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Karcher HD 13/35 PE Cage Service Manual

Summary of HD 13/35 PE Cage

  • Page 1

    English 5.906-441.0 rev. 01 (06/10) 1 hd 9/50-4 cage hd 13/35-4 cage hd 9/50 pe cage hd 13/35 pe cage service manual.

  • Page 2

    2 english 5.906-441.0 rev. 01 (06/10) contents 1 preface 4 2 safety instructions 4 2.1 hazard levels 4 3 technical features 4 3.1 drive 4 3.1.1 hd 9/50-4 cage, hd 13/35-4 cage 4 3.1.2 hd 9/50 pe cage, hd 13/35 pe cage 4 3.2 pump 4 3.3 control 4 3.3.1 hd 9/50-4 cage, hd 13/35-4 cage 4 3.3.2 hd 9/50 p...

  • Page 3

    English 5.906-441.0 rev. 01 (06/10) 3 4.9.6 replace the piston 30 4.10 pump maintenance 33 4.10.1 replace the overflow valve 33 5 basic settings and service procedures 34 5.1 setting the maximum working pressure 34 5.2 setting the minimum working pressure 34 5.3 adjusting the full load speed (pe mod...

  • Page 4

    4 english 5.906-441.0 rev. 01 (06/10) good service work requires extensive and practice-oriented train- ing 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, w...

  • Page 5

    English 5.906-441.0 rev. 01 (06/10) 5 1 trigger gun 2 lever for hand spray gun 3 safety catch 4 high pressure hose 5 operating hour counter 6 storage for spray pipe 7 push handle 8 indicator lamp operation status / malfunction 9 power switch 10 indicator lamp lack of water fuse (option) 11 hose/cabl...

  • Page 6

    6 english 5.906-441.0 rev. 01 (06/10) 1 cover, switch box 2 indicator lamp lack of water fuse (option) 3 indicator lamp operation status / malfunction 4 appliance switch (s1) 5 fuse (f1), 1at 6 circuit board (a1) 7 dip switch 1 not used 2 leakage monitoring (default setting: on) 3 not used 4 30 minu...

  • Page 7

    English 5.906-441.0 rev. 01 (06/10) 7 the indicator lamps display the operating states (green) and inter- ruptions (red). Reset: Î set the appliance switch to "0". Î wait for a while. Î set the appliance switch to "i". Operating status display: – continuous green: the appliance is now ready for oper...

  • Page 8

    8 english 5.906-441.0 rev. 01 (06/10) 1 power nozzle with covering nut 2 spray lance 3 trigger gun 4 lever for hand spray gun 5 safety catch 6 high pressure hose 7 oil fill neck (gears) 8 gear 9 oil level indicator (gears) 10 oil drain screw (gears) 11 hose switch 12 tank lid 13 fuel tap 14 oil fill...

  • Page 9

    English 5.906-441.0 rev. 01 (06/10) 9 1 battery connection cable (+) 2 battery terminal (+) 3 battery (voltage and capacity, see "specifications“) 4 battery terminal (-) 5 battery connection cable (-) 6 battery holder 1 air filter box 2 fuel tap 3 oil filling screw (engine) 4 ignition plug spark plu...

  • Page 10

    10 english 5.906-441.0 rev. 01 (06/10) 1 oil drain screw, right 1 fuel tank 2 rubber grommet 3 halting plate 4 fuel tap the fuel tap is screwed to the support plate and is sealed with a rubber grommet on the tank..

  • Page 11

    English 5.906-441.0 rev. 01 (06/10) 11 1 fuse 25 a (charging current) 2 ignition plug 3 switch amplifier, lack of oil fuse 4 solenoid for electric starter 5 cover of motor electrics the individual wires of the wire harness are colour-coded. 1 cable to shut off the electrical fuel supply Î the connec...

  • Page 12

    12 english 5.906-441.0 rev. 01 (06/10) 1 lock 2 cover, air filter box 3 air filter insert 4 fastening screws, air filter box 5 air filter box 1 adjustment, choke 2 seal, valve cover 3 fastening screw, valve cover 4 valve cover 5 deaeration hose, crankshaft casing 6 cable, fuel solenoid 7 fuel pump 8...

  • Page 13

    English 5.906-441.0 rev. 01 (06/10) 13 a tightening torque 35 nm the speed control lowers the motor speed when the hand spray gun is closed. – default setting of the carburator flap while motor is not running: 42 mm – grease all o-rings with silicone grease 6.288-028.0 prior to in- stallation. 1 fas...

  • Page 14

    14 english 5.906-441.0 rev. 01 (06/10) install the intermediate gear: Î slide the toothed gear onto the shaft of the high pressure pump. Î align the toothed wheel so that the shaft protrudes by 13±0,2 mm from the toothed wheel. Î coat the threaded pin with soluble screw protection and tighten it. 1 ...

  • Page 15

    English 5.906-441.0 rev. 01 (06/10) 15 1 fastening screw 2 union joint 3 filter pot 4 water inlet with geka coupling 5 filter inlay, 100 µm 6 hose connection instead of the geka coupling 1 oil filling nozzle 2 crankshaft bearing cover 3 oil level indicator 4 oil drain screw 5 high pressure connectio...

  • Page 16

    16 english 5.906-441.0 rev. 01 (06/10) 1 lock screw, suction side, with o-ring 2 disc 3 suction valve with o-ring 4 ceramic piston 5 piston screw 6 oil seal ring 7 push bar 8 pump casing 9 bolt, push bar 10 oil drain screw 11 piston rod top 12 crankshaft 13 piston rod bottom 14 piston rod screw 15 o...

  • Page 17

    English 5.906-441.0 rev. 01 (06/10) 17 1 oil filling nozzle 2 pump casing 3 crankshaft bearing cover with crankshaft bearing and o-ring 4 crankshaft housing cover, with o-ring 5 piston rod bottom, marked 6 crankshaft bearing with flange, o-ring and shaft seal 7 crankshaft 8 piston rod top, marked 9 ...

  • Page 18

    18 english 5.906-441.0 rev. 01 (06/10) 1 lockscrew, pressure side, with o-ring 2 pressure valve, with o-ring 3 cylinder head 4 o ring 5 lock screw, suction side, with o-ring 6 suction valve with o-ring 1 cylinder head 2 hollow screw, suction side, with 2 o-rings 3 membrane seal, pressure switch 4 ho...

  • Page 19

    English 5.906-441.0 rev. 01 (06/10) 19 1 safety valve, preset opening pressure hd 13/35: 50 mpa (500bar) opening pressure hd 9/50: 64 mpa (640 bar) no additional test necessary 2 dry run protection switch, switch point 0.07 mpa (0.7 bar) nom- inal pressure 4.7.5 safety valve, dry run protection swit...

  • Page 20

    20 english 5.906-441.0 rev. 01 (06/10) 1 crown nut 2 disc (back ring) 3 low pressure seal 4 support ring, low pressure seal 5 support disc, brass 6 disc (back ring) 7 high pressure seal 8 support ring, high pressure seal 9 cylinder head note grease the low and high pressure seals generously with sil...

  • Page 21

    English 5.906-441.0 rev. 01 (06/10) 21 1 screw socket 2 o ring 3 injector 4 valve 5 o ring 6 o ring 7 valve seat 8 spring 9 valve bolt 10 o-ring set 11 disc 12 spring 13 disc 14 o-ring set 15 control piston 16 spring plate, bottom 17 o ring 18 o ring 19 overflow valve housing 20 lock nut, adjustment...

  • Page 22

    22 english 5.906-441.0 rev. 01 (06/10) positions 1 through 46 same as with "overflow, exploded view". Assembly instructions first, insert the overflow casing (19), then insert the spring plate, bottom (16) with spring (12), disc (13) and o-ring kit (14). A high pressure b return (low pressure, sucti...

  • Page 23

    English 5.906-441.0 rev. 01 (06/10) 23 Î turn off the appliance switch and secure against restart. Î shut off water supply. Î 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. Î open the lockscrews of the 3 ...

  • Page 24

    24 english 5.906-441.0 rev. 01 (06/10) Î insert the lockscrews of the suction valves and tighten them to 40 nm (grease o-rings). Î loosen the lockscrews of the pressure valves. Pull the pres- sure valves out with the pliers 4.901-062.0. If the valve seat (a in fig. 014) ) gets stuck in the pump head...

  • Page 25

    English 5.906-441.0 rev. 01 (06/10) 25 Î unscrew the overflow or slightly loosen the hollow screws that secure the overflow. Î loosen the 8 screws from the pump head. Î carefully pull out the cylinder head using both hands. Î loosen the screw inserts of the stopper bushings using the special tool 5....

  • Page 26

    26 english 5.906-441.0 rev. 01 (06/10) 1 crown nut 2 disc 3 low pressure seal 4 support ring, low pressure seal 5 brass support disc 6 disc 7 high pressure seal 8 support ring, high pressure seal 9 cylinder head.

  • Page 27

    English 5.906-441.0 rev. 01 (06/10) 27 Î insert the new washers into the screw insert. Î insert and press in the new seal package into the cylinder head using the installation sleeve and the driver. Observe the se- quence. Î tighten the stopping bushings using the special tool 5.511- 001.0 to 50 nm....

  • Page 28

    28 english 5.906-441.0 rev. 01 (06/10) Î loosen the 4 flange screws from the pump casing. Î carefully remove the pump casing using the proper tools at the respective pockets. Î remove the casing lid from the pump casing by opening the four screws. Î mark the bearing shells with the piston rod so tha...

  • Page 29

    English 5.906-441.0 rev. 01 (06/10) 29 Î dismantle both the flange bearings at the pump casing; to do that, first loosen the four screws at the flange. At the end, you can pull out the flange bearings. Tightening torque 20 nm. Î press the piston rods backwards to the end-position and take out the cr...

  • Page 30

    30 english 5.906-441.0 rev. 01 (06/10) removing the oil seal rings 1 special pliers to remove the oil seal rings 2 oil seal ring 3 pump casing Î remove 3 oil seals from the pump housing with the special pli- ers. Note make sure that the boring is not damaged when the oil seal rings are removed. Î af...

  • Page 31

    English 5.906-441.0 rev. 01 (06/10) 31 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...

  • Page 32

    32 english 5.906-441.0 rev. 01 (06/10) Î 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. Î assemble back the parts in the reverse sequence. Î fill in sae 90 oil (part no. 6.288-061.0) to the sight glass (ap- prox. 1l...

  • Page 33

    English 5.906-441.0 rev. 01 (06/10) 33 Î remove the holding bow on the pressure switch (hd 9/50-4 cage and hd 13/35-4 cage only). Note for this, push out the support bow using a screw-driver. Î pull the pressure switch off the overflow. Î loosen the hollow screws on the overflow valve evenly and re-...

  • Page 34

    34 english 5.906-441.0 rev. 01 (06/10) 1 adjustment screw, high pressure 2 lock nut, adjustment screw, high pressure 3 spindle of the pressure/quantity regulation 4 adjustment screw, low pressure 5 lock nut, adjustment screw, low pressure 6 housing of the overflow valve Î fasten the test manometer t...

  • Page 35

    English 5.906-441.0 rev. 01 (06/10) 35 6 troubleshooting fault remedy appliance is not running; indicator lamp links green operational readiness period (30 min- utes) has expired. Switch on/off the appli- ance again. Self shut-off after 30 minutes; switch on/ off the appliance again. Unit does not w...

  • Page 36

    36 english 5.906-441.0 rev. 01 (06/10) 7 technical specifications type hd 13/35-4 1.367-150.0 hd 9/50-4 1.367-151.0 hd 13/35 pe 1.367-500.0 hd 9/50 pe 1.367-501.0 power connection - voltage v 400 current type hz 3~50 connection output kw 15 mains fuse (slow-blow) a 25 maximum allowed net impedance o...

  • Page 37

    English 5.906-441.0 rev. 01 (06/10) 37 see next pages. Note:please use the circuit diagram that is valid for the actual ver- sion of the unit. 7.1 special tools pliers 4.901-062.0 drawing tool 6.815-013.0 drive mandrel 6.815-229.0 insertion tool 6.815-209.0 installation man- drel, shaft seal ring 6....