Kärcher HD 16/15-4 Service Manual Download | Manualshive

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English

5.906-494.0 Rev. 01 (04/11)

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HD 25/15-4, HD 20/15-4, HD 16/15-4
Service Manual

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Summary of Contents for HD 16/15-4

Page 1: ...English 5 906 494 0 Rev 01 04 11 1 HD 25 15 4 HD 20 15 4 HD 16 15 4 Service Manual ...

Page 2: ... 5 4 1 Pump diagram 10 5 4 2 Remove the crank drive 11 5 4 3 Cylinder head uninstall 12 5 4 4 Overflow 14 5 4 5 Regulate the working pressure by means of the rotary know on the gun 16 5 5 Electrical system 17 5 5 1 Open the switchbox 17 5 5 2 Remove the appliance switch rotary knob 17 5 5 3 Motor protection electronics 18 5 5 4 Functional description of the motor protection electronics 18 5 5 5 Si...

Page 3: ...3 6 2 2 Fault indication 23 6 3 Device is not building up pressure 23 6 4 High pressure side is leaky 23 6 5 High pressure pump is vibrating 23 7 Technical specifications 24 7 1 Technical Documentation 25 8 Circuit diagram 25 9 Special tools 25 10 Tightening torques 26 10 1 HD 25 15 4 26 10 2 HD 20 15 4 26 10 3 HD 16 15 4 26 11 Oil grades 26 ...

Page 4: ...rsons or damage to property This service manual applies to the following applianc es HD 25 15 4 1 367 121 0 HD 20 15 4 1 367 131 0 HD 16 15 4 1 367 105 0 The procedure for service work is the same for all three models Device specific features are empha sized in the text 3 piston crankshaft pump Stainless steel piston with ceramic sleeves Cylinder head made of brass Pressure and suction valves made...

Page 5: ...lter 3 Pump 4 Overflow casing and pressure regulation 5 Accessory compartment 6 Strut for crane loading 7 Push handle 8 Appliance electronics electric box appliance switch 9 Storage hook for cables and hoses 10 Drive motor connection box 11 Electric motor drive 12 Wheel quick close cap 3 7 Attachment sets Attachment kit Order number Swivel casters 2 851 042 0 Hose drum 2 440 002 0 Operating hour c...

Page 6: ...mp 10 Valve screws pressure side 11 Pump head fastening screws 12 Valve screws suction side 1 Oil drain screw 2 Oil sight glass 3 Connecting flange for drive motor pump 4 Electro motor 5 Drive motor connection box 6 Valve screws pressure side 7 Oil container plug 8 Manometer 9 Overflow casing pressure regulation 10 Water inlet 11 Water filter 12 Type plate pump 4 3 Pump Detail HD 25 15 4 4 4 Pump ...

Page 7: ...0 Rev 01 04 11 7 1 Water filter 2 Water inlet 3 Oil drain screw 4 Oil sight glass 5 High pressure outlet 6 Accessory compartment 1 Indicator lamp 2 Power switch 3 Intake for hourmeter option 4 5 Front view 4 6 Rear view ...

Page 8: ...8 English 5 906 494 0 Rev 01 04 11 1 Lock detent 2 Accessory compartment 3 Information sign 4 Hinge storage compartment 5 Cover 6 Lock pin 7 Type plate appliance 4 7 View from the inside ...

Page 9: ... filter for contamination clean if required Assemble it back in the reverse sequence Unscrew the oil drain screw and collect used oil Replace washers of the oil drain screw Screw in the oil drain screws and tighten them Slowly fill in new oil until the MAX marking on the oil sight glass Drain the oil in a collection basin Pull the support bow from the pressure switch Remove the pressure switch Che...

Page 10: ...10 English 5 906 494 0 Rev 01 04 11 Let the high pressure pump tilt down Note Oil can leak during this tilting process Remove the high pressure pump from the electric motor ...

Page 11: ... 15 Piston rod screw 16 Oil bath 17 Crankshaft housing cover with O ring 18 Crankshaft bearing 1 x left 1 x right 19 Oil fill container 20 Distance labyrinth discs 21 Crown nut 22 Disc 23 Low pressure seal 24 Support ring low pressure seal 25 Brass support disc 26 Disc 27 High pressure seal 28 Support ring high pressure seal 29 Valve screw pressure side with O ring 30 Pressure valve with O ring 31...

Page 12: ...rom the crankshaft cas ing Pull out the piston with the push rods from the crankshaft casing Remove the oil seal rings using a special pliers 1 Oil fill container 2 Pump casing 3 Crankshaft bearing cover with crankshaft bearing and O ring 4 Crankshaft casing cover 5 Piston rod bottom parts marked 6 Crankshaft 7 Crankshaft bearing with flange O ring and shaft seal 8 Piston rod top parts marked 9 Pu...

Page 13: ...out the cylinder head using both hands The removed cylinder head cross section seal setup see pump diagram 1 Crown nut 2 Disc 3 Low pressure seal 4 Support ring low pressure seal 5 Support disc brass 6 Disc 7 High pressure seal 8 Support ring high pressure seal 9 Cylinder head Always replace the entire set of seals Grease the low and high pressure seals generous ly with special silicone grease pri...

Page 14: ... O ring 21 Spring plate bottom 22 Spring 23 Spring plate top 24 Sphere 25 Lock nut adjustment screw low pressure 26 Adjustment screw low pressure 27 Spindle of the pressure quantity regulation 28 Adjustment screw high pressure 29 Lock nut adjustment screw high pressure 30 Turning handle 31 Node piece 32 Control piston pressure switch 33 Membrane seal 34 Support bow pressure switch 35 Pressure swit...

Page 15: ...ow pressure 9 Spring 10 Housing overflow valve 11 Spring plate bottom 12 Manometer 13 Control piston 14 O ring 15 O ring 16 O ring 17 Valve seat 18 O ring 19 Valve bolt 20 Spring 21 Nozzle insert 22 O ring 23 Screw socket 24 O ring 25 O ring 26 Spring 27 Valve bolt 28 O ring 29 Node piece 30 Hollow screw suction side 31 Valve seat 32 Hollow screw pressure side 33 O ring 34 Disc 35 O ring 36 Contro...

Page 16: ...h pressure Turn the adjustment screw high pressure so that the pressure display on the test manometer equals the maximum working pressure in the Chapter Specifications Secure the adjustment screw for high pressure by tightening the locknut Seal the adjustment screw for high pressure and the lock nut with locking paint Setting the minimum working pressure Install thenew high pressure nozzle Rotate ...

Page 17: ...AT 6 Gentle start electronics 7 Control transformer fuse 2 0 AT 8 Cover of switchbox Loosen 4 screws and remove the lid of the casing Carefully pull the indicator lamp out of the socket in the lid and place the lid on the side Carefully remove the lid cap Loosen the screw on the shaft and remove the knob 1 Shaft seal 2 Indicator lamp 3 Indicator lamp no function 5 5 Electrical system 5 5 1 Open th...

Page 18: ...n contact blinks red twice Switch off and locking of the machine if the wind ing protection contact opens Over or under voltage current asymmetry blinks red thrice Switch off and locking of the machine in case the secondary voltage of the control transformer is less than 17 volts AC under voltage Switch off and locking of the machine in case the secondary voltage of the control transformer is more...

Page 19: ...splay Run lights up after the motor has been started Possible reasons for malfunctions of the gentle start electronics Overvoltage of the voltage supply more than 27V Multiple motor starts per minute 30 seconds of trailing control of the motor protection electronics is not active Corrosion and or moisture in the components Check whether both phases are present Check if the voltage supply 24V is pr...

Page 20: ...DISIS 1 Support ring 2 O ring Unscrew all fastening screws Remove the half of the handle shell The open gun trigger lock removed Remove the lever press out the pin on the joint Unscrew the locking screw use a 12 mm hexagon socket wrench Pull the pin out toward the front Press the piston out from the front Make sure that the springs do not jump out 5 6 1 Disassemble hand spray gun ...

Page 21: ...ramic disc on spray pipe side 2 Ceramic disc on gun side The ceramic disc on the gun side is rigidly connected to the gun connection The ceramic disc on the spray pipe side is connected to the regulator and therefore adjustable Offset holes in the ceramic discs can adjust the flow volume when rotating the discs This illustration shows the two overlapping ceramic discs and the wa ter flow blue with...

Page 22: ...fety pin 6 coupling 7 Spring 8 Valve ball 9 Piston 10 Spray pipe connection 11 O rings support ring When this lever is actuated the valve ball is pressed against the spring toward the bottom by the piston The node piece is completely replaced during the re pair procedure Remove the quick connect with pliers The quick connect cannot be reused Remove the wheel watch for the spacer Grease the axle wi...

Page 23: ...ssure hose hose connections and hand spray gun for leaks 2x blinking red Engine overload overheat Set the appliance switch to 0 Allow device to cool down Set the appliance switch to I Water pressure is too low Ensure adequate water line pressure 3x blinking red Fault in the voltage supply Check main connections and mains fuse 4x blinking red Power consumption is too high Call Customer Service Wron...

Page 24: ...ance data Working pressure appliance manometer MPa bar 3 15 30 150 3 15 30 150 3 15 30 150 Servopress pressure manometer on the ap pliance outlet MPa bar 14 8 148 15 150 15 3 153 Max permissible pressure MPa bar 19 5 195 19 5 195 19 5 195 Water flow rate l h l min 2320 39 1900 32 1520 25 Nozzle size 155 125 100 Recoil force of trigger gun N 120 96 77 Noise emission Sound pressure level EN 60704 1 ...

Page 25: ...ings and seats 4 901 062 0 Inner driver diameter 14 5 to 18 5 mm 6 815 013 0 Installation mandrel high and low pressure seal 6 815 211 0 Installation sleeve high pressure seal 6 815 214 0 Installation mandrel oil seal 6 815 223 0 Insertion tool crown wrench 6 815 209 0 Special tool HP 20 15 4 piston diameter 25 mm Order number Pliers to remove the rings and seats 4 901 062 0 Inner driver diameter ...

Page 26: ... 15 4 Gear cover 11 Nm Hollow screws on cylinder head 50 Nm Valve screws 200 Nm Cylinder head screws 40 Nm Piston screws 15 Nm Oil drain screw 40 Nm Crankshaft bearing cover screws 25 Nm Piston rod screws 18 22 Nm 10 3 HD 16 15 4 Gear cover 11 Nm Hollow screws on cylinder head 50 Nm Valve screws 200 Nm Cylinder head screws 40 Nm Piston screws 15 Nm Oil drain screw 40 Nm Crankshaft bearing cover sc...

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