Kärcher HDS 5/11 U, Service Manual

Page: 39 / 50

English 5.906-487.0 Rev. 00 (04/10)
39
The entire top part must be removed to perform the
following work:
–
Working on the pump
–
Working on the motor
–
Working on the electric box of the motor
–
Working on the blower
–
Working on the fuel pump
The exact explanation of the work steps is detailed in
Chapters 5.9 to 5.11.
Work steps for dismantling:
 Completely remove the high pressure hose and
put it to the side.

Lay the appliance on its rear.
 Reconnect the fuel hoses on the fuel tank and the
fuel pump.
 Open the screw connection on the fuel line.
 Set up the appliance.
 Remove the exhaust temperature sensor (holding
clip).
 Unplug the protective conductor cable on the
burner cover.
 Unplug the ignition transformer.
 Pull the detergent hose off of the pump head.

Loosen the screws on the base plate of the on-de-
mand heater (2 screws in front, 1 screw on the
right).
 Remove the safety block (2 screws).
 Remove the high pressure on the safety block
(holding clip).
 Remove the electric box and rest it toward the
front.
 Disconnect the connector of the temperature con-
trol 95°C.
 Place it behind the appliance and pull the top part
a little out of the bottom part.
 Lay the appliance on its rear.
 Completely remove the bottom part from the top
part.
The electric box on the motor is now accessible.
Further to the removal of the pump kit, blower, fuel
pump.

Remove the motor cover (6 screws).
 Remove the fuel pump.
 Remove the pump kit.
 Perform repairs on pump, motor, electrical sys-
tem.
Carry out a brief test run before the assembly!
Work steps for assembly:

Place the pump kit into the bottom part with all rub-
ber buffers.

Install the safety block (2 screws).
 Position the motor cover with rubber buffers and
fasten it tentatively (2 screws).
Perform a brief test run (without fuel pump).
 Attach the high pressure hose to the safety block
(clip), with a swivel for the U version.
After successful test run:
 Remove the motor cover and the safety block (2
screws each).
 Install the fuel pump with coupling.
 Replace all rubber bearings.

Install the motor cover (6 screws).
 Insert the bottom part onto the aluminium pipes of
the horizontally placed top part.
 Position all hoses and cables properly.
 Set up the appliance and let the top part slide
down into the bottom part.
 Install the safety block onto the high pressure line
(2 screws).
 Secure the high pressure on the safety block
(holding clip).
Make sure that the mains cables, other cables and
hoses are routed properly!
 Attach the base plate of the on-demand heater (2
screws in front, 1 screw on the right).
 Lay the appliance on its rear.

Connect the fuel hoses with the fuel pump and the
fuel tank.
 Set up the appliance.

Insert the temperature controller 95°C.
 Install the temperature sensor, protective conduc-
tor and the power supply of the ignition transform-
er.

Guide the detergent hose through the back wall
and connect it to the injector.
 Insert the electric box.

UX version: Guide the high pressure hose through
the appliance, place it on the hose drum and se-
cure it (holding clip).
6 Basic settings and service procedures
6.1 Brief overview, dismantling / assembly
6.1.1 Upper section