Kärcher CV 38/2 User manual

English 5.906-485.0 Rev. 00 (05/09) 1
CV 38/2
CV 48/2
Service Manual

2 English 5.906-485.0 Rev. 00 (05/09)
Contents
1 Preface 3
2 Safety instructions 3
3 Technical Features 3
4 Parts of the system 4
5 Basic settings and service procedures 5
6 Maintenance and care 8
7 Troubleshooting 11
8 Technical specifications 13
9 Circuit diagram 14

English 5.906-485.0 Rev. 00 (05/09) 3
Good service work requires extensive and practice-oriented train-
ing as well as well-structured training materials.
Hence we offer regular basic and advanced training programmes
covering the entire product range for all service engineers.
In addition to this, we also prepare service manuals for important
appliances - these can be initially used as instruction guides and
later on as reference guides.
Apart from this, we also regular information about product en-
hancements and their servicing.
If you should require supplements, have corrections or questions
regarding this document, please address these citing the following
subject to:
[email protected]
The responsible product specialist will take care of your issue.
Copying and duplication of texts and diagrams as well as
third-party access to this information is permitted only with
the explicit permission of the company:
Alfred Kärcher GmbH & Co. KG
P O Box 160
D - 71349 Winnenden
www.kaercher.com
Danger
Immediate danger that can cause severe injury or even death.
몇Warning
Possible hazardous situation that could lead to severe injury or
even death.
Caution
Possible hazardous situation that could lead to mild injury to per-
sons or damage to property.
Structure:
– Two-motoric brush vacuum
– Height adjustable handle
– The height of the brush head can be adjusted to match the pile
height of the carpet (with indicator lamp).
– 3-fold filter: Dust filter (fleece filter), motor protection filter, ex-
haust filter
– Filter filling display
– CV 38/2: Working width 335 mm (13.2 in.)
– CV 48/2: Working width 430 mm (16.9 in.)
Drive:
– Suction turbine (blower motor)
– Thesecondmotordrivesthebrushrollerbymeansofa toothed
gear (brush motor).
1 Preface
Subject: Fall 108579
2 Safety instructions
2.1 Hazard levels
3 Technical Features

4 English 5.906-485.0 Rev. 00 (05/09)
1 Brush cover
2Brush
3 Brush head
4 Indicator bundle
(CV 38/2 only)
5 Unlocking brushg head
6 Upholstery nozzle
7 Crevice nozzle
8 Handle adjustment
9 Indicator lamp on the filter housing (red)
10 Handle
11 Suction hose
12 Suction pipe
13 Power switch
14 Filter bag
15 Filter cover
16 Motor filter
17 Blower filter
18 Pile height adjustment knob
(Standard series in position 2)
19 Indicator lamp - Electronic brush control (orange)
4 Parts of the system
18
19
4
3
1
2
10
11
12
13
14
15
16
17
9
8
5
7
6

English 5.906-485.0 Rev. 00 (05/09) 5
1 Fastening screws for rear cover
2 Cable hook
3 Handle adjustment
4 Rear cover
Unscrew locking screws.
Remove rear cover.
Replace the cable hook or the handle adjustment.
Install the new cable hook or a new handle adjustment in re-
verse sequence.
1 Top cover
2 Fastening screws for top cover
3 Power cord
4 Suction hose connection
5 Safety ring
Unscrew locking screws.
Remove top cover.
1 Connection plug of the mains cable
2 Power switch
3 Connection plug of the circuit board
4 Power cord
5 Top cover
6 Ring
7 Washer ring
8 Suction hose connection neck
Remove washer ring.
Insert new washer ring.
1 Connection plug of the circuit board
2 Connection plug of the earth cable (protective conductor)
3 Connection plug of the mains cable
4 Ferrit ring (anti-interference ring)
5 Power cord
6 Clamp for mains cable
7 Indicator lamp
5 Basic settings and service procedures
5.1 Replace the cable hook or the handle adjust-
ment
5.2 Remove top cover.
1
2
1
3
4
1
1
2 4 5 1 2
3
5.3 Replace washer ring
5.4 Replacing the mains cable
8 1 2
7
6
5
4
3
1
2
3
4
6
5
8
7

6 English 5.906-485.0 Rev. 00 (05/09)
8 Circuit board with casing
Pull the connection plug of the mains cable off the appliance
switch (top).
Remove the clamp.
Remove the mains cable from the cable guide.
Install the new mains cable in reverse sequence.
The low pressure sensor on the printed circuit board measures the
vacuum in the suction system. With rising vacuum pressure (filter
bagis full),the indicatorlamp glows.Ifthecircuitboard isdefective,
it must be replaced including the casing.
1 Vacuum hose of the circuit board
2 Circuit board with casing
3 Connection for vacuum hose
Pull the connection plug of the circuit board off the appliance
switch (bottom).
Remove the connection plug of the earth cable (protective con-
ductor)
Remove the circuit board.
Install the new circuit board in reverse sequence.
Note: When installing the circuit board with casing, make sure that
the vacuum hose is properly connected to the connection.
1 Lock the journal for the slide plate
2 Fastening screws for brush head cover
3 Slide plate
Turn the lock journal by 90° in anti-clock-wise direction.
Fold the slide plate up and remove it.
Unscrew locking screws.
1 Pile height adjustment knob
2 Brush head cover
3 Brush head
4 Indicator lamp - Electronic brush control (orange)
Remove the pile height adjustment knob
Remove the brush head cover.
5.5 Replace the circuit board
1
2
3
5.6 Removing the brush head cover
2
2
2 1
1
2
3
1 2
3 4

English 5.906-485.0 Rev. 00 (05/09) 7
1 Switch cam
2 Brush motor switch
3 Brush motor
4 Brush motor electronics
5 Safety bumper
6 Brush head casing
7 Bearing bowl incl. spring clamp
8 Fastening screws of the casing top
9 Housing top
1 Drive pinions of the brush motor
2Drivebelt
3 Fastening screws of the drive bearing
4 Drive bearing of the brush
5 Brush motor
Unscrew locking screws.
Pull out the drive bearing.
Remove the drive belt.
Remove the brush motor.
Install the new brush motor in reverse sequence.
As required: Clean the inside of the indicator lamp cover (or-
ange) of the brush head cover of carbon brush residue.
1 Impeller
2 Impeller cover
3Steelspring
4 Metal clip
5 Opening of impeller
1 Filter cover
2 Bearing locations
3 Filter casing
Lift up the complete filter casing and remove it from the bearing
locations.
Remove the filter cover.
5.7 Replace the brush motor
1
2
3
4
7
6
5
8 9
1
2
3
4
3
5
5.8 Pile height adjustment
5.9 Replacing the suction turbine
1
2
3
5
4
2
1
2
3
11 2 11
3
4
5

8 English 5.906-485.0 Rev. 00 (05/09)
1 Fastening screws of the casing top
2 Housing top
3 Bearing bowl incl. spring clamp and switch cams
4 Bearing bowl incl. spring clamp
Pull the bearing bowls off to the side.
Unscrew locking screws.
Remove the top part of the casing.
1 Suction turbine
2Powercord
3 Terminal strip of the suction turbine
4 Connection cable to the brush head
5 Connection cable of the suction turbine
Remove the suction turbine.
Pull the connecting cable of the suction turbine out of the termi-
nal strip.
Install the new suction turbine in reverse sequence.
Note: The mains cable must be routed as shown in the illustration
within the respective pins (see arrows).
1 Casing bottom
2Powercord
3 Seal
Remove the seal.
Insert new seal.
Note: The seal must be placed precisely into the guide groove of
the casing bottom to protect the suction turbine from contamina-
tion.
5.10 Replace seal
1
2
3
4
5
1
2
3
6 Maintenance and care

English 5.906-485.0 Rev. 00 (05/09) 9
CV 38/2

10 English 5.906-485.0 Rev. 00 (05/09)

English 5.906-485.0 Rev. 00 (05/09) 11
7 Troubleshooting
2
3
2
1

12 English 5.906-485.0 Rev. 00 (05/09)
– No electrical voltage.
Check cables, plugs, fuse, and socket.
– Thermostat switched off the motor because of overheating
Pull mains plug, replace blocked filters, or remove blockage
from the suction hose.
The unit is operational again after it has cooled down.
Check the brush for blocking objects.
Remove obstructions from brush head, suction pipe and suc-
tion hose.
Replace the filter bag.
Replace blower filter and motor protection filter.
Check the pile height adjustment knob for correct adjustment.
CV 38/2 only: The brush must be replaced when it is worn out.
Thedegreeofwearis shownby acomparisonwith theindicator
bundle of a different colour. The brush must be replaced when
the black bristles are at the same level as the red ones.
Remove obstructions from brush head, suction pipe and suc-
tion hose.
Replace the filter bag.
Set the adjustment knob for pile height to the lower pile height.
Replace brush.
7.1 Motor does not run
7.2 Unsatisfying suction result
7.3 The red indicator lamp on the filter housing is
ON
7.4 The orange indicator lamp - Electronic brush
control is ON
7.5 The orange indicator lamp - Electronic brush
control is also ON at lowest level

English 5.906-485.0 Rev. 00 (05/09) 13
The technical specification sheet and the circuit diagram will be in-
cluded in the next version of the spare parts CD (DISIS) and in the
Intranet.
– Technical specification sheet:
Folder "Central / Service Info Int'l / Technical Specifications"
– Circuit diagram:
Folder "Central / Service Info Int'l / Circuit Diagram"
The operating instructions and the spare parts list can be request-
ed in paper form with the respective part numbers from our spare
parts service department.
There are no special tools necessary.
No data.
8 Technical specifications
Appliance type Appliance no.: Circuit diagram Operating in-
structions Spare parts list
CV38/2 EU, 220-240 V, 1~ 50/60 Hz 1.033-315.0 0.089-192.0 5.962-949.0 5.970-967.0
CV 38/2 GB, 220-240 V, 1~ 50/60 Hz 1.033-316.0 0.089-192.0 5.962-949.0 5.970-967.0
CV 38/2 AU, 240 V, 1~ 50/60 Hz 1.033-317.0 0.089-192.0 5.962-949.0 5.970-967.0
CV 38/2 USA, 120 V, 1~ 60 Hz 1.033-318.0 0.089-205.0 5.963-274.0 5.971-026.0
CV 48/2 EU, 220-240 V, 1~ 50/60 Hz 1.057-310.0 0.089-192.0 5.962-949.0 5.970-967.0
CV 48/2 GB, 220-240 V, 1~ 50/60 Hz 1.057-311.0 0.089-192.0 5.962-949.0 5.970-967.0
CV 48/2 AU, 240 V, 1~ 50/60 Hz 1.057-312.0 0.089-192.0 5.962-949.0 5.970-967.0
CV 48/2 USA, 120 V, 1~ 60 Hz 1.057-313.0 0.089-205.0 5.963-274.0 5.971-026.0
8.1 Special tools
8.2 Tightening torques

14 English 5.906-485.0 Rev. 00 (05/09)
9 Circuit diagram
1
23456789
10
11
12 13
PE
L2
L1
5190952
0000
2018352
SLP
fma
SMD-W
PRESSURE CONTROL BRUSH MONITORING
GB
D F E
H1
ROTE KONTROLL-LAMPE
FILTERTÜTENWECHSEL
L1/L2
ENTSTÖRDROSSELN
M1 M2 N1 N2 P1 R1/R2 S1 S2 X1
SAUGTURBINE BÜRSTMOTOR SCHALTELEKTRONIK SCHALTELEKTRONIK DRUCKSCHALTER ANTISTATIKABLEITUNG HAUPTSCHALTER SCHALTER BÜRSTMOTOR NETZSTECKER
UNTERDRUCK KONTROLLE BÜRSTENKONTROLLE
X2
KLEMMLEISTE
M1 M2 N1 N2 P1 R1/R2 S1 S2 X1
VACUUM MOTOR BRUSH MOTOR ELECTRONIC SWITCH UNIT ELECTRONIC SWITCH UNIT PRESSURE SWITCH WIRE ANTISTATIC MAINSWITCH SWITCH BRUSH MOTOR POWER SUPPLY PLUG
X2
TERMINAL STRIP
H1
RED INDICATOR LIGHT
L1/L2
CHOKES
EXCHANGING FILTER BAG
TÉMOIN DE CONTRôLE ROUGE
CHANGER LE SACHET-FILTRE
TURBINE D´ASPIRATION MOTEUR DE BROSSE UNITÉ ÉLECTRONIQUE UNITÉ ÉLECTRONIQUE INTERRUPTEUR À PRESSION CABLE ANTISTATIQUE INTERRUPTEUR PRINCIPAL INTERRUPTEUR PRISE D´ALIMENTATION D´ÉNERGIE BORNE PLATE
MOTEUR DE BROSSE
CONTRôLE DE LA BROSSE COMMANDE DE PRESSION
H1 M1 M2 N1 N2 P1 R1/R2 S1 S2 X1 X2 L1/L2
INDUCTANCE TESTIGO DE CONTROL (ROJO)
CAMBIAR LA BOLSA DE FILTRO
H1
TURBINA DE ASPIRACIÓN MOTOR DEL CEPILLO SISTEMA ÉLECTRÒNICO SISTEMA ÉLECTRÒNICO INTERRUPTOR DE PRESIÓN CABLE ANTIESTÁTICO INTERRUPTOR PRINCIPAL INTERRUPTOR ENCHUFE DE SUMINISTRO DE ENERGIA TIRA TERMINAL
CONTROL DEL CEPILLO CONTROL DE PRESIÓN
MOTOR DEL CEPILLO
M1 M2 N1 N2 P1 R1/R2 S1 S2 X1 X2 L1/L2
INDUCTIVIDAD
X1
N1
1~
P1
H1
P
X3
X2
M
M1
X4
S1
2 1
5 4
1~
M
M2
L2
L1
X11
R1
R2
X2
1
2
S2
S1
S4 S3 S5
N2
S2
1
2
Perfil del aluminio Aluminium Profil Aluminium Profile Profil en aluminium
230/240V 1~ 50/60Hz
GB
230V
X1
BRAUN BROWN BRUN
BLAU BLUE BLEU
X1
ANLAGE plant installat. AUFTRAG order no. order no.
ORT location lieu
BENENNUNG identification identification ANLAG.-BEZ. plant desig. denomin.
Stromlaufplan circuit diagram plan de circuit CV38/2 CV48/2 EUR
ZEICHNUNGS-NR. drawing-no. Dessin No.
BLATT page page
BLATTZ. page tot. page tot.
18.02.09
Datum date date
ANZ.
no. no.
Ä-IND.
ch.-ind. ch.-ind.
NORM
stand. stand.
GEPR. check
vérif.
GEZ.
draft
dessin.
File:
CV382_CV482_EU
ura
11
0.089-192.0
= SLP + S
Winnenden
ÄND./FR.
change/rel. change/rel.
ERS.F.
exch. of
rempl.
Dokument document
Dok-Vers.
doc-vers. doc-vers.
Dok-Nr.
doc-no. doc-no.

English 5.906-485.0 Rev. 00 (05/09) 15
1
23456789
10
11
12 13
PE
L2
L1
PE
5194512
00
2021889
SLP
fma
SMD-W
PRESSURE CONTROL BRUSH MONITORING
GB
D F E
H1
ROTE KONTROLL-LAMPE
FILTERTÜTENWECHSEL
L1/L2
ENTSTÖRDROSSELN
M1 M2 N1 N2 P1
SAUGTURBINE BÜRSTMOTOR SCHALTELEKTRONIK SCHALTELEKTRONIK DRUCKSCHALTER
UNTERDRUCK KONTROLLE BÜRSTENKONTROLLE
M1 M2 N1 N2 P1
VACUUM MOTOR BRUSH MOTOR ELECTRONIC SWITCH UNIT ELECTRONIC SWITCH UNIT PRESSURE SWITCH
H1
RED INDICATOR LIGHT
L1/L2
CHOKES
EXCHANGING FILTER BAG
TÉMOIN DE CONTRôLE ROUGE
CHANGER LE SACHET-FILTRE
TURBINE D´ASPIRATION MOTEUR DE BROSSE UNITÉ ÉLECTRONIQUE UNITÉ ÉLECTRONIQUE INTERRUPTEUR À PRESSION
CONTRôLE DE LA BROSSE COMMANDE DE PRESSION
H1 M1 M2 N1 N2 P1 L1/L2
INDUCTANCE TESTIGO DE CONTROL (ROJO)
CAMBIAR LA BOLSA DE FILTRO
H1
TURBINA DE ASPIRACIÓN MOTOR DEL CEPILLO SISTEMA ÉLECTRÒNICO SISTEMA ÉLECTRÒNICO INTERRUPTOR DE PRESIÓN
CONTROL DEL CEPILLO CONTROL DE PRESIÓN
M1 M2 N1 N2 P1 L1/L2
INDUCTIVIDAD
S1 S2
HAUPTSCHALTER SCHALTER BÜRSTMOTOR
S1 S2
MAINSWITCH SWITCH BRUSH MOTOR INTERRUPTEUR PRINCIPAL INTERRUPTEUR
MOTEUR DE BROSSE
S1 S2
INTERRUPTOR PRINCIPAL INTERRUPTOR
MOTOR DEL CEPILLO
S1 S2
X1
100/120V 1~ 50/60Hz
X1
N1
1~
P1
H1
P
X3
X2
M
X4
S1
2 1
5 4
1~
M
X11
Perfil del aluminio Aluminium Profil Aluminium Profile Profil en aluminium
X2
S2
S1
S4 S3 S5
N2
S2
1
2
1
2
00
M2
M1
Q1
X1
NETZSTECKER
X2
KLEMMLEISTE
X1
POWER SUPPLY PLUG
X2
TERMINAL STRIP PRISE D´ALIMENTATION D´ÉNERGIE BORNE PLATE
X1 X2
ENCHUFE DE SUMINISTRO DE ENERGIA TIRA TERMINAL
X1 X2 Q1
THERMOSCHALTER
Q1
THERMO SWITCH
Q1
INTERRUPTEUR THERMOSTATIQUE
Q1
INTERRUPTOR TERMAL
ANLAGE plant installat. AUFTRAG order no. order no.
ORT location lieu
BENENNUNG identification identification ANLAG.-BEZ. plant desig. denomin.
Stromlaufplan circuit diagram plan de circuit CV38/2 CV48/2 US
ZEICHNUNGS-NR. drawing-no. Dessin No.
BLATT page page
BLATTZ. page tot. page tot.
18.02.09
Datum date date
ANZ.
no. no.
Ä-IND.
ch.-ind. ch.-ind.
NORM
stand. stand.
GEPR. check
vérif.
GEZ.
draft
dessin.
File:
CV382_CV482_US
ura
11
0.089-205
= SLP + S
Winnenden
ÄND./FR.
change/rel. change/rel.
ERS.F.
exch. of
rempl.
Dokument document
Dok-Vers.
doc-vers. doc-vers.
Dok-Nr.
doc-no. doc-no.