Kärcher HDS 9/50 De Tr1 Service Manual
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Kärcher HDS 9/50 De Tr1 Service Manual

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HDS 9/50 De Tr1
HDS 13/35 De Tr1
HDS 13/20 De Tr1
HDS 17/20 De Tr1
Service Manual
1
English 5.906-736.0 Rev. 00 (07/15)

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Summary of Contents for Kärcher HDS 9/50 De Tr1

  • Page 1 HDS 9/50 De Tr1 HDS 13/35 De Tr1 HDS 13/20 De Tr1 HDS 17/20 De Tr1 Service Manual English 5.906-736.0 Rev. 00 (07/15)

  • Page 2: Table Of Contents

    Contents Contents Preface Regarding this service manual Target groups for this manual Environmental protection Safety instructions General Hazard levels Symbols on the plant Hearing protection Technical Features General Field of application Pump Electronics system Detergent Accessories Type plate Vehicle identification number Parts of the system View with closed front and rear cover View with opened front and rear cover...
  • Page 3 8.7.9 Service motor 8.7.10 Service pump 8.7.11 Service burner 8.7.12 Service gun Function Flow pattern Overview sensor technology and electrical components 9.2.1 Switching functions of the sensor technology Axle / drawbar Lights Covers Water tanks (2x250 l) Storage compartments Battery / inverter Water inlet 9.10 Swimmer tank 9.11 Water distribution...
  • Page 4 10.10 Water connection 10.10.1 Operation with external water supply 10.10.2 Operation with water from the water tanks 10.11 Refill fuel 10.12 Refill detergent 10.13 Refill liquid softener 11 Basic settings and service procedures 11.1 Axle / drawbar 11.1.1 Lubricate the brake on the drawbar 11.1.2 Lubricating the crank drive of the support wheel 11.1.3 Replacing wheel Lights...
  • Page 5 11.12.5 Cleaning / changing the temperature sensor exhaust gas 11.12.6 Cleaning / changing the temperature sensor warm water 11.12.7 Dismantling the booster heater 11.13 Settings, burner 11.14 High pressure outlet 11.14.1 Uninstall / install high-pressure hose 11.14.2 Dismantling the pressure gauge 11.14.3 Changing the bypass unit with safety valve 11.15 Motor 11.9.1 Check oil level and refill oil...

  • Page 6: Preface

    Preface Good service work requires extensive and practice-orient- international-service@de.kaercher.com ed training as well as well-structured training materials. Hence we offer regular basic and advanced training pro- Subject: Fall 119377 grammes covering the entire product range for all service The responsible product specialist will take care of your is- engineers.

  • Page 7: Hazard Levels

    Please remember: Operating the equipment – that you have understood all the instructions If the equipment is operated in a close room – that all users of the plant are informed about the instruc- , exhaust must be lead through appropriate pipes or –...

  • Page 8: Technical Features

    – – 2 x 250 l water storage tanks – 1 x 35 litre float container – Field of application HDS 9/50 De Tr1 HDS 13/20 De Tr1 – – HDS 13/35 De Tr1 HDS 17/20 De Tr1 – –...

  • Page 9: Type Plate

    Type plate Exemplary illustration for type HDS 13/200 De Tr1 1 Appliance description 2 Performance data motor, speed motor, total weight trailer 3 Information regarding the flow rate, working pressure, maximum pressure of the safety valve, maximum work temperature, maximum supply temperature 4 Superior configurable part number 5 Information burner: maximum burner power, reference to heating coil type, max.

  • Page 10: Parts Of The System

    Parts of the system View with closed front and rear cover 1 Reflector (on both sides) 12 Connector vehicle lighting 2 Rear cover 13 Tear-off rope 3 Combined brake/tail light with direction indicator (left) 14 Towing hitch 4 Recessed grip of the rear cover or hose inlet with 15 Parking brake closed rear cover 16 Coupling lever...

  • Page 11: View With Opened Front And Rear Cover

    View with opened front and rear cover 1 Diesel engine 2 Intermediate gear 3 High-pressure pump 4 Safety block 5 Exhaust 6 Expansion tank motor coolant English 5.906-736.0 Rev. 00 (07/15)
  • Page 12 1 Maintenance opening water tank (left) 2 Air filter diesel engine 3 Nameplate 4 Battery 5 Vehicle identification number 6 Burner blower 7 Fuel pump 8 Continuous heater 9 Ignition transformer 10 Maintenance opening water tank (right) English 5.906-736.0 Rev. 00 (07/15)
  • Page 13 1 Cover plate (right) 2 Cover plate (left) 3 Supply tap water tanks 4 Drain-off tap 5 Antifreeze hose 6 Water pipes 7 Water filter 8 Manometer 9 Supply frost protection or parking position for GEKA low-pressure connection 10 Return flow frost protection or parking position for high- pressure connection 11 Tank lid 12 Operating field...
  • Page 14 1 Detergent container (HDS 13/20 and HDS 17/20 only) 11 Liquid softener container 2 Filter detergent suction hose (HDS 13/20 and HDS 17/ 12 Antifreeze container 20 only) 13 Filling nozzle fuel tank with sieve 3 Detergent suction hose with level switch (HDS 13/20 14 Ball tap frost protection and HDS 17/20 only) 15 Filling level indicator water tanks...
  • Page 15 1 Cover plates The cover plates can be lifted up and removed. 1 Connection tank on the left side - tank on the right side 2 Supply from the float container 3 Stop cock drain water tanks 4 Supply to the high-pressure pump 5 Stop cock water tanks 6 Supply from water tank on the right 1 Maintenance flap on the right...
  • Page 16 View with opened maintenance flap on the left 1 Inverter 2 Thermostat switch water temperature in the float con- tainer View with opened maintenance flap on the right 1 Thermostat switch emission temperature View with opened maintenance flap on the right 1 Level sensor for fuel tank 2 Fuel line motor and burner English 5.906-736.0 Rev.

  • Page 17: Bottom View

    Bottom view 1 Temperature sensor booster heater 2 High-pressure line from the boiler to the high-pressure connection 3 High-pressure line from the safety block to the boiler 4 Heat exchanger 5 Drain screw heat exchanger 6 Axle (drawbar) NOTE In the underbody area, there is the oil drain screw of the motor as well as the drain screw for emptying the diesel tank.

  • Page 18: Operator Console

    Operator console 7.4.1 Operator console 1 Display 2 Operating type switch 3 Indicator light preheating (red) 4 Indicator light standby mode (red), the charge control is active 5 Key switch 6 Indicator lamp front cover/emergency stop (red) 7 Operating mode cold/warm water (0-100 °C, temperature selection) 8 Operating mode frost protection NOTE...
  • Page 19 During normal operating mode, the control panel display alternates between: Normal operation – Service: Due maintenance tasks to be performed by – the customer service (see care and maintenance). If more than one maintenance procedure is required, these will be shown in sequence. If no maintenance procedures are required, nothing will be shown.
  • Page 20 Display malfunction 1 Malfunction no. 2 Motor off (OFF) List malfunction number with corresponding error mes- sage ERROR 1 – Charging current ERROR 3 – Coolant or temperature water in the float container ERROR 4 – Water shortage ERROR 5 –...

  • Page 21: Control Panel, View From The Inside

    7.4.2 Control panel, view from the inside Electric components are located in the control cabinet and in the control cabinet door. English 5.906-736.0 Rev. 00 (07/15)
  • Page 22 Electric components in the control cabinet 10 Relay K6, coolant 1 Relay K4 (safety relay Yanmar) 11 Relay K9, charge regulator 2 Relay K7, release 12 Relay K8, release burner 3 Fuse F1, 30A: Blower motor 13 Relay K10, (bypass relay) 4 Fuse F2, 30A: Pre-heat 14 Time relay K10T 5 Fuse F3, 30A...
  • Page 23 Electric components in the control cabinet door 1 Printed circuit board A1 with display 2 Indicator light H3 front cover/emergency stop (red) 3 Operating type switch 4 Indicator light H1 preheating (red) 5 Key switch 6 Indicator light H2 charge regulator (red) English 5.906-736.0 Rev.

  • Page 24: Control Boards, Control Panel

    7.4.3 Control boards, control panel Control board A1 9 PRINTED CIRCUIT BOARD: Connection between con- Inputs trol board A1 and distributor board A2 1 LCH1: Monitoring oil pressure diesel engine 10 TRANSFORMER 1: Connection transformer 1 (24V AC) 2 LCH2: Monitoring temperature water in the float con- 11 TRANSFORMER 2: Connection transformer 2 (24V AC) tainer and monitoring temperature coolant diesel en- 12 ABGASTH: Thermostat switch emission temperature...
  • Page 25 Distributor printed circuit board A2 Inputs 1 WSK: Level switch water shortage float container 2 DSEIN: Pressure switch 3 DSAUS: Charge regulator 4 OELSI: Level switch detergent can 5 PRINTED CIRCUIT BOARD: Connection between con- trol board A1 and distributor board A2 Outputs 6 VERBRENNST: Solenoid valve fuel supply burner, 24V AC, 3A...

  • Page 26: Operations

    Operations General information on the operation 8.1.1 Safety instructions DANGER It is not possible to specify a generally valid operation time, Risk of explosion! since this depends on several factors: Do not spray flammable liquids. Proneness to blood circulation deficiencies (cold, numb –...

  • Page 27: Speed Control For Pressure And Volume Regulation

    8.1.4 Speed control for pressure and volume regulation HDS 9/50, HDS 13/35 only: NOTE If the motor speed is increased, the operating pressure also rises. This can be read from the pressure gauge. Increasing the speed: –  Push up the lever of the speed control. Reducing the speed: –...

  • Page 28: Interrupting Operation

    8.1.7 Interrupting operation  Release the lever on the trigger gun. NOTE NOTE If there are less then 5 litres of diesel in the fuel tank, the When the lever of the hand spray gun is released, the en- device switches off automatically. It can be switched back gine continues to run at zero speed.

  • Page 29: Operating Displays

    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 Maintenance for motor due after 200 h. Perform maintenance pro- cedure.

  • Page 30: Liquid Softener Mode

    Liquid softener mode 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 31  Close the supply tap of the water tanks and the drain tap. With unit types HDS 13/20 and HDS 17/20:  Set the detergent dosing valve to the maximum dosing level.  Take the detergent suction lance out of the container and put it down in a way that it can be sucked empty in the frost protection mode.

  • Page 32: Flush The Anti-Freeze Out Of The High-Pressure Circuit

     The antifreeze liquid is pumped through the appliance in a circuit.  Lead the residual water via the frost protection hose into the anti-freeze container.  As soon as antifreeze exits the antifreeze hose, wait 5 seconds, and put the actuation lever of the frost protec- tion ball tap in the horizontal position.

  • Page 33: Service Switch

    Service switch 1 Service switch 2 Position marking 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 34: Service Functions With Display

    Service functions with display 1 Setting, water temperature Service mode If the service switch is in the "Service" position upon switching on the device, the service mode of the device is activated. Selection of the service functions The available service functions are selected via the water temperature setting.

  • Page 35: Quick Overview For Reading The Service Functions

    8.7.1 Quick overview for reading the service functions  Turn off the appliance.  65°C - service diesel engine.  Make a note of the position of the service switch.  70°C - service pump.  Set the service switch to Service. ...

  • Page 36: Test Actuators / Test Output Signals

    8.7.4 Test actuators / test output signals NOTE In order to change between the actuators, keep the service switch on "SET" for one second. In order to operate the selected actuator, set the service switch to level "4". Display Explanation Remark Manual switch-on/off of the following actuators: NOTE...

  • Page 37: Input Test Of The Signals

    8.7.7 Input test of the signals NOTE The test takes place as follows:  Operate the sensor manually.  Observe the indicator change on the display. If the indi- cation changes upon operation, the sensor is OK. Display Explanation Remark Indication of the current switching statuses of the NOTE following sensors:...

  • Page 38: Service Motor

    Display Explanation Remark ERROR 1 * Cleaning operation with – Charging current cold water is possible. ERROR 3 – Coolant or temperature water in the float con- For details on the cause of tainer the malfunction and its recti- ERROR 4 fication see Chapter 13.

  • Page 39: Service Pump

    8.7.10 Service pump Display Explanation Remark Delete service: Number of total pump maintenances Turn off the appliance. Total operation duration of the pump Hold SET (2-3 seconds). Operation duration pump since the last mainte- Turn on the appliance. nance NOTE The maintenance counter is automatically increased by 1 The fault memory is also de-...

  • Page 40: Function

    Function Flow pattern Colour assignment: 17 Pressure switch black: Water 18 Overflow valve red: Detergent 19 Backflow valve brown: Fuel (diesel) 20 Safety valve blue: Cooling circuit motor 21 Flow switch 1 Antifreeze container 22 Motor burner blower 2 Liquid softener container with level switch and dosing 23 Continuous heater valve 24 Temperature sensor burner...

  • Page 41: Overview Sensor Technology And Electrical Components

    Overview sensor technology and electrical components 1 Battery 14 Valve liquid softener 2 Motor burner blower 15 Level switch liquid softener container 3 Valve fuel burner 16 Inverter 4 Starter motor 17 Safety switch cover opening (cover switch) 5 Alternator 18 Thermostat switch water temperature in the float con- 6 Flame sensor tainer...

  • Page 42: Switching Functions Of The Sensor Technology

    9.2.1 Switching functions of the sensor technology NOTE Indication motor ON/OFF The following switching functions serve the general under- NOTE standing of the respective functionality as well as the pos- The ON/OFF indication of the motor is controlled via the sibility how which sensor can be tested.
  • Page 43 Dosing liquid softener, valve -Y4 Level switch float container (-S13) Burner programme selected and flow present: Float contact closed: Pulse time liquid softener is approx. 85ms, equals ap- Filling level OK. – – prox. 0.5 ml. Float contact open: The waiting time between the pulses depends on the Diesel engine stops after 4 seconds.
  • Page 44 Burner operation, contactor K8 For the release of the burner the following conditions must be met: Flow present (-S7). – Level fuel tank > 3 bars. – Temperature sensor booster heater (-R 3) is connect- – Hot water operation selected. –...

  • Page 45: Axle / Drawbar

    Axle / drawbar 1 Parking brake 2 Connector vehicle lighting 3 Support wheel crank handle 4 Support wheel 5 Overrun brake 6 Tear-off rope 7 Coupling lever 8 Towing hitch The axle is an approved purchased item with its own type NOTE plate for axle and overrun unit that is located in the front Further information about the operation and maintenance...
  • Page 46 1 Reflector (on both sides) 2 Marker light (on both sides) English 5.906-736.0 Rev. 00 (07/15)

  • Page 47: Covers

    Covers Front cover 1 Recessed grip 2 Hood 3 Locking Rear cover 1 Hood 2 Handle 3 Locking The entire technical unit with motor, high-pressure pump NOTE and burner is located underneath the front cover. An ex- It is not possible to operate the trailer in normal operation haust opening serves the discharge of the exhaust gases when the front cover is opened! The safety switched must of the burner and the diesel engine.

  • Page 48: Water Tanks (2X250 L)

    Water tanks (2x250 l) 1 Maintenance opening tank on the right 2 Maintenance opening tank on the left The trailer is equipped with two water tanks that are con- nected to each other. Each tank has a capacity of 250 li- tres.

  • Page 49: Storage Compartments

    Storage compartments 1 Storage operating instructions 2 Storage compartment for trigger gun 3 Storage compartment for 2nd spray lance 4 Storage compartment for helmet Slide-in units, which can be used as storage compart- ments, are integrated in the rotation parts of the two water tanks.
  • Page 50 Battery 12V, 36Ah 1 Battery terminal (+), red 2 Battery (voltage and capacity, see "Specifications“) 3 Battery terminal (-), black 4 Battery holder View with opened maintenance flap on the left 1 Inverter Inverter The control board A1 requires a supply voltage of 24V AC. This is generated by the inverter by conversion of the in- coming battery voltage (12V DC).

  • Page 51: Water Inlet

    Water inlet Low-pressure hose drum 1 Water supply hose 2 Brake lever Connection to an external water supply is established by means of the water supply hose DN19, connection, max. length: 30 metres To unroll or roll up the hose, the brake must be released. For this purpose, open the brake lever in the counter- clockwise direction.
  • Page 52 In the lower area of the float container the sensors for the filling level monitoring (empty message) and water temper- ature are mounted onto a joint holder. 1 Support 2 Temperature sensor 3 Filling level monitoring (empty message) 4 Inflow return line of high-pressure pump View with opened maintenance flap on the left 1 Thermostat switch water temperature in the float con- tainer...

  • Page 53: Water Distribution

    9.11 Water distribution 1 Connection tank on the left side - tank on the right side 2 Supply from the float container 3 Stop cock drain water tanks 4 Supply to the high-pressure pump 5 Stop cock water tanks 6 Supply from water tank on the right Operation with water supply via the water tanks float container (2) and the supply (6) of the corresponding When the tap (5) is open, water flows from the float con-...

  • Page 54: Heat Exchanger

    1 Liquid softener reservoir 2 Level sensor 1 Liquid softener reservoir 2 Level sensor 3 Dosing valve 9.13 Heat exchanger 1 Supply from the water distribution 2 Supply to the high-pressure pump The heat exchanger serves the motor cooling and the si- multaneous preheating of the washing water.

  • Page 55: High-Pressure Pump

    9.14 High-pressure pump Overview pump types 13/20 and 17/20 1 Overflow 2 Speed control idle mode / full load 3 Pump head 4 Pressure switch 5 Valve set frost protection 6 Supply water with fine filter 7 Intermediate gear 8 Detergent supply to the pump 1 Pump casing 2 Outlet high pressure 3 Outlet return line to the float container...

  • Page 56: Pump Diagram (General)

    9.14.1 Pump diagram (general) Schematic diagram for all pump types 1 Lock screw, suction side, with O-ring 21 Disc (back ring) 2 Disc 22 Low pressure seal 3 Suction valve with O-ring 23 Support ring, low pressure seal 4 Ceramic piston 24 Support disc, brass 5 Piston screw 25 Disc (back ring)

  • Page 57: Function Frost Protection Valve

    9.14.2 Function frost protection valve 1 Casing 2 Valve 3 Spring If pressure is applied to the casing (1) during operation of the pump, the valve (2) closes and no flow is possible. In low pressure operation the spring (3) pushes onto the valve (2) so that the gate of the valve is opened.

  • Page 58: Function Speed Control Full Load / Idle Mode

    9.14.4 Function speed control full load / idle mode 1 Screwed sealing plug 2 Spring 3 Piston 4 Casing 5 Bowden cable 6 Adjustment screw If pressure is applied to the casing (5) during operation of In work brakes the spring (2) pushes back the piston (3) so the pump, the piston (3) is pressed against the spring (2) that the Bowden cable slackens and the motor is operated and thus pulls the Bowden cable (6) into the casing.

  • Page 59: Crank Drive Disassembled

    9.14.5 Crank drive disassembled Illustration for pump types 13/20 and 17/20 1 Bearing (closed bearing side) 2 Crankshaft 3 Cover oil filler neck 4 Cover 5 Piston rod 6 Covering lid 7 Screw 8 Oil sight glass 9 Screwed sealing plug 10 O ring 11 Seal casing cover 12 Bearing (open bearing side)
  • Page 60 Illustration for pump types 9/50 and 13/35 1 Covering lid 2 Screw 3 Seal casing cover 4 Piston rod 5 O ring 6 Container 7 Stopper 8 Cover oil filler neck 9 Cylinder roller bearing 10 O ring 11 Screw 12 Bearing (open bearing side) 13 Radial seal 14 Shaft seal ring...

  • Page 61: Cylinder Head: High-Pressure Valve And Water Inlet / Piston Seals

    9.14.6 Cylinder head: High-pressure valve and water inlet / piston seals Illustration for pump types 13/20 and 17/20 High-pressure valves and water inlet 1 Valve screw 2 O ring 3 Suction valve 4 Pressure valve Piston seals 5 Seal kit English 5.906-736.0 Rev.
  • Page 62 Illustration for pump types 9/50 and 13/35 High-pressure valves and water inlet 1 Valve screw 2 O ring 3 Suction valve 4 Pressure valve Piston seals 5 Screwed sealing plug 6 O ring 7 Seal kit 8 Bushing 9 Seal kit English 5.906-736.0 Rev.

  • Page 63: Cylinder Head, Overflow Valve

    9.14.7 Cylinder head, overflow valve Exemplary illustration for all 4 pump types 1 Overflow 2 Hollow screw 3 Banjo bolt bypass 4 Pump head NOTE Both hollow screws must be loosened or tightened simul- taneously while exchanging the knot section in order to avoid damage to the O-rings.

  • Page 64: Overflow

    9.15 Overflow Exemplary illustration. The overflow valves for the 4 1 Spring pumps are similarly designed, they differ in the spring force 2 Control piston relative to the pressure range. 3 Spring The overflow valves are permanently set and sealed. 4 Valve bolt 5 Valve A High-pressure inlet...

  • Page 65: Safety Block

    9.16 Safety block Safety block 200bar 1 Screwed sealing plug 2 Flow switch 3 Clamping bracket 4 High-pressure outlet to the booster heater 5 High pressure input 6 Safety valve 7 Adjusting screw NOTE The safety valve can be adjusted in the range 185-250bar. The presetting at 240bar is done in the factory.

  • Page 66: Safety Valve

    9.16.1 Safety valve 1 Spring 2 Valve ball 3 Valve seat Illustration for pump types 13/20 and 17/20 1 Spring 2 Valve disks 3 Valve seat Illustration for pump types 9/50 and 13/35 If the overflow valve is defective, the safety valve guides For safety valve 200bar only the entire flow rate of the pump to the outside and thus pro- The opening pressure of the safety valve is adjusted with...

  • Page 67: Flow Switch

    9.16.2 Flow switch 1 Magnetic piston Illustration for pump types 13/20 and 17/20 Illustration for pump types 9/50 and 13/35 1 Magnetic piston The flow switch prevents the burner from switching on in In case of an insufficient water volume, the flow switch im- case of missing or insufficient water volume and thus pro- mediately switches the burner off in warm water operation tects the booster heater from overheating.

  • Page 68: Burner Blower With Fuel Pump

    9.17 Burner blower with fuel pump 1 Continuous heater 2 Fuel pump 3 Blower lid 4 Pressure line 5 Rubber collar 6 Solenoid valve 7 Setting fuel pressure 8 Fuel line 9 Filter 10 Return 1 Rubber collar 2 Air flap 3 Screw 4 Burner blower 1 Solenoid valve...

  • Page 69: Booster Heater (With Ignition Transformer)

    1 Blower wheel 2 Fastening screw blower wheel Burner blower The blower supplies the burner with combustion air. The air flap is used to adjust the air value to optimised combustion values. The blower wheel is mounted to the motor shaft by means of 2 feather keys.

  • Page 70: Type Plate Of Heating Coil

    View with opened maintenance flap on the right 1 Thermostat switch emission temperature NOTE When the set emission temperature of 292°C +/-7K is ex- ceeded, the burner switches off automatically. Restart after a temperature drop by 9 +/-4.5K. 9.18.1 Type plate of heating coil The type plate of the heating coil can be read through the exhaust stack.

  • Page 71: Sectional View (Exemplary)

    9.18.2 Sectional view (exemplary) 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 pipe 12 Exhaust nozzle, on-demand heater 5 Burning chamber 6 Boiler floor 7 Boiler input 8 Air supply from burner blower English 5.906-736.0 Rev.
  • Page 72 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 73: Burner

    9.19 Burner 3,5 mm +/-0,5 3,0 mm +/-0,5 1 Ignition electrodes Burner 2 Fuel nozzle holder There is a strong spark created between the two ignition 3 Fuel nozzle electrodes to ensure that the injected fuel will ignite. 4 Spray angle 45° or 60°, depending on the type of appli- The necessary ignition voltage is generated by the ignition ance transformer.

  • Page 74: Output Of Flow-Type Heater

    1 Ignition electrode 2 Fuel nozzle 3 Pressure plate 1 Ignition electrode 2 Fuel nozzle 9.20 Output of flow-type heater View from below 1 Temperature sensor warm water 2 High-pressure line from the booster heater to the high- pressure connection 3 High-pressure line from the safety block to the boiler NOTE The temperature sensor measures the warm water tem-...

  • Page 75: High Pressure Connection

    9.21 High pressure connection 1 Manometer 2 Catch high-pressure hose reel 3 High-pressure hose drum 4 High pressure hose There is also equipment without a high-pressure hose reel. In this case, a separate high-pressure hose is connected to the high-pressure connection in the area of the pressure gauge.
  • Page 76 Diesel engine 1 Connection coolant hose 2 Filling hole motor oil (top) 3 Thermostat switch motor 4 Connection coolant hose 5 Cooling fan, motor Diesel engine 1 Expansion tank motor coolant 2 Exhaust system 3 Muffler 4 Air filter 5 Starter 6 Alternator Diesel engine 1 Heat exchanger...
  • Page 77 Diesel engine - circuit coolant 1 Connection coolant hose 2 Connection from the expansion tank motor coolant 3 Drain screw coolant 4 Connection from the water distribution 5 Connection to the HP pump Antifreeze motor  Check the coolant circuit of the motor for sufficient an- tifreeze, refill antifreeze as needed.

  • Page 78: Speed Control - Full Load / Idling Speed

    9.22.1 Speed control - full load / idling speed 1 Bowden cable speed control from the piston on the high-pressure pump 2 Deflection 3 Speed control motor The speed control lowers the motor speed when the hand spray gun is closed. 1 Speed control (full load / idle mode) 2 Bowden cable to the motor English 5.906-736.0 Rev.

  • Page 79: Speed Control For Changing Volume And Pressure

    9.22.2 Speed control for changing volume and pressure NOTE This equipment is only available for HDS 9/50 and HDS 13/35. 1 Speed control (full load / idle mode) 2 Bowden cable from the control lever (limitation max. motor speed for controlling volume and pressure) 3 Control lever for speed control 4 Speed control motor The Bowden cable from the control lever limits the maxi-...

  • Page 80: Fuel Tank

    9.23 Fuel tank 1 Tank filler neck with cap The fuel tank is located in the air casing, which separates the motor compartment from the operator side. NOTE If the refuelling is done by means of cans, the accompany- ing filter sieve should be inserted in the tank filler neck in order to retain potential dirt particles.

  • Page 81: Detergent Dosing Unit

    9.24 Detergent dosing unit NOTE This equipment is only available for HDS 13/20 and HDS 17/20. Detergent is drawn via the dosing valve from the detergent container. The dosing level is adjusted via the dosing valve. With pump operation the solenoid valve before the high-pressure pump opens and injects detergent to the supply water.
  • Page 82 Detergent dosing valve 1 Connection from the detergent tank (labelled with "1") 2 Connection to the pump (labelled with "P") Solenoid valve dosing detergent 1 Motor flange 2 Connection from the detergent tank 3 Solenoid valve 4 Connection to the pump 5 Pump casing NOTE The solenoid valves opens subject to the pressure switch...
  • Page 83 1 Fine filter 2 Aperture NOTE In order to improve the suction behaviour of the pump for the detergent, an orifice plate is installed in the inlet to the fine filter. English 5.906-736.0 Rev. 00 (07/15)

  • Page 84: Preparations For Service Tasks

    Preparations for service tasks 10.1 Transport If the trailer needs to be moved for service tasks, this can CAUTION be done in trailer operation or by means of a crane. Risk of injury and damage! Observe the weight of the ap- pliance when you transport it.

  • Page 85: Install The Device And Align It

    10.2 Install the device and align it 1 Parking brake 2 Plug storage 3 Crank for support wheel adjustment Choose the installation site in a way that the exhaust gas opening is not covered.  Lock parking brake.  Lower the support wheel by means of the crank. ...

  • Page 86: Opening The

    10.3 Opening the front cover View from the inside 1 Lock 2 Catch hook NOTE The lock of the front cover is equipped with an additional catch hook in order to prevent unintended opening. The catch hook must, like with a motorcar, be pushed to the side manually after opening the lock to release the locking mechanism.

  • Page 87: Service Tasks With Opened

    10.4 Service tasks with opened front cover A safety switch stops the motor upon opening the front This is necessary, for example, for setting tasks on the cover, starting the motor is not possible when the front cov- burner, for sensor tests, etc. er is open.

  • Page 88: Lifting The Trailer From The Bottom For Maintenance Tasks

    10.5 Lifting the trailer from the bottom for maintenance tasks 10.5.1 Lifting with a jack DANGER Danger on account of falling trailer. When lifting the trailer by means of a jack, ensure that it stands on a solid, level ground! Ensure that the trailer is secured against rolling away with all wheels that are on the ground.

  • Page 89: Lifting By Means Of A Car Lift

    1 Cross strut of the axle 2 Support point jack  Lift the trailer on the square tube of the cross strut in the area of the suspension. Exemplary illustration for lifted trailer. 10.5.2 Lifting by means of a car lift ATTENTION Risk of damage to equipment.

  • Page 90: Dismantling The Front Plate

    10.6 Dismantling the front plate For service tasks in the front area of the motor compart- to enable better access to, for example, the safety block or ment, it may be advisable to remove the front plate in order the fine filter in the pump inlet. ...

  • Page 91: Dismantling The Maintenance Flap On The Right

    10.7 Dismantling the maintenance flap on the right The maintenance flap on the right must be dismantled for ture or at the filling level sensor and the fuel lines of the die- service tasks on the thermostat switch emission tempera- sel tank.

  • Page 92: Dismantling The Maintenance Flap On The Left

    10.8 Dismantling the maintenance flap on the left For service tasks on the thermostat switch water tempera- ture or on the inverter, the maintenance flap on the left must be dismantled. 1 Maintenance flap on the left 2 Hose air filter - motor ...

  • Page 93: Disassembly Of The Pvc Protective Plates For Service Tasks From The Bottom

    10.9 Disassembly of the PVC protective plates for service tasks from the bottom For service tasks from the bottom, the two PVC protective For the disassembly of the booster heater, it is enough to plates must be dismantled. remove the right PVC plate. NOTE For tasks on the heat exchanger as well as for draining the For the oil change of the motor it is enough to remove the...

  • Page 94: Operation With Water From The Water Tanks

    10.10.2 Operation with water from the water tanks  Open stop cock water tanks.  Uncoil the water hose from the hose reel and connect it to the water supply (e.g. tap).  Open the water supply. The water tanks are filled via the float container. When the water tanks are filled, the float valve in the float con- tainer closes.

  • Page 95: Basic Settings And Service Procedures

    Basic settings and service procedures DANGER ATTENTION Prior to all work on the device that can be performed with- Risk of damage to equipment. With all service tasks, en- out the drive running, switch off the key switch and remove sure that no parts fall into the booster heater through the the key.

  • Page 96: Front Light - Replacing The Lamps

    11.2 Lights 11.2.1 Front light - replacing the lamps  Unscrew 2 screws.  Remove bowl of the lamp.  Change lamp. Lamp type: C5W-12V, part number 7.651-009.0 11.2.2 Rear light - replacing the lamps  Unscrew 4 screws.  Remove bowl of the lamp. ...

  • Page 97: Replace The Gas Pressure Damper

    11.3 Covers 11.3.1 Replace the gas pressure damper Rear cover 1 Fastening bolt with fork on the cover 2 Gas pressure damper 3 Fastening bolt with ball head on air casing NOTE The piston rod is installed towards the cover side. 1 Fastening bolt with fork on the cover 2 Splint CAUTION...
  • Page 98 Front cover 1 Gas pressure damper 2 Fastening bolt with ball head on the cover 3 Fastening bolt with ball head on air casing NOTE The piston rod is installed towards the air casing side. 1 Nut with washer 2 Splint 3 Ball head CAUTION Risk of damage!

  • Page 99: Dismantling Covers

     Push the ball head out of the retainer by slightly hitting it.  Repeat the same procedure on the opposite side of the gas pressure damper and exchange the gas pressure damper. 11.3.2 Dismantling covers NOTE CAUTION The disassembly of the two covers is similar and is only il- Risk of damage! lustrated exemplarily based on the front cover.

  • Page 100: Charge / Replace Battery / Check Fluid Level

     Carefully remove the cover and put it down in a clean, secure place. 11.4 Battery / inverter 11.4.1 Charge / replace battery / check fluid level WARNING CAUTION Risk of injury! Risk of damage! Battery acid is very corrosive! Always wear acid-resistant Prior to connecting the charger, the connecting cables to goggles, gloves and an apron when working with battery the controller must be disconnected from the battery.
  • Page 101  In order to access the connection of the positive termi- nal, fold up and remove the red protective cover. CAUTION Risk of damage! Do not place tools on top of the battery if the protective cover has been removed, as this could lead to a short cir- cuit.

  • Page 102: Replace The Inverter

    11.4.2 Replace the inverter View with opened maintenance flap on the left 1 Inverter  Dismantle the maintenance flap on the left.  Disconnect the supply voltage and connection 24V AC in the control cabinet.  Unscrew 4 screws from the bottom. ...

  • Page 103: Liquid Softener

     Disconnect the external water supply from the mains.  Empty the trough area.  Unscrew the filter cup.  Take out the filter inlay.  Clean filter insert or replace if too dirty.  Install the filter cup and hand-tighten it. NOTE Check for leaks as soon as water is applied again.
  • Page 104  Remove the console with the cover from the liquid sof- tener container. 1 Container liquid softener 2 Fastening clips 3 Level switch liquid softener 4 Dosing valve  Unclip the container from the anchor.  Empty the container, contain liquid softener. 1 Bracket 2 Dosing valve ...

  • Page 105: Swimmer Tank

    1 Level switch liquid softener  Pull the level switch out of the container bottom.  If necessary, exchange the level switch. Observe the cable run with the electrical connection! NOTE If spare parts are required, the container is available com- plete with the level switch.
  • Page 106  Unscrew the screws. 1 Inlet hose 2 Connection float valve  Detach the supply hoses from the two float valves.  Lift the locking catch on the float valve.  Push out the float valve. 1 Swimmer valve English 5.906-736.0 Rev. 00 (07/15)

  • Page 107: Exchanging The Level Switch / Temperature Sensor

    11.7.2 Exchanging the level switch / temperature sensor Illustration with dismantled float valves.  Unscrew the holder for the temperature sensor and lev- el switch in the lower area of the float container. 1 Support 2 Temperature sensor water in the float container (green cable) 3 Level switch float container (grey cable) Level switch float container...

  • Page 108: Heat Exchanger (16Kw)

    View with opened maintenance flap on the left 1 Thermostat switch water temperature in the float con- tainer 2 Screw  Unscrew the maintenance flap on the left.  Upon changing the temperature sensor: disconnect it at the thermostat switch. ...

  • Page 109: Clean Heat Exchanger

    11.8.2 Clean heat exchanger  Lift the trailer, disassembly of both PVC protective plates at the bottom.  Uninstall the high-pressure line from the safety block to the booster heater.  Unscrew the holder of the heat exchanger from the bot- tom plate.

  • Page 110: Check Oil Level And Refill Oil

    1 Pump casing 2 Oil filling nozzle 3 Overflow 4 Speed control idle mode / full load 5 Pressure switch 6 Valve set frost protection 7 Pump head 8 Outlet return line to the float container 9 Outlet high pressure NOTE The following pictures apply exemplarily! If the various pump types differ, the relevant shots are illustrated.

  • Page 111: Oil Change In High Pressure Pump

    11.9.2 Oil change in high pressure pump NOTE CAUTION Dispose of the waste oil according to the local provisions. Risk of burns when draining hot oil. Replace the oil while the motor has operating temperature. Align the appliance horizontally prior to the oil change. Pump types 13/20 and 17/20 1 Pump casing 2 Cover filling hole...

  • Page 112: Cleaning The Fine Filter

    11.9.3 Cleaning the fine filter 1 Union nut water hose 2 Fine filter 3 Lock nut filter casing  Unpressurize the appliance.  Open the union nut of the water supply, remove hose. NOTE It is recommended to dismantle the front plate to provide better access to the lower area of the fine filter.
  • Page 113 1 Fine filter 2 Aperture NOTE Make sure not to lose the orifice plate in the inlet of the fine filter! English 5.906-736.0 Rev. 00 (07/15)

  • Page 114: Check And Adjust The Speed Control Full Load / Idle Mode

    11.9.4 Check and adjust the speed control full load / idle mode 1 Speed control 2 Bowden cable to the motor  Open the screw of the piston. NOTE When the screw is loosened, the spring pushes onto the screw head. ...

  • Page 115: Replacing Wear Parts Of The Overflow Device

    1 Bowden cable from the piston to the high-pressure pump 2 Deflection 3 Speed control motor  If necessary, change the entire unit.  Detach the Bowden cable at the deflection.  Pull the piston with the Bowden cable out of the casing. ...
  • Page 116  Unscrew the lower casing part of the overflow device from the pump. NOTE Ensure that also the valve seat with the O-ring is removed from the pump casing; remove by means of pliers if neces- sary. Wear parts: 1 Casing with taper seat 2 Spring 3 Valve seat with O-ring ...

  • Page 117: Changing The Valve Frost Protection

    11.9.6 Changing the valve frost protection  Disconnect the hose from the valve box.  Unscrew the valve box for the frost protection from the pump. ATTENTION Risk of damage to equipment. Observe torque of 35- 40 Nm, as otherwise the casing can get damaged. NOTE Ensure that the valve seat underneath is not unscrewed, too.

  • Page 118: Changing The Pressure Switch

    Components in the disassembled condition 1 O ring 2 O ring 3 Valve 4 Spring 11.9.7 Changing the pressure switch 1 Holding bow 2 Pressure switch  Push the retaining bracket to the front.  Remove the pressure switch towards the top. 1 Valve casing ...

  • Page 119: Replace The Suction Valves

     Remove the valve from the pump seat. Components in the disassembled condition 1 Piston with tappet 2 Spring 3 Valve casing 4 Diaphragm 11.9.8 Replace the suction valves.  Switch off the operating mode switch and secure it against restart. ...
  • Page 120  Pull out the suction valves using special pliers (4.901- 602.0). If the valve seat gets stuck in the pump head, you can pull it out using the drawing tool (6.815-013.0). Suction/pressure valve setup English 5.906-736.0 Rev. 00 (07/15)
  • Page 121  Press in the new suction valves (lubricate the O-rings with silicon grease). NOTE Ensure the correct alignment of the valve crosspieces.  Insert the lockscrews of the suction valves and tighten them to 40 Nm (grease O-rings). English 5.906-736.0 Rev. 00 (07/15)

  • Page 122: Replace Pressure Valves

    11.9.9 Replace pressure valves  Switch off the operating mode switch and secure it against restart.  Shut off water supply.  Take the pressure off the high pressure system by opening the gun. Check the pressure ratio of the high pressure system on the pump manometer.
  • Page 123  Press in the new pressure valves manually (grease the O-rings). NOTE Ensure the correct alignment of the valve crosspieces. English 5.906-736.0 Rev. 00 (07/15)

  • Page 124: Replace The Overflow Valve

    11.9.10 Replace the overflow valve 1 Connection high pressure 2 Connection of frost protection valve 3 Connection return flow (bypass)  Disconnect the connections at the overflow valve. 1 Banjo bolt pressure side 2 Banjo bolt bypass  Evenly unscrew the banjo bolts on the overflow valve and remove the overflow valve.

  • Page 125: Cylinder Head, Uninstall

    11.9.11 Cylinder head, uninstall  Unscrew the overflow or slightly loosen the hollow screws that secure the overflow.  Unscrew the 8 screws from the pump head.  Carefully pull out the cylinder head using both hands. ATTENTION Do not cant during the removal as the ceramic sleeves could break! ...
  • Page 126 Pump types 9/50 and 13/35 1 Screwed sealing plug 2 O ring 3 Seal kit 4 Bushing 5 Seal kit  Insert the new washers into the screw insert.  Insert and press in the new seal package into the cylin- der head using the installation sleeve and the driver.

  • Page 127: Replace The Oil Rings

     Tighten the stopping bushings using the special tool 5.511-001.0 to 50 Nm.  Assemble the cylinder head in the reverse sequence. 11.9.12 Replace the oil rings  Disconnect crankshaft casing from the intermediate gear of the diesel engine NOTE For details see further back in the chapter.
  • Page 128  Mark the bearing shells with the piston rod so that they do not get interchanged during assembling. NOTE Every bearing cup must later be refastened to the same piston rod with the same alignment. Therefore, mark the components prior to removal. ...
  • Page 129  Dismantle both flange bearings on the pump casing; in order to do so, the 4 screws on the flange must be loos- ened respectively. At the end, you can pull out the flange bearings. Tightening torque 20 Nm. English 5.906-736.0 Rev. 00 (07/15)
  • Page 130 NOTE With the 200bar pumps tapered roller bearings are used. The axial load is adjusted on the open bearing side by means of spacer discs (adjustment is performed by the factory!). Ensure that the relevant spacer disc(s) are con- clusively reinstalled! ...

  • Page 131: Replace The Piston

     Unscrew the piston screws using an Allen wrench and pull out the piston rod from the rear. 1 Special pliers to remove the oil seal rings 2 Oil seal ring 3 Pump casing  Remove 3 oil seals from the pump housing with the special pliers.
  • Page 132  After replacing the oil groove rings, the piston rod is pushed back into the straight pushing guide and the pistons are screwed on (observe tightening torque, see in the back). Clean the threads before screwing, apply screw securing adhesive (soluble) to the threading of the piston.
  • Page 133 1 Oil fill container 2 Pump casing 3 Crankshaft bearing cover with crankshaft bearing and O-ring 4 Crankshaft housing cover with O-ring 5 Piston rod bottom parts, marked 6 Crankshaft bearing with flange, O-ring and shaft seal 7 Crankshaft 8 Piston rod top parts, marked 9 Push bar English 5.906-736.0 Rev.
  • Page 134  Now, the crankshaft can be put back in. Fixate it with flange bearings. Then screw the bearing cups into the piston rod Nm = 8...9.  Assemble back the parts in the reverse sequence.  Fill in oil up to the sight glass. Oil fill volume and type Pump gear 350/500bar pump: 1.3ltr SAE 90...

  • Page 135: Safety Block

    11.10 Safety block 11.10.1 Safety block for 200bar devices Safety block 200bar 1 Adjustment screw 2 Safety valve 3 Clamping bracket 4 Reed switch 5 High pressure pipe to the on-demand heater 6 Screwed sealing plug NOTE Only when changing the safety block, a complete removal is required.
  • Page 136  Disconnect the high-pressure outlet to the booster heater.  Unscrew the screw for fastening the safety block form the console, remove the block. Clean / change the reed switch for flow monitoring NOTE Observe the installation position of the reed switch on the casing: The marking on the reed switch points centrally to the casing! 1 Reed switch...

  • Page 137: Safety Block For 350/500Bar Devices

     Loosen screws.  Remove and clean magnetic pen. Adjust safety valve NOTE The safety valve is adjusted via the pressure increase in the system with the burner turned on, so that it limits the pressure increase to the max. permissible value (see Specifications) with the gun closed.

  • Page 138: Burner Blower With Fuel Pump

    11.11 Burner blower with fuel pump Overview 1 Continuous heater 2 Fuel pump 3 Blower lid 4 Pressure line 5 Rubber collar 6 Solenoid valve 7 Setting fuel pressure 8 Fuel line 9 Filter 10 Return 11.11.1 Change fuel filter 1 Filter ...

  • Page 139: Dismantling The Burner Blower

    View with pulled out clip. 1 Solenoid valve 2 Fuel line 3 Pressure line 4 Fuel pump 5 coupling 6 Return  Remove the pump unit with the coupling from the cas- ing.  Remove magnetic coil.  Remove the connections of the fuel line (supply), pres- sure line and return, remove lines.
  • Page 140  Carefully slide the blower unit to the back so that the branch is pulled out of the rubber cuff.  Lift the blower and put it down horizontally.  Mark the position of the air flap. 1 Screw 2 Screw for locking the air flap 3 Air flap ...
  • Page 141 1 Fan wheel 2 Screw  Open the screw at the hub.  Pull the fan wheel off. NOTE Removing the fan wheel requires some force. Carefully wobble the fan wheel all around and lever it out. 1 Fitting key ...

  • Page 142: Motor Burner Blower: Changing The Carbons

    11.11.4 Motor burner blower: Changing the carbons 1 Nut  Disconnect battery.  Loosen 2 nuts.  Remove the hood. NOTE In the original condition, these are special nuts that fasten the cover. After the first opening, it is recommended to re- place them with stop nuts.

  • Page 143: Cleaning The Air Duct

     Pull back the retaining spring.  Insert new carbon block and push it in.  Electrically connect the carbon block. 1 Protective element 2 Tensioning ring  Insert the protective element in a way that it is located under the clamping point of the clamping ring. ...

  • Page 144: Booster Heater

    11.12 Booster heater 11.12.1 Dismantling / cleaning the burner cover 1 Burner cover 2 Ignition cable 3 Flame sensor  Unscrew the holder for the flame sensor.  Remove the plug for the ignition cable. 1 Screw 2 Fuel line ...

  • Page 145: Adjusting The Ignition Electrodes

    11.12.2 Adjusting the ignition electrodes -NOTICE You need to carefully adjust the distance between the igni- tion electrodes to bring about a stronger ignition spark. Replace burnt out ignition electrodes. 1 Pressure plate 2 Fuel nozzle 3 Ignition electrodes 4 Screw 5 Burner cover 1 Connection fuel line 2 Fuel nozzle holder...

  • Page 146: Changing The Ignition Transformer

    11.12.3 Changing the ignition transformer 1 Ignition transformer 2 Screw 3 Cable connections  Remove 3 cables from the ignition transformer.  Loosen the screw.  Disconnect the ignition transformer electrically. NOTE Observe the cable run with the electrical connection! NOTE The two lower cable connections connect the ignition elec- trodes.

  • Page 147: Cleaning / Changing The Temperature Sensor Warm Water

    View with opened maintenance flap on the right 1 Screw 2 Support 3 Thermostat switch emission temperature  Unscrew the maintenance flap on the right.  Upon changing the temperature sensor: disconnect it at the thermostat switch.  Upon replacement with thermostat switch: Open screws, remove the holder and unscrew the ther- mostat switch from the holder.

  • Page 148: Dismantling The Booster Heater

    11.12.7 Dismantling the booster heater 1 Exhaust  Unscrew the burner cover.  Pull out the temperature sensor emission temperature.  Unscrew the coolant container and ignition transformer.  Unscrew the exhaust pipe from the muffler.  Uninstall the burner blower completely with the con- sole.

  • Page 149: Settings, Burner

    11.13 Settings, burner NOTE An accurate basic adjustment of the burner is only possible if the heating coil was previously thoroughly desooted and the deposits were removed. 1 Adjustment screw, fuel pressure 2 Pressure line to the burner 3 Fuel pump 4 Return hose to the fuel tank 5 Suction hose, fuel NOTE...
  • Page 150 1 Air door, air volume adjustment 2 Stop screw NOTE Adjusting the air flaps in the plus direction increases the air quantity, adjustment in the minus direction reduces the air quantity.  Measure the air pressure on the burner cover (special Measure water temperature ...

  • Page 151: High Pressure Outlet

    11.14 High pressure outlet 11.14.1 Uninstall / install high-pressure hose 1 High-pressure hose (uncoiled) 2 Hose connection  Unwind the HP hose from the hose reel.  Disconnect the hose at the hose connection. 11.14.2 Dismantling the pressure gauge 1 Screw connection 2 Manometer ...
  • Page 152 1 Safety valve 2 Pipe connection NOTE The pressure of the safety valve is permanently adjusted to 6 bar and cannot be changed.  Remove both hoses from the plug connection.  Unscrew C-coupling for the water hose. 1 Screw ...

  • Page 153: Motor

    11.15 Motor DANGER CAUTION Risk of injury! Risk of burns. Prior to working on the alternator, make sure Before carrying out any tasks on the machine, switch off the exhaust system has cooled off. the key switch and the battery switch and remove the key. Prevent inadvertent startups of the appliance during Main- tenance Procedures via third persons by attaching signs on the appliance and the spray unit.
  • Page 154 Diesel engine 1 Expansion tank motor coolant 2 Exhaust system 3 Muffler 4 Air filter 5 Starter 6 Alternator English 5.906-736.0 Rev. 00 (07/15)
  • Page 155 11.15.1 Check and top up coolant CAUTION Risk of injury! Risk of damage! The motor can overheat if there is a lack of coolant. Turn Observe the brand of antifreeze used. The mixture can the motor off immediately and let it cool down. cause a chemical reaction and hazardous substances can If the motor is so overheated, that water vapors escape, be generated.

  • Page 156: Cleaning/Replacing The Air Filter

    11.15.2 Cleaning/replacing the air filter 1 Air filter 2 Blow-out lip  Loosen the spring tension bracket, remove the cover and eliminate the dust deposits. NOTE Severely contaminated or defective filter inserts must al- ways be replaced.  Take out the filter inlay. ...
  • Page 157 11.15.3 Checking / replacing the V-belt of the alternator Check the tension of the V-belt CAUTION Risk of damage! If the V-belt is not sufficiently tensioned, this can cause an overheating of the engine and to an insufficient battery charge. Defective V-belts must be replaced immediately.

  • Page 158: Replace The Alternator

    1 Alternator 2 Screw  Slightly loosen the screw for fastening the alternator.  Move the alternator towards the motor and slacken the V-belt this way. 1 V-belt 2 Fan wheel  Remove and unthread the V-belt over the fan wheel. NOTE When installing the V-belt, position the alternator in a way that the V-belt has the relevant tension again;...

  • Page 159: Check The Oil Level On The Motor / Refill Motor Oil

    11.15.5 Replacing the starter 1 Connecting cable 2 Starter 3 Nut  Disconnect battery.  Disconnect the earth connection and the connection cable from the starter.  Open the nuts, remove the starter.  Install and electrically connect new starter. Mind the cable run! ...

  • Page 160: Perform Oil Change / Replace Oil Filter

    11.15.7 Perform oil change / replace oil filter NOTE Replace the oil while the motor has operating temperature. Align the appliance horizontally prior to the oil change. Dispose of the waste oil according to the local provisions. View from below 1 Heat exchanger 2 Oil drain screw engine The oil drain screw is located on the bottom of the motor...
  • Page 161 1 Seal  Coat the washer of the new oil filter with oil before fitting it. 1 Seal seat  Clean the seal seat and apply oil prior to installation of the new oil filter.  Screw the oil filter in finger tight. ...

  • Page 162: Change Fuel Filter

    11.15.8 Change fuel filter NOTE Collected diesel fuel must be disposed of according to lo- cal regulations. 1 Valve tap 2 Fuel filter  As a precaution, place suitable container or absorbing sheets underneath the fuel filter.  Set the valve to "OFF", for this purpose, turn the tap up- wards.

  • Page 163: Empying The Water Separator

    11.15.9 Empying the water separator NOTE Collected diesel fuel must be disposed of according to lo- cal regulations. 1 Water separator 2 Valve tap  As a precaution, place suitable container or absorbing sheets underneath the water separator.  Set the valve to "OFF", for this purpose, turn the tap up- wards.

  • Page 164: Checking The Oil Level On The Intermediate Gear And Refilling Transmission Oil

    11.15.10Checking the oil level on the intermediate gear and refilling transmission oil 1 Intermediate gear 2 Cover filling hole 3 Oil sight glass 4 Oil drain screw  Check the oil level in the intermediate gear.  If the oil level is below the oil looking glass, add oil. ...

  • Page 165: Dismantling Intermediate Gear With High-Pressure Pump From The Motor / Replacing Elastomer Ring Coupling

    11.15.12Dismantling intermediate gear with high-pressure pump from the motor / replacing elastomer ring coupling  Disconnect the high-pressure outlet and return line from the pump head.  Disconnect water supply and optionally the detergent connection from the pump head. NOTE This detergent connection is only available with the devic- es HDS 13/20 and HDS 17/20.
  • Page 166  Unscrew the screw of the front rubber buffer support. NOTE The structure with the 350/500 bar pumps is similar. 1 Drive shaft  Remove the pump with the intermediate gear from the drive shaft. NOTE If necessary, support by levering out in the recesses on the flange area of the motor plate.

  • Page 167: Removing The Intermediate Gear From The High-Pressure Pump

    11.15.13Removing the intermediate gear from the high-pressure pump NOTE The pictures are of a purely informative nature, they do not depict the situation on the mini trailer.  Drain the oil from the intermediate gear.  Unscrew 4 screws and remove the casing. ...

  • Page 168: Draining The Diesel

     Unscrew 4 screws and remove the flange from the pump unit. NOTE Ensure that no O-rings are lost! NOTE After assembly, fill oil (SAE 90) into the oil filler neck while the appliance is in a horizontal position until the oil level reaches the upper edge of the oil level indicator.

  • Page 169: Checking / Replacing The Level Sensor Fuel

    11.16.2 Checking / replacing the level sensor fuel View with opened maintenance flaps 1 Level sensor for fuel tank 2 Support 3 Nut  Unscrew both maintenance flaps.  Unscrew 2 nuts.  Unthread the holder, mind the cable while doing so. ...

  • Page 170: Clean Filter At The Detergent Suck Hose

     Check level sensor for proper function. For this purpose, set the float contact to the various fill- ing level positions on the level sensor and match it with the relevant indication on the display.  If necessary, disconnect and replace the level sensor on the control, observe cable run! NOTE If no bargraph of the fuel tank is depicted, there is a fault in...

  • Page 171: Changing The Detergent Dosing Valve

    11.17.2 Changing the detergent dosing valve 1 Dosage valve for detergent  Detach the hoses on the back of the valve (open clamp by means of pliers)  Slightly push in the catches of the valve from the back and pull off the valve towards the front. Detergent dosing valve 1 Connection from the detergent tank (labelled with "1") 2 Connection to the pump (labelled with "P")
  • Page 172 1 Valve body 2 Tappet with hexagon nut 3 Magnet coil  Open the hexagon nut on the tappet.  Pull the tappet out of the valve body.  Clean the valve body.  Clean the tappet with a soft cloth if necessary. NOTE When changing the complete solenoid valve, the hoses must be disconnected and the valve must be unscrewed...

  • Page 173: Adjustment Of The Working Pressure And The Water Volume In Combination With The Motor Speed

    11.18 Adjustment of the working pressure and the water volume in combination with the motor speed NOTE The description for adjustment is done jointly for all unit types. Deviations that must be observed with the unit types HDS 13/20 and 17/20 are listed separately. The technical data required for this is listed in Chapter 15.
  • Page 174  Open gun. With HDS 13/20 and HDS 17/20: Completely open the pressure and volume regulation on the gun (set to "+").  Set the maximum speed (+/-50 1/min) on the stop screw full load.  Secure the setting by means of a locknut. ...

  • Page 175: Speed

    1 Adjustment screw, high pressure 2 Lock nut, adjustment screw, high pressure 3 Spindle, pressure and quantity regulation 4 Housing, overflow valve Adjustment overflow device NOTE The adjustment is done with the test nozzle.  Install the test manometer (special tool) to the high- pressure connection.

  • Page 176: Care

    Care The device must always be kept in a clean condition. Main- tenance cleaning must be performed periodically by the operator or service personnel considering the state of ATTENTION cleanliness. Risk of damage to equipment. When cleaning the motor The exterior cleaning can be performed with a high-pres- compartment, ensure that electrical components, plug sure device, however, a minimum distance of 1-2 metres connections and the air filter are spared widely.
  • Page 177 1 Water pipes 2 High pressure hose  Disconnect the trigger gun from the high-pressure hose.  Connect the high-pressure hose to the frost protection inlet.  Disconnect the water hose from the water supply.  Connect the water hose to the return flow of the frost protection.

  • Page 178: Removing The Soot From The Heating Coil

    12.2 Removing the soot from the heating coil DANGER Risk of chemical burns from strong brine! Wear safety gog- gles and protective gloves. Observe the safety instructions for the detergent!  Let the device warm up in the burner operation, then switch it off.

  • Page 179: Troubleshooting

    Troubleshooting 13.1 Faults with display The malfunction is shown on the display as follows. 1 Malfunction no. 2 Indication, for how many hours the malfunction has oc- curred NOTE Further information about the test of the sensor technology can be found in Chapter 9.2.1. Display Possible cause ERROR 1...
  • Page 180 Display Possible cause ERROR 9* Thermostat switch or temperature switch defective. Emission temperature Burner has been wrongly set. Heating coil is sooted. Check heating coil for internal deposits. ERROR 10* Sensor defective / cable break / short circuit. Temperature sensor booster heater ERROR 11* Nozzle holder is soiled.

  • Page 181: Faults Without Display On The Console

    13.2 Faults without display on the console Fault Possible cause Water pressure too low / Check / clean the water filter. The device does not reach the full Check water supply volume, increase if necessary. pressure Check the water quantity in the two 250 l tanks Open stop cock water tanks.

  • Page 182: Troubleshooting Yanmar Diesel Engine

    13.3 Troubleshooting Yanmar diesel engine English 5.906-736.0 Rev. 00 (07/15)

  • Page 183: Maintenance Plans

    Maintenance plans 14.1 Inspection and maintenance checklist NOTE The current inspection and maintenance checklist 5.965- 663.0 is recorded in the DISIS. 14.2 Maintenance plan trailer English 5.906-736.0 Rev. 00 (07/15)
  • Page 184 English 5.906-736.0 Rev. 00 (07/15)

  • Page 185: Maintenance Plan Yanmar Diesel Engine

    14.3 Maintenance plan Yanmar diesel engine English 5.906-736.0 Rev. 00 (07/15)

  • Page 186: Technical Specifications

    Technical specifications HDS 9/50 DeTr1 HDS 13/35 HDS 17/20 HDS 13/20 DeTr1 DeTr1 DeTr1 Internal combustion engine Idling speed 1600 1600 1600 1600 Full load speed (gun opened) 3100 3100 3100 2700 Amount of oil Oil grade 15 W40 15 W40 15 W40 15 W40 Motor type...
  • Page 187 HDS 9/50 DeTr1 HDS 13/35 HDS 17/20 HDS 13/20 DeTr1 DeTr1 DeTr1 Safety valve <70,4 <48,4 <25,8 25,8 completely opened (Testing manometer) Overflow valve opening pressure 58,5 - 58,5 37,5 - 38,5 21,0 - 22,0 21,0 - 22,0 (Testing manometer) Water shortage safeguard OFF 50 - 150 50 - 150...

  • Page 188: Tightening Torques

    15.1 Tightening torques HDS 13/20 and 17/20 - high-pressure pump HDS 13/20 and 17/20 - overflow device English 5.906-736.0 Rev. 00 (07/15)
  • Page 189 HDS 13/20 and 17/20 - safety block English 5.906-736.0 Rev. 00 (07/15)
  • Page 190 HDS 9/50 and 13/35 - pump head English 5.906-736.0 Rev. 00 (07/15)
  • Page 191 HDS 9/50 and 13/35 - speed control HDS 9/50 and 13/35 - frost protection valve HDS 9/50 and 13/35 - overflow device English 5.906-736.0 Rev. 00 (07/15)
  • Page 192 HDS 9/50 and 13/35 - transmission HDS 9/50 and 13/35 - safety block English 5.906-736.0 Rev. 00 (07/15)

  • Page 193: Special Tools

    Special tools Special tools 4.742-025.0 Test pressure gauge 0 - 250 bar (HDS 13/20, HDS 17/20) 4.742-040.0 Test pressure gauge 0 - 800 bar (HDS 9/50, HDS 13/35) 4.901-060.0 Pressure gauge fuel pressure for measuring the pump pressure of the fuel pump at the burner cover Soot pump 6.775-001.0...
  • Page 194 Special tools 6.423-029.0 Thermometer exhaust gas measurement for measuring the exhaust gas temperature Air pressure gauge at the burner cover no Kärcher part number Recommendation: Testo 510, order number 0560 05610 Hose set: Order number 0554 0448 Measurement CO2 content in the exhaust gas of the burner no Kärcher part number Recommendation: Testo 320 or Testo 320-2-LL required accessories for both measuring devices:...
  • Page 195 Special tools 5.901-055.0 Installation mandrel for HP seals for piston D20mm (HDS 13/20, HDS 17/20) 6.815-258.0 Installation mandrel for oil seals (HDS 13/20, HDS 17/20) 6.815-209.0 Screw attachment locking screw (HDS 9/50, HDS 13/35) (Crown wrench for brass bush low-pressure seals) 5.111-128.0 Installation sleeve for piston D14mm (HDS 9/50)
  • Page 196 Special tools Oil filter wrench no Kärcher part number Recommendation: Oil filter claw HAZET 2172 6.491-361.0 Revolution counter for motor speed 6.803-003.0 Magnetic field tester for the function test of magnetic coils 6.768-004.0 Hardness indicators for measuring the overall water hardness English 5.906-736.0 Rev.

  • Page 197: Circuit Diagram

    Circuit diagram NOTE Please use the circuit diagram associated with the ma- chine. An excerpt of the circuit diagram, version 07/2015, is en- closed for your information. English 5.906-736.0 Rev. 00 (07/15)
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This manual is also suitable for:

Hds 13/35 de tr1Hds 13/20 de tr1Hds 17/20 de tr1

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