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  4. BD 45/40
  5. Service Manual

Karcher BD 45/40 Service Manual

Summary of BD 45/40

  • Page 1

    English 5.906-269.0 rev. 00 (03/11) 1 br/bd 45/40 br/bd 55/40 service manual.

  • Page 2

    2 english 5.906-269.0 rev. 00 (03/11) 1 contents 1 contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 safety instruct...

  • Page 3

    English 5.906-269.0 rev. 00 (03/11) 3 5.9.1 version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.9.2 version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5.10 cover dirt water reservoir . . ...

  • Page 4

    4 english 5.906-269.0 rev. 00 (03/11) 8 basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 8.1 factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 8.2 setup menu . . . . . . . ....

  • Page 5

    English 5.906-269.0 rev. 00 (03/11) 5 10.1.2 br model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 11 troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 11.1 faults without display . . . . ....

  • Page 6

    6 english 5.906-269.0 rev. 00 (03/11) good service work requires extensive and practice- oriented training as well as well-structured training materials. Hence we offer regular basic and advanced training programmes covering the entire product range for all service engineers. In addition to this, we...

  • Page 7

    English 5.906-269.0 rev. 00 (03/11) 7 – no water pump, the water flows to the cleaning head via gravity. – water volume regulation via ball tap. – automatic water stop when brushes stop by sole- noid valve water inlet. – fill level indicator of fresh water reservoir. – tank-in-tank system (2-piece)....

  • Page 8

    8 english 5.906-269.0 rev. 00 (03/11) 1 push handle 2 switch bow, brush motor 3 dirt water discharge hose 4 lock for push handle adjustment 5 fresh water tank 6 foot actuation of transport roller 7 floor group 8 scraper roller of suction bar 9 vacuum bar 10 wheel (driven with w bp pack) 11 transport...

  • Page 9

    English 5.906-269.0 rev. 00 (03/11) 9 1 push handle 2 switch bow, brush motor 3 dirt water discharge hose 4 lock for push handle adjustment 5 lift handle of fresh water reservoir 6 fresh water tank 7 scraper roller of suction bar 8 vacuum bar 9 floor group 10 wheel (driven with w bp pack) 11 transpo...

  • Page 10

    10 english 5.906-269.0 rev. 00 (03/11) 1 push handle 2 switch bow, brush motor 3 dirt water discharge hose 4 lock for push handle adjustment 5 fresh water tank 6 foot actuation of transport roller 7 floor group 8 scraper roller of suction bar 9 vacuum bar 10 wheel (driven with w bp pack) 11 transpor...

  • Page 11

    English 5.906-269.0 rev. 00 (03/11) 11 1 push handle 2 switch bow, brush motor 3 dirt water discharge hose 4 lock for push handle adjustment 5 lift handle of fresh water reservoir 6 fresh water tank 7 scraper roller of suction bar 8 vacuum bar 9 floor group 10 wheel (driven with w bp pack) 11 transp...

  • Page 12

    12 english 5.906-269.0 rev. 00 (03/11) 1 drive motor switch (w bp pack only) 2 info button, rotary and button function (w bp pack only) 3 key switch (w bp pack only) 4 emergency stop button (w bp pack only) 5 rotary handle - water volume dosing valve 6 detergent switch (w bp pack only, option on c b...

  • Page 13

    English 5.906-269.0 rev. 00 (03/11) 13 1 drive motor switch (w bp pack only) 2 info button, rotary and button function (w bp pack only) 3 program selection switch 4 detergent switch (w bp pack only, option on c bp pack) 5 rotary handle - water volume dosing valve 6 fresh water level display 7 lever,...

  • Page 14

    14 english 5.906-269.0 rev. 00 (03/11) 1 detergent compartment (foldable and removable) 2 detergent tank (accessory) 3 lid (with ventilation pipe and ball backflow valve) 4 ventilation pipe 5 cap for ventilation pipe (slotted) 6 connection of detergent hose 7 connection for ventilation of detergent ...

  • Page 15

    English 5.906-269.0 rev. 00 (03/11) 15 1 detergent tank (accessory) 2 detergent compartment 3 dirt water discharge hose 1 detergent hose 2 vent opening 3 closure of detergent reservoir 4 filter sieve 5.4.2 version 2.

  • Page 16

    16 english 5.906-269.0 rev. 00 (03/11) 1 winch, raise/lower suction bar 2 wing nut, suction bar attachment 3 wing nut, setting of the tilting position of the suc- tion bar 4 vacuum lip 5 tilt roller 6 suction hose 7 scraper roller note the front suction lip is grooved by default, the rear one is smo...

  • Page 17

    English 5.906-269.0 rev. 00 (03/11) 17 1 suction turbine 2 connecting cable 3 sound insulation hose 4 support bow, sound insulating hose 5.6 suction turbine.

  • Page 18

    18 english 5.906-269.0 rev. 00 (03/11) 1 pedal for changing brushes 2 rotation wheel contact pressure 3 scraper roller 4 cleaning head 5.7 bd cleaning head 5.7.1 overview.

  • Page 19

    English 5.906-269.0 rev. 00 (03/11) 19 1 pinion of disc brush 2 gear belt 3 drive pinion, brush motor 4 brush motor 1 supply hose for fresh water 2 solenoid valve for water inlet 3 connecting cable 5.7.2 brush drive 5.7.3 solenoid valve for water inlet.

  • Page 20

    20 english 5.906-269.0 rev. 00 (03/11) 1 threaded rod 2 rotation wheel contact pressure 1 threaded rod 2 hookup, contact roller 1 contact roller the rotation wheel can be used to set the contact pressure and for appliances without travel drive the propulsion speed. Contact pressure / reduce speed: t...

  • Page 21

    English 5.906-269.0 rev. 00 (03/11) 21 1 waste container 2 cleaning head 3 lockscrew, brush roller holder 4 brushing rollers 5 unlocking button for brush roller holder 6 scraper roller 7 water distribution bar note the waste is transported using the dustpan for mod- els br 45-55/40 c and thrown over...

  • Page 22

    22 english 5.906-269.0 rev. 00 (03/11) 1 cleaning head 2 supply hose for fresh water 3 solenoid valve for water inlet 4 brush motor 5 gear 6 toothed belt cover 7 transport roller 1 brush roller driver 1 drive pinion, brush motor 2 gear belt 3 tension pulley 4 drive pinion, brush rollers 5.8.2 brush ...

  • Page 23

    English 5.906-269.0 rev. 00 (03/11) 23 1 supply hose for fresh water 2 solenoid valve for water inlet 3 connecting cable 5.8.3 solenoid valve for water inlet.

  • Page 24

    24 english 5.906-269.0 rev. 00 (03/11) 1 transport roller 2 hookup for transport roller 3 sheathed cable 4 deflection pulley, winch when you operate the foot pedal, the transport roller is swivelled out via a winch and a deflection roller. The push handle must be pressed down slightly dur- ing this ...

  • Page 25

    English 5.906-269.0 rev. 00 (03/11) 25 1 foot pedal 2 transport roller after lifting the appliance via the lift handle, the transport roller can be swivelled out or in with the foot pedal. The appliance can now be pushed freely. 5.9.2 version 2.

  • Page 26

    26 english 5.906-269.0 rev. 00 (03/11) 1 fresh water tank lock 2 lock of waste water reservoir cover (model 2 only) 3 suction channel opening 4 seal 5 float 5.10 cover dirt water reservoir.

  • Page 27

    English 5.906-269.0 rev. 00 (03/11) 27 1 suction pipe wastewater 2 dirt water reservoir 3 drain opening, wastewater 4 baffle 5 lint sieve suction channel 6 fresh water reservoir filler neck 5.11 wastewater reservoir 5.11.1version 1.

  • Page 28

    28 english 5.906-269.0 rev. 00 (03/11) 1 suction pipe wastewater 2 dirt water reservoir 3 drain opening, wastewater 4 lint sieve suction channel 5 lock of waste water reservoir cover 6 fresh water reservoir filler neck 5.11.2version 2.

  • Page 29

    English 5.906-269.0 rev. 00 (03/11) 29 1 fuse on battery and terminal 2 battery 3 battery - terminal 4 battery + terminal 5 solenoid valve for water inlet 6 setup and function bp 6.1 battery (bp pack only).

  • Page 30

    30 english 5.906-269.0 rev. 00 (03/11) 1 drive motor switch (w bp pack only) 2 indicator lamp - battery monitoring 3 indicator lamp - fault 4 program selection switch 5 emergency-stop button 6 rotary handle - water volume dosing valve 7 detergent switch (w bp pack only, option on c bp pack) 8 key sw...

  • Page 31

    English 5.906-269.0 rev. 00 (03/11) 31 1 drive motor switch (w bp pack only) 2 indicator lamp - battery monitoring 3 indicator lamp - fault 4 program selection switch 5 rotary handle - water volume dosing valve 6 detergent switch (w bp pack only, option on c bp pack) 7 key switch (w bp pack only) 8 ...

  • Page 32

    32 english 5.906-269.0 rev. 00 (03/11) note model 1: reset of the red battery monitoring led with a charge status of the battery of 25.8 v. You cannot continue until you do this. Model 2: this does not require a reset of the battery monitoring led. When the battery is first connected to an appliance...

  • Page 33

    English 5.906-269.0 rev. 00 (03/11) 33 1 control pcb, info button and display (w bp pack only) 2 program selection switch 3 key switch (w bp pack only) 4 detergent switch (w bp pack only, option on c bp pack) 5 rotary handle - water volume dosing valve 6 emergency-stop button (model 1 only) 7 indica...

  • Page 34

    34 english 5.906-269.0 rev. 00 (03/11) 1 display (w bp pack only) 2 control pcb display (w bp pack only) 3 info button, rotary and button function (w bp pack only) 4 indicator lamps "battery monitoring and fault" 5 terminal strip (x10/a1) 6 terminal strip (x11/a1) 7 terminal strip (x3/a1) 8 terminal...

  • Page 35

    English 5.906-269.0 rev. 00 (03/11) 35 1 terminal strip (x10/a1) 2 terminal strip (x11/a1) 3 terminal strip (x3/a1) 4 terminal strip (x1/a1) 5 terminal strip (x2/a1) 6 terminal strip (x5/a1) 7 connector plug (x16/a1) 8 connector plug (x15/a1) 9 connection (x9/a1) 10 connection (x6/a1) 11 relay (k2) ...

  • Page 36

    36 english 5.906-269.0 rev. 00 (03/11) 1 ventilator wheel, charger 2 charger 3 terminal strip (x7) 4 connector plug (x4) 5 connector plug (x5) 6 mains connection ground (x3) 7 mains connection (l2-x2) 8 mains connection (l1-x2) 9 fuse (f2) 6.3.2 battery charger (bp pack only).

  • Page 37

    English 5.906-269.0 rev. 00 (03/11) 37 1 terminal strip (x7) 2 connector plug (x4) 3 connector plug (x5) 4 connector plug (x3) 5 connector plug (x1) 6 connector plug (x2) 7 fuse (f2) 3 2 1 4 5 6 7.

  • Page 38

    38 english 5.906-269.0 rev. 00 (03/11) 1 switch bow, brush motor 2 microswitch support 3 micro switch 4 connecting cable, microswitch 1 microswitch support 6.4 switch bow, brush motor 6.4.1 microswitch installed.

  • Page 39

    English 5.906-269.0 rev. 00 (03/11) 39 1 detergent hose to the pump 2 detergent pump 3 detergent hose to the cleaning head 1 detergent pump 2 pump rotor 3 pump input 4 pump outlet 5 connecting cable to the flowmeter 6 cover cap, pump rotor 1 detergent hose 2 transport rolls 6.5 detergent pump (w bp ...

  • Page 40

    40 english 5.906-269.0 rev. 00 (03/11) 1 fresh water tank 2 flowmeter 3 flowmeter support 1 flowmeter support 2 fastening screws, cover 3 flowmeter 4 remove the lid of the flowmeter 5 hall sensor 6.6 flowmeter.

  • Page 41

    English 5.906-269.0 rev. 00 (03/11) 41 1 drive motor 2 drive shaft 3 gear 6.7 travel drive (w bp pack only) 6.7.1 version 1.

  • Page 42

    42 english 5.906-269.0 rev. 00 (03/11) 1 drive motor 2 differential gear 3 drive wheel 6.7.2 version 2.

  • Page 43

    English 5.906-269.0 rev. 00 (03/11) 43 6.8 operator functions (w bp pack) 6.8.1 startup - driving switch the programme selector switch (s2) to position “drive" switch on the drive switch (s4) display suction trailing switch-off same switch off the key switch (s0) yes suction turbine (m2) active and ...

  • Page 44

    44 english 5.906-269.0 rev. 00 (03/11) continued from previous page. Display battery: e...F activate the operator func- tions: – wet scrubbing – suction – polishing – parameterization – factory setting – led displays drive motor (m1) ready deadman switch (s3) actuated? No yes the drive motor (m3) st...

  • Page 45

    English 5.906-269.0 rev. 00 (03/11) 45 6.8.2 wet scrubbing (with vacuuming) initial use display battery: e...F shutting down switch the programme selector switch (s2) to position “wet scrubbing with vacuuming" drive switch (s4) switched off suction turbine (m2) active cleanspeed active ("cleanspeed ...

  • Page 46

    46 english 5.906-269.0 rev. 00 (03/11) continued from previous page. No drive switch (s4) switched on? Yes the drive motor (m3) starts via the on ramp and moves forward con- tinuously at 4 km/h. Cleanspeed? No yes yes time delay 5 seconds no display cleanspd.: ---- switch off the drive switch (s4) t...

  • Page 47

    English 5.906-269.0 rev. 00 (03/11) 47 6.8.3 polishing (without vacuuming) initial use display battery: e...F shutting down switch the programme selector switch (s2) to position “wet scrubbing without vacuuming" drive switch (s4) switched off cleanspeed active ("cleanspeed edit" set to "1" in setup ...

  • Page 48

    48 english 5.906-269.0 rev. 00 (03/11) continued from previous page. No drive switch (s4) switched on? Yes the drive motor (m3) starts via the on ramp and moves forward con- tinuously at 4 km/h. Cleanspeed? No yes yes time delay 5 seconds no display cleanspd.: ---- switch off the drive switch (s4) t...

  • Page 49

    English 5.906-269.0 rev. 00 (03/11) 49 6.8.4 vacuuming (without scrubbing) initial use display battery: e...F shutting down switch the programme selector switch (s2) to position “suction" drive switch (s4) switched off suction turbine (m2) active cleanspeed active ("cleanspeed edit" set to "1" in se...

  • Page 50

    50 english 5.906-269.0 rev. 00 (03/11) continued from previous page. Cleanspeed? No yes yes time delay 5 seconds no display cleanspd.: ---- switch off the drive switch (s4) the drive motor (m3) is continuously stopped on the brake ramp. The braking reaction cannot be influenced due mechanical free- ...

  • Page 51

    English 5.906-269.0 rev. 00 (03/11) 51 6.8.5 polishing (without vacuuming) initial use display battery: e...F shutting down switch the programme selector switch (s2) to position “polish" drive switch (s4) switched off cleanspeed active ("cleanspeed edit" set to "1" in setup menu) display battery: e....

  • Page 52

    52 english 5.906-269.0 rev. 00 (03/11) continued from previous page. Cleanspeed? No yes yes time delay 5 seconds no display cleanspd.: ---- switch off the drive switch (s4) the drive motor (m3) is continuously stopped on the brake ramp. The braking reaction cannot be influenced due mechanical free- ...

  • Page 53

    English 5.906-269.0 rev. 00 (03/11) 53 6.8.6 polishing (with vacuuming) initial use display battery: e...F shutting down switch the programme selector switch (s2) to position “polishing with vacuuming" drive switch (s4) switched off suction turbine (m2) active cleanspeed active ("cleanspeed edit" se...

  • Page 54

    54 english 5.906-269.0 rev. 00 (03/11) continued from previous page. Cleanspeed? No yes yes time delay 5 seconds no display cleanspd.: ---- switch off the drive switch (s4) the drive motor (m3) is continuously stopped on the brake ramp. The braking reaction cannot be influenced due mechanical free- ...

  • Page 55

    English 5.906-269.0 rev. 00 (03/11) 55 6.8.7 parameterization (w bp pack, option on c bp / c bp pack) shutting down initial use display battery: e...F time delay 5 seconds display cleanspeed: ii suction: power fact: power dose: 1.0% information menu factory setting no no yes yes display apply? Displ...

  • Page 56

    56 english 5.906-269.0 rev. 00 (03/11) continued from previous page. Yes factory reset was run no time delay 5 seconds no time delay 5 seconds yes display (blinking) fact:power no yes display (blinking) fact:fine time delay 5 seconds no yes display fact:fine new setting saved display fact:fine new s...

  • Page 57

    English 5.906-269.0 rev. 00 (03/11) 57 programmes parameter driving wet scru bbing with vacu uming wet scru bbing withou t vacuuming suction polishing polishing with vacuuming remark cleanspeed x x x x x fact x x x x for br 45-55/40 only suction x x x dose x x option (upgrade kit) information menu x...

  • Page 58

    58 english 5.906-269.0 rev. 00 (03/11) 6.9 operator functions (c bp / bp pack) 6.9.1 startup - operation off programme selector switch (s2) in position wet scrubbing with vacuuming or wet scrubbing without vacuuming or suction or polishing or polishing with vacuuming trailing of suction turbines yes...

  • Page 59

    English 5.906-269.0 rev. 00 (03/11) 59 6.9.2 wet scrubbing (with vacuuming) initial use led "battery" (green) shutting down switch the programme selector switch (s2) to position “wet scrubbing with vacuuming" suction turbine (m2) active speed reset suction turbine speed (m2) active, if set to "1" in...

  • Page 60

    60 english 5.906-269.0 rev. 00 (03/11) 6.9.3 polishing (without vacuuming) initial use led "battery" (green) shutting down switch the programme selector switch (s2) to position “wet scrubbing without vacuuming" detergents active, if set to "1" in the setup menu fact active if set to "1" in the setup...

  • Page 61

    English 5.906-269.0 rev. 00 (03/11) 61 6.9.4 vacuuming (without scrubbing) initial use led "battery" (green) shutting down switch the programme selector switch (s2) to position “suction" suction turbine (m2) active speed reset suction turbine speed (m2) active, if set to "1" in the setup menu (optio...

  • Page 62

    62 english 5.906-269.0 rev. 00 (03/11) 6.9.5 polishing (without vacuuming) initial use led "battery" (green) shutting down switch the programme selector switch (s2) to position “polish" fact active if set to "1" in the setup menu led "battery" (green) red led "fault" is glowing continuous- ly after ...

  • Page 63

    English 5.906-269.0 rev. 00 (03/11) 63 6.9.6 polishing (with vacuuming) initial use led "battery" (green) shutting down switch the programme selector switch (s2) to position “polishing with vacuuming" suction turbine (m2) active speed reset suction turbine speed (m2) active, if set to "1" in the set...

  • Page 64

    64 english 5.906-269.0 rev. 00 (03/11) 1 rotary handle - water volume dosing valve 2 program selection switch 1 appliance off 2 wet scrubbing (with vacuuming) 3 polishing (without vacuuming) 4 vacuuming (without scrubbing) 5 polishing (without vacuuming) 6 polishing (with vacuuming) 7 setup and func...

  • Page 65

    English 5.906-269.0 rev. 00 (03/11) 65 1 power cord 2 program selection switch 3 de-interference capacitor 4 operating capacitor 7.1.3 overview of operator console inside.

  • Page 66

    66 english 5.906-269.0 rev. 00 (03/11) 1 floor group 2 brush motor cover 3 cleaning head 4 connection cable cleaning head 5 supply hose for fresh water 7.2 floor group.

  • Page 67

    English 5.906-269.0 rev. 00 (03/11) 67 8 basic settings 8.1 factory settings process switch menu, factory setting br/bd 45-55/40 c/w bp (pack) - series 02/10 proces s name parameter fa ctory setti ng m in:step:m ax remar k s br/bd 45-55/40 c bp br/bd 45-55/ 40 c bp pack br/bd 45-55/ 40 w bp pac k tr...

  • Page 68

    68 english 5.906-269.0 rev. 00 (03/11) 8.2 setup menu 8.2.1 access to setup menu (w bp pack) display battery: e...F switch the programme selector switch (s2) to po- sition “wet scrubbing without vacuuming" press the info button three times within 2 seconds. Display parameter setup time delay 5 secon...

  • Page 69

    English 5.906-269.0 rev. 00 (03/11) 69 continued from previous page. Display display deutsch maschinentyp: r englisch entladespg: 21.0v francais standby: 30 min italiano saugnachlauf: 10s espanal geschw.: portugues beschl.Rampe: 3 nederlands bürst.Rampe: 9 dansk cleanspdedit: 1 norsk suctred.Edit: 1...

  • Page 70

    70 english 5.906-269.0 rev. 00 (03/11) 8.2.2 saving in setup menu (w bp pack) access to setup menu display battery: e...F display maschinentyp: r entladespg: 21.0v standby: 30 min saugnachlauf: 10s geschw.: beschl.Rampe: 3 bürst.Rampe: 9 cleanspdedit: 1 suctred.Edit: 1 dose-edit: 1 strom fahr: 15a s...

  • Page 71

    English 5.906-269.0 rev. 00 (03/11) 71 continued from previous page. Parameter value fixed adjustment value blinks no time delay 4 seconds yes the new parameter val- ue is adjusted while blinking no time delay 4 seconds display exit setup yes the new parameter value is displayed and saved blinking e...

  • Page 72

    72 english 5.906-269.0 rev. 00 (03/11) 8.2.3 display setup manu (w bp pack) display parameter setup (exclusively for models with display and info button), sequence and factory settings, 10/09 parameter factory setting min:step:max remarks se- quence service access maschine type: r 1 br 45/40bd 45/ 4...

  • Page 73

    English 5.906-269.0 rev. 00 (03/11) 73 power b / w: 60 a 60a 30 a:1 a:60 a max. Regular power of the brush. In case of overload, the power is limited to the set up value for 15 seconds until the shut-off with fault message occurs. A new startup requires off or a key switch reset. 12 x power turb: 30...

  • Page 74

    74 english 5.906-269.0 rev. 00 (03/11) 1 handle fastening screws. 2 fastening screws, casing cover 3 covering lid unscrew fastening screws of the casing cover. Loosen the fastening screws of the handle. Remove the housing cover. 1 appliance switch with motor protection switch replace the motor prote...

  • Page 75

    English 5.906-269.0 rev. 00 (03/11) 75 1 operator console 2 fastening screws unscrew locking screws. Remove the control panel. 9.2 remove operating panel.

  • Page 76

    76 english 5.906-269.0 rev. 00 (03/11) 1 fastening screws 2 appliance cover, rear unscrew locking screws. Remove device cover from the rear 9.3 remove rear appliance cover.

  • Page 77

    English 5.906-269.0 rev. 00 (03/11) 77 note the service module can be connected starting with control version 2.0. The service programme of the service module must be at least version v 4.0. Remove rear appliance cover. 1 control board 2 connection plug service module connect both connecting cables ...

  • Page 78

    78 english 5.906-269.0 rev. 00 (03/11) remove operating panel. 1 drive motor switch 2 indicator lamps "battery monitoring and fault" 3 control pcb display pull the connector plug off the drive motor switch. Connect the resistance measurement device to the plug connections on the drive motor switch. ...

  • Page 79

    English 5.906-269.0 rev. 00 (03/11) 79 remove rear appliance cover. 1 connector plug programme selector switch 2 control board pull the connector plug of the progamme selector switch from the control pcb. Connect the resistance measurement device to the connector plug of the programme selector switc...

  • Page 80

    80 english 5.906-269.0 rev. 00 (03/11) remove rear appliance cover. 1 charger 2 control board remove all connector plugs from the control pcb and the charger. Remove the entire sheet metal plate from the ap- pliance. Replace the control pcb or the charger. Installation in reverse order note if you c...

  • Page 81

    English 5.906-269.0 rev. 00 (03/11) 81 if too little or no detergent is applied, the detergent dosing pump must be checked. 1 detergent dosing pump check cables for corrosion and moisture. Check cables for tight fit. 1 detergent dosing pump 2 detergent hose check the detergent hose in the detergent ...

  • Page 82

    82 english 5.906-269.0 rev. 00 (03/11) remove rear appliance cover. Pull the connector plug of the terminal strip x10 from the control pcb. Connect a resistance measuring device to the connector plug of the terminal strip x10 between pin 8 and pin 17. Target value: switch bow of brush motor in idle ...

  • Page 83

    English 5.906-269.0 rev. 00 (03/11) 83 remove rear appliance cover. Turn the programme selector switch to position 3 "wet scrubbing". Measure the voltage on the control pcb of termi- nal strip x10 between pin 2 and pin 11. Target value: switch bow of brush motor in idle position – 0 volts switch bow...

  • Page 84

    84 english 5.906-269.0 rev. 00 (03/11) remove rear appliance cover. Turn the programme selector switch to position 4 "vacuuming". Measure the voltage on the control pcb between terminal strips x15 and x13. Target value: whisper mode – 15.0 +/- 0.2 volt power mode – battery voltage installation in re...

  • Page 85

    English 5.906-269.0 rev. 00 (03/11) 85 1 voltage regulator tilt the fresh water reservoir rearward. Connect the voltage regulator in the power circuit. Turn the key switch (s0) to position "1". Reduce the voltage slowly to 21 volts or the dis- charge set up in the setup menu. Target value: – the shu...

  • Page 86

    86 english 5.906-269.0 rev. 00 (03/11) the battery must be fully charged prior to the inspec- tion to obtain a reliable result. The following checks must then be made: measurement of the idle voltage the idle voltage provides a measure for the charging status of a maintenance-free battery. If this v...

  • Page 87

    English 5.906-269.0 rev. 00 (03/11) 87 battery measuring log - maintenance-free battery 1. Measurement - idle voltage measure the idle voltage with charged battery without consumers. Battery block 1 2 3 4 5 6 2. Measurement - load test measure the battery voltage several times while the turbine is t...

  • Page 88

    88 english 5.906-269.0 rev. 00 (03/11) replacing a battery due to old age with 12 volt battery blocks, the complete battery set must be replaced in case of damage. Taking out of operation if batteries are not to be used for a while, the following must be observed when storing them: – disconnect the ...

  • Page 89

    English 5.906-269.0 rev. 00 (03/11) 89 connect the charger to the batteries. Connect the voltage meter and clip-on ammeter to the batteries. Plug in mains connector and switch on charger. Determine the current and voltage measuring val- ues after switching on the charger and record them. Determine t...

  • Page 90

    90 english 5.906-269.0 rev. 00 (03/11) – during the i constant phase, the charger is charged with the nominal current (see typeplate on charger) and the charge voltage will increase slower or faster depending on the charge condi- tion. After that, the charger will switch to u con- stant phase. – in ...

  • Page 91

    English 5.906-269.0 rev. 00 (03/11) 91 1 fastening screw 2 scraper roller 3 vacuum lip mounting 4 vacuum lip 5 vacuum bar clean the vacuum lips on the suction bar and check for wear and damage. If necessary, turn or replace the vacuum lips. Pull the fastening screw, scraper roller vacuum lip mount o...

  • Page 92

    92 english 5.906-269.0 rev. 00 (03/11) 1 fastening screw 2 support roller loosen the fastening screw of the support rollers, if necessary remove the fastening screw and re- place the support roller. Adjust the support rollers until the suction lips are parallel and rest flush on the floor. 9.5.3 adj...

  • Page 93

    English 5.906-269.0 rev. 00 (03/11) 93 1 locking screw for fresh water reservoir 2 fresh water tank unscrew the locking screw for the fresh water res- ervoir. Tilt the fresh water reservoir rearward. 1 fastening screw 2 hose clip 3 connecting cable 4 sound insulation hose remove the connection cable...

  • Page 94

    94 english 5.906-269.0 rev. 00 (03/11) 1 pedal for changing brushes 2 rotation wheel contact pressure 3 scraper roller 4 cleaning head empty the dirt water reservoir. Swivel out the transport roller. Loosen the disc brush from the actuator via the brush change pedal. Remove the disc brush. 9.7 bd cl...

  • Page 95

    English 5.906-269.0 rev. 00 (03/11) 95 1 contact roller 2 bow brush change 3 transport roller 4 actuator, disc brush 5 cleaning head place the new disc brush underneath the cleaning head. Swivel the transport roller back in. Lower the appliance onto the disc brush until it locks into the actuator..

  • Page 96

    96 english 5.906-269.0 rev. 00 (03/11) 1 pinion of disc brush 2 gear belt 3 drive pinion, brush motor 4 brush motor pull the toothed belt off of the pinion of the disc brush. Remove the toothed belt from the drive pinion. Place a new toothed belt onto the drive pinion. Slide the toothed belt onto th...

  • Page 97

    English 5.906-269.0 rev. 00 (03/11) 97 1 waste container 2 cleaning head 3 lockscrew, brush roller holder 4 brushing rollers 5 unlocking button for brush roller holder 6 scraper roller 1 waste container 2 cleaning head 3 unlocking button for brush roller holder empty the dirt water reservoir. Swivel...

  • Page 98

    98 english 5.906-269.0 rev. 00 (03/11) 1 cleaning head 2 water distribution bar the water distribution strip is removed from the cleaning head and can be cleaned under running wa- ter. Installation in reverse order 9.8.2 replacing the water distribution bar.

  • Page 99

    English 5.906-269.0 rev. 00 (03/11) 99 remove the cover, model 1 1 toothed belt cover 2 fastening screws unscrew locking screws. Remove the cover from the toothed belt. Remove the cover, model 2 1 toothed belt cover 2 fastening screws unscrew locking screws. Remove the cover from the toothed belt. 1...

  • Page 100

    100 english 5.906-269.0 rev. 00 (03/11) remove operating panel. 1 fastening screw, wastewater reservoir 2 fresh water tank 1 fresh water tank 2 fastening screw, wastewater reservoir unscrew locking screws. Remove the dirt water reservoir. 1 seal of wastewater reservoir 2 interior side of fresh water...

  • Page 101

    English 5.906-269.0 rev. 00 (03/11) 101 if the motor runs poorly or insufficiently, the carbon brushes could be worn. 1 closing head 2 carbon brush 3 drive motor unscrew the locking cover. Remove the carbon brushes. Clean/replace the carbon brushes. Screw in the locking cover. 9.10 travel drive (w b...

  • Page 102

    102 english 5.906-269.0 rev. 00 (03/11) 10 maintenance and care 10.1 exchange times 10.1.1bd model wear part part number exchange time in minutes disc brush 4.905-003 5 seal ring fw-sw 5.363-647 10 scraper roller of suction bar 5.515-267 10 roller d60 5.515-280 10 rubber lip set 6.273-213 10 gear be...

  • Page 103

    English 5.906-269.0 rev. 00 (03/11) 103 10.1.2br model wear part part number exchange time in minutes brush roller 4.762-392 5 skid 5.056-010 15 seal ring fw-sw 5.363-647 10 scraper roller of suction bar 5.515-267 10 roller d60 5.515-280 10 rubber lip set 6.273-213 10 gear belt 6.348-429 15 rubber p...

  • Page 104

    104 english 5.906-269.0 rev. 00 (03/11) 11 troubleshooting 11.1 faults without display fault remedial action appliance cannot be started – check if the mains plug is connected (ep only). – the appliance is in standby mode. Set the programme selector switch to position "1" (drive / off) and then to t...

  • Page 105

    English 5.906-269.0 rev. 00 (03/11) 105 brushes do not turn – check the electrical connection on the brush motor. – check whether the brush rollers / disc brush is blocked / remove for- eign matters / replace brush rollers / disc brushes. – check/replace the toothed belt. – check /replace the applia...

  • Page 106

    106 english 5.906-269.0 rev. 00 (03/11) 11.2 faults with display (w bp pack only) display er- ror cod es fault source measures led dis- play fault driv- ing possi- ble vacu- uming possi- ble scrub- bing possi- ble polish- ing possi- ble brush motor fault=1 1 short circuit in the brush motor call cus...

  • Page 107

    English 5.906-269.0 rev. 00 (03/11) 107 pcb. Fault=4 5 pcb defec- tive call customer service. Perma- nent light pcb. Fault=4 6 pcb defec- tive perma- nent light pcb. Fault=4 7 pcb defec- tive perma- nent light brush motor fault=2 8 cable rup- ture in the brush motor 2* blinking x x suction turbine f...

  • Page 108

    108 english 5.906-269.0 rev. 00 (03/11) suction turbine fault=3 20 overload suction mo- tor turn the programme selector switch to the position "drive". Then select the cleaning programme once more. If the fault re- curs, call customer service. 3* blinking x x brush overload! 21 overload on brush mot...

  • Page 109

    English 5.906-269.0 rev. 00 (03/11) 109 note when a fault occurs, you must always set the pro- gramme selector switch to the "drive" position and set the existing key switch to position "0". Wait approx 15 seconds before restarting. If the fault recurs, call customer service. Battery fault! 32 batte...

  • Page 110

    110 english 5.906-269.0 rev. 00 (03/11) 12 technical specifications br 45/40 c bp br 45/40 c bp pack bd 45/40 c bp bd 45/40 c bp pack power nominal voltage v 24 battery capacity ah (5h) - 105 - 105 average power consumption w 650 suction engine output w 600 brush motor performance w 600 suction turb...

  • Page 111

    English 5.906-269.0 rev. 00 (03/11) 111 values determined as per en 60335-2-72 total oscillation value m/s² uncertainty k m/s² 0,2 sound pressure level l pa db(a) 72 67 uncertainty k pa db(a) 1 1 sound power level l wa + uncertainty k wa db(a) 88 83 br 45/40 c bp br 45/40 c bp pack bd 45/40 c bp bd ...

  • Page 112

    112 english 5.906-269.0 rev. 00 (03/11) br 55/40 c bp br 55/40 c bp pack bd 55/40 c bp bd 55/40 c bp pack power nominal voltage v 24 battery capacity ah (5h) - 105 - 105 average power consumption w 650 suction engine output w 600 brush motor performance w 600 suction turbine cleaning power, air quan...

  • Page 113

    English 5.906-269.0 rev. 00 (03/11) 113 values determined as per en 60335-2-72 total oscillation value m/s² uncertainty k m/s² 0,2 sound pressure level l pa db(a) 72 67 uncertainty k pa db(a) 1 1 sound power level l wa + uncertainty k wa db(a) 88 83 br 55/40 c bp br 55/40 c bp pack bd 55/40 c bp bd ...

  • Page 114

    114 english 5.906-269.0 rev. 00 (03/11) br 45/40 w bp pack br 55/40 w bp pack bd 45/40 w bp pack bd 55/40 w bp pack power nominal voltage v 24 battery capacity ah (5h) 105 average power consumption w 750 suction engine output w 600 brush motor performance w 600 drive motor output w 130 suction turbi...

  • Page 115

    English 5.906-269.0 rev. 00 (03/11) 115 permissible overall weight kg 210 transport weight kg 165 (dose 170) values determined as per en 60335-2-72 total oscillation value m/s² uncertainty k m/s² 0,2 sound pressure level l pa db(a) 72 67 uncertainty k pa db(a) 1 1 sound power level l wa + uncertaint...

  • Page 116

    116 english 5.906-269.0 rev. 00 (03/11) br 45/40 c ep br 55/40 c ep bd 45/40 c ep bd 55/40 c ep power nominal voltage v/hz 230 / 1~50 average power consumption w 1100 1200 suction engine output w 830 780 830 780 brush motor performance w 800 suction turbine cleaning power, air quantity l/s 40 cleani...

  • Page 117

    English 5.906-269.0 rev. 00 (03/11) 117 the technical specification sheet will be included in the next version of the spare parts cd (disis) and in the kaercher-inside (https://kaercher-inside.Com). The operating instructions and the spare parts list can be requested in paper form with the respectiv...

  • Page 118

    118 english 5.906-269.0 rev. 00 (03/11) no data. 13 special tools voltage regulator 6.803-025.0 14 tightening torques.

  • Page 119

    English 5.906-269.0 rev. 00 (03/11) 119 15 circuit diagrams 15.1 version 1 15.1.1br/bd 55/40, 45/40 c ep (circuit diagram 0.088-845) -c1 -y1 -c2 -m2 m 1~ -q1 1 3 2 4 1 n pe -m1 rt sw pe bl bn m 1~ 1a 01 2 3 4 1 30µ f ws ws 2a 2 l n 3a 3 4a 4 0,22µf ws bl ws rt bn bn bl ws bl bl gn/ge w3 bn bl gn /g ...

  • Page 120

    120 english 5.906-269.0 rev. 00 (03/11) 15.1.2br/bd 55/40, 45/40 c bp (circuit diagram 0.088-843) -m1 m -s5 1 1a -s3 -f1 - -x1 + -g1 - + -a0 -s2 s2/w s2/pin 2 s2/pin 1 s2/pin 0 -m4 -a1 x6 x7 x11/6 x11/7 x11/4 x11/5 x11/14 x11/13 x11/12 x11/11 x10/8 x10/17 x11/3 x11/10 x10/9 x10/18 x9 x13 x15 x14 x8 ...

  • Page 121: -M1

    English 5.906-269.0 rev. 00 (03/11) 121 15.1.3br/bd 55/40, 45/40 c bp pack / w bp pack (circuit diagram 0.088-844) -m1 m -a1 x6 x7 x11/6 x11/7 x11/4 x11/5 x11/14 x11/13 x11/12 x11/11 x11/2 x11/1 x11/8 x11/9 x10/8 x10/17 x11/3 x11/10 x10/9 x10/18 x9 x13 x15 x14 x8 x10/2 x10/11 x10/3 x10/4 x10/12 x3 x...

  • Page 122

    122 english 5.906-269.0 rev. 00 (03/11) 15.1.4br/bd 55/40, 45/40 wrb (circuit diagram 0.088-966 italy) w6 -y1 x1 x2 -m2 m -a1 x6 x7 x11/6 x11/7 x11/4 x11/5 x11/14 x11/13 x11/12 x11/11 x11/1 x10/8 x10/17 x11/3 x11/10 x10/9 x10/18 x9 x13 x15 x14 x8 x10/2 x10/11 x10/3 x10/4 x10/12 x12 x16 x11/8 x11/9 x...

  • Page 123

    English 5.906-269.0 rev. 00 (03/11) 123 15.2 version 2 15.2.1br/bd 55/40, 45/40 c ep (circuit diagram 0.088-845) -c1 -y1 -c2 -m2 m 1~ -q1 1 3 2 4 1 n pe -m1 rt sw pe bl bn m 1~ 1a 01 2 3 4 1 30µ f ws ws 2a 2 l n 3a 3 4a 4 0,22µf ws bl ws rt bn bn bl ws bl bl gn/ge w3 bn bl gn /g e x1 230v/50hz 16a w...

  • Page 124

    124 english 5.906-269.0 rev. 00 (03/11) 15.2.2br/bd 55/40, 45/40 c bp low cost (circuit diagram 0.088-892) option r t -m1 m -a1 x6 x7 x5/3 x5/4 x5/7 x5/8 x5/2 x5/1 x5/5 x5/6 x4/3 x4/6 x13 x15 x4/5 x4/2 x14 1 1a -s2 s2/w s2/pin 2 s2/pin 1 s2/pin 0 -m2 m -y1 x1 x2 -f1 -g1 rt bn 16mm² 10mm² rt bn 0,75m...

  • Page 125

    English 5.906-269.0 rev. 00 (03/11) 125 15.2.3br/bd 55/40, 45/40 c bp (circuit diagram 0.088-843) option - flachbandkabel w23 w31 -m1 m -s5 1 1a -s3 -f1 - -x1 + -g1 - + -a0 -s2 s2/w s2/pin 2 s2/pin 1 s2/pin 0 -m4 -a1 x6 x7 x11/6 x11/7 x11/4 x11/5 x11/14 x11/13 x11/12 x11/11 x10/8 x10/17 x11/3 x11/10...

  • Page 126

    126 english 5.906-269.0 rev. 00 (03/11) 15.2.4br/bd 55/40, 45/40 c bp pack / w bp pack (circuit diagram 0.088-844) option - drahtbrücken bei fahrantrieb entfernen remove jumper for traction retirer jumper pour la traction quitar puente para la tracción + - -m1 m -a1 x6 x7 x11/6 x11/7 x11/4 x11/5 x11...

  • Page 127

    English 5.906-269.0 rev. 00 (03/11) 127 15.3 legend a0 control pcb, info button and display module (option) a1 control board c1 operation capacitor (30 µf) c2 de-interference capacitor (0,22 µf) f1 main switch (100 a) g1 battery 24 v / 100 ah h1 indicator lamps "battery monitoring and fault" m1 brus...