Difficulty

Moderate

Steps

55

Time Required

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Sections

8

  • Karcher Pressure Washers 15209900 2018 Opening Procedure
  • 13 steps
  • Karcher Pressure Washers 15209900 2018 Electrical Box Cover Removal
  • 2 steps
  • Capacitor
  • 3 steps
  • Switch
  • 3 steps
  • Electrical Box
  • 3 steps
  • Karcher Pressure Washers 15209900 2018 Pump Rebuild Part 1
  • 6 steps
  • Karcher Pressure Washers 15209900 Pump Removal
  • 4 steps
  • Karcher Pressure Washer 15209900 2018 Pump Rebuild
  • 21 steps

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Introduction

In order to complete this, you will need the pump rebuild kit. All of the parts that are replaced in this rebuild are listed in the guide.

Some of the body screws are deeply recessed and require a T15 driver with a 5-inch long shaft in order to reach.

Part of this procedure requires removing the pump assembly, with is partially filled with oil. You must refill the oil during reassembly. The part number for the oil is 6.288-219.0.

What you need

Step 1

              Safety precautions
  • Before you begin, make sure to power off and unplug the device from the outlet.
  • Unscrew the output hose from the pressure washer.

Before you begin, make sure to power off and unplug the device from the outlet.

Unscrew the output hose from the pressure washer.

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Step 2

              Remove the rubber strap
  • Unlatch and remove the yellow rubber strap.

Unlatch and remove the yellow rubber strap.

Step 3

              Unscrew the hand grip
  • Use a T20 driver to remove the two 55mm-long screws securing the hand grip.

Use a T20 driver to remove the two 55mm-long screws securing the hand grip.

Step 4

              Remove the hand grip
  • Remove the hand grip from the extension bars.

Remove the hand grip from the extension bars.

Step 5

              Unscrew the top panels
  • Use a T15 driver to remove the six screws securing the top black plastic panels on either side of the device.

Use a T15 driver to remove the six screws securing the top black plastic panels on either side of the device.

Step 6

              Remove the top panels
  • Remove the two plastic panels.

Remove the two plastic panels.

Step 7

              Unscrew the plastic feet
  • Remove the two T15 screws securing the plastic feet—one screw on either side.

Remove the two T15 screws securing the plastic feet—one screw on either side.

Step 8

              Remove the plastic feet
  • Unclip and remove the plastic feet.

Unclip and remove the plastic feet.

Step 9

              Unscrew the housing
  • Use a T15 driver to remove the ten screws securing the housing halves together.
  • Remove the T15 screw underneath the wheel axle.

Use a T15 driver to remove the ten screws securing the housing halves together.

Remove the T15 screw underneath the wheel axle.

Step 10

              Remove the housing
  • Set the device on its side.
  • Lift the housing half away from the body.
  • If the housing half does not separate, check to make sure you removed all the body screws.
  • Remove the housing.
  • Screws may get stuck inside the plastic housing. Be careful not to lose any screws.

Set the device on its side.

Lift the housing half away from the body.

If the housing half does not separate, check to make sure you removed all the body screws.

Remove the housing.

Screws may get stuck inside the plastic housing. Be careful not to lose any screws.

Step 11

              Release the cord strain relief
  • Slide the power cord strain relief out its notch on the plastic housing.

Slide the power cord strain relief out its notch on the plastic housing.

Step 12

              Remove the motor
  • Lift the motor assembly out of the plastic housing and set it aside.

Lift the motor assembly out of the plastic housing and set it aside.

Step 13

              Reassembly tip
  • Reassembly tip: Use these images to help reassemble the housing back around the motor.
  • Make sure that all five bushings are in place.
  • In order for the housing to fit properly, the bushings must fit in their respective mounts.
  • Make sure that the yellow tube is properly notched onto the housing.
  • Make sure that the power cord strain relief sits correctly in the housing notch.

Reassembly tip: Use these images to help reassemble the housing back around the motor.

Make sure that all five bushings are in place.

In order for the housing to fit properly, the bushings must fit in their respective mounts.

Make sure that the yellow tube is properly notched onto the housing.

Make sure that the power cord strain relief sits correctly in the housing notch.

Step 14

              Unscrew the electrical box cover
  • Use a T20 driver to remove the four screws securing the electrical box cover.

Use a T20 driver to remove the four screws securing the electrical box cover.

Step 15

              Remove the electrical box cover
  • Lift the cover off of the electrical box.

Lift the cover off of the electrical box.

Step 16

              Loosen the capacitor
  • Tilt the capacitor upward slightly to gain access to the connectors.

Tilt the capacitor upward slightly to gain access to the connectors.

Step 17

              Unplug the capacitor
  • Use your fingers to pull each capacitor connector directly off of their spade plug.

Use your fingers to pull each capacitor connector directly off of their spade plug.

Step 18

              Remove the capacitor
  • Remove the capacitor.
  • Reassembly note: The wires are non-polarized and can connect into either plug on the capacitor.

Remove the capacitor.

Reassembly note: The wires are non-polarized and can connect into either plug on the capacitor.

Step 19

              Remove the plate spring
  • Remove the plate spring from the electrical box.

Remove the plate spring from the electrical box.

Step 20

  • Pull the switch out of the electrical box.
  • Disconnect the four spade connectors from the the switch.

Pull the switch out of the electrical box.

Disconnect the four spade connectors from the the switch.

Step 21

              Remove the switch
  • Remove the switch.
  • Reassembly tip: Use the second photo as a reference to help you properly re-wire the switch.

Remove the switch.

Reassembly tip: Use the second photo as a reference to help you properly re-wire the switch.

Step 22

              Remove the grounding screw
  • Use a flat head screwdriver to remove the screw securing the ground wire in the electrical box.

Use a flat head screwdriver to remove the screw securing the ground wire in the electrical box.

Step 23

              Unscrew the electrical box
  • Use a T30 driver to remove the two bolts securing the electrical box to the motor assembly.

Use a T30 driver to remove the two bolts securing the electrical box to the motor assembly.

Step 24

              Remove the electrical box
  • Lift the electrical box away from the motor assembly, taking care to feed the wires through the cutout.
  • Remove the electrical box.

Lift the electrical box away from the motor assembly, taking care to feed the wires through the cutout.

Remove the electrical box.

Step 25

              Remove the excess current cover plate
  • Use a T30 driver to remove the two bolts securing the excess current cover plate.

Use a T30 driver to remove the two bolts securing the excess current cover plate.

Step 26

  • Remove the excess current cover plate.

Remove the excess current cover plate.

Step 27

              Remove the excess current valve
  • Use a pair of pliers to grasp the blue tab on the excess current valve.
  • Pull firmly to extract the excess current valve from the pump assembly.

Use a pair of pliers to grasp the blue tab on the excess current valve.

Pull firmly to extract the excess current valve from the pump assembly.

Step 28

              Replace the excess current valve
  • Lubricate the replacement valve’s O-rings with the grease included in the rebuild kit.
  • Press the replacement valve back into the pump.
  • Replace the cover plate with a new one from the rebuild kit.

Lubricate the replacement valve’s O-rings with the grease included in the rebuild kit.

Press the replacement valve back into the pump.

Replace the cover plate with a new one from the rebuild kit.

Step 29

              Replace the fine filter
  • Use pliers to grasp the tip of the fine filter in the water intake connector.
  • Pull the fine filter out of the intake.
  • Replace the fine filter with a new one from the rebuild kit.

Use pliers to grasp the tip of the fine filter in the water intake connector.

Pull the fine filter out of the intake.

Replace the fine filter with a new one from the rebuild kit.

Step 30

              Remove the cylinder head plate
  • Use a hammer and pin punch to tap the cylinder head plate out of its groove.
  • Remove the cylinder head plate.

Use a hammer and pin punch to tap the cylinder head plate out of its groove.

Remove the cylinder head plate.

Step 31

              Set the motor upright
  • Set the motor assembly upright with the pump assembly on the top.
  • The pump assembly is filled with oil. This step prevents the oil from spilling out when you remove the pump.

Set the motor assembly upright with the pump assembly on the top.

The pump assembly is filled with oil. This step prevents the oil from spilling out when you remove the pump.

Step 32

              Loosen the pump assembly
  • Use a 1/2" socket to remove the four long bolts holding the pump assembly to the motor.
  • Re-assembly tip: The bolts hold the pump under pressure against the motor assembly. During reassembly, gradually tighten the bolts in a cross pattern.

Use a 1/2" socket to remove the four long bolts holding the pump assembly to the motor.

Re-assembly tip: The bolts hold the pump under pressure against the motor assembly. During reassembly, gradually tighten the bolts in a cross pattern.

Step 33

              Remove the pump assembly
  • Lift the pump assembly off of the motor.

Lift the pump assembly off of the motor.

Step 34

              Remove the pump oil
  • Pour the pump oil out of the motor housing. If the oil looks serviceable, save it for reassembly.
  • Reassembly tip: The piston assembly is sealed with oil, and the motor housing acts as an oil pan. Before you attach the pump to the motor, fill the piston well with oil, up to the bearing plate.

Pour the pump oil out of the motor housing. If the oil looks serviceable, save it for reassembly.

Reassembly tip: The piston assembly is sealed with oil, and the motor housing acts as an oil pan. Before you attach the pump to the motor, fill the piston well with oil, up to the bearing plate.

Step 35

              Replace the motor/pump O-ring
  • Remove the motor/pump O-ring from the motor assembly.
  • Replace the O-ring with a new one from the rebuild kit.
  • Be sure to lubricate the O-ring with the grease included in the rebuild kit.

Remove the motor/pump O-ring from the motor assembly.

Replace the O-ring with a new one from the rebuild kit.

Be sure to lubricate the O-ring with the grease included in the rebuild kit.

Step 36

              Separate the pump assembly
  • Use a large flat head screwdriver to loosen the cylinder head from the piston assembly.
  • Pull the cylinder head and piston assembly apart.

Use a large flat head screwdriver to loosen the cylinder head from the piston assembly.

Pull the cylinder head and piston assembly apart.

Step 37

              Remove the pistons
  • Remove the three pistons and pressure springs from the piston assembly.

Remove the three pistons and pressure springs from the piston assembly.

Step 38

              Reassembly point
  • Return to this step after you have finished the pump rebuild, and follow the instructions in reverse to reassemble your device.
  • Reassembly tip: Before putting the pump back together, make sure you have installed the following parts:
  • Three grooved rings
  • Three suction valves
  • One throttle piece
  • One joining piece
  • Three white washers

Return to this step after you have finished the pump rebuild, and follow the instructions in reverse to reassemble your device.

Reassembly tip: Before putting the pump back together, make sure you have installed the following parts:

Three grooved rings

Three suction valves

One throttle piece

One joining piece

Three white washers

Step 39

              Remove the white washers
  • Use a pick tool to remove the three white washers from the piston cylinders.

Use a pick tool to remove the three white washers from the piston cylinders.

Step 40

              Remove the black washers
  • Use a pick tool to remove the three black washers from the piston cylinders.

Use a pick tool to remove the three black washers from the piston cylinders.

Step 41

              Remove the grooved rings
  • Use a screwdriver to dislodge and remove the three grooved rings from the piston cylinders.

Use a screwdriver to dislodge and remove the three grooved rings from the piston cylinders.

Step 42

              Replace the rings and washers
  • Replace the sets of grooved rings, black washers, and white washers with new ones from the rebuild kit.
  • Apply grease to the replacement grooved rings.
  • Note the orientation of the grooved rings when you insert them into the piston cylinder.
  • When you replace the black washers, note that they are keyed to the piston cylinders.

Replace the sets of grooved rings, black washers, and white washers with new ones from the rebuild kit.

Apply grease to the replacement grooved rings.

Note the orientation of the grooved rings when you insert them into the piston cylinder.

When you replace the black washers, note that they are keyed to the piston cylinders.

Step 43

              Replace the valve pin
  • Use a large flat head screwdriver to unscrew the green nozzle insert from the cylinder head.

Use a large flat head screwdriver to unscrew the green nozzle insert from the cylinder head.

Step 44

  • Tip the nozzle down to dump out the nozzle insert.
  • Replace the gray valve pin with a new one from the rebuild kit.
  • Screw the green nozzle insert back into the port.

Tip the nozzle down to dump out the nozzle insert.

Replace the gray valve pin with a new one from the rebuild kit.

Screw the green nozzle insert back into the port.

Step 45

              Replace the black grooved rings
  • Remove the three black grooved rings from the cylinder head.
  • Replace the rings with new ones from the rebuild kit.
  • Reassembly tip: The groove side of the rings should sit against the cylinder head.

Remove the three black grooved rings from the cylinder head.

Replace the rings with new ones from the rebuild kit.

Reassembly tip: The groove side of the rings should sit against the cylinder head.

Step 46

              Replace the suction valves
  • Use pliers to pull the three suction valves out of the cylinder head.
  • Replace the suction vales with ones ones from the rebuild kit.

Use pliers to pull the three suction valves out of the cylinder head.

Replace the suction vales with ones ones from the rebuild kit.

Step 47

              Replace the throttle
  • Use pliers to remove the throttle piece from the cylinder head.
  • Replace the throttle piece with a new one from the rebuild kit.
  • Reassembly tip: The throttle piece is directional. The end with the larger opening should face the cylinder head.

Use pliers to remove the throttle piece from the cylinder head.

Replace the throttle piece with a new one from the rebuild kit.

Reassembly tip: The throttle piece is directional. The end with the larger opening should face the cylinder head.

Step 48

              Remove the joining piece
  • Use pliers to remove the joining piece from the cylinder head.

Use pliers to remove the joining piece from the cylinder head.

Step 49

              Loosen the center drain plug
  • Insert an L-shaped pick tool into the hole that was previously covered by the joining piece.
  • Press upwards to loosen the center drain plug.
  • The drain plug is firmly held in place and may require significant force to loosen.

Insert an L-shaped pick tool into the hole that was previously covered by the joining piece.

Press upwards to loosen the center drain plug.

The drain plug is firmly held in place and may require significant force to loosen.

Step 50

              Remove the center drain plug
  • Remove the center drain plug.

Remove the center drain plug.

Step 51

              Remove the plastic valve
  • Remove the plastic valve from the center cylinder.

Remove the plastic valve from the center cylinder.

Step 52

              Remove the remaining plugs and valves
  • Insert an L-shaped pick tool into the connecting channel on each side of the center cylinder.
  • Press upwards to loosen the drain plug.
  • Remove the black drain plug and the plastic valve underneath it.
  • Repeat the process for the remaining drain plug and valve.

Insert an L-shaped pick tool into the connecting channel on each side of the center cylinder.

Press upwards to loosen the drain plug.

Remove the black drain plug and the plastic valve underneath it.

Repeat the process for the remaining drain plug and valve.

Step 53

              Remove the valve washers
  • It is likely that the metal valve washers did not come out with the plastic valves. Follow this step to remove the metal valve washers from the cylinder head.
  • Use needle-nose pliers to grasp the lip on the metal valve washers.
  • Pull the metal valve washers straight out of the cylinder head.

It is likely that the metal valve washers did not come out with the plastic valves. Follow this step to remove the metal valve washers from the cylinder head.

Use needle-nose pliers to grasp the lip on the metal valve washers.

Pull the metal valve washers straight out of the cylinder head.

Step 54

              Replace the plugs and valves
  • This photo shows how the pieces stack within the cylinder head.
  • Replace the drain plugs and valves with new ones from the rebuild kit.
  • Drop the valve back into the cylinder head.
  • Press the drain plug back onto the cylinder head.

This photo shows how the pieces stack within the cylinder head.

Replace the drain plugs and valves with new ones from the rebuild kit.

Drop the valve back into the cylinder head.

Press the drain plug back onto the cylinder head.

Step 55

              Replace the joining piece
  • Replace the joining piece with a new one from the rebuild kit.
  • At this point, you should have replaced all the parts that came with your rebuild kit. Click here to jump back to step 38, and follow the instructions in reverse order to reassemble the device.

Replace the joining piece with a new one from the rebuild kit.

At this point, you should have replaced all the parts that came with your rebuild kit. Click here to jump back to step 38, and follow the instructions in reverse order to reassemble the device.

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                    Arthur Shi

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DONALD - Sep 5, 2020

Reply

where do I get the part numbers for a pump rebuild kit/ as opposed to ordering the individual items??

PIERRE - Apr 12, 2021

Reply

what is the part # for the pump rebuild kit.

PAUL - Nov 26, 2021

Reply

Don’t waste your time. Toss this thing in the trash.