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Karcher HDS 10/20 Service Manual

Summary of HDS 10/20

  • Page 1

    Service manual hds middle range 1.071-..., 1.077-... Hds 7/12, hds 8/17, hds 9/18, hds 10/20 hds premium range 1.071-... Hds 12/18, hds 13/20 service manual 04.2008 5.906-433.0

  • Page 2

    Hds middle range / hds premium range page 2 / 127 service manual 04.2008.

  • Page 3

    Hds middle range / hds premium range foreword service manual 04.2008 page 3 / 127 foreword good service work requires comprehensive and practical training as well as clear documents. We therefore provide regular basic training and further training courses for service technicians covering our whole r...

  • Page 4

    Contents hds middle range / hds premium range page 4 / 127 service manual 04.2008 contents 1 equipment features ............................................................................................ 6-9 1.1 technical features .......................................................................

  • Page 5

    Hds middle range / hds premium range contents service manual 04.2008 page 5 / 127 contents 3.1.10 operating hours ..................................................................................................... 74 3.1.11 handgun switchings since the handgun service ................................

  • Page 6

    Equipment features hds middle range / hds premium range page 6 / 127 service manual 04.2008 general: mobile hot water high-pressure cleaner with various power ratings for commercial use. – high-performance burner with vertical heat- ing coil and continuous ignition. – integrated scale inhibitor. – s...

  • Page 7

    Hds middle range / hds premium range equipment features service manual 04.2008 page 7 / 127 1 push handle (2x) 2 cover, top storage compartment 3 safety latch, softgrip easy-press handgun 4 rotary control 5 trigger lever 6 softgrip easy-press handgun 7 cap, fuel tank 8 high-pressure hose 9 rotatable...

  • Page 8

    Equipment features hds middle range / hds premium range page 8 / 127 service manual 04.2008 1.3 view from the rear (unit without hose reel) 13 1 indicator lights 2 program switch (q1) 3 adjustment, water temperature 4 spray lance holder, rh 5 cap, scale inhibitor tank 6 storage, mains cable 7 storag...

  • Page 9

    Hds middle range / hds premium range equipment features service manual 04.2008 page 9 / 127 1.4 view from the rear (unit with hose reel) 15 1 2 3 4 5 7 8 9 14 12 6 16 18 17 20 19 21 22 10 11 1 indicator lights 2 program switch (q1) 3 adjustment, water temperature 4 spray lance holder, rh 5 cap, scal...

  • Page 10

    Unit function hds middle range / hds premium range page 10 / 127 service manual 04.2008 2.1 control panel 1 indicator led 0, pump (red) 2 indicator led 1, rotational direction (red) 3 indicator led 2, operation (green) 4 indicator led 3, fuel (yellow) 5 indicator led 4, cleaning agent tank 1 (yellow...

  • Page 11

    Hds middle range / hds premium range unit function service manual 04.2008 page 11 / 127 2.1 control panel functions of the led displays in operating mode symbol activity meaning / action 1 x flashing led no. 0 2 x flashing 3 x flashing 4 x flashing 1 x flashing light up 1 1 x flashing 2 light up 3 l...

  • Page 12

    Unit function hds middle range / hds premium range page 12 / 127 service manual 04.2008 symbol activity meaning / action led no. Light up 8 scale inhibitor level switch detects empty or units on the tag* of the scale inhibitor bottle have been used up. 1 x flashing 5 hours after-running time have ex...

  • Page 13

    Hds middle range / hds premium range unit function service manual 04.2008 page 13 / 127 2.1 control panel template for numerical value displays the template below can be placed on the led displays of the control panel for improved recognition of the numerical value displays in the service functions....

  • Page 14

    Unit function hds middle range / hds premium range page 14 / 127 service manual 04.2008 2.1 control panel.

  • Page 15

    Hds middle range / hds premium range unit function service manual 04.2008 page 15 / 127 2.1.1 control panel, view from inside 1 11 2 3 5 6 4 7 8 9 10 12 13 1 service switch and adjustment, scale inhibitor metering 2 control circuit transformer (t1) 3 current transformer 4 fuse 2.0 at (6.644-052) for...

  • Page 16

    Unit function hds middle range / hds premium range page 16 / 127 service manual 04.2008 2.1.2 printed circuit board, control panel 1 2 3 4 5 8 9 11 12 13 14 15 16 17 18 19 20 21 1 connection, cleaning agent tank 1 level sensor 2 connection, cleaning agent tank 2 level sensor 3 connection, fuel tank ...

  • Page 17

    Hds middle range / hds premium range unit function service manual 04.2008 page 17 / 127 2.2 control panel with display (hds 13/20 only) 1 display 2 program switch „off“ position 3 program switch „cold water operation“ position 4 program switch „eco mode*“ position 5 program switch „hot water/steam o...

  • Page 18

    Unit function hds middle range / hds premium range page 18 / 127 service manual 04.2008 2.2.1 status displays display note explanation pump maintenance due burner maintenance due accessories maintenance due 2.2.2 maintenance - operating liquids display note explanation scale inhibitor empty. Scale i...

  • Page 19

    Hds middle range / hds premium range unit function service manual 04.2008 page 19 / 127 2.2.3 error messages display note explanation rotating field incorrect. Motor thermal contact (wsk) in the motor has actuated. Mains voltage too low or too high or phase has failed or motor current too high. Chec...

  • Page 20

    Unit function hds middle range / hds premium range page 20 / 127 service manual 04.2008 2.2.4 error messages with service requirement display note explanation low-water protection sticks 10 short start-ups/leakage contactor does not switch temperature sensor (ntc) is defective flame sensor detects i...

  • Page 21

    Hds middle range / hds premium range unit function service manual 04.2008 page 21 / 127 2.2.5 dgt setting display note explanation scale inhibitor metering set according to the water hardness. This display appears for 3s if the scale inhibitor setting is changed. Important! Service mode position. Af...

  • Page 22

    Unit function hds middle range / hds premium range page 22 / 127 service manual 04.2008 2.3 storage compartments 1 2 3 5 top storage compartment bottom storage compartment (in unit without hose reel only) 3 4 8 7 5 6 9 10 11 1 cover, top storage compartment 2 storage, operating instructions 3 retain...

  • Page 23

    Hds middle range / hds premium range unit function service manual 04.2008 page 23 / 127 2.4 unit cover latch, unit cover lug, restraining cable 1 4 3 2 5 6 7 1 top storage compartment 2 unit cover 3 latch, unit cover 4 screwdriver 5 restraining cable, unit cover 6 lug, restraining cable 7 hinge, uni...

  • Page 24

    Unit function hds middle range / hds premium range page 24 / 127 service manual 04.2008 2.5 view from the right, unit cover removed 1 10 11 12 13 16 17 18 19 20 22 21 15 14 2 3 4 5 6 7 1 fuel line to the continuous-flow heater 2 electrical box, motor 3 burner fan 4 oil refill container, pump 5 motor...

  • Page 25

    Hds middle range / hds premium range unit function service manual 04.2008 page 25 / 127 2.6 service switch service switch in „service“ position service switch in „off“ position service switch in „set“ position 1 2 adjusting the water hardness the scale inhibitor metering (rm 110/111) is adjusted acc...

  • Page 26

    Unit function hds middle range / hds premium range page 26 / 127 service manual 04.2008 2.7 fuel tank fuel tank (diesel, heating oil) 1 cap, fuel tank 2 seal, fuel tank cap 3 tank inlet, fuel tank with prefilter 4 fuel filter 5 level sensor, fuel tank 6 fuel tank (diesel, heating oil) 3 1 2 6 4 5 fu...

  • Page 27

    Hds middle range / hds premium range unit function service manual 04.2008 page 27 / 127 scale inhibitor tank (rm 110/111) 3 1 2 2.8 scale inhibitor 1 cap, scale inhibitor tank 2 seal, scale inhibitor tank cap 3 scale inhibitor tank (rm 110/111) 4 level sensor, scale inhibitor tank 5 metering valve, ...

  • Page 28

    Unit function hds middle range / hds premium range page 28 / 127 service manual 04.2008 2.8 scale inhibitor 2.8.2 metering via rfid (european version) the scale inhibitor is metered in accordance with the setting at the service switch. The setting is described under 2.6 service switch. Metering take...

  • Page 29

    Hds middle range / hds premium range unit function service manual 04.2008 page 29 / 127 2.8 scale inhibitor 1 2 rfid read-write electronics top rfid unit with read-write electronics rfid tag, underneath the label 3 2 5 4 how the rfid works rfid (radio frequency identification) means identification w...

  • Page 30

    Unit function hds middle range / hds premium range page 30 / 127 service manual 04.2008 2.9 float tank 2 3 4 1 float tank the float tank (2) is integrated in the chassis. It is located on the right-hand side, underneath the scale inhibitor tank. The float tank uniformly supplies the pump with water....

  • Page 31

    Hds middle range / hds premium range unit function service manual 04.2008 page 31 / 127 2.10 cleaning agent tank 1 cleaning agent tank 1 (left-hand side) 1 2 suction hose with filter level sensor, cleaning agent tank 1 1 cleaning agent tank 1 2 cap, cleaning agent tank 1 3 screw plug with suction ho...

  • Page 32

    Unit function hds middle range / hds premium range page 32 / 127 service manual 04.2008 2.11 cleaning agent tank 2 suction hose with filter (removed) level sensor, cleaning agent tank 2 (removed) 1 4 cleaning agent tank 2 (right-hand side) 3 1 5 6 1 2 cleaning agent tank 2 the cleaning agent tank 2 ...

  • Page 33

    Hds middle range / hds premium range unit function service manual 04.2008 page 33 / 127 2.12 motor (air-cooled) 1 2 3 4 6 5 7 8 9 10 12 11 1 electrical box, motor 2 burner fan 3 fuel pump 4 solenoid valve, fuel pump 5 fan, motor cooling 6 motor retainer, lh (2x) 7 motor retainer, rh (2x) 8 pump head...

  • Page 34

    Unit function hds middle range / hds premium range page 34 / 127 service manual 04.2008 2.12 motor (air-cooled) 3 6 7 12 14 13 15 16 17 20 1 2 4 5 22 10 9 8 23 24 26 25 27 28 1 connection cable, motor 2 fan wheel, motor cooler 3 stator 4 motor bearing, rear (b bearing) 5 motor shaft 6 rotor 7 housin...

  • Page 35

    Hds middle range / hds premium range unit function service manual 04.2008 page 35 / 127 2.13 electrical box, air-cooled motor 5 7 8 9 11 12 13 4 1 3 14 1 earth point 2 terminal strip 3 earth connection, motor housing 4 motor contactor (k1) 5 interference suppression filter 6 printed circuit board, m...

  • Page 36

    Unit function hds middle range / hds premium range page 36 / 127 service manual 04.2008 2.14 motor (water-cooled) 1 7 2 4 5 3 6 8 9 10 11 12 1 electrical box, motor 2 burner fan 3 cooling coil, motor cooler 4 fuel pump 5 solenoid valve, fuel pump 6 motor retainer, lh (2x) 7 motor retainer, rh (2x) 8...

  • Page 37

    Hds middle range / hds premium range unit function service manual 04.2008 page 37 / 127 2.14 motor (water-cooled) 3 6 7 13 15 14 16 17 18 21 1 2 4 5 23 10 9 8 24 25 27 26 28 29 11 1 connection cable, motor 2 cooling coil, motor cooler 3 stator 4 motor bearing, rear (b bearing) 5 motor shaft 6 rotor ...

  • Page 38

    Unit function hds middle range / hds premium range page 38 / 127 service manual 04.2008 2.15 electrical box, water-cooled motor 4 6 7 8 9 11 12 3 1 2 13 1 earth point 2 earth connection, motor housing 3 motor contactor (k1) 4 interference suppression filter 5 printed circuit board, motor distributor...

  • Page 39

    Hds middle range / hds premium range unit function service manual 04.2008 page 39 / 127 2.16 pump 7 1 2 3 4 5 6 9 10 11 1 handle, pressure and flow control valve 2 screw plug, pressure side (3x) 3 pump head screw (4x) 4 pump head 5 suction bridge with water connection 6 screw plug, suction side (4x)...

  • Page 40

    Unit function hds middle range / hds premium range page 40 / 127 service manual 04.2008 2.17 safety block 6 1 2 3 4 5 7 9 10 1 connection cable, reed switch 2 screw plug, low-water protection 3 clamp holder, reed switch 4 reed switch, low-water protection 5 high-pressure pipe to the continuous flow ...

  • Page 41

    Hds middle range / hds premium range unit function service manual 04.2008 page 41 / 127 2.17 safety block 1 12 2 3 4 5 6 7 8 9 11 13 14 15 16 17 1 connection cable, reed switch 2 screw plug, low-water protection 3 spring 4 clamp holder, reed switch 5 reed switch, low-water protection 6 magnetic pist...

  • Page 42

    Unit function hds middle range / hds premium range page 42 / 127 service manual 04.2008 2.17 safety block safety valve if the pressure switch or overflow valve are defective, the safety valve feeds the whole flow rate of the pump to the float tank and therefore protects the unit and accessories agai...

  • Page 43

    Hds middle range / hds premium range unit function service manual 04.2008 page 43 / 127 3 3 3 1 5 6 7 2 3 9 10 11 8 4 12 14 17 18 16 15 1 return to the fuel tank 2 pressure line to the burner 3 screw, fan cover, inner section (4x) 4 fan cover, inner section 5 fuel line (inlet) from the fuel tank 6 a...

  • Page 44

    Unit function hds middle range / hds premium range page 44 / 127 service manual 04.2008 2.18 burner fan with fuel pump fuel pump with coupling 6 1 2 3 4 impeller with fuel pump removed fuel pump the fuel pump (2) is directly connected to the motor shaft via the coupling (6) and the impeller (7). It ...

  • Page 45

    Hds middle range / hds premium range unit function service manual 04.2008 page 45 / 127 2.19 continuous-flow heater 1 capillary tube, exhaust temperature limiter 2 earth connection, burner 3 cover, continuous-flow heater 4 screw, burner (3x) 5 latch, unit cover 6 inspection glass, flame monitoring s...

  • Page 46

    Unit function hds middle range / hds premium range page 46 / 127 service manual 04.2008 2.19 continuous-flow heater 1 2 8 9 5 4 7 6 3.

  • Page 47

    Hds middle range / hds premium range unit function service manual 04.2008 page 47 / 127 2.19 continuous-flow heater the water from the high-pressure pump enters the internal heating coil winding (8) from underneath, is heated as it flows through and exits downwards again from the external heating co...

  • Page 48

    Unit function hds middle range / hds premium range page 48 / 127 service manual 04.2008 2.20 burner burner, view from above burner, removed, view from below fuel nozzle and ignition electrodes 1 connection, pressure line for fuel 2 inspection glass, flame monitoring system 3 connection, ignition ele...

  • Page 49

    Hds middle range / hds premium range unit function service manual 04.2008 page 49 / 127 2.20 burner 1 ignition electrodes 2 burner cover 3 fuel nozzle 4 spraying angle 45° or 60 °, depending on the unit type 5 retaining screw, ignition electrodes ignition electrodes a strong ignition spark is formed...

  • Page 50

    Unit function hds middle range / hds premium range page 50 / 127 service manual 04.2008 1 9 2 3 4 7 6 8 1 baseplate 2 outlet, continuous-flow heater 3 temperature sensor, hot water outlet 4 clamp holder 5 chassis 6 connection cable, temperature sensor 7 inlet, continuous flow heater 8 bottom, contin...

  • Page 51

    Hds middle range / hds premium range unit function service manual 04.2008 page 51 / 127 2.22 softgrip easy-press handgun 1 2 3 1 safety latch 2 handgun cover 3 trigger lever 4 high-pressure hose 5 safety bolt 6 needle bearing on high-pressure hose 7 coupling, handgun - hose 8 o-ring, hose/handgun se...

  • Page 52

    Unit function hds middle range / hds premium range page 52 / 127 service manual 04.2008 4 3 5 1 2.23 pressure and flow control valve with rotary control the pressure and flow control valve is designed as a rotary control between the handgun and spray lance. There are two ceramic discs (1, 2) inside ...

  • Page 53

    Hds middle range / hds premium range unit function service manual 04.2008 page 53 / 127 2.24 functional diagram, pressure operation.

  • Page 54

    Unit function hds middle range / hds premium range page 54 / 127 service manual 04.2008 2.24 functional diagram, pressure operation 1 cleaning agent tank 1 2 cleaning agent suction hose with filter 3 level sensor, cleaning agent tank 1 (optional) 4 cleaning agent suction hose with filter 5 level sen...

  • Page 55

    Hds middle range / hds premium range unit function service manual 04.2008 page 55 / 127 2.25 functional diagram, suction feed operation.

  • Page 56

    Unit function hds middle range / hds premium range page 56 / 127 service manual 04.2008 2.25 functional diagram, suction feed operation 1 cleaning agent tank 1 2 cleaning agent suction hose with filter 3 level sensor, cleaning agent tank 1 (optional) 4 cleaning agent suction hose with filter 5 level...

  • Page 57

    Hds middle range / hds premium range unit function service manual 04.2008 page 57 / 127 2.26 pressure and flow control valve function 1 11 2 3 4 5 6 7 8 9 10 12 13 15 16 1 threaded stud, max. Pressure adjustment 2 lock nut, threaded stud 3 spindle, half-load 4 stop sleeve, half-load 5 spring 6 overf...

  • Page 58

    Unit function hds middle range / hds premium range page 58 / 127 service manual 04.2008 2.26 pressure and flow control valve function 2.26.1 pressure and flow control valve, manually using handle the pressure and flow control valve with the handle (see page 104, item 1) is used to relieve the motor ...

  • Page 59

    Hds middle range / hds premium range unit function service manual 04.2008 page 59 / 127 2.27 pressure switch function 1 high-pressure outlet (unpressurised) 2 pressure gauge (unpressurised) 3 non-return valve (closed) 4 rotary knob 5 overflow valve (closed) 6 throttle bore 7 pressure switch, „off“ (...

  • Page 60

    Unit function hds middle range / hds premium range page 60 / 127 service manual 04.2008 2.27 pressure switch function 1 high-pressure outlet, operating pressure 2 pressure gauge, operating pressure 3 non-return valve (open) 4 rotary knob 5 overflow valve (closed) 6 throttle bore 7 pressure switch, „...

  • Page 61

    Hds middle range / hds premium range unit function service manual 04.2008 page 61 / 127 1 high-pressure outlet, switch-off pressure 2 pressure gauge, switch-off pressure 3 non-return valve (closed) 4 rotary knob 5 overflow valve (open) 6 throttle bore 7 pressure switch, „off“ (open) 8 water inlet 9 ...

  • Page 62

    Unit function hds middle range / hds premium range page 62 / 127 service manual 04.2008 2.27 pressure switch function 1 high-pressure outlet (unpressurised) 2 pressure gauge (unpressurised) 3 non-return valve (closed) 4 rotary knob 5 overflow valve (closed) 6 throttle bore 7 pressure switch, „off“ (...

  • Page 63

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 63 / 127 3.1 service functions with led display functional selection via water temperature setting display of the settings via led indicators service mode if the service switch is in the „service“ ...

  • Page 64

    Basic settings and service procedures hds middle range / hds premium range page 64 / 127 service manual 04.2008 3.1.1 adjusting the stopping behaviour function 30 °c led display meaning on30min behaviour of the unit after 30 minutes’ continuous operation. Setting is saved. Unit switches off after 30...

  • Page 65

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 65 / 127 3.1.3 flame sensor brightness value function 45 °c led display meaning ldrtest display of the brightness value measured by the flame sensor. The value is displayed by the leds, digit for d...

  • Page 66

    Basic settings and service procedures hds middle range / hds premium range page 66 / 127 service manual 04.2008 3.1.4 rfid query function 45 °c + „set“ led display meaning rfidonoff info on the printed circuit board, whether the unit is equipped with metering via rfid or not. Unit with rfid unit wit...

  • Page 67

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 67 / 127 65 °c 70 °c 75 °c 3.1.6 testing the water temperature setting and program switch function 55 °c led display meaning encprogtest this function can be used to test the program switch and the...

  • Page 68

    Basic settings and service procedures hds middle range / hds premium range page 68 / 127 service manual 04.2008 function led display meaning setting 80 °c 85 °c 90 °c 95 °c 3.1.6 testing the water temperature setting and program switch 100 °c 112 °c 125 °c 140 °c 155 °c the temperature setting must ...

  • Page 69

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 69 / 127 function led display meaning setting program switch „cold“ position program switch „eco“ position program switch „hot“ position 3.1.6 testing the water temperature setting and program swit...

  • Page 70

    Basic settings and service procedures hds middle range / hds premium range page 70 / 127 service manual 04.2008 function led display meaning service switch „off“ position setting 3.1.7 testing the service switch 60 °c encdgttest display of the service switch position. Service switch „1“ position ser...

  • Page 71

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 71 / 127 function led display meaning oil level sensor closed (float at top) setting 3.1.8 testing the sensors 65 °c inputtest this function can be used to display the states of the individual sens...

  • Page 72

    Basic settings and service procedures hds middle range / hds premium range page 72 / 127 service manual 04.2008 3.1.9 fault memory function 70 °c led display meaning errors this function is used to read out the fault memory. The faults are displayed in 2 steps: 1. Led display of the fault type (see ...

  • Page 73

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 73 / 127 3.1.9 fault memory function led display meaning temperature sensor fault. Short circuit or cable break. Fault types flame sensor detects no or too little light. Flame sensor detects light....

  • Page 74

    Basic settings and service procedures hds middle range / hds premium range page 74 / 127 service manual 04.2008 3.1.10 operating hours function 75 °c led display meaning stundenpwr display of the operating time (unit switched on) in hours. The value is displayed by the leds, digit for digit, whereby...

  • Page 75

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 75 / 127 3.1.11 handgun switchings since the handgun service function 80 °c led display meaning si_pistole display of the handgun switchings since the last time the handgun was serviced. The value ...

  • Page 76

    Basic settings and service procedures hds middle range / hds premium range page 76 / 127 service manual 04.2008 3.1.12 handgun services function 85 °c led display meaning sctr_pistole handgun service display. The value is displayed by the leds, digit for digit, whereby each led stands for a numerica...

  • Page 77

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 77 / 127 3.1.13 handgun switchings since initial operation function 90 °c led display meaning totalpistole display of the handgun switchings since initial operation of the unit. The value is displa...

  • Page 78

    Basic settings and service procedures hds middle range / hds premium range page 78 / 127 service manual 04.2008 3.1.14 operating time of the burner since the burner service function 95 °c led display meaning si_brenner display of the burner’s operating time in hours since the burner was last service...

  • Page 79

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 79 / 127 3.1.15 burner services function 100 °c led display meaning sctr_brenner burner service display. The value is displayed by the leds, digit for digit, whereby each led stands for a numerical...

  • Page 80

    Basic settings and service procedures hds middle range / hds premium range page 80 / 127 service manual 04.2008 3.1.16 burner operation since initial operation function 112 °c led display meaning totalbrenner display of the burner’s operating time in hours since initial operation of the unit. The va...

  • Page 81

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 81 / 127 3.1.17 operating time of the pump since the pump service function 125 °c led display meaning si_pumpe display of the pump’s operating time in hours since the pump was last serviced. The va...

  • Page 82

    Basic settings and service procedures hds middle range / hds premium range page 82 / 127 service manual 04.2008 3.1.18 pump services function 140 °c led display meaning sctr_pumpe pump service display. The value is displayed by the leds, digit for digit, whereby each led stands for a numerical value...

  • Page 83

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 83 / 127 function 155 °c led display meaning totalpumpe display of the pump’s operating time in hours since initial operation of the unit. The value is displayed by the leds, digit for digit, where...

  • Page 84

    Basic settings and service procedures hds middle range / hds premium range page 84 / 127 service manual 04.2008 3.2 service functions with display functional selection via water temperature setting the settings are shown in the display service mode if the service switch is in the „service“ position ...

  • Page 85

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 85 / 127 3.2.1 adjusting the stopping behaviour shut-off after 30 min continuous operation is activated. Display note explanation 30 °c shut-off after 30 min continuous operation is not activated (...

  • Page 86

    Basic settings and service procedures hds middle range / hds premium range page 86 / 127 service manual 04.2008 >=471: dark 3.2.4 flame sensor brightness value flame sensor test. Brightness value display. Display note explanation 45 °c 1023 less than 0°c is displayed as 0°c. 3.2.5 testing the temper...

  • Page 87

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 87 / 127 3.2.7 testing the service switch selected scale inhibitor setting display note explanation 60 °c 3.2.8 testing the sensors description from left to right: fuel sensor level (level 7 of 8 l...

  • Page 88

    Basic settings and service procedures hds middle range / hds premium range page 88 / 127 service manual 04.2008 3.2.9 fault memory note use set to switch to the next fault. The fault memory can be deleted with switch off - hold set - switch on. Mains voltage too high display note explanation 70 °c m...

  • Page 89

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 89 / 127 exhaust thermostat has tripped display note explanation cable break or short circuit in temperature sensor clear soot from boiler check exhaust thermostat check temperature sensor flame se...

  • Page 90

    Basic settings and service procedures hds middle range / hds premium range page 90 / 127 service manual 04.2008 3.2.11 handgun switchings since handgun service number of handgun switchings since last mainte- nance (service) display note explanation 80 °c 22 589 3.2.12 handgun services number of time...

  • Page 91

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 91 / 127 3.2.15 burner services number of times burner serviced display note explanation 100 °c 1 count up maintenance: switch off unit hold set switch on important: fault memory is also deleted 3....

  • Page 92

    Basic settings and service procedures hds middle range / hds premium range page 92 / 127 service manual 04.2008 3.2.17 operating time of the pump since the pump service pump operating time since the last maintenance (service) display note explanation 125 °c 11h 3.2.18 pump services number of times p...

  • Page 93

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 93 / 127 3.3 burner setting fuel pump, fuel pressure adjustment air flap, air volume adjustment 1 pressure line to the burner 2 fuel pump 3 adjusting screw, fuel pressure 4 suction hose, fuel 5 ret...

  • Page 94

    Basic settings and service procedures hds middle range / hds premium range page 94 / 127 service manual 04.2008 3.4 installing the air circuit on the outer jacket insert clamping ring in the air circuit installed clamping ring with rubber collar locking lever 1 clamping ring 2 air circuit (rubber co...

  • Page 95

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 95 / 127 1 2 3 4 5 6 1 adjusting screw, high pressure 2 lock nut, high pressure adjusting screw 3 spindle, pressure and flow control valve 4 adjusting screw, low pressure 5 lock nut, low pressure a...

  • Page 96

    Basic settings and service procedures hds middle range / hds premium range page 96 / 127 service manual 04.2008 1 2 3 4 5 6 1 adjusting screw, high pressure 2 lock nut, high pressure adjusting screw 3 spindle, pressure and flow control valve 4 adjusting screw, low pressure 5 lock nut, low pressure a...

  • Page 97

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 97 / 127 3.6 adjusting the operating pressure using standard handgun without rotary control 1 2 3 4 5 6 1 adjusting screw, high pressure 2 lock nut, high pressure adjusting screw 3 spindle, pressur...

  • Page 98

    Basic settings and service procedures hds middle range / hds premium range page 98 / 127 service manual 04.2008 3.6 adjusting the operating pressure using standard handgun without rotary control 1 2 3 4 5 6 1 adjusting screw, high pressure 2 lock nut, high pressure adjusting screw 3 spindle, pressur...

  • Page 99

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 99 / 127 3.7 removing the hose reel 3.7.1 replacing the high-pressure hose – switch off unit and release pressure. – completely unwind hose from the hose reel. – turn the hose reel until the bolted...

  • Page 100

    Basic settings and service procedures hds middle range / hds premium range page 100 / 127 service manual 04.2008 3.7 removing the hose reel 3.7.2 replacing the rotating union seal – remove bolt-on half-shell and high-pressure hose (see chapter 3.7.1). – remove countersunk screw (1). – turn hose reel...

  • Page 101

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 101 / 127 3.7 removing the hose reel 3.7.2 replacing the rotating union seal (continued) – remove half-shell (1) with bearing block (2) and crank (3). – use pliers (6) to remove circlip (7) from th...

  • Page 102

    Basic settings and service procedures hds middle range / hds premium range page 102 / 127 service manual 04.2008 3.7 removing the hose reel 3.7.2 replacing the rotating union seal (continued) – only if necessary: undo the high-pressure line (1) using open-end spanner (sw 27) and remove the two screw...

  • Page 103

    Hds middle range / hds premium range basic settings and service procedures service manual 04.2008 page 103 / 127 3.8 removing the pressure gauge push in left-hand retaining clip by hand. Removing the pressure gauge – remove control panel retaining screws and open control panel. – push in the left-ha...

  • Page 104

    Basic settings and service procedures hds middle range / hds premium range page 104 / 127 service manual 04.2008 3.9 adjusting the safety valve rotating handle of the pressure and flow control valve adjusting the safety valve – twist in the rotating handle (1) of the pressure and flow control valve ...

  • Page 105

    Hds middle range / hds premium range circuit diagram service manual 04.2008 page 105 / 127 4.1 circuit diagram – 0.088-021 (hds 7/12).

  • Page 106

    Circuit diagram hds middle range / hds premium range page 106 / 127 service manual 04.2008 4.1 circuit diagram – 0.088-021 (hds 7/12).

  • Page 107

    Hds middle range / hds premium range circuit diagram service manual 04.2008 page 107 / 127 4.1 circuit diagram – 0.088-021 (hds 7/12).

  • Page 108

    Circuit diagram hds middle range / hds premium range page 108 / 127 service manual 04.2008 4.2 circuit diagram – 0.088-025 (hds 8/17, hds 9/18).

  • Page 109

    Hds middle range / hds premium range circuit diagram service manual 04.2008 page 109 / 127 4.2 circuit diagram – 0.088-025 (hds 8/17, hds 9/18).

  • Page 110

    Circuit diagram hds middle range / hds premium range page 110 / 127 service manual 04.2008 4.2 circuit diagram – 0.088-025 (hds 8/17, hds 9/18).

  • Page 111

    Hds middle range / hds premium range circuit diagram service manual 04.2008 page 111 / 127 4.3 circuit diagram – 0.088-052 (hds 10/20, hds 12/18).

  • Page 112

    Circuit diagram hds middle range / hds premium range page 112 / 127 service manual 04.2008 4.3 circuit diagram – 0.088-052 (hds 10/20, hds 12/18).

  • Page 113

    Hds middle range / hds premium range circuit diagram service manual 04.2008 page 113 / 127 4.3 circuit diagram – 0.088-052 (hds 10/20, hds 12/18).

  • Page 114

    Circuit diagram hds middle range / hds premium range page 114 / 127 service manual 04.2008 4.4 circuit diagram – 0.088-026 (hds 13/20).

  • Page 115

    Hds middle range / hds premium range circuit diagram service manual 04.2008 page 115 / 127 4.4 circuit diagram – 0.088-026 (hds 13/20).

  • Page 116

    Circuit diagram hds middle range / hds premium range page 116 / 127 service manual 04.2008 4.4 circuit diagram – 0.088-026 (hds 13/20).

  • Page 117

    Hds middle range / hds premium range troubleshooting service manual 04.2008 page 117 / 127 5 troubleshooting measure unit is not running (no led display) – check/replace mains voltage, connection cable and mains fuse. – check fuse (f1). – check/replace unit switch. – check/replace the pressure switc...

  • Page 118

    Troubleshooting hds middle range / hds premium range page 118 / 127 service manual 04.2008 measure water leak between cylinder head and piston housing – leak of 1 drip per minute and piston is allowable. – check/replace high-pressure and low-pressure seals. Fault oil leak between cylinder head and p...

  • Page 119

    Hds middle range / hds premium range technical specifications service manual 04.2008 page 119 / 127 6 technical specifications unit type hds 7/12-4 m unit no. 1.077-401 circuit dia- gram 0.089-021 operating in- structions 5.962-127 spare parts list 5.970-808 hds 7/12-4 mx 1.077-451 0.089-021 5.962-1...

  • Page 120

    Technical specifications hds middle range / hds premium range page 120 / 127 service manual 04.2008 8 tightening torque cylinder head screws 50 - 60 nm piston housing 5 - 7 nm handgun, pressure control 40 nm high-pressure outlet 6 - 8 nm pressure valves, threaded connection 40 - 45 nm pressure switc...

  • Page 121

    Hds middle range / hds premium range index service manual 04.2008 page 121 / 127 9 index a accessories ................................................... 6 adjust co 2 value .......................................... 93 adjusting screw with drillhole, safety valve .....................................

  • Page 122

    Index hds middle range / hds premium range page 122 / 127 service manual 04.2008 9 index connecting pin ............................................. 52 connection cable, fuel pump solenoid valve ............................................................. 43 connection cable, ignition transformer ...

  • Page 123

    Hds middle range / hds premium range index service manual 04.2008 page 123 / 127 9 index fuel nozzle ............................... 47,48,49,54,56 fuel pressure line .................................... 54,56 fuel pump ...................... 33,36,43,44,54,56,93 fuel return line ......................

  • Page 124

    Index hds middle range / hds premium range page 124 / 127 service manual 04.2008 9 index lock nut, high pressure adjusting screw ..................................... 95,96,97,98,104 lock nut, low pressure adjusting screw ............................................ 95,96,97,98 lock nut, stop sleeve...

  • Page 125

    Hds middle range / hds premium range index service manual 04.2008 page 125 / 127 9 index pressure switch, "on" (open) ................. 60,61 pressure valve ........................................ 34,37 printed circuit board ................................ 54,56 printed circuit board, control pane...

  • Page 126

    Index hds middle range / hds premium range page 126 / 127 service manual 04.2008 9 index service functions with led display .............. 63 service mode .......................................... 63,84 service position ............................................ 25 service switch (change setting)...

  • Page 127

    Hds middle range / hds premium range index service manual 04.2008 page 127 / 127 9 index w washer .................................................... 34,37 water connection with fine water filter ......... 8,9 water connection ......................................... 54 water hose, suction side .....