B 80 W Service Manual - RefurbFloorCare | Used commercial floor

B 80 W Service Manual - RefurbFloorCare | Used commercial floor
B 80 W
Service Manual
English 5.950-645.0 Rev. 00 (12/12)
1
Contents
1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Hazard levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3
Technical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4
Parts of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Inside view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Top of appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Wastewater reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Bottom view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Brush heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 BR cleaning head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 BD cleaning head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.3 S 65 (Swing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Operator console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Programme settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Intelligent Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Yellow intelligent key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2 Grey Intelligent Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.3 Red intelligent key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Auto Fill-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Fresh water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Tank lid ventilation system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Tank rinse system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 Suction turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9 Charger control electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 Acuation of detergent dosing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Basic settings and service procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Replace the fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Operator console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Replace the programme selector switch . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Check the programme selector switch . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.3 Check the travel switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.4 Replace the drive switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.5 Replacing the control panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.6 Check the self-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Unhook the cover of the wastewater reservoir . . . . . . . . . . . . . . . . . . . . . . .
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6.4 Replace the fill level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 Replace the water dosing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 Replace the water dosing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5.2 Replacing the ball cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.6 Clean the flowmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.7 Replacing the water pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.8 Detergent dosing (DOSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.8.1 Replace the detergent dosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.8.2 Replacing the pump hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7 Tank rinse system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.9.1 Replace the hose ring with nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.10 Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.10.1 Replace the float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.10.2 Replace the lint sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.11 Replace suction hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.12 Replace the wastewater drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.13 Removing the wastewater reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.14 Battery and battery charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.14.1 Removing the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.14.2 Check the maintenance-free batteries . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.14.3 Check the maintenance-free batteries . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.14.4 Measuring the battery voltage under load . . . . . . . . . . . . . . . . . . . . . . 37
6.14.5 Measuring the battery voltage under load until the appliance shuts off . 37
6.14.6 Notes regarding the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.14.7 Check the final discharge voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.14.8 Test the charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.14.9 Charger characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.14.10 Cable channel underneath the batteries . . . . . . . . . . . . . . . . . . . . . . 45
6.15 Brush head, BR model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.15.1 Replace the brush head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.15.2 Replacing the drive belt of the brush drive . . . . . . . . . . . . . . . . . . . . . . 46
6.15.3 Replace the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.15.4 Replace the axle on the brush intake . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.15.5 Replace the brush motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.15.6 Replace the glide contacts on the brush motor . . . . . . . . . . . . . . . . . . 49
6.15.7 Replace the bow with sealing lip and deflector roller (BR model "S" only)
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6.15.8 Setting the brush head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.16 Brush head (BD model). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.15.1 Replace the brush head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.16.2 Replacing the disc brush pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.16.3 Replace the bow to release the disc brush . . . . . . . . . . . . . . . . . . . . . 53
6.16.4 Removing the motor with gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.15.6 Replace the glide contacts on the brush motor . . . . . . . . . . . . . . . . . . 49
6.16.6 Replace the sealing lip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.16.7 Replacing the deflector roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.17 Brush head S 65 (Swing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.17.1 Replace the brush head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
English 5.950-645.0 Rev. 00 (12/12)
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6.18
6.19
6.20
6.21
6.22
6.23
6.17.2 Remove the housing lid.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.17.3 Replace the drive belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.17.4 Replace deflection pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.17.5 Replace the motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.17.6 Replace the glide contacts on the brush motor . . . . . . . . . . . . . . . . .
6.17.7 Replacing the pulley on the excenter . . . . . . . . . . . . . . . . . . . . . . . . .
6.17.8 Replacing the excenter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.17.9 Replace water distribution pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.16.7 Replacing the deflector roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush head suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.18.1 Overview of lifter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.18.2 Removing the lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.18.3 Adjust the quick tensioning lever on the lifter . . . . . . . . . . . . . . . . . . .
6.18.4 Adjust the brush head pick-up on the lifter . . . . . . . . . . . . . . . . . . . . .
Lifting motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.19.1 Replacing the lifting motor of the brush head . . . . . . . . . . . . . . . . . . .
6.19.2 Replacing the lifting motor of the vacuum barpick . . . . . . . . . . . . . . .
Drive and wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.20.1 Replace the drive motor with gear axle . . . . . . . . . . . . . . . . . . . . . . .
6.20.2 Replace the wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.20.3 Replacing the steering roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.21.1 Replace the vacuum bar suspension . . . . . . . . . . . . . . . . . . . . . . . . .
6.21.2 Replace the vacuum bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.21.3 Replacing the suction turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.21.4 Replacing the glide contacts of the suction turbine . . . . . . . . . . . . . .
Control electronics/charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.22.1 Open the control electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.22.2 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.22.3 Replace fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.22.4 Replace the mains cable of charger. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.1 Current measurement of lifting motor vacuum bar . . . . . . . . . . . . . . .
6.23.2 Voltage measurement of lifting motor vacuum bar . . . . . . . . . . . . . . .
6.23.3 Resistance measurement micro switch lifting motor vacuum bar. . . .
6.23.4 Check the charge current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.5 Current pickup of suction turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.6 Current pick-up of the brush motor. . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.7 Current pickup: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.8 Voltage measurement transport drive under full load . . . . . . . . . . . . .
6.23.9 Voltage measurement suction turbine . . . . . . . . . . . . . . . . . . . . . . . .
6.23.10 Brush motor voltage measurement . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.11 Voltage measurement relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23.12 Voltage measurement lifting motor brush head on terminal X9 . . . .
6.23.13 Current measurement of lifting motor vacuum bar . . . . . . . . . . . . . .
6.23.14 Resistance measurement micro switch lifting motor brush head . . .
6.23.15 Voltage measurement water pump on terminal X6 . . . . . . . . . . . . .
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6.23.16 Current measurement of water pump. . . . . . . . . . . . . . . . . . . . . . . .
6.23.17 Voltage measurement detergent dosing pump on terminal X6 (5/13)
6.23.18 Voltage measurement detergent dosing pump (0.5%) on terminal X6
(5/14)
6.23.19 Voltage measurement water dosing valve on terminal X6 (3/4) . . . .
6.23.20 Voltage measurement release signal water dosing valve on terminal
X6 (12/4)
6.23.21 Voltage measurement water dosing valve on terminal X6 (11/4) . . .
6.23.22 Resistance measurement of float switch of wastewater tank . . . . . .
6.24 Connect the service module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.25 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Maintenance and care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1
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7.3
7.4
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Replacing the suction lips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the vacuum bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check seal on the cover of the wasterwater tank / replace. . . . . . . . . . . . . .
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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1 Faults without display on the console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.2 Faults with display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.3 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9
Software diagrams and parameter overview . . . . . . . . . . . . . . . . . . . . . . 87
9.1 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Factory setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Main menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1 Function overview of the yellow intelligent key. . . . . . . . . . . . . . . . . . .
9.3.2 Function overview of the grey intelligent key . . . . . . . . . . . . . . . . . . . .
9.3.3 Function overview of red intelligent key . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Special submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.1 Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.2 Key menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.3 Battery menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.4 Manual control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Overview of special functions and basic settings . . . . . . . . . . . . . . . . . . . . .
9.5.1 Summary and basic setting of key menu . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 System parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Debug Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 87
. 87
. 88
. 88
. 89
. 91
. 93
.
.
.
.
93
94
94
97
. 98
. 98
100
101
10 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.1
10.2
10.3
10.4
Exchange times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105
105
106
106
11 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
11.1 B80W 0.089-434.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
English 5.950-645.0 Rev. 00 (12/12)
5
1
Preface
3
Good service work requires extensive and practiceoriented training as well as well-structured training
materials.
Hence we offer regular basic and advanced training
programmes covering the entire product range for all
service engineers.
In addition to this, we also prepare service manuals
for important appliances - these can be initially used
as instruction guides and later on as reference
guides.
Apart from this, we also regular information about
product enhancements and their servicing.
If you should require supplements, have corrections
or questions regarding this document, please address these citing the following subject to:
international-service@de.kaercher.com
Subject:
Fall 114253
The responsible product specialist will take care of
your issue.
Copying and duplication of texts and diagrams as
well as third-party access to this information is
permitted only with the explicit permission of the
company:
Alfred Kärcher GmbH & Co. KG
P O Box 160
D -71349 Winnenden
www.kaercher.com
2
Safety instructions
2.1 Hazard levels
 Danger
Immediate danger that can cause severe injury or
even death.
몇 Warning
Possible hazardous situation that could lead to severe injury or even death.
Caution
Possible hazardous situation that could lead to mild
injury to persons or damage to property.
6 English 5.950-645.0 Rev. 00 (12/12)
Technical Features
The scrubber vacuum is used for wet cleaning or polishing of level floors.
Working width
– BR version: 650 mm +750 mm
– BD version: 650 mm +750 mm
Filling quantities
– Fresh water tank: 80 l
– Waste water reservoir: 80 l
Drive
The device is self-moving; the drive motor is feed by
four batteries.
The drive motor can pick up a max. of 38 A of current
for a duration of 2 minutes and can then handle short
inclines.
brake
The appliance is equipped with an emergency brake
that is operated with a foot pedal.
Device variants
The scrubber vacuum cleaner is offered in the following model:
– 24 V DC
Key
KIK System (KÄRCHER INTELLIGENT KEY)
Standby
The control will go to standby after a predefined time
period in idle.
– After 30 minutes if no controls are actuated.
– After 10 minutes if RFID is not activated.
The control needs to be switched off and back on
again using the programme selector switch.
Operating hour counter
The operating hours are saved in the control panel
board and in the control electronics. After a board is
replaced, the operating hours are taken over by the
other board.
Maintenance interval display
Maintenance intervals are displayed for the operator
at defined times to achieve the best cleaning results.
Display after 20 hours:
– Clean the vacuum bar!
Display after 100 hours:
– Check the wear on the brush!
– Check the suction lip!
– Clean turbine sieve!
– Clean the fresh water filter!
after 200 hours:
– Service timer
The display can be reset by pressing the I button.
Chassis
– The chassis is independent of the brush head.
– Innovative control system for even easier operation (KIK-KÄRCHER INTELLIGENT KEY)
– Reduced sound level.
– Colour coding of the control and maintenance elements.
The operating elements for the cleaning process
are yellow.
The controls for the maintenance and service are
light gray.
Water dosing valve
The water dosing valve is actuated electronically.
Suction turbine
Encapsulated quiet turbine.
Wastewater reservoir
– Wastewater reservoir rinsing system (option)
– Coarse dirt sieve
– Tank closure venting function
– The wastewater reservoir can be pivoted sideways.
Fresh water tank
Auto Fill-In (option)
Floor head quick exchange system
– Simple - no tools required
– The following brush heads are available:
D 65 + D 75
R 65 + R 75
S 65 (Swing) to remove and grind polymer coatings.
Floor head drive
– Both brushes are turning toward each other.
– The floor head is raised and lowered via the lifting
motor.
Vacuum bar
– The vacuum bar is raised and lowered via the lifting motor.
– The appliance can be operated with a curved or
straight vacuum bar.
Charger
– All battery-powered scrubber vacuums are
equipped with a charger with a wide-range voltage
power supply (100-240 V 50-60 HZ).
– The charger parameters can be adapted to the integrated battery.
Battery
– The package appliances are also equipped with
batteries.
– The appliance can be operated with 170 Ah, 180
Ah and 240 Ah batteries.
Homebase System
– Different options are offered, i.e. to carry a mop,
cloths and detergent bottles with you.
3.1 Type plate
The type plate shows whether the appliance was
configured or confectioned.
Type plate configured
The appliance was manufactured in the plant according to customer specifications.
The part number is issued automatically during the
configuration process.
1 Serial number
2 Part number
The serial number refers to the part number 1.259010.2.
Type plate confectioned
The appliance consists solely of a rump unit. The appliance can be assembled with the different assemblies on site.
1 Serial number
2 Part number
The serial number refers to the part number of the
rump unit 2.259-002.00.
Type plate material model
Complete appliances as requested by the market are
preproduced under this part number.
1 Serial number
2 Part number
The serial number refers to the part number 0.300032.0.
The part number 0.3xx-xxx.x and the serial number
S/N are required for technical enquiries.
DISIS
Base appliance 2.xxx-xxx.x must be entered into the
search box of the DISIS.
English 5.950-645.0 Rev. 00 (12/12)
7
4
Parts of the system
4.1 Front view
1 Basket
2 Cover dirt water reservoir
3 Detergent hose
4 Detergent reservoir (option)
5 Fresh water reservoir filler neck
6 Fresh water tank
7 Unlocking device, left disc brush
8 Brush head (BD model only)
9 Disc brush
10 Scraper roller
11 Unlocking device, right disc brush
12 Drive wheel
13 Steering roller
14 Vacuum bar
8 English 5.950-645.0 Rev. 00 (12/12)
15 Dirt water reservoir
16 Lid cap
17 Strip to attach accessories
18 Handle with travel switch
4.2 Rear view
1
2
3
4
5
Recessed grip
Auto Fill-In
Fresh water level display
Parking brake/ foot brake pedal
Star handle screw for adjusting the height of the
vacuum bar
6 Star handle screw
7 Deflector
8 Vacuum lip mounting
9 Support roller, vacuum bar
10 Rotary handle to incline the vacuum bar
11 Suction hose
12 Wing screw of suction bar support
13 Suction lips
14 Screw-on lid, fresh water drain with sieve
15 Dirt water drain hose
16 Cable hook, rotating
17 Mains cable of charger
18 Cable hook, rotating
19 Water quantity regulator
20 Program selection switch
21 Drive switch, forward/reverse
22 Rotating button for drive speed
23 Intelligent Key
24 Display
25 Info button
English 5.950-645.0 Rev. 00 (12/12)
9
4.3 Inside view
1 Connection cable suction turbine
2 Dirt water reservoir
3 Suction channel cover
4 Batteries
5 Dirt water drain hose
6 Suction hose
7 Coil Chain
Swivel the tank upward
 Hold the wastewater reservoir by the handle recess and swivel the reservoir upwards toward the
side.
10 English 5.950-645.0 Rev. 00 (12/12)
4.3.1 Top of appliance
1 Suction channel cover
2 Screws
4.3.2 Wastewater reservoir
1 Seal of cover of wastewater reservoir
2 Nozzles
3 Opening in suction channel, connection for air
channel of suction turbine
4 Fluff filter
5 Float
6 Disc
7 Hose ring
8 Protective cover
1
2
3
4
5
Wastewater stub
Coarse dirt sieve
Dirt water reservoir
Float of wastewater tank
Fluff filter
Suction turbine air channel
English 5.950-645.0 Rev. 00 (12/12)
11
4.4 Bottom view
1 Steering roller
2 Brake linkage
3 Drive wheel
4 Push rod, brush head
5 Detergent dosing pump (DOSE)
6 Water dosing valve
7 Quick coupler connection
8 Brush head connection plug
9 Drive motor
10 Mop rest
11 Screw-on lid, fresh water drain with sieve
12 Fresh water hose
13 Vacuum bar suspension
14 Parking brake/ foot brake pedal
12 English 5.950-645.0 Rev. 00 (12/12)
4.5 Brush heads
4.5.1 BR cleaning head
4.5.2 BD cleaning head
1 BR cleaning head "S", with sealing lips
2 BR cleaning head, without sealing lips
1
2
3
4
5
6
7
8
Sealing lip, left (S version only)
Brush roller, rear
Coarse dirt container
Sealing lip, right (S version only)
Slide shoe
Scraper roller
Water distribution bar
Brush roller, front
1 Disc brush pick-up left
2 Disc brush, left
3 Water distribution hose, left
4 T-piece
5 Water distribution hose, right
6 Disc brush, right
7 Seal strip
8 Scraper roller
9 Disc brush pick-up, right
10 Floor plate
English 5.950-645.0 Rev. 00 (12/12)
13
4.5.3 S 65 (Swing)
4.6 Accessories
1 Basket
To carry detergent bottles and cleaning supplies.
1
2
3
4
5
6
Pick-up, grinding pad
Eccentric
Scraper roller
Water distributor pipe, right
T-piece
Water distributor pipe, left
1 Clip
To attach broom and mop.
2 Hook
To hang up cleaning accessories.
3 Hook
To hang up cleaning accessories.
Homebase - application example
14 English 5.950-645.0 Rev. 00 (12/12)
5
Function
5.1 Functional diagram
1 Float
2 Dirt water discharge hose
3 Float of wastewater tank
4 Dirt water reservoir
5 Suction turbine
6 Fresh water tank
7 Water pump
8 Screw-on lid, fresh water drain with filter sieve
9 Vacuum bar
10 Flowmeter
11 Fresh water hose
12 Water volume dosing valve
13 Detergent injector
14 Water distribution bar
15 Detergent dosing (DOSE)
16 Cleaning agent container
English 5.950-645.0 Rev. 00 (12/12)
15
5.2 Operator console
1
2
3
4
5
6
7
8
Display
Info button
Water quantity regulator
Sliding handle
Drive switch, forward/reverse
Program selection switch
Rotating button for drive speed
Intelligent Key
Program selection switch
The appliance is switched on and off by rotating the
programme selector switch and the different cleaning
programmes can be selected.
Info button
In connection with the grey and red intelligent keys,
the info button can be used to access menus and appliance settings. You can set different adjustments on
the appliance, depending on the use and the conditions on site. Depending on the access rights, appliance-specific data can be shown.
Display
The display will show all menus and appliance settings that were retrieved via the info button, as well as
the battery status, fault messages and maintenance
interval information.
Drive switch
16 English 5.950-645.0 Rev. 00 (12/12)
You can use the drive switch to select the driving direction. By pressing your thumb on the top tilting section of the drive switch, you will drive the appliance
forward. If you pull on the top tilting section, the appliance will move backwards. The drive speed is regulating by the force of pressure on the switch.
Rotary knob for drive speed
You can use the rotary knob for drive speed, you can
steplessy adjust the maximum speed, which the appliance is to drive during its use.
Water quantity regulator
Adjust the detergent flow using the water regulation
knob.
Battery balance
The balance indicates mandatory information regarding the existing battery power. The battery indicator
shows the available battery capacity, which is calculated from the supplied power of the battery charger
to the battery and the power consumed by the battery.
The battery balance is shown as bars and the last 2
minutes in minute steps.
If the battery of the appliance is disconnected and reconnected, the battery indicator shows the battery
voltage as a bar graph. This can be read by the dot
next to the bar.
This display is less accurate and is calculated from
the battery voltage. After the empty battery is completely charged, the battery indicator will display the
battery balance once again.
5.2.1 Programme settings
1 OFF
Device is switched off
2 Transport mode
Driving to the Place of Use.
3 Eco mode
Wet clean the floor (with reduced brush speed and
water volume) and vacuum up wastewater (with
reduced suction und reduced suction force).
4 Normal mode
Wet clean the floor and vacuum up dirt water.
5 Increased brush contact pressure
Wet clean the floor (with increased brush contact
pressure and max. water volume) and vacuum up
wastewater.
6 Intense mode
Wet clean the floor (with increased brush contact
pressure and max. water volume) and let the detergent soak in.
7 Vacuum mode
Suck in the dirt fleet.
8 Polishing mode
Polish the floor without the application of liquid and
max. brush contact pressure.
English 5.950-645.0 Rev. 00 (12/12)
17
5.3 Intelligent Key
User-specific releases are saved in the intelligent
key. The appliance can only be put into operation after the intelligent key has been inserted.
There are three different key types with different colours and their corresponding user groups.
Key colour
User group
Yellow
Operator
Grey
Supervisor / Facility Manager
(M)
Red
Service technician (S)
5.3.1 Yellow intelligent key
Appliance functions cannot be modified.
The user can work with preset programmes at the
start of his day via programme selector switches. No
adjustment possibility.
5.3.2 Grey Intelligent Key
The Supervisor/Facility Manager can define access
rights/releases of appliance functions for the yellow
user key.
The Supervisor/Facility Manager has access to almost all relevant appliance functions, but not to service parameters.
5.3.3 Red intelligent key
The service technician has access to all parameters
and appliance functions.
The service technician can also issue rights for the
yellow user key.
Note
If two intelligent keys are used at the same time,
faults can be caused in the control electronics.
Always use the intelligent keys individually.
18 English 5.950-645.0 Rev. 00 (12/12)
5.4 Auto Fill-In
1 Water pipes
2 Safety overflow
For the quick filling of the fresh water tank.
If the automatic shut-off does not react, the water will
flow out of the safety overflow.
 Connect the water hose with the quick coupling.
 Open the water tap.
The fill process stops automatically as soon as the
tank is full.
 Turn off tap.
 Pull off the water hose.
Function
The water will run into the tank via the quick coupling
and the water filter through the valve.
Here, the water flows through the small diaphragm
bore, pushes the diaphragm back at the same time
and opens the valve.
The float is pressed upwards once the fresh water
tank is full.
After the seal of the float linkage closes the outlet
opening, a stronger water pressure builds up behind
the diaphragm and closes the valve.
Note
If the form hose is not installed, water will spray out of
the safety overflow opening during the tank filling process.
Notes regarding removal
– The water filter cannot be replaced.
– The cover is clamped on and can be pushed out.
– The seal of the safety overflow can be pushed out
of the front plate.
– The O-ring seal can be taken out of the front plate.
English 5.950-645.0 Rev. 00 (12/12)
19
5.5 Fresh water drain
1 Cover
2 Quick coupling
3 Seal of safety overflow
4 Front plate
5 Float
6 Float linkage
7 Form hose
8 Valve
9 Cover
10 Diaphragm
11 O-Ring
12 Seal of float linkage
13 Screws
14 Water filter
1 Screw-on lid, fresh water drain with filter sieve
2 Fresh water hose
Large fresh water drain for a quick drain of the fresh
water tank. If needed, you can use the water hose to
rinse the fresh water tank via the large opening.
1 Screw-on lid, fresh water drain with filter sieve
2 Inside of lid with water connection
3 Filter sieve
In order to protect all components from contamination, there is a filter sieve installed between the tank
and the screw-on lid.
20 English 5.950-645.0 Rev. 00 (12/12)
5.6 Tank lid ventilation system
To ventilate and dry out the wastewater tank.
1 Lid cap
2 Intake
 To ventilate the tank, press the lid lock toward the
inside and insert it into the pick-up.
5.7 Tank rinse system (option)
Note
The protective cap prevents wastewater from entering the tank rinse system.
If the protective cap is not attached to the hose coupling, it will function as a spacer between the tank and
the lid during tank rinsing.
1 Protective cover
2 Water pipes
The The wastewater tank is cleaned after the cleaning process via the nozzle system.
 Remove the protective cap.
 Connect the water hose via the quick coupling.
 Place the wastewater drain hose over a suitable
drain and open the locking cap.
 Open the water tap and rinse the tank.
5.8 Suction turbine
1
2
3
4
Hose connection
Protective cover
Hose ring
Nozzles
1 Suction turbine
2 Suction channel cover
3 Cooling air outlet, suction turbine motor
4 Cooling air inlet, suction turbine motor
5 Wastewater tank exhaust air outlet
The suction turbine is located beneath the suction
channel cover.
The suction turbine has a trailing time of 5 seconds
after the programme selector switch has been set to
a programme without suctioning.
English 5.950-645.0 Rev. 00 (12/12)
21
5.9 Charger control electronics
1 Charger
2 Connecting cable for charger
3 Control electronics
4 Connection cable lifting motor vacuum bar
5 Support plate, control electronics
The charger is controlled by the control electronics.
The necessary charger parameters for the built-in
battery are selected in the control electronics.
5.10 Acuation of detergent dosing
1 Detergent dosing pump (DOSE)
The detergent dosing is actuated from 0.....3% in
0.5% increments as per the set up dosing.
The actuation is running if:
– the brush is running,
– there is water flow,
– the dosing is set up.
22 English 5.950-645.0 Rev. 00 (12/12)
6
Basic settings and service procedures
 Danger
Risk of injury! Before working on the appliance, remove the Intelligent Key and the mains plug of the
charger.
Drain and dispose of the dirt water and the residual
fresh water.
 Danger
Switch the appliance off and unplug the mains plug
prior to performing any service work.
With battery-operated appliances, disconnect the
battery at the negative terminal.
6.2 Operator console
6.2.1 Replace the programme selector switch
6.1 Replace the fuse
1 Operator console
2 Screws, operator console
 Pull off the rotary knob of the programme selector
switch.
 Unscrew the screws.
1
2
3
4
Batteries
Nut with flange
Fuse F1 (125 A)
Positive cable
 Hold the wastewater reservoir by the handle recess and swivel the reservoir upwards toward the
side.
Note
Press the positive cable against the nut with flange
while unscrewing the nut. The flange must not be
damaged, as this would render the fuse useless.
 Unscrew the nut.
 Remove the positive cable.
 Replace the fuse.
 Unscrew the screws on the left and right side of
the control panel.
 Tilt the operating panel forward.
1 Screws, casing halves of the control panel
 Loosen the screws and separate the casing
halves.
English 5.950-645.0 Rev. 00 (12/12)
23
6.2.2 Check the programme selector switch
1 Screws, programme selector switch
 Unscrew the screws.
1 Program selection switch
2 Resistance measuring gauge
3 Plug
 Connect the resistance measurement device to
the plug connections of the respective coloured
cables.
See table below.
1 Operating panel board
2 Plug, programme selector switch
3 Program selection switch
 Pull out the plug on the printed circuit board on the
operating panel and remove the programme selector switch.
24 English 5.950-645.0 Rev. 00 (12/12)
Switch setting
Resistance measurement between
Nominal
value in
Ohm
OFF
white
–
Transport
mode
white
yellow
<50
Eco mode
white
yellow
green
<50
Normal mode white
green
<50
Increased
white
brush contact
pressure
green
brown
–
Intense
mode
white
yellow
green
brown
<50
Vacuum
mode
white
yellow
brown
<50
Polishing
mode
white
brown
<50
6.2.3 Check the travel switch.
Check the travel switch.
1 Operating panel board
2 Plug, drive switch
Note
The potentiometer is tested in debug mode or with
the measuring gauge on the operator panel board.
 Open the operating panel.
 Pull out the plug on the control panel board.
Control panel board plug terminal X3
1 Travel direction switch forward/reverse (grey,
pink, yellow)
2 Speed (white, green, brown)
Control electronics negative point
 Turn the device on and set it to transport mode.
English 5.950-645.0 Rev. 00 (12/12)
25
Measurment between the
negative
point and ...
Note / switch position
Result in
VDC
pink
Unplug the plug for the ~ U/batt
travel switch from the
negative 1
control panel board and V
measure on the pink
plug terminal X3 of the
control panel board.
pink
Leave the travel switch
plug on terminal connector X3 of the control
panel board in place.
~ 15 V
Conduct all subsequent measurements with the plug
in place.
 Plug in the travel switch plug on terminal connector X3 of the control panel board.
Measurment between the
negative
point and ...
Note / switch position
Result in
VDC
grey
Travel regulator 0 position
0V
grey
Travel regulator forward ~ 15 V
yellow
Travel regulator 0 position
yellow
Travel regulator reverse ~ 15 V
1 Driving lever
2 Drive switch
3 Square
4 Plug, drive switch
Observe during installation:
0V
Check the speed potentiometer
Measurment between the
negative
point and ...
Note / switch position
Result in
VDC
white
Travel regulator 0 position
~2V
brown
Travel regulator 0 position
0V
green
Travel regulator max.
forward drive
<2V
green
Travel regulator max.
reverse drive
<2V
1 Notch
2 Countersunk bore
3 Connecting cable
 The notch in the small bushing must be across
from the connecting cable.
Note
The notch will not be visible until the safety ring is removed.
6.2.4 Replace the drive switch
 Open the operating panel.
 Pull out the plug on the printed circuit board on the
operating panel and remove the drive switch with
drive lever.
26 English 5.950-645.0 Rev. 00 (12/12)
1 Countersunk bore
 Install the potentiometer so that the countersunk
bores point toward the screw head.
The following faults can occur in case of incorrect installation:
– The appliance is moving backwards instead of forward.
– The display shows "Release gas pedal" even
though it has not been pressed.
6.2.5 Replacing the control panel board
1
2
3
4
Info button
Water quantity regulator
Program selection switch
Rotating button for drive speed
 Open the operating panel.
 Pull off the info button, regulator button for the water volume, programme selector switch and the rotary knob for the drive speed.
1 Operating panel board
2 Holder, operating panel PCB
 Press the holder of the operating panel PCB
slightly toward the outside and remove the operating panel PCB.
1 Rotating button for drive speed
2 Antenna for key signals
3 Display
4 Info button
5 Water quantity regulator
6 Holder, operating panel PCB
7 Program selection switch
8 Plug, CAN-BUS to control electronics
9 Plug (K0), connection to control electronics
10 Plug, programme selector switch
11 Plug, drive switch
12 Drive switch
 Disconnect all plugs from the operating panel
PCB.
6.2.6 Check the self-test
Check whether a fault is present at the control panel
board or the control electronics.
1 Plug (K0), connection to control electronics
2 Jumper
 Open the operating panel.
 Remove the plug.
 Bridge plug contacts.
If there is no fault on the control panel board, the device will switch on immediately, even if no KIK key
has been inserted.
The battery indicator is displayed when the KIK key is
inserted.
None of the device's functions are available.
Caution
If the polarity is reversed (positive and negative terminals), the control electronics are destroyed.
English 5.950-645.0 Rev. 00 (12/12)
27
6.3 Unhook the cover of the wastewater
reservoir
1 Cover dirt water reservoir
 Open the cover.
 Slide the cover to the side.
 Remove the lid.
1 Rubber grommet
2 Filling level display
 Remove the rubber grommets with a screwdriver.
6.4 Replace the fill level indicator
6.5 Replace the water dosing unit
6.5.1 Replace water dosing valve
1
2
3
4
5
6
1 Top rubber grommet
2 Filling level display
3 Bottom rubber grommet
28 English 5.950-645.0 Rev. 00 (12/12)
Water dosing valve
Angle plate
Screws
Halting plate
Ball tap
Screws
6.6 Clean the flowmeter
1 Screws
2 Water dosing valve
3 Angle plate
 Unscrew the screws.
 Remove the water dosing valve.
 Loosen the screws on the support plate.
 Remove the ball cock from the water dosing valve.
 Remove the connecting cable from the water dosing valve.
1 Screws
2 Cover
 Unscrew the screws.
 Remove cover.
6.5.2 Replacing the ball cock
1
2
3
4
5
Fresh water hose from the fresh water tank
Flowmeter
Screws
Fresh water hose to the brush head
Cable plug
 Remove the cable plug.
 Unscrew the screws.
1
2
3
4
Ball tap
Ball cock actuator
Angle plate
Pick-up of ball cock actuator
 Remove the screws from the support plate.
 Remove the ball cock from the angle plate.
 Separate the hose connections from the ball cock.
English 5.950-645.0 Rev. 00 (12/12)
29
1
2
3
4
Lid, flowmeter
Seal ring
Magnets
Rotor
 Remove the lid and the rotor from the flowmeter.
1 Rotor axis
 Clean the rotor axle and the interior.
6.7 Replacing the water pump
1 Water pump
2 Locking nose
 Press the locking nose down.
30 English 5.950-645.0 Rev. 00 (12/12)
1 Plug contacts
2 Water pump
3 Water hoses
 Disconnect the plug-in contacts.
 Remove the water hoses.
6.8 Detergent dosing (DOSE)
6.8.1 Replace the detergent dosing
11 Hose connection, detergent hose from the detergent container
12 Hose connection, detergent hose to the fresh water hose
13 Supply/control cable
6.8.2 Replacing the pump hose
1
2
3
4
5
Screws
Halting plate
Detergent hose to the fresh water hose
Detergent hose from the detergent container
Detergent dosing (DOSE)
 Unscrew the screws.
 Remove the detergent hoses from the detergent
dosing.
Hold the detergent hoses up and secure them to
prevent detergent from leaking out.
 Remove the cable.
1
2
3
4







Detergent hose
Cable connector
Pump hose
Pump wheel
Remove the detergent pump.
Remove the lid.
Remove the pump hose from the pump wheel.
Remove the cable ties.
Remove the pump hose.
Install the new pump hose.
Check the function of the pump.
Detergent dosing open
1 Casing bottom
2 Signal cable from flowmeter
3 Plug-in contact supply/control cable
4 Control chip
5 Plug contact signal cable
6 Motor connection
7 Motor
8 Housing top
9 Cable screw connection, nut
10 Cable screw connection
English 5.950-645.0 Rev. 00 (12/12)
31
6.9 Tank rinsing system
6.9.1 Replace the hose ring with nozzles
1
2
3
4
Protective cover
Hose connection
Hose ring
Nozzle with holder
1 Hose ring
2 Screw
3 Nozzle with holder
 Remove the protective cap.
 Loosen screws.
 Remove the screws from the hose clamp.
 Remove the hose ring with nozzles.
32 English 5.950-645.0 Rev. 00 (12/12)
6.10 Float
6.10.2Replace the lint sieve
6.10.1Replace the float
1
2
3
4
Float
Pickup mandrel
Disc
Fluff filter
 Compress the pickup mandrel.
 Remove the float.
Note
Make sure that the disc is installed. It prevents the
floater from slipping across the intake mandrel and
losing its function.
1
2
3
4
Float
Fluff filter
Pickup mandrel
Disc
1 Fluff filter
 Compress the pickup mandrel.
 Remove the float.
 Rotate the lint sieve counter-clockwise and remove it.
 Clean or replace the lint sieve if necessary.
6.11 Replace suction hose.
1 Suction hose
2 Vacuum bar
 Pull out the suction hose from the vacuum bar.
English 5.950-645.0 Rev. 00 (12/12)
33
1 Suction hose
2 Dirt water reservoir
 Empty the dirt water reservoir.
 Tilt the wastewater reservoir on its side.
 Pull out the suction hose off of the wastewater reservoir.
1 Dirt water drain hose
 Remove the wastewater drain hose.
6.13 Removing the wastewater reservoir
6.12 Replace the wastewater drain hose
1 Hose clip
2 Dirt water reservoir
3 Dirt water drain hose
 Empty the dirt water reservoir.
 Tilt the wastewater reservoir on its side.
 Loosen the hose clip.
 Wastewaster drain hose off of the wastewater reservoir.
34 English 5.950-645.0 Rev. 00 (12/12)
1 Dirt water reservoir
2 Connecting cable of the suction turbine and float
of wastewater reservoir
3 Coil Chain
4 Suction hose
5 Dirt water drain hose
6 Cover hinges
 Empty the dirt water reservoir.
 Tilt the wastewater reservoir on its side.
 Pull out the suction hose off of the wastewater reservoir.
 Remove the wastewater drain hose.
6.14 Battery and battery charger
6.14.1Removing the batteries
1 Connection cable suction turbine
2 Connecting cable float of wastewater tank
 Separate the connecting cable of the suction turbine from float of wastewater reservoir.
1 Negative terminal (under the protective cap)
Appliance battery connection
2 Battery terminal connector
3 Batteries
4 Positive terminal with main fuse (under the protective flap)
Appliance battery connection
 Empty the dirt water reservoir.
 Tilt the wastewater reservoir on its side or remove
it.
 Loosen the terminal screw connections and remove them from the terminals.
 Remove the batteries.
1 Screws
2 Threaded bolt
3 Coil Chain
 Unscrew the screws.
 Remove the threaded bolt.
 Remove the wastewater reservoir with cover hinges from the appliance.
English 5.950-645.0 Rev. 00 (12/12)
35
6.14.2Check the maintenance-free batteries
The battery must be fully charged prior to the inspection to obtain a reliable result.
The following checks must then be made:
Measurement of the idle voltage
The idle voltage provides a measure for the charging
status of a maintenance-free battery.
If this value is below a certain limit, this indicates that
the battery is not charged.
You can estimate the approximately available charge
from the idle voltage.
The following values apply with:
Exide gel batteries
6 volt block battery
Charge approx.
> 6,42
Volt
100 %
> 6,30
Volt
75 %
> 6,20
Volt
50 %
> 6,00
Volt
25 %
> 6,00
Volt
Deep discharge
The idle voltage should reach at least 6.15 Volts.
If these values are not met, the battery must be
charged first.
Hoppecke AGM Fleece Batteries
6 volt block battery
Charge approx.
> 6,46
Volt
100 %
> 6,30
Volt
75 %
> 6,15
Volt
50 %
> 6,00
Volt
25 %
> 5,85
Volt
Deep discharge
The idle voltage should reach at least 6.36 Volts.
If these values are not met, the battery must be
charged first.
6.14.3Check the maintenance-free batteries
The battery must be fully charged prior to the inspection to obtain a reliable result. The reason for this is
that the acid layer is not removed until the charge is
depleted due to the initiated electrolysis.
Measuring the acid density during charging is prohibited.
Check the battery fluid level and refill distilled water if
necessary. If water is refilled, a charge must be conducted before measuring the idle voltage.
The following checks must then be made:
36 English 5.950-645.0 Rev. 00 (12/12)
Measuring idle voltage (quick test)
6 volt block
battery
6,36-6,45 6,18
5,91
<5,91
Charge condition about
(%)
100%
20%
Deep
discharge
50%
The idle voltage should reach at least the limit value
of 6.10 Volts.
If these values are not met, the battery must be
charged first.
Measuring the acid density with the battery acid
meter (quick test)
Acid density
(kg/l)
1,29
1,21
1,13
<1,13
Charge condition about
(%)
100%
50%
20%
Deep
discharge
The difference between the battery blocks/battery
cells should not exceed 0.04 kg/l. If a battery block /
a battery cell is outside this tolerance, this battery
block / battery cell must be replaced.
Battery acid meter
Practice:
The above mentioned values are guide values at 30
°C temperature.
In practice, the battery temperature influences the
acid density and the voltage.
Rule of thumb:
1. 15 °C deviation from 30 °C changes the measuring
value of the density by 0.01 kg/l.
2. Acid density + 0.84 ~ idle voltage of battery cell.
Measuring the battery under load
With all measurements, the difference must not exceed the following voltage under load:
Exide batteries:
– between the 6 volt battery blocks 0.1 volts
Hoppecke batteries:
– between the 6 volt battery blocks 0.2 volts
If the difference between the battery blocks/battery
cells is larger, the battery block/battery cell with the
lowest voltage must be replaced.
6.14.4Measuring the battery voltage under load
Note
The battery terminals must be checked prior to the
load test.
The battery terminals must always be clean and tight.
 Switch the appliance on and take the suction turbine and the cleaning head into operation on an insensitive floor.
Important: The consumers must run continuously
during this test.
The load test can also be performed while the suction turbine is turned on.
 Use a voltmeter / multimeter to measure and record the battery voltage of every individual battery
block.
Measure the current using a clip-on ammeter during the voltage measurement and record it.
 The battery block with the lowest battery voltage
must be replaced if it is outside the tolerance values.
See item "Limit value of battery voltage between
the individual battery blocks".
If this procedure still does not indicate clearly that
there is a faulty cell, the third measurement must be
performed after the second load test.
6.14.5Measuring the battery voltage under load
until the appliance shuts off
 Use a voltmeter / multimeter to measure and record the battery voltage of every individual battery
block.
Measure the current using a clip-on ammeter during the voltage measurement and record it.
 Operate the appliance until the discharge end voltage / the total discharge protection shuts the appliance off.
Result
In case of a problem, one or more battery blocks /
battery cells will be significantly different from each
other so that the fault can be pinpointed without
doubt.
Limit value – battery voltage between the individual battery blocks for maintenance-free and lowmaintenance batteries.
With all measurements, the different must not exceed
the following voltage under load:
Exide batteries
– between the 6 volt battery blocks 0.1 volts
Hoppecke batteries
– between the 6 volt battery blocks 0.2 volts
English 5.950-645.0 Rev. 00 (12/12)
37
Battery measuring log - maintenance-free battery
1. Measurement - idle voltage
Measure the idle voltage with charged battery without consumers.
Battery block
1
2
3
4
2. Measurement - load test
Measure the battery voltage several times while the turbine is turned on.
Battery block
1
2
3
4
3. Measurement - load test
Measure the battery voltage while the turbine is turned on, shortly before the discharge end voltage is triggered.
Battery block
1
2
3
4
Record further machine data
Appliance type:
Battery type:
Order number of appliance:
Manufacturer:
Serial number:
Part number:
Purchase date:
Operating hours of appliance:
Hours
Have the pole clamps been tightened?
Are damages visible on the battery?
Current pickup
Drive motor
Ampere
Suction turbine
Ampere
Brush motor
Ampere
All consumers during
cleaning.
Ampere
Discharge end voltage
When does the discharge
end voltage get triggered.
Volt
Runtime indication
How long was the customer able to work with
the appliance when the
batteries were still fully
functional?
Hours / minutes
Battery date
Is indicated near the battery terminal on the battery.
Date or code
How long / how often is the appliance used per
day / per week?
38 English 5.950-645.0 Rev. 00 (12/12)
Hours / day
Hours / week
6.14.6Notes regarding the battery
Replacing a maintenance-free battery due to old
age
If the 6 volt battery blocks have reached more than
100 loading cycles or if they have been in use for
more than 6 months, replacing the battery block with
a new one is no longer worth it. We recommend replacing the entire battery set.
Taking out of operation
If batteries are not to be used for a while, the following
must be observed when storing them:
– Disconnect the negative battery connection on the
battery and store the cable so that it cannot inadvertently come into contact with the negative terminal of the battery.
– Only store batteries while charged.
– The storage location should be cool (the self-discharge rates will be lower).
Maintenance-free batteries:
– Recharge once the battery capacity is lower than
60%.
Maintenance-free batteries:
– Monthly test of the acid density.
– Recharge once the density has fallen below 1.23
kg/l.
Discharge end voltage or total discharge protection
The settings of the discharge end voltage must be
checked to ensure that the runtime of the machine is
not limited and that the battery cannot deeply discharge.
6.14.7Check the final discharge voltage
Final discharge voltage with variable value
The final discharge voltage is variable and is regulated automatically, so that the max. admissible battery
capacity can be taken out without damaging the batteries.
If a lot of current is taken, the final discharge voltage
is deeper than with smaller current volumes.
The variable value can be monitored in debug mode.
What is important, is that the correct battery is set up
in the battery manager.
Function of the final discharge voltage
All units are operated until the variable value is
reached. The brush motor shuts off with a time delay
of 60 seconds and "Battery depleted" is displayed on
the display. The suction turbine continues to run until
the trailing time has elapsed and then shuts off.
The drive motor can be used until the voltage has
reached the set value of 18 volts. This will also shut
the drive motor off.
1 Voltage regulator
Checking the fixed value with the voltmeter.
 Tilt the wastewater reservoir on its side.
 Connect the voltage regulator in the power circuit.
 Plug in the Intelligent Key.
 Turn the programme selection switch to Programme 4 - intense mode - wet floor cleaning.
Do not press the drive lever.
 Reduce the voltage slowly to the discharge voltage that is defined in the setup menu.
Target value:
– See Table for Shut-off voltage in chapter "Battery
menu" (entry at A = 10 A).
Note
The switching off takes place with a 60 second delay.
As an alternative, 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 display shows "Battery depleted".
 At that moment, read the battery voltage.
In this case, the brush motor and the turbine shut off.
With the model ---W BP, the drive motor is still active.
Important: The voltage test must take place under
load.
6.14.8Test the charger
 Connect the charger to the batteries.
 Connect the voltage meter and clip-on ammeter to
the batteries.
 Plug in mains connector and switch on charger.
 Determine the current and voltage measuring values after switching on the charger and record
them.
 Determine the current and voltage measuring values after about 10 minutes and record them.
The measuring 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.
English 5.950-645.0 Rev. 00 (12/12)
39
Charger data:
Appliance type:
Charge:
Manufacturer
daily:
Order number of appliance:
After each use:
Serial number:
Weekly:
Purchase date:
When was the last
charge:
Are damages visible on the battery?
Performance values of the charger with the battery connected immediately after the start of the charging process (maximum, continuous current value):
Charge voltage:
Volt
Charge current (constant current!):
Ampere
Performance values of the charger with the battery connected after approx. 10 minutes:
Charge voltage:
Volt
Charge current (constant current!):
Ampere
40 English 5.950-645.0 Rev. 00 (12/12)
Regulated charge ID line IUI charger for maintenance-free batteries
Volt/Zelle
Ampere
AGM / Fliesbatterie 2,4 / Gel 2,35
AGM / Fliesbatterie 2,25 / Gel 2,3
Spannung
Strom
Zeit
I-Konstantphase U-Konstantphase
Hauptladung
Nachladung Erhaltungsladung
IUIa means:
I = constant current line
U = constant voltage line
I = constant current line recharging
a = automatic switch-off (transition to maintenance
charge)
Regulated charge ID line IUI charger for lowmaintenance batteries
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
charged with the nominal current (see typeplate
on charger) and the charge voltage will increase
slower or faster depending on the charge condition. After that, the charger will switch to U constant phase.
– In the U constant phase, the voltage remains constant and the current sinks continuously. After
that, the charger 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 switch to maintenance charge.
– The recharging phase serves to achieve the complete transformation of the active mass in all cells.
–
–
During the maintenance charge, the fully charged
battery status remains at constant voltage. The
maintenance charge has no time limits.
English 5.950-645.0 Rev. 00 (12/12)
41
Display shows charging process
6.14.9Charger characteristics
Different charging characteristics are saved in the
control electronics, belonging to the respective batteries.
If a battery is to be used, for which there is no suitable
charging characteristic, you must contact the battery
manufacturer.
Charging characteristics, status of Feb. 3, 2012
1 Charge voltage [V]
2 Charge current [A]
3 Sulphating
4 I phase (CC)
5 Charge voltage
6 U phase (CV)
7 Charging current
8 Ia phase (Ia)
9 Retention charging (EL)
10 Charging time
42 English 5.950-645.0 Rev. 00 (12/12)
During the battery charging process, the battery status is shown on the display.
In case of battery problems, you must always ensure
that the correct battery has been set up in the battery
menu.
The charge parameters are adapted to the battery
type.
The following depicts the saved charging characteristics, which can be remedied with the battery manufacturer.
Parameter
Battery
EXIDE
GF12105V
HOPPECKE
6TB170
EXIDE
GF06 180V
EXIDE
EXIDE
GF06 240V FT06 180 Wet
GEL
AGM
GEL
GEL
WET
Part number:
6.654-141.0
6.654-242.0
6.654-130.0
6.654-119.0
6.654-086.0
t0max
Max. time of the
desulphating phase
[min]
60
60
60
60
60
U0
Top threshold for
the desulphating
phase [V]
20,4
20,4
20,4
20,4
20,4
I0
Current in the desulphating phase [A]
1,4
1,7
2,3
4,8
3,6
t1min
Minimum time for
the I phase [min]
10
10
10
10
10
t1max
Maximale Zeit für
die I-Phase [min]
540
540
540
540
420
I1
Current in the I
phase [A]
18
27
27
35
28
t12max
Minimum time for
the I+U phase [min]
720
840
720
720
600
U2
Conversion voltage
from I to U phase [U]
28,2
28,8
28,2
28,2
28,8
t3min
Minimum time for
the Ia phase [min]
60
120
60
60
60
t3max
Maximum time for
the Ia phase [min]
240
300
240
240
240
t3 – Factor
Recharging time =
(t1+t2)*t3 factor
1,0
0,5
1,0
1,0
0,6
I3
Current in the Ia
phase [A]
1,6
2,3
2,3
3,1
9,0
Umax
Max. voltage in the
Ia phase [U]
36
36
36
36
36
U4
Voltage during the
retention charge [U]
27,6
27
27,6
27,6
26,8
I4
Maximum current
during the retention
charge [I]
1,6
2,7
2,3
3,1
9
English 5.950-645.0 Rev. 00 (12/12)
43
Shut-off voltage of device, status of Feb. 3, 2012
1 Voltage [V]
2 Discharge voltage [A]
Parameter Battery
Part number:
3 Voltage
4 discharge current
5 Switch-off voltage
EXIDE
GF12105V
HOPPECK
E
6TB170
GEL
AGM
EXIDE
EXIDE
GF06 180V GF06 240V
GEL
GEL
6.654-141.0 6.654-242.0 6.654-130.0 6.654-119.0
EXIDE
FT06 180
Wet
WET
6.654-086.0
Discharge voltage [A] Shut-off voltage [V]
Low
Batt A
20
23,4
23
23,5
23,6
23,2
Low
Batt B
40
21,1
22,8
23,1
23,3
22,1
Low
Batt C
60
19,6
22,7
22,3
22,9
21,1
Low
Batt D
80
19,4
22,6
20,8
22,3
19,8
Low
Batt E
100
19,2
22,5
19,9
21,3
19,6
44 English 5.950-645.0 Rev. 00 (12/12)
6.14.10Cable channel underneath the batteries
 Switch to "Manual actuation" with the grey or red
key.
 Select the brush head.
 Lower the brush head by pressing the I button.
Check the progress of the lowering.
 1. Compress the holding clamp.
2. Pull the holding clamp all the way up and out.
1 Cover, cable channel
2 Screws
 Remove batteries.
 Loosen screws.
1
2
3
4
Suspension
Brush head
Holding pin
Lock
 Push the lock back slightly and pull out the holding
bolt.
 Raise the pick-up.
1 Cable in the cable channel
2 Cover, cable channel
 Lift the cover.
The cables in the cable channel are freely accessible.
6.15 Brush head, BR model
6.15.1Replace the brush head
1 Lid, plug for mains connection
2 Connection cable of brush head
 Remove the lid of the power connection.
1 Retaining clip
2 Brush head pick up on the push bar
3 Brush head
1 Brush head plug
 Remove the plug of the brush head.
English 5.950-645.0 Rev. 00 (12/12)
45
6.15.2Replacing the drive belt of the brush drive
1 Hose coupling
 Disconnect the hose coupling.
 Pull the brush head out toward the front.
Sequence of brush head installation:
1.
Push the brush head in all the way to the push
bar.
2.
Insert the fastening clamps into the brush
head pick-ups on the push bar.
3.
Open the quick tensioning lever on the suspension.
4.
Position the brush head under the suspension.
5.
Switch to "Manual actuation" with the grey or
red key.
6.
Select the brush head.
7.
Lower the suspension by pressing the I button.
Check the progress of the lowering and adjust
the brush head as needed.
Lower the suspension enough for the holes on
the suspension to be parallel to the pick-up on
the brush head.
8.
Slide in holding bolt.
The holding bolt must be able to move easily
without pressure.
9.
Move the brush head back and forth slightly to
remove any tension.
10. Close the quick tensioning lever.
46 English 5.950-645.0 Rev. 00 (12/12)
1 Cover, drive belt
2 Screws
 Unscrew the screws and remove the lid.
1
2
3
4
5
6
Motor screws
Gear casing screws
Pulley
Drive belt
Drive pinion
Gear housing
 Loosen the screws on the motor.
 Remove the drive belt.
 Insert a new drive belt.
1
2
3
4
Pulley
Screwdriver
Drive belt
Drive pinion
 Lift the motor up with a screwdriver and tension
the drive belt.
 Tighten the screws on the motor.
6.15.3Replace the pulley
1 Press-in tool
2 Gear housing
3 Brush pick-up
 Press the pulley onto the brush pick-up by means
of a press-in tool.
 Insert the safety ring.
6.15.4Replace the axle on the brush intake
1 Safety ring
2 Pulley
 Remove the drive belt.
 Remove the safety ring.
1 Safety ring
2 Axle
 Remove the brush rollers from the brush head.
 Remove the pulley.
 Remove the safety ring.
1 Puller tool
2 Pulley
 Remove the pulley and replace it.
English 5.950-645.0 Rev. 00 (12/12)
47
6.15.5Replace the brush motor
1 Gear housing
2 Axle with brush roller intake
 Lightly strike the axle with a rubber hammer. Drive
the axle out of the casing.
1
2
3
4
5
6
1 Cover of brush head plug
2 Screws
 Unscrew the screws.
 Remove the cover.
Axle with brush roller intake
Ball bearing
Fitting key
Pulley
Safety ring
Safety ring
1 Brush head plug
2 Cable tension guard
3 Screws
 Unscrew the screws.
 Disconnect the plug elements.
 Remove the drive belt cover.
1 Rubber nose on the brush roller pick-up
2 Washer ring
The rubber nose is used to balance the brush width
tolerances.
There is a seal ring on the ball bearing that prevents
water from entering the ball bearing.
48 English 5.950-645.0 Rev. 00 (12/12)
1 Brushing rollers
2 Screws
 Remove the brush rollers.
 Unscrew the screws and remove gear casing from
the brush head.
6.15.6Replace the glide contacts on the brush
motor
1 Motor screws
 Unscrew the screws.
 Remove the motor from the gear casing.
Installation aid
1 Plug elements
2 Cable connector
 Install a cable tie as a guide aid on every plug element.
The plug elements can be guided through the
opening on the brush head easier by using cable
ties.
1 Screw
2 Cover, motor carbon
 Remove the brush motor.
 Loosen screws.
 Remove the cover of the motor carbon.
1 Nut, glide contact
2 Glide contact
3 Press spring
 Lift the contact spring and pull the glide contact out
of the chute.
 Carefully place the contact spring onto the chute.
English 5.950-645.0 Rev. 00 (12/12)
49
1 Glide contact
2 Nut, glide contact
 Unscrew the nut and replace the glide contact.
 Perform this procedure on both glide contacts.
6.15.7Replace the bow with sealing lip and deflector roller (BR model "S" only)
1
2
3
4
5
Safety ring
Axle bolt with star handle
Scraper roller
Safety ring
Bow with seal lip
6.15.8Setting the brush head
1
2
3
4
Axle bolt with star handle
Safety ring
Scraper roller
Bow with seal lip
 Remove the safety ring.
1 Axis pins
2 Safety ring
 Remove the safety ring.
 Remove the bow with seal lip from the axle bolt.
 Remove the axle bolt.
50 English 5.950-645.0 Rev. 00 (12/12)
1 Brushing rollers
2 Screws
3 Gear housing
 Place the brush head on an even surface.
 Insert the brush rollers.
 Loosen the screws on both gear casings.
 Shake the brush head briefly for the brush rollers
and the gear housing to settle.
 Tighten the screws.
 Coat a corresponding area of the floor with chalk
and drive the brush head over it.
 Switch on the brush head, lower it and briefly
brush the chalk-coated area.
 Raise the brush head and remove it from the
chalk-coated area.
6.16 Brush head (BD model)
6.16.1Replace the brush head
1 Sweeping track, rear brush
2 Sweeping track, front brush
 Check the sweeping track of the two brushes. The
must run at the same width and parallelly.
1 Retaining clip
2 Brush head pick up on the push bar
3 Brush head
 Switch to "Manual control" with the grey or red key.
 Select the brush head.
 Lower the brush head by pressing the I button.
Check the progress of the lowering.
 1. Compress the holding clamp.
2. Pull the holding clamp all the way up and out.
1 Lifter
2 Brush head intake
3 Quick tensioning lever
 The setting is adjusted by sliding the brush head
intake and the quick tensioning lever.
 If the sweeping track is set up correctly, tighten the
quick tensioning lever.
1
2
3
4
Suspension
Brush head
Holding pin
Lock
 Push the lock back slightly and pull out the holding
bolt.
 Raise the pick-up.
English 5.950-645.0 Rev. 00 (12/12)
51
Sequence of brush head installation:
1 Lid, plug for mains connection
2 Connection cable of brush head
 Remove the lid of the power connection.
1 Brush head plug
 Remove the plug for the power connection.
1.
Push the brush head in all the way to the push
bar.
2.
Insert the fastening clamps into the brush
head pick-ups on the push bar.
3.
Open the quick tensioning lever on the suspension.
4.
Position the brush head under the suspension.
5.
Switch to "Manual actuation" with the grey or
red key.
6.
Select the brush head.
7.
Lower the suspension by pressing the I button.
Check the progress of the lowering and adjust
the brush head as needed.
Lower the suspension enough for the holes on
the suspension to be parallel to the pick-up on
the brush head.
8.
Slide in holding bolt.
The holding bolt must be able to move easily
without pressure.
9.
Move the brush head back and forth slightly to
remove any tension.
10. Close the quick tensioning lever.
6.16.2Replacing the disc brush pick-up
1 Hose coupling
 Disconnect the hose coupling.
 Pull the brush head out toward the front.
52 English 5.950-645.0 Rev. 00 (12/12)
1
2
3
4
5
6
7
8
Water distribution hose, left
Bow to release the disc brush, left
Disc brush pick-up left
Floor plate
Bow to release the disc brush, right
Disc brush pick-up, right
Sealing lip
Water distribution hose, right
6.16.4Removing the motor with gear
1 Disc brush intake
2 Screw
 Loosen the screw.
 Remove the disc brush intake.
6.16.3Replace the bow to release the disc brush
1
2
3
4
Bow to release the disc brush, left
Bow guide
Spring
Bow holder
 Unscrew the screws on the holders.
 Unhook the springs.
 Remove the bow through the guides.
1 Bow to release the disc brush
2 Screws
3 Floor plate
 Unscrew the screws.
 Remove the floor plate.
 Remove the disc brush pick-up.
1 Gear axle
2 Screws
 Unscrew the screws.
 Remove the gear with motor.
English 5.950-645.0 Rev. 00 (12/12)
53
 Remove the brush motor.
 Loosen screws.
 Remove the cover of the glide contacts.
1 Gear
2 Motor
3 Screws
 Unscrew the screws.
1 Gear
2 Motor
6.16.5Replace the glide contacts on the brush
motor
1 Screw
2 Cover, glide contacts
54 English 5.950-645.0 Rev. 00 (12/12)
1 Nut, glide contact
2 Glide contact
3 Press spring
 Lift the contact spring and pull the glide contact out
of the chute.
 Carefully place the contact spring onto the chute.
1 Glide contact
2 Nut, glide contact
 Unscrew the nut and replace the glide contact.
 Perform this procedure on both glide contacts.
6.16.6Replace the sealing lip
6.17 Brush head S 65 (Swing)
6.17.1Replace the brush head
The replacement takes place just like with the brush
head BR model.
6.17.2Remove the housing lid.
1 Sealing lip
2 Edge trim
 Remove the sealing lip from the edge trim.
6.16.7Replacing the deflector roller
1 Safety ring
2 Axis pins
3 Scraper roller
 Remove the safety ring.
 Take the pivot pin out of the holder.
1
2
3
4
Covering lid
Screws
Lid, plug for mains connection
Screw
 Unscrew the screws.
 Remove the housing cover.
English 5.950-645.0 Rev. 00 (12/12)
55
1
2
3
4
5
6
7
Brush motor
Motor plate
Pulley, drive
Drive belt
Reversal rollers
Pulley, excenter
Power connector plug
1
2
3
4
Drive belt
Motor plate
Motor plate screws
Screwdriver
 Lift the motor plate up with two screwdrivers and
tension the drive belt.
 Loosen the screws on the motor plate.
6.17.4Replace deflection pulleys
6.17.3Replace the drive belt
1
2
3
4
5
6




Brush motor
Motor plate screws
Screws, brush motor
Drive belt
Motor plate
Pulley, drive
Remove the casing lid.
Loosen the screws on the motor.
Remove the drive belt.
Install a new drive belt.
1 Nuts, pad pick-up
2 Screws, pad pick-up
3 Pad pick-up
 Remove the casing lid.
 Remove the drive belt.
 Loosen the mounting nuts.
 Unscrew the screws.
 Remove the pad pick-up.
1 Screws, base
 Unscrew the screws.
 Remove the base with the deflection pulleys.
56 English 5.950-645.0 Rev. 00 (12/12)
1
2
3
4
Screw, axle mount
Safety ring, interior
Safety ring, exterior
Axle
 Remove the interior safety ring.
1
2
3
4
5
6
7
8
Axle with deflector pulley
Screws
Pulley
Ball bearing
Safety ring, exterior
Safety ring, interior
Screw, axle mount
Base
6.17.5Replace the motor.
1 Base
2 Axle
 Drive the axle out of the base with a driver tool.
1 Screw
2 Power connector plug
 Remove the casing lid.
 Loosen the screw.
English 5.950-645.0 Rev. 00 (12/12)
57
6.17.7Replacing the pulley on the excenter
1
2
3
4
5
6




Brush motor
Motor plate screws
Screws, brush motor
Drive belt
Motor plate
Pulley, drive
Loosen the screws on the motor.
Remove the drive belt.
Unscrew the screws of the motor.
Remove the motor.
1 Screw
2 Disc
3 Pulley
 Remove the motor.
 Loosen the screw.
6.17.6Replace the glide contacts on the brush
motor
The replacement takes place just like with the brush
head BR model.
Sample picture, excenter removed
1 Puller tool
2 Screw
3 Pulley
 Screw the screw into the pulley.
 Attach the puller tool and remove the pulley.
58 English 5.950-645.0 Rev. 00 (12/12)
6.17.8Replacing the excenter
1
2
3
4
1 Excenter screws
2 Carrier lid
3 Excenter disc with rubber collar




Safety ring
Disc
Screw
Excenter disc with rubber collar
Loosen the screw.
Remove the excenter disc.
Unscrew the excenter screws.
Remove the excenter from the brush head.
1
2
3
4
Carrier lid
Screw with disc
Excenter disc with rubber collar
Excenter with pulley
1 Excenter disc with rubber collar
2 Carrier lid
3 Screws
 Remove the casing lid.
 Remove the drive belt.
 Remove the pad pick-up.
 Unscrew the screws.
 Remove the carrier lid.
1 Rubber collar
English 5.950-645.0 Rev. 00 (12/12)
59
Excenter setup
1
2
3
4
5
6
7
8
6.17.10Replacing the deflector roller
Excenter axis
Seal disc
Ball bearing
Spacer ring
Pulley
Fitting key
Excenter sleeve
Safety ring
6.17.9Replace water distribution pipes
1 Scraper roller
2 Axis pins
3 Safety ring
 Remove the pad pick-up.
 Remove the axle bolt.
 Remove the scraper roller.
6.18 Brush head suspension
6.18.1Overview of lifter
1
2
3
4
5
Retaining clip
Water distributor pipe, left
T-piece
Water distributor pipe, right
Cable connector
 Remove the pad pick-up.
 Remove the cable ties.
 Pull water distribution pipes off of the holding
clamps.
1 Water distributor pipe, left
2 T-piece
3 Water distributor pipe, right
60 English 5.950-645.0 Rev. 00 (12/12)
1
2
3
4
5
6
7
Support right
Pick-up, lifting motor
Lifter
Support left
Brush head pick-up
Quick tensioning lever
Brush head adjustment
6.18.3Adjust the quick tensioning lever on the lifter
1 Lifter
2 Spring
3 Damping lever
6.18.2Removing the lifter
1 Quick tensioning lever
2 Tension nut
3 Brush head intake
 Close the quick tensioning lever.
 Tighten the tension nut to 6 Nm.
Caution
The quick tensioning lever must be closed tightly and
resting on the end stop.
If the device is operated with a loose quick tensioning
lever the brush head pick-up can break.
6.18.4Adjust the brush head pick-up on the lifter
To attach different brush heads, the brush head pickup must be adjusted according to the pick-up points
on the brush head.
1 Support
2 Lifter
3 Screws
 Remove the brush head.
 Unscrew the screws and remove the holder.
1
2
3
4
1
2
3
4
Lifting motor brush head
Bolts
Lifter
Damping lever
 Remove the safety ring from the bolt.
 Pull out the bolt.
 Remove the lifter.
Lifter
Rear brush head pick-up
Quick tensioning lever
Front brush head pick-up
 Open the quick tensioning lever.
 Move the brush head pick-up:
Front adjustment: BD
Rear adjustment: BR
 Close the quick tensioning lever.
Check the brush level, adjust if required.
English 5.950-645.0 Rev. 00 (12/12)
61
6.19 Lifting motors
6.19.1Replacing the lifting motor of the brush
head
1 Holder of upper pick-up
2 Lifting motor brush head
3 Bottom pick-up on lifter
 Remove the brush head.
 Lower the lifter.
 Hold the wastewater reservoir by the handle recess and swivel the reservoir upwards toward the
side.
 Remove the holder of the upper pick-up.
1 Sleeve
 Remove the sleeve.
Caution
Hold the lifting motor so it does not drop.
62 English 5.950-645.0 Rev. 00 (12/12)
1 Safety ring
2 Spindle head, lifting motor
3 Bolts
 Remove the safety ring.
 Pull out the bolt.
 Disconnect the connecting cable.
 Remove the lifting motor.
1 Upper mount
2 Motor
3 Spindle casing
4 Spindles
5 Safety ring
6 Disc
7 Bolts
8 Connecting cable, motor
9 Signal cable end switch
10 Sleeve
Note
The lifting motor is controlled via a micro switch. The
micro switch is not adjustable.
The micro switch shuts off the lifting motor in its upper
position. The bottom position is electronically controlled via the two brush motors.
6.19.2Replacing the lifting motor of the vacuum
barpick
6.20 Drive and wheels
6.20.1Replace the drive motor with gear axle
The drive motor and the gear axle can only be replaced as one unit if they are defective.
1 Lifting motor connecting cable
2 Rear cover
3 Motor
 Open the rear cover.
 Remove the connecting cable from the support
plate of the control electronics.
1
2
3
4
5




Lifting motor connecting cable
Rear cover
Motor
Halting plate
Bolts with nuts
Screws
Coil Chain
 Unscrew the nut on the bolt.
 Remove the bolt.
 Loosen screws.
 Remove the holding plate.
 Remove the lifting motor.
Note
The lifting motor is controlled via two micro switches.
The micro switches are not adjustable.
One micro switch shuts off the lifting motor in its upper position, the second one in the bottom position.
Holder, gear axle
Push rod, brush head
Screws
Gear axle with drive motor
Connection cable, drive motor
Remove the brush head.
Remove the batteries.
Tilt the appliance to the side and rest it.
Unscrew the screws and remove the holder.
1
2
3
4
5
6
7
1 Push rod, brush head
2 Lock hook
 Press the hook on the push rod slightly toward the
middle of the appliance until the push rod can be
pivoted toward the bottom.
 Press the push rod all the way down.
 Unscrew the screws.
 Remove the holder.
English 5.950-645.0 Rev. 00 (12/12)
63
 Remove the gear axle with drive motor toward the
bottom.
 Remove the connecting cable on the control electronics.
Repair solution
Steering roller mount / drive motor mount
6.20.2Replace the wheel
1 Washer
2 Screw
3 Wheel
 Loosen the screw.
 Pull the wheel off the axle.
1 Steering roller mount
If you should not be able to mount from the bottom
anymore, you can install long M8 carriage bolts from
the top.
1 Holes
2 Lock screw M8
 In this case, drill the bores to 8.5 mm.
 Insert the lock screw into the hole from above.
 Install the steering roller/drive motor and fasten
them from the bottom with self-locking hex nuts.
1 Axle stub
2 Fitting key
 Install the new wheel onto the greased axle stub.
Note
Pay attention to the installation position of the wheel!
The shorter part of the wheel hub is located on the
outside.
6.20.3Replacing the steering roller
1 Screws
2 Steering roller
 Unscrew the screws.
 Remove the steering roller and replace it.
64 English 5.950-645.0 Rev. 00 (12/12)
6.21 Suction system
6.21.2Replace the vacuum bar.
6.21.1Replace the vacuum bar suspension
1
2
3
4
5
6
Holder, vacuum bar suspension holder
Screw, vacuum bar suspension holder
Vacuum bar suspension
Screw on the rotary handle.
Rotary handle to incline the vacuum bar
Screw on the rotary handle with washer
 Unscrew the screw from the holder.
 Remove the vacuum bar suspension with holder.
 Unscrew both screws on the rotary handle and
disassemble the vacuum bar suspension.
When disassembling the vacuum bar suspension
make sure you will remember how to reassemble
them. This will facilitate the assembly process.
1 Suction hose
2 Wing screws of suction bar support
 Pull out the suction hose from the vacuum bar.
 Loosen the wingscrews of the vacuum bar suspension and pull the vacuum bar out of the intake.
6.21.3Replacing the suction turbine
1 Suction channel cover
2 Screws
 Hold the wastewater reservoir by the handle recess and swivel the reservoir upwards toward the
side.
 Unscrew the screws.
1 Rotary handle, bottom
2 Rotary handle, top
3 Vacuum bar pick-up
4 Vacuum bar suspension
5 Bow
6 Spring
7 Holder, vacuum bar suspension holder
8 Screw, vacuum bar suspension holder
9 Screw on the rotary handle with washer
10 Screw on the rotary handle.
 Replace defective parts.
1
2
3
4
Screws
Holder, suction turbine
Suction turbine
Connecting cable, suction turbine
 Unscrew the screws.
 Remove the holder with the suction turbine and
separate the holder from the suction turbine.
English 5.950-645.0 Rev. 00 (12/12)
65
6.21.4Replacing the glide contacts of the suction
turbine
1 Connecting cable, suction turbine
 Remove the connecting cable.
 Replace the suction turbine.
Note
If the suction turbine is damaged by water entering,
the float in the wastewater reservoir cover must be
checked for its functionality.
1 Cover cap, glide contact
 Pull out the cover cap from the suction turbine toward the top.
1 Connection plug, glide contact
2 Glide contact
3 Press spring
 Lift the contact spring.
1 Glide contact
 Pull the glide contact out of the chute.
 Carefully place the contact spring onto the chute.
 Pull out the connecting plug.
 Perform this procedure on both glide contacts.
66 English 5.950-645.0 Rev. 00 (12/12)
6.22 Control electronics/charger
6.22.1Open the control electronics
The control electronics must be opened to perform
voltage measurements.
Caution
Risk of destruction by electrostatic discharge (ESD)!
The following measures must be taken prior to working on electronic components to avoid damages:
– Wear ESD shoes.
– Touch one of the battery terminals with your hand
for equipotential.
– Do not remove the electronics from their packaging until you are ready to start the installation.
Note
The factory settings must be loaded prior to replacing
the control or the charger.
Please check the device as to whether this measure
has solved the fault.
 Disconnect the battery for 1 minute and then reconnect the battery (reset).
 Check battery voltage under load.
 Check the voltage input to the control electronics
under load.
 Transfer the current software to the control electronics and the control panel board.
Note
After replacing the control, you must set up the correct battery type in the battery menu; otherwise, the
battery may be damaged!
The charge parameters are derived from the set up
battery type and are only present in the control and
not in the charger.
Check the language and the brush head used and
adjust if necessary.
1
2
3
4
5
Charger
Connecting cable for charger
Control electronics
Connection cable lifting motor vacuum bar
Support plate, control electronics
Terminals of the control electronics
1 Terminal MF2 rt, drive motor
2 Terminal MF1 sw, drive motor
3 Connection (GND)
4 Connection +24V
5 Connection CAN-BUS operating panel
6 Terminal X8, service module
7 Terminal X7, safety sensor
8 Terminal X6, output
9 Terminal X1
10 Terminal X3
11 Not assigned
12 Terminal vacuum+, suction turbine
13 Terminal brush+, brush motor
1 Screw
2 Support plate, control electronics
 Remove rear appliance cover.
 Unscrew the screw and open the support plate toward the bottom.
English 5.950-645.0 Rev. 00 (12/12)
67
6.22.2Charger
6.23 Electrical measurements
6.23.1Current measurement of lifting motor vacuum bar
1
2
3
4
Charger
Connecting cable for charger
Terminal data transfer cable (patch cable)
Terminal charge cable
6.22.3Replace fan
1
2
3
4
Charger
Connecting cable, fan
Fan
Rubber cone
 Remove the top part of the casing.
 Pull the ventilators off of the rubber cones.
 Pull the connecting cable of the fan off the PCB.
6.22.4Replace the mains cable of charger
1
2
3
4




Cable screw connection
Charger
Mains cable of charger
Support plate
Remove rear appliance cover.
Open the support plate by folding it toward the bottom
Unplug the mains cable from the charger.
Loosen the cable screw connection and remove it
from the support plate.
68 English 5.950-645.0 Rev. 00 (12/12)
1 Lift motor suction bar
2 Measuring device
3 Lifting motor cable
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the measuring device to the lifting motor
cable as shown in the illustration.
 Actuate drive lever.
 Measure the current.
6.23.2Voltage measurement of lifting motor vacuum bar
6.23.3Resistance measurement micro switch lifting motor vacuum bar
1 Measuring device
2 Plug for lifting motor cable
Lifting motor retracted:
 Connect the measuring probe on the plug-in contact 3 (X9).
 Connect the measuring probe on the plug-in contact 7 (X9).
Measured value: 0.5 Ohm
Lifting motor extended:
 Connect the measuring probe on the plug-in contact 3 (X9).
 Connect the measuring probe on the plug-in contact 2 (X9).
Measured value: 0.5 Ohm
6.23.4Check the charge current
1 Voltage measuring device
2 Plug contact lifting motor cable
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device to the lifting
motor cable plug-in contact as shown in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, approx. battery voltage.
1 Charging cable
2 Measuring device
 Connect the charger to the current network.
 Connect the measuring device to the charging cable as shown in the illustration.
 Measure the current.
The measured value must be max. 35 A.
English 5.950-645.0 Rev. 00 (12/12)
69
6.23.5Current pickup of suction turbine
6.23.7Current pickup:
1 Battery cable (+24 Volt)
2 Measuring device
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the measuring device to the battery cable
as shown in the illustration.
 Actuate drive lever.
 Measure the current.
1 Battery cable (+24 Volt)
2 Measuring device
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the measuring device to the battery cable
as shown in the illustration.
 Actuate drive lever.
 Measure the current.
6.23.6Current pick-up of the brush motor
6.23.8Voltage measurement transport drive under full load
1 Battery cable (+24 Volt)
2 Measuring device
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the measuring device to the battery cable
as shown in the illustration.
 Actuate drive lever.
 Measure the current.
70 English 5.950-645.0 Rev. 00 (12/12)
1 Voltage measuring device
2 Connection, MF1 sw
3 Connection, MF2 rt
 Plug in the Intelligent Key.
 Set the programme selector switch to transport
mode and wait until the self-test on the operating
panel display is completed.
 Connect the voltage measuring unit to connec-
tions "MF1 sw" and "MF2 rt" as shown in the illustration.
 Set the rotary knob for drive speed to "MAX".
 Press the driving lever all the way to the stop.
Display on the voltage measuring unit, approx. 20 V.
6.23.9Voltage measurement suction turbine
1 Measuring device
2 Measuring probe on the suction+, suction turbine
3 Measuring probe on negative terminal
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, approx. battery voltage.
6.23.10Brush motor voltage measurement
1 Measuring device
2 Measuring probe on the connection brush+, brush
motor
3 Measuring probe on negative terminal
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, approx. battery voltage.
6.23.11Voltage measurement relay
1 Measuring device
2 Measuring probe on the cable plug of the magnetic coil top
3 Measuring probe on the cable plug of the magnetic coil bottom
 Plug in the Intelligent Key.
English 5.950-645.0 Rev. 00 (12/12)
71
 Turn the programme selector switch to transport
mode.
 Connect the voltage measuring device as shown
in the illustration.
Display on the voltage measuring unit, approx. battery voltage.
6.23.12Voltage measurement lifting motor brush
head on terminal X9
1 Measuring device
2 Measuring probe on the plug-in contact 5 (X9).
3 Measuring probe on the plug-in contact 10 (X9).
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, approx. battery voltage.
6.23.13Current measurement of lifting motor vacuum bar
1 Measuring device
2 Lifting motor cable
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the measuring device to the lifting motor
cable as shown in the illustration.
 Actuate drive lever.
 Measure the current.
6.23.14Resistance measurement micro switch
lifting motor brush head
1 Measuring device
2 Plug for lifting motor cable
72 English 5.950-645.0 Rev. 00 (12/12)
Lifting motor retracted:
 Connect the measuring probe on the plug-in con-
tact 8 (X9).
 Connect the measuring probe on the plug-in contact 9 (X9).
Measured value: 0.5 Ohm
Lifting motor extended:
 Connect the measuring probe on the plug-in contact 8 (X9).
 Connect the measuring probe on the plug-in contact 4 (X9).
Measured value: 0.5 Ohm
6.23.15Voltage measurement water pump on terminal X6
6.23.16Current measurement of water pump
1 Connecting cable water pump
2 Measuring device
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the measuring device to the connecting
cable of the water pump as shown in the illustration.
 Actuate drive lever.
 Measure the current.
6.23.17Voltage measurement detergent dosing
pump on terminal X6 (5/13)
1 Measuring device
2 Measuring probe on the plug-in contact 7 (X6).
3 Measuring probe on the plug-in contact 15 (X6).
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, approx. battery voltage.
1 Measuring device
2 Measuring probe on the plug-in contact 5 (X6).
3 Measuring probe on the plug-in contact 13 (X6).
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, approx. battery voltage.
English 5.950-645.0 Rev. 00 (12/12)
73
6.23.18Voltage measurement detergent dosing
pump (0.5%) on terminal X6 (5/14)
1 Measuring device
2 Measuring probe on the plug-in contact 5 (X6).
3 Measuring probe on the plug-in contact 14 (X6).
 Plug in the Intelligent Key.
 Set the detergent dosing to 0.5%.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
display:
Adjustment mode
Dosage
Voltage
measurement
Eco mode
0,5 %
1.5 V
Normal mode
1,0 %
2.2 V
Increased brush contact pressure
3,0 %
6.7 V
Intense mode
3,0 %
6.7 V
74 English 5.950-645.0 Rev. 00 (12/12)
6.23.19Voltage measurement water dosing valve
on terminal X6 (3/4)
1 Measuring device
2 Measuring probe on the plug-in contact 3 (X6).
3 Measuring probe on the plug-in contact 4 (X6).
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, approx. battery voltage.
6.23.20Voltage measurement release signal water dosing valve on terminal X6 (12/4)
1 Measuring device
2 Measuring probe on the plug-in contact 4 (X6).
3 Measuring probe on the plug-in contact 12 (X6).
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, approx. battery voltage.
The release signal will be emitted once the brushes
run. Only then will the water dosing valve work. If
there is no release signal, the water dosing valve is
not functional.
6.23.21Voltage measurement water dosing valve
on terminal X6 (11/4)
Water dosing valve in idle position
1 Measuring device
2 Measuring probe on the plug-in contact 11 (X6).
3 Measuring probe on the plug-in contact 4 (X6).
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
display:
Measured with the red KIK key.
– Dosing valve closed ~ 4.6 V.
– Water dosing valve open, 1.8 - 3.6 V depending on
the setting of the regulating knob for the water volume.
English 5.950-645.0 Rev. 00 (12/12)
75
Water volume setting 62%
1 Measuring device
2 Measuring probe on the plug-in contact 11 (X6).
3 Measuring probe on the plug-in contact 4 (X6).
 Plug in the Intelligent Key.
 Turn the programme selector switch to the respective programme.
 Connect the voltage measuring device as shown
in the illustration.
 Actuate drive lever.
Display on the voltage measuring unit, 2.46 Volt.
6.23.22Resistance measurement of float switch
of wastewater tank
Tank empty, float in bottom position on terminal
X6 (2/10)
1 Measuring device
2 Measuring probe on the plug-in contact 2 (X6).
3 Measuring probe on the plug-in contact 10 (X6).
 Connect the measuring device to the float switch
plug X6 (2/10) as shown in the illustration.
Measured value: Overload.
76 English 5.950-645.0 Rev. 00 (12/12)
Tank full, float in upper position
1 Measuring device
2 Measuring probe on the plug-in contact 2 (X6).
3 Measuring probe on the plug-in contact 10 (X6).
 Connect the measuring device to the float switch
plug X6 (2/10) as shown in the illustration.
Measured value: 0 Ohm
6.24 Connect the service module
Note
A prerequisite is the service programme software
version V5.1.
The service programme software is available at
Kärcher Inside.
The service module A9 must be updated with the lastest version of the service module software.
Caution
Only use service programme software version V5.1
or higher.
Do not connect service programme software V5.0 or
older to the appliance. This could lead to malfunctions of the appliance or the destruction of the control
panel and control board.
or the control electronics might get damaged otherwise.
 Connect the PC/laptop to the service module A9
via the USB interface.
 Plug in the Intelligent Key.
 Set the programme selector switch of the machine
to position 1.
 Start the service programme.
 Perform automatic scanning to recognize the device automatically.
 If the device is not recognised, the selection must
be repeated.
– LED blinks on service module.
Transfer the new software
 Select the update software.
Select the software, transfer it to the device and
follow the programme instructions.
Do not interrupt the download!
Note
The display of the device switches off during the software transfer.
The successfully transferred software can be displayed on the device.
After transferring the software, the following settings
must be made using the grey or red KIK key.
– Load the factory settings.
– Adjust the used brush head to "R or D".
– Set up the charge curve for the installed battery
used in the battery menu.
 Turn the device off and back on.
The device can be started after all the settings
have been made.
1
2
3
4
5
6
7




Negative wire
Y split service bus cable
USB interface cable between A9 and laptop
Service module A9
AMP bushing
Negative terminal
Connection, service module A9 into the module
bus
Turn off the appliance.
Integrate the service module A9 into the module
bus of the machine (you will only need the white
bus plug).
Connect the black AMP bushing of the Y split service bus cable to the black AMP plug of A9.
Tightly connect the negative wire of the Y split service bus cable to the negative connection of the
machine. This is important as the service module
Service programme for floor cleaners and sweepers V5.1
English 5.950-645.0 Rev. 00 (12/12)
77
6.25 Parking brake
1 Crank
2 Parking brake/ foot brake pedal
 Bend the crank slightly.
 Remove the crank from the pedal linkage.
1
2
3
4
5
6
Steering roller
Brake linkage
Parking brake/ foot brake pedal
Screws
Floor plate
Steering roller
 Remove the steering rollers.
 Loosen screws.
 Remove the floor plate.
1
2
3
4
Brake linkage
Chassis
Spring
Pedal linkage
 Remove the brake linkage from the chassis.
1 Crank
2 Screws
3 Parking brake/ foot brake pedal
 Loosen screws.
78 English 5.950-645.0 Rev. 00 (12/12)
1 Latching tabs
2 Vice
3 Brake linkage
 Push the brake linkage into the lock noses with the
vice.
7
Maintenance and care
7.1 Replacing the suction lips
If the suction lips are worn down by about 1 cm, they
must be reversed.
If the suction lips are worn out or defective, they must
be replaced.
1 Suction hose
2 Wing screws of suction bar support
3 Wear indicator
 Pull out the suction hose from the vacuum bar.
 Loosen the wingscrews of the vacuum bar suspension and pull the vacuum bar out of the intake.
1
2
3
4
5
6
Suction lip holder
Rear vacuum lip
Front vacuum lip
Star handle screw
Sleeve
Deflector disc
 Remove the deflector discs.
1 Suction lip holder
 Pull the suction lip holder off on both sides.
1 Star handle screw
2 Deflector disc
 Loosen the star handle screws on both sides of
the vacuum bar.
1 Rear vacuum lip
2 Front vacuum lip
 Pull the suction lips out on the side, replace if required
English 5.950-645.0 Rev. 00 (12/12)
79
 When assembling the vacuum bar ensure the cor-
rect seating of the sleeve.
7.2 Clean the vacuum bar
1 Brush roller
 Check the bristle length.
Replace the brush roller if the bristles are shorter
than 10 mm.
7.4 Check seal on the cover of the wasterwater tank / replace.
1 Front vacuum lip
2 Suction support
3 Rear vacuum lip
 Clean the suction lips.
 Clean the contamination off the vacuum stub.
7.3 Replacing the brush rollers
1 Unlock, bearing lid
2 Brush roller
3 Bearing lid
 Move the brush head into the top position
 Press the release button of the bearing cover and
remove the bearing covers from the brush head.
 Pull the brush roller out of the brush head.
80 English 5.950-645.0 Rev. 00 (12/12)
1 Seal
2 Cover dirt water reservoir
 Check the seal for contamination and defects.
Clean or replace if necessary.
8
Troubleshooting
8.1 Faults without display on the console
Fault
Remedial action
Appliance cannot be started
–
–
–
–
–
–
–
–
–
–
–
Machine does not move
–
–
–
–
–
–
–
–
Appliance travels slowly
–
Check whether the intelligent key has been inserted.
The appliance is in standby mode.
Set the programme selector switch to position "1" (OFF) and then to
the desired programme.
Connect / check / charge batteries.
Check battery charge control.
Check/replace the fuse.
Check / replace programme selector switch.
Check/replace the main relay.
Check/replace the circuit board (A1).
Check the connecting cable between the control panel board and the
programme selector switch.
Check if the charger is connected / unplug.
Check / replace the charger.
Check if the charger is connected / unplug.
Check/replace the fuse.
Check / replace programme selector switch.
Check/replace the circuit board (A1).
Check/replace drive motor.
Emergency brake closed / open.
Drive motor has reached 90°C for more than 20 seconds / let it cool
off.
Battery voltage too low / charge battery / perform reset with Easy Operation Button
Drive motor has reached 80°C. Motor voltage was reduced to 1/3.
No or insufficient water supply – Check / fill up fresh water reservoir.
– Unscrew the lock of the fresh water reservoir. Remove and clean the
fresh water filter. Insert the filter and screw in the lock.
– Check / clean the water supply.
– Check / clean / replace water dosing valve; remove obstruction / kink
location.
– Check/replace the water pump.
– Check / clean the water distribution channel.
Insufficient vacuum performance
–
–
–
–
–
–
–
–
–
–
Suction turbine does not run
Check whether the suction performance is set to "Whisper".
Clean / check / replace the seal between wastewater reservoir and
cover and check for tightness.
Check / replace the float.
Check / clean the lint trap.
Check / clean / replace the vacuum lips on the suction bar.
Check if the suction hose is chocked / cracked; remove obstruction /
replace if necessary.
Check whether the cover on the wastewater drain hose is closed.
Check the setting of the vacuum bar.
Check/replace the suction turbine.
Check whether the wastewater reservoir is closed properly.
Wastewater reservoir full / empty.
– Float switch of wastewater tank is blocked or defective / replace.
–
English 5.950-645.0 Rev. 00 (12/12)
81
Fault
Remedial action
Suction turbine does not
switch off after trailing time
–
Float switch of wastewater tank is blocked or defective / replace.
Insufficient cleaning result
–
Check / clean / replace the brushes for wear and tear and contamination.
Bristle length at least 10 mm.
Check / fill up fresh water reservoir.
Check / clean the water supply.
Check / adjust the detergent supply.
Check / clean / replace the solenoid valve for the water supply.
Check the brush rotation direction and speed (FACT).
–
–
–
–
–
Vacuum bar cannot be raised / – Lifting mechanics blocked / check / remove blockage.
lowered.
– Check / replace programme selector switch.
– Check / replace the micro switch of the lifting motor.
– Check the lifting motor via test mode.
Lifting mechanics blocked / check / remove blockage.
Check / replace programme selector switch.
– Check / replace the micro switch of the lifting motor.
– Check the lifting motor via test mode.
Cleaning head cannot be
raised / lowered.
–
Detergent is not getting mixed
in
–
–
–
–
–
–
Brushes do not turn
–
If the over-current switch in the electronics system has been triggered,
remove the intelligent key and reinsert it.
Switch on/off the appliance again.
Check the electrical connection on the brush motor.
Check the brush motor via test mode.
Check whether the brush rollers / disc brush is blocked / remove foreign matters / replace brush rollers / disc brushes.
Check/replace the toothed belt.
Check / replace control PCB.
Check connector on cleaning head / insert.
Check / replace programme selector switch.
–
Wiring "W9“ between the control and the charger is interrupted.
–
–
–
–
–
–
–
Charger is not working
ventilator on charger does not
start up
Check the content of the cleaning agent container
Check / replace the detergent pump.
Check the detergent hose.
Increase the water volume.
Check flowmeter for obstructions / clean.
The appliance has a short runt- – The charger parameters in the control electronics are adjusted incorime.
rectly.
– Check / replace the batteries.
Tank cannot be filled with water valve (Auto fill-in)
–
Sieve contaminated / clean / replace.
Water valve (Quick fill in) does
not shut off
–
Diaphragms plugged / clean / replace.
Electronic malfunctions
–
Switch on/off the appliance again.
Check battery voltage (> 22.0 V)
– Disconnect the battery for 2 minutes.
– Take the appliance into operation again
–
82 English 5.950-645.0 Rev. 00 (12/12)
8.2 Faults with display
Display shows
Description / cause
Remedy
ERR_U_BATT_001
Battery voltage too low.
Charge, replace battery.
ERR_K1_002
Check if the contact of the main contactor Replace main contactor.
is stuck.
ERR_ZK_2V_003
ERR_ZK_10V_004
Internal fault of control electronics.
–
–
–
–
–
ERR_5V_005
Fault in 5 V supply voltage.
Switch on/off the appliance again.
Check the battery connection.
Measure the battery voltage (>22V).
Disconnect the load connections to
the different consumers to detect
possible short circuits.
Check cables to the drive motor, the
brushes and the suction turbine motor for short circuits.
Switch on/off the appliance again.
Internal fault.
– Replace control electronics.
–
–
ERR_U_H1_006
Internal fault of control electronics.
–
–
ERR_U_H1_007
–
ERR_U_H1_008
–
ERR_U_H1_009
–
–
Switch on/off the appliance again.
Check battery voltage (>22V).
Disconnect the battery for 2 minutes.
If the fault is still present, conduct further testing:
Disconnect the drive motor MF+ and
MF- and switch the appliance on.
If the faults persist, replace the control electronics.
If the fault disappears, check the wiring of the drive motor.
Disconnect the suction turbine and
the brush motor and switch the appliance on.
If the faults persist, replace the control electronics.
If the fault disappears, check the wiring of the drive motor.
ERR_K1_010
Diagnosis of the main contactor and its ac- – Switch on/off the appliance again.
tuation.
– Check battery voltage (>22V).
– Disconnect the battery for 2 minutes.
– Check/replace the main contactor.
– Replace control electronics.
ERR_K1_011
Diagnosis of the main contactor and its ac- – Switch on/off the appliance again.
tuation.
– Check battery voltage (>22V).
– Check the cables to the main contactor.
– Replace main contactor.
ERR_K1_012
ERR_K1_013
ERR_K1_014
Diagnosis of the watchdog and its actuation.
Switch on/off the appliance again.
– Check battery voltage.
– Replace control electronics.
–
English 5.950-645.0 Rev. 00 (12/12)
83
Display shows
Description / cause
Remedy
ERR_FR_015
Power is applied to the brush motor, although no output is switched.
–
ERR_FR_016
Short circuit deteced on brush drive.
–
ERR_FR_017
Power is applied to the suction turbine, al- – Switch on/off the appliance again.
though no output is switched.
– Check battery voltage (>22V).
– Disconnect the battery for 2 minutes.
– Check the brush motor cables.
– Replace control electronics.
ERR_FR_018
Short circuit deteced on suction turbine
drive.
–
ERR_FR_022
Voltage on the drive switch outside permissible range.
–
Switch on/off the appliance again.
Check battery voltage (>22V).
– Disconnect the battery for 2 minutes.
– Check the brush motor cables.
– Replace control electronics.
–
Disconnect the cables to the brush
motor, then turn the appliance on.
– If the fault disappears, find the cable
fault.
– If the fault persists, replace the control electronics.
Disconnect the cables to the suction
turbine, then turn the appliance on.
– If the fault disappears, find the cable
fault.
– If the fault persists, replace the control electronics.
–
–
–
–
Switch on/off the appliance again.
Check the drive switch.
Check the operating field cables.
Replace the drive switch.
Replace the operating panel PCB.
ERR_FR_024
Directional switch in the drive switch, illog- – Check the operating field cables.
ical status.
– Replace the drive switch.
– Replace the operating panel PCB.
ERR_STL_026
until
ERR_STL_043
Internal fault of control electronics.
–
ERR_U_BATT_044
Check battery voltage.
–
Check battery voltage (>22V).
ERR_TEMP_045
until
ERR_TEMP_048
Overtemperature in the performance
jumpers.
–
Take appliance to an ambient temperature of +10 to +30°C too cool it
off.
If the battery has charged over 23 V
and the ambient temperature is below 40°C, there is a fault in the control electronics.
– Replace control electronics.
ERR_I_BÜRSTE_049 Overcurrent of the brush motors.
–
ERR_I_TURB_050
–
Overcurrent of the suction turbine.
84 English 5.950-645.0 Rev. 00 (12/12)
Remove possible blockage of the
brush drive.
– Check the cables to the brush motor
(insulation error).
– The selection of the brushes might
not be suitable for the floor surface?
Remove possible blockage of the
suction turbine.
– Check the suction turbine for ease of
movement.
– Check the cables for damage.
Display shows
Description / cause
Remedy
ERR_PWM_FM_051
Fault in the travel drive.
–
Check the cables to the travel drive.
Check the drive motor for damages.
– Replace the drive motor.
–
ERR_PWM_TB_052
Fault in the brush or suction turbine drive. – Check the cables to the drive.
– Check the motor for damages.
– Replace the motor.
ERR_BT53
Fault in CAN bus to control part.
–
DaliErr:_000
Err:CS000_TO000
Number of checksum faults / time-out
faults.
CS: Fault appears > if 50 consecutive
faults have occurred.
TO: Fault appears > if 50 consecutive
faults have occurred.
–
DaliErr:_000
Err:CS051_TO051
No communication with the control electronics.
–
Bat voll
Charging process terminated.
–
Check the patch cable (yellow) between the control electronics and the
operating panel PCB and replace if
necessary.
– Replace the operating panel PCB.
– Replace control electronics.
–
–
Check battery voltage.
Replace control electronics.
Check the connecting cable.
Check / replace the charger.
Incorrect polarity on the relay coil K1.
Check the positive and negative cables.
English 5.950-645.0 Rev. 00 (12/12)
85
8.3 Warning messages
Display shows
Description
Warning temp
– Check the suction turbine and the
Warning temperature >80 °C
brush motor for overload.
reached. The actuation of the
suction turbine or the brush motor
is only occurring with 2/3 of the
nominal PWM
Red. I motor
Actuation of drive motor reduced. – Check/let the drive motor cool off.
Hindernis Ignor.
Safety sensor active.
–
Bus Error Lader
Charging process interrupted by
communication fault to charger.
–
Charging fault
Charging characteristic could not
be adhered to.
–
Check / replace the charger.
Charging complete
Charging process completed successfully.
FR Loesen
Drive regulator actuated during
startup.
–
Release drive regulator.
Test/replace the drive regulator.
Internal fault of control panel
board.
–
ERR_BTSTL_019
Can bus fault
–
ERR_BTSTL018
– Check/replace the bus cable.
Bus cable defective.
Voltage supply to the control pan- – Replace operating panel PCB.
el board incorrect.
– Replace control electronics.
ERR_BTSTL_001
ERR_BTSTL_002
ERR_BTSTL_003
ERR_BTSTL_004
Remedy
Check/replace the safety sensor
if an obstacle is not the cause.
Check/replace the three-prong
cable between the charger and
the control.
– Check / replace the charger.
–
Transfer the current control panel
board software to the control panel board via the service module.
– If the fault persists, replace the
control panel board.
ERR_BTSTL_005
ERR_BTSTL_006
ERR_BTSTL_007
ERR_BTSTL_008
ERR_BTSTL_009
ERR_BTSTL_010
ERR_BTSTL_011
ERR_BTSTL_012
ERR_BTSTL_013
ERR_BTSTL_014
ERR_BTSTL_018
86 English 5.950-645.0 Rev. 00 (12/12)
Check / replace the patch cable.
– Replace operating panel PCB.
– Replace the performance part.
9
Software diagrams and parameter overview
9.1 Operating elements
The selection of the individual modes is effected by turning the programme selection switch.
 Turn the programme selection switch to select the modes.
The adjustment of the water volume is effected directly via the rotary knob water.
Note
The adjustment of the water volume via the operator menu is not possible.
The adjustment of the driving speed is effected via the rotary knob driving speed.
Note
The adjustment of the driving speed via the operator menu is not possible.
The menu is navigated via the information button (info button).
Note
The menus displayed relative to the selected mode. Not all menus are available in every
mode.
 Rotate the info button to select the parameter.
 Press the info button to confirm the selection.
9.2 Factory setting
The factory settings can be restored in the menu of
the grey and red intelligent key.
Note
Many faults result from incorrect settings. Load the
factory settings for troubleshooting!
After loading the factory settings, switch of the programme selector switch so that the new parameters
can be applied. After that, the following parameters
must be set up:
 the language
 Basic settings
 Check battery selection and charging curve
 Check the selection of the brush head
English 5.950-645.0 Rev. 00 (12/12)
87
9.3 Main menus
Note
The menus displayed relative to the selected mode.
The diagram shows all available menus as an overview.
9.3.1 Function overview of the yellow intelligent key
Welcome
<Modus>
Speed
Transport-Mode
ECO-Mode
2, 3
0%...100%
Time delay
Scrub+Vacuum
3
Scrub+Vacuum
Water
Scrub
0%...100%
Vacuum
Polishing
RM-Dosage
0%...3,5%
1,3
1,3
Vacuum
OFF Medium Power
1,3
Brush speed
Fine Whisper Power
1,3
Contact pressure
0%...100%
Spray extraction
2,3
ON OFF
3
1
Selection not permanent. The setting will be lost
if the program selection switch is adjusted.
2
Selection depends on the position of the programme selection switch
88 English 5.950-645.0 Rev. 00 (12/12)
Those menus must be enabled in the key menu.
9.3.2 Function overview of the grey intelligent key
Welcome
<Modus>
Speed
Transport-Mode
0%...100%
ECO-Mode
Time delay
Scrub+Vacuum
Scrub+Vacuum
Water
Scrub
0%...100%
Vacuum
Polishing
Operating Hours
RFID
Key menu
see Key menu
2
BasicSettings
see BasicSettings
System Parameter
see System Parameter
Test Mode
2
Battery Menu
see Battery Menu
Brush speed
1,2
Fine Whisper Power
English 5.950-645.0 Rev. 00 (12/12)
89
Contact pressure
1,2
0%...100%
Vacuum
1,2
OFF Medium Power
1,2
RM-Dosage
0%...3,5%
Brush-head
2
D...R...S
Spray extraction
2
ON OFF
Settings
Reset?
Language
Version
BT: X.XX / LT:X.XX
1
Selection not permanent. The setting will be lost
if the program selection switch is adjusted.
2
Selection depends on the position of the programme selection switch
90 English 5.950-645.0 Rev. 00 (12/12)
9.3.3 Function overview of red
intelligent key
Welcome
<Modus>
Speed
Transport-Mode
0%...100%
ECO-Mode
<Zeitverzögerung>
Scrub+Vacuum
Scrub+Vacuum
Water
Scrub
0%...100%
Vacuum
Polishing
Operating Hours
RFID
Key menu
see Key menu
2
BasicSettings
see BasicSettings
Debug
see Debug
2
Test Mode
System Parameter
see System Parameter
Battery Menu
see Battery Menu
English 5.950-645.0 Rev. 00 (12/12)
91
1,2
Brush speed
Fine Whisper Power
1,2
Contact pressure
0%...100%
1,2
Vacuum
OFF Medium Power
1,2
RM-Dosage
0%...3,5%
Brush-head
2
D...R...S
Spray extraction
2
ON OFF
Settings
Reset?
RESET
Service Reset
Language
Version
BT: X.XX / LT:X.XX
1
Selection not permanent. The setting will be lost
if the program selection switch is adjusted.
2
Selection depends on the position of the programme selection switch
92 English 5.950-645.0 Rev. 00 (12/12)
9.4 Special submenus
9.4.1 Basic settings
BasicSettings
Brush speed
1
Fine Whisper Power
Vacuum
OFF Medium Power
RM-Dosage
0%...3,5%
Speed
0%...100%
Water
0%...100%
Contact pressure
0%...100%
EXIT
EXIT
The menu Basic settings can only be selected in
the cleaning programmes.
Note
The values set up here are only active if the yellow
user key does not have any restrictions. If the factory
settings are loaded in the menu, all basic settings
programmes are reset and must be set up again.
1
Selection depends on the brush head. Is only displayed with the R-head.
English 5.950-645.0 Rev. 00 (12/12)
93
9.4.2 Key menu
RFID
Key menu
Access
Yes / No
Language
Traction speed
Yes / No
Brush speed
Yes / No
Vacuum speed
Yes / No
RM-Dosage
Yes / No
Water
Yes / No
Contact pressure
Yes / No
Write to key*
Yes / No
Write to key
Exit
*Additional yellow keys can be described using the
set up parameters.
Note
This menu allows the user of the yellow user key additional settings with the I button.
The user can only use the enabled parameters.
Parameter are active immediately and until a new
cleaning programme is selected via the programme
94 English 5.950-645.0 Rev. 00 (12/12)
selector switch. After that, the standard values are restored.
Note
After selecting the key menu, the key to be programmed must be inserted in the key holder within 10
seconds.
9.4.3 Battery menu
Battery Menu
Ladekurve 0
Battery I>>
Ladekurve 1
Battery II>>
Hoppecke 6TB170
Ladekurve 2
Ladekurve 3
Battery IV>>
Exide GF06240V
Ladekurve 4
Battery V>>
Exide FT06180WET
Ladekurve 5
Switch-off voltage: see table
Battery III >>
Exide GF06180V
Battery VI>>
XFC
<Ladekurve 6-9>
Battery VII...X
kundenspezifisch
Exit
Switchoff voltage
Battery I
Charging
curve = 0
Battery II
Charging
curve = 1
Battery III
Charging
curve = 2
Battery IV
Charging
curve = 3
Battery V
Charging
curve = 4
Battery VI
Charging
curve = 5
Battery VIII X
Charging
curve = 6
Low
Batt...
EXIDE
GF12V105
A
HOPPECK
E 6TB170
EXIDE
GF06180V
EXIDE
GF06240V
EXIDE
FT06180W
ET
XFC rapid
External
charge cacharger, cuspable, exter- tomisable
nal charger
A = 10 A 23.4 V
23.0 V
23.5 V
23.6 V
23.2 V
23.5 V
23.5 V
B = 30 A 21.1 V
22.8 V
23.1 V
23.3 V
22.1 V
23.5 V
23.5 V
C= 50 A
19.6 V
22.7 V
22.3 V
22.9 V
21.1 V
23.5 V
23.5 V
d = 60 A
19.4 V
22.6 V
20.8 V
22.3 V
19.8 V
23.5 V
23.5 V
E = 70 A 19.2 V
22.5 V
19.9 V
21.3 V
19.6 V
23.5 V
23.5 V
English 5.950-645.0 Rev. 00 (12/12)
95
These values refer to the switch-off of the brush motor and suction turbine units. The switch-off differs
with the current pickup.
The switch-off takes place after 60 seconds plus turbine trailing time.
Switch-off of drive motor at 18 V.
96 English 5.950-645.0 Rev. 00 (12/12)
9.4.4 Manual control
The individual aggregates for a function test can be
specifically controlled via this menu. When exiting a
sub-menu and when terminating the programme, all
aggregates are reset to the starting position.
Test Mode
Brushes
ON OFF
Vacuum
ON OFF
Water
ON OFF
DOSE
ON OFF
Squeegee
<senken, heben>
Brush-head
<senken, heben>
Exit
The DOSE function is only available when the water
valve is opened.
1
English 5.950-645.0 Rev. 00 (12/12)
97
9.5 Overview of special functions and basic settings
9.5.1 Summary and basic setting of key menu
Program
Transport
Eco
Scrubbing & vacuuming
Key
Key
Key
yellow
Operating hours
Speed
X
Key menu
grey
red
X
yellow
grey
red
X
X
X
X
X
X
Basic settings
Debug
grey
red
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
yellow
X
X
Manual control
X
X
System parameters
X
X
X
X
X
X
Battery menu
X
X
X
X
X
X
X
X
X
X
X
X
Water
Brush head
D
D
Brush speed
Whisper
Power
Contact pressure
20%
40%
Suction
Medium
Power
RM-Dosing
0,5%
1,0%
Spray extraction
Settings
X
X
Service reset
X
X
X
X
X
the language
EN
EN
EN
EN
EN
EN
Version
X
X
X
X
X
X
Program
Scrubbing & vacuuming
Scrubbing
Key
Key
yellow
grey
red
Operating hours
X
Speed
grey
red
X
X
X
X
X
X
X
Key menu
X
X
X
X
Basic settings
X
X
X
X
Debug
yellow
X
X
Manual control
System parameters
X
X
X
X
Battery menu
X
X
X
X
Water
X
X
X
X
Brush head
Brush speed
Power
98 English 5.950-645.0 Rev. 00 (12/12)
Power
Program
Scrubbing & vacuuming
Scrubbing
Contact pressure
60%
80%
Suction
Power
RM-Dosing
3%
3%
Spray extraction
Settings
X
X
Service reset
X
X
X
X
the language
EN
EN
EN
EN
Version
X
X
X
X
Program
Vacuuming
Polishing
Key
Key
yellow
grey
red
Operating hours
X
Speed
grey
red
X
X
X
X
X
X
X
Key menu
X
X
X
X
Basic settings
X
X
X
X
Debug
yellow
X
X
Manual control
System parameters
X
X
X
X
Battery menu
X
X
X
X
X
X
Water
Brush head
Brush speed
Power
Contact pressure
100%
Suction
Power
RM-Dosing
Spray extraction
Off
Off
Settings
X
X
Service reset
X
X
the language
EN
EN
EN
EN
Version
X
X
X
X
English 5.950-645.0 Rev. 00 (12/12)
99
9.5.2 System parameters
Parameter
Factory setting Description
vRampInc
1
Acceleration ramp, larger numbers means faster acceleration.
vRampDec
20
Brake ramp, higher numbers means stronger braking
vRampIncss
2
Acceleration ramp, if sonar module is installed, larger numbers mean
faster acceleration.
vRampDecss
20
Brake ramp, if sonar module is installed, higher numbers mean stronger
braking
I_MB_MAX
80 A
Maximum permanent current of the brush drive
I_MT_MAX
30 A
Maximum permanent current of the suction turbine
LPotiSpeed
20
Speed pot, minimum value*
RPotiSpeed
70
Speed pot, maximum value*
LPotiWater
20
Water pot, minimum value*
RPotiWater
70
Water pot, maximum value*
NLZ Turbine
10 s
Trail time of the suction turbine, if you switch from a vacuum programme
to a programme without vacuuming.
Switch position OFF leads to an immediate stop of the entire machine.
Here, the general contactor is separated. A trail is then no longer possible.
Brush delay
2s
Trail time brush drive
Fact Fine
30 %
Brush speed, fine clean
Fact Whisper
60 %
Brush speed, whisper clean
Fact Power
100 %
Brush speed, power clean
Suction Low
70 %
Suction turbine speed, suction low
Suction High
100 %
Suction turbine speed, suction high
IRegBKminD
28 A
Minimum brush current, D-head
IRegBKmaxD
60 A
Maximum brush current, D-head
IRegBKminR
20 A
Minimum brush current, R-head
IRegBKmaxR
70 A
Maximum brush current, R-head
IRegBKminS
10 A
Minimum brush current, S-head
IRegBKmaxS
15 A
Maximum brush current, S-head
IRegBK-KP
50
Amplification factor of the current control of the brush drive. High value
= strong change, low value = soft change
 Move the rotary knob for driving speed / water vol-
Changing the potentiometer stop positions
Setting the minimum values:
 Move the rotary knob for driving speed / water volume into the left end position.
 Press the I button.
 Press the I button to confirm.
 The value is adopted.
*
Setting maximum values:
100 English 5.950-645.0 Rev. 00 (12/12)
ume into the right end position.
 Press the I button.
 Press the I button to confirm.
 The value is adopted.
9.6 Debug Mode
Menu entry
Description
S000 G000
S+G
vs 0.0 vi 0.0
vs
Information
vi
in % depending on the drive switch ac- Nominal and regulated value of the
tuation
speed control.
Set the rotary knob for drive speed
Setpoint speed
to max. speed.
Actual speed
H1: 0.0V 0.0A
H1
during forward drive
H2: 0.0V 0.0A
H2
during reverse drive
T018 018 018 018
T
Temperatures to the MOSFET.
Normal = all values are approximately the same.
T 0.0A M 0.0A P000
T
Suction turbine motor current
Active current.
M
permissible max. current
P
Speed in %
B
Brush motor current
M
permissible max. current
P
Speed in %
IM
Motor current of drive motor
B 0.0A M 0.0A P000
IM 0A 1200/4500
Drive motor voltage and drive motor
current.
1200 equals 12 A
4500 equals 45 A
The drive motor current must be between 12 and 45 A no longer than 2
minutes in an 8 minute period.
Then, the current is reduced to 12
A.
Overcurrent timer 2 minutes / overcurrent timer 8 minutes
QS 0.0V Qi 0.0V
QS
Motor nominal source voltage
24 V at max. drive speed setting on
the potentiometer.
Qi
Motor actual source voltage
Actual voltage to drive motor.
U_5V : 5.00V
U
Internal 5 V supply voltage
Ubatt: 24.1V
Ubatt
Battery voltage
AhCnt: 360000As
Current consumption counter [As]
AhMin: 36000As
Non-removable capacity with drained
battery pack [As]
Ibatt: 000A
Active total current
LowBatt: 22.0V
Low voltage limit with active loading
current
BK 0A Soll 0A
Hub PWM 0% STP1
Calculate battery capacity:
AhCnt - AhMin / 3600 = momentary
residual capacity
The low voltage limit changes depending on the switched on consumer.
Brush motor current (contact pressure brush)
Lifting motor pulse width modulation:
24V? 100%. The speed is proportional to the voltage.
English 5.950-645.0 Rev. 00 (12/12)
101
Menu entry
Description
Information
S:00/36.0V/00.0A
Charge status / nominal charge voltage / nominal charge current
000 24.0V/00.0A
Charge timer / actual charge voltage /
actual charge current
The debug mode must be switched
off during the charging mode so that
no interferences occur.
Dali Err 000
ERR: CSXXX T0XXX
Number of faults during the charge
process
Check the cable to the charger.
Number of checksum faults
Information for developers.
Number of timeout faults
Exit
Back to main menu
102 English 5.950-645.0 Rev. 00 (12/12)
10 Technical specifications
BR appliance
B 80
R 55
R 65
R 75
BD appliance
B 80
D 55
D 65 D 75
Power
Nominal voltage
V
24
Battery capacity
Ah (5h)
170, 180, 240
Average power consumption
W
2200
Drive motor output (rated output)
W
350
Suction engine output
W
580
Brush engine output
W
2 x 600
Vacuuming
Vacuum power, air volume (max.)
l/s
220
Vacuuming power, negative pressure (max.) mbar / kPa
167 / 16,7
Cleaning brushes
Brush speed
1/min
600 - 1300
180
Dimensions and weights
Theoretical surface cleaning performance
m²/h
3300
3900
4500
3300
3900 4500
Max. working range incline
%
2
Fresh/dirt water reservoir volume
l
80/80
Max. water temperature
°C
60
Net weight (transport weight)
kg
280 (with 240 Ah batteries)
Total weight (ready to operate)
kg
360 (with 240 Ah batteries)
Values determined as per EN 60335-2-72
0,1
Total oscillation value
m/s2
0,1
Uncertainty K
m/s2
dB(A)
69
Sound pressure level LpA
Uncertainty KpA
dB(A)
2
dB(A)
83
Sound power level LWA + Uncertainty KWA
Power consumption
Drive speed, forward
km/h
0,5 - 6
Drive speed, reverse
km/h
0,5 - 4,5
Brush motor, unloaded
A
7 - 13
10 - 16
Brush motor
A
28,5 - 31,5
Brush rollers at medium load on concrete plate
Brush motor, overload after 10 to -20 seconds
A
75 - 85
delay at:
Suction turbine
A
20 - 26
Vacuum bar lifted and tank lid closed
Drive motor on even surface
A
12 - 16
Max. current pick-up of drive motor
A
38
Current pick-up of drive motor, lasts until
A
28
Drive motor: Within 8 minutes, for a duration of
A
28 - 38
2 minutes:
After that, limited to
A
28
Charger
A
35
Max. Load current during the charging of a depleted battery
Charger
Load current in the recharging phase at:
maintenance-free batteries
A
0,5 - 1
low-maintenance battery
A
4-5
Lifting motor brush head
A
2,8 - 4,9
Lift motor suction bar
A
1,0 - 3,0
Detergent pump at max. flow volume
A
0,4
Water quantity
Water pump with max. water volume
I/min
>7,0
Detergent pump, max. feed volume
I/min
>0,20
English 5.950-645.0 Rev. 00 (12/12)
103
Batteries
Kärcher
part number
Nominal
voltage
Nominal
capacity
Battery
type
Runtime (h) at power pickup (A)
plain
[V]
[Ah]
6.654-086.0
4x6
180
6.654-119.0
4x6
6.654-124.0
6.654-242.0
medium
Load cycles at
medium load
rough
[h]
[A]
[h]
[A]
[h]
[A]
FT...WET
wa
2,6
55
2
70
1,4
90
650 - 700
240
GIV wf
3,5
55
2,7
70
2,1
90
400 - 450
4x6
180
GIV wf
2,6
55
2
70
1,5
90
330 - 370
4x6
170
AGM wf
2,3
55
1,7
70
1,3
90
320 - 370
104 English 5.950-645.0 Rev. 00 (12/12)
10.1 Exchange times
Part designation
Exchange time
in minutes
Part designation
Exchange time
in minutes
Lift motor suction bar
15
Swivel casters
20
Drive wheels
15
Dirt water drain hose
5
Suction hose
5
Parking brake
45
Vacuum bar holder
15
Battery fuse
10
40
Batteries
15
Glide contacts drive motor
25
BD brush head
Detergent dosing pump
20
Worm gear
45
Pump hose of the detergent dosing pump
15
Glide contact kit brush motor
60
Motor of brush drive
35
Flowmeter
10
Ball bearing, brush drive
70
Water valve
20
Disc brush
5
Float, wastewater reservoir, electrical
15
Brush head BR
Float, wastewater reservoir, mechanical
1
Lint sieve, suction turbine
Mains cable - charger
10
Operating field
20
Electronic performance part
25
Charger
15
Potentiometer drive lever
20
Suction turbine
20
Glide contacts of the suction turbine
20
Drive motor
Motor of brush drive
30
Gear belt
10
1
Glide contact kit brush motor
60
Brush head
10
50
Brush head intake
20
Ball bearing, brush drive assembly
Brush head steering
15
Brush roller
5
Lifting motor brush head
25
Wiping flap
10
Scraper roller of suction bar
5
10.2 Technical Documentation
Appliance type
Appliance
no.
Circuit diagram
operating instruc- Spare parts list
tions
B 80 W BP
2.259-001.0 0.089-434.0
5.964-361.0
5.971-446.0
B 80 W BP DOSE
2.259-002.0 0.089-434.0
5.964-361.0
5.971-446.0
English 5.950-645.0 Rev. 00 (12/12)
105
10.3 Special tools
Intelligent Key, red
5.035-337.0
Voltage regulator
6.803-025.0
Multimeter
6.803-022.0
Torque wrench
6.815-090.0
Set service module
2.816-117.0
Molex puller tool
6.816-086.0
Hebe acid meter for low-maintenance batteries
6.803-015.0
10.4 Tightening torques
Locknut brush head pickup with the quick tensioning lever closed
106 English 5.950-645.0 Rev. 00 (12/12)
6 Nm
11 Circuit diagram
The current technical specification sheets and circuit
diagrams will be included in the next version of the
spare parts CD DISIS/DISIPlus and in the kaercherinside (https://kaercher-inside.com).
Please always use the current circuit diagram.
The circuit diagram in the service manual is not updated.
11.1 B80W 0.089-434.0
English 5.950-645.0 Rev. 00 (12/12)
107
108 English 5.950-645.0 Rev. 00 (12/12)
English 5.950-645.0 Rev. 00 (12/12)
109
110 English 5.950-645.0 Rev. 00 (12/12)
A1
Performance electronics
A3
Electronics safety sensor
A4
Service module
F1
Fuse 125A
G1
Battery, 12V
G2
Battery, 12V
H1
Beacon lamp (option)
K1
Main contactor
M1
Drive motor
M2
Brush motor
M3
Suction turbine
M4
Detergent dosing pump
M5
Water pump
M6
Lift motor suction bar
M6
Micro switch of lifting motor vacuum bar
S1/S2
M7
Lifting motor brush head
M7
Mikroschalter Hubmotor Bürstenkopf
S1/S2
M4
Dosing pump
S1
Program selection switch
S2
Drive regulator
U1
Battery charger
X1
Mains plug
Y1
Water valve
English 5.950-645.0 Rev. 00 (12/12)
111
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