Kärcher BD 100 R Service Manual Download

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Service Manual 08.2007

5.906-252.0

BR/BD 100/250 R / RI
BR/BD 120/250 R / RI

1.480- . . .

Service Manual

Summary of Contents for BD 100 R

Page 1: ...Service Manual 08 2007 5 906 252 0 BR BD 100 250 R RI BR BD 120 250 R RI 1 480 Service Manual ...

Page 2: ...BR BD 100 250 R BP RI Page 2 171 Service Manual 08 2007 ...

Page 3: ...for the whole product range In addition we compile service manuals for the main units which can be used as instructions to start with and as a reference work later on In addition we issue regular Service Information about on going developments of our products The texts and pictures can only be copied and duplicated or passed on to third parties after obtaining explicit permission from ALFRED KÄRCH...

Page 4: ... 3 3 1 Initial operation and information menu 54 3 3 1 1 Initial operation and information menu head CPU from version 1 2 54 3 3 1 2 Initial operation and information menu head CPU up to version 1 1 55 3 3 2 Driving 56 3 3 2 1 Driving head CPU from version 1 2 56 3 3 2 2 Driving head CPU up to version 1 1 57 3 3 3 Wet scrubbing with suction 58 3 3 4 Wet scrubbing without suction 59 3 3 5 Suction w...

Page 5: ...u 5 3 1 Setup menu head CPU from version 1 2 91 5 3 1 1 Access to the setup menu 91 5 3 1 2 System menu and driving module parameters 92 5 3 1 3 Cleaning module and lifting module parameters 93 5 3 2 Setup menu head CPU up to version 1 1 94 5 3 2 1 Access to the setup menu 94 95 5 3 2 2 System menu and driving module parameters 96 5 3 2 3 Cleaning module and lifting module parameters 97 5 3 3 Save...

Page 6: ... 148 6 3 5 Significant errors Lifting module A4 149 6 3 6 Significant errors Accessories module A5 150 7 Maintenance work 151 152 8 Circuit diagrams 153 162 8 1 Circuit diagram 0 088 734 0 Head CPU A1 153 8 2 Circuit diagram 0 088 876 0 Head CPU A1 154 8 3 Circuit diagram 0 088 876 0 0 088 876 0 Driving module A2 155 8 4 Circuit diagram 0 088 876 0 0 088 876 0 Cleaning module A3 156 8 5 Circuit di...

Page 7: ...Technology depending on the cleaning tasks and floor surface Power Clean 100 Whisper Clean 65 Fine Clean 40 Water system Fresh water tanks on left and right sides of the unit Dirty water tank with float switch Water supply to brush head with water pump 10 Step water volume adjustment with electric metering valve Vacuum system Suction motor EC draws the dirty water into the dirty water tank When th...

Page 8: ... light optional Function Suspension of the pre sweeping unit via a fle xible parallelogram system max deflection 15 cm Main brush drive via belt system Automatic filter cleaning Repetition every 5 minutes for 5 seconds adjustable Automatic shut off in case of blockage Mainbrushandsidebrushraising loweringvia additional lifing motor and Bowden cable sy stem Other functions See BR BD 100 250 R Gener...

Page 9: ...irty water tank 4 Fresh water tank left 5 Brush head BR version 6 Suction beam straight design 7 Side sealing strip with spring pressure 8 Water filter 9 Electromagnetic brake Y1 10 Front wheel wheel hub motor M1 11 Recess for headlight optional 12 Seat 13 Steering wheel 1 4 View from the left hand side 2 3 4 5 7 12 11 8 10 9 13 6 1 ...

Page 10: ...rew steering column adjustment max 2 cm 2 Steering column 3 Deflection roller both sides 4 Brake pedal 5 Drive pedal 6 Side sealing strip with spring pressure 7 Brush head BD version 8 Fresh water tank right 9 Cover dirty water tank 1 5 View from the right hand side 9 3 5 1 2 4 3 7 6 8 ...

Page 11: ...r dirty water tank 2 Drain hose dirty water tank 3 Connection suction hose suction beam 4 Cleaning opening dirty water tank 1 6 Rear view 1 4 5 8 2 6 7 5 3 5 Deflection roller suction beam 6 Support roller for suction beam 7 Suction beam straight design 8 Drain hose fresh water tank ...

Page 12: ...in the neutral position The freewheeling lever 4 disengages the electromagnetic brake 5 of the hub motor M1 During transport with an external towing machine the connection cable of the wheelhubmotor M1 mustbedisconnected otherwise the driving module A2 is destroyed at a speed higher than 2 km h 2 Basic motor 6 km h 8 climbing capacity 15 climbing capacity Motor version 1 8 km h Motor version 2 6 k...

Page 13: ...e 6 Adjusting screw brush pattern 7 Side sealing strip BR version 8 Rear wing screw fastening 9 Coarse dirt container BR version 10 Brush head BR version 11 Brush head support bracket BD version 12 Side sealing strip BD version 13 Brush head BD version 14 Spring 4x brush head 15 Lifting motor brush head M20 Note Thesprings 14 protectandrelievethelifting motor 15 of the brush head 1 9 8 7 6 5 4 3 2...

Page 14: ...n beam 6 1 2 4 3 5 3 8 7 8 10 11 10 11 9 1 Drain hose dirty water tank 2 Cleaning opening dirty water tank 3 Deflection roller with star grip for repla cing turning the rubber strips 4 Suction beam straight design 5 Rubber strip 6 Drain hose fresh water tank 7 Lifting motor suction beam M30 lower raise 8 Springs 2x suction beam 9 Spring lifting motor M30 10 Wing screws 2x adjusting suction beam ti...

Page 15: ...uction motor M4 The suction motor 3 EC electronically con trolled generates a vacuum in the dirty water tank with which the dirty water is drawn in from the suction beam The suction motor 3 is located behind the right fresh water tank Drain and remove the fresh water tank Remove the three retaining screws on the mounting plate 1 Push the fresh water tank forwards slightly and remove upwards 1 4 2 ...

Page 16: ...agent to the injection point in the water inlet hose to the brush head Cleaning agent metering pump M6 and water pump M5 2 5 Water system 1 Shut off valve 2 Water filter 3 Metering valve Y2 4 Water pump M5 5 Cleaning agent metering pump M6 optional 6 Cleaning agent suction hose with float 7 Space for cleaning agent canister 8 Cleaning agent canister optional 2 1 5 4 Cleaning agent canister optiona...

Page 17: ...der the instrumentpanelandsignalswhenthefreshwater has to be topped up Thelevelmeter 2 showsthecurrentfreshwater level in the display by means of bars 10 bars maximum fresh water level 2 5 Water system Metering valve Y2 Metering valve Y2 In this metering valve 7 there are no microswitches instead the position is recorded by a potentiometer 6 1 2 3 6 5 7 Filling level meter B2 4 V Measured values v...

Page 18: ...ecting plug X99 square metering valve Y2 Connecting plug X99 of the metering valve Y2 1 2 Pin 1 Battery voltage 24 volt Pin 2 24 volt if water pump ON 0 volt if water pump OFF Pin 3 Earth 0 volt Pin 4 Control voltage for servo motor 1 7 1 9 volt metering valve maxi mum open 3 1 3 3volt meteringvalveminimum open 0 volt metering valve closed Pin 1 Pin 2 Pin 3 Pin 4 ...

Page 19: ... Air intake suction motor 8 Flat pleated filter 9 Seal tank cover 10 Lever for recycling mode optional 2 6 Dirty water tank with recycling function optional 1 9 8 6 7 5 2 3 4 Lever for recycling mode optional 10 Recycling mode optional The lever 10 for recycling mode is located on the left next to the driver s seat Thelever 10 canbeusedtoswitchtherecycling mode ON OFF Lever setting A recycling mod...

Page 20: ...full indicator lamp 8 Fault indicator lamp 9 Battery monitoring indicator lamp 10 Parking brake active indicator lamp 11 Key switch S0 12 Display warning and information module A0 13 14 15 16 1 10 9 8 7 6 2 3 4 5 17 18 11 12 13 Info Mode switch rotary and pusch button function 14 Pushbutton horn S3 15 Program switch S9 16 Direction of travel changeover switch S2 17 EMERGENCY STOP push button S1 18...

Page 21: ... without suction 6 Polishing with suction 7 Hand cleaning without drive function with wall floor ceiling tool optional 8 Service mode see Chapter 5 3 2 only up to version 3 4 5 6 7 1 2 Note The program switch S9 has 8 switching positions The hand cleaning 7 position is optional and the corresponding manual suction set can be retrofitted From version service mode is accessed via positions 1 5 of th...

Page 22: ...ainst static electricity The discharge lug 4 prevents static electrici ty from developing which could destroy or damage the control electronics Seat sensor S10 The seat sensor S10 is integrated in the seat 1 and is not accessible 1 Seat 2 Connection cable seat sensor S10 3 Distribution box EXT X1 4 Discharge lug Under the driver s seat on metal frame Note The seat sensor S10 is activated as soon a...

Page 23: ...ith battery 9 Seat folded up 10 Central plug X1 2 10 Battery low maintenance with filling system 10 1 9 3 8 2 4 6 5 7 All the unit s electrical components are connec ted with the block battery 6 654 136 through the central plug 10 If the upper section of the central plug 10 is pulled out the whole unit is isolated The electromagnetic brake Y1 is ac tivated Note An external battery charger is conne...

Page 24: ...he battery Note battery polarity 2 Plug mains plug into plug socket Switch on unit Euro plug 230V 50Hz CE plug 400V 50Hz 3 Green LED HL lit unit charging 4 Green LED NL lit recharging mode 5 Yellow LED LE lit battery full charge maintenance 6 Red LED ST lit FAULT Check battery connection Check battery polarity 7 If mains switch not lit check mains fuse ATTENTION Run unit in dry rooms only protect ...

Page 25: ...t optional 2 Side brush optional 3 Side brush suspension optional 4 Bowden cable deflection pully optional 5 Bowden cable side brush suspension optional Side brush suspension 1 1 3 2 4 5 6 3 7 6 Spring side brush suspension optional 7 Side brush motors M10 and M11 optional 8 Lifting motor M40 side brush 6 4 5 8 ...

Page 26: ...100 250 R BP RI Page 26 171 Service Manual 08 2007 2 13 Pre sweeper unit BR BD 100 250 RI only 1 Pre sweeper unit 2 Side brush LH 3 Side brush motor RH 4 Side brush RH 5 Transport roller 2x 6 Debris container LH RH 1 2 3 5 6 4 ...

Page 27: ...ge 27 171 Service Manual 08 2007 2 13 Pre sweeper unit view from the front side brush 1 6 5 2 3 5 6 4 4 1 Pre sweeper unit 2 Side brush LH 3 Side brush motor M41 LH 4 Bracket side brush motor suspension 5 Side brush motor M42 RH 6 Side brush RH ...

Page 28: ... Page 28 171 Service Manual 08 2007 2 13 Pre sweeper unit side view 1 Front wheel wheel hub motor M1 2 Cover main brush 3 Sealing lip side 4 Transport roller 5 Side brush RH 6 Bracket side brush motor suspension 7 Side brush LH 1 3 4 7 6 5 2 ...

Page 29: ...BR BD 100 250 R BP RI Technical features Page 29 171 Service Manual 08 2007 2 13 Pre sweeper unit side view 1 Filter case cover 2 Handwheel filter locking system 3 Filter case housing 1 3 2 ...

Page 30: ...Locking nut below Adjust parallelism The hexagonal rods 2 3 are used to align and adjust the pre sweeper unit The nuts 1 4 are used to lock the rods in place The setting is correct when the sweeping unit is adjusted parallel to the floor 4 1 Note Theadjustingrodsoftheparallelogrammust be adjusted to a length of 200 mm 7 88 in measured from centre pivot head to centre pivot head 200 mm 7 88 in ...

Page 31: ...Pre sweeping unit Adjust parallelism If the adjusting rods of the parallelogram have been adjusted to a length of 200 mm 7 88 in there is a distance of 55 mm 2 17 in between theframeofthebaseunit 1 andthepre sweeping unit 2 This dimension 55 mm 2 17 in is ab solutely necessary for fault free function of the parallelogram If necessary readjust 55 mm 2 17 in 2 1 ...

Page 32: ...ter shaker indicator lamp ON OFF 3 Display Warning and information module A0 4 Indicator lamp Pre sweeper ON OFF 5 Information button rotary and keying function 1 2 4 5 6 9 10 6 7 6 Switch pre sweeper unit S6 7 Push button horn S3 8 Program switch S9 9 EMERGENCY STOP push button S1 10 Direction of travel changeover switch S2 4 3 7 8 ...

Page 33: ... Fan motor M13 4 Bowden cables raise lower main brush 5 Bowden cables raise lower side brush 6 Lifting motor main brush and side brush 7 Bowden cable course dirt flap 8 Printed circuit board A4 1 lifting module 9 Printed circuit board A3 1 cleaning module 10 Electrical box 11 Bottom part of filter case 12 Top part of filter case 1 11 2 3 12 10 8 9 7 4 6 5 4 ...

Page 34: ... Page 34 171 Service Manual 08 2007 2 13 Pre sweeper unit debris container 1 Debris container RH 1 The pre sweeper unit is equipped with two de bris containers The debris containers are atta ched on the LH and RH side of the pre sweeper unit ...

Page 35: ...es Page 35 171 Service Manual 08 2007 2 13 Pre sweeper unit housing cover open 1 Housing cover pre sweeper unit 2 Electrical box 3 Filter case 4 Round filter 5 Handwheel filter locking system 6 Impeller fan housing 7 Fan motor 2 7 1 3 4 5 6 ...

Page 36: ...ing 5 Rubber grommet dust guard 6 Retainer plate 7 Handwheel filter locking system 8 Rubber plug 2 round filter If the round filter is blocked it must be removed from the filter case Loosen retaining screws 3 Turn the retainer plate 6 slightly in an anti clockwise direction Pullonthehandwheel 7 untiltheretainerhas been pulled out of the round filter The round filter 2 can be removed 2 1 3 3 6 5 4 ...

Page 37: ...BR BD 100 250 R BP RI Technical features Page 37 171 Service Manual 08 2007 2 13 Pre sweeper unit motor filter shaker 1 Filter case 2 Filter shaker motor M14 2 1 ...

Page 38: ...Technical features BR BD 100 250 R BP RI Page 38 171 Service Manual 08 2007 2 13 Pre sweeper unit impeller fan system 1 Impeller fan housing 2 Drive belt fan 3 Fan motor M13 1 3 2 1 2 3 ...

Page 39: ...features Page 39 171 Service Manual 08 2007 2 13 Pre sweeper unit lifting motor main brush side brush 1 Lifting motor M40 main brush and side brush 2 Bowden cables raise lower side brush 3 Bowden cables raise lower main brush 1 3 2 3 ...

Page 40: ...BR BD 100 250 R BP RI Page 40 171 Service Manual 08 2007 2 13 Pre sweeper unit motor main brush 1 Motor M12 main brush 2 Drive shaft motor 3 Tension roller 4 Drive belt 5 Pulley 6 Tension spring tension roller 2 3 5 1 4 6 ...

Page 41: ... Pre sweeper unit retainer LH main brush 1 Adjust locknut Bowden cabel 2 Adjust locknut Bowden cabel 3 Bowden cables raise lower main brush 4 Drive belt main brush 5 Pulley main brush 6 Rocker arm main brush retainer 7 Tension spring tension roller 8 Tension roller 3 4 8 7 5 6 2 1 ...

Page 42: ...unit retainer LH main brush 1 Rocker arm main brush retainer 2 Tension spring 3 Tension roller 4 Hollow screw with internal spring 5 Main brush rocker arm vibration damper 6 Pulley main brush 6 1 2 3 5 5 Thevibrationdamper 5 preventsthemainbrush from rocking by rubbing on the debris container 4 ...

Page 43: ...al features Page 43 171 Service Manual 08 2007 2 13 Pre sweeper unit retainer RH main brush 1 Rocker arm main brush retainer 2 Retainer centering arbor 3 Centering arbor 4 Main brush 5 Bowden cable raise lower main brush 1 5 4 3 2 ...

Page 44: ...strip 1 Mounting plate small sealing strip 2 Sealing strip side 3 Mounting plate large sealing strip 1 3 mm 0 039 in 0 118 in 2 3 1 The sealing strip 2 is mounted and its height adjusted using the retaining screws 5x arrow The distance between the floor and sealing strip 2 should be 1 3 mm 0 039 in 0 118 in ...

Page 45: ... BP RI Technical features Page 45 171 Service Manual 08 2007 2 13 Pre sweeper unit coarse dirt flap 1 Side brush LH 2 Coarse dirt flap 3 Sealing lip front 4 Side brush RH 5 Return spring coarse dirt flap 2 3 4 1 3 2 5 ...

Page 46: ...Technical features BR BD 100 250 R BP RI Page 46 171 Service Manual 08 2007 2 13 Pre sweeper unit pedal arrangement 1 Drive pedal 2 Brake pedal 3 Steering column 4 Coarse dirt flap pedal 4 2 1 3 ...

Page 47: ... to brush head 9 Water distribution tube 10 Brush roller 2x rotational direction towards each other 11 Brush motors M2 M3 12 Drive belt 13 Brush head BR version 14 Coarse dirt container BR version 15 Switchover valve to recycling mode optional 16 Recycling water hose to switchover valve optional 17 Suction beam 18 Drain hose dirty water 19 Suction hose 20 Filter for recycling mode optional 21 Suct...

Page 48: ...g screws 7 Brush head retainer 8 Guide brush head top 9 Guide brush head right 10 Retainer springs 3 11 Lower hole retainer for brush head guide BR version 12 Bracket 13 Upper hole retainer for brush head guide BD version 6 1 3 2 6 7 9 8 10 4 5 11 13 12 5 9 The brush head BR version is fastened with the guides 5 9 in the lower hole 11 of the bracket 12 The brush head BD version is fastened with th...

Page 49: ...chapter 5 3 3 depending on the brush motor s current consumption Example 4 bars of contract pressure are set at the display This corresponds to a brush motor current con sumption of 50 A The electronics relieve or load the brush motors through the lifting motor until the 50 A are reached This current is then auto matically retained Note It the brush head tends to severe vibrations audible up and d...

Page 50: ...R BD 100 250 RI only 11 1 4 8 7 9 6 5 2 3 10 1 Fan motor 2 Filter impeller fan and housing 3 Main brush over throw principle 4 Lifting module A4 1 5 Side brush motor LH 6 Side brush LH 7 Side brush RH 8 Transport roller 1x left 1x right 9 Side brush motor RH 10 Debris container LH RH 11 Filter case with round filter ...

Page 51: ... 2 Filter impeller fan and housing 3 Lifting module A4 1 4 Side brush motor RH 5 Side brush RH 6 Transport roller 1x 7 Main brush over throw principle 8 Debris container LH RH 9 Main frame connection parallelogram 10 Filter case with round filter 7 9 Note The parallelogram 9 of the mainframe connection allows on uneven floors a maximum deflection of 15 cm 5 91 in ...

Page 52: ...duced at a later date Rotary function Keying function Inching function Note Access by selecting the menu items takes place using the information button The info button symbols used see figure Rotary function forselectingthemenu Key function for confirming the menu selection Inching function for fine adjustment e g limit switch Manufacture settings see also Chapter 3 3 9 Info button with functions ...

Page 53: ...ode The respective test modes can be selected using the rotary function info button After sel ectionthedisplaybeginstoflash after 3 seconds this means that the test mode is active and the tests can be carried out 2 Display mode I drive I brush I motor I Lifting motor brush head I lifting motor suction beam Direction of travel switch function Seat switch function Drive pedal function Elect Ball val...

Page 54: ...min Operating time User 2 002h45min Speed 0 0km h Version control 08 1 2 Version drive module 1 2 Typ01 Version lift module 1 1 0 Version clean module 1 1 2 Version clean module 2 1 2 Version lift module 2 1 0 Machine model BR100 250R Alfred Kärcher GmbH Co KG Active operator functions If the rotary pulse generator is turned in an anti clockwise direction the cursor acts in the opposite direction ...

Page 55: ...s Drive Chap 3 3 2 Wet scrubbing Chap 3 3 3 3 3 4 Suction Chap 3 3 5 Polishing Chap 3 3 6 3 3 7 Hand cleaning Chap 3 3 8 Display Battery E F Water C E F no no yes yes no yes no Display information menu operating hours 00000h working time user 1 working time user 2 speed 0 00km h version master module version accessory module version traction module version cleaning module version lift module 1 ver...

Page 56: ...2 forward reverse Driver s pedal pressed Magnet sensor B1 Driver s seat previously vacated And occupied again Drive motor M1 active Magnet brake YO triggered Drive motor M1 remains stopped Drive motor M1 Stop Magnet brake YO active Red LED active Note For more drive comfort the travel direction switch S2 can be actuated as required with the drive pedal depressed The machine gently brakes to a stop...

Page 57: ...rive pedal pressed Magnetic sensor B1 Direction of travel switch S2 forwards reverse yes no yes no Drive motor M1 active Magnetic brake Y1 released Drive motor M1 stop Magnetic brake Y1 active Red LED active Note For increased drive convenience the direction of travel switch S2 can be actuated as required with the drive pedal depres sed The machine gently brakes to a stop and automatically acceler...

Page 58: ...ay flashing brush pressure II Change value Display brush pressure II new set value saved Display flashing water quantity IIIIII Display flashing water quantity II Change value Display water volume water quantity II new set value saved yes no yes no yes no yes no yes no yes no no no Note i Button If the i button is not pressed for longer than 10 seconds the program automatically switches back to Di...

Page 59: ...no yes no yes no yes no no no Note i Button If the i button is not pressed for longer than 10 seconds the program automatically switches back to Display Battery water Operator menu scrubbing displays Water quantity min max Adjustable when stopped Chemical metering min max Adjustable when stopped Brush pressure only adjustable in drive mode FACT Adjustable when stopped Brush after run Adjustable wh...

Page 60: ...gram switch to Pos 4 Suction motor M4 ON Lifting motor suction beam M30 lowers suction beam if direction of travel switch S2 switched to forwards Operator menu vacuum Working speed Adjustable when stopped Quit info display Adjustable when stopped Quit operator menu Adjustable when stopped Note i Button If the i button is not pressed for longer than 10 seconds the program automatically switches bac...

Page 61: ...nly adjustable in driving operation FACT Adjustable when stopped Brush after run Adjustable when stopped Working speed Adjustable when stopped Quit info display Adjustable when stopped Quit operator menu Adjustable when stopped Display brush pressure IIIIII Switch program switch to Pos 5 If the drive motor M1 is active the lifting motor lowers the brush head M20 Start brush motors M2 M3 Initial st...

Page 62: ...opped Brush after run Adjustable when stopped Working speed Adjustable when stopped Quit info display Adjustable when stopped Quit operator menu Adjustable when stopped Display brush pressure IIIIII Switch program switch to Pos 6 Suction motor M4 ON suction beam lifting motor M30 lowers suction beam if direction of travel switch S2 switched into forwards direction If drive motor active M1 Lifting ...

Page 63: ... 3 8 Hand cleaning with wall ceiling floor tool optional Display Battery E F Water C E F Initial startup Shutdown procedure Switch program switch to Pos 7 empty field Suction motor ON LED manual vacuuming suction motor green active LED brake red active Driving motor inactive ...

Page 64: ... depressed 1 1km h 2 2km h 6 6km h 3 Wet scrubbing without suction Water volume 5 1 8 see 2 Chemical metering 0 0 5 Brush pressure ON 4 0 8 Brush speed FACT Power Clean Power Clean Whisper Clean Fine Clean after stop 2s 0s 3s Working speed 4 1 6 4 Suction without srubbing mode Working speed 4 1 6 Brush pressure ON 4 0 8 5 Polishing without suction Brush speed FACT Power Clean Power Clean Whisper C...

Page 65: ... FILTER SHAKER MODULE A0 INFO USERPANEL A1 MASTER MODULE Operating system Sequence of machine events Error diagnosis Debugging Expansible serial network cable Bus PC Firmware download Diagnosis Parameterizati on Displaytext download Lights Hydraulic valves Cabin options Micro switches Battery charger Charging management Linear actuators Side broom option Micro switches Drive motor Magnetic brake H...

Page 66: ... integrated RS 485 bus system Kärcher bus with RS 485 communication core A1 A2 A3 A4 A5 KOPF CPU MASTER MODULE CPU MODULE X4 OUT X3 IN S9 X7 IN X2 OUT X8 OUT X1 IN X3 IN X3 OUT X2 OUT X2 IN FAHRMODUL TRACTION MODULE MODULE DE MOTEUR CLEANMODUL CLEANING MODULE MODULE DE NETTOYAGE HUBMODUL LIFTING MODULE MODULE DE MOTEUR DE COURSE ZUBEHÖRMODUL ACCESSORY MODULE MODULE D ACCESSOIRES A0 ...

Page 67: ...cation core A1 A2 A3 A4 A5 KOPF CPU MASTER MODULE CPU MODULE X4 OUT X3 IN S9 X7 IN X2 OUT X8 OUT X1 IN X3 IN X3 OUT X2 OUT X2 IN FAHRMODUL TRACTION MODULE MODULE DE MOTEUR CLEANMODUL CLEANING MODULE MODULE DE NETTOYAGE HUBMODUL LIFTING MODULE MODULE DE MOTEUR DE COURSE ZUBEHÖRMODUL ACCESSORY MODULE MODULE D ACCESSOIRES A0 A4 1 X2 OUT X3 IN HUBMODUL LIFTING MODULE MODULE DE MOTEUR DE COURSE ZUBEHÖR...

Page 68: ...LE CPU MODULE X4 OUT X3 IN S9 X7 IN X2 OUT X8 OUT X1 IN X3 IN X3 OUT X2 OUT X2 IN FAHRMODUL TRACTION MODULE MODULE DE MOTEUR CLEANMODUL CLEANING MODULE MODULE DE NETTOYAGE HUBMODUL LIFTING MODULE MODULE DE MOTEUR DE COURSE ZUBEHÖRMODUL ACCESSORY MODULE MODULE D ACCESSOIRES A0 A4 1 X3 OUT X2 IN HUBMODUL LIFTING MODULE MODULE DE MOTEUR DE COURSE ZUBEHÖR KEHRMASCHINE ACCESSORIES SWEEPING MACHINE ACCE...

Page 69: ...the driving module A2 is directly connected to the head CPU module A1 see figure Before this however the fuses must be removed from the connected modules here A3 A4 A5 Kärcher bus with RS 485 communication core A1 A2 A3 A4 A5 KOPF CPU MASTER MODULE CPU MODULE X4 OUT X3 IN S9 X7 IN X2 OUT X8 OUT X1 IN X3 IN X3 OUT X2 OUT X2 IN FAHRMODUL TRACTION MODULE MODULE DE MOTEUR CLEANMODUL CLEANING MODULE MO...

Page 70: ... 1 Warning and information module A0 2 Ribbon cable W201 34 pin 3 EMERGENCY STOP push button S1 4 Direction of travel changeover switch S2 5 Head CPU module A1 6 Pushbutton horn S3 7 Key switch S0 8 Ribbon cable W202 21 pin 8 1 2 6 4 5 7 3 Note If the head CPU module A1 is replaced it is necessary to calibrate the accelerator see Chapter 5 1 5 1 and to backup the operating hours counter ...

Page 71: ...Terminal strips not available used 2 Programming plug X1 A4 3 Terminal strip X3 A4 4 Terminal strip X2 A5 5 Terminal strip X3 A5 6 Terminal strip X6 A5 warning beacon light 7 Terminal strip X2 A4 8 Terminal strip X10 A5 working light 9 Horn H1 10 Fan electronics compartment M7 11 Terminal strip X4 A4 12 Terminal strip X5 A4 13 Printed circuit board lifting module A4 14 Printed circuit board access...

Page 72: ...ectronic Control Circuits BR BD 100 250 R BP RI Page 72 171 Service Manual 08 2007 4 7 Driving module A2 and Cleaning module A3 30 1 2 3 4 5 6 7 8 9 10 11 25 12 13 14 15 16 17 26 18 20 19 21 22 23 24 31 27 29 28 ...

Page 73: ...ard A3 19 Printed circuit board A2 20 Connecting terminal X11 A2 driving motor negative M1 21 Connecting terminal X1 A2 battery positive F2 22 Connecting terminal X10 A2 battery negative 23 Connecting terminal X12 A2 driving motor positive M1 24 Fuse F1 brown 25 Fuse F4 green 26 Support point battery negative post 27 Connection battery positive for printed circuit board A2 28 Insulating nut 29 Con...

Page 74: ...ular Electronic Control Circuits BR BD 100 250 R BP RI Page 74 171 Service Manual 08 2007 4 8 Lifting module A4 1 optional and Cleaning module A3 1 optional 1 2 8 9 10 11 12 17 16 15 3 5 18 6 7 14 4 13 19 ...

Page 75: ...otor M3 Note Connections at the relevant terminal strips and performance values for fuses see circuit diagram 0 088 734 Tightening torque M5 press fitted connection 10 2 2 Nm M6 press fitted connection 9 11 3 9 Nm M8 threaded bolt 5 5 Nm M10 threaded bolt 17 0 Nm Lifting module A4 1 optional Cleaning module A3 1 optional 7 8 9 11 5 4 3 2 1 13 10 18 16 17 15 14 6 11 Connecting terminal X6 A3 1 batt...

Page 76: ...oint battery negative post see page 72 Item 26 12 Connecting plug connection to accesso ries module A5 terminal strip X3 A5 see page 71 Item 5 13 Connecting plug connection to cleaning module A3 terminal strip X1 A3 see page 74 Item 3 Service module A9 The service module A9 can be used to diagno se a unit to find errors and faults It is used for parameterisation display adjust ment and for downloa...

Page 77: ...on cable Kärcher bus with RS 485 communication core Note The service module A9 may only be used from a head CPU version 2 1 If the earth connection is incorrectly connected or is not connected at all the modules concerned A1 A9 can be damaged or destroyed Separate documentation exists for the application software The software is available via the Kärcher Inside portal A1 A2 A3 A4 A5 KOPF CPU MASTE...

Page 78: ...e motor 0A Seat switch 1 Accelerator 0 3V Temperature drive electronics 33 C I_brush roller 0A I_Suction motor 0A Temp cleaning electronics 25 C Temp lift motor Electronics 36 C I_Main brush 0A I_Broom 0A I_Sweep fan 0A Temp sweep electronics 18 C Temp lift electronics sweep unit 28 C Travel direction Switch 1 Control panel switches KEH Sweeping operation S6 USR User 1 2 S7 CD Chemical metering S8...

Page 79: ...tem you can switch off all active drives simultaneously using the I button inch function On off function or open closed See 5 1 2 1 Requirements The metering cycle must first be released in the setup menu Parameter menu system parameters Chemical metering On 1 Off 0 1 with 1 Only then is the test cycle available The test cycle is started and stopped with the i Button inch function The following un...

Page 80: ...or on off The current can also be measured during the functional check Brush roller Suction motor Main brush Broom Sweep fan Note Switch off the key switch S0 to quit test mode Switch program switch S9 to Pos 2 wet scrub with vacuuming Display I_Suction motor yes no Last selected component display Switch program switch S9 to Pos 1 Drive no yes Measure current Suction motor on service Yellow LED se...

Page 81: ...ing motor is switched off via the overload current in the blockage phase Note If the rotary pulse generator is turned in an anti clockwise direction the cursor acts in the opposite direction i e the menu is called up from the last to the first parameter The last saved cursor can be called up again after quitting the menu e g by switching back to the standard display battery display Switch off the ...

Page 82: ...ES H I 0 0A On Off function or open closed see 5 1 2 1 Function notes The i button inch function con tinuously press activates the component during the active period the LED service yellow lights up When the limit position microswitch ES is reached the LED goes out and ES H or L appears in the display depending on the position Further the motor current I 0 0A is also displayed This value also retu...

Page 83: ... and Switch on key switch SO no Call up service operator menu See 5 1 5 3 Adjust brush pattern On Off function or o pen closed See 5 1 2 1 Drive pedal calibration See 5 1 5 1 LED test See 5 1 5 2 Call up service operator menu Move BK AB I_brush 0A Move BK AUF I_brush 0A Fan on off 0 0mA Magnet brake open closed Calibrate accelerator pedal lluminated symbol test Note If the rotary pulse generator i...

Page 84: ...Calibrate accelerator pedal yes no yes yes no no no yes Display Release accelerator pedal Do not press both pedals must be in the original position Then Display Floor forwards accelerator pedal Fully floor pedal and hold Then Display Floor accelerator pedal backwards Fully floor left pedal and hold Then Calibration o k Display Accelerator pedal calibration completed 3s Display Difference 500 Min 6...

Page 85: ...h the display At the last position the cursor jumps back to the 1st posi tion cycle Display Illuminated symbol test WDB Illuminated symbol test Pre sweep active Illuminated symbol test Service mode Parallel to the display the corresponding LED is also active for approx 2 sec IIlluminated symbol test Chemicals tank empty Illuminated symbol test Filter cleaning Illuminated symbol test Parking brake ...

Page 86: ... Busmon operation 0 0 off 1 R W 2 W O MoD 00 CD 00 Addr 00 100 h 00 Module 1 1 F 2 3 C 4 5 H 6 Z 7 L Module 2 1 F 2 3 C 4 5 H 6 Z 7 L Module 3 1 F 2 3 C 4 5 H 6 Z 7 L Module 4 1 F 2 3 C 4 5 H 6 Z 7 L Module 5 1 F 2 3 C 4 5 H 6 Z 7 L ENC W FF PUSH 0 li 0 re 0 F 0F 0M 00 Analog 0 Cycle time is 1ms µs I 000A U O 07 00 Rup 0 Rdown 0 I Brush 0A Is 0A T 0ms Information menu Operating notes If the i butt...

Page 87: ...closed module temprat clean unit 18 C switch brush head upper 0 lower 0 I_linear actuator Brush head 0 0A switch squeegee upper 1 lower 0 I_linear actuator squeegee 0 0A temp lift module clean unit 23 C temp accessory module 28 C I_blower sweep 0 0A switch sweep unit upper 1 lower 0 I_linear actuator sweepunit 0 1A temp liftmodule clean unit 32 C Keep I button Key function depressed and switch on ...

Page 88: ...cuum 3 Wet scrubbing 4 Vacuum 5 Polish 6 Polish vacuum 7 Empty field manual vacuuming 8 Empty field Service Button Press once Condition none none none none none none none Sit on seat Drive units On Off Fan electronics compartment M7 Brush motors M2 M3 Suction motor M4 Water pump M5 Chemical pump optional M6 Water metering valve Y2 open close LED Panel Magnetic brake Y2 open close LED Service Yello...

Page 89: ...21 provided this function is activated in the setup menu Chap 5 3 H Brush head lifting motor M20 Moves downwards according to the button activation inching mode until it reaches the limit position and is switched off by electronic current limiter microswitch S20 provided this function is activated in the setup menu Chap 5 3 Suction beam lifting motor M30 Moves upwards according to the button activ...

Page 90: ...m switch S9 to Pos 2 Scrub Vacuum Switch program switch S9 to Pos 3 Wet Scrub Access to TEST MODE see chapter 5 2 1 Rotary function LED Service yellow active Brush head lifting motor M20 Moves according to key actuation down to the limit position and is switched off by the electronic current limiter or limit switch S20 S21 Brush motor M2 M3 active Suction beam lifting motor M30 Moves according to ...

Page 91: ...nufacturer settings Display contrast min IIII max Information menu Diagnosis information Parameter setup menu Delete user operating time Information menu Operating notes on display Accept manufacturer settings If the manufacturer settings are to be accepted the display must first be found using the i button rotary function and then acknowledge using the i button inch function The Manufacturer sett...

Page 92: ...5 3 4 Max speed Forwards 6 0 km h Max speed Reverse 3 5 km h Starting ramp 2 Braking ramp 4 Max motor current 125A Max braking current 125A Overload limit 70 A Gas poti type 1 Gas poti supply 8 0V Motor constant 0 045 m Vs Language selection 0 0 German 1 Engl Machine model BR100 250RI Beacon lights during reverse travel 0 Standby time 30 min Discharge voltage 32 4 V 1 80 V Z Reset voltage 37 8V 2 ...

Page 93: ... no yes no yes no Display Return to setup module selection Display Parameter menu clean module 2 Display Return to setup module selection Display Parameter menu lifting module 2 Display Return to setup module selection yes no yes no Display max speed M2 D S 40 max speed M2 U S 40 max speed M2 D S 40 max speed M2 U S 40 Note If the I button is turned in an anti clockwise direction the cursor works ...

Page 94: ...Battery E F Water C E F yes no Keep I button function depressed and switch on key switch SO Display self diagnosis Self test o k SETUP MENU Continuation next page Main relay K1 switches off Display shutdown takes a few seconds Switch off key switch SO Main relay K1 switched on Display enter TESTER MODE 10s Display Activate module parameter setup To TEST MODE See Chapter 5 2 Note To quit setup menu...

Page 95: ... parameter setup Display Parameter menu System parameters See Chapter 5 3 2 2 Parameter menu Driving module See Chapter 5 3 2 2 Parameter menu Lifting module See Chapter 5 3 2 3 yes no Note If the i button is not pressed the program automatically switches back to Activate parameter setup module flashing The switchover times are for Activate parameter setup module 10sec In the setup menu 30 sec The...

Page 96: ... seconds the program automatically switches back to Activate parameter setup module flashing The unit must then be restarted as described in Chapter 5 3 2 1 Change and save PARAMETERS See Chapter 5 3 3 Display Display sel language 0 0 German 1 Engl scrubber model BR BD 100 250R beacon active du ring reversion 0 time to standby 30 Min min DOD voltage 32 4V 1 8V Z minimum brush pressure 40A move bru...

Page 97: ... System parameters and drive module See Chapter 5 2 2 Display Parameter menu lifting module Display return to SETUP module selection yes no yes no no yes Display max speed M2 D S 30 max speed M2 U S 30 Change and save system parameters See Chapter 5 3 3 Note If the i button is not pressed for 30 seconds the program automatically switches back to Activate parameter setup module flashing The unit mu...

Page 98: ...lue is displayed flashing yes no 30s New parameter value is displayed Flash function ends yes no 30s Next parameter value is displayed yes no no yes Return to setup module selection no yes Old value is retained Changes are saved yes no Display Quit parameter setup menu no yes no yes Display Parameter menu System parameter Note If the I button is turned in the anti clockwise direction the cursor wo...

Page 99: ...ff until the operating hours counter has been reloaded from the clean module Oth erwise the reading saved in the head CPU is adopted Note If the i button is not pressed within 30 seconds the program automatically switches to Battery E F OpHrs 3h 37m Then restart as described in Chapter 5 3 1 1 Note In the information menu access see Chapter 3 3 1 the reloaded operating hours level must then be che...

Page 100: ...s 5s Time during which the sweeper still runs when the machine at a standstill before the main brush side brush and fan switch off and the brush head is raised 11 X Display only for RI versions Sweeper fan after run time from stop 5 s 5s 0s 1s 20s Length of time during which sweeper suction fan still runs when machine at a standstill before it switches off 12 X Display only for RI versions Warning...

Page 101: ... setting min step max Notes max speed M2 D S 40 40 15 5 70 Slow nominal speed controller for downward travel of brush lift motor in the pressure control phase Order Service access Development access 1 X Lift module 1 Clone 1 Controls for suction beam scrubber head Available in a Basic unit b Basic unit side brush c Basic unit pre sweeper max speed M2 U S 60 60 15 5 70 Slow nominal speed of the spe...

Page 102: ...working lights and held head vacuum set mounting kits do not require any settings to be entered in the setup menu 4 Wheel nub motor option with 8 km h see Chapter 2 1 Ifadrivemotorwithaspeedof8km hisinstalled the following adjustment must be made in the drive module setup menu a Max forwards speed 8 0 km h b Max reverse speed 4 0 km h c Motor constant 0 07 m Vs Note The chemical metering function ...

Page 103: ...column 4x 10 Castellated nut steering head SW 36 11 Steering bearing 12 Sprocket wheel 13 Steering head 14 Cables wheel hub motor M1 and elec tromagnetic brake Y1 15 Wheel hub motor M1 16 Steering rod with toothed wheel Steering column 4 5 13 7 1 2 3 16 15 12 8 11 10 4 7 6 14 Steering head and wheel nub motor The steering head 13 is fixed to the steering bearing 11 with a castellated nut 10 Note T...

Page 104: ...d 8 Housing cover 9 Retaining screws lifting motor M30 10 Cover 11 Retaining screws 2x right microswitch S30 12 Switch cam on piston rod 13 Retaining screws 2x left microswitch S31 14 Connections microswitches S30 S31 1 2 3 4 5 6 8 9 10 1 7 6 12 13 11 Remove the spring 4 and retaining screw 3 Remove the retaining screws 2 with the spe cial tool see Chapter 7 then remove the housing cover 8 Both mi...

Page 105: ...ctuatingthemicroswitch 3 in this position Adjusting lower limit position micro switch S21 The lifting motor M20 lowers the brush head control speed v1 If the brushes are still 10mm 0 394in fromtheground positionB page106 the limit switch S20 switches and the lowering speedoftheliftingmotorisreduced controlspeed v2 The lifting motor M20 is not switched off The lifting motor is switched off or limit...

Page 106: ...keit v1 Hubmotor Regelgeschwindigkeit v2 Obere Endstellung S20 offen Untere Endstellung S21offen Hinweis zur Einstellung Der obere Endschalter muss so eingestellt werden dass zwischen Bürstenkopf und Rahmen noch ca 1 cm Abstand ist Der untere Endschalter muss so eingestellt werden dass die Hubmotorspindel nicht gegen den Anschlag Block läuft Funktion der Mikroschalter Die Endschalter S20 und S21 s...

Page 107: ...rsion Remove the wing nuts 1 and 5 Remove mounting plate 4 Remove cover plate 6 Loosen the 4 retaining screws 12 of the mo tor Remove drive belts 8 Install new drive belts tauten and tighten the retaining screws 12 of the motor The V belt tension is determined by the position of the motor shaft 11 Replace brush roller BR version 1 Wing nut front 2 Brush roller 3 Holding arbor 4 Mounting plate brus...

Page 108: ...nt brush roller 5 Adjusting screws 2x BR version Adjust the parallel brush pattern Check brush pattern BR BD BR version Coataflatareawithchalkanddriveoveritwith the machine Lower the brush head 1 in tester mode see Chapter 5 1 and let the brushes run for approx 3 seconds Raise the brush head 1 and reverse with the machine Check the brush pattern 3 4 The brush pattern of both brush rollers must be ...

Page 109: ...ush head retainer 10 Unlock the EMERGENCY STOP button in sert the battery plug X1 and raise the brush head guide again Thebrushheadcanbepulledofffromtheside Install in the reverse order 1 Cover electrical box 2 Screws electrical box 4x 3 Splash guard 4 Guide 2x brush head 5 Retaining screws 2x 6 Positive connection brush motors M2 M3 7 Terminal strip 2x 8 Negative connection brush motors M2 M3 9 R...

Page 110: ...anel 1 and remove the floor panel The drive sensor 3 no longer has to be cali brated using the retaining screws 2 The calibration takes place automatically in setup mode in the Parameter menu driving modu le seeChapter5 3 Todothis onlytheupper drive pedal position must be simulated and confirmed Thesameappliestothelowerdrive pedal position 3 1 2 4 Note When installing the floor panel 1 ensure the ...

Page 111: ...the carbon brush 5 used must be at least 50 of the new carbon brush Drive motor 125A 12 mm 0 473 in Drive motor 180A 16 mm 0 630 in Replace if necessary Wheel hub motor M1 Screw plug 4 1 2 3 6 5 1 Steering head 2 Carbon brush cover 3 Electromagnetic brake Y1 4 Front wheel 5 Carbon brush wheel hub motor M1 6 Retaining screw carbon brush 7 Transmission oil screw plug 400 ccm mineral oil viscosity IS...

Page 112: ... against rolling away Remove ram protector 4 1 2 Circlip Pull off the tyre Recess on tyre 2 3 2 Raise the front wheel of the unit and secure Lever out the circlip 1 using a screw driver and remove Pull the tyre 2 off the hub motor Install the new tyre note the installed position see arrow photo below Reinstall the circlip 1 Note The wheel hub motor M1 must not be dismantled removed to change the t...

Page 113: ...ake Y1 7 Transmission wheel hub motor M1 8 Brake disc magnetic brake Y1 9 Feeler gauge 10 Pressure plate magnetic brake Y1 11 Sleeve screw 12 Brake air gap 3 9 5 10 11 12 Note The brake disc 8 is 10 3 mm 0 406 in thick The thickness must not fall below the lower worn dimension of 7 5 mm 0 296 in in this case the brake disc 8 must be replaced Beforeinstallingthebrakedisc 8 degrease the brake lining...

Page 114: ...imes at the circumference Set the electromagnetic brake Y1 with the mounting plate If the installed brake air gap 7 does not measu re 0 3 mm 0 8 mm 0 012 in 0 032 in the brake air gap 7 must be set as follows Release three mounting screws refer to page 113 item 3 by using the Allen wrench 2 Screw the sleeve screws 8 in or out accor dingly by using the wrench 6 Tighten the mounting screws refer to ...

Page 115: ...le to right drum brake Adjust the rear wheel brake 1 2 3 1 4 5 7 7 5 8 6 6 Note The wheels must brake uniformly and symmetrically when the foot brake is pressed The rear wheel brakes can be adjusted separa tely on both sides if necessary Loosen lock nuts 6 Use the adjusting nuts 7 to tighten or loosen the Bowden cable Tighten the lock nuts 6 again Check the brake Note The brake must securely hold ...

Page 116: ...tion motor Water pump Electrical water valve Water filter Fresh water tank right Fresh water tank Dirty water tank Fine dust filter in dirty water tank Recycling filter in dirty water tank Drain hose fresh water or dirty water tank Suction beam lifting motor Seat switch Driving motor Drive controller Steerer steering column Rear wheel Brake drum not including adjustments Brake cable each side Brus...

Page 117: ... Test connection cable module A0 A1 A2 using test mode Check replace instrument panel printed circuit board Test replace driving module printed circuit board A2 using test mode Check replace drive motor M1 using test mode Replace main printed circuit board A1 Noises in the area of the wheel hub motor Adjust castellated nut see Chapter 5 3 1 Check replace steering bearing No or too little water sup...

Page 118: ...strips on suction beam Check replace suction hose Check adjust suction beam setting Test microswitch S30 S31 of the lifting motor M30 using test mode adjust replace Suction motor won t run Suction beam raised Dirty water tank full Check replace fuse F3 Test float switch S12 using test mode replace Test program selector switch S9 replace Test replace suction motor M4 using test mode Check cable con...

Page 119: ...ctor switch S9 test mode replace Test lifting motor M20 test mode replace Test lifting module printed circuit board A4 test mode replace Brush motor won t start Check replace fuse F3 Test brush motor M2 M3 using test mode replace Check cable connections remove defective cables Test cleaning module printed circuit board A3 using test mode replace Poor braking effect Test electromagnetic brake Y1 us...

Page 120: ...tem S6 switch Check replace program switch S9 Check replace micro switch of lower side brush S40 Check replace micro switch of upper side brush S41 Check replace lifting motor of side brush M40 Check replace lift module of side brush A4 1 Main brush cannot be lifted lowered only for RI version with pre sweeping unit Check if mechanical blockage is present repair blockage Check function of side bru...

Page 121: ...e key switch 4 must dis play a high ohm value When switched on the key switch 4 must display a low ohm value If necessary replace the key switch 4 Check replace fuse F1 Check fuse F1 replace defective fuse The fuse is located on the mounting plate of the cleaning module A3 see Chapter 4 7 Check replace EMERGENCY OFF but ton S1 Check the EMERGENCY OFF button 3 analo gous to the key switch 4 Central...

Page 122: ...ce the filter if necessary Check water hose to brush head for blockage kink and check remove Check water hose from tank up to brush head for blockage Remove any kinks in the hose Ensure the hose is laid correctly especially in the BR version Check the function of the metering valve Y2 replace Check the function of the servo motor 3 of the metering valve Y2 4 replace if necessary Fresh water filter...

Page 123: ...tion pipe view from below Fresh water distribution pipe Check clean replace fresh water distributi on pipe The fresh water distribution pipe 1 is located in front of the front brush roller It must be turned so that the holes face upwards 1 Fresh water distribution pipe 2 Connection for fresh water distribution pipe 1 2 1 ...

Page 124: ...ividual parts of the suction beam Suction beam fitted Check replace suction hose Check the suction hose 5 for leaks and blok kages clean replace if necessary Check adjust the suction beam setting Loosen knurled grips 2 Align the suction beam 3 so that it is straight Tighten the knurled grips 2 Loosen the wing screws 1 Align the suction beam 3 inclination adjust ment Tighten the wing screws 1 Note ...

Page 125: ...at switch S11 If the float switch 1 does not switch off when the dirty water tank has reached its maximum level it must be checked or replaced Check that the float switch 1 moves easily and smoothly Removetheretainingscrewonthefloatswitch 1 Pull the float switch 1 from the retainer and check replace Check cable connections to the printed circuit board for interruptions replace defective cables The...

Page 126: ...roup Chapter 6 2 1 Chapter 6 2 4 and carry out the measures listed to remove the fault Display format Process restricted Module abbreviation Clone Code 1 2 xyz 1 9 0 9 5 6 Consecutive No Error class Problem level The machine can contain several identical modules however they control different functions currently max 2 clones Note Words in bold print represent the standard display text Drive F Load...

Page 127: ...odule abbreviation Clone Code 1 2 xyz 1 9 0 9 0 1 Consecutive No Error class Problem level The machine can contain several identical modules however they control different functions currently max 2 clones Note Words in bold print represent the standard display text Drive F Load L Light Z System K Vacuum H C Scrub H C Sweep H C Beispiele Drive function fault F1 141 Error code Description of the err...

Page 128: ... mechanisms Machine model BR 100 250 R Basic unit Scrubbing rollers M2 M3 Suction motor M4 Water pump M5 Metering pump M6 Water valve Y2 Level sensors Cleaning module clone A3 Cleaning module clone A3 a Suction beam lifting motor M30 Brush head lifting motor M20 Lifting module clone A4 Lifting module clone A4 1 BR 100 250 R with side brush Scrubbing rollers M2 M3 Suction motor M4 Water pump M5 Met...

Page 129: ...quently a single event can cause faults from many modules Example Main relay coil K1 short circuits Faults and warnings K1 131 F1 121 H1 631 Z1 631 are generated Decisive is that the cause always is a fault therefore has a number circuit 0xx or 1xx The main relay coilshort circuit k1 131 inthisexamplehas the result that the drive module A2 does not receive any load circuit voltage the contactor do...

Page 130: ...ct drive motor M1 from A2 X11 X12 2 Perform key switch S0 reset 3 If fault remains replace A2 4 Search for the incorrect connection of the chassis to the battery ground Eliminate the connection 5 Clean the drive motor M1 of coal dust 6 Check the drive motor M1 for moisture that may have penetrated HD cleaning 7 Replace drive motor M1 if necessary Fault detected in power electronics for the brake Y...

Page 131: ... completely contact the head CPU A1 3 Search repair error in bus cables 4 If fault remains replace A2 Drive module A2 does not receive any voltage at the power electronic unit F1 121 1 Check fuse F2 2 Check if the battery voltage is between 14 50V If not check the battery 3 Short circuiting of another module is possible Disconnect all lines from the module and reconnect beginning with the drive mo...

Page 132: ...minals 3 Check motor supply cable for crimped kinked and worn areas 4 If fault remains replace A2 Cable break A2 X6 3 4 1 Check all cable connections for proper seating 2 Disconnect A2 X6 and check brake Y1 for low resistance 20 40 Ohm 3 Check cable for crimped kinked and worn areas 4 If fault remains replace A2 Cabling error switch inputs A2 X5 F1 151 1 Check to verify that all connected switches...

Page 133: ...y switch S0 reset 2 Check module module may be defective Power electronic of drive motor M1 is over loaded Controls are hot Cool off 1 Switch off key switch S0 2 Let control unit cool for at least 5 minutes 3 Switch on key switch S0 and preferably continue at level 4 If fault remains replace A2 Horn H1 is faulty F1 511 1 Completely disconnect plug A2 X6 2 Press horn switch S3 again 3 If fault rema...

Page 134: ...s A5 X2 2 A5 X3 2 A5 X2 5 and A5 X3 5 completely contact the head CPU A1 3 Search repair error in bus cables 4 If fault remains replace A5 Accessories module A5 does not receive any voltage at the power electronic unit Z1 121 1 Check if main relay K1 is closed and if relay coil lines are completely connected with head CPU A1 2 Check fuse cut out F4 for the accessories module A5 and replace if nece...

Page 135: ...6 or X10 Z1 511 1 Check supply lines to the connected consumers A5 X6 or X10 for consistency short circuits or loose plug connections 2 Check if the consumers H2 H3 H4 have high impedance or are short circuiting if necessary replace 3 If fault remains replace A5 Supply in load circuit interrupted Z1 631 1 Check supply connection A4 DR1 for proper seating 2 Check supply lines and fuses for the modu...

Page 136: ...e concerned 2 Search for fault in bus line 1 or at A1 X4 1 H Fault detected in jumpers of lifting motors Hy 022 1 Disconnect lifting motor M20 A4 X5 2 6 2 Perform key switch S0 reset If the error remains 3 Disconnect lifting motor M30 A4 X4 2 6 4 Perform key switch S0 reset If the error remains 5 Replace A4 clone concerned otherwise 6 search where the chassis erroneously has a connection to the ba...

Page 137: ...or remains replace A3 clone in question Communications error between lift module A4 and head CPU A1 Hy 111 1 Check if bus plugs A4 X2 and A4 X3 are connec ted 2 Check if bus lines A4 X2 2 A4 X3 2 A4 X2 5 A4 X3 5 completely contact the head CPU A1 3 Search repair error in bus cables 4 If the error remains replace A4 clone in question H Lift module A4 does not receive voltage at the power electronic...

Page 138: ...oad on A4 DR3 Hy 132 Refer to Hy 131 steps 3 5 however for A4 DR3 Short circuit or overload on A3 X8 Cy 131 1 Check fuse F3 125A replace if necessary 2 Disconnect motor M2 A3 X8 3 Perform key switch S0 reset If the error is replaced by another then search for short circuit in cables and repair If necessary replace motor at M2 A3 X8 4 If the error remains replace A3 clone in question Short circuit ...

Page 139: ...m 1 Disconnect lifting motor M50 at A4 2 X4 2 6 2 Perform key switch S0 reset 3 If fault remains replace module A4 2 4 Check lifting motor M50 for low impedance Check motor supply cable for crimped kinked and worn areas Check Molex plug connections Check motor carbon Equipment version BR BD 100 250 RI with side brush 1 Disconnect lifting motor M40 at A4 1 X4 2 6 2 Perform key switch S0 reset 3 If ...

Page 140: ... X5 1 5 8 2 Check if the limit switch is correctly assigned to A4 X5 5 and A4 X5 8 and root A5 X5 1 3 Check if one or both limit switches are crossed 4 Check if a short circuit exists between the limit switch lines 5 Check if the lifting motor M20 is defective or mechanically blocked 6 Replace A4 clone concerned H Limit switch A4 X4 1 5 8 in contradiction Hy 622 Refer to Hy 621 however for A4 X4 1...

Page 141: ...1 111 1 Check if bus plugs A1 X3 and A1 X4 are connec ted 2 Check if bus lines A1 X3 2 after A1 X4 2 AND A1 X3 5 after A1 X4 5 are completely connected 3 Search for errors in lines No 2 and No 5 of all bus cables and repair 4 Test single module coupling connect head CPU A1 with only one random module as direct bus If error is replaced by another test with other modules until the malfunctioning mod...

Page 142: ...tacts are sticking K1 122 1 Perform key switch S0 reset 2 If fault remains replace main relay K1 Overload short circuit main relay coil K1 K1 131 1 Disconnect a line on main relay coil K1 2 Perform key switch S0 reset If the error is replaced by another then search for short circuit in cabling from the coil to plug A1 X11 and repair 3 If fault remains replace A1 4 In case of another error check if...

Page 143: ... error in process control developer 2 Replace A1 with A1 for new firmware Protocol error in bus transmission K1 172 1 Perform key switch S0 reset several times 2 If errors continue test single module coupling for this connect head CPU A1 with only one ran dom module as direct bus If error is replaced by another test with other modules until the mal functioning module is found Replace the mal funct...

Page 144: ...otor hot let cool down Betriebsstunden auf 0 gesetzt operating hours set to 0 Steuerung heiss Abkühlen lassen module temp high let cool down Schütz offen Not Aus Knopf contactor open emergen button Abschaltung Bus versorgung fehlt shutdown missing bus supply User messages A user message is an unformatted message dis play User messages allow the operator to analyze unacceptable machine conditions o...

Page 145: ...r occurred Operating hour during which the last error occurred Operating minute during which the last error occurred Currently implemented module description Note The event counter returns to 0 when the maximum value has been reached Display pattern of module error codes Module description Head CPU module A1 0 Drive module A2 1 Cleaning module A3 clone 1 2 Cleaning module A3 clone 2 3 Lifting modu...

Page 146: ...rrespondence with the protocol definition Master slave sequence is inconsistent Defective bus driver Malfunction of module processors Software error K1 172 2 Buffer overflow The requested number of service parameters has exceeded the reserved buffer capacity If the program selector switch is continuously activated in a short period for example every se cond an overflow is possible if modules remai...

Page 147: ... module supply line burned through Cable break of the module supply Download electronic unit is defective F1 121 2 Excess module tempe rature Temperature in load cir cuit stage exceeded the approved value or ambi ent temperature is too high Blocked drive motor M1 Overload on steep ramps Cooling fan is defective Cooling vents are plugged User messages 3 Unacceptableaccelera tor value Accelerator vo...

Page 148: ...31 1 Power supply is not between 14V 50V Missing load circuit supply Main relay coil K1 open Fuse for module supply line is burned through Wire break of the module supply Defective downloading electronicunitatdrivemodule C1 121 C2 121 2 Excess module tempe rature Temperature in load cir cuit stage has exceeded the approved value or ambient temperature is too high Blocked brush motors Defective coo...

Page 149: ...odule supply line is burned through Wire break of the module supply Defective downloading elec tronic unit at drive module H1 121 H2 121 2 Excess module tempe rature Temperature in load cir cuit stage has exceeded approved value or ambi ent temperature is too high Blocked lifting motors Blocked side brush motors Defective cooling fan Cooling vents are plugged High load currents Anwender meldungen ...

Page 150: ...odule sup ply Defective downloading electro nic unit at drive module Z1 121 2 Excess module tempe rature Temperature in load cir cuit stage has exceeded the approved value Allconsumersoperateatthecur rent limit light valves Defective cooling fan Cooling vents are plugged User messages 3 Correctable error in the parameter memory System parameter CRC is incorrect during the storage of new parame ter...

Page 151: ...toothedsegmentandthetoothedheadofthesteering pinion must be between 1 mm and 2 5 mm O Test the functioning of the brush head lower raise O Test the brushes for functionality and wear O Test the brush level O Test the wiping lips on the cleaning head Test the mobility of the wiping lips O Check the settings of the brush contact pressure O Test the drive belt of the brushes for tension and wear O Ch...

Page 152: ...ace the dust filter O Check the carbon brushes in the traction motor and brush drive for wear replace the carbon brushes if necessary O Replace the toothed belt in the brush head O Additional instructions for version R I Check the freedom of movement of all moving parts of the sweeping assembly O Test the function of the coarse dirt valve O Check the dust filter for damage O Check the cleaning fun...

Page 153: ...BR BD 100 250 R BP RI Circuit diagrams Page 153 171 Service Manual 08 2007 8 1 Circuit diagram 0 088 734 0 Head CPU A1 ...

Page 154: ...Circuit diagrams BR BD 100 250 R BP RI Page 154 171 Service Manual 08 2007 8 2 Circuit diagram 0 088 876 0 Head CPU A1 ...

Page 155: ...BR BD 100 250 R BP RI Circuit diagrams Page 155 171 Service Manual 08 2007 8 3 Circuit diagram 0 088 734 0 0 088 876 0 Driving module A2 ...

Page 156: ...Circuit diagrams BR BD 100 250 R BP RI Page 156 171 Service Manual 08 2007 8 4 Circuit diagram 0 088 734 0 0 088 876 0 Cleaning module A3 ...

Page 157: ...BR BD 100 250 R BP RI Circuit diagrams Page 157 171 Service Manual 08 2007 8 5 Circuit diagram 0 088 734 0 0 088 876 0 Cleaning module Pre sweeper unit A3 1 ...

Page 158: ...Circuit diagrams BR BD 100 250 R BP RI Page 158 171 Service Manual 08 2007 8 6 Circuit diagram 0 088 734 0 0 088 876 0 Lifting module A4 ...

Page 159: ...BR BD 100 250 R BP RI Circuit diagrams Page 159 171 Service Manual 08 2007 8 7 Circuit diagram 0 088 734 0 0 088 876 0 Lifting module Side brush A4 1 ...

Page 160: ...Circuit diagrams BR BD 100 250 R BP RI Page 160 171 Service Manual 08 2007 8 8 Circuit diagram 0 088 734 0 0 088 876 0 Lifting module Pre sweeper unit A4 2 ...

Page 161: ...BR BD 100 250 R BP RI Circuit diagrams Page 161 171 Service Manual 08 2007 8 9 Circuit diagram 0 088 734 0 0 088 876 0 Accessory module A5 ...

Page 162: ...r M5 Water pump M6 Cleaning agent metering pump Option M7 Fan electronics M10 Side brush motor Option M11 Side brush motor Option M12 Brush motor Option M13 Fan motor Option M14 Motor filter cleaning Option M20 Lifting motor Brush head M30 Lifting motor Suction beam M40 Lifting motor Side brush Option M41 Side brush motor Option M42 Side brush motor Option M50 Lifting motor Pre sweeper unit Option...

Page 163: ... 961 388 0 5 970 364 0 0 088 876 0 BD 100 250 R BP 1 480 211 0 0 088 734 0 5 961 388 0 5 970 364 0 0 088 876 0 BD 100 250 R BP Pack 1 480 221 0 0 088 734 0 5 961 388 0 5 970 364 0 0 088 876 0 BR 100 250 RI BP 1 480 311 0 0 088 734 0 5 961 388 0 5 970 364 0 0 088 876 0 BR 100 250 RI BP Pack 1 480 321 0 0 088 734 0 5 961 388 0 5 970 364 0 0 088 876 0 BD 100 250 RI BP 1 480 411 0 0 088 734 0 5 961 38...

Page 164: ...wrench 2 25 Nm 6 815 090 0 Extraction tool for modular plugs Molex 6 816 086 0 Scope of supply service package chapter 4 9 2 816 117 0 Voltage regulator 6 803 025 0 Fuse 1A 6 644 126 0 11 Tightening torques Cleaning module and drive module also refer to chapter 4 7 and 4 8 M5 press fitted connection 2 2 Nm M5 plug in connection 4 0 Nm M6 press fitted connection 3 9 Nm M6 plug in connection 4 0 Nm ...

Page 165: ... Y1 113 Brake lever drum brake 115 Brake pedal 10 46 103 Brush drive assembly cover plate 13 Brush head BD version 10 13 107 Brush head BR version 9 13 47 48 108 Brush head maintenance work 107 109 Brush head mounting parts 48 Brush head retainer 48 109 Brush head support bracket BD version 13 Brush head support bracket BR version 13 Brush motors M2 M3 47 Brush motors overload indicator light M2 M...

Page 166: ...Cleaning module and Lifting module parameters 97 Cleaning opening dirty water tank 11 14 Coarse dirt container BR version 13 47 Coarse dirt flap 45 Coarse dirt flap pedal 46 Connecting plug X1 with the battery charger 24 Connecting plug X7 17 Connecting plug X99 18 Connecting terminal X1 A2 73 Connecting terminal X10 A2 73 Connecting terminal X10 A3 73 Connecting terminal X10 A3 1 75 Connecting te...

Page 167: ...se 23 Filling valve 23 Filling level meter B2 17 Filter case 35 37 Filter case cover 29 Filter case housing 29 Filter case with round filter 50 51 Filter for recycling mode optional 47 Filter impeller fan and housing 50 51 Filter mounting plate 125 Filter shaker control light only RI version ON OFF 20 Filter shaker indicator lamp ON OFF 32 Filter shaker motor 37 Flat pleated filter 19 125 Float sw...

Page 168: ...g code 126 Metal bushing 124 Metering valve Y2 16 17 47 122 Microswitch S20 brush head lowered 105 Microswitch S20 cam 105 Microswitch S21 brush head raised 105 Microswitch S21 cam 105 Microswitch S30 suction beam lowered 104 Microswitch S31 suction beam raised 104 Modular system BR BD 100 250 R 65 Modular system BR BD 100 250 R with side brush optional 67 Modular system BR BD 100 250 RI 68 Module...

Page 169: ...h head retainer 109 Retaining screws for filter mounting plates 124 Retaining screws belt housing 107 Retaining screws freewheeling lever 113 Retaining screws lifting motor M30 104 Retaining screws motor 107 Retaining screws steering column 103 Return spring coarse dirt flap 45 Ribbon cable W201 34 pin 70 Ribbon cable W202 21 pin 70 Rocker arm main brush retainer 41 43 Round filter 35 36 Rubber gr...

Page 170: ...hnical features BR BD 120 250 RI 8 Technical specifications 163 Tension roller 40 42 Tension spring 42 Terminal strip 109 Terminal strip X1 A3 73 Terminal strip X1 A3 1 75 Terminal strip X1 A5 71 Terminal strip X10 A5 71 Terminal strip X12 A3 73 Terminal strip X12 A3 1 75 Terminal strip X2 A2 73 Terminal strip X2 A3 73 Terminal strip X2 A3 1 75 Terminal strip X2 A4 71 Terminal strip X2 A4 1 75 Ter...

Page 171: ...ater pump M5 16 47 Water system 7 16 18 Water volume too low 122 123 WBD spray suction tool optional ON OFF 20 Wet scrubbing with suction 58 Wet scrubbing without suction 59 Wheel hub motor M1 12 103 112 113 Wheel hub motor tyres M1 111 112 Wing nut front 107 Wing nut rear 107 Wing screw steering column adjustment 10 Wing screws adjusting suction beam tilt 14 Wing screws for fixing the suction bea...

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