Kärcher AP 100 M Service Manual Download Page 26

Page: 26 / 53

English

5.906-508.0 Rev. 00 (11/10)

Note

The terminal strip is located on the suction turbine
plate next to the suction turbine.

Preliminary tasks:

Remove operating panel.

Remove the wastewater reservoir.

Remove suction turbine plate.

1 Connecting block

Check the cables by means of the following table.

Installation in reverse order

Note

After the assembly, check all hoses for leaks.

5.4

Electrical system

5.4.1 Check the population of the terminal strip

Plug-in location

Cable color

Connected component

black

EMC filter

empty

white

EMC filter

light brown/black

Appliance switch ON/OFF

blue

Appliance switch ON/OFF

empty

black

Appliance switch ON/OFF

black

High pressure/low pressure solenoid valve

orange

Pump switch

red

Fuse 5 A

light brown

Fuse 7 A

black

Suction turbine

black

High pressure/low pressure solenoid valve

black

Suction turbine

black

Pump motor

white

Pump motor

Summary of Contents for AP 100 M

Page 1: ...English 5 906 508 0 Rev 00 11 10 1 AP 100 50 M Service Manual ...

Page 2: ...15 4 11 Scrubbing brush 16 4 12 Wastewater reservoir 17 4 13 Discharge hoses 18 4 14 Water function diagram 19 5 Service tasks 20 5 1 Control terminal 20 5 1 1 Remove operating panel 20 5 1 2 Removing the switch 20 5 1 3 Remove the detergent dosing valve 21 5 1 4 Remove the connection of the high pressure hose 22 5 1 5 Remove the fuses 23 5 2 Wastewater reservoir 24 5 2 1 Removing the wastewater r...

Page 3: ... 39 5 10 Fresh water tank 40 5 10 1 Remove the supply hose for fresh water 40 5 10 2 Remove the return hose for fresh water 40 5 10 3 Remove the fresh water drain hose 41 5 10 4 Clean replace the water filter 41 5 10 5 Remove the fresh water reservoir 42 5 11 Hand spraygun 45 5 11 1 Replace the high pressure hose 45 5 11 2 Disassemble hand spray gun 46 5 12 Floor nozzle 47 5 12 1 Adjust the distan...

Page 4: ...ets can be dangerous if im properly used The jet may not be directed at persons animals live electrical equip ment or at the appliance itself The high pressure cleaner must only be used while standing According to the applicable regulations the appliance must never be used on the drinking water supply without a system separator Use a suitable system separator manufactured by KÄRCHER or as an alter...

Page 5: ...on hose for detergent 5 Dirt water reservoir 6 Connection of high pressure hose 7 Trigger gun 8 Cable hook rotating 9 High pressure hose 10 Spray lance 11 Guiding rolls with fixed position brake 12 Suction pipe 13 Floor nozzle 14 Suction hose 15 Tool holder 16 Fill hose fresh water 4 Setup and function 4 1 Front view ...

Page 6: ... 2 Suction hose detergent 3 Cover dirt water reservoir 4 Suction hose 5 Fresh water tank cover 6 Fresh water tank 7 Dirt water reservoir 8 Drainage hose for fresh water 9 Power cord 10 Dirt water discharge hose 11 Cleaning agent container 4 2 Rear view ...

Page 7: ...English 5 906 508 0 Rev 00 11 10 7 1 Cover dirt water reservoir 2 Fresh water tank cover 3 Suction hose 4 Fresh water tank 5 Drainage hose for fresh water 6 Dirt water reservoir 4 3 Right view ...

Page 8: ... 0 Rev 00 11 10 1 Suction hose connection 2 Connection of high pressure hose 3 Sliding handle 4 Dirt water reservoir 5 Dirt water discharge hose 6 Cable hook rotating 7 high pressure hose 8 Hand blowing gun 4 4 Left view ...

Page 9: ...English 5 906 508 0 Rev 00 11 10 9 1 Water filter 2 Wheel support 3 Supply hose for fresh water 4 Adjustment wheel for pressure control valve 5 Air outlet suction turbine 4 5 View from below ...

Page 10: ...tch ON OFF 6 Pump fuse 7 Pump switch 8 Dosage valve for detergent 9 Connection of high pressure hose 1 Dosing of detergent container 1 2 Dosing of detergent container 2 Note Adding one of the detergents only works in low pres sure operating mode switch on the pump set to MIN 4 6 Control terminal 4 6 1 Control elements 4 6 2 Dosage valve for detergent ...

Page 11: ...nglish 5 906 508 0 Rev 00 11 10 11 1 Switch of suction turbine 2 Fuse for suction turbine 3 Appliance switch ON OFF 4 Pump fuse 5 Pump switch 6 Dosage valve for detergent 4 6 3 Operating panel from below ...

Page 12: ...5 906 508 0 Rev 00 11 10 Note The suction turbine sits underneath the wastewater reservoir 1 Connecting block 2 High pressure low pressure solenoid valve 3 Detergent injector 4 Suction turbine 4 7 Suction turbine ...

Page 13: ...English 5 906 508 0 Rev 00 11 10 13 1 Pump motor 2 High pressure pump 3 High pressure hose 4 Supply hose for fresh water 4 8 High pressure pump ...

Page 14: ...nglish 5 906 508 0 Rev 00 11 10 1 Nozzle screws 2 Spray lance 3 Hand blowing gun 4 Lever for hand spray gun 1 Hand spray gun casing 2 Safety lever 3 Lever for hand spray gun 4 Corner valve 4 9 Hand spraygun ...

Page 15: ...English 5 906 508 0 Rev 00 11 10 15 1 Front vacuum lip 2 Rear vacuum lip 3 Floor nozzle 4 Adjustment wheel height adjustment impeller 5 Impeller 4 10 Floor nozzle ...

Page 16: ...5 906 508 0 Rev 00 11 10 1 Front vacuum lip 2 Rear vacuum lip 3 Scrubbing brushes 4 Water nozzles Note A scrubbing brush can be attached as an accessory to clean severely contaminated surfaces 4 11 Scrubbing brush ...

Page 17: ...10 17 1 Dirt water discharge hose 2 Cover dirt water reservoir 3 Dirt water reservoir 1 Rough dirt filter with swimmer ball 2 Cleaning opening of the dirt water reservoir 1 Rough dirt filter 2 Swimmer ball 4 12 Wastewater reservoir ...

Page 18: ... water drain hose is also used as a fill level display For environmental protection reasons the wastewa ter must be disposed of according to its type of con tamination The fresh water that has been mixed with detergent must be disposed of according the detergent manu facturer s instructions 4 13 Discharge hoses ...

Page 19: ...mmer ball 10 Cleaning agent container 11 Dirt water discharge hose 12 Drainage hose for fresh water 13 Dirt water reservoir 14 Suction turbine 15 Detergent injector 16 High pressure low pressure solenoid valve 17 Pressure relief valve 18 High pressure pump 19 Pump motor 20 Waterfilter 21 Fresh water tank 22 Fresh water reservoir filler neck 23 Hand blowing gun 4 14 Water function diagram 23 9 10 2...

Page 20: ...r leaks Preliminary tasks Î Remove operating panel 1 Fastening nut 2 Cable connector 3 Cover Î Remove the cable ties Î Loosen the mounting nuts Î Remove cover 1 Lock 2 Operator console Î Pull the plug connections from the switches Î Press the locks together and slide the switch out Installation in reverse order Note Observe the plug arrangement during installation After the assembly check all hose...

Page 21: ...ry handle 1 Detergent hose Î Loosen the hose clamp and pull the detergent hoses off 1 Fastening nut Î Loosen the mounting nuts Î Remove the dosing valve toward the rear Installation in reverse order Note Do not transpose the hoses during installation After the assembly check all hoses for leaks 5 1 3 Remove the detergent dosing valve ...

Page 22: ...nnection nut Î Unscrew the nut from the high pressure hose con nection hold the high pressure connection from behind during this procedure Î Remove the high pressure hose connection to ward the rear 1 High pressure hose connection nut 2 Connection of high pressure hose 3 Spacer discs Î Observe the number of spacers during installation Installation in reverse order Note After the assembly check all...

Page 23: ...ting nuts Î Remove cover 1 Operator console 2 Cover flap Î Pull out the connecting plug Î Unscrew the fastening nut with the cover flap Î Remove the fuse toward the rear Installation in reverse order Note The fuse of the suction turbine left has a power of 5 A the fuse of the pump right has 7 A After the assembly check all hoses for leaks 5 1 5 Remove the fuses ...

Page 24: ...er reservoir toward the rear Installation in reverse order Note After the assembly check all hoses for leaks Preliminary tasks Î Remove the wastewater reservoir 1 Hose clip 2 Dirt water discharge hose Î Place the wastewater reservoir upside down Î Loosen the hose clamp from the wastewater drain hose Î Pull the wastewater drain hose off of the wastewa ter reservoir Installation in reverse order Not...

Page 25: ...e hose clamps from the fresh water hose and the detergent hose and pull the hoses off Î Pull the high pressure hose from the pump Installation in reverse order Note After the assembly check all hoses for leaks Preliminary tasks Î Empty the fresh water tank and waste water reser voir Î Lay the device on the side Î Pry the lid cap off of the wheel 1 Tension cap Î Press the tension cap out Î Remove w...

Page 26: ...y check all hoses for leaks 5 4 Electrical system 5 4 1 Check the population of the terminal strip Plug in location Cable color Connected component 1 black EMC filter 2 empty 3 white EMC filter 4 light brown black Appliance switch ON OFF 5 blue Appliance switch ON OFF 6 empty 7 black Appliance switch ON OFF 8 black High pressure low pressure solenoid valve 9 orange Pump switch 10 red Fuse 5 A 11 l...

Page 27: ...tewater reservoir Î Remove suction turbine plate 1 Connection plug 2 EMC filter 3 Suction turbine plate Î Remove the connector plug on the EMC filter Î Unscrew the protective conductor Installation in reverse order Note After the assembly check all hoses for leaks 5 4 2 Replacing the mains cable ...

Page 28: ...f the suction turbine Î Remove the suction turbine 1 Fastening nut of the protective conductor 2 Connecting block 3 Fastening screw Î Unscrew the fastening screws of the terminal strip Î Remove the terminal block Î Unscrew the protective conductor from the suction turbine plate Î Remove all the cable ties 1 High pressure low pressure solenoid valve 2 Fastening screw Î Unscrew the fastening screws ...

Page 29: ...rews of the suction tur bine plate Î Raise the suction turbine plate Î Connect the clip on ammeter to the suction tur bine Î Turn on the appliance Î Switch the suction turbine on Î Read the current pickup on the clip on ammeter Î Target value 4 5 A If the nominal value is not reached you can assume a defective suction turbine Check carbon brushes prior to replacing the suction turbine replace 5 5 ...

Page 30: ...ening screws 2x Î Remove the cover of the suction turbine motor 1 Carbon brush housing 2 Fastening screw Î Unscrew locking screws Î Remove the carbon brush housing 1 Carbon brush housing 2 Press spring 3 Carbon brush Î Pull the carbon brush with press spring out of the carbon brush housing Note If a carbon brush is shorter than 9 5 mm both carbon brushes must be replaced Install the new carbon bru...

Page 31: ...of the suction turbine Î Remove the suction turbine Install the new suction turbine in reverse order Note While installing the suction turbine please ensure that the sealing ring sits stably on the suction turbine If the sealing ring is not installed correctly the cleaning results are unsatisfactory due to the weak suction power After the assembly check all hoses for leaks 5 5 4 Replacing the suct...

Page 32: ...pressure hose from the high pressure pump Î Unscrew the fastening screws 4x of the high pressure pump Î Remove the high pressure pump from the pump motor 1 Pump casing 2 Piston rod Î Grease the piston rod prior to use Installation in reverse order 1 High pressure pump 2 Lubrication nipple After the installation the high pressure pump must be filled with grease via the grease fittings Note After th...

Page 33: ... 1 Pump cylinder 2 Suction valve 3 Pump head 4 Seal 5 Pressure valve 6 Washer ring Î Check the suction and pressure valves for wear and tear damage Î Remove the pump cylinder 1 Piston rod 2 Pump casing 3 Piston guide Î Check the piston rod and the piston guide for wear and tear damage 1 Seal 2 Pump cylinder Î Remove and dispose of the seals in the pump cyl inder Î Please observe the installation s...

Page 34: ...heck all hoses for leaks Preliminary tasks Î Remove the wheel support Î Connect the clip on ammeter to the pump motor Î Turn on the appliance Î Switch on pump Î Read the current pickup on the clip on ammeter Î Target value 2 0 2 5 A Check the pump motor mechanically Preliminary tasks Î Remove the high pressure pump 1 Pump motor 2 Swash plate Î Check the swash plate of the pump motor for wear and t...

Page 35: ...or 2 Connection plug Î Pull off unscrew the connection plug of the pump motor 1 Pump motor 2 Fastening nut Î Remove the fastening nuts of the pump motor on both sides Î Remove the pump motor Installation in reverse order Note After the assembly check all hoses for leaks 5 6 4 Remove the pump motor ...

Page 36: ...e switch on the pump to MAX Î Read the current pickup on the clip on ammeter Î Target value 0 2 A Preliminary tasks Î Remove suction turbine plate 1 High pressure low pressure solenoid valve 2 Fastening nut Î Loosen the mounting nuts Î Pull off the high pressure low pressure solenoid valve 1 Solenoid valve pin Î Unscrew the solenoid valve pin 5 7 High pressure low pressure solenoid valve 5 7 1 Che...

Page 37: ...English 5 906 508 0 Rev 00 11 10 37 1 Valve 2 Spring 3 Casing Î Check the solenoid valve pin for wear and tear damage Installation in reverse order Note After the assembly check all hoses for leaks ...

Page 38: ...essures The pressure control valve may only be tightened by max three revolutions Preliminary tasks Î Remove the wheel support 1 High pressure pump 2 Return connection for fresh water 3 Pressure relief valve Î Unscrew the fresh water return hose Î Remove the high pressure hose Î Remove the high pressure pump 1 Pressure relief valve 2 High pressure pump 3 High pressure hose Î Unscrew the pressure c...

Page 39: ...ring Î Check the seal of the detergent injector for wear and tear damage 1 Detergent injector 2 Restrictor Î Check the throttle gasket of the detergent injector for wear and tear damage Note Screw the throttle in all the way 1 Angle connection 2 Seal disc 3 Detergent injector 4 Detergent injector pickup 5 Washer ring Note During reassembly check the seal and the gasket for wear and tear damage and...

Page 40: ...sks Î Remove the wheel support 1 High pressure pump 2 Fresh water return hose 3 Hose clip 4 Pump motor 5 Fastening screw 6 High pressure hose Î Loosen the hose clamp on the high pressure pump Î Remove the fresh water return hose 1 Fresh water tank 2 Fresh water return hose 3 Hose clip Î Loosen the hose clamp on the fresh water reser voir Î Remove the fresh water return hose Installation in reverse...

Page 41: ...der Note After the assembly check all hoses for leaks If the filter sieve in the water filter is dirty it must be cleaned or replaced if necessary 1 Fresh water tank 2 Filter pot 3 Waterfilter Î Empty the fresh water reservoir Î Unscrew the filter cup Î Clean replace the filter insert Î Place the cleaned or new filter insert in the filter cup and tighten the screws of the filter cup Î Fill up fres...

Page 42: ...ervoir Î Unscrew the rear fastening screws Î Pull fresh water drain hose off of the wastewater reservoir 1 Fastening screw Î Unscrew locking screws Î Remove wastewater reservoir toward the rear Î Lay the device on the side 1 Water filter 2 Wheel support 3 Fastening screw Î Unscrew the fastening screws of the wheel sup port Î Carefully remove the wheel support Î Loosen the hose clamps from the fres...

Page 43: ...ng screws of the terminal strip Î Remove the terminal block Î Unscrew the protective conductor from the suction turbine plate Î Remove all the cable ties 1 Fresh water tank 2 Water filter 3 Supply hose for fresh water 4 Hose clip Î Loosen the hose clamps on the fresh water reser voir and on the water filter Î Remove the fresh water supply hose 1 Fresh water tank 2 Fresh water return hose 3 Hose cl...

Page 44: ... English 5 906 508 0 Rev 00 11 10 1 Steering roller 2 Fastening nut Î Loosen the mounting nuts Î Remove the steering roller Installation in reverse order Note After the assembly check all hoses for leaks ...

Page 45: ...un 3 Kink protection 4 High pressure hose Î Remove the kink protection from the hand spray gun 1 Fastening clamp 2 Washer ring 3 Trigger gun 4 Kink protection 5 High pressure hose Î Remove the high pressure hose from the hand spray gun Assemble in reverse order Note Make sure the seal is not damaged during assembly After the assembly check all hoses for leaks 5 11 Hand spraygun 5 11 1Replace the h...

Page 46: ...nd spray gun 1 Handle shell 2 Fastening screw Î Remove the fastening screws of the handle half Î Remove the handle shell 1 Hand spray gun casing 2 Safety lever 3 Lever for hand spray gun 4 Corner valve Î Check the installation components of the hand spray gun for wear and tear damage Assemble in reverse order 5 11 2Disassemble hand spray gun ...

Page 47: ...nozzle 2 Locking 3 Front vacuum lip Check the vacuum lips of the floor nozzle for wear and tear damage If necessary replace the vacuum lips Î Swivel the lock to the side Î Pull the front vacuum lip out of the side of the guide groove and replace it 1 Adjusting screw 2 Running roller 3 Rear vacuum lip 4 Floor nozzle Î Turn the adjustment screw in an anticlockwise di rection Î Fold the casters up to...

Page 48: ... the hose holder and the handle on the suc tion pipe Î Connect high pressure hose to the hand spray gun 1 Fastening screw Î Loosen the fastening screw 1 Front vacuum lip 2 Rear vacuum lip 3 Running roller Î Remove the caster Î Remove the vacuum lips from the bottom Installation in reverse order Note The structured side of the vacuum lip must point out wards 5 13 Scrubbing brush accessory 5 13 1Con...

Page 49: ...nary tasks Î Empty the fresh water tank and waste water reser voir Î Lay the device on its side 1 Steering roller 2 Fastening nut Î Loosen the mounting nuts Î Replace the steering roller Assemble in reverse order 5 14 Replace the steering roller ...

Page 50: ...n pipe and the floor nozzle for blockages clean if required Operator Check the connection between the suction hose and the appli ance Operator Clean the sieve in the wastewater reservoir Operator Check the suction hose for tightness replace if required Operator Check whether the cover on the wastewater drain hose is closed Operator Clean the floater in the dirt water tank Operator Check vacuum lip...

Page 51: ... power negative pressure kPa 15 Dimensions and weights Fresh dirt water reservoir volume l 111 70 Length mm 914 Width mm 628 Height mm 1092 Weight kg 93 Values determined as per EN 60355 2 79 Hand arm vibration value Hand spraygun m s2 2 5 Spray lance m s2 2 5 Uncertainty K m s2 0 5 Sound pressure level LpA dB A 79 Uncertainty KpA dB A 3 Sound power level LWA Uncertainty KWA dB A 95 Part no BTA AP...

Page 52: ...H VACUUM CIRCUIT BREAKER POWER BLU BRN GRN YEL POWER CORD SOLENOID VACUUM MOTOR PUMP MOTOR 7 WIRE HARNESS 1 2 3 4 6 7 8 12 11 10 9 13 14 15 16 5 BLK WHT RED ORG BLK WHT WHT GRN YEL GRN YEL BLK WHT BLK GRN YEL ORG WHT RED BLK BLK ON OFF FILTER BLK BLU BLU WHT BLK BLK GRN YEL WHT BLK WHT BLK BLU BRN EMI ...

Page 53: ... cable Pump Circuit Breaker Pump fuse Pump motor Pump motor Pump switch Pump switch Solenoid High pressure low pressure solenoid valve Vacuum Circuit Breaker Fuse for suction turbine Vacuum motor Suction turbine Vacuum switch Switch for vacuuming 7 Wire Harness Cable string with 7 cables Cable colours blk black blu blue brn brown grn yel green yellow org orange red red wht white wht blk white blac...

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Kärcher AP 100 M, Service Manual

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Summary of Contents for AP 100 M

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