Karcher HD 9/100 De Skid Operating instructions 1 - Page 19

Maintenance work for the high-pressure pump Changing oil ṇ WARNING Risk of scalding The oil in the high-pressure pump becomes very hot and cause scalding if touched. Do not unscrew the oil drain plug while the device is in operation. Allow the device to cool down before changing the oil. Note See the "Technical data" chapter for the oil volume and type 1. Unscrew the oil drain plug. Illustration L 1 Oil filler neck 2 Oil level gauge 3 Oil drain plug 2. Drain the oil into a suitable collection container. 3. Screw in the oil drain plug. 4. Unscrew the cap of the oil filler neck. 5. Slowly fill with new oil until the level is in the middle of the oil level display. The air bubbles must escape. 6. Screw on the cap of the oil filler neck. Check the tightening torque of the pump screws Description Cylinder fastening Pump head fastening Number 1...18 19...22 Tightening torque 40 Nm 35 Nm Illustration M 1. Check all screws for corrosion. Have corroded screws replaced by the Customer Service department. 2. Set the torque wrench to the value specified in the table above. 3. Tighten the screws in the sequence 1...22 specified above until the torque wrench clicks to indicate that the correct torque has been reached. Cleaning the filter On delivery, the filter is equipped with a filter fleece that retains particles with sizes of 100 µm or larger. A filter fleece that retains particles with sizes of 50 µm or larger is required when using a rotary nozzle. Filter fleece 100 µm 50 µm Order number 6.414-074.0 6.414-073.0 1. Close the water inlet. 2. Unscrew the filter casing. 3. Replace the soiled filter fleece with a new filter fleece. 4. Attach the filter casing. 5. Vent the device. Checking the tension of the V-belt in the advance pressure pump 1. Turn the key-operated switch to position "0". 2. Determine the tension of the V-belt by using an Op- tibelt frequency meter. Nominal frequency 56...62 Hz. Illustration N 1 V-belt of the advance pressure pump 3. If the measured frequency deviates from the nominal frequency, the tension of the V-belt must be readjusted. 4. Check the V-belt for cracks, traces of oil and wear. If the V-belt touches the bottom of the pulley, it means the V-belt is worn. 5. If the V-belt is damaged, fouled with oil or worn, replace the V-belt. Adjusting tension of the V-belt in the advance pressure pump 1. Loosen the locking screws. Illustration O 1 Advance pressure pump 2 Locking screw 3 Tensioning screw 2. Adjust the tension of the belt by using the tensioning screw. 3. Tighten the locking screws. 4. Check the tension of the V-belt. 5. If necessary, repeat the process until the tension of the belt is correct. Maintenance work on the engine Draining the water separator The red float in the lower section of the water separator floats on the water. It indicates whether there is any water in the separator. 1. Turn the fuel cock to the "OFF" position. Illustration P 1 Venting screw 2 Fuel cock 3 Red float 4 Drain tap 2. Hold a fuel-resistant container underneath the water separator. 3. Open the drain tap. Note: If no water escapes after opening the drain tap, unscrew the venting screw 2...3 revolutions. 4. Drain the accumulated water (until the red float is located at the bottom of the water separator). 5. Close the drain tap. 6. If necessary, tighten the venting screw again. 7. Turn the fuel cock to the "ON" position. 8. To vent the fuel system, turn the engine switch to po- sition "1". 9. Wait 15 seconds. 10. Check the water separator for fuel leaks. Cleaning the water separator The red float in the lower section of the water separator floats on the water. It indicates whether there is any water in the separator. 1. Turn the fuel cock to the "OFF" position. Illustration P 1 Venting screw 2 Fuel cock 3 Red float 4 Drain tap 2. Hold a fuel-resistant container underneath the water separator. 3. Open the drain tap. Note: If no water escapes after opening the drain tap, unscrew the venting screw 2...3 revolutions. 4. Drain the accumulated water (until the red float is located at the bottom of the water separator). 5. Close the drain tap. 6. If necessary, tighten the venting screw again. 7. Remove the transparent cap. 8. Remove the red float from the cap. 9. Dispose of the contaminated fuel in the cap properly. 10. Clean the inside of the cap. 11. Clean the red float. 12. Clean the filter element in the water separator; re- place it if damaged. 13. Insert the filter element with the O-ring into the support. 14. Insert the float into the transparent cap. 15. Check the condition of the O-ring; replace the O-ring if necessary. 16. Reattach the cap. 17. Turn the fuel cock to the "ON" position. 18. To vent the fuel system, turn the engine switch to po- sition "1". 19. Wait 15 seconds. 20. Check the water separator for fuel leaks. Emptying the fuel tank The fuel tank must be emptied on a regular basis in order to remove water and dirt deposits from the tank. 1. Turn the key-operated switch to position "0". 2. Place a suitable container underneath the fuel drain screw. 3. Remove the cap from the fuel filling nozzle. 4. Unscrew the fuel drain screw. 5. Empty the tank until pure diesel fuel flows out. 6. Reinsert and tighten the drain screw. 7. Replace the cap of the filling nozzle and tighten it. 8. Check the fuel tank for leaks. Checking the engine oil level 1. Stop the engine. 2. Place the device on a level surface. 3. Pull out the dipstick and wipe it clean. Illustration K 1 Minimum oil level 2 Maximum oil level 3 Engine oil dipstick 4 Engine oil cap 4. Insert the dipstick into the engine as far as possible, then remove it again to check the oil level. ATTENTION Risk of damage If contaminated or incorrect oil is used, it can damage the engine and reduce its service life. Only use the specified type of oil (see "Technical data"). Make sure the engine oil is not contaminated with any particles. Thoroughly clean the oil cap and dipstick and the surrounding areas. Do not mix different types of oil. Do not exceed the maximum oil level. 5. If the oil level is near or below the lower limit marking on the dipstick: a Unscrew the oil cap on the engine. b Fill the recommended oil up to the upper limit marking. Do not overfill. 6. Reinsert the dipstick into the engine as far as possi- ble. 7. Replace and tighten the oil cap. Check the coolant level 1. Check the coolant level in the coolant expansion tank. When the engine is cold, the coolant level must be in line with, or slightly above, the lower marking. Note If the coolant is above the upper marking, it can escape from the tank due to thermal expansion that occurs when the engine is hot. ṇ WARNING Risk of scalding Engine coolant can splash out and cause severe burns. Do not open the radiator cap. Always top up coolant via the expansion tank. ATTENTION Risk of damage Using the wrong coolant can result in the formation of rust and scale Only use approved coolant. Only use clean coolant. Clean the radiator cap and the adjoining surfaces before removing the radiator cap. Do not mix different coolants. 2. If the coolant level is low, top up via the expansion tank. Checking the tension of the V-belt 1. Turn the key-operated switch to position "0". 2. Use your thumb to depress the V-belt of the engine. When exerting a force of 100 N, the V-belt should sag 7...10 mm. Illustration Q 1 V-belt of the engine 3. If the V-belt of the engine sags any more than this, the tension of the V-belt must be increased. 4. Check the V-belt for cracks, traces of oil and wear. If the V-belt touches the bottom of the pulley, it means the V-belt is worn. 5. If the V-belt is damaged, fouled with oil or worn, replace the V-belt. Adjusting the tension of the V-belt 1. Loosen the locking screw. Illustration R 1 Locking screw 2 Generator 2. Use a rod to push the generator away from the engine block and tighten the locking screw. 3. Check the tension of the engine V-belt. 4. If necessary, repeat the process until the tension of the belt is correct. Replacing the V-belt 1. Replace the old V-belt of the engine with a new V-belt. 2. Adjust the tension of the engine V-belt in such a way that it sags 5...8 mm when subjected to a force of 100 N. 3. Operate the device for 5 minutes. 4. The engine V-belt must then sag 7...10 mm when subjected to a force of 100 N. If not, adjust the tension of the belt again. Replacing the fuel filter 1. Stop the engine and let it cool down. 2. Turn the fuel cock to the "OFF" position. 3. Unscrew the fuel filter in a counter-clockwise direc- tion by using a filter wrench. 4. Wet the seal of the new fuel filter with diesel fuel. 5. Screw in the new fuel filter clockwise by hand until it rests against the contact surface. 6. Use a filter wrench to tighten the new fuel filter to 20...23 Nm or turn it 1 more revolution after coming into contact with the contact surface. 7. Turn the fuel cock to the "ON" position. 8. To vent the fuel system, turn the engine switch to position "1". 9. Wait 15 seconds. 10. Check the fuel filter for fuel leaks. English 19