Kärcher SCW 2.4/25 G, Service Manual

Page 1: ...English 9 808 136 0 Rev 00 09 18 1 SCW 2 4 25G Service Manual...

Page 2: ...tenance chart Trouble shoo ng chart Trouble shoo ng process Understanding the di erence between low cavita on and pulsa ng pressure Pulsa on Cavita on Low pressure Spray bar will not spin Vibra on Str...

Page 3: ...der Test pressure o the pump Inspec ng spray bar swivel Inspec ng spray bar Inspec ng spray bar swivel moun ng Cleaning speed Replacing a thermal relief valve Changing spray bar swivel Changing spray...

Page 4: ...ff the appliance and in case of applianc es connected to mains pull out the power cord before cleaning and performing any maintenance tasks on the machine Relieve the high pressure system of all press...

Page 5: ...on with ceramic sleeves Pump head made of brass Suc on and high pressure valves made of stainless steel Unloader bypass valve Trigger gun Spray lance Power nozzle Compact frame Flat free res 21 stainl...

Page 6: ...al number 8 Code consisting of part number serial number 4 7 Symbols on the machine Keep hands and feet away from rotating spray bar This product and accessories may contain a chemical known to the St...

Page 7: ...English 9 808 136 0 Rev 00 09 18 7 1 Water filter 2 High pressure pump 3 Unloader valve 4 Thermal relief valve 4 9 Flow pa1ern...

Page 8: ...English 9 808 136 0 Rev 00 09 18 8 5 Overview of the appliance 1 2 3 4 5 10 9 8 7 2 13 11 12 14 6 5 1 Call outs SCW 2 4 25G...

Page 9: ...English 9 808 136 0 Rev 00 09 18 9 1 15 17 16 6 7 22 21 20 18 19 23 24...

Page 10: ...ck oil engine 9 Switch on o 10 Dip s ck oil pump 11 Swivel surface cleaner 12 Storage for spray wand 13 Tire at free 14 Knob handle adjustment 15 Unloader by pass valve 16 Inlet fresh water 17 Starte...

Page 11: ...fold bolt 5 2 Pump overview 2 1 1 3 4 3 5 2 2 Pump head cross sec on overview 1 Outlet high pressure check valve 2 Outlet high pressure valve cap 3 Outlet port 4 High pressure packing 5 Ceramic piston...

Page 12: ...6 0 Rev 00 09 18 12 1 Dips ck oil 2 Oil seal 3 High pressure packing 4 Low pressure packing 5 Piston guide 6 Wrist pin 7 Connec ng rod 8 bearing cranksha 9 Cranksha 5 2 3 Pump cross sec on overview 4...

Page 13: ...ass port 7 Inlet port 8 Banjo bolt inlet pump 9 Banjo bolt outlet pump 10 Ball subassembly 5 3 Unloader Bypass valve overview 1 4 3 2 10 5 9 6 7 8 5 4 Filter high pressure overview 1 Housing nozzle lt...

Page 14: ...once every three months A good quality ball bearing grease is recommended DO NOT OVER GREASE THE BEARING 5 5 Swivel High pressure overview 1 2 2 3 4 5 5 6 Thermal relief valve overview 1 inlet port 2...

Page 15: ...djust 100 hours or 6 months 6 4 8 Change 300 hours or yearly 6 4 9 PUMP OIL Inspect Oil level daily 6 4 10 Change A er rst 50 hours then eve ry 500 hours or annually 6 4 11 SURFACE CLEANER SWIVEL Weep...

Page 16: ...E Vibra on 6 3 6 CLEANING PATTERN NOT GOOD STREAKING Cleaning pa ern is streaked 6 3 7 Spray bar swivel is weeping or dripping water 6 3 8 1 Spray bar swivel is leaking lots of water 6 3 8 2 WATER LEA...

Page 17: ...ng drawn into the suc on side of the pump The water gaps or air bubbles will explode when the water is trying to be pressurized producing vibra on noise and dam age to many components Figure 1 represe...

Page 18: ...nue to 4 4 Inspect packings and ceramic pistons See sec on 6 5 2 If packings and ceramic pistons are good con nue to 5 5 Call Technical support for further instruc on 6 3 4 Low pressure 1 Inspect the...

Page 19: ...al support for further instruc on 1 The swivel will weep underneath cover Weeping is nor mal The swivel uses water to help lubricate it s oa ng seal 6 3 7 Streaked cleaning pa1ern 6 3 8 Spray bar swiv...

Page 20: ...pump oil Test machine to see if milky oil returns If pump oil is again milky or water has not been introduced to the oil from cleaning con nue to 2 2 Water can be introduced from condensa on This can...

Page 21: ...evels as this will cause engine damage 6 4 Scheduled maintenance ac vi es 6 4 1 Inspec ng engine oil 6 4 2 Changing engine oil Drain the used oil when the engine is warm Warm oil drains quickly and co...

Page 22: ...r lter or with a damaged air lter will allow dirt to enter the engine causing rapid en gine wear 1 Foam air lter element Clean in warm soapy water rinse and allow to dry thoroughly Or clean in non amm...

Page 23: ...e tank to see if it needs to be cleaned See sec on 6 4 7 6 Install new lter and gasket 7 Install fuel tank back on to engine 8 Install fuel line Make sure to inspect the fuel line and re place if need...

Page 24: ...and can be seen when looking into the fuel tank Inspect the lter to see if it needs to be replaced See sec on 6 4 5 5 Clean the fuel tank with non ammable solvent and allow it to dry thoroughly 6 Ins...

Page 25: ...spark plug is seated ghten to compress the sealing washer Tighten 1 8 1 4 turn a er the spark plug seats to compress the washer Note A loose spark plug can overheat and damage the engine Over ghtenin...

Page 26: ...oil drains quickly and completely 1 Put the machine where the pump is on a perfectly level surface 2 Place a suitable container below the pump oil drain plug 1 to catch the used oil then remove the oi...

Page 27: ...Remove pressure nozzles 5 4 Install new pressure nozzles Nozzles should be installed into the rota ng bar with the spray fan parallel to the ro ta ng bar See gure 2 5 NOTE There is also a single high...

Page 28: ...sembly back together 6 Install the high pressure lter 2 back into the tee The lter is direc onal 4 Make sure it is plumbed correctly with the water ow towards the tee Make sure to use the correct amou...

Page 29: ...check valve O rings for dam age Replace if needed To test the check valves stand the valves with their seats facing upwards Fill them with water If a valve is leaking the water will seep out of the b...

Page 30: ...is will help to inspect ceramic piston for damage and or cracks Replace if needed Make sure to clean piston prior to pu ng pump back together 4 Push and pull on each piston to check for any play in th...

Page 31: ...lumbing where the thermal protector was 3 Coupler a test gauge between the pressure hose and the gun test machine If the machine cavita on stopped re place thermal protector with a new one 4 Install t...

Page 32: ...isted on the serial plate 4 Test machine with spray wand trigger Machine should have a running pressure of 2500 psi and a spike pressure of less than 500 psi Spike is the pressure read on the gauge wh...

Page 33: ...ct nip ple to the pump outlet and the garden hose ngs back to the pump inlet 1 Install test gauge test hose test gun test nozzle make sure to use size of nozzle listed on the seri al plate 2 Test mach...

Page 34: ...leak 2 Make sure all the pressure is released from the system 3 Manually turn spin the spray bar to see if the swivel is locked or bound or loose or leaking If it is and there is nothing from 1 that...

Page 35: ...c ng spray bar 6 5 10 Inspec ng spray bar swivel moun ng 1 Visually inspect top side and bo om side of the spray bar swivel to see if there is any damage that would allow the swivel moun ng to be loos...

Page 36: ...the thermal protector for the inlet plumbing 2 Install new thermal relief valve Make sure to use the correct thread sealant 6 5 13 Changing spray bar swivel 1 Remove spray bar See sec on 6 5 14 2 Usi...

Page 37: ...h remove the bo om banjo bolt ng from the pump 4 Install the new un loader 5 Install test gauge test hose test gun test nozzle make sure to use size of nozzle listed on the serial plate 1 Test machine...

Page 38: ...the crankcase cover 4 Test machine for a short period of me to get the seal and oil warm Let machine sit to con rm there is not an oil leak 6 5 16 Inspec ng back side of pump for oil leak 2 3 4 4 4 4...

Page 39: ...ide of pump for oil leak 1 1 Inspect to see if oil is leaking from under the pump mani fold 2 If it is remove the pump from the engine then remove the pump manifold from the crankcase 3 Inspect where...

Page 40: ...gun for leak 6 5 21 Inspec ng spray bar trigger for leak 1 Test machine with pressure Release the spray bar trigger gun Inspect for leaking out of the end of the spray bar 2 If there is leaking out of...

Page 41: ...g Available on DISISplus in the chapter Catalogue Karcher special tools catalog Available on DISISplus in the chapter Catalogue Grease gun 6 417 023 0 Karcher standard tool trolley Equipped with tools...

Page 42: ...18 42 7 2 Tools required O ring pick 8 707 467 0 Pressure test gauge 5000 psi cold water 8 712 208 0 Pressure packing inser on and oil seal removal tool kit 8 756 590 0 Hearing protec on 6 025 513 0...

Page 43: ...ORQUE SPECIFICATION 8 706 321 0 12 N m 8 718 829 0 50 66 N m 8 733 007 0 8 10 N m 8 750 768 0 7 8 N m 8 752 824 0 10 Ft lbs 8 754 854 0 55 Ft lbs 8 754 855 0 10 Ft lbs 8 933 020 0 10 Ft lbs 9 196 307...

Page 44: ...English 9 808 136 0 Rev 00 09 18 44 This page was inten onally le blank...