Kärcher KM 100, KM 100 R D Operating Instructions Manual

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KM 100/100 R D

1.280-114

www.kaercher.com

5.960-836 A2008261 05/04

KM 100/100 R D

Betriebsanleitung 3

Ersatzteilliste 187

Operating instructions 21

Spare Parts List 187

Notice d'utilisation 39

Liste des pièces de rechange 187

Istruzioni per l'uso 57

Elenco pezzi di ricambio 187

Gebruiksaanwijzing 75

Reserveonderdelenlijst 187

Instrucciones de servicio 93

Lista de piezas de requesto 187

Käyttöohje 111

Varaosalista 187

Driftinstruktion 129

Reservdelslista 187

Οδηγίες λειτουργίας 147

Бнфбллбкфйкб 187

Руководство по эксплуатации 168

Запасные части 187

Operating instructions KM 100/100 R D English

Contents

For your own safety! 22

General notes 22 Risk of overturning on too high gradients! 23 Risk of overturning when taking bends rapidly! 23 Danger of tipping over given an unstable travelling surface! 23 Danger of tipping over given a sideways incline that is too large! 23

For our environment 23

Please dispose of packaging environmentally responsibly 23 Please dispose of scrapped units environmentally- responsibly23 Please dispose of batteries and accumulators ecologically 23 Please do not allow engine oil, fuel oil, diesel and petrol 23

Intended use 23

Function description sweeping machine 23

Control elements 24

Machine parts 24

Before first operating 24

Open/close unit cover 24 Moving road sweeping machine with automotive power 24 Operating sweeping machine without automotive power 25 Unloading instructions 25

Before every operation 25

General notes 25 Testing and maintenance work 25

Commissioning 25

Adjust driver seat 25 Start machine 26 Run machine 26 Sweeping operation 27 Manual filter cleaning 27 Stop machine 28 Empty the swept material container 28

Usage instructions 28

Safety instructions when sweeping 28 Sweeping dry ground 28 Sweeping damp or wet ground 28 Driving over obstacles 29

Decommissioning 29

Transport 29

Transport instructions 29

Cleaning and maintenance 29

Internal cleaning 29 External cleaning 29

Maintenance intervals 29

Elapsed-time meter 29 Maintenance by the customer 29 Maintenance by the customer service department 30

Maintenance tasks 30

Notes on safety 30 Battery safety instructions 30 Mount and connect battery 30 Charge the battery 30 Checking the battery acid level 31 Check the (fill) level of the fuel tank 31 Refill fuel 31 Check the tyre air pressure 31 Changing wheels 31 Check engine oil level and top-up 32 Change the engine oil 32 Checking/replacing the air cleaner 32 Check and top up the hydraulic oil level 33 Checking the vacuum system 33 Check the side brush 33 Replacing side brush 33 Check the sweep roller 33 Replace the sweep roller 34 Check sweeping pattern of the main brush 34 Adjusting and replacing sealing strips 35 Replace the dust filter 35 Replacing the filter box seal 36 Checking traction belt 36 Changing fuses 36

Fault instructions 36

Accessories 37

Technical data 37

EC conformity declaration 38

Operating instructions KM 100/100 R D English

For your own safety!

General notes

Reading and observing prior to use of the machine is essential!

— Notify your sales outlet if during

unpacking you detect damage that has occurred in transit.

! Read the operating instructions

of your machine prior to its initial operation and especially observe the safety notes.

— The warning and information

labels attached to the machine provide important information on its safe operation.

— In addition to the instructions in

the operating instructions, general safety- and accident prevention-regulations from lawgivers must be followed.

Use

! The machine is to be used

exclusively according to the specifications given in these operating instructions.

! Prior to its use the machine and

its attachments must be checked for their proper condition and operational reliability. It must not be used if its condition is not faultless.

— No modifications permitted on the

machine.

— The machine is for sweeping

outdoor surfaces.

— Never absorb explosive liquids,

inflammable gases or undiluted acids and solvents! These include petrol, paint thinner or fuel oil, which can develop explosive vapours or mixtures due to the turbulance of the suction air, and also acetone, undiluted acids and solvents, since these attack the materials used in the manufacture of the machine.

— Do not sweep up/absorb burning

or smouldering objects.

Only if clearly identified as such is this machine suitable for suction removal of health hazardous dusts.

Observe the safety-related notes given in the operating instructions.

— Suitable only for the surfaces

listed in the operating instructions.

— The appliance may be used on

only the areas cleared for its use by the factory owner or a person authorized by him.

— Keep clear of the danger area. Its

operation in explosion hazardous locations is prohibited.

— The following applies generally:

Keep combustible materials away from the machine (danger of explosions-/fire).

Operation

— The rules, regulations and

stipulations applying to motor vehicles must always be observed.

— The operator must use the

machine for its agreed proper purpose. When driving it he must allow for the site’s conditions, and when working with the machine be must look out for bystanders, especially children.

— The machine may only be used

by persons instructed in how it is to be used, who have proved their capability to use it and who have expressly been instructed to use it.

— It is forbidden for children or

juveniles to operate the machine.

! The ignition key must be

removed from machines provided with it in order to prevent unauthorised use of the machine.

! The machine must never be left

unsupervised while the motor is running. The operator is not allowed to leave the machine unless the engine has been turned off, the machine is secured against unintended movements, the parking brake, if provided, is actuated, and the ignition key has been removed.

— On slopes the angle of inclination

to the side and in the direction of motion must not exceed the value given in the operating instructions.

Transport

! The motor must be turned off

when the machine is transported.

! Secure the machine with guy

belts, ropes or chains.

! Immobilise the machine at the

wheels with chocks.

Maintenance

! Switch off the machine and, if

provided with one, remove the ignition key prior to cleaning it and performing maintenance work on it or when resetting it to a different operation.

! The battery plug connection or

the battery must be disconnected for work on the electrical installation of battery-powered machines.

— Do not clean the machine with

fluid jets.

— Repairs may only be carried out

by approved customer service centres or by technical personnel trained in this field which are familiar with all relevant safety regulations.

— Mobile, commercially used

machines are subject to the safety inspection in compliance with VDE 0701.

— Use only the main brushes/side

brushes supplied with the machine or specified in the operating instructions. Using other main brushes/side brushes can be detrimental to safety.

— The machine is not be be

cleaned by hosing down or with a high-pressure water jet (danger of short circuits or other damage).

Accessories and spare parts

— Only accessories and spare parts

cleared by the manufacturer may be used. Genuine accessories and spare parts ensure that the machine can be operated safely and trouble-free.

Ride-on machine

— Ride-on machines are not

approved for public road traffic. Please ask your retailer for the conversion kit for streetworthiness.

— Giving companions lifts is not

permissible.

— Ride-on machines may be set in

motion only from the seat.

Machines with a combustion engine

! The exhaust opening must not be

sealed.

! Do not bend over or touch the

exhaust opening (danger of burns).

! Do not touch or grasp the drive

motor (danger of burns).

! Adequate ventilation and

extraction of exhaust emissions must be provided when operating the machine indoors. (Danger of poisoning)

! Exhaust gases are toxic and

damaging to health; do not inhale them.

! The engine takes approx. 3...4 s

to run down after being shut off. Never enter operating area during this period!

Operating instructions KM 100/100 R D English

The following must be observed when refuelling machines with a combustion engine: ! Only the fuel specified in the

operating instructions may be used. An explosion hazard exists with unsuitable fuels.

! The engine must be switched off. ! Do not fill-in fuel in closed rooms. ! Make sure that no fuel comes

into contact with hot surfaces.

! Do not use any burning or

glowing objects or carry or put them near the machine during refuelling (explosion hazard).

! Fill the tank at the most 1 cm

below the lower edge of the filler neck, since the fuel expands in heat.

! Wipe off spilled over fuel and

close tank cap tightly.

Risk of overturning on too high gradients!

Danger!

The machine could topple over when driving and turning on slopes.

— Drive only on slopes up to 18 %

in the travelling direction.

— At right angles to direction of

travel only negotiate gradients up to a maximum of 15 %.

Risk of overturning when taking bends rapidly!

Danger!

The machine can topple-over when driving fast around curves.

! Drive slowly in curves.

Danger of tipping over given an unstable travelling surface!

Danger!

The machine can tip over given an unstable travelling surface.

! Move the machine exclusively on

a solid travelling surface.

Danger of tipping over given a sideways incline that is too large!

Danger!

The machine can tip over given an incline of more than 15 %.

For our environment

Please dispose of packaging environmentally responsibly

The packaging materials are recyclable. Please do not throw the packaging in with household rubbish but take it to a recycling centre.

Please dispose of scrapped units environmentallyresponsibly

Scrapped units consist of valuable recyclable materials that should be taken to a recycling centre. Batteries, oil and similar products must not be allowed to contaminate the environment. Therefore, please dispose of scrapped units via appropriate disposal systems.

Please dispose of batteries and accumulators ecologically

Batteries and accumulators contain substances that are not allowed to contaminate the environment. Please, therefore, dispose of them in appropriate recycling systems.

Please do not allow engine oil, fuel oil, diesel and petrol

to contaminate the environment. Please protect the ground and dispose of used oil ecologically.

Intended use

— This sweeping machine is

designed for sweeping surfaces in outdoor areas.

— It is not intended for use on

public traffic routes.

— It is not suitable for health-

hazardous dusts.

Function description sweeping machine

The KM 100/100 R sweeper operates according to the throwover principle. — The side brush (3) cleans corners

and edges of the sweeping surface and transports the dirt in the path of the main brush.

— The rotating main brush (4)

transports the dirt directly into the debris container (5).

— The dust swirled up in the

container is separated by way of the dust filter (2) and the filtered, clean air removed by the suction turbine (1).

Operating instructions KM 100/100 R D English

Control elements

1. Steering wheel

2. Raising/lowering coarse-dirt flap pedal

3. Forward driving/reversing drive pedal

Machine parts

1. Unit cover

2. Debris container (bilateral)

3. Coarse-dirt flap

4. Roller

5. Side brush

Before first operating

The sweeper is provided with a hydrostatic drive. Therefore, when the freewheel lever is engaged in its top position it is only possible to push the machine.

Open/close unit cover

! Pull stay bar out of the bracket

Moving road sweeping machine with automotive power

! Open unit cover, engage stay bar

1. Raising/lowering main brush

2. Raise/lower side brush

3. Filter de-duster

4. Ignition switch

5. Elapsed-time meter

6. Horn

Open unit cover ! Lift unit cover up at the provided

handle grip

In its open position the unit cover is secured by a stay bar.

! Insert the stay bar into the

adapter at the suction turbine

! to close the unit cover pull the

stay bar out of its slot and engage it in the bracket in the unit cover

! Snap freewheel lever in place in

the bottom position

— Drive system and parking brake

are active

Operating instructions KM 100/100 R D English

Operating sweeping machine without automotive power

Danger!

Immobilise the machine against inadvertent movement prior to engaging the freewheel. The brake is ineffective once the freewheel has been engaged.

! Open unit cover, engage stay bar

! Pull freewheel lever up and latch

it in place in this position

— This makes the drive system

inoperable, it is possible to push the machine

Note:

— When the sweeper is not self-

powered do not move it over longer distances and not faster than 6 km/h .

Unloading instructions

Warning!

When the machine is loaded the freewheel lever must generally be engaged in its bottom position. Only then are the drive system and the parking brake operable.

— The machine was secured on a

pallet with stretch belts or ropes for safe transport. Proceed as follows when unloading:

! Cut the plastic packing tape and

remove the film.

! Connect battery (see

maintenance work chapter)

! Remove the blocks for securing

the wheels and drive the machine off the pallet using a suitable ramp.

Warning!

Do not use a fork lifter for unloading; the machine can be damaged by it.

Before every operation

General notes

! Stand sweeper on a flat surface ! Remove the ignition key

Testing and maintenance work

! Check engine oil level * ! Check level of the fuel tank * ! Check level of hydraulic oil * ! Check side brushes * ! Check main brush * ! Empty the swept material

container

! Check tyre inflation pressure *

* See maintenance work chapter for instructions

Commissioning

Warning!

It is not permissible to cover the air suction openings behind the driver’s seat. It is not permissible to deposit objects next to or behind the seat.

Suction openings

Adjust driver seat

! Open unit cover, engage stay bar

! Slightly loosen wing nuts of seat

runners

! Push the seat into the

appropriate position

! Retighten wing nuts

Note:

There is a further adjustment possibility if the adjusting range is insufficient

Operating instructions KM 100/100 R D English

! Unscrew the 4 screws at the seat

contact switch plate

! Remove the plate ! Turn the seat forward

! Unscrew the 4 screws of the seat

mounting

! Shift seat and refasten with

screws

! Remount seat contact switch

plate

Start machine

! Open unit cover, engage stay bar

Open the fuel tap

! Slide lever towards "O"

! Close unit cover ! Sit on the driver seat ! Do NOT actuate the drive pedal!

! Main brush switch in its upper

position

! Side brush switch in its upper

position

Note:

Never actuate the starter motor for more than 10 s. Wait at least 10 s before actuating the starter motor again.

Run machine

Prior to start of the machine

! Main brush switch in its upper

position

Freewheel lever of axle drive must be in its bottom position

! Start machine

Drive forwards ! Slowly press the driving pedal

Note:

The machine is equipped with a seat contact switch. The machine is switched off as the driver leaves the seat and the parking brake automatically actuated.

! Turn ignition key beyond

position 1

! When the machine starts, release

ignition key

! Side brush switch in its upper

position

Operating instructions KM 100/100 R D English

Sweeping operation

Warning!

In order to avoid damaging the floor do not operate the sweeper while it is stationary.

Drive backwards ! Slowly press the driving pedal

Note:

Driving behaviour — The driving speed can be varied

continuously with the driving pedals.

— Avoid abrupt actuation of the

pedal because this could damage the hydraulic system.

— Slightly release drive pedal if

power decrease is registered uphill.

Braking

! Release the driving pedal; the

machine brakes automatically and comes to a standstill.

! Lower main brush

— Sweeping with the main brush

! The coarse-dirt flap must be

briefly raised for sweeping in largish objects up to a height of 60 mm, e.g. drinks cans.

Raise coarse-dirt flap ! Press pedal forwards and keep it

depressed

! To lower it, lift foot off pedal

— Sweeping with raised coarse-dirt

flap

Note:

An optimal cleaning effect can be achieved only when the coarse-dirt flap is completely lowered

! Lower side brushes (for

sweeping in border areas

— Sweeping with side brushes

Notes:

— The main brush and the side

brushes start automatically.

! First it is always necessary to

activate the main brush, since otherwise the sweeping system does not start.

— The sweeping system is

activated using the rocker switch at the instrument panel.

— The vacuum system must be

checked if the side brush cannot be lowered.

See maintenance tasks chapter for description

Vacuum canister for lowering the side brush (to the left and next to the front wheel viewed from the front

Manual filter cleaning

Clean the dust filter regularly when sweeping large surfaces.

! Press filter cleaning switch

briefly. The dust filter is cleaned for approx. 15 seconds. Do not open the unit cover during this period.

Operating instructions KM 100/100 R D English

Stop machine

! Raise the side broom

! Raise the sweep roller

! Open unit cover, engage stay bar

Close fuel shut-off valve ! Slide lever towards "S"

Note:

The machine is provided with an automatic parking brake, which is activated when the engine is stopped and the driver leaves his seat.

Empty the swept material container

! Wait until automatic filter

dedusting is completed and the dust has settled before opening the debris container and emptying it.

! Pull out debris container

! Empty the swept material

container

! Slide in and lock the debris

container

! Then perform the same

operations on the opposite debris container

Usage instructions

Safety instructions when sweeping

Warning!

— Never sweep up packing straps,

wires or the like as this could damage the sweeping mechanism.

— When the coarse-dirt flap is

open, the main brush can hurl stones or stone chips forwards. Make sure that nobody, no animals or objects are endangered.

Notes:

! For optimum cleaning effect,

match the driving speed to suit the actual conditions.

! During operation the debris

container should be emptied at regular intervals.

! Lower the sweeping roller for

surface sweeping.

! Lower the side broom for

cleaning side edges.

Sweeping dry ground

! Close the bypass cover on left

behind the seat

Sweeping damp or wet ground

! Turn ignition key to "0" and

remove it

Note:

The dust filter is automatically dedusted for approx. 15 s after shutting down of the machine. Do not open the unit cover while this is going on.

! Open the bypass cover on left

behind the seat

— This protects the filter from damp

Operating instructions KM 100/100 R D English

Driving over obstacles

Fixed obstacles of up to 50 mm in height

! Slowly and carefully drive over

them in the forward direction.

Fixed obstacles over 50 mm in height

! May be driven-over only with a

suitable ramp.

Decommissioning

Please heed the following if sweeper is not to be used for a lengthy period:

! Stand sweeper on a flat surface ! Raise the sweep roller and side

broom to prevent damage to the bristles

! Turn ignition key to "0" and

remove it

! Close fuel shut-off valve ! Secure sweeper to stop it rolling

away

! Clean inside and outside of

sweeper

! Turn off the machine on a

protected and dry place

! Change the engine oil ! Disconnect the batteries ! Recharge the battery at intervals

of approx. 2 months

Transport

Transport instructions

Warning!

When the machine is loaded the freewheel lever must generally be engaged in its bottom position. Only then are the drive system and the parking brake operable. Uphill or downhill the machine must always be moved automotively.

! Turn ignition key to "0" and

remove it

! Empty tank ! Secure the machine with wedges

on the wheels

! Secure the machine with stretch

belts or ropes

Fastening areas

Notes:

Observe markings for fastening areas on base frame! (chain symbols) For loading or unloading the machine may be operated on slopes of only up to a max. of 18 %

Cleaning and maintenance

! Stand sweeper on a flat surface ! Turn ignition key to "0" and

remove it

Internal cleaning

Danger!

Wear dust mask! Wear safety goggles!

! Open unit cover, engage stay bar ! Clean with a rag ! Blow-out with compressed air

External cleaning

Clean with a damp cloth previously soaked in mild suds

Note:

Do not use any aggressive cleaning agents!

Maintenance intervals

Elapsed-time meter

Elapsed-time meter indicates maintenance interval times.

Maintenance by the customer

Daily maintenance

! Check the engine oil level ! Check axle drive oil level ! Check the tyre air pressure ! Check roller and side brush for

wear and trapped straps

! Check the function of all

operating controls

Maintenance weekly

! Check air filter ! Check oil level of sweeping

hydraulics

! Check hydraulic hose for leaks ! Check freedom of movement of

Bowden cables and moving parts

! Check setting and wear of

sealing strips in sweeping area

! Check vacuum system (operation

of lowering side brushes)

Maintenance every 100 operating hours

! Enging-oil change (first change

after 20 operating hours)

! Check operation of seat contact

switch

! Checking the battery acid level ! Check tightness, wear and

operation of drive belts (V-belts and round belts)

Maintenance according to degree of wear

! Replace sealing strips ! Replacing the sweep roller ! Replacing the side broom

See maintenance tasks chapter for description

Note:

Where maintenance is undertaken by the customer, all service and maintenance work must be carried out by a qualified employee. A Kärcher specialist dealer can be consulted whenever support is necessary.

Operating instructions KM 100/100 R D English

Maintenance by the customer service department

Maintenance after 20 operating hours

First inspection

Maintenance every 100 operating hours

Maintenance every 300 operating hours

Note:

To safeguard warranty rights, during the warranty period all service and maintenance work must be performed by an authorised Kärcher after sales service.

Maintenance tasks

Notes on safety

Warning!

Preparations

! Stand sweeper on a flat surface ! Turn ignition key to "0" and

remove it

Danger!

— The engine takes approx. 3...4 s

to run down after being shut off.

! Never enter operating area

during this period!

! Allow the machine to adequately

cool down prior to all maintenance and repair work

! Do not touch hot parts such as

the driving engine and exhaust system.

Please do not allow engine oil, fuel oil, diesel and petrol

to contaminate the environment. Please protect the ground and dispose of used oil ecologically.

Battery safety instructions

Danger!

Always heed safety precautions for handling batteries! Observe the operating instructions Work on batteries is permitted only after instruction by trained personnel

Danger!

! Wear safety goggles and

protective clothing

! Observe regulations for the

prevention of accidents as well as DIN VDE 0510, VDE 0105 T.1

Danger!

Risk of fire and explosion!

— Smoking prohibited — No naked flames, glowing

embers or sparks in the vicinity of batteries

— Do not place any objects or tools

on the battery because voltage is always present between the battery poles

— Areas in which batteries are

charged must be well ventilated, as highly explosive gas forms during charging

Danger of acid burns!

! Rinse out or rinse off splashes of

acid in the eye or on the skin with copious quantities of clean water

! Then consult a doctor

immediately

! Wash contaminated clothing with

water

Please dispose of batteries and accumulators ecologically

Batteries and accumulators contain substances that are not allowed to contaminate the environment. Please, therefore, dispose of them in appropriate recycling systems.

Mount and connect battery

! Open unit cover, engage stay bar

! Place battery in the battery

mounting

! Screw mountings to bottom of

battery

! Connect battery terminal clip (red

wire) to positive terminal post (+)

! Connect battery-terminal clip to

negative terminal post (-)

Note:

When removing the battery care must be taken to ensure that first the negative terminal post lead is disconnected. Check that the battery poles and pole connectors are protected adequately with pole protecting grease

Charge the battery

Danger!

! Always heed safety precautions

for handling batteries!

! It is essential to observe the

instructions provided by the manufacturerer of the charging unit

! Disconnect the batteries ! Connect positive terminal post

lead of the battery charger with the battery’s positive terminal post connection

! Connect negative terminal post

lead of battery charger with the battery’s negative terminal post connection

! Plug in power plug and switch on

charger

Operating instructions KM 100/100 R D English

Checking the battery acid level

Warning!

! Regularly check the fluid level of

acid-filled batteries.

! Screw out all cell plugs

! If the fluid level is too low fill up

cells with distilled water up to mark

! Charge the battery ! Screw in the cell plugs

Check the (fill) level of the fuel tank

! Open unit cover, engage stay bar

Fill level indicator

Refill fuel

Danger!

Explosion hazard

— Do not fill-in fuel in closed rooms

! Shut-off the engine

— Smoking and naked flames

prohibited

! Open tank cap ! Refuel with "Diesel" ! Fill tank to a maximum of 1 cm

below the bottom edge of the filler pipe

! Wipe off overflowed fuel and

close tank cap

Check the tyre air pressure

! Set inflation pressure of front tyre

to 6 bar.

! The air pressure in the rear tyres

must be set to 6 bar.

Changing wheels

Danger!

Preparations

! Stand sweeper on a flat surface ! Remove the ignition key ! Wear warning clothing when

performing repair work on public streets where it is dangerous because of moving traffic .

! Check that the ground is stable ! Protect the machine additionally

from moving with a wheel chock

Recommended express assistance:

! Check the tyre tread for

imbedded objects

! Remove the objects ! Use a suitable, commercially

available tyre repair agent

Notes:

Comply with the recommendations of the respective manufacturers Continuing the journey is possible if the recommendations of the product manufacturer are observed Change the tyre or the wheel as soon as possible

! Unscrew the wheel nuts ! Place the jack in position

Operating instructions KM 100/100 R D English

Fixing point for jack (front wheel)

Jack fixing point (rear wheels)

! Lift the machine with the jack ! Remove the wheel nuts ! Slide the wheel off ! Position the spare wheel ! Screw on wheel nuts ! Lower the machine with the jack ! Tighten the wheel nuts

Check engine oil level and top-up

Danger!

Danger of burns!

! Let the engine cool-down ! Wait at least 5 minutes after

stopping engine before performing the check

! Open unit cover, engage stay bar

! Turn out oil dip stock ! Wipe and insert oil dip stick

! Fill engine oil using the oil

change pump 6.491-538

! Close the oil fill opening ! Wait for at least 5 minutes ! Check the engine oil level

For oil grade see: Technical data

Change the engine oil

! Turn out oil dip stock

! Suck out engine oil with oil-

change pump 6.491-538 through the oil filler

! Fill in new engine oil with a clean

6.491-538 oil change pump using the oil filler

For oil grade see: Technical data

Checking/replacing the air cleaner

! Open unit cover, engage stay bar

! Unscrew wing nut

Note:

Use suitable, commercially available jacks

! Pull out oil dip stick

— At least a third of the oil dip stick

must be immersed into the oil.

— Refill engine oil up to lower edge

of tank inlet if the oil level is below it.

! Close the oil fill opening ! Wait for at least 5 minutes ! Check the engine oil level

! Remove, check and clean filter

insert

! Insert clean or new filter insert

into the suction container.

! Tighten the wing nut

Operating instructions KM 100/100 R D English

Check and top up the hydraulic oil level

Note:

The sweeper is provided with two hydraulic circuits:

1. Sweeping hydraulics circuit

! Check of fill level in the storage

reservoir

! Open unit cover, engage stay bar

The oil level must be between the "MIN" and "MAX" marks.

! Open the cap to refill ! Fill in hydraulic oil ! Close reservoir

For oil grade see: Technical data

2. Axle drive circuit

! Check of fill level in

compensating reservoir

Warning!

This check may be performed only when the engine is cold.

! Open unit cover, engage stay bar

! Remove the reservoir cap

— In the reservoir its bottom may

just be covered with oil

! If necessary, carefully replenish

with oil

! Close reservoir

For oil grade see: Technical data

Checking the vacuum system

— Adding a sweeping system is

with the aid of a vacuum system.

Note:

Always first add the main brush, since otherwise the side brush does not rotatet.

— The vacuum canister for lowering

the side brush is to be checked for leaks and proper connection of the hose if the side brush cannot be lowered; attach the hose, if necessary.

Hose connection to vacuum canister of side brush lowering

— The vacuum system is leaking if

the side brush can still not be lowered. In this case after-sales service must be contacted.

Check the side brush

! Raise the side broom ! Drive sweeper over a flat, smooth

surface covered with a clear layer of dust

! Lower side brush and start up ! Raise the side broom ! Drive aside backwards ! Check the sweep mirror

Width of sweeping range should be between 40 - 50 mm

Note:

— The sweeping pattern is

automatically adjusted to wear of the brushes due to the floating suspension of the side brush.

— Replace the side brush when the

bristles are too worn.

Replacing side brush

! Unscrew fastening screws

(3 pieces) at the underside

! Slip side brush on carrier and

screw it tight

Check the sweep roller

! Stand sweeper on a flat surface ! Raise the sweep roller ! Turn ignition key to "0" and

remove it

! Secure the machine against

rolling away using a wedge

! Remove the debris container

from both sides of the unit

! Remove tapes and string from

the sweep roller

Operating instructions KM 100/100 R D English

Replace the sweep roller

— Replacing it is necessary when

the sweeping effect visibly deteriorates due to wear of the bristles.

! Stand sweeper on a flat surface ! Raise the sweep roller ! Turn ignition key to "0" and

remove it

! Secure the machine against

rolling away using a wedge

! Remove the debris container

from both sides of the unit

! Unscrew front screw of right side

panellint

! Unscrew screws

! Screw out screw at main brush

bracket

! Remove lifting rod from peg

! Lift off cover and remove main

brush

Note:

Pay attention to the position of the bristle set when installing the new main brush!

! Mount main brush cover ! Slide lifting linkage onto peg ! Slide main brush bracket onto

peg

! Retighten screw at the main

brush bracket

! Fit and tighten fastening screws

of main brush cover

! Screw on side panelling ! Insert the swept material

container

Check sweeping pattern of the main brush

! Raise the sweep roller ! Raise the side broom ! Drive the sweeper on a flat and

smooth floor noticeably covered with dust or chalk

! Lower the main brush and rotate

it briefly

! Raise the sweep roller ! Depress pedal to raise the

coarse-dirt flap and keep it depressed

! Back the machine away

The form of the sweeping pattern forms a regular rectangle, that is between 50 - 70 mm wide.

Note:

— Due to the floating suspension of

the main brush The sweeping pattern automatically adapts itself to wear of the bristles.

— The main brush must be replaced

when the bristles are too worn.

! Unscrew rear screws of right side

panelling

! Remove bracket of main brush

pivoting arm

! Push main brush into main brush

box and position it onto the driving peg

Operating instructions KM 100/100 R D English

Adjusting and replacing sealing strips

! Stand sweeper on a flat surface ! Raise the sweep roller ! Turn ignition key to "0" and

remove it

! Secure the machine against

rolling away using a wedge

! Remove the debris container

from both sides of the unit

! Screw off side panelling on both

sides

! Unscrew front screw of side

panelling

Front sealing strip

! Slightly loosen fastening nut at

the front sealing strip, unscrew it to replace it

! Screw on new sealing strip but

do not yet tighten nuts

Rear sealing strip

! The floor clearance of the sealing

strip is set so that it bends backward with a lag of 5 - 10 mm

! Replace if worn

! Dismantle the sweeping drum

Side sealing strips

! Slightly loosen fastening nuts of

the side sealing strip, unscrew them to replace it

! Screw on new sealing strip but

do not yet tighten nuts

! In order to set the clearance to

the floor slide in the 1 - 2 mm spacer

! Align the sealing strip ! Tighten nuts

! Screw on side panelling ! Insert the swept material

container

Replace the dust filter

Danger!

! Empty the debris container prior

to beginning work on replacing the dust filter

! Wear a dust protection mask

when working on the filter system

! Observe the safety precautions

for handling fine dust

! Open unit cover, engage stay bar

! Unscrew rear screws of side

panelling

! Align the sealing strip ! Set the sealing strip’s clearance

to the floor so that it bends backwards with a lag of 35 - 40 mm

! Tighten nuts

! Unscrew fastening nuts of the

rear sealing strip

! Screw on new sealing strip

! Pull out handle of filter bracket to

limit and engage it

! Take out finned filter ! Insert the new filter

Operating instructions KM 100/100 R D English

! On the drive side, engage the

carrier into the holes

! Re-engage the handle of filter

dedusting

Note:

Make sure when mounting the new filter that the lamella are not damaged

Checking traction belt

Danger!

The engine takes approx. 3...4 s to run down after being shut off. Never enter operating area during this period!

! Turn ignition key to "0" and

remove it

! Open unit cover, engage stay bar

Drive control/electronics fuses

! Unscrew the screws at both sides

of the covering

Note:

— See interior for fuse allocation — Use only fuses with the same

current rating

Electric starter fuse in the engine compartment

! Open unit cover

! Replacing blown fuses

! Close unit cover

Fault instructions

Machine will not start

! Sit on the driver seat ! Fill fuel tank ! Check fuse of electric starter,

replace if necessary

! Charge the battery ! Notify the Kärcher service station

Engine runs erratically

! Clean or replace the air cleaner ! Check fuel feed ! Notify the Kärcher service station

Motor running but machine not moving

! Check position of freewheel lever ! Notify the Kärcher service station

Engine runs, but machine only moves slowly

! Warm up the machine for

approx. 3 min. at temperatures below zero

! Notify the Kärcher service station

Replacing the filter box seal

Remove filter box seal from the groove in the unit cover and insert the new seal

Check round belts and V-belts for tightness, wear and damage

Changing fuses

The drive control electronics are beneath the front covering. The fuse for the electric starter is in the engine compartment The front covering must be removed or the unit cover opened when a fuse has to be replaced.

! Replacing blown fuses ! Refasten front covering

Machine not sweeping properly

! Check main brush and side brush

for wear, replace them, if necessary

! Check the operation of the

coarse-dirt flap

! Check sealing strips for wear,

adjust or replace them as required

! Check (sweeping) hydraulic

system for leaks

! Check the seal on the vacuum

system

! Notify the Kärcher service station

Operating instructions KM 100/100 R D English

Machine making dust

! Empty debris container ! Check drive belts for the suction

turbine

! Check sealing cup at the suction

turbine

! Check dust filter, dedust or

replace it

! Check filter box seal ! Check sealing strips for wear,

adjust or replace them as required

Poor sweeping around the edges

! Replacing the side broom ! Check sealing strips for wear,

adjust or replace them as required

! Notify the Kärcher service station

Activation of side brush or main brush does not function

! Check the seal on the vacuum

system

! Check (sweeping) hydraulic

system for leaks

! Notify the Kärcher service station

The lowering mechanism of the side brushes or the main brush does not function

! Check the seal on the vacuum

system

! Notify the Kärcher service station

Accessories

Side brush 6.905-986

Provided with standard bristles for indoor and outdoor surfaces.

Soft side broom 6.906-133

For fine dust on indoor surfaces, resistant to moisture.

Hard side broom 6.906-065

For cleaning hard to remove dirt from outdoor surfaces.

Standard main brush 6.906-375

Wearproof and wetproof. Universal bristles for indoor and outdoor cleaning.

Main brush soft 6.906-533

With natural bristles specially for sweeping fine dust on smooth indoor floors. Not moisture-resistant, not for abrasive surfaces.

Main brush hard 6.906-532

For removing stubborn external dirt, damp-proof.

Dust filter 6.414-532

Technical data

Unit data

Length x width x height

2006 x 1005 x 1343 mm Empty weight 315 kg Permissible total weight 535 kg Driving speed

8 km/h Sweeping speed 6 km/h Climbing ability max. 18 % Main brush diameter 285 mm Main brush width 710 mm Side brush diameter 450 mm Area performance without side brush 7300 m²/h with side brush 10400 m²/h Working width without side brush 710 mm with side brush 1000 mm Volume of debris container 100 litres Protection class drip-proof

IPX 3

Engine

Type Yanmar L70AE-DE,

1-cylinder four stroke Displacement 296 cm³ Power, max. 4,4 kW/6 PS

at 3600 1/min Fuel, diesel 3,3 l Type of protection IP 22 Battery 12 V, 44 Ah Fuel consumption ca. 1,5 l/h

Oil types

Engine approx. 1,1 l

SAE 15 W 40 Sweeper hydraulics HVLP 46 Axle drive SAE 10 W 60

Tyres

Large-size, front 4.00-4 Air pressure - front 6 bar Large-size, rear 4.00-8 Air pressure - rear 6 bar

Brake

Service brake hydrostatic Parking brake automatic

(with spring)

Filter and suction system

Fine dust filter surface 6,0 m² Filter’s application class U for non-health hazardous dusts Rated vacuum of suction system 12 mbar Rated volumetric flow of suction system 50 l/s

Ambient conditions

Temperature -5 - +40° C Atmospheric humidity, non-dew developing 0 - 90 %

Machine vibration

Total vibration value (ISO 5349) Right arm 1,8 m/s² Left arm 1,8 m/s² Feet/seat area 0,7 m/s²

Noise emission

Sound pressure level (EN 60704-1) 83 dB(A) Garanteed sound power level (2000/14/EC) 101 dB(A)

Operating instructions KM 100/100 R D English

EC conformity declaration

We hereby declare that the machine specified below as the marketed desigh, the machine specified below complies with the relevant fundamental safety and health requirements of the EC directives listed below. Modification of the machine without our approval invalidates this declaration.

Product: Ride-on vacuum sweeper

Type: 1.280-xxx

Relevant EC directives

EC machine directive (98/37/EC) EC directive on electromagnetic compatability (89/336/EEC) amended by 91/263/EEC, 92/31/EEC, 93/68/EEC EC guideline on noise emissions (2000/14/EU)

Applied harmonised standards

DIN EN 292-1 DIN EN 292-2 DIN EN 60335-1 DIN EN 60335-2-72 DIN EN 50082-2:1995

Internal measures ensure that the in series produced units always comply with the requirements of current EC directives and applied standards. The signatories act for and in authority of management.

5.957-666 (01/02)

Alfred Kärcher Limited Partnership. Registered office: Winnenden. Registration court: Waiblingen, HRA 169. Personally liable partner. Kärcher Reinigungstechnik GmbH. Registered office Winnenden, 2404 Waiblingen Company Register, HRB

Managing directors: Dr. Bernhard Graf, Hartmut Jenner, Georg Metz

Alfred Kärcher GmbH & Co.KG Cleaning Systems Alfred-Kärcher-Strasse 28-40 P.O.Box 160 D-71349 Winnenden Phone: ++49 7195 14-0 Fax :++49 7195 14-2212

Applied national standards

CISPR 12

Applied conformity valuation method

Appendix V

Measured sound power level:

KM 100/100 R D 99 dB(A)

Guaranteed sound power level:

KM 100/100 R D 101 dB(A)

ETL KM 100/100 R D

KM 100/100 R D

1.280- 114.0

6.394- 048.0

6.491- 641.0

6.491- 642.0

6.368-217.0

6.435- 253.0

6.375- 212.0

6.414- 532.0

6.491- 532.0

4.120- 343.0

7.306- 031.0

6.491- 640.

5.115- 233.0

7.306- 031.0

7.304- 012.0

6.435- 408.0

6.906. 375.0

6.905- 986.0

03.2003

187

Kärcher KM 100, KM 100 R D Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual