cleaning, or removal of any part, shut off power and relieve pressure. This product must be grounded. If it should malfunction or breakdown, grounding provides a path of least High Pressure. Keep clear of nozzle. resistance for electric current to reduce the risk of electric shock. This product is equipped with a cord Close cover before operating machine. having an equipment-grounding conductor and a grounding plug. The plug must be plugged into an Warning: If connection is made to a potable water appropriate outlet that is properly installed and system, the system shall be protected against backflow. grounded in accordance with all local codes and ordinances. This appliance is intended for commercial use. DANGER Improper connection of the equipment- grounding conductor can result in a risk of electrocution. Check with a qualified electrician or service personnel if Do not spray electrical apparatus and wiring. 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 This machine has been designed for use with cleaning installed by a qualified electrician. Do not use any type chemicals supplied or recommended by the of adaptor with this product. manufacturer. The use of other cleaning chemicals may affect the operation of the machine and void the warranty. GROUND FAULT CIRCUIT INTERRUP- TER PROTECTION SAVE THESE INSTRUCTIONS.

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).

5.961-163 A 2006087 (09/03) I English Operating instructions HD 9000 E USA

For our environment, disposal 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.

i 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.

Warranty The warranty terms and conditions issued by our responsible sales company in each country apply. In case of a warranty claim, please contact your dealer or your nea- rest authorised customer service agent.

II 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

Contents For our environment, disposal Warranty Packaging Operating materials

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. Design and function 1. Design 2. Flow diagram of water cycle 3. Overall flow diagram 4. Flow diagram of compressed air distributors 5. Functional description Water inlet 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) III English Operating instructions HD 9000 E USA

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 Cleaning agent

ONLY FOR AUTHORISED H. System installation QUALIFIED PERSONNEL 1. Installation 2. Connections 3. High-pressure installation 4. Water hardness 5. Preparations for the initial startup 6. Installation plan

I Customer service

IV 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

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: n be appropriately qualified. n precisely observe these operating instructions.

2. Safety information and tips The following symbols are used in these operating instructions:

! 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 observe this information can lead to slight injuries or damage to property.

i Important! Denotes tips for use and important information.

3. Hazard sources The water in the high-pressure module is highly-pressurised in places. It can escape from damaged components. This results in potential injury and possible burn hazards.

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A. For your safety General hazards

! Hazard! n Injury 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 pressure at the end of operation. n Burn hazards due to hot system parts. Do not touch any non-insulated pipes and hose cou- plings when running the system with hot water. n Injury 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. n Explosion hazard. This high-pressure module must not be run in potentially explosive rooms. n Explosion 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.

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A. For your safety Hazards while working on the high-pressure module Maintenance works may only be carried out by: n customer service agents approved by the manufacturer. n authorised skilled persons.

! Hazard! n Injury 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. n Electric 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! n Never touch electric cables, plug-in connections and terminal boxes if your hands are wet. n Electrical 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. n The water jet of mobile cleaning units (e.g. high-pressure cleaners) must never be pointed at electrical units or systems. n All parts within the working area that conduct electricity must be protected against water jets and sprays. n Systems may only be connected to properly grounded electricity sources. n Any work on electrical parts of the facility may only be carried out by a qualified electrician.

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A. For your safety 4. Hazards due to the accessories The high-pressure module is the component of downstream high-pressure cleaning equipment. Apart from the safety information given here, you must also observe the safety information for the high-pressure cleaning equipment.

! Hazard! n Poisoning 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. n Health 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 downstream equipment. The high-pressure water is distributed via a fixed-installation pipeline.

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A. For your safety i Important! Only use clean water as the high-pressure medium. Soiling leads to premature wear or deposits.

Water quality requirements:

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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.

5.961-163 A 2006087 (09/03) A5 English Operating instructions HD 9000 E USA

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 machine must be clearly specified and observed. Unclear accountabilities are a safety risk. The owner/operator must: n provide the machine operator with access to the operating instructions. n ensure that the machine operator has read and under- stood them.

9. Safety measures at the place of installation

! Hazard! n The high-pressure module must be installed in a stable way on a level and firm ground.

10. Safety installations n The system is shutdown by the EMERGENCY STOP switch or the master switch of the high-pressure cleaning equipment. n Overpressure escapes via a pneumatically operated ball valve.

11. Emergency procedures n Press the emergency stop button n Set the master switch to the „0“ position. n Shut off the water supply n Release pressure

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A. For your safety 12. Guidelines and regulations n The „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 commercial 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. n Comply with the Hazardous Materials Regulations (Gef Stoff V) when handling cleaning agents. n Please also observe any local regulations concerning electrical connections, water and wastewater connection. These regulations can be obtained from the utility supply companies. n Connection works may only be carried out by Kärcher’s customer service personnel or authorised skilled persons and compliance with these regulations.

5.961-163 A 2006087 (09/03) A7 English Operating instructions HD 9000 E USA

B. Design and function 1. Design

Figure B.1 Front view 1 Bypass valve 2 Low-pressure hoses 3 Low-pressure inlet 4 Cooling water inlet

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B. Design and function

Figure B.2 Rear view 1 Terminal box 9.1 High-pressure solenoid valve 2 High-pressure pump 1 underbody wash (optional) 3 High-pressure pump 2 9.2 High-pressure solenoid valve gantry 4 High pressure feed gantry 10 High-pressure pump hoses 5 High pressure feed 11 High-pressure water manometer underbody wash 12 High-pressure pressure switch 6 Pulsation damper 13 Pushbutton for manually switching the 7 Frost protection supply gantry (optional) solenoid valve 8 Frost protection supply underbody wash (optional)

5.961-163 A 2006087 (09/03) B2 English Operating instructions HD 9000 E USA

B. Design and function 2. Flow diagram of water cycle

Figure B.3 Flow diagram of water cycle 1 „Motor cooling“ solenoid valve 10 High-pressure non-return valve 2 Pressure regulator 11 High-pressure manometer 3 Cooling water inlet 12 Pressure switch 4 Water inlet (tank) 13 High-pressure outlet 5 Overflow 14 Vibration damper 6 „Water inlet“ float valve 15 Safety valve 7 Storage tank 16 High-pressure pump 1 8 Level probe 17 High-pressure pump 2 9 „Bypass“ solenoid valve

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B. Design and function 3. Overall flow diagram

Figure B.4 Overall flow diagram Non-return valve 1 High-pressure outlet V Shut-off valve underbody wash Y Solenoid valve 2 High-pressure outlet gantry no normally open 4 Frost protection inlet nc normally closed FW Water supply flow diagram SV Float valve

5.961-163 A 2006087 (09/03) B4 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

234

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)

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B. Design and function 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 operating pressure, the pressure switch (12, Figure B.3) swit- ches off. The safety valves (15, Figure B.3) provide additional safety.

5.961-163 A 2006087 (09/03) B6 English Operating instructions HD 9000 E USA

B. Design and function 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.

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C. Operation This high-pressure module is provided as a component of downstream high-pressure cleaning equipment. Therefore, it can only be started up within this installation. The water is taken from a downstream storage tank provided on site. The electricity is supplied via an electric distributor. An EMERGENCY STOP switch and a master switch are loca- ted on this distributor. The electrical connection to the electricity network is provided on site.

1. Switching off in emergencies n Press the emergency stop button n Set the master switch to the „0“ position. n Shut off the water supply n Release pressure

2. Initial operation n Open the water supply n Set the master switch to the „I“ position. System is ready to run.

3. Operation

5.961-163 A 2006087 (09/03) C1 English Operating instructions HD 9000 E USA

C. Operation n Health hazard due to cleaning agent. The water given off by the module is not drinking water quality due to the cleaning agents added. n Burns hazard due to hot system parts. Do not touch any non-insulated pipes and hose cou- plings when running the system with hot water. n Injury 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. n Explosion hazard. This high-pressure module must not be run in potentially explosive rooms. n Explosion 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.

The high-pressure module is operated and controlled externally from an operating panel. This operating panel is also part of the downstream high-pressure cleaning equipment (central control unit). The system’s internal controls are secondary to the central controls on site and performs the following tasks: – Supply to the high-pressure pumps. – Protection against overload and short-circuit. – Staggered pump startup (to prevent current peaks during start up). – Evaluation of the control inputs.

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C. Operation 4. Shut-down procedures n Set the master switch to the „0“ position. n Shut off the water supply n Release pressure

5. Frost protection The parts carrying water must be protected against frost, as they can otherwise be destroyed. If the high-pressure module is to be operated during frosty periods, it must be installed in a frost-free location. Outdoorwater pipes must be frost proof (e.g. insulation and steam tracing) or must be drained during the frost period.

6. Shutdown If the high-pressure module is to be shutdown during the frost period, it has to be flushed with an anti-freeze solution first. Anti-freeze solutions generally protect against corrosion at the same time.

5.961-163 A 2006087 (09/03) C3 English Operating instructions HD 9000 E USA

D. Technical specifications

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D1 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

D. Technical specifications

Low-pressure inlet G2" High-pressure outlet G1" with M 30 x 1.5 fitting

5.961-163 A 2006087 (09/03) D2 English Operating instructions HD 9000 E USA

E. Maintenance 1. Maintenance instructions The basis of safe operation of the high-pressure module is its regular maintenance according to the following maintenance schedule.

Only use the manufacturer’s original spare parts or parts recommended by them like n Spare and wearing parts, n Accessories, n Resources and consumables, n Cleaning agents.

! Hazard! Accident hazard while working on the high-pressure module Before starting any work n Turn off the water supply, to do this close off the water faucet . n Injury hazard due to due to escaping, possibly hot water jet. Release the pressure before carrying out any work on the high-pressure module. n Electric shock hazard! Before carrying out any work on the high-pressure module, switch off and secure the master switch.

Who is allowed to carry out maintenance work? n Owner/operator Works with the note „Operator“, may only be carried out by persons who have received the necessary instruction, who can safely operate and maintain the high-pressure system. n Customer service Works with the note „Customer Service“, may only be carried out by Kärcher’s customer service fitters.

Maintenance contract In order to guarantee reliable operation of the high-pressure module, we recommend you conclude a maintenance contract. Please contact the Kärcher customer service department responsible for you.

E1 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

E. Maintenance 2. Manual controls For your own safety and the safety of others, the high- pressure module must be switched off before service and maintenance works are carried out. However, not all the parts of the system to be serviced are easily accessible. This makes it necessary to move certain parts during the service and maintenance works. For this reason the operating mode „manual control“ is provided. The manual control is selected using the manual unit in the central controls of the downstream high- pressure cleaning equipment. Please refer to the „Mainte- nance“ section in the operating instruction for this high- pressure cleaning equipment about selecting this type of operation.

Manual controls/ water/ pumps

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5.961-163 A 2006087 (09/03) E2 English Operating instructions HD 9000 E USA

E. Maintenance 3. General maintenance schedule

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E3 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

E. Maintenance

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5.961-163 A 2006087 (09/03) E4 English Operating instructions HD 9000 E USA

E. Maintenance

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Figure E.1 Bypass valve

E5 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

E. Maintenance 4. Oil change

! Hazard! Burns hazard due to hot oil and hot system parts. Leave the pump to cool for 15 minutes before changing the oil.

i 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.

Oil grade and quantity: See technical specifications. Figure E.3 Oil change The oil change must be carried out as follows for each pump: n High-pressure pump Keep a collection container for waste oil available. n Check the oil level at the pump. n Screw out the oil drain plug (3) and collect the waste oil. n Screw in the oil drain plug (3). n Slowly pour in the new oil up to the mark on the oil level indicator (2). n Hand in the waste oil to the collection points provided.

5.961-163 A 2006087 (09/03) E6 English Operating instructions HD 9000 E USA

E. Maintenance 5. Descaling

! Hazard! Explosion hazard due to combustible gases! Smoking prohibited during descaling. Ensure good ventilation.

Caution! Caustic burns hazard due to acids! Wear safety goggles and protective gloves.

Scale deposits in the water system of the high-pressure module lead to larger pipe resistances and possibly to the failure of calcified components. According to the statutory provisions, only tested boiler cleaning compounds (descaling acid) with a test mark may be used for descaling. The high-pressure system should preferably be descaled using KÄRCHER descaler (RM 100 ASF, free of hydrochloric acid, Part No. 6.287-008 or RM 101 ASF, contains hydrochloric acid, Part No. 6.287-013). These agents are compatible with the materials used in the system. After descaling, we recommend flushing through the high-pressure module with an alkali solution to neutralize the acid residues (pH value 7–8). Comply with the instructions for use and the accident prevention regulations (concentrations according to the information given on the container label), above all VBG1, Art. 4, 14, 44–47.

Procedure Descaling the high-pressure system: Lift up the high-pressure hose at the system infeed and hang it in the storage tank. Run for a short time in circula- tion mode with the descaling acid prepared in the container, leave to take effect, rinse.

Descaling the pump motor cooling coil If the cooling water flow rate falls below approx. 300 l/h, despite adequate water precharge pressure and a clean strainer in the pressure reducing valve, the cooling coil must be descaled.

Close the cooling water inlet. Pull off the water hose at the solenoid valve and hang it in a collection container. Pull off the cooling water hose at the storage tank, hang it up and pour in the descaling agent and flush through several times.

E7 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

F. Troubleshooting Fault messages are transmitted to the external central controls and are evaluated there (see operating instructions for the downstream high-pressure cleaning equipment). Faults can also be identified at the high-pressure module, e.g. due to an incorrect display at a manometer or due to loud noises/large vibrations in a pump.

! Hazard! Accident hazards while working on the high-pressure module Before carrying out any work n Turn off the water supply, to do this close off the water faucet n Injury hazard due to escaping, possibly hot water jet. Release the pressure and wait for the high-pressure module to cool before carrying out any work on it. n Electric shock hazard. Switch off and secure the master switch on the high- pressure module before starting any work.

1. Who can remedy the faults? Faults, which are not listed in the following tables may only be remedied by the customer service.

n Owner/operator Works with the note „Operator“, may only be carried out by persons who have received the necessary instruction, who can safely operate and maintain the high-pressure system.

n Electricians Works with the note „Qualified Electrician“ may only be carried out by people who have completed professio- nal or vocational training in electrical engineering, or as a skilled electrician.

n Customer service Works with the note „Customer Service“, may only be carried out by Kärcher’s customer service fitters.

5.961-163 A 2006087 (09/03) F1 English Operating instructions HD 9000 E USA

F. Troubleshooting 2. Faults in the mechanisms

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F2 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

G. Accessories Cleaning agent Cleaning agents make the cleaning tasks easier. The table lists a selection of cleaning agents. Always read the information on the packaging and observe the local regulations before using cleaning agents.

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The following types of cleaning agents are not permitted to be used on or in this high-pressure module: n Cleaning agents containing azotic acid (nitric acid) n Cleaning agents containing active chlorine. Use of such cleaning agents damages the high-pressure module.

5.961-163 A 2006087 (09/03) G1 English Operating instructions HD 9000 E USA

H. System installation ONLY FOR ! Hazard! AUTHORISED Dangerous voltage! QUALIFIED PERSONNEL The electrical installation may only be carried out be a qualified electrician and according to the local valid regulations, in Germany these are the VDE regulations. Electric shock hazard! – Systems may only be connected to properly grounded electricity sources. – All parts within the working area that conduct electricity must be protected against water jets and sprays.

Environmental hazard due to waste water The local waste water disposal regulations must be observed.

Poisoning or injury hazard due to cleaning agent! Protective measures are to be taken when handling cleaning agent concentrates containing substances harmful to health. In particular, safety goggles, protective gloves and protective clothing must be worn. Observe the information leaflets supplied with the cleaning agent and the local regulations. Keep cleaning agents out of reach of unauthorized persons.

i Important! When connecting the high-pressure module to the drinking water network, observe the local network disconnec- tion regulations. In Germany, these are the DVGW regulations, especially DIN 1988 and the guidelines of the VDMA leaflet 24416 „Fixed installation high-pressure cleaning systems“.

ONLY FOR AUTHORISED QUALIFIED PERSONNEL

H1 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

H. System installation 1. Installation ONLY FOR The high-pressure module must be installed in a stable AUTHORISED way on a level and firm ground. The system should be QUALIFIED PERSONNEL installed in a dry, non potentially explosive environment. It should be installed on firm and level ground. The high- pressure module must be easily accessible for maintenance works. The room temperature must not exceed 40°C. Using the 140 mm long unit feet makes maintenance easier. If there is a lack of space, the elastic feet can be used on their own.

2. Connections The water supply and electricity connection required must be designed for continuous operation. The specified connected loads are given in the technical specifications. The water supply line is to be fitted with a shut-off fitting and must be flexibly connected with a pressure hose to the high-pressure module. Insufficient water is supplied if the pipe cross-section is too small or the precharge pressure too low. To prevent damage to pumps, insufficient water leads to the shutdown of the high-pressure module. If the precharge pressure or the pressure peaks in the pipe system are too high, it is important to install an upstream pressure reducing valve. An additional cold water connection is required for the motor cooling of the high-pressure pump. There must be a water connection at the place of installation. The electrical connection is made at the terminal box. The internal controls are connected from the central controls of the downstream high-pressure cleaning equipment.

ONLY FOR AUTHORISED QUALIFIED PERSONNEL

5.961-163 A 2006087 (09/03) H2 English Operating instructions HD 9000 E USA

H. System installation 3. High-pressure installation ONLY FOR The connection between the fixed installation pipeline and AUTHORISED the system is to be made as a high-pressure hose line. QUALIFIED PERSONNEL The fixed installation pipeline must be laid as straight as possible.High-pressure pipes are to be laidin accordance with the regulations and, taking into consideration the change in length due to heat and pressure effects, with damped loose and fixed clamps. The following recommendations should be adhered to, in order to keep the pressure losses in the high-pressure lines as low as possible:

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1"h/l0000 19¾x 1NDx1

When using the aforementioned guideline values, an allowance must of course be made for the length of the pipe and the number of changes in direction and fittings.

4. Water hardness Excessive water hardness (>15° dH) can lead to deposits and malfunctions. Use a descaler mounting kit if the water hardness is higher.

5. Preparations for the initial startup n Flush the pipeline on site. Check the whole high- pressure system for correct installation and leaks. n Install the electrical connection according to the technical specifications in the operating instructions . n Check the function of the scale inhibitor equipment, if required. n Check the water inlet for the required supply rate and permissible temperature. n Set the cooling water flow rate for the high-pressure pumps (see „Technical Specifications“, connected loads) at the adjusting wheel (a) of the pressure regulator. Tighten the locking screw (b). n Install the overflow drainage for the storage tank. Figure H.1 Adjusting wheel of the pressure regulator

ONLY FOR AUTHORISED QUALIFIED PERSONNEL

H3 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

H. System installation ONLY FOR AUTHORISED QUALIFIED PERSONNEL

n Check the oil level at the high-pressure pumps: Remove the sealing plug (C) at the oil tank. n Check the rotational direction of the precharge pressure pumps (only for hot water systems).

Figure H.2 High-pressure pump

ONLY FOR AUTHORISED QUALIFIED PERSONNEL

5.961-163 A 2006087 (09/03) H4 English Operating instructions HD 9000 E USA

H. System installation 6. Installation plan ONLY FOR AUTHORISED QUALIFIED PERSONNEL

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ONLY FOR AUTHORISED QUALIFIED PERSONNEL

H5 5.961-163 A 2006087 (09/03) HD 9000 E USA Operating instructions English

I. Customer service

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5.961-163 A 2006087 (09/03) I1