Kärcher BD 40/12 C Bp Pack Service Manual Download Page 3

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5.906-510.0 Rev. 00 (12/10)

4.19

Electrical system

4.19.1

Measuring points and fuse

4.19.2

DIP switch

Reading faults

Check the maintenance-free batteries

6.1

1. Measurement - idle voltage

6.2

2. Measuring the battery under load

6.3

3. Measuring the battery under load

6.4

Limit value – battery voltage between the individual battery blocks

6.5

Battery measuring log - maintenance-free battery

6.6

Replacing a battery due to old age

6.7

Test the charger

6.8

Regulated charge ID line IUI charger for maintenance-free batteries

Circuit diagram

7.1

Legend of the electrical components

Specifications

Water function diagram

10 Tools needed for installation (not supplied)

11 Exchange times

Summary of Contents for BD 40/12 C Bp Pack

Page 1: ...5 906 510 0 Rev 00 12 10 1 BD 40 12 C Bp Pack Service Manual ...

Page 2: ...etup and function 6 4 0 1 Operator console 4 1 Power switch 4 2 Handle 8 4 3 Suction bar lift 8 4 4 Inclination settings 10 4 5 Water filter 4 6 Remove the suction bar 11 4 7 Turn or replace vacuum lips 12 4 8 Check the vacuum bar setting 12 4 9 Setting the vacuum Bar 12 4 10 Dismantling installing the brush head 12 4 11 Brush head drive 13 4 12 Removing the suction turbine 14 4 13 Replace solenoi...

Page 3: ...attery under load 20 6 4 Limit value battery voltage between the individual battery blocks 20 6 5 Battery measuring log maintenance free battery 20 6 6 Replacing a battery due to old age 21 6 7 Test the charger 22 6 8 Regulated charge ID line IUI charger for maintenance free batteries 22 7 Circuit diagram 23 7 1 Legend of the electrical components 23 8 Specifications 24 9 Water function diagram 25...

Page 4: ... tips and important information about the product First pull out the plug from the mains before carrying out any tasks on the machine After completing the maintenace work check all safe ty and protective devices for correct installation and proper function The scrubbing vacuum cleaner is used for the wet cleaning of level floors It can be easily adjusted to the cleaning task by set ting the water ...

Page 5: ...bine trailing time 2 seconds Overvoltage shut off Turbine 20 8 V Overvoltage shut off Brush motor 21 0 V Overload shut off at 20a 1A The holm can be swivelled from the vertical posi tion by about 90 in both directions With max wastewater volume the floater in the wastewater reservoir closes so that no further suc tion is possible Actuate the brush switch with the operating lever pressed down to sw...

Page 6: ... 8 Cable hook rotating 9 Suction hose 10 Charger 11 Battery charging display 12 Solenoid valve 13 Water volume regulating valve 14 Fresh water filter 15 Battery 16 Dirt water reservoir 17 Vacuum bar 18 Cleaning head 19 Disc brush 20 Fresh water reservoir filler neck 21 Fill hose included 22 Cover dirt water reservoir 23 Float 24 Counter sunk screw to lock the wastewater reservoir 4 Setup and funct...

Page 7: ...h for brush operations 5 Switch for fresh water detergent solution 1 Screws 2 Casing Unscrew locking screws Remove the housing 1 Switch 2 Nut Replace the switch Apply the fixation glue to the thread and tighten the nut to a torque of 0 3 Nm fingertight Perform a function test 4 0 1 Operator console 4 1 Power switch ...

Page 8: ...Installation Please observe the screw length Installation Observe the lever layout 1 Nut To preset the bowden cable screw the nut onto the threaded rod for about 1 cm To lock the suction bar lift pull the lever all the way up Must click when it locks 4 2 Handle 4 3 Suction bar lift ...

Page 9: ...9 1 Spring Pretension the spring by 1 4 turn Insert the spring into the groove Installation Observe the lever position 1 Bottom adjustment 2 Top adjustment Installation The Bowden cable can be adjusted on the top and the bottom ...

Page 10: ... 3 Clamping screw Unscrew the countersunk screws Loosen the clamping screw Remove the segment toothed wheel 1 Nut 2 Hand lever Unscrew the nut from the threaded rod Remove the manual lever 1 Pipe 2 Threaded rod 3 Lock Pull the pipe out of the clamp Pull the threaded rod with lock out toward the top 4 4 Inclination settings ...

Page 11: ...ctional control Note The stop valve must be closed before opening the water filter 1 Water filter 2 Locking tap Close the stop valve Unscrew the filter cup Remove the sieve and rinse it Installation in reverse order 1 Suction hose 2 Cross handle for fastening of vacuum bar 3 Vacuum bar Pull off the suction hose Loosen cross handles Remove the vacuum bar 4 5 Water filter 4 6 Remove the suction bar ...

Page 12: ...m process will start Lower the vacuum bar Push the appliance forward a bit Switch off suction turbine switch Adjustment of the vacuum bar adjust if necessary 1 Nut 2 Wheel Loosen the nut Move the wheel upwards or downwards Tighten nut Check the setting of the vacuum bar 1 Bowden cable 2 Screw Loosen screws Remove the bowden cable 4 7 Turn or replace vacuum lips 4 8 Check the vacuum bar setting 4 9...

Page 13: ...plint Pull out the bolt 1 Ring 2 Hose Slide the ring back and pull the hose off at the same time Pull out the hose Pull the brush head out toward the front 1 Brush head 2 Safety ring Reverse the brush head Remove the safety ring 1 Flange Remove the flange 4 11 Brush head drive ...

Page 14: ... the motor 1 Cover 2 Carbon brush Remove the cover Replace carbon brushes Assemble in reverse order Note The water supply for the brush must not be plugged 1 Bowden cable Unscrew the bowden cable from the brush head 1 Counter sunk screw 4 12 Removing the suction turbine ...

Page 15: ... connection 3 Nuts 4 Suction turbine Remove the cover caps Disconnect pole terminal to positive pole Cover the battery and protect it from short circuit Disconnect the connector Unscrew the nuts Remove the suction turbine Note Replace damaged foam filter 1 Cover 2 Carbon brush 2x Remove cover Check carbon brush of the suction turbine replace if required Installation in reverse order ...

Page 16: ...time Pull out the hose Unscrew the nuts Remove the solenoid valve 1 Screw 2 Wheel cap Loosen screws Remove the wheel cover 1 Wheel 2 Cylinder roller bearing Remove wheel Check the cylinder roller bearing for damage and replace if necessary Installation in reverse order 4 13 Replace solenoid valve 4 14 Removing the wheel ...

Page 17: ...witches off the charging process Insert the mains plug into the socket 1 Battery is discharged red 2 Battery is charged halfway yellow 3 Battery is charged green Lights up when the brush drive switch is switched on 1 Battery is charged 2 Battery is discharged Battery runtime The battery runtime on smooth ground and medium discharge current 16 A is 1 hour 15 min Values for GEL battery 4 15 Fill in ...

Page 18: ...screws Remove the hood 1 Power supply for battery 2 Turbine 3 Brush motor 4 Solenoid valve water 5 Fuse 30 A Measuring values to Turbine U battery voltage Current pickup 10 A Brush motor U battery voltage Current pickup 4 1 A loaded Solenoid valve U battery voltage Current pickup 0 3 A Fuse 30 A U battery voltage 4 19 Electrical system 4 19 1 Measuring points and fuse ...

Page 19: ...ttery is com pletely discharged the appliance will shut off The appliance be run for 1 minute after switching it off and back on before it will shut off again due to to tal discharge Fault diagnosis function Display in the battery status field by respective blinking of LEDs 4 19 2 DIP switch 5 Reading faults Fault Visualisation Suction turbine overload LED1 blinks LED 2 is lit continuously Brush m...

Page 20: ... indicate clearly that there is a faulty cell the third measurement must be performed after the second load test Use a voltmeter multimeter to measure and record the battery voltage of every individual bat tery block Measure the current using a clip on ammeter dur ing the voltage measurement and record it Operate the appliance until the discharge end volt age the total discharge protection shuts t...

Page 21: ...maining battery blocks and the new battery block individually You can use a laborato ry device for that The load voltage must be set to exactly 7 14 volts The load current must not ex ceed 14 A 100 Ah The load current must have decreased to under 4 A 100 Ah at the end of the battery block 6 5 1 Measurement load test Battery block 1 Battery block 2 Battery block 3 Battery block 4 Battery block 5 Ba...

Page 22: ...ring result of the I constant phase in the main charge must be close to the manufacturer s values of the charger See typeplate of charger AGM glass mat battery 2 4 gel 2 35 AGM glass mat battery 2 25 gel 2 3 IUIa means I constant current line U constant voltage line I constant current line recharging a automatic switch off transition to maintenance charge During the I constant phase the charger is...

Page 23: ...5 906 510 0 Rev 00 12 10 23 7 Circuit diagram 7 1 Legend of the electrical components ...

Page 24: ...tion bar up 10A 1A Max feed volume of the suction turbine remove suction hose from the suc tion bar and connect it to the measuring device 20 l s 2 l s Max vacuum pressure of the suction turbine with the suction opening close pull off the suction hose from the suction bar and connect it to the measuring device 85 mbar 10 mbar Speed brush 150 rpm 10 rpm Current pickup of brush mo tor on cement slab...

Page 25: ...ter tank 3 Dirt water reservoir 4 Suction hose 5 Locking tap 6 Vacuum bar 7 Fresh water filter 8 Solenoid valve 9 Dirt water drain hose 10 Disc brush 11 Drain off tap 12 Fresh water reservoir filler neck 13 Cover dirt water reservoir 9 Water function diagram ...

Page 26: ...n hose 5 Suction hose 5 Batteries 10 Threaded rod Driving lever 25 Turbine 15 Bowden cable Vacuum bar 20 Brush motor 20 Fresh water tank 45 Vacuum bar 5 Water filter 15 Wheel per piece 5 Electronics system 15 Charger 20 Power switch per piece 10 Joint of push handle 15 Solenoid valve 20 Threaded rod for drive lever adjustment 25 Suction lips 10 ...

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