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Kärcher HDS Middle series Service Manual

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Service Manual
HDS Middle Range
1.071-..., 1.077-...
HDS 7/12, HDS 8/17, HDS 9/18, HDS 10/20
HDS Premium Range
1.071-...
HDS 12/18, HDS 13/20
Service Manual 04.2008
5.906-433.0

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  Summary of Contents for Kärcher HDS Middle series

  • Page 1 Service Manual HDS Middle Range 1.071-..., 1.077-... HDS 7/12, HDS 8/17, HDS 9/18, HDS 10/20 HDS Premium Range 1.071-... HDS 12/18, HDS 13/20 Service Manual 04.2008 5.906-433.0...
  • Page 2 HDS Middle Range / HDS Premium Range Page 2 / 127 Service Manual 04.2008...
  • Page 3 HDS Middle Range / HDS Premium Range Foreword Foreword Good service work requires comprehensive and practical training as well as clear documents. We therefore provide regular basic training and further training courses for service technicians covering our whole range of products. In addition, we produce service manuals for the most important units, which can initially be used as instructions and later for reference purposes.
  • Page 4: Table Of Contents

    Contents HDS Middle Range / HDS Premium Range Contents Equipment Features .................... 6-9 Technical Features ....................6 View from the front....................7 View from the rear (unit without hose reel) ..............8 View from the rear (unit with hose reel) ..............9 Unit Function ....................10-62 Control panel ....................
  • Page 5 HDS Middle Range / HDS Premium Range Contents Contents 3.1.10 Operating hours ..................... 74 3.1.11 Handgun switchings since the handgun service ........... 75 3.1.12 Handgun services ....................76 3.1.13 Handgun switchings since initial operation ............77 3.1.14 Operating time of the burner since the burner service .......... 78 3.1.15 Burner services .....................
  • Page 6: Equipment Features

    Equipment Features HDS Middle Range / HDS Premium Range 1.1 Technical Features General: Electronics: Mobile hot water high-pressure cleaner with – Program switch. various power ratings for commercial use. – Flame sensor (optional). – High-performance burner with vertical heat- – Water temperature control with temperature ing coil and continuous ignition.
  • Page 7: View From The Front

    HDS Middle Range / HDS Premium Range Equipment Features 1.2 View from the front 1 Push handle (2x) 11 Transport wheel (2x) 2 Cover, top storage compartment 12 Transport handle 3 Safety latch, softgrip easy-press 13 Swivel castor handgun 14 Swivel castor with parking brake* 4 Rotary control 15 Chassis 5 Trigger lever...
  • Page 8: View From The Rear (Unit Without Hose Reel)

    Equipment Features HDS Middle Range / HDS Premium Range 1.3 View from the rear (unit without hose reel) 1 Indicator lights 11 Chassis 2 Program switch (Q1) 12 Water connection with fine water filter 3 Adjustment, water temperature 13 Tread 4 Spray lance holder, RH 14 Cap, cleaning agent tank 1 5 Cap, scale inhibitor tank...
  • Page 9: View From The Rear (Unit With Hose Reel)

    HDS Middle Range / HDS Premium Range Equipment Features 1.4 View from the rear (unit with hose reel) 1 Indicator lights 12 High-pressure hose 2 Program switch (Q1) 13 Chassis 3 Adjustment, water temperature 14 Water connection with fine water filter 4 Spray lance holder, RH 15 Tread 5 Cap, scale inhibitor tank...
  • Page 10: Unit Function

    Unit Function HDS Middle Range / HDS Premium Range 2.1 Control panel 1 Indicator LED 0, pump (red) 13 Program switch „Eco Mode*“ position 2 Indicator LED 1, rotational direction (red) 14 Program switch „Hot Water/Steam Ope- ration“ position 3 Indicator LED 2, operation (green) 15 Program switch 4 Indicator LED 3, fuel (yellow) 16 Adjustment, water temperature...
  • Page 11 HDS Middle Range / HDS Premium Range Unit Function 2.1 Control panel Functions of the LED displays in operating mode LED No. Symbol Activity Meaning / Action Insufficient oil. Check/top up the oil level of the high-pressure 1 x flashing pump.
  • Page 12 Unit Function HDS Middle Range / HDS Premium Range 2.1 Control panel Functions of the LED displays in operating mode LED No. Symbol Activity Meaning / Action light up Scale inhibitor level switch detects empty or units on the tag* of the scale inhibitor bottle have been used up. 1 x flashing 5 hours after-running time have expired, burner is blocked.
  • Page 13 HDS Middle Range / HDS Premium Range Unit Function 2.1 Control panel Template for numerical value displays The template below can be placed on the LED displays of the control panel for improved recognition of the numerical value displays in the service functions. Template for placing on the control panel Service Manual 04.2008 Page 13 / 127...
  • Page 14 Unit Function HDS Middle Range / HDS Premium Range 2.1 Control panel Page 14 / 127 Service Manual 04.2008...
  • Page 15: Control Panel, View From Inside

    HDS Middle Range / HDS Premium Range Unit Function 2.1.1 Control panel, view from inside 1 Service switch and adjustment, scale 7 Mains cable inhibitor metering 8 Adjustment, water temperature 2 Control circuit transformer (T1) 9 Program switch 3 Current transformer 10 Printed circuit board, control panel 4 Fuse 2.0 AT (6.644-052) for control 11 Cleaning agent metering valve...
  • Page 16: Printed Circuit Board, Control Panel

    Unit Function HDS Middle Range / HDS Premium Range 2.1.2 Printed circuit board, control panel DIP switches (8) 1 Connection, cleaning agent tank 1 level sensor All DIP switches are set to „OFF“ in the factory. The following functions can be activated by 2 Connection, cleaning agent tank 2 level changing these settings: sensor...
  • Page 17: Control Panel With Display (Hds 13/20 Only)

    HDS Middle Range / HDS Premium Range Unit Function 2.2 Control panel with display (HDS 13/20 only) 1 Display 8 Metering valve, cleaning agent 2 Program switch „OFF“ position 9 Metering range, cleaning agent 1 3 Program switch „Cold Water Operation“ 10 Metering range, cleaning agent 2 position 11 Pressure gauge...
  • Page 18: Status Displays

    Unit Function HDS Middle Range / HDS Premium Range 2.2.1 Status displays Note Status and maintenance displays are displayed consecutively, like in a slide show. Each image is displayed for 3 seconds. The fault displays remain until the unit is switched off. Display Explanation Note...
  • Page 19: Error Messages

    HDS Middle Range / HDS Premium Range Unit Function 2.2.3 Error messages Display Explanation Note Invert phase in the commuta- Rotating field incorrect. ting pole plug Switch off unit and Motor thermal contact (WSK) in the motor has actuated. let the motor cool down. Check mains connection.
  • Page 20: Error Messages With Service Requirement

    Unit Function HDS Middle Range / HDS Premium Range 2.2.4 Error messages with service requirement Note One display is used here for several faults. It may be possible to localise the fault by reading out the fault memory. Display Explanation Note Check low-water protection.
  • Page 21: Dgt Setting

    HDS Middle Range / HDS Premium Range Unit Function 2.2.5 DGT setting Display Explanation Note Scale inhibitor metering set according to the water hardness. This display appears for 3s if the scale inhibitor setting is changed. Important! Service mode position. After switching back on the unit will be in Service mode.
  • Page 22: Storage Compartments

    Unit Function HDS Middle Range / HDS Premium Range 2.3 Storage compartments Top storage compartment Bottom storage compartment (in unit without hose reel only) 1 Cover, top storage compartment 9 Storage compartment, bottom 2 Storage, operating instructions 10 Bottle holder for round scale inhibitor bottle or cleaning agent bottle 3 Retaining screw, top storage compartment (4x)
  • Page 23: Unit Cover

    HDS Middle Range / HDS Premium Range Unit Function 2.4 Unit cover Open unit cover and remove if necessary – To open the unit cover (2), use a screwdriver (4) to push down the locking device (3) and to turn it through 90° to the left. –...
  • Page 24: View From The Right, Unit Cover Removed

    Unit Function HDS Middle Range / HDS Premium Range 2.5 View from the right, unit cover removed 1 Fuel line to the continuous-flow heater 12 Housing, fine water filter 2 Electrical box, motor 13 SDS hose, to the safety block 3 Burner fan 14 Splashback, safety valve 4 Oil refill container, pump...
  • Page 25: Service Switch

    HDS Middle Range / HDS Premium Range Unit Function 2.6 Service switch Adjusting the water hardness The scale inhibitor metering (RM 110/111) is adjusted according to the local water hardness (ask the local water supply company or determine using a hardness tester 6.768-004). Water hardness Setting °dH...
  • Page 26: Fuel Tank

    Unit Function HDS Middle Range / HDS Premium Range 2.7 Fuel tank 1 Cap, fuel tank 2 Seal, fuel tank cap 3 Tank inlet, fuel tank with prefilter 4 Fuel filter 5 Level sensor, fuel tank 6 Fuel tank (diesel, heating oil) Fuel tank (diesel, heating oil) Fuel tank (diesel, heating oil) Level sensor, fuel tank...
  • Page 27: Scale Inhibitor

    HDS Middle Range / HDS Premium Range Unit Function 2.8 Scale inhibitor 2.8.1 Metering via tank (export version) The scale inhibitor is metered in accordance with the setting at the Service switch. The setting is described under 2.6 Service switch. Metering takes place in Program switch position „Eco“...
  • Page 28 Unit Function HDS Middle Range / HDS Premium Range 2.8 Scale inhibitor 2.8.2 Metering via RFID (European version) The scale inhibitor is metered in accordance with the setting at the Service switch. The setting is described under 2.6 Service switch. Metering takes place in Program switch position „Eco“...
  • Page 29 HDS Middle Range / HDS Premium Range Unit Function 2.8 Scale inhibitor How the RFID works RFID (Radio Frequency Identification) means identification with the help of high frequency. Underneath the label (4) on the scale inhibitor bottle there is a transponder (microchip with antenna, also called a tag) (5).
  • Page 30: Float Tank

    Unit Function HDS Middle Range / HDS Premium Range 2.9 Float tank Float tank The float tank (2) is integrated in the chassis. It is located on the right-hand side, underneath the scale inhibitor tank. The float tank uniformly supplies the pump with water.
  • Page 31: Cleaning Agent Tank 1

    HDS Middle Range / HDS Premium Range Unit Function 2.10 Cleaning agent tank 1 Cleaning agent tank 1 The cleaning agent tank 1 (1) is located in the rear part of the chassis. Suction hose The retaining plug with suction hose (3) connection is located between the continuous flow heater and the bottom storage compartment or the hose reel.
  • Page 32: Cleaning Agent Tank 2

    Unit Function HDS Middle Range / HDS Premium Range 2.11 Cleaning agent tank 2 Cleaning agent tank 2 The cleaning agent tank 2 (1) is located in the right-hand part of the chassis. Suction hose The retaining plug with suction hose (3) connection is located above the right-hand transport wheel.
  • Page 33: Motor (Air-Cooled)

    HDS Middle Range / HDS Premium Range Unit Function 2.12 Motor (air-cooled) Oil drain plug The oil drain plug is located on the underside of the pump housing. 1 Electrical box, motor 2 Burner fan 3 Fuel pump 4 Solenoid valve, fuel pump 5 Fan, motor cooling 6 Motor retainer, LH (2x) 7 Motor retainer, RH (2x)
  • Page 34 Unit Function HDS Middle Range / HDS Premium Range 2.12 Motor (air-cooled) 8 Shaft seal, motor shaft 9 Motor bearing, front (A bearing) 10 Swash plate with thrust ball bearing 11 Retaining screw, swash plate 12 Oil drain plug 13 Cleaning agent intake 14 Suction side, pump 15 Suction valve 16 Piston...
  • Page 35: Electrical Box, Air-Cooled Motor

    HDS Middle Range / HDS Premium Range Unit Function 2.13 Electrical box, air-cooled motor 1 Earth point 9 Connection, oil level sensor 2 Terminal strip 10 Connection, motor thermal contact 3 Earth connection, motor housing 11 Connection, control panel printed circuit board 4 Motor contactor (K1) 12 Connection, fuel solenoid valve...
  • Page 36: Motor (Water-Cooled)

    Unit Function HDS Middle Range / HDS Premium Range 2.14 Motor (water-cooled) Oil drain plug The oil drain plug is located on the underside of the pump housing. 1 Electrical box, motor 2 Burner fan 3 Cooling coil, motor cooler 4 Fuel pump 5 Solenoid valve, fuel pump 6 Motor retainer, LH (2x)
  • Page 37: Motor (Water-Cooled)

    HDS Middle Range / HDS Premium Range Unit Function 2.14 Motor (water-cooled) 10 9 8 Shaft seal, motor shaft 9 Motor bearing, front (A bearing) 10 Retaining screw, swash plate 11 Swash plate 12 Guide shoe 13 Oil drain plug 14 Cleaning agent intake 15 Suction side, pump 16 Suction valve...
  • Page 38: Electrical Box, Water-Cooled Motor

    Unit Function HDS Middle Range / HDS Premium Range 2.15 Electrical box, water-cooled motor 1 Earth point 8 Connection, oil level sensor 2 Earth connection, motor housing 9 Connection, control panel printed circuit board 3 Motor contactor (K1) 10 Connection, motor thermal contact 4 Interference suppression filter 11 Connection, fuel solenoid valve 5 Printed circuit board, motor distributor...
  • Page 39: Pump

    HDS Middle Range / HDS Premium Range Unit Function 2.16 Pump 1 Handle, pressure and flow control valve 8 Locking clamp, „OFF“ pressure switch 2 Screw plug, pressure side (3x) 9 Pressure switch, „OFF“ 3 Pump head screw (4x) 10 SDS hose, to the safety block 4 Pump head 11 Pressure switch, „ON“...
  • Page 40: Safety Block

    Unit Function HDS Middle Range / HDS Premium Range 2.17 Safety block 1 Connection cable, reed switch 2 Screw plug, low-water protection 3 Clamp holder, reed switch 4 Reed switch, low-water protection 5 High-pressure pipe to the continuous flow heater 6 Connection hose, pressure gauge 7 Safety block with water strainer 8 SDS hose, from the high-pressure pump...
  • Page 41 HDS Middle Range / HDS Premium Range Unit Function 2.17 Safety block 1 Connection cable, reed switch 10 Moulded part, ball guide 2 Screw plug, low-water protection 11 Water outlet, safety valve 3 Spring 12 Adjusting screw with drillhole, safety valve 4 Clamp holder, reed switch 13 Spring, safety valve...
  • Page 42: Safety Block

    Unit Function HDS Middle Range / HDS Premium Range 2.17 Safety block Safety valve Low-water protection and dry running protection If the pressure switch or overflow valve are defective, the safety valve feeds the whole flow The low-water protection prevents the burner rate of the pump to the float tank and therefore from switching on if there is no or insufficient protects the unit and accessories against...
  • Page 43: Burner Fan With Fuel Pump

    HDS Middle Range / HDS Premium Range Unit Function 2.18 Burner fan with fuel pump 1 Return to the fuel tank 2 Pressure line to the burner 3 Screw, fan cover, inner section (4x) 4 Fan cover, inner section 5 Fuel line (inlet) from the fuel tank 6 Adjustment, fuel pressure 7 Fuel pump 8 Continuous-flow heater...
  • Page 44: Burner Fan With Fuel Pump

    Unit Function HDS Middle Range / HDS Premium Range 2.18 Burner fan with fuel pump Fuel pump The fuel pump (2) is directly connected to the motor shaft via the coupling (6) and the impeller (7). It pumps fuel from the tank and back again via the return, even during cold water operation.
  • Page 45: Continuous-Flow Heater

    HDS Middle Range / HDS Premium Range Unit Function 2.19 Continuous-flow heater 1 Capillary tube, exhaust temperature 8 Ignition cable limiter 9 Connection cable, ignition transformer 2 Earth connection, burner 10 Ignition transformer 3 Cover, continuous-flow heater 11 Screw, continuous flow heater cover (3x) 4 Screw, burner (3x) 12 Fuel line, from the fuel pump 5 Latch, unit cover...
  • Page 46 Unit Function HDS Middle Range / HDS Premium Range 2.19 Continuous-flow heater Page 46 / 127 Service Manual 04.2008...
  • Page 47 HDS Middle Range / HDS Premium Range Unit Function 2.19 Continuous-flow heater 1 Ignition electrodes The water from the high-pressure pump enters the internal heating coil winding (8) from 2 Fuel nozzle underneath, is heated as it flows through and 3 Boiler base exits downwards again from the external heating 4 Boiler inlet...
  • Page 48: Burner

    Unit Function HDS Middle Range / HDS Premium Range 2.20 Burner 1 Connection, pressure line for fuel 2 Inspection glass, flame monitoring system 3 Connection, ignition electrode (2x) 4 Burner cover 5 Fuel nozzle 6 Ignition electrode 7 Baffle plate Burner, view from above Burner, removed, view from below Fuel nozzle and ignition electrodes...
  • Page 49: Burner

    HDS Middle Range / HDS Premium Range Unit Function 2.20 Burner 3.5 mm +/- 0.5 3.0 mm +/- 0.5 1 Ignition electrodes Ignition electrodes 2 Burner cover A strong ignition spark is formed between the two ignition electrodes (1) ensuring that the 3 Fuel nozzle injected fuel is safely and reliably ignited.
  • Page 50: Outlet, Continuous-Flow Heater

    Unit Function HDS Middle Range / HDS Premium Range 2.21 Outlet, continuous-flow heater 1 Baseplate 6 Connection cable, temperature sensor 2 Outlet, continuous-flow heater 7 Inlet, continuous flow heater 3 Temperature sensor, hot water outlet 8 Bottom, continuous flow heater 4 Clamp holder 9 Pressure line, from the safety block 5 Chassis...
  • Page 51: Softgrip Easy-Press Handgun

    HDS Middle Range / HDS Premium Range Unit Function 2.22 Softgrip easy-press handgun When the trigger lever (3) is pressed, the valve 1 Safety latch piston (11) presses the valve ball (10) downwards 2 Handgun cover against the spring (9). The water can flow from 3 Trigger lever the hose (4) through the handgun into the spray 4 High-pressure hose...
  • Page 52: Pressure And Flow Control Valve With Rotary Control

    Unit Function HDS Middle Range / HDS Premium Range 2.23 Pressure and flow control valve with rotary control The pressure and flow control valve is designed as a rotary control between the handgun and spray lance. There are two ceramic discs (1, 2) inside the high-pressure duct.
  • Page 53: Functional Diagram, Pressure Operation

    HDS Middle Range / HDS Premium Range Unit Function 2.24 Functional diagram, pressure operation Service Manual 04.2008 Page 53 / 127...
  • Page 54: Functional Diagram, Pressure Operation

    Unit Function HDS Middle Range / HDS Premium Range 2.24 Functional diagram, pressure operation 1 Cleaning agent tank 1 30 Exhaust connecting sleeve 2 Cleaning agent suction hose with filter 31 Exhaust temperature sensor 32 Adjustment, water temperature 3 Level sensor, cleaning agent tank 1 (optional) 33 Printed circuit board 4 Cleaning agent suction hose with filter...
  • Page 55: Functional Diagram, Suction Feed Operation

    HDS Middle Range / HDS Premium Range Unit Function 2.25 Functional diagram, suction feed operation Service Manual 04.2008 Page 55 / 127...
  • Page 56: Functional Diagram, Suction Feed Operation

    Unit Function HDS Middle Range / HDS Premium Range 2.25 Functional diagram, suction feed operation 1 Cleaning agent tank 1 44 Solenoid valve, scale inhibitor 2 Cleaning agent suction hose with filter 45 Level sensor, scale inhibitor tank 46 Scale inhibitor tank 3 Level sensor, cleaning agent tank 1 (optional) 47 Float valve...
  • Page 57: Pressure And Flow Control Valve Function

    HDS Middle Range / HDS Premium Range Unit Function 2.26 Pressure and flow control valve function 1 Threaded stud, max. pressure 10 Cleaning agent supply with non-return adjustment valve 2 Lock nut, threaded stud 11 Suction bridge with water connection 3 Spindle, half-load 12 Sleeve with throttle bore 13 Pressure switch, „OFF“...
  • Page 58: Pressure And Flow Control Valve Function

    Unit Function HDS Middle Range / HDS Premium Range 2.26 Pressure and flow control valve function 2.26.1 Pressure and flow control valve, manually using handle The pressure and flow control valve with the handle (see page 104, Item 1) is used to relieve the motor during primarily part-load operation.
  • Page 59: Pressure Switch Function

    HDS Middle Range / HDS Premium Range Unit Function 2.27 Pressure switch function 0 volt 1 High-pressure outlet (unpressurised) 2.27.1 Unit is switched off When the unit is switched off and the handgun is 2 Pressure gauge (unpressurised) open, the system is unpressurised and off-load. 3 Non-return valve (closed) Both pressure switches (7) and (11) as well as 4 Rotary knob...
  • Page 60 Unit Function HDS Middle Range / HDS Premium Range 2.27 Pressure switch function 24 volt 1 High-pressure outlet, operating pressure 2.27.2 The unit is switched on and the handgun opened 2 Pressure gauge, operating pressure After switching on the unit with the handgun open 3 Non-return valve (open) the motor contactor tightens and closes the 4 Rotary knob...
  • Page 61 HDS Middle Range / HDS Premium Range Unit Function 2.27 Pressure switch function 24 volt 1 High-pressure outlet, switch-off pressure 2.27.3 Handgun is closed When the handgun is closed a short-term 2 Pressure gauge, switch-off pressure overpressure occurs in the system. This causes 3 Non-return valve (closed) the overflow valve (5) to open and the whole 4 Rotary knob...
  • Page 62: Unit Function

    Unit Function HDS Middle Range / HDS Premium Range 2.27 Pressure switch function 24 volt 1 High-pressure outlet (unpressurised) 2.27.4 Handgun is reopened with unit switched on 2 Pressure gauge (unpressurised) As soon as the handgun is opened, the pressure 3 Non-return valve (closed) enclosed between the non-return valve (3) and 4 Rotary knob...
  • Page 63: Basic Settings And Service Procedures

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1 Service functions with LED display Service mode If the Service switch is in the „Service“ position when the unit is switched on, the unit’s Service mode is activated (pump does not run). Selecting the service functions The available service functions are selected via the water temperature setting (1).
  • Page 64: Adjusting The Stopping Behaviour

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.1 Adjusting the stopping behaviour Setting Function LED display Meaning 30 °C ON30MIN Behaviour of the unit Unit switches off after 30 minutes’ after minutes’ continuous operation. continuous operation. Setting is saved.
  • Page 65: Flame Sensor Brightness Value

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.3 Flame sensor brightness value Measured value Function LED display Meaning 45 °C LDRTEST Display of the brightness Numerical value „0“ value measured by the flame sensor. The value is displayed by the LEDs, digit for digit, whereby each LED Numerical value „1“...
  • Page 66: Rfid Query

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.4 RFID query Setting Function LED display Meaning 45 °C RFIDONOFF Info on the printed circuit Unit with RFID „SET“ board, whether the unit equipped with metering via RFID or not.
  • Page 67: Testing The Water Temperature Setting And Program Switch

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.6 Testing the water temperature setting and program switch Setting Function LED display Meaning 55 °C ENCPROGTEST This function can be 30 °C used to test the program switch and the regulator water temperature setting.
  • Page 68 Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.6 Testing the water temperature setting and program switch Setting Function LED display Meaning 55 °C 80 °C 85 °C 90 °C 95 °C 100 °C 112 °C 125 °C 140 °C 155 °C...
  • Page 69 HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.6 Testing the water temperature setting and program switch Setting Function LED display Meaning 55 °C ENCPROGTEST The test for the Program Program switch „Cold“ position switch is started by actuating the Inching function of the Service switch again (continue...
  • Page 70: Testing The Service Switch

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.7 Testing the Service switch Setting Function LED display Meaning 60 °C ENCDGTTEST Display of the Service Service switch „OFF“ position switch position. Service switch „1“ position Service switch „2“ position Service switch „3“...
  • Page 71: Testing The Sensors

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.8 Testing the sensors Setting Function LED display Meaning 65 °C INPUTTEST This function can be Oil level sensor closed (float at top) used to display the states of the individual sensors.
  • Page 72: Fault Memory

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.9 Fault memory Fault types Function LED display Meaning 70 °C ERRORS This function is used to Overvoltage detected in Trans- read out the fault former 1. memory. The faults are displayed in 2 steps: Undervoltage detected in Trans-...
  • Page 73: Fault Memory

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.9 Fault memory Fault types Function LED display Meaning 70 °C Temperature sensor fault. Short circuit or cable break. Flame sensor detects no or too little light. Flame sensor detects light. RFID read-write electronics are defective.
  • Page 74: Operating Hours

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.10 Operating hours Value Function LED display Meaning 75 °C STUNDENPWR Display of the operating Numerical value „0“ time (unit switched on) in hours. The value is displayed by the LEDs, digit for digit, whereby each LED Numerical value „1“...
  • Page 75: Handgun Switchings Since The Handgun Service

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.11 Handgun switchings since the handgun service Value Function LED display Meaning 80 °C SI_PISTOLE Display of the handgun Numerical value „0“ switchings since the last time the handgun was serviced.
  • Page 76: Handgun Services

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.12 Handgun services Value Function LED display Meaning 85 °C SCTR_PISTOLE Handgun service Numerical value „0“ display. The value is displayed by the LEDs, digit for digit, whereby each LED stands for a numerical Numerical value „1“...
  • Page 77: Handgun Switchings Since Initial Operation

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.13 Handgun switchings since initial operation Value Function LED display Meaning 90 °C TOTALPISTOLE Display of the handgun Numerical value „0“ switchings since initial operation of the unit. The value is displayed by the LEDs, digit for digit, whereby each LED...
  • Page 78: Operating Time Of The Burner Since The Burner Service

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.14 Operating time of the burner since the burner service Value Function LED display Meaning 95 °C SI_BRENNER Display of the burner’s Numerical value „0“ operating time in hours since the burner was last serviced.
  • Page 79: Burner Services

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.15 Burner services Value Function LED display Meaning 100 °C SCTR_BRENNER Burner service display. Numerical value „0“ The value is displayed by the LEDs, digit for digit, whereby each LED stands for a numerical value from 0 to 9 Numerical value „1“...
  • Page 80: Burner Operation Since Initial Operation

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.16 Burner operation since initial operation Value Function LED display Meaning 112 °C TOTALBRENNER Display of the burner’s Numerical value „0“ operating time in hours since initial operation of the unit.
  • Page 81: Operating Time Of The Pump Since The Pump Service

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.17 Operating time of the pump since the pump service Value Function LED display Meaning 125 °C SI_PUMPE Display of the pump’s Numerical value „0“ operating time in hours since the pump was last serviced.
  • Page 82: Pump Services

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.1.18 Pump services Value Function LED display Meaning 140 °C SCTR_PUMPE Pump service display. Numerical value „0“ The value is displayed by the LEDs, digit for digit, whereby each LED stands for a numerical value from 0 to 9 Numerical value „1“...
  • Page 83: Pump Operation Since Initial Operation

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.1.19 Pump operation since initial operation Value Function LED display Meaning 155 °C TOTALPUMPE Display of the pump’s Numerical value „0“ operating time in hours since initial operation of the unit.
  • Page 84: Service Functions With Display

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.2 Service functions with display Service mode If the Service switch is in the „Service“ position when the unit is switched on, the unit’s Service mode is activated (pump does not run). Selecting the service functions The available service functions are selected via the water temperature setting (1).
  • Page 85: Adjusting The Stopping Behaviour

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.2.1 Adjusting the stopping behaviour Display Explanation Note 30 °C Shut-off after 30 min continuous operation is Switchover with SET activated. Shut-off after 30 min continuous operation is not Switchover with SET activated (manufacture settings).
  • Page 86: Flame Sensor Brightness Value

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.2.4 Flame sensor brightness value Display Explanation Note 45 °C <471: light Flame sensor test. Brightness value display. >=471: dark 1023 3.2.5 Testing the temperature sensor Display Explanation Note 50 °C Temperature sensor test.
  • Page 87: Testing The Service Switch

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.2.7 Testing the Service switch Display Explanation Note 60 °C selected scale inhibitor setting 3.2.8 Testing the sensors Explanation Note 65 °C Description from left to right: Fuel sensor level (Level 7 of 8 levels) Motor thermal contact open Oil refill container is not empty Exhaust thermostat is open...
  • Page 88: Fault Memory

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.2.9 Fault memory Note Use SET to switch to the next fault. The fault memory can be deleted with switch OFF - hold SET - switch ON. Display Explanation Note 70 °C...
  • Page 89: Fault Memory

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.2.9 Fault memory Display Explanation Note 70 °C Clear soot from boiler Exhaust thermostat has tripped Check exhaust thermostat Cable break or short circuit in temperature sensor Check temperature sensor Flame sensor did not detect a flame although the Clean inspection glass burner was switched on...
  • Page 90: Handgun Switchings Since The Handgun Service

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.2.11 Handgun switchings since handgun service Display Explanation Note 80 °C Number of handgun switchings since last mainte- nance (service) 22 589 3.2.12 Handgun services Display Explanation Note Count up maintenance: 85 °C Switch off unit...
  • Page 91: Burner Services

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.2.15 Burner services Display Explanation Note Count up maintenance: 100 °C Switch off unit Hold SET Number of times burner serviced switch ON Important: Fault memory is also deleted 3.2.16 Burner operation since initial operation Display...
  • Page 92: Operating Time Of The Pump Since The Pump Service

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.2.17 Operating time of the pump since the pump service Display Explanation Note 125 °C Pump operating time since the last maintenance (service) 3.2.18 Pump services Display Explanation Note 140 °C Count up maintenance:...
  • Page 93: Burner Setting

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.3 Burner setting Note: Precise basic setting of the burner is only possible if the heating coil has been thoroughly cleaned of soot and the inner deposits have been removed beforehand. Measuring the water temperature –...
  • Page 94: Installing The Air Circuit On The Outer Jacket

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.4 Installing the air circuit on the outer jacket When installing the outer jacket (continuous flow heater) in the unit the air circuit (rubber collar) can fall off the outer jacket. This makes installation more difficult.
  • Page 95: Adjusting The Operating Pressure Using The Rotary Control On The Handgun

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.5 Adjusting the operating pressure using the rotary control on the handgun Adjusting the maximum operating pressure Note: The opening pressure of the overflow valve is adjusted using the rotary control. –...
  • Page 96: Adjusting The Operating Pressure Using The Rotary Control On The Handgun

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.5 Adjusting the operating pressure using the rotary control on the handgun Adjusting the minimum operating pressure – Install test pressure gauge at high-pressure connection. – Connect the high-pressure hose with handgun and rotary control to the test pressure gauge.
  • Page 97: Adjusting The Operating Pressure Using Standard Handgun Without Rotary Control

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.6 Adjusting the operating pressure using standard handgun without rotary control Adjusting the maximum operating pressure Note: The maximum operating pressure is set using the standard handgun without rotary control.
  • Page 98: Adjusting The Operating Pressure Using Standard Handgun Without Rotary Control

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.6 Adjusting the operating pressure using standard handgun without rotary control Adjusting the minimum operating pressure – Install test pressure gauge at high-pressure connection. – Connect the high-pressure hose with standard handgun at the test pressure gauge.
  • Page 99: Removing The Hose Reel

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.7 Removing the hose reel 3.7.1 Replacing the high-pressure hose – Switch off unit and release pressure. – Completely unwind hose from the hose reel. – Turn the hose reel until the bolted-on half-shell (1) points upwards.
  • Page 100 Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.7 Removing the hose reel 3.7.2 Replacing the rotating union seal – Remove bolt-on half-shell and high-pressure hose (see Chapter 3.7.1). – Remove countersunk screw (1). – Turn hose reel (2) until the half-shell points upwards and remove another two countersunk screws (3).
  • Page 101 HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.7 Removing the hose reel 3.7.2 Replacing the rotating union seal (continued) – Remove half-shell (1) with bearing block (2) and crank (3). – Use pliers (6) to remove circlip (7) from the axle (5).
  • Page 102: Removing The Hose Reel

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.7 Removing the hose reel 3.7.2 Replacing the rotating union seal (continued) – Only if necessary: Undo the high-pressure line (1) using open-end spanner (SW 27) and remove the two screws in the rear bearing block (see page 101 Item 10 and 11).
  • Page 103: Removing The Pressure Gauge

    HDS Middle Range / HDS Premium Range Basic Settings and Service Procedures 3.8 Removing the pressure gauge Removing the pressure gauge – Remove control panel retaining screws and open control panel. – Push in the left-hand retaining clip (3) behind the pressure gauge (1) by hand.
  • Page 104: Adjusting The Safety Valve

    Basic Settings and Service Procedures HDS Middle Range / HDS Premium Range 3.9 Adjusting the safety valve Adjusting the safety valve – Twist in the rotating handle (1) of the pressure and flow control valve at the pump up to the limit stop („+“...
  • Page 105: Circuit Diagrams

    HDS Middle Range / HDS Premium Range Circuit Diagram 4.1 Circuit diagram – 0.088-021 (HDS 7/12) Service Manual 04.2008 Page 105 / 127...
  • Page 106 Circuit Diagram HDS Middle Range / HDS Premium Range 4.1 Circuit diagram – 0.088-021 (HDS 7/12) Page 106 / 127 Service Manual 04.2008...
  • Page 107 HDS Middle Range / HDS Premium Range Circuit Diagram 4.1 Circuit diagram – 0.088-021 (HDS 7/12) Service Manual 04.2008 Page 107 / 127...
  • Page 108: Circuit Diagram - 0.088-025 (Hds 8/17, Hds 9/18)

    Circuit Diagram HDS Middle Range / HDS Premium Range 4.2 Circuit diagram – 0.088-025 (HDS 8/17, HDS 9/18) Page 108 / 127 Service Manual 04.2008...
  • Page 109 HDS Middle Range / HDS Premium Range Circuit Diagram 4.2 Circuit diagram – 0.088-025 (HDS 8/17, HDS 9/18) Service Manual 04.2008 Page 109 / 127...
  • Page 110 Circuit Diagram HDS Middle Range / HDS Premium Range 4.2 Circuit diagram – 0.088-025 (HDS 8/17, HDS 9/18) Page 110 / 127 Service Manual 04.2008...
  • Page 111: Circuit Diagram - 0.088-052 (Hds 10/20, Hds 12/18)

    HDS Middle Range / HDS Premium Range Circuit Diagram 4.3 Circuit diagram – 0.088-052 (HDS 10/20, HDS 12/18) Service Manual 04.2008 Page 111 / 127...
  • Page 112 Circuit Diagram HDS Middle Range / HDS Premium Range 4.3 Circuit diagram – 0.088-052 (HDS 10/20, HDS 12/18) Page 112 / 127 Service Manual 04.2008...
  • Page 113 HDS Middle Range / HDS Premium Range Circuit Diagram 4.3 Circuit diagram – 0.088-052 (HDS 10/20, HDS 12/18) Service Manual 04.2008 Page 113 / 127...
  • Page 114: Circuit Diagram - 0.088-026 (Hds 13/20)

    Circuit Diagram HDS Middle Range / HDS Premium Range 4.4 Circuit diagram – 0.088-026 (HDS 13/20) Page 114 / 127 Service Manual 04.2008...
  • Page 115 HDS Middle Range / HDS Premium Range Circuit Diagram 4.4 Circuit diagram – 0.088-026 (HDS 13/20) Service Manual 04.2008 Page 115 / 127...
  • Page 116: Circuit Diagrams

    Circuit Diagram HDS Middle Range / HDS Premium Range 4.4 Circuit diagram – 0.088-026 (HDS 13/20) Page 116 / 127 Service Manual 04.2008...
  • Page 117: Troubleshooting

    HDS Middle Range / HDS Premium Range Troubleshooting 5 Troubleshooting Fault Measure Unit is not running (no LED – Check/replace mains voltage, connection cable and mains display) fuse. – Check fuse (F1). – Check/replace unit switch. – Check/replace the pressure switch. –...
  • Page 118 Troubleshooting HDS Middle Range / HDS Premium Range 5 Troubleshooting Fault Measure Water leak between cylinder – Leak of 1 drip per minute and piston is allowable. head and piston housing – Check/replace high-pressure and low-pressure seals. Oil leak between cylinder –...
  • Page 119: Technical Specifications

    HDS Middle Range / HDS Premium Range Technical specifications 6 Technical specifications Unit type Unit No. Circuit dia- Operating in- Spare parts list gram structions HDS 7/12-4 M 1.077-401 0.089-021 5.962-127 5.970-808 HDS 7/12-4 MX 1.077-451 0.089-021 5.962-127 5.970-808 HDS 8/17-4 M 1.077-601 0.089-025 5.962-127...
  • Page 120: Tightening Torque

    Technical specifications HDS Middle Range / HDS Premium Range 8 Tightening torque Cylinder head screws 50 - 60 Nm Piston housing 5 - 7 Nm Handgun, pressure control 40 Nm High-pressure outlet 6 - 8 Nm Pressure valves, threaded connection 40 - 45 Nm Pressure switch, threaded connection 30 - 35 Nm...
  • Page 121: Index

    HDS Middle Range / HDS Premium Range Index 9 Index Burner cover ........... 48,49 Burner fan with fuel pump ......43,44 Accessories ...........6 Burner fan ...... 24,33,36,43,44,54,56 Adjust CO value .......... 93 Burner operation since initial operation ... 80,91 Adjusting screw with drillhole, Burner services ........
  • Page 122 Index HDS Middle Range / HDS Premium Range 9 Index Connecting pin ..........52 Cooling coil, motor cooler ......36,37 Connection cable, fuel pump solenoid Countersunk screws ........100 valve ............. 43 Coupling ............44 Connection cable, ignition transformer ..45 Coupling, handgun - hose ......
  • Page 123 HDS Middle Range / HDS Premium Range Index 9 Index Fuel nozzle ....... 47,48,49,54,56 Hose from the motor cooler to the fine Fuel pressure line ........54,56 water filter ............. 56 Fuel pump ...... 33,36,43,44,54,56,93 Hose reel, high-pressure hose .......9 Fuel return line .........
  • Page 124 Index HDS Middle Range / HDS Premium Range 9 Index Lock nut, high pressure adjusting screw ........95,96,97,98,104 Oil drain plug ......24,33,34,36,37 Lock nut, low pressure adjusting Oil level sensor ......33,34,36,37 screw ..........95,96,97,98 Oil refill container, pump ... 24,33,34,36,37 Lock nut, stop sleeve, half-load ....
  • Page 125 HDS Middle Range / HDS Premium Range Index 9 Index Pressure switch, "ON" (open) ....60,61 Retaining screw, top storage compartment .. 22 Pressure valve ........34,37 Retaining screws, bearing block ....100 Printed circuit board ........ 54,56 Retaining screws, half-shell ......99 Printed circuit board, control panel ..
  • Page 126 Index HDS Middle Range / HDS Premium Range 9 Index Service functions with LED display ....63 Service mode .......... 63,84 Tank inlet, fuel tank with prefilter....26 Service position ..........25 Technical Features .........6 Service switch (change setting) ....63,84 Technical specifications ......
  • Page 127: Index

    HDS Middle Range / HDS Premium Range Index 9 Index Washer ............ 34,37 Water connection with fine water filter ..8,9 Water connection ......... 54 Water hose, suction side ......39 Water hose, to the pump ......24 Water inlet from the high-pressure pump ..41 Water inlet hose ..........