Kärcher CV 66/2 Bedienungsanleitung

English 1

CV 66/2

Service Manual

5.906-479.0 Rev 00 01/09

2 English

Contents

2 Safety instructions 3

2.1 Hazard levels 3

3 Technical Features 3

3.1 Operation and control 3

3.2 Vacuuming 3

3.3 Electrical system 3

4 Setup and function 4

4.1 Appliance view 4

4.2 View from below 4

5 Basic settings and service procedures 4

5.1 General information 4

5.2 Remove operating panel 5

5.3 Replacing the mains cable 5

5.4 Replace appliance switch 5

5.5 Replace wire harness 6

5.6 Removing the handle 6

5.7 Removing the appliance hood 7

5.8 Replacing the drive belt of the brush roller 9

5.9 Clean/replace the suction channel 10

5.10 Replacing the brush rollers 11

5.11 Replace the toothed belt in the brush head gear 11

5.12 Replace suction turbine 12

5.13 Remove the brush head. 12

5.14 Remove the height adjustment of the brush head 13

5.15 Remove the microswitch of the brush motor 13

5.16 Replace the pressure switch 14

6 Troubleshooting 15

7 Circuit diagram

8 Technical specifications 16

9 Special tools 16

10 Tightening torques 16

English 3

Good servicing requires detailed and practice-oriented training

as well as good well-structured training materials.

Henceweofferregularbasicandadvancedtrainingprogrammes

covering the entire product range for all service engineers.

In addition to this, we also prepare service manuals for important

appliances - these can be initially used as instruction guides and

later on as reference guides.

Apart from this, we also regular information about product en-

hancements and their servicing.

If you should require supplements, have corrections or questions

regarding this document, please address these citing the follow-

ing subject to:

[email protected]

The responsible product specialist will take care of your issue.

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

P O Box 160

D - 71349 Winnenden

www.kaercher.com

Danger

Immediate danger that can cause severe injury or even death.

The appliance is only to be used for dry cleaning of floors.

The appliance can be used in a forward motion by pushing it on

the push handle.

Thebrushrollerbrushesdirtoutofthefloorcovering.Thesuction

turbineproducesa vacuumpressure,which pullsthe dirt fromthe

brush head into the filter bag.

Due to the one-sided arrangement of the brushes, the right side

of the appliance can clean all the way to the edge.

Note:

If the display for a full filter bag is illuminated, switch the appli-

ance off and replace the filter bag.

The switches for the operation of the appliance are located in the

push handle.

– Mains connection 220 - 240V / 50 - 60Hz / 16A.

1 Preface

Subject: Case 107171

2 Safety instructions

2.1 Hazard levels

3 Technical Features

3.1 Operation and control

3.2 Vacuuming

3.3 Electrical system

4 English

1 Pushing handle, adjustable

2 Cable clamp

3 Cable holder, rotating

4 Storage compartment

5 Lock of pushing handle

6 Lid of filter chamber

7 Suction hose connection (for optional suction set)

8 Fuse for brush drive

9 Fuse for suction turbine

10 Display 'Filter bag is full'

11 Power switch

1 Brush roller

2 Brush head

3 Brush head gear

4 Drive belt cover

5 Brush motor support plate

6 Safety sheet metal plates, brush roller removal

ÎThere are sharp edges in the appliance! Wear gloves during

the disassembly.

ÎThe cables are secured by cable ties. If a cable tie is re-

moved, it must replaced with a new one.

ÎWatch for cable connections during removal and installation.

If connectors or lines are damaged, they must be replaced.

ÎSome of the plastic parts cannot be removed without being

damaged and must be replaced.

ÎIncreased force is required for the hood.

ÎThe appliance is very heavy! 2 persons are required for lifting

and tilting.

ÎPerform the function test after the work is completed

4 Setup and function

4.1 Appliance view

4.2 View from below

4.3 Special accessories

Description Order No.

Dry vacuum set to clean cor-

ners and edges 8.630-501.0

5 Basic settings and service procedures

5.1 General information

English 5

The operating panel includes the appliance switch, the fuses for

the brush motor and the suction turbines and the ring core throt-

tles. The operating panel is connected to the appliance via a har-

ness, which is routed along the right handlebar.

ÎRemove the marked screws.

ÎPull the cover off toward the back.

ÎReroute the mains cable during removal

If the mains cable or the mains plug are damaged, they must be

replaced.

ÎRemove the cover (see "Disassembly of operating panel")

ÎCarefully open cable tie (cut)

ÎDisconnect the connectors on the supply line

ÎSeparate the protective conductor from the grounding clip.

For this, loosen the nut and pull of all the ring ferrules. The

protective conductor is installed last.

ÎRemove the traction relief: Unscrew the locknut, hold against

traction relief

ÎPull the mains cable out toward the back

ÎRoute a new mains cable

ÎRestore the protective conductor and the connections

ÎBundle the cables with the harness

ÎReinstall the cover

A defective appliance switch must be completely replaced.

ÎRemove the cover (see "Disassembly of operating panel")

ÎCarefully open cable tie (cut)

ÎRemove the connections from the switch

ÎPress together the locking nose on the switch

ÎPull the switch from the holder toward the bottom

ÎInsert new switch - observe the installation position: Pin point-

ing toward the bottom, use mark "Off" on the operating panel

as a guide

5.2 Remove operating panel

5.3 Replacing the mains cable 5.4 Replace appliance switch

6 English

ÎRestore cable connections. Contact arrangement:

ÎBundle the cables with the harness

ÎReinstall the cover

ÎCheck the function and make sure that the switch was in-

stalled in the correct position.

ÎRemove the cover (see "Disassembly of operating panel")

ÎCarefully open cable tie (cut)

ÎDisconnect the connectors on the wire harness

ÎRemove the operating from the handle by removing 4 screws

from the side

ÎTake the operating panel off toward the front and pull out the

wire harness through the side boring. Do not damage the

plug!

ÎRemove the handle and the handlebars (see "Removing the

handle")

ÎPull the wire harness out of the column

ÎDisconnect the connectors in the appliance

ÎRoute a new wire harness

ÎRestore the connections

ÎReassemble the handle and the operating panel

The handle must be removed in order to be able to remove the

appliance hood. The handle can be adjusted via a shaft and

locks. This adjustment must be dismounted in the shown se-

quence to prevent damage.

ÎRemove the plastic cover from the right side (side without ad-

justment lever).

ÎUnscrew the screw from the shaft and remove the column in-

cluding the lock.

ÎPulltheshaftout of theleftside.Theadjustmentlever and the

shaft are connected via a joint. The connection is secured by

a splint. The plastic cap can only be removed if this splint and

the connecting piece are removed.

5.5 Replace wire harness

5.6 Removing the handle

English 7

To change a broken height adjustment lever, you must proceed

as described above.

ÎTurn the lever by 90° and pull it out to remove the lever from

the plastic cover

ÎReplace the splint after removing it

ÎAssemble the handle and the adjustment in reverse order of

removal

Several disassembly steps are necessary to remove the appli-

ance hood, which are described in more detail in other chapters.

These points are not specifically marked in the text.

ÎRemove operating panel

ÎRemoving the handle

ÎRemove the wheel cover. For this, lift the cover using a

screwdriver and carefully release it.

ÎIf the locking nose should break off, the cover must be re-

placed.

ÎUnscrew the screw from the wheel shaft

ÎRemoving the wheel

ÎRemove the fastening angles on both sides

ÎTilt the appliance rearward

ÎRemove the brush motor - loosen all 4 screws

ÎRemove the brush motor and pull of the drive belt

5.7 Removing the appliance hood

8 English

ÎDisconnect the cables of the brush motor at the connectors

ÎTilt appliance back

ÎRemove the cover with filter basket

ÎUnscrew the screws on the hinge (increased force: The

screws are secured with screw adhesive

ÎDisconnect the micro switch cable in the appliance from the

connections

ÎLoosen the hose clamp on the suction hose, do not pull off

ÎPull the suction hose off the brush head

ÎRemove the cover from the appliance and set aside

ÎRemove the suction turbine and disconnect the connections

ÎDisconnect the connector on the pressure switch

ÎDo not remove the pressure switch

ÎUnscrew the fastening screw at the top of the frame

ÎSlide the wire harness into the appliance sot that it will not be

pinched when the hood is lifted

ÎLift the hood off evenly toward the top, agitate a little

ÎIf you are unable to lift off the appliance hood, pull the side

parts apart a little.

ÎThere is a support strut in the frame. If the hood gets stuck on

it, it must be removed.

English 9

Position of the support strut - appliance hood removed for clarity.

ÎOpen the fastening screws of the strut on both sides.

ÎThe strut will fall into the inside of the appliance

ÎThe appliance hood can now be removed.

ÎWhen the appliance is assembled, this strut must be installed

pointing straight up.

ÎWhen the hood is attached, the strut will be pushed into its

original position.

ÎInstall the hood from the rear to the front

ÎIf you experience difficulties when installing the hood, watch

for edges, use rubber hammer if necessary

ÎWhile installing, check and ensure that no cables are crushed

ÎAssembly of the appliance in reverse order

The brush roller is connected to the drive motor via a drive belt.

If the drive belt is worn or damaged, it must be replaced.

ÎRemove the screws on the belt cover

ÎRemove cover

ÎLoosen the screws on the support plate of the brush motor -

do not remove all the way

ÎSlide the support plate up to relax the drive belt

ÎRetighten the screws

ÎRemovethedrivebeltfromthefrontrollerandpullit out of the

appliance

ÎRoutea new drive belt ontotherolleronthemotor and stretch

it across the top roller - make sure that all guides are in their

grooves

5.8 Replacing the drive belt of the brush roller

10 English

Position of the drive belt - display with removed appliance hood.

ÎLoosen the screw on the support plate

ÎSlide the support plate down to tension the drive belt

ÎMake sure you slide the support plate straight - do not tilt

ÎCheck the tension of the drive belt, adjust if necessary

ÎTighten all screws on the brush motor support plate.

ÎReinstall the drive belt cover

Thereisa suction channel cover on the brush head. This channel

can be removed to clean the suction channel.

ÎRemove the appliance cover

ÎLoosen all 8 screws on the suction channel cover

ÎRemove the suction channel cover

ÎClean the suction channel

ÎClean the suction channel seal prior to installation

ÎIf the seal was damaged during removal, it must be replaced:

Remove the old seal, clean the adhesive surfaces, apply new

seal.

ÎReinstall the suction channel cover

ÎReinstall the appliance hood

5.9 Clean/replace the suction channel

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