Kärcher HDS-E 8/16-4M Service Manual Download

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English 5.906-548.0 Rev. 00 (04/12)

HDS-E 8/16-4 M

Service Manual

Summary of Contents for HDS-E 8/16-4M

Page 1: ...English 5 906 548 0 Rev 00 04 12 1 HDS E 8 16 4 M Service Manual...

Page 2: ...0 4 5 View of the right side appliance hood open 11 5 Function 12 5 1 Operator console 12 5 1 1 Indicator lamps 13 5 2 Interior of operating panel 15 5 2 1 Open the operating panel 15 5 2 2 Operating...

Page 3: ...sed 44 5 13 4 The gun is reopened when the appliance is switched on 45 5 14 Functional description of the control 46 5 14 1 Hot water cold water solenoid valves 46 5 14 2 Water shortage safeguard 46 5...

Page 4: ...re seal packages 77 6 6 4 Replace high pressure seals 78 6 6 5 Remove the suction jumper replace the seals and the suction valves 78 6 6 6 Remove the high pressure valves 79 6 7 Replace the water fine...

Page 5: ...otected from inadvertent startup Mobile hot water high pressure cleaner in different performance classes for commercial use Electrically heated boiler Water supply with coarse dirt filter and fine fil...

Page 6: ...l Thermal insulation 2 detergent tanks Content of detergent tank 1 10 l Content of detergent tank 2 20 l Detergent dosing valve on the device with auto matic clear rinse in zero position Rotary regula...

Page 7: ...gun 5 Lever for hand spray gun 6 Trigger gun 7 Spray lance 8 High pressure hose 9 High pressure nozzle stainless steel 10 Bearing wheel 11 Mounting location for transport 12 Steering roller with fixed...

Page 8: ...M 110 RM 111 6 Hose hook 7 Folding compartment 8 Pouring vent for detergent 2 9 Chassis 10 High pressure connection 11 Connection for water supply with filter 12 Step depression 13 Power supply 14 Pou...

Page 9: ...plate 3 Boiler fastening screws 4 Boiler drain screw 5 High pressure line 6 High pressure line bracket 7 Connection for water supply with filter 8 High pressure connection Note The floor plate is inte...

Page 10: ...e bottles 1 Device documentation 2 Storage for rotor nozzle 3 Screw for storage compartment 4 Storage for high pressure nozzle 5 Screw for operating panel 6 Storage compartment for accessories 7 Boile...

Page 11: ...box motor 5 Oil tank 6 High pressure pump 7 Solenoid valve for cold water 8 Solenoid valve for warm water 9 Suction hose for detergent 10 High pressure hose between pump and safety valve 11 System car...

Page 12: ...Indicator lamp boiler fault red 7 Indicator lamp service orange 8 Indicator lamp system care yellow 9 Manometer 10 Dossing range of detergent tank 1 11 Dosage valve for detergent 12 Dossing range of...

Page 13: ...minutes Pump and heater are switched off glow Heater is switched on blinks twice Engine overloaded overheated winding protective contact open Set the appliance switch to 0 OFF Allow device to cool dow...

Page 14: ...form them glow Note Heater can only operate 5 more hours System care tank is empty or units on the RFID tag are used up see Sys tem care with RFID Replace the system care bottle blinks once Note Heate...

Page 15: ...r to the device must be shut off pull mains plug and it must be protected from inadvertent startup 1 Closing flap for storage compartment 2 Screw Open the covering flap of the storage compart ment Uns...

Page 16: ...1 2 Service switch 3 Control transformer T2 4 Transducer 5 Power switch 6 Temperature controller 7 Control electronics 8 Dosage valve for detergent 9 Control transformer fuse 10 Temperature limiter be...

Page 17: ...on lack of water 14 PCB motor distributor connection 15 Grounding connection of control electronics 16 Control transformer T1 connection 17 Control transformer T2 connection 18 Auxiliary relay K5 conn...

Page 18: ...h Caution Severe reduction of the pump idle time Do not acti vate the pump trailing DIP Adjust ment by the manu facturer Function 1 OFF 2 OFF 3 OFF No pump trailing 4 OFF Dosing of system care RM 110...

Page 19: ...using a screwdriver or a coin and turn it by 90 counter clockwise Open the device hood 1 Wire rope 2 Support Unhook the wire rope 1 Hinge Unclip the hinge clamp and slide it out toward the top Remove...

Page 20: ...ks Measure the water using the water hardness test ing set order no 6 768 004 0 Set the service switch according to the water hard ness in the table All device settings can be modified using the servi...

Page 21: ...Plug 5 Hose to the boiler The system reports the system care empty via the level sensor in the system care tank RFID electronics tag on the system care bottle After the empty message you can keep wor...

Page 22: ...also called a tag The write read electronics inside the appliance can read data from the tag and also write data to the tag The power supply is sent to the tag from the radio fre quency field The wri...

Page 23: ...ating element 9 Heating element 24 kW 10 Sensor of the temperature limiter 11 Hot water outlet 12 Temperature sensor 13 Cold water outlet 14 Rinse line outlet to the detergent dosing valve 15 System c...

Page 24: ...ed into a cold and hot water reser voir by a removable sheet metal part The water runs into the cold water reservoir via a float valve and is then transferred to the hot water reser voir Unscrew the c...

Page 25: ...n the Chapter Boiler The model with a heating output of 12 kW has an ad ditional quick heating chamber and is described in the following 1 Separator wall between hot water cold water res ervoirs 2 Cov...

Page 26: ...ck of water fuse prevents the heating element from being switched on when there is a water short age The control electronics captures the hot water tem perature via the temperature sensor and switches...

Page 27: ...s not installed in the photograph 1 Suction hose for detergent 2 1 Filter 2 Suction hose for detergent The suctioning of the detergent can also be per formed outside the appliance For this the suction...

Page 28: ...regulation 2 Oil tank 3 Motor 4 Cooling coil of water cooling 5 Electric box motor 6 Blower casing of engine air cooling 7 Motor intake 8 Oil level sensor 9 Pump head 10 Solenoid valve for cold water...

Page 29: ...ssure valve 3 Pump head screw 4 Suction jumper screw 5 Suction jumper 6 Solenoid valve for warm water 7 Solenoid valve for cold water 8 Suction hose for detergent 9 Pressure switch OFF 10 Fastener 11...

Page 30: ...30 English 5 906 548 0 Rev 00 04 12 1 Union joint 2 Disc 3 Suction jumper 1 Union joint 2 Disc 3 Groove for disc...

Page 31: ...ing 9 Swash plate 10 Fastening screw swash plate 11 Axial ball bearing swash plate 12 Oil drain screw 13 Piston guide 14 Suction side pump 15 Suction valve 16 Piston 17 High pressure seal 18 Low press...

Page 32: ...ck ring 9 Brass support disc Note Pay attention to installation position of the seals High pressure and low pressure seals consist of a 3 part seal package each To increase the standstill time the fol...

Page 33: ...iter relay K5 8 Ferrite core in the motor supply line 9 Connection pressure switch ON 10 Connection pressure switch OFF 11 Oil level sensor connection 12 Control electronics connection operating panel...

Page 34: ...er con tactor 8 Ferrite core in the motor supply line 9 Connection pressure switch ON 10 Connection pressure switch OFF 11 Oil level sensor connection 12 Control electronics connection operating panel...

Page 35: ...K5 8 Ferrite core in the motor supply line 9 Connection pressure switch ON 10 Connection pressure switch OFF 11 Oil level sensor connection 12 Control electronics connection operating panel 13 Connect...

Page 36: ...ust be re placed as a complete unit The date of manufacture is imprinted on the node piece It is composed of the month letters A to L for January through December and year 1 digit number 1 for 2011 2...

Page 37: ...cs can adjust the flow volume and the pressure when rotating the discs 1 Ceramic disc on spray pipe side 2 Ceramic disc on gun side This illustration shows the two overlapping ceramic discs and the wa...

Page 38: ...pump 8 Swimmer valve 9 Level sensor for system care 10 Cold water tank 11 Warm water tank 12 Overflow 13 Water shortage safeguard 14 Temperature sensor 15 Temperature controller 16 Heating element 17...

Page 39: ...Pressure and volume regulation 25 Pressure switch ON 26 Manometer 27 Rinse hose of the detergent dosing valve 28 Dosage valve for detergent 29 Detergent suction hose with filter 30 Detergent Tank 31 D...

Page 40: ...6 Pressure spring 7 Overflow piston 8 High pressure valve 3x 9 Pump piston 3x 10 Suction valve 3x 11 Detergent infeed with backflow valve 12 Suction jumper with water connection 13 Sleeve with thrott...

Page 41: ...pressure and volume regulation on the pump must always be closed all the way direc tion on the handle otherwise the device will shut off prematurely If the rotary regulator is partially closed the pre...

Page 42: ...s and motor contactor are for understanding purposes only In reality the information from the two pressure switches is transferred directly to the control electron ics which in turn controls the motor...

Page 43: ...In reality the information from the two pressure switches is transferred directly to the control electron ics which in turn controls the motor contactor After switching on the appliance and with the...

Page 44: ...sed This will open the overflow valve and the entire flow volume streams into the suction chamber of the pump through the throttle bore As soon as the overflow valve opens the pressure re taining valv...

Page 45: ...re for understanding purposes only In reality the information from the two pressure switches is transferred directly to the control electron ics which in turn controls the motor contactor As soon as t...

Page 46: ...ystem care tank is empty the reciprocating pump is not activated dry run protection 5 14 Functional description of the control 5 14 1Hot water cold water solenoid valves Pump start First the respectiv...

Page 47: ...ice switch setting Rotate the service switch into the service position Turn on the appliance Set the thermostat to the desired function see de scription of the different functions below The current se...

Page 48: ...leaks 38 C Testing the indicator lamps 38 C SET Device with without RFID 40 C Water temperature display 43 C Function control of device switch and ther mostat 47 C Service switch setting display 50 C...

Page 49: ...setting will be saved Switching using SET The device switches off after 30 min utes of standby operation The heater in the boiler also shuts off The device does not switch off after 30 minutes of stan...

Page 50: ...0 04 12 6 1 8 RFID query Function adjustment Display Significance 38 C SET RFIDONOFF Information to the control elec tronics whether the device is equipped with supplemental dos ing via RFID Device wi...

Page 51: ...or The value is shown digit by digit via the indicator lamps The display is repeated after a pause Example A temperature of 27 C is meas ured The indicator lamps light up in the following sequence PAU...

Page 52: ...ST Use this function to test the de vice switch and the thermostat In order to start the test Rotate the service switch to SET and release it Turn the thermostat to 30 C By increasing the thermostat s...

Page 53: ...English 5 906 548 0 Rev 00 04 12 53 Function adjustment Display Significance 43 C 60 C 63 C 67 C 70 C 73 C 77 C 80 C 83 C 85 C Adjust thermostat to 43 C after the test...

Page 54: ...ng of the device switch Operating with cold water Eco efficiency setting Operating with hot water 6 1 11Check the service switch Function adjustment Display Significance 47 C ENCDGTTEST Service switch...

Page 55: ...level sensor open too little oil ON pressure switch not actuat ed Auxiliary relay of heating ele ment contactor closed Float contact of lack of water fuse closed float up OFF pressure switch not actu...

Page 56: ...e fault memory is displayed Example PAUSE Significance The pump has been operating for 14 hours since the fault Winding protection contact open oc curred High voltage range Low voltage range Overcurre...

Page 57: ...D electronics defective End of the fault memory and display of the software version Example Software version 1 8 53 C SET Clearing the error memory Set the thermostat to 53 C Rotate the service switch...

Page 58: ...sed up bottles is displayed The value is shown digit by digit via the indicator lamps The display is repeated after a pause Example 12 bottles of system care were consumed The indicator lamps light up...

Page 59: ...ost recent gun serv ice The value is shown digit by digit via the indicator lamps The display is repeated after a pause Example The gun was actuated 430 times since the last gun service The indicator...

Page 60: ...l be increased by 1 The fault memory will be deleted 6 1 16Gun services Function adjustment Display Significance 63 C SCTR_PISTOLE Number of gun services The value is shown digit by digit via the indi...

Page 61: ...t started up The value is shown digit by digit via the indicator lamps The display is repeated after a pause Example The gun was actuated 9483 times since the device was put into service The indicator...

Page 62: ...t heater service in hours The value is shown digit by digit via the indicator lamps The display is repeated after a pause Example The heater has been in operation for 47 hours since the last heater se...

Page 63: ...ill be increased by 1 The fault memory will be deleted 6 1 19Heater service Function adjustment Display Significance 73 C SCTR_BOILER Display of the heater service The value is shown digit by digit vi...

Page 64: ...initial device startup in hours The value is shown digit by digit via the indicator lamps The display is repeated after a pause Example The heater has been in operation for 32 hours since the initial...

Page 65: ...pump service in hours The value is shown digit by digit via the indicator lamps The display is repeated after a pause Example The pump has been in operation for 31 hours since the last pump service T...

Page 66: ...will be increased by 1 The fault memory will be deleted 6 1 22Pump services Function adjustment Display Significance 83 C SCTR_PUMPE Display of the pump services The value is shown digit by digit via...

Page 67: ...nitial device startup in hours The value is shown digit by digit via the indicator lamps The display is repeated after a pause Example The pump has been in operation for 32 hours since the initial de...

Page 68: ...elapsed since the last occurrence hours High voltage range Low voltage range Overcurrent Asymmetrical phases Winding protection contact motor is open Lack of water for more than 120 seconds Auxiliary...

Page 69: ...of the heater since heater service 73 C SET Every 600 oper ating hours Service high pressure pump Read the operating hours of the pump 80 C Reading faults 53 C Replace the high and low pressure seals...

Page 70: ...n the gun to the po sition of lowest pressure direction Actuate the trigger on the gun and switch on the appliance Pull off the rotary handle on the pressure regula tor Loosen the locknut of the adjus...

Page 71: ...ating handle of the pressure regula tor on the pump anti clockwise direction all the way to the stop Pull off the rotary handle on the pressure regula tor Loosen the locknut of the adjustment screw fo...

Page 72: ...ft 2 Pressure hose 3 Washer ring 4 Manometer 5 Fastening clip right Loosen the fastening clip on the left behind the manometer using your finger 1 Screwdriver Loosen the fastening clip on the right us...

Page 73: ...adjustment screw for high pressure Screw in the high pressure adjustment screw all the way This blocks the overflow valve Turn on the appliance 1 Safety valve 2 Adjustment screw Slowly close the shut...

Page 74: ...e the cover from the electric box 1 Screw 2 Cable from motor 3 Motor contactor K1 4 Circuit breaker F1 Disconnect the cable from the motor to K1 red black yellow 2x green at K1 Disconnect the circuit...

Page 75: ...with the supply hose from the suction jump er 1 Retaining clip 2 Pressure switch connecting cable Lever IN OUT the holding clamps of the connect ing cables to the pressure switch Pull the connecting c...

Page 76: ...ten them Unscrew the oil drain screw and catch the oil Un screw both mounting screws and replace with aux iliary screws M6x110 special tools Remove the lockscrews M8x40 or M12x50 Unscrew the mounting...

Page 77: ...seal from the bushing 1 Low pressure seal 2 Support ring 3 Bushing Grease the new support ring and the low pressure seal and install them The groove of the seal must point toward the bushing Complete...

Page 78: ...itioning The suction jumper must be removed to replace the suction valves Note For the HDS 5 12 the suction jumper is made of plas tic and does not contain a connection for the deter gent suction hose...

Page 79: ...4 Valve screw Unscrew the valve screws Remove the high pressure valves using a special pliers Check the high pressure valves for leaks Insert the high pressure valves observe installa tion positionin...

Page 80: ...heating output of 36 kW approx 600 operating hours and approx 28 dH water hardness The boiler must be cleaned and decalcified every 400 operating hours Decalcify the boiler using decalcifier e g RM 10...

Page 81: ...ecure against inadvertent connection and ensure that no voltage is flowing to the appliance Set the appliance switch to 0 OFF Disconnect the mains plug from the socket Remove the device hood see Devic...

Page 82: ...ble manner Remove the spools from the solenoid valves Unscrew the covering nut Disconnect the cable of the heating element in the electric box Lift the boiler from the device 1 Spring ring 2 Lock nut...

Page 83: ...r 2 pipe wrench Remove the heating element 1 Specifications 2 Date of manufacture Month Year Check whether all seals have been installed and are seated correctly prior to assembly 1 Spacer 2 Flange Pl...

Page 84: ...e is flowing to the appliance 1 Turning handle Pull the rotary handle off the device switch 1 Fastening screws Unscrew locking screws Pull the device switch off toward the inside The thermostat is rem...

Page 85: ...to technical data Pump leaky Note 3 drops minute are allowed Note Condensate can cause increased drop gener ation on the device Leak in the high pressure system Check high pressure system and connect...

Page 86: ...5 Max operating temperature of hot water C 85 Switch off temperature of hot water C 98 Operating temperature during continuous operation with 15 C input temperature C 30 45 57 Detergent suck in l h l...

Page 87: ...030 0 Installation mandrel with sleeve for high pressure oil seals D 18 mm 2 901 033 0 Installation screws piston guidance 2x M6x110 7 304 467 0 Adapter system 2000 M22x1 5 with extended acorn nut 4 4...

Page 88: ...Suction jumper 20 22 Pressure switch 30 35 Connection of detergent hose 30 35 Oil tank 3 5 4 Motor Swash plate 12 15 Oil drain screw 20 25 B bearing 9 10 Ventilator casing motor 2 2 5 Ventilator cover...

Page 89: ...English 5 906 548 0 Rev 00 04 12 89 Note Please observe the most current circuit diagrams in DISIS 11 Circuit diagrams...

Page 90: ...90 English 5 906 548 0 Rev 00 04 12...

Page 91: ...English 5 906 548 0 Rev 00 04 12 91...

Page 92: ...92 English 5 906 548 0 Rev 00 04 12 12 Cut out masks to place on the operating panel...

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Kärcher HDS-E 8/16-4M, Service Manual

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