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Karcher KMR 1250 LPG Service Manual

Other manuals for KMR 1250 LPG: User Instructions

Summary of KMR 1250 LPG

  • Page 1

    5.905-262 09.02 kmr 1250 (kmr 1250 b, kmr 1250 lpg, kmr 1250 d) 1.091- . . . Service manual karcher kmr 2 5 0 1 karcher kmr 2 5 0 1 5.905-122 4-str oke internal comb ustion engines ser vice-man ual 5.905-122.

  • Page 2

    2 foreword kmr 1250 b, lpg, d foreword good servicing requires extensive and relevant training as well as comprehensible reference documents. We therefore offer basic and advanced training courses for the full range of our products to all service technicians on a regular basis. In addition, we produ...

  • Page 3

    3 kmr 1250 b, lpg, d table of contents contents unit functions ........................................................................................................... 4-15 overview ......................................................................................................................

  • Page 4

    4 unit functions kmr 1250 b, lpg, d 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 brak...

  • Page 5

    5 kmr 1250 b, lpg, d unit functions 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 (l...

  • Page 6

    6 unit functions kmr 1250 b, lpg, d view from front 1 gas cylinder (lp gas) 2 steering wheel 3 driver seat 4 lifting mechanism for debris container 5 rear wheel, chain-driven 6 fuel tank for kmr b / d 7 engine kmr b / lpg / d 8 lh side brush (option) 9 front wheel 10 head lights 11 rh side brush 12 ...

  • Page 7

    7 kmr 1250 b, lpg, d unit functions 1 lever dust pickup, close / open 2 button clean dust filter (s2) 3 button lower debris container (s6)* 4 button raise debris container(s8)* 5 button tilt debris container (s7)* 6 lever parking brake 7 lever coarse-dirt flap 8 headlight switch (s4) 9 operating hou...

  • Page 8

    8 unit functions kmr 1250 b gasoline engine (honda gx 270) 1 stop screw, throttle valve 2 idle jet 3 bypass 4 throttle valve 5 idle orifice 6 idle jet bore and idle air channel 7 carburetor throat (venturi) 8 idle air inlet 9 choke valve 10 main air jet 11 idle system 12 emulsion tube 13 air orifice...

  • Page 9

    9 kmr 1250 b unit functions gasoline engine (honda gx 270) float system when float chamber (14) is empty, fuel passes from fuel tank into float chamber (14) via the 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)...

  • Page 10

    10 unit functions kmr 1250 b, lpg, d 1 valve guard 2 lp gas line 3 cylinder shutoff valve 4 outlet tube 5 lp gas cylinder 6 sun shield 7 lp gas in gaseous state 8 lp gas in liquid state 9 carburetor 10 engine 11 vacuum line 12 lp gas line 13 gas filter 14 solenoid valve, gas supply 15 mixture contro...

  • Page 11

    11 kmr 1250 b, lpg, d unit functions – the presence of frost 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 ...

  • Page 12

    12 unit functions kmr 1250 b, lpg, d diesel engine (yanmar l 70 ae-de) 1 drive shaft 2 housing, engine 3 piston 4 cylinder head 5 injector 6 fuel feed line 7 fuel line from fuel tank 8 injection pump 9 shim 10 housing, injection pump 11 cam shaft injection system the injection pump (8) delivers fuel...

  • Page 13

    13 kmr 1250 b, lpg, d unit functions diesel engine (yanmar l 70 ae-de) injection pump (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 valve (7). Injection timing is determine...

  • Page 14

    14 unit functions kmr 1250 b, lpg, d steering and drive power 1 rh drive chain 2 impeller fan 3 drive belt, impeller fan 4 drive belt, hydrostatic transmission 5 hydrostatic transmission 6 lh drive chain 7 brush roller 8 drive belt, brush roller 9 drive belt, lh side brush (option) 10 lh side brush ...

  • Page 15

    15 kmr 1250 b, lpg, d unit functions 1 hydraulic unit 2 engine b / lpg / d 3 steering wheel 4 operator seat 5 debris container, raised 6 impeller fan 7 dust filter sweeping system 8 rear wheel 9 debris container, lowered 10 hydrostatic transmission 11 brush roller 12 coarse-dirt flap 13 front wheel ...

  • Page 16

    16 troubleshooting information 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) chec...

  • Page 17

    17 kmr 1250 b, lpg, d troubleshooting information check voltage on starter solenoid – hold ignition switch in position ii. – measure the voltage between solenoid ter- minal and vehicle ground. – if the meter fails to indicate a voltage, wiring must be checked for possible defect. – if a voltage is p...

  • Page 18

    18 troubleshooting information kmr 1250 b, lpg, d check regulator original when the engine is running, the alternator gener- ates a continuous current flow. The regulator automatically adapts this current as required (depending on battery charge status and electri- cal load). – start engine and allo...

  • Page 19: - S3

    19 kmr 1250 b, lpg, d troubleshooting information 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. – connect an ohmmeter to check seat contact switch for continuity...

  • Page 20

    20 troubleshooting information kmr 1250 b, lpg, d starter turns engine but engine fails to start check compression release lever (diesel engine) – engine is equipped with compression release lever. During engine starting, it can be actu- ated for a short while to ease overcoming engine resistance at...

  • Page 21

    21 kmr 1250 b, lpg, d troubleshooting information check freewheeling function the transmission features a freewheeling lever which can be used to engage or disengage the drive power. Starting with s/n 10121, this freewheeling lever is permanently mounted on the transmission link- age. It is held in ...

  • Page 22

    22 troubleshooting information kmr 1250 b, lpg, d checking drive pedal original a linkage connects the drive pedal to the shift lever (2) on the transmission (7). When the drive pedal is not actuated, the shaft-mounted leg spring (6) always returns this lever to the center position . When at the cen...

  • Page 23

    23 kmr 1250 b, lpg, d troubleshooting information engine runs but machine fails to move shift lever on transmission adjusting drive pedals checking drive pedal revised a linkage connects the drive pedals to the shift lever (4) on the transmission (1). When the drive pedals are not actuated, the pull...

  • Page 24

    24 troubleshooting information kmr 1250 b, lpg, d engine runs but machine fails to move adjust hydrostatic transmission starting with serial no. 11482 to serial no. 11882, the hydrostatic transmission (1) is installed in a slanted position. As the slant is not adjustable, engine and transmission dri...

  • Page 25

    25 kmr 1250 b, lpg, d troubleshooting information insert hydrostatic transmission note: starting with serial no. 10 053, the transmis- sion is slanted forward, putting less strain on the drive belt. Check and observe parking brake effectiveness and belt tension when a new transmission is in- stalled...

  • Page 26

    26 troubleshooting information kmr 1250 b, lpg, d note: for operating and maintenance instructions, consult the operator manual for this engine. Check engine oil level – engine oil level must be between the min and max markings on the dipstick. Top up engine oil – the dipstick hole is used to add ne...

  • Page 27

    27 kmr 1250 b, lpg, d troubleshooting information carburetor w/ fuel cock and sediment bowl 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. Adjust...

  • Page 28

    28 troubleshooting information kmr 1250 lpg maintenance procedures (lpg engine) set co value (lpg engine) to adjust co value, the following measuring de- vices will be needed: – tachometer, p/n 6.491-361 – exhaust analyser. Procure suitable co an- alyser locally; requires measuring range up to 2% co...

  • Page 29

    29 kmr 1250 lpg troubleshooting information maintenance procedures (lpg engine) 2. Set co value at operating speed – set accelerator lever on instrument panel to max position (operating speed). – measure operating rpm and adjust via stop screw (6) on carburetor as required. Operat- ing speed has to ...

  • Page 30

    30 störungshilfe kmr 1250 d note: for operating and maintenance instructions, consult the operator manual for this engine. Check engine oil level – engine oil level must be between the min and max markings on the dipstick. Top up engine oil – the dipstick hole is used to add new oil to the engine. F...

  • Page 31

    31 kmr 1250 d störungshilfe maintenance procedures (diesel engine) governor adjusting screw, diesel engine checking fuel solenoid valve, diesel engine adjusting engine operating speed, diesel engine 1 2 2 5 6 3 4 406 peak hold 406a 1006a 606v 406v khz 9 8 7 10 11 1 adjusting screw, operating speed 2...

  • Page 32

    32 troubleshooting information 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%, a...

  • Page 33

    33 kmr 1250 b, lpg, d 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 combina...

  • Page 34

    34 troubleshooting information 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 de...

  • Page 35

    35 kmr 1250 b, lpg, d troubleshooting information 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 respecti...

  • Page 36

    36 troubleshooting information kmr 1250 b, lpg, d 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...

  • Page 37

    37 kmr 1250 b, lpg, d 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...

  • Page 38

    38 troubleshooting information kmr 1250 b, lpg, d coarse debris flap in open position sealing shaker motor flange 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 ...

  • Page 39

    39 kmr 1250 b, lpg, d 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 du...

  • Page 40

    40 troubleshooting information 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, it was attached to the filter housing. With the filter housing lowered, the seal must reliably seal of...

  • Page 41

    41 kmr 1250 b, lpg, d 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 a...

  • Page 42

    42 troubleshooting information kmr 1250 b, lpg, d check terminals (x 10 / x 11) in filter hous- ing power for the filter cleaning motor is supplied via two spring-loaded contact terminals (1). With the debris container lowered, spring-load- ed contact points (1) mounted on the divider baffle must re...

  • Page 43

    43 kmr 1250 b, lpg, d 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 a voltmeter, check input voltage of m2 hydraulic unit betw...

  • Page 44

    44 troubleshooting information kmr 1250 b, lpg, d 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 ...

  • Page 45

    45 kmr 1250 b, lpg, d troubleshooting information hydraulic unit w/ pressure relief valve adjusting pressure relief valve 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 curr...

  • Page 46

    46 troubleshooting information kmr 1250 b, lpg, d excessive steering free play adjusting steering free play adjust steering free play wear and tear and stretching of the steering chain (1) may cause excessive steering free play. If steering free play becomes too large, the steering chain must be tig...

  • Page 47

    47 kmr 1250 b, lpg, d troubleshooting information.

  • Page 48

    Kmr 1250 b, lpg, d 48 hydraulic block diagram 0.087-964 original through s/n 10441 a, b pressure connection, hydraulic unit d1 throttle valve d2 throttle valve d3 throttle valve db pressure relief valve hp hydraulic unit m2 electric motor, hydraulic unit p hydraulic pump r1/r2 non-return valve rb pi...

  • Page 49

    Kmr 1250 b, lpg, d 49 a, b pressure connection, hydraulic unit d throttle valve db pressure relief valve e filler / purge screw f filter hp hydraulic unit m2 electric motor, hydraulic unit p hydraulic pump r non-return valve rb pipe-break valve s throttle valve y1 solenoid valve – tilt debris contai...

  • Page 50

    Kmr 1250 b, lpg, d 50 electrical circuit diagram 0.087-963 (kmr 1250 b) note: unmarked wiring has cross-section of .75 sq. Mm 3 1 6 -a1 x4 x5 x2 x3 x1 x6 -s1 50a 30 ii 0 i 0,1 -g2 g -f4 (15a) -p1 h -g1 -f1 (10a) -s3 -s9 -a2 -e2 -e4 -s6 1 2 -s5 1 2 -y2 -s7 1 2 4 5 -y1 1 2 -f3 (60a) -s8 4 5 -m2 + - -s...

  • Page 51

    Kmr 1250 b, lpg, d 51 a1 filter cleaning control a2 ignition e1-e4 headlights f1 fuse - filter cleaning motor f2 fuse - control voltage f3 fuse - hydraulic unit f4 fuse - alternator g1 battery g2 alternator h1 indicator lamp - headlights h2 horn k1 relay - filter cleaning motor m1 starter m2 hydraul...

  • Page 52

    Kmr 1250 b, lpg, d 52 electrical circuit diagram 0.088-151 (kmr 1250 lpg) note: unmarked wiring has cross-section of .75 sq. Mm 0,75 qmm (sw/rt) 15 m g h 5 6 m -a2 x11 x10 5 6 5 6 5 6 5 6 5 6 5 6 3 -f4 (15a) 12v/44 ah -m3 g1 + - (ws) -f3 (60a) x4 x5 -f1 (10a) -f2 (7,5a) x1 x2 x3 x4 -a1 1,5 qmm (rt) ...

  • Page 53

    Kmr 1250 b, lpg, d 53 electrical circuit diagram 0.088-151 (kmr 1250 lpg) a1 filter cleaning control a2 ignition e1-e4 headlights f1 fuse - filter cleaning motor f2 fuse - control voltage f3 fuse - hydraulic unit f4 fuse - alternator g1 battery g2 alternator h1 indicator lamp - headlights h2 horn m1...

  • Page 54

    Kmr 1250 b, lpg, d 54 electrical circuit diagram 0.088-097 (kmr 1250 d) note: unmarked wiring has cross-section of .75 sq. Mm -m1 30 50a m g1 + - -a1 x4 x5 x2 x3 x1 x6 -f1 (10a) -f2 (7,5a) -m3 m -y2 1 2 -m2 + - m -s5 1 2 -s9 -h2 -y3 1 2 -e1 -e3 -e2 -e4 -s3 -f3 (60a) -s1 50a 30 ii 0 i 0,1 -s4 1 2 4 5...

  • Page 55

    Kmr 1250 b, lpg, d 55 electrical circuit diagram 0.088-097 (kmr 1250 d) a1 filter cleaning control a2 ignition e1-e4 headlights f1 fuse – filter cleaning motor f2 fuse - control voltage f3 fuse – hydraulic unit f4 fuse – alternator g1 battery g2 alternator h1 indicator lamp – headlights h2 horn m1 s...

  • Page 56

    Kmr 1250 b, lpg, d 56 maintenance procedures for b, lpg & d models 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/fil...

  • Page 57

    Kmr 1250 b, lpg, d 57 maintenance procedures for b, lpg & d (after operating hours) maintenance procedures 8 100 200 300 400 500 600 700 800 900 1000 engine oil - check o o o o o o o o o o o main drive belt tension - check o o o o o o o o o o o main drive belt - replace o o engine air cleaner - clea...

  • Page 58

    Kmr 1250 b, lpg, d 58 service weight (operational) 420 kg permitted gross weight 600 kg length 1650 mm / 64.96 in width 1000 mm / 39.37 in height 1270 mm / 50 in driving speed, forward, max. 7 - 8 km/h driving speed, reverse, max. 4 - 6 km/h climbing ability, max. 18 % width, sweeping path w/o side ...

  • Page 59

    Kmr 1250 b, lpg, d 59 engine, kmr 1250 b / lpg (p/n 6.491-573) designation honda gx 270 type 4-stroke no. Of cylinders 1 displacement 270 cm 3 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 ...

  • Page 60

    Kmr 1250 b, lpg, d 60 special tools ignition spark tester, gasoline & lp gas engine mechanical tachometer (all engines) digital tachometer for gasoline and lp gas engine digital tachometer for gasoline and lp gas engine from a distance of approx. 100 mm (4 in.), point this digital tachometer at spar...

  • Page 61

    Kmr 1250 b, lpg, d 61 special tools multimeter w/ test probes 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 k Ω ) p/n 6.803-022 spark plug wre...

  • Page 62

    Kmr 1250 b, lpg, d 62 dual-function hand pump leak detection spray 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...

  • Page 63

    Kmr 1250 b, lpg, d 63 index a adjust hydrostatic transmission 24 parking 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 rolle...

  • Page 64

    Kmr 1250 b, lpg, d 64 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 ...

  • Page 65

    Kmr 1250 b, lpg, d 65 replace brush 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...