Kärcher HD 6/15 M User manual

HD 6/15, HD 7/17 (M/MX)
HD 7/14-4, HD 7/16-4, HD 8/18-4 (M/MX) with HD-M
Cage variants
5.906-780.0 (05/18)

2 English
Contents
1 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Hazard levels . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Shown in this service handbook . . . . . . . . . . . . . 3
3.1 Structure of function groups . . . . . . . . . . . . . . . . 3
3.2 Textual display . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Technical features. . . . . . . . . . . . . . . . . . . . . . . . 3
4.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.4 Overflow valve with pressure switch. . . . . . . . . . 4
4.5 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.6 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.7 Recommended accessories . . . . . . . . . . . . . . . . 4
5 Overview of the unit . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Overview of electrical box HD 6/15 MX . . . . . . . 7
5.2 Overview of electrical box HD 8/18 M. . . . . . . . . 8
5.3 Pump head HD 6/15 MX overview . . . . . . . . . . . 8
5.4 Pump head HD 8/18 M overview . . . . . . . . . . . . 8
6 HD 6/15 M/MX cross-section drawings. . . . . . . . 9
7 HD 8/18 M cross-section drawings . . . . . . . . . . . 13
8 HD 7/17 M cross-section drawings . . . . . . . . . . . 17
9 Structure of service group. . . . . . . . . . . . . . . . . . 18
9.1 010 Safety instructions . . . . . . . . . . . . . . . . . . . . 18
9.2 020 Structure overview . . . . . . . . . . . . . . . . . . . . 18
9.3 030 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.4 040 Service activities . . . . . . . . . . . . . . . . . . . . . 19
9.4.1Opening / closing the cover . . . . . . . . . . . . . . . . 19
9.4.2Opening / closing the electrical box . . . . . . . . . . 19
9.4.3Removing/installing the electrical box HD 6/15 MX 20
9.4.4Removing/installing the electrical box HD 8/18 M 20
9.4.5Removing/installing the chassis . . . . . . . . . . . . . 20
9.4.6Removing/installing the hose reel angle piece . . 21
9.4.7Removing/installing, disassembling the shoulder
module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.4.8Removing/installing a wheel . . . . . . . . . . . . . . . . 23
9.4.9Removing/installing the hose reel. . . . . . . . . . . . 23
9.4.10Removing/installing the power switch linkage. . 24
9.5 050 Service and inspection. . . . . . . . . . . . . . . . . 25
9.5.1Cleaning the water filter . . . . . . . . . . . . . . . . . . . 25
9.6 060 Fault diagnosis. . . . . . . . . . . . . . . . . . . . . . . 25
9.7 070 Special features / other . . . . . . . . . . . . . . . . 25
10 Electrical system service group . . . . . . . . . . . . . 26
10.1 010 Safety instructions . . . . . . . . . . . . . . . . . . . . 26
10.2 020 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.3 030 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.4 040 Service activities . . . . . . . . . . . . . . . . . . . . . 27
10.4.1Removing/installing the capacitor . . . . . . . . . . . 27
10.4.2Removing/installing the motor circuit breaker. . 27
10.4.3Removing/installing the motor circuit breaker. . 27
10.4.4Removing/installing the power supply cable . . . 28
10.4.5Removing/installing the power supply cable . . . 28
10.4.6Removing/installing the power switch. . . . . . . . 28
10.4.7Removing/installing the contactor HD 8/18 M. . 29
10.4.8Removing/installing the motor HD 6/15 MX . . . 29
10.4.9Removing/installing the motor HD 8/18 M . . . . 30
10.5 050 Service and inspection. . . . . . . . . . . . . . . . . 30
10.6 060 Fault diagnosis. . . . . . . . . . . . . . . . . . . . . . . 30
10.7 070 Special features / other . . . . . . . . . . . . . . . . 30
11 Pump service group . . . . . . . . . . . . . . . . . . . . . . 31
11.1 010 Safety instructions . . . . . . . . . . . . . . . . . . . . 31
11.2 020 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.3 030 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.4 040 Service activities . . . . . . . . . . . . . . . . . . . . . 32
11.4.1Removing/installing the pipeline HD 6/15 MX . . 32
11.4.2Removing/installing the pump head . . . . . . . . . 32
11.4.3Removing/installing high pressure seals. . . . . . 33
11.4.4Removing/installing the suction valves HD 6/15 MX 34
11.4.5Removing/installing the suction valves HD 8/18 M 35
11.4.6Removing/installing the pressure retention valves
HD 6/15 MX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.4.7Removing/installing the pressure retention valves
HD 8/18 M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.4.8Removing/installing the pressure valves HD 6/15
MX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.4.9Removing/installing the pressure valves HD 8/18 M 37
11.4.10Removing/installing the pressure switch . . . . . 38
11.4.11Removing/installing the startup valve HD 6/15 MX 38
11.4.12Removing/installing the pressure relief valve HD 6/
15 MX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.4.13Removing/installing the pressure relief valve HD 8/
18 M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.4.14Removing/installing the low pressure seals . . . 39
11.4.15Removing/installing the pump set (non-cage vari-
ants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.4.16Removing/installing the pump set (cage variants) 40
11.4.17Removing/installing the pistons and oil seals. . 41
11.4.18Removing/installing the swash plate for 2-pole mo-
tors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.4.19Removing/installing the swash plate for 4-pole mo-
tors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.4.20Removing/installing the A bearing, B bearing, radi-
al shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.4.21Removing/installing the overflow valve . . . . . . 45
11.5 050 Service and inspection . . . . . . . . . . . . . . . . .46
11.5.1Draining/replacing the pump oil . . . . . . . . . . . . . 46
11.6 060 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . 46
11.7 070 Special features / other . . . . . . . . . . . . . . . . . 46
12 Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . 46
13 Technical documentation . . . . . . . . . . . . . . . . . . . 47
13.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
13.3 Special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13.4 Circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 51

English 3
1 Foreword
Good service work requires extensive and practical train-
ing and clear documentation. That’s why we offer all ser-
vice technicians regular basic training and advanced
training for the entire product range.
We also create service handbooks for the important units
that can initially be used as instructions and later as refer-
ence material.
Furthermore, we provide regular service information on the
development of the products.
If you have amendments, corrections or queries regarding
this document, please send them with the following subject
line:
[email protected]ercher.de
The corresponding product specialist will be take care of
your concerns.
Copying and duplication of the texts and pictures as
well as passing them on to third parties require the ex-
plicit authorization of the company:
Alfred Kärcher GmbH & Co. HG
Postfach 160
D-71349 Winnenden
www.kaercher.com
2 Safety instructions
Service and maintenance work may only be performed by
suitably qualified and specially trained personnel.
Observe the safety instructions in the chapters!
DANGER
Danger of lethal electric shock from electrical voltage.
Switch off the device immediately and unplug the mains
plug before performing work.
몇CAUTION
Risk of injury from escaping high-pressure water.
Depressurise the system prior to all work.
몇CAUTION
Risk of burns from hot surfaces.
Allow the device to cool down prior to all work.
2.1 Hazard levels
DANGER
Indication of an imminent threat of danger that will lead to
severe injuries or even death.
몇WARNING
Indication of a potentially dangerous situation that may
lead to severe injuries or even death.
몇CAUTION
Indication of a potentially dangerous situation that may
lead to minor injuries.
ATTENTION
Indication of a potentially dangerous situation that may
lead to damage to property.
3 Shown in this service handbook
3.1 Structure of function groups
3.2 Textual display
Preparatory tasks
1Numerical legend
1. Guideline
ATTENTION
Safety instructions
Note on dangers, source of errors.
4 Technical features
General
Water volume 600 to 800 l/h
Pressure 140 to 180 bar
Connection output 3.1 to 4.6 kW
Drivable device, modular device or cage device ver-
sions available
Device without detergent suction
Addition of detergent via the cup foam lance or a sepa-
rate injector
No pressure regulation via servo control (single-phase
devices). Pressure regulation via a separate power con-
trol spray lance
Power nozzle included in scope of delivery
High-pressure pump
3-piston axial pump with stainless steel pistons
Specially hardened piston with fine-ground surface
Piston diameters of 12, 14 and 18 mm
Swash plate with axial bearing
Brass cylinder head and water-bearing parts
Pressure relief system
Startup valve (single-phase devices)
Startup valve, pressure relief valve and pressure switch
piston run in replaceable brass sleeves - no wear at the
cylinder head
Easy oil change via oil drain hose and oil tank
Standing and lying operation possible
Electrical system, drive
Air-cooled electric motor with winding protection contact
Overcurrent switch, 1 piece for single-phase devices
and 2 pieces for three-phase devices
Annealed rotor for good motor startup (HD 6/15 M)
Aluminium winding package (HD 6/15 M)
Motors for single-phase and three-phase operation
Two-pole and four-pole motors
Two-pole pressure switch
Equipment
Retractable push handle
Carrying handle
Nozzle storage for triple nozzle and rotary nozzle
Transport retainer for surface cleaner
Holder for cup foam lance
Subject: Case 123352
010 Safety instructions
020 Overview
030 Function
040 Service activities
050 Service and inspection
060 Fault diagnosis
070 Special features/other

4 English
Cable clips
Rubber strap as transport lock for mains cable and high-
pressure hose (not with CX variant)
Additional spray lance holder with a clamp for transport
Metal sieve in water connection
Accessories possible
Rotary nozzle
Foam lance
Power Control spray lance
4.1 Intended use
Use this high-pressure cleaner only for the following types
of work:
Use the high-pressure jet for cleaning machines, vehi-
cles, buildings, tools and similar objects.
We recommend using a rotary nozzle as a special acces-
sory for stubborn soiling.
The HD...Plus is supplied with a rotary nozzle.
4.2 Scope
This service handbook applies for the following units:
HD 6/15, HD 7/17 (M/MX)
HD 7/14-4, HD 7/16-4, HD 8/18-4 (M/MX)
The figures in this service manual show the HD 6/15 MX
and HD 8/18 M devices.
Other models have a comparable structure.
4.3 Safety devices
Safety devices protect the user and may not taken out of
operation or functionally circumvented.
Adhere to the safety instructions in the chapters!
4.4 Overflow valve with pressure switch
When the water quantity is reduced via the pressure/quan-
tity control, the overflow valve opens and some of the wa-
ter flows back to the suction side of the pump (not with
single-phase devices).
When the trigger on the high-pressure gun is release, the
pressure switch switches off the high-pressure pump and
the high-pressure jet stops.
The pump switches on again when the trigger is pulled.
4.5 Safety valve
The safety valve opens when the permissible operating
pressure is exceeded and the water flows back to the suc-
tion side of the pump.
4.6 Type plate
The type plate is located on the left-hand side.
1Operating pressure (max.)
2Working pressure
3Flow rate
4Power supply
5Device designation
6Connection output
7Part number
8Operating weight
9Year of manufacture
10 Serial number
11 Degree of protection
12 Nozzle size
13 Input temperature (max.)
14 Barcode. Includes the part number and the serial num-
ber
15 Manufacturer's address
4.7 Recommended accessories
Foam lance
4.112-053.0
Foam lance TR Basic 1 (corresponds to nozzle 038) for 400-600
l/h
4.112-054.0
Foam lance TR Basic 2 (corresponds to nozzle 045) for 700-800
l/h
4.112-055.0
Foam lance TR Basic 3 (corresponds to nozzle 038) for 900-2500
l/h

English 5
1Foam nozzle
2Driving nozzle
3Suction hose
4Gate
5Bottle
6Detergent injector nozzle
7Air injector nozzle
8sieve
The foam lance is used for adding detergent when per-
forming high pressure cleaning.
The water flow through the driving nozzle and detergent in-
jector nozzle generates a vacuum that sucks detergent out
of the bottle. The pluggable gate set (sizes 1 - 3) defines
the amount of detergent injected. The water-detergent
mixture passes through the air injector nozzle and sucks in
air through the foam nozzle. The water-detergent-air mix-
ture is intensively mixed by the sieve. The generated foam
is expelled through the adjustable foam nozzle.
The foam lance is adjusted to suit the device power via dif-
ferent sizes of driving nozzles and detergent injector noz-
zles.
Note
Flush the foam nozzle clear after work and occasionally
clean or replace the sieve as necessary.

6 English
5 Overview of the unit
1Water connection
2Pump set
3Rotary knob
4Power supply cable
5Hose reel (X variants only)
6Handle
7Trigger spray gun
8Pipelines (X variants only)
9Shoulder module with spray lance holder
10 Type plate
11 High-pressure outlet (Standard variant)

English 7
HD-M Cage variant
5.1 Overview of electrical box HD 6/15 MX
1Power supply cable
2Capacitor
3Motor circuit breaker reset bow
4Motor circuit breaker
5Actuator
6Power switch

8 English
5.2 Overview of electrical box HD 8/18 M
1Power supply cable
2Circuit breaker
3Motor circuit breaker reset bow
4Motor circuit breaker
5Actuator
6Power switch
5.3 Pump head HD 6/15 MX overview
1Suction valves
2Suction bridge
3Water inlet
4Startup valve
5Pressure relief valve
6Pressure switch
7High-pressure outlet
8Pressure retention valve
9Pressure valves
5.4 Pump head HD 8/18 M overview
1Suction valves
2Suction bridge
3Water inlet
4Pressure relief valve
5Overflow valve
6Pressure switch
7High-pressure outlet
8Pressure retention valve
9Pressure valves

English 9
6 HD 6/15 M/MX cross-section drawings
Cylinder head
1Suction/pressure valve
2Plugs
3Retaining plate
4Caps
5Pressure retention valve
6Sleeve
7Sleeves
8Plate
9Pressure relief valve
10 Cylinder head
11 Plugs
12 Water inlet with filter
13 Suction bridge
14 Sleeve

10 English
Startup valve
1Spring
2Valve seat
3Ball
4Sleeve
5Startup valve
Note
Replacement startup valve only as a complete unit.
The startup valve eases the motor startup in single-phase devic-
es.
The spring holds the ball open when the device is switched off.
The motor starts up without back-pressure. After the motor has
starts up, the water pressure closes the ball against the spring
force.
Pressure switch
1Pressure switch
Note
Replacement pressure switch only as a complete unit.
2Sleeve
3Complete pressure switch piston
4Seal
Note
The seal prevents leakage water from penetrating into
the electrical box.
Overflow valve
1Pressure relief
2Spring
3Piston
4Valve seat
Note
Replacement pressure limiter only as a complete unit.
The pressure limiter protects the device from overpressure. After
switching the device off via the gun, the pressure is reduced to
approx. 50 bar. This preserves the pipeline system and eases
opening of the gun.
When the gun is closed, the pressure tip opens the return line to
the suction chamber via the valve seat against the spring force.
The pressure relief also opens briefly.

English 11
HD 6/15 M/MX pump set
1Radial shaft seal
2Ball bearing (A bearing)
3Swash plate
4Axial bearing
5Piston
6Piston guide
7Washer (plastic)
8Low pressure seal
9Washer (brass)
10 Socket
11 O-ring
12 High pressure seal
13 Gasket package

12 English
Straight thrust guide
1Washer
2Piston spring
3Piston
4Oil groove ring
5Piston guide
Motor
1Casing
2Rotor
3Winding
4Air guide
5Fan
6Ball bearing (B bearing)
7Radial shaft seal
8Ball bearing (A bearing)
9Motor shaft

English 13
7 HD 8/18 M cross-section drawings
Cylinder head
1Suction bridge
2Screws
3Suction/pressure valve
4Valve screws
5Pressure retention valve
6Overflow valve
7Pressure relief valve
8Water inlet with filter

14 English
Overflow valve
1Spring
2Tap er
3Valve seat
4Sleeve
5Piston
6Overflow valve
7Complete pressure limiter spare parts kit
8Servo valve spare parts kit
Note
Replacementcompletepressurelimiterandvalveservo
only available as a complete spare parts kit.
The overflow valve is used for pressure regulation and pro-
vide overpressure protection.
The pressure in the system rises or falls according to the
setting of the rotary control on the gun. When the pressure
is sufficiently high, the piston lifts the taper more or less
from the valve seat and water flows back to the suction
side.
Pressure switch
1Sleeve
2Complete pressure switch piston
3Seal
Note
The seal prevents leakage water from penetrating into
the electrical box.
Replacement pressure switch only as a complete unit.
The pressure switch switches off the device in the case of over-
pressure.
A sufficiently high water pressure in the device presses the pres-
sure switch piston against the spring force and actuates the mi-
croswitch. The device switches off and then on again after
pressure reduction.

English 15
Pressure relief valve
1Pressure relief valve
2Valve screw
After the device is switched off, the pressure relief valve lowers
the device pressure to approx. 50 bar via the gun. This preserves
the pipeline system and eases opening of the gun.
When the gun is closed, the pressure tip briefly opens the return
line to the suction chamber, thus reducing the device pressure.
Pump set HD 8/18 M
1Radial shaft seal
2Tapered ball bearing (A bearing)
3Swash plate
4Axial bearing
5Piston
6Piston guide
7Washer (plastic)
8Low pressure seal
9Washer (brass)
10 Socket
11 O-ring
12 High pressure seal

16 English
Motor HD 8/18 M
1Casing
2Rotor
3Winding
4Air guide
5Fan
6Ball bearing (B bearing)
7Radial shaft seal
8Tapered ball bearing (A bearing)
9Motor shaft

English 17
8 HD 7/17 M cross-section drawings
Pump set
1Radial shaft seal
2Ball bearing (A bearing)
3Swash plate
4Axial bearing
5Piston
6Piston guide

18 English
9 Structure of service group
9.1 010 Safety instructions
DANGER
Danger of lethal electric shock from electrical voltage.
Switch off the device immediately and unplug the mains
plug before performing work.
몇CAUTION
Risk of injury from escaping high-pressure water.
Depressurise the system prior to all work.
몇CAUTION
Risk of burns from hot surfaces.
Allow the device to cool down prior to all work.
9.2 020 Structure overview
19.4.2 Opening / closing the electrical box
9.4.3 Removing/installing the electrical box HD 6/15 MX
9.4.4 Removing/installing the electrical box HD 8/18 M
29.4.1 Opening / closing the cover
39.4.6 Removing/installing the hose reel angle piece
49.4.9 Removing/installing the hose reel
59.4.7 Removing/installing, disassembling the shoulder
module
69.4.5 Removing/installing the chassis
79.4.8 Removing/installing a wheel
89.4.10 Removing/installing the power switch linkage

English 19
9.3 030 Function
No special functional features.
9.4 040 Service activities
Note Unless otherwise described, installation is performed in re-
verse order.
9.4.1 Opening / closing the cover
1Rotary knob
2Cover
3Screws
1. Turn the rotary knob to position "0".
2. Unscrew the screws.
3. Remove the cover.
9.4.2 Opening / closing the electrical box
9.4.1 Opening / closing the cover
1Cover
2Screws
1. Unscrew the screws.
2. Remove the cap.

20 English
9.4.3 Removing/installing the electrical box HD 6/15 MX
9.4.2 Opening / closing the electrical box
10.4.1 Removing/installing the capacitor
10.4.4 Removing/installing the power supply cable
10.4.2 Removing/installing the motor circuit breaker
10.4.6 Removing/installing the power switch
1Electrical box
1. Remove the electrical box.
9.4.4 Removing/installing the electrical box HD 8/18 M
9.4.2 Opening / closing the electrical box
10.4.3 Removing/installing the motor circuit breaker
10.4.5 Removing/installing the power supply cable
10.4.6 Removing/installing the power switch
10.4.7 Removing/installing the contactor HD 8/18 M
1Electrical box
1. Remove the electrical box.
9.4.5 Removing/installing the chassis
11.4.15 Removing/installing the pump set (non-cage variants)
1Screws
2Chassis
1. Unscrew the screws.
2. Remove the chassis.