Kärcher AP 100 M User manual

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English 5.906-508.0 Rev. 00 (11/10) 1
AP 100/50 M
Service Manual
2 English 5.906-508.0 Rev. 00 (11/10)
1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Hazard levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Symbols on the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Technical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Cleaning operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Vacuuming operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3.1 Floor nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Setup and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Right view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Left view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 View from below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Control terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6.1 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6.2 Dosage valve for detergent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6.3 Operating panel from below. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7 Suction turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.9 Hand spraygun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.10 Floor nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.11 Scrubbing brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.12 Wastewater reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.13 Discharge hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.14 Water function diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Service tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Control terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.1 Remove operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.2 Removing the switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.3 Remove the detergent dosing valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.4 Remove the connection of the high pressure hose . . . . . . . . . . . . . . . . 22
5.1.5 Remove the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Wastewater reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.1 Removing the wastewater reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.2 Remove the drain hose for wastewater . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 Wheel support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.1 Remove the wheel support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.2 Removing the wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.1 Check the population of the terminal strip . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.2 Replacing the mains cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Suction turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.1 Removing the suction turbine plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.2 Check the suction turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
English 5.906-508.0 Rev. 00 (11/10) 3
5.5.3 Replacing the abrasive coals of the suction turbine. . . . . . . . . . . . . . . . 30
5.5.4 Replacing the suction turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6.1 Remove the high pressure pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6.2 Disassemble the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.6.3 Check the pump motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.6.4 Remove the pump motor.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.7 High pressure/low pressure solenoid valve. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.7.1 Check the high pressure/low pressure solenoid valve. . . . . . . . . . . . . . 36
5.7.2 Remove the high pressure/low pressure solenoid valve . . . . . . . . . . . . 36
5.8 Remove the pressure control valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.9 Remove detergent injector.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.10 Fresh water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.10.1 Remove the supply hose for fresh water . . . . . . . . . . . . . . . . . . . . . . . 40
5.10.2 Remove the return hose for fresh water. . . . . . . . . . . . . . . . . . . . . . . . 40
5.10.3 Remove the fresh water drain hose. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.10.4 Clean/replace the water filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.10.5 Remove the fresh water reservoir.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.11 Hand spraygun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.11.1 Replace the high pressure hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.11.2 Disassemble hand spray gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.12 Floor nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.12.1 Adjust the distance of the vacuum lips. . . . . . . . . . . . . . . . . . . . . . . . . 47
5.12.2 Replacing the vacuum lips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.13 Scrubbing brush (accessory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.13.1 Connect the scrubbing brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.13.2 Replace the vacuum lips of the scrubbing brush . . . . . . . . . . . . . . . . . 48
5.14 Replace the steering roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 Value table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.1 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 English 5.906-508.0 Rev. 00 (11/10)
Good service work requires extensive and practice-
oriented training as well as well-structured training
materials.
Hence we offer regular basic and advanced training
programmes covering the entire product range for all
service engineers.
In addition to this, we also prepare service manuals
for important appliances - these can be initially used
as instruction guides and later on as reference
guides.
Apart from this, we also regular information about
product enhancements and their servicing.
If you should require supplements, have corrections
or questions regarding this document, please ad-
dress these citing the following subject to:
The responsible product specialist will take care of
your issue.
Copying and duplication of texts and diagrams as
well as third-party access to this information is
permitted only with the explicit permission of the
company:
Alfred Kärcher GmbH & Co. KG
P O Box 160
D -71349 Winnenden
www.kaercher.com
Warning
First remove the mains plug before doing any job on
the vacuum cleaner.
Safety devices serve to protect the user and must not
be rendered inoperational or their functions by-
passed.
Danger
Immediate danger that can cause severe injury or
even death.
Warning
Possible hazardous situation that could lead to se-
vere injury or even death.
Caution
Possible hazardous situation that could lead to mild
injury to persons or damage to property.
High-pressure jets can be dangerous if im-
properly used. The jet may not be directed
at persons, animals, live electrical equip-
ment or at the appliance itself. The high
pressure cleaner must only be used while
standing.
According to the applicable regulations, the
appliance must never be used on the drinking
water supply without a system separator. Use
a suitable system separator manufactured by
KÄRCHER; or, as an alternative, a system separator
as per EN 12729 Type BA. Water flowing through a
system separator is considered non-drinkable.
Caution
Always connect the system separator to the water
supply, never directly to the appliance!
This multi-purpose cleaning appliance is intended for
wet cleaning with or without detergent and to vacuum
up the wastewater.
This appliance is intended for inside use.
Applying detergent solution with the low-pressure
jet.
Removing dirt with the high pressure jet.
Applying and vacuuming detergent solution with
the floor jet (accessory).
Detergent suction with fine filter from free-standing
container
Detergent suction via injector in vacuum.
The suction turbine creates a vacuum in the waste-
water reservoir.
The waste water is thus pumped from the floor nozzle
into the waste water reservoir through the suction
hose.
If the wastewater reservoir is full, the float closes the
suction opening.
The vacuum lips located on the floor nozzle can be
replaced without any tool.
The distance between the vacuum lip and the floor
can be adjusted without any tool.
1 Preface
Subject: Fall 111268
2 Safety instructions
2.1 Hazard levels
2.2 Symbols on the machine
3 Technical Features
3.1 Cleaning operations
3.2 Cleaner
3.3 Vacuuming operations
3.3.1 Floor nozzle
English 5.906-508.0 Rev. 00 (11/10) 5
1 Suction hose connection
2 Operator console
3 Cover dirt water reservoir
4 Suction hose for detergent
5 Dirt water reservoir
6 Connection of high pressure hose
7 Trigger gun
8 Cable hook, rotating
9 High pressure hose
10Spray lance
11Guiding rolls with fixed position brake
12Suction pipe
13Floor nozzle
14Suction hose
15Tool holder
16Fill hose, fresh water
4 Setup and function
4.1 Front view
6 English 5.906-508.0 Rev. 00 (11/10)
1 Sliding handle
2 Suction hose - detergent
3 Cover dirt water reservoir
4 Suction hose
5 Fresh water tank cover
6 Fresh water tank
7 Dirt water reservoir
8 Drainage hose for fresh water
9 Power cord
10Dirt water discharge hose
11Cleaning agent container
4.2 Rear view
English 5.906-508.0 Rev. 00 (11/10) 7
1 Cover dirt water reservoir
2 Fresh water tank cover
3 Suction hose
4 Fresh water tank
5 Drainage hose for fresh water
6 Dirt water reservoir
4.3 Right view
8 English 5.906-508.0 Rev. 00 (11/10)
1 Suction hose connection
2 Connection of high pressure hose
3 Sliding handle
4 Dirt water reservoir
5 Dirt water discharge hose
6 Cable hook, rotating
7 high pressure hose
8 Hand blowing gun
4.4 Left view
English 5.906-508.0 Rev. 00 (11/10) 9
1 Water filter
2 Wheel support
3 Supply hose for fresh water
4 Adjustment wheel for pressure control valve
5 Air outlet, suction turbine
4.5 View from below
10 English 5.906-508.0 Rev. 00 (11/10)
1 Fill hose, fresh water
2 Suction hose connection
3 Switch for vacuuming
4 Fuse for suction turbine
5 Appliance switch ON/OFF
6 Pump fuse
7 Pump switch
8 Dosage valve for detergent
9 Connection of high pressure hose
1 Dosing of detergent container 1
2 Dosing of detergent container 2
Note
Adding one of the detergents only works in low pres-
sure operating mode (switch on the pump set to MIN).
4.6 Control terminal
4.6.1 Control elements
4.6.2 Dosage valve for detergent
English 5.906-508.0 Rev. 00 (11/10) 11
1 Switch of suction turbine
2 Fuse for suction turbine
3 Appliance switch ON/OFF
4 Pump fuse
5 Pump switch
6 Dosage valve for detergent
4.6.3 Operating panel from below
12 English 5.906-508.0 Rev. 00 (11/10)
Note
The suction turbine sits underneath the wastewater
reservoir.
1 Connecting block
2 High pressure/low pressure solenoid valve
3 Detergent injector
4 Suction turbine
4.7 Suction turbine
English 5.906-508.0 Rev. 00 (11/10) 13
1 Pump motor
2 High-pressure pump
3 High pressure hose
4 Supply hose for fresh water
4.8 High-pressure pump
14 English 5.906-508.0 Rev. 00 (11/10)
1 Nozzle screws
2 Spray lance 3 Hand blowing gun
4 Lever for hand spray gun
1 Hand spray gun casing
2 Safety lever
3 Lever for hand spray gun
4 Corner valve
4.9 Hand spraygun
English 5.906-508.0 Rev. 00 (11/10) 15
1 Front vacuum lip
2 Rear vacuum lip
3 Floor nozzle
4 Adjustment wheel, height adjustment, impeller
5 Impeller
4.10 Floor nozzle
16 English 5.906-508.0 Rev. 00 (11/10)
1 Front vacuum lip
2 Rear vacuum lip
3 Scrubbing brushes
4 Water nozzles
Note
A scrubbing brush can be attached as an accessory
to clean severely contaminated surfaces.
4.11 Scrubbing brush
English 5.906-508.0 Rev. 00 (11/10) 17
1 Dirt water discharge hose
2 Cover dirt water reservoir
3 Dirt water reservoir
1 Rough dirt filter with swimmer ball
2 Cleaning opening of the dirt water reservoir
1 Rough dirt filter
2 Swimmer ball
4.12 Wastewater reservoir
18 English 5.906-508.0 Rev. 00 (11/10)
1 Dirt water discharge hose
2 Drainage hose for fresh water
Note
The fresh water drain hose is also used as a fill level
display.
For environmental protection reasons, the wastewa-
ter must be disposed of according to its type of con-
tamination.
The fresh water that has been mixed with detergent
must be disposed of according the detergent manu-
facturer's instructions.
4.13 Discharge hoses
English 5.906-508.0 Rev. 00 (11/10) 19
1 high pressure hose
2 Suction hose
3 Fill hose, fresh water
4 Connection of high pressure hose
5 Dosage valve for detergent
6 Suction hose connection
7 Cover dirt water reservoir
8 Suction hose for detergent
9 Swimmer ball
10Cleaning agent container
11Dirt water discharge hose
12Drainage hose for fresh water
13Dirt water reservoir
14Suction turbine
15Detergent injector
16High pressure/low pressure solenoid valve
17Pressure relief valve
18High pressure pump
19Pump motor
20Waterfilter
21Fresh water tank
22Fresh water reservoir filler neck
23Hand blowing gun
4.14 Water function diagram
23
9
10
21
22 11
13
12
14
2 543
20 19 18 1617 15
6 7 81
20 English 5.906-508.0 Rev. 00 (11/10)
1 Fastening screw
2 Operator console
ÎUnscrew the suction hoses for the detergent from
the detergent containers.
ÎUnscrew locking screws.
ÎRemove the control panel.
ÎDisconnect the connections.
Installation in reverse order
Note
After the assembly, check all hoses for leaks.
Preliminary tasks:
ÎRemove operating panel.
1 Fastening nut
2 Cable connector
3 Cover
ÎRemove the cable ties.
ÎLoosen the mounting nuts.
ÎRemove cover.
1 Lock
2 Operator console
ÎPull the plug connections from the switches.
ÎPress the locks together and slide the switch out.
Installation in reverse order
Note
Observe the plug arrangement during installation.
After the assembly, check all hoses for leaks.
5 Service tasks
5.1 Control terminal
5.1.1 Remove operating panel 5.1.2 Removing the switch
/