Karcher Karcher-Pressure-Washer-Repair-Manuals/Karcher-Pressure-Washer-Basic-Troubleshooting-Training-2005 Repair Manuals
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Karcher Basic Training 2005
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
Agenda
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
1. Basic Theory
2. Troubleshooting
3. Tools, Specifications, and Adjustments
4. Bulletins
5. 32-bit DISIS
6. Pump Service Handbooks
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
Water Flow
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
A backflow check valve (9) fitted to the main water connection
prevents detergent from entering the supply network.
The water inlet hose should be at least 25 foot long. The elasticity
of this hose prevents the recoil that occurs when the handgun is
closed from causing damage to the pump and the supply network.
The water flows from the main water connection with associated
backflow check valve (9) to the pump (13).
The pump (13) delivers the water through the high-pressure hose
(1), the handgun (16) and the spray lance (17) to the change-over
nozzle (18).
Operating pressure and flow rate are adjusted by means of the
pressure and flow control (14).
If the change-over nozzle (18) is set to high-pressure, the nonreturn valve (3) seals off the detergent suction hose (5) so that no
water can flow into the detergent reservoir (6).
The injector (2) draws detergent out of the detergent reservoir (6) as
soon as the metering valve (4) is opened and the change-over
nozzle (18) has been set to low-pressure.
When drawing water from an open tank (7), the water inlet hose
(10) must be replaced with a suction hose equipped with a filter and
non-return valve (8).
The motor (electric models) is cooled solely by the flow of air
created by the fan wheel (11) (air-cooling).
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Swash Plate with Axial Bearing
The pistons are driven via the swash plate (8) which is
directly mounted to the motor shaft (1) with a
tolerance ring (2), key, cheese head screw or nut
depending on the model.
As soon as the motor shaft rotates, the swash plate
rotates as well, and the pistons (12) move backwards
and forwards.
The piston stroke depends upon the angle of
inclination of the swash plate (8). The greater the
inclination, the longer the stroke. One revolution of the
swash plate gives one suction stroke and one pressure
stroke.
The pistons (12) are pressed against the axial bearing
(9) of the swash plate (8) by powerful springs (11).
Swash plate and pistons are permanently bathed in oil
(oil type - SAE 15W40).
The axial bearing (9) greatly reduces the friction
between the pistons and the swash plate, so that in
spite of their inherently low starting torque, singlephase motors can start up without any difficulty even
when the handgun is closed.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Pistons with Seals
The 3 pistons are manufactured from tempered,
surface-hardened steel and are non-corrosive
with regards to detergents and rust.
The pump delivery capacity is determined by
•The rotational speed of the motor
•The diameter of the piston
•The length of the piston stroke.
The piston (11) on higher pressure units (above
2400 psi) is fitted with a high-pressure seal (2)
and a low-pressure seal (6). Lower pressure
units (2400 psi and under) only have a highpressure seal (2).
The oil seal (8), mounted in the piston housing,
seals the housing and piston and retains the oil
in the reservoir.
There are leakage channels (9) in the piston
housing through which water or oil can drip out
into the open.
A water leakage rate of 1 drop per piston per
minute is allowable during high-pressure
operation. Oil leakage is not permissible and
indicates worn oil seals or defective piston.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Suction and Pressure Valves
Suction and pressure valves are not always
constructed the same way, although they may
appear very similar.
Valve plate with guide shafts (3) are only used
when the flow of water inside the cylinder
head is irregular, causing the valve plates to
show a tendency to “flutter”.
The sealing surface between the valve plate
(4) and the valve seat (5) is flat in the type of
construction shown in the illustration. Other
types have a conical sealing surface. This
brings about a reduction in noise.
Valve plate (3) and valve seat (5) are
manufactured from either plastic or stainless
steel depending upon the particular unit
involved.
Careful attention must be paid to the position
in which pressure valves are fitted (8) when
the direction of flow is lateral, so that the flow
resistance is reduced and the working life of
the valve cages are increased.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Valve Function
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Pressure and Flow Control, Manual with Overflow Valve
1. Manual pressure and flow control by
turning rotary knob
When the handgun is opened, the entire pump
capacity flows through the injector (2) to the
high-pressure outlet (1).
As a result of the action of the injector (2), the
pressure in the control chamber (14) is lower
than in the pressure chamber (11).
This means that the spindle (16) in the
overflow valve remains in the upper position
and closes off the path between the pressure
chamber (11) and the suction chamber (10).
By turning the rotary knob (3) to move the
regulating spindle (4) downwards, the
overflow valve can be opened in a continuous
movement.
A part of the pump capacity then flows from
the pressure chamber (11) into the suction
chamber (10) and the operating pressure and
flow rate drop to the amount that has been set
by turning the knob.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Pressure and Flow Control, Manual with Overflow Valve
2. When the handgun is closed
When the handgun is closed, no water flows
through the injector (2). The pressure chamber
(11) and the control chamber (14) are linked
by a connecting channel (12) and the pressure
in both areas are the same.
As the surface of the piston (13) in the control
chamber (14) is larger than in the pressure
chamber (11), it is pressed downwards
together with the overflow valve spindle (16).
This causes the entire pump capacity to flow
from the pressure chamber (11) into the
suction chamber (10) (circulation mode).
The pump continues to run, but only maintains
the circulation pressure.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Pressure and Flow Control, Manual with Overflow Valve
3. When the handgun is opened
When the handgun is opened, the pressure in
the pressure chamber (11) and in the control
chamber (14) drops suddenly.
The spring (15), together with the restricted
pressure at the entrance to the injector (2),
pushes the piston (13) upwards.
The overflow valve spindle (16) then closes off
the circulation of water between the pressure
chamber (11) and the suction chamber (10) and
the pump builds up the operating pressure once
more.
This switchover action will not function if
there is no injector fitted or it is worn out.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
High-Pressure Pump General Information
The high-pressure pump consists of a
swash plate and three pistons with
powerful springs.
The pistons each have a high-pressure
seal, a low-pressure seal (some models),
an oil seal, and a suction and highpressure check valve.
The bearings, swash plate, and pistons
w/springs are permanently bathed in oil.
The oil is sealed in the gearbox by a
rotary shaft seal on the swash plate shaft
and by oil seals on the pistons.
The swash plate is secured directly to
the motor shaft hence the term “direct
drive”. As soon as it rotates, the pistons
are pushed forward one after another
(pressure stroke) and forced back by the
springs (suction stroke).
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Suction and Pressure Stroke Illustration
Suction Stroke –When the pistons are
forced backwards by the spring, the
pressure valve closes and water from the
suction chamber/supply line is drawn in
through the open suction valve.
Pressure Stroke –when the swash plate
pushes the piston forward, the suction
valve closes and water is pushed
through the open pressure valve to the
high-pressure outlet. The pressure that is
generated is dependent on the flow rate
and the diameter of bore (orifice size) of
the high-pressure nozzle.
Suction Stroke –Pressure Stroke –Suction Stroke –Pressure Stroke –Suction Stroke –
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Overflow Valve with Pressure Switch (Electric Models)
1. The handgun has been opened
With the handgun open and the pump running, the
injector (1) causes the pressure in the control
chamber (5) to be approx. 145 psi lower than in the
pressure chamber (2).
The overflow piston is in the upper position, where
it actuates the contact in the pressure switch (9) via
the pin (8). The electrical circuit is completed and
the motor runs.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Overflow Valve with Pressure Switch (Electric Models)
2. The handgun is closed
If the handgun is closed, water no longer flows
through the injector (1). As a result the pressure in
both the pressure chamber (2) and the control
chamber (5) is the same.
Due to the larger surface of the overflow piston
(16) in the control chamber (5) than in the pressure
chamber (2), the overflow piston is pressed
downwards and opens the connection between the
pressure chamber and the suction chamber.
At the same time the contact on the pressure switch
(9) is opened by means of the pin (8), the electrical
circuit is interrupted and the motor is switched off.
When the handgun is closed, the pressure in the
pressure chamber rises abruptly for an instant. The
non-return valve (17) closes and before the motor
comes to a halt, the peak of pressure is dissipated
through the connecting channel (11) by the pressure
relief valve (10). The cutout pressure remains in the
system for as long as the handgun is closed.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
For Karcher Pressure Washer Parts Call 606-678-9623 or 606-561-4983
Overflow Valve with Pressure Switch (Electric Models)
3. The handgun is opened
If the handgun is opened again, the pressure in the
high-pressure hose and in the control chamber (5)
drops off. The pressure spring (15) underneath the
overflow piston (16) pushes the piston upwards and
closes the contact in the pressure switch (9) by
means of the pin (8). The electrical circuit is
completed and the motor starts without any
backpressure.
Karcher Basic Training 2005 –Instructor Ken Carithers
www.mymowerparts.com
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