Kärcher ICC 1 S D User manual

ICC 1 S D
1.142-...
Service Manual
5.905-432
03.01

2
Foreword ICC 1 S D
Foreword
Good servicing requires extensive and relevant training as well as comprehensible refer-
ence documents.
Wethereforeregularlyofferallservicetechnicianbothbasicandadvancedtrainingcourses
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 KÄRCHER GmbH & Co.
INTERNATIONAL SERVICE TRAINING
P.O. Box 160
D-71349 Winnenden
http://www.karcher.de

3
ICC 1 S D Table of Contents
Table of Contents
Unit Functions ...................................................................................5 - 24
Technical Features....................................................................................................5
Equipment Features .......................................................................................... 6 - 15
Front view ............................................................................................................................6
Side brush view ....................................................................................................................7
Rearview .............................................................................................................................8
Raiseddebriscontainer view................................................................................................9
Controlelements ................................................................................................................10
Combinationinstrument .....................................................................................................11
Frontfusebox.....................................................................................................................12
Controlconsole,open view ................................................................................................13
Side console, open view.....................................................................................................14
Engine compartment, view from left ...................................................................................15
Engine compartment, view from right .................................................................................16
Engine compartment, view toward rear ..............................................................................17
Fueltank ............................................................................................................................18
Heater ................................................................................................................................19
Engine compartment, view from rear..................................................................................20
Function Groups ..............................................................................................22 - 24
Sweepingandvacuum system...........................................................................................22
Watersystem .....................................................................................................................23
Basic Settings and Service Procedures......................................... 25 - 55
Engine ...............................................................................................................25 - 32
Fuel ....................................................................................................................................25
Cooling...............................................................................................................................26
Speedadjustment ..............................................................................................................28
Engine shut-off solenoid valve ...........................................................................................29
Air cleaner ..........................................................................................................................30
Engineoil ...........................................................................................................................31
Drive pump belt ..................................................................................................................32
Sweeping Mechanism......................................................................................33 - 37
Sweeping pattern ............................................................................................................... 33
Spraynozzles.....................................................................................................................34
Vacuum intake....................................................................................................................35
Warning buzzer,debriscontainer .......................................................................................36
Debriscontainer .................................................................................................................37
Running Gear ...................................................................................................38 - 44
Greasefittings ....................................................................................................................38
Brake..................................................................................................................................39
Wheel change / Steering wheel ..........................................................................................41
Toe-inadjustment ...............................................................................................................42
Shock absorber..................................................................................................................43
Towing and transporting .....................................................................................................44

4
Table of Contents ICC 1 S D
Hydraulic System .............................................................................................45 - 52
Hydraulicfluid.....................................................................................................................45
Hydraulicfluidfilter .............................................................................................................46
Emergencypump(option) ..................................................................................................47
Drive pedal .........................................................................................................................48
Checkingworkingpressures ..............................................................................................49
Pressurereliefvalve...........................................................................................................51
Pumps ...............................................................................................................................52
Impeller fan .......................................................................................................53 - 55
Changing impeller fan ........................................................................................................53
Adjusting magnetic brake...................................................................................................55
Troubleshooting..................................................................................... 56
Circuit Diagram.......................................................................................58
Circuit Diagram – Search List ..............................................................64
Hydraulic Block Diagram ......................................................................66
Hydraulic Line Diagram......................................................................... 68
Specifications .........................................................................................70
Fuses .......................................................................................................70
Special Tools .......................................................................................... 71
Assembly Torque Ratings ....................................................................71

5
ICC 1 S D UnitFunctions
Technical Features
The ICC 1 S D is a high-performance sweeping
machinedesignedforprofessionalusein indus-
trialserviceandmunicipal fleet applications.
The unit may be licensed for road traffic.
Depending on the country of operation, single-
unitapprovalbytheresponsibleHighwayTraffic
Authority may be required.
Drivepower
– 3-cyl.KubotaD722water-cooleddiesel
engine (similar to KMR 1700 D).
– Forwardandreverse, 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
separatebrake lever.
– Braking action on rear wheels only via
hydraulicsystem.
Sweepingsystem
– 2 inward rotating side brushes
– Sweepingrollernot required
Vacuumsystem
– 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.
Watersystem
– Water tank with filter and water pump
– Water jets on side brushes and in air
channel to reduce dusting, and for
lubricating air channel.
Steering
– Hydraulic steering on front wheels
Hydraulicsystem
– Rearwheels,individually poweredby
hydraulicmotors.
– 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
andenginecooling.

6
UnitFunctions ICC 1 S D
Equipment Features – Front view
10
9
87 6 5
4
3
2
1
11
1 Cover, debris container
2 Debris container
3 Dual-circuit radiator
(hydraulic fluid / engine coolant)
4 Operator seat
5 Support caster, vacuum intake
6 Side brush, LH
7 Bumper
8 Turn signals
9 Side brush, RH
10 Head lamps
11 Air exhaust, debris container

7
ICC 1 S D UnitFunctions
Equipment Features – Sidebrush view
1 Pressurized gas spring, side brush
2 Stop screw, side brush bottom position
3 Adjusting screws, side brush sweeping
pattern
4 Hydraulic motor, LF side brush
5 LH side brush
6 RH side brush
7 Bumper

8
UnitFunctions ICC 1 S D
Equipment Features – Rear view
1 Safety beacon
2 Filler neck, fuel tank
3 RH side brush
4 Side cover panel
5 Rear cover panel
6 Water tank
7 Filler neck, water tank
1
2
3
4
5
6
7

9
ICC 1 S D UnitFunctions
Equipment Features – Raised debris container view
1 Debris container
2 Air exhaust
3 Debris container cover
4 Water tank
5 Rear cover panel
1
2
3
4
5
6
7
8
6 Removable grille, dual-circuit radiator
(hydraulic fluid / engine coolant)
7 LH side brush
8 Vacuum channel

10
UnitFunctions ICC 1 S D
Equipment Features – Control elements
1 Switch, four-way flashers (S12)
2 Combination instrument (P1)
3 Steering wheel
4 Ignition switch (S1)
5 Combination switch (S13)
6 Switch (S16), working spotlights
(option)
7 Switch, windshield wiper (S6)
8 Switch, cabin heater fan (S7)
9 Switch, windshield defroster fan (S15)
10 Switch, safety beacon (S14)
11 Drive pedal, reverse
12 Drive pedal, forward
13 Lever, Raise / Lower debris container
14 Lever, Raise / Lower side brush and
vacuum inlet (with brush speed control)
15 Lever, Open / Close coarse debris flap
16 Switch, impeller fan (S9)
17 Switch, water pump (S8)
18 Operating hours counter, impeller fan
(option) (P2)
19 Manual throttle, engine speed control
20 Metering valve, side brush water volume
21 Metering valve, vacuum channel water
volume
22 Pedal, parking brake / operating brake
23 Changeover button, parking brake /
operating brake
0
KÄRCHER
KÄRCHER
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11
12
13
14
15
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17
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11
ICC 1 S D UnitFunctions
Equipment Features – Combination instrument
Indicator lights and displays
1 Debris container raised
2 Pre-glow cycle activated
3 Excessive engine coolant temperature
4 Spare
5 Low charging current warning
6 Low engine oil pressure warning
7 Blocked air cleaner warning
8 Headlamps ON
9 Turn signal ON
10 Operating hours counter
11 Fuel level indicator

12
UnitFunctions ICC 1 S D
Equipment Features – Fuse box
Fuses
F1 Ignition switch
F2 Four-way flashers
F3 Impeller fan brake
F4 Magnetic clutch
F5 Water pump
F6 Fan, cabin heater
F7 Windshield wiper
F8 Turn signals / horn
F9 Headlamps
F10 Position lamps, RH
F11 Position lamps, LH
F12 Engine stop solenoid
F13 Safety beacon
F14 Fan, windshield defroster
F15 Stop lights
F16 Headlamps
Relays
K1 Ignition switch
K2 Fan, cabin heater
K3 Water pump
K4 Safety beacon
K5 Turn signals
K6 Windshield wiper
K7 Fan, windshield defroster
K8 Headlamps
M5 Fan, windshield defroster
X1 Plug connector
Note:
The fuse box is located below the instrument
panel.

13
ICC 1 S D UnitFunctions
Equipment Features – Control console, open view
D2 Control module, engine shut-off solenoid
S14 Switch, safety beacon
S15 Switch, windshield defroster fan
S7 Switch, cabin heater fan
S6 Switch, windshield wiper
S16 Switch, working spotlights (option)
S13 Combination switch
S1 Ignitionswitch

14
UnitFunctions ICC 1 S D
Equipment Features – Side console, open view
1 Mounting thread for lever, Raise / Lower
debris container
2 Mounting thread for lever, Raise / Lower
side brush and vacuum intake
3 Pressure relief valve
4 Bowden cable, coarse debris flap
5 Hydraulic line, Lower debris container
6 Hydraulic line, Lower brushes,
Sweeping
7 Hydraulic fluid inlet
8 Hydraulic line, Raise brushes
9 Hydraulic line, Lower brushes
10 Manualthrottle
11 Control module, impeller fan brake (D3)
12 Switch, debris container warning buzzer
(S18)
13 Hydraulic line, Raise debris container
14 Hydraulic line, Sweeping operating
15 Hydraulic line to hydraulic fluid tank

15
ICC 1 S D UnitFunctions
Equipment Features – Engine compartment, view from left
1 Magnetic clutch, vacuum impeller fan
2 Filler neck, engine oil
3 Glow plug
4 Injector nozzle
5 Injectionpump
6 Oil dip stick
7 Air intake hose
8 Fuelfilter
9 Engine
10 Tension roller, V-belt
11 V-belt
12 Magnetic brake, vacuum impeller fan

16
UnitFunctions ICC 1 S D
Equipment Features – Engine compartment, view from right
1 Oil dip stick
2 Coolant radiator electric fan
3 Adjustment screw, V-belt tension
4 Magnetic brake, vacuum impeller fan
5 Exhaust manifold
6 Starter
7 Oil filler neck
8 Alternator

17
ICC 1 S D UnitFunctions
Equipment Features – Engine compartment, view toward rear
1 RH limit switch, debris container (S10)
2 LH limit switch, debris container (S11)
3 Air cleaner
4 Engine cover
5 LH stop screw, debris container
6 RH stop screw, debris container

18
UnitFunctions ICC 1 S D
Equipment Features – Fuel tank
1 Fuel level sensor
2 Fuel filler neck
3 Fuel tank
1
2
3

19
ICC 1 S D UnitFunctions
Equipment Features – Heater
1 Hot water supply hose
2 Heat exchanger
3 Warm water return hose
4 Heater fan shroud

20
UnitFunctions ICC 1 S D
Equipment Features – Engine compartment, view from rear