K5 FULL CTRL 1.324-630 Service Manual

K5 Full Control Plus
Service Manual
English 5.906-800.0 Rev. 00 (12/16) 1

Contents
Preface 4
Safety instructions 4
Hazard levels 4
Description in this service manual 5
Service groups 5
Functional group structure 5
Textual description 5
Technical Features 6
Intended use 6
Field of application 6
Safety installations 6
Lock trigger gun 6
Overflow valve with pressure switch 6
Type plate 6
AB Service group setup 7
010 Safety information 7
General 7
020 Overview 7
030 Function 7
040 Service activities 8
ABST Uninstall / install hose reel 8
ABGH Uninstalling / installing casing 9
ABRD Uninstall / install wheels 10
ABSB Uninstall / install push handle 10
050 Maintenance and inspection 10
060 Error diagnosis 11
070 Peculiarities/ others 11
AE Service group pump 11
General 11
020 Overview 11
030 Function 13
AESG Uninstall / install valve gear casing 13
AERR Uninstall / install backflow valve detergent 14
AEZK Uninstall / install cylinder head 14
AEVT Uninstall / install valves and seals 15
AEKF Uninstall / install piston guide 15
AETS Uninstall / install swash plate 16
AEKL Uninstall / install ball bearing and grooved ring 17
AH Service group electrics 18
General 18
020 Overview 18
030 Function 19
Removing/installing AHHA hoist drive 19
AHDT installing/removing pressure sensor 20
AHEK Uninstall / install electrical box 20
2 English 5.906-800.0 Rev. 00 (12/16)

AJ Service group trigger gun 21
General 21
020 Overview 21
030 Function 21
AJEK installing/removing electrical box 21
Troubleshooting 23
Technical specifications 26
Special tools 27
Circuit diagram 28
English 5.906-800.0 Rev. 00 (12/16) 3

Preface
Good service work requires extensive and practice-orient-
ed training as well as well-structured training materials.
Hence we offer regular basic and advanced training pro-
grammes covering the entire product range for all service
engineers.
In addition to this, we also prepare service manuals for im-
portant appliances - these can be initially used as instruc-
tion guides and later on as reference guides.
Apart from this, we also regular information about product
enhancements and their servicing.
If you should require supplements, have corrections or
questions regarding this document, please address these
citing the following subject to:
international-service@de.kaercher.com
Subject: Fall 122429
The responsible product specialist will take care of your is-
sue.
Copying and duplication of texts and diagrams as well
as third-party access to this information is permitted
only with the explicit permission of the company:
Alfred Kärcher GmbH & Co. KG

Postfach 160
71349 Winnenden (Germany)
www.kaercher.com
Safety instructions
Service and maintenance tasks may only be performed by
qualified and specially trained specialists.
Observe safety information in the chapters!
 DANGER
Prior to all work on the appliance, switch off the appliance
and pull the power plug.
몇 CAUTION
Risk of damage by electrostatic discharge (ESD)! Take
suitable measures for discharging electrostatic charge pri-
or to performing work on the appliance electronics.
Hazard levels
 DANGER
For an immediate danger which can lead to severe injuries
or death.
몇 WARNING
For a possibly dangerous situation which could lead to se-
vere injuries or death.
몇 CAUTION
For a possibly dangerous situation which can lead to minor
injuries or property damage.
ATTENTION
Pointer to a possibly dangerous situation, which can lead
to property damage.
Note
Indicates useful tips and important information.
4 English 5.906-800.0 Rev. 00 (12/16)

Description in this service manual
Service groups
Example:
Install/uninstall ANRA wheel axle
AN RA Install/uninstall wheel axle
Service group Component Activity
Functional group structure

010 Safety instructions
020 Overview
030 Function
040 Service activities
050 Maintenance and inspection
060 Error diagnosis
070 Peculiarities/ others
080 - 100 Not assigned
Textual description
 Instruction
 Preparatory operations
1
2 Key numerical
A
B Key alphanumerical
– Enumeration / General list
 Safety note
Pointer to hazards, sources of errors.
English 5.906-800.0 Rev. 00 (12/16) 5

Technical Features
– Full Control Plus System
– 3 piston axial pump with stainless steel piston
– Pressure relief system
– Electric motor with thermal motor protection switch.
– Retractable push handle
– Carrying handle
Intended use
This high pressure cleaner is designed for domestic use
only.
– for cleaning machines, vehicles, buildings, tools, fa-
cades, terraces, gardening tools, etc. by means of a
high-pressure water jet (if necessary, with additional
cleaning agents).
– with accessories, replacement parts and cleaning
agents approved by KÄRCHER. Please observe the in-
formation accompanying the cleaning agents.
Field of application
This service manual describes the appliance family:
– K 5 Full Control Plus
Safety installations
Safety devices serve to protect the user and must not be
rendered in operational or their functions bypassed.
Observe safety information in the chapters!
Lock trigger gun

This lock locks the lever of the trigger gun and prevents the
inadvertent start of the appliance.
Overflow valve with pressure switch
The overflow valve prevents the permissible working pres-
sure from being exceeded.
If the lever on the trigger gun is released the pressure
switch turns off the pump, the high pressure jet is stopped.
If the lever is pulled the pump is turned on again.
Type plate
The type plate is located on the rear of the appliance.
1 Serial number
2 IP rating/ protection class
3 Sound power level LWA
4 Bar code. Contains part and serial number.
5 Address of manufacturer
6 Part number
7 Specifications
8 Max. flow rate
6 English 5.906-800.0 Rev. 00 (12/16)

AB Service group setup
010 Safety information
General
Observe general safety information! – To avoid risks, all repairs and replacement of spare
Service and maintenance tasks may only be performed by parts may only be carried out by the authorised custom-
qualified and specially trained specialists. er service personnel.
 DANGER – Only use accessories and spare parts which have been
approved by the manufacturer. The exclusive use of
– Switch off the appliance and, in case of appliances con-
original accessories and original spare parts ensures
nected to the mains, pull out the power cord before
that the appliance can be operated safely and trouble
cleaning and performing any maintenance tasks on the
free.
machine.
– Allow the appliance to cool down prior to performing
– Maintenance work may only be carried out by approved
customer service outlets or experts in this field who are service tasks.
familiar with the respective safety regulations.
020 Overview
ABGH Uninstalling / installing casing

ABRD Uninstall / install wheels
ABSB Uninstall / install push handle
ABST Uninstall / install hose reel
030 Function
No special functional characteristics.
English 5.906-800.0 Rev. 00 (12/16) 7

Note
Unless otherwise described, the installation takes place in
reverse order.
ABST Uninstall / install hose reel
1 Hollow shaft
2 Safety clip
3 High pressure hose
 Completely roll off the high-pressure hose from the

hose drum.
 Pull out the safety clip.
 Remove the high pressure hose from the hollow shaft.
1 Hose drum
2 Safety disc
 Remove the safety disc.

 Pull off hose reel casing shells towards the front.
1 Safety disc
2 Rotating grommet
 Remove the safety discs.

 Pull off rotating grommet.
Note
Check O-rings for damage.
8 English 5.906-800.0 Rev. 00 (12/16)

1 Bayonet flange
2 Knob
3 Clip
 Push the button forward.

 The clamp should disengage.
 Turn the bayonet flange in a clockwise direction.
 Pull off bayonet flange.
Installation information
The clamp must audibly engage in the groove on both
sides during installation.
Observe the hose guide.
1 High pressure hose

2 Hose guide
3 Hose drum
ABGH Uninstalling / installing casing

 ABST Uninstall / install hose reel
1 Bumper
2 Bolts
3 Screws
 Unscrew the screws

 Pull out the bolt.
 Remove bumper.
English 5.906-800.0 Rev. 00 (12/16) 9

1 Screws
2 Casing
 Unscrew the screws.

 Remove the housing.
Note
Use special tools.
Screwdriver bit T15
6.815-150.0
Torques Nm
Screws 1.2...1.9
ABRD Uninstall / install wheels

1 Screw
2 Casing
3 Wheel
 Unscrew the screw.

 Remove the wheel.
Note
The axle will position itself centrally upon insertion.
ABSB Uninstall / install push handle

 ABGH Uninstalling / installing casing
 Remove the pump kit.
1 Casing
2 Push handle
3 End piece
4 Screws
 Pull the push handle upward.

 Pull off end pieces.
 Remove the push handle.

Service group does not contain any maintenance and in-
spection points.
10 English 5.906-800.0 Rev. 00 (12/16)

060 Error diagnosis
The service group does not contain any error diagnosis.
The service group does not contain any peculiarities.
AE Service group pump

General
Observe general safety information! – Only use accessories and spare parts which have been
Service and maintenance tasks may only be performed by approved by the manufacturer. The exclusive use of
qualified and specially trained specialists. original accessories and original spare parts ensures
 DANGER that the appliance can be operated safely and trouble
free.
– Switch off the appliance and, in case of appliances con-
– Allow the appliance to cool down prior to performing
cleaning and performing any maintenance tasks on the service tasks.
machine.
customer service outlets or experts in this field who are
– To avoid risks, all repairs and replacement of spare
parts may only be carried out by the authorised custom-
er service personnel.
020 Overview
NOTE  The installation device is equipped with several retain-

 For easier installation and for function testing, it is rec- ers and can thus be used for unit models WCM X-
ommended to use an installation device. Range K4 - K7 and WCM K4 - K7 FC.
English 5.906-800.0 Rev. 00 (12/16) 11

AESG Uninstall / install valve gear casing
AEZK Uninstall / install cylinder head
AEKF Uninstall / install piston guide
AEVT Uninstall / install valves and seals
12 English 5.906-800.0 Rev. 00 (12/16)

AETS Uninstall / install swash plate
AEKL Uninstall / install ball bearing and grooved ring
AERR Uninstall / install backflow valve detergent
030 Function
Note
reverse order.
AESG Uninstall / install valve gear casing

1 High-pressure outlet
2 Valve gear casing
3 Screws
4 Pipe
 Remove high-pressure outlet.

 Take off the pipe.
1 Clip
2 Hoist drive
 Remove the clip.

 Remove hoist drive.
English 5.906-800.0 Rev. 00 (12/16) 13

1 Screws
2 Valve gear casing

 Take off the valve gear casing.
몇 CAUTION
Piston guide is tensioned by piston springs.
Hold down piston guide.
Torques Nm
Screw M8 19...24
AERR Uninstall / install backflow valve detergent

 AESG Uninstall / install valve gear casing
1 Nozzle insert
2 Pin
3 Valve bolt
Check valve
4 Valve gear casing
5 Bypass valve
6 Overflow
7 Backflow valve, detergent
 Drive out pins.

 Remove the check valve.
Check O-ring for damage.
AEZK Uninstall / install cylinder head

The procedure conforms to the task:
14 English 5.906-800.0 Rev. 00 (12/16)

AEVT Uninstall / install valves and seals
1 Mould part
2 Support ring
3 Grooved ring
4 Cylinder head
5 Moulded seal
6 Connection piece
 Replace valves and seals as necessary.

 Installation position as per illustration.
 The mould part is welded in the series.
The mould part is destroyed upon removal.
The mould part replacement is plugged in.
Replace the mould parts completely.
Check the O-ring. Replace if necessary.
AEKF Uninstall / install piston guide

1 Grooved ring
2 Piston guide
3 O ring
4 Piston
 Remove the piston guide and the piston.

 Check nut rings, replace if necessary.
몇 CAUTION
Piston guide is tensioned by piston springs.
Pay attention to the correct fitting position during reinstal-

lation.
1 Safety disc
2 Piston
3 Springs
4 Piston guide
 Check piston for wear.

 Check springs.
Observe piston condition diagram.

In case of a missing or poor condition diagram, the turning
of the piston is not guaranteed.
English 5.906-800.0 Rev. 00 (12/16) 15

AETS Uninstall / install swash plate
 AEKF Uninstall / install piston guide
1 Pressure disc
Ball bearing
2 Motor flange
3 Screws
 Remove pressure disc.

 Remove ball bearing.
 Remove motor flange.
Note
The pressure disc and ball bearing are loosely supported.
1 Screw
2 Swash plate
3 Rotor
 Fixate rotor.
 Remove swash plate.
Torques Nm
Screw M8 28...35
1 Ball bearing
2 Motor
Rotor must sit as far into the ball bearing as possible.
16 English 5.906-800.0 Rev. 00 (12/16)

Ensure correct seating of the O-rings.
AEKL Uninstall / install ball bearing and grooved ring

 AETS Uninstall / install swash plate
1 Motor flange
 Lay down the motor flange.

 Tap out the grooved ring and the ball bearing.
When inserting the grooved ring, lay the motor flange
down flat.
Do not cant the grooved ring.
When pressing in the ball bearing, lay the motor flange
down flat.

spection points.
060 Error diagnosis


English 5.906-800.0 Rev. 00 (12/16) 17

AH Service group electrics
General
Observe general safety information! original accessories and original spare parts ensures
Service and maintenance tasks may only be performed by that the appliance can be operated safely and trouble
qualified and specially trained specialists. free.
 DANGER – Allow the appliance to cool down prior to performing
– Switch off the appliance and, in case of appliances con- service tasks.
machine.
– Only use accessories and spare parts which have been
020 Overview
Removing/installing AHHA hoist drive

AHDT installing/removing pressure sensor
AHEK Uninstall / install electrical box
18 English 5.906-800.0 Rev. 00 (12/16)

030 Function
Note
reverse order.
Removing/installing AHHA hoist drive
1 Electronics system
2 Plug
 Remove the plug.
1 Clip
2 Hoist drive

 Remove hoist drive.
English 5.906-800.0 Rev. 00 (12/16) 19

AHDT installing/removing pressure sensor
2 Plug
 Remove the plug.
1 Clip
2 Pressure sensor

 Replace the pressure sensor.
Lightly grease the O-rings.
AHEK Uninstall / install electrical box

2 Plug
3 Wiring
4 Screw

 Remove wiring.
 Remove the plug
 Remove the electrical box.
20 English 5.906-800.0 Rev. 00 (12/16)

spection points.
060 Error diagnosis


AJ Service group trigger gun

General
Observe general safety information! original accessories and original spare parts ensures
Service and maintenance tasks may only be performed by that the appliance can be operated safely and trouble
qualified and specially trained specialists. free.
 DANGER – Allow the appliance to cool down prior to performing
– Switch off the appliance and, in case of appliances con- service tasks.
machine.
– Only use accessories and spare parts which have been
020 Overview
030 Function
Note
reverse order.
AJEK installing/removing electrical box
1 Screws
2 Casing

 Remove the casing half bowl.
English 5.906-800.0 Rev. 00 (12/16) 21

1 Electrical box
Trigger gun
2 Casing
 Take out electrical box.
Coupling of the high-pressure gun

Before initial startup, the high-pressure gun must be cou-
pled to the high-pressure cleaner.
 Insert the mains plug into the socket.
 Immediately thereafter, simultaneously press
the + and - buttons on the high-pressure gun.
 Hold down the buttons until the entire signal
strength symbol flashes.
Once coupling is complete, all six pressure lev-
els will be displayed.

spection points.
060 Error diagnosis


22 English 5.906-800.0 Rev. 00 (12/16)

Troubleshooting
Fault Cause Correction

Appliance is not running There is no voltage in the machine. Check whether the voltage indicated
on the type plate corresponds to the
voltage of the mains supply.
Check the mains connection cable for
damages.
Check electrical box for continuity
(electric machine) and replace if nec-
essary.
Release the lever of the hand spray
gun; the appliance will switch on.
Appliance is not running Check the control piston. – Check the control piston for proper
function / grease, replace as nec-
essary.
– Check the seals and replace if re-
quired.
Appliance is not building up pressure Bypass valve defective. – Check the bypass valve for proper
function / grease, replace as nec-
essary.
quired.
Appliance is not building up pressure Air within the system – Vent appliance.
– Switch on the appliance without
connection the HP hose (max. 2
minutes) and run it until the water
discharging from the HP outlet is
free of bubbles. Switch off appli-
ance and reconnect HP hose.
Appliance is not building up pressure Suction area blocked Pull out the mains plug and clean the
suction area
Appliance is not building up pressure Suction hose or connection adapter – Manually tighten the suction hose
not screwed in correctly or completely. and the connection adapter.
– Check the suction hose and con-
nector adapter for leaks.
Appliance is not building up pressure Insufficient water quantity – Check setting at the spray lance.
– Check water flow quantity.
Appliance is not building up pressure Swash plate loose/damaged – Check the seating of the swash
plate.
– Check the swash plate of the pump
motor for wear and tear / damage.
Device is humming/device does not Capacitor defective Replace electrical box.
start
– Appliance vibrates strongly Suction or pressure valves damaged/ – Clean the suction and pressure
– Pressure loss soiled. valves.
– Check the pressure and suction
valves for leaks / replace.
– Only replace the valves as a set.
– Check/clean/replace water fine fil-
ter.
English 5.906-800.0 Rev. 00 (12/16) 23

The device switches itself ON and Leakage at the pump. – Check components (valve gear
OFF again at short intervals. casing/high-pressure outlet) for
damage, fractures/cracks (frost
damage), replace as necessary.
quired.
Pump does not run or suddenly comes Power supply interrupted Check fuses and electrical connec-
to a standstill during operations tions
Strong pressure variations Nozzle soiled – Clean high-pressure nozzle: Re-
move dirt and debris from the noz-
zle bore, using a needle and rinse
through with water from the front.
– Check/clean/replace the water fine
filter.
Strong pressure variations Insufficient water quantity Check water flow quantity.
Detergent is not being sucked in Suction area blocked Clean the suction area and hoses,
rinse if necessary.
Detergent is not being sucked in Chemical valve defective. Clean/rinse, replace as necessary.
Detergent is not being sucked in Low or no detergent flow – Set multijet spray lance to deter-
gent application position.
– Check the spray lance nozzle for
obstructions.
The pump pumps water into the chem- Chemical valve defective. Clean/rinse, replace as necessary.
ical container.
Oil is leaking at the pump Oil leakage on the piston guide. – Check the seals and replace if re-
quired.
– (Oil groove ring, O-ring)
– Pressure loss – Pressure disc not in position. – Check components.

– Increased noise generation in the – Piston springs broken. – Replace components as neces-
pump area – Piston worn. sary.
– Piston stuck.
Water escapes at the motor casing. Water leaks between the motor casing – Check the seals and replace if re-
and the pump housing. quired.
– Ensure the correct seating of the
seal during installation.
Pressure levels not shown in the dis- Battery depleted. Check battery; replace, if needed.
play.
Pressure levels not shown in the dis- Pressure sensor defective. Replace pressure sensor.
play.
Pressure regulation not possible. – Pressure sensor defective. In the exclusion process, check
whether the hoist drive adjusts audi-
bly.
Check board (emitting signal present).
If the hoist drive and board are all
right, replace the pressure sensor.
Pressure regulation not possible. – Hoist drive defective. – Select pressure levels.
– The hoist drive must adjust audibly.
– Check hoist drive, replace if neces-
sary.
To test, insert the device and set
the power switch to switch setting
0.
Couple the high-pressure gun.
24 English 5.906-800.0 Rev. 00 (12/16)

Pressure regulation not possible. – Electrical box gun defective. – Check battery; replace, if needed.
– Couple the high-pressure gun with
a high-pressure gun of identical de-
sign.
Wakeup function of the gun is defec- Battery depleted. Check battery; replace, if needed.
tive
(activated by pulling the trigger of the
trigger gun).
Wakeup function of the gun is defec- Switch contacts of the gun defective. Check the switching mechanism on
tive the bottom of the gun's electrical box.
trigger gun).
Wakeup function of the gun is defec- – Electrical box gun defective. – Replace electrical box guns.
tive – PCB defective. – Check/replace the circuit board.
trigger gun).
No emitting signal (display of gun) PCB defective. Check/replace the circuit board.
English 5.906-800.0 Rev. 00 (12/16) 25

Technical specifications
Electrical connection
Voltage 230 V
1~50 Hz
Connected load 2.1 kW
Type of protection IP X5
Protective class I
Mains fuse (slow-blow) 10 A
Water connection
Max. feed pressure 1.2 MPa
Max. feed temperature 40 °C
Min. feed volume 10 l/min
Max. Suction height 0.5 m
Performance data
Working pressure 12.5 MPa
Max. permissible pressure 14.5 MPa
Water flow rate 7.5 l/min
Max. flow rate 8.3 l/min
Detergent flow rate 0.3 l/min
Recoil force of the trigger gun 17 N
Dimensions and weights
Length 411 mm
Width 305 mm
Height 584 mm
Weight, ready to operate with accessories 15.3 kg
Values determined as per EN 60335-2-79
Hand-arm vibration value 1.0 m/s2
Uncertainty K 0.6 m/s2
Sound pressure level LpA 76 dB(A)
Uncertainty KpA 3 dB(A)
Sound power level LWA + Uncertainty KWA 92 dB(A)
Subject to technical changes.
26 English 5.906-800.0 Rev. 00 (12/16)

Special tools
Adapter system 2000, M22x1.5 with ex- 4.401-072.0 Screwdriver bit T15 6.815-150.0
tended union nut
Removal pliers, pressure/suction valves 4.901-062.0 Installation mandrel oil seal, high-pres- 5.901-224.0
and water sieves sure seal
Installation sleeve, high pressure seal 5.901-223.0
Adapter set 2.643-037.0 Adapter 4.403-003.0
Electric measuring appliance 6.803-022.0 Test manometer for working pressure 4.401-072.0
English 5.906-800.0 Rev. 00 (12/16) 27

Circuit diagram
When working on the device, please always use the cur-

rent circuit diagram in DISIS.
28 English 5.906-800.0 Rev. 00 (12/16)

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K5 Full Control Plus

English 5.906-800.0 Rev. 00 (12/16) 1

2 English 5.906-800.0 Rev. 00 (12/16)

English 5.906-800.0 Rev. 00 (12/16) 3

Alfred Kärcher GmbH & Co. KG

4 English 5.906-800.0 Rev. 00 (12/16)

Functional group structure

English 5.906-800.0 Rev. 00 (12/16) 5

Lock trigger gun

6 English 5.906-800.0 Rev. 00 (12/16)

ABGH Uninstalling / installing casing

English 5.906-800.0 Rev. 00 (12/16) 7

 Completely roll off the high-pressure hose from the

 Remove the safety disc.

 Remove the safety discs.

8 English 5.906-800.0 Rev. 00 (12/16)

 Push the button forward.

1 High pressure hose

ABGH Uninstalling / installing casing

 Unscrew the screws

English 5.906-800.0 Rev. 00 (12/16) 9

 Unscrew the screws.

ABRD Uninstall / install wheels

 Unscrew the screw.

ABSB Uninstall / install push handle

 Pull the push handle upward.

050 Maintenance and inspection

10 English 5.906-800.0 Rev. 00 (12/16)

AE Service group pump

NOTE  The installation device is equipped with several retain-

English 5.906-800.0 Rev. 00 (12/16) 11

12 English 5.906-800.0 Rev. 00 (12/16)

AESG Uninstall / install valve gear casing

 Remove high-pressure outlet.

 Remove the clip.

English 5.906-800.0 Rev. 00 (12/16) 13

 Unscrew the screws.

AERR Uninstall / install backflow valve detergent

 Drive out pins.

AEZK Uninstall / install cylinder head

14 English 5.906-800.0 Rev. 00 (12/16)

 Replace valves and seals as necessary.

AEKF Uninstall / install piston guide

 Remove the piston guide and the piston.

Pay attention to the correct fitting position during reinstal-

 Check piston for wear.

Observe piston condition diagram.

English 5.906-800.0 Rev. 00 (12/16) 15

 Remove pressure disc.

16 English 5.906-800.0 Rev. 00 (12/16)

AEKL Uninstall / install ball bearing and grooved ring

 Lay down the motor flange.

050 Maintenance and inspection

060 Error diagnosis

070 Peculiarities/ others

English 5.906-800.0 Rev. 00 (12/16) 17

Removing/installing AHHA hoist drive