Kärcher HDS Middle series User manual

Service Manual
HDS Middle Range
1.071-..., 1.077-...
HDS 7/12, HDS 8/17, HDS 9/18, HDS 10/20
HDS Premium Range
1.071-...
HDS 12/18, HDS 13/20
Service Manual 04.2008 5.906-433.0

HDS Middle Range / HDS Premium Range
Page 2 / 127 Service Manual 04.2008

HDS Middle Range / HDS Premium Range Foreword
Service Manual 04.2008 Page 3 / 127
Foreword
Good service work requires comprehensive and practical training as well as clear documents.
We therefore provide regular basic training and further training courses for service technicians
covering our whole range of products.
Inaddition,weproduce servicemanuals forthe mostimportant units,which caninitially beused as
instructions and later for reference purposes.
Furthermore, we regularly provide service information about new product developments.
Shouldyouhaveanyadditions,correctionsorquestionsregardingthisdocument,pleasesendthem
to the following quoting the given subject:
[email protected]
The texts and images are not to be copied, reproduced or given to third parties without our explicit
prior consent:
ALFRED KÄRCHER GmbH & Co.
CUSTOMER SERVICE TRAINING
Postfach 160
D-71349 Winnenden
www.kaercher.com
Subject: Fall 105756
We reserve the right to introduce technical changes without prior notice.

Contents HDS Middle Range / HDS Premium Range
Page 4 / 127 Service Manual 04.2008
Contents
1 Equipment Features ............................................................................................6-9
1.1 Technical Features..................................................................................................6
1.2 View from the front...................................................................................................7
1.3 View from the rear (unit without hose reel)..............................................................8
1.4 View from the rear (unit with hose reel)...................................................................9
2 Unit Function ...................................................................................................10-62
2.1 Control panel ................................................................................................. 10-16
2.1.1 Control panel, view from inside..............................................................................15
2.1.2 Printed circuit board, control panel ........................................................................16
2.2 Control panel with display (HDS 13/20 only).............................................. 17-21
2.2.1 Status displays ......................................................................................................18
2.2.2 Maintenance - operating liquids .............................................................................18
2.2.3 Error messages.....................................................................................................19
2.2.4 Error messages with service requirement ............................................................20
2.2.5 DGT setting ...........................................................................................................21
2.2.6 Self-service mode..................................................................................................21
2.3 Storage compartments ..........................................................................................22
2.4 Unit cover ..............................................................................................................23
2.5 View from the right, unit cover removed................................................................24
2.6 Service switch.......................................................................................................25
2.7 Fuel tank ................................................................................................................26
2.8 Scale inhibitor .................................................................................................. 27-29
2.9 Float tank ...............................................................................................................30
2.10 Cleaning agent tank 1............................................................................................31
2.11 Cleaning agent tank 2............................................................................................32
2.12 Motor (air-cooled) ............................................................................................ 33-34
2.13 Electrical box, air-cooled motor .............................................................................35
2.14 Motor (water-cooled) ....................................................................................... 36-37
2.15 Electrical box, water-cooled motor ........................................................................38
2.16 Pump .....................................................................................................................39
2.17 Safety block..................................................................................................... 40-42
2.18 Burner fan with fuel pump ................................................................................ 43-44
2.19 Continuous-flow heater.................................................................................... 45-47
2.20 Burner .............................................................................................................. 48-49
2.21 Outlet, continuous-flow heater...............................................................................50
2.22 Softgrip easy-press handgun ................................................................................51
2.23 Pressure and flow control valve with rotary control ..............................................52
2.24 Functional diagram, pressure operation .......................................................... 53-54
2.25 Functional diagram, suction feed operation..................................................... 55-56
2.26 Pressure and flow control valve function ........................................................ 57-58
2.27 Pressure switch function ................................................................................. 59-62
3 Basic Settings and Service Procedures ......................................................62-104
3.1 Service functions with LED display...................................................................63
3.1.1 Adjusting the stopping behaviour...........................................................................64
3.1.2 Adjusting the leakage behaviour............................................................................64
3.1.3 Flame sensor brightness value .............................................................................65
3.1.4 RFID query ............................................................................................................66
3.1.5 Testing the temperature sensor.............................................................................66
3.1.6 Testing the water temperature setting and program switch............................. 67-69
3.1.7 Testing the Service switch ....................................................................................70
3.1.8 Testing the sensors...............................................................................................71
3.1.9 Fault memory ................................................................................................... 72-73

HDS Middle Range / HDS Premium Range Contents
Service Manual 04.2008 Page 5 / 127
Contents
3.1.10 Operating hours.....................................................................................................74
3.1.11 Handgun switchings since the handgun service...................................................75
3.1.12 Handgun services .................................................................................................76
3.1.13 Handgun switchings since initial operation............................................................77
3.1.14 Operating time of the burner since the burner service ..........................................78
3.1.15 Burner services.....................................................................................................79
3.1.16 Burner operation since initial operation..................................................................80
3.1.17 Operating time of the pump since the pump service .............................................81
3.1.18 Pump services ......................................................................................................82
3.1.19 Pump operation since initial operation ...................................................................83
3.2 Service functions with display...........................................................................84
3.2.1 Adjusting the stopping behaviour...........................................................................85
3.2.2 Adjusting the leakage behaviour............................................................................85
3.2.3 RFID query ............................................................................................................85
3.2.4 Flame sensor brightness value .............................................................................86
3.2.5 Testing the temperature sensor.............................................................................86
3.2.6 Testing the water temperature setting and program switch...................................86
3.2.7 Testing the Service switch ....................................................................................87
3.2.8 Testing the sensors...............................................................................................87
3.2.9 Fault memory .........................................................................................................88
3.2.9 Fault memory .........................................................................................................89
3.2.10 Operating hours.....................................................................................................89
3.2.11 Handgun switchings since the handgun service...................................................90
3.2.12 Handgun services .................................................................................................90
3.2.13 Handgun services since initial operation...............................................................90
3.2.14 Operating time of the burner since the burner service ..........................................90
3.2.15 Burner services.....................................................................................................91
3.2.16 Burner operation since initial operation..................................................................91
3.2.17 Operating time of the pump since the pump service .............................................92
3.2.18 Pump services ......................................................................................................92
3.2.19 Pump operation since initial operation ...................................................................92
3.3 Burner setting ........................................................................................................93
3.4 Installing the air circuit on the outer jacket ............................................................94
3.5 Adjusting the operating pressure using the rotary control on the handgun ..... 95-96
3.6 Adjusting the operating pressure using standard handgun without rotary control .97-98
3.7 Removing the hose reel................................................................................. 99-102
3.8 Removing the pressure gauge ............................................................................103
3.9 Adjusting the safety valve ...................................................................................104
4 Circuit Diagrams ..........................................................................................105-116
4.1 Circuit diagram – 0.088-021 (HDS 7/12) ..................................................... 105-107
4.2 Circuit diagram – 0.088-025 (HDS 8/17, HDS 9/18) ................................... 108-110
4.3 Circuit diagram – 0.088-052 (HDS 10/20, HDS 12/18) ............................... 111-113
4.4 Circuit diagram – 0.088-026 (HDS 13/20) ................................................... 114-116
5 Troubleshooting ..........................................................................................117-118
6 Technical specifications ....................................................................................119
7 Special tools .......................................................................................................119
8 Tightening torque ...............................................................................................120
9 Index .............................................................................................................121-127

Equipment Features HDS Middle Range / HDS Premium Range
Page 6 / 127 Service Manual 04.2008
General:
Mobile hot water high-pressure cleaner with
various power ratings for commercial use.
– High-performance burner with vertical heat-
ing coil and continuous ignition.
– Integrated scale inhibitor.
– Steam operation (water temperatures up to
155 °C) with separate steam nozzle.
– Burnerfanandfuelpumpdirectlyontheelec-
tric motor.
Unit connected load:
– 3.4 kW (HDS 7/12-4 M/MX).
– 5.5 kW (HDS 8/17-4 M/MX).
– 6.4 kW (HDS 9/18-4 M/MX).
– 7.8 kW (HDS 10/20-4 M/MX).
– 8.4 kW (HDS 12/18-4 S/SX).
– 9.3 kW (HDS 13/20-4 S/SX).
Pump:
– 3 piston axial pump with stainless steel pis-
tons, with ceramic coating in several models.
– Cylinder head made of brass.
– High-pressure and suction valves made of
stainless steel.
– Working pressure: 3-20 MPa (30-200 bar).
– Water volume: 350-1300 l/h.
– With pressure gauge.
– Overflowvalvewithpressureandflowcontrol
valve.
– Float tank.
– Safety valve.
– Fine water filter.
Electronics:
– Program switch.
– Flame sensor (optional).
– Water temperature control with temperature
sensor.
– Exhaust temperature limiter.
– Low-water protection.
– Dry running protection for pump.
– Levelsensorforfuel,scaleinhibitorandclean-
ing agent tanks (partly optional).
– Operating hours counter.
– Fault memory.
– Component check.
– Faultmonitoring.
– Rotary direction monitoring.
Cleaning agent:
– 2 cleaning agent tanks.
– Cleaning agent suction with fine filter.
– Metering valve on unit with automatic rinsing
in neutral position.
– Cleaning agent operation with low pressure
and high pressure.
Accessories:
– Rotary control for pressure and flow control
valve
– Softgrip easy-press handgun
– Stainless steel spray lance, rotatable
– Power nozzle (25°), (stainless steel)
– Steam nozzle (brass)
1.1 Technical Features

HDS Middle Range / HDS Premium Range Equipment Features
Service Manual 04.2008 Page 7 / 127
1 Push handle (2x)
2 Cover, top storage compartment
3 Safety latch, softgrip easy-press
handgun
4 Rotary control
5 Trigger lever
6 Softgrip easy-press handgun
7 Cap, fuel tank
8 High-pressure hose
9 Rotatable spray lance
10 High-pressure nozzle
11 Transport wheel (2x)
12 Transport handle
13 Swivel castor
14 Swivel castor with parking brake*
15 Chassis
16 Unit cover
17 Exhaust gas flue, continuous-flow heater
18 Latch, unit cover
*) HDS 7/12 and HDS 8/17 have one swivel
castor only.
1.2 View from the front
1
2
3
4
7
9
10
11
12
16
18
5
6
8
14
13
17
15

Equipment Features HDS Middle Range / HDS Premium Range
Page 8 / 127 Service Manual 04.2008
1.3 View from the rear (unit without hose reel)
13
1 Indicator lights
2 Program switch (Q1)
3 Adjustment, water temperature
4 Spray lance holder, RH
5 Cap, scale inhibitor tank
6 Storage, mains cable
7 Storage compartment, bottom
8 Mains cable
9 Cap, cleaning agent tank 2
10 High-pressure outlet
1
2
3
4
5
7
8
9
12
10
6
14
16
15
18
17
19
20
11 Chassis
12 Water connection with fine water filter
13 Tread
14 Cap, cleaning agent tank 1
15 Storage, high-pressure hose
16 Cap, fuel tank
17 Adjustment, cleaning agent metering
18 Spray lance holder, LH
19 Pressure gauge
20 Cover, top storage compartment
11

HDS Middle Range / HDS Premium Range Equipment Features
Service Manual 04.2008 Page 9 / 127
1.4 View from the rear (unit with hose reel)
15
1
2
3
4
5
7
8
9
14
12
6
16
18
17
20
19
21
22
10
11
1 Indicator lights
2 Program switch (Q1)
3 Adjustment, water temperature
4 Spray lance holder, RH
5 Cap, scale inhibitor tank
6 Storage, mains cable
7 Hose reel, high-pressure hose
8 Mains cable
9 Cap, cleaning agent tank 2
10 Crank handle, hose reel
11 Recess, hose reel locking device
12 High-pressure hose
13 Chassis
14 Water connection with fine water filter
15 Tread
16 Cap, cleaning agent tank 1
17 Storage, high-pressure hose
18 Cap, fuel tank
19 Adjustment, cleaning agent metering
20 Spray lance holder, LH
21 Pressure gauge
22 Cover, top storage compartment
13

Unit Function HDS Middle Range / HDS Premium Range
Page 10 / 127 Service Manual 04.2008
2.1 Control panel
1 Indicator LED 0, pump (red)
2 Indicator LED 1, rotational direction (red)
3 Indicator LED 2, operation (green)
4 Indicator LED 3, fuel (yellow)
5 Indicator LED 4, cleaning agent tank 1
(yellow)
6 Indicator LED 5, motor (red)
7 Indicator LED 6, burner (red)
8 Indicator LED 7, service (orange)
9 Indicator LED 8, scale inhibitor (yellow)
10 Indicator LED 9, cleaning agent tank 2
(yellow)
11 Program switch „OFF“ position
12 Program switch „Cold Water Operation“
position
16
18
1 2 3 4 5
6 7 8 9 10
11
12
13
14
19
20
13 Program switch „Eco Mode*“ position
14 Program switch „Hot Water/Steam Ope-
ration“ position
15 Program switch
16 Adjustment, water temperature
17 Metering valve, cleaning agent
18 Metering range, cleaning agent 1
19 Metering range, cleaning agent 2
20 Pressure gauge
15
17
* Note
In„EcoMode“thewatertemperatureiskept
at60°C(+/-9).Adjustedwatertemperatures
< 60°C are effective, settings > 60°C re-
main ineffective.

HDS Middle Range / HDS Premium Range Unit Function
Service Manual 04.2008 Page 11 / 127
2.1 Control panel
Functions of the LED displays in operating mode
Symbol Activity Meaning / Action
1 x flashing
LED No.
02 x flashing
3 x flashing
4 x flashing
1 x flashing
lightup
1
1 x flashing
2
lightup3
lightup4
1 x flashing
52 x flashing
3 x flashing
4 x flashing
1 x flashing
6
2 x flashing
3 x flashing
lightup7
Insufficientoil.Check/topuptheoillevelofthehigh-pressure
pump.
Leakage. Check high-pressure system for leaks.
Dry running. Check water inlet/ensure water supply.
Reed switch sticks. Check safety block/repair reed switch.
Motorrotates in the wrong direction.Switch off the unit and
rotate the phase inverter in the unit plug through 180°.
Unit is ready for operation.
Unit was either in continuous operation for 30 minutes or
was in standby operation for 30 minutes.
Fuel tank is empty. Add more fuel.
Cleaning agent tank 1 is empty. Add more cleaning agent
(HDS 12/18 only).
Fault in the motor contactor (motor current below 1.5 A for
3 seconds although contactor connected). Check/replace
contactor.
Motorthermalcontactisopen/defective.Determine/remove
cause. Replace the motor
Current asymmetry or undervoltage or overvoltage. Check
mains connection.
Current consumption too high. Check mechanics for
resistance. Check mains connection.
Exhaust thermostat is open. Check exhaust temperature/
replace thermostat. Perform burner maintenance.
.
Flamesensorsignalsburnerfault.Cleanandcheckburner,
ignition and fuel system.
RFID read-write electronics are defective - replace.
Service work is due.
4 x flashing Temperaturesensorfault.Cablebreak(temperaturebelow
-5 °C, although burner is on) or short-circuit (temperature
above 220 °C for a lengthy period).

Unit Function HDS Middle Range / HDS Premium Range
Page 12 / 127 Service Manual 04.2008
Symbol Activity Meaning / Action
LED No.
lightup
8Scale inhibitor level switch detects empty or units on the
tag* of the scale inhibitor bottle have been used up.
1 x flashing 5 hours after-running time have expired, burner is blocked.
Insert new scale inhibitor bottle.
lightup Cleaning agent tank 2 is empty. Add more cleaning agent
(HDS 12/18 only).
9
* Note
The tag is an electronic component on the
new rectangular scale inhibitor bottle.The
tagislocatedbehindthebottlelabel.Thetag
can be electronically read and written. See
also Chapter 2.8.2.
2.1 Control panel
Functions of the LED displays in operating mode

HDS Middle Range / HDS Premium Range Unit Function
Service Manual 04.2008 Page 13 / 127
2.1 Control panel
Template for numerical value displays
ThetemplatebelowcanbeplacedontheLEDdisplaysofthecontrolpanelforimprovedrecognition
of the numerical value displays in the service functions.
Template for placing on the control panel

Unit Function HDS Middle Range / HDS Premium Range
Page 14 / 127 Service Manual 04.2008
2.1 Control panel

HDS Middle Range / HDS Premium Range Unit Function
Service Manual 04.2008 Page 15 / 127
2.1.1Control panel, view from inside
1
11
2
3
5
6
4
7
8
9
10
12
13
1 Service switch and adjustment, scale
inhibitormetering
2 Control circuit transformer (T1)
3 Current transformer
4 Fuse 2.0 AT (6.644-052) for control
circuit transformer T1
5 Terminal strip
6 Earthpoint
7 Mains cable
8 Adjustment, water temperature
9 Program switch
10 Printed circuit board, control panel
11 Cleaning agent metering valve
12 Pressure gauge
13 Exhaust temperature limiter
14 Cable comb
14

Unit Function HDS Middle Range / HDS Premium Range
Page 16 / 127 Service Manual 04.2008
2.1.2Printed circuit board, control panel
1 2 3 4 5
8
9
111213
14
15
16
17
18
19
20
21
1 Connection, cleaning agent tank 1 level
sensor
2 Connection, cleaning agent tank 2 level
sensor
3 Connection, fuel tank level sensor
4 Connection, scale inhibitor level switch
5 Connection, current transformer
6 Connection, flame sensor
7 Connection, temperature sensor
8 DIP switches
9 Connection, program switch
10 Connection, RFID
11 Connection, service switch
12 Connection, water temperature
adjustment
13 Connection, motor distributor printed
circuit board
14 Earth connection, printed circuit board
15 Connection, control circuit transformer 1
16 Connection, control circuit transformer 2
(optional)
17 Connection, exhaust temperature limiter
18 Connection, low-water protection
19 Connection, scale inhibitor solenoid valve
20 Connection, solenoid valve
cleaning agent 1 (optional)
21 Connection, solenoid valve
cleaning agent 2 (optional)
22 Codingpin
23 Recess for coding pin
6
DIP switches (8)
All DIP switches are set to „OFF“ in the factory.
The following functions can be activated by
changing these settings:
DIP1 on: Not rotational direction monitoring (in
single phase units)
DIP2 on: Flame sensor is evaluated
DIP3 on: Pump after-running for soft start-up
operation
DIP4 on: Metering of scale inhibitor liquid for
water volume ≥1000 litres
Plug coding
Theplugsfortheprintedcircuitboardconnections
havecodingpins(22)andmatchingrecessesin
the printed circuit board holder (23) so that only
the respective appropriate plug can be plugged
into a connection.
22 23
7
10

HDS Middle Range / HDS Premium Range Unit Function
Service Manual 04.2008 Page 17 / 127
2.2 Control panel with display (HDS 13/20 only)
1 Display
2 Program switch „OFF“ position
3 Program switch „Cold Water Operation“
position
4 Program switch „Eco Mode*“ position
5 Program switch „Hot Water/Steam Ope-
ration“ position
6 Program switch
7 Adjustment, water temperature
7
9
2
3
4
5
10
11 6
8
14
13
12
1
8 Metering valve, cleaning agent
9 Metering range, cleaning agent 1
10 Metering range, cleaning agent 2
11 Pressure gauge
12 Level, cleaning agent tank 2
13 Level, cleaning agent tank 1
14 Level,fuel
* Note
In„EcoMode“thewatertemperatureiskept
at60°C(+/-9).Adjustedwatertemperatures
< 60°C are effective, settings > 60°C re-
main ineffective.

Unit Function HDS Middle Range / HDS Premium Range
Page 18 / 127 Service Manual 04.2008
2.2.1Status displays
Display NoteExplanation
Pump maintenance due
Burner maintenance due
Accessories maintenance due
2.2.2Maintenance - operating liquids
Display NoteExplanation
Scale inhibitor empty.
Scale inhibitor bottle missing or the 5 hours’ after-running time
have expired. The burner is blocked.
Top bar: Fuel level (8 levels)
Middle bar: Cleaning agent 1 level (4 levels)
Bottom bar: Cleaning agent 2 level (4 levels)
In the event of a cable break the respective bar is not displayed at
all.
Perform maintenance.
Reset pump hours.
Perform maintenance.
Reset burner hours.
Perform maintenance.
Reset handgun switchings.
High-pressure pump oil refill container is empty.
Insert new bottle.
Insert new bottle.
Add more oil.
Note
Statusandmaintenancedisplaysaredisplayedconsecutively,likeinaslideshow.Eachimage
is displayed for 3 seconds.
The fault displays remain until the unit is switched off.

HDS Middle Range / HDS Premium Range Unit Function
Service Manual 04.2008 Page 19 / 127
2.2.3Error messages
Display NoteExplanation
Rotating field incorrect.
Motor thermal contact (WSK) in the motor has actuated.
Mains voltage too low or too high or phase has failed or motor current
too high.
Check mains connection.
Check pump for sluggishness.
Insufficient water
Invert phase in the commuta-
ting pole plug
.
Switch off unit and
let the motor cool down.
Exhaust temperature too high Perform burner maintenance.
Time monitoring active for 30
min, continuous pause/
continuous operation
Open water tap.
Ensure water supply.
Switch off unit and then
switch on again.

Unit Function HDS Middle Range / HDS Premium Range
Page 20 / 127 Service Manual 04.2008
2.2.4Error messages with service requirement
Display NoteExplanation
Low-water protection sticks
10 short start-ups/leakage
Contactor does not switch
Temperature sensor (NTC) is defective
Flame sensor detects impermissible state
Check low-water protection.
Remove leaks in the high-
pressure system.
Check contactor.
Check current transformer
installation.
This fault is not saved.
Check NTC
NTC cable chafed bare
Possible causes:
- Fuel solenoid valve
- Fuel line/filter
- External light
- Inspection glass is sooty
- Scale in combustion chamber
- Fuel empty and
fuel empty signal is defective
RFID read-write electronics are defective Check connection with RFID
read-write electronics.
Note
One display is used here for several faults. It may be possible to localise the fault by reading
out the fault memory.