HDS 1000 DE - Endress & Reiser

5.959-083 06/01
HDS 1000 DE

E N G L I S H
Contents
I. Technical data ..................... 4
II. Important notes ................... 6
III. Operation ............................ 8
IV. Application .......................... 9
V. Care and maintenance...... 10
VI. Trouble shooting................ 12
VII. General Notes ................... 14
VIII. Spare parts list .................. 15
HDS 1000 DE
3

HDS 1000 DE
I. Technical data
Engine: Yanmar L90 AE-DE
Air-cooled single-cylinder 4-stroke diesel engine with hand and
electric start
Rated power at 3600 rpm KW (Hp) 6.6 (9)
Specific fuel consumption g/kWh 250
Performance
Operating pressure bar 40 – 200
Operating pressure at steam-stage (with steam nozzle) bar < 32
Max. allowable operating pressure bar 230
Min. water inlet volume l/h 1000
Flow rate l/h 450 – 900
Flow rate, steam-stage l/h 450
Temperature
Max. feed temperature °C 30
Max. working temperature, high-pressure stage °C 98
Permissible working temperature, steam-stage °C 155
Max. heating fuel consumption at temperature increase to 58 °C kg/h 5.56
Dimensions
Length mm 1100
Width mm 750
Height mm 785
High-pressure hose, length m 15
Capacities
Fuel tank l 34
Cleaning agent suction (infinitely adjustable) l/h 0 – 40
Net weight of the machine without accessories kg 185
Sound level Lpa dB (A) 93
Noise level Lwa dB (A) 107
4

1 Hand starter
2 Electric starter
3 Engine fuel tank
4 Pressure gauge
5 Starter battery
6 High-pressure nozzle
7 Spray lance
8 Handgun
9 High-pressure hose
10 High-pressure outlet
11 Burner fuel tank
12 Water inlet (G 3/4")
13 Adjustment wheel for pressure
and flow regulation
14 Pulsation damper
15 Fuel pump
16 Blower
17 Electrical box
18 Oil sight glass, pump
19 Safety valve
20 Burner cover
21 Continuous-flow heater
22 Spark-plug connector
23 Sight glass
HDS 1000 DE
24 Tuyere connection
25 Float tank
26 Container for liquid softener
27 Solenoid valve, liquid softener
28 Low water protection
29 Filter – low water protection
30 Pressure switch
31 Pump for oil filler container
32 High-pressure pump
33 Rating plate
34 Oil drain plug, engine
35 Oil dip stick, engine
5

HDS 1000 DE
II. Important notes
Unpacking the machine
– Should you find that damage has occurred during transport, inform your dealer immediately.
Fitting accessories
– Connect high-pressure hose to handgun and spray lance and connect to high-pressure outlet of the
pump. Attach nozzle to the spray lance. Please refer to the diagram for positions.
Check the oil level of the high-pressure pump
– Check the oil level at the oil sight-glass. Do not put the machine into operation if the oil level has sunk
below “MIN”. Top up with oil as required (see Technical Data).
Engine
– Before using the machine for the first time, read the operating instructions provided by the engine
manufacturer and take special note of the safety instructions.
– Check the oil level of the engine. Do not put the machine into operation if the oil level has sunk below
“MIN”. Top up with oil as required.
Care of the battery
– The battery has been filled and charged at the factory. If the acid level in the battery approaches
the “MIN” mark, fill with distilled water up to the “MAX” mark.
Water supply
Fit a water hose of at least 3/4" and connect it to the water tap. A suitable 3/4" water hose is available
from Kärcher under Order no. 4.440-222.
– The water supply must yield at least 16 litres per minute.
– Observe the regulations of your water supply company.
– The machine is fitted with a strainer at the pump inlet. Check the strainer regularly for contamination.
Fuel supply
Fuel tank for burner
Fill the fuel tank for the burner with a light fuel oil or diesel oil.
Caution!
Even when operating with cold water, fill the fuel tank until the indicator light showing “fuel tank
empty” goes out. Dry-running will damage the fuel pump.
6

Fuel tank
Fill the fuel tank for the engine with diesel.
Caution!
The fuel tank should not be topped up when the engine is running or hot.
There is a risk of fire and explosion.
Do not smoke and keep away from sparks and flames.
Do not spill fuel. Wipe up spilled fuel.
Always close fuel tank and fuel canister properly.
Fuel vapours are poisonous; do not breathe them in.
Lime-scale protection
– Fill container with Kärcher scale-inhibitor fluid, Order no. 2.780-001.
HDS 1000 DE
– Inquire about local hardness of water from the supply company responsible or determine it by means
of a water-hardness testing kit, Order no. 6.768-004.
– Install pulse generator in electrical cabinet.
Water hardness 5 10 15 20 25 30
Scale 10 8 7 6.5 6 5.5
– Operating without lime-scale protection may cause the heating coil to become furred.
Frost protection
If the unit is stored without having been emptied or rinsed thoroughly with a glycol-based antifreeze at
sub-zero temperatures, it will be ruined.
The best form of protection from sub-zero temperatures is to place the unit and accessory (handgun,
spray lance, high-pressure hose) in a covered area protected from frost.
Action of the safety devices
Low-water protection
The low-water protection device stops the burner from switching on when there is insufficient water.
When there is sufficient water supply, the float with magnet is pressed to the right and the magnet
causes the reed contact to close.
Only at this point can the fuel valve open. A strainer stops the low-water protection device from
becoming contaminated and must be cleaned once a week.
Overflow valve
When the handgun is closed, the overflow valve opens and the high-pressure pump feeds the water
back to the suction side of the pump. This stops the maximum permitted operating pressure from being
exceeded. The overflow valve is adjusted by means of lock nuts in the factory.
Safety valve
The safety valve is an additional protection in the high-pressure cleaner against undue high pressure.
It opens, for example, when the handgun is closed in burner mode. The safety valve is sealed.
No change is allowed to be made to its setting.
Pressure switch
The pressure switch switches the burner off if there is a fall below the minimum operating pressure and
switches on again when there is a rise above the minimum operating pressure.
7

HDS 1000 DE
III. Operation
1. Initial operation (cold-water mode)
– Open water inlet.
– Unit switch to position “SYMBOL Burner off”.
– Start engine according to operating instructions.
– Retract lever of handgun.
The pump first extracts air out of the unit. After a short time water will come out of the nozzle.
8
Caution! The water jet being emitted effects a recoil force or torque on the handgun,
so grip the handgun firmly.
– If during operation you release the lever of the handgun, the overflow valve will open and a water
circulation will take place inside the pump. At the same time, the revolutions per minute of the engine
will be reduced from operating speed to idling speed by the speed regulator fitted to the cylinder head.
– The switch-over pressure of approx. 240 bar remains in the system between overflow valve and
handgun.
– A further retraction of the lever releases this pressure, the overflow valve closes, the engine
accelerates to operating speed and the spraying pressure is reasserted.
2. Hot water mode
– Set the temperature regulator to the desired working temperature, the maximum being 98 °C. The
burner is thereby switched on. At a maximum demand on the pump, the water temperature rises in
accordance with the setting on the thermostat, but not above 98 °C.
3. Regulate pressure and water flow
The unit is fitted with a servopress device. Operating pressure and rate of flow can be infinitely adjusted
by the regulator wheel on the handgun. The temperature regulator may be set to a maximum of 98 °C.
4. Steam stage mode
If the temperature regulator is to be set higher than 98 °C, the nozzle on the spray lance should be
exchanged for a steam nozzle.
– Set the temperature regulator to 150 °C.
– Set the regulator wheel on the handgun to MIN stop position.
5. Spraying with cleaning agent
– Hang the cleaning agent hose with filter into container of cleaning agent.
– The proportion of cleaning agent in the water flow can be adjusted infinitely up to a rate of
approx. 5 %.
Cleaning methods
a) Single-step method
Spray on the cleaning agent with high pressure.
b) Two-step method
Spray on the cleaning agent with low pressure and leave it to take effect (1 – 5 minutes).
Spray away the dirt with the high-pressure water jet (without cleaning agent).

6. Storing the unit
– Set unit switch to position “Burner off”.
– Set cleaning agent metering valve to “0”.
– Flush unit through for at least 30 seconds.
– Close handgun, the engine will adjust to idling speed.
– Switch off engine.
Caution! Never switch off the engine under full load with the handgun open.
– Close fuel tap.
– Close off water supply.
– Retract lever of the handgun until no more water comes out.
The unit is now without pressure.
IV. Application
HDS 1000 DE
The high-pressure cleaner HDS 1000 DE is specially designed for use where no electrical connection
is available and where the work requires the use of hot water. The unit is particularly suitable for cleaning
facades, machines and construction-site vehicles in the open air.
Choice of operating pressure
The choice of operating pressure is dependent on the cleaning task in hand. In cases of severe and
encrusted dirt, the highest possible pressure should be used. For tiled walls, pressure should not exceed
50 bar to avoid damaging the grouting.
The operating pressure is dependent on the nozzle and is limited by the switch-off pressure of the
overflow valve as indicated above.
Apart from the working pressure and the distance from the object being cleaned, the form of the jet
determines the effectiveness of the high-pressure jet. The 0° pencil jet has the greatest mechanical
effectiveness and is used, for example, on heavily contaminated machines and parts. In normal cases
a 25° nozzle is used.
The high-pressure cleaner is fitted with a 25° Kärcher power nozzle at the factory. Special applications
may call for the fitting of other nozzles.
Order
no.
Nozzle
type
Spray
angle
Pressure
bar
5.765-032 00050 0 °C 200 50
2.883-399 25050 25 °C 200 50
Recoil
force N
Cleaning agent
In accordance with the guidelines laid down for liquid jet cleaners, § 5.4, the only cleaning agents
permitted are those to which the manufacturer of the unit gives approval.
We recommend the use of Kärcher cleaning agents. Unsuitable cleaning agents can damage the highpressure
cleaner and the object which is to be cleaned.
– For further information, please ask for product-specific documentation on the cleaning and care
products range.
– Please note the instructions for use on the label of the drum and in the product information sheets.
9

HDS 1000 DE
V. Care and maintenance
Care and maintenance work forms part of the responsibility of the operator. It must be carried out
with care and precision in order to maintain the operational efficiency of the unit.
a) Engine: Maintenance in accordance with the engine
manufacturer’s operating instruction manual
b) High-pressure cleaner
1. Maintenance Schedule:
weekly Oil level: if the oil is milky or if the oil-level has fallen below the “MIN” mark,
change the oil or top it up (see V.2.) as the case may be.
Clean filter of the low-water protection device.
monthly Remove tuyere connection and clean ignition electrodes or adjust
electrode gap.
half-yearly or as
necessary
2. Oil change
– Drain off oil at the drain plug into a collecting tray.
– Fasten drain plug again.
– Fill with oil up to the “MAX” mark.
– Oil type: Hypoid oil SAE 15 W/40. (Order no. 6.288-050, 1 litre)
3. Decarbonising the heating coil
Undo all connections to the boiler cover (cloth seal, spark-plug connector, fuel line, fastening
screws). The boiler is entirely disassembled and the heating coil dismantled. The heating coil can
then be cleaned (e.g. with a second unit).
10
Empty and clean burner fuel tank.
Clean filter before burner fuel pump and fuel nozzle.
Remove sulphur and carbon from heating coil (see V.3.).
Oil change (see V.2.).

HDS 1000 DE
4. Removal of internal deposits
If there are internal deposits in the pipe lines, the flow resistance increases with the result that the
overflow protection can switch over.
According to legal regulations, only boiler cleansing compounds which have certification marks can be
used to remove the deposits:
RM 100 6.287-008 dissolves limestone and simple compounds consisting of limestone
and detergent residues.
RM 101 6.287-013 dissolves deposits which cannot be dissolved with RM 100.
Procedure
Caution! The gases that are given off are combustible.
Do not smoke and provide good ventilation.
– Fill a 20-litre container 3/4 full of water.
– Add one litre of boiler-cleansing compound to the 15 litres of water.
– Connect water hose direct to the pump head and hang the free end in the container.
– Connect the spray lance without nozzle and insert in the container.
– Switch unit switch to “Burner on”, until approx. 40 °C has been reached.
– Turn off unit and let it stand for 20 minutes.
– Then pump the unit until empty.
Caution: When the descaling process is in action, the handgun must always remain pressed.
– To conclude, we recommend the use of an alkaline solution (e.g. RM 81) to be pumped through the
unit via the detergent tank to provide protection against corrosion and to neutralise the acid residue.
5. Repairs
The safety valve is adjusted and sealed in the factory; it may not be changed. Checking of the overflow
valve and safety valve should be carried out only by a specialist technician.
6. High-pressure hoses
Devote special attention to the hoses. Every high-pressure hose must accord with the safety
regulations and must be marked with the maximum permitted operating pressure, the manufacturer’s
set date for usage and the manufacturer.
High-pressure hoses may not be kinked, stretched, crushed or damaged in any other way. Damaged
high-pressure hoses are in danger of bursting and must be replaced without delay.
High-pressure hoses of short service life and those which are not repaired properly are extraordinarily
dangerous. Therefore use only certificated and marked high-pressure hoses.
Kärcher original high-pressure hoses meet the safety requirements.
7. Notes on the fuel pump for the burner
Even when the unit is running in cold-water mode, it must not be allowed to operated without fuel oil or
diesel in the fuel tank, otherwise there is a danger that the fuel pump will dry-run and in consequence
the drive clutch and fuel pump will be destroyed.
11

HDS 1000 DE
VI. Trouble shooting
Fault Cause Remedy
1. Engine does not run a) Fuel tank empty
Check, fill up.
2. Unit does not come
up to pressure
3. Burner does not
ignite or flame goes
out whilst unit in
operation
12
b)
c)
a)
b)
c)
d)
e)
f)
g)
h)
i)
k)
a)
b)
c)
d)
e)
f)
g)
Spark plug
Other causes
Pump is sucking in air
Strainer at pump inlet blocked
Pump has not been bled
Pump or overflow valve defective
Safety valve out of adjustment
Insufficient water supply
Cleaning agent valve leaking,
cleaning agent pump sucks in air
Strainer in front of low water
protection device dirty
Safety valve leaking
Cleaning agent container empty
No ignition spark (can be
ascertained through sight glass
in burner cover)
Burner fuel tank empty
Fuel filter blocked
Insufficient sputtering of the burner
nozzle
Fuel pump or coupling defective
Low water protection device does
not operate
Thermostat defective or set too low
See operating instructions, engine
See operating instructions, engine
Check water hose
Open water inlet
Clean strainer
Switch off unit, retract handgun
lever, switch on unit with opened
handgun, if necessary repeat
procedure.
Call in Customer Service
Call in Customer Service
Open water tap
Check and seal
Dismantle strainer and clean it
Call in Customer Service
Fill up cleaning agent container or
set cleaning agent valve to “0”.
Clean electrode and adjust electrode
gap. Check ignition transformer and
spark-plug connector.
Top up
Dismantle and clean
Dismantle filter and clean it
Disassemble and replace damaged
parts.
Water supply not sufficient.
Reed switch or magnetic pistons
defective.
Replace or set higher

Fault Cause Remedy
4. Water jet uneven a)
5. No suction of
cleaning agent
6. Flow protection
does not switch on
– no flame
b)
a)
b)
a)
b)
c)
d)
e)
Nozzle blocked
Safety valve out of adjustment
Cleaning agent filter blocked or
container empty
Cleaning agent hoses, cleaning
agent metering valve leaking or
blocked.
Water supply valve closed
Insufficient water
Strainer in front of flow protection
blocked
Valves in the high-pressure pump
leaking or dirty
Water pressure too low
HDS 1000 DE
Blow nozzle through with
compressed air. If necessary clean
with a pin or similar.
Call in Customer Service
Clean or fill up
Check and clean
Open it
Provide for adequate water supply
Check, dismantle strainer and clean
Check valve plates and seatings,
if necessary replace.
Remedy problem
7. Oil looks milky-white a) Leaking seal Call in Customer Service
13

HDS 1000 DE
VII. General Notes
1. System test pressure and design accord with the statutory regulations for steam boilers.
2. The “Richtlinien für Flüssigkeitsstrahler” (Guidelines for liquid jets) issued by the Verband der
gewerblichen Berufsgenossenschaften, available from Carl Heymanns-Verlag KG, Luxemburger
Str. 449, 5000 Köln 41, apply in the Federal Republic of Germany.
3. In accordance with the “Richtlinien der Flüssigkeitsstrahler” (paragraph VI.1.), high-pressure jets
must be inspected at least every 12 months by an expert; the results of the inspection must be put
in writing.
Kärcher Customer Service maintenance engineers are experts and can carry out this prescribed
inspection at your premises.
4. The volume of water in the unit amounts to less than 10 litres. The unit is therefore subject to no
installation regulations as far as the boiler is concerned. When operating with temperatures of over
100 °C in unsupervised operation, the burner must be fitted with a flame monitoring system.
Regulations of the local building authorities should be observed.
5. The heating facility is a furnace which, according to the first ordinance for the implementation of the
Federal law on the protection against noxious emissions, must be checked once a year for its
adherence to emission control values by your area chimney sweep responsible for such tasks. The
operator of the high-pressure cleaner must arrange for the measurement to take place.
6. Safety inspection agreement
You can enter into a safety inspection agreement with Kärcher. This includes the inspection with
inspection badge and inspection record as required under VII.3. and VII.5.
7. Maintenance agreement
You can also enter into a maintenance agreement with Kärcher. It involves all the care and
maintenance operations as in V.1. Maintenance Schedule. The maintenance agreement contains in
it the safety inspection agreement.
8. Accessories
Wrong, unsuitable or defective accessories impair the functioning of your Kärcher unit. Their use is
dangerous. Ask us or your dealer about suitable and tested accessories. A Kärcher original
accessory is practical and tailor-made.
9. Spare parts
Be aware that the use of other than original spare parts can lead to the occurrence of faults and also
to bad accidents when these parts have not been manufactured properly, or when they do not exactly
replace the original part. They can also make the operation of the unit unreliable.
Original spare parts offer the guarantee that you will always be able to operate your unit safely and
free of faults.
You will find the numbers of a selection of the most commonly required replacement parts on the back
cover.
14

HDS 1000 DE
1.811-936.0
5.063-664.0
5.731-039.0
5.321-177.0
7.307-181.0
5.132-010.0
5.132-010.0
7.305-023.0
5.045-211.0
5.321-023.0
4.820-946.0
4.760-355.0
5.363-300.0
6.303-025.0
6.654-074.0
6.654-026.0
2.880-296.0
5.401-210.0
5.321-493.0
5.826-020.0
6.654-075.0
4.820-732.0
5.321-493.0
4.760-355.0
5.826-020.0
4.775-254.0
5.042-252.0
6.491-261.0
6.491-262.0
5.042-402.0
2.880-296.0
6.390-185.0
6.362-422.0
6.390-185.0
6.390-185.0
10.12.1999