Service Handbook High-Pressure Washer Pump 3.532
Contents
1. Detergent filter amp y High pressure valve cap 3 High pressure valve basket 3 High pressure valve spring 3 High pressure valve plate 3 High pressure valve seat 3 6 T 47 High pressure valve plate 48 Pump head ________ 49 Pump head bolt 4 Pump 629 9 28 01 3 22 PM Page 5 For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Swash Plate Assembly The three pistons 9 are driven by the swash plate assembly 6 7 8 which is mounted on a pump shaft 3 In the case of a vertically configured machine a drive bolt is screwed into the engine shaft and then inserted into the pump shaft As soon as the engine shaft rotates the swash plate assembly 6 7 8 rotates as well This caus es the pistons 9 to move backwards and forwards The piston stroke depends upon the angle of the swash plate assembly 6 7 8 The greater the angle of the swash plate the longer the piston stroke One revolution of the swash plate gives the pistons one suction stroke and one pressure stroke Oil Bath The swash plate and pistons are bathed in oil oil type 15W40 non detergent This pump does not have a drain plug oil reservoir and sight glass In order to add oil in this case the pump head 48 and piston hous ing 11 will have to be removed If servicing a pump without a sight glass the oil level is just above the high side of the swash disk 8 Pistons With Seals The three2. 3 22 PM Page 15 e SECTION 4 DETERGENT DELIVERY FAILURE _ 1 Pump shaft wee 2 0il bath housing 3 Swash plate shaft seal 3 Fastening cap ee 4 Forward O ring 4 Deflector cap 15 Screw 2 35 Nipple 6 Thermal relief i 36 Detergent valve housing non return check valve 7 Thermal relief valve 37 0 rin 6 Swash plate housing lt 9 8 Spring 38 Ball bearing 7 Swash plate ball bearing 9 Bypass valve i yp p 39 Spring 8 Swash disk 20 Water inlet 40 Detergent tube 9 Piston lt X K 1 Detergent filter 10 Piston spring N Y a inlet filter metering valve 11 Piston housing A_G Sa High pressure valve cap 3 12 Slot holes 3 fT A High pressure valve basket 3 z High pressure valve spring 3 23 Throttle High pressure valve plate 3 24 Low pressure valve seat 3 R High pressure valve seat 3 25 Low pressure valve plate 3 sd 26 Low pressure valve spring 3 y 27 Low pressure valve basket 3 Pa r z 47 High I I 28 0il seal 3 igh pressure valve plate 29 Seal retaining ring 3 48 Pump head 30 Bushing 3 31 High pressure seal 3 32 Nozzle insert Se 34 Water outlet pie Seed 49 Pump head bolt 4 Detergent Delivery Failure A Pump Not Drawing Detergent or Water Exiting Detergent Tube Detergent filter 41 or check valve 3
3. pistons 9 are pressed against the swash disk 8 of the swash plate assembly 6 7 8 by powerful piston springs 10 These three pistons are manufactured from tempered surface hardened steel and are non corrosive with regards to detergents and rust The pump delivery capacity is determined by the rotational speed of the motor the diameter of the pistons the length of the piston stroke The pistons 9 are fitted with a high pressure bushing 30 The three pistons each have an oil seal 28 mounted in the piston housing 11 These three oil seals along with the shaft seal 3 retain the oil in the oil bath housing The slot holes 12 are in the piston housing 11 and allow water or oil to drip out into the open A water leakage rate of one drop per piston per minute is allow able during high pressure operation If oil is leaking from the slot holes 12 there is either a leak in the oil seals or there is piston dam age Low Pressure and High Pressure Check Valves Each piston 9 works with one low pressure check valve 24 27 and one high pressure check valve 43 46 Each of these check valves is constructed of the same basic components the valve basket spring valve plate with guide shaft and the valve seat with O ring The sealing surface between the valve plate 25 and the valve seat 24 is conical The valve plate and valve seat are manufactured from either plastic or stainless steel depending upon the pa
4. 6 may be clogged or damaged High pressure nozzle on trigger gun may be damaged B Pump Is Cycling Nozzle insert 32 is damaged and must be replaced www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 16 c SECTION 4 DETERGENT DELIVERY FAILURE SOLUTIONS A Pump Not Drawing Detergent or Water Exiting Detergent Tube B Pump is Cycling 7 Reassemble placing spring behind ball to push against detergent check valve 1 Pump Not Drawing Detergent or 8 Reassemble and reinstall nipple and hose Water Exiting Detergent Tube 1 Check that nozzle is in low chemical position figure 25 B Nozzle Insert 1 Remove nozzle insert with a screwdriver figure 27 2 Check that metering valve on pickup filter is open figure 25 2 Pull out nozzle insert figure 28 3 Check pickup filter for clogs figure 25 Figure 27 4 Check detergent tube for holes and kinks 3 Check nozzle for wear and damage 5 Remove detergent check valve assembly 4 Check that opening through nozzle is not clogged e Remove detergent tube and clear if necessary e Unscrew nipple Figure 28 Figure 26 e Remove detergent check valve figure 26 e Inspect O ring ball and spring inset figure 26 nipple e If necessary replace ball spring and O ring e If ball sticks to O ring use screw driver or paper clip to push ball b
5. Bypass Valve Worn O rings on the bypass valve 19 or a bypass valve hanging up High Pressure Check Valve High pressure valve 43 46 fails to function properly Low Pressure Check Valve Low pressure valve 24 27 fails to function properly Water Leaks See Section 2 Water Leaks Water leaks Pump is Cycling See Section 4 Detergent Delivery Failure Nozzle insert 32 is damaged and must be replaced www mymowerparts com Pump 629 9 28 01 3 22 PM Page 8 For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 SECTION 1 LOW WATER PRESSURE SOLUTIONS A Water Supply B Nozzle C Water Inlet Filter D Bypass Valve E High Pressure Check Valve A Water Supply Cold Water Only 1 Check faucet 4 0 gpm is required 2 Outside diameter of hose should be 3 4 3 Maximum length of hose should be 50 4 The inlet water pressure should not exceed 90 psi 5 Hose should not be kinked or damaged B Nozzle Check function and setting of original spray wand nozzle not pic tured by using an in house nozzle If pump functions properly with in house nozzle but malfunctions with original nozzle replace nozzle C Water Inlet Filter 1 Remove filter with pair of valve pliers figure 1 figure 1 2 Clean filter 3 Replace filter if it is torn bent or missing 4 Reinstall filter Note If water inlet filter is missing or damaged further damage may have occur
6. For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump _ Service Handbook High Pressure Washer Pump 4 3 532 629 0 10 00 www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Pag A www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 3 e TROUBLESHOOTING OVERVIEW How to Use This Manual It is not necessary to read this entire manual to find a solution to a problem This manual identifies four basic ways the pump may malfunction Find the section that defines the malfunction of the pump Turn to that section s overview page and identify the specific problem Then go to the solutions page for that specific Tools Necessary to Service the problem If you don t know what the problem is work your way KARCHER High Pressure Washer Pump through the section until you find and correct the problem Part 3 532 629 0 Low Water Pressure Section 1 Special Tools e Valve pliers cee eee eae 4 901 062 Water Leaks Section 2 e Installation tool 0e0e0eeeeeee 2 901 036 HP seal oil seal Oil Leaks Section 3 Silicon grease cece eae 6 288 044 for packing and O rings Lithium grease 000e ee eae 6 288 079 for O rings on bypass valve Non detergent pump oil 15W40 6 288 050 0 Detergen
7. ack Note Leaving detergent in pump will cause ball to stick 6 Put silicone grease on hose nipple and place O ring on nipple The grease holds the O ring to the nipple ma www mymowerparts com
8. e 13 B Weep Holes High Pressure Seals e Put tool into sleeve and press until seal pops into place 1 Remove 4 pump head bolts using socket wrench figure 11 figure 14 figure 14 figure 11 e Remove tool and then remove sleeve figure 15 2 Remove pump head A figure 12 3 Reassemble pump head 3 Turn the pump head over and carefully remove the three high pressure seals figure 12 www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 12 o SECTION 3 OIL LEAKS 1 Pump shaft _ 2 0il bath housing _ 3 Swash plate shaft seal 13 Fastening cap oo e 14 Deflector cap 15 Screw 2 4 Forward O ring 16 Thermal relief valve housing 4b 17 Thermal relief valve 6 Swash plate housing 7 Swash plate ball bearing a _ 18 Spring _ 19 Bypass valve 8 Swash disk g ee 9 Piston lt XG RAA 10 Piston spring MR a Og 3 ot oc AIA oe oars pi 11 Piston housing A LYS S ae 12 Slot holes 3 23 Throttle 24 Low pressure valve seat 3 25 Low pressure valve plate 3 26 Low pressure valve spring 3 27 Low pressure valve basket 3 28 Oil seal 3 29 Seal retaining ring 3 30 Bushing 3 31 High pressure seal 3 32 Nozzle insert 34 Water outlet Problems That Cause Oil Leaks A Oil Reser
9. estricted pressure at the entrance to the nozzle insert 32 pushes the bypass valve upwards This causes the bypass valve to close and the pump builds up pressure once more Thermal Relief Valve If the pump should continue to run in bypass mode for an extend ed amount of time max 5 min the water circulating within the pump will reach a temperature level that will cause internal damage This is prevented by the thermal relief valve 17 The thermal relief valve will release the hot water and then automati cally reset itself Detergent Delivery System In this system there is a nozzle insert 32 in the water outlet 34 The entire pump capacity flows through the nozzle insert to the spray gun Detergent can only be drawn in by the nozzle insert 32 if the nozzle of the spray wand has been set to low pressure This causes the pump pressure to fall to approximately 435 PSI low pressure and the greatest degree of negative pressure 11 6 PSI is generated at the lateral hole in the nozzle insert so that detergent can be drawn into the unit via the detergent suction tube 40 and detergent filter 41 If the spray nozzle on the spray wand is set for high pressure operation the hole in the nozzle insert 32 does not create any negative pressure and no detergent can be drawn into the unit The detergent non return valve 36 consists of a small spring 39 with a ball 38 O ring 37 and nipple 35 When operating in the de
10. pressure valve seat 3 26 Low pressure valve spring 3 7 27 Low pressure valve basket 3 X So gt 47 High I lat 28 0il seal 3 Oe SR OSSE NAVO paie 29 Seal retaining ring 3 30 Bushing 3 31 High pressure seal 3 32 Nozzle insert 34 Water outlet _ _______ 49 Pump head bolt 4 Problems That Cause Water Leaks A Thermal Relief Valve The thermal relief valve 17 protects the pump from hot water temperatures in bypass mode If the thermal relief valve is damaged or does not reset there will be a continual leak Check thermal relief valve 17 Weep Holes High Pressure Seals Water leaking from the weep holes 12 can indicate a leak in the high pressure seals Check seals 31 for damage www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 11 e SECTION 2 WATER LEAKS SOLUTIONS A Thermal Relief Valve A Thermal Relief Valve B Weep Holes High Pressure Seals 1 Remove fastening cap and deflector cap figure 2 4 Replace all three seals using installation tool e Place seal flat side down on installation tool e Fill groove with silicone grease figure 12 Place brass sleeve in pump head figure 10 2 Remove thermal relief valve housing figure 10 3 Remove thermal relief valve figure 10 inset 4 Inspect valve and replace with new valve if necessary figur
11. r inlet housing 2 Pull out piston guide assembly 3 Drain oil into suitable container 4 Turn over piston guide housing and pry out bushings i figure 17 figure 19 e Place seal in housing using installation tool figure 19 e Push until seal hits bottom 7 Check pistons for damage and scoring figure 20 Replace if necessary Figure 17 5 Inspect bushings and replace if necessary 6 Remove the three oil seals with flat head screwdriver figure 18 Figure 20 8 Clean piston surface 9 Reassemble figure 18 www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 14 o SECTION 3 OIL LEAK SOLUTIONS C Pump Shaft Seal C Pump Shaft Seal figure 21 i E p figure 24 1 Unscrew nut on swash plate housing figure 21 and remove 3 Remove the pump shaft seal by tapping the seal towards the front of the oil reservoir using a suitable tool inset figure 24 4 Clean pump shaft seal surface e To replace pump shaft seal place seal into oil bath housing figure 23 e Push into place figure 23 3 Turn housing over and knock out the bearing by tapping it towards the front of the oil the reservoir using a suitable tool figure 22 ma www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01
12. red inside the pump D Bypass Valve 1 Remove fastening cap and deflector cap figure 2 figure 2 ea 2 Remove thermal relief valve housing figure 3 figure 3 3 Pull out bypass valve figure 4 m figure 4 4 Inspect bypass valve for damage and lubrication Inadequate lubrication will cause valve to stick 5 Inspect O rings for nicks or cuts Replace if necessary 6 Grease only large O rings with lithium grease figure 4 inset 7 Replace bypass valve E High Pressure Check Valve 1 Remove valve plate by tapping plate with screwdriver and hammer figure 5 2 Remove 3 plastic valve caps figure 5 inset plastic valve caps figure 5 www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 9 c SECTION 1 WATER PRESSURE SOLUTIONS F Low pressure Check Valve G Water Leaks H Pump Cycling 3 Remove valve with valve pliers figure 6 springs figure 9 figure 6 4 Check valve for wear debris and pitting figure 7 Replace if necessary Figure 9 4 Check valve for wear debris and pitting inset figure 9 Note If any one low pressure valve is damaged all three valves should be replaced 5 Lightly grease 0 rings with silicone grease 6 Reassemble and reinstall Note low pressure check valves must be ordered as a unit Individual check valve pa
13. rticular unit involved When the piston 9 is forced backwards by the piston spring 10 in the oil bath housing 1 the high pressure check valve 43 46 clos es and water is drawn in through the supply line suction chamber at the water inlet 20 through the inlet filter 21 and through the open low pressure check valve 24 27 When the piston 9 is pushed forward by the swash disk 8 the low pressure check valve closes and water is conveyed through the open high pressure check valve to the high pressure outlet The pressure that is generated is dependent upon the flow rate and the orifice diameter of the of the high pressure nozzle o KARCHER OVERVIEW Bypass Valve When the trigger of the spray gun is pulled the entire pump capacity flows through the nozzle insert 32 to the water outlet 34 At this time the bypass valve remains in the upper position and closes off the path between the pressure chamber and the suction chamber When the trigger of the spray gun is released water ceases to flow through the nozzle insert 32 The pressure above the by pass valve 19 rises which causes the bypass valve to be pressed downwards This will cause the pump to run in the bypass mode The pump continues to run but only maintains the circulation pressure When the trigger of the spray gun is again pulled the pressure in the high pressure hose drops suddenly The spring inside the bypass valve 19 together with the r
14. rts can not be ordered separately G Water Leaks See Section 2 Water Leaks figure 7 H Pump is Cycling See Section 4 Detergent Delivery Failure 5 Grease O rings lightly with silicone grease and reassemble figure 7 inset F Low Pressure Check Valve 1 Remove water inlet housing with socket wrench 4 bolts figure 8 Figure 8 2 Remove piston housing figure 8 inset 3 Remove low pressure check valves including valve disks and ma www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 10 A SECTION 2 WATER LEAKS _ 2 Oil bath housing 3 Swash plate shaft seal _13 Fastening cap _ 4 Forward O ring 35 Nipple _ 16 Thermal relief 36 Detergent valve housing non return check valve _ 17 Thermal relief valve R 37 0 ring 18 Spring o lt 38 Ball bearing te 19 Bypass valve lt p 39 Spring 20 Water inlet E 40 Detergent tube BO 21 Water 41 Detergent filter A 21M 1 Detergent fil 10 Piston spring 7 inlet filter with metering valve i be 11 Piston housing High pressure valve cap 3 12 Slot holes 3 SK High pressure valve basket 3 EXN a High pressure valve spring 3 23 Throttle High pressure valve plate 3 24 Low pressure valve seat 3 gt J ty 25 Low pressure valve plate 3 ata g 6 High
15. t Delivery Failure Section 4 Always wear safety rated eye protection and clothing Tae Generic Tools TA contact KARCHER technical support e Allen Wrench 8mm e Allen Wrench 6mm e Socket Wrench 13mm Torx TX30 Socket Wrench Needle Nose Pliers Rubber Mallet Pliers Flat Head Screwdriver Phillips Head Screwdriver Hammer Safety Goggles www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 4 e MASTER DIAGRAM 1 Pump shaft 2 Oil bath housing 3 Swash plate shaft seal ATE RS 13 Fastening cap o lt e 14 Deflector cap ft 15 Screw 2 16 Thermal relief valve housing pes 17 Thermal relief valve 4 Forward O ring 18 Spring g _ 19 Bypass valve 20 Water inlet 8 ZA KIDDE AIA i Lig S lt 7 nr 10 Piston spring CY 11 Piston housing 12 Slot holes 3 23 Throttle 24 Low pressure valve seat 3 25 Low pressure valve plate 3 26 Low pressure valve spring 3 27 Low pressure valve basket 3 28 Oil seal 3 29 Seal retaining ring 3 30 Bushing 3 31 High pressure seal 3 32 Nozzle insert 34 Water outlet 35 36 nol 37 38 39 40 41 with metering valve 6 www mymowerparts com Nipple Detergent n return check valve O ring Ball bearing Spring Detergent tube
16. tergent mode the negative pressure created by the nozzle insert 32 causes the ball to be drawn away from the O ring 37 against the tension of the spring 39 Detergent can then be drawn into the unit When operating in the high pressure mode the ball 38 seals off the detergent connection so that no water can flow into the con tainer of detergent www mymowerparts com Pump 629 9 28 01 3 22 PM Page 6 For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 KARCHER OVERVIEW amp SPECS ei PART NUMBERS High Pressure Washer Pump 3 532 629 0 ITEM S DESCRIPTION PART QTY IN PUMP 4 wach plate sra tan beaming _ 7401 te50 1 i 1 7 i N 1 18 Sing te wi tem 7 a i 20 Water net rouda winem ai wa 1 _ z 24 25 Low pressure valve seat plate 4 580 330 0 3 26 27 spring basket ITEM S DESCRIPTION PART QTY IN PUMP 6965 3940 onl 5 ing i ea 45 46 plate and seat High pressure valve plate 0 Pump head 5 550 249 Pump head bolts 7 304 097 0 Ball bearing included with part 34 BEME EEMI BEME w NOT PICTURED IN DIAGRAM e o Tiere ose conection onsena 1 Piston spring retaining clip 5 030 625 0 3 www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 7 e SECTION 1 LOW WATER PRESSURE _ 1 Pump shaft _ 2 0il bath housing 3 S
17. voir If the oil bath housing 2 is overfilled oil will leak B Weep Holes Oil Seals or Piston Damage 35 Nipple 36 Detergent non return check valve 37 0 ring Ball bearing Spring Detergent tube 41 Detergent filter with metering valve y High pressure valve cap 3 High pressure valve basket 3 High pressure valve spring 3 High pressure valve plate 3 6 High pressure valve seat 3 ee 47 High pressure valve plate AG 48 Pump head 49 Pump head bolt 4 If oil is leaking from the weep holes 12 there is a leak in the oil seals 28 or 31 or there is piston damage Pump Shaft Seal A damaged or worn pump shaft seal 3 www mymowerparts com For Karcher Pressure Washer Parts Call 606 678 9623 or 606 561 4983 Pump 629 9 28 01 3 22 PM Page 13 c A Oil Reservoir B Weep Hole s Oil Seals A Oil Reservoir 1 Oil level should be 1 8 above swash disk Overfilling causes oil 1 1 seals and revlaceiit leaks figure 16 Inspect oil seals and replace if necessary e Soak new oil seals in water for 10 minutes inset figure 19 e Make sure housing is clean and dry e Place oil seal in to recessed end of installation tool Groove in seal should face oil Brass sleeve is not used e Do not grease groove in oil seal figure 16 B Weep Holes Oil Seals 1 Remove piston guide housing and wate
18. wash plate shaft seal e 13 Fastening cap _ 4 Forward O ring 14 Deflector cap 15 Screw 2 35 Nipple 16 Thermal relief 5 Swash plate shaft ball bearing so ees hosi valve housing _ 36 Detergent non return check valve _ 17 Thermal relief valve g 37 0 ring 6 Swash plate housing Cy A ae p 18 Spring a 8 Swash disk S gt 38 Ball bearing 7 Swash plate ball bearing 19 Bypass valve 39 Spring 20 Water inlet 40 Detergent tube 9 Piston lt 41 Detergent filter 10 Piston spring be 11 Piston housing 12 Slot holes 3 with metering valve ig High pressure valve cap 3 High pressure valve basket 3 High pressure valve spring 3 23 Throttle High pressure valve plate 3 24 Low pressure valve seat 3 25 Low pressure valve plate 3 26 Low pressure valve spring 3 27 Low pressure valve basket 3 A High pressure valve seat 3 47 High pressure valve plate es 28 Oil seal 3 29 Seal retaining ring 3 30 Bushing 3 31 High pressure seal 3 Xe 48 Pump head 32 Nozzle insert Se 34 Water outlet seo 4 49 Pump head bolt 4 Problems That Cause Low Water Pressure Water Supply A problem with the water supply Use cold water only Worn Nozzle A worn nozzle on the spray gun Water Inlet Filter A clogged water inlet filter 20
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