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B 80 W Service Manual - RefurbFloorCare

1. 1 Cable in the cable channel 2 Cover cable channel Lift the cover The cables in the cable channel are freely acces sible 6 15 Brush head BR model 6 15 1Replace the brush head 1 Retaining clip 2 Brush head pick up on the push bar 3 Brush head 2 Switch to Manual actuation with the grey or red key 2 Select the brush head 3 Lower the brush head by pressing the button Check the progress of the lowering 3 1 Compress the holding clamp 2 Pull the holding clamp all the way up and out Ed e D EE d RANT ar I d x Se v F CHR P T E p Z d E z M TM d i e a j Sa e e Es i E d Fd a PF w j Fd a Fr A ri d j a E E A a E F a F n q A d L i d i p a d I Gl 1 Suspension 2 Brush head 3 Holding pin 4 Lock 2 Push the lock back slightly and pull out the holding bolt gt Raise the pick up 1 Lid plug for mains connection 2 Connection cable of brush head gt Remove the lid of the power connection 1 Brush head plug gt Remove the plug of the brush head English 5 950 645 0 Rev 00 12 12 45 1 Hose coupling 3 Disconnect the hose coupling 3 Pull the brush head out toward the front Sequence of brush head installation 1 10 Push the brush head in all the way to the push bar Insert the fastening clamps into the brush head pick ups on the push bar Open the quick tensioning lever on t
2. Clean the fresh water filter after 200 hours Service timer The display can be reset by pressing the button Chassis The chassis is independent of the brush head Innovative control system for even easier opera tion KIK KARCHER INTELLIGENT KEY Reduced sound level Colour coding of the control and maintenance ele ments 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 side ways 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 R65 R 75 o 65 Swing to remove and grind polymer coat ings 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 lift ing 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 pa
3. Homebase application example 14 English 5 950 645 0 Rev 00 12 12 5 1 Functional diagram CONOR WD gt 9 Float Dirt water discharge hose Float of wastewater tank Dirt water reservoir Suction turbine Fresh water tank Water pump Screw on lid fresh water drain with filter sieve 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 8 KARCHER ER a __ Display Info button Water quantity regulator Sliding handle Drive switch forward reverse Program selection switch Rotating button for drive speed Intelligent Key 0 JO ci WD 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 ap pliance settings You can set different adjustments on the appliance depending on the use and the condi tions on site Depending on the access rights appli ance specific data can be shown Display The display will show all menus and appliance set tings that were retrieved via the info button as well as the battery status fault messages and maintenance interval information Drive switch
4. gt Remove rear appliance cover 3 Unscrew the screw and open the support plate to ward the bottom Charger Connecting cable for charger Control electronics Connection cable lifting motor vacuum bar Sune plate control electronics 0O BON F ign A E gaits 24V GND MET met aupisichernung siehe Eatterpol F1125A T A 6 682 64 08 80 BP Main fuse ses battery terminal KS ibile ae von pole de battere Terminals of the control electronics Terminal MF2 rt drive motor Terminal MF1 sw drive motor Connection GND Connection 24V Connection CAN BUS operating panel Terminal X8 service module Terminal X7 safety sensor Terminal X6 output 9 Terminal X1 10 Terminal X3 11 Not assigned 12 Terminal vacuum suction turbine 13 Terminal brush brush motor 0 JO Om P WN English 5 950 645 0 Rev 00 12 12 67 6 22 2Charger 6 23 Electrical measurements 6 23 1Current measurement of lifting motor vacu 1 Charger 2 Connecting cable for charger 3 Terminal data transfer cable patch cable 4 Terminal charge cable 6 22 3Replace fan 1 Charger 2 Connecting cable fan 3 Fan 4 Rubber cone 3 Remove the top part of the casing 3 Pull the ventilators off of the rubber cones gt Plug in the Intelligent Key 2 Pull the connecting cable of the fan off the PCB 3 Turn the programme selector switch to the respec 6 22 4Replace the mains cable of charger tive programme 1 Lift mo
5. 16 Enolish 5 950 645 0 Rev 00 12 12 You can use the drive switch to select the driving di rection By pressing your thumb on the top tilting sec tion of the drive switch you will drive the appliance forward If you pull on the top tilting section the appli ance will move backwards The drive speed is regu lating 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 ap pliance 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 regard ing the existing battery power The battery indicator shows the available battery capacity which is calcu lated from the supplied power of the battery charger to the battery and the power consumed by the bat tery The battery balance is shown as bars and the last 2 minutes in minute steps If the battery of the appliance is disconnected and re connected 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 com pletely charged the battery indicator will display the battery balance once again 5 2 1 Programme settings P 5 ex w n Professional 1 OFF Device is switched off 2
6. 3 Remove the ball cock from the angle plate 3 Separate the hose connections from the ball cock 6 6 Clean the flowmeter 1 Screws 2 Cover Unscrew the screws gt Remove cover Fresh water hose from the fresh water tank Flowmeter Screws Fresh water hose to the brush head 5 Cable plug 3 Remove the cable plug Unscrew the screws A UN English 5 950 645 0 Rev 00 12 12 29 DO ODLEE L 1 Lid flowmeter 2 Sealring 3 Magnets 4 Rotor gt 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 2 Press the locking nose down 30 English 5 950 645 0 Rev 00 12 12 1 Plug contacts 2 Water pump 3 Water hoses 3 Disconnect the plug in contacts 3 Remove the water hoses 6 8 Detergent dosing DOSE 6 8 1 Replace the detergent dosing Screws Halting plate Detergent hose to the fresh water hose Detergent hose from the detergent container 5 Detergent dosing DOSE gt Unscrew the screws gt Remove the detergent hoses from the detergent dosing Hold the detergent hoses up and secure them to prevent detergent from leaking out gt Remove the cable AUNI 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 to
7. 6 23 4 Check the charge current 0 0 ccc eee 6 23 5 Current pickup of suction turbine 2 0 00 eee eee 6 23 9 Voltage measurement suction turbine 6 23 10 Brush motor voltage measurement lusu 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 4 English 5 950 645 0 Rev 00 12 12 10 11 6 23 16 Current measurement of water pump 0 00 eee eee 73 6 23 17 Voltage measurement detergent dosing pump on terminal X6 5 13 73 6 23 18 Voltage measurement detergent dosing pump 0 5 on terminal X6 5 14 EP 6 23 19 Voltage measurement water dosing valve on terminal X6 3 4 74 6 23 20 Voltage measurement release signal water dosing valve on terminal X6 12 4 75 6 23 21 Voltage measurement water dosing valve on terminal X6 11 4 75 6 23 22 Resistance measurement of float switch of wastewater tank 76 6 24 Connect the service module 0 cc ees 76 0 25 FAKNO DAKE wns vba octaua ea i AE e e Pat de MS A d 18 Maintenance and care 79 7 1 Replacing thie suction IPS y Ne coe dai weed ee a dence 79 742 EE ine Vac Dal cupra e me Ep tno diede uos tee be 80 7 3 Replacing the
8. 6 9 1 Replace the hose ring with nozzles anaana naaa 92 OTO Foa osuna Ero eno asias qi deside dt Sa dais 33 6 10 1 Replace the float iaa EROR APO Reo a RE RS REOR a ees 2199 6 10 2 Replace the lint Sieve 1 eee ees 33 6 11 Replace suction hoSe 0 eee 33 6 12 Replace the wastewater drain hose 0 0 ee nooo 94 6 13 Removing the wastewater reservoir llle 94 6 14 Battery and battery charger 0 0 0 eee 95 6 14 1 Removing the batteries llle 35 6 14 2 Check the maintenance free batterieS o oooo o o 36 6 14 3 Check the maintenance free batterieS o oooo oo 36 6 14 4 Measuring the battery voltage under load sor 6 14 5 Measuring the battery voltage under load until the appliance shuts off 37 6 14 6 Notes regarding the baten 39 6 14 7 Check the final discharge voltage o ooooooooooo 39 6 14 8 Test the charger sevi or XE eda e o acea oec t e d 39 6 14 9 Charger characteristics no 42 6 14 10 Cable channel underneath the batteries 45 6 15 Brush head BR mod l i auis ee n eRe a Se d etr Lac o e en 45 6 15 1 Replace the brush head 0 0 ccc ee eens 45 6 15 2 Replacing the drive belt of the brush drive 46 6 15 3 Replace the pulley 0 0 0 cee eee 47 6 15 4 Replace the axle on the brush intake 0 eae 47 6 15 5 Replac
9. A Load cycles at part num voltage capacity medium load ee ICI srmo ass EI sssemeo axe 170 AGMw 29 55 17 70 19 00 em 104 English 5 950 645 0 Rev 00 12 12 10 1 Exchange times Part designation Exchange time Part designation Exchange time in minutes in minutes n E EF 4 Lift motor suction bar Mains cable charger Lift motor suction bar Operating field Electronic performance part 5 Potentiometer drive lever Suction turbine Glide contacts of the suction tur bine Drive motor Glide contacts drive motor Detergent dosing pump Pump hose of the detergent dos ing pump Flowmeter Water valve Float wastewater reservoir elec trical Float wastewater reservoir me chanical Lint sieve suction turbine Brush head Brush head intake Brush head steering Lifting motor brush head 10 2 Technical Documentation Appliance type Appliance Circuit diagram operating instruc Spare parts list tions n 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 9 9 1 446 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 batieries 6 803 015
10. M Red Service technician S 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 The Supervisor Facility Manager can define access rights releases of appliance functions for the yellow user key The Supervisor Facility Manager has access to al most all relevant appliance functions but not to ser vice parameters 5 4 Auto Fill In f 4 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 3 Connect the water hose with the quick coupling gt Open the water tap The fill process stops automatically as soon as the tank is full gt Turn off tap 3 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 pro Cess Notes regarding removal he water filter cannot be r
11. gt Remove the brush head 3 Unscrew the screws and remove the holder 1 Lifting motor brush head 2 Bolts 3 Lifter 4 Damping lever gt Remove the safety ring from the bolt 3 Pull out the bolt 3 Remove the lifter 6 18 3Adjust the quick tensioning lever on the lift 1 Quick tensioning lever 2 Tension nut 3 Brush head intake 2 Close the quick tensioning lever 3 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 pick up must be adjusted according to the pick up points on the brush head 1 Lifter 2 Rear brush head pick up 3 Quick tensioning lever 4 Front brush head pick up 3 Open the quick tensioning lever 3 Move the brush head pick up Front adjustment BD Rear adjustment BR 2 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 2 Lifting motor brush head 3 Bottom pick up on lifter gt Remove the brush head 3 Lower the lifter 3 Hold the wastewater reservoir by the handle re cess and swivel the reservoir upwards toward the side 3 Remove the holder of the upper pick up 1 Slee
12. i 2 2 540 540 540 420 U2 Conversion voltage 28 8 28 2 28 2 28 8 from to U phase U t3min Minimum time for the la phase min t3max Maximum time for the la phase min t3 Factor Recharging time 1 0 5 1 0 1 0 t1 t2 t3 factor 13 Current in the la 1 6 phase A Umax Max voltage in the 36 36 36 36 36 la phase U U4 Voltage during the 27 6 retention charge U l4 Maximum current 6 2 9 3 1 during the retention charge I English 5 950 645 0 Rev 00 12 12 43 12 3 4 5 Voltage hschargae Current ee ees Dt Off voltage Voltage V Discharge Current A Shut off voltage of device status of Feb 3 2012 3 Voltage 1 Voltage V 4 discharge current 2 Discharge voltage A 5 Switch off voltage Parameter Battery EXIDE HOPPECK EXIDE GF12105V E GF06 180V GF06 240V FTO6 180 6TB170 Wet GEL AGM WET Part number 6 654 141 0 6 654 242 0 6 654 130 0 6 654 119 0 6 654 086 0 Ge voege A Shut off AB Low 234 23 235 236 232 4 Batt A Low 1 2 0 3 1 3 9 2 1 Batt B Low 19 6 22 7 22 3 22 9 21 1 Batt C Low 19 4 22 6 20 8 22 3 19 8 Batt D Low 100 19 2 22 5 19 9 21 3 19 6 Batt E 44 English 5 950 645 0 Rev 00 12 12 6 14 10Cable channel underneath the batteries NO Ue i S r m 1 H P 4 s e M H LE l d i a F Wi Le 1 S TE OX tl y 1 Cover cable channel 2 Screws gt Remove batteries Loosen screws
13. 0 Rev 00 12 12 6 23 20Voltage measurement release signal wa ter 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 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 2 Connect the voltage measuring device as shown in the illustration 3 Actuate drive lever Display on the voltage measuring unit approx bat tery 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 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 2 Connect the voltage measuring device as shown in the illustration gt 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 vol ume English 5 950 645 0 Rev 00 12 12 75 Water volume setting 62 T y EN AP tron CT 28104 I T L Me M we A 1 Measuring device 2 Measuring pro
14. 1 SS e rye SE SR WER geese il 4 ag O X 2 da re i x E 5 Ei A i ds s 1s be EI E ge ce GE ees Ev yz a eve bold ap uonoe as TS cJ 3 E 3 a euuueibold ap uoge pes TS e 325 uoppejas upon TS S E m Jje uuueIDOId TS a SOL a JaMod Ty xiuo rpisjasbungsis TV Ee edoutid OINEWOINE J0ydn L1SJUI T3 jedi uud nape TM JOPEWOI WELW Tx zynuxsydneH TA ETI 28 DE Ga cA WY LOD E euayeq 79 19 auapeq 79 19 Aleyeq 29 19 auayeg 79 19 ano F 19 d E AZT Ier A EM SI el 9w ENT vert Di T t palap elep IX rri Nes SLU TX nd samod Tx Si Jg Ce TX E ay amp ueyeq ej ep jopetue TM euegeq ap maey 1n bey Mpeg rn jeejebapejeuiayeg TN English 5 950 645 0 Rev 00 12 12 107 0 11de gt ep ezeqe jap UODAIS ap 00 ZW Kaes Yg I0ouuqnH latent 2s TS d LN sejanbse ep UOIDEAS S ap OJO OW Aneons S LA ap INOW OW asbaanbs MOO Suny gW UayeqNes J0JOWqnH Old Ek zS OW A euiob ep e jiqoose uope aje ap Joyou ap sauoydnuiayul 0ihl ZS TS OW Jneons aeraj ap ANAJOW sunayzdruaqui Qdiw ZS TS OW BAGSAns JOJO AN SeuoMS 0 DIN ZS TS OW ueseqbnes ioyouiqnH Jeneuosontid ZS TS OW pu sp EIDAEN ZA ene ap equioq CN soonumb eJopeouisop equiog nee ep ones ep euueA ZA sid Krier da uondo aruy eSesop ep adwod pW uondo Aasiueup dund Buisop by uondo anuay eduindieisog pW i 9 JU Uu ve Tm T m A mna D x x ep
15. 3 5 2 d Fa E Vacuum 4 co NS OFF Medium Power el 1 3 Wy Brush speed l e Fine Whisper Power 411 Y E Fa 4WMi ontact pressure MR 0 100 229 ON i j Spray extraction 4 ub ON OFF s hose menus must be enabled in the key menu Selection not permanent The setting will be lost if the program selection switch is adjusted 2 Selection depends on the position of the pro gramme selection switch 88 English 5 950 645 0 Rev 00 12 12 9 3 2 Function overview of the grey intelligent key Welcome Transport Mode ECO Mode l Time delay Scrub Vacuum Scrub Vacuum Scrub Vacuum Polishing 8 m ae Bs KS Gi Speed O 100 Water 0 100 Operating Hours Key menu see Key menu 2 BasicSettings see BasicSettings System Parameter see System Parameter 2 Test Mode Battery Menu see Battery Menu 12 Brush speed Fine Whisper Power English 5 950 645 0 Rev 00 12 12 89 1 2 Contact pressure 0 100 1 2 Vacuum OFF Medium Power RM Dosage 2 0 3 5 2 Brush head D R S 2 Spray extraction ON OFF Settings Reset Language Version BT X XX LEX XX Selection not permanent The setting will be lost if the program selection switch is adjusted 2 Selection depends on the position of the pro gramme selection switch 90 English 5 950 645 0 Rev 00 12 12 9 3 3 Fu
16. 645 0 Rev 00 12 12 1 Screw axle mount 2 Safety ring interior 3 Safety ring exterior 4 Axle gt Remove the interior safety ring 1 Base 2 Axle gt Drive the axle out of the base with a driver tool 8 7 Axle with deflector pulley Screws Pulley Ball bearing Safety ring exterior Safety ring interior Screw axle mount Base o ON OOF O b i 17 5Replace the motor n 1 Screw 2 Power connector plug gt Remove the casing lid 3 Loosen the screw English 5 950 645 0 Rev 00 12 12 57 6 17 7Replacing the pulley on the excenter 1 Brush motor 2 Motor plate screws 3 Screws brush motor 1 Screw 4 Drive belt 2 Disc 5 Motor plate 3 Pulley 6 Pulley drive gt Remove the motor Loosen the screws on the motor gt Remove the drive belt gt Unscrew the screws of the motor H 3 Remove the motor 6 17 6Replace the glide contacts on the brush dee CH 4d GA The replacement takes place just like with the brush n A I head BR model Loosen the screw Sample picture excenter removed 1 Puller tool 2 Screw 3 Pulley gt Screw the screw into the pulley 3 Attach the puller tool and remove the pulley 58 English 5 950 645 0 Rev 00 12 12 6 17 8Replacing the excenter 1 Safety ring 2 Disc 3 Screw 4 Excenter disc with rubber collar JA 3 Loosen the screw Ee NAH gt Remove the excenter disc 2 Carrier lid 2 Unscrew the excenter screws 3 E
17. Chain 3 Unscrew the screws gt Remove the threaded bolt gt Remove the wastewater reservoir with cover hing es from the appliance 6 14 Battery and battery charger 6 14 1Removing the batteries 1 Negative terminal under the protective cap Appliance battery connection 2 Battery terminal connector 3 Batteries 4 Positive terminal with main fuse under the protec tive flap Appliance battery connection 3 Empty the dirt water reservoir gt Tilt the wastewater reservoir on its side or remove it 3 Loosen the terminal screw connections and re move them from the terminals gt Remove the batteries 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 inspec tion to obtain a reliable result The following checks must then be made Measurement of the idle voltage The idle voltage provides a measure for the charging status of a maintenance free battery If this 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 ap prox gt 6 42 Volt 100 gt 6 30 Volt 19 gt 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 Batte
18. O gt E Ladekurve 4 AR E i E OI Exide FTosigoweT YY Ee 2 P Ai gt Ladekurve 5 G 5 x Batiery VI 1 gt gt E ll X FC V y FAS lt Ladekurve 6 9 gt B Alike 8 1 Battery VII X Ke kundenspezifisch Mens yt 0 Switch Battery Battery ll Battery lll Battery IV Battery V Battery VI Battery VIII off volt Charging Charging Charging Charging Charging Charging X age curve 0 curve 1 curve 2 curve 3 curve 4 curve 5 Charging curve 6 Low EXIDE HOPPECK EXIDE XFC rapid External Batt GF12V105 EGTB170 GF06180V GFO6240V FT06180W charge ca charger cus A ET pable exter tomisable nal charger English 5 950 645 0 Rev 00 12 12 95 These values refer to the switch off of the brush mo tor and suction turbine units The switch off differs with the current pickup The switch off takes place after 60 seconds plus tur bine 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 AB IZ Test Mode 8 Brushes CA ms EUM ON OFF Vacuum ON OFF Water ON OFF p DOSE Al Y ON OFF F A L MEE L 0 0 Squeegee lt senken heben gt Brush head lt
19. 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 de tergent soak in Vacuum mode ouck 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 af ter the intelligent key has been inserted There are three different key types with different col ours and their corresponding user groups 5 3 1 Yellow intelligent key 5 3 2 Grey Intelligent Key 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 Supervisor Facility Manager
20. and rest it 2 Unscrew the screws and remove the holder cu ui AUN Lifting motor connecting cable Rear cover Motor Halting plate Bolts with nuts Screws 7 Coil Chain Unscrew the nut on the bolt gt Remove the bolt OO P On gt Loosen screws 1 Push rod brush head 3 Remove the holding plate 2 Lock hook gt Remove the lifting motor gt Press the hook on the push rod slightly toward the Note middle of the appliance until the push rod can be The lifting motor is controlled via two micro switches pivoted toward the bottom The micro switches are not adjustable 3 Press the push rod all the way down One micro switch shuts off the lifting motor in its up Unscrew the screws per position the second one in the bottom position 3 Remove the holder English 5 950 645 0 Rev 00 12 12 63 3 Remove the gear axle with drive motor toward the 6 20 2Replace the wheel bottom 3 Remove the connecting cable on the control elec tronics WE Repair solution Steering roller mount drive motor mount e E um e a O l af 1 Washer Z A PS ID P 2 Screw E ID 3 Wheel DA 0 9 WU MP Loosen the screw Ce Ye y fp 225 gt Pull the wheel off the axle ax UV ta ES 1 2 y fo d A 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 Axle stub 2 Fitting ke
21. ao EBD Ne ULM EE REA 107 English 5 950 645 0 Rev 00 12 12 5 Good service work requires extensive and practice oriented training as well as well structured training materials Hence we offer regular basic and advanced training programmes covering the entire product range for all service engineers In addition to this we 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 ad dress 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 Karcher GmbH amp Co KG P O Box 160 D 71349 Winnenden WWW kaercher com 2 Safety instructions 2 1 Hazard levels A Danger Immediate danger that can cause severe injury or even death A Warning Possible hazardous situation that could lead to se vere 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 S Lucena Fe
22. de vice 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 termi nals 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 3 Open the cover 2 Slide the cover to the side gt Remove the lid 6 4 Replace the fill level indicator 1 Top rubber grommet 2 Filling level display 3 Bottom rubber grommet 28 English 5 950 645 0 Rev 00 12 12 1 Rubber grommet 2 Filling level display gt Remove the rubber grommets with a screwdriver 6 5 Replace the water dosing unit 6 5 1 Replace water dosing valve 3 4 5 6 Ree HAMM Ls Ka i 1 Water dosing valve 2 Angle plate 3 Screws 4 Halting plate 5 Ball tap 6 Screws RS i i E SN 1 Ta i E gt H as eh 1 c pl 3 ks 1 Screws 2 Water dosing valve 3 Angle plate gt Unscrew the screws 3 Remove the water dosing valve 3 Loosen the screws on the support plate 2 Remove the ball cock from the water dosing valve 3 Remove the connecting cable from the water dos ing valve 6 5 2 Replacing the ball cock e 1 Ball tap 2 Ball cock actuator 3 Angle plate 4 Pick up of ball cock actuator gt Remove the screws from the support plate
23. k 1 Screws programme selector switch 3 Unscrew the screws 1 Operating panel board 2 Plug programme selector switch 3 Program selection switch 3 Pull out the plug on the printed circuit board on the operating panel and remove the programme se lector switch 24 English 5 950 645 0 Rev 00 12 12 6 2 2 Check the programme selector switch 1 Program selection switch 2 Resistance measuring gauge 3 Plug 3 Connect the resistance measurement device to the plug connections of the respective coloured cables See table below Resistance measure ment between Nominal value in Transport mode Increased white green brush contact brown pressure Intense white mode Vacuum white yellow mode brown Polishing mode 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 3 Open the operating panel 3 Pull out the plug on the control panel board 1 Travel direction switch forward reverse grey pink yellow 2 Speed white green brown Control electronics negative point 3 Turn the device on and set it to transport mode English 5 950 645 0 Rev 00 12 12 25 Result in VDC Measur ment be tween the negative point and Note switch position Unplug the plug for the U batt travel switch from the negative 1 control p
24. 0 10 4 Tightening torques Locknut brush head pickup with the quick tensioning lever closed 6 Nm 106 English 5 950 645 0 Rev 00 12 12 O O oO C C QD D D E V C OQ Es cS H d EN O LJ o j EB o T E O D C D Ben Ben O o C H o Be mum Qu O c Ke o L D gt Ka ab o Be mum E O D O gt O E D Be o c OO Same K O ircuit di 11 C The circuit diagram in the service manual is not up dated D ta O YI D C X D E mm E O E iv o A 9 Q 9 H e C O o Ke C o D Yi iv o 0 O D Ke 0 C E D c O Bn ab x 0 o ES D Ke 0 E E ca _ O O gt O O C D 2 _ gt O D X m D o gt 0 gt OO E v O A E e co Y o CO o o CO D T T T uompedse ep eulqin EW uoneudse p SUN CH AQQOLW uunn5eA EN SUICUMMONES EM wl SAC r f EW u EE ep OK Uhr 1 5 EUDIELU e ep Jope n5eu zs inajenGey ZS udeidouse zs JajBa uyey z5 ojide ep 10304 T ZIW ZIN asso ap menu T ZW ZW JOJOW usruq T eW ZIW JOS ng TWN 7 TT Sa LK a pee d Eu At vo LAM uoDoer ep IOW TW ISL ep neo TIN JOVOW uomen TIN Joyourm ej TW CN Tai epuajod ep o3Iuo meja eulajsis Ty uoneyueuie p enbruo n eje awasis Ty GG us i wg nm rh m om E
25. Actuate drive lever Display on the voltage measuring unit approx bat tery voltage 1 Chemins cable 2 Measuring device 3 Connect the charger to the current network 3 Connect the measuring device to the charging ca ble as shown in the illustration gt 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 ic ZE SAX 00 2207 i pu S d I Wh 1 Battery cable 24 Volt 2 Measuring device 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 2 Connect the measuring device to the battery cable as shown in the illustration gt Actuate drive lever 3 Measure the current 6 23 6Current pick up of the brush motor Wees A IO D E VE ei o VW d g AN Za mu Ws a e ae om e w w mm mm e Soe e PECH Ee Mo EE e em me CS EEN 1 Battery cable 24 Volt 2 Measuring device 3 Plug in the Intelligent Key gt Turn the programme selector switch to the respec tive programme 3 Connectthe measuring device to the battery cable as shown in the illustration 3 Actuate drive lever 3 Measure the current 70 English 5 950 645 0 Rev 00 12 12 6 23 7Current pickup YET ep AP tronic LE Aas 100 nut uam MINA TT e 1 Ba ttery cable 24 Volt 2 Measuring device 3 Plug in the Intelligent Key 3 Turn t
26. Do not connect service programme software V5 0 or older to the appliance This could lead to malfunc tions of the appliance or the destruction of the control panel and control board ss Ko E 424v GND 1 N ys ieuptsicherung siehe Batteriepol C DC Main fuse see battery terminal E generale voir pole de batterie x25 L XB rem S T E 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 3 Turn off the appliance 3 Integrate the service module A9 into the module bus of the machine you will only need the white bus plug 3 Connect the black AMP bushing of the Y split ser vice bus cable to the black AMP plug of A9 3 Tightly connect the negative wire of the Y split ser vice bus cable to the negative connection of the machine This is important as the service module NO oR WD ch or the control electronics might get damaged oth erwise 2 Connect the PC laptop to the service module A9 via the USB interface gt Plug in the Intelligent Key 2 Setthe programme selector switch of the machine to position 1 gt Start the service programme 3 Perform automatic scanning to recognize the de vice automatically 3 If the device is not recognised the selection must be repeated LED blinks on service module Transfer the new software 2 Select the updat
27. KARCHER B 80 W Service Manual English 5 950 645 0 Rev 00 12 12 1 o stent t PTT 6 Salely INSWUCIIONS iiid he ee cared ee rpg 6 2 e Elek 224 44 0550 aber dole don dra dod n Rod igi odia aed os oa ae eu nee 270 Technical Features canoso a 02 3 8 eee es een sete does 6 dl UDS 2 1 tac eo ee Parts or die SVSIGITI EEN 8 AT FON WN OW us dedere A pe ebd ee ee Ua dubie iat 8 42 Red VEW E EE fo yal que dana ate oae doa ee al ae eat do ra 09 A NSIC EE 10 7 9 1 LOD Ol apDIIali6 GO ss vcra d ode era eoo ede a e bab a ei ed 11 4 3 2 Wastewater reservolr llle 11 LM discuenbul P T ee 12 d o oou ud qute tcs aqu oes a uc ied uud E nee 13 A Dil BR Clean QM asnicar dd iia dijera deba 13 4 5 2 BD cleaning A 31 9 39 E teh Xe Era ew ca eid eh Wh ed 13 2 9 99 65 OWING curn wi Eee fed aate mda anata ne Deui Moses td 14 4 0 JACCOSSOLIGS 4442845 ER Casi ee e Red eet i o t eed 14 audi ara R a EE 15 o4 FUNCIONA ladra arte AE EE Oe 15 2 Operator CONSE cs ce t ode Embroidered ues det 16 5 2 1 Programme settings EEN m i Did JDtellideliE e Ga s daer as ned id a qr aod es 18 5 3 1 Yellow intelligent key 18 5 3 2 Grey Intelligent key 18 5 9 9 Red IDtellidehit Ke ouod d ebur SUE Eau e es c Se BS oes 18 Sed AMO Elle otn a n teen ro eiua oe bruce eee uds god 19 5 5 HEROS WLC arall s s dandi nd ee ac fee Ri ah ett Bet ee tlg ome Bom Jodie e
28. Saee Sol a de 20 5 6 Tank lid ventilation system llle BIS 21 5 7 Tank rinse system option 21 5 9 SUCTION TUIDING ee e oae n o eh de dale dro DR Een 21 5 9 Charger control elechoncs llle 22 5 10 Acuation of detergent dosing llle 22 Basic settings and service procedures 23 61 Replace Ne IS Qus oar ato a pd E IR v ee ure dpi 23 62 ODEhAIOnCONSOlEs 214 co eine von e E EE 23 6 2 1 Replace the programme selector switch ss 23 6 2 2 Check the programme selector switch ce eens 24 6 2 3 Check the travel switch llli 25 6 2 4 Replace the drive switch ee eee 26 6 2 5 Replacing the control panel board oooooooooooo 27 6 2 6 Check the Seli teSt Segen ERE Oe ete HR ERE XE Se dex En cns 27 6 3 Unhook the cover of the wastewater reservoir o o ooooooo 28 2 English 5 950 645 0 Rev 00 12 12 6 4 Replace the fill level indicator llle 28 6 5 Replace the water dosing unt 28 6 5 Replace the water dosing unt 28 6 5 2 Replacing the ball cock llle 29 6 6 Clean the flowmeter lille 29 6 7 Replacing the water PUMP 2 0 ccc II 30 6 8 Detergent dosing DOE 231 6 8 1 Replace the detergent dosing 31 6 8 2 Replacing the pump hose 0 0 cee ee ee ees 31 5 Tank rinse system option 21
29. T r e ee eege eg n See Ge dA eg ee ege e 1 Measuring device 2 Measuring probe on the plug in contact 5 X6 3 Measuring probe on the plug in contact 13 X6 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 3 Connect the voltage measuring device as shown in the illustration gt Actuate drive lever Display on the voltage measuring unit approx bat tery voltage English 5 950 645 0 Rev 00 12 12 73 6 23 18Voltage measurement detergent dosing 6 23 19Voltage measurement water dosing valve pump 0 5 on terminal X6 5 14 on terminal X6 3 4 HEREIN EE 1 Measuring device 2 Measuring probe on the plug in contact 5 X6 3 Measuring probe on the plug in contact 14 X6 3 Plug in the Intelligent Key 2 Set the detergent dosing to 0 5 3 Turn the programme selector switch to the respec tive programme 3 Connect the voltage measuring device as shown in the illustration 3 Actuate drive lever display 1 Measuring device 2 Measuring probe on the plug in contact 3 X6 3 Measuring probe on the plug in contact 4 X6 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 3 Connect the voltage measuring device as shown in the illustration gt Actuate drive lever Display on the voltage measuring unit approx bat Voltage tery voltage measure IO AL SN 0 96 le 74 English 5 950 645
30. akes 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 Vi 1 Safety ring 2 Axis pins 3 Scraper roller gt Remove the safety ring 1 Covering lid gt Take the pivot pin out of the holder 2 Screws 3 Lid plug for mains connection 4 Screw 3 Unscrew the screws 3 Remove the housing cover English 5 950 645 0 Rev 00 12 12 55 ie En EA Wis dia 1 Drive belt 2 Motor plate Motor plate 3 Motor plate screws Pullev drive 4 Screwdriver Driv ii It Lift the motor plate up with two screwdrivers and di tension the drive belt 3 Loosen the screws on the motor plate Brush motor Pulley excenter 1 2 3 4 5 Reversal rollers Power connector plug 6 17 4Replace deflection pulleys 6 17 3Replace the drive belt 1 Nuts pad pick up 2 Screws pad pick up 3 Pad pick up 3 Remove the casing lid 3 Remove the drive belt 3 Loosen the mounting nuts 3 Unscrew the screws gt Remove the pad pick up Brush motor Motor plate screws Screws brush motor Drive belt Motor plate 6 Pulley drive gt Remove the casing lid Loosen the screws on the motor gt Remove the drive belt 3 Install a new drive belt 0O BON 1 Screws base 3 Unscrew the screws gt Remove the base with the deflection pulleys 56 English 5 950
31. anel board and V measure on the pink plug terminal X3 of the control panel board Leave the travel switch plug on terminal con nector X3 of the control panel board in place Conduct all subsequent measurements with the plug in place 3 Plug in the travel switch plug on terminal connec tor X3 of the control panel board tween the Note switch position Result in VDC negative point and grey Travel regulator O posi 0 V tion i V Measur ment be Travel regulator forward 15 V tion yellow Travel regulator reverse Check the speed potentiometer Measur ment be tween the negative point and white Travel regulator O posi tion brown Travel regulator O posi tion Note switch position Result in green Travel regulator max lt 2V forward drive green Travel regulator max lt 2V reverse drive 6 2 4 Replace the drive switch gt Open the operating panel 3 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 Driving lever 2 Drive switch 3 Square 4 Plug drive switch Observe during installation 2 Countersunk bore 3 Connecting cable 3 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 re moved 1 Countersunk bore 3 Install the potentiometer so that the counters
32. arging characteristic you must contact the battery manufacturer 12 3 4 5 6 ETIEN Charging Voltage Desulfation E Stage CC Charging Voltage V Charging Curent A Charging characteristics status of Feb 3 2012 1 Charge voltage V 2 Charge current A 3 Sulphating 4 phase CC 5 Charge voltage 6 U phase CV 7 Charging current 8 la phase la 9 Retention charging EL 10 Charging time 42 English 5 950 645 0 Rev 00 12 12 U Stage CV During the battery charging process the battery sta tus 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 characteris tics which can be remedied with the battery manu facturer T 8 9 10 Salle E la Stage la Float Stage EL Umax la U2 EL I3 EL Charging time Parameter Battery EXIDE HOPPECKE EXIDE GF12105V 6TB170 GF06 180V GF06 240V FTO6 180 Wet WET Part number 6 654 141 0 6 654 242 0 6 654 130 0 6 654 119 0 6 654 086 0 tOmax Max time of the desulphating phase C eo Top threshold for the desulphating phase V Current in the desul phating phase A timin Minimum time for the phase min timax Maximale Zeit f r 5 die l Phase min l1 Current in the phase A t12max Minimum time for 7 the 1 U phase min
33. atures The scrubber vacuum is used for wet cleaning or pol ishing of level floors Working width BR version 650 mm 750 mm BD version 650 mm 750 mm Filling quantities Fresh water tank 80 Waste water reservoir 80 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 follow ing model 24V DC Key KIK System KARCHER 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
34. be on the plug in contact 11 X6 3 Measuring probe on the plug in contact 4 X6 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 3 Connect the voltage measuring device as shown in the illustration 3 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 ER Ar tronic C Ah m NITRATO 1 Measuring device 2 Measuring probe on the plug in contact 2 X6 3 Measuring probe on the plug in contact 10 X6 3 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 CN W BE AR tronic Be ME ONO 1 Measuring device 2 Measuring probe on the plug in contact 2 X6 3 Measuring probe on the plug in contact 10 X6 3 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 f The service programme software is available at Karcher Inside The service module A9 must be updated with the last est version of the service module software Caution Only use service programme software version V5 1 or higher
35. brush rollers llle 80 7 4 Check seal on the cover of the wasterwater tank replace 80 lge le Ee Le do e BEEN 81 8 1 Faults without display on feconsole 2 0 00 eee 81 8 2 EauliS e e EE 83 Gis Eet le te Re LEE 86 Software diagrams and parameter overview 87 9 1 Operating elements 87 9 2 FaGlOly SCuING A a a a a aa a e t 87 O23 E Ee Rn EE 88 9 3 1 Function overview of the yellow intelligent key 88 9 3 2 Function overview of the grey intelligent key 89 9 3 3 Function overview of red intelligent key 91 94 Special SUDMENUS x sa x aA ESSE anden 93 94 o s sis c wnt es ded AS ae ee eR ees 93 SA EEN 94 94 3 Battery Ie DUE A acu tc dei eon 99 9 CA C CRI eae ae e we eee 94 DAA Manta COMIN OE x cote si oie A eee GE ha tae d Ne es 97 9 5 Overview of special functions and basic settings 98 9 5 1 Summary and basic setting of key menu 98 9 5 2 oOVSten parameters cara aces erani e cep x AUS PEE 100 9 6 DeDUG MOOG u d eebe SE Ee ee Ba E Rote c odo des 101 Technical specifications 9 au 22r ia 103 TOT Exchange TMCS it Ee aee oe Oe Be e OU ao Se dU ee s 105 10 2 Technical Documentation sua a ia 105 10 3 ee Melo EEN 106 10 4 igntening Torgu S uud ceat 3c ae o e OD Na aed ae es 106 Circuit diagEalli i22 22 x aco inn did on dedos BM a A0 io e aea s 107 1t B80W 0 089 434 0 i x d ex was
36. contactor is stuck ERR ZK 2V 003 Internal fault of control electronics Switch on off the appliance again ERR ZK 10V 004 Check the battery connection Measure the battery voltage gt 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 mo tor for short circuits ERR 5V 005 Fault in 5 V supply voltage owitch on off the appliance again Internal fault Replace control electronics ERR U H1 006 Internal fault of control electronics Switch on off the appliance again ERR U H1 007 Check battery voltage gt 22V Disconnect the battery for 2 minutes ERR U H1 008 If the fault is still present conduct fur ERR U H1 009 ther testing Disconnect the drive motor MF and MF and switch the appliance on If the faults persist replace the con trol electronics If the fault disappears check the wir ing of the drive motor Disconnect the suction turbine and the brush motor and switch the appli ance on If the faults persist replace the con trol electronics If the fault disappears check the wir ing 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 gt 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 of
37. cross the intake mandrel and losing its function 1 Float 2 Fluff filter A 3 Pickup mandrel 1 Suction hose 4 Disc 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 3 Empty the dirt water reservoir 2 Tilt the wastewater reservoir on its side 3 Pull out the suction hose off of the wastewater res ervoir 6 12 Replace the wastewater drain hose 1 Hose clip 2 Dirt water reservoir 3 Dirt water drain hose gt Empty the dirt water reservoir 3 Tilt the wastewater reservoir on its side 3 Loosen the hose clip gt Wastewaster drain hose off of the wastewater res ervoir 34 English 5 950 645 0 Rev 00 12 12 k ie we T irit 1 Dirt water drain hose 3 Remove the wastewater drain hose 6 13 Removing the wastewater reservoir 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 gt Empty the dirt water reservoir 3 Tilt the wastewater reservoir on its side 3 Pull out the suction hose off of the wastewater res ervoir gt Remove the wastewater drain hose Be 1 Connection cable suction turbine 2 Connecting cable float of wastewater tank 2 Separate the connecting cable of the suction tur bine from float of wastewater reservoir 1 Screws 2 Threaded bolt 3 Coil
38. d easier by using cable ties 6 15 6Replace the glide contacts on the brush motor 1 Screw 2 Cover motor carbon gt Remove the brush motor Loosen screws gt Remove the cover of the motor carbon 1 Nut glide contact 2 Glide contact 3 Press spring 2 Lift the contact spring and pull the glide contact out of the chute gt Carefully place the contact spring onto the chute English 5 950 645 0 Rev 00 12 12 49 P 4 1 Glide contact 2 Nut glide contact 3 Unscrew the nut and replace the glide contact 3 Perform this procedure on both glide contacts 6 15 7Replace the bow with sealing lip and deflec tor roller BR model S only 1 Axle bolt with star handle 2 Safety ring 3 Scraper roller 4 Bow with seal lip gt Remove the safety ring A 1 Axis pins 2 Safety ring 3 Remove the safety ring gt Remove the bow with seal lip from the axle bolt gt Remove the axle bolt 50 English 5 950 645 0 Rev 00 12 12 oafety ring Axle bolt with star handle Scraper roller Safety ring Bow with seal lip 15 8Setting the brush head O Om PS GO M 1 Brushing rollers 2 Screws 3 Gear housing gt Place the brush head on an even surface 3 Insert the brush rollers 3 Loosen the screws on both gear casings 2 Shake the brush head briefly for the brush rollers and the gear housing to settle 3 Tighten the screws gt Coat a corresponding area of th
39. e floor with chalk and drive the brush head over it 2 Switch on the brush head lower it and briefly brush the chalk coated area 2 Raise the brush head and remove it from the chalk coated area brush 2 Sweeping track front brush 2 Check the sweeping track of the two brushes The must run at the same width and parallelly Fo CD P e e w r 1 L a 7 E dl Je e B SE e e h DE r bg C E d E i a e p 3 k 1 Lifter 2 Brush head intake 3 Quick tensioning lever 3 The setting is adjusted by sliding the brush head intake and the quick tensioning lever 3 f the sweeping track is set up correctly tighten the quick tensioning lever 6 16 Brush head BD model 6 16 1Replace the brush head 1 Retaining clip 2 Brush head pick up on the push bar 3 Brush head 3 Switch to Manual control with the grey or red key 2 Select the brush head 3 Lower the brush head by pressing the button Check the progress of the lowering 3 1 Compress the holding clamp 2 Pull the holding clamp all the way up and out n i gt E a EN T x m H 2 m i a A Es 1 Ki c ZIP gt SC ESO F Se EI s af a Ri a s a 2 a s n S e T al z a a E a y h a F a d Pi A d A La n Li P d F T a 1 Suspension 2 Brush head 3 Holding pin 4 Lock 3 Push the lock back slightly and pull out the holding bolt gt Raise the p
40. e 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 soft ware transfer The successfully transferred software can be dis played 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 Setup the charge curve for the installed battery used in the battery menu 3 Turn the device off and back on The device can be started after all the settings have been made Service programme for floor GEES and sweepers V5 1 English 5 950 645 0 Rev 00 12 12 77 6 25 Parking brake Steering roller Brake linkage Parking brake foot brake pedal Screws Floor plate 6 Steering roller 3 Remove the steering rollers 3 Loosen screws gt Remove the floor plate 0O BON 1 Crank 2 Screws 3 Parking brake foot brake pedal Loosen screws 78 English 5 950 645 0 Rev 00 12 12 1 Crank 2 Parking brake foot brake pedal 3 Bend the crank slightly 3 Remove the crank from the pedal linkage y 2 3 4 1 Brake linkage 2 Chassis 3 Spring 4 Pedal linkage 3 Remove the brake linkage from the chassis en ir aY 5 F d j v A TF D R 8 4 1 Latching tabs 2 Vice 3 Brake linkage 3 Push the brake linkage into the loc
41. e the brush motor 2 0 0 0 cece eee eee ees 48 6 15 6 Replace the glide contacts on the brush motor 49 6 1 A Replace the bow with sealing lip and deflector roller BR model S on y 90 6 15 8 Setting the brush head 50 6 16 Br sh nead tBD THodel iu eeu a tor et 4400 Sede DE EE Eb e doe ed ol 6 15 1 Replace the brush head illii 45 6 16 2 Replacing the disc brush pick up 00000 eee eee 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 eee 55 6 16 7 Replacing the deflector roller o o o ooooooooo 55 6 17 Brush head S 65 SWING sau qm Ree A eg Bas 6 17 1 Replace the brush head 0 0 cc eee ees NS English 5 950 645 0 Rev 00 12 12 3 6 18 6 19 6 20 6 21 6 22 6 23 6 17 2 Remove the housing lid 0 00 cee oo 6 17 3 Replace the drive belt 0 0 0 0 0 ce eee 6 17 4 Replace deflection pulleys ooooooooonoooo 6 17 5 Replace the motor EE o 6 17 6 Replace the glide contacts on the brush motor 6 17 7 Replacing the pulley on the excenter o o o oooooooo 6 17 8 Replacing the excenter 0 000 ees 6 17 9 Replace water distribution pipes 6 16 7 Replacing the d
42. eflector roller o o o oooooooo Brush head suspension EE 6 19 1 Overview of lt 6 18 2 Removing the lifter llle 6 18 3 Adjust the quick tensioning lever on the lifter 6 18 4 Adjust the brush head pick up on the lifter LIUNGUMOIONS c veras ss ee iod eg don enin ean acd di bbe ad 6 19 1 Replacing the lifting motor of the brush head 6 19 2 Replacing the lifting motor of the vacuum barpick Drive ANd wleels x sse aud ee RED PERDRE Ege seq edhe cies 6 20 1 Replace the drive motor with gear axle 6 20 2 Replace the wheel 0 0 0 cee eee eee 6 20 3 Replacing the steering roller o o ooooooo SUCTION SY SUC EE 6 21 1 Replace the vacuum bar suspension n nananana aa aaa 6 21 2 Replace the vacuum bar 6 21 3 Replacing the suction ube 6 21 4 Replacing the glide contacts of the suction turbine Control elechoniceichager llli 6 22 1 Open the control electronics 0 0 00 cee eee SA Ee cee D bu ued hake 0 22 3 Beplace Tabl siciliana cid fun e Ran aA eA eet 6 22 4 Replace the mains cable of charger 0000 c eee eee Electrical measurements n anaana aaa 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
43. eplaced The cover is clamped on and can be pushed out he 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 Screw on lid fresh water drain with filter sieve 2 Fresh water hose Large fresh water drain for a quick drain of the fresh Cover water tank If needed you can use the water hose to Quick coupling rinse the fresh water tank via the large opening Seal of safety overflow Front plate Float a Float linkage Sa Form hose fh a Valve 9 Cover 10 Diaphragm 11 O Ring 12 Seal of float linkage 13 Screws AOE gp em P 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 contamina tion there is a filter sieve installed between the tank and the screw on lid Le 1 1 2 3 4 5 6 D 8 e a TE 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 3 To ventilate the tank press the lid lock toward the inside and insert it into the pick up 5 Tank rinse system option 1 Hose connection 2 Protective cover 3 Hose ring 4 Nozzles Note The protective cap prevents wastewater from enter ing the tank rinse system If the protective cap is not attached to the hose co
44. er valve English 5 950 645 0 Rev 00 12 12 111
45. eries Hauptladung Ula means constant current line U constant voltage line constant current line recharging a automatic switch off transition to maintenance charge During the constant phase the charger is charged with the nominal current see typeplate on charger and the charge voltage will increase slower or faster depending on the charge condi tion After that the charger will switch to U con stant phase Inthe U constant phase the voltage remains con stant and the current sinks continuously After that the charger will switch to constant phase Inthe 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 com plete transformation of the active mass in all cells I Kontantphase U Kontantphase Nachladung Erhaltungsladung Spannung eit I Nachladung Erhaltungsladung 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 bat teries If a battery is to be used for which there is no suitable ch
46. eter for obstructions clean Brushes do not turn Ifthe 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 for eign 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 Charger is not working Wiring WO between the control and the charger is interrupted ventilator on charger does not start up The appliance has a short runt The charger parameters in the control electronics are adjusted incor i rectly Check replace the batteries Tank cannot be filled with wa Sieve contaminated clean replace ter valve Auto fill in Water valve Quick fill in does Diaphragms plugged clean replace not shut off Electronic malfunctions Switch on off the appliance again Check battery voltage gt 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 ERH U BATT 001 Battery voltage too low Charge replace battery ERR K1 002 Check if the contact of the main contactor Replace main
47. ew 14 _ amp 13 12 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 2 uw cub 29 6 7 BR cleaning head S with sealing lips BR cleaning head without sealing lips 1 2 3 4 NM 8 10 9 8 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 6 8 7 6 8 Scraper roller Sealing lip left S version only 9 Disc brush pick up right Brush roller rear 10 Floor plate Coarse dirt container Sealing lip right S version only Slide shoe Scraper roller Water distribution bar Brush roller front CONOR WD 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 Clip To attach broom and mop 2 Hook To hang up cleaning accessories Pick up grinding pad 3 Hook Eccentric To hang up cleaning accessories Scraper roller Water distributor pipe right T piece Water distributor pipe left OO PS Go b i
48. f the appliance again ERR K1 012 tuation Check battery voltage gt 22V Check the cables to the main contac ERR_K1_013 tor Replace main contactor ERR_K1_014 Diagnosis of the watchdog and its actua Switch on off the appliance again tion Check battery voltage Replace control electronics English 5 950 645 0 Rev 00 12 12 83 ERR_FR_015 Power is applied to the brush motor al Switch on off the appliance again though no output is switched Check battery voltage gt 22V Disconnect the battery for 2 minutes Check the brush motor cables Replace control electronics ERR FR 016 Short circuit deteced on brush drive Disconnect the cables to the brush motor then turn the appliance on fthe fault disappears find the cable fault fthe fault persists replace the con trol electronics ERR ER 017 Power is applied to the suction turbine al Switch on off the appliance again though no output is switched Check battery voltage gt 22V Disconnect the battery for 2 minutes Check the brush motor cables Replace control electronics ERR FR 018 Short circuit deteced on suction turbine Disconnect the cables to the suction drive turbine then turn the appliance on Ifthe fault disappears find the cable fault fthe fault persists replace the con trol electronics ERH ER 022 Voltage on the drive switch outside per Switch on off the appliance again missible range Check the d
49. f the vacuum stub 7 3 Replacing the brush rollers d A EZ M j a P a S fe F e gt M HR 1 Unlock bearing lid 2 Brush roller 3 Bearing lid 3 Move the brush head into the top position 3 Press the release button of the bearing cover and remove the bearing covers from the brush head 3 Pull the brush roller out of the brush head 80 English 5 950 645 0 Rev 00 12 12 1 Brush roller 3 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 waster water tank replace 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 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 Machine does not
50. ger 2 Determine the current and voltage measuring val ues after switching on the charger and record them 2 Determine the current and voltage measuring val ues after about 10 minutes and record them The measuring result of the constant phase in the main charge must be close to the manufacturer s val ues 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 appli After each use ance 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 pro cess maximum continuous current value Charge current constant current Performance values of the charger with the battery connected after approx 10 minutes Charge current constant current 40 English 5 950 645 0 Rev 00 12 12 Regulated charge ID line IUI charger for mainte nance free batteries Volt Zelle Ampere AGM Fliesbatterie 2 4 Gel 2 35 AGM Fliesbatterie 2 25 Gel 2 3 Spannung Zeit I Konstantphase U Konstantphase i Hauptladung IUla means constant current line U constant voltage line constant current line recharging a automatic switch off transition to maintenance charge Regulated charge ID line IUI charger for low maintenance batt
51. gt Replace defective parts CONOR WD 6 21 2Replace the vacuum bar ch 1 Suction hose 2 Wing screws of suction bar support 3 Pull out the suction hose from the vacuum bar 3 Loosen the wingscrews of the vacuum bar sus pension and pull the vacuum bar out of the intake 6 21 3Replacing the suction turbine uction channel cover 2 Screws 3 Hold the wastewater reservoir by the handle re cess and swivel the reservoir upwards toward the side Unscrew the screws 1 Screws 2 Holder suction turbine 3 Suction turbine 4 Connecting cable suction turbine Unscrew the screws gt 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 mun i aka i A x X m m om Wax E e 1 Connecting cable suction turbine gt Remove the connecting cable 3 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 66 English 5 950 645 0 Rev 00 12 12 6 21 4Replacing the glide contacts of the suction turbine 1 Cover cap glide contact 3 Pull out the cover cap from the suction turbine to ward the top 1 Connection plug glide contact 2 Glide contact 3 Press spring 3 Lift the contact spring y T um j T d p 1 Glide contact 3 Pull the glide contact out of the chute gt Carefull
52. he brush pick up by means of a press in tool 3 Insert the safety ring 1 Safety ring 2 Axle Remove the brush rollers from the brush head 3 Remove the pulley gt Remove the safety ring English 5 950 645 0 Rev 00 12 12 47 1 Gear housing 2 Axle with brush roller intake 3 Lightly strike the axle with a rubber hammer Drive the axle out of the casing o T Axle with brush roller intake Ball bearing Fitting key Pulley oafety ring oafety ring oci On 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 6 15 5Replace the brush m y _ e r otor F 1 Cover of brush head plug 2 Screws 2 Unscrew the screws gt Remove the cover 1 Brush head plug 2 Cable tension guard 3 Screws 3 Unscrew the screws 3 Disconnect the plug elements gt Remove the drive belt cover 1 Brushing rollers 2 Screws 3 Remove the brush rollers 3 Unscrew the screws and remove gear casing from the brush head A 1 Motor screws Unscrew the screws gt Remove the motor from the gear casing Installation aid 1 Plug elements 2 Cable connector 3 Install a cable tie as a guide aid on every plug ele ment The plug elements can be guided through the opening on the brush hea
53. he current 6 23 14Resistance measurement micro switch lifting motor brush head 1 Measuring device 2 Plug for lifting motor cable Lifting motor retracted 3 Connect the measuring probe on the plug in con tact 8 X9 3 Connect the measuring probe on the plug in con tact 9 X9 Measured value 0 5 Ohm Lifting motor extended 3 Connect the measuring probe on the plug in con tact 8 X9 3 Connect the measuring probe on the plug in con tact 4 X9 Measured value 0 5 Ohm 6 23 15Voltage measurement water pump on ter minal X6 1 Measuring device 2 Measuring probe on the plug in contact 7 X6 3 Measuring probe on the plug in contact 15 X6 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 3 Connect the voltage measuring device as shown in the illustration 3 Actuate drive lever Display on the voltage measuring unit approx bat tery voltage 6 23 16Current measurement of water pump RR A temo XE b E v CARS 1004 2308 IEN UR 1 Connecting cable water pump 2 Measuring device 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 3 Connect the measuring device to the connecting cable of the water pump as shown in the illustra tion gt Actuate drive lever 3 Measure the current 6 23 17Voltage measurement detergent dosing pump on terminal X6 5 13 E wg P a ISES TELI
54. he programme selector switch to the respec tive programme 3 Connect the measuring device to the battery cable as shown in the illustration gt Actuate drive lever 3 Measure the current 6 23 8Voltage measurement transport drive un der full load 1 Voltage measuring device 2 Connection MF1 sw 3 Connection MF2 rt 3 Plug in the Intelligent Key 2 Set the programme selector switch to transport mode and wait until the self test on the operating panel display is completed 3 Connect the voltage measuring unit to connec tions MF1 sw and MF2 rt as shown in the illus tration gt Set the rotary knob for drive speed to MAX 3 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 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 2 Connect the voltage measuring device as shown in the illustration gt Actuate drive lever Display on the voltage measuring unit approx bat tery 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 gt Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 2 Con
55. he sus pension Position the brush head under the suspen sion Switch to Manual actuation with the grey or red key Select the brush head Lower the suspension by pressing the but ton 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 Slide in holding bolt The holding bolt must be able to move easily without pressure Move the brush head back and forth slightly to remove any tension Close the quick tensioning lever 46 English 5 950 645 0 Rev 00 12 12 6 15 2Replacing the drive belt of the brush drive Cover drive belt o 2 Screws Unscrew the screws and remove the lid Motor screws Gear casing screws Pulley Drive belt Drive pinion 6 Gear housing Loosen the screws on the motor gt Remove the drive belt 2 Insert a new drive belt 1 2 3 4 9 1 Pulley 2 Screwdriver 3 Drive belt 4 Drive pinion gt Lift the motor up with a screwdriver and tension the drive belt 3 Tighten the screws on the motor 6 15 3Replace the pulley s BA G S e e lie Ben ut F 1 Safety ring 2 Pulley 3 Remove the drive belt gt Remove the safety ring E A B A Um 1 Puller tool 2 Pulley gt Remove the pulley and replace it 1 Press in tool 2 Gear housing 3 Brush pick up 3 Press the pulley onto t
56. hed on con current BK 0A Soll OA A Ge motor current contact pres Hub PWM 0 STP1 UE brush Lifting motor pulse width modula tion 24V 100 The speed is propor tional to the voltage English 5 950 645 0 Rev 00 12 12 101 Ween Description Wemge 8 00 36 0V 00 0A Charge status nominal charge volt status nominal charge volt The debug mode must be switched debug mode must be switched age nominal charge current off during the charging mode so that 000 24 0V 00 0A pers hoi timer actual charge voltage Im nece actual ae current Dali Err 000 Number of faults during the charge Check the cable to the charger ERR CSXXX TOXXX process Number of checksum faults Information for developers Number of timeout faults of timeout faults 5 opp 102 English 5 950 645 0 Rev 00 12 12 10 Technical specifications BR appliance BD appliance B 80 B 80 R55 R65 R75 D55 D65 D75 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 m h 3300 3900 4500 3300 3900 4500 Max working range incline Yo 2 Fresh dirt water rese
57. ick up English 5 950 645 0 Rev 00 12 12 51 1 Lid plug for mains connection 2 Connection cable of brush head gt Remove the lid of the power connection 1 Brush head plug gt Remove the plug for the power connection 1 Hose coupling 3 Disconnect the hose coupling gt Pull the brush head out toward the front 52 English 5 950 645 0 Rev 00 12 12 Sequence of brush head installation 10 Push the brush head in all the way to the push bar Insert the fastening clamps into the brush head pick ups on the push bar Open the quick tensioning lever on the sus pension Position the brush head under the suspen sion owitch to Manual actuation with the grey or red key Select the brush head Lower the suspension by pressing the but ton 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 olide in holding bolt The holding bolt must be able to move easily without pressure Move the brush head back and forth slightly to remove any tension Close the quick tensioning lever 6 16 2Replacing the disc brush pick up CONOR cnm 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 1 Disc b
58. ile the turbine is turned on 3 Measurement load test Measure the battery voltage while the turbine is turned on shortly before the discharge end voltage is trig gered Record further machine data Appliance type Battery type Order number of appli Manufacturer ance Serial number Part number Purchase date Operating hours of appli Hours ance 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 Discharge end voltage When does the discharge end voltage get triggered Runtime indication How long was the cus tomer able to work with the appliance when the batteries were still fully Ampere Volt Hours minutes functional Date or code Battery date Is indicated near the bat tery terminal on the bat tery How long how often is the appliance used per day per week Hours day Hours week 38 English 5 950 645 0 Rev 00 12 12 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 re placing the entire battery set Taking out of operation If batteries are not to be used for a while the foll
59. 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 3 Tilt the wastewater reservoir on its side gt Connect the voltage regulator in the power circuit gt Plug in the Intelligent Key 3 Turn the programme selection switch to Pro gramme 4 intense mode wet floor cleaning Do not press the drive lever gt Reduce the voltage slowly to the discharge volt age 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 3 Connect the voltmeter directly to the battery and operate the appliance until the display shows Bat tery depleted gt 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 3 Connect the charger to the batteries gt Connect the voltage meter and clip on ammeter to the batteries 3 Plug in mains connector and switch on char
60. is outside the tolerance val ues 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 3 Use a voltmeter multimeter to measure and re cord the battery voltage of every individual battery block Measure the current using a clip on ammeter dur ing the voltage measurement and record it 2 Operate the appliance until the discharge end volt age the total discharge protection shuts the appli ance 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 individ ual battery blocks for maintenance free and low maintenance 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 a 2 Measurement load test Measure the battery voltage several times wh
61. k noses with the vice 7 1 Replacing the suction lips 7 Maintenance and care 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 3 Pull out the suction hose from the vacuum bar 2 Loosen the wingscrews of the vacuum bar sus pension and pull the vacuum bar out of the intake E i HE gt E bg vg E e z 2 D mu ss 0 ei WT e Ge 4 a a Le Su s 3 M Ch i 1 Star handle screw 2 Deflector disc gt Loosen the star handle screws on both sides of the vacuum bar Os a S Suction lip holder Rear vacuum lip Front vacuum lip Star handle screw Sleeve 6 Deflector disc gt Remove the deflector discs 0O PS Go b i 1 Suction lip holder 3 Pull the suction lip holder off on both sides a Fn ya M T a be ET kd 7 S y r a a d 5 is PS XM LUI e z le CH P ty SMS q 1 Rear vacuum lip 2 Front vacuum lip 3 Pull the suction lips out on the side replace if re quired English 5 950 645 0 Rev 00 12 12 79 gt When assembling the vacuum bar ensure the cor rect seating of the sleeve 7 2 Clean the vacuum bar MO LA 1 Front vacuum lip 2 Suction support 3 Rear vacuum lip 2 Clean the suction lips 2 Clean the contamination of
62. loaded in the menu all basic settings programmes are reset and must be set up again Selection depends on the brush head Is only dis played with the R head English 5 950 645 0 Rev 00 12 12 93 9 4 2 Key menu Sali a E x a EA A d Fi d le Key menu aw A d j A a Sa E Access Pe Yes No Jl Language Traction speed Yes No Brush speed Yes No Vacuum speed Yes No RM Dosage Yes No N Water da Yes No Contact pressure Yes No Write to key Yes No Write to key Exit e cl ll Additional yellow keys can be described using the selector switch After that the standard values are re set up parameters stored Note Note This menu allows the user of the yellow user key ad After selecting the key menu the key to be pro ditional settings with the button grammed must be inserted in the key holder within 10 The user can only use the enabled parameters seconds Parameter are active immediately and until a new 9 4 3 Battery menu cleaning programme is selected via the programme 94 English 5 950 645 0 Rev 00 12 12 NE Ladekurve 0 NE VIL Exide GF 12v 1054 PI2 gt Battery gt gt NE Ladekurve 1 es EN emi EA z atter SILA Hoppecke etB170 DO de SE Ladekurve 2 7 N B esteril WE 1 g J atter JL Exide GF06180V Y KS ES tL a AE Ladekurve 3 Be m Battery IV D ZI Exide GF06240V as ee O S
63. model Complete appliances as requested by the market are preproduced under this part number 1PX3 CC LKARCHER B80 W Bp 2 259 002 0 0 300 032 0 SIN Year PD m 380kg DC 24V DC 24V 1330W Allred Karcher A a G Ae e 1354 Winnenden Made in Germany 1 2 1 Serial number 2 Part number The serial number refers to the part number 0 300 032 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 CONOR Go bi 9 18 17 16 15 14 13 12 GR 10 Basket Cover dirt water reservoir Detergent hose Detergent reservoir option Fresh water reservoir filler neck Fresh water tank Unlocking device left disc brush Brush head BD model only 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 25 24 23 22 21 20 19 18 17 16 15 14 13 1211 10 Recessed grip Auto Fill In Fresh water level display Parking brake foot brake pedal Star handle screw for adjusting the height of the vac
64. move 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 Op eration Button Appliance travels slowly 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 perfor Check whether the suction performance is set to Whisper mance 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
65. n faster acceleration vRampDecss Brake ramp if sonar module is installed higher numbers mean stronger braking prowa 70 Wer pot maxima vals ooo 70 NLZ Turbine 10s 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 possi ble Suction Low Suction turbine speed suction low Suction High 100 Suction turbine speed suction high Sueton urine speed geng IRegBK KP 90 Amplification factor of the current control of the brush drive High value strong change low value soft change 3 Move the rotary knob for driving speed water vol Changing the potentiometer stop positions ume into the right end position Setting the minimum values 2 Press the button 3 Move the rotary knob for driving speed water vol 3 Press the button to confirm ume into the left end position 3 The value is adopted gt Press the button 2 Press the button to confirm 3 The value is adopted Setting maximum values 100 English 5 950 645 0 Rev 00 12 12 9 6 Debug Mode Menuenty Description imtormaton S000G000 S G in in depending on the drive switch ac on the drive switch ac Nominal and regulated value of the regulated value of the tuation speed control Set the rotary knob for drive speed vs 0 0 vi 0 0 vs Setpoi
66. nction overview of red intelligent key Welcome Transport Mode Speed O 100 ECO Mode l S Zeitverz gerung Scrub Vacuum Scrub Vacuum Water Scrub 0 100 Vacuum Polishing Operating Hours Key menu see Key menu l a BasicSettings see BasicSettings Debug see Debug dn 8 2 Albes Test Mode M S dr System Parameter see System Parameter Battery M _ gt e ab attery Menu Kafe see Battery Menu English 5 950 645 0 Rev 00 12 12 91 ai e Brush speed Fine Whisper Power 1 2 Contact pressure 0 100 1 2 Vacuum OFF Medium Power RM Dosage 0 3 5 Brush head D R S 2 Spray extraction ON OFF Settings Reset RESET fy i Service Reset Language FK L Le amp 00 Version BT X XX LEX XX Selection not permanent The setting will be lost if the program selection switch is adjusted 2 Selection depends on the position of the pro gramme selection switch 92 English 5 950 645 0 Rev 00 12 12 9 4 Special submenus 9 4 1 Basic settings 1 Brush speed Fine Whisper Power Vacuum OFF Medium Power RM Dosage 0 3 5 Speed O 100 Water 0 100 Contact pressure 0 100 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
67. nect the voltage measuring device as shown in the illustration gt Actuate drive lever Display on the voltage measuring unit approx bat tery voltage 6 23 11Voltage measurement relay 1 Measuring device 2 Measuring probe on the cable plug of the magnet ic coil top 3 Measuring probe on the cable plug of the magnet ic coil bottom gt Plug in the Intelligent Key English 5 950 645 0 Rev 00 12 12 71 3 Turn the programme selector switch to transport mode 3 Connect the voltage measuring device as shown in the illustration Display on the voltage measuring unit approx bat tery 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 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 3 Connect the voltage measuring device as shown in the illustration gt Actuate drive lever Display on the voltage measuring unit approx bat tery voltage 72 English 5 950 645 0 Rev 00 12 12 6 23 13Current measurement of lifting motor vac uum bar 1 Measuring device 2 Lifting motor cable gt Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 3 Connect the measuring device to the lifting motor cable as shown in the illustration gt Actuate drive lever 3 Measure t
68. ntspeed speed Setpoint speed y max speed a Actual speed H1 0 0V 0 0A Ne forward drive Drive motor voltage and drive motor T018 018 018 018 Temperatures to the MOSFET Normal all values are approxi mately the same T 0 0A M 0 0A P000 T Suction turbine motor current turbine motor current Active current i eei erem permissible max current pt Speed in 96 B 0 0A M 0 0A P000 MN Brush motor current permissible max current permissie max ren Pan Motor current of drive motor 1200 equals 12 A 4500 equals 45 A The drive motor current must be be tween 12 and 45 A no longer than 2 minutes in an 8 minute period Then the current is reduced to 12 A IM OA 1200 4500 Overcurrent timer 2 minutes overcur rent timer 8 minutes QS 0 0V Qi 0 0V Motor nominal source voltage 24 V at max drive speed setting on the potentiometer O Motor actual source Motor actual source voltage Actual voltage to drive motor U_5V 5 00V os ats Internal 5 V supply voltage Ubatt 24 1V Ubatt Battery voltage AhCnt 360000As gn are Current consumption counter Current consumption counter As Calculate battery capacity AhMin 36000As Non removable capacity with drained APON AhMin 3600 momentary battery pack As residual capacity Ibatt 000A Active total current total current The low voltage limit changes de LowBatt 22 0V Low voltage limit with active loading os iio das Pen on the switc
69. owing must be observed when storing them Disconnect the negative battery connection on the battery and store the cable so that it cannot inad vertently come into contact with the negative ter minal of the battery Only store batteries while charged The storage location should be cool the self dis charge 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 protec tion 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 dis charge 6 14 7Check the final discharge voltage Final discharge voltage with variable value The final discharge voltage is variable and is regulat ed automatically so that the max admissible battery capacity can be taken out without damaging the bat teries 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
70. p 9 Cable screw connection nut 10 Cable screw connection 11 Hose connection detergent hose from the deter gent container 12 Hose connection detergent hose to the fresh wa ter hose 13 Supply control cable 6 8 2 Replacing the pump hose 1 Detergent hose 2 Cable connector 3 Pump hose 4 Pump wheel gt Remove the detergent pump 3 Remove the lid gt Remove the pump hose from the pump wheel 3 Remove the cable ties gt Remove the pump hose 3 Install the new pump hose 3 Check the function of the pump 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 Protective cover 2 Hose connection 3 Hose ring 4 Nozzle with holder 1 Hose ring 2 Screw 3 Nozzle with holder gt Remove the protective cap 3 Loosen screws 3 Remove the screws from the hose clamp 3 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 Fr l x c Bo gj 1 Float mE 1 Fluff filter 2 Pickup mandrel gt Compress the pickup mandrel 3 Disc gt Remove the float 4 Fluff filter 3 Rotate the lint sieve counter clockwise and re gt Compress the pickup mandrel move it 3 Remove the float 3 Clean or replace the lint sieve if necessary Note 6 11 Replace suction hose Make sure that the disc is installed It prevents the floater from slipping a
71. rameters can be adapted to the in tegrated battery Battery he 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 accord ing to customer specifications The part number is issued automatically during the configuration process F eG CC KARCHER i 3 EE a B80 W 2 259 002 0 1 259 010 2 SIN Year C m 380kg DC 24V DC 24V 1330W WANA Allred Karcher oe e ei Gg SH TIT 713564 Winnenden Made in Germany 1 2 1 Serial number 2 Part number The serial number refers to the part number 1 259 010 2 Type plate confectioned The appliance consists solely of a rump unit The ap pliance can be assembled with the different assem blies on site earr o aa LG mmc mmer wk E f PX3 C Y amp KARCHER A ee B80 W Bp DOSE 2 259 002 0 SiN TC Tear m 380kg DC 24V 1330W Allred Karcher SE e w e 11364 Winnenden Made in Germany 1 2 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
72. ries 6 volt block battery Charge ap prox gt 6 46 Volt 100 96 15 gt 5 85 Volt 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 inspec tion 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 prohib ited Check the battery fluid level and refill distilled water if necessary If water is refilled a charge must be con ducted before measuring the idle voltage The following checks must then be made Deep discharge 36 English 5 950 645 0 Rev 00 12 12 Measuring idle voltage quick test 6 volt block 6 36 6 45 6 18 5 91 5 91 battery Charge con 100 50 20 dition about 76 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 1 29 1 21 1 13 lt 1 13 kg l Charge con 100 50 20 dition about 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 e Batte
73. rive 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 ERH STL 026 Internal fault of control electronics fthe battery has charged over 23 V until and the ambient temperature is be ERR GIL 043 low 40 C there is a fault in the con trol electronics Replace control electronics ERH U BATT 044 Check battery voltage Check battery voltage gt 22V Take appliance to an ambient tem ERR TEMP 045 Overtemperature in the performance until jumpers perature of 10 to 30 C too cool it EH TEMP 048 off ERR I B RSTE 049 Overcurrent of the brush motors 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 ERH TURB 050 Overcurrent of the suction turbine Remove possible blockage of the suction turbine Check the suction turbine for ease of movement Check the cables for damage 84 English 5 950 645 0 Rev 00 12 12 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 dri
74. rush intake 2 Screw Loosen the screw Remove the disc brush intake 6 16 3Replace the bow to release the disc brush 1 Bow to release the disc brush left 2 Bow guide 3 Spring 4 Bow holder 3 Unscrew the screws on the holders 3 Unhook the springs 3 Remove the bow through the guides 6 16 4Removing the motor with gear 1 Bow to release the disc brush 2 Screws 3 Floor plate 3 Unscrew the screws gt Remove the floor plate 2 Remove the disc brush pick up ici 73m Ne We OC ei 1 Gear axle 2 Screws Unscrew the screws gt Remove the gear with motor English 5 950 645 0 Rev 00 12 12 53 b e AC gt a e e 7 acm AM 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 gt Remove the brush motor Loosen screws 3 Remove the cover of the glide contacts p 1 Nut glide contact 2 Glide contact 3 Press spring 3 Lift the contact spring and pull the glide contact out of the chute gt Carefully place the contact spring onto the chute 1 2 2 1 Glide contact 2 Nut glide contact 3 Unscrew the nut and replace the glide contact 3 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 t
75. rvoir volume 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 Total oscillation value m s 0 1 Uncertainty K m s 0 1 Sound pressure level L dB A 69 Uncertainty K dB A 2 Sound power level Lw Uncertainty Kwa dB A 83 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 de pleted 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 l min gt 7 0 Detergent pump max feed volume l min 20 20 English 5 950 645 0 Rev 00 12 12 103 Batteries Karcher Nominal Nominal Battery Runtime h at power pickup
76. ry 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 ex ceed 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 2 Switch the appliance on and take the suction tur bine and the cleaning head into operation on an in sensitive floor Important The consumers must run continuously during this test The load test can also be performed while the suc tion turbine is turned on 3 Use a voltmeter multimeter to measure and re cord the battery voltage of every individual battery block Measure the current using a clip on ammeter dur ing the voltage measurement and record it 3 The battery block with the lowest battery voltage must be replaced if it
77. s 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 A Danger Risk of injury Before working on the appliance re move the Intelligent Key and the mains plug of the charger Drain and dispose of the dirt water and the residual fresh water A 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 1 Replace the fuse 1 Batteries 2 Nut with flange 3 Fuse F1 125 A 4 Positive cable 3 Hold the wastewater reservoir by the handle re cess 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 gt Unscrew the nut gt Remove the positive cable gt Replace the fuse 6 2 Operator console 6 2 1 Replace the programme selector switch KARCHER 1 Operator console 2 Screws operator console 3 Pull off the rotary knob of the programme selector switch 3 Unscrew the screws 3 Unscrew the screws on the left and right side of the control panel 3 Tilt the operating panel forward 1 Screws casing halves of the control panel 3 Loosen the screws and separate the casing halves English 5 950 645 0 Rev 00 12 12 23 2 A e LES ud
78. senken heben gt The DOSE function is only available when the water valve is opened 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 i i E Opertinghows 7 X X X mw 70K E X ek O ES Seene ee Dew TT Wat O X X 0 1 a a s System parameters X X e X X X Bawerymens nn Weer mud O 9 9 1 Contact pressure A Ste a e me e Swwemdm 7 0 g open KK p X X smere p ko memo am nn mm Versi n nn rn nn ge e qe mm Torey a Operating hours nn Seed kymm X X e IX Basie sings nn e Donn Manara 0 0 a System parameters nn Penne A Weer Bras ad Ke 3 Ke d 7 d TT T XI X ox X x X x Ke XI X X x lt X X x Ke Ke 98 English 5 950 645 0 Rev 00 12 12 Contact pressure 60 C ane ze O 11 FS Service reset wienn ae Pa S regen eum Polishing O ow es a am e Operating hours nn Seed Key mena X X X X wg X X Wawscmi 700 S System parameters KR pennen KR Water a S S Bras ed CS PO Comas pressure me Seier rm mg 1 1 Spray ero A A Seis smera nn mems mn nm nm nien X 0 X X English 5 950 645 0 Rev 00 12 12 99 9 5 2 System parameters Acceleration ramp larger numbers means faster acceleration Brake ramp higher numbers means stronger braking 2 vRamplncss Acceleration ramp if sonar module is installed larger numbers mea
79. the suction turbine Check whether the wastewater reservoir is closed properly Suction turbine does not run Wastewater reservoir full empty Float switch of wastewater tank is blocked or defective replace English 5 950 645 0 Rev 00 12 12 81 Suction turbine does not Float switch of wastewater tank is blocked or defective replace switch off after trailing time Insufficient cleaning result Check clean replace the brushes for wear and tear and contamina tion 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 Cleaning head cannot be Lifting mechanics blocked check remove blockage raised lowered Check replace programme selector switch Check replace the micro switch of the lifting motor Check the lifting motor via test mode Detergent is not getting mixed Check the content of the cleaning agent container in Check replace the detergent pump Check the detergent hose ncrease the water volume Check flowm
80. tment 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 3 Rotate the info button to select the parameter 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 pro gramme selector switch so that the new parameters can be applied After that the following parameters must be set up the language B Basic settings B Check battery selection and charging curve m Check the selection of the brush head Press the info button to confirm the selection 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 over view 9 3 1 Function overview of the yellow intelligent key Welcome Transport Mode 2 3 Speed O 100 ECO Mode Time delay Scrub Vacuum Scrub Vacuum Wer Scrub 0 100 Vacuum Polishing A 1 3 eeng d d aoe RM Dosage Nonen F PE 0
81. tor suction bar 2 Measuring device 3 Lifting motor cable gt Connect the measuring device to the lifting motor cable as shown in the illustration gt Actuate drive lever Measure the current 4 1 E a AAA PA Nau Wa hin ag E t ection 1 Cable screw conn 2 Charger 3 Mains cable of charger 4 Support plate gt Remove rear appliance cover 2 Open the support plate by folding it toward the bot tom 3 Unplug the mains cable from the charger 3 Loosen the cable screw connection and remove it from the support plate 68 English 5 950 645 0 Rev 00 12 12 6 23 2Voltage measurement of lifting motor vacu 6 23 3Resistance measurement micro switch lift um bar ing motor vacuum pal d 1 Meaning device 2 Plug for lifting motor cable Lifting motor retracted 3 Connect the measuring probe on the plug in con tact 3 X9 3 Connect the measuring probe on the plug in con tact 7 X9 Measured value 0 5 Ohm Lifting motor extended 3 Connect the measuring probe on the plug in con tact 3 X9 3 Connect the measuring probe on the plug in con tact 2 X9 Measured value 0 5 Ohm 6 23 4Check the charge current Voltage measuring device 2 Plug contact lifting motor cable 3 Plug in the Intelligent Key 3 Turn the programme selector switch to the respec tive programme 3 Connectthe voltage measuring device to the lifting motor cable plug in contact as shown in the illus tration gt
82. tween the charger and the control Check replace the charger Charging fault Charging characteristic could not Check replace the charger be adhered to Charging complete Charging process completed suc cessfully FR Loesen Drive regulator actuated during Release drive regulator Startup Test replace the drive regulator ERR BTSTL 001 Internal fault of control panel Transfer the current control panel ERR BTSTL 002 board board software to the control pan el board via the service module ERR BTSTL 003 fthe fault persists replace the ERR BTSTL 004 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 ERR BTSTL 019 Can bus fault Check replace the patch cable Replace operating panel PCB Replace the performance part ERR BTSTLO018 Bus cable defective Check replace the bus cable Voltage supply to the control pan Replace operating panel PCB el board incorrect Replace control electronics 86 English 5 950 645 0 Rev 00 12 12 9 Software diagrams and parameter overview 9 1 Operating elements The selection of the individual modes is effected by turning the programme selection switch 3 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 adjus
83. u pling 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 clean ing process via the nozzle system 3 Remove the protective cap gt Connect the water hose via the quick coupling gt Place the wastewater drain hose over a suitable drain and open the locking cap 2 Open the water tap and rinse the tank 5 8 Suction turbine 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 e q ON www _ 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 O 396 in 0 5 increments as per the set up dosing The actuation is running if the brush i
84. ueyod ap o2iuomeje Ewaysis TV uoneiueuire p anbiuo aja AWAS S TY i gt 9X I ty soiuo ppape amod Ty o yluo gyajasSunysie Ty EXD TS OW gt cs Jenpisa enby Jopeynuuooo Diui 7S ajes nee IN3J NLISJUIO DIW Ze IREM e35e M UX IMS O DIUJ ZS Jassewznuu s teyeupsobr Ze 108 English 5 950 645 0 Rev 00 12 12 ELO HD eiedwe TH aieudo4A5 TH due 5uneyo TH eypnejunpuns TH GBA A e e e e e mm em em rm e rm as b ET oa ODIAIeS ep o npoul py Josuas ofoueyul extus ep anpoul py Inaxde gt e5noiegui a npow adas py JOSUAS pae jui hpoueotAJeS bY JOSU3S JO I2 YUT JosuasAjajes S2100 02349 Ey 4oSsuas jojes xiu01 9 3 v 10suasAj3Jes ooiuopo e Pulajsis v JosuasAjajes anbuoupaya v English 5 950 645 0 Rev 00 12 12 109 00000000000000020a8 00060000000n0209go0d 0000000000000 110 English 5 950 645 0 Rev 00 12 12 A1 A3 A4 F1 G1 G2 H1 K1 M1 M2 M3 M4 M5 M6 M6 951 92 M7 M7 51 92 M4 S1 S2 U1 X1 Y1 Performance electronics Electronics safety sensor Service module Fuse 125A Battery 12V Battery 12V Beacon lamp option Main contactor Drive motor Brush motor Suction turbine Detergent dosing pump Water pump Lift motor suction bar Micro switch of lifting motor vacuum bar Lifting motor brush head Mikroschalter Hubmotor B rstenkopf Dosing pump Program selection switch Drive regulator Battery charger Mains plug Wat
85. unk bores point toward the screw head The following faults can occur in case of incor rect installation The appliance is moving backwards instead of for ward The display shows Release gas pedal even though it has not been pressed 6 2 5 Replacing the control panel board 1 Info button 2 Water quantity regulator 3 Program selection switch 4 Rotating button for drive speed 3 Open the operating panel 3 Pull off the info button regulator button for the wa ter volume programme selector switch and the ro tary knob for the drive speed 1 Operating panel board 2 Holder operating panel PCB 2 Press the holder of the operating panel PCB slightly toward the outside and remove the operat ing panel PCB 12 111098 T Rotating button for drive speed Antenna for key signals Display Info button Water quantity regulator Holder operating panel PCB Program selection switch 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 3 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 CONOR corn yoaquosT 1 Plug KO connection to control electronics 2 Jumper 3 Open the operating panel 3 Remove the plug 3 Bridge plug contacts If there is no fault on the control panel board the
86. uum 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 0O PS Go b i CO 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 Connection cable suction turbine Dirt water reservoir Suction channel cover Batteries Dirt water drain hose Suction hose Coil Chain Swivel the tank upward 3 Hold the wastewater reservoir by the handle re cess and swivel the reservoir upwards toward the side NOOR WD 10 English 5 950 645 0 Rev 00 12 12 4 3 1 Top of appliance 1 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 Hose ring 8 Protective cover 1 Wastewater stub 2 Coarse dirt sieve 3 Dirt water reservoir 4 Float of wastewater tank 5 Fluff filter Suction turbine air channel English 5 950 645 0 Rev 00 12 12 11 4 4 Bottom vi
87. ve Check the cables to the drive Check the motor for damages Replace the motor ERR_BT53 Fault in CAN bus to control part Check the patch cable yellow be tween the control electronics and the operating panel PCB and replace if necessary Replace the operating panel PCB Replace control electronics DaliErr 000 Number of checksum faults time out Check battery voltage Err CS000 TOOO0 faults Replace control electronics CS Fault appears if 50 consecutive faults have occurred TO Fault appears if 50 consecutive faults have occurred DaliErr 000 No communication with the control elec Check the connecting cable Err CS051 TOO51 tronics Check replace the charger Bat voll Charging process terminated Incorrect polarity on the relay coil K1 Check the positive and negative ca bles English 5 950 645 0 Rev 00 12 12 85 8 3 Warning messages Warning temp Warning temperature gt 80 C Check the suction turbine and the reached The actuation of the brush motor for overload suction turbine or the brush motor is only occurring with 2 3 of the nominal PWM Red motor Actuation of drive motor reduced Check let the drive motor cool off Hindernis Ignor Safety sensor active Check replace the safety sensor if an obstacle is not the cause Bus Error Lader Charging process interrupted by Check replace the three prong communication fault to charger cable be
88. ve gt 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 3 Remove the safety ring 3 Pull out the bolt 3 Disconnect the connecting cable gt Remove the lifting motor 1 hu A ee e Raw Je T Fi mem VK D G TUN TT ma VE inma e J 1 tht AN Y Rei 10 Upper mount Motor Spindle casing Spindles Safety ring Disc Bolts 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 con trolled via the two brush motors CONOR WD 6 19 2Replacing the lifting motor of the vacuum 6 20 Drive and wheels barpick 6 20 1Replace the drive motor with gear axle pg c3 The drive motor and the gear axle can only be re 7 placed as one unit if they are defective ERIN M e Ve 1 Lifting motor connecting cable 2 Rear cover 3 Motor 3 Open the rear cover 2 Remove the connecting cable from the support plate of the control electronics Holder gear axle Push rod brush head Screws Gear axle with drive motor 5 Connection cable drive motor gt Remove the brush head gt Remove the batteries 3 Tilt the appliance to the side
89. xcenter disc with rubber collar 1 Carrier lid 2 Screw with disc 3 Excenter disc with rubber collar 4 Excenter with pulley 1 Excenter disc with rubber collar 2 Carrier lid 3 Screws gt Remove the casing lid gt Remove the drive belt gt Remove the pad pick up Unscrew the screws gt Remove the carrier lid 1 Rubber collar English 5 950 645 0 Rev 00 12 12 59 Excenter setup 1 Excenter axis 2 Seal disc 3 Ball bearing 4 Spacer ring 5 Pulley 6 Fitting key 7 Excenter sleeve 8 Safety ring 6 17 9Replace water distribution pipes Retaining clip Water distributor pipe left T piece Water distributor pipe right 5 Cable connector gt Remove the pad pick up gt Remove the cable ties 3 Pull water distribution pipes off of the holding clamps ZS Go bi A 7 D 1 Water distributor 2 T piece 3 Water distributor pipe right 60 English 5 950 645 0 Rev 00 12 12 6 17 10Replacing the deflector roller 1 Scraper roller 2 Axis pins 3 Safety ring 3 Remove the pad pick up gt Remove the axle bolt Remove the scraper roller 6 18 Brush head suspension 6 18 1O0verview of lifter Support right Pick up lifting motor Lifter Support left Brush head pick up Quick tensioning lever Brush head adjustment NO of WD 1 Lifter 2 Spring 3 Damping lever 6 18 2Removing the lifter 1 Support 2 Lifter 3 Screws
90. y 3 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 Holes 2 Lock screw M8 3 In this case drill the bores to 8 5 mm 3 Insert the lock screw into the hole from above 3 Install the steering roller drive motor and fasten them from the bottom with self locking hex nuts 2 ie 1 Screws 2 Steering roller 3 Unscrew the screws 3 Remove the steering roller and replace it 64 English 5 950 645 0 Rev 00 12 12 6 21 Suction system 6 21 1Replace the vacuum bar suspension EDS Sa 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 6 Screw on the rotary handle with washer 3 Unscrew the screw from the holder gt Remove the vacuum bar suspension with holder 3 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 3 0O BON 10 9 oy Rotary handle bottom Rotary handle top Vacuum bar pick up Vacuum bar suspension Bow Spring Holder vacuum bar suspension holder Screw vacuum bar suspension holder 9 Screw on the rotary handle with washer 10 Screw on the rotary handle
91. y place the contact spring onto the chute gt Pull out the connecting plug 3 Perform this procedure on both glide contacts 6 22 Control electronics charger 6 22 10pen 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 work ing 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 packag ing 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 3 Disconnect the battery for 1 minute and then re connect the battery reset 3 Check battery voltage under load 3 Check the voltage input to the control electronics under load 3 Transfer the current software to the control elec tronics and the control panel board Note After replacing the control you must set up the cor rect 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 screw 2 Support plate control electronics

B 80 W Service Manual - RefurbFloorCare

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