Kärcher KMR 1250 B, Service Manual

Page 1: ...5 905 262 09 02 KMR 1250 KMR 1250 B KMR 1250 LPG KMR 1250 D 1 091 Service Manual KARCHER KMR 2 5 0 1 KARCHER KMR 2 5 0 1 5 905 122 4 Stroke Internal Combustion Engines Service Manual 5 905 122...

Page 2: ...signed to serve as an essential reference in the future To augment our product related communications we regularly distribute service information bulletins providing details about ongoing product deve...

Page 3: ...Procedures gasoline and LPG engine 26 27 Maintenance Procedures LPG engine 28 29 Maintenance Procedures diesel engine 30 31 Parking Brake No Function 32 Brush Roller Poor Performance 33 34 Brush Roll...

Page 4: ...ver principle Debris container is located at rear of brush roller Two position adjustment of brush roller via control lever Center position Rigid brush roller suspension for level surfaces Bottom posi...

Page 5: ...s seat As the gasoline tank is discon nected its use is strictly prohibited The carburetor has been converted to LP gas operation The engine compartment accommodates an additional gas regulator requi...

Page 6: ...l 3 Driver seat 4 Lifting mechanism for debris container 5 Rear wheel chain driven 6 Fuel tank for KMR B D 7 Engine KMR B LPG D 8 LH side brush option 9 Front wheel 10 Head lights 11 RH side brush 12...

Page 7: ...ting hours counter 10 Button two hand operation hydraulic S5 11 Lever LH side brush Raise Lower option 12 Lever brush roller Raise Lower suspension rigid or floating 13 Lever RH side brush Raise Lower...

Page 8: ...re and idle air channel 7 Carburetor throat venturi 8 Idle air inlet 9 Choke valve 10 Main air jet 11 Idle system 12 Emulsion tube 13 Air orifice 14 Float chamber 15 Mainjet 16 Adjusting screw idle mi...

Page 9: ...e volume of air fuel mixture that is al lowed to flow through the idle orifice 5 Partial load operation Engine speed rises when the throttle valve 4 opens and the volume of the air fuel mixture being...

Page 10: ...seous state 8 LP gas in liquid state 9 Carburetor 10 Engine 11 Vacuum line 12 LP gas line 13 Gas filter 14 Solenoid valve gas supply 15 Mixture control screw MIN eng speed 16 Gas regulator 17 Choke li...

Page 11: ...ylinderareremovedbymeans of a small magnet Setting ignition key to Pos 1 ON opens so lenoid valve 14 allowing LP gas to flow from gas filter 13 into primary chamber of gas reg ulator 16 Here aspring l...

Page 12: ...ump 11 Cam shaft Injection system The injection pump 8 delivers fuel to the injec tor nozzle 5 via fuel line 6 The fuel is then injected into the combustion chamber above the engine piston 3 where the...

Page 13: ...on pump fails to deliv er fuel the entire injection pump assembly must be removed and checked Note Injection pump service and repair are the exclusivedomainofalicensedservicefacil ity Injector assembl...

Page 14: ...elt hydrostatic transmission 5 Hydrostatic transmission 6 LH drive chain 7 Brush roller 8 Drive belt brush roller 9 Drive belt LH side brush option 10 LH side brush option 11 Chain steering 12 RH side...

Page 15: ...3 Steering wheel 4 Operator seat 5 Debris container raised 6 Impeller fan 7 Dust filter Sweeping system 8 Rear wheel 9 Debris container lowered 10 Hydrostatic transmission 11 Brush roller 12 Coarse di...

Page 16: ...rom unit Check fuse F4 and wiring When the engine is running the battery receives a steady charge current from the alternator The fuse F4 15 A rating protects this circuit The fuse is located beneath...

Page 17: ...possible defect If a voltage is present but starter fails to turn starter is defective and must be replaced Note The connecting wiring for the starter sole noid are not shown in electrical diagram Che...

Page 18: ...ot be measured this indicates that the alternator is faulty and must be replaced Checking regulator charging current Starter Fails to Turn Engine Checking regulator charging current Check regulator RE...

Page 19: ...placed Heavilyfouledsparkplugsmustbereplaced Usingafeelergauge measureelectrodegap and bend electrodes to adjust as required To compress captive seal washer on new spark plug screw in plug hand tight...

Page 20: ...only Compression release lever diesel engine 4 2 1 3 5 6 7 Using Diesel fuel diesel engine Exceptionally low outdoor temperatures may cause diesel fuel to congeal In this condition fuel is no longer s...

Page 21: ...tion 1 Transmission engaged Position 2 Transmission disengaged Note It is important to prevent inadvertent disen gagement of the freewheeling lever Other wise no drive power can be applied and engine...

Page 22: ...e Thislimitmustbeobservedespeciallyinthe case of units licensed for road travel It is essential that the shaft mounted leg spring 6 securely rests against the dog pin 4 and stop pin 5 and that it does...

Page 23: ...sepedalsatequalanglesfromthehorizontal Twoadjustingscrews 5and6 beneaththedrive pedals limit pedal travel and at the same time determine the max drive speed see technical specifications Note These lim...

Page 24: ...is possible to adjusttheinclineofthehydrostatictransmission To this end the holding bracket 3 was provided with an elongated hole Loosen adjusting bolt 2 Positionhydrostatictransmissionsothatdrive bel...

Page 25: ...smission is in stalled Note The KMR 1250 is fitted with three different transmission shafts Owingtotheirdifferentpropertiesandphysi cal construction these transmissions are not interchangeable Part no...

Page 26: ...olume refer to Specifications Note Ensure environmentally safe disposal of used engine oil Clean air filter element When filter element is dirty replace the paper filter element 2 To clean filter elem...

Page 27: ...d LPG engine Clean sediment bowl Set fuel cock 2 to OFF position Removesedimentationcup 3 completewith O ring and wash out with nonflammable cleaner or inert cleaning solvent Allow to dry thoroughly t...

Page 28: ...nstrument panel to MIN position Idle speed shouldbebetween1250and1550RPM see also technical specifications Let engine warm up for a few minutes Using a floor jack raise front of unit and remove muffle...

Page 29: ...r stop screw 6 by applying sealing lacquer Check CO value inside muffler tailpipe Adjusting operating speed Setting CO value w mixture stop screw oper speed Using the mixture control screw idle speed...

Page 30: ...plug and allow engine oil to drain Securely replace oil drain plug Note Ensure environmentally safe disposal of used engine oil Fill engine with new oil For oil type and re quired volume refer to Spec...

Page 31: ...must be fixed by applying sealing lacquer Governor adjusting screw CAUTION Governor spring 6 must be hooked into hole on governor lever 3 exactly as shown Adjustingscrew 4 mustbefixedwith sealing lac...

Page 32: ...more than 5 to 10 mm 0 20 0 40 in Brake adjustment is accomplished with adjust ing nut 5 Starting with serial no 10600 a pull spring is installed on the operating lever 9 This ensures a more easy mov...

Page 33: ...erating lever lower brush roller to center position Swing RH side hatch 3 upward Remove safety bolt 2 at lower end of fork head A B and pivot rod toward the rear Turn knurled screw 3 counterclockwise...

Page 34: ...mm 0 60 in Modify sweeping pattern The sweeping pattern is modified by means of the central adjustment screw To increase pattern contact area Turn out adjusting screw counterclockwise To increase pat...

Page 35: ...ebelt 6 islocatedonthesmallersheave of the belt pulley 7 Loosen tension roller 2 remove drive belt 4 and brush roller arm 3 Loosen tension rollers 8 and 10 remove drive belt 9 Disconnect the drive bel...

Page 36: ...to this surface and set parking brake Lower side brush and allow to run for ap prox 15 to 30 seconds Continue by raising sidebrush backingsweeperofftestsurface The bottom position of the side brush is...

Page 37: ...rip 4 to original position and snap into place Install filter enclosure 3 and lock clip fas teners 2 Check rubber sleeve To prevent filter replacement problems caused by premature corrosion of the loc...

Page 38: ...coarse debris flap Whenthecoarsedirtflapisopen thebrushroller flings the dirt and dust away toward the front without sweeping it up The coarse debris flap 5 must open and shut easily If required clea...

Page 39: ...so that it cannot swing out inadvertently during travel in moun tainous terrain The control cable 3 for the hatch 4 is attached tothelever 6 Pressingtheleverbackwardwhile raising the debris container...

Page 40: ...on brush well rear view with raised container Checking tire pressure Check seals on brush well The three seals shown at left serve to seal off the brush roller well from the debris container The seals...

Page 41: ...to be drawn into the engine compartment and engine proper and enter the engine Replace older sealing lips with new lat eral sealing lips 4 They are cut differently at the back Check sealing lips at en...

Page 42: ...or input voltage Fuse F1 filter cleaning motor on A1 circuit board Filter cleaning Motor No Function Check input voltage at M3 filter cleaning motor Each time ignition switch is set to 0 position filt...

Page 43: ...not shown in the electri cal circuit diagram Check solenoid valves Y1 Y2 Measurements and Using the voltmeter check input voltage on solenoid valves Y1 and Y2 at connecting plug If voltage is present...

Page 44: ...separately 1 Hydraulic fluid filler neck Y1 Solenoid valve Tilt Container Y2 Solenoid valve Raise Lower Container Check hydraulic fluid When the unit is cold the use of nonstandard hydraulic fluid wi...

Page 45: ...ldvalveinsert 3 withwrench loosen lock nut 2 on valve adjusting screw Usingaflatscrewdriver turnadjustingscrew One half CW turn increases current draw by roughly 4 to 5 A approx 10 bar approx 145 psi...

Page 46: ...uts of mounting bolts 2 and tighten chain 1 by shifting steering column 3 in elon gated holes Retighten mounting nuts Replace chain Loosen nuts of mounting bolts 2 and shift steering column 3 in elong...

Page 47: ...47 KMR 1250 B LPG D Troubleshooting Information...

Page 48: ...lve D3 Throttle valve DB Pressure relief valve HP Hydraulic unit M2 Electric motor hydraulic unit P Hydraulic pump R1 R2 Non return valve RB Pipe breakvalve Y1 Solenoid valve Tilt debris container Y2...

Page 49: ...M2 Electric motor hydraulic unit P Hydraulic pump R Non return valve RB Pipe breakvalve S Throttlevalve Y1 Solenoid valve Tilt debris container Y2 Solenoid valve Raise Lower debris container Z1 Liftin...

Page 50: ...4 S4 2 5 E1 E3 X1 5 X1 1 X1 4 X1 6 M1 30 50a M X1 2 X1 3 15 15 50 12V 44 Ah 1 5 qmm rt 1 5 qmm bl sw 2 5 qmm rt sw 16 qmm sw 16 qmm rt rt gr 10 qmm rt 1 5 qmm sw 1 5 qmm rt X11 X10 K1 1 5 qmm sw 1 qmm...

Page 51: ...ontact S4 Switch Headlights S5 Button Hydraulics S6 Button Lower Container S7 Button Tilt Container S8 Button Raise Container S9 Oil level switch S10 Button Horn V1 V4 Diode X1 Plug 6 pin X10 11 Conta...

Page 52: ...30 II 0 I 0 1 15 50 10 qmm rt 30 1 50a 1 5 qmm bl sw S9 S3 ge X1 2 2 5 qmm rt sw S2 1 2 1 2 S5 V1 V2 V3 V4 1 5 qmm rt sw 1 2 S10 1 qmm rt sw 10 qmm rt H2 1 qmm rt bl rt bl rt bl 1 qmm rt bl S6 S7 S8 1...

Page 53: ...itch Headlights S5 Button Hydraulics S6 Button Lower Container S7 Button Tilt Container S8 Button Raise Container S9 Oil level switch S10 Button Horn S11 Button Choke V1 V4 Diode X1 Connecting plug 6...

Page 54: ...S1 50a 30 II 0 I 0 1 S4 1 2 4 5 S2 3 2 S8 4 5 G2 G P1 h F4 15A S6 1 2 4 5 Y1 1 2 S7 1 2 4 5 V2 V3 V4 V1 X1 44Ah K1 X11 X10 15 54 H1 3 6 gn rt sw rt br br ws 10 qmm 1 5qmm ge 1 5 qmm sw 1 5 qmm rt sw 2...

Page 55: ...r cleaning S3 Switch Seat contact S4 Switch Headlights S5 Button Hydraulics S6 Button Lower Container S7 Button Tilt Container S8 Button Raise Container S9 Button Horn V1 V4 Diode X1 Connecting plug 4...

Page 56: ...ter for damage Weekly by operator Check sealing lips in sweeping system for wear and proper adjustment Every 100 hours Check air cleaner filter for damage Change engine oil Checkbrushrollerandsidebrus...

Page 57: ...ydraulic system fluid level check O O O O O O O O O O Control cables all moving parts check for easy travel O O O O O O O O O O Unit drive system functions check forward reverse freewheeling O O O O O...

Page 58: ...1 95 in Main brush diameter 285 mm 11 22 in Main brush speed at engine operating speed 560 580 RPM Side brush diameter 450 mm 17 72 in Side brush speed at engine operating speed 57 63 RPM Coarse dirt...

Page 59: ...1 Displacement 270 cm3 Drive belt engine clearance with 20 N 3 8 mm 0 12 0 32 in Operating speed 2 600 2 700 RPM Idle speed 1 250 1 550 RPM Output 9 bhp at 3600 RPM 6 6 kW fuel tank capacity Diesel 6...

Page 60: ...hometer for gasoline LP gas and diesel engine Engine speed is determined by reading engine vibrations Tachometer is placed at suitable lo cation on engine e g valve cover When res onancespringisextend...

Page 61: ...volts Diode test function Resistance measuring 0 15 k P N 6 803 022 Spark plug wrench for gasoline and LP gas engine Unscrews spark plug from cylinder head P N 6 815 088 Magnetic field tester Magnetic...

Page 62: ...fea tures switchover valve to generate vacuum or pressure Pressure Vacuum mode P N 6 473 400 Leak detection spray for LP gas engines Indispensable when checking LP gas system for leaks P N 6 282 033...

Page 63: ...n switch 16 input voltage 42 oil level switch 19 regulator 18 rubber sleeve 37 seal 40 sealing lips 41 seat contact switch 19 solenoid valves 43 spark plug 19 starter M1 17 terminals 42 tire pressure...

Page 64: ...7 51 53 55 Impeller fan 14 15 39 Indicator lamp Headlights 51 53 55 Injection pump 13 Injection system 12 Injector assembly 13 L Leak detection spray 62 Lever brush roller 7 coarse dirt flap 7 dust p...

Page 65: ...Engine 16 17 18 Turns Engine but Engine Fails to Start 19 20 Steering 58 Steering and Drive Power 14 Steering wheel 6 14 15 Suction and filtering system 4 Sweeping mechanism 58 Sweeping pattern Check...