Kärcher HDS 9/50 De Tr1 Service Manual Download

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English

5.906-736.0 Rev. 00 (07/15)

HDS 9/50 De Tr1
HDS 13/35 De Tr1
HDS 13/20 De Tr1
HDS 17/20 De Tr1
Service Manual

Summary of Contents for HDS 9/50 De Tr1

Page 1: ...English 5 906 736 0 Rev 00 07 15 1 HDS 9 50 De Tr1 HDS 13 35 De Tr1 HDS 13 20 De Tr1 HDS 17 20 De Tr1 Service Manual...

Page 2: ...on on the operation 26 5 Safety instructions 6 8 1 2 Water supply 26 8 1 3 Turning on the Appliance 26 8 1 4 Speed control for pressure and volume regulation 27 8 1 5 Set working pressure and flow rat...

Page 3: ...Safety block 65 9 16 1 Safety valve 66 9 16 2 Flow switch 67 9 17 Burner blower with fuel pump 68 9 18 Booster heater with ignition transformer 69 9 18 1 Type plate of heating coil 70 9 18 2 Sectional...

Page 4: ...rature sensor 107 11 8 Heat exchanger 16kW 108 11 8 1 Replacing the heat exchanger 108 11 8 2 Clean heat exchanger 109 11 9 High pressure pump 109 11 9 1 Check oil level and refill oil 110 11 9 2 Oil...

Page 5: ...sion oil 164 11 15 11 Oil change intermediate gear 164 11 15 12 Dismantling intermediate gear with high pressure pump from the motor replacing elastomer ring coupling 165 11 15 13 Removing the interme...

Page 6: ...ipe by drinking large quantities of permeate To avoid danger to persons animals and property before the first operation of the system read the operation instructions all safety notices according to th...

Page 7: ...such as pumps and motors Be careful when opening the system allow system parts to cool down first DANGER Electrical hazard Disconnect the battery prior to replacing electric components DANGER Pointer...

Page 8: ...pressure switch and flow switch Dry run protection for the pump Temperature monitoring float container Motor monitoring oil pressure and temperature of the coolant Level switch for liquid softener an...

Page 9: ...number 7 Address of manufacturer 8 Bar code Contains part and serial number 9 Serial number 10 Year of manufacture NOTE The type plate is located in the motor compartment be tween the high pressure p...

Page 10: ...ake tail light with direction indicator right 8 Recessed grip of the front cover on both sides 9 Marker light on both sides 10 Block wedge 11 Support wheel 12 Connector vehicle lighting 13 Tear off ro...

Page 11: ...English 5 906 736 0 Rev 00 07 15 11 1 Diesel engine 2 Intermediate gear 3 High pressure pump 4 Safety block 5 Exhaust 6 Expansion tank motor coolant 7 2 View with opened front and rear cover...

Page 12: ...15 1 Maintenance opening water tank left 2 Air filter diesel engine 3 Nameplate 4 Battery 5 Vehicle identification number 6 Burner blower 7 Fuel pump 8 Continuous heater 9 Ignition transformer 10 Main...

Page 13: ...tap water tanks 4 Drain off tap 5 Antifreeze hose 6 Water pipes 7 Water filter 8 Manometer 9 Supply frost protection or parking position for GEKA low pressure connection 10 Return flow frost protecti...

Page 14: ...nt for trigger gun 6 Storage compartment for spray lance 7 High pressure hose 8 High pressure hose drum 9 Emergency stop button 10 Low pressure hose drum 11 Liquid softener container 12 Antifreeze con...

Page 15: ...removed 1 Connection tank on the left side tank on the right side 2 Supply from the float container 3 Stop cock drain water tanks 4 Supply to the high pressure pump 5 Stop cock water tanks 6 Supply fr...

Page 16: ...he left 1 Inverter 2 Thermostat switch water temperature in the float con tainer View with opened maintenance flap on the right 1 Thermostat switch emission temperature View with opened maintenance fl...

Page 17: ...e boiler to the high pressure connection 3 High pressure line from the safety block to the boiler 4 Heat exchanger 5 Drain screw heat exchanger 6 Axle drawbar NOTE In the underbody area there is the o...

Page 18: ...protection NOTE In the ECO mode the water temperature is maintained at 60 9 Set water temperatures 60 C are effective NOTE The indicator light preheating lights up for approx 4 sec onds if the key sw...

Page 19: ...rner deactivated fuel shortage 3 Motor on ON or motor off OFF 4 Liquid softener tank RM110 detergent tank CHEM OK empty 5 Operating hour counter 6 Operating hours until next service NOTE The indicatio...

Page 20: ...switch pressure switch ERROR 6 Fuel sensor ERROR 7 Motor oil pressure ERROR 9 Emission temperature ERROR 10 Temperature sensor booster heater ERROR 11 Flame sensor image bright blind ERROR 12 Flame se...

Page 21: ...English 5 906 736 0 Rev 00 07 15 21 Electric components are located in the control cabinet and in the control cabinet door 7 4 2 Control panel view from the inside...

Page 22: ...ver switch 8 Fuse F6 3A Connection transformer 1 and 2 as well as power supply printed circuit board 9 Relay K5 oil pressure 10 Relay K6 coolant 11 Relay K9 charge regulator 12 Relay K8 release burner...

Page 23: ...components in the control cabinet door 1 Printed circuit board A1 with display 2 Indicator light H3 front cover emergency stop red 3 Operating type switch 4 Indicator light H1 preheating red 5 Key swi...

Page 24: ...ing by encoder 9 PRINTED CIRCUIT BOARD Connection between con trol board A1 and distributor board A2 10 TRANSFORMER 1 Connection transformer 1 24V AC 11 TRANSFORMER 2 Connection transformer 2 24V AC 1...

Page 25: ...RCUIT BOARD Connection between con trol board A1 and distributor board A2 Outputs 6 VERBRENNST Solenoid valve fuel supply burner 24V AC 3A 7 Connection relay K9 release burner 24V AC 3A 1 Encoding pin...

Page 26: ...s closed If the front cover is opened the device shuts down and the indicator light is on NOTE Due to the bleeding procedure the speed of the motor may vary until the final operating pressure has been...

Page 27: ...ntainer ATTENTION Unsuitable detergents can cause damage to the appliance and to the object to be cleaned Place the detergent suction hose in a container filled with detergent and tighten the screw ca...

Page 28: ...ANGER Danger of scalding by hot water After operation with hot water the device must be operated with open end hand gun with cold water for at least two minutes ATTENTION Never stop the motor under fu...

Page 29: ...p hours Maintenance for burner due after 600 h Perform maintenance pro cedure Reset burner hours Maintenance for accessory due after 80000 gun switching op erations Perform maintenance pro cedure Rese...

Page 30: ...are synchronous After 5 seconds the error message ERROR 5 occurs Prepare the antifreeze in the antifreeze container Se lect the mixing ratio of the water antifreeze as per the instructions of the anti...

Page 31: ...ost protection inlet Disconnect the water hose from the water supply Connect the water hose to the return flow of the frost protection Open the filling hole of the float container In order to do so lo...

Page 32: ...the frost protection Open the filling hole of the float container In order to do so loosen the wing screw and push the cover to the left Fill 20 litres of fresh water into the float container and clos...

Page 33: ...ings of the device can be ed ited by means of the service switch and the control panel From the Service position the service switch can be turned a little further to the SET position From this posi ti...

Page 34: ...already be set upon switching on the device and the service switch must be kept in the SET position for 2 3 seconds 1 Display Changing the settings The indication of the current setting takes place v...

Page 35: ...e gun Turn off the appliance Bring the service switch back into the position taken down before Turn on the appliance NOTE The service indicators for motor pump burner and gun are deleted if SET is hel...

Page 36: ...actuator test C the check can only take place via the clearly audible switching of the relay on the printed circuit board A1 As the solenoid valve fuel is in the safety chain further cri teria for ac...

Page 37: ...0 8 8 8 Level sensor for fuel tank 0 8 Tank empty 8 8 Tank full Indication position of the dip switches ON OFF on the control board A1 A Flow WASSERSI B Emission temperature ABGASTH C Filling level f...

Page 38: ...Switch off after 45 minutes continuous break ERROR 15 Switch off after 45 minutes continuous opera tion Cleaning operation with cold water is possible For details on the cause of the malfunction and i...

Page 39: ...otal operation duration burner Operation duration burner since the last mainte nance Delete service Turn off the appliance Hold SET 2 3 seconds Turn on the appliance NOTE The maintenance counter is au...

Page 40: ...nto the float container via the water filter When connected to the mains the operation takes place with external water supply as an alternative both tanks can be filled and the operation takes place i...

Page 41: ...tergent container 13 Level switch float container 14 Valve liquid softener 15 Level switch liquid softener container 16 Inverter 17 Safety switch cover opening cover switch 18 Thermostat switch water...

Page 42: ...the diesel engine the fault mes sage ERROR 7 appears Indication motor ON OFF NOTE The ON OFF indication of the motor is controlled via the signal input of the motor oil pressure switch and the charg...

Page 43: ...ve deter gent Y2 is activated when the gun is pressed The quan tity of the detergent is controlled via the dosing valve Level switch float container S13 Float contact closed Filling level OK Float con...

Page 44: ...inuous operation is deactivated The diesel engine does not switch off after 45 minutes of continuous operation 45 minutes continuous break The switch off continuous break is activated The diesel engin...

Page 45: ...ll components for the operation of the high pressure unit are located NOTE Further information about the operation and maintenance can be found in the relevant documents of the manufacturer These are...

Page 46: ...46 English 5 906 736 0 Rev 00 07 15 1 Reflector on both sides 2 Marker light on both sides...

Page 47: ...components are located underneath the rear cover The covers are equipped with gas pressure dampers for support upon opening and for keeping the cover open Every cover is equipped with a lockable lock...

Page 48: ...For inspection purposes each tank is equipped with a maintenance opening ATTENTION The tanks must not be filled via the maintenance openings The supply must always take place via the water filter in...

Page 49: ...he battery i e on the terminal poles and cell connectors DANGER Risk of injury Ensure that wounds never come into contact with lead Always clean your hands after having worked with batteries Frost pro...

Page 50: ...tage and capacity see Specifications 3 Battery terminal black 4 Battery holder View with opened maintenance flap on the left 1 Inverter Inverter The control board A1 requires a supply voltage of 24V A...

Page 51: ...d softener container 1 Filler neck 2 Swimmer ball 3 Water inlet NOTE The filling level indicator does not show the water level in the float container but the level in the two 250 l water tanks Float t...

Page 52: ...unted onto a joint holder 1 Support 2 Temperature sensor 3 Filling level monitoring empty message 4 Inflow return line of high pressure pump View with opened maintenance flap on the left 1 Thermostat...

Page 53: ...ump 4 takes place via the inlets of the float container 2 and the supply 6 of the corresponding water tanks Operation with external water supply When operated with external water supply the tap 5 is c...

Page 54: ...perature increase with the full water volume is max with HDS 9 50 13 5K with HDS 13 35 10 0K with HDS 17 20 7 5K with HDS 13 20 7 0K When the motor is running and no water removal takes place via the...

Page 55: ...7 Intermediate gear 8 Detergent supply to the pump 1 Pump casing 2 Outlet high pressure 3 Outlet return line to the float container 4 Overflow Overview pump types 9 50 and 13 35 1 Pump casing 2 Oil fi...

Page 56: ...ft 13 Piston rod bottom 14 Piston rod screw 15 Oil bath 16 Crankshaft housing cover with O ring 17 Crankshaft bearing 1 x left 1 x right 18 Oil filling nozzle 19 Distance labyrinth discs 20 Crown nut...

Page 57: ...for the bleeding of the pump NOTE If the valve is defective the maximum pump pressure is no longer reached In this case the valve must be renewed 1 Casing 2 Piston 3 Spring 4 Tappet 5 Diaphragm If pr...

Page 58: ...o the casing This way the speed control on the motor is changed and the motor reaches the maximum speed In work brakes the spring 2 pushes back the piston 3 so that the Bowden cable slackens and the m...

Page 59: ...0 and 17 20 1 Bearing closed bearing side 2 Crankshaft 3 Cover oil filler neck 4 Cover 5 Piston rod 6 Covering lid 7 Screw 8 Oil sight glass 9 Screwed sealing plug 10 O ring 11 Seal casing cover 12 Be...

Page 60: ...ing cover 4 Piston rod 5 O ring 6 Container 7 Stopper 8 Cover oil filler neck 9 Cylinder roller bearing 10 O ring 11 Screw 12 Bearing open bearing side 13 Radial seal 14 Shaft seal ring 15 O ring 16 S...

Page 61: ...61 Illustration for pump types 13 20 and 17 20 High pressure valves and water inlet 1 Valve screw 2 O ring 3 Suction valve 4 Pressure valve Piston seals 5 Seal kit 9 14 6 Cylinder head High pressure v...

Page 62: ...ev 00 07 15 Illustration for pump types 9 50 and 13 35 High pressure valves and water inlet 1 Valve screw 2 O ring 3 Suction valve 4 Pressure valve Piston seals 5 Screwed sealing plug 6 O ring 7 Seal...

Page 63: ...njo bolt bypass 4 Pump head NOTE Both hollow screws must be loosened or tightened simul taneously while exchanging the knot section in order to avoid damage to the O rings Tightening torque hollow scr...

Page 64: ...turn D Connection of frost protection valve 1 Spring 2 Control piston 3 Spring 4 Valve bolt 5 Valve Function If the pressure on the high pressure outlet increases the control piston 2 is lifted up wit...

Page 65: ...alve can be adjusted in the range 185 250bar The presetting at 240bar is done in the factory Safety block 350 500bar 1 Clamping bracket 2 Flow switch 3 Screwed sealing plug 4 High pressure outlet to t...

Page 66: ...ises by ap prox 20 bar above the permissible operating pressure the valve ball or the valve plate with 350 and 500bar devices is lifted off the valve seat and part of the flow volume flows to the outs...

Page 67: ...flow the solenoid piston is pushed against the pressure spring The solenoid piston closes the contact of the reed switch With warm water operation this opens the fuel solenoid valve and the burner ign...

Page 68: ...pressure line 4 Fuel pump 5 Coupling unit 6 Filter Fuel pump The fuel pump is connected directly to the motor shaft via the coupling piece and the blower wheel During warm water operation the installe...

Page 69: ...es The blower wheel is mounted to the motor shaft by means of 2 feather keys The motor of the burner blower only runs in warm water op eration 1 Fuel line 2 Capillary exhaust temperature monitor 3 Bur...

Page 70: ...ion temperature of 292 C 7K is ex ceeded the burner switches off automatically Restart after a temperature drop by 9 4 5K The type plate of the heating coil can be read through the exhaust stack 1 Yea...

Page 71: ...te 4 Flame pipe 5 Burning chamber 6 Boiler floor 7 Boiler input 8 Air supply from burner blower 9 Boiler exterior double walled 10 Heating coil spiral exterior 11 Heating coil spiral interior 12 Exhau...

Page 72: ...floor is made of fire resistant insulating con crete It prevents a radiation of the heat and is used to re route the flames The adjustment of the burner to good exhaust values is achieved via the air...

Page 73: ...ic requirement for the proper function of the burner for good exhaust values and the long idle time of the ignition electrodes There is always a ignition spark between the two ignition electrodes duri...

Page 74: ...below 1 Temperature sensor warm water 2 High pressure line from the booster heater to the high pressure connection 3 High pressure line from the safety block to the boiler NOTE The temperature sensor...

Page 75: ...the hose reel by inserting the catch into a hole in the hose reel ATTENTION Never unroll or roll up the high pressure hose while it is un der pressure 1 Exhaust system 2 Expansion tank motor coolant...

Page 76: ...p 3 Thermostat switch motor 4 Connection coolant hose 5 Cooling fan motor Diesel engine 1 Expansion tank motor coolant 2 Exhaust system 3 Muffler 4 Air filter 5 Starter 6 Alternator Diesel engine 1 He...

Page 77: ...r transmission 1 Drive shaft 2 Claw clutch 3 Elastomer ring 4 Flange plate The power transmission from the motor to the intermediate gear takes place by means of a claw coupling One half of the claw c...

Page 78: ...ol from the piston on the high pressure pump 2 Deflection 3 Speed control motor The speed control lowers the motor speed when the hand spray gun is closed 1 Speed control full load idle mode 2 Bowden...

Page 79: ...mode Control lever for the limitation of the max motor speed for controlling volume and pressure NOTE If the motor speed is increased the operating pressure also rises This can be read from the pressu...

Page 80: ...lter sieve should be inserted in the tank filler neck in order to retain potential dirt particles View with opened maintenance flap on the right 1 Filling level probe fuel tank 2 Fuel line to the dies...

Page 81: ...eration the solenoid valve before the high pressure pump opens and injects detergent to the supply water 1 Dosage valve for detergent 2 Cleaning agent container By default 20 litre containers are prov...

Page 82: ...ent tank 3 Solenoid valve 4 Connection to the pump 5 Pump casing NOTE The solenoid valves opens subject to the pressure switch of the pump If no detergent is desired the detergent dosing valve must be...

Page 83: ...English 5 906 736 0 Rev 00 07 15 83 1 Fine filter 2 Aperture NOTE In order to improve the suction behaviour of the pump for the detergent an orifice plate is installed in the inlet to the fine filter...

Page 84: ...ailer when retracted Remove the chocks from underneath the wheels and place them in their holders Release parking brake Check the brake lights direction indicators tail lights and the license plate li...

Page 85: ...ks to prevent it from rolling away Disconnect the towing vehicle Align the appliance horizontally with the support wheel ATTENTION Risk of malfunctions and damages to the appliance The appliance must...

Page 86: ...ch hook must like with a motorcar be pushed to the side manually after opening the lock to release the locking mechanism 1 Angle for locking the catch hook 2 Lock shackle View with slightly opened fro...

Page 87: ...tch must be bridged This is necessary for example for setting tasks on the burner for sensor tests etc DANGER Danger on account of rotating components exhaust gas and hot surfaces Service tasks with o...

Page 88: ...round Ensure that no unauthorised person releases the jack and thus can cause a lowering of the trailer NOTE It is recommended to use an appropriate floor jack as shown ATTENTION Risk of damage to equ...

Page 89: ...lifted trailer ATTENTION Risk of damage to equipment Use the designated lifting points when lifting the trailer by means of a car lift Ensure that the surrounding plastic parts that are in some cases...

Page 90: ...ws for fastening the front plate at the bottom 1 Angle for locking the catch hook Unscrew the 4 screws for fastening the front plate at the top NOTE Mind the angle for the lock of the catch hook which...

Page 91: ...e nance flap on the air casing ATTENTION Risk of damage to equipment Ensure that the cables are not damaged upon unthreading Unthread the maintenance flap ATTENTION Risk of damage to equipment The exh...

Page 92: ...ntled 1 Maintenance flap on the left 2 Hose air filter motor If necessary remove the hose from the air filter Unscrew the 6 screws for the fastening of the mainte nance flap on the air casing Unthread...

Page 93: ...C plates on the frame Carefully pull out the PVC plate NOTE Pay attention to how the PVC plate above the black plate in the centre of the vehicle is inserted so that it can be re installed correctly D...

Page 94: ...iller cap and insert the filter sieve After removal of the filter sieve clip the loss prevention device back onto the tank filler neck HDS 13 20 HDS 17 20 only DANGER Risk of injury Use K rcher produc...

Page 95: ...grease gun NOTE The lubrication interval depends on the general use of the trailer regular checks of the smoothness are necessary for this purpose Activate the emergency brake Slightly loosen 5 screws...

Page 96: ...lamp Change lamp Lamp type 1 License plate lights R10W BA15s 12V part number 7 651 006 0 2 Direction indicator lamp PY21W BAU15s 12V part number 7 651 027 0 3 Reverse light P21W BA15s 12V part number...

Page 97: ...uncontrolledly Do not open the hood too far this may damage the hood and the appliance Ensure that the appliance is not lifted up with the hood The hood fastener is not suitable for this kind of load...

Page 98: ...lled towards the air casing side 1 Nut with washer 2 Splint 3 Ball head CAUTION Risk of damage Secure the cover against falling shut uncontrolledly Do not open the hood too far this may damage the hoo...

Page 99: ...ated exemplarily based on the front cover CAUTION Risk of damage Secure the cover against falling shut uncontrolledly Always have at least two people performing these tasks Consider the weight of the...

Page 100: ...cid level might need to be checked The motor must be turned off to charge the battery CAUTION Risk of damage Prior to connecting the charger the connecting cables to the controller must be disconnecte...

Page 101: ...battery using lowest possible level of charging current Disconnect the charger in the reverse order after the charging process is completed Connect the connecting cable to the positive terminal on th...

Page 102: ...bserve the cable run with the electrical connection NOTE Mind the correct polarity upon the connection as the in verter will otherwise be without any function 1 Lubricating nipple rotating grommet Gre...

Page 103: ...eplace if too dirty Install the filter cup and hand tighten it NOTE Check for leaks as soon as water is applied again 1 Liquid softener reservoir 2 Level sensor If necessary clean the magnetic ring of...

Page 104: ...g clips 3 Level switch liquid softener 4 Dosing valve Unclip the container from the anchor Empty the container contain liquid softener 1 Bracket 2 Dosing valve Carefully push the support to the side P...

Page 105: ...itch Observe the cable run with the electrical connection NOTE If spare parts are required the container is available com plete with the level switch Illustration with dismantled container for liquid...

Page 106: ...906 736 0 Rev 00 07 15 Unscrew the screws 1 Inlet hose 2 Connection float valve Detach the supply hoses from the two float valves Lift the locking catch on the float valve Push out the float valve 1...

Page 107: ...that the quadrangular protective casing of the level switch immerses into the recess of the float container Temperature sensor water in the float container If necessary loosen nut unscrew the sensor f...

Page 108: ...2 Supply to the high pressure pump 3 Support 4 Connection coolant hose 5 Drain screw coolant 6 Connection from the expansion tank motor coolant Lift the trailer disassembly of both PVC protective plat...

Page 109: ...r on the side towards the booster heater Clean the bundle of pipes with compressed air or clean ing sticks Overview pump types 13 20 and 17 20 1 Overflow 2 Speed control idle mode full load 3 Pump hea...

Page 110: ...evant shots are illustrated 1 Pump casing 2 Cover filling hole 3 Oil drain screw 4 Oil sight glass Check the oil level in the oil level gauge of the pump casing If the oil level is below the oil looki...

Page 111: ...n screw 4 Oil sight glass Pump types 9 50 and 13 35 1 Pump casing 2 Cover filling hole 3 Oil sight glass 4 Oil drain screw 5 Oil catch pan Place a suitable container below the pump gear Turn out the o...

Page 112: ...nion nut of the water supply remove hose NOTE It is recommended to dismantle the front plate to provide better access to the lower area of the fine filter Unscrew the complete casing including the loc...

Page 113: ...English 5 906 736 0 Rev 00 07 15 113 1 Fine filter 2 Aperture NOTE Make sure not to lose the orifice plate in the inlet of the fine filter...

Page 114: ...cable to the motor Open the screw of the piston NOTE When the screw is loosened the spring pushes onto the screw head Check the piston movement for free run by means of special pliers Grease O rings...

Page 115: ...n the idle state of the motor NOTE Readjusting the Bowden cable is possible at its ends For this purpose loosen the lock nuts and turn the adjusting screws The adjustment is OK if the spring at the mo...

Page 116: ...valve seat with the O ring is removed from the pump casing remove by means of pliers if neces sary Wear parts 1 Casing with taper seat 2 Spring 3 Valve seat with O ring If necessary change the entire...

Page 117: ...ATTENTION Risk of damage to equipment Observe torque of 35 40 Nm as otherwise the casing can get damaged NOTE Ensure that the valve seat underneath is not unscrewed too Unscrew the casing 1 Valve Pull...

Page 118: ...ve 4 Spring 1 Holding bow 2 Pressure switch Push the retaining bracket to the front Remove the pressure switch towards the top 1 Valve casing Unscrew the valve box of the pressure switch from the pump...

Page 119: ...casing 4 Diaphragm Switch off the operating mode switch and secure it against restart Shut off water supply Take the pressure off the high pressure system by opening the gun Check the pressure ratio o...

Page 120: ...906 736 0 Rev 00 07 15 Pull out the suction valves using special pliers 4 901 602 0 If the valve seat gets stuck in the pump head you can pull it out using the drawing tool 6 815 013 0 Suction pressur...

Page 121: ...07 15 121 Press in the new suction valves lubricate the O rings with silicon grease NOTE Ensure the correct alignment of the valve crosspieces Insert the lockscrews of the suction valves and tighten t...

Page 122: ...system by opening the gun Check the pressure ratio of the high pressure system on the pump manometer Loosen the lockscrews of the pressure valves Pull the pressure valves out with the pliers 4 901 062...

Page 123: ...English 5 906 736 0 Rev 00 07 15 123 Press in the new pressure valves manually grease the O rings NOTE Ensure the correct alignment of the valve crosspieces...

Page 124: ...Banjo bolt pressure side 2 Banjo bolt bypass Evenly unscrew the banjo bolts on the overflow valve and remove the overflow valve NOTE The banjo bolts must be loosened or tightened evenly to avoid damag...

Page 125: ...g the removal as the ceramic sleeves could break Loosen the screw inserts of the stopper bushings using the special tool 6 815 209 0 and take out the seals us ing the pliers 4 901 062 0 Pump types 13...

Page 126: ...0 and 13 35 1 Screwed sealing plug 2 O ring 3 Seal kit 4 Bushing 5 Seal kit Insert the new washers into the screw insert Insert and press in the new seal package into the cylin der head using the inst...

Page 127: ...el engine NOTE For details see further back in the chapter Exemplary illustration for pump types 9 50 and 13 35 1 Pump casing 2 Cover filling hole 3 Oil sight glass 4 Oil drain screw 5 Oil catch pan U...

Page 128: ...rod so that they do not get interchanged during assembling NOTE Every bearing cup must later be refastened to the same piston rod with the same alignment Therefore mark the components prior to removal...

Page 129: ...0 Rev 00 07 15 129 Dismantle both flange bearings on the pump casing in order to do so the 4 screws on the flange must be loos ened respectively At the end you can pull out the flange bearings Tighte...

Page 130: ...arings are used The axial load is adjusted on the open bearing side by means of spacer discs adjustment is performed by the factory Ensure that the relevant spacer disc s are con clusively reinstalled...

Page 131: ...l seal ring 3 Pump casing Remove 3 oil seals from the pump housing with the special pliers NOTE Make sure that the boring is not damaged when the oil seal rings are removed NOTE The pictures are of a...

Page 132: ...ack into the straight pushing guide and the pistons are screwed on observe tightening torque see in the back Clean the threads before screwing apply screw securing adhesive soluble to the threading of...

Page 133: ...2 Pump casing 3 Crankshaft bearing cover with crankshaft bearing and O ring 4 Crankshaft housing cover with O ring 5 Piston rod bottom parts marked 6 Crankshaft bearing with flange O ring and shaft s...

Page 134: ...back in Fixate it with flange bearings Then screw the bearing cups into the piston rod Nm 8 9 Assemble back the parts in the reverse sequence Fill in oil up to the sight glass Oil fill volume and type...

Page 135: ...e safety block a complete removal is required Work on the reed switch and for pressure adjustment on the safety valve can also be performed in the installed con dition The safety valve can be adjusted...

Page 136: ...ck Clean change the reed switch for flow monitoring NOTE Observe the installation position of the reed switch on the casing The marking on the reed switch points centrally to the casing 1 Reed switch...

Page 137: ...urn to stop Set the safety valve to approx 220 230 bar The opening pressure of the safety valve is adjusted with the adjustment screw Rotation to the right increases the opening pressure rotation to t...

Page 138: ...ter the filter re move hoses Change filter ATTENTION Collect the residual amount of diesel from the line and seal the line If the diesel tank is not empty diesel will permanently leak when the line is...

Page 139: ...and return remove lines ATTENTION Collect the residual amount of diesel from the line and seal the line If the diesel tank is not empty diesel will permanently leak when the line is not sealed NOTE E...

Page 140: ...ly Mark the position of the air flap 1 Screw 2 Screw for locking the air flap 3 Air flap Unscrew the screw for locking the air flap Open 2 screws of the casing top 1 Air flap Position the air flap hor...

Page 141: ...wheel all around and lever it out 1 Fitting key Remove the two feather keys of the motor shaft Unscrew 4 screws Remove the bottom part of the blower Unscrew 4 screws Push out the motor towards the bac...

Page 142: ...ing ring NOTE In order to have better access to the 4 carbons later on it is recommended to remove the fuel pump to unscrew the console of the blower unit from the frame and to put down the unit horiz...

Page 143: ...r jacket on the booster heater Clean the rubber cuff and the outer jacket in the instal lation area Install the rubber cuff on the outer jacket Insert the clamping part with the chamfer towards the bo...

Page 144: ...he fuel line Unscrew 2 screws from the cover NOTE When detaching the connection of the fuel line pay atten tion to possibly leaking diesel Remove the complete burner unit 1 Connections ignition electr...

Page 145: ...Replace burnt out ignition electrodes 1 Pressure plate 2 Fuel nozzle 3 Ignition electrodes 4 Screw 5 Burner cover 1 Connection fuel line 2 Fuel nozzle holder 3 Fuel nozzle 4 Ignition electrodes 5 Scre...

Page 146: ...nt part NOTE When sliding the flame sensor into the support ensure that it is in the correct position Otherwise the support cannot be closed NOTE When changing the flame sensor it must be electrically...

Page 147: ...lder Disconnect the cable connection NOTE Observe the cable run with the electrical connection View from below 1 Temperature sensor warm water 2 High pressure line from the booster heater to the high...

Page 148: ...e from the safety block to the boiler Dismantle the PVC protective plate on the right Remove the high pressure line from the booster heater to the high pressure connection Detach the connection of the...

Page 149: ...stment screw fuel pressure 2 Pressure line to the burner 3 Fuel pump 4 Return hose to the fuel tank 5 Suction hose fuel NOTE Rotation in the plus direction increases the fuel supply ro tation in the m...

Page 150: ...air slider Measure the soot value CO2 content and the exhaust temperature special tools measuring gauges Adjusting the fuel pressure Set the fuel pressure and water temperature via the set screw Adjus...

Page 151: ...nnection Remove the pressure gauge 1 Bypass unit 2 Water pipes 3 High pressure hose NOTE The unit is located at a console that must be dismantled to completely unthread the bypass unit The following p...

Page 152: ...m the plug connection Unscrew C coupling for the water hose 1 Screw Open the nuts of the two hose connections Unscrew the screws of the console fastening Carefully unthread the bypass unit from the co...

Page 153: ...unit CAUTION Risk of burns Prior to working on the alternator make sure the exhaust system has cooled off Diesel engine 1 Fuel filter 2 Exhaust 3 Preformed hose from the air filter 4 Cooling fan motor...

Page 154: ...154 English 5 906 736 0 Rev 00 07 15 Diesel engine 1 Expansion tank motor coolant 2 Exhaust system 3 Muffler 4 Air filter 5 Starter 6 Alternator...

Page 155: ...olant in the expansion tank of the motor coolant while the motor is cold The liquid level has to be between MIN and MAX If necessary refill coolant Open the cover on the expansion tank of the motor co...

Page 156: ...mpressed air max 2 bar from the inside Clean the inside of the air filter housing with a cloth Insert the filter inlay into the air filter casing Attach the cover and fasten it by means of the spring...

Page 157: ...belt ten sion It should be able to push in the V belt with position A 10 14mm with position B 7 10mm with position C 9 13mm NOTE The preferred test position is B Replacing V belt Loosen the 4 screws...

Page 158: ...re that the metal tab is on the inside and the screw with the wash er on the outside 1 Alternator 2 Screw Disconnect battery Mark the position of the alternator on the retainer for ori entation Slight...

Page 159: ...Increased risk of fire 1 Upper cover filling hole 2 Oil dipstick Remove the oil dip wipe it and reinsert it Remove the oil dip one more time and check the oil level The oil level is correct if it is w...

Page 160: ...Oil drain screw engine The oil drain screw is located on the bottom of the motor casing Lift the trailer unscrew the protective plate on the bot tom left Place a catch pan underneath the oil drain sc...

Page 161: ...urn the oil filter another 1 8 turn using the oil filter wrench Unscrew the upper cover from the oil filler neck Slowly fill 3 5 litres of fresh motor oil specification see table below into the oil fi...

Page 162: ...OFF leaking of diesel upon opening the filter casing is avoided Loosen the lock union nut NOTE Observe the rotation direction The casing is screwed down from the bottom Unscrew the filter casing Clean...

Page 163: ...urn the tap up wards NOTE In the valve position OFF leaking of diesel upon opening the filter casing is avoided Loosen the lock union nut NOTE Observe the rotation direction The casing is screwed down...

Page 164: ...glass 4 Oil drain screw NOTE Replace the oil while the motor has operating temperature Align the appliance horizontally prior to the oil change CAUTION Risk of burns when draining hot oil Let the oil...

Page 165: ...connecting plug of the pressure switch remove the plug Unscrew the screw of the speed control and remove the entire unit of the speed control towards the top NOTE Ensure that no O rings are lost Unsc...

Page 166: ...2 Claw clutch 3 Elastomer ring 4 Flange plate If necessary exchange the elastomer ring For this pur pose pull out the drive shaft and replace the elastomer ring NOTE If the entire claw coupling must b...

Page 167: ...situation on the mini trailer Drain the oil from the intermediate gear Unscrew 4 screws and remove the casing Open the safety screw Pull off the toothed wheel NOTE Upon installation push the toothed...

Page 168: ...he upper edge of the oil level indicator Dispose of fuel that cannot be used again in accordance with the local regulations View from below 1 Drain screw fuel tank NOTE The drain screw is located on t...

Page 169: ...ensor out on the flap of the cuff as this can get damaged in the pro cess due to the tight fitting Pull out the level sensor from the tank towards the top 1 Level sensor for fuel tank Detach the cable...

Page 170: ...sensor on the control observe cable run NOTE If no bargraph of the fuel tank is depicted there is a fault in the level sensor of the fuel tank or it is not properly con nected 1 Suction lance with sc...

Page 171: ...lve towards the front Detergent dosing valve 1 Connection from the detergent tank labelled with 1 2 Connection to the pump labelled with P Solenoid valve dosing detergent 1 Connection from the deterge...

Page 172: ...valve body Clean the valve body Clean the tappet with a soft cloth if necessary NOTE When changing the complete solenoid valve the hoses must be disconnected and the valve must be unscrewed from the b...

Page 173: ...tandard settings on the high pressure pump and the motor A 20mm B 20mm C 75mm 1 Stop screw full load 2 Stop screw idle mode D 27 5mm E 18 5mm Hand throttle lever Insert test nozzle into the spray gun...

Page 174: ...setting safety valve NOTE The safety valves are preset by the factory HDS 13 20 and 17 20 The presetting at 240bar is done in the factory HDS 9 50 and 13 35 The safety valve is permanently set and sta...

Page 175: ...lation on the gun set to Open the lock nut on the overflow device Turn the adjustment screw high pressure until the test pressure on the pressure gauge is reached see tech nical data NOTE If this scre...

Page 176: ...ording to statutory requirements only tested and ap proved boiler cleansing compounds with a certification mark may be used for removal RM 101 order no 6 287 013 removes deposits These agents are gear...

Page 177: ...the filter of the water inlet Finally clean it NOTE In the frost protection mode flow is recognised however no pressure This is OK in this operating mode and does not lead to a fault message The fault...

Page 178: ...to react for approx 15 min utes Unscrew the screws from the boiler jacket and remove the boiler jacket towards the top NOTE Collect the leaking water in order to dispose it of in an en vironmentally s...

Page 179: ...he motor fan insufficient Motor fan defective ERROR 4 Water shortage Water filter soiled Water supply volume or pressure too low Water tanks 2x250 l empty or stop cock water tanks closed Float valve s...

Page 180: ...incorrectly adjusted Flame sensor defective Fuel pump defective coupling fuel pump defective Solenoid valve fuel is defective Ignition transformer faulty Blower motor defective ERROR 12 Flame sensor i...

Page 181: ...crankcase Leakiness of 1 drop per minute and piston is acceptable Check replace high pressure and low pressure seals Water is not being heated Check correct temperature settings Check clean replace fl...

Page 182: ...182 English 5 906 736 0 Rev 00 07 15 13 3 Troubleshooting Yanmar diesel engine...

Page 183: ...906 736 0 Rev 00 07 15 183 NOTE The current inspection and maintenance checklist 5 965 663 0 is recorded in the DISIS 14 Maintenance plans 14 1 Inspection and maintenance checklist 14 2 Maintenance pl...

Page 184: ...184 English 5 906 736 0 Rev 00 07 15...

Page 185: ...English 5 906 736 0 Rev 00 07 15 185 14 3 Maintenance plan Yanmar diesel engine...

Page 186: ...05 1 0 0 05 1 0 0 05 1 0 Min input amount water l h 1000 1500 1800 1500 max water supply temperature C 30 30 30 30 Diameter of the inlet hose DN 19 19 19 19 High pressure nozzle series nozzle Type 15...

Page 187: ...ph 1 35 2 25 2 25 2 25 Fuel pump set pressure MPa 1 0 1 3 1 0 1 3 1 0 1 3 1 0 1 3 max air pressure at the burner cover mmWS 2 5 3 5 3 0 5 0 3 0 5 0 3 0 5 0 Heating output kW 65 97 105 105 Speed blower...

Page 188: ...188 English 5 906 736 0 Rev 00 07 15 HDS 13 20 and 17 20 high pressure pump HDS 13 20 and 17 20 overflow device 15 1 Tightening torques...

Page 189: ...English 5 906 736 0 Rev 00 07 15 189 HDS 13 20 and 17 20 safety block...

Page 190: ...190 English 5 906 736 0 Rev 00 07 15 HDS 9 50 and 13 35 pump head...

Page 191: ...English 5 906 736 0 Rev 00 07 15 191 HDS 9 50 and 13 35 speed control HDS 9 50 and 13 35 frost protection valve HDS 9 50 and 13 35 overflow device...

Page 192: ...192 English 5 906 736 0 Rev 00 07 15 HDS 9 50 and 13 35 transmission HDS 9 50 and 13 35 safety block...

Page 193: ...2 040 0 Test pressure gauge 0 800 bar HDS 9 50 HDS 13 35 4 901 060 0 Pressure gauge fuel pressure for measuring the pump pressure of the fuel pump at the burner cover 6 775 001 0 Soot pump for measuri...

Page 194: ...in the exhaust gas of the burner no K rcher part number Recommendation Testo 320 or Testo 320 2 LL required accessories for both measuring devices Power Supply Device case Flue gas probe 4 901 062 0 R...

Page 195: ...17 20 6 815 258 0 Installation mandrel for oil seals HDS 13 20 HDS 17 20 6 815 209 0 Screw attachment locking screw HDS 9 50 HDS 13 35 Crown wrench for brass bush low pressure seals 5 111 128 0 6 815...

Page 196: ...r part number Recommendation Oil filter claw HAZET 2172 6 491 361 0 Revolution counter for motor speed 6 803 003 0 Magnetic field tester for the function test of magnetic coils 6 768 004 0 Hardness in...

Page 197: ...glish 5 906 736 0 Rev 00 07 15 197 NOTE Please use the circuit diagram associated with the ma chine An excerpt of the circuit diagram version 07 2015 is en closed for your information 17 Circuit diagr...

Page 198: ...198 English 5 906 736 0 Rev 00 07 15...

Page 199: ...English 5 906 736 0 Rev 00 07 15 199...

Page 200: ...200 English 5 906 736 0 Rev 00 07 15...

Page 201: ...English 5 906 736 0 Rev 00 07 15 201...

Page 202: ...202 English 5 906 736 0 Rev 00 07 15...

Page 203: ...English 5 906 736 0 Rev 00 07 15 203...

Page 204: ...204 English 5 906 736 0 Rev 00 07 15...

Page 205: ...English 5 906 736 0 Rev 00 07 15 205...

Page 206: ...206 English 5 906 736 0 Rev 00 07 15...

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Kärcher HDS 9/50 De Tr1, Service Manual

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