Kärcher HD 6/15-4 Service Manual Download | Manualshive

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English 5.906-565.0 Rev. 00 (12/12)

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HD 6/15-4, HD 7/11-4

Service Manual

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Summary of Contents for HD 6/15-4

Page 1: ...English 5 906 565 0 Rev 00 12 12 1 HD 6 15 4 HD 7 11 4 Service Manual ...

Page 2: ...d 13 7 2 Remove the appliance cover 15 7 3 Oil change 15 7 4 Clean water filter 16 7 5 Replacing the water connection 16 7 6 Removing the pressure switch 17 7 7 Dismantling the cylinder head 17 7 8 Replacing the high and low pressure gaskets 18 7 8 1 Replace the low pressure seals 18 7 8 2 Replace high pressure seals 18 7 8 3 Installing the cylinder head 19 7 9 Replacing the valves 20 7 10 Checkin...

Page 3: ...acing the mains cable 30 7 20 Access to the terminal box of the electric motor 31 7 21 Replacing the electric motor 32 8 Troubleshooting 33 8 1 Appliance is not running 33 8 2 Pressure does not build up in the appliance 33 8 3 Water is leaking at the pump 33 8 4 Oil is leaking at the pump 33 8 5 Pump is vibrating 33 8 6 Appliance often turns on and off when hand spray gun is closed 33 9 Technical ...

Page 4: ...ates useful tips and important information Danger Risk of electric shock Prior to opening the electric casing the appliance must be de energised pull the mains plug and se cured against accidental restart Notes about the ingredients REACH You will find current information about the ingredients at www kaercher com REACH Mobile cold water high pressure cleaner in different performance categories for...

Page 5: ...pical operating weight 5 Flow rate 6 Nozzle size 7 Max feed temperature 8 Address of manufacturer 9 Bar code Contains part and serial number 10 Max feed pressure 11 Max operating over pressure 12 Connected load 13 Main Supply 14 Serial number 15 Appliance description 16 Symbol Never operate on the drinking water net without a system separator 5 7 Type plate ...

Page 6: ...dle 2 High pressure hose 3 Machine frame 4 Wheel 5 Waterfilter 6 High pressure connection 7 High pressure pump 8 Nozzle screws Power nozzle 9 Cover 10 Spray lance 11 Power switch 12 Trigger gun 13 Rotary coupling 6 Parts of the system 6 1 Overview ...

Page 7: ... 12 7 1 Trigger gun storage clip 2 Oil level indicator 3 Oil drain screw 4 Storage for spray pipe 5 Step depression 6 Nameplate 7 Water connection 8 Mains cable with mains plug 9 Cable hook rotating 10 Storage compartment for hoses ...

Page 8: ...ish 5 906 565 0 Rev 00 12 12 1 Cover 2 Storage compartment 3 Water connection 4 Motor 5 Pressure and volume regulation 6 Cylinder head 7 Crankcase 8 Oil fill screw 9 Flange 10 Storage compartment for nozzles ...

Page 9: ...0 Rev 00 12 12 9 1 Power switch 2 Water drain 3 Startup capacitor 4 Operating capacitor 5 Resistor 6 Connection terminals 7 Cable from the motor 5 wires 8 Cord grip 9 Power cable 3 wires 10 Cable from the pressure switch ...

Page 10: ... 12 Danger First pull out the plug from the mains before carrying out any tasks on the machine Activate hand spray gun until device is pressure less 7 Basic settings and service procedures 7 1 Overview appliance components 7 1 1 Frame ...

Page 11: ...English 5 906 565 0 Rev 00 12 12 11 A Locking screw delivery condition B Ventilation screw operation 7 1 2 Motor 7 1 3 Crank drive ...

Page 12: ...12 English 5 906 565 0 Rev 00 12 12 ...

Page 13: ...English 5 906 565 0 Rev 00 12 12 13 7 1 4 Cylinder head ...

Page 14: ...14 English 5 906 565 0 Rev 00 12 12 ...

Page 15: ...evice hood Unscrew oil drain plug Drain the oil in a collection basin Fix in the oil drain screw and tighten it Torque 20 25 Nm Turn the oil fill screw out Fill in new oil slowly air bubbles should go out The oil level must be at the centre of the oil level display Screw in oil filling screw Close cover 7 2 Remove the appliance cover 7 3 Oil change ...

Page 16: ...Unscrew the filter casing Take out the filter inlay Clean the filter casing Clean the filter inlay Install the water filter Loosen the hose clip Pull out the hose Unscrew 2 screws Remove connection nozzle 7 4 Clean water filter 7 5 Replacing the water connection ...

Page 17: ...following steps prior to dismantling the cylinder head Loosen the valve screws see Replacing valves Remove pressure switch see Removing the pressure switch Loosen the pressure retaining valve see Check pressure retaining valve Loosen the overflow valve see Check overflow valve Unscrew 8 screws Carefully pull out the cylinder head using both hands 7 6 Removing the pressure switch 7 7 Dismantling th...

Page 18: ...isc 4 Washer ring 5 Spreader ring Assemble new low pressure gasket packages as shown above Reuse the brass tins in doing so Lightly grease the sealing rings inside grease 6 288 079 0 Lightly grease the O rings Push the low pressure gasket packages onto the ceramic sleeves of the piston Dismantle the high pressure gasket packages by means of valve pliers 1 Brass disc 2 Disc 3 Washer ring 4 Spreader...

Page 19: ...the disc inside the brass disc Insert both discs of the high pressure gasket pack age in the cylinder head together Centre the cylinder head on the pistons and push it up to the crankshaft casing in one go Note If the cylinder head is pulled back during installation e g because it was jammed during installation there is a risk that the gasket packages depacketize and are no longer seated correctly...

Page 20: ... new valve Check the O ring of the valve screw replace if necessary Insert and tighten the valve screw torque 40 45 Nm Unscrew the connecting piece Remove the check valve 1 O ring 2 Valve body 3 Spring Check the valve body spring and O ring Check the valve seat in the cylinder head Replace defect parts Reassemble the valve 7 9 Replacing the valves 7 10 Checking the pressure retaining valve ...

Page 21: ...1 Pull off the rotary handle Unscrew the overflow valve wrench size 32 mm Clean valve Check ball for wear Clean valve seat Check valve seat for wear Dismantle the worn valve seat by means of valve pliers 7 11 Checking the overflow valve ...

Page 22: ...s while the motor is running Check the set pressure and readjust if necessary Tighten the lock nut without moving the adjust ment nut Screw in the threaded pin and tighten it Reinstall the original power nozzle on the spray lance Completely unscrew the adjustment nut with the rotary handle in an anti clockwise direction Turn on the appliance Working pressure of approx 3 MPa 30 bar is ap plied Open...

Page 23: ... grease 6 288 079 Reinstall the mechanics of the pressure switch Dismount cylinder head see Dismounting the cylinder head Pull the low pressure gaskets off the piston see Replacing high and low pressure gaskets replac ing low pressure gaskets Loosen screws Caution Risk of damage Do not directly touch the ceramic piston with pliers If a tool is required for removal use a piece of hose for protectio...

Page 24: ...ylinder head see Dismounting the cylinder head Place an oilpan underneath the pump Loosen 4 screws Remove the lid Drain and collect the oil Note If chips of destroyed pump components are visible in the crankshaft casing or in the oil the pump is dam aged and a repair no longer reasonable In this case replace the entire crank drive Dismounting the ceramic piston see Replacing the ceramic piston Rem...

Page 25: ... the crankshaft casing 1 Cover 2 Bearing cover Loosen 4 screws Remove the lid Caution Risk of damage for the subjacent ball bearing and the gasket seat in the crankshaft casing Do not position the screwdriver to close to the edge of the cover Drive the screwdriver into the cover and prise the cover open Remove the safety ring from the shaft Push all pistons completely towards the cylinder head 7 1...

Page 26: ...ameter of the pressing mandrel so that the press in force acts on the outer ring of the ball bearing Press a new ball bearing into the crankshaft cas ing Pull the piston rod with the piston out of the crank shaft casing Caution Risk of damage for the gasket seat Carefully use a screwdriver when dismantling the gasket Push the oil seal out of the crankshaft casing from the inside to the outside or ...

Page 27: ...or the ball bearing When pressing the crankshaft in support the ball bearing at the inner and outer ring Insert the crankshaft in the crankshaft casing and press it in in small steps Between every step en sure that the piston rods are not jammed or dam aged by the crankshaft Replace needle bearing if necessary Heat the flange the needle bearing will fall out Press new needle bearing all the way in...

Page 28: ...bearing shells of the piston rods ob serve marking Apply soluble screw securing adhesive to the screws and tighten them with 9 11 Nm Attach the lid to the crankshaft casing Grease the shaft in the area of the feather key grease 6 869 088 Attach the pump to the motor Install the cylinder head Refill fresh oil The oil level is checked at the sight gauge the lev el should be at least up to the middle...

Page 29: ...he lid Opening the electric casing see Opening the electric casing Unlock 2 snap in noses and pull off rotary knob 1 Locking nose 2 Rotary knob 3 Cam 4 Stopper 5 Switch 6 Catch spring for switch position Note The rotary knob must be attached in a way that the cam is seated between the two limit stops Press the detents together and push the switch through the lid 7 17 Open the electric casing 7 18 ...

Page 30: ...ectric casing 1 Back panel Loosen 4 screws Remove back panel Loosen the nut Take out the traction relief from the holder Opening the electric casing see Opening the electric casing 1 Cord grip 2 Screw 3 Power cord Unscrew 2 screws Remove the traction relief Disconnect the mains cable Install a new power cable 7 19 Replacing the mains cable ...

Page 31: ...ctric casing see Opening the electric casing 1 Cord grip 2 Screw Unscrew 2 screws Remove the traction relief Lift the electric casing and turn it around the right pipe in an anti clockwise direction Loosen 4 screws Remove the lid cw clockwise direction ccw anti clockwise direction Note Only use terminal assignment cw 7 20 Access to the terminal box of the elec tric motor ...

Page 32: ... de energised pull the mains plug and se cured against accidental restart Remove the high pressure pump from the electric motor Detach the electric motor from the frame Pull the electric motor out from under the electric casing Open the junction box of the electric motor Disconnect the cable 7 21 Replacing the electric motor ...

Page 33: ...tings of the transfer port 3 drops per minute are permitted and can come out from the lower side of the appliance Replace high and low pressure gaskets Replace the oil seals Replace the shaft seal rings Clean water filter Check the water suction pipes for leaks Deaerate the appliance see Start up Check the pump for leaks Check the high pressure hose and the hand spray gun for leaks Check the press...

Page 34: ...tion Max feed temperature C 60 Min feed volume l h l min 900 1000 Suck height from open container 20 C m 0 5 Max feed pressure MPa bar 1 0 10 Performance data Working pressure MPa bar 7 15 70 150 7 11 70 110 Max operating over pressure MPa bar 19 190 15 150 Nozzle size 036 050 Flow rate l h l min 600 10 700 11 7 Max recoil force of hand spray gun N 29 Values determined as per EN 60355 2 79 Hand ar...

Page 35: ...ion mandrel high pressure gasket 5 901 227 0 Installation sleeve high pressure seal 5 901 226 0 Test manometer for working pres sure 4 401 072 0 Test nozzle 25018 for HD 6 15 and HD 7 11 5 765 092 0 9 3 Torques Cylinder head Nm 20 25 Valve screw Nm 40 45 Oil drain screw Nm 20 25 Pressure switch Nm 28 32 Locking screw cylinder head Nm 40 45 Overflow valve Nm 40 45 Threaded pin at the lock nut of th...

Page 36: ...36 English 5 906 565 0 Rev 00 12 12 The circuit diagram in the service manual is not up dated When working on the device please always use the current circuit diagram in DISIS 9 4 Circuit diagram ...

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