Stiga HPS 110 Programming manual

Year of manifacture 2018--->2021
Revision 0 (10/4/2018)
Troubleshooting
Manual
HIGH PRESSURE CLEANERS
HPS 110 - HPS 235 R - HPS 345 R - HPS 550 R - HPS 650 R

Maintenance Guide HPC 1 / 17
1. Summary
1. Summary.........................................................................................................................1
2. Identification and procedures ..........................................................................................2
2.1 Identification .............................................................................................................2
2.2 Warranty validity.......................................................................................................2
2.3 Out-of-warranty service repairs.................................................................................2
2.4 Fault reporting...........................................................................................................2
2.5 Spare parts request..................................................................................................3
3. Safety regulations............................................................................................................3
4. Controls and Main components.......................................................................................4
5. Specifications, schedules and appendices......................................................................5
5.1 Electrical data...........................................................................................................5
5.2 Electric Motor type....................................................................................................5
5.3 Operating supplies....................................................................................................5
5.3.1 Recommended oil types .............................................................................................. 5
5.3.2 Recommended lubrication ........................................................................................... 6
5.3.3 Recommended adhesive............................................................................................. 6
6. Maintenance....................................................................................................................7
7. Cleaning and Storage......................................................................................................7
8. Troubleshooting...............................................................................................................7
9. Servicing (Disassembly –Checks –Assembly).............................................................10
9.1 Servicing the Inlet Filter and Nozzle .......................................................................10
9.2 Servicing the Inlet Valves .......................................................................................11
9.3 SServicing the Outlet Valves ..................................................................................13
9.4 Servicing the Oil Seals and Pistons........................................................................14
9.5 Servicing the Swashplate Bearings ........................................................................15
9.6 Servicing the Wet End............................................................................................15
9.7 Servicing the TSS System......................................................................................16
10. Electrical Diagram......................................................................................................17

Maintenance Guide HPC 2 / 17
2. Identification and procedures
General informations:
This chapter covers all the main aspects of the relationship between the Manufacturer and the Service
Centres.
A close collaboration between the Manufacturer and the Service Centres is key to solving problems
in the most effective way as well as maintaining an image of efficiency and reliability.
Compliance with these brief and simple guidelines will facilitate this task and prevent general
misunderstandings and time-wasting procedures for both the manufacturer and the service centre.
2.1 Identification
Each machine has a label attached on the back side, which states the technical specifications, the
model and the serial number.
The model and serial number must be shown on each repair sheet when requests are made
under warranty, and are mandatory for spare part orders.
2.2 Warranty validity
The warranty is supplied under the terms and the limits of the contractual relations in force.
2.3 Out-of-warranty service repairs
The Service Centre shall issue a report containing the machine’s serial number, a summary of the
problem, the repairs carried out and any spare parts used for each repair operation performed on the
machine.
A copy of this report must be retained to be made available to the Manufacturer together with the parts
in case of any subsequent disputes with Customers.
2.4 Fault reporting
The Manufacturer welcomes any reports on faults that recur with particular frequency. It gives the
opportunity for a careful inspection of the problem and the implementation of corrective action at an in-
production level.

Maintenance Guide HPC 3 / 17
Similarly, the Manufacturer shall report faults discovered on the machines produced, with
recommendations for the most suitable procedures to remediate the same.
2.5 Spare parts request
When requesting spare parts, the code number must be given, referring to the exploded charts for
the year of manufacture, shown on the identification label [2.1Identification]
3. Safety regulations
General information:
This chapter covers the main aspects of a servicing procedure and the general rules for guaranteeing
a successful service, which respects the safety of the machine.
A) Qualification of operators
All maintenance, disassembly and repairs must be carried out by expert mechanics who are familiar
with all the accident prevention and safety regulations after reading through the procedures in this
manual.
B) Safety measures
All the machines are manufactured in accordance with the strict European safety regulations in force.
To maintain these levels of safety in the long term, the Service Centres should work to this end by
making appropriate checks every time there is the chance to do so.
In particular, every time work is performed on the machine, the Service Centre should:
1) check:
that the casings and protection guards have not been removed;
that the labels bearing instructions or provisions have not been removed or have become
illegible (these form an integral part of the safety system).
2) they should also:
reassemble inefficient, damaged or missing casings and protection guards;
replace illegible labels;
not endorse any repair or modification on the machine which results in a change in
performance or use that is improper or different from the purpose for which it was
designed and approved;
warn the Customer that failure to comply with the above points shall result in the
automatic cancellation of the Warranty whereby the Manufacturer is relieved from all
and any responsibility.
C) Precautions during servicing
The operations described in this manual do not entail particularly hazardous situations besides the
normal hazard relatedto mechanical operations and that can be avoided by taking the necessary care
and attention normally required for this type of work.
As well as following the usual accident prevention regulations that apply to most repair shops, we
recommend you:
ensure that other persons cannot accidentally carry out actions that may physically
endanger those working on the machine;
always use original spare parts and accessories;
disconnect the electrical power supply before carrying out user maintenance;
high pressure jets can be dangerous. Never direct the water jet at persons, pets, live
electrical equipment or towards the machine itself;
never try to clean clothes or footwear on yourself or other persons;
ENSURE that all people or animals are kept at a minimum distance of 16 yd. (15m).
D) Necessary equipment
All the operations can be carried out with the tools normally used in a reputable workshop

Maintenance Guide HPC 4 / 17
4. Controls and Main components
Nr.
Description
Nr.
Description
1
Lance
8
Pressure regulator
2
Gun with safety catch
9
Handle
3
Electric cable with plug
10
Pressure gauge
4
High pressure hose
11
ON/OFF Knob
5
Detergent tank
12
Wheels
6
Nozzle
13
Hose reel handle
7
Detergent regulator
14
Tube unlock button
3
2
HPS 650 RG
1
4
5
HPS 345 R
6
7
8
9
10
11
12
13
14

Maintenance Guide HPC 5 / 17
5. Specifications, schedules and appendices
All the data shown in the table below are reported on the "Identification Label" (2.1) that we
recommend you consult before any intervention on the machine.
Type
Model Name
Voltage
Frequency in Hz
Power in kW Weight in kg
Water Flow in l/min
Max Water Flow in
l/min
Pressure in MPa
(bar)
Max Suply Temp.
In (°C)
Max Pressure in Mpa
(bar)
Max Supply
Pressure in Mpa
(bar)
HPS 110 HPS 110 220-240~ 50/60 1.4 5.2 5 6.5 7,4 (74) 50 11 (110) 1 (10)
HPS 235 R HPS 235 R 220-240~ 50/60 1.8 12.3 5.5 7.3 10 (100) 50 13,5 (135) 1 (10)
HPS 345 R HPS 345 R
220-240~ 50 2.1 17.4 6 7.5 11 (110) 50 14,5 (145) 1 (10)
HPS 550 R HPS 550 R
220-240~ 50 2.5 24.4 6.7 8.6 13 (130) 50 15 (150) 1 (10)
HPS 650 RG HPS 650 RG
220-240~ 50 2.8 27 8.3 9.1 14 (140) 50 15 (150) 1 (10)
5.1 Electrical data
Current absorbed(Ampere at 230 Volt )
HPS 110
HPS 235 R
HPS 345 R
HPS 550 R
HPS 650 RG
5.5
8,5
8
11
13
The table shows reference values when measured using the current clamp with the machine
working at high pressure. ± 10% deviations from the table values are allowed.
5.2 Electric Motor type
5.3 Operating supplies
Recommended oil types
The swash plate housing is filled with SAE 30 oil (for the quantity see table below) during the
production phase.
In case of servicing where the oil must be changed, STIGA recommends to use SAE 15W40.
OIL quantity (ml)
HPS 110
HPS 235 R
HPS 345 R
HPS 550 R
HPS 650 RG
65
60
60
60
80

Maintenance Guide HPC 6 / 17
Recommended lubrication
White silicone grease for O-rings, sealings (MOLYCOTE PG54 type)
Recommended adhesive
Thread lock RED Loctite 243, alternatively Loctite 245
Thread lock GREEN Loctite 680, alternatively Loctite 270 or 271
The exploded view below relates to HPS 650 RG model, but the information is valid for all models.
GREASE(To be used on all OR rings, and where indicated( Pic.1)
LOCTITE (RED LOCTITE: to be used on detergent connection and where
indicated (Pic.1)
Pic, 1

Maintenance Guide HPC 7 / 17
6. Maintenance
Instructions on how to perform proper maintenance are provided in the owner’s manual.
The Service Centre should undertake tokeep themachine in perfect working order tuning the machine
whenever possible.
By performing the following checks:
presence of damage caused by: improper use, abuse or negligence, impact. Presence of
limescale;
condition of the electric cable and plug (complete, original, damage, tampered with;
general condition of the machine: cleanliness, nozzle (limescale), condition of inlet water filter;
evident leaks: oil/water.
By performing a functional test at the end of each servicing operation, to check that the operations
performed are effective. The test must be conducted in compliance with the safety regulations
regarding the use of the machine
The functional test is carried out as follows:
connect the original accessories deliveredwith the machine: Gun, Lance, High Pressure Hose,
Inlet Water Filter
connect the Pressure Washer to the electrical and water supply (see User Manual)
open the gun (pull the trigger) and switch the pressure washer on
proceed with the functional test for a few minutes, repeat various gun open/gun closed cycles
Note abrupt pressure fluctuations, abnormal noise or vibration of the machine or its
accessories. Visually check for oil or water leaks.
7. Cleaning and Storage
Instructions to perform proper cleaning and indications for correct storage longer than 30 days, are
provided in the owner’s manual.
Please follow the instructions provided in the owner's manual - "Maintenance and storage” chapter.
8. Troubleshooting
General information:
This chapter deals with the problems connected to the malfunctioning of the machine along with the
probable cause and the remedial action to be taken.
The owner’s manual already gives a basic troubleshooting guide to assist the user in solving the most
common possible malfunctions.
The following session will omit the basic troubleshooting and will only focus on the possible
malfunctions and remedies requiring the intervention of skilled servicing operators.
Section A - Pressure/Flow
Nr.
PROBLEM
Nr.
PROBABLE CAUSE
REMEDY
1
The Pressure Washer
does not reach the
correct pressure (see
unit data plate
2.1Identification)
ATTENTION
(if vibration of the HPC
hose is present, see **).
1
Incorrect setting of adjustable
lance head.
Move the adjustable lance head to the High
Pressure position (see User Manual).
2
Nozzle worn.
Check machine with a new lance, if
confirmed, replace lance/nozzle.
3
Wrong nozzle.
4
TSS (Bypass) system
malfunction.
Check function of TSS actuator piston and
micro switch, if necessary, replace complete
TSS using service kit.
**5
Inlet water filter dirty/damaged.
Clean filter or replace it if damaged.
**6
Air in pump.
Switch the machine OFF, pull trigger and
wait for a continuous flow of mains pressure
water to flow out.
**7
Valves dirty/damaged.
Clean valves (replacement preferred).
Replace valves using service kit.

Maintenance Guide HPC 8 / 17
Section A - Pressure/Flow
Nr.
PROBLEM
Nr.
PROBABLE CAUSE
REMEDY
2
Pressure fluctuations in
continuous use (trigger
pulled) (if the motor
switches ON/OFF see
B.2).
1
Inlet water filter dirty/damaged.
Clean filter or replace it if damaged.
2
Valves dirty/damaged.
Clean valves (replacement preferred).
Replace valves using service kit.
3
Malfunctions indicated by
client but not present in
functional test.
1
Pressure fluctuation.
Water supply from a water tank or well -
connect unit to mains water supply
2
Pressure/Flow reduced with
noise/vibration.
Cavitation (air in the water supply). Request
client to check his water hose/connectors.
3
Reduced flow.
Insufficient water supply and/or incorrect
water supply hose (see User Manual).
Section B –Electrical (Amps)
Nr.
PROBLEM
Nr.
PROBABLE CAUSE
REMEDY
1
Electric motor does not
start
1
ON/OFF switch in position
OFF or faulty.
Turn switch to ON position.
Check/replace ON/OFF switch.
2
Power lead/plug damaged or
disconnected.
Insert plug in mains socket.
Replace mains lead and plug.
3
TSS system malfunction.
Check function of TSS actuator piston and
micro switch, if necessary, replace complete
TSS using service kit.
4
(Brush motor) Brushes
worn/faulty.
Replace brushes.
5
(Induction motor) Condenser
faulty.
Check/Replace condenser.
6
Nozzle blocked.
Check machine with a new lance, if
confirmed, clean nozzle.
7
Gun faulty.
Check/replace gun.
8
In presence of burnt smell,
check motor
See B.6.Check for water ingress in motor.
Power supply not correct (see unit data plate).
Use of incorrect extension lead or generator
(see User Manual).
9
In case of machine out of use
for a long time.
Disconnect the power supply and manually
turn the motor fan to unblock the pump.
2
With trigger pulled, motor
switches ON and OFF.
1
TSS system malfunction.
Check function of TSS actuator piston and
micro switch, if necessary, replace complete
TSS using service kit.
2
(Brush motor) Brushes
worn/faulty.
Replace brushes.
3
ON/OFF switch faulty.
Check/replace ON/OFF switch.
4
False contact.
Check machine wiring.
3
With trigger pulled, motor
switches OFF after a
certain period of time.
1
Nozzle partially blocked.
Check machine with a new lance, if
confirmed, clean/replace lance/nozzle.
2
Motor thermal protection has
intervened because of
overheating of the motor,
confirmed if the motor will
restart after cooling. Eliminate
cause of overheating. Nb.
Repeated intervention of the
protector will cause it to fail
If the thermal protector has been damaged
because of repeated intervention, replace
motor (for induction motor) or motor/pump
assembly (for brush motor).
4
Motor hums but will not
start (induction motor
only).
1
In case of machine out of use
for a long time.
Disconnect the power supply and manually
turn the motor fan to unblock the pump.
2
Condenser.
Check/Replace condenser.
5
Malfunctions indicated by
client but not present in
functional test.
1
Motor hums but will not start
(induction motor only).
Power supply not correct (see unit data plate).
Use of incorrect extension lead or generator
(see User Manual).
2
Motor does not start.

Maintenance Guide HPC 9 / 17
Section B –Electrical (Amps)
Nr.
PROBLEM
Nr.
PROBABLE CAUSE
REMEDY
6
Motor Straining (High
current
absorbed5.1Electrical
data)).
1
Nozzle partially blocked.
Check machine with a new lance, if
confirmed, clean nozzle.
2
Inlet water filter
dirty/damaged.
Clean filter or replace it if damaged.
3
Valves dirty/damaged.
Clean valves (replacement preferred).
Replace valves using service kit.
4
(Brush motor) Brushes
worn/faulty.
Replace brushes.
5
Motor bearings damaged.
Check/Replace motor (induction motor).
Check/Replace motor-pump ass.y (brush
motor).
6
Incorrect oil level, oil leak.
(See D.2).
7
Swashplate worn.
Check/Replace swashplate (induction motor).
Check/Replace (complete motor pump ass.y
(brush motor).
7
Current absorbed too
low(5.1Electrical data)
1
Nozzle worn.
(Pressure also low) Check machine with a
new lance, if confirmed, replace lance/nozzle.
2
Valves dirty/damaged
(See A.2.2).
8
Motor briefly starts
('hiccups') with gun
closed (trigger released).
1
Micro leak on high pressure
circuit (from pump outlet to
trigger) picked up by TSS
system.
Identify the micro-leak and repair.
Section C - Noise
Nr.
PROBLEM
Nr.
PROBABLE CAUSE
REMEDY
1
Abnormal Noise
(See also A.3.2)
(with low pressure see ##
1)
##1
Cavitation.
(See A.1.5-7)
2
Motor bearings damaged.
(See B.6.5)
3
Contact with motor fan.
Check fan / contact with fan.
Motor overheating can cause fan to dislodge
from motor shaft allowing contact (See B.1.8)
4
Oil level low.
Top up oil
Section D - Leaks
Nr.
PROBLEM
Nr.
PROBABLE CAUSE
REMEDY
1
Water Leak
1
Pump water seals
worn/damaged.
Replace pump water seals. Nb. Part subject
to normal wear. Nbb. Use of the pressure
washer even for a brief period without
correct water supply can 'burn' the seals,
damaging them permanently (see User
manual).
2
O rings on connections between
accessories worn/damaged.
Replace O Rings Nb. Part subject to normal
wear.
3
Gun
Check/replace gun. Nb. Part subject to
normal wear.
4
Water inlet/outlet connectors.
Check/replace using service kit. Nb. Part
subject to normal wear.
5
High pressure hose
damaged/faulty.
Replace hose. Nb. Part subject to normal
wear.
6
Cracked pump head.
Check/Replace cracked pump head
(induction motor)
Check/Replace motor pump ass.y (brush
motor)
7
Connector loose (water filter,
HPC Hose etc.).
Tighten connector/replace seal.
2
Oil Leak
1
Pump oil seals worn/damaged.
Check/Replace with piston/seal Service Kit.
2
Pistons worn/damaged.
3
Oil venting because of high
pressure water ingress from the
pump..
(Emulsified oil) Replace all water and oil
seals, check/replace pistons.

Maintenance Guide HPC 10 / 17
Section E - VARIOUS
Nr.
PROBLEM
Nr.
PROBABLE CAUSE
REMEDY
1
No detergent flow
(machines with
integrated detergent
tank)
1
Incorrect setting of adjustable
lance head (where applicable).
Put the adjustable lance head to the LOW
Pressure position (see User Manual).
2
Detergent too dense.
Dilute with water.
3
Use of HP hose extension
Use with original hose only
4
Detergent regulator knob on
CLOSED position (where
applicable)
Move flow regulator knob to OPEN
position (see User Manual)
5
Detergent system
blocked/clogged
Check, clean or replace using Service Kit
2
No detergent flow
(machines with
detergent tank on lance)
1
Detergent too dense
Dilute with water
2
Tank Nozzle/Filter/tube blocked
Clean tank Nozzle/Filter/tube
Replace if necessary
9. Servicing (Disassembly –Checks –Assembly)
General information:
This chapter deals with all the more complex work connected with the replacement or repair of
malfunctioning or worn parts.
The descriptions must follow a logical sequence and can include operations not specifically connected
to a particular type of repair.
9.1 Servicing the Inlet Filter and Nozzle
We consider this activity the first check before starting the service activities:
1. Check the inlet filter condition
2. Check the variable lance and “Rotopower”nozzle and clean with the cleaning tip tool
Adjustable Nozzle

Maintenance Guide HPC 11 / 17
Turbo and Rotary Nozzle
After having checked the above, test the machine with the new accessory; if the problem
persists, proceed as follows
9.2 Servicing the Inlet Valves
The following exploded view and pictures relate to the HPS 345 R model, but the information is valid
for all models.
58 –Valves + seals kit
To perform the checks and the disassembles illustrated below, it is necessary to start by removing the
MOTOR/PUMP Unit.
To avoid damage and to facilitate subsequent operations, before starting the disassembly of the
Pump Head, please remove the suction pipe and the TSS.
HPS 345 R

Maintenance Guide HPC 12 / 17
It is highly recommended to place the pump horizontally over a basin to recover the oil.
Remove the pump head bolts using a wrench, during the disassembling operation use one hand to
keep the pump head pushed downwards to contrast the piston springs pressure.
After removing the inlet valves with a rounded end pliers, check if the O-rings are OK and if the valves
have any impurities inside; in any case we recommend you replace them with a new KIT.
In order to keep the valve O-rings in place it is possible to use silicon grease(see 5.3.2).
CAUTION: WHEN REFITTING THE PUMP HEAD DO NOT FORGET TO RESTORE THE
PRESSURE SWITCH VALVE.

Maintenance Guide HPC 13 / 17
9.3 Servicing the Outlet Valves
The following exploded view and pictures relate to the HPS 550 R model, but the information is valid
for all models.
74 –Valves + seals kit
Remove the pump head and use pliers to remove the outlet valves. Check to see if the valves are
damaged or there are any impurities; in any case we recommend you replace them with a new KIT.
Make sure that the O-rings have been removed from their position and fit the new valves kit with the
new OR. In order to keep the valve O-rings in place it is possible to use silicon grease (see 5.3.2)..
71- PLUG ................13 ÷ 20 Nm (25 Nm for HPS 650 RG)
HPS 550 R

Maintenance Guide HPC 14 / 17
9.4 Servicing the Oil Seals and Pistons
The oil seals are placed inside the pump body and you need a flat screwdriver to remove them; be
careful not to scratch the piston guide. In order to fit the new oil seals, use your fingers to place it into
the correct position and use a plug that fits the outside diameter of the seal. It isalways recommended
to change all the oil seals.
73 –Piston + seals kit

Maintenance Guide HPC 15 / 17
9.5 Servicing the Swash plate Bearings
Remove the four screws that fasten the pump head in place. Remove the oil and clean the pump body
and top-up with new SAE 15W40 oil.
9.6 Servicing the Wet End
Water leaks between the head and pump body are a sign of advanced wear of the seals and they
must be replaced. After having disassembled the pump head with a screw driver, remove the water
seals; be careful not to scratch them.
Normally when water leaks from the seals, it is due to excessive wear or damage caused by
impurities. In any case were commend you change all the water seals.
ATTENTION: THE GASKETS ARE PRESSURE FITTED AND FOR THIS REASON COULD
BE DIFFICULT TO REMOVE.

Maintenance Guide HPC 16 / 17
9.7 Servicing the TSS System
In some models, to facilitate the removal of the TSS (switch and valve-piston set), it is
recommended to remove the suction pipe
Remove the TSS switch by simply pushing
the switch box from the bottom upwards and
diagonally; unscrew the TSS system bolt
using a wrench as shown in the picture. After
removing the TSS piston, also remove the
piston set using a ring pliers tool.
Make sure that the O-rings have been
removed from their position and use silicon
grease (see 5.3.2)to keep the new O-ring in
place during the assembly operation.
72 –TSS kit
To facilitate the removal of the TSS (switch
and valve-piston set), it is recommended to remove the suction pipe.

Maintenance Guide HPC 17 / 17
10. Electrical Diagram
Cable Colours
Initials
a
Azure
M
Motor
S1
TSS Switch
b
Blue
T
Thermal protection
N
Neutral
n
Black
C
Capacitor
L1
Phase (line)
r
Red
S
Main Switch
HPS 110 –HPS 235 R
HPS345R - HPS550R - HPS650RG