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Karcher Pressure Washers 15209900 2018 Motor Replacement

Introduction

This guide shows how to remove and replace the entire motor assembly for the Karcher 15209900 electric pressure washer.

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

  1. Karcher Pressure Washers 15209900 2018 Motor Replacement, Safety precautions: step 1, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Safety precautions: step 1, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Safety precautions: step 1, image 3 of 3

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

    • Unscrew the output hose from the pressure washer.

    Edit

  2. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the rubber strap: step 2, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the rubber strap: step 2, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the rubber strap: step 2, image 3 of 3

    • Unlatch and remove the yellow rubber strap.

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  3. Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the hand grip: step 3, image 1 of 1

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

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  4. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the hand grip: step 4, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the hand grip: step 4, image 2 of 2

    • Remove the hand grip from the extension bars.

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  5. Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the top panels: step 5, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the top panels: step 5, image 2 of 2

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

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  6. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the top panels: step 6, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the top panels: step 6, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the top panels: step 6, image 3 of 3

    • Remove the two plastic panels.

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  7. Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the plastic feet: step 7, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the plastic feet: step 7, image 2 of 2

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

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  8. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the plastic feet: step 8, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the plastic feet: step 8, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the plastic feet: step 8, image 3 of 3

    • Unclip and remove the plastic feet.

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  9. Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the housing: step 9, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the housing: step 9, image 2 of 2

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

    • Remove the T15 screw underneath the wheel axle.

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  10. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the housing: step 10, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the housing: step 10, image 2 of 2

    • 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.

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  11. Karcher Pressure Washers 15209900 2018 Motor Replacement, Release the cord strain relief: step 11, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Release the cord strain relief: step 11, image 2 of 2

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

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  12. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the motor: step 12, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the motor: step 12, image 2 of 2

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

    Edit

  14. Karcher Pressure Washers 15209900 2018 Motor Replacement, Reassembly tip: step 13, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Reassembly tip: step 13, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Reassembly tip: step 13, image 3 of 3

    • 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.

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  15. Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the electrical box cover: step 14, image 1 of 1

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

    Edit

  16. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the electrical box cover: step 15, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the electrical box cover: step 15, image 2 of 2

    • Lift the cover off of the electrical box.

    Edit

  17. Karcher Pressure Washers 15209900 2018 Motor Replacement, Loosen the capacitor: step 16, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Loosen the capacitor: step 16, image 2 of 2

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

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  18. Karcher Pressure Washers 15209900 2018 Motor Replacement, Unplug the capacitor: step 17, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Unplug the capacitor: step 17, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Unplug the capacitor: step 17, image 3 of 3

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

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  19. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the capacitor: step 18, image 1 of 1

    • Remove the capacitor.

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

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  20. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the plate spring: step 19, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the plate spring: step 19, image 2 of 2

    • Remove the plate spring from the electrical box.

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  21. Karcher Pressure Washers 15209900 2018 Motor Replacement: step 20, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement: step 20, image 2 of 2

    • Pull the switch out of the electrical box.

    • Disconnect the four spade connectors from the the switch.

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  22. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the switch: step 21, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the switch: step 21, image 2 of 2

    • Remove the switch.

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

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  23. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the grounding screw: step 22, image 1 of 1

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

    Edit

  24. Karcher Pressure Washers 15209900 2018 Motor Replacement, Unscrew the electrical box: step 23, image 1 of 1

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

    Edit

  25. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the electrical box: step 24, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the electrical box: step 24, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the electrical box: step 24, image 3 of 3

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

    • Remove the electrical box.

    Edit

  26. Karcher Pressure Washers 15209900 2018 Motor Replacement, Set the motor upright: step 25, image 1 of 1

    • 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.

    Edit

  27. Karcher Pressure Washers 15209900 2018 Motor Replacement, Loosen the pump assembly: step 26, image 1 of 1

    • Use a 13mm 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.

    Edit

  28. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the pump assembly: step 27, image 1 of 2 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the pump assembly: step 27, image 2 of 2

    • Lift the pump assembly off of the motor.

    Edit

  29. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the pump oil: step 28, image 1 of 1

    • 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.

    Edit

  30. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the bearing plate: step 29, image 1 of 1

    • Remove the bearing plate from the motor assembly.

    • Reassembly tip: The side of the plate with the ringed groove should face the bearings.

    Edit

  31. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the bearing ring: step 30, image 1 of 1

    • Remove the bearing ring.

    Edit

  32. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the motor bushings: step 31, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the motor bushings: step 31, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the motor bushings: step 31, image 3 of 3

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

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  33. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the motor cover: step 32, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the motor cover: step 32, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the motor cover: step 32, image 3 of 3

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

    Edit

  34. Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the blower wheel: step 33, image 1 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the blower wheel: step 33, image 2 of 3 Karcher Pressure Washers 15209900 2018 Motor Replacement, Remove the blower wheel: step 33, image 3 of 3

    • 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.

    Edit

  35. Karcher Pressure Washers 15209900 2018 Motor Replacement: step 34, image 1 of 1

    • Only the motor assembly remains.

    Edit
Conclusion

To reassemble your device, follow these instructions in reverse order.

3 other people completed this guide.

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