Kärcher HD 10/25 S VEX User manual

English 5.905-945.0 Rev. 00 (06/15) 1
HD 10/25 S
HD 13/18 S
Service Manual

2 English 5.905-945.0 Rev. 00 (06/15)
1 Contents
2 Preface 3
3 Safety instructions 3
3.1 Hazard levels 3
4 Technical Features 4
4.1 Drive 4
4.2 Pump 4
4.3 Detergent system 4
4.4 Electrical system 4
4.5 Electronics system 4
4.6 Other features 4
4.7 Field of application 5
4.8 Type plate 5
5 Parts of the system 6
5.1 Front view 6
5.2 View from behind 7
5.3 View from below 8
5.4 Front view (without cover) 9
5.5 Front view (electric box opened) 10
6 Function 11
6.1 Motor/pump unit 11
6.2 Water filter 11
6.3 Pump diagram 12
6.4 Hand spraygun 15
6.5 Pressure and volume regulation 16
6.6 Triple nozzle 17
6.7 Electronics system 18
6.7.1 Pump monitoring 18
6.7.2 Leakage monitoring 18
6.7.3 Motor protection 18
6.7.4 Display 18
6.7.5 Reset 19
6.7.6 Setting the DIP switches 19
6.8 Bypass valve 20
7 Basic settings and service procedures 21
7.1 Adjusting the overflow valve 21
7.2 Trigger gun with servopress pressure regulator 21
7.3 Trigger gun standard 21
7.4 Hose drum 22
7.4.1 Remove the hose drum 22
7.4.2 Uninstall / install high-pressure hose 22
7.4.3 Replace the seal of the rotary grommet 23
8 Troubleshooting 25
9 Technical Documentation 26
9.1 Technical specifications 26
10 Special tools 27
11 Circuit diagram 29
12 Torques 30

English 5.905-945.0 Rev. 00 (06/15) 3
Good service work requires extensive and practice-orient-
ed training as well as well-structured training materials.
Hence we offer regular basic and advanced training pro-
grammes covering the entire product range for all service
engineers.
In addition to this, we also prepare service manuals for im-
portant appliances - these can be initially used as instruc-
tion guides and later on as reference guides.
Apart from this, we also regular information about product
enhancements 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 is-
sue.
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
Service and maintenance tasks may only be performed by
qualified and specially trained specialists.
Observe safety information in the chapters!
DANGER
Prior to all work on the appliance, switch off the appliance
and pull the power plug.
Shut off water supply.
Drain off water pressure.
DANGER
Foranimmediatedangerwhichcanleadtosevereinjuries
or death.
몇WARNING
For a possibly dangerous situation which could lead to se-
vere injuries or death.
몇CAUTION
Forapossiblydangeroussituation whichcanlead tominor
injuries or property damage.
ATTENTION
Pointer to a possibly dangerous situation, which can lead
to property damage.
Note
Indicates useful tips and important information.
2 Preface
Subject: Fall 119269
3 Safety instructions
3.1 Hazard levels

4 English 5.905-945.0 Rev. 00 (06/15)
These AC devices are the new top models among the mo-
bile high-pressure cleaners of the super-class devices.
Their compact and vertical design allows easy handling
and space-saving storage.
–3 piston axial pump, piston with ceramic coating
–Cylinder head and water inlet made of brass
–High-pressure and suction valves made of stainless
steel
–Direct shutoff with closed gun via pressure switch con-
trol
–Overflow valve for pressure and quantity regulation
–Control injector
–Pressure holding valve
–Manometer
–Detergent injector
–Detergent check valve
–Detergent dosing valve on the cover of the detergent
tank.
–Power switch without overload protection
–Winding protection contact
–The pressure switch switches an additional contactor
that breaks all 3 phases of the power supply
Note
Thanks to the additional contactor, the service life of the
pressure switch is extended significantly.
–Automatic safety switch-off after 30 minutes of non-op-
eration
–Automatic safety switch-off in case of leakage
–Protection against running on 2 phases
–Protection against over and low voltage
–Operating display (LED) for displaying operating states
and malfunctions
–Softgrip-Easypress gun with improved ergonomics
–Highest operating comfort thanks to improved, continu-
ous pressure and water volume regulation
–Servopress rotary regulator with ceramic insert
–Integrated water filter with 100 μm mesh for the protec-
tion of the pump
–Good mobility on stairs thanks to large full rubber
wheels (Ø 300 mm)
–Easy oil level check from the outside, without removal
of the casing cover
4 Technical Features
4.1 Drive
4-pin, electro mo-
tor Cooling rpm Voltage/cur- rent type
HD 10/25 S/SX Water-cooled 1500 400 V / 3~ /
50 Hz
HD 13/18 S/SX Water-cooled 1500 400 V / 3~ /
50 Hz
4.2 Pump
4.3 Detergent system
4.4 Electrical system
4.5 Electronics system
4.6 Other features

English 5.905-945.0 Rev. 00 (06/15) 5
This service manual describes the following appliances:
The type plate is located on the rear of the appliance.
1 Appliance description
2 Connected load
3 Part number
4 Year of manufacture
5 Serial number
6 Nozzle size
7 Address of manufacturer
8 Bar code. Contains part and serial number.
9 Max. feed temperature
10 Typical operating weight
11 Max. operating over-pressure
12 Type of protection
13 Working pressure
14 Flow rate
15 Main Supply
4.7 Field of application
Appliance type Appliance no.
HD 10/25 S 1.286-120.0
HD 10/25 SX 1.286-500.0
HD 13/18 S 1.292-100.0
HD 13/18 SX 1.292-500.0
4.8 Type plate

6 English 5.905-945.0 Rev. 00 (06/15)
5 Parts of the system
5.1 Front view
1 Mains plug
2 Mains connection
3 Water connection
4 Oil level indicator
5 Power switch Q1/S1
6 Operating display (LED) D1
7 Screw of the cover
8 Storage, power cord
9 Transport handle
10 Power press regulator
Pressure/ quantity regulation
11 Lock trigger gun
12 Trigger gun
13 Lever for trigger gun
14 High pressure hose
15 Spray lance
16 Manometer
17 High pressure connection
18 Triple nozzle
19 Connection of high pressure
hose

English 5.905-945.0 Rev. 00 (06/15) 7
Unit without hose drum 1 Storage, power cord
2 Storage dirt grinder
3 Storage triple nozzle
4 Kick plate to tilt the appliance
5 Wheel
6 Storage compartment for accessories
7 Detergent tank lid
Dosing valve
8 Transport handle
5.2 View from behind

8 English 5.905-945.0 Rev. 00 (06/15)
Device with hose drum 1 Crank, hose drum
2 Hose drum
3 Storage dirt grinder
4 Storage triple nozzle
5 Wheel
6 Kick plate to tilt the appliance
7 Storage compartment for accessories
8 Detergent tank lid
Dosing valve
9 Transport handle
Unit without hose drum
5.3 View from below
1 Rubber feet
2 Screw plug pressure retaining valve
3 Locking screw for pressure valve
4 Pressure switch Q2
5 Lid of water supply
6 Pump head
7 Mains connection

English 5.905-945.0 Rev. 00 (06/15) 9
Device with hose drum
Unit without hose drum
1 Rubber feet
2 Screw plug pressure retaining valve
3 Locking screw for pressure valve
4 Pressure switch Q2
5 Lid of water supply
6 Pump head
7 Mains connection
8 High pressure hose
5.4 Front view (without cover)
1 Motor M1
2 Manometer
3 Detergent connection with check valve
4 Detergent injector
5 High pressure connection
6 Overflow valve
7 Water connection
8 Mains connection
9 Oil drain screw
10 Water filter
11 Oil tank
12 Oil container lid
13 Electronics system
14 Power switch Q1/S1
15 Operating display (LED) D1

10 English 5.905-945.0 Rev. 00 (06/15)
Device with hose drum 1 High-pressure hose from the pump to the
hose reel
2 Motor M1
3 Manometer
4 Detergent connection with check valve
5 Detergent injector
6 Bypass valve
7 Duct high-pressure hose
8 Overflow valve
9 Water connection
10 Mains connection
11 Water filter
12 Oil tank
13 Oil container lid
14 Electronics system
15 Power switch Q1/S1
16 Operating display (LED) D1
5.5 Front view (electric box opened)
1 Control chip A1
2 Transformer T1
3 Cable clamp
4 Contactor K1
5 Power switch Q1/S1
6 Operating display (LED) D1

English 5.905-945.0 Rev. 00 (06/15) 11
1 Motor bearing
2 Motor cover
3 Motor shaft
4 Water cooling
5 Stator
6 Rotor
7 Shaft seal ring
8 Fitting key
9 Oil bath
10 Swash plate
11 Piston spring
12 Screw plug pressure retaining valve
13 Suction valve
14 Pressure valve
15 Locking screw for pressure valve
16 High pressure seal
17 Low pressure seal
18 Oil seal
19 Plunger
20 Holding plate of piston spring
21 Slide shoe
22 Fastening screw, swash plate
23 Motor bearing
1 Supply motor cooling
2 Supply pump
3 Supply water filter
4 Filter casing
5 Water filter
6 Washer ring
7 Cap
6 Function
6.1 Motor/pump unit
6.2 Water filter

12 English 5.905-945.0 Rev. 00 (06/15)
Trigger gun and servopress rotary regulator opened:
When the power press regulator is opened all the way, the
water flows from the pressure room through the pressure
holding valve via the control pressure injector to the high
pressure outlet.
The ball of the overflow valve is pressed onto the valve
seat by the pump pressure and thus seals the connecting
boring to the suction chamber.
The manometer displays the working pressure in the pres-
sure room.
But, due to the affect of the control pressure injector, there
is less pressure in the connecting boring.
6.3 Pump diagram
1 Manometer
2 Pressure holding valve
3 Pressure switch B1
4 Connecting boring to overflow valve
5 Overflow valve ball
6 Connecting boring to suction room
7 Piston rod
8 Connecting boring from the overflow valve
to the control pressure injector
9 Detergent injector
10 High pressure outlet
11 Control pressure injector
12 Pressure room with pressure valves

English 5.905-945.0 Rev. 00 (06/15) 13
Servopress rotary regulator partially closed:
With the power press regulator partially closed, the pres-
sure in the pressure room will not rise any further. Howev-
er, due to less water volume, the effect of the control
pressure injector decreases, so that the pressure in the
connecting boring rises. Thus, the piston rod is pressed
slightly to the right against the spring pressure. The cone
tip of the rod slightly pushes the ball out of its seat so that
a part of the flow rate flows to the suction chamber.
The pressure switch is slightly pushed to the right due to
theincreasedpressureintheconnectingboring,butnotfar
enough to switch off the pressure switch.
1 Manometer
2 Pressure holding valve
3 Pressure switch B1
4 Connecting boring to overflow valve
5 Overflow valve ball
6 Connecting boring to suction room
7 Piston rod
8 Connecting boring from the overflow valve
to the control pressure injector
9 Detergent injector
10 High pressure outlet
11 Control pressure injector
12 Pressure room with pressure valves

14 English 5.905-945.0 Rev. 00 (06/15)
Trigger gun closed:
Upon closing the trigger gun, the pressure in the pressure
room rises abruptly. This pressure peak will affect the pis-
ton rod and the pressure switch via the connecting boring.
The ball is pressed out of its seat by the piston road and
the entire flow volume can flow to the suction room via the
connecting boring.
The pressure switch switches the motor off.
Assoon as thetriggergun is closed,thepressure retaining
valve closes. This way the entire system pressure is
locked between the trigger gun and the pressure retaining
valve.
When the gun is opened again, the pressure in the system
decreases rapidly, the overflow valve returns to its original
position and the pressure switch switches the motor back
on.
1 Manometer
2 Pressure holding valve
3 Pressure switch B1
4 Connecting boring to overflow valve
5 Overflow valve ball
6 Connecting boring to suction room
7 Piston rod
8 Connecting boring from the overflow valve
to the control pressure injector
9 Detergent injector
10 High pressure outlet
11 Control pressure injector
12 Pressure room with pressure valves

English 5.905-945.0 Rev. 00 (06/15) 15
1 Lock trigger gun
2 Casing shell
3 Hand lever
4 High pressure hose
5 Hose guide
6 Safety clip
7 Needle bearing
8 Coupling high-pressure hose/trigger gun
9 O ring
10 Node piece
Function
When the manual lever is actuated, the valve in the node
piece opens and the water can flow from the hose through
the gun into the spray lance.
Note
The node piece cannot be repaired and must be replaced
as a complete unit.
The date of manufacture is imprinted on the node piece. It
is composed of the month (letters A to L for January
through December) and year (1-digit number 1 for 2011, 2
for 2012, etc.).
Example: H1 = August 2011
6.4 Hand spraygun

16 English 5.905-945.0 Rev. 00 (06/15)
1 Connection trigger gun
2 Connecting pin
3 Ceramic disc on gun side
4 Ceramic disc on spray pipe side
5 Casing of rotating regulator
6 Handle of rotary regulator
7 Spray lance connection
The pressure and volume regulation is designed as a rota-
ry regulator between the trigger gun and the spray lance.
Therearetwoceramicdiscswithinthehighpressure chan-
nel.
The ceramic disc is rigidly connected with the connection
of the trigger gun. The ceramic disc is connected to the ro-
tary switch and therefore adjustable. Offset holes in the ce-
ramic discs can adjust the flow volume and the pressure
when rotating the discs.
This illustration shows the two overlapping ceramic discs
and the water flow (blue) with different opening angles
(from 0° to 90°).
With the minimal setting, the water flows through a small
hose in the middle of the ceramic discs.
Water flow with opening angle 0° - 90°
6.5 Pressure and volume regulation

English 5.905-945.0 Rev. 00 (06/15) 17
A Position point jet
B Initial position
C Position flat stream
Function
The triple nozzle has two adjustable positions. By rotating
the nozzle head, you can switch between the chemicals
nozzle (low pressure) and the high-pressure nozzles.
The selection between spotlight nozzle and the flat jet noz-
zle is done by turning the spray lance while the hand lever
of the trigger gun is released.
In the process, the valve ball rolls in front of one of the two
nozzles and closes it.
To adjust the point jet, hold the trigger gun in the initial po-
sition and turn the handle to the left. Turn the handle to the
right for the flat stream.
The valve ball is kept in the selected position by the pres-
sure during work.
1 Detail nozzle
High pressure
2 Flat jet nozzle
High pressure
3 Chemicals nozzle (low pressure)
4 Spray pipe connection
5 High pressure channel
6 Valve ball
7 Adjustable nozzle head
6.6 Triple nozzle

18 English 5.905-945.0 Rev. 00 (06/15)
The device is equipped with a control and monitoring elec-
tronic system that monitors a number of functions.
In case of a continuous operation or a continuous break of
30 minutes, the immediate switch-off and locking of the de-
vice takes place.
Moreover, a visual signal is issued via the operating dis-
play (LED).
Both functions can be deactivated by means of the DIP
switch (see circuit diagram).
The system checks the device for leaks by monitoring the
pressure switch. If the pressure switch opens twice within
2 seconds and this recurs 10 times within 10 minutes, the
immediate switch-off and locking of the device takes place.
Moreover, a visual signal is issued via the operating dis-
play (LED).
This function can be deactivated by means of the DIP
switch (see circuit diagram).
If one phase fails, in case of excessive temperature, low
voltage or in case of a voltage difference between 2 phas-
es > 50 V, the immediate switch-off and locking of the de-
vice takes place.
Moreover, a visual signal is issued via the operating dis-
play (LED).
The excess temperature may occur due to the following
reasons:
–Over or low voltage
–Overload
–Poor motor cooling (water shortage or high tempera-
ture of the cooling water)
Operating display:
Error message:
6.7 Electronics system
6.7.1 Pump monitoring
6.7.2 Leakage monitoring
6.7.3 Motor protection
6.7.4 Display
LED illuminates
green Operation in order
LED blinks green Disconnection from the mains (time-
out)
LED is red Contactor or pressure switch not in
order
LED blinks red once Leak
LED blinks red twice Winding protection contact was trig-
gered
LED blinks red three
times Power supply
LED blinks red four
times Power consumption is too high End motor blockade

English 5.905-945.0 Rev. 00 (06/15) 19
The resetting of the system in case of faults takes place by
switching on and off the power switch.
6.7.5 Reset
6.7.6 Setting the DIP switches
ON OFF
1 1-phase device 3-phase device
2 Do not use No after run of the pump
3 Leakage monitoring No monitoring
4 30 minutes switch-off continuous operation / continu-
ous pause No switch-off

20 English 5.905-945.0 Rev. 00 (06/15)
Device with hose drum
Function
The bypass valve is to keep the pressure loss at a mini-
mum in high pressure operation.
In high pressure operation, the piston opens against the
spring force of the pressure spring and lets the water flow
to the high pressure outlet via the valve seat. This circum-
vents the nozzle insert. No detergent is suctioned and the
pressure loss remains low.
In low pressure operation, the pressure spring presses the
piston onto the valve seat and closes the water flow. The
entirewatervolumeflowsthroughthenozzleinsertand the
detergent is suctioned via the adapter.
6.8 Bypass valve
1
2
3
5
4
6
7
8
9
11
10
12
13
14
B
A
C
Position Description Nm
1 Detergent fitting 12 - 15
2 Sphere
3 Screw spring
4 Screwed sealing plug 15 - 17
5 Nozzle insert 1,5 - 2,5
6 Valve seat
7 Node piece
8 Liner, replaceable
9 O ring
10 Support ring
11 Piston
12 Valve bolt
13 Hexagonal screw 25 - 30
14 Pressure spring
A High pressure input
B High-pressure outlet
C Detergent inlet