Kärcher Puzzi 30/4 User manual

1English 5.905-007.0 Rev. 00 (06/14) 1
Puzzi 30/4
Service Manual

2 English 5.905-007.0 Rev. 00 (06/14)
Contents
Preface 4
Safety instructions 5
Danger or hazard levels 5
Description in this service manual 5
Service groups 5
Functional group structure 5
Textual description 5
Technical Features 6
General 6
Tools used 6
Field of application 7
Safety installations 7
Type plate 7
Overview of the appliance 8
Front view 8
View from behind 9
Overview service cover removed 10
Overview cover at the bottom removed 11
Overview of the components 12
AB service group bodywork / chassis 16
010 Safety information 16
General 16
020 Overview 16
030 Function 17
040 Service activities 17
Uninstall / install push handle 17
Uninstall / install holder for suction pipe 17
Uninstall / install steering roller 18
Uninstall / install running wheel 19
Remove the service cover 19
050 Maintenance and inspection 20
060 Error diagnosis 20
070 Peculiarities/ others 20
AC Service group suction system 21
010 Safety information 21
020 Overview 21
030 Function 17
040 Service activities 17
Uninstall / install waste water cover 22
Replacing the seal of the waste water cover 22
Uninstall / install suction nozzle 22
Uninstall/ install suction turbine 23
Uninstall / install flat fold filter 25
Uninstall / install suction hose connecting piece 25
050 Maintenance and inspection 20
060 Error diagnosis 20
070 Peculiarities/ others 20
AD Service group water system 27
010 Safety information 27
020 Overview 27
030 Function 27

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040 Service activities 28
Uninstall / install water pump 28
Uninstall / install hose from pump to the spray hose connection 28
Uninstall / install spray hose connection 29
Uninstall / install hose from the fresh water tank to the water pump 29
Uninstall / install float switch 30
Uninstall / install heating rods 31
Clean/ replace fresh water sieve 31
Uninstall / install water level indicator 32
Uninstall / install nozzle tip 32
050 Maintenance and inspection 33
060 Error diagnosis 33
070 Peculiarities/ others 33
AH service group electrics 34
010 Safety information 34
020 Overview 34
030 Function 34
040 Service activities 35
Unistall / install socket 35
Uninstall / install rotary switch 36
Uninstall/install appliance electronics 37
Uninstall / install heat sensor 38
Uninstall / install sensor 39
050 Maintenance and inspection 39
060 Error diagnosis 39
070 Peculiarities/ others 39
Technical Documentation 40
Technical specifications 40
Special tools 40
Circuit diagram 40

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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:
[e-mail]
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
Preface
Subject: Case 117515

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Service and maintenance tasks may only be performed by
qualified and specially trained specialists.
Observe safety information in the chapters!
DANGER
First pull out the plug from the mains before carrying out
any tasks on the machine.
CAUTION
Risk of damage by electrostatic discharge (ESD)! Take
suitable measures for discharging electrostatic charge pri-
or to performing work on the appliance electronics.
DANGER
Pointer to immediate danger, which leads to severe inju-
ries or death.
몇WARNING
Pointer to a possibly dangerous situation, which can lead
to severe injuries or death.
몇CAUTION
Pointer to a possibly dangerous situation, which can lead
to minor injuries.
ATTENTION
Pointer to a possibly dangerous situation, which can lead
to property damage.
Example: Install/uninstall ANRA wheel axle
Observe the allocation of service groups to the appliance
componentsintheoverviewdiagraminChapter"Overview
over the service and functional groups".
Instruction
Preparatory operations
1
2 Key numerical
A
B Key alphanumerical
–Enumeration / General list
Safety note
Pointer to hazards, sources of errors.
Safety instructions
Danger or hazard levels
Description in this service manual
Service groups
ON RA Install/uninstall wheel axle
Service group Component Activity
Functional group structure
010 Safety instructions
020 Overview
030 Function
040 Service activities
050 Maintenance and inspection
060 Error diagnosis
070 Peculiarities/ others
080 - 100 Not assigned
110 Replacement times
Textual description

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This spray extraction device is used as a wet cleaning de-
vice for carpets.
It can be adapted to the relevant cleaning task by setting
the rotary switch.
The wastewater tank can be removed for easier emptying.
A capacity of the fresh and waste water tank of 30 l allows
effective cleaning with long action times.
An additional socket is available for the connection of the
additional brush washing head PW 30/1.
Technical Features
General
Tools used
–Screwdriver T15
–Screwdriver T20
–Screwdriver T25
–Screwdriver T27
–Screwdriver T30
–Open-end wrench SW8
–Open-end wrench SW17
–Open-end wrench SW19
–Open-end wrench SW22
–Open-end wrench SW27
–Hexagon key 8

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This service manual describes the appliance Puzzi 30/4.
Safety devices serve to protect the user and must not be
rendered in operational or their functions bypassed.
Observe safety information in the chapters!
The type plate is located at the back on the service cover.
1 IP rating/ protection class
2 Part number
3 Year of manufacture
4 Weight
5 Admissible temperature range
6 Address of manufacturer
7 Bar code. Contains part and serial number.
8 Specifications
9 Performance data
10 Serial number
11 Appliance description
Field of application
Safety installations
Type plate

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Overview of the appliance
Front view
1 Suction hose
2 Pushing handle, adjustable
3 Rotating knob S1
4 Fastening screw for push-handle
5 Socket for additional brush washing head PW 30/1 X2
6 Holder for suction pipe
7 Impeller
8 Fresh water sieve
9 Steering roller with fixed position brake
10 Floor nozzle for carpet cleaning
11 Lid of the fresh water tank
12 Dirt water reservoir, detachable
13 Carrying handle of the wastewater container
14 Suction pipe
15 Spray hose
16 Suction hose connection
17 Spray hose connection
18 Bender

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View from behind
1Nameplate
2 Adapter for accessories (homebase) including cable
hooks
3 Power cord X1
4 Service cover
5 Filling level display

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Reset button
When filling in hot water from approx. 65-70°C, the heat
sensor switches off the electronics.
The electronics can be reset with the reset button.
Overview service cover removed
1 Suction turbine M1
2 Appliance electronics
3 Hose to the spray hose connection
4 Reset button
5 Hose from the fresh water tank
6 Water pump M2
7 Suction air tube

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Overview cover at the bottom removed
1 Float switch
2 Heating rods
3 Hose from the fresh water tank to the water pump

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Overview of the components

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Observe general safety information!
Service and maintenance tasks may only be performed by
qualified and specially trained specialists.
DANGER
First pull out the plug from the mains before carrying out
any tasks on the machine.
CAUTION
Risk of damage by electrostatic discharge (ESD)! Take
suitable measures for discharging electrostatic charge
prior to performing work on the appliance electronics.
AB service group bodywork / chassis
010 Safety information
General
020 Overview

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Casing
In the casing
–Rotating knob
–Fresh water tank
–Suction turbine
–Water pump
–Appliance electronics
–Chassis
are installed
Unscrew the screws on both sides of the push handle.
Pull the push handle out of the holders.
Loosen screws.
Hold up the nut.
030 Function
040 Service activities
Uninstall / install push handle
Uninstall / install holder for suction pipe

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Unscrew the screws.
Remove steering roller.
Loosen the nut.
Uninstall / install steering roller

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Remove the wheel cover.
Lever the clamping washer off the axle.
Use a new clamping washer upon installation.
Unscrew the screws.
Put the service cover aside.
Uninstall / install running wheel
Remove the service cover

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Check wheels for ease of movement.
Check whether the axle is bent.
The service group does not contain any peculiarities.
050 Maintenance and inspection
060 Error diagnosis
Findings Possible cause Correction
Damage, cracks External mechanical impact Replace casing, instruct operator
Casing distorted Thermal impact Replace casing
070 Peculiarities/ others