Kärcher HDS 9/50 De Tr1 Manuals

Table of Contents

• 2

  1 Contents

  • 2

    Table of Contents

• 6

  2 Preface

• 6

  3 Regarding This Service Manual

  • 6

    Target Groups for This Manual

• 6

  4 Environmental Protection

• 6

  5 Safety Instructions

  • 6

    General
  • 7

    Hazard Levels
  • 7

    Symbols On the Plant
  • 7

    Hearing Protection

• 8

  6 Technical Features

  • 8

    General
  • 8

    Field of Application
  • 8

    Pump
  • 8

    Electronics System
  • 8

    Detergent
  • 9

    Type Plate
  • 9

    Vehicle Identification Number

• 10

  7 Parts of the System

  • 10

    View with Closed Front and Rear Cover
  • 11

    View with Opened Front and Rear Cover
  • 17

    Bottom View
  • 18

    Operator Console
    • 21

      Control Panel, View From the Inside
    • 24

      Control Boards, Control Panel

• 26

  8 Operations

  • 26

    General Information On the Operation
    • 26

      Water Supply
    • 26

      Turning On the Appliance
    • 27

      Speed Control for Pressure and Volume Regulation
    • 27

      Set Working Pressure and Flow Rate
    • 27

      Operation with Detergent
    • 28

      Interrupting Operation
    • 28

      Turning Off the Appliance
  • 29

    Operating Displays
  • 29

    Maintenance Operating Fluids
  • 30

    Liquid Softener Mode
  • 30

    Machine Frost Protection
    • 30

      Anti-Freeze Flush in the High-Pressure Circuit
    • 32

      Flush the Anti-Freeze Out of the High-Pressure Circuit
  • 33

    Service Switch
  • 34

    Service Functions with Display
    • 35

      Quick Overview for Reading the Service Functions
    • 35

      Set Up the Switching Off Process
    • 35

      Brightness Value of the Flame Sensor
    • 36

      Test Actuators / Test Output Signals
    • 36

      Test Temperature Sensor Booster Heater
    • 36

      Function Check Service Switch
    • 37

      Input Test of the Signals
    • 37

      Display Fault Memory and Software Version
    • 38

      Service Motor
    • 39

      Service Pump
    • 39

      Service Burner
    • 39

      Service Gun

• 40

  9 Function

  • 40

    Flow Pattern
  • 41

    Overview Sensor Technology and Electrical Components
    • 42

      Switching Functions of the Sensor Technology
  • 45

    Axle / Drawbar
  • 45

    Lights
  • 47

    Covers
  • 48

    Water Tanks (2X250 L)
  • 49

    Storage Compartments
  • 49

    Battery / Inverter
  • 51

    Water Inlet
  • 51

    Swimmer Tank
  • 53

    Water Distribution
  • 53

    Liquid Softener
  • 54

    Heat Exchanger
  • 55

    High-Pressure Pump
    • 56

      Pump Diagram (General)
    • 57

      Function Frost Protection Valve
    • 57

      Function Pressure Switch
    • 58

      Function Speed Control Full Load / Idle Mode
    • 59

      Crank Drive Disassembled
    • 61

      Cylinder Head: High-Pressure Valve and Water Inlet / Piston Seals
    • 63

      Cylinder Head, Overflow Valve
  • 64

    Overflow
  • 65

    Safety Block
    • 66

      Safety Valve
    • 67

      Flow Switch
  • 68

    Burner Blower with Fuel Pump
  • 69

    Booster Heater (With Ignition Transformer)
    • 70

      Type Plate of Heating Coil
    • 71

      Sectional View (Exemplary)
  • 73

    Burner
  • 74

    Output of Flow-Type Heater
  • 75

    High Pressure Connection
  • 75

    Motor (Water-Cooled)
    • 78

      Speed Control - Full Load / Idling Speed
    • 79

      Speed Control for Changing Volume and Pressure
  • 80

    Fuel Tank
  • 81

    Detergent Dosing Unit

• 84

  10 Preparations for Service Tasks

  • 84

    Transport
    • 84

      Trailer Operation
    • 84

      Transport By Crane
  • 85

    Install the Device and Align It
  • 86

    Opening the
  • 87

    Service Tasks with Opened
  • 88

    Lifting the Trailer From the Bottom for Maintenance Tasks
    • 88

      Lifting with a Jack
    • 89

      Lifting By Means of a Car Lift
  • 90

    Dismantling the Front Plate
  • 91

    Dismantling the Maintenance Flap On the Right
  • 92

    Dismantling the Maintenance Flap On the Left
  • 93

    Disassembly of the PVC Protective Plates for Service Tasks From the Bottom
  • 93

    Water Connection
    • 93

      Operation with External Water Supply
    • 94

      Operation with Water From the Water Tanks
  • 94

    Refill Fuel
  • 94

    Refill Detergent
  • 94

    Refill Liquid Softener

• 95

  11 Basic Settings and Service Procedures

  • 95

    Axle / Drawbar
    • 95

      Lubricate the Brake On the Drawbar
    • 95

      Lubricating the Crank Drive of the Support Wheel
    • 95

      Replacing Wheel
    • 96

      Front Light - Replacing the Lamps
    • 96

      Rear Light - Replacing the Lamps
    • 97

      Replace the Gas Pressure Damper
    • 99

      Dismantling Covers
    • 100

      Charge / Replace Battery / Check Fluid Level
    • 102

      Replace the Inverter
  • 102

    Water Inlet
    • 102

      Lubricating the Rotating Grommet Low-Pressure Hose Reel
    • 102

      Clean Water Filter
  • 103

    Liquid Softener
    • 103

      Cleaning the Level Switch
    • 103

      Exchanging the Level Switch / Dosing Valve
  • 105

    Swimmer Tank
    • 105

      Exchanging Float Valves
    • 107

      Exchanging the Level Switch / Temperature Sensor
  • 108

    Heat Exchanger (16Kw)
    • 108

      Replacing the Heat Exchanger
    • 109

      Clean Heat Exchanger
  • 109

    High-Pressure Pump
    • 110

      Check Oil Level and Refill Oil
    • 111

      Oil Change in High Pressure Pump
    • 112

      Cleaning the Fine Filter
    • 114

      Check and Adjust the Speed Control Full Load / Idle Mode
    • 115

      Replacing Wear Parts of the Overflow Device
    • 117

      Changing the Valve Frost Protection
    • 118

      Changing the Pressure Switch
    • 119

      Replace the Suction Valves
    • 122

      Replace Pressure Valves
    • 124

      Replace the Overflow Valve
    • 125

      Cylinder Head, Uninstall
    • 127

      Replace the Oil Rings
    • 131

      Replace the Piston
  • 135

    Safety Block
    • 135

      Safety Block for 200Bar Devices
    • 137

      Safety Block for 350/500Bar Devices
  • 138

    Burner Blower with Fuel Pump
    • 138

      Change Fuel Filter
    • 138

      Dismantling the Fuel Pump
    • 139

      Dismantling the Burner Blower
    • 142

      Motor Burner Blower: Changing the Carbons
    • 143

      Cleaning the Air Duct
  • 144

    Booster Heater
    • 144

      Dismantling / Cleaning the Burner Cover
    • 145

      Adjusting the Ignition Electrodes
    • 146

      Changing the Ignition Transformer
    • 146

      Cleaning / Changing the Flame Sensor
    • 146

      Cleaning / Changing the Temperature Sensor Exhaust Gas
    • 147

      Cleaning / Changing the Temperature Sensor Warm Water
    • 148

      Dismantling the Booster Heater
  • 149

    Settings, Burner
  • 151

    High Pressure Outlet
    • 151

      Uninstall / Install High-Pressure Hose
    • 151

      Dismantling the Pressure Gauge
    • 151

      Changing the Bypass Unit with Safety Valve
  • 153

    Motor
    • 156

      Cleaning/Replacing the Air Filter
    • 158

      Replace the Alternator
    • 159

      Check the Oil Level On the Motor / Refill Motor Oil
    • 160

      Perform Oil Change / Replace Oil Filter
    • 162

      Change Fuel Filter
    • 163

      Empying the Water Separator
    • 164

      Checking the Oil Level On the Intermediate Gear and Refilling Transmission Oil
    • 164

      Oil Change Intermediate Gear
    • 165

      Dismantling Intermediate Gear with High-Pressure Pump From the Motor / Replacing Elastomer Ring Coupling
    • 167

      Removing the Intermediate Gear From the High-Pressure Pump
    • 168

      Draining the Diesel
    • 169

      Checking / Replacing the Level Sensor Fuel
    • 170

      Clean Filter at the Detergent Suck Hose
    • 171

      Changing the Detergent Dosing Valve
    • 171

      Cleaning / Changing the Solenoid Valve Dosing Detergent
  • 173

    Adjustment of the Working Pressure and the Water Volume in Combination with the Motor Speed
  • 175

    Speed

• 176

  12 Care

  • 176

    Descaling
  • 178

    Removing the Soot From the Heating Coil

• 179

  13 Troubleshooting

  • 179

    Faults with Display
  • 181

    Faults Without Display On the Console
  • 182

    Troubleshooting Yanmar Diesel Engine

• 183

  14 Maintenance Plans

  • 183

    Inspection and Maintenance Checklist
  • 183

    Maintenance Plan Trailer
  • 185

    Maintenance Plan Yanmar Diesel Engine

• 186

  15 Technical Specifications

  • 188

    Tightening Torques

• 193

  16 Special Tools

• 197

  17 Circuit Diagram