- DL manuals
- Karcher
- Pressure Washer
- HD 13/35 PE Cage
- Service Manual
Karcher HD 13/35 PE Cage Service Manual - 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 cover (motor)
15 Oil fill neck (pump)
16 Safety valve
17 Oil filter (engine)
18 Dry run safe guard (lack of water fuse, option)
19 Thermostat valve
20 Speed control
21 Water connection with filter
22 Oil drain screw (pump)
23 Oil level indicator (pump)
24 High pressure connection
25 Oil dip (engine)
26 Manometer
27 Pressure/ quantity regulation
28 Accessory compartment
29 Storage for spray pipe
30 Battery
31 Indicator lamp lack of water fuse (option)
32 Machine switch (engine)
33 Petrol engine
34 Oil drain screw (engine)
35 Choke knob
36 Air filter
37 Fuel tank
38 Operating hours counter/tachometer
39 Push handle
40 Strut for crane loading
4.4
Total view HD 13/15 PE, HD 9/50 PE
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....