96801 ICC1D service manual
Contents
1. 70 Special 25 eat een TAG 71 Assembly Torque Ratings nnns 71 ICC1SD Technical Features The ICC 1 S Dis a high performance sweeping machine designed for professional use indus trial service and municipal fleet applications The unit may be licensed for road traffic Depending on the country of operation single unit approval by the responsible Highway Traffic Authority may be required Drive power 3 Kubota D722 water cooled diesel engine similar to KMR 1700 D Forward and reverse variable speed control with two separate foot pedals Brake Foot brake serves as operating brake acting on both front wheels via brake cables Parking brake can be set via separate brake lever Braking action on rear wheels only via hydraulic system Sweeping system 2 inward rotating side brushes Sweeping roller not required Vacuum system Sweeping debris is shredded by impeller fan picked up by vacuum stream and conveyed into debris container Impeller fan driven via magnetic clutch and V belt with magnetic brake Water system Water tank with filter and water pump Water jets on side brushes and in air channel to reduce dusting and for lubricating air channel Unit Functions Steering Hydraulic steering on front wheels Hydraulic system Rear wheels individually powered by hydrauli2. Service Manual ICC 1 SD 1 142 5 905 432 03 01 ICC1SD Foreword Good servicing requires extensive and relevant training as well as comprehensible refer ence documents We therefore regularly offer all service technician both basic and advanced training courses for the full range of our products In addition we produce service handbooks for the major equipment which can be used initially as instructional material and later as sources of reference Furthermore we regularly distribute service information bulletins that provide details about further developments to the products The copying and duplicating the text and the illustrations as well as passing them on to a third parties requires the express approval of ALFRED K RCHER GmbH amp Co INTERNATIONAL SERVICE TRAINING P O Box 160 D 71349 Winnenden http www karcher de ICC1SD Table of Contents Table of Contents Unit m 5 24 Technical 5 Equipment Features 6 15 thins 6 Side OLS TW 7 PAGAN 8 Raised debris container view 9 10 Gorbiriation st ifle ioco Mie
3. nsialed oca Ca Glow igs compar 1 Smin war pump Sie console 72 So Swich magret uch Sie console 72 Sit Swich debs combiner RH Engine compat 2 Suh wag Buz reversing Engine compan 519 Switch stop lights Pos Designation Installed location v2 Diode vs Diode Oncomecingwire 1 va Diode 1611 youeas 1n2412 a s I 99I Hydraulic Block Diagram ICC1SD Hydraulic block diagram 0 088 258 66 ICC1SD Hydraulic Block Diagram Hydraulic block diagram 0 088 258 13 13 1 13 2 13 3 15 16 17 18 19 Hydraulic fluid tank Hydraulic fluid filter return line Oil cooler Combustion engine Assembly drive components Precharge valve Precharge pump Hydraulic pump drive Non return valve Control valve low acceleration Bypass valve Hydraulic motor R amp L drives Hydraulic pump steering Valve block steering Steering valve Steering cylinder Hydraulic pump side brushes d
4. Ee e Hydraulic pressure drive system 4 bar Hydraulic pressure side brushes at operating speed bar Pressure relief valve side brushes debris bar Fyresize ee acsi vete pets eee tes patto ordo ates ba e tas Size VOOR doo Tyre pressure front rear ete tec t Ded eios bar Fuses Fi eoe Gots e per Ere 5 F2 Fo rway flashers marei 10 F3 Impeller fan Drake 5 Magnetic Clut h c 5 15 F Dm a 7 5 F7 Windshield cre een 7 5 ES MONA cse bei orte treo 7 5 7 5 F10 Positi n lamps oie mui Co a 5 Position lamps 5 15 F13 Warning 10 F14 Windshield defroster 20 S 7 5 P16 Headlamp E epe ide 7 5 rel V RE Etuis cl 30 F18 Radiator
5. Bowden cable detached Setlever 3 to Neutral position Turn switch clockwise until 9 switching noise is heard Turn switch 9 counter clockwise one half turn Note Due to confined working space removal or rotation of hydraulic hoses on control block may be required Adjusting warning buzzer switch 36 ICC 1SD Basic Settings and Service Procedures Sweeping Mechanism Debris container a A met Debris container Container swivel bolt 2x oO S Le Ja OE T il Un Removing debris container Raise debris container until level and shut off engine Lifting cylinder retaining bolt 2x LH side panel LH lifting cylinder Attach rope slings to crane hook and debris container as shown Carefully raise crane hook until rope is taut Remove retaining bolts 3 on LH and RH lifting cylinders Remove both container swivel bolts 2 on LH and RH side panels Using suitable tools push LH and RH side panels outward and raise crane hook to lift off debris container 37 Basic Settings and Service Procedures Running Gear Grease fittings DE d 22 WI A i or IY X Lubricating side brush suspension
6. 81 14 j 3 ON N M E 4 UN 9 es WG pA 7 S T 9 8 NS y NS Lax I AS m 19 l 0 9S o 18 8 D a e 9r v id Xp OF 5 8 i 19 co o d c y a Vass Lees 815 LIS oc IS UK y EM 5 9 O N N 1m os 77 y wwbg Wi voe Zt 81 i e e 0 6 1 8 1 1 9 9 Y 6 58 Designation fosser Ege corame Ignition switch Cab control console Oil pressure switch Engine compartment S3 Temperature switch i cleaner Switch reversing buzzer S18 Switch warning buzzer Raise Lower debris container sensor shutoff Inside control console cover lt 880 0 a S I 9221 Circuit Diagram Circuit diagram 0 088 215 page 2 ICC1SD 2a E L 2 a Q a e e IN d y we LLLI lt 5 8 P s
7. a 3 50 LOIT TA Eze D WM DW ES o 1 Shut off valve 2 Water filter 3 Water pump 4 Solenoid valve water pump 24 ICC 1SD Engine Fuel Cleaning fuel system Bleeding air from fuel system 1 Fuel shut off valve Knurled retaining ring Fuel filter bowl Air bleeding screw Basic Settings and Service Procedures Cleaning fuel filter Close fuel shut off valve 1 by turning counter clockwise one quarter turn Loosen and unscrew knurled retaining ring 2 and remove fuel filter bowl 3 complete with contents Replace fuel filter insert 3 Bleeding air from fuel system Loosen air bleeding screw 4 approx 2turns Start engine and allow to run until exiting fuel no longer contains air bubbles Tighten air bleeding screw 4 while engine is running 25 Basic Settings and Service Procedures Engine Cooling Ge RAR xU K Checking cooling fan motor 26 ICC1SD Checking topping up engine coolant Prior to checking coolant level allow engine to cool The proportion of antifreeze in the engine coolant must not exceed 50 percent Raise the debris container Check coolant level in expansion tank With engine cold topup engine coolantto the min mark in expansion tank
8. 38 ICC1SD Lubricating steering knuckles Lubricate grease fittings on both steering knuckles arrow on front axle with 3 5 shots from grease gun Lubricating axle mounting Lubricate grease fittings arrow on front axle mounting with 3 5 shots from grease gun Lubricating side brush suspension Lubricate grease fittings arrow on side brush suspension with 3 5 shots from grease gun ICC1SD Basic Settings and Service Procedures Running Gear Brake 1 Adjusting screw Adjusting brakes Drum brake Brake lever Nore Parking barke and operating brake act on both front wheels via brake cables drum brake Braking action on rear wheels is by hydraulics only R Lock nut The Bowden brake cables are adjusted by means of the adjusting screw 1 Loosen lock nut 4 Turn adjusting screw 1 to adjust brake When the front wheel is raised with a floor jack it mustturn freely without chafing of brake linings on brake drum 39 Basic Settings and Service Procedures ICC1SD Running Gear Brake view from below 35 a A 40 Floor panel Actuating spring stop light switch Protective cap stop light switch S 19 Bowden cable to LH drum brake Bowden cable to RH drum brake Bowden cable for setting parking brake Replacing stop light switch Remove actuating spring from eyelet 2 Pul
9. 6 Bypass valve Close bypass line 4 with blind plug to 7 Testing set special tool prevent admission of contaminants 8 Hydraulic drive pump Screw connecting union 1 of testing set 7 onto T joint 2 and tighten Start engine and run at full throttle Note Fully depress Forward drive pedal A pressure reading below 100 bar indicates a defective drive pump or drive motor With all hydraulic components working properly a pressure of 150 to 180 bar must be indicated on testing gauge After conclusion of pressure test remove testing set and return all hydraulic connec tors to their previous positions Ensure that connections are tight 49 Basic Settings and Service Procedures ICC1SD Hydraulic System Checking working pressures continued 1 2 3 ea 1 Pressure side connection Checking hydraulic pressure for side brushes and debris container 2 Unscrew pressure line to control block 3 3 Pressure line to control block side from pressure side connection 1 console Install T joint 2 between pressure side 4 Testing set special tool connection 1 and pressure line 3 5 Hydraulic pump side brushes and debris Container Install testing set 4 on T joint 2 Start engine and run at full throttle Raise side brush cylinders until they rest against the stops With side brushes engaged and rotatin
10. E 30 70 ICC1S D KUBOTA D722 2650 2800 800 900 10 W 40 3 8 78 12 44 14 16 4 6 1400 160 180 30 15 20 150 1350 HV 46 35 150 180 60 80 160 145 80 10 165 65 13 2 9 2 9 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt ICC1SD Specifications Special tools Testing eqUipM EN M TI 2 639 387 Tachometer ee 6 491 361 Magnetic field tester 6 803 003 Assembly torque ratings Rearavheels ooo Ru MA ELLE E A 100 Nm Eront wheels 90 Nm 71
11. 5 EM FS x E iE Q E 2 Ld 5 3 Ga EN 9 s 5 2 ge rd S 4 pm Ld 5 3 L F u S E d 9 me s 8 5 T x 1 gt see gt 8 E i E C TN gt T 9 4 2 2 gt lt oD 5 nc N H 5 LJ LG ES ua L Y o lt 1 9 x 8 fed KK yc 5 lt 25 lt gt x We 2 wv Q i a mai x Q 8 4l 28 ES 60 19 Thuren _ i i 7 i ia Switch folding seat Cab under seat Switch water pump Control console container container S11 RH limit switch debris Water tank raise debris container container Switch working spotlights Control console 15 Switch windshield Control console defroster V4 V6 On connecting wire of unit Plug connector Control console Y2 Magnetic clutch impeller Engine compartment fan Impeller fan brake Engine compartment 2 880 0 2 a 51599 Circuit Diagram ICC1SD Circuit
12. Read engine speed on tachometer Adjust Bowden cable 8 in such a way that throttle lever 5 touches adjusting screw 4 Make necessary corrections on clamp bolt 6 or adjusting nut 7 as required Refer to Specifications for operating speed settings Note The adjusting screws 3 and 4 are preset and sealed at the factory They must not be adjusted Breaking the seal will void manufacturer s warranty and operating license ICC1SD Basic Settings and Service Procedures Engine Engine shut off solenoid valve Manual actuation of engine shut off solenoid valve Checking magnetic field Engine shut off solenoid valve As soon as the ignition switch S1 is set to position 0 with the engine running the engine shut off controlresponds andthe solenoid valve 1 attracts This shuts off the fuel supply inlet causing the engine to stop After about 15 seconds solenoid valve switches off again and opens fuel supply inlet 1 Solenoid valve engine shut off 2 Lever engine stop In the event that the solenoid valve 1 fails to shut off the fuel supply when the ignition key is setto position 0 the solenoid valve can also be actuated manually Shut off engine Move engine shut off lever in direction of arrow until it stops and hold until engine comes to a standstill Caution Stay clear of rotating components Checking engine shu
13. Troubleshooting Starter fails to turn engine Check replace fuse F1 Check ground connection between engine and chassis Check battery G1 voltage electrolyte level amp density Check replace ignition switch S1 Check voltage at starter relay Check voltage at starter terminals Check replace starter Starter turns engine but engine Check battery voltage does not start Check fuel level top up as required Check replace fuel filter Check replace air cleaner element Check replace fuse F12 Check replace fuse F1 Check replace glow plug control module D1 Check replace engine shutoff solenoid valve Y1 Check starter drive gear Battery Charge Check cable connections on alternator indicator lamp illuminates Check alternator Check adjust V belt tension Multifunctional display Excessive Check engine coolant level top up as required engine coolant temperature Check adjust V belt tension alternator water pump Check radiator for leaks and clogging Check replace cooling fan motor Oil Pressure Check top up engine oil level indicator lamp illuminates Check replace oil pressure switch S2 connections and lamps Defective vehicle lighting Check replace fuses connectors lamps Warning beacon without function Check plug connectors Check replace fuse F13 Check replace lamp Windshield wiper without
14. Checking cooling system for leaks The radiator is a combination of two cooling circuits one for hydraulic fluid the other for engine coolant The fan transports the cooling air from the outside into the engine compartment passing it through the dual circuit radiator Check radiator hoses connections and the radiator itself for leaks Checking cooling fan functions The fan must start as soon as the ignition key is turned to position 1 Check electrical connections and fuses and replace as required Measure voltage applied to electric motor f required replace connecting cable relay electric motor When replacing the fan it must be noted that the cable inlet connection onthe electric motor points downward ICC1SD Engine Cooling Checking engine coolant temperature switch 1 Plug in connector 2 Engine coolant temperature switch S3 Basic Settings and Service Procedures Checking engine coolant temperature switch Start engine Ifthe Engine Coolant Temperature indicator lightonthe combination instrument illuminates also when the engine is cold the connecting cable must be checked for a short circuit against vehicle ground With engine running bridge the connector 1 to vehicle ground indicator lamp must illuminate and buzzer must sound Replace temperature switch 2 as required Note A radiator that is blocked by dirt and debris will cause ove
15. ede 35 Warning buzzer debris container roma e ee ee tht ende Ce EE rane e eg 36 EE 37 Running Gear e 38 44 38 39 Wheel change Steering 41 FOGHM AGUS UME IG RE 42 Shock abSOTDO 43 Towing and transporting ice eee e Dh 44 Table of Contents ICC1SD Hydraulic 45 52 Hydraulic 45 Hydraulic fluid E 46 Emergency pump option RD ritenuti 47 enn 48 Checking working pressures 49 Pressure relief valve ID ie 51 uio 52 Impeller 53 55 Changing impeller fan cote onte igne 53 Adjusting magnetic Drake dead ovest dnte oU 55 Troubleshooting Lecce eiie ie ecceecc e mnnn nnnn nnmnnn nennen 56 Gircuit DIagram oe oeil 58 Circuit Diagram Search 116 64 Hydraulic Block Diagram 66 Hydraulic Line Diagram cesser eee oe oon oett 68 jefe eec 70 giri
16. Hydraulic pump steering Hydraulic pump side brushes and debris container Hydraulic cylinder debris container Hydraulic motor RH drive motor Hydraulic pump drive components Hydraulikzylinder side brushes and vacuum intake Bypass valve Hydraulic cylinder debris container Hydraulic motor LH drive motor Hydraulic fluid tank Emergency pump option Hydraulic oil cooler Hydraulic Line Diagram 69 Specifications Specifications Diesel COMING x Type Operating speed RPM Idle speed P RPM Oil type diesel Type Oil capacity diesel engine etie rtm tr rue Rud Sound noise level dB A Battery ertet Dux V Battery low maintance capacity Ah Driving speed forward max km h Driving speed reverse max esses km h Width of sweeping path mm Side brushes max speed RPM Ground clearance w side brushes raised mm Ground clearance w vacuum intake lowered mm Ground clearance w vacuum intake mm Debris container raised height 2 2 mm Hydraulic fluid VD iet a rette t te diac Hydraulic fluid capacity
17. a A Reverse drive switch 48 ICC1SD Setting NEUTRAL on hydraulic drive pump If the unit creeps forward or backward without drive pedals being actuated settingthe NEUTRAL position on the hydraulic drive pump will be required Loosen lock nut on cam bolt Turn cam bolt arrow until unit no longer creeps Tighten lock nut on cam bolt Adjusting drive pedal inclination Whenin rest position the Forward drive pedal must be positioned in parallel with the Reverse drive pedal The drive pedal position can be adjusted at each linkage pivot point Detach fork 2 from lever 1 Loosen lock nut 5 Turn fork 2 on the threaded rod 4 in pedal linkage 3 clockwise or counter clockwise as required Reattach fork 2 to lever 1 Note When making adjustments ensure that pedal linkage travels freely and without chafing ICC1SD Basic Settings and Service Procedures Hydraulic System Checking working pressures 8 Oy M 48 0 22 XM 7 6 5 1 Connecting union on testing setup Checking drive hydraulic pressure 2 Tjoint Secure unit by setting parking brake 3 Connecting union on bypass line Unscrew connecting union 3 from T joint 2 4 Bypass line 2 Loosen connecting union 5 from bypass 5 Connecting union on bypass valve valve 6 Swivel bypass line 4 sideways
18. air cleaner warning Headlamps ON Turn signal ON Operating hours counter Fuel level indicator Unit Functions 11 Unit Functions ICC 1SD Equipment Features Fuse box F13 F14 K1 F1 K5 F2 F3 NS D F6 D K3 7 UJ RD F8 7 JIN lt gt 9 lt EZ ks eX NL KG K4 F11 F12 2 ZS SY F16 F15 Fuses Relays F1 Ignition switch K1 Ignition switch F2 Four way flashers K2 Fan cabin heater F3 Impeller fan brake K3 Water pump F4 Magnetic clutch K4 Safety beacon F5 Water pump K5 Turn signals Fe Fan cabin heater K6 Windshield wiper F7 Windshield wiper K7 Fan windshield defroster F8 Turn signals horn Headlamps F9 Headl M5 Fan windshield defroster F10 Position lamps RH X1 Plug connector F11 Position lamps LH F12 Engine stop solenoid F13 Safety beacon Note F14 Fan windshield defroster The fuse box is located below the instrument l F15 Stop lights ais F16 Headlamps 12 ICC1SD Equipment Features Control console open view D2 14 15 7 56 16 13 1 1 13 16 6 7 15 14 Control module engine shut off solenoid Switch safety beacon Switch windshield defroster fan Switch cabin heater fan Switch windshield wiper Switch working spotlights option Combination switch Ignition switch Unit Functions 13 ICC1SD Unit Funct
19. c motors 2 side brushes individually powered by hydraulic motors and raised by hydraulic cylinders Debris container raised by two hydraulic cylinders Electrical cooling fan for hydraulic fluid and engine cooling Unit Functions ICC1SD Equipment Features Front view 11 1 10 9 8 7 6 5 1 Cover debris container 9 Side brush RH 2 Debris container 10 Head lamps 3 Dual circuit radiator 11 Air exhaust debris container hydraulic fluid engine coolant Operator seat Support caster vacuum intake Side brush LH Bumper N O A Turn signals ICC1SD Unit Functions Equipment Features Sidebrush view p 1 Pressurized gas spring side brush Stop screw side brush bottom position Adjusting screws side brush sweeping Hydraulic motor LF side brush LH side brush RH side brush N O A Bumper Unit Functions ICC1SD Equipment Features Rear view zem 4 1 7 wee 2 6 3 C 1 5 4 1 Safety beacon 2 Filler neck fuel tank 3 RH side brush 4 Side cover panel 5 Rear cover panel 6 Watertank 7 Filler neck water tank ICC1SD Unit Functions Equipment Features Raised debris container view 8 a A c m Debris container Air exhaust Debris container cover Water ta
20. diagram 0 088 215 page 3 2 gt 5 2 o 7 M gt N g o 9 E H S 8 f ur kE F 5 S B gt lt e 69 gt VA x gt e 8 C y gt lt ex T oz T 3 00 4 V x x z 8258 5 5 L clo amp 1 1 ae bia 5 EO 85 N lt 5 SE lt B 2 13 K1 2 13 62 59 Pos Designation stated Location _ Pes _ 2 880 0 2 a s I 99I v9 oy A mi 1 1 2 3 3 4 5 6 N 3 9 10 11 F13 Installed location Fuse windshield wiper Fuse warning beacon C D 2 Warning buzzer reversing Rear cover panel debris container 8 Relay ignition switch Relay windshield defroster 8 9 Relay radiator fan NIOLA O C 1611 Hna 0811221 59
21. ebris container Control block Pressure relief valve Proportional valve for pos 16 and 17 Control valve debris container Pipe break safety valve Hydraulic cylinder debris container Hydraulic motors side brushes Hydraulic cylinder side brushes vacuum intake Throttle valve Emergency hand pump option 67 Hydraulic Line Diagram Hydraulic line diagram 2 706 010 ICC1SD 1 2 3 4 m y In GER 5 18 B 17 1 52 54 86 6 Bm 7 ri J 4 n i 15 14 13 11 ICC1SD Hydraulic line diagram 2 706 010 1 oN O o A PD 10 12 13 15 16 17 18 Hydraulic motor LH side brush Steering valve Hydraulic motor RH side brush Hydraulic cylinder steering Valve block steering Control block side console
22. ement 1 with protective tube 2 by pulling both out of filler neck 3 Hydraulic fluid filter Insertnewfilter element 1 in protective tube 2 Install protective tube 2 with filter element 1 1 in filler neck 3 ee UDE Replace cover start thread clockwise and 3 Filler neck turn until hand tight 46 ICC 1SD Basic Settings and Service Procedures Hydraulic System Emergency pump option 1 Lever emergency pump 2 Lever Raise Lower debris container Raise Lower debris container To carry out repairs the emergency pump 1 can be used to raise the debris container without the need to start the engine To raise debris container set the Debris Container lever 2 on the side console to Raise position hold lever and actuate emergency pump lever 1 in a pumping motion until debris containerhas been raised to desired height To lower debris container set the Debris Container lever 2 on the side console to Lower position hold lever and actuate emergency pump lever 1 in a pumping motion until debris container has been lowered to desired position 47 Basic Settings and Service Procedures Hydraulic System Drive pedal Setting NEUTRAL position on hydraulic pump Pedal linkage 1 Lever Fork adjuster Pedallinkage Threaded rod Lock nut
23. function Check replace fuse F7 Check replace relay K6 Check replace wiper motor 4 Windshield wiper fails to return Replace wiper motor M4 to parking position Stop light without function Check replace fuse F15 Check replace stop light switch 19 Engine runs but machine fails to Release parking brake move Close bypass valve Check brake pedal return Check throttle linkage Check adjust pressure on drive hydraulics 56 ICC1SD Troubleshooting Troubleshooting Engine cannot be shut off Check engine shutoff control module D2 Check replace ignition switch S1 Check replace engine shutoff solenoid valve Y1 No fuel tank level indication Check replace fuel level sensor B1 Brushes fail to rotate or rotate too Check pressure in working hydraulic circuit slowly Adjust pressure relief valve Blower without function Check replace switches S10 511 on debris container Check replace relay K1 Check replace fuse F4 Check adjust V belt Check magnetic clutch Vacuum intake cannot be lowered Check linkage for obstruction or blockage raised Check replace valve on control block Check pressure in working hydraulic circuit Adjust pressure relief valve Debris container cannot be raised Check replace valve on control block Check pressure in working hydraulic circuit Switch off side brushes Adjust p
24. g a pressure of 60to 80 bar mustbe indicated on testing gauge Foradjustment of pressure relief valve refer to page 51 50 ICC1SD Basic Settings and Service Procedures Hydraulic System Pressure relief valve Adjusting pressure relief valve The pressure relief valve is used to adjust the working pressure for functions such as Raise Lower Debris Container and raising lowering side brushes and vacuum intake Remove mounting screws 2x see arrows Tilt up seat Remove mounting screws 2x see arrows Liftside console approx 30 mmuntil pressure relief valve can be seen Note As a prerequisite the unit must have been prepared as described on page 50 Side console raised adjusting pressure relief valve R Loosen lock nut 1 Using Allen wrench 3 adjust pressure by turning screw 2 Turning clockwise increases pressure Turning counter clockwise reduces pressure For nominal value refer to Specifications Lock nut Adjusting screw Allen wrench 5 mm size Side console raised 51 Basic Settings and Service Procedures Hydraulic System Pumps Installing hydraulic pumps a A 52 Mounting bolts Hydraulic pumps Battery Connecting sleeve engine hydraulic pump Alternator ICC1SD Removing hydraulic pumps The hydraulic pumps powering the worki
25. herwise hydraulic motors on rear wheels may be damaged Attach tow rope to towing eye arrow Winchunitonto transport vehicle and secure to tie down points 44 ICC1SD Basic Settings and Service Procedures Hydraulic System Hydraulic fluid Note When carrying out procedures on the hydraulic system care must be taken to maintain extreme cleanliness throughout Even minor contaminations may cause component damage or complete system failure Checking hydraulic fluid level The inspection glass for checking the level in the hydraulic fluid tank is located in the front left wheel well Topping up hydraulic fluid The filler neck is located beneath the operator seat Note When installing the threaded cover ensure that it can be turned easily Otherwise thread damage through cross threading may result Install cover only hand tight Filler neck hydraulic fluid 1 Dip stick 2 Pressure gauge return pressure 3 Cover 45 Basic Settings and Service Procedures ICC1SD Hydraulic System Hydraulic fluid filter Replacing hydraulic fluid filter Replacement ofthe hydraulic fluid filter is required when indication of pressure gauge is in red range Note Engine must be shut off before the filter can be changed Tilt up operator seat Unscrew filler neck cover Removefilter el
26. ions Equipment Features Side console open view Mounting thread for lever Raise Lower debris container Mounting thread for lever Raise Lower side brush and vacuum intake Pressure relief valve Bowden cable coarse debris flap Hydraulic line Lower debris container Hydraulic line Lower brushes Sweeping Hydraulic fluid inlet Hydraulic line Raise brushes 10 11 12 13 14 15 Hydraulic line Lower brushes Manual throttle Control module impeller fan brake D3 Switch debris container warning buzzer S18 Hydraulic line Raise debris container Hydraulic line Sweeping operating Hydraulic line to hydraulic fluid tank 14 ICC1SD Unit Functions Equipment Features Engine compartment view from left 1 2 12 3 1 SC Jos 4 SS 10 AVE 40 4 P igi i gt 9 8 7 6 1 Magnetic clutch vacuum impeller fan 8 Fuelfilter 2 Filler neck engine oil 9 Engine 3 Glow plug 10 Tension roller V belt 4 Injector nozzle 11 V belt 5 Injection pump 12 Magnetic brake vacuum impeller fan 6 Oil dip stick 7 Air intake hose Unit Functions ICC1SD Equipment Features Engine compartment view from right N O Oil dip stick Coolant radiator electric fan Adjustment screw V belt tension Magnetic brake vacuum impeller fan Exhaust manifold Starter filler neck N O A WO N g
27. l off protective cap 3 from stop light switch Remove electrical cable Replace stop light switch ICC1SD Basic Settings and Service Procedures Running Gear Wheel change Steering wheel Front axle jacking point Removing steering wheel Changing rear wheel Secure unit to prevent rolling and loosen wheel bolts Insert round steel bar 20 mm dia into rear jacking eye Place hydraulic jack under protruding round bar and jack up unit Support unit with block Change wheel tighten wheel nuts thentorque to finish refer to Specifications for torque rating Note Round steel bar must be cradled in jack head notch Changing front wheel Secure unit to prevent rolling and loosen wheel bolts Place hydraulic jack under front axle near wheel to be changed and jack up unit Support unit with block Change wheel tighten wheel nuts then torque to finish refer to Specifications for torque rating Removing steering wheel 1 2 Pull center cap off steering wheel 1 Remove center nut from steering shaft Install suitable pulling tool using tapped holes 2 Pull off steering wheel Steering wheel Tapped holes 2x 41 Basic Settings and Service Procedures ICC1SD Running Gear Toe in adjustment Adjusting toe in Set steering wheel for straight ahead travel Hookmeasuring tape into one of
28. level must be between MIN and MAX marks on oil dip stick arrow If oil level is found to be below MIN mark top up with engine oil immediately Do not overfill engine oil to above MAX mark Refer to Specifications for type of engine oil required Changing oil filter Drain engine oil Remove oil filter 2 using cartridge wrench Clean sealing surface at filter base Apply thin film of engine oil to rubber seal of new filter cartridge Start new filter cartridge on threaded base and turn until hand tight Checking oil pressure switch Startengine Oil pressure indicator lamp must extinguish If indicator lamp fails to extinguish check top up engine oil first Check for switching voltage on terminal of connecting cable If a voltage is present oil pressure switch must be replaced If no voltage is present connecting cable must be checked for possible short circuit against vehicle ground Note Whenthe indicator lamp lights up the engine will not be shut off 31 Basic Settings and Service Procedures ICC1SD Engine Drive Pump belt Changing drive pump belt Loosen and remove six mounting bolts 1 Pull pumps 2 far enough toward the rear to separate coupling sleeve 3 from engine drive shaft gap wide enough to allow drive belt to be passed through Loosen belt tensioning roller Replace drive pump belt 4 Re adjust belt tention r
29. n channel in place 53 Basic Settings and Service Procedures ICC1SD Impeller fan continued 1 Retaining bolt Changing impeller fan continued 2 mpellerfan Deflect steering all the way to the left Remove hydraulic lines from steering cylinder Detach accelerator cable at side panel see page 36 Slide out impeller fan front panel sideways between fuel tank and axle Remove center bolt and washer 1 from impeller fan 2 Pull off impeller fan 2 toward the front Grease impeller shaft Install new impeller fan on shaft Install retaining bolt and washer 1 and tighten Assemble all components in reverse order of disassembly Ensure proper seating of seal between vacuum channel and debris container 54 ICC1SD Impeller fan a A Brake lining Shim 7 343 026 Bolt Magnet coil Basic Settings and Service Procedures Adjusting magnetic brake To ensure proper functioning of the magnetic brake the air gap 1 between brake lining 2 and drive plate must be adjusted An adjustment will be required only if the magnetic brake has been replaced Using the feeler gauge check air 1 once around the entire circumference Toadjustair gap add a sufficient number of shims 3 under the bolts 4 until an even air gap of 0 3 0 1 mm has been achieved 55 Troubleshooting ICC1SD
30. ng hydraulics and steering are mounted beneath the battery 3 as an extension of the engine drive shaft Drain hydraulic fluid into clean container Remove all hydraulic lines from pumps 2 Remove a total of six mounting bolts 1 Pull pumps off toward the rear Installing hydraulic pumps Install pumps complete with connecting sleeve 4 engine drive shaft Install then tighten a total of six mounting bolts 1 Connect all hydraulic lines Note When mounting bolts have been thightened connecting sleeve 4 muststill have free axial travel Binding connecting sleeves may cause damage to hydraulic pump bearings and to engine ICC1SD Impeller fan N O CO Vacuum hose Hose clamp Front axle carrier Front wheel Mounting bolts Strut frame support Fuel tank Co AIE Basic Settings and Service Procedures LS Changing impeller fan Raise front of unit approx 200 mm or drive on inclined ramp Raise debris container to highest position and secure Loosen and remove bolts 5 on strut 6 attached to front axle carrier 3 Remove heater assembly and place toward rear with heater hoses still attached Remove seat Tilt up seat panel 90 angle and detach pressurized gas spring Loosen hose clamp 2 on vacuum hose 1 and pull off vacuum hose toward the front Remove mounting screws from impeller fan front panel leaving suctio
31. nk Rear cover panel Removable grille dual circuit radiator hydraulic fluid engine coolant LH side brush Vacuum channel Unit Functions Equipment Features Control elements a A 23 22 Switch four way flashers S12 Combination instrument P1 Steering wheel Ignition switch S1 Combination switch S13 Switch S16 working spotlights option Switch windshield wiper S6 Switch cabin heater fan S7 Switch windshield defroster fan 15 Switch safety beacon S14 Drive pedal reverse Drive pedal forward Lever Raise Lower debris container 15 16 17 18 19 20 21 22 23 ICC1SD 21 20 s Lever Raise Lower side brush and vacuum inlet with brush speed control Lever Open Close coarse debris flap Switch impeller fan S9 Switch water pump S8 Operating hours counter impeller fan option P2 Manual throttle engine speed control Metering valve side brush water volume Metering valve vacuum channel water volume Pedal parking brake operating brake Changeover button parking brake operating brake ICC1SD Equipment Features Combination instrument Indicator lights and displays O O 2 0 m Debris container raised Pre glow cycle activated Excessive engine coolant temperature Spare Low charging current warning Low engine oil pressure warning Blocked
32. oller 1 Mounting screws 6x Pumps Coupling sleeve Belt drive pump a AR V belt alternator Alternator V belt 32 ICC1SD Basic Settings and Service Procedures Sweeping Mechanism Sweeping pattern Adjusting sweeping pattern Check tire pressure see Specifications Loosen clamp bolts 1 Adjust lateral inclination of side brush 2 Tighten clamp bolts 1 Clamp bolts 2x Side brush Stop screw Lock nut Loosen lock nut 4 Turn stop screw 3 to adjust side brush contact pressure on ground Tighten lock nut 4 Adjusting brush contact pressure Checking sweeping pattern The sweeping pattern should be formed like a moon shaped sickle approx 120 to 150 Raise side brushes Drive sweeping machine onto flat and level ground that is evenly covered with dust Lower side brushes and allow to run for a few seconds Raise side brushes back up machine ca 120 150 Check sweeping pattern Direction of travel Checking sweeping pattern 33 Basic Settings and Service Procedures ICC1SD Sweeping Mechanism Spray nozzles Cleaning spray nozzles on side brush Loosen union nut 1 and remove nozzle Blow out spray nozzle with pressurized air from front 2 Replace as required Install spray nozzle 2 and tighten union nu
33. ressure relief valve Debris container cannot be lowered Check replace valve on control block Switch off side brushes Engine emits black smoke Check replace air cleaner element Check fuel return lines Machine fails to develop sufficient Check clean chain curtain in debris container Check vacuum intake Check impeller fan Check adjust replace sealing lips on vacuum intake Check vacuum intake condition remove blockage Check replace seal in vacuum channel Check adjust replace seals on debris container Clogged suction tube Check adjust water feed volume Check clean replace spray nozzles at vacuum intake No water at spray nozzles Check top up water tank Check clean water filter Check replace water pump M2 Check position of water shutoff valve Check replace solenoid valve Y3 Water pump without function Check replace fuse F5 Check replace relay K3 Check replace water pump M2 57 ICC1SD ircuit Diagram 0 088 215 1 ircuit diagram C t3 Ua 18 Vara gt m N 3 9 x Ww SH YS ES ZS ed e Mer a ig er a 69 J 4 1 gi y AS S ES X
34. rtemperature of engine coolant and hydraulic fluid Therefore when the indicator lamp illuminates the first step to be taken should be to investigate the radiator for free air passage Whenthe indicator lamp lights up the engine will not be shut off 27 Basic Settings and Service Procedures Engine Speed adjustments Adjusting idle speed Checking engine speed with vibration tachometer 1 Lever engine shut off solenoid Stop screw engine shut off solenoid Adjusting screw idle speed Adjusting screw operating speed Throttle lever Clamp bolt Bowden cable Adjusting nut Bowden cable Bowden cable C Solenoid valve engine shut off N ICC1SD Adjusting idle speed Note Engine speed may be checked with the use of a stroboscope digital tachometer or vibration tachometer referto Special Tools Push manual throttle lever on right hand side panel all the way in Adjust Bowden cable 8 in such a way that throttle lever 5 contacts adjusting screw 3 Make necessary corrections on clamp bolt 6 or adjusting nut 7 as required Referto Specifications for idle speed settings Adjusting operating speed Accelerate engine until operating speed has been reached Hold tachometer in close contact with valve cover or engine block Turn rotating plate of vibration tachometer until resonance spring attains maximum deflection
35. t Alternator ICC1SD Unit Functions Equipment Features Engine compartment view toward rear a A RH limit switch debris container 510 LH limit switch debris container S11 Air cleaner Engine cover LH stop screw debris container RH stop screw debris container 17 Unit Functions Equipment Features Fuel tank 1 Fuel level sensor 2 Fuelfiller neck 3 Fueltank 18 ICC1SD gt OO N ICC1SD Equipment Features Heater 4 INLA lt 5 Hot water supply hose Heat exchanger Warm water return hose Heater fan shroud Unit Functions Unit Functions Equipment Features Engine compartment view from rear ICC1SD 8 20 17 16 15 1413 12 1110 9 ICC1SD Equipment Features Engine compartment view from rear 1 Relay radiator fan K9 2 Control module pre glow D1 3 Fuse radiator fan F18 4 Fuse glow plugs F17 5 Splash water guard 6 Hydraulic line to hydraulic motor RR wheel 7 Battery 8 Hydraulic line to steering valve 9 Hydraulic line to side brushes debris container control block 10 Water pump 11 Hose to water pump inlet 12 Hydraulic pumps side brushes debris container steering 13 Hydraulic line
36. t 1 Spray nozzles on side brush 1 Union nut 2 Spray nozzle 34 ICC 1SD Sweeping Mechanism Vacuum intake Coarse dirt flap Sealing lip Caster adjusting clamp bolt 4x Adjusting screw Lock nut Support caster vacuum intake Adjusting guide rods 2x ss Basic Settings and Service Procedures Adjusting vacuum intake Lower vacuum intake Loosen clamp bolts 3 on both sides Loosen lock nuts 5 on both sides Using adjustment screws 4 adjust vacuum intake in such a way that the front sealing lip 2 atthe coarse dirt flap 1 has about O to 1 mm ground clearance Using guide rods 7 adjust sealing lip 2 to provide about 10 to 18 ground clearance at rear After each adjustment again checkthe other measurements 35 Basic Settings and Service Procedures ICC1SD Sweeping Mechanism Warning buzzer debris container Adjusting warning buzzer switch Pull knobs off control levers 2 3 Remove panel mounting screws 4 Detach Bowden cable atinjection pump see page 28 Lift cover panel 5 Unscrew union nut 7 Detach Bowden cable 8 Opening side console Lever coarse dirt flap Lever side brushes and vacuum intake Lever debris container Panel mounting screws 4x Cover panel Manualthrottle Union nut Bowden cable N O C A Switch warning buzzer S18
37. t off solenoid valve Check fuse F 12 Set ignition switch to 0 position Measure magnetic field on solenoid valve no later than 5 seconds after setting ignition key to position switching voltage is present and the solenoid valve does not attract it must be replaced dfnoswitching voltage is present connecting cables and D2 engine shut off control module must be checked and replaced as required 29 Basic Settings and Service Procedures ICC1SD Engine Air cleaner Checking replacing air cleaner When the Air Cleaner Warning indicator light in the combination instrument illuminates the air cleaner mustbe cleaned or its cartridge replaced 3 Detach air cleaner cover 5 and clean together with air cleaner housing 1 not wash Loosen clamp 4 Clean or replace filter cartridge 3 Press in warning switch button 2 to reset Checking air cleaner 1 Aircleaner housing Warning switch reset button Filter cartridge Clamp a A 30 ICC1SD Engine Engine oil Changing oil filter Checking oil pressure switch 1 Oil pressure switch 2 Olilfilter Basic Settings and Service Procedures Checking engine oil level After shutting off engine allow at least five minutes to pass before checking oil level Oil
38. te 11 Front t se DOX ee coc mee pda tim 12 Control console open view e 13 Side console open view eee 14 Engine compartment view from left 15 Engine compartment view from 422 224 16 Engine compartment view toward rear 0 17 hc eee Em 18 EE 19 Engine compartment view from enne enn 20 Function Gro PS e 22 24 Sweeping and vacuum system ek recreo RC e uu Cbr de eh rud 22 lulu M 23 Basic Settings and Service Procedures 25 55 In m H 25 32 25 RO ae EE 26 sSpeed adjustm en p 28 Engine shut off solenoid valve oec eese peti ete ohne 29 m ce TENE 30 ee TEE 31 Drive pump et e cu atia 32 SWEEPING Mechanism cire ter rh eun nnn nion nn nna reg renen bre 33 37 Sweeping pattern T 33 rudes er 34 eren NE dedo ea tole leo nU
39. the tire tread grooves Hooking measuring tape into tread groove Pass measuring tape under unit and across to opposite wheel Read mesaurement x on tread groove corresponding to opposite wheel Measuring front wheel toe in With toe in properly adjusted dimension x at the front of tyres is 5 mm smaller than the dimension at rear of tyres Direction of travel X 5mm X mm Correct front wheel toe in adjustment 42 ICC1SD Running Gear Shock absorber gt A c Upper mounting bolt Loading ramp Lower mounting bolt Shock absorber Basic Settings and Service Procedures Replacing shock absorber Move unit with one wheel onto loading ramp 2 of approx 150 mm height Turn steering wheel to the left or right Remove upper shock absorber mounting bolt 1 Remove lower shock absorber mounting bolt 3 Take out shock absorber 4 Note New shock absorber must be manually extended to proper length before installation 43 Basic Settings and Service Procedures ICC1SD Running Gear Towing and transport VS Important The unit may be towed only with bypass valve open Towing with closed bypass valve will damage hydraulic drive components Towing speed must not exceed walking speed and towed distance must be less than 250 m Ot
40. to hydraulic fluid tank 14 Hydraulic line to hydraulic motor RR wheel 15 Hydraulic line from bypass valve 16 Bypass valve with changeover lever free wheel 17 Water filter 18 Water shut off valve 19 Hydraulic line to bypass valve 20 Hydraulic line to hydraulic motor LR wheel 21 Hydraulic pump driving operation 22 Hydraulic line to hydraulic motor LR wheel Note When removing the battery start by disconnecting the negative terminal and then remove the positive terminal Unit Functions 21 Unit Functions ICC1SD Function Groups Sweeping amp Vacuum system 1 Grille plate deflection plate 10 Vacuum duct 2 Air exhaust 11 Support casters 3 Chain curtain 12 Vacuum inlet 4 Deflection plate 13 Side brush 5 Cover 14 Spray nozzles 6 Debris container 7 Fresh water tank 8 Engine 9 Impellerfan 22 ICC1SD Function Groups Water system A C d Water tank Shut off valve Water filter Water pump Non return valve Metering valve vacuum channel Spray nozzle vacuum channel Spray nozzle 2x side brushes Unit Functions 9 Metering valve side brushes 10 Tankfilllevel indicator in operator cab Effective with serial no 10200 solenoid valve was replaced by non return valve 23 Unit Functions ICC1SD Function Groups Water system
Download Pdf Manuals
Related Search