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KMR 1250 Service Manual - Cleaning Equipment Parts.com

1. etae ade radeon Er ON RU NS 10 11 Diesel Engine YANMAR L 70 AE DE nennen enint nennen 12 13 Steering and Re EE 14 Sweeping E T 15 Troubleshooting Information eccccceseeseeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeseeeeeeeeeeeeeeeees 4 15 Starter Falls to Turn Engine EE 16 18 Starter Turns Engine but Engine Fails to Start Ra 19 20 Engine Runs but Machine Fails to Move a 21 25 Maintenance Procedures gasoline and LPG engine sseeeeees 26 27 Maintenance Procedures LPG engine ue 28 29 Maintenance Procedures diesel engine ere renen erne 30 31 Parking Brake enee EE 32 Brush Roller Poor Performance ette ede deer d dents 33 34 Brush Roller NO R tfati r ME 35 Side Brushes Poor Sweeping Perflormancoe I 36 Excessive Unit DUSTING deer a a A RE E ARE ege beer lgd 37 41 Filter cleaning Motor No Function U EE 42 Hydraulic Unit No Function pa e E EE 43 Debris Container Very Slow ASOBID EE 44 Debris Container No Full Ascent erne 45 Excessive Steering Free Play SEENEN Eege ee 46 Hiydraulic Block Diagram sussie ze itus ence oca ux aep aa aD REC RE DAR apo boe AE EE EeEEdsebe 48 49 Electrical Circuit Dia
2. Continue to hold valve insert 3 with wrench loosen lock nut 2 on valve adjusting screw Usingaflatscrewdriver turn adjusting screw One half CW turn increases current draw by roughly 4 to 5 A approx 10 bar approx 145 psi Finish by tightening lock nut on adjusting screw again installing screw cap 1 Install hydraulic unit Perform function test and measure current draw Hydraulic unit adjust pressure relief valve Remove hydraulic unit but do not discon nect hydraulic hoses Remove screw cap 4 Cap conceals ad justing screw 5 Using a stubby screwdriver turn adjusting screw One half CW turn increases current draw by roughly 4 to 5 A approx 10 bar approx 145 psi Finish by installing screw cap 4 Install hydraulic unit Perform function test and measure current draw Cap Lock nut Valve insert Screw cap Adjusting screw O Go N 45 Troubleshooting Information Excessive Steering Free Play Adjusting steering free play 1 Steering chain 2 Mounting bolts w nuts 3 Steering column shaft inside 46 KMR 1250 B LPG D 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 chain must be tighted replaced as required Tighten steering chain Loosen nuts of mounting bolts 2 and tighten chain 1 by shifting st
3. HP Z2 AAA i RB O B A 2 wiel P mn XD S DB Pressure connection hydraulic unit Throttle valve Pressure relief valve Filler purge screw Filter Hydraulic unit Electric motor hydraulic unit Hydraulic pump R HB Y1 Y2 Zi Non return valve Pipe break valve Throttle valve Solenoid valve Tilt debris container Solenoid valve Raise Lower debris container Lifting cylinder Tilting cylinder w gas strut damper 49 OGS e e e B SLP STVZO 2 1 10 qmm T t F4 i F3 O 15A 60A 5 D e K 2 5 qmm rt sw Y V1 1 5 qmm 0 75 qmm 1 qmm 10 qmm 2 a 2 sw rt Y v2 rt sw rt 50a 15 50 15 ge b X1 V V3 1 e EE Ree 810 D ovv S9 zi S3 R7 A Y v4 Sp 30 30 1 Oe HL S L 1 5 qmm S1 1 5 qmm 16 qmm rt ay oy rt sw 3 rt A2 3 111614 1 qmm RA rt bl Q 2 5 qmm 1 5 qmm 285 e e N rt rt H1 amm co rt o 94 rt bl rt bl G G1 IL 3 1 5 qmm 1 1 4 4 l T ge i S2 S6 Ah N A g eil js a E m ke
4. 10 qmm Checking voltage on hyaraulic unit Troubleshooting Information Note Troubleshooting may proceed with engine shut off Check hydraulic unit Check F3 fuse The F3 fuse protects only the hydraulic unit It is located beneath the elec trical box Using avoltmeter check input voltage of M2 hydraulic unit between thick red cable pos itive polarity 10 sq mm cross section and matching black cable negative polarity Using the voltmeter check input voltage on motor relay Perform measurement with ig nition switch set to position l With buttons S5 and S8 actuated control voltage must be present at relay If measurements removed components and produce a voltage reading but hydraulic motor is not running the hydraulic unit is defective and must be replaced Note The wiring connections between relay and hydraulic motor are not shown in the electri cal circuit diagram Check solenoid valves Y1 Y2 Measurements and 9 Using the voltmeter check input voltage on solenoid valves Y1 and Y2 at connecting plug If voltage is present solenoid valves will switch with an audible click If there is no voltage present check power sup ply vehicle ground connections and both but tons S5 and S8 for proper functioning The solenoid valves are not available as spare parts If a defect is found the entire hydraulic assembly must be replaced F3
5. Note The connection on cylinder shutoff valve 3 must face straight up extraction of LP gas in gaseous state Carburetor in LP gas operation example Unit Functions The presence offrost on any part of the LP gas system indicates a possible leak Close the cylinder shutoff valve 3 immediately Apply suitable leak detection medium soapy water or Leak Detecting Spray 6 282 033 to gas lines solenoid valve gas regulator and gas hose to carburetor Open cylinder shutoff valve 3 and check for formation of bubbles The unit may be returned to service only after thor ough repairs have been carried out by ap proved specialists Note The LP gas system of the unit must be in spected by a licensed expert in 6 month intervals The results of each inspection must be made available in the form of a test cer tificate An expertis deemed to be a person who based on his professional education and skills pos sesses sufficient knowledge of and expertise in the field of LP gas systems and who is sufficiently familiar with applicable working directives and accident prevention regulations as well as commonly accepted procedures of this technology all of the above enabling him to evaluate determine and assess the safe operational state of LP gas systems Note For information on other maintanance and adjustments of the engine refer to the Serv ice manual 4 Stroke Internal Combus
6. 2 700 RPM Idle speed 1 250 1 550 RPM Output 9 bhp at 3600 RPM 6 6 kW fuel tank capacity Diesel 6 Engine oil capacity SAE 15 W 40 1 1 I Battery maintenance free 12V 44 Ah Starter electrical Hydraulic unit Class hydraulic fluid DIN HVLP 51524 2 Type hydraulic fluid HV 46 System capacity 1 5 Protection category splash water protected Current draw hydraulic motor max 70 A Current draw of 70 A permits lifting container loadoff approx 105 115 kg Noise level Measured in accordance with DIN 45 635 T36 and DIN 45648 standards at operating speed of 2700 RPM subjective reading at operator position is 79 5 dB A 59 Special Tools Digital tachometer for gasoline and LP gas engine 60 KMR 1250 B LPG D 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 P N 6 491 359 Mechanical tachometer 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 onance spring is extended until deflection is larg est with engine running scale indicates engine speed P N 6 491 361 Digital tachometer for gasoline
7. 7 in the filter receptacle a rubber sleeve 9 was in stalled on units with S N 10518 and up Defective or missing rubber sleeve 9 should be replaced or retrofitted refer to service bulletin no 1998 045 Debris container Filter enclosure clip fasteners Filter enclosure Hand grip 5 6 Replace dust filter Locator pin Compression spring Rubber sleeve Q NN CO CON 37 Troubleshooting Information Excessive Unit Dusting Coarse debris flap in open position 1 2 3 4 5 6 7 5 38 Seal ring Flange assembly Welded ring mating rim for seal ring Retainer control cable Coarse debris flap Adjusting screw coarse debris flap Control cable Sheet metal guard KMR 1250 B LPG D 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 Pull off seal ring 1 check and replace as required To seal the openings apply silicon sealer around the entire circumference outside the welded ring 3 Replace seal ring 1 ensure proper seat ing Check coarse debris flap When the coarse dirtflap is open the brush roller 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
8. 9 This ensures a more easy movement of the brake when the operating lever 9 is actuated Wire and casing cable Brake caliper Brake piston Brake pulley Adjusting nut Brake lever Pull spring Pull spring Operating lever parking brake Pull spring OO o Jo Oo ON l CH KMR 1250 B LPG D Brush Roller Poor Performance Removing brush roller arm Extracting brush roller Brush roller installed position Arrow points FWD Troubleshooting Information 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 Check control cables The combination of excessive strains at deflec tion pulleys and repeated road soiling exert con siderable stresses on mechanical control cables If required check cable routing clean cables and lubricate with new grease P N 6 288 107 Replace brush roller Stop and park the machine engage parking break Using the operating 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 Remove brush roller arm 4 Open turn lock latch 5 and swing hinged brush roller hatch toward front of unit Extract
9. Controls 7 D Debris Container No Full Ascent 45 Very Slow Ascent 44 Debris container 58 Debris container lowered raised 15 Descent stop valve 49 Diesel Engine YANMAR L 70 AE DE 12 13 Diesel fuel 20 Digital tachometer 60 Diode 51 53 55 Drive belt brush roller 14 hydrostatic transmission 14 LH side brush 14 RH side brush 14 impeller fan 14 drive chain RH 14 Drive pedal 7 Drive shaft 12 Drive system 4 Driver seat 6 Driving and sweeping data 58 Dual function hand pump 62 Dust filter 15 E Electric motor hydraulic unit 48 49 Electrical Circuit Diagram 50 51 52 53 54 55 Engine 6 10 14 15 KMR 1250B 5 KMR 1250 B LPG 59 KMR 1250 D 5 59 KMR 1250 LPG 5 63 Engine Runs but Machine Fails to Move 21 22 23 24 25 Excessive Steering Free Play 46 Excessive Unit Dusting 37 38 39 40 41 F Filter 49 Filter cleaning control 51 53 55 Filter cleaning motor 51 53 55 No Function 42 Flange 13 Float chamber equalization 9 Float system 9 Front wheel 6 15 Fuel feed line 12 13 Fuel tank for KMR B D 6 Full load operation 9 Fuse 58 Alternator 51 53 55 control voltage 51 53 55 Filter cleaning motor 51 53 55 Hydraulic unit 51 53 55 G Gas cylinder LP Gas 6 Gas regulator 11 Gas system 11 Gasoline Engine HONDA GX 270 8 9 H Head lights 6 Headlight switch 7 Headlights 51 53 55 HONDA GX 270 5 Horn 51 53 55 Hydraulic Block Diagram 48 49 Hydraulic Unit No Fu
10. clean the control cable 7 and lubricate with new grease P N 6 288 107 or spray in with teflon spray P N 6 288 125 When opened the gap of the coarse debris flap 5 should be at least 40 mm 1 58 in wide In its lowered state it should trail by approx 10 to 20 mm 0 40 0 80 in The coarse debris flap 5 is adjusted with the adjusting screw 6 Note Ifthe coarse debris flap trails excessively it may get caught in the brush roller When replacing the control cable 7 care must be taken that the retainer 4 remains in the orig inal horizontal position This prevents the coarse debris flap from being pulled inward again after a short while breaking the control cable as a result To straighten out the retainer 4 orto access the adjusting screw 6 the sheet metal guard 8 must be removed KMR 1250 B LPG D Excessive Unit Dusting M Pd Lever dust pickup close open Troubleshooting Information 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 When the sweeping debris container is raised it also automatically closes the hatch 4 This prevents dustor objects to be drawn into the large open intake opening 7 in this state The righ
11. every 1000 hours Refer to table on opposite page KMR 1250 B LPG D Maintenance Procedures for B LPG amp D after operating hours Maintenance procedures 8 100 200 200 400 soo 600 700 aoo eno 1000 Engine ol check LO o EN o EN c EN co HEM oc EN Main drive bettersion check 8 o i o NONI o Eo o NON o NEN Main drive bot replace SS E Si o e j Engine air cleaner oean repce O o o o o o o o o 0 Drive chains px for wear and tension Cooling air intake check seal air intake check seal Spark plugs check clean B and LPG only Spark plugs replace B and LPG only relsedinertcap cenow o o o o o o LP gas cylinder check connect ion must point up LPG only LP gas system check for leaks LPG ends Tire pressure check pressure check e a E E E E menssen ojojoj olojo olooto Control cables amp all moving parts check for easy travel Unit drive system functions check forward reverse rS R Parking brake function check brake function check s ER ER E EE o o o o o o 9 o 9 occ KS KS KS K EE Dust filter check Dust fiter check replace Sealing strips in sweeping system check for adjustment amp wear Soa ER E3 BB EE Brush roller amp side brushes check roller amp side brushes check Sweeping pattern main brush roller amp side brushes check Pease of ol oo of o o o o o_
12. it was attached to the filter housing With the filter housing lowered the seal must reliably seal off the transition to the housing 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 must be replaced as required Check impeller fan drive belt The drive belt see page 14 pos 3 is elastic and cannot be adjusted Replace belt as required Check tire pressure A too low tire pressure causes a sinking of the sealing lips and sealing strips and thus a worse sweeping result See Specifications for tire pressures KMR 1250 B LPG D Excessive Unit Dusting Sealing lips air intake Troubleshooting Information Adjust sealing lips sealing strips in the sweeping area 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 Damaged or worn sealing lips sealing strips must be replaced The front sealing lip 1 cannot be adjusted If worn it should be replaced as soon as possible Adjustlateral sealing strips 3 to provide a ground clearance of approx 1 to 3 mm 0 04 0 12 in Adjustrear sealing lip 4 with an afterrunning clearance of approx 10 to 20 mm 0 40 0 80 in Note Always consider the weight of the driver when
13. 1 5 qmm 1 qmm 15 ge GH ge Mu m 16 qmm Y e sw X1 X1 2 5 qmm swiws E1 O E3 O rt CU 30 50a 11 0 75 qmm 0 75 qmm i Pi eism us EN 1 1 s E2 X EA x zau M1 G2 ui i 1 5 qmm Y2 Y1 N M2 io od X1 sw 3 10 qmm sw gr i Note Unmarked wiring has cross section of 75 sq mm a 5d1 g 0S2L HIN KMR 1250 B LPG D Electrical Circuit Diagram 0 087 963 KMR 1250 B Ai A2 E1 E4 F1 F2 F3 F4 G1 G2 Hi H2 K1 Mi M2 M3 P1 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 V1 V4 xi X10 11 Yi Y2 Filter cleaning control Ignition Headlights Fuse Filter cleaning motor Fuse control voltage Fuse Hydraulic unit Fuse Alternator Battery Alternator Indicator lamp Headlights Horn Relay filter cleaning motor Starter Hydraulic unit Filter cleaning motor Operating hours counter Ignition switch Button Filter cleaning Switch Seat contact Switch Headlights Button Hydraulics Button Lower Container Button Tilt Container Button Raise Container Oil level switch Button Horn Diode Plug 6 pin Contacts Filter cleaning motor Solenoid valve Tilt debris container Solenoid valve Raise Lower debris container O L A bl bn ge gr gn rt or rs sw WS Detachable wiring connection Graphic symbol for wiring connection Vehicle earth ground Female coupling X1 connecting plug Male coupling X1 connecting
14. Fuse hydraulic unit M2 Hydraulic unit S5 Button Two Hand Operation S6 Button Lower Debris Container S7 Button Tilt Debris Container S8 Button Raise Debris Container Y1 Solenoid valve Tilt Debris Container Y2 Solenoid valve Raise Lower Container 43 Troubleshooting Information KMR 1250 B LPG D Debris Container Very Slow Ascent Hydraulic unit Bleeding purging air from lifting cylinder 44 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 As the hydraulic unit is maintenance free and should not be opened It must be replaced as an assembly if required With the debris container lowered the hydraulic fluid level should be approx 2 to 3 cm 0 80 1 18 in below the edge of the filler neck Note Extremely clean working conditions and work habits are a prerequisite for working on the hydraulic system After a replacement all hydraulic system com ponents automatically purge themselves when the raising mechanism is actuated repeatedly As aresult only the lifting cylinder must be purged 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 will cause the debris container to be rais
15. brush roller 6 Turn brush roller adjustment screw clock wise until seated Install new brush roller then replace brush roller arm Note Groundclearance of raised brush roller must be at least 10 mm 0 40 in Side hatch Safety bolt Knurled screw Brush roller arm Turn lock latch for hinged brush roller hatch 6 Brush roller OD Go NN 33 Troubleshooting Information Brush Roller Poor Performance Modifying sweeping pattern Setting sweeping pattern 34 KMR 1250 B LPG D 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 Raise brush roller and with coarse debris hatch open reverse a few feet Note Sweeping pattern width should be between 30and50 mm 1 18 1 97 in Parallel devia tion should be less than 15 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 pattern contact area Turn in adjustment screw clockwise Set correct sweeping pattern A wedge shaped sweeping pattern may be set by adjusting brush roller suspension on the fork head 1 This may be accomplished by manip ulating the fork head on either left hand or ri
16. clearance of raised side brush must be approx 10 to 15 mm 0 40 0 60 in LT Note The side brush must be easily moved down and up by means of the control lever When operating it extends approx 15 cm 5 9 in beyond the machine footprint with exten sion radius limited by a chain 1 Chain Deflection pulley Control cable Control cable adjustment ground clear ance Drive belt Intermediate shaft Stop screw contact pressure Side brush Q N D Jo 01 Checking sweeping patterns 36 KMR 1250 B LPG D Excessive Unit Dusting Lifting filter box Replacing dust filter ORIGINAL REVISED Installing rubber sleeve Troubleshooting Information 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 Unsnap clip fasteners 2 on filter enclosure Swing filter enclosure 3 forward then lift off Unfold hand grip 4 pull out and unlock by means of a 90 degree turn Remove old dust filter 5 Insert new dust filter 6 Return hand grip 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 locator pin
17. re quired volume 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 element blow through with compressed air from the inside out or firmly tap on hard surface to dislodge caked on dust Do not brush off because this would press dust particles into paper fibers Wash foam ring 2 with a mild solution of house hold detergent Rinse thoroughly and allow to dry Immerse foam insert in clean engine oil and squeeze to remove excess Oil If too much oil is allowed to remain in foam insert the engine will smoke while running 1 Foam ring 2 Paper element 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 A A AH 7 NS Adjusting engine operating speed Clean sediment bowl Set fuel cock 2 to OFF position Remove sedimentation cup 3 complete with O ring and wash out with nonflammable cleaner or inert cleaning solvent Allow to dry thoroughly then install and tighten securely Set fuel cock 2 again to OPEN position Check for possible leaks around sedimenta tion cup Note Ensure t
18. seat contact switch must be jumpered Jumper must again be removed once en gine has started Using Diesel fuel diesel engine Exceptionally low outdoor temperatures may cause diesel fuel to congeal In this condition fuel is no longer supplied to the engine To prevent this condition occurring add vis cosity agents winterized diesel fuel or dena tured alcohol to the tank before cold weath er sets in Ifthe fuel congeals replace fuel tank content with winterized diesel fuel or add viscosity agents Continue by allowing the power sweeper to warm up in a cold environment with engine idling Fuel filter diesel engine only Oil filler neck Lever compression release Injector line Injector Tank filler cap Seal ring Fuel filter NOOR Go M 20 KMR 1250 B LPG D Engine Runs but Machine Fails Freewheeling lever on transmission Troubleshooting Information 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 applying a force of 2 kg 20 N to the center of the longest span Replace drive belt as required ensuring thatten sion roller has first been relaxed Check freewheeling function The transmission features a freewheeling lever which can be used to engage or disengage t
19. suspension rigid or floating Lever RH side brush Raise Lower Throttle lever Button horn S10 Ignition switch S1 Choke Drive pedal GI ang brave 13 14 15 16 17 18 Function available only in conjunction with two hand operation button 10 See circuit diagram Unit Functions KMR 1250 B Gasoline Engine HONDA GX 270 21 20 19 18 17 16 5 15 14 1 Stop screw throttle valve 12 Emulsion tube 2 Idlejet 13 Air orifice 3 Bypass 14 Float chamber 4 Throttle valve 15 Main jet 5 Idle orifice 16 Adjusting screw idle mixture 6 Idle jet bore and idle air channel 17 Fuelinlet 7 Carburetor throat venturi 18 Inlet float valve 8 Idle air inlet 19 Float 9 Chokevalve 20 Float valve w float needle 10 Main airjet 21 Float 11 Idle system KMR 1250 B Gasoline Engine HONDA GX 270 Float system When float chamber 14 is empty fuel passes from fuel tank into float chamber 14 viathe float valve inlet 18 The rising fuel level causes the float 21 to be raised The inflow of fuel is interrupted when the float 21 causes the float valve to close Drawing fuel for engine operation from the float chamber 14 causes the float 21 to be lowered which in turn opens the float valve 18 This cyclical procedure ensures a constant level of fuel inside the float chamber 14 Float chamber equalization On the carburetor side the airspace inside the float housing is connected with the outs
20. 5 LP gas cylinder 14 Solenoid valve gas supply 6 Sun shield 15 Mixture control screw MIN eng speed 7 LP gas in gaseous state 16 Gas regulator 8 LP gas in liquid state 17 Choke lifting solenoid 9 Carburetor 18 Mixture control screw MAX eng speed 10 KMR 1250 B LPG D LP Gas Engine HONDA GX 270 Gas system Opening the shutoff valve 3 on the LP gas cylinder 5 causes gas to flow through the gas filter 13 At this point possible contaminants are trapped in a paper filter and metallic par ticles from gas cylinder are removed by means 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 loaded valve reduc es gas pressure to approximately 150 mbar 2 2 psi When starter begins to crank engine 10 a vacuum is created in the suction channel Through vacuum line 11 this vacuum acts onlow pressure diaphragm in secondary stage of gas regulator Diaphragm opens low pres sure valve and gas can be drawn into engine Pressing choke button causes choke lifting solenoid 17 to open low pressure valve al lowing gas to flow directly through carburetor and into engine This function is particularly important in cold starting situations To pre vent high level enrichment of intake mixture with LP gas choke button should not be pressed for longer than 3 5 seconds
21. 50 B LPG D Sweeping system Hydraulic unit Engine B LPG D Steering wheel Operator seat Debris container raised Impeller fan Dust filter O oR G M Unit Functions 10 11 12 13 14 Rear wheel Debris container lowered Hydrostatic transmission Brush roller Coarse dirt flap Front wheel Side brush 15 Troubleshooting Information Starter Fails to Turn Engine Fuse F4 in electrical box Checking ignition switch S1 while removed from unit 16 KMR 1250 B LPG D 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 A1 Circuit board F1 Fuse motor filter cleaning 10 A F2 Fuse control voltage 7 5 A Check battery voltage Check battery voltage with voltmeter Check electrolyte level on low maintenance battery If required recharge battery using external battery charger e g P N 6 654 046 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 the electrical box Check fuse and replace as required Check all wiring and connections between alternator and battery F4 Fuse generator Check ignition switch S1 Remove screws oninstrument panel 2 and carefully li
22. KARCHER Service Manual KMR 1250 KMR 1250 B KMR 1250 LPG KMR 1250 D 1 091 5 905 262 09 02 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 In addition we produce service manuals for the major units in our product line While these are ideal for initial use as instruction manuals they are designed 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 development Copyright Notice Copyright 2002 by Alfred K rcher GmbH amp Co All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means i e electronic mechanical photocopying recording or otherwise without the written permission of Alfred K rcher GmbH amp Co ALFRED K RCHER GmbH amp Co Customer Service Training P O Box160 71349 Winnenden Germany http www karcher de KMR 1250 B LPG D Table of Contents Contents Unit le E 4 15 RE 4 5 View from EOI E 6 edel 7 Gasoline Engine HONDA GX 270 tn E Prem tpe eer en dere 8 9 LP Gas Engine HONDA GX 270
23. S9 S10 S11 V1 V4 xi X10 11 Yi Y2 Y3 Y4 Filter cleaning control Ignition Headlights Fuse Filter cleaning motor Fuse control voltage Fuse Hydraulic unit Fuse Alternator Battery Alternator Indicator lamp Headlights Horn Starter Hydraulic unit Filter cleaning motor Operating hours counter Ignition switch Button Filter cleaning Switch Seat contact Switch Headlights Button Hydraulics Button Lower Container Button Tilt Container Button Raise Container Oil level switch Button Horn Button Choke Diode Connecting plug 6 pin Contacts Filter cleaning motor Solenoid valve Tilt debris container Solenoid valve Raise Lower debris container Solenoid valve Fuel shutoff valve Choke lifting solenoid Detachable wiring connection Graphic symbol for wiring connection Vehicle earth ground Female coupling X1 connecting plug Male coupling X1 connecting plug blue brown yellow grey green red orange rose pink black white 53 vs 10 qmm rt 3 qmm PT 2 5 qmm F4 rt sw 15A 50a 15 54 o Lou uM N 30 S1 e 1 5 qmm 1 5 qmm 2 5 qmm 1 5 qmm rt rt sw rt ke rt mr 1 5 qmm rt ge X4 X5 F1 F2 I A1 10A 7 5A K1 S2 X1 X2 X3 X6 AN 2 5 qmm 2 5 qmm 2 5 qmm rt gr px T gn ws sw ge rt gr sw T I Ee Me A 0 ws Ton I 30 50a L rt
24. and LP gas engine From a distance of approx 100 mm 4 in point this digital tachometer at spark plug wire and switch on tester Set to 4 Stroke 4 Taktmotor position to read speed of running engine P N 6 803 012 KMR 1250 B LPG D Special Tools Spark plug wrench for gasoline and LP gas engine Multimeter Multimeter must meet the following minimum re quirements AC DC measuring amps volts Diode test function Resistance measuring 0 15 kQ P N 6 803 022 Magnetic field tester For testing magnetic fields on solenoid valves P N 6 803 003 Spark plug wrench for gasoline and LP gas engine Unscrews spark plug from cylinder head P N 6 815 088 61 Special Tools Dual function hand pump CONOS COLC Leak detection spray 62 a ge KMR 1250 B LPG D CO tester Measures CO component in exhaust emissions Measuring range gt 2 CO content Resolution 0 0196 Includes suction pump LCD display Dual function hand pump For checking integrity of diaphragm in LP gas regulators LP gas engines Hand pump 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 KMR 1250 B LPG D Index A Adjust hydrostatic transmission 24 parkin
25. cushion switch contacts are closed Adjust or replace seat contact switch as re quired Check spark plug gasoline and LPG engine If ceramic insulator shows signs of break age of cracking spark plug mustbe replaced Heavily fouled spark plugs mustbe replaced Usingafeeler gauge measure electrode gap and bend electrodes to adjust as required To compress captive seal washer on new spark plug screw in plug hand tight then tighten 1 2 turn Tighten used spark plugs only by 1 8 to 1 4 turn Check oil level switch S9 gasoline and LPG engine In the event that the engine oil level drops down too far the oil level switch cuts out the ignition This causes the engine to stall and will prevent engine restarts Remove the terminal of the yellow wire Using the ohmmeter check the connecting terminal for continuity Ifthe oil level is sufficiently high there will be no continuity If the oil level is too low there must be con tinuity Top up engine oil or replace oil level switch as required 19 Troubleshooting Information KMR 1250 B LPG D Starter Turns Engine but Engine Fails to Start Check compression release lever diesel engine Engineis 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 Note To enable engine to start with hood open
26. doing setup work On original units the lateral sealing lips 3 were cut in such a way that a gap existed between these and the rear sealing lip 4 It provided access for fine dust 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 engine air intake Together the sealing lip 6 and 7 on the air channel carburetor and the seal on the air chan nel blower provide dust free air to be drawn into the engine The cross section of the sealing lip 6 and 7 on the air channel carburetor was optimized Seal ing strip must be checked for the new cross section and possible damage and must be re placed as required The seal 8 on the air channel carburetor must be checked for damage and deformation and replaced as required 1 Front sealing lip Lateral sealing strip Lateral sealing strip Rear sealing lip Direction of motion Sealing lip IR air channel carbure tor Sealing lip EEE air channel carbure tor 8 Seal air channel blower OO oh N 41 Troubleshooting Information Filter cleaning Motor No Function Fuse F1 filter cleaning motor on A1 circuit board 42 KMR 1250 B LPG D Check terminals X 10 X 11 in filter hous ing Power for the filter cleaning motor is supplied via t
27. drostatic 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 Transmission thru S N 10366 Note The KMR 1250 is fitted with three different transmission shafts Owing to their different properties and physi cal construction these transmissions are not interchangeable Part no Serial no Features 6 454 074 thru 10336 1 pedal 6 454 088 10337 thru 11481 2 pedals 6 454 116 11482 and up slanted installation REVISED Transmission serial no 11482 and up 25 Troubleshooting Information KMR 1250 B LPG D Maintenance Procedures gasoline and LPG engine Air cleaner w foam insert and paper element 26 Note For operating and maintenance instructions consultthe 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 Thedipstick hole is used to add new oil to the engine For oil type and required volume check unit Specifications Change engine oil Place a suitable catch tray beside the unit While holding oil drain hose in catch tray remove oil plug and allow engine oil to drain Securely replace oil drain plug Fill engine with new oil For oil type and
28. e 7 Injection timing is determined by the thickness and number of shims 2 in shim pack Note Checking injection timing and related fine adjustment are the exclusive domain of a licensed service facility In the event that the injection pump fails to deliv er fuel the entire injection pump assembly must be removed and checked Note Injection pump service and repair are the exclusive domain of alicensed service facil ity Injector assembly The fuel that is conveyed to the injector by the injection pump is transported through the feed channel 14 pastthe nozzle valve 13 and then sprayed into the engine combustion chamber Pump piston Shim pack Flange Fuel inlet Pressure valve holder Valve spring Pressure valve Housing injection pump Piston spring 10 Holder piston spring 11 Housing injector 12 Valve spring 13 Nozzle valve 14 Fuel feed line OO o Jo Oo ON 13 Unit Functions Steering and Drive Power OO OO Jo Oo ON 14 RH drive chain Impeller fan Drive belt impeller fan Drive belt hydrostatic transmission Hydrostatic transmission LH drive chain Brush roller Drive belt brush roller Drive belt LH side brush KMR 1250 B LPG D 10 11 12 13 14 15 option LH side brush option Chain steering RH side brush Drive belt brush roller Drive belt RH side brush Steering wheel Engine KMR 12
29. e the max drive speed see technical specifications Note This limit must be observed especially in the 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 not slip past these two limiters check intermediate plate 3 With the drive pedal at center position and with the parking brake released the unit may move neither forward nor backward The drive pedal must travel without jerking or binding Note All adjusting screws must be fixed with seal ing lacquer 22 KMR 1250 B LPG D Troubleshooting Information Engine Runs but Machine Fails to Move Adjusting drive pedals 1 2 3 4 5 6 23 Transmission Drive pedal linkage Pull spring Shift lever Adjusting screw FWD drive Adjusting screw REV drive Checking drive pedal 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 When at the center position the drive pedals should be adjusted so that the forward and re verse pedals at equal angles from the horizontal Two adjusting screws 5 and 6 beneath the drive pedals limit pedal travel and at the same time determine the max drive speed see technical specifications Note These limi
30. ed KMR 1250 LPG Troubleshooting Information Maintenance Procedures LPG engine Setting CO value w mixture stop screw oper speed Solenoid valve Gas regulator Mixture control screw idle speed Carburetor stop screw Mixture control screw operating speed N O O Go 2 Set CO value at operating speed Setaccelerator 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 hasto be between 2600 and 2700 RPM see also technical specifications With adjustment completed fix carburetor stop screw 6 by applying sealing lacquer Check CO value inside muffler tailpipe Using the mixture control screw idle speed 7 operating speed set CO value on gas regulator 4 nominal CO value is 0 5 Withthe correct adjustment engine mustrun smoothly and quietly and provide reliable starting With adjustment completed fix mixture con trol screw 7 by applying sealing lacquer 29 Storungshilfe 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 oillevel mustbe between the MIN and MAX markings on the dipstick Top up engine oil Thedipstick hole is used to add new oil to the engine Foroiltype and required volume refer to Specifications C
31. ed only very slowly The correct choice of hydraulic fluid see Spec ifications facilitates working at temperatures to 10 C 14 F without difficulty Purge lifting cylinder Raise container to the top position and sup port to prevent inadvertent descent Press Raise Container button again while at the same time cracking the purge screw on the lifting cylinder When all air has escaped andhydraulicfluid exits without bubbles tight en purge screw Wipe up hydraulic fluid runoff and check flu id level in reservoir DANGER FATAL INJURY HAZARD Raised container must be reliably supported while personnel is working underneath KMR 1250 B LPG D Debris Container No Full Ascent ORIGINAL Hydraulic unit w pressure relief valve REVISED Adjusting pressure relief valve Troubleshooting Information 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 The current draw provides a measure of the opening pressure set on the pressure relief valve Hydraulic unit adjust pressure relief valve Remove hydraulic unit but do not discon nect hydraulic hoses Holding valve insert 3 with wrench unscrew cap of pressure relief valve 1 The cap conceals the valve adjusting screw
32. eering column 3 in elon gated holes Retighten mounting nuts Replace chain Loosen nuts of mounting bolts 2 and shift steering column 3 in elongated holes far enough to allow removal of steering chain 1 Install new steering chain ensuring that front wheel points straight ahead when steering wheel is in center non deflected position Tighten chain 1 by shifting steering column 3 in elongated holes Retighten mounting nuts KMR 1250 B LPG D Troubleshooting Information 47 KMR 1250 B LPG D Hydraulic Block Diagram 0 087 964crmm through S N 10441 A B D1 D2 D3 DB HP M2 48 HP Y1 Z1 Z2 AAA r2 bas on ps B A e R1 Y2 Tiley DB Pressure connection hydraulic unit Throttle valve Throttle valve Throttle valve Pressure relief valve Hydraulic unit Electric motor hydraulic unit Hydraulic pump R1 R2 RB Y1 Y2 Zi Non return valve Pipe break valve Solenoid valve Tilt debris container Solenoid valve Raise Lower debris container Lifting cylinder Tilting cylinder w gas strut damper KMR 1250 B LPG D Hydraulic Block Diagram 0 088 234G8 5 from S N 10442 A B DB HP M2 Z1
33. er tension at spring at hydrostatic drive Impeller fan vacuum with closed suction hose 58 KMR 1250 B LPG D 420 600 1650 1000 1270 7 8 4 6 18 750 1000 1300 80 1400 6 105 115 10 15 10 30 50 285 560 580 450 57 63 50 10 20 1 3 10 20 300 4 00 4 6 6 44 10 7 5 60 15 EI 5 5 10 10 12 kg kg mm 64 96 in mm 39 37 in mm 50 in km h km h 96 mm 29 53 in mm 39 97 in mm 51 18 in mm 55 12 in m2 kg sec mm 0 39 in mm 1 17 1 95in mm 11 22 in RPM mm 17 72 in RPM mm 1 95 in mm 0 39 0 78 in mm 0 04 0 12 in mm 0 39 0 78 in mm 11 81 in GPR bar 87 psi bar 87 psi Nm A A A A mm 0 20 0 39 in mbar 0 1 0 2 psi 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 1 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 Idle speed 1 250 1 550 RPM Output 9 bhp at 3600 RPM 6 6 kW fuel tank capacity standard grade lead free gasoline 6 Engine oil capacity SAE 15 W 40 1 1 I Battery maintenance free 12V 44 Ah Starter electrical Exhaust value 0 5 Engine KMR 1250 D P N 6 491 604 Designation YANMAR L 70 AE DE Type 4 Stroke No of cylinders 1 Displacement 270 cm Drive belt engine clearance with 20 N 3 8 mm 0 12 0 32 in Operating speed 2 600
34. ft off instrument panel Check ignition switch 1 for continuity at its various positions 0 1 2 Key position Connection Function 0 30 1 15 Engine Stop 1 30 15 54 Inoperation 2 30 50 Starter 1 Ignition switch S1 2 Screws instrument panel 3 Ignition switch bottom view KMR 1250 B LPG D Troubleshooting Information Starter Fails to Turn Engine Check starter M1 Hold ignition switch in position Il Jfavoltage is present but starter fails to turn starter is defective and must be replaced Check voltage on starter solenoid Hold ignition switch in position Il Measure the voltage between solenoid ter minal and vehicle ground Ifthe meter fails to indicate a voltage wiring must be checked for possible defect Jfavoltage 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 Checking voltage on starter solenoid 17 Troubleshooting Information Starter Fails to Turn Engine Checking regulator charging current ws White wire rt Red wire 1 Plug coupling 2 Round male plug w female coupling 18 KMR 1250 B LPG D Check regulator Whenthe engineisrunning the alternator gener ates a continuous current flow The regulator automatically adapts this current as required depending on battery char
35. g brake 32 pressure relief valve 45 sealing lips sealing strips 41 steering free play 46 Adjusting screw idle mixture 8 Alternator 51 53 55 B Battery 51 53 55 Brush Roller No Rotation 35 Poor Performance 33 34 Brush roller 14 15 Button Choke 53 clean dust filter 7 Filter cleaning 53 55 Filter shaker 51 Horn 7 51 53 55 Hydraulics 51 53 55 Lower Container 51 53 55 lower debris container 7 Raise Container 51 53 55 raise debris container 7 Tilt Container 51 53 55 tilt debris container 7 two hand operation hydraulic 7 C Carburetor 10 Chain steering 14 Change engine oil 26 30 Check air cleaner element 30 battery voltage 16 coarse debris flap 38 compression release lever 20 control cable 33 36 drive belt side brush 36 drive pedal 22 23 dust pickup 39 engine oil level 26 30 filter receptacle 38 freewheeling function 21 fuel solenoid valve 31 fuse 16 hydraulic unit 43 44 ignition 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 33 40 voltage 17 Check replace Brush roller drive belt 35 Sweeping drive belt 35 Choke 7 lifting solenoid 53 system function 9 Clean air filter element 26 Clean sediment bowl 27 CO tester 62 Coarse dirt flap 15 Connecting plug 4 pin 55 Connecting plug 6 pin 53 Contacts Filter cleaning motor 51 53 55
36. ge status and electri cal load Start engine and allow to run Using aclip on ammeter measure regulator charging current on X1 plug coupling white wire on male connector or red wire on female coupling of X1 connector If a charging current cannot be measured this indicates that the alternator is faulty and mustbe replaced Check regulator Units of recent manufacture no longer feature the X1 plug coupling Wires are connected by individual round plug couplings instead Start engine and allow to run Using aclip on ammeter measure regulator charging current on red and white wire cou pling If a charging current cannot be measured this indicates that the alternator is faulty and mustbe replaced KMR 1250 B LPG D Troubleshooting Information Starter Turns Engine but Engine Fails to Start S37 d Checking seat contact switch S3 0 70 0 80 mm 0 028 0 031 in Checking spark plug gasoline amp LPG engine Checking oil level switch S9 gasoline amp LPG engine 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 Connectan ohmmeter to check seat contact switch for continuity With a physicalload on the seat cushion the switch opens and there is no continuity Inthe absence of a physical load on the seat
37. ght hand side or on both sides 1 Fork head 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 Check replace brush roller drive belt 4 This drive belt 4 is located on the vehicle left in the brush well If required replace drive belt after relaxing ten sion roller 2 Check replace sweeping drive belt 6 This drive belt 6 islocated on the smaller sheave 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 belt 6 from the belt pulley 7 Remove drive belt 11 Loosen intermediate shaft at the flange mounting 11 The drive belt 6 can now be removed Place new drive belt 6 on intermediate shaft 12 and on the smaller of the two sheaves on pulley 7 Reinstall all previously removed components inreversedsequence thentighten drive belts Belt pulley intermediate shaft Tension roller main roller drive Brush roller arm Drive belt brush roller Belt pulley brush roller Drive belt sweeping drive Belt pulley engine Tension roller hydrostatic transmiss
38. gram 1 u u u J 50 55 Maintenance Procedures for B LPG amp D Models 56 57 Technical Specifications Fu d eR SEED a Ru oa CU FR 58 59 Special Tools uuu uuu uuu n Men C as iissa iae ain ii 60 62 e euer Egeter 63 65 Unit Functions Drive system When the hood is lifted up toward the rear all components become accessible for mainte nance purposes Hydrostatic transmission with mechanical free wheeling device provides variable control of forward and reverse driving speeds Parking brake lever actuates transmission mounted disc brake No footbrake required Transmission provides braking effect Transmission impeller fan brush roller and side brushes are belt driven Rear wheels are chain driven To start engine driver must occupy operator seat seat contact switch Discharge of debris container via electrically driven hydraulic unit Sweeping system Brush roller counter rotates against direction of unit motion throw over 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 position Floating brush roller suspen sion for uneven surfaces Quick cha
39. h roller 33 chain 46 dust filter 37 Side brush 6 s Set CO value 28 29 Operating RPM adjustment 27 29 31 Set engine operating speed 31 Side brush 15 Poor Sweeping Performance 36 side brush 6 14 Solenoid valve Fuel shutoff valve 53 55 Raise Lower Container 48 49 51 53 55 Tilt Container 48 49 51 53 55 Spark plug wrench 61 Special Tools 60 61 Starter 51 53 55 Fails to Turn 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 adjust 36 Sweeping system 4 15 Switch Headlights 51 53 55 Seat contact 51 53 55 T tank capacity 59 Technical specifications 58 59 Throttle lever 7 Throttle valve 48 49 Tighten steering chain 46 Tilting cylinder w gas strut assist 48 49 Tires 58 Top up engine oil 26 30 Transmission drive belt 21 two hand operation 4 7 43 45 V View from front 6 W Weights and dimensions 58 Y YANMAR L 70 AE DE 5 12 13 59 65
40. hange engine oil Place a suitable catch tray beside the unit While holding oil drain hose in catch tray remove oil 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 Specifications Check air filter element When filter element is dirty replace the paper filler element Tocleanfilter element blowthrough with compressed air from the inside out or firmly tap on hard surface to dislodge caked on dust Do not brush off because this would press dust particles into paper fibers Air cleaner w paper element diesel engine 30 KMR 1250 D St rungshilfe Maintenance Procedures diesel engine Operating RPM adjustment Engine operating speed referto technical spec ifications is set by means ofthe 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 A into hole on governorlever 3 exactly as shown Adjusting screw 4 must be fixed with sealing lacquer Screw may not be tampered with as this would change the entire engine setup Check fuel solenoid valve Upon engine shutdown atthe ignition switch the fuelsolenoid valve 8 shuts off fuel supply through the injector line 7 Ifthe eng
41. hat no spilled fuel remains in area around carburetor before starting engine When engine has started check sedimen tation cup for leaks Carburetor w fuel cock and sediment bowl 1 Adjusting screw engine operating RPM 2 Fuel cock 3 Sedimentation cup 27 Troubleshooting Information KMR 1250 LPG Maintenance Procedures LPG engine Setting CO value w mixture control screw idle speed 28 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 1 Set CO value at idle speed Start engine and set accelerator lever on instrument panel to MIN position Idle speed should be between 1250and 1550 RPM see also technical specifications Let engine warm up for a few minutes Using a floor jack raise front of unit and remove muffler guard 1 There is no other way to access the muffler outlet Measure CO value inside mufflertailpipe 2 Using the mixture control screw idle speed 5 set CO value on gas regulator 4 nom inal CO value is 0 5 Withthe correct adjustment engine mustrun smoothly and quietly and provide reliable starting With adjustment completed fix mixture con trol screw 5 by applying sealing lacquer Muffler guard Muffler Solenoid valve Gas regulator Mixture control screw idle spe
42. he drive power Starting with S N 10121 this freewheeling lever is permanently mounted on the transmission link age It is held in place in the engaged position by a stop bracket Even with the drive engaged the unit may be slowly pushed by hand However the drive must be disengaged clockwise rotation if the unit is to be moved over extended distances Position 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 braking will be ineffective 21 Troubleshooting Information KMR 1250 B LPG D Engine Runs but Machine Fails to Move ia Si a c e ORIGINAL Adjusting drive pedal Drive pedal linkage Shift lever Intermediate plate Dog pin in shift lever Stop pin in transmission Shaft mounted leg spring Transmission Adjusting screw o Jo Om FWD Checking drive pedal 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 When at the center position the drive pedal ad justment should provide for equal angles from the horizontal for both forward and return foot rests An adjusting screw 8 beneath the drive pedal limits pedal travel and atthe same tim
43. ide at mosphere by means of a channel This facili tates the equalization of the pressure equilibri um inside the float chamber as the fuel level ris es or falls Idling operation Whenthe engine is idling the throttle valve 4 is fully closed This causes negative pressure to occur be tween the throttle 4 and the crown of the engine piston with the latter moving toward bottom dead center while the intake valve is open The atmospheric pressure inside the float chamber 14 then causes fuel to be con veyed through the main jet 15 and idle jet 2 Theidlejet 2 controlstheflowoffuelthrough the idle bypass channel 3 The fuel then blends with the air being drawn in through the idle air channel 6 The resulting air fuel mixture then flows into the engine The idle mixture adjusting screw 16 con trols the 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 drawn through the idle jet 2 increases Unit Functions Full load operation Infullloadoperation the throttle is wide 4 open Air flows through the carburetor throat or venturi 7 Because the diameter ofthe ven turi outlet is smaller than that of the intake the air is accelerated as it passes through This increased flow velocity causes nega tive pressure to occur atthe o
44. ine fails to shut off Check connecting wire 9 for secure con nection Use magnetic field tester 11 to determine if a magnetic field is generated upon actuating the ignition switch confirmation by beeptone on magnetic field tester OR Use Clip on ammeter 10 to determine switching on off at ignition switch will cause a current at connecting wire 9 Inthe absence of acurrentflow the fuel solenoid valve 8 is defective and must be replaced Adjusting screw operating speed Throttle control cable Governor lever Adjusting screw governor Governor spring Governor spring Injector line Fuel solenoid valve Connecting wire Clip on ammeter Multimeter Magnetic field tester o OO Jo Oo SS ON mk mk O 31 Troubleshooting Information Parking Brake No Function Parking brake w pull spring 32 KMR 1250 B LPG D 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 Atthe sametime tension X of the pull spring 7 may not extend by 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
45. ion Drive belt hydrostatic transmission 10 Tension roller sweeping drive belt 11 Flange mounting 12 Intermediate shaft M Driving engine O OO Jo Oo ON Removing intermediate shaft 35 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 Check control cable side brush The control cable 3 is subjected to considera ble strain through exposure to road soiling If required check cable routing via deflection pul ley 2 for ease of movement Clean and lubri cate with new grease P N 6 288 107 Replace side brush The side brush is attached to the underside of the transmission by means of three bolts Sweeping pattern Check adjust Sprinkle a level surface evenly with fine sand Drive machine onto this surface and set parking brake Lower side brush and allow to run for ap prox 15 to 30 seconds Continue by raising side brush backing sweeper off test surface The bottom position of the side brush is ad justed by means of the stop screw 7 The sweeping pattern should be shaped like a I K T 7g Wm nal maon Sinka x Thetop position of the side brush is adjusted by manipulating the control cable adjustment 4 Ground
46. nction 43 Hydraulic unit 15 48 49 51 53 55 59 adjust pressure relief valve 45 Hydrostatic transmission 14 15 25 Idling operation 9 Ignition 51 53 55 Ignition spark tester 60 Ignition switch 7 51 53 55 Impeller fan 14 15 39 Indicator lamp Headlights 51 53 55 Injection pump 13 Injection system 12 Injector assembly 13 64 KMR 1250 B LPG D L Leak detection spray 62 Lever brush roller 7 coarse dirt flap 7 dust pickup 7 LH side brush 7 parking brake 7 RH side brush 7 Side brush 6 LH drive chain 14 LH side brush 14 Lifting cylinder 48 49 Lifting mechanism 6 LP Gas Engine HONDA GX 270 10 11 Magnetic field tester 61 Maintenance intervals 56 Maintenance Procedures diesel engine 30 31 gasoline and LPG engine 26 27 LPG engine 28 B LPG amp D Model 57 B LPG amp D Models 56 Mechanical tachometer for gasoline LP gas and di 60 Mixture control screw MAX eng speed 10 Mixture control screw MIN eng speed 10 Multimeter 61 N Noise level 59 Non return valve 48 49 O Oil level sensor 51 53 Operating hours counter 7 51 53 55 Operating time 59 Operator seat 15 P Parking Brake No Function 32 Partial load operation 9 Pipe break valve 48 49 Plug 6 pin 51 Pressure connection hydraulic unit 48 49 Pressure relief valve 48 49 Purge lifting cylinder 44 R Rear wheel 15 Rear wheel chain driven 6 Relay filter cleaning motor 51 KMR 1250 B LPG D Replace brus
47. nge brush roller replacement No tools required Side brush automatically extends outward when lowered Coarse dirt flap accommodates pickup of bev erage cans etc Hydraulic discharge of debris container in raised position two hand operation KMR 1250 B LPG D Suction and filtering system Dust pickup at brush roller Large capacity dust filter with mechanical dust removal Each time engine is shut off dust filter is sub jected to automatic cleaning cycle of approx 15 second duration Impeller fan with closeable exhaust air hatch for wet sweeping operation Quick change dust filter replacement No tools required Impeller fan driven by elastic belt No tension adjustment required KMR 1250 B LPG D Engine KMR 1250 B Single cylinder air cooled gasoline engine HONDA GX 270 w electric starter Uses standard grade unleaded gasoline Engine features oil level sensor Engine 1250 LPG With the exception of the conversion to run on liquefied petroleum gas LPG the unit is iden tical to the basic KMR 1250 B version Thegasoline engineisthe same asinthe KMR 1250 B HONDA GX 270 The LP gas cylinder is mounted behind the driver 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 required t
48. o adjust the air fuel mixture for the engine The mechanical choke has been converted to electrical control it acts upon the gas regula tor 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 Features compression release for short term operation to help overcome top dead center when starting the engine Unit Functions Unit Functions KMR 1250 B LPG D View from front Roo e e o N O m 0 M o Gas cylinder LP Gas Steering wheel Driver seat Lifting mechanism for debris container Rear wheel chain driven Fueltank for KMR B D Engine KMR B LPG D LH side brush option Front wheel Head lights RH side brush Controls see page 7 KMR 1250 B LPG D i i Controls 11 12 13 14 15 16 17 Unit Functions Lever dust pickup Close Open Button clean dust filter S2 Button lower debris container S6 Button raise debris container S8 Button tilt debris container S7 Lever parking brake Lever coarse dirt flap Headlight switch S4 Operating hours counter Button two hand operation hydraulic S5 Lever LH side brush Raise Lower option OO OO Jo Oo Go N 12 Lever brush roller Raise Lower
49. plug blue brown yellow grey green red orange rose pink black white 51 eS 10 qmm rt 2 Ka 2 K e K F4 M T 2 5 qmm E 15A a Ha X1 rt sw Y wo Sw V1 1 qmm rt sw Y v2 ge lu f 1 1 o Ee mum V3 E m S10 2 Y 10 qmm Em S2 S11 s5 m Y v4 H2 E eee TM iu iod 1 5 qmm 1 qmm E rt rt rt sw J L L rt sw rt bl 9 9 1 qmm re sed 0 75 qmm uo C rt bl switt 1 1 14 4 ah NN o 2 S7 2 5 S8 5 pcm 2 LL s EE Ee qmm n x 1 5 qmm y a ge rt T 1 qmm ge j qmm 1 X1 w X1 sw ws 2 qmm ws 30 50a I E1 X E3 Q 075mm Jozsqmm LF M 1 qmm ws br Ss 1 qmm T ge sw E ge i i E sss E2 QQ E4 X IW CX X X Las sol G2 2 2 2 2 M1 Y4 Y3 Y2 Y1 M2 X1 t5qmm sw gr sw 10 qmm e e e e e e Note Unmarked wiring has cross section of 75 sq mm 5d1 0SZL HWX 161 8800 wesbelgq 1Ino11 2911199 3 a 5d1 g 0S2L HIN KMR 1250 B LPG D Electrical Circuit Diagram 0 088 151 KMR 1250 LPG A1 A2 E1 E4 F1 F2 F3 F4 G1 G2 H1 H2 M1 M2 M3 P1 S1 S2 S3 S4 S5 S6 S7 S8
50. sw M gt G2 n P1 X10 X11 d an M1 gn ws nl M3 oo S V1 V2 V3 V4 1 5 qmm rt sw 1 5 qmm sw 9 1qmm 1qmm 1qmm F3 rt sw rt sw rt sw 60A 1 S5 gt Dr S3 k gt I br I br 1 H2 17 Ya X 2 1 qmm _ 10 qmm rt bl sw 1 4 1 4 4 2 5 2 5 ya 5 S6 S7 S8 t t br rt ws br 1 1 Y2 2 Y1 2 M2 jJ 10 qmm Note Unmarked wiring has cross section of 75 sq mm a 0SZL HIN 260 880 0 ure16eiq HN 2911199 3 q 5d1 g 0S2L HIN KMR 1250 B LPG D Electrical Circuit Diagram 0 088 097 KMR 1250 D A1 A2 E1 E4 F1 F2 F3 F4 G1 G2 H1 H2 M1 M2 M3 P1 S1 S2 S3 S4 S5 S6 S7 S8 S9 V1 V4 xi X10 11 Yi Y2 Y3 Filter cleaning control Ignition Headlights Fuse Filter cleaning motor Fuse control voltage Fuse Hydraulic unit Fuse Alternator Battery Alternator Indicator lamp Headlights Horn Starter Hydraulic unit Filter cleaning motor Operating hours counter Ignition switch Button Filter cleaning Switch Seat contact Switch Headlights Button Hydraulics Button Lo
51. t hand side panel conceals a forked spring loaded lever 6 When lowered almost to the bottom position the container presses the lever forward This causes the container to be locked up in its end position so that it cannot swing out inadvertently during travel in moun tainous terrain The control cable 3 for the hatch 4 is attached to the lever 6 Pressing the lever backward while raising the debris container closes the hatch Pressing the lever forward while lowering the debris container causes the hatch 4 again to be opened by the coil spring 5 Note When the lever is set to the SUN position 8 the hatch 4 must be fully open The lever 4 operating the hatch musttravel easily enough to allow itto be opened by the coil spring 5 without problems 1 Housing impeller fan 2 Control cable connected from lever 8 on instrument panel to hatch 4 3 Control cable connected from lever 6 to hatch 4 4 Hatch 5 Coil spring 6 Debris container locking lever 7 ntake opening 8 Lever dust pickup close open 39 Troubleshooting Information Excessive Unit Dusting Seal on filter housing RAS et e Seals on brush well rear view with raised container Checking tire pressure 40 KMR 1250 B LPG D 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
52. tion Engines 5 905 122 Gas regulator O Go N Engines using LP gas as a fuel are equipped with a gas regulator which feeds LP gas to the carburetor of a gasoline engine The carbure tor generates an air fuel mixture which is drawn into the combustion chamber for ignition Gas inlet Air intake Air fuel mixture outlet Mixing chamber Gas jet 11 Unit Functions KMR 1250 B LPG D Diesel Engine YANMAR L 70 AE DE O OO Jo Oo ON mak ch 12 Drive shaft Housing engine Piston Cylinder head Injector Fuel feed line Fuel line from fuel tank Injection pump Shim Housing injection pump 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 extreme engine compression causes the fuel to self ignite Note For information on other maintenance and adjustments ofthe engine refertothe Serv ice manual 4 Stroke Internal Combustion Engines 5 905 122 KMR 1250 B LPG D Unit Functions Diesel Engine YANMAR L 70 AE DE Injection pump cross section Injector assembly cross section 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 valv
53. ts must be observed especially in the case of units licensed for road travel With the drive pedals at center position and with the parking brake released the unit may move neither forward nor backward The drive pedal must travel without jerking or binding Note All adjusting screws must be fixed with seal ing lacquer Troubleshooting Information KMR 1250 B LPG D Engine Runs but Machine Fails to Move Adjusting hydrostatic transmission fer to service bulletin no 2001 042 Hydrostatic transmission 1 2 Bolt w stop nut 3 Holding bracket hydrostatic transmission 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 andtransmission drive belts may fail after a short while Starting with serial no 11883 it is possible to adjust the incline of the hydrostatic transmission To this end the holding bracket 3 was provided with an elongated hole Loosen adjusting bolt 2 Position hydrostatic transmission so that drive belts run straight in belt pulleys Securely tighten adjusting bolt and seal with safety paint 2 Note Retrofitting kit 2 882 530 is available for units with serial no s 11482 through 11883 Re 24 KMR 1250 B LPG D Troubleshooting Information Engine Runs but Machine Fails to Move Insert hy
54. utlet side ofthe main jet 15 Pressure inside the float chamber 14 is equalized via an atmospheric relief channel Because atmosphericpressure ishigherthan the pressure in the carburetor throat 7 fuel is transported from the float chamber 14 and pressed through the main jet 15 into the emulsion tube 12 The air flowing through the main air jet 10 is blended with the fuel that is flowing through the orifices of the emulsion tube 12 This mixture is then drawn into the carbure tor throat 7 where it is enriched with more air before passing into the engine Choke system function The choke valve 9 should be closed only when starting a cold engine This causes the following to happen The closed choke valve 9 allows less air to be drawn into the carburetor throat 7 However the fuel volume being drawn in through the main jet 15 remains the same This causes the fuel component in the air fuel mixture to rise with the richer mixture providing easier engine starting Note For information on other maintenance and adjustments of the engine refer to the Serv ice manual 4 Stroke Internal Combustion Engines 5 905 122 Unit Functions KMR 1250 B LPG D LP Gas Engine HONDA GX 270 15 14 13 12 1 Valve guard 10 Engine 2 LP gas line 11 Vacuum line 3 Cylinder shutoff valve 12 LP gas line 4 Outlet tube 13 Gas filter
55. vene fol of of e ofe lole e o Live electrical wiring and contact points check Fuel filter change bu mr and LPG only MN clearance check Drive chains Drive chains replace CO emissions check analyze LPG only 57 Technical specifications Service weight operational Permitted gross weight Length Width Height Driving speed forward max Driving speed reverse max Climbing ability max Width sweeping path w o side brush Width sweeping path w 1 side brush Width sweeping path w 2 side brushes Debris container usable capacity max Debris container lifting height min Debris container surface area dust filter Debris container lifting weight Debris container filter cleaning cycle after running time Main brush ground clearance raises Sweeping pattern width Main brush diameter Main brush speed at engine operating speed Side brush diameter Side brush speed at engine operating speed Coarse dirt flap raised min Coarse dirt flap after running Side sealing strips ground clearance Rear selling strip after running Tires diameter Tires designation Tire pressure front Tire pressure rear Tires torque wheel stud make up Fuses filter cleaning motor F1 Fuses control voltage F2 Fuses hydraulic motor F3 Fuses generator F4 Steering turns full LH RH deflection Steering free play on steering wheel max Parking brake brake lev
56. wer Container Button Tilt Container Button Raise Container Button Horn Diode Connecting plug 4 pin Contacts Filter cleaning motor Solenoid valve Tilt Container Solenoid valve Raise Lower Contain Solenoid valve Fuel shutoff valve O L A bl bn ge gr gn rt or rs SW ws Detachable wiring connection Graphic symbol for wiring connection Vehicle earth ground Female coupling X1 connecting plug Male coupling X1 connecting plug blue brown yellow grey green red orange rose pink black white 55 KMR 1250 B LPG D Maintenance Procedures for B LPG amp D Models Wartung Maintenance KMR 1250 Maintenance intervals Maintenance procedures are performed at the following intervals Daily by operator Check oil level Check tire pressure Check brush roller for wear and snagged strings banding etc Check air cleaner filter for damage Weekly by operator Check sealing lips in sweeping system for wear and proper adjustment 56 Every 100 hours Check air cleaner filter for damage Change engine oil Checkbrushroller and side brushes for wear and replace as required By service specialist after 8 hours every 100 hours every 300 hours every 500 hours
57. wo spring loaded contact terminals 1 With the debris container lowered spring load edcontactpoints 1 mounted on the divider baffle must reliably make connection with rigid mating contacts 2 ondebris container being depressed by approx 3 to 4mm 0 12 0 16 in in the proc ess Clean contacts adjust contact position by install ing flat washers or replace contacts as required 1 Contacts on divider baffle spring loaded 2 Contact points on debris container rigid Check input voltage at M3 filter cleaning motor Each time ignition switch is set to 0 position filter cleaning motor automatically runs for ap prox 15 seconds Pressing filter cleaning button while engine is running ignition switch in I position starts 15 second filter cleaning cycle To prevent dislodged dust from being drawn into suction turbine air flap must be closed before hand Raise debris container Press filter cleaning button Checkvoltage oncontactterminals X10 X1 1 Ifthere is no voltage present start by check ing fuse F1 10 A on A1 circuit board then check terminals X2 X3 Ifa voltage is present without shaker motor running check motor for ohmic resistance KMR 1250 B LPG D Hydraulic Unit No Function Checking F3 fuse S5 S6 A m 1 0 75 qmm rt ws F3 60A

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