Kärcher HD 9/50-4 Cage Service Manual Download Page 9 | Manualshive

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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 plug (type: ZGR5A (NGK), J16CR-U (DENSO))

5

Oil cooler

6

Hose, oil cooler

7

Oil filter

1

Cooling fan, motor

2

Oil cooler

3

Fuel filter

4

Cover of air filter box

5

Choke knob

6

Oil dip (engine)

7

Motor electrics

8

Appliance switch with ignition key (motor)

9

Indicator lamp lack of water fuse (option)

4.5

Petrol engine HD 13/15 PE, HD 9/50 PE

4.5.1

Battery

4.5.2 Motor

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Summary of Contents for HD 9/50-4 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: ...9 50 PE 9 4 5 1 Battery 9 4 5 2 Motor 9 4 5 3 Motor electrics 11 4 5 4 Air filter 12 4 5 5 Motor with removed air filter box 12 4 5 6 Speed control 13 4 5 7 Intermediate gear 14 4 6 Water connection with water fine filter 15 4 7 Pump 15 4 7 1 Pump diagram 16 4 7 2 Crank drive disassembled 17 4 7 3 Cylinder head high pressure valves and water inlet 18 4 7 4 Cylinder head overflow valve 18 4 7 5 Saf...

Page 3: ...low 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 model only 34 6 Troubleshooting 35 7 Technical specifications 36 7 1 Special tools 37 7 2 Tightening torques 37 8 Circuit diagram 37 ...

Page 4: ...trans ported easily due to its large air filled tyres and powder coated steel pipe frame with its built in crane hook 4 pin air cooled three phase motor with 1400 rpm 24 PS 17 76 kW 2 cylinder petrol motor Honda GX 670 3 piston crankshaft pump Ceramic piston Diameter 16 mm at HD 13 35 Diameter 14 mm at HD 9 50 Cylinder head made of brass Pressure and suction valves made of stainless steel valve ca...

Page 5: ...on 11 Hose cable holder 12 Power cable with plug 13 Lack of water fuse dry run safe guard option 14 Safety valve 15 Oil filling nozzle 16 Pressure switch 17 Pressure quantity regulation 18 Accessory compartment 19 Oil drain screw pump 20 Water connection with filter 1 Geka 21 Oil level indicator 22 High pressure connection 23 Manometer 24 Power nozzle with covering nut 25 Spray lance 26 Strut for ...

Page 6: ... 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 minute continuous operation continuous break default setting ON 8 Electronics system 9 Fuse F2 2AT 10 Control transformer T1 11 Contactor K1 12 Soft starter board A2 4 2 Switch box HD 13 35 4 Cage HD 9 50 4 Cage ...

Page 7: ...is leaky Check high pressure hose hose connections and hand spray gun for leaks blinks red twice Engine is too hot Set the appliance switch to 0 Allow device to cool down Set the appliance switch to I blinks red thrice Fault in the voltage supply Check main connections and mains fuse blinks red four times Excessive power consumption Check replace motor Check pump for blockage make it work 1 Cranks...

Page 8: ...e 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...

Page 9: ... 2 Fuel tap 3 Oil filling screw engine 4 Ignition plug Spark plug type ZGR5A NGK J16CR U DENSO 5 Oil cooler 6 Hose oil cooler 7 Oil filter 1 Cooling fan motor 2 Oil cooler 3 Fuel filter 4 Cover of air filter box 5 Choke knob 6 Oil dip engine 7 Motor electrics 8 Appliance switch with ignition key motor 9 Indicator lamp lack of water fuse option 4 5 Petrol engine HD 13 15 PE HD 9 50 PE 4 5 1 Battery...

Page 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: ...e electrical fuel supply Î The connector to the electrical fuel shut off must be disconnect ed in order to connect the dry run protection switch The operating hour display shows the speed while the motor is run ning and the number of operating hours when the appliance is at a standstill 1 Sensor cable for operating hour display The sensor cable of the operating hour counter tachometer is fas tened...

Page 12: ...e cover 3 Fastening screw valve cover 4 Valve cover 5 Deaeration hose crankshaft casing 6 Cable fuel solenoid 7 Fuel pump 8 Choke knob 9 Fuel filter 10 Fuel hose fuel pump filter 11 Carburator 12 Fuel hose to carburator 13 Connection to air filter box 14 Oil filling screw engine 15 Adjustment screw motor speed 4 5 4 Air filter 4 5 5 Motor with removed air filter box ...

Page 13: ...d 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 Fastening boring for the speed control in the cylinder head of the high pressure pump 2 Fastening boring for the thermal valve 4 5 6 Speed control ...

Page 14: ...discs 7 0 mm and 4 screws The washers under the screw head are only required on the elongated borings 몇 Warning Risk of damage Use only spacer discs that are 7 00 mm long The spacer discs included in the package of the intermediate gear are 6 0 mm long and must not be used Î Fasten the intermediate gear to the high pressure pump using 4 screws Î Fasten the high pressure pump to the counter holder ...

Page 15: ... 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 connection 4 6 Water connection with water fine filter 1 2 3 4 2 3 5 6 4 7 Pump ...

Page 16: ...rod bottom 14 Piston rod screw 15 Oil bath 16 Crankshaft housing cover with O ring 17 Crankshaft bearing 1 x left 1 x right 18 Oil filling nozzle 19 Distance labyrinth discs 20 Crown nut 21 Disc back ring 22 Low pressure seal 23 Support ring low pressure seal 24 Support disc brass 25 Disc back ring 26 High pressure seal 27 Support ring high pressure seal 28 Lockscrew pressure side with O ring 29 P...

Page 17: ...rankshaft 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 Push bar 4 7 2 Crank drive disassembled 1 2 3 4 5 6 7 8 9 ...

Page 18: ...ow valve housing 8 High pressure connection 9 Lock nut adjustment screw low pressure 10 Adjustment screw low pressure 11 Spindle pressure and quantity regulation 12 Lock nut adjustment screw high pressure 13 Adjustment screw high pressure Note Both hollow screws must be loosened or tightened simultaneously while exchanging the knot section in order to avoid damage to the O rings Tightening torque ...

Page 19: ...y 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 switch ...

Page 20: ...t 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 silicone grease 6 288 072 0 prior to installation 4 7 6 Cylinder head piston seals 1 2 3 4 5 6 7 8 9 ...

Page 21: ...24 Sphere 25 Spindle of the pressure quantity regulation 26 Adjustment screw high pressure 27 Lock nut adjustment screw high pressure 28 Turning handle 29 Valve disks 30 O ring 31 O ring 32 O ring 33 Control piston pressure switch 34 Control piston pressure switch 35 Spring 36 O ring 37 Disc guide 38 O ring 39 Support ring 40 Screw socket 41 Control piston pressure switch 42 O ring 43 O ring 44 Ho...

Page 22: ...ng plate bottom 16 with spring 12 disc 13 and O ring kit 14 A High pressure B Return low pressure suction side C High pressure outlet Function If the pressure on the high pressure outlet increases the control piston 15 is lifted up with the valve bolt 9 and the excess pres sure escapes to the suction side of the high pressure pump 4 8 2 Overflow valve cross section drawing ...

Page 23: ...anometer Î Open the lockscrews of the 3 suction valves and replace the O rings Î Pull out the suction valves using special pliers 4 901 602 0 If the valve seat gets stuck in the pump head you can pull it out using the drawing tool 6 815 013 0 Suction pressure valve setup Î Press in the new suction valves lubricate the O rings with sili con grease 4 9 Seal high pressure pump 4 9 1 Replace the press...

Page 24: ...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 you can pull it out using the interior driver 6 815 013 0 see Replacing suction valves Î Press in the new pressure valves manually grease the O rings 4 9 3 Replace pressure valves ...

Page 25: ... 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 5 511 001 0 and and take out the washers using the pliers 4 901 062 0 4 9 4 Cylinder head uninstall ...

Page 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: ...lation sleeve and the driver Observe the se quence Î Tighten the stopping bushings using the special tool 5 511 001 0 to 50 Nm Î Assemble the cylinder head in the reverse sequence Flange the crankshaft casing off the electric motor Î Turn out the oil drain screw at the bottom of the pump casing and collect the oil in a suitable container 4 9 5 Replace the oil rings ...

Page 28: ...he casing lid from the pump casing by opening the four screws Î Mark the bearing shells with the piston rod so that they do not get interchanged during assembling Î Loosen the bearing shells of the piston rod and take out the bearing shells Note Every bearing cup must later be refastened to the same piston rod with the same alignment Therefore mark the components prior to removal ...

Page 29: ...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 crank shaft Î Unscrew the piston screws using an Allen wrench and pull out the piston rod from the rear ...

Page 30: ...e removed Î After replacing the oil groove rings push the piston rod back into the straight pushing guide and screw on the pistons tight ening torque HD 9 50 20 Nm HD 13 35 8 9 Nm Clean the threads before screwing apply screw securing adhesive solu ble to the threading of the piston 19 shaft seal ring order no 6 367 032 0 20 discs order no 5 116 095 0 27 sleeves order no 5 111 035 0 28 seal rings ...

Page 31: ... 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 marked 9 Push bar ...

Page 32: ...w 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: ...switch off the overflow Î Loosen the hollow screws on the overflow valve evenly and re move the overflow valves Note The hollow screws must be loosened or tightened simultaneously to avoid damage to the O rings when the overflow valve is re placed Tightening torque hollow screw pressure side 160 Nm Tightening torque hollow screw suction side 40 Nm 4 10 Pump maintenance 4 10 1 Replace the overflow ...

Page 34: ...h pressure and the lock nut with locking paint Î Fasten the test manometer to the high pressure connection Î Connect the high pressure hose with the hand spray gun and the spray lance to the test manometer Î Install thenew high pressure nozzle Î Turning on the appliance Î Press the lever on the hand spray gun Î Turn in the rotary handle of the pressure quantity regulation counter clockwise until i...

Page 35: ...r fine filter Appliance ventilation Check replace high pressure nozzle Check replace the pressure and suction valves Check adjust replace overflow valve Appliance continu ously turns on and off while hand spray gun is closed Check hand spray gun for leaks and re place if necessary Check the O rings on the high pressure hose for leaks replace if necessary Check the pressure holding valve for leaks ...

Page 36: ...g pressure MPa bar 10 35 100 350 15 50 150 500 10 35 100 350 15 50 150 500 Max permissible pressure MPa bar 50 500 64 640 50 500 64 640 Water flow rate l min l h 500 1300 8 3 21 500 900 8 3 15 500 1300 8 3 21 500 900 8 3 15 Nozzle size 15049 15030 15046 15028 Recoil force of trigger gun N 93 79 93 79 Noise emission Sound pressure level EN 60704 1 dB A 78 91 Guaranteed sound power level 2000 14 EC ...

Page 37: ...ion tool 6 815 209 0 Installation man drel shaft seal ring 6 815 223 0 Installation sleeve 6 815 228 0 7 2 Tightening torques Hollow screw pressure side 160 Nm Hollow screw suction side 40 Nm Crown nut 50 Nm Valve screws Cylinder head screws 40 Nm Piston screws HD 13 35 20 Nm Piston screws HD 9 50 9 Nm Oil drain screw 40 Nm Crankshaft bearing cover screws 18 0 22 Nm Oil pan cover 5 Nm Piston rod s...

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