Kärcher KMR 1250 B Service Manual
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Kärcher KMR 1250 B Service Manual

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Service Manual

R
H E
R C
K A
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H E
R C
K A
5.905-122
KMR 1250
(KMR 1250 B, KMR 1250 LPG, KMR 1250 D)
1.091- . . .
5.905-262
09.02

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  • Page 1: Service Manual

    Service Manual 5.905-122 KMR 1250 (KMR 1250 B, KMR 1250 LPG, KMR 1250 D) 1.091- . . . 5.905-262 09.02...
  • Page 2 Foreword KMR 1250 B, LPG, D Foreword Good servicing requires extensive and relevant training as well as comprehensible reference documents. We therefore offer basic and advanced training courses for the full range of our products to all service technicians on a regular basis.

  • Page 3: Table Of Contents

    KMR 1250 B, LPG, D Table of Contents Contents Unit functions ......................4-15 Overview ..........................4-5 View from front .......................... 6 Controls ............................. 7 Gasoline Engine (HONDA GX 270) ..................8-9 LP Gas Engine (HONDA GX 270) ..................10-11 Diesel Engine (YANMAR L 70 AE-DE) ................12-13 Steering and Drive Power ......................

  • Page 4: Unit Functions

    Unit Functions KMR 1250 B, LPG, D Drive system Suction and filtering system – When the hood is lifted up toward the rear, all – Dust pickup at brush roller. components become accessible for mainte- – Large-capacity dust filter with mechanical dust nance purposes.
  • Page 5 Engine 1250 D With the exception of the different engine type, the unit is identical to the basic KMR 1250 B version. – Single-cylinder, air-cooled diesel engine (YAN- MAR L 70 AE-DE) w/ electric starter.

  • Page 6: View From Front

    Unit Functions KMR 1250 B, LPG, D View from front Gas cylinder (LP Gas) Steering wheel Driver seat Lifting mechanism for debris container Rear wheel, chain-driven Fuel tank for KMR B / D Engine KMR B / LPG / D...

  • Page 7: Controls

    KMR 1250 B, LPG, D Unit Functions Controls 16 17 Lever dust pickup, Close / Open 12 Lever brush roller, Raise / Lower (suspension: rigid or floating) Button clean dust filter (S2) 13 Lever RH side brush, Raise / Lower...

  • Page 8: Gasoline Engine (Honda Gx 270)

    Unit Functions KMR 1250 B Gasoline Engine (HONDA GX 270) Stop screw, throttle valve 12 Emulsion tube Idle jet 13 Air orifice Bypass 14 Float chamber Throttle valve 15 Main jet Idle orifice 16 Adjusting screw, idle mixture Idle jet bore and idle air channel...
  • Page 9 KMR 1250 B Unit Functions Gasoline Engine (HONDA GX 270) Float system Full load operation When float chamber (14) is empty, fuel passes In full load operation, the throttle is wide (4) open: from fuel tank into float chamber (14) via the float –...

  • Page 10: Lp Gas Engine (Honda Gx 270)

    Unit Functions KMR 1250 B, LPG, D LP Gas Engine (HONDA GX 270) Valve guard 10 Engine LP gas line 11 Vacuum line Cylinder shutoff valve 12 LP gas line Outlet tube 13 Gas filter LP gas cylinder 14 Solenoid valve, gas supply Sun shield 15 Mixture control screw (MIN eng.
  • Page 11 KMR 1250 B, LPG, D Unit Functions LP Gas Engine (HONDA GX 270) Gas system – The presence of frost on any part of the LP gas system indicates a possible leak. Close the – Opening the shutoff valve (3) on the LP gas cylinder shutoff valve (3) immediately.

  • Page 12: Diesel Engine (Yanmar L 70 Ae-De)

    Unit Functions KMR 1250 B, LPG, D Diesel Engine (YANMAR L 70 AE-DE) Drive shaft Injection system Housing, engine The injection pump (8) delivers fuel to the injec- tor nozzle (5) via fuel line (6). The fuel, is then Piston...

  • Page 13: Diesel Engine (Yanmar L 70 Ae-De)

    KMR 1250 B, LPG, D Unit Functions Diesel Engine (YANMAR L 70 AE-DE) Injection pump The injection cam on the camshaft shuttles the injection pump piston (1) back and forth. Fuel is conveyed to the injection nozzle via pressure valve (7).

  • Page 14: Steering And Drive Power

    Unit Functions KMR 1250 B, LPG, D Steering and Drive Power RH drive chain (option) Impeller fan 10 LH side brush (option) Drive belt, impeller fan 11 Chain, steering Drive belt, hydrostatic transmission 12 RH side brush Hydrostatic transmission 13 Drive belt, brush roller...

  • Page 15: Sweeping System

    KMR 1250 B, LPG, D Unit Functions Sweeping system Hydraulic unit Rear wheel Engine B / LPG / D Debris container, lowered Steering wheel 10 Hydrostatic transmission Operator seat 11 Brush roller Debris container, raised 12 Coarse-dirt flap Impeller fan...

  • Page 16: Troubleshooting Information

    Troubleshooting Information KMR 1250 B, LPG, D Starter Fails to Turn Engine Check fuse F1/F2 Fuse F2 protects the entire control voltage cir- cuitry. This fuse is located on the A1 circuit board. – Check fuse and replace as required.
  • Page 17 KMR 1250 B, LPG, D Troubleshooting Information Starter Fails to Turn Engine Check starter M1 – Hold ignition switch in position II. – If a voltage is present but starter fails to turn, starter is defective and must be replaced.

  • Page 18: Starter Fails To Turn Engine

    Troubleshooting Information KMR 1250 B, LPG, D Starter Fails to Turn Engine Check regulator ORIGINAL When the engine is running, the alternator gener- ates a continuous current flow. The regulator automatically adapts this current as required (depending on battery charge status and electri- cal load).

  • Page 19: Starter Turns Engine But Engine Fails To Start

    KMR 1250 B, LPG, D Troubleshooting Information Starter Turns Engine but Engine Fails to Start Checking S3 seat contact switch Note: Actuating the starter without a load on the seat will crank the engine but not start it! – Disconnect wire connections from seat con- tact switch.

  • Page 20: Starter Turns Engine But Engine Fails To Start

    Troubleshooting Information KMR 1250 B, LPG, D Starter Turns Engine but Engine Fails to Start Check compression release lever (diesel engine) – Engine is equipped with compression release lever. During engine starting, it can be actu- ated for a short while to ease overcoming engine resistance at top dead center.

  • Page 21: Engine Runs But Machine Fails To Move

    KMR 1250 B, LPG, D Troubleshooting Information Engine Runs but Machine Fails to Move Transmission drive belt The transmission drive belt tension is adjusted by means of the tension roller. The drive belt must be sufficiently tight so that it will not wow through more than 3 to 8 mm (0.12-0.32 in) when...
  • Page 22 Troubleshooting Information KMR 1250 B, LPG, D Engine Runs but Machine Fails to Move Checking drive pedal ORIGINAL A linkage connects the drive pedal to the shift lever (2) on the transmission (7). When the drive pedal is not actuated, the shaft-mounted leg spring (6) always returns this lever to the center position .
  • Page 23 KMR 1250 B, LPG, D Troubleshooting Information Engine Runs but Machine Fails to Move Checking drive pedal REVISED A linkage connects the drive pedals to the shift lever (4) on the transmission (1). When the drive pedals are not actuated, the pull spring (3) al- ways returns this lever to the center position.
  • Page 24 Troubleshooting Information KMR 1250 B, LPG, D Engine Runs but Machine Fails to Move Adjust hydrostatic transmission Starting with serial no. 11482 to serial no. 11882, the hydrostatic transmission (1) is installed in a slanted position. As the slant is not adjustable, engine and transmission drive belts may fail after a short while.
  • Page 25 KMR 1250 B, LPG, D Troubleshooting Information Engine Runs but Machine Fails to Move Insert hydrostatic transmission Note: Starting with serial no. 10 053, the transmis- sion is slanted forward, putting less strain on the drive belt. Check and observe parking brake effectiveness and belt tension when a new transmission is in- stalled.

  • Page 26: Maintenance Procedures (Gasoline And Lpg Engine)

    Troubleshooting Information KMR 1250 B, LPG, D Maintenance Procedures (gasoline and LPG engine) Note: For operating and maintenance instructions, consult the Operator Manual for this engine. Check engine oil level – Engine oil level must be between the MIN and MAX markings on the dipstick.

  • Page 27: Maintenance Procedures (Gasoline And Lpg Engine)

    KMR 1250 B, LPG, D Troubleshooting Information Maintenance Procedures (gasoline and LPG engine) Operating RPM adjustment The engine operating speed (refer to „Specifica- tions“) is set by means of the adjustment screw (1). Once the setting is correct, the screw must be fixed with sealing lacquer.

  • Page 28: Maintenance Procedures (Lpg Engine)

    Troubleshooting Information KMR 1250 LPG Maintenance Procedures (LPG engine) Set CO value (LPG engine) To adjust CO value, the following measuring de- vices will be needed: – Tachometer, P/N 6.491-361 – Exhaust analyser. Procure suitable CO an- alyser locally; requires measuring range up to 2% CO.

  • Page 29: Maintenance Procedures (Lpg Engine)

    KMR 1250 LPG Troubleshooting Information Maintenance Procedures (LPG engine) 2. Set CO value at operating speed – Set accelerator lever on instrument panel to MAX position (operating speed). – Measure operating RPM and adjust via stop screw (6) on carburetor as required. Operat- ing speed has to be between 2600 and 2700 RPM (see also “technical specifications”).

  • Page 30: Maintenance Procedures (Diesel Engine)

    Störungshilfe KMR 1250 D Maintenance Procedures (diesel engine) Note: For operating and maintenance instructions, consult the Operator Manual for this engine. Check engine oil level – Engine oil level must be between the MIN and MAX markings on the dipstick. Top up engine oil –...
  • Page 31 KMR 1250 D Störungshilfe Maintenance Procedures (diesel engine) Operating RPM adjustment Engine operating speed (refer to “technical spec- ifications”) is set by means of the adjusting screw (1). With adjustments completed, the screw must be fixed by applying sealing lacquer. Governor adjusting screw CAUTION Governor spring (6) must be hooked...

  • Page 32: Parking Brake - No Function

    Troubleshooting Information KMR 1250 B, LPG, D Parking Brake – No Function Adjust parking brake Note: With the parking brake released, there must be NO braking effect, and the wire and cas- ing cable (1) must be fully relaxed. The parking brake is required to securely hold the unit in place when applied on a grade of 25%, and with the unit loaded to capacity.

  • Page 33: Brush Roller - Poor Performance

    KMR 1250 B, LPG, D Troubleshooting Information Brush Roller – Poor Performance Check tire pressure Uneven tire pressure in the rear wheels causes the power sweeper to tilt sideways and run lop- sided. The result may be a substandard sweep- ing pattern and the cleaning result is not satisfy- ing.

  • Page 34: Brush Roller – Poor Performance

    Troubleshooting Information KMR 1250 B, LPG, D Brush Roller – Poor Performance Check sweeping pattern – Close dust pickup hatch. – Drive mobile sweeper onto dusty surface, and set parking brake. – Lower brush roller (lever in center position), and allow to run in place for a few seconds.

  • Page 35: Brush Roller - No Rotation

    KMR 1250 B, LPG, D Troubleshooting Information Brush Roller – No Rotation Check / replace Brush roller In the event that wrap-around string or banded materials block the brush roller, the latter must be deinstalled and obstructions removed. Adjust drive belt tension rollers to allow approx. 10 mm depression of the respective drive belts.

  • Page 36: Side Brushes - Poor Sweeping Performance

    Troubleshooting Information KMR 1250 B, LPG, D Side Brushes – Poor Sweeping Performance Check drive belt side brush The side brush is driven by elastic drive belt (5) via intermediate shaft (6). Belt replacement necessitates deinstallation of intermediate shaft (6) (see page 35, pos. 12).

  • Page 37: Excessive Unit Dusting

    KMR 1250 B, LPG, D Troubleshooting Information Excessive Unit Dusting Replace dust filter A noticeable deposit of dust at the impeller fan exhaust indicates a poorly installed or defective dust filter. – Raise debris container (1) to half of its travel, and secure against dropping.
  • Page 38 Troubleshooting Information KMR 1250 B, LPG, D Excessive Unit Dusting Check filter receptacle A noticeable accumulation of dust in the engine compartment indicates a leaky filter receptacle. The seal ring (1) is defective or the three open- ings on flange (2) are too large, and protrude beyond the welded ring (3).
  • Page 39 KMR 1250 B, LPG, D Troubleshooting Information Excessive Unit Dusting Check dust pickup – When sweeping on dry ground, the hatch (4) will be opened with the lever (8) to allow air to enter the impeller fan. – When sweeping on moist or wet ground, the hatch must be closed again to prevent mois- ture from entering the dust filter.
  • Page 40 Troubleshooting Information KMR 1250 B, LPG, D Excessive Unit Dusting Check seal on filter housing Up until S/N 10033, the seal was applied to the impeller fan inlet. Later, in an effort to improve seal effectiveness, it was attached to the filter housing.
  • Page 41 KMR 1250 B, LPG, D Troubleshooting Information Excessive Unit Dusting Adjust sealing lips / sealing strips in the sweeping area 10-20 mm The sealing lips and sealing strips serve essen- tial functions. They maintain the vacuum level in the sweeping area required for proper function- ing, ensuring dust-free sweeping operations at the same time.

  • Page 42: Filter Cleaning Motor - No Function

    Troubleshooting Information KMR 1250 B, LPG, D Filter cleaning Motor – No Function Check terminals (X 10 / X 11) in filter hous- Power for the filter cleaning motor is supplied via two spring-loaded contact terminals (1). With the debris container lowered, spring-load-...

  • Page 43: Hydraulic Unit - No Function

    KMR 1250 B, LPG, D Troubleshooting Information Hydraulic Unit – No Function Note: Troubleshooting may proceed with engine shut off. (60A) Check hydraulic unit Check F3 fuse. The F3 fuse protects only the hydraulic unit. It is located beneath the elec- trical box.

  • Page 44: Debris Container - Very Slow Ascent

    Troubleshooting Information KMR 1250 B, LPG, D Debris Container – Very Slow Ascent Check hydraulic unit By contamination within the hydraulic system, the debris container can no longer be raised after a brief operating period. The fine orifices in the hydraulic unit are blocked.

  • Page 45: Debris Container - No Full Ascent

    KMR 1250 B, LPG, D Troubleshooting Information Debris Container – No Full Ascent Adjust pressure relief valve Raise empty or full debris container to maximum attainable height (two-hand operation). In this position hold on the two buttons and measure the current draw of the hydraulic unit (see “tech- nical specification”).

  • Page 46: Excessive Steering Free Play

    Troubleshooting Information KMR 1250 B, LPG, D Excessive Steering Free Play Adjust steering free play Wear and tear and stretching of the steering chain (1) may cause excessive steering free play. If steering free play becomes too large, the steering...
  • Page 47 KMR 1250 B, LPG, D Troubleshooting Information...

  • Page 48: Hydraulic Block Diagram

    KMR 1250 B, LPG, D Hydraulic Block Diagram 0.087-964 through S/N 10441 ORIGINAL A, B Pressure connection, hydraulic unit R1/R2 Non-return valve Throttle valve Pipe-break valve Throttle valve Solenoid valve – Tilt debris container Solenoid valve – Raise/Lower debris Throttle valve...
  • Page 49 KMR 1250 B, LPG, D Hydraulic Block Diagram 0.088-234 from S/N 10442 REVISED A, B Pressure connection, hydraulic unit Non-return valve Throttle valve Pipe-break valve Pressure relief valve Throttle valve Solenoid valve – Tilt debris container Filler / purge screw Solenoid valve –...
  • Page 50 B/=SLP STVZO/2.1 10 qmm (rt) (15A) (60A) 2,5 qmm (rt/sw) 1,5 qmm 1 qmm 10 qmm 0,75 qmm (bl/sw) (rt/sw) (rt) (sw/rt) 15/50 (ge) -S10 30.1 1,5 qmm 1,5 qmm 1,5 qmm 16 qmm (rt/sw) (rt) (sw) (rt) 1 qmm (rt/bl) 2,5 qmm 1,5 qmm...

  • Page 51: Electrical Circuit Diagram

    KMR 1250 B, LPG, D Electrical Circuit Diagram 0.087-963 (KMR 1250 B) Filter cleaning control Detachable wiring connection Ignition Graphic symbol for wiring connection E1-E4 Headlights Vehicle earth/ground Fuse - Filter cleaning motor Female coupling (X1 connecting plug) Fuse - control voltage...
  • Page 52 10 qmm (rt) 2,5 qmm 1,5 qmm (rt/sw) (15A) (60A) (bl/sw) 1 qmm (rt/sw) (ge) 15/50 -S10 10 qmm -S11 30.1 (rt) 1 qmm 1,5 qmm 1,5 qmm 1,5 qmm 2,5 qmm 1,5 qmm 6 qmm (rt/bl) (rt/sw) (rt) (sw) (rt) (rt) 1 qmm...
  • Page 53 KMR 1250 B, LPG, D Electrical Circuit Diagram 0.088-151 (KMR 1250 LPG) Filter cleaning control Detachable wiring connection Ignition Graphic symbol for wiring connection E1-E4 Headlights Vehicle earth/ground Fuse - Filter cleaning motor Female coupling (X1 connecting plug) Fuse - control voltage...
  • Page 54 10 qmm (rt) 2,5 qmm (rt/sw) 1 qmm 1 qmm 1 qmm (rt/sw) (rt/sw) (rt/sw) 15A) (60A) 15/54 (br) (br) 1,5 qmm 1,5 qmm 2,5 qmm 1,5 qmm 1,5 qmm 1 qmm 5 qmm 10 qmm (rt) (rt/sw) (rt) (rt) (rt/sw) (rt/bl) (sw)
  • Page 55 KMR 1250 B, LPG, D Electrical Circuit Diagram 0.088-097 (KMR 1250 D) Filter cleaning control Detachable wiring connection Ignition Graphic symbol for wiring connection E1-E4 Headlights Vehicle earth/ground Fuse – Filter cleaning motor Female coupling (X1 connecting plug) Fuse - control voltage Male coupling (X1 connecting plug) Fuse –...

  • Page 56: Maintenance Procedures For B, Lpg & D Models

    KMR 1250 B, LPG, D Maintenance Procedures for B, LPG & D Models Täglich Daily 6 bar Wartung Maintenance KMR 1250 Wöchentlich Alle 100 h Weekly Every 20 mm Maintenance intervals Every 100 hours Maintenance procedures are performed at the –...

  • Page 57: Maintenance Procedures

    KMR 1250 B, LPG, D Maintenance Procedures for B, LPG & D (after operating hours) Maintenance procedures 1000 Engine oil - check Main drive belt tension - check Main drive belt - replace Engine air cleaner - clean / replace...

  • Page 58: Technical Specifications

    KMR 1250 B, LPG, D Technical specifications Service weight (operational) 420 kg Permitted gross weight 600 kg Length 1650 mm / 64.96 in Width 1000 mm / 39.37 in Height 1270 mm / 50 in Driving speed, forward, max. 7 - 8 km/h Driving speed, reverse, max.
  • Page 59 KMR 1250 B, LPG, D Technical specifications Engine, KMR 1250 B / LPG (P/N 6.491-573) Designation HONDA GX 270 Type 4-Stroke No. of cylinders Displacement 270 cm Drive belt engine, clearance with 20 N 3 - 8 mm / 0.12-0.32 in Operating speed 2.600 - 2.700 RPM...

  • Page 60: Special Tools

    KMR 1250 B, LPG, D Special Tools Ignition spark tester (for gasoline and LP gas engine) Remove spark plug connector from spark plug and push onto spark tester. Connect clamp to suitable conductor (e.g., engine cooling fins). If ignition is in good working condition, cranking engine with starter will produce visible sparks between points of spark tester.
  • Page 61 KMR 1250 B, LPG, D Special Tools Multimeter Multimeter must meet the following minimum re- quirements: – AC / DC measuring (amps, volts) – Diode test function – Resistance measuring (0-15 kΩ) P/N 6.803-022 Multimeter w/ test probes Magnetic field tester For testing magnetic fields on solenoid valves.

  • Page 62: Special Tools

    KMR 1250 B, LPG, D Special Tools CO tester Measures CO component in exhaust emissions. – Measuring range > 2% CO content – Resolution: 0.01% – Includes suction pump – LCD display CO Tester for LPG engine Dual-function hand pump For checking integrity of diaphragm in LP gas regulators (LP gas engines).

  • Page 63: Index

    Electrical Circuit Diagram 50, 51, 52, 53, 54, 55 input voltage 42 Engine 6, 10, 14, 15 oil level switch 19 KMR 1250 B 5 regulator 18 KMR 1250 B / LPG 59 rubber sleeve 37 KMR 1250 D 5, 59 seal 40 KMR 1250 LPG 5...
  • Page 64 KMR 1250 B, LPG, D Engine Runs but Machine Fails to Move 21, 22, 23, 24, 25 Leak detection spray 62 Excessive Steering Free Play 46 Lever Excessive Unit Dusting 37, 38, 39, 40, 41 brush roller 7 coarse-dirt flap 7...
  • Page 65 KMR 1250 B, LPG, D Replace brush roller 33 chain 46 dust filter 37 Side brush 6 Set CO value 28, 29 Operating RPM adjustment 27, 29, 31 Set engine operating speed 31 Side brush 15 Poor Sweeping Performance 36...

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Kmr 1250Kmr 1250 dKmr 1250 lpg

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