Karcher Pressure Washers 15209900 2018 Motor Replacement

ID: 132941

Description: This guide shows how to remove and replace the...

Steps:

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

3. Unlatch and remove the yellow rubber strap.

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

5. Remove the hand grip from the extension bars.

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

7. Remove the two plastic panels.

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

9. Unclip and remove the plastic feet.

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

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

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

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

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

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

25. Lift the cover off of the electrical box.

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

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

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

30. Remove the plate spring from the electrical box.

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

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

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

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

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

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

41. Use a 13mm socket to remove the four long bolts holding the pump assembly to the motor.
42. Re-assembly tip: The bolts hold the pump under pressure against the motor assembly. During reassembly, gradually tighten the bolts in a cross pattern.

43. Lift the pump assembly off of the motor.

44. Pour the pump oil out of the motor housing. If the oil looks serviceable, save it for reassembly.
45. 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.

46. Remove the bearing plate from the motor assembly.
47. Reassembly tip: The side of the plate with the ringed groove should face the bearings.

48. Remove the bearing ring.

49. Pull the two rubber bushings off of each side of the motor.

50. Pull the black motor cover off of the motor assembly.

51. Insert a pry bar or a flat head screwdriver between the blower wheel and the motor assembly.
52. Pry to loosen the blower wheel from the motor.
53. Slide the blower wheel off of the motor assembly.

54. Only the motor assembly remains.