1. Foreword 2 1.1 Note on RE 160 K 2 2. Safety regulations 2 3
Contents
1. 621RA093 KN e Undo fastening screws in cover Remove cover and fan shroud Note The fastening screw is se cured with Loctite 621RA094 KN Block the fanwheel with a screw driver 1 but without damaging it e Undo fastening screw 2 Examine fanwheel and replace if necessary 621RA095 KN e Undo fastening screws on drive housing 621RA096 KN e Carefully prise drive housing off stator housing with two screw drivers alternately working crosswise in small steps Do not damage the housing 621RA097 KN e Draw drive housing off stator with rotor RE 140 K 160 K 621RA098 KN e Press rotor out of drive housing and swashplate with suitable arbor 621RA099 KN e Remove swashplate 1 from drive housing Remove shoulder bearing e Remove screw plug 2 and plug 3 Uniformly heat drive housing to approx 80 C on a hotplate or with a hot air fan the shoulder bearing will then drop out of the housing Important Wear gloves Press oil seal down and out of drive housing with a screwdriver RE 140 K 160 K Adan M e Press ball bearing out of stator with suitable arbor Important Oil seals shoulder bearings and ball bearings which have been removed must always be replaced by new parts RE 160 K e Undo fastening screws for fan shroud Remove fan shroud e Remove clamping ring 1 with standard extrac2. 621RA018 BL Z e Prise off cover 1 with a small screwdriver e Prise off retainer 2 with a screwdriver and remove it e Pull high pressure hose 3 out of spray gun 621RA064 BL e Undo fastening screws in right hand handle moulding Remove right hand handle moulding noting the valve lever and high pressure port 28 621RA065 BL Note A split support ring 1 is fitted on the high pressure connection To remove the ring it must be pushed apart at the gap and then pulled off The support ring must not be overextended This is the case if it protrudes strongly from the groove e Replace O ring 2 The remaining procedure for disassembling and assembling the spray gun is the same as on high pressure cleaners of series RE 101 K Additional steps 621RA066 BL e Remove connecting elements 1 from spray lance 2 e Replace O rings 3 10 2 Spray lance spray head a a 3 q a N e Undo locking screw 1 on spray head Unscrew spray head from spray lance noting the nozzle and spring 621RA068 BL e Remove nozzle 1 and spring 2 from spray lance e Replace O rings 3 4 621RA069 BL e Undo fastening screws in handle moulding of spray lance Remove handle moulding RE 140 K 160 K 621RA070 BL e Remove spray lance 1 from handle moulding e Remove spray head connecting e
3. Motor hums but does not run when switched on Motor does not start when switched on Motor stops Cause Mains voltage too low Spray gun closed Pump stiff blocked or frozen Extension lead with wrong cross section Connector has not been plugged in correctly break in power supply Mains fuse has been tripped Overload protection in winding tripped because motor overheating or overloaded Spray head soiled Remedy Check electrical connection Actuate spray gun Turn motor by hand as described for Starting up after prolonged storage User Manual Use correct cable cross section see User Manual Check plug cable and switch Refit mains fuse Check that supply voltage matches specified machine voltage Switch off machine and allow to cool for at least 3 minutes Clean nozzle in spray head Note A correct power supply is essential if the machines are to operate faultlessly The voltage drop in the motor during operation must not be excessive otherwise the motor will turn too slowly and take up too much power This causes the windings to heat up and the overload switch cuts out the machine after only a short period of operation Moreover the machine cannot build up the rated power output and problems may arise during the starting phase i e between switching on the motor and reaching the nominal speed RE 140 K 160 K 5 HOUSING 5 1 Removing fitting the 621RA001 BL e Unscrew high pressure hose
4. 1 e Unscrew hose connector 2 from water inlet 621RA002 BL e Undo fastening screws rear screw not shown e Remove shroud Ensure that spring nuts and power cable are not lost Reassemble parts in reverse order 5 2 Removing installing motor pump unit 621RA084 KN e Disconnect detergent intake hose from metering valve Remove shroud see 5 1 Stand machine upright RE 140 K 621RA085 KN e Undo fastening screw on motor pump unit steadying the machine with the other hand at the same time 621RA086 KN e Lift motor pump unit out of frame 621RA087 KN RE 160 K e Undo fastening nuts on motor pump unit steadying the bolts at the same time if necessary Hold the machine steady and ensure that washers are not lost Lay machine in a horizontal position 621RA005 BL e Lift motor pump unit out of frame Ensure that rubber buffers screws and washers are not lost All models Reassemble parts in reverse order RE 140 K 160 K 5 3 Chassis 6 SAFETY CONTROL BLOCK Important The O rings must always be replaced when carrying out repair work Before assembling the parts all moving parts sealing rings and screw threads must be thinly coated with special grease for high pressure cleaners 0781 145 3516 Exceptions to this rule are mentioned where appropriate 621RA007 BL e
5. 160 K 6 3 Set pressure control system Connect test pressure gauge 5910 850 3205 between high pressure port and high pressure hose Connect water inlet and high pressure hose imal a Oo N lt oc N o e Completely unscrew the micro switch adjusting screw 1 witha size 2 5 hexagon socket wrench Switch on machine Open spray gun Set maximum working pressure on spray lance e Back off adjusting nut 2 until pressure has dropped completely e Screw adjusting nut in again until reading on pressure gauge no longer increases maximum working pressure The setting is adjusted precisely by slowly backing off and scre wing in the adjusting nut RE 140 K 160 K The bypass valve is set correctly when the adjusting nut is screwed in precisely to the point necessary for the maximum pressure reading on pressure gauge to be barely reached Let machine run for approx 10 seconds Operate the spray gun two or three times Note The maximum pressure and cutout pressure settings are determined by the adjusting nut Ensure that the cutout pressure does not become too high by scre wing the nut in further The cutout pressure pressure at which the bypass valve opens must be 5 bar higher than the maximum working pressure see 3 2 To check the setting Close spray gun and read off cutout pressure value on pressure gauge If the value is too high Open
6. Align metering valve so that intake connector points back to intake hose Screw banjo bolt into safety control block and tighten securely 621RA084 KN 621RA090 KN e Disconnect detergent intake e Remove O ring 1 from banjo hose from metering valve bolt Pull banjo bolt out of metering valve Clean and examine all parts replace if necessary Clean valve seat in safety control block Reassemble parts in reverse order Fit valve ball in banjo bolt A x 2 is lt oc N e Pull split pin 1 out of adjusting knob 2 e Remove adjusting knob 2 RE 140 K 160 K 13 7 HIGH PRESSURPUMP 7 1 Screen in intake port water inlet e Unscrew hose connector from water inlet see 5 1 621RA026 BL e Remove screen from intake port with pliers clean it and replace if necessary Reassemble parts in reverse order 14 7 2 Removing installing delivery valves Remove shroud see 5 1 and motor pump unit see 5 2 Remove safety control block see 6 1 The delivery valves are removed and installed in the same way as on the high pressure cleaners of series RE 102 K 104 K and 106 K Important Different valves are used in the high pressure cleaners RE 140 K 160 K see spare parts list 621RA023 BL Note Where possible defective valves should only be replaced as a complete unit O ring 1 valve head 2 plate 3 spring 4 and cage 5 The
7. e Insert rotor with drive housing in stator and align in the original installation position Carefully drive the drive housing home with a rubber hammer 621RA095 KN e Turn in fastening screws Note Tighten fastening screws down alternately to avoid stressing the housing Tighten fastening screws down with a torque of 7 Nm Fit fanwheel on shaft and block it with a screwdriver Wet fastening screw with Loctite 242 and tighten it securely Refit pump housing see 7 4 and valve block see 7 3 Fill with oil see chapter 11 Reassemble remaining parts in reverse order 22 RE 160 K e Press oil seal 1 into drive housing from the pump side using assembly arbor 4112 893 2401 Open side faces pump 621RA059 BL e Press new ball bearings 1 onto drive shaft with suitable tubing cut away in diagram Oil sealing lip of oil seal Press drive housing onto drive side ball bearing of rotor drive shaft with notch for feather key Insert rotor with drive housing in stator and align in original installation position compare markings Turn in fastening screws upper screw with fastening clamp for capacitor Note Tighten fastening screws alternately to avoid stressing the housing Tighten fastening screws down with a torque of 7 Nm 621RA060 BL e Place bearing cover on drive shaft Turn in fastening screws Note Tighten fa
8. intake valves must also be checked see 7 2 if delivery valves are soiled or damaged Check correct functioning before installing valves 7 3 Removing installing valve block and intake valves Remove shroud see 5 1 and motor pump unit see 5 2 Remove safety control block see 6 1 Remove delivery valves if necessary see 7 2 e Undo fastening screws 1 e Remove retaining plate 2 with microswitch The intake valves are removed and installed in the same way as on the high pressure cleaners of series RE 102 K 104 K and 106 K Important Different valves are used in the high pressure cleaners RE 140 K 160 K see spare parts list Pull valve discs out of valve block RE 140 K 160 K po a N QO lt a N o Note Where possible defective valves should only be replaced as a complete unit O ring 1 valve head 2 plate 3 spring 4 and cage 5 The intake valves and delivery valves are identical Brass valve block only e Fit valve discs 6 Check correct functioning before installing valves Reassemble parts in reverse order Ensure that all O rings are fitted and that the valve block is not mi saligned when fitted Turn in fastening screws Insert microswitch and turn in fastening screws Tighten fastening screws on valve block down crosswise 15 Nm RE 140 K 160 K 7 4 Removing inst
9. 8 18 21 23 27 28 28 30 31 31 31 STIHL 2000 Andreas Stihl AG amp Co Waiblingen 1 1 FOREWORD This Repair Manual contains a detailed description of the fundamental repair work on STIHL high pressure cleaners of series STIHL RE 140 K 160 K A test bed with the necessary water and power supplies should be provided for the repair work The unit must be connected to the pressurized water supply and the fault described by the customer reproduced with the customer demonstrating the fault if necessary The customer s attention must be drawn to the User Manual if the machine is operated incorrectly Faults may be due to several causes The Summary of possible faults should therefore be consulted see 4 The illustrated spare parts lists must also be used for all repair work These lists show the installation position and order in which the individual assemblies should be assembled Microfilms are more up to date than printed spare parts lists Note the Technical Information bulletins They contain information on technical changes implemented after publication of this Repair Manual The Technical Information bulletins also supplement the spare parts list until a new edition is printed Repair Manuals and Technical Information bulletins should always be kept on hand wherever repairs are carried out They must not be passed on to third parties Only original STIHL spare parts
10. RA032 BL e Undo fastening screws in cover e Undo fastening screws in cover e Lift switch housing up taking of switch housing of switch housing Ensure that care not to damage the wires nuts are not lost Disconnect plug connector and e Examine gasket 1 and replace protective earth conductor Remove cable lugs from switch if necessary Ensure that the serrated washer is not lost Remove switch see 9 2 2 Reassemble parts in reverse order Remove switch see 9 2 2 Remove cover Remove cover 24 RE 140 K 160 K 9 2 2 Switch Remove shroud see 5 1 Remove cover of switch housing see 9 2 1 Note Note circuit diagram if necessary produce a drawing clearly showing which wire note colour is connected to the respective terminals y 621RA033 B A e Remove retaining screw 1 in rotary knob Remove rotary knob T xt oe Ed a a Cc e Examine O ring 1 in rotary knob and replace if necessary RE 140 K 160 K e Undo fastening screws on switch with size 2 5 hexagon socket wrench Check the various parts and replace if necessary Reassemble parts in reverse order 621RA036 BL e Note installation position of switch the two lugs 1 on the switch fit between the bumps 2 in the cover Grease O ring before refitting rotary knob 9 2 3 Power cable Remove shr
11. RE 140 K 160 K 10 14 CONTENTS 1 Foreword 1 1 Note on RE 160 K 2 Safety regulations 3 Technical specifications 3 1 Motor 3 2 Pump 3 3 Weights and dimensions 3 4 Capacities 3 5 Tightening torques 4 Summary of possible faults 4 1 High pressure pump 4 2 Electric motor 5 Housing 5 1 Removing fitting the shroud 5 2 Removing installing the motor pump unit 5 3 Chassis 6 Safety control block 6 1 Removing installing the safety control block 9 6 2 Removing installing the control piston 6 3 Setting the pressure control system 6 4 Injector 6 5 Non return valve 6 6 Detergent metering and non return valve 7 High pressure pump 7 1 Screen in intake port water inlet 7 2 Removing installing delivery valves 7 3 Removing installing valve block and intake valves RE 140 K 160 K 14 7 4 7 5 7 6 7 7 8 1 8 2 10 10 1 10 2 11 12 12 1 12 2 Removing installing pump housing and pump piston Disassembly assembly of pump piston Replacing high pressure cups and oil seals Replacing thrust bearings Electric motor Removal Installation Electrical system Circuit diagram Removing installing electrical components Switch housing Switch Power cable Capacitor Microswitch Spray attachment Spray gun Spray lance spray head Oil change Special tools and service tools Special tools Service tools 15 15 16 17 1
12. Remove handle Note The permissible working pressure of the machine has been set on the safety control block by the manufacturer and must not be changed A lead seal is fitted to the safety control block for this reason The permissible working pressure must be reset after all repairs and a new lead seal fitted to the safety control block e Undo fastening screws with size 5 hexagon socket wrench Remove handle and replace if necessary 621RA008 BL Remove retainer and shaft e Undo fastening screws with size 5 hexagon socket wrench Remove retainer and shaft Proceed as described for the high pressure cleaners of series STIHL RE 310 K 340 K and 440 K for changing wheels Replace faulty parts Reassemble parts in reverse order RE 140 K 160 K 6 1 Removing installing the safety control block Remove shroud see 5 1 and motor pump unit see 5 2 Note The screw plug should only be removed if leaking e Undo fastening screws O e Carefully remove the safety control block Ensure that the adjusting screw for the micro switch O rings and delivery valves are not lost e Replace O rings To replace the safety control block housing Remove control piston see 6 2 injector see 6 4 non return valve see 6 5 and detergent metering valve see 6 6 Reassemble pa
13. allation Important When installing the motor ensure that the correct rotor stator and ball bearings are used for the model to be repaired see spare parts list RE 140 K 621RA101 KN 621RA103 KN e Press oil seal into drive housing from the pump side using assembly arbor 4112 893 2401 1 Open side faces pump 621RA104 KN 621RA105 KN e Press inner race of shoulder bearing in drive housing onto drive shaft with suitable tubing inside diameter slightly larger than inner bearing race until it is flush with the shoulder Important Note installation position of shoulder bearing 1 and oil seal 2 refer to schematic drawing with swashplate 3 and rotor shaft 4 Zz x o lt a N e Press new ball bearing into stator with the aid of suitable tubing outside diameter 34 mm RE 140 K 160 K e Press new shoulder bearing into drive housing until flush with housing using suitable tubing same outside diameter as outer bearing race Oil sealing lip of oil seal Insert rotor in drive housing Note The centre shaft of the swashplate is perpendicular to the axis of rotation The tube must be positioned here when installing the swashplate z ra KR is lt x a N e Press swashplate onto drive shaft with suitable tubing 21 621RA108 KN
14. alling pump housing and pump piston Remove valve block 7 3 Drain oil see chapter 11 The pump housing and pump piston are removed and installed in the same way as on the high pressure cleaners of series RE 102 K 104 K and 106 K Note Steady the pump housing when undoing the fastening screws so that it is not pushed aside by the force of the springs 75 Disassembly assembly of the pump piston Remove pump piston see 7 4 Remove spring and washer Remove circlip re a N Tt io lt a N o e Examine piston 1 spring 2 washer 3 and circlip 4 and replace if necessary Reassemble parts in reverse order Ensure that washer is fitted correctly 15 7 6 Replacing the high pressure cups and oil seals Remove pump piston see 7 4 The high pressure cups and oil seals are removed and installed in the same way as on the high pressure cleaners of series RE 102 K 104 K and 106 K with the following additional steps e The oil seals 1 in the pump housing are mounted on support rings 2 e The oil seals can be prised out by applying an implement in the recesses 8 in the pump housing N 621RA044 BL RE 160 K e The high pressure cups 1 in the valve block are likewise mounted on a support ring 2 16 7 621RA092 KN RE 140 K RE 160 K Installation position of the oil seals and high pressure cups 1 High pres
15. as far as possible with new sealing ring 621RA012 BL e Unscrew high pressure hose connection with size 30 fork wrench Replace O ring in high pressure port 621RA016 BL e Pull injector out of safety control block housing with hook 5910 890 2900 Engage hook in two holes in injector housing 12 Reassemble parts in reverse order 6 5 Non return valve Remove safety control block see 6 1 Remove injector see 6 4 K a a N N Q lt a N o e Pull spring 1 and piston 2 out of safety control block housing use pliers if necessary e Replace O ring 3 on piston Clean valve seat in safety control block housing Reassemble parts in reverse order Insert piston in housing with O ring facing inwards Ensure that piston and spring are seated correctly Refit injector and safety control block RE 140 K 160 K 6 6 Detergent metering and non return valve Note The detergent intake comprises a detergent metering valve a detergent non return valve and an injector nozzle in the high pressure port The injector must also be examined see 6 4 if faults arise in the detergent intake 621RA089 KN 621RA091 KN e Unscrew banjo bolt from safety e Fit valve spring with narrow end control block Ensure that the facing ball spring and ball of the non return valve are not lost in the process
16. hine in normal use and need not be changed If the machine is used in more demanding conditions or for commercial purposes the oil must be changed every six months 100 ml SAE 15 W 40 Oil capacity Oil grade Remove shroud see 5 1 and motor pump unit see 5 2 if necessary Lay the motor pump unit down so that the screw plug points upwards 621RA114 KN RE 140 K e Release and remove the screw plug Replace O ring 621RA027 BL RE 160 K e Undo screw plug with 1 4 size 7 hexagon socket wrench 30 621RA028 BL All models e Turn motor pump unit on its side and let oil drain completely into a sufficiently large container RE 160 K Note The pressure compensa ting valve should only be removed if leaking or damaged Proceed as follows 621RA029 BL e Carefully prise relief valve off with a screwdriver Do not damage housing Examine relief valve and replace if necessary 621RA062 BL e Replace O ring 1 Grease relief valve before pressing it into place All models Fill with 100 ml oil oil grade as specified above RE 140 K Insert and lock screw plug RE 160 K Turn in screw plug and secure with a torque of 7 Nm All mode
17. l SAE 15 W 40 3 5 Tightening torques Assembly Safety control block to valve block Valve block to pump housing Pump housing to drive housing Drive housing to stator housing Bearing cover and drive housing to stator housing Screw plug drive housing Remarks Connecting element Socket head screw Socket head screw Socket head screw Socket head screw Hex bolt Hexagonal socket head bolt 1 Thread must be clean and dry 2 RE 140 K only 3 RE 160 K only Thread size M5x30 M6x35 M6x30 M5x25 M6x25 R1 4 Tightening torque Nm 15 10 Remarks RE 140 K 160 K 4 SUMMARY OF POSSIBLE FAULTS 4 1 High pressure pump Problem Pump runs but does not build up the specified pressure Pressure fluctuates or drops Pump does not run smoothly Safety control block cycles after switching off the spray gun constant audible switching sound pump becomes hot Oil contains water Oil leak RE 140 K 160 K Cause Pressure control sleeve not set correctly Nozzle in spray head worn Air in system Leak in high pressure system Shortage of water Water feed hose too long or cross section too small Water filter clogged Pump draws air High pressure cups worn Water feed temperature is too high Intake line is damaged pump draws air Intake delivery valves of high pressure pump soiled or worn Leak in high pressure system so that safety control bl
18. lement 2 and coupling 3 621RA071 BL e Replace O rings on spray lance 1 2 and on coupling 3 Note All O rings must be well greased before being fitted 621RA072 BL e Force both locking pins 1 second pin not shown in diagram out of nozzle sleeve with a wire dia 1 5 mm 2 RE 140 K 160 K 621RA073 BL e Remove nozzle sleeve 1 e Remove retainer 2 for leaf springs from housing 3 Important The leaf springs have extremely sharp edges Beware of injuries Always wear gloves when handling the leaf springs a t N fo lt x a N o e Replace O ring 1 in retainer for leaf springs Leaf springs should only be removed if damaged Proceed as follows 621RA075 BL e Disengage leaf spring catch 1 e Remove leaf spring with pliers Leaf springs which have been removed must always be replaced by new ones Examine all parts for damage and replace if necessary Ensure the correct nozzle is used see spare parts list Reassemble parts in reverse order Note installation position of nozzle and springs Ensure that the connector and the coupling are correctly seated in the handle mouldings Finally check correct functioning of nozzle sleeves with regard to jet pattern and pressure control 29 11 OIL CHANGE The oil in this high pressure cleaner is designed to ensure permanent lubrication of the mac
19. ls Reassemble parts in reverse order RE 140 K 160 K 12 SPECIAL TOOLS AND SERVICE TOOLS 12 1 Special tools No Part name 1 Hook 2 Assembly device assembly arbor and sleeve 3 Assembly arbor 4 Extractor 5 1 4 hexagon socket wrench 6 Torque wrench 7 Torque wrench 8 Test pressure gauge 12 2 Service accessories No Part name 1 Special grease waterproof 50 g tube 2 Locking paint standard RE 140 K 160 K Part No 5910 890 2900 4726 890 2200 4112 893 2401 4703 890 4500 5910 890 0300 5910 890 0310 5910 850 3205 Part No 0781 145 3516 Use Removing injector from safety control block housing Drawing valve body out of safety control block Fitting high pressure cups in valve block with support rings Installing oil seals in pump housing Forcing oil seal into drive housing Drawing ball bearings off drive shaft Screw plug in drive housing Setting pressure control system Use O rings high pressure cups sliding surfaces in contact with water Adjusting nut and adjusting screw for pressure setting on control piston 31
20. may be used 1 1 Note on RE 160 K Please refer to the preceding Repair Manual for the RE 160 K if the procedures described and illustrated in this Repair Manual do not correspond with your machine 2 Safety regulations High pressure cleaners may only be repaired by qualified electricians in accordance with DIN VDE 0701 and accident prevention regulations VBG 4 in Germany with due regard for national safety regulations and the provisions of the User Manual RE 140 K 160 K 3 TECHNICAL SPECIFICATIONS 3 1 Motor Voltage Frequency Power output Fuse Protection class Type of protection 3 2 Pump Max working pressure Permissible excess pressure Flow rate Suction lift Max water feed temperature Pressurized water supply In suction operation 3 3 Weights and dimensions Length approx Width approx Height approx Weight approx 3 4 Capacities High pressure pump Oil grade Depends on country concerned Australia New Zealand GB N Ireland Malaysia RE 140 K 160 K RE 140 K 230 V 240 V 50 Hz 60 Hz 2 3 2 9 KW 16 A l IP X5 140 bar 150 bar 500 I h 0 5 m 50 C 40 C 370 mm 270 mm 860 mm 20 0 kg 100 ml SAE 15 W 40 10A 13A RE 160 K 230 V 240 V 50 Hz 60 Hz 2 2 3 3 kW 16 A IP X5 150 bar 160 bar 500 550 I h 0 5m 50 C 40 370 mm 270mm 860 mm 25 0 kg 100 m
21. ock does not switch over correctly and the bypass does not open completely High pressure cups worn Gaskets in high pressure pump worn Remedy Set required working pressure Replace nozzle Vent system briefly operate machine without high pressure hose Seal high pressure system Turn on water tap keep within maximum suction head max 0 5 m Use specified water feed hose Clean water filter in pick up body and pump inlet Check intake line for leaks and replace if necessary Replace high pressure cups Reduce water feed temperature see technical specifications Replace intake line Clean or replace valves Seal clean and grease the safety control block Replace high pressure cups Replace gaskets Problem No supply of detergents Weak ragged unclean jet Cause Detergent tank is empty Detergent metering valve is closed Pressure control sleeve not set to CHEM High pressure hose coupling is not screwed tight Detergent intake hose clogged Injector clogged Gasket on high pressure hose connection defective or missing High pressure nozzle in spray head is soiled or worn Remedy Fill detergent tank Set required detergent quantity on metering valve Set pressure control sleeve to CHEM Tighten screw coupling Clean Clean Replace or fit gasket Clean high pressure nozzle with nozzle cleaning needle or replace if necessary RE 140 K 160 K 4 2 Electric motor Problem
22. ool 4726 890 2200 in the same way as the high pressure cups Do not damage the sealing lip Insert support rings in pump housing and press in with assembly arbor Reassemble remaining parts in reverse order Installation position of guide bushing see diagram 7 7 Replacing thrust bearings Remove shroud see 5 1 and motor pump unit see 5 2 Remove safety control block see 6 1 valve block see 7 3 and pump housing see 7 4 The outer thrust bearing is removed and installed in the same way as on the high pressure cleaners of series RE 102 K 104 K and 106 K RE 160 K only 621RA046 BL e Pull swashplate 1 and inner thrust bearing off the drive shaft pa a N boy QO lt x a N Koj Examine the various parts of the outer see RE 102 104 106 K and inner thrust bearing and replace if necessary upper washer 1 cage with bearing rollers 2 and bottom washer 3 17 All models Reassemble parts in reverse order Note All parts of the thrust bea ring and the swashplate must be well oiled before being installed 18 8 ELECTRIC MOTOR 8 1 Removal Remove shroud see 5 1 Remove switch housing see 9 2 1 and microswitch see 9 2 5 RE 160 K only Remove power cable see 9 2 3 and capacitor see 9 2 4 All models Drain oil see chapter 11 Remove valve block see 7 3 and pump housing see 7 4 RE 140 K
23. oud see 5 1 Remove cover of switch housing see 9 2 1 Note Note circuit diagram if necessary produce a drawing clearly showing which wire note colour is connected to the respective terminals RE 140 K Remove lugs of power cable from switch 621RA111 KN e Prise cable grommet 1 out of housing and pull it out of the housing with the power cable RE 160 K e Disconnect protective earth conductor 1 Note the serrated washer 25 621RA038 BL e Press cable grommet 1 out of housing and pull it out of the housing with the power cable a a Q N Q lt x a N o All models e Unscrew cable gland with fork wrench Wrench size 22 for upper nut Wrench size 24 for lower nut Check power cable cable gland and anti kink tube and replace if necessary Reassemble parts in reverse order 26 9 2 4 Capacitor Remove shroud see 5 1 Remove cover of switch housing see 9 2 1 Note Note circuit diagram if necessary produce a drawing clearly showing which wire note colour is connected to the respective terminals Disconnect capacitor connecting leads RE 140 K alls 621RA112 KN e Press capacitor out e Check O ring on capacitor and replace if necessar
24. rts in reverse order and ensure that O rings are fitted e Carefully insert adjusting screw 1 into opening 2 in microswitch Turn in fastening screws and tighten down crosswise with a torque of 7 Nm Then set the working and cutout pressure see 6 3 and refit the lead seal on the safety control block 10 6 2 Removing installing the control piston Remove shroud see 5 1 e Carefully prise off U bar 1 with a screwdriver if necessary and pull it out e Draw control piston 2 out of safety control block housing ol a vt rx Q lt a N Koj e O rings 1 2 on control piston must always be replaced Examine control piston for signs of damage and replace completely if necessary Ensure that correct control piston is fitted spare parts list 621RA013 BL a a wo O lt x a N o e Draw valve body out of safety control block with hook 5910 890 2900 Remove ball and valve seat insert from safety control block e Replace O ring 1 in valve body Examine valve body ball and valve seat insert replace if ne cessary Clean valve seat in safety control block Reassemble parts in reverse order Note Thinly coat valve seat insert valve body and O ring with special grease for high pressure cleaners 0781 145 3516 before fitting them Fit control piston and secure with U bar e Then set pressure control system see 6 3 RE 140 K
25. spray gun Back off adjusting nut slightly Close spray gun Check cutout pressure Repeat this procedure until the specified cutout pressure see above has been reached The working pressure must not decrease at the same time reading on pressure gauge when spray gun is open The cutout pressure must also remain constant If necessary the setting must be repeated or the high pressure cleaner examined for leaks The microswitch is set with the aid of the adjusting screw when the motor is running and with the spray gun closed Turn adjusting screw in until motor cuts out Then turn on another half turn Check setting at minimum pressure and correct if necessa ry Actuate spray gun several times The motor must switch on when the spray gun is opened and off when it closes repeat adjustment if necessary Seal setting of locknut and adjusting screw with locking paint Remove test pressure gauge 11 6 4 Injector Unscrew high pressure hose remove shroud if necessary see 5 1 a a N io lt a N o e Drive injector nozzle 1 out of injector housing with a pin dia 2 mm e Replace O rings in injector Examine injector nozzle and housing replace if necessary Clean valve seat in safety control block housing Thoroughly grease injector and O rings before refitting them special grease 0781 145 3516 Screw high pressure hose connection in
26. stening screws alternately to avoid stressing the housing Tighten fastening screws down with a torque of 7 Nm Slide fanwheel onto shaft and drive it home a a Oo Q lt x a N Koj e Slide clamping ring onto fanwheel shaft and drive it home with a size 30 insert and a rubber hammer Reassemble remaining parts in reverse order RE 140 K 160 K 9 ELECTRICAL SYSTEM 9 1 Circuit diagram Important The national safety regulations must be observed without fail The power cable must be unplugged from the socket outlet at all times while carrying out repairs al a N KR io lt a N o B4 Microswitch C1 Capacitor M1 Motor with overload protection Q1 Master switch W1 Connecting lead RE 140 K 160 K 23 9 2 Removing installing electrical components 9 2 1 Switch housing Remove shroud see 5 1 Note Note circuit diagram if necessary produce a drawing clearly showing which wire note colour is connected to the respective terminals 621RA110 KN 621RA031 BL e Examine gasket 1 of switch e Examine gasket 1 of switch housing and replace if necessary housing and replace if necessary Reassemble parts in reverse order Undo fastening screws of switch housing RE 140 K RE 160 K 621RA109 KN 621RA030 BL 621
27. sure cup Support ring Valve block Oil seal Support ring Pump housing Guide bushing NOOB WP All models Note Use assembly device 4726 890 2200 assembly arbor and sleeve to fit the high pressure cups and oil seals Proceed as follows 321RA078 BL e Coat inner surface of assembly sleeve 4726 890 2200 with special grease 391RAN70 RI e Fill the grooves of the high pressure cups and oil seals with special grease 0781 145 3516 a a o fo 3 lt x a N e Coat the new high pressure cup 1 with special grease 0781 145 3516 and press onto assembly arbor 4726 890 2200 together with support ring 2 RE 140 K 160 K 521RA081 BL e Slide assembly arbor with high pressure cup into the larger opening in the assembly sleeve interior of sleeve is tapered Press sleeve against a soft level and clean surface and adjust arbor until cup is flush with end of sleeve Position complete assembly device on valve block The collar fits into the seat of the high pressure cup a a N O lt L a j N e Drive high pressure cup into seat in valve block with the assembly arbor Fill grooves of oil seals with spe cial grease 0781 145 3516 RE 140 K 160 K 321RA083 BL e Slide oil seal onto assembly arbor with the groove facing upwards The sealing lip of the oil seal fits into the recess on the assembly arbor Press oil seal into pump housing with assembly t
28. tor Remove fanwheel carefully pri 621RA100 KN 621RA048 BL a a D Tt oa lt L a z N o sing it off with a screwdriver if ne cessary Examine fanwheel and replace if necessary 621RA050 BL e Undo fastening screws in bearing cover 621RA051 BL e Carefully prise bearing cover off stator with two screwdrivers Do not damage stator housing or bearing cover Remove bearing cover 19 621RA052 BL N e Remove feather key 1 from drive shaft Mark installation position of drive housing on stator 621RA053 BL e Undo fastening screws on drive housing Ensure that the fastening clamp for the capacitor is not lost a a lt wo Q lt x a zen N o e Carefully draw drive housing out of stator with rotor Do not damage housing 20 621RA055 BL e Examine ball bearing 1 in bearing cover and replace if ne cessary e Draw ball bearing off drive shaft in order to replace it 621RA056 BL e Press rotor out of drive shaft with suitable arbor Examine ball bearing of drive housing and remove as described above if necessary a a N wo Q lt a N o e Press oil seal down and out of drive housing with a screwdriver Unscrew valve Important Oil seals and ball bearings which have been removed must always be replaced by new parts RE 140 K 160 K 8 2 Inst
29. y Replace defective parts RE 160 K Press cable grommet out of housing and pull out of housing with connecting lead as for power cable see 9 2 3 e Release fastening clamp 1 and pull capacitor out sideways Remove fastening clamp if necessary Replace defective parts All models Reassemble parts in reverse order Ensure that O ring and grommet are correctly seated RE 140 K 160 K 9 2 5 Microswitch Remove shroud see 5 1 Remove cover of switch housing see 9 2 1 Note Note circuit diagram if necessary produce a drawing clearly showing which wire note colour is connected to the respective terminals Disconnect connecting lead from microswitch Press grommet out of housing and pull out of housing together with connecting lead as for power cable see 9 2 3 Remove safety control block see 6 1 e Undo fastening screws on microswitch Replace defective parts Reassemble parts in reverse order RE 140 K 160 K Ensure that grommet is seated correctly 10 SPRAY ATTACHMENT Important O rings must always be replaced when carrying out repairs All moving parts and sealing rings must be thinly coated with special grease for high pressure cleaners 0781 145 3516 before assembling the parts 27 10 1 Spray gun 621RA063 BL e Turn spray lance 1 90 anti clockwise to release from spray gun 2 and remove it N
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