Kärcher PW 20 User manual

English 5.906-507.0 Rev. 00 (08/10) 1
PW 20, PW 30/1
Service Manual

2 English 5.906-507.0 Rev. 00 (08/10)
Contents
1 Preface 3
2 Safety instructions 3
2.1 Hazard levels 3
3 Technical Features 3
3.1 Required tools 3
4 Parts of the system 3
5 Basic settings and service procedures 6
5.1.1 Remove the covering plate 6
5.1.2 Replacing the brush roller - PW 20 6
5.1.3 Replace the brush motor 6
5.1.4 Replacing the mains cable 7
5.1.5 Replace the interference filter 7
5.1.6 Replace the appliance switch, safety switch 7
4.2 PW 30/1 5
5.2.1 Replacing the brush roller 7
5.2.2 Replace the motor. 9
5.2.3 Replace the interference filter 11
5.2.4 Replace toothed drive wheel 11
5.2.5 Replace appliance switch 11
5.2.6 Replace the spray hose 11
5.2.7 Replace the spray nozzle 12
5.2.8 Replace the spray valve 12
5.2.9 Replacing the mains cable 13
5.2.10 Replace the running roller 13
5.2.11 Reset the safety switch 13
6 Maintenance and care 14
6.1 After each operation 14
6.2 Half-yearly 14
7 Troubleshooting 14
8 Technical specifications 14
8.1 Special tools 14
8.2 Tightening torques 14
9 Circuit diagram 15
4.1 PW 20 15
4.2PW 30/1 16

English 5.906-507.0 Rev. 00 (08/10) 3
Good service work requires extensive and practice-
oriented training as well as well-structured training
materials.
Hence we offer regular basic and advanced training
programmes covering the entire product range for all
service engineers.
In addition to this, we also prepare service manuals
for important appliances - these can be initially used
as instruction guides and later on as reference
guides.
Apart from this, we also regular information about
product enhancements and their servicing.
If you should require supplements, have corrections
or questions regarding this document, please ad-
dress these citing the following subject to:
[email protected]
The responsible product specialist will take care of
your issue.
Copyingandduplicationoftextsand diagrams as
well as third-party access to this information is
permitted only with the explicit permission of the
company:
Alfred Kärcher GmbH & Co. KG
P O Box 160
D -71349 Winnenden
www.kaercher.com
Danger
Immediate danger that can cause severe injury or
even death.
몇Warning
Possible hazardous situation that could lead to se-
vere injury or even death.
Caution
Possible hazardous situation that could lead to mild
injury to persons or damage to property.
Note
indicates useful tips and important information.
Structure:
–Brush width PW 20: 290 mm
–Brush width PW 30/1: 315 mm
–Drive motor, shielded, with built-in overload fuse.
–Spray, brush, vacuum in one work process.
–Wide spray nozzles ensure an even spray on the
full brush width.
–Quick coupling for easy handling.
–Philips screwdriver, large
–Flat tip screwdriver, large
–Combination pliers
–Open wrench SW 13, 10, 8
–Hexagonal socket wrench SW 5, 4, 3, 2
1 Preface
Subject: Fall 109999
2 Safety instructions
2.1 Hazard levels
3 Technical Features
3.1 Required tools

4 English 5.906-507.0 Rev. 00 (08/10)
1Casing
2 Power cord
3 Spray hose
4 Power switch
5 Running roller
6 Safety switch
7 Mount for swivel arm
8 Valve handle
9 Suction pipe
10Carrying handle
1 Brush roller
2 Spray nozzles
3 Covering plate
4 Brush roller drive
5 Running roller
4 Parts of the system
4.1 PW 20
9 810
4367
1
5 2

English 5.906-507.0 Rev. 00 (08/10) 5
1 Power switch
2 Holding plate
3 Running roller
4 Safety switch
5 Hood
6Casing
7 Spray hose
8 Valve handle
9 Suction pipe
10Power cord
1 Running roller
2 Brush roller
3 Spray hose
4 Spray nozzle
4.2 PW 30/1
10
5
1
4
9
8
2
6
3
7

6 English 5.906-507.0 Rev. 00 (08/10)
Danger
First pull out the plug from the mains before carrying
out any tasks on the machine.
1 Fastening screws
2 Covering plate
ÎUnscrew locking screws.
ÎRemove the covering plate.
1 Brush motor
2Swivelarm,right
3 Brush roller drive
4 Brush roller
5 Swivel arm, left
6 Safety switch
7Powerswitch
8 Terminal strip
9 Spray hose
10Spray channel
11Power cord
12Anti-interference filter
ÎPlace the PW 20 on its back and swivel up the
brush roller
ÎUnscrew and withdraw both bolts on the front of
the brush.
ÎRemove the toothed belt.
ÎRemove the brush.
ÎAssembly of the brush in reverse sequence.
1 Brush motor
2 Fastening screw for brush motor
3 Drive pinion
4 Mount for swivel arm
5 Gear belt
6 Cover
7 Spray nozzles
8 Fastening screws for cover
9 Nozzle tube
ÎPlace the PW 20 on its back and swivel up the
brush roller
ÎUnscrew and withdraw both bolts on the front of
the brush.
ÎRemove the toothed belt.
ÎRemove the brush.
ÎUnscrew the fastening screws for the cover.
ÎRemove cover.
ÎRemove the toothed belt, replace if necessary.
ÎRemove the fastening screw of the drive pinion.
5 Basic settings and service procedures
5.1 PW 20
5.1.1 Remove the covering plate
11 1
1
32
112
3
116 7
45 2
8 9 10
5.1.2 Replacing the brush roller - PW 20
5.1.3 Replace the brush motor
2
7
3
4
5
6
198

English 5.906-507.0 Rev. 00 (08/10) 7
ÎRemove the connecting cable from the brush mo-
tor.
ÎUnscrew the fastening screws (2x) for the brush
motor.
ÎRemove the brush motor.
ÎInstall the new brush motor in reverse sequence.
1 Brush motor
2 Anti-interference filter
3 Power cord
4 Clamp for mains cable
5 Power switch
6 Safety switch
7 Terminal strip
ÎRemove the clamp for mains cable.
ÎUnscrew the ground cable (protective conductor)
from the terminal strip.
ÎRemove the phase and the zero conductor from
the terminal strip.
ÎThread the mains cable through the grommet.
ÎInstall the new mains cable in reverse sequence.
ÎRemove the connecting cable of the noise filter on
the brush motor and unscrew it from the terminal
strip.
ÎReplace the interference filter.
ÎConnect the new noise filter.
ÎRemove the connecting cable from the appliance
switch/safety switch.
ÎReplace the appliance switch, safety switch.
ÎConnect the appliance switch, safety switch.
1 Brush roller
2 Brush roller cover
3 Fastening screws
ÎPlace the PW 30/1 on its back.
ÎUnscrew locking screws.
ÎRemove the brush roller cover plate.
1 Toothed belt cover
2 Fastening screws
ÎUnscrew locking screws.
ÎRemove cover.
5.1.4 Replacing the mains cable
5.1.5 Replace the interference filter
5.1.6 Replace the appliance switch, safety switch
14 26 35
7
5.2 PW 30/1
5.2.1 Replacing the brush roller

8 English 5.906-507.0 Rev. 00 (08/10)
1 Toothed wheel, brush roller
2 Fastening screw, brush roller
3 Gear belt
4 Toothed drive wheel
ÎRemove the fastening screw from the brush roller.
1 Toothed wheel, brush roller
2 Gear belt
3 Toothed drive wheel
ÎRemove the toothed belts from the toothed
wheels.
ÎPull the brush roller out of the brush head.
ÎInstall the new brush roller in reverse order.
ÎInsert the brush roller into the guide bore of the
brush roller cover plate.
1 Elongated hole
2 Toothed wheel, brush roller
ÎWatch for the correct seating of the threaded
sleeve in the elongated hole when installing the
brush roller.
ÎScrew in the fastening screw of the brush roller.

English 5.906-507.0 Rev. 00 (08/10) 9
1 Fastening screw, brush roller
ÎTension the toothed belt at the fastening screw
and tighten the fastening screw using suitable
tools.
ÎScrew in the toothed belt cover.
1 Toothed belt cover
2 Fastening screws
ÎUnscrew locking screws.
ÎRemove cover.
ÎRemove the fastening screw from the brush roller.
1 Toothed wheel, brush roller
2 Gear belt
3 Toothed drive wheel
ÎRemove the toothed belts from the toothed
wheels.
ÎPull the brush roller out of the brush head.
5.2.2 Replace the motor.

10 English 5.906-507.0 Rev. 00 (08/10)
1 Motor holder
2 Fastening screws, motor support
ÎUnscrew locking screws.
1 Motor
ÎCarefully remove the motor from the casing.
1 Connector
2 Motor connection plug
3 Cable connector screw, noise filter
4 Anti-interference filter
ÎRemove the connector from the motor.
ÎPull the motor connection plug from the motor.
ÎUnscrewthecableconnectorscrewfromthenoise
filter on the motor.
1 Protective cap (2x)
2 Motor fastening screws (2x)
ÎRemove the protective caps from the motor fas-
tening screws.
ÎUnscrew the motor fastening screws.
1 Toothed drive wheel
2 Grub screw (2x)
ÎLoosen both grub screws from the toothed drive
wheel.
ÎPull the toothed drive wheel for the motor axle.
ÎSeparate the motor from the motor support.
ÎReplace the motor in reverse order.
Note
Prior to fastening the motor support, clean the dirt off
the seal rubber.
ÎTension the toothed belt as described in Chapter
5.2.1.

English 5.906-507.0 Rev. 00 (08/10) 11
ÎRemove the motor as described in Chapter 5.2.2.
1 Motor connection plug
2 Cable connector screw, noise filter
3 Anti-interference filter
4 Connecting cable, noise filter
ÎPull the motor connection plug from the motor.
ÎUnscrewthecableconnectorscrewfromthenoise
filter on the motor.
ÎRemove the connecting cable from the appliance
switch/safety switch.
ÎInstall the new noise filter in reverse order.
ÎInstall the motor as described in Chapter 5.2.2.
The removal of the toothed drive wheel is described
in the Chapter 5.5.2.
1 Power switch
ÎPush out the appliance switch from the casing us-
ing a screwdriver.
1 Connecting cable (4x), appliance switch
ÎRemove the appliance switch from the casing.
Note
In order to avoid failures, remember the plug connec-
tions of the different connecting cables on the appli-
ance switch.
ÎRemove all four connecting cable from the appli-
ance switch.
ÎReplace the appliance switch and install it in re-
verse order.
1 Spray hose
2 Lock nut
3 Spray nozzle
ÎPlace the PW 30/1 on its back.
ÎUnscrew the knurled nut.
ÎPull the spray hose from the spray nozzle.
5.2.3 Replace the interference filter
5.2.4 Replace toothed drive wheel
5.2.5 Replace appliance switch
5.2.6 Replace the spray hose

12 English 5.906-507.0 Rev. 00 (08/10)
1 Spray valve
2 Spray hose
3 Lock nut
ÎUnscrew the knurled nut.
ÎPull the spray hose from the spray nozzle.
1Hoseinlet
2 Spray hose
3 Suction pipe
ÎPull the spray hose from the hose grommets.
ÎReplace the spray hose and install it in reverse or-
der.
ÎPull the spray hose from the spray nozzle as de-
scribed in Chapter 5.2.6.
1 Hexagonal (SW 13)
2 Spray nozzle (SW 10)
ÎHold the hexagonal with the wrench (SW 13).
ÎUnscrew the spray nozzle using a wrench (SW
10).
ÎReplace the spray nozzle and install it in reverse
order.
ÎPull the spray hose from the spray valve as de-
scribed in Chapter 5.2.6.
1 Spray hose
2 Lock nut
3 Fastening screws, spray valve
4Sprayvalve
5 Connection hose
ÎUnscrew the fastening screw from the spray valve
and remove the spray valve.
ÎReplace the spray valve and install it inreverse or-
der.
5.2.7 Replace the spray nozzle
5.2.8 Replace the spray valve

English 5.906-507.0 Rev. 00 (08/10) 13
ÎRemove the motor as described in Chapter 5.2.2.
ÎRemove the mains cable from the connector on
the motor.
ÎLoosen the hexagonal (arrow).
ÎRemove the cable ties from the suction pipe.
ÎReplace the mains cable and install it in reverse
order.
ÎInstall the motor as described in Chapter 5.2.2.
1 Running roller
2 Fastening screw, running roller
ÎPlace the PW 30/1 on its back.
ÎLoosen the fastening screw.
ÎReplace the running roller and install it in reverse
order.
The safety switch is an overload protector switch and
is located underneath the protective cap (arrow). If
the brush roller is blocked, the safety switch will
switch off the appliance.
In order to restart the appliance, reset the safety
switch as follows:
ÎUnscrew the protective cap from the casing using
a suitable flat tip screwdriver.
ÎPress the safety switch to reset it.
ÎInsert the protective cap and tighten it.
5.2.9 Replacing the mains cable
5.2.10Replace the running roller
5.2.11Reset the safety switch

14 English 5.906-507.0 Rev. 00 (08/10)
Danger
First pull out the plug from the mains before carrying
out any tasks on the machine.
ÎRinse PW 20 or PW 30/1 with clear water.
ÎClean the brush roller of lint and dirt.
ÎCheck the spray pattern of the nozzle mouth
piece; if it is irregular, clean the nozzle and the
mouthpiece.
ÎClean the suction hose and nozzles if the suction
performance is reduced.
ÎCheck the toothed gear wear and the tension, re-
place if required.
ÎCheck brush wear, replace brush if required.
Danger
First pull out the plug from the mains before carrying
out any tasks on the machine.
Note
If the brush is blocked, the brush motor is shut off.
ÎSwitch the brush drive off at the appliance switch.
ÎCheck brush to see if there are impurities and re-
move blocking objects, if any.
ÎRemove the safety cap and press the safety
switch by means of a screwdriver.
ÎReinstall the safety cap.
The status of the attached circuit diagram represents
the creation date of the service manual. This circuit
diagram is not updated. When working on the device,
please always use the current circuit diagram in
Kärcher-Inside.
There are no special tools necessary.
No data.
6 Maintenance and care
6.1 After each operation
6.2 Half-yearly
7 Troubleshooting
7.1 Brush is blocked
8 Technical specifications
Appliance type Appliance
no.: Circuit dia- gram Operating in- structions Spare parts list
PW 20 *EU, 220-240 V, 1~ 50/60 Hz 1.735-121.0 0.087-346.0 5.960-684.0 5.955-330.0
PW 30/1 *EU, 220-240 V, 1~ 50/60 Hz 1.913-100.0 0.089-258.0 5.963-318.0 5.957-953.0
PW 30/1 *EU, 220-240 V, 1~ 50/60 Hz 1.913-101.0 0.089-258.0 5.963-318.0 5.957-953.0
8.1 Special tools
8.2 Tightening torques

English 5.906-507.0 Rev. 00 (08/10) 15
9 Circuit diagram
9.1 PW 20

16 English 5.906-507.0 Rev. 00 (08/10)
9.2 PW 30/1