Kärcher CV 66/2 User manual
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:
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
12
3
4
5
6
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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