Stihl RE 521 RE 551 RE 581 RE 661 RE 961 Pressure Washer Service Repair Manual
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VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
These repair instructions include a detailed description of the essential repair tasks for the following series: STIHL RE 521, RE 551, RE 581, RE 661 and RE 961. The descriptions also apply for the PLUS models. Exceptions are cited in the text. A test bed with the necessary water and power supplies should 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. A fault on the machine may be due to several causes. For troubleshooting, refer to the “Summary of possible faults” (b 5) and the STIHL Service Training System “High-pressure cleaners”.
- 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. 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.
TABLE OF CONTENTS:
1. Introduction 3
2. Safety regulations 3
3. Technical Specifications 4
3.1 Motor 4
3.2 Pump 4
3.3 Burner 4
3.4 Weights and dimensions 4
3.5 Capacities 5
3.6 Sound pressure level 5
3.7 Settings for the automatic scale inhibitor system 5
3.8 Settings for CO2 content, O2 content and soot 5
3.9 Tightening torques 6
4. Functional description, function diagram 8
4.1 Water conducting system 8
4.1.1 High-pressure pump 8
4.1.2 Automatic scale
inhibitor system 9
4.1.3 Regulation valve block 9
4.1.4 Adding detergent,
automatic clear rinse 10
4.2 Heating system 10
4.2.1 Heat exchanger 11
4.2.2 Level monitoring
in the fuel tank 11
4.3 Safety system 11
4.3.1 Safety valve 12
4.3.2 Flow monitor 12
4.3.3 Temperature control 12
4.3.4 Thermal release 13
4.3.5 Monitoring the flame 13
4.4 Function diagram 13
5. Summary of
possible faults 15
5.1 Control panel,
significance of the
various indicators 15
5.2 Diagnostic codes
RE 661, RE 961 17
5.3 Flow diagram of highpressure
pump 19
5.4 Summary of
electric motor faults 23
5.5 Summary of heating
system faults 25
6. Cover, chassis 27
6.1 Open shroud and
right covers, close
RE 521, RE 551,
RE 581 27
6.2 Open shroud and
cover, close
RE 661, RE 961 27
6.3 Shove the motor/pump
unit into service
position 28
6.4 Exchanging castors 29
6.5 Changing a wheel 29
6.6 Hose reel
(PLUS models) 30
6.6.1 Removing / mounting
the hose reel 30
6.6.2 Seal high-pressure
connection
RE 551 PLUS,
RE 581 PLUS 31
6.6.3 Removing / installing
hose reel RE 551 PLUS,
RE 581 PLUS 33
6.6.4 Removing / installing
hose and cable drum
RE 661 PLUS,
RE 961 PLUS 33
6.6.5 Seal high-pressure
connection
RE 661 PLUS,
RE 961 PLUS 35
6.7 High-pressure
connection of models
without hose reel 36
7. Regulation valve
block 37
7.1 Safety valve 37
7.2 Non-return valve 38
7.3 Flow monitor 39
7.4 Start-Stop switch 40
7.4.1 Removing/installing 40
7.4.2 Setting the Start-Stop
switch 40
7.5 Reed switch 41
7.5.1 Removing/installing 41
7.5.2 Setting 42
7.6 Hydraulic accumulator
RE 661, RE 961 43
7.7 Bypass valve and
control piston 43
7.8 Removing / installing the
regulation valve block 46
7.9 Adjusting pressure
control 46
8. High-pressure pump 48
8.1 Screen in intake port 48
8.2 Removing / installing
intake port 48
8.3 Removing / fitting
the injector 49
8.4 Removing / installing
intake / delivery valves 50
8.5 Valve block and high
pressure cups
Removing / installing 51
8.6 Removing / installing
ceramic pistons 53
8.7 Oil expansion tank and
float-operated switch
Removing / installing 54
8.8 Removing / installing
pump housing 55
8.9 Open pump housing 56
8.10 Disassemble pump
housing RE 521,
RE 551, RE 581 56
8.11 Disassemble pump
housing
RE 661, RE 961 59
8.12 Disassembly /
assembly of
connecting rods 62
8.13 Exchange piston
oil seals 63
8.14 Exchange camshaft
sealing ring
RE 661, RE 961 64
9. Remove / install
electric motor 64
10. Adding detergent,
automatic clear rinse 68
11. Automatic scale
inhibitor system 69
11.1 Adjust hardness 69
11.2 Removing and installing
the scale inhibitor
metering valve 69
2 RE 521, RE 551, RE 551 PLUS, RE 581, RE 581 PLUS, RE 661, RE 661 PLUS, RE 961, RE 961 PLUS
Contents
11.3 Scale inhibitor
concentrate level
monitor 70
12. Heating system 71
12.1 Set burner 71
12.2 Solenoid 73
12.3 Fan housing 74
12.3.1 Removing / installing 74
12.3.2 Disassembly /
assembly 74
12.4 Burner motor 76
12.5 Burner insert 76
12.5.1 Removing/installing 76
12.5.2 Nozzle assembly and
ignition electrodes,
Removing / installing 77
12.6 Heat exchanger 78
12.6.1 Removing / installing
heating coil 78
12.6.2 Removing / installing
burner casing 80
12.7 Removing / installing
insulation 81
12.8 Temperature sensor 81
12.9 Thermal release 81
12.10 Monitoring the flame 82
12.11 Level display and floatoperated
switch
in the fuel tank 83
13. Electrical system 85
13.1 ESD precautions 85
13.2 Connecting /
disconnecting
electrical components 85
13.3 RE 521, RE 551,
RE 581 86
13.3.1 Opening / closing
switch box cover 86
13.3.2 Printed circuit board
with main switch 86
13.3.3 Turn motor idle
off / on 87
13.3.4 Setting
maintenance interval 88
13.3.5 Pressure gauge 89
13.3.6 Detergent
metering valve 89
13.3.7 Contactor 90
13.3.8 Fuses 90
13.3.9 Transformer 90
13.3.10 Removing / installing
switch box housing 91
13.3.11 Power cables 91
13.3.12 Capacitors
RE 521, RE 551 92
13.4 RE 661, RE 961 93
13.4.1 Opening / closing
switch box cover 93
13.4.2 Display
operating hours 93
13.4.3 Setting
temperature display 94
13.4.4 Turn motor idle off/on 94
13.4.5 Setting maintenance
interval 94
13.4.6 Circuit board
function test 95
13.4.7 Main switch 96
13.4.8 Display unit with
temperature control 97
13.4.9 Pressure gauge 98
13.4.10 Detergent
metering valve 99
13.4.11 Circuit board 100
13.4.12 Contactor 100
13.4.13 Fuses 101
13.4.14 Relay 101
13.4.15 Transformer 102
13.4.16 Terminal blocks 103
13.4.17 Power cables 103
13.4.18 Removing / installing
switch box 104
13.5 Disconnect
the electric motor 104
13.6 Removing / installing
ignition transformer 105
14. Spray attachment 106
14.1 VarioPress gun 106
14.2 Spray lance,
spray head 108
14.3 Remove/install 110
15. Maintenance 111
15.1 Maintenance
schedule 111
15.2 Reading out
operating hours 112
15.3 Check oil level,
change oil 112
15.4 Clean screen
in water feed 113
15.5 Replace fuel filter 114
15.6 Replace fuel nozzle 114
15.7 Check fuel for water 114
15.8 Cleaning fuel tank
RE 661, RE 961 115
15.9 Cleaning fuel tank
RE 521, RE 551,
RE 581 115
15.10 Descaling 116
15.11 Cleaning heating coil 117
15.12 Setting the burner 118
15.13 Setting the fuel pump 118
15.14 Set soot level,
CO2 content 119
15.15 Calculate exhaust
loss 122
16. Special tools
and service tools 124
16.1 Special
Servicing Tools 124
16.2 Service accessories 125
17. Circuit diagrams 126
17.1 Legends to circuit
diagrams: RE 521,
RE 551, RE 581 126
17.2 Circuit diagram for
RE 521,
Legend (b 17.1) 127
17.3 Circuit diagram for
RE 551
Legend (b 17.1) 128
17.4 Circuit diagram for
RE 581
Legend (b 17.1) 129
17.5 Legend to circuit
diagram for RE 661,
RE 961 130
17.6 Circuit diagram
for RE 661, RE 961
Legend (b 17.5) 131
FILE FORMAT:
LANGUAGE:ENGLISH
PAGES:134
DOWNLOADABLE:YES
FILE TYPE:PDF
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