RE 140 K, 160 K

CONTENTS

1. Foreword 2 7.4 Removing / installing

pump housing and
1.1 Note on RE 160 K 2 pump piston 15
7.5 Disassembly /
assembly of
2. Safety regulations 2 pump piston 15
7.6 Replacing
high-pressure cups
3. Technical and oil seals 16
specifications 3 7.7 Replacing thrust
bearings 17
3.1 Motor 3
3.2 Pump 3
3.3 Weights and 8. Electric motor 18
dimensions 3
3.4 Capacities 3 8.1 Removal 18
3.5 Tightening torques 4 8.2 Installation 21

4. Summary of 9. Electrical system 23

possible faults 5
9.1 Circuit diagram 23
4.1 High-pressure pump 5 9.2 Removing / installing
4.2 Electric motor 7 electrical components 24
9.2.1 Switch housing 24
9.2.2 Switch 25
5. Housing 8 9.2.3 Power cable 25
9.2.4 Capacitor 26
5.1 Removing / 9.2.5 Microswitch 27
fitting the shroud 8
5.2 Removing /
installing the motor / 10. Spray attachment 27
pump unit 8
5.3 Chassis 9 10.1 Spray gun 28
10.2 Spray lance,
spray head 28
6. Safety control block 9

6.1 Removing / installing 11. Oil change 30

the safety control block 9
6.2 Removing / installing
the control piston 10 12. Special tools and
6.3 Setting the pressure service tools 31
control system 11
6.4 Injector 12 12.1 Special tools 31
6.5 Non-return valve 12 12.2 Service tools 31
6.6 Detergent metering
and non-return valve 13

7. High-pressure pump 14

7.1 Screen in intake port

(water inlet) 14
7.2 Removing / installing
delivery valves 14
7.3 Removing / installing
valve block and
intake valves 14
© 2000, Andreas Stihl AG & Co., Waiblingen

RE 140 K, 160 K 1
1. FOREWORD 1.1 Note on RE 160 K 2. Safety regulations

This Repair Manual contains a Please refer to the preceding High-pressure cleaners may only
detailed description of the Repair Manual for the RE 160 K if be repaired by qualified
fundamental repair work on STIHL the procedures described and electricians (in accordance with
high-pressure cleaners of series illustrated in this Repair Manual do DIN VDE 0701 and accident
STIHL RE 140 K, 160 K. not correspond with your machine. prevention regulations VBG 4 in
Germany) with due regard for
A test bed with the necessary national safety regulations and the
water and power supplies should provisions of the User Manual.
be provided for the repair work.
The unit must be connected to the
pressurized water supply and the
fault described by the customer
reproduced, with the customer
demonstrating the fault if
necessary. The customer’s
attention must be drawn to the
User Manual if the machine is
operated incorrectly.

Faults may be due to several

causes. The "Summary of
possible faults" should therefore
be consulted see 4.

The illustrated spare parts lists

must also be used for all repair
work. These lists show the
installation position and order in
which the individual assemblies
should be assembled. Microfilms
are more up-to-date than printed
spare parts lists.

Note the "Technical Information"

bulletins! They contain
information on technical changes
implemented after publication
of this Repair Manual. The
Technical Information bulletins
also supplement the spare parts
list until a new edition is printed!

Repair Manuals and Technical

Information bulletins should
always be kept on hand wherever
repairs are carried out.

They must not be passed on to

third parties.

Only original STIHL spare parts

may be used!

2 RE 140 K, 160 K
3. TECHNICAL SPECIFICATIONS

RE 140 K RE 160 K

3.1 Motor

Voltage: 230 V / 240 V *) 230 V / 240 V *)

Frequency: 50 Hz / 60 Hz *) 50 Hz / 60 Hz *)
Power output: 2.3 - 2.9 kW *) 2.2 - 3.3 kW *)
Fuse: 16 A **) 16 A **)
Protection class: I I
Type of protection: IP X5 IP X5

3.2 Pump

Max. working pressure: 140 bar 150 bar

Permissible excess pressure: 150 bar 160 bar
Flow rate: 500 l/h 500 - 550 l/h *)
Suction lift: 0.5 m 0.5 m
Max. water feed temperature:
- Pressurized water supply: 50 °C 50 °C
- In suction operation: 40 °C 40 °C

3.3 Weights and dimensions

Length approx.: 370 mm 370 mm

Width approx.: 270 mm 270 mm
Height approx.: 860 mm 860 mm
Weight approx.: 20.0 kg 25.0 kg

3.4 Capacities

High-pressure pump: 100 ml 100 ml

Oil grade: SAE 15 W 40 SAE 15 W 40

*) Depends on country concerned

**) Australia / New Zealand: 10 A

**) GB / N. Ireland / Malaysia: 13 A
**)

RE 140 K, 160 K 3
3.5 Tightening torques

Tightening torque
Assembly Connecting element Thread size Nm Remarks

Safety control block Socket-head screw M5x30 7 1)

to valve block

Valve block to Socket-head screw M6x35 15 1)

pump housing

Pump housing to Socket-head screw M6x30 10 1)

drive housing

Drive housing to Socket-head screw M5x25 7 1) 2)

stator housing

Bearing cover and Hex bolt M6x25 7 1) 3)

drive housing to
stator housing

Screw plug, Hexagonal socket-head bolt R1/4" 7 3)

drive housing

Remarks

1) Thread must be clean and dry

2) RE 140 K only
3) RE 160 K only

4 RE 140 K, 160 K
4. SUMMARY OF POSSIBLE FAULTS
4.1 High-pressure pump

Problem Cause Remedy

Pump runs, but does not build Pressure control sleeve not Set required working pressure
up the specified pressure set correctly

Nozzle in spray head worn Replace nozzle

Air in system Vent system; briefly operate

machine without
high-pressure hose

Leak in high-pressure system Seal high-pressure system

Pressure fluctuates or drops Shortage of water Turn on water tap, keep within
maximum suction head
(max. 0.5 m)

Water feed hose too long or Use specified water

cross-section too small feed hose

Water filter clogged Clean water filter in pick-up

body and pump inlet

Pump draws air Check intake line for leaks and

replace if necessary

High-pressure cups worn Replace high-pressure cups

Pump does not run smoothly Water feed temperature is Reduce water feed temperature
too high (see technical specifications)

Intake line is damaged, Replace intake line

pump draws air

Intake / delivery valves of Clean or replace valves

high-pressure pump
soiled or worn

Safety control block cycles after Leak in high-pressure system so Seal, clean and grease the
switching off the spray gun that safety control block does not safety control block
(constant audible switching sound), switch over correctly and the
pump becomes hot bypass does not open completely

Oil contains water High-pressure cups worn Replace high-pressure cups

Oil leak Gaskets in high-pressure pump Replace gaskets

worn

RE 140 K, 160 K 5
Problem Cause Remedy

No supply of detergents Detergent tank is empty Fill detergent tank

Detergent metering valve Set required detergent quantity

is closed on metering valve

Pressure control sleeve Set pressure control sleeve

not set to "CHEM." to "CHEM."

High-pressure hose coupling Tighten screw coupling

is not screwed tight

Detergent intake hose clogged Clean

Injector clogged Clean

Gasket on high-pressure hose Replace or fit gasket

connection defective or missing

Weak, ragged, High-pressure nozzle in Clean high-pressure nozzle

unclean jet spray head is soiled or worn with nozzle-cleaning needle
or replace if necessary

6 RE 140 K, 160 K
4.2 Electric motor

Problem Cause Remedy

Motor hums but does not run Mains voltage too low Check electrical connection
when switched on
Spray gun closed Actuate spray gun

Pump stiff Turn motor by hand as described

(blocked or frozen) for "Starting up after prolonged
storage" (User Manual)

Extension lead with wrong Use correct cable cross-section

cross-section (see User Manual)

Motor does not start Connector has not been plugged Check plug, cable and switch
when switched on in correctly, break in power supply

Mains fuse has been tripped Refit mains fuse

Motor stops Overload protection (in winding) Check that supply voltage matches
tripped because motor specified machine voltage.
overheating or overloaded Switch off machine and allow
to cool for at least 3 minutes.

Spray head soiled Clean nozzle in spray head

Note: A correct power supply is essential if the machines are to operate faultlessly. The voltage drop in the
motor during operation must not be excessive, otherwise the motor will turn too slowly and take up too much
power. This causes the windings to heat up and the overload switch cuts out the machine after only a short
period of operation. Moreover, the machine cannot build up the rated power output and problems may arise
during the starting phase, i.e. between switching on the motor and reaching the nominal speed.

RE 140 K, 160 K 7
5. HOUSING 5.2 Removing / installing
5.1 Removing / fitting the motor / pump unit

1 2

621RA001 BL

621RA087 KN
621RA084 KN
• Unscrew high-pressure hose (1). • Disconnect detergent intake RE 160 K
hose from metering valve. • Undo fastening nuts on motor /
• Unscrew hose connector (2) pump unit, steadying the bolts at
from water inlet. - Remove shroud (see 5.1). the same time if necessary.
Hold the machine steady and
- Stand machine upright. ensure that washers are not lost.
- Lay machine in a horizontal
RE 140 K position.

621RA005 BL
621RA085 KN
621RA002 BL

• Undo fastening screws (rear • Undo fastening screw on motor / • Lift motor / pump unit out of
screw not shown). pump unit, steadying the frame. Ensure that rubber
machine with the other hand at buffers, screws and washers
• Remove shroud. the same time. are not lost.
Ensure that spring nuts and
power cable are not lost. All models

Reassemble parts in reverse order. Reassemble parts in reverse order.

621RA086 KN

• Lift motor / pump unit out of

frame.

8 RE 140 K, 160 K
5.3 Chassis 6. SAFETY CONTROL 6.1 Removing / installing
BLOCK the safety control block

Important: The O-rings must - Remove shroud (see 5.1) and

always be replaced when carrying motor / pump unit (see 5.2).
out repair work.
Before assembling the parts, all Note: The screw plug should only
moving parts, sealing rings and be removed if leaking.
screw threads must be thinly
coated with special grease
for high-pressure cleaners

621RA007 BL
0781 145 3516. Exceptions to
this rule are mentioned where
appropriate.

• Remove handle: Note: The permissible working

pressure of the machine has been
• Undo fastening screws with set on the safety control block by
size 5 hexagon socket wrench. the manufacturer and must not be
changed. A lead seal is fitted to
- Remove handle and replace if the safety control block for this
necessary. reason.
The permissible working pressure
must be reset after all repairs and
a new lead seal fitted to the safety
control block.

621RA009 BL
621RA008 BL

Remove retainer and shaft: • Undo fastening screws.

• Undo fastening screws with

size 5 hexagon socket wrench.

- Remove retainer and shaft.

Proceed as described for the

high-pressure cleaners of series
STIHL RE 310 K, 340 K and 440 K
for changing wheels.

Replace faulty parts.

Reassemble parts in reverse order.

621RA010 BL

• Carefully remove the safety

control block. Ensure that the
adjusting screw for the micro-
switch, O-rings and delivery
valves are not lost.

• Replace O-rings.
RE 140 K, 160 K 9
 6.2 Removing / installing the
control piston

To replace the safety control block - Remove shroud (see 5.1).

housing:
Remove
- control piston (see 6.2),
- injector (see 6.4),
- non-return valve (see 6.5) and
- detergent metering valve
(see 6.6).

Reassemble parts in reverse order

and ensure that O-rings are fitted.

• Draw valve body out of

safety control block with hook
5910 890 2900. Remove ball
and valve-seat insert from safety
control block.

• Replace O-ring (1) in valve body.

- Examine valve body, ball and

valve-seat insert; replace if ne-
cessary.

- Clean valve seat in safety control

2 block.

Reassemble parts in reverse order.

621RA013 BL

Note: Thinly coat valve-seat

1 insert, valve body and O-ring with
special grease for high-pressure
cleaners 0781 145 3516 before
• Carefully insert adjusting • Carefully prise off U-bar (1) with fitting them.
screw (1) into opening (2) in a screwdriver if necessary and
microswitch. pull it out. - Fit control piston and secure with
U-bar.
- Turn in fastening screws and • Draw control piston (2) out of
tighten down crosswise with a safety control block housing. • Then set pressure control
torque of 7 Nm. system (see 6.3).

- Then set the working and cutout

pressure (see 6.3) and refit the
lead seal on the safety control
block.
621RA014 BL

2
1

• O-rings (1, 2) on control piston

must always be replaced.
- Examine control piston for signs
of damage and replace
completely if necessary. Ensure
that correct control piston is fitted
(spare parts list).

10 RE 140 K, 160 K
6.3 Set pressure
control system

- Connect test pressure gauge The bypass valve is set correctly - Then turn on another half-turn.
5910 850 3205 between high- when the adjusting nut is screwed
pressure port and high-pressure in precisely to the point necessary - Check setting at minimum
hose. for the maximum pressure pressure and correct if necessa-
(reading on pressure gauge) to be ry.
- Connect water inlet and high- barely reached.
pressure hose. - Actuate spray gun several times.
- Let machine run for approx. The motor must switch on when
10 seconds. Operate the spray the spray gun is opened and
gun two or three times. off when it closes; repeat
adjustment if necessary.
Note: The maximum pressure
and cutout pressure settings are - Seal setting of locknut and
determined by the adjusting nut. adjusting screw with locking
Ensure that the cutout pressure paint.
does not become too high by scre-
wing the nut in further. - Remove test pressure gauge.

The cutout pressure (= pressure

at which the bypass valve opens)
must be 5 bar higher than the
maximum working pressure
1 (see 3.2).

To check the setting:

- Close spray gun and read off

cutout pressure value on
2
621RA076 BL

pressure gauge.

If the value is too high:

- Open spray gun.

• Completely unscrew the micro-
switch adjusting screw (1) with a - Back off adjusting nut slightly.
size 2.5 hexagon socket wrench.
- Close spray gun.
- Switch on machine.
- Check cutout pressure.
- Open spray gun.
Repeat this procedure until the
- Set maximum working pressure specified cutout pressure (see
on spray lance. above) has been reached. The
working pressure must not
• Back off adjusting nut (2) decrease at the same time
until pressure has dropped (reading on pressure gauge when
completely. spray gun is open).

• Screw adjusting nut in again until The cutout pressure must also
reading on pressure gauge no remain constant. If necessary, the
longer increases (maximum setting must be repeated or the
working pressure). high-pressure cleaner examined
for leaks.
- The setting is adjusted precisely
by slowly backing off and scre- The microswitch is set with the aid
wing in the adjusting nut. of the adjusting screw when the
motor is running and with the
spray gun closed:

- Turn adjusting screw in until

motor cuts out.
RE 140 K, 160 K 11
6.4 Injector 6.5 Non-return valve

- Unscrew high-pressure hose, - Remove safety control block

remove shroud if necessary (see 6.1).
(see 5.1).
- Remove injector (see 6.4).

621RA017 BL
1

• Drive injector nozzle (1) out of

injector housing with a pin
(dia. 2 mm).

• Replace O-rings in injector.

- Examine injector nozzle and

housing; replace if necessary.

- Clean valve seat in safety control

block housing.

Reassemble parts in reverse order.

- Thoroughly grease injector and

O-rings before refitting them 3
(special grease 0781 145 3516). 2

621RA022 BL
621RA012 BL

- Screw high-pressure hose 1

connection in as far as possible
with new sealing ring.
• Unscrew high-pressure hose • Pull spring (1) and piston (2) out
connection with size 30 fork of safety control block housing
wrench. (use pliers if necessary).

- Replace O-ring in high-pressure • Replace O-ring (3) on piston.

port.
- Clean valve seat in safety control
block housing.

Reassemble parts in reverse order.

- Insert piston in housing with

O-ring facing inwards.

- Ensure that piston and spring

are seated correctly.

Refit injector and safety control

block.

• Pull injector out of safety

control block housing with hook
5910 890 2900.
Engage hook in two holes in
injector housing.

12 RE 140 K, 160 K
6.6 Detergent metering and
non-return valve

Note: The detergent intake

comprises a detergent metering
valve, a detergent non-return
valve and an injector nozzle in the
high-pressure port.
The injector must also be
examined (see 6.4) if faults arise
in the detergent intake.

621RA091 KN
621RA089 KN
• Unscrew banjo bolt from safety • Fit valve spring with narrow end
control block. Ensure that the facing ball.
spring and ball of the non-return
valve are not lost in the process. - Align metering valve so that
intake connector points back to
intake hose.

- Screw banjo bolt into safety

control block and tighten
securely.

1
621RA084 KN

621RA090 KN

• Disconnect detergent intake • Remove O-ring (1) from banjo

hose from metering valve. bolt.

- Pull banjo bolt out of metering

valve.

- Clean and examine all parts,

replace if necessary.

- Clean valve seat in safety control

block.

Reassemble parts in reverse order.

1 - Fit valve ball in banjo bolt.

621RA088 KN

• Pull split pin (1) out of adjusting

knob (2).

• Remove adjusting knob (2).

RE 140 K, 160 K 13
7. HIGH-PRESSURPUMP 7.2 Removing / installing 7.3 Removing / installing valve
7.1 Screen in intake port delivery valves block and intake valves
(water inlet)
• Unscrew hose connector from - Remove shroud (see 5.1) and - Remove shroud (see 5.1) and
water inlet (see 5.1). motor / pump unit (see 5.2). motor / pump unit (see 5.2).

- Remove safety control block - Remove safety control block

(see 6.1). (see 6.1).

The delivery valves are removed - Remove delivery valves if

and installed in the same way as necessary (see 7.2).
on the high-pressure cleaners of
series RE 102 K, 104 K and 106 K.

Important: Different valves are

used in the high-pressure cleaners
RE 140 K, 160 K (see spare parts
list).
621RA026 BL

1 2
2
1 1
3
4
5 1

621RA025 BL
621RA023 BL

1 1

• Remove screen from intake port Note: Where possible, defective • Undo fastening screws (1).
with pliers, clean it and replace if valves should only be replaced as
necessary. a complete unit (O-ring (1), valve • Remove retaining plate (2) with
head (2), plate (3), spring (4) and microswitch.
Reassemble parts in reverse order. cage (5)). The intake valves
must also be checked (see 7.2) if The intake valves are removed
delivery valves are soiled or and installed in the same way as
damaged. on the high-pressure cleaners of
series RE 102 K, 104 K and 106 K.
- Check correct functioning before
installing valves. Important: Different valves are
used in the high-pressure cleaners
RE 140 K, 160 K (see spare parts
list).

- Pull valve discs out of valve

block.

14 RE 140 K, 160 K
 7.4 Removing / installing 7.5 Disassembly / assembly
pump housing and of the pump piston
pump piston
- Remove valve block (7.3). - Remove pump piston (see 7.4).
1
2
- Drain oil (see chapter 11). - Remove spring and washer.
3
4 The pump housing and pump - Remove circlip.
5 piston are removed and installed
6 in the same way as on the high-

621RA024 BL
pressure cleaners of series
RE 102 K, 104 K and 106 K.

Note: Steady the pump housing

when undoing the fastening
Note: Where possible, defective screws so that it is not pushed
valves should only be replaced as aside by the force of the springs.
a complete unit (O-ring (1), valve
head (2), plate (3), spring (4) and
cage (5)). The intake valves and
delivery valves are identical.

Brass valve block only:

• Fit valve discs (6).

- Check correct functioning before

installing valves.

Reassemble parts in reverse order. 4

3
Ensure that all O-rings are fitted
and that the valve block is not mi- 2

621RA042 BL
saligned when fitted. 1
- Turn in fastening screws.

- Insert microswitch and turn in • Examine piston (1), spring (2),

fastening screws. washer (3) and circlip (4) and
replace if necessary.
- Tighten fastening screws on
valve block down crosswise Reassemble parts in reverse
(15 Nm). order. Ensure that washer is fitted
correctly.

RE 140 K, 160 K 15
7.6 Replacing the high-pressure
cups and oil seals

- Remove pump piston (see 7.4).

3 2 3
The high-pressure cups and oil
seals are removed and installed in 1
the same way as on the high-
pressure cleaners of series
6
RE 102 K, 104 K and 106 K, with
the following additional steps:

621RA092 KN
4

621RA078 BL
5 5

RE 140 K • Coat inner surface of assembly

sleeve 4726 890 2200 with
special grease.

RE 160 K

2 3 2 3
1
1
3 7

5
621RA045 BL
621RA043 BL

621RA079 BL
4
6 6

• The oil seals (1) in the pump Installation position of the oil seals • Fill the grooves of the high-
housing are mounted on support and high-pressure cups: pressure cups and oil seals with
rings (2). 1 High-pressure cup special grease 0781 145 3516.
2 Support ring
• The oil seals can be prised 3 Valve block
out by applying an implement in 4 Oil seal
the recesses (3) in the pump 5 Support ring
housing. 6 Pump housing
7 Guide bushing

All models 1
2
Note: Use assembly device
4726 890 2200 (assembly arbor
and sleeve) to fit the high-pressure
cups and oil seals.
1
621RA044 BL

621RA080 BL

Proceed as follows:
2

RE 160 K • Coat the new high-pressure

cup (1) with special grease
• The high-pressure cups (1) in 0781 145 3516 and press onto
the valve block are likewise assembly arbor 4726 890 2200
mounted on a support ring (2). together with support ring (2).

16 RE 140 K, 160 K
 7.7 Replacing thrust bearings

- Remove shroud (see 5.1) and

motor / pump unit (see 5.2).

- Remove safety control block

(see 6.1), valve block (see 7.3)
and pump housing (see 7.4).

The outer thrust bearing is

621RA081 BL

621RA083 BL
removed and installed in the same
way as on the high-pressure
cleaners of series RE 102 K,
104 K and 106 K.
• Slide assembly arbor with • Slide oil seal onto assembly
high-pressure cup into the larger arbor with the groove facing
opening in the assembly sleeve upwards. The sealing lip of the
(interior of sleeve is tapered). oil seal fits into the recess on the
assembly arbor.
- Press sleeve against a soft, level
and clean surface and adjust - Press oil seal into pump
arbor until cup is flush with end housing with assembly tool RE 160 K only
of sleeve. 4726 890 2200 in the same
way as the high-pressure cups.
- Position complete assembly Do not damage the sealing lip.
device on valve block. The
collar fits into the seat of the - Insert support rings in pump
high-pressure cup. housing and press in with
assembly arbor. 1
Reassemble remaining parts in

621RA046 BL
reverse order.

- Installation position of guide

bushing: see diagram.
• Pull swashplate (1) and inner
thrust bearing off the drive shaft.

3
2
1
621RA047 BL
621RA082 BL

• Drive high-pressure cup into seat Examine the various parts of the
in valve block with the assembly outer (see RE 102/104/106 K) and
arbor. inner thrust bearing and replace if
necessary: upper washer (1), cage
- Fill grooves of oil seals with spe- with bearing rollers (2) and bottom
cial grease 0781 145 3516. washer (3).

RE 140 K, 160 K 17
 8. ELECTRIC MOTOR
8.1 Removal

All models - Remove shroud (see 5.1).

Reassemble parts in reverse order. - Remove switch housing

(see 9.2.1) and microswitch
Note: All parts of the thrust bea- (see 9.2.5).
ring and the swashplate must be
well oiled before being installed. RE 160 K only

621RA095 KN
- Remove power cable (see 9.2.3)
and capacitor (see 9.2.4).

All models
• Undo fastening screws on drive
- Drain oil (see chapter 11). housing.

- Remove valve block (see 7.3)

and pump housing (see 7.4).

RE 140 K

621RA096 KN
621RA093 KN

• Undo fastening screws in cover. • Carefully prise drive housing off

stator housing with two screw-
- Remove cover and fan shroud. drivers:
- alternately, working crosswise,
Note: The fastening screw is se- - in small steps.
cured with Loctite. Do not damage the housing.

2 1
621RA097 KN
621RA094 KN

• Block the fanwheel with a screw- • Draw drive housing off stator
driver (1), but without damaging it. with rotor.

• Undo fastening screw (2).

- Examine fanwheel and replace if

necessary.

18 RE 140 K, 160 K
 - Examine fanwheel and replace if
necessary.

621RA098 KN

621RA100 KN
• Press rotor out of drive housing • Press ball bearing out of stator
and swashplate with suitable with suitable arbor.
arbor.
Important! Oil seals, shoulder
bearings and ball bearings which
have been removed must always
be replaced by new parts.

RE 160 K

621RA050 BL
621RA048 BL
621RA099 KN

• Remove swashplate (1) from • Undo fastening screws for fan • Undo fastening screws in
drive housing. shroud. bearing cover.

Remove shoulder bearing: - Remove fan shroud.

• Remove screw plug (2) and

plug (3).

- Uniformly heat drive housing to

approx. 80 °C on a hotplate or
with a hot-air fan; the shoulder
bearing will then drop out of the 1
housing.

Important! Wear gloves!

- Press oil seal down and out of

621RA051 BL
621RA049 BL

drive housing with a screwdriver.

• Remove clamping ring (1) with • Carefully prise bearing cover off
standard extractor. stator with two screwdrivers.
Do not damage stator housing or
- Remove fanwheel, carefully pri- bearing cover.
sing it off with a screwdriver if ne-
cessary. Remove bearing cover.

RE 140 K, 160 K 19
 Important: Oil seals and ball
bearings which have been
removed must always be replaced
by new parts.
1

621RA052 BL

621RA055 BL
• Remove feather key (1) from • Examine ball bearing (1) in
drive shaft. bearing cover and replace if ne-
cessary.
- Mark installation position of drive
housing on stator. • Draw ball bearing off drive shaft
in order to replace it.
621RA053 BL

621RA056 BL

• Undo fastening screws on • Press rotor out of drive shaft with

drive housing. Ensure that the suitable arbor.
fastening clamp for the capacitor
is not lost. - Examine ball bearing of drive
housing and remove as
described above if necessary.
621RA054 BL

621RA057 BL

• Carefully draw drive housing • Press oil seal down and out of
out of stator with rotor. Do not drive housing with a screwdriver.
damage housing.
- Unscrew valve.

20 RE 140 K, 160 K
8.2 Installation

Important: When installing the

motor, ensure that the correct
rotor, stator and ball bearings are
used for the model to be repaired
(see spare parts list).

621RA105 KN
621RA103 KN
• Press oil seal into drive • Press inner race of shoulder
housing from the pump bearing in drive housing onto
side using assembly arbor drive shaft with suitable tubing
4112 893 2401 (1). Open side (inside diameter slightly larger
faces pump. than inner bearing race) until it is
flush with the shoulder.

RE 140 K

3 3
4

2
621RA101 KN

621RA106 KN
621RA104 KN

Important: Note installation • Press new shoulder bearing into Note: The centre shaft of the
position of shoulder bearing (1) drive housing until flush with swashplate is perpendicular to the
and oil seal (2); refer to schematic housing using suitable tubing axis of rotation. The tube must be
drawing with swashplate (3) and (same outside diameter as outer positioned here when installing the
rotor shaft (4). bearing race). swashplate.

- Oil sealing lip of oil seal.

- Insert rotor in drive housing.

621RA102 KN

621RA107 KN

• Press new ball bearing into • Press swashplate onto drive

stator with the aid of suitable shaft with suitable tubing.
tubing (outside diameter 34 mm).

RE 140 K, 160 K 21
 621RA058 BL

621RA060 BL
621RA108 KN
1

• Insert rotor with drive housing in RE 160 K • Place bearing cover on drive
stator and align in the original shaft.
installation position. • Press oil seal (1) into drive
housing from the pump - Turn in fastening screws.
- Carefully drive the drive housing side using assembly arbor
home with a rubber hammer. 4112 893 2401. Open side Note: Tighten fastening screws
faces pump. alternately to avoid stressing the
housing.

- Tighten fastening screws down

with a torque of 7 Nm.

- Slide fanwheel onto shaft and

drive it home.

1
621RA059 BL
621RA095 KN

• Turn in fastening screws. • Press new ball bearings (1) onto

drive shaft with suitable tubing
Note: Tighten fastening screws (cut away in diagram).
down alternately to avoid stressing
the housing. - Oil sealing lip of oil seal.

- Tighten fastening screws down - Press drive housing onto

with a torque of 7 Nm. drive-side ball bearing of rotor
(drive shaft with notch for feather
- Fit fanwheel on shaft and block it key).
with a screwdriver.
- Insert rotor with drive housing
- Wet fastening screw with in stator and align in original
Loctite 242 and tighten it installation position (compare
securely. markings).

- Refit pump housing (see 7.4) - Turn in fastening screws (upper

621RA061 BL

and valve block (see 7.3). screw with fastening clamp for
capacitor).
- Fill with oil (see chapter 11).
Note: Tighten fastening screws
Reassemble remaining parts in alternately to avoid stressing the • Slide clamping ring onto
reverse order. housing. fanwheel shaft and drive it home
with a size 30 insert and a
- Tighten fastening screws down rubber hammer.
with a torque of 7 Nm.
Reassemble remaining parts in
reverse order.

22 RE 140 K, 160 K
9. ELECTRICAL SYSTEM 9.1 Circuit diagram

Important!
The national safety regulations
must be observed without fail!

The power cable must be L1 N PE

unplugged from the socket outlet
at all times while carrying out
repairs.

W1

Q1

B4
P

C1

M
M1 1~
621RA077 BL

B4 = Microswitch
C1 = Capacitor
M1 = Motor with overload protection
Q1 = Master switch
W1 = Connecting lead

RE 140 K, 160 K 23
9.2 Removing / installing electrical components
9.2.1 Switch housing

- Remove shroud (see 5.1).

1 1
Note: Note circuit diagram; if
necessary, produce a drawing
clearly showing which wire
(note colour) is connected to the
respective terminals.

621RA031 BL
621RA110 KN
• Examine gasket (1) of switch • Examine gasket (1) of switch
housing and replace if necessary. housing and replace if necessary.

Reassemble parts in reverse order. • Undo fastening screws of switch

housing.

RE 140 K RE 160 K

1
621RA030 BL

621RA032 BL
621RA109 KN

• Undo fastening screws in cover • Undo fastening screws in cover • Lift switch housing up, taking
of switch housing. of switch housing. Ensure that care not to damage the wires.
nuts are not lost.
- Disconnect plug connector and • Examine gasket (1) and replace
protective earth conductor. - Remove cable lugs from switch. if necessary.
Ensure that the serrated washer
is not lost. - Remove switch, see 9.2.2. Reassemble parts in reverse order.

- Remove switch, see 9.2.2. - Remove cover.

- Remove cover.

24 RE 140 K, 160 K
9.2.2 Switch 9.2.3 Power cable

- Remove shroud (see 5.1). - Remove shroud (see 5.1).

- Remove cover of switch housing - Remove cover of switch housing

(see 9.2.1). (see 9.2.1).

Note: Note circuit diagram; if Note: Note circuit diagram; if

necessary, produce a drawing necessary, produce a drawing
clearly showing which wire clearly showing which wire

621RA035 BL
(note colour) is connected to the (note colour) is connected to the
respective terminals. respective terminals.

• Undo fastening screws on switch

with size 2.5 hexagon socket
wrench.

- Check the various parts and RE 140 K

replace if necessary.
- Remove lugs of power cable
Reassemble parts in reverse order. from switch.

2 1 2

621RA111 KN
621RA033 BL

621RA036 BL

• Remove retaining screw (1) in • Note installation position of • Prise cable grommet (1) out of
rotary knob. switch: the two lugs (1) on the housing and pull it out of the
switch fit between the bumps (2) housing with the power cable.
- Remove rotary knob. in the cover.

- Grease O-ring before refitting

rotary knob.

1
1
621RA037 BL
621RA034 BL

• Examine O-ring (1) in rotary RE 160 K

knob and replace if necessary.
• Disconnect protective earth
conductor (1). Note the serrated
washer.

RE 140 K, 160 K 25
 9.2.4 Capacitor

- Remove shroud (see 5.1).

- Remove cover of switch housing

(see 9.2.1).
1
Note: Note circuit diagram; if
necessary, produce a drawing
clearly showing which wire

621RA038 BL

621RA040 BL
1 (note colour) is connected to the
respective terminals.

- Disconnect capacitor connecting

• Press cable grommet (1) out of leads. • Release fastening clamp (1) and
housing and pull it out of the pull capacitor out sideways.
housing with the power cable.
- Remove fastening clamp if
necessary.

- Replace defective parts.

RE 140 K
All models

Reassemble parts in reverse order.

- Ensure that O-ring and grommet

are correctly seated.
621RA039 BL

621RA112 KN

All models • Press capacitor out.

• Unscrew cable gland with fork • Check O-ring on capacitor and

wrench: replace if necessary.
- Wrench size 22 for upper nut
- Wrench size 24 for lower nut - Replace defective parts.

- Check power cable, cable gland RE 160 K

and anti-kink tube and replace if
necessary. - Press cable grommet out of
housing and pull out of housing
Reassemble parts in reverse order. with connecting lead (as for
power cable, see 9.2.3).

26 RE 140 K, 160 K
9.2.5 Microswitch 10. SPRAY ATTACHMENT

- Remove shroud (see 5.1). Ensure that grommet is seated Important: O-rings must always
correctly. be replaced when carrying out
- Remove cover of switch housing repairs. All moving parts and
(see 9.2.1). sealing rings must be thinly coated
with special grease for high-
Note: Note circuit diagram; if pressure cleaners 0781 145 3516
necessary, produce a drawing before assembling the parts.
clearly showing which wire
(note colour) is connected to the
respective terminals.

- Disconnect connecting lead from

microswitch.

- Press grommet out of housing

and pull out of housing together
with connecting lead (as for
power cable, see 9.2.3).

- Remove safety control block

(see 6.1).
621RA113 KN

• Undo fastening screws on

microswitch.

- Replace defective parts.

Reassemble parts in reverse order.

RE 140 K, 160 K 27
10.1 Spray gun 10.2 Spray lance, spray head

1 1
2

621RA065 BL
621RA063 BL

621RA067 BL
1
2

• Turn spray lance (1) 90° anti- Note: A split support ring (1) is • Undo locking screw (1) on spray
clockwise to release from spray fitted on the high-pressure head.
gun (2) and remove it. connection. To remove the ring, it
must be pushed apart at the gap - Unscrew spray head from spray
and then pulled off. The support lance, noting the nozzle and
ring must not be overextended. spring.
This is the case if it protrudes
strongly from the groove.

• Replace O-ring (2).

621RA018 BL

4
2
The remaining procedure for
disassembling and assembling
the spray gun is the same as on
high-pressure cleaners of series
RE 101 K.
3

621RA068 BL
Additional steps: 2
1 1
3

• Prise off cover (1) with a small • Remove nozzle (1) and
screwdriver. spring (2) from spray lance.

• Prise off retainer (2) with a • Replace O-rings (3, 4).

screwdriver and remove it.

• Pull high-pressure hose (3) out

of spray gun.
621RA064 BL

1 3
621RA066 BL

621RA069 BL

• Undo fastening screws in • Remove connecting elements (1) • Undo fastening screws in handle
right-hand handle moulding. from spray lance (2). moulding of spray lance.

- Remove right-hand handle • Replace O-rings (3). - Remove handle moulding.

moulding, noting the valve, lever
and high-pressure port.

28 RE 140 K, 160 K
 3
2 1

621RA070 BL

621RA075 BL
621RA073 BL
2 1 3
1

• Remove spray lance (1) from • Remove nozzle sleeve (1). • Disengage leaf spring catch (1).
handle moulding.
• Remove retainer (2) for leaf • Remove leaf spring with pliers.
• Remove spray head connecting springs from housing (3).
element (2) and coupling (3). Leaf springs which have been
Important: The leaf springs have removed must always be replaced
extremely sharp edges. Beware by new ones.
of injuries! Always wear gloves
when handling the leaf springs. - Examine all parts for damage
and replace if necessary.
Ensure the correct nozzle is
1 2 3 used (see spare parts list).

Reassemble parts in reverse order.

Note installation position of nozzle

and springs.
621RA071 BL

Ensure that the connector and the

coupling are correctly seated in
the handle mouldings.
• Replace O-rings on spray
lance (1, 2) and on coupling (3). - Finally check correct functioning
of nozzle sleeves with regard to
Note: All O-rings must be well jet pattern and pressure control.
greased before being fitted.

1
621RA074 BL
621RA072 BL

• Force both locking pins • Replace O-ring (1) in retainer for

(1, second pin not shown in leaf springs.
diagram) out of nozzle sleeve
with a wire dia. 1.5 mm (2). Leaf springs should only be
removed if damaged. Proceed as
follows:

RE 140 K, 160 K 29
11. OIL CHANGE

The oil in this high-pressure

cleaner is designed to ensure
permanent lubrication of the
machine in normal use and need
not be changed.
1
If the machine is used in more
demanding conditions or for

621RA062 BL
621RA028 BL
commercial purposes, the oil must
be changed every six months.

Oil capacity: 100 ml

Oil grade: SAE 15 W 40
All models • Replace O-ring (1).
- Remove shroud (see 5.1) and
motor / pump unit (see 5.2) if • Turn motor / pump unit on its - Grease relief valve before
necessary. side and let oil drain completely pressing it into place.
into a sufficiently large container.
- Lay the motor / pump unit down All models
so that the screw plug points RE 160 K
upwards. - Fill with 100 ml oil (oil grade as
Note: The pressure compensa- specified above).
ting valve should only be removed
if leaking or damaged. Proceed RE 140 K
as follows:
- Insert and lock screw plug.

RE 160 K

- Turn in screw plug and secure

621RA114 KN

with a torque of 7 Nm.

All models

RE 140 K Reassemble parts in reverse order.

• Release and remove the screw

plug.

- Replace O-ring.
621RA027 BL

621RA029 BL

RE 160 K • Carefully prise relief valve off

with a screwdriver. Do not
• Undo screw plug with 1/4" damage housing.
(size 7) hexagon socket wrench. - Examine relief valve and replace
if necessary.

30 RE 140 K, 160 K
12. SPECIAL TOOLS AND SERVICE TOOLS
12.1 Special tools

No. Part name Part No. Use

1 Hook 5910 890 2900 Removing injector from safety control block housing
Drawing valve body out of safety control block

2 Assembly device 4726 890 2200 Fitting high-pressure cups in valve block
(assembly arbor and sleeve) with support rings
Installing oil seals in pump housing

3 Assembly arbor 4112 893 2401 Forcing oil seal into drive housing

4 Extractor 4703 890 4500 Drawing ball bearings off drive shaft

5 1/4" hexagon socket wrench Screw plug in drive housing

6 Torque wrench 5910 890 0300

7 Torque wrench 5910 890 0310

8 Test pressure gauge 5910 850 3205 Setting pressure control system

12.2 Service accessories

No. Part name Part No. Use

1 Special grease, waterproof, 0781 145 3516 O-rings, high-pressure cups,

50 g tube sliding surfaces in contact with water

2 Locking paint, standard Adjusting nut and adjusting screw

for pressure setting on control piston

RE 140 K, 160 K 31