HDS 2000 Super
5.956-535 A 2009680 (11/04)
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HDS 2000 Super
GB
1. Diagram of the appliance
1 Summary of operating instructions
18 Service/fault indicator window
2 Cover flap for storage compartment
3 Instrument panel
4 Water inlet
5 Swivel caster with parking brake
6 High-pressure outlet (x 2)
7 High-pressure nozzle
8 Unit cover lock
19 Filler hole for liquid softener
20 Filler hole for detergents (x 2)
21 Warning light – SERVICE
22 Warning light – FAULT
23 Unit main switch
24 Temperature regulator
25 Indicator light – FUEL
9 Unit cover
10 Spray lance
26 Indicator light – LIQUID SOFTENER
27 Indicator light – DETERGENT
28 Warning light – INCORRECT MOTOR
ROTATION, reverse polarity of power
supply
11 Pressure and flow control
(Servopress)
12 Spraying handgun with high-pressure hose
12a Safety catch of hand-held spray gun
13 Push handle
29 Pressure gauge
30 Detergent metering valve
31 ON/OFF switch for automatic detergent
control (AUTO-CHEM)
14 Power supply connection with polarity-
reversing plug
15 Support rails for use with forklift
16 Fuel tank inlet
32 Indicator light – detergent supply for
AUTO-CHEM
17 Storage compartment for accessories
17
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2. Flow-path schematic
1 Water inlet
20 Vibration damper
21 Continuous-flow heater
22 Burner blower
23 Fuel pump
2 Water cooling, motor 1
3 Water cooling, motor 2
4 Water filter
5 Float tank 1
24 Low-fuel valve
6 Liquid softener reservoir (DGT)
7 Solenoid valve, DGT
8 Float tank 2
9 High-pressure pump 1
10 High-pressure pump 2
11 Overflow valve
25 Flame monitor
26 Fuel tank
27 Temperature regulator
28 Sealing cap for high-pressure outlet 2
29 Spraying handgun
30 High-pressure nozzle
12 Pressure switch, 10 bar
13 Non-return valve
14 Pressure switch, 30 bar
15 Pressure switch, 100 bar
16 Vibration damper
31 Dual detergent metering valve
32 Detergent solenoid valve 1
33 Detergent solenoid valve 2
34 Detergent level sensor 1 with filter
35 Detergent level sensor 2 with filter
36 Detergent reservoir 1
17 Pressure gauge
18 Safety valve
37 Detergent reservoir 2
19 Low-water safety device
18
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3. Technical Data
1.071-111
1.071-261
1.071-281
Power connection
Voltage
Type of current
Connected load
Mains fuse (slow)
400 V
3~50 Hz
12 kW
25 A
230 V
3~50 Hz
12 kW
50 A
420 V
3~50 Hz
12 kW
25 A
Water connection
Supply temperature (max.)
30 °C
Supply rate (min.)
2000 l/h
(33,3 l/min)
Suction height fom open tank
at a water temperature of 20 °C
0,5 m
Performance data
Operating pressure
3-18 MPa (30–180 bar)
Flow rate
Operating temperature (max.)
Detergent intake
850–1800 l/h
140/80 °C
(14,2-30 l/min)
0–50 l/h
140 kW
(0-0,8 l/min)
Burner capacity
Recoil force of hand-held spray gun
at operating pressure (max.)
92 N
Noise emission
Sound pressure level (EN 60704-1)
75 dB(A)
Garanteed sound power level (2000/14/EC)
90 dB(A)
Machine vibration
Rated vibration value (ISO 5349)
Handgun
m/s²
m/s²
Spray lance
Dimensions
Length
Width
Height
1500 mm
834 mm
1015 mm
280 kg
25 l
Weight without accessories
Fuel tank
Fuel
EL fuel oil or diesel
Detergent tank
Pump oil quantity
Pump oil type (order no. 6.288-016)
2x 25 l
2x 0,75 l
Hypoid SAE 90
19
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4. Start-up
• Check the oil level in the oil tank. Do not start
4.1 Environmental protection
the appliance if the oil level has dropped
below “MIN”. Top up the oil as required (see
tech. data, chap. 3).
• Pleasedisposeofpackagingenvironmentally
responsibly.
The packaging materials are recyclable.
Please do not throw the packaging in with
household rubbish but take it to a recycling
centre.
4.5 Pouring in the fuel
• The appliance is delivered with an empty fuel
tank.
• Fill the fuel tank with diesel or a light fuel oil
before the initial start-up.
– When the fuel tank is empty, the fuel
pump will operate dry and will be
damaged.
– Unsuitable fuels must not be used,
e.g. petrol (danger of explosion).
• Please dispose of scrapped units
environmentally-responsibly.
Scrappedunitsconsistofvaluablerecyclable
materials that should be taken to a recycling
centre. Batteries, oil and similar products
must not be allowed to contaminate the
environment. Therefore, please dispose of
scrapped units via appropriate disposal
systems.
4.6 Pouring in the liquid softener
• The liquid softener prevents the heating
element from becoming calcified when
operating with hard supply water. The liquid
softener is added in drops to the supply water
in the water tank. The metering is set to an
average value at the factoy. This setting may
be adjusted to local conditions by customer
service.
• Please ensure engine oil, fuel oil, diesel and
petrol
to contaminate the environment. Please
protect the ground and dispose of used oil
ecologically.
• Pour the RM 110 liquid softener (included in
standard delivery) into the filling orifice of the
white tank.
4.2 Unpacking the appliance
• Please contact your dealer immediately if, on
unpackingtheappliance,youdiscoverdamage
has been caused during trans-portation.
• You can also work without liquid softener
whenoperatingwithsoftwater,e.g.rainwater.
In this case you should remove the small (!)
cover from the white tank and place the
supplied spring underneath on the cover
support.Thenreplacethecover.Thisprevents
theindicatorlightontheinstrumentpanelfrom
continually flashing. This spring must be
removed when operating with supply water.
4.3 Attaching the accessories
• Attach the two handles to the appliance.
• Fitthespraylancetothehand-heldspraygun
with pressure flow control.
• Connectthehigh-pressurehoseaccordingly.
• Attach the high-pressure nozzle to the spray
lance.
• Tighten all union nuts hand-tight.
4.4 Checking the oil level of the
high-pressure pump
• Before the initial start-up, open the appliance
hood and cut the tip off the oil tank cover
(venting the oil housing).
20
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4. Start-up
4.7 Connecting the water
4.9 Intended use
• See technical data, chap. 3 for connected
• Use the appliance to clean machines,
loads.
vehicles, buildings, tools, etc.
• Attachthesupplyhosetotheapplianceandto
thewaterline.Thesupplyhoseisnotincluded
in standard delivery.
• Clean facades, patios, garden implements,
etc. with the high-pressure spray only, i.e.
without detergent. We recommend the dirt
blaster, a special accessory, for stubborn
dirt.
• If you draw in the water from an open tank,
you should
• If the machine is used at petrol stations or in
otherhazardousareas,theappropriatesafety
regulations must be observed.
– disconnectthewatersupplyfromthepump
head
– unscrew the upper supply hose from the
water tank and connect to the pump head.
• Pleaseensurewastewatercontainingmineral
oil
– use a water supply hose which has a
minimum diameter of 3/4" and a suction
filter.
does not contaminate soil, lakes and rivers or
theseweragesystem.Therefore,pleasewash
engines and underbodies only in appropriate
washing installations provided with oil traps.
• Until the pump has drawn in the water, you
should:
– rotate the pressure and volume control to
“MAX”,
– close the detergent metering valve.
4.8 Connecting the power
• See technical data, chap. 3 for connected
loads.
• The voltage stated on the rating plate must
correspondtothevoltageofthepowersource.
• First, position the appliance switch to “STOP”
and then put the electric plug into the socket.
• If the motor rotates in the wrong direction, the
electronic control circuit will switch the motor
off after a few seconds. The INCORRECT
MOTORROTATIONwarninglightilluminates.
Disconnect the power input plug. This plug is
equipped with a device for reversing polarity.
Apply a screwdriver at the prescribed point,
press it inwards and rotate both terminals
through 180°.
Attach the power input plug again.
• If you are using an extension lead, it should
alwaysbecompletelyunwoundfromthecable
drum and have an adequate cross-section.
Mains voltage
230 V
10 m
30 m
6 mm²
10 mm²
400 V
4 mm²
6 mm²
21
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5. Operation
5.1 Venting the appliance
5.3 Adjusting the Operating Pressure
and Flow Rate
• Open the water intake.
• Allow the appliance to run without the high-
pressurehoseuntilthewateremergeswithout
bubbles.
With the servo pressure valve on the hand spray
gun
– Adjust operating pressure and flow rate
(+/–) by rotating the pressure/flow control
(infinitely variable).
• Then connect the high-pressure hose.
• If the spray lance and high-pressure nozzle
have already been fitted to the high-pressure
hose, you can vent the appliance as follows:
With the hand-held spray gun open, switch
the appliance on and off several times at
intervalsof10secondsuntilthewateremerges
fromthehigh-pressurehosewithoutbubbles.
The two pumps are switched in and out via
pressure switches depending on the demand for
water.
5.4 Operating with cold water
• Switch the appliance switch to “ ”.
5.2 High-pressure nozzle
• The effectiveness of the high-pressure jet
depends to a great extent on the spray angle.
A 25° fan jet nozzle is usually employed
(included in standard delivery).
5.5 Operating with hot water
• Setthethermostattothedesiredtemperature.
• We recommend the following cleaning
temperatures:
• Other nozzles are available as accessories.
0° full jet nozzle
30–50 °C for light dirt
max. 60 °C for dirt which contains protein,
e.g. in the food industry
for stubborn dirt.
40° fan jet nozzle
60–90 °C for cleaning vehicles, machines
for sensitive surfaces.
Dirt blaster
• Switch the appliance switch to “
”.
• If you also increase the operating pressure
and flow rate, you also change the water
temperature.
for thick layers of dirt.
Variable angle nozzle
with adjustable spray angle
• At first always direct the high-pressure jet
from a greater distance at the object which is
to be cleaned, thereby preventing damage
from excessive pressure.
22
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5. Operation
5.6 Operating with steam
5.8 Operating with detergent
• When operating temperatures are above
98°C,theoperatingpressuremustnotexceed
32 bar. Thus, the standard high-pressure
nozzle must be replaced by a steam nozzle
(available as an accessory).
• Fill the detergent tank.
• This unit is equipped with an automatic
detergent control system. The automatic
control can be switched on or off by means of
a toggle switch on the instrument panel.
• Adjust the thermostat to the desired tem-
perature.
• We recommend the following cleaning
5.8.1 Manual detergent control
temperatures:
• The toggle switch for automatic detergent
100–110 °C fordepreservation,dirtcontaining
high levels of grease
control (AUTO-CHEM) must be set to “ 0 “.
• Adjust the detergent metering valve for the
required concentration and source of
detergent, Chem l or Chem ll.
up to 140 °C for thawing aggregates, partial
cleaning of facades.
When the handgun is opened, the high-
pressure pumps are switched on and
detergent is added to the water.
• Rotate the pressure and volume control on
the pump head to the lowest value.
• When you have finished operating the
appliance with steam, you should adjust the
appliance switch to the “ ” symbol, and run
the appliance for approx. 2 minutes with the
gun open to allow it to cool down.
5.8.2 Automatic detergent control
(AUTO-CHEM)
1. Set the toggle switch for automatic detergent
control (AUTO-CHEM) to “ l “.
2. Adjust the detergent metering valve for the
required concentration and source of
detergent, Chem l or Chem ll.
5.7 Operating with two handguns
• The unit has two high-pressure outlets, to
which it is possible to connect two hand-held
spray guns.
3. Openthehandgun.Thehigh-pressurepumps
start up. If required, detergent can be added
to the water as follows:
• Unscrew the blanking plug from the second
high-pressure outlet and connect another
handgun via a high-pressure hose
(accessories).
4. Close the handgun.
5. Open the handgun again immediately after it
has been closed (within a max. of 3 sec.)
• The high-pressure nozzle suitable for use
with one handgun should be replaced with
two nozzles (Nozzle size 25052)
The yellow indicator lamp next to the toggle
switch illuminates to show that detergent
metering has been switched on.
• The two pumps are switched in and out via
pressure switches depending on the demand
for water.
– If the handgun remains closed for longer
than 3 seconds before it is opened again,
no detergent is added to the water.
6. Whenthehandgunisclosedagain,thesupply
of detergent is automatically switched off.
The yellow indicator light extinguishes.
If detergent is required once more, repeat the
procedure outlined in paras. 3, 4, 5, and 6.
23
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HDS 2000 Super
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5. Operation
• In order to protect the environment, we
recommend that detergent is used sparingly.
Comply with the metering recommendation
on the detergent container label.
5.9 Interrupting operation
• If you release the trigger of the hand-held
spray gun, the appliance switches off. If the
triggerispulledagain, theapplianceswitches
on again.
• We offer an individual range of detergents
and preservatives and therefore guarantee
trouble-free operation. Please ask for advice,
or request our catalogue or detergent
information leaflets.
• If operation is interrupted for more than 30
minutes,theappliancewillnotswitchonwhen
the trigger is pulled (safety shutdown).
• No maintenance/ fault message appears in
the display window. The appliance is ready to
use again if you switch the appliance switch
off and then on again.
Only those detergents may be used which
have been authorized by the manufacturer of
the appliance.
Unsuitable detergents can damage the
appliance and the object which is to be
cleaned.
5.10 Switching off the appliance
• We recommend the following cleaning
method:
Warning!
Danger of scalding with hot water.
After operating it with hot water or steam the unit
must be cooled for at least two minutes by
operatingitwithcoldwateranditsopenhandgun.
Step 1: Loosening the dirt
Spray on detergent sparingly and allow to
react for 1–5 minutes.
Step 2: Removing the dirt
Spray off the dissolved dirt with the high-
pressure jet.
• Switch the appliance off and pull the electric
plug out of the socket.
• When you have finished working with
detergent, you should set the detergent
metering valve to “0” and rinse the appliance
thoroughly with the gun open for approx.
1 minute.
• Close the water intake.
• Pull the gun trigger until the appliance is
depressurized.
• Securetheguntriggerwiththesafetycatchto
prevent the gun from accidentally opening.
24
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6. Care and maintenance
6.1 SERVICE warning light is
illuminated
Always disconnect the appliance from
the electric mains supply before carrying
out any maintenance work.
• Ifcertainmaintenanceworkisrequiredonthe
basisofelapsedoperatinghours,thiswarning
lightilluminates.
• You can arrange a regular safety inspection
with your dealer or take out a maintenance
contract. Please ask for advice.
• Contact
your
Customer
Service
representative and arrange for maintenance
to be carried out.
Required Maintenance Work
– Optical inspection
– Check high-pressure connections for leaks
– Clean fuel tank and filter
– Check pump for leaks
– Change pump oil
– Clean strainer in water inlet on both float tanks
– Clean strainer before the low-water safety device
– Decarbonize heater element*
– Descale heater element*
– Clean/replace ignition electrodes*
– Clean/replace Burner nozzles*
– Adjust burner*
– Check pump overflow valve for leaks*
– Check high-pressure hose*
– Clean hand spray gun
– Check pressure damper*
* These maintenance tasks should be carried out by the Customer Service only.
25
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6. Care and maintenance
• When the oil has completely drained, screw
6.2 Visual Inspection
the oil drain plug back in and slowly pour in oil
up to the “MAX” position on the oil tank (air
bubbles must escape).
• Checking the connector cable
The connector cable must not be damaged
(risk of electricution). A damaged connector
cable must be replaced immediately by an
authorized Customer Service/qualified elec-
trician.
• See technical data, chapter 3 for quantity and
type of oil.
• Check the high-pressure hose
6.6 Cleaning the Strainer Upstream of
the Low-water Safety Device
Thehigh-pressurehosemustnotbedamaged
(risk of bursting). A damaged high-pressure
hose must be replaced immediately.
• Unscrew the high-pressure hose from the
pump head at the safety block.
• Rotate an M8 screw into the strainer hole and
use it to pull the strainer out.
6.3 Cleaning the fuel Tank
• Remove the tank from the appliance (first
unscrewthehandle,appliancehoodandcover
from the switch box).
6.7 Protection from frost
• Frost will damage the appliance if it is not
drained completely of water. In winter the
appliance should be kept in a room which is
above freezing point. Otherwise, it is
recommended to drain the appliance or rinse
it thoroughly with anti-freeze.
• Dispose of the remaining fuel.
• Rinse out the tank thoroughly. If you rinse out
the tank with water, allow it to dry completely.
• Replace the fuel filter.
• Draining the appliance
6.4 Pump leaks
– Unscrew the water intake hose and high-
pressure hose from the appliance.
• 3 drops per minute are permissible. You
shouldcontactcustomerserviceiftheleakage
is more rapid.
– Unscrew the supply line from the base of
the boiler and allow the heating element to
drain.
– Allow the appliance to run for a max. of
1 minute until the pump and the lines have
drained.
6.5 Changing the oil
• If the oil is milky (water in the oil), contact
• Anti-freeze
customer service immediately.
During extended down-time periods, it is
recommendedtopumpananti-freezethrough
theappliance.Thisalsoprotectstheappliance
to a certain degree from corrosion.
• Unscrew the oil drain plug and dispose of the
old oil via an authorized collecting point
(protection of the environment).
• Observe the following if the unit is connected
to a flue:
Dangerofdamagecausedbycoldairentering
through the flue. Disconnect unit from flue at
outside temperatures below 0°C.
26
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7. Troubleshooting
7.1 FAULT warning light is illuminated
Always disconnect the appliance from
the electric mains supply before carrying
out any repair work.
• Thiswarninglightilluminatesifthereisafault.
• When you open the storage compartment
cover flap, you will see the electronic display
in the view window.
• The warning light extinguishes when you
have corrected the fault and switched the
appliance back on.
Display
Corrective Action
p
I
– Increase water supply volume
– Clean strainer in water connection
– Clean strainer before the low-water safety device
p
P
– Replace the reed switch of the low-water safety device*
– Clean the low-water safety device*
p
p
Q
R
– Repair leak in the high-pressure system
– Decarbonize heater element*
– Readjust burner*
– Replace exhaust gas thermostat*
p
p
S
T
– Check fuses and voltage on all 3 phases.*
– Replace air pressure switch*
– Check amount of fuel in tank
– Check that burner is functioning correctly*
– Check fuel nozzle, ignition electrodes and ignition cable,
and replace if required*
– Clean burner*
– Motor overload
p
U
– Winding thermo-protection or thermal relay has triggered
– Remove cause of motor overload
* These faults should be corrected by Customer Service or a qualified electrician only.
27
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7. Troubleshooting
7.2 Indicator lights
7.5 Detergent is not being drawn in
• Clean the detergent suction hose and filter.
• Clean the metering valve for cleaning agent.
• Indicator light for fuel tank lights up
– Refill with fuel.
– Check that the fuel level sensor is
functioning correctly.
• Clean the non-return valve on the pump head
and the connection for the detergent suction
hose.
• Indicator light for liquid softener lights up
• Checkallthedetergenthosesandconnections
– Refill with RM 110 liquid softener.
for leaks.
– Clean the electrodes in the liquid softener
tank.
• Checkwhetherthedetergentsolenoidvalves
have opened.
• If warning light for detergent illuminates
– Refill with detergent.
• Indicator light for incorrect motor rotation
7.6 Burner does not ignite
illuminates
• The ignition sparks can be observed through
the inspection window in the burner cover.
The appliance has a continuous ignition., i.e.
even when operating with cold water an
ignition spark must be visible. Clean, adjust
or replace the ignition electrodes as required.
– See chapter 4.7.
7.3 The appliance does not come up to
pressure
– Fill the fuel tank.
• Fill the detergent tank or set the metering
– Check that the fuel pump and the fuel
solenoid valve function correctly.
valve to zero.
• Vent the appliance (see Operation, chap. 5).
– Clean the strainer in the low-water safety
device.
• Clean strainer in water inlet on both float
tanks.
– Change the fuel filter.
• Checkthewaterintakevolume(seetechnical
– Clean the sensor for the electronic flame
monitor.
data, chap. 3).
• Check all the supply lines to the pump for
leaks and blockages.
7.7 The temperature is not reached
when operating with hot water/steam
7.4 The pump is knocking
• Set the thermostat higher.
• Check all the supply lines to the pump, also
• Reduce the operating pressure and the flow
thedetergentsystem,forleaksandblockages.
rate.
• Vent the appliance (see Operation, chap. 5).
28
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8. General Information
8.1 Safety equipment
8.3 Spare parts
Overflow valve with 2 pressure switches
Please note that the use of other than Kärcher
spare parts can result in damage and even
serious accidents if these parts have not been
correctly manufactured, if they do not replace
the Kärcher spare part exactly or if they result in
unsafe operation of the appliance.
When the water flow rate is reduced with the
servocompressionvalveonthehand-heldspray
gun or with the flow regulator on the pump head,
the overflow valve opens and some of the water
flows back to the pump suction side.
Kärchersparepartsguaranteethattheappliance
can be operated safely and trouble-free.
Iftheguniscompletelyclosed,enablingallofthe
water to flow back to the pump suction side, the
pressure switch located on the overflow valve
switches off the pump.
A selection of the most common spare-part
numbers are listed at the end of these operating
instructions.
If the hand-held spray gun is opened again, the
pressure switch located on the cylinder head
switches on the pump again. The overflow valve
is set and lead-sealed at the factory.
8.4 Guarantee
Thetermsofguaranteeissuedbyourcompetent
distribution company are valid in every country.
If the appliance malfunctions in any way, we
shall rectify the fault free of charge within the
period of guarantee, provided the cause can be
attributed to faulty material or a manufacturing
error.
Adjustmentsmustonlybecarriedoutbycustomer
service.
Safety valve
Thesafetyvalveopenswhenthepressureswitch
is defective. The safety valve is set and lead-
sealed at the factory. Adjustments may only be
carried out by customer service.
The guarantee will only come into force when
your dealer has completely filled out, stamped
andsignedtheenclosedreplycardoncompletion
of sale and when you have sent the reply card to
the distribution company in your country.
Low-water safety device
Thelow-watersafetydevicepreventstheburner
from switching on when the water is low. A
strainer prevents the safety device from
becoming fouled and must be cleaned regularly.
In the event of a claim on the guarantee, please
consult your dealer with accessories and receipt
of purchase or contact your nearest authorized
customer service centre.
8.2 Accessories
Incorrect, badly fitting or defective accessories
impair the function of the appliance and are
dangerous. It is advisable to use Kärcher
accessories which are made-to-order. Your
dealer will be glad to advise you.
29
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