Lechler XactClean HP+ Manual

21
Maintenance
Instructions
XactClean®HP+

2
Content Page
Introduction 3
Maintenance 1 4
Maintenance 2 5
Maintenance 3 6
Disassembly of housing 7– 9
Disassembly of connection piece (optional) 9-10
Disassembly of spray head and bearing unit 11
Correct inspection 12
Assembly of spray head with bearing unit 13
Assembly of connection piece (optional) 14-16
Mounting of housing 17
Assembly of spray head with housing 18-20
CONTENT

3
INTRODUCTION
This manual shows the maintenance of the Lechler tank cleaning nozzle XactClean® HP+.
Please note: The Lechler assembly tool (order no. 05S.590.16.00.00.0) is additionally
required for maintenance 3.
The assembly tool can be reused. The spare parts package is required only once per
maintenance.
Depending on the operating conditions, we recommend dierent maintenance intervals
(maintenance 1 - 3). At each maintenance interval, a visual inspection of the parts must
always be carried out for wear and tear. We recommend replacing the O-rings each time a
sealing point is opened.
Note: Use suitable lubricant for EPDM O-rings.
Spray head
Bearing unit
Pin
Gear unit Housing
Collar bushing
Guide disk
Connection pieceTurbine
O-rings
bearing unit
O-rings
gear unit
O-rings guide disk
O-ring
connection piece

4
MAINTENANCE 1
It is recommended to perform maintenance 1 every 500 operating hours.
The spare parts package 1 contains the following parts:
Spare parts package 1
Name Quantity Product number Order number
Pin 1 pc. 5S5.000.K8.00.25.0
5S5.000.1Y.00.50.0O-ring 45 x 1.5 mm 4 pcs. 095.015.E9.11.53.0
O-ring 50 x 1.5 mm 4 pcs. 095.015.E9.11.54.0
The following steps from this maintenance manual are necessary for carrying out
maintenance 1:
Disassembly of housing Steps 1 – 9
Correct inspection Steps 19 – 20
Assembly of spray head with bearing unit Step 27
Mounting of housing Steps 33 – 36
Assembly of spray head with housing Method A or B
1x Pin
Material: PEEK
5S5.000.K8.00.25.0
4x O-ring ø 50x1.5mm
Material: EPDM
095.015.E9.11.54.0
4x O-ring ø 45x1.5mm
Material: EPDM
095.015.E9.11.53.0
Note: The PEEK pin transmits torque from the gearbox to the spray head shaft. If
too much torque is applied via the spray head, the pin deforms and protects thereby
the gear unit from damage. If the pin has been deformed, it must be replaced.

5
MAINTENANCE 2
It is recommended to perform maintenance 2 every 1000 operating hours.
The spare parts package 2 contains the following parts:
Spare parts package 2
Name Quantity Product number Order number
Pin 1 pc. 5S5.000.K8.00.25.0
5S5.000.1Y.00.60.0
O-ring 45 x 1.5 mm 4 pcs. 095.015.E9.11.53.0
O-ring 50 x 1.5 mm 4 pcs. 095.015.E9.11.54.0
Gear unit 1 pc. 5S5.000.1Y.00.20.0
Turbine 1 pc. 5S5.000.T7.00.12.0
Collar bushing 1 pc. 5S5.000.1Y.00.13.0
The following steps from this maintenance manual are necessary for carrying out
maintenance 2:
Disassembly of housing Steps 1 – 9
Correct inspection Steps 19 – 20
Assembly of spray head with bearing unit Step 27
Mounting of housing Steps 33 – 36
Assembly of spray head with housing Method A or B
4x O-ring ø 45x1.5mm
Material: EPDM
095.015.E9.11.53.0
4x O-ring ø 50x1.5mm
Material: EPDM
095.015.E9.11.54.0
1x Pin
Material: PEEK
5S5.000.K8.00.25.0
1x Gear unit
Material: 1.4404
5S5.000.1Y.00.20.0
1x Turbine
Material: ZX-324V2T
5S5.000.T7.00.12.0
1x Collar bushing
Material: 1.4404
5S5.000.1Y.00.13.0

6
MAINTENANCE 3
It is recommended to perform maintenance 3 after 1.500 operating hours.
The spare parts package 3 contains the following parts:
Spare parts package 3
Name Quantity Product number Order number
Pin 1 pc. 5S5.000.K8.00.25.0
5S5.000.1Y.00.70.0
O-ring 45 x 1.5 mm 4 pcs. 095.015.E9.11.53.0
O-ring 50 x 1.5 mm 4 pcs. 095.015.E9.11.54.0
Bearing unit 1 pc. 5S5.000.1Y.00.30.0
O-ring 27.5 x 1.5 mm 1 pc. 095.015.E9.11.55.0
O-ring 31 x 1.5 mm 1 pc. 095.015.E9.08.34.0
O-ring 25 x 1.0 mm 1 pc. 095.015.E9.06.97.0
·
The following steps from this maintenance manual are necessary for carrying out
maintenance 3:
Disassembly of housing Steps 1 – 9
Disassembly of spray head and bearing unit Steps 14 – 18
Correct inspection Steps 19 – 20
Assembly of spray head with bearing unit Steps 21 – 27
Mounting of housing Steps 33 – 36
Assembly of spray head with housing Method A or B
For maintenance 3 the Lechler assem-
bly tool order no. 05S.590.16.00.00.0.
is required.
Tip
1x Pin
Material: PEEK
5S5.000.K8.00.25.0
1x O-ring ø 27.5x1.5mm
Material: EPDM
095.015.E9.11.55.0
1x O-ring ø 25x1mm
Material: EPDM
095.015.E9.06.97.0
1x Bearing unit
Material: 1.4404
5S5.000.1Y.00.30.0
4x O-ring ø 50x1.5mm
Material: EPDM
095.015.E9.11.54.0
4x O-ring ø 45x1.5mm
Material: EPDM
095.015.E9.11.53.0
1x O-ring ø 31x1.5mm
Material: EPDM
095.015.E9.08.34.0

7
To dismantle the XactClean® HP+, please open the housing first.
The housing is screwed o by using a
suitable fork or pliers wrench and a vice
with protective jaws. As a result, the
sprayhead will become detached from
the housing. The connecting piece does
not have to be dismantled.
1
2 3
All threads of XactClean® HP+ are
right-hand threads.
Tip
DISASSEMBLY OF HOUSING
Remove the pin.
Note: The housing should be fixed in the vice. Please be aware of that both, connec-
ting piece and the housing are fixed in the vice.

8
Remove the O-ring from the housing. The gear unit can be removed upwards.
Remove the O-ring from the underside of
the gear unit.
The turbine can be removed upwards.
4 5
6 7
8
Remove collar bushing.
DISASSEMBLY OF HOUSING

9
Remove the O-rings from the bearing unit.
DISASSEMBLY OF CONNECTION PIECE (optional)
For the maintenance intervals 1 – 3 it is not necessary to open the connection piece. In case
that the connecting piece is nevertheless opened, the o-rings are included in the respective
spare parts package and can be used for the assembly of the connection piece (pls. see
steps 28-32).
Remove guide disk.
The connection piece can be screwed
on by using a suitable fork or pliers
wrench and a vice with protective jaws.
The housing should be tightened so that
the bearing unit and the housing are
tightened.
10 11
9
DISASSEMBLY OF HOUSING

10
Remove the O-ring.
12
Remove the O-rings from the connecting
piece.
13
DISASSEMBLY OF CONNECTION PIECE (optional)
DISASSEMBLY OF CONNECTION PIECE (optional)

11
DISASSEMBLY OF SPRAY HEAD AND BEARING
UNIT
Use both grooves in the spray head shaft
to separate the spray head from the
bearing unit.
For dismounting and mounting the
spray head the Lechler assembly tool
(05S.590.16.000.00.0) is required.
14 15
Place the cylindrical pins of the Lechler
assembly tool in the provided grooves of
the bearing unit.
Use the appropriate pliers or fork wrench
to unscrew the spray head by means of
the Lechler assembly tool. The wrench
size is 30 mm
17
Remove the three O-rings from the
bearing unit.
16
18

12
CORRECT INSPECTION
19 Turn the drive shaft with the pin fitted to
check the function of the gear unit. The
rotation should be carried out with mini-
mum friction and should not stagnate.
20
To check whether the entire unit (gear
unit and turbine) is functioning, the turbi-
ne must be inserted into the gear unit.
In the next step, with the pin mounted,
turn the drive shaft for a few revolutions.
If the gear unit cannot be turned by hand
or has a large play, the gear unit must be
replaced.

13
Mount the O-rings on the bearing unit
(O-Ring 27.5 x 1.5 mm).
ASSEMBLY OF SPRAY HEAD WITH BEARING
UNIT
When assembling, make sure that the parts to be replaced are replaced by the new parts
from the spare parts package.
Mount the O-ring on the bearing unit
(O-Ring 25 x 1.0 mm).
With the use of the Lechler assembly
tool, the O-ring 25 x 1.0 mm is additi-
onally centered. This ensures that the
O-ring is in the correct position during
further assembly.
The Lechler assembly tool is required for
mounting the bearing units on the spray
head.
Insert the Lechler assembly tool.
21
23
22
24
Mount the O-ring on the spray head
(O-Ring 31 x 1.5 mm).
Screw the bearing unit together until the
gap dimension is approx. 1.8 mm.

14
Mount the O-ring 45 x 1.5 mm and
O-ring 50 x 1.5 mm on the connection
piece exactly into the groove provided for
this purpose. Make sure that the O-rings
are not damaged by the thread. So that
the O-ring (45 x 1.5 mm) does not fall
out of the groove during assembly, it is
recommended to place the O-ring with a
thin film of grease (use suitable grease) in
the groove.
The bearing unit should be tightened with
a torque of 40 Nm.
Then snap the O-ring 31 x 1.5 mm into
the groove.
The second O-ring 50 x 1.5 mm must
first be positioned on the outside dia-
meter of the connection piece for easy
installation.
2625
27
ASSEMBLY OF SPRAY HEAD WITH BEARING
UNIT

15
Mount the first O-ring 50 x 1.5 mm and
O-ring 45 x 1.5 mm on the connection
piece exactly into the groove provided for
this purpose. Make sure that the O-rings
are not damaged by the thread.
28
The second O-ring 50 x 1.5 mm must
first be positioned on the outside dia-
meter of the connection piece for easy
installation.
ASSEMBLY OF CONNECTION PIECE (optional)
Fit the O-ring 45 x 1.5 mm in the housing
exactly into the groove provided for this
purpose.
29
Insert the guide disk into the housing and
screw it to the connection piece.
30

16
31
Screw the connection piece together until
the gap dimension is approx. 1.8 mm.
32
Then snap the O-ring 50 x 1.5 mm into
the groove.
ASSEMBLY OF CONNECTION PIECE (optional)

17
MOUNTING OF HOUSING
Insert the collar bushing so that the
triangle engages in the guide disk.
Insert the O-ring 45 x 1.5 mm and make
sure that the O-ring fits exactly in the
provided groove.
34
Insert turbine.
35
Insert the gear unit incl. pin into the
housing. The gear unit must be turned
slightly so that the teeth of the turbine
and gear interlock.
Align the pin centered towards the center.
33
36

18
ASSEMBLY OF SPRAY HEAD WITH HOUSING
The position of the pin is indicated by a
permanent marker on the outside of the
housing.
Mark the position of the grooves with a
permanent marker on the outside of the
spray head spindle on the bearing unit.
The two markings serve to position the
bearing unit and the housing in which the
gear unit is located.
The thread of the bearing unit is screwed
into the housing. The markings must be
held in position during screwing.
37a 37b
37c 37d
There are two methods for mounting the bearing unit with the housing.
Method A

19
Screw the bearing unit into the housing
by hand, up to a gap dimension of
approx. 3 mm. If a slight resistance can
be felt, it is possible that the pin has not
yet snapped into the two grooves.
Rotate the spray head by hand while blocking the turbine with a finger until the horizontal
pin audibly clicks into the grooves. The preload of the pin against the bearing unit must be
adjusted by unscrewing and screwing it in.
38a
38b
Method B
ASSEMBLY OF SPRAY HEAD WITH HOUSING

20
Continue screwing the bearing unit up
to a gap dimension of approx.1.8 mm.
Then snap the O-ring 50 x 1.5 mm into
the groove.
Screw the bearing unit into the housing
by hand.
The housing is tightened with a torque of
50 Nm using a vice and torque wrench
(wrench 50).
40
To check that all parts are correctly assembled, turn the spray head. The spray head
should be carried out with minimal eort. In no way, should the spray head be turned
erratically. It is normal that the rotation can stagnate a little bit, but the spray head should
still be rotatable.
39
41
ASSEMBLY OF SPRAY HEAD WITH HOUSING