Difficulty
Moderate
Steps
34
Time Required
Suggest a time??
Sections
7
- 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 Pump Removal
- 4 steps
- Motor
- 6 steps
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0
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Introduction
Some of the body screws are deeply recessed and require a T15 driver with a 5-inch long shank in order to reach.
Replacing the motor 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
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 26
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 27
Remove the pump assembly
- Lift the pump assembly off of the motor.
Lift the pump assembly off of the motor.
Step 28
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 29
Remove the bearing plate
- Remove the bearing plate from the motor assembly.
- Reassembly tip: The side of the plate with the ringed groove should face the bearings.
Remove the bearing plate from the motor assembly.
Reassembly tip: The side of the plate with the ringed groove should face the bearings.
Step 30
Remove the bearing ring
- Remove the bearing ring.
Remove the bearing ring.
Step 31
Remove the motor bushings
- Pull the two rubber bushings off of each side of the motor.
Pull the two rubber bushings off of each side of the motor.
Step 32
Remove the motor cover
- Pull the black motor cover off of the motor assembly.
Pull the black motor cover off of the motor assembly.
Step 33
Remove the blower wheel
- Insert a pry bar or a flat head screwdriver between the blower wheel and the motor assembly.
- Pry to loosen the blower wheel from the motor.
- Slide the blower wheel off of the motor assembly.
Insert a pry bar or a flat head screwdriver between the blower wheel and the motor assembly.
Pry to loosen the blower wheel from the motor.
Slide the blower wheel off of the motor assembly.
Step 34
- Only the motor assembly remains.
Only the motor assembly remains.
To reassemble your device, follow these instructions in reverse order.
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