Kärcher BD 45/40 Service Manual Download Page 2

Page: 2 / 127

English 5.906-269.0 Rev. 00 (03/11)

Contents

1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Hazard levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 General notes on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Technical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Travel drive (W only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Water system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Vacuuming operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Cleaning operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Brushing rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.2 Disc brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Ep model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.2 Bp model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Setup and function - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Front view (BD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Front view (BR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Detergent compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Vacuum bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Suction turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 BD cleaning head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.2 Brush drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.3 Solenoid valve for water inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.4 Contact pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 BR cleaning head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.2 Brush drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.3 Solenoid valve for water inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 Transport roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for 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: ...l 7 4 6 2 Bp model 7 5 Setup and function general 8 5 1 Front view BD 8 5 1 1 Version 1 8 5 1 2 Version 2 9 5 2 Front view BR 10 5 2 1 Version 1 10 5 2 2 Version 2 11 5 3 Rear view 12 5 3 1 Version 1...

Page 3: ...tion on C Bp Pack 39 6 6 Flowmeter 40 6 7 Travel drive W Bp Pack only 41 6 7 1 Version 1 41 6 7 2 Version 2 42 6 8 Operator functions W Bp Pack 43 6 8 1 Startup driving 43 6 8 2 Wet scrubbing with vac...

Page 4: ...enoid valve for water inlet 83 9 4 11 Check supply voltage of the drive motor 83 9 4 12 Check supply voltage of the suction turbine 84 9 4 13 Check the charge voltage 84 9 4 14 Checking the total disc...

Page 5: ...gram 0 088 845 119 15 1 2 BR BD 55 40 45 40 C Bp circuit diagram 0 088 843 120 15 1 3 BR BD 55 40 45 40 C Bp Pack W Bp Pack circuit diagram 0 088 844 121 15 1 4 BR BD 55 40 45 40 WRB circuit diagram 0...

Page 6: ...property Danger Risk of injury Vor allen Arbeiten am Ger t Schl sselschalter und Batterie Hauptschalter ausschalten und Schl ssel abziehen If the appliance must be started up for mainte nance procedur...

Page 7: ...a propulsion The brush rotation direction is in opposite directions for vehicles with drives 1 disc brush with rapid exchange system Brush drive system with toothed belt Control handle 6 level program...

Page 8: ...ater 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 roller 12 Cleaning head 13 Scraper roller of clean...

Page 9: ...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 transport roller 12 Cleaning head 13 Scraper roller of...

Page 10: ...tment 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 roller 12 Cleaning head 13 Scraper...

Page 11: ...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 transport roller 12 Cleaning head 13 Button for br...

Page 12: ...ary handle water volume dosing valve 6 Detergent switch W Bp Pack only option on C Bp Pack 7 Fresh water level display 8 Lever raise lower suction bar 9 Rotary handle water volume dosing valve 10 Suct...

Page 13: ...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 raise lower suction bar 8 Water volume dosing valve 9 Wing s...

Page 14: ...ble 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...

Page 15: ...sh 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 Vers...

Page 16: ...front suction lip is grooved by default the rear one is smooth Both suction lips can be reversed in case of wear and tear 1 Winch raise lower suction bar 2 Locking tab 3 Lever raise lower suction bar...

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: ...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 Soleno...

Page 20: ...peed Contact pressure reduce speed Turn the rotation wheel to the left Contact pressure increase speed Turn the rotation wheel to the right If the rotation wheel is turned to the right the thread ed r...

Page 21: ...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 thr...

Page 22: ...d 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 pul...

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: ...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 procedure to be able to swiv...

Page 25: ...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 fre...

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: ...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...

Page 28: ...6 269 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...

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: ...dicator 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 switch W Bp Pack only 9 Info...

Page 31: ...y and button function W Bp Pack only 9 Display W Bp Pack only 1 Appliance off 2 Wet scrubbing with vacuuming 3 Polishing without vacuuming 4 Vacuuming without scrubbing 5 Polishing without vacuuming 6...

Page 32: ...tinuously Remaining capacity 20 40 22 3 V 0 2 V 60 80 discharge level 2 Slowly blinks yellow 40 60 Slowly blinks yellow red 20 40 Slowly blinks red Remaining capacity 0 20 21 0 V 0 2 V If the indicato...

Page 33: ...lection 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 Indicator lamps Batter...

Page 34: ...trip X10 A1 6 Terminal strip X11 A1 7 Terminal strip X3 A1 8 Terminal strip X1 A1 9 Terminal strip X2 A1 10 Terminal strip X5 A1 11 Connector plug X16 A1 12 Connector plug X15 A1 13 Connection X6 A1 1...

Page 35: ...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 12 Relay K1 13 Connector plug X12 A1 14 Connector plug...

Page 36: ...0 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...

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: ...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 install...

Page 39: ...mp 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 Transpo...

Page 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 Flowmet...

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: ...0 Yes Suction turbine M2 active and Self test OK No Display self test Switch off the key switch S0 No Self test OK Shutting down Yes Initial use Display Fault displays Deadman switch actuated continu...

Page 44: ...g Parameterization Factory setting LED displays Drive motor M1 ready Deadman switch S3 actuated No Yes The drive motor M3 starts via the on ramp and moves forward con tinuously at 4 km h Release the d...

Page 45: ...OSE active DOSE Edit set to 1 in setup menu option Display Battery E F Red LED Fault is glowing continuous ly After approx 10 seconds of overload the following will be shut off Brush motor Solenoid va...

Page 46: ...rive 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 The drive motor M3 is conti...

Page 47: ...OSE Edit set to 1 in setup menu option Display Battery E F Red LED Fault is glowing continuous ly After approx 10 seconds of overload the following will be shut off Brush motor Solenoid valve water Do...

Page 48: ...rive 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 The drive motor M3 is conti...

Page 49: ...witch S4 switched off Suction turbine M2 active Cleanspeed active Cleanspeed Edit set to 1 in setup menu Suction turbine speed M2 SUCTred Edit set to 1 in setup menu Display Battery E F Drive motor M3...

Page 50: ...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 cann...

Page 51: ...continuous ly After approx 10 seconds of overload the following will be shut off Brush motor Solenoid valve water Dosing pump detergent optional Display Brush overload Red LED Fault is blinking Switc...

Page 52: ...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 cann...

Page 53: ...menu Display Battery E F Red LED Fault is glowing continuous ly After approx 10 seconds of overload the following will be shut off Brush motor Solenoid valve water Dosing pump detergent optional Displ...

Page 54: ...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 cann...

Page 55: ...p 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 Display S...

Page 56: ...revious 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 n...

Page 57: ...vacuuming Wet scrubbing without 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 Informatio...

Page 58: ...lishing or Polishing with vacuuming Trailing of suction turbines Yes Suction turbine M2 active and self test ok No Shutting down Initial use LED Battery green Switch the pro gramme selector switch S2...

Page 59: ...the setup menu FACT active if set to 1 in the setup menu LED Battery green Red LED Fault is glowing continuous ly After approx 10 seconds of overload the following will be shut off Brush motor Soleno...

Page 60: ...nu LED Battery green Red LED Fault is glowing continuous ly After approx 10 seconds of overload the following will be shut off Brush motor Solenoid valve water Dosing pump detergent optional Red LED F...

Page 61: ...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 t...

Page 62: ...etup menu LED Battery green Red LED Fault is glowing continuous ly After approx 10 seconds of overload the following will be shut off Brush motor Solenoid valve water Dosing pump detergent optional Re...

Page 63: ...in the setup menu option only FACT active if set to 1 in the setup menu LED Battery green Red LED Fault is glowing continuous ly After approx 10 seconds of overload the following will be shut off Bru...

Page 64: ...am 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: ...ine Clean In the setup menu by selecting the appliance type D FACT de activated The disc brush rotates at 90 speed Via appliance type R is availa ble to FACT as follows Power Clean 100 speed Whisper C...

Page 68: ...y 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 seconds No Ye...

Page 69: ...s Standby 30 min Italiano Saugnachlauf 10s Espanal Geschw Portugues Beschl rampe 3 Nederlands B rst rampe 9 Dansk CleanspdEdit 1 Norsk SUCTred Edit 1 Svenska DOSE Edit 1 Suomi Strom Fahr 15A Polski St...

Page 70: ...Battery E F Display Maschinentyp R Entladespg 21 0V Standby 30 min Saugnachlauf 10s Geschw Beschl rampe 3 B rst rampe 9 CleanspdEdit 1 SUCTred Edit 1 DOSE Edit 1 Strom Fahr 15A Strom B W 60A Strom Tu...

Page 71: ...m 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 par...

Page 72: ...X Suction trail 10 s 10s 0s 5s 60s Trail time of the suction turbine if you switch from one vacuum programme to a programme without vacuuming or to OFF 4 X Speed 3 00 01 05 Max drive speed in transpor...

Page 73: ...switch reset 12 X Power turb 30A 30A 15 A 1 A 30 A Max regular power of the turbine In case of overload the power is limited to the set up value for 15 seconds until the shut off with fault message oc...

Page 74: ...ing 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 mot...

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: ...B cable to the computer Select control type Select the setting Service programme operates compact control Click online connection Green LED blinks on service module Remove operating panel 1 Key switch...

Page 78: ...Ohm If one of the values is not reached the switch is de fective and must be replaced Installation in reverse order Remove operating panel 1 Key switch 2 Detergent switch Pull the connector plug off t...

Page 79: ...switch is de fective and must be replaced Installation in reverse order 9 4 5 Check the programme selector switch Switch setting Resistance measurement between Target value 2 Wet scrubbing with vacuum...

Page 80: ...unction the battery should be separated from the appliance for about 10 seconds This is necessary for the energy cells capacitors which will support the processor voltage for a while to be able to dra...

Page 81: ...dosing volume The detergent dosing pump can also be checked while it is removed In this case the dosing volume does not correspond to the values in the specifications Connect the brown wire positive...

Page 82: ...pulled 2 Ohm If one of the values is not reached the microswitch or the connecting cable is defective and must be re placed Installation in reverse order Remove rear appliance cover Turn the programm...

Page 83: ...ch bow brush motor pulled Battery voltage Installation in reverse order Remove rear appliance cover Turn the programme selector switch to position 1 Drive Measure the voltage on the control PCB betwee...

Page 84: ...strips X15 and X13 Target value Whisper mode 15 0 0 2 Volt Power mode Battery voltage Installation in reverse order Remove rear appliance cover Plug in the main plug Measure the voltage on the control...

Page 85: ...ive you can check the total discharge protection using the voltmeter or the voltage tester Connect the voltmeter directly to the battery and operate the appliance until the green LED of the battery co...

Page 86: ...ual bat tery block Measure the current using a clip on ammeter dur ing the voltage measurement and record it The battery block with the lowest battery voltage must be replaced if it is outside the tol...

Page 87: ...data Appliance type Battery type Order number of appli ance Manufacturer Serial number Part number Purchase date Operating hours of appli ance Hours Have the pol shoes been tightened Are damages visi...

Page 88: ...tery and store the cable so that it cannot inad vertently come into contact with the negative ter minal of the battery Only store batteries while charged The storage location should be cool the self d...

Page 89: ...U constant voltage line I constant current line recharging a automatic switch off transition to maintenance charge 9 4 17Test the charger Appliance type Charge Manufacturer daily Order number of appli...

Page 90: ...will switch to I constant phase In the I constant recharging phase the voltage will rise to the values indicated in the diagrams and the current value remains constant After that the charger will swi...

Page 91: ...ction bar on both sides Pull the vacuum lips out of the side of the guide grooves and turn or replace them Note Both suction lips can be reversed by 180 A scraper roller must be replaced if it is dama...

Page 92: ...r 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 flus...

Page 93: ...necting cable 4 Sound insulation hose Remove the connection cable Loosen the hose clamp and pull the sound insulat ing hose off Remove the fastening screws of the suction tur bine Remove the suction t...

Page 94: ...tation 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...

Page 95: ...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 th...

Page 96: ...r 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 the pinion of the d...

Page 97: ...Unlocking button for brush roller holder Empty the dirt water reservoir Swivel out the transport roller Press the unlocking button for brush roller holder Swivel the brush roller holder out Remove the...

Page 98: ...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...

Page 99: ...cover 2 Fastening screws Unscrew locking screws Remove the cover from the toothed belt 1 Drive pinion brush motor 2 Gear belt 3 Toothed belt tension pulley 4 Drive pinion brush rollers Loosen the tens...

Page 100: ...tewater reservoir Unscrew locking screws Remove the dirt water reservoir 1 Seal of wastewater reservoir 2 Interior side of fresh water reservoir 3 Fastening screw seal Note The seals must be coated wi...

Page 101: ...y 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 Trav...

Page 102: ...348 384 15 Rubber profile 6 366 043 10 Drain hose 6 391 070 5 Suction hose 6 391 474 5 Carbon brush suction turbine 6 610 220 10 Ball bearing brush drive 7 401 173 40 Scraper roller of cleaning head...

Page 103: ...366 043 10 Drain hose 6 391 070 5 Suction hose 6 391 474 5 Carbon brush suction turbine 6 610 220 10 Ball bearing brush drive 6 401 363 20 Scraper roller of cleaning head 6 435 341 5 Wheel D200 6 435...

Page 104: ...or No or insufficient water supply Check fill up fresh water reservoir Check clean the water supply Check clean replace the solenoid valve for the water supply Insufficient vacuum perform ance Clean c...

Page 105: ...oothed belt Check replace the appliance switch with motor protection switch Ep only Check replace control PCB Charger is not working ventilator on charger does not start up Wiring W9 between the contr...

Page 106: ...i ble Polish ing possi ble Brush motor fault 1 1 Short circuit in the brush motor Call customer service 1 blinking X X Suction turbine fault 1 2 Short circuit in suction motor 1 blinking X X Check bat...

Page 107: ...cb Fault 4 11 PCB defec tive Perma nent light Pcb Fault 4 12 PCB defec tive Perma nent light Pcb Fault 4 13 PCB defec tive Perma nent light Pcb Fault 4 14 PCB defec tive Perma nent light Pcb Fault 4 1...

Page 108: ...cleaned again Inform Customer Service at any rate 4 blinking Driving motor fault 1 24 Short circuit in driving motor 1 blinking X X X Drive motor fault 2 25 Drive motor wire break age 2 blinking X X...

Page 109: ...king Emergency stop switch Model 1 only 33 Emergency stop button has been pressed display is only possi ble in the charging mode Release emergency stop button Switch off the key switch Dis connect the...

Page 110: ...Fine Clean 500 600 Power consumption Brush motor unloaded A 3 5 5 5 FACT FACT not possible Power Clean 7 11 Whisper Clean 4 8 Fine Clean 1 5 4 5 Brush motor on concrete plate A 30 45 20 40 Detergent...

Page 111: ...d as per EN 60335 2 72 Total oscillation value m s 2 5 Uncertainty K m s 0 2 Sound pressure level LpA dB A 72 67 Uncertainty KpA dB A 1 1 Sound power level LWA Uncertainty KWA dB A 88 83 BR 45 40 C Bp...

Page 112: ...0 600 Power consumption Brush motor unloaded A 3 5 5 5 FACT FACT not possible Power Clean 7 11 Whisper Clean 4 8 Fine Clean 1 5 4 5 Brush motor on concrete plate A 30 45 20 40 Detergent pump flow rate...

Page 113: ...d as per EN 60335 2 72 Total oscillation value m s 2 5 Uncertainty K m s 0 2 Sound pressure level LpA dB A 72 67 Uncertainty KpA dB A 1 1 Sound power level LWA Uncertainty KWA dB A 88 83 BR 55 40 C Bp...

Page 114: ...lean 500 600 Power consumption Brush motor unloaded A 3 5 5 5 FACT FACT not possible Power Clean 7 11 Whisper Clean 4 8 Fine Clean 1 5 4 5 Brush motor on concrete plate A 30 45 20 40 Current pickup A...

Page 115: ...165 Dose 170 Values determined as per EN 60335 2 72 Total oscillation value m s 2 5 Uncertainty K m s 0 2 Sound pressure level LpA dB A 72 67 Uncertainty KpA dB A 1 1 Sound power level LWA Uncertainty...

Page 116: ...mm 96 450 550 Brush speed 1 min 1000 1200 125 165 Power consumption Brush motor unloaded A 3 0 4 5 3 0 5 0 Brush motor on concrete plate 4 5 6 5 3 5 5 5 Shutoff of brush motor with overload shut off t...

Page 117: ...517 0 BR 45 40 C Bp Pack AT 1 533 115 0 0 088 844 0 5 963 150 0 5 970 517 0 BD 45 40 C Bp Pack AT 1 533 116 0 0 088 844 0 5 963 150 0 5 970 517 0 BR 45 40 C DOSE Hofer AT 1 533 117 0 0 088 844 0 5 96...

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: ...5 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 0 1 2 3 4 1 30 F ws ws 2a 2 L N 3a 3 4a 4 0 22 F ws bl ws rt bn bn bl ws bl bl gn ge W3...

Page 120: ...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 X10 2 X10 11 X10 3 X10 4 X10 12 X3 X12 X16 M M2 M Y1 X1 X2 rt bn 16mm rt bn 0 75mm 2 5mm bn rt 0 5mm s...

Page 121: ...10 12 X3 X12 X16 X5 1 X5 2 X5 3 S5 1 1a S3 S4 1 1a A0 S2 S2 W S2 PIN 2 S2 PIN 1 S2 PIN 0 M4 S1 11 12 S0 G M M M2 M M3 M Y1 X1 X2 F1 G1 U1 X1 X2 X3 X4 X5 X7 1 X7 2 X7 3 DC gn ge bn bl 3X1mm 230V 50Hz 1...

Page 122: ...0 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 X11 2 X10 6 X10 15 X3 S2 S2 W S2 PIN 2 S2 PIN 1 S2 PIN 0 X1 F1 S3 M1 M S0 G M S1 11 12 M3 M A0 S4 1...

Page 123: ...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 0 1 2 3 4 1 30 F ws ws 2a 2 L N 3a 3 4a 4 0 22 F ws bl ws rt bn bn bl ws bl bl gn ge W3 bn bl gn...

Page 124: ...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 16mm 10mm rt bn 0 75mm 2 5mm bn rt 24V 100Ah 100A W...

Page 125: ...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 X10 6 X10 15 X9 X13 X15 X14 X8 X10 2 X10 11 X10 3 X10 4 X10 12 X3 X12 X16 M M2 M Y1 X1 X2 rt bn 16mm rt b...

Page 126: ...1 2 X11 1 X11 8 X11 9 X10 8 X10 17 X11 3 X11 10 X10 9 X10 18 X10 6 X10 15 X9 X13 X15 X14 X8 X10 2 X10 11 X10 3 X10 4 X10 12 X3 X12 X16 X5 1 X5 2 X5 3 S5 1 1a S3 S4 1 1a A0 S2 S2 W S2 PIN 2 S2 PIN 1 S2...

Page 127: ...Indicator lamps Battery monitoring and fault M1 Brush motor M2 Suction turbine M3 Drive motor option M4 Detergent pump option Q1 Appliance switch with motor protection switch S0 Key switch option S1...

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Kärcher BD 45/40, Service Manual

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