Related Manuals for Kärcher HD 9/50-4 Cage
Summary of Contents for Kärcher HD 9/50-4 Cage
- Page 1 HD 9/50-4 Cage HD 13/35-4 Cage HD 9/50 PE Cage HD 13/35 PE Cage Service Manual English 5.906-441.0 Rev. 01 (06/10)
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Page 2: Table Of Contents
HD 9/50-4 Cage, HD 13/35-4 Cage 3.3.2 HD 9/50 PE Cage, HD 13/35 PE Cage Accessories Setup and function Total view HD 13/35-4 Cage, HD 9/50-4 Cage Switch box HD 13/35-4 Cage, HD 9/50-4 Cage 4.2.1 Indicator lamp Electric motor HD 13/15-4, HD 9/50-4... - Page 3 4.9.6 Replace the piston 4.10 Pump maintenance 4.10.1 Replace the overflow valve Basic settings and service procedures Setting the maximum working pressure Setting the minimum working pressure Adjusting the full load speed (PE model only) Troubleshooting Technical specifications Special tools Tightening torques Circuit diagram English 5.906-441.0 Rev.
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Page 4: Preface
– High pressure hose 10 m Copying and duplication of texts and diagrams as well as HD 9/50-4 Cage: DN 8, 64 MPa (640 bar) third-party access to this information is permitted only with HD 13/35-4 Cage: DN 10, 62 MPa (620 bar) the explicit permission of the company: –... -
Page 5: Setup And Function
Setup and function Total view HD 13/35-4 Cage, HD 9/50-4 Cage 1 Trigger gun 18 Accessory compartment 2 Lever for hand spray gun 19 Oil drain screw (pump) 3 Safety catch 20 Water connection with filter, 1" Geka 4 High pressure hose... -
Page 6: Switch Box Hd 13/35-4 Cage, Hd 9/50-4 Cage
Switch box HD 13/35-4 Cage, HD 9/50-4 Cage 1 Cover, switch box 11 Contactor (K1) 2 Indicator lamp lack of water fuse (option) 12 Soft starter board (A2) 3 Indicator lamp operation status / malfunction 4 Appliance switch (S1) 5 Fuse (F1), 1AT... -
Page 7: Indicator Lamp
Check electrics/replace defective component. 4.2.1 Indicator lamp – blinks red once: The indicator lamps display the operating states (green) and inter- High-pressure side is leaky. ruptions (red). Check high pressure hose, hose connections and hand spray Reset: gun for leaks. Set the appliance switch to "0". -
Page 8: Total View Hd 13/15 Pe, Hd 9/50 Pe
Total view HD 13/15 PE, HD 9/50 PE 1 Power nozzle with covering nut 21 Water connection with filter 2 Spray lance 22 Oil drain screw (pump) 3 Trigger gun 23 Oil level indicator (pump) 24 High pressure connection 4 Lever for hand spray gun 5 Safety catch 25 Oil dip (engine) 6 High pressure hose... -
Page 9: Petrol Engine Hd 13/15 Pe, Hd 9/50 Pe
Petrol engine HD 13/15 PE, HD 9/50 PE 4.5.1 Battery 4.5.2 Motor 1 Battery connection cable (+) 2 Battery terminal (+) 1 Air filter box 3 Battery (voltage and capacity, see "Specifications“) 2 Fuel tap 4 Battery terminal (-) 3 Oil filling screw (engine) 5 Battery connection cable (-) 4 Ignition plug 6 Battery holder... - Page 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. English 5.906-441.0 Rev. 01 (06/10)
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Page 11: Motor Electrics
4.5.3 Motor electrics 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. -
Page 12: Air Filter
4.5.4 Air filter 1 Lock 4 Fastening screws, air filter box 2 Cover, air filter box 5 Air filter box 3 Air filter insert 4.5.5 Motor with removed 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... -
Page 13: Speed Control
4.5.6 Speed control 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. -
Page 14: Intermediate Gear
4.5.7 Intermediate gear Install the intermediate gear: Fasten the intermediate gear to the high pressure pump using 4 screws. Fasten the high pressure pump to the counter holder Slide the toothed gear onto the shaft of the high pressure pump. Align the toothed wheel so that the shaft protrudes by 13±0,2 1 Oil level indicator mm from the toothed wheel. -
Page 15: Water Connection With Water Fine Filter
Water connection with water fine filter 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 Pump 1 Oil filling nozzle 2 Crankshaft bearing cover 3 Oil level indicator 4 Oil drain screw 5 High pressure connection... -
Page 16: Pump Diagram
4.7.1 Pump diagram 24 Support disc, brass 1 Lock screw, suction side, with O-ring 2 Disc 25 Disc (back ring) 3 Suction valve with O-ring 26 High pressure seal 4 Ceramic piston 27 Support ring, high pressure seal 5 Piston screw 28 Lockscrew, pressure side, with O-ring 6 Oil seal ring 29 Pressure valve, with O-ring... -
Page 17: Crank Drive Disassembled
4.7.2 Crank drive disassembled 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 Push bar... -
Page 18: Cylinder Head, High Pressure Valves And Water Inlet
4.7.3 Cylinder head, high pressure valves and water inlet 1 Lockscrew, pressure side, with O-ring 4 O ring 2 Pressure valve, with O-ring 5 Lock screw, suction side, with O-ring 3 Cylinder head 6 Suction valve with O-ring 4.7.4 Cylinder head, overflow valve 1 Cylinder head 10 Adjustment screw, low pressure 2 Hollow screw, suction side, with 2 O-rings... -
Page 19: Safety Valve, Dry Run Protection Switch
4.7.5 Safety valve, dry run protection switch 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 English 5.906-441.0 Rev. -
Page 20: Cylinder Head, Piston Seals
4.7.6 Cylinder head, piston seals 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 silicone... -
Page 21: Overflow Valve
46 Hollow screw, pressure side 21 Adjustment screw, low pressure 22 Spring 47 O ring 23 Spring plate, top 48 O ring 24 Sphere * HD 13/35-4 Cage and HD 9/50-4 Cage only 25 Spindle of the pressure/quantity regulation English 5.906-441.0 Rev. 01 (06/10) -
Page 22: Overflow Valve, Cross Section Drawing
4.8.2 Overflow valve, cross section drawing 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, suction side) C High-pressure outlet... -
Page 23: Seal High Pressure Pump
Seal high pressure pump 4.9.1 Replace the pressure and suction valves Turn off the appliance switch and secure against restart. Shut off water supply. 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. -
Page 24: Replace Pressure Valves
Insert the lockscrews of the suction valves and tighten them to 40 Nm (grease O-rings). Press in the new pressure valves manually (grease the O- rings). 4.9.3 Replace pressure valves Loosen the lockscrews of the pressure valves. Pull the pres- sure valves out with the pliers 4.901-062.0. -
Page 25: Cylinder Head, Uninstall
4.9.4 Cylinder head, uninstall Unscrew the overflow or slightly loosen the hollow screws that secure the overflow. Loosen the 8 screws from the pump head. Carefully pull out the cylinder head using both hands. 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). - Page 26 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 English 5.906-441.0 Rev. 01 (06/10)
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Page 27: Replace The Oil Rings
Insert the new washers into the screw insert. Tighten the stopping bushings using the special tool 5.511- 001.0 to 50 Nm. Assemble the cylinder head in the reverse sequence. 4.9.5 Replace the oil rings Flange the crankshaft casing off the electric motor Turn out the oil drain screw at the bottom of the pump casing and collect the oil in a suitable container. - Page 28 Loosen the 4 flange screws from the pump casing. Carefully remove the pump casing using the proper tools at the respective pockets. Remove the casing lid from the pump casing by opening the four screws. Loosen the bearing shells of the piston rod and take out the bearing shells.
- Page 29 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. Press the piston rods backwards to the end-position and take out the crank shaft.
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Page 30: Replace 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 (order no. 7.362-029.0) 29 screws (order no. 7.306-244.0) Removing the oil seal rings 1 Special pliers to remove the oil seal rings 2 Oil seal ring 3 Pump casing Remove 3 oil seals from the pump housing with the special pli-... - Page 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, marked 9 Push bar English 5.906-441.0 Rev.
- Page 32 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. Assemble back the parts in the reverse sequence. Fill in SAE 90 oil (part no. 6.288-061.0) to the sight glass (ap- prox.
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Page 33: Pump Maintenance
4.10 Pump maintenance 4.10.1 Replace the overflow valve 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. Note The hollow screws must be loosened or tightened simultaneously to avoid damage to the O-rings when the overflow valve is re- placed. -
Page 34: Basic Settings And Service Procedures
Basic settings and service procedures Setting the maximum working pressure Setting the minimum working pressure Fasten the test manometer to the high-pressure connection. Connect the high-pressure hose with the hand spray gun and the spray lance to the test manometer. Install thenew high pressure nozzle. -
Page 35: Troubleshooting
Troubleshooting Fault Remedy Fault Remedy Oil escapes be- Replace the oil seals. Appliance is not Operational readiness period (30 min- tween the cylinder running; indicator utes) has expired. Switch on/off the appli- head and the pump lamp links green ance again. housing Self shut-off after 30 minutes;... -
Page 36: Technical Specifications
Technical specifications Type HD 13/35-4 HD 9/50-4 HD 13/35 Pe HD 9/50 Pe 1.367-150.0 1.367-151.0 1.367-500.0 1.367-501.0 Power connection Voltage Current type 3~50 Connection output Mains fuse (slow-blow) Maximum allowed net impedance (0.075+j0.075) Petrol motor Honda GX 670, 2 cylinder, 4-stroke Maximum torque at 3600 rpm kW/HP 17/24... -
Page 37: Special Tools
Special tools Tightening torques Pliers 4.901-062.0 Hollow screw, pressure side 160 Nm Hollow screw, suction side 40 Nm Crown nut 50 Nm Valve screws Drawing tool 6.815-013.0 Cylinder head screws 40 Nm Piston screws, HD 13/35 20 Nm Piston screws, HD 9/50 9 Nm Drive mandrel 6.815-229.0...