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Kärcher HDS 7/12 M Service Manual

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HDS 7/12 M, HDS 8/18 M,
HDS 9/18 M, HDS 10/20 M,
HDS 12/18 S, HDS 13/20 S
Service Manual
1
English 5.906-432.0 Rev. 00 (06/15)

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Table of Contents

   Summary of Contents for Kärcher HDS 7/12 M

  • Page 1 HDS 7/12 M, HDS 8/18 M, HDS 9/18 M, HDS 10/20 M, HDS 12/18 S, HDS 13/20 S Service Manual English 5.906-432.0 Rev. 00 (06/15)
  • Page 2: Table Of Contents

    Contents Preface Safety instructions Hazard levels Technical Features General Connection performance of appliance Pump Electronics system Detergent Accessories Field of application Type plate Parts of the system Front view View from the back, (device without hose reel) View from the back, (device with hose reel) Operator console 5.4.1 Control panel with LED indicator 5.4.2 Template numerical value display...
  • Page 3 6.19.2 Safety block (water shortage safeguard new) 6.19.3 Function water shortage safeguard and dry-run protection 6.19.4 Function of safety valve 6.20 Burner blower with fuel pump 6.21 Booster heater (with ignition transformer) 6.22 Booster heater (with ignition transformer new) 6.22.1 Type plate of heating coil 6.22.2 Ignition transformer 6.22.3 Flame sensor with holder on the burner 6.22.4 Sectional view booster heater...
  • Page 4 7.28 Brightness value of the flame sensor 7.29 Testing the temperature sensor 7.30 Testing the water temperature setting and the programme switch 7.31 Test service switch 7.32 Testing the sensors 7.33 Error memory 7.34 Operating hours 7.35 Gun switching operations since gun service 7.36 Gun services 7.37 Gun services since initial startup 7.38 Operation duration of the burner since startup...
  • Page 5: Preface

    Preface Good service work requires extensive and practice-orient- international-service@de.kaercher.com ed training as well as well-structured training materials. Subject: Fall 105756 Hence we offer regular basic and advanced training pro- The responsible product specialist will take care of your is- grammes covering the entire product range for all service sue.
  • Page 6: Accessories

    Accessories Rotary regulator for pressure and quantity regulation Power nozzle (stainless steel) – – Soft grip - easy press gun Steam nozzle (brass) – – Stainless steel spray lance, rotating – Field of application HDS 7/12-4 M/MX HDS 10/20-4 M/MX –...
  • Page 7: Parts Of The System

    Parts of the system Front view 1 Push handle 10 High pressure nozzle 2 Cover, upper storage compartment 11 Transport wheel (2x) 3 Safety catch, soft grip - easy press gun 12 Transport bracket 4 Rotating regulator 13 Steering roller 5 Hand lever 14 Steering roller with fixed position brake 6 Soft grip - easy press gun...
  • Page 8: View From The Back, (device Without Hose Reel)

    View from the back, (device without hose reel) 1 Indicator lamps 2 Programme selector switch (Q1) 3 Storage spray pipe 4 Setting, water temperature 5 Closure, liquid softener tank 6 Storage, power cord 7 Storage compartment 8 Supply Cord 9 Closure detergent tank 2 10 High pressure outlet 11 Chassis 12 Water connection with water fine filter...
  • Page 9: View From The Back, (device With Hose Reel)

    View from the back, (device with hose reel) 1 Indicator lamps 12 Chassis 2 Programme selector switch (Q1) 13 High pressure hose 3 Storage spray pipe 14 Water connection with water fine filter 4 Setting, water temperature 15 Tread 5 Closure, liquid softener tank 16 Closure detergent tank 1 6 Storage, power cord 17 Storage high-pressure hose...
  • Page 10: Operator Console

    Operator console 5.4.1 Control panel with LED indicator 1 Control LED 0, pump (red) 13 Programme switch position "ECO mode" Note 14 Programme switch position "Hot water / steam opera- Symbol depending on unit model. tion" 2 Control LED 1, rotation direction (red) 15 Programme switch 3 Control LED 2, operation (green) 16 Setting, water temperature...
  • Page 11 LED no. Symbol Activity Meaning / measure 1 x blinking Lack of oil. Check/fill oil level of the high pressure pump; repair leaks. 2 x blinking Leakage. 10 short startups. Check the high-pressure system for leaks. 3 x blinking Dry running (2 minutes). Check / ensure the water supply. 4 x blinking Reed switch or solenoid is sticky.
  • Page 12 LED no. Symbol Activity Meaning / measure 1 x blinking Exhaust thermostat open. Check/replace emission temperature/ thermostat. Perform maintenance on the burner. 2 x blinking Flame sensor reports burner fault. Clean and check the burner, ig- nition and fuel system. 3 x blinking RFID write-read electronics is defective - replace.
  • Page 13: Template Numerical Value Display

    5.4.2 Template numerical value display For the better distinguishability of numeric value displays in the service functions the template below can be placed on the LED displays of the control panel. English 5.906-432.0 Rev. 00 (06/15)
  • Page 14 English 5.906-432.0 Rev. 00 (06/15)
  • Page 15: Control Panel, View From The Inside

    5.4.3 Control panel, view from the inside Service switch and dosing liquid sof- Setting, water temperature tener Programme switch Control transformer 10 Control chip Transducer 11 Detergent dosing valve Fuse 2.0 AT for control transformer 12 Manometer (6.644-052) 13 Exhaust temperature monitor Terminal strip 14 Cable comb Ground point...
  • Page 16: Printed Circuit Board, Control Panel

    5.4.4 Printed circuit board, control panel 1 Connection, level sensor detergent tank 1 12 Connection water temperature setting 2 Connection, level sensor detergent tank 2 13 PCB motor distributor connection 3 Connection of level sensor for fuel tank 14 Grounding connection control PCB 4 Connection of level sensor for liquid softener 15 Control transformer T1 connection 5 Transducer connection...
  • Page 17: Control Panel With Display Indication (hds 13/20 Only)

    1 Encoding pin 2 Recess for encoding pin Plug coding The plugs for the PCB connections are designed with en- coding pins and their matching recesses in the PCB base so that only the matching plug can be attached to the re- spective connection.
  • Page 18: Operating Displays

    Function Operating displays Note Operating and maintenance displays are shown one after the other like in a slide show. Each picture for 3 seconds. The fault displays remain until the device is switched off. Display Explanation Remark Upper bar: Level fuel (8 stages) Centre bar: Level detergent 1 (4 stages) Lower bar: Level detergent 2 (4 stages) In case of a cable break the relevant bar is not displayed.
  • Page 19: Setting Liquid Softener

    Setting liquid softener Display Explanation Remark Set liquid softener dosing in accordance with the water hard- ness. This display appears for 3s if the liquid softener setting is changed. Attention service mode position. After the restart, the device will be in the service mode. This display remains until another liquid softener setting is se- lected.
  • Page 20: Storage Compartments

    Storage compartments 1 Cover, upper storage compartment 8 Storage replacement nozzles 2 Storage operating instructions 9 Storage dirt grinder 3 Fastening screws upper storage compartment (4x) 10 Storage compartment bottom 4 Storage compartment top 11 Bottle holder for round liquid softener bottle or deter- 5 Nameplate gent bottle 6 Fastening screw control panel...
  • Page 21: Cover

    Cover Note Open cover and dismantle if necessary 1 Screwdriver 2 Storage compartment top 3 Lock of appliance hood 4 Cover  Push in the locking mechanism of the cover and turn it by 90°.  Open the appliance hood. 1 Locating lug arrestor cable 2 Arrestor cable cover ...
  • Page 22: View From The Right, Cover Removed

    View from the right, cover removed 1 Fuel line to the booster heater 12 Casing water fine filter 2 Electric box, motor 13 SDS hose to the safety block 3 Burner blower 14 Splashboard, safety valve 4 Oil refill container pump 15 Safety valve 5 Motor 16 Water shortage safeguard...
  • Page 23: Revised Device Design (with Filter Before The Pump And Electronic Ignition Transformer)

    6.7.1 Revised device design (with filter before the pump and electronic ignition transformer) 1 Fuel line to the booster heater 10 SDS hose to the safety block 2 Electric box, motor 11 Splashboard, safety valve 3 Burner blower 12 Safety valve 4 Oil refill container pump 13 Water shortage safeguard 5 Motor...
  • Page 24: Service Switch

    Service switch 1 Position marking 2 Service switch Setting the water hardness The setting of the liquid softener dosing is done in accord- ance with the local water hardness (ask your local water supply company or determine by means of a hardness tester).
  • Page 25: Fuel Tank

    Fuel tank 1 Closure fuel tank 2 Seal fuel tank closure 3 Filler neck 1 Fuel filter 2 Level sensor for fuel tank 3 Fuel tank 1 Level sensor for fuel tank English 5.906-432.0 Rev. 00 (06/15)
  • Page 26: Liquid Softener

    6.10 Liquid softener 6.10.1 Feed via tank (export variant) The feed of the liquid softener takes place in accordance with the setting on the service switch. The setting is de- scribed under 6.8 "Service switch". The feed only takes place in the programme switch position "ECO" and "Warm water"...
  • Page 27: Feed Via Rfid (europe Variant)

    1 Liquid softener reservoir 2 Level sensor 3 Dosing valve 6.10.2 Feed via RFID (Europe variant) The feed of the liquid softener takes place in accordance with the setting on the service switch. The setting is de- scribed under 6.8 "Service switch". The feed only takes place in the programme switch position "ECO"...
  • Page 28 1 Liquid softener bottle 2 Screws 3 RFID - attachment 1 RFID - attachment 2 Bottle opener - insertion 1 Liquid softener bottle 2 Sealing Note The sealing is pierced upon inserting the bottle. English 5.906-432.0 Rev. 00 (06/15)
  • Page 29: Functionality Rfid

    6.10.3 Functionality RFID RFID (Radio Frequency Identification) stands for the iden- tification by means of high frequency. There is a transponder under the label on the softener bot- tle (microchip with antenna, also called tag). The write-read electronics installed in the RFID attachment can read data from the tag and also write data to the tag.
  • Page 30: Swimmer Tank

    1 Label 2 RFID tag, behind the label Note Tag is an electronic component on the new square soften- er bottle. The tag is located behind the bottle label. The tag can be read and written on electronically. 6.11 Swimmer tank Float tank The float container is integrated in the chassis.
  • Page 31: Detergent Tank

    6.12 Detergent Tank 6.12.1 Detergent tank 1 Detergent tank 1 (volume 10l) The detergent tank 1 is located in the rear part of the chas- sis. Suction hose The plug with the connection of the suction hose is located between the booster heater and the lower storage com- partment or the hose reel.
  • Page 32: Detergent Tank 2

    1 Level sensor (option) 6.12.2 Detergent tank 2 Detergent tank 2 (volume 20l) The detergent tank 2 is located in the right part of the chas- sis. Suction hose The plug with the connection of the suction hose is located above the right transport wheel.
  • Page 33: Detergent Dosing Valve

    1 Stopper 2 Cleaning agent filter 3 Detergent tank 2 1 Level sensor (option) 2 Stopper 3 Detergent tank 2 4 Float 6.13 Detergent dosing valve Detergent dosing valve with automatic clear rinsing in zero position 1 Water 2 Detergent tank 1 3 Detergent tank 2 4 Pump English 5.906-432.0 Rev.
  • Page 34: Motor (air-cooled)

    6.14 Motor (air-cooled) 1 Electronics system 8 Pump head 2 Burner blower 9 Oil level sensor 3 Fuel pump 10 Oil fill container 4 Solenoid valve 11 Handle, pressure and volume regulation 5 Blower, motor cooling 12 Cover 6 Engine mount, left 7 Engine mount, right 1 Cover 2 Oil level sensor...
  • Page 35: Motor (air-cooled)

    6.14.1 Motor (air-cooled) 1 Connecting cable, motor 14 Suction side 2 Fan wheel 15 Suction valve 3 Stator 16 Piston 4 Motor bearing, rear (B bearing) 17 High pressure seal 5 Motor shaft 18 Low pressure seal 6 Rotor 19 Oil seal 7 Casing 20 Piston spring 8 Shaft seal ring...
  • Page 36: Electrical Box, Air-cooled Motor

    6.15 Electrical box, air-cooled motor Ground point Connection of coiling protection con- tact Terminal strip Connection printed circuit board, oper- Connection to earth, motor ating panel Engine contactor Connection fuel solenoid valve Anti-interference filter Connection motor protection Board, motor distributor Connection is not used Connection pressure switch ON Cable comb...
  • Page 37: Engine (water-cooled)

    6.16 Engine (water-cooled) 1 Electronics system 8 Pump head 2 Burner blower 9 Oil level sensor 3 Cooling coil 10 Oil fill container 4 Fuel pump 11 Handle, pressure and volume regulation 5 Solenoid valve 12 Cover 6 Engine mount, left 7 Engine mount, right Oil drain screw The oil drain screw is located on the bottom of the pump...
  • Page 38: Engine (water-cooled)

    6.16.1 Engine (water-cooled) 1 Connecting cable, motor 15 Suction side 2 Cooling coil 16 Suction valve (green with HDS 13/20) 3 Stator 17 Piston 4 Motor bearing, rear (B bearing) 18 High pressure seal 5 Motor shaft 19 Low pressure seal 6 Rotor 20 Oil seal 7 Casing...
  • Page 39: Electrical Box, Water-cooled Engine

    6.16.2 Electrical box, water-cooled engine 1 Ground point 8 Oil level sensor connection 2 Connection to earth, motor 9 Connection printed circuit board, operating panel 3 Engine contactor 10 Connection of coiling protection contact 4 Anti-interference filter 11 Connection fuel solenoid valve 5 Board motor distributor 12 Connection motor protection 6 Connection pressure switch ON...
  • Page 40: Pump

    6.17 Pump 1 Handle, pressure and volume regulation 2 Screwed sealing plug 3 Screws pump head 4 Pump head 5 Suction jumper 6 Screwed sealing plug 7 Water pipes 8 Safety bracket, pressure switch OFF 9 Pressure switch OFF 10 SDS hose to the safety block 11 Pressure switch ON 12 Safety bracket, pressure switch ON English 5.906-432.0 Rev.
  • Page 41: Revised Version With Filter Before The Pump

    6.17.1 Revised version with filter before the pump 1 Handle, pressure and volume regulation 7 Filter 2 Screwed sealing plug 8 Safety bracket, pressure switch OFF 3 Screws pump head 9 Pressure switch OFF 4 Pump head 10 SDS hose to the safety block 5 Suction jumper 11 Pressure switch ON 6 Screwed sealing plug...
  • Page 42: Safety Block

    6.18 Safety block 1 Connecting cable, reed switch 7 Safety block 2 Screwed sealing plug 8 SDS hose 3 Clamping bracket 9 Adjustment screw, safety valve 4 Reed switch 10 Valve ball 5 High pressure pipe to the on-demand heater 6 Connection hose pressure gauge 1 Connection hose pressure gauge 2 Valve ball...
  • Page 43: Safety Block (water Shortage Safeguard Old)

    6.19 Safety block (water shortage safeguard old) 1 Connecting cable, reed switch 10 Mould part 2 Screwed sealing plug 11 Water outlet 3 Spring 12 Adjusting screw 4 Clamping bracket 13 Spring, safety valve 5 Reed switch 14 Casing 6 Magnetic piston 15 Spring plate 7 Holes 16 Valve ball...
  • Page 44: Water Shortage Safeguard As Cartridge

    6.19.1 Water shortage safeguard as cartridge Note The cartridge replaces the previous design with piston and spring. 6.19.2 Safety block (water shortage safeguard new) Note Recommended installation direction: The lower drilled hole of the cartridge points towards the high-pressure pipe to the booster heater.
  • Page 45: Function Water Shortage Safeguard And Dry-run Protection

    6.19.3 Function water shortage safeguard and dry-run protection The lack of water fuse prevents the burner from switching on in case of missing or insufficient water volume and thus protects the on-demand heater from overheating. With an opened gun and a sufficient water flow the sole- noid is lifted against the force of gravity in the cartridge.
  • Page 46: Burner Blower With Fuel Pump

    6.20 Burner blower with fuel pump 1 Return 2 Pressure line 3 Screw 4 Blower lid 5 Fuel line 6 Setting fuel pressure 7 Fuel pump 8 Continuous heater 9 Connecting cable solenoid valve 10 Suction opening, burner blower 11 Solenoid valve for fuel 12 Fastening screw fuel pump 13 Blower lid English 5.906-432.0 Rev.
  • Page 47 1 Rubber collar 2 Lock 3 Air door, air volume adjustment 4 Stop screw 5 Burner blower 1 Solenoid valve 2 Coupling unit 3 Connection pressure line 4 Setting fuel pressure 5 Fuel pump 6 Fastening screw Uninstall fuel pump Detach pressure line.
  • Page 48: Booster Heater (with Ignition Transformer)

    6.21 Booster heater (with ignition transformer) 1 Capillary exhaust temperature monitor 9 Connection cable ignition transformer 2 Protective conductor 10 Ignition transformer 3 Cover 11 Screw burner cover 4 Screws burner 12 Fuel line 5 Locking screw for appliance hood 13 Heating coil with type plate 6 Sight glass, ignition monitoring (option) 14 Exhaust temperature sensor...
  • Page 49: Booster Heater (with Ignition Transformer New)

    6.22 Booster heater (with ignition transformer new) 1 Electronic ignition transformer 7 Exhaust nozzle, on-demand heater 2 Fastening screw of ignition transformer 8 Type plate of heating coil 3 Screws for burner cover (3 x) 9 Exhaust temperature sensor 4 Sight glass, ignition monitoring (option) 10 Connection for air pressure measurement 5 Burner cover 11 Capillary exhaust temperature monitor...
  • Page 50: Ignition Transformer

    6.22.2 Ignition transformer Various ignition transformers are installed in the devices. With older devices or devices for special voltages the con- ventional ignition transformers are still used. Electronic ignition transformer The integrated electronic ignition transformer (see picture above) is meanwhile used for all devices, except the devic- es for special voltages.
  • Page 51: Sectional View Booster Heater

    6.22.4 Sectional view booster heater 1 Ignition electrodes 9 Boiler exterior, double-walled 2 Fuel nozzle 10 Heating coil spiral, exterior 3 Pressure plate 11 Heating coil spiral, interior 4 Flame ring 12 Exhaust nozzle, on-demand heater 5 Burning chamber 6 Boiler floor 7 Boiler input 8 Air supply from burner blower English 5.906-432.0 Rev.
  • Page 52 Mode of operation The water from the high pressure pump enters the interior heating coil spiral, is heated while flowing through and ex- its to the bottom from the heating coil spiral. The fuel is vaporised by the fuel nozzle and ignited by the spark of the ignition electrodes.
  • Page 53: Burner

    6.23 Burner 1 Looking glass 2 Connection pressure line 3 Connection ignition electrode 4 Connection for air pressure measurement 5 Burner cover 1 Ignition electrode 2 Fuel nozzle 3 Pressure plate 1 Ignition electrode 2 Fuel nozzle English 5.906-432.0 Rev. 00 (06/15)
  • Page 54: Burner

    6.24 Burner 1 Ignition electrodes 2 Fuel nozzle holder 3 Fuel nozzle 4 Spray angle 45° or 60°, depending on the type of appli- ance 5 Screw 6 Burner cover Burner There is a strong spark created between the two ignition electrodes to ensure that the injected fuel will ignite.
  • Page 55: Output, Booster Heater

    6.25 Output, booster heater 1 Floor plate 6 Connecting cable temperature sensor 2 Output of flow-type heater 7 Input of flow-type heater 3 Temperature sensor water 8 Bottom booster heater 4 Clamping bracket 9 Pressure line of the safety block 5 Chassis English 5.906-432.0 Rev.
  • Page 56: Hand Spraygun

    6.26 Hand spraygun 1 Lock trigger gun 2 Casing shell 3 Hand lever 4 High pressure hose 5 Hose guide 6 Safety clip 7 Needle bearing 8 Coupling high-pressure hose/trigger gun 9 O ring 10 Node piece Function When the manual lever is actuated, the valve in the node piece opens and the water can flow from the hose through the gun into the spray lance.
  • Page 57: Pressure And Volume Regulation

    6.27 Pressure and volume regulation 1 Connection trigger gun 2 Connecting pin 3 Ceramic disc on gun side 4 Ceramic disc on spray pipe side 5 Casing of rotating regulator 6 Handle of rotary regulator 7 Spray lance connection The pressure and volume regulation is designed as a rota- ry regulator between the trigger gun and the spray lance.
  • Page 58: Functional Diagram Of Pressure Water Operation (water-cooled Motor)

    6.28 Functional diagram of pressure water operation (water-cooled motor) English 5.906-432.0 Rev. 00 (06/15)
  • Page 59 1 Detergent tank 1, volume 10 l 27 Exhaust temperature sensor 2 Detergent suction hose with filter 28 Setting, water temperature 3 Level sensor, detergent tank 1 (option) 29 Printed circuit board (PCB) 4 Detergent suction hose with filter 30 Temperature sensor 5 Level sensor, detergent tank 2 (option) 31 Heating coil 6 Detergent tank 2, volume 20 l...
  • Page 60: Functional Diagram Vacuuming Operation

    6.29 Functional diagram vacuuming operation English 5.906-432.0 Rev. 00 (06/15)
  • Page 61 1 Detergent tank 1 2 Detergent suction hose with filter 3 Level sensor, detergent tank 1 4 Detergent suction hose with filter 5 Level sensor, detergent tank 2 6 Detergent tank 2 7 Suction hose with filter and check valve 8 Open container 9 Dosage valve for detergent 10 Suction hose for detergent...
  • Page 62: Vacuuming Operations

    6.30 Vacuuming operations Note If the appliance is used for vacuuming, the rinse hose of the detergent dosing valve must be plugged onto the re- spective plug to prevent erroneous air suction. Furthermore, the fine filter must be uninstalled and the wa- ter supply hose must be connected directly to the high pressure pump.
  • Page 63: Pressure And Volume Regulation

    6.31 Pressure and volume regulation 1 Threaded pin, max. pressure setting 10 Detergent infeed with backflow valve 2 Locknut threaded pin 11 Suction jumper with water connection 3 Semiload spindle 12 Sleeve with throttle bore 4 Half-load stop sleeve 13 Pressure switch "OFF" 5 Pressure spring 14 Valve seat 6 Overflow piston...
  • Page 64: Function Pressure And Volume Regulation

    6.31.1 Function pressure and volume regulation Manually with a pressure regulator on the high pres- With the rotary regulator on the gun sure pump The pressure and volume regulation via the rotary regula- The pressure and volume regulation via the handle on the tor on the gun should only be used during occasional par- high pressure pump is used to relieve the motor with most- tial load operation.
  • Page 65: Functional Description Of Pressure Switch

    6.32 Functional description of pressure switch 6.32.1 Appliance is switched off 0 Volt 1 High pressure outlet (without pressure) When the appliance is switched off and the gun is open, 2 Manometer (without pressure) the pressure is taken from the system and it is without volt- 3 Pressure retaining valve (closed) age.
  • Page 66: The Appliance Is Switched On And The Gun Is Open

    6.32.2 The appliance is switched on and the gun is open 24 Volt 1 High pressure outlet, working pressure After switching on the appliance and with the gun open, the 2 Manometer, working pressure contactor will be actuated and closes the contacts. 3 Pressure retaining valve (open) This will start the motor and the pump will build up the 4 Pump is running...
  • Page 67: Gun Is Closed

    6.32.3 Gun is closed 24 Volt 1 High pressure outlet, shut-off pressure As soon as the overflow valve opens, the pressure retain- 2 Manometer, shut-off pressure ing valve closes and the shut-off pressure is locked be- 3 Pressure retaining valve (closed) tween the gun and the pressure retaining valve.
  • Page 68: The Gun Is Reopened When The Appliance Is Switched On

    6.32.4 The gun is reopened when the appliance is switched on 24 Volt 1 High pressure outlet (without pressure) The pressure switch "ON" closes, which in turn will close 2 Manometer (without pressure) the control circuit. 3 Pressure retaining valve (closed) The motor contactor is actuated, closes the contacts, the 4 Pump is running motor starts up and the pump rebuilds the working pres-...
  • Page 69: Basic Settings And Service Procedures

    Basic settings and service procedures Remove the hose drum 7.1.1 Uninstall / install high-pressure hose 1 Casing shell, hose reel 2 Screws  Release pressure.  Unwind the HP hose from the hose reel.  Unscrew the screws.  Remove the casing shell. 1 Clip ...
  • Page 70: Renew O-rings Axle, Hose Reel

    7.1.2 Renew O-rings axle, hose reel  7.1.1Uninstall / install high-pressure hose 1 Screw 2 Casing shell, hose reel  Loosen screws.  Turn the hose reel. 1 Casing shell, hose reel 2 Screws  Unscrew the screws. 1 Screws 2 Bearing block ...
  • Page 71 1 Casing shell, hose reel 2 Bearing block 3 Crank  Remove the front part of the hose reel. 1 Hose drum 2 Safety ring 3 Pipeline with axle 4 Node piece 5 Pliers  Remove the retaining ring.  Remove the knot. ...
  • Page 72: Uninstall / Install Pipeline With Axle

    7.1.3 Uninstall / install pipeline with axle  7.1.2Renew O-rings axle, hose reel 1 Rear bearing block 2 Screws 3 O rings 4 Pipeline with axle Note Align the pipeline with axle at a right angle to the rear bear- ing block.
  • Page 73: Uninstall / Install Pressure Gauge

    Uninstall / install pressure gauge 1 Manometer  Unscrew the screws on the control panel.  Manually push in the left clip. 1 Manometer 2 Screwdriver  Push in the right clip by means of a screwdriver. 1 Screw connection 2 Manometer 3 Clips ...
  • Page 74: Adjust Safety Valve

    Adjust safety valve 1 Turning handle  Screw in the twist grip of the pressure and volume reg- ulation on the pump all the way to the stop (towards "+").  Pull off the rotary handle. 1 Adjusting screw 2 Counter-nut ...
  • Page 75: Service Functions With Led Display

    Service functions with LED display 1 Setting, water temperature Service mode If the service switch is in the "Service" position (screwdriv- er symbol) upon switching on the device, the service mode of the device is activated (pump is not running). Selection of the service functions The available service functions are selected via the water temperature setting.
  • Page 76: Set Up The Switching Off Process

    Set up the switching off process Function Adjustments LED indicator Important 30 °C ON30MIN The device switches off after 30 minutes of (30/30 °C) Behaviour of device after continuous operation. 30 minutes of continuous operation. The setting will be saved. The device does not switch off after 30 min- utes of continuous operation (factory set- ting).
  • Page 77: Brightness Value Of The Flame Sensor

    Brightness value of the flame sensor Function Adjustments LED indicator Important 45 °C LDRTEST Digit value "0" (40/35 °C) Display of the brightness value measured by the flame sensor. The value is displayed digit by digit by the LEDs, Digit value "1" with every LED standing for a numeric value from 0 - 9 in accordance with its...
  • Page 78: Rfid Query

    RFID query Function Adjustments LED indicator Important 45 °C RFIDONOFF Device with RFID Menu access: Information to the printed Select 45°C „SET“ circuit board whether the Switch off device. Hold device is equipped with SET. Turn on the ma- (40/-- °C feed via RFID.
  • Page 79: Testing The Water Temperature Setting And The Programme Switch

    7.10 Testing the water temperature setting and the programme switch Function Adjustments LED indicator Important 55 °C ENCPROGTEST 30 °C (46/38 °C) With this function, the pro- (30/30 °C) gramme switch and the controller for the water temperature setting can be tested.
  • Page 80 Function Adjustments LED indicator Important 55 °C 80 °C (46/38 °C) (58/46 °C) 85 °C (60/48 °C) 90 °C (63/50 °C) 95 °C (66/52 °C) 100 °C (68/54 °C) 112 °C (70/55 °C) 125 °C (74/56 °C) 140 °C (77/58 °C) 155 °C (80/60 °C) The temperature setting must finally be set...
  • Page 81 Function Adjustments LED indicator Important 55 °C ENCPROGTEST Programme switch position "cold" (46/38 °C) By operating the pushbut- ton function of the service switch (continue to turn to "SET" position and re- lease) again, the test for Programme switch position "eco" the programme switch is started.
  • Page 82: Testing The Service Switch

    7.11 Testing the service switch Function Adjustments LED indicator Important 60 °C ENCDGTTEST Service switch position "OFF" (48/40 °C) Service switch setting dis- play. Service switch position "1" Service switch position "2" Service switch position "3" Service switch position "4" Service switch position "Service"...
  • Page 83: Testing The Sensor

    7.12 Testing the sensor Function Adjustments LED indicator Important 65 °C INPUTTEST Lack of oil fuse closed (float up). (50/42 °C) Use this function to dis- play the status of the dif- ferent sensors. Every LED displays the status of a certain sensor. "ON"...
  • Page 84: Error Memory

    7.13 Error memory Function Adjustments LED indicator Important 70 °C ERRORS Overvoltage detected on transformer 1. (52/44 °C) This functions serves to read the fault memory. The faults are displayed in 2 steps: 1 LED display of the fault Low voltage detected on transformer 1. type (see on the right).
  • Page 85 Function Adjustments LED indicator Important 70 °C Temperature sensor fault. Short circuit or (52/44 °C) cable break. Flame sensor recognises no or not enough light. Flame sensor recognises light. RFID write-read electronics defective. End of the fault memory. Instead of the op- erating hours, the version of the installed software is displayed here.
  • Page 86: Operating Hours

    7.14 Operating hours Function Adjustments LED indicator Important 75 °C STUNDENPWR Digit value "0" (55/45 °C) Indication of the con- sumed RM 110/111 bot- tles. The value is displayed digit by digit by the LEDs, Digit value "1" with every LED standing for a numeric value from 0 - 9 in accordance with its number.
  • Page 87: Gun Switching Operations Since Gun Service

    7.15 Gun switching operations since gun service Function Adjustments LED indicator Important 80 °C SI_PISTOLE Digit value "0" (58/46 °C) Display of the gun switch- ings since the most recent gun service. The value is displayed digit by digit by the LEDs, Digit value "1"...
  • Page 88: Gun Services

    7.16 Gun services Function Adjustments LED indicator Important 85 °C SCTR_PISTOLE Digit value "0" (60/48 °C) Display of gun services. The value is displayed digit by digit by the LEDs, with every LED standing for a numeric value from 0 Digit value "1"...
  • Page 89 Function Adjustments LED indicator Important 85 °C When switching on the device, the gun switching operations since the gun service (SI_PISTOLE) are reset to "0", the service counter gun (SCTR_PISTOLE) is increased by 1 and the fault memory is deleted. „SET“...
  • Page 90: Gun Switches Since Initial Startup

    7.17 Gun switches since initial startup Function Adjustments LED indicator Important 90°C TOTALPISTOLE Digit value "0" (63/50 °C) Display of the gun switch- ings since device was first started up. The value is displayed digit by digit by the LEDs, Digit value "1"...
  • Page 91: Operation Duration Of The Burner Since Burner Service

    7.18 Operation duration of the burner since burner service Function Adjustments LED indicator Important 95°C SI_Brenner Digit value "0" (66/52 °C) Display of the operation duration of the burner in hours since the last burn- er service. The value is displayed Digit value "1"...
  • Page 92: Burner Service

    7.19 Burner service Function Adjustments LED indicator Important 100°C SCTR_BRENNER Digit value "0" (68/54 °C) Display of the burner ser- vice. The value is displayed digit by digit by the LEDs, with every LED standing Digit value "1" for a numeric value from 0 - 9 in accordance with its number.
  • Page 93 Function Adjustments LED indicator Important 100°C When switching on the device, the burner operation duration since the burner service (SI_BRENNER) is reset to "0", the service counter burner (SCTR_BRENNER) is increased by 1 and the fault memory is de- „SET“ leted.
  • Page 94: Burner Operation Since Initial Startup

    7.20 Burner operation since initial startup Function Adjustments LED indicator Important 112°C TOTALBRENNER Digit value "0" (70/55 °C) Display of the operation duration of the burner in hours since the initial startup of the device. The value is displayed Digit value "1" digit by digit by the LEDs, with every LED standing for a numeric value from 0...
  • Page 95: Operating Hours Of The Pump Since Pump Service

    7.21 Operating hours of the pump since pump service Function Adjustments LED indicator Important 125°C SI_PUMPE Digit value "0" (74/56 °C) Display of the operating time of the pump since the last pump service in hours. The value is displayed Digit value "1"...
  • Page 96: Pump Service

    7.22 Pump service Function Adjustments LED indicator Important 140°C SCTR_PUMPE Digit value "0" (77/58 °C) Display of the pump ser- vices. The value is displayed digit by digit by the LEDs, with every LED standing Digit value "1" for a numeric value from 0 - 9 in accordance with its number.
  • Page 97 Function Adjustments LED indicator Important 140°C When switching on the device, the pump operation duration since the pump service (SI_PUMPE) is reset to "0", the service counter pump (SCTR_PUMPE) is increased by 1 and the fault memory is deleted. „SET“ (77/58 °C „SET“) English 5.906-432.0 Rev.
  • Page 98: Pump Operation Since Initial Startup

    7.23 Pump operation since initial startup Function Adjustments LED indicator Important 155°C TOTALPUMPE Digit value "0" (80/60 °C) Display of the operating time of the pump since the initial device startup in hours. The value is displayed Digit value "1" digit by digit by the LEDs, with every LED standing for a numeric value from 0...
  • Page 99: Servicefunktionen Mit Displayanzeige

    7.24 Servicefunktionen mit Displayanzeige 1 Setting, water temperature Service mode If the service switch is in the "Service" position (screwdriv- er symbol) upon switching on the device, the service mode of the device is activated (pump is not running). Selection of the service functions The available service functions are selected via the water temperature setting.
  • Page 100: Set Up The Switching Off Process

    7.25 Set up the switching off process Display Explanation Remark 30°C Switch-off after 30 minutes of continuous operation Switching with SET is activated. Switch-off after 30 minutes of continuous operation Switching with SET is not activated (factory setting). 35°C Switch-off after 30 minutes of continuous break is Switching with SET activated.
  • Page 101: Rfid Query

    7.27 RFID query Display Explanation Remark 45°C Device is equipped with RFID. Menu access: Select 45°C „SET“ Switch off device. Hold SET. Turn on the machine. Re- lease SET. Select settings with SET. Device is not equipped with RFID. Menu access: Select 45°C Check the setting when replacing the printed circuit Switch off device.
  • Page 102: Testing The Water Temperature Setting And The Programme Switch

    7.30 Testing the water temperature setting and the programme switch Display Explanation Remark 55°C Output image for temperature selector switch test. Use SET to access the tem- perature selector switch test. Temperaturwahlschaltertest. Es wird die am Tem- Wenn der Temperaturwahls- peraturwahlschalter gewählte Temperatur an- chaltertest fertig ist, muss gezeigt.
  • Page 103: Testing The Sensors

    7.32 Testing the sensors Display Explanation Remark 65°C Description from left to right: In case of a cable break with Level stage fuel sensor (stage 7 of 8) a level sensor no stage is Thermal motor protection switch open. displayed. Oil refill container not empty Exhaust thermostat open.
  • Page 104: Error Memory

    7.33 Error memory Note With switch-off - hold SET - switch-on the fault memory Use SET to switch over to the next fault. can be deleted. Display Explanation Remark 70°C Mains voltage too high Check the supply voltage. Mains voltage too low Check the supply voltage.
  • Page 105 Display Explanation Remark Exhaust thermostat has triggered. Decarbonize boiler. Check exhaust gas thermo- stat. Cable break or short circuit with water temperature Check temperature sensor. sensor Flame sensor does not detect a flame although the Clean the looking glass. burner was switched on Check fuel supply.
  • Page 106: Operating Hours

    7.34 Operating hours Display Explanation Remark 75°C Indication of the consumed RM 110/111 bottles. 7.35 Gun switching operations since gun service Display Explanation Remark 80°C Number of gun switching operations since the last Maintenance after 80000 maintenance gun switching operations 7.36 Gun services Display Explanation...
  • Page 107: Operation Duration Of The Burner Since Startup

    7.38 Operation duration of the burner since startup Display Explanation Remark 95°C Operation duration burner since the last mainte- Maintenance after 400 burn- nance er hours. 7.39 Burner service Display Explanation Remark 100°C Number of burner maintenances Delete service. Turn off the appliance. Hold SET (2-3 seconds).
  • Page 108: Pump Services

    7.42 Pump services Display Explanation Remark 140°C Number of pump maintenances Delete service. Turn off the appliance. Hold SET (2-3 seconds). Turn on the appliance. Note The fault memory is also de- leted. 7.43 Pump operation since initial startup Display Explanation Remark 155°C...
  • Page 109: Quick Overview For Reading The Service Functions

    7.44 Quick overview for reading the service functions  Turn off the appliance.  80 (58/46)°C - Gun switching operations since the last  Make a note of the position of the service switch. gun service (maintenance every 80000 switching oper- ...
  • Page 110: Overview Of A Quick Check Of The Device Status

    7.46 Overview of a quick check of the device status Read the fault memory in service mode at 70 (52/44)°C. Advance with "SET". Every fault type is saved only once, together with the passed hours since it has last occurred. Overvoltage detected hours ago: Low voltage range detected hours ago: Excess current detected hours ago:...
  • Page 111: Settings, Burner

    7.47 Settings, burner 1 Pressure line to the burner 2 Fuel pump 3 Suction hose, fuel 4 Adjustment screw, fuel pressure 5 Return hose to the fuel tank Measure water temperature  Install the shut-off valve with thermometer (special tool) on the appliance outlet.
  • Page 112: Installation Air Duct On The Outer Jacket

    7.48 Installation air duct on the outer jacket 1 Clamp ring 2 Air guidance 3 Exterior coat  Clean the air duct and the outer jacket in the installation area.  Install the air duct on the outer jacket.  Grease clamping ring. ...
  • Page 113: Adjusting The Working Pressure With The Rotary Regulator On The Gun

    7.49 Adjusting the working pressure with the rotary regulator on the gun 7.49.1 Setting the maximum working pressure 1 Adjustment screw, high pressure 2 Lock nut, adjustment screw, high pressure 3 Spindle, pressure and quantity regulation 4 Adjustment screw, low pressure 5 Lock nut, adjustment screw, low pressure 6 Housing, overflow valve ...
  • Page 114: Setting The Minimum Working Pressure

    7.49.2 Setting the minimum working pressure 1 Adjustment screw, high pressure 2 Lock nut, adjustment screw, high pressure 3 Spindle, pressure and quantity regulation 4 Adjustment screw, low pressure 5 Lock nut, adjustment screw, low pressure 6 Housing, overflow valve ...
  • Page 115: Setting The Working Pressure With Standard Gun Without Rotary Knob

    7.50 Setting the working pressure with standard gun without rotary knob 7.50.1 Setting the maximum working pressure 1 Adjustment screw, high pressure 2 Lock nut, adjustment screw, high pressure 3 Spindle, pressure and quantity regulation 4 Adjustment screw, low pressure 5 Lock nut, adjustment screw, low pressure 6 Housing, overflow valve ...
  • Page 116: Setting The Minimum Working Pressure

    7.50.2 Setting the minimum working pressure 1 Adjustment screw, high pressure 2 Lock nut, adjustment screw, high pressure 3 Spindle, pressure and quantity regulation 4 Adjustment screw, low pressure 5 Lock nut, adjustment screw, low pressure 6 Housing, overflow valve ...
  • Page 117: Troubleshooting

    Troubleshooting Failure Measure Device is not running (no LED/display indication) Check/replace mains voltage, connecting cable and mains – fuse. Check the fuse (F1). – Check/replace the power switch. – Check/replace the pressure switch – Check/adjust/replace control transformer. – Check/replace the temperature fuse. –...
  • Page 118: Error Messages

    Error messages Display Explanation Remark Rotating field of the motor incorrect. Perform a phase inversion in the commutating pole plug. Thermal motor protection switch (WSK) in the motor has Switch off the device and al- tripped. low the motor to cool down. Mains voltage too low or too high or phase failed or the motor Check power supply.
  • Page 119: Error Message With Service Demand

    Error message with service demand Note One display for multiple faults is used here. By reading the fault memory, the fault can possibly be localized. (Service mode 70°C) Display Explanation Remark Water shortage safeguard (reed switch or magnetic piston is Check water shortage safe sticky).
  • Page 120: Technical Specifications

    Technical specifications Appliance type Appliance no. Circuit diagram Operating instructions Spare parts list HDS 7/12-4 M 1.077-410.0 0.089-021 5.964-883.0 5.972-064.0 HDS 7/12-4 MX 1.077-450.0 0.089-021 5.964-883.0 5.972-064.0 HDS 8/18-4 M 1.077-609.0 0.089-025 5.964-883.0 5.972-275.0 HDS 8/18-4 MX 1.077-650.0 0.089-025 5.964-883.0 5.972-275.0 HDS 9/18-4 M 1.077-810.0...
  • Page 121: Special Tools

    Special tools Electric measuring appliance 6.803-022.0 Shut-off valve with thermometer 2.901-030.0 Removal pliers, pressure/suction valves 4.901-062.0 Installation mandrel oil seal, high-pressure 5.901-062.0 and water sieves seal Piston diameter 18mm Installation sleeve, high pressure seal 5.901-118.0 Piston diameter 18mm Installation mandrel oil seal, high-pressure 5.901-055.0 seal Piston diameter 20mm...
  • Page 122 Soot pump 6.775-001.0 Puller for swashing plate 4.901-038.0 Soot filter paper 6.775-002.0 Soot pattern scale 6.775-003.0 Thermometer 6.432-029.0 Hardness indicator A 6.768-004.0 Indicator paper 6.768-006.0 Obtain recommended measuring devices, Testo 320 or Testo 320-2-LL - measuring device CO2, directly from the supplier. Note Additionally required for both measuring devices:...
  • Page 123 Mounting screws for piston guide (M8 x 7.304-403.0 Mounting screws for piston guide (M6 x 7.304-467.0 110) English 5.906-432.0 Rev. 00 (06/15)
  • Page 124: Circuit Diagram

    Circuit diagram Note Circuit diagram 0.089-021.0 HDS 7/12 Please observe the most current circuit diagrams in DISIS. English 5.906-432.0 Rev. 00 (06/15)
  • Page 125 Circuit diagram 0.089-021.0 HDS 7/12 English 5.906-432.0 Rev. 00 (06/15)
  • Page 126 Circuit diagram 0.089-025.0 HDS 8/18, HDS 9/18 English 5.906-432.0 Rev. 00 (06/15)
  • Page 127 Circuit diagram 0.089-025.0 HDS 8/18, HDS 9/18 English 5.906-432.0 Rev. 00 (06/15)
  • Page 128 Circuit diagram 0.088-952.0 HDS 10/20, HDS 12/18 English 5.906-432.0 Rev. 00 (06/15)
  • Page 129 Circuit diagram 0.088-952.0 HDS 10/20, HDS 12/18 English 5.906-432.0 Rev. 00 (06/15)
  • Page 130 Circuit diagram 0.089-9026.0 HDS 13/20 English 5.906-432.0 Rev. 00 (06/15)
  • Page 131 Circuit diagram 0.089-9026.0 HDS 13/20 English 5.906-432.0 Rev. 00 (06/15)

This manual is also suitable for:

Hds 8/18 mHds 9/18 mHds 10/20 mHds 12/18 sHds 13/20 s

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