BR/BD 65/80 W (B80W)

Service Manual

English 5.906-468.0 Rev. 00 (02/09) 1

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 Contents

1 Preface 4

2 Safety instructions 4

2.1 Safety Devices 4

3 Technical Features 4

3.1 Drive 4
3.2 Brush system 4
3.3 Water System 4
3.4 Suction system 4
3.5 Electrical system 4

4 Setup and function 5

4.1 Front view 5

4.2 Rear view 6
4.3 Control terminal 8
4.3.1 Operating elements and displays 8
4.3.2 Operating panel from below 8
4.3.3 Drive control 8
4.4 Display controls 9
4.4.1 Open the operator menu 9
4.4.2 Open the setup menu 10
4.4.3 Open the debug mode 11
4.5 Circuit board (A1) 12
4.6 Water filling system (option) 13
4.7 Water filter 13
4.8 Drain tap for fresh water 13
4.9 parking brake 13
4.10 Vacuum bar 14
4.11 Cover opened. 14
4.12 Battery 15
4.13 Water stop valve 15
4.14 Detergent dosing pump (DOSE) 16
4.15 Raise/lower brush head 17
4.16 Water pump 18
4.17 Discharge flag against static electricity 18
3.1 Drive 4
4.19 Suction turbine 18
4.20 Brush head (BD model) 19
4.21 Brush head, BR model 19

5 Basic settings and service procedures 20

5.1 Replace filling system 20

5.2 Setting the vacuum Bar 20
5.3 Clean/replace the vacuum lips 21
5.4 Check/replace the support roller on the vacuum bar. 21
5.5 Removing the suction turbine 21

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 5.6 Remove the drive unit 22
5.7 Remove the BD brush head 22
5.8 Replace the disc brushes on the BD brush head 23
5.9 Remove the BR brush head 23
5.10 Replace the brush rollers on the BR brush head 24
5.11 Replace the drive belt 24
5.12 Remove the brush drive on the BR brush head 25
5.13 Clean water filter. 25
5.14 Adjust drive control 25

6 Circuit diagram 26

6.1 Circuit diagram 0.089-050.0 BAT models 26

6.2 Circuit diagram 0.089-051.0 BAT PACK models 27
6.3 Legend of the electrical components 28

7 Troubleshooting 29

7.1 Troubleshooting without display 29

7.2 Troubleshooting with display 29

8 Specifications 30

9 Special tools 30

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 1 Preface
Good service work requires extensive and practice-oriented train-
ing 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 en-
hancements and their servicing.
If you should require supplements, have corrections or questions
regarding this document, please address these citing the following
subject to:
international-service@de.kaercher.com
Subject: Fall 106533
The responsible product specialist will take care of your issue.
Copying and duplication of texts and diagrams as well as
third-party access to this information is permitted only with
the explicit permission of the company:
Alfred Kärcher GmbH & Co. KG
P O Box 160
D - 71349 Winnenden
www.kaercher.com
2 Safety instructions
2.1 Safety Devices
Safety devices serve to protect the user and must not be rendered
inoperational or their functions bypassed.
2.1.1 Emergency-stop button
To put all functions out of operation immediately.
2.2 Hazard levels
Note
Indicates useful tips and important information about the product.
3 Technical Features
The appliance is used for the wet cleaning of level floors. It can be
easily adjusted to suit the required cleaning task by adjusting the
water quantity, the contact pressure of the brushes and the waste
water suction.
A working width of 650 mm and a capacity of 80 l each of the fresh
and dirt water reservoirs enable an effective cleaning even when
the machine is used for long duration.
The device is self-moving; the drive motor is powered by four bat-
teries.
The batteries can be charged using a charger connected to a 230
V socket.
A charger is already integrated in the "Pack" model.
3.1 Drive
– Voltage supplied by 4 maintenance-free, 6 volt batteries (180
Ah).
– Two front wheels driven by DC motor with differential drive.
– 2 rear swivel casters.
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3.2 Brush system
– Brush head with 2 brush rollers (BR model) or 2 disc brushes
(BD model).
– Brush speed adjustable in three steps (FACT).
– Brush head is lowered by means of pedal, brush drive is
switched on simultaneously. By pressing the pedal down, the
brush head is lifted and the brush drive is switched off. If the
travel drive is shut off when the appliance is operated (brush
head lowered and brushes are rotating), the brushes will run
another 2 to 5 seconds until they are switched off automatically
(trailing time adjustable).
– The brush contact pressure can be adjusted at the lever.
– Brush replacement is possible without tools.
3.3 Water System
– Install fresh water reservoir and waste water reservoir in appli-
ance (tank-in-tank system).
– The electrical swimmer in the wastewater reservoir shuts off
the suction turbine once the maxium fill level is reached (time
delay approx. 5 seconds).
– Mechanical swimmer closes the suction opening in the lid, if the
wastewater foams excessively.
– Water pump to feed fresh water to the brush head.
– The fresh water amount can be regulated with a dosing valve
according to the contamination level.
– When the appliance stands still, a water stop valve interrupts
the supply flow of fresh water to the brush head.
– Detergent dosing via detergent dosing pump (DOSE).
3.4 Suction system
– The vacuum bar is lowered with a lever, the suction turbine is
switched on simultaneously. If the vacuum bar is raised, the
suction turbine will switch back off (trailing time approx. 10 sec-
onds).
– Longlife suction turbine, without carbon brushes.
– Operation possible with straight and bent vacuum bar.
– The vacuum bar can be adjusted in horizontal position and tilt-
ed without tools.
– The vacuum lips can be replaced without the use of tools.
3.5 Electrical system
– The electrical assemblies are located easily accessible behind
the charger and below the operating panel.
– The appliance comes to a sudden halt when you press the
emergency stop button.
– Standby function after 30 minutes break in operation.
 4 Setup and function
4.1 Front view

1 Guide handle
2 Drain hose for wastewater
3 Water reservoir
4 Vacuum bar
5 Drive wheel
6 Left scraper roller
7 Right scraper roller
8 Brush head (BD model only)
9 Brush head (BR model)
10 Cover

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 4.2 Rear view

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 1 Operator console 14 Lever for adjusting the brush contact pressure
2 Driving lever 15 Pedal for raising/lowering the brush head
3 Guide handle 16 Waterfilter
4 Battery charger (U1) (BAT PACK model) 17 LED (red), fault on battery charger or battery
5 Suction hose 18 LED (green), battery fully charged
6 Vacuum bar 19 LED (yellow), batteries are being charged
7 Pedal for parking brake
8 Fresh water filling system
9 Drain hose for wastewater
10 Connection cable for battery charger (U1)
11 Fastening screws (2x), cover plate
12 Detergent reservoir (option)
13 LED indicator lamps on the battery charger (U1)

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 1 Plug (X11)
4.3 Control terminal
2 Connection terminal (X10), magnetic sensor (B1)
4.3.1 Operating elements and displays 3 Operating panel board (A2)
4 Connection terminal (X9), microswitch suction turbine (M5) and
detergent pump (M6)
5 Plug (X7A), ground
6 Key switch (S1)
7 Emergency-stop button (S2)
8 Connection terminal (X7), circuit board (A1)
9 Connection terminal (X8), key switch (S1) and Emergency stop
button (S2)
10 Connection terminal (X13), safety sensor (option)

4.3.3 Drive control

Note
The indicator lamp brush overload blinks when the adjusted
I_MB_Max value is almost reached. When the set I_MB_Max val-
ue is reached or exceeded, the indicator lamp will be illuminated
permanently.
If the set I_MB_Max value is exceeded for more than 5 seconds,
there will be an automatic switch-off.
1 Shaft with magnet
1 Fastening screws (4x), operating panel
2 Side plate
2 Indicator lamps
3 Toothed gear segment
3 Display
4 Halting plate
4 Driving lever
5 Return spring
5 Emergency shut-off switch
6 Toothed gear
6 Key switch
7 Magnetic sensor (B1), drive control
7 Info button
8 microswitch (S3), suction turbine (M5)
8 Indicator lamp suction turbine ON (D1) (green)
9 Connection cable, magnetic sensor (B1)
9 Indicator lamp water pump ON (D2) (green)
10 Connection cables, microswitch (S6)
10 Indicator lamp "Wastewater tank full" (D4) (red)
11 Indicator lamp brush overload (D3) (red)
12 Indicator lamp parking brake (D5) (red)
13 Indicator lamp battery (D6) (red)

4.3.2 Operating panel from below

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 4.4 Display controls
4.4.1 Open the operator menu

The user can use the operator menu to query the basic settings of
the appliance.
Î Turn on the appliance using the key switch. The basic display
"battery" appears immediately.
Î The following information can be retrieved and partially
changed by using the info button:

Display on the moni- Explanations

tor
Batterie: Basic display for the current battery
charge. 8 fields = 100%
Water Basic display for the set water volume
1 - 10 fields.
CleanSpdFwd=60% Displays the set cleaning speed in for-
ward drive in % of the max. value.
If the option "Clean Speed edit“ is set
"ON" in the setup menu, this setting
can be changed by pressing the info
button in and turning it.
CleanSpdRev=60% Displays the set cleaning speed during
reverse drive in % of the max. value.
Changes to the setting are made as
with CleanSpdFwd.
FACT=Power Displays the set brush speed (FACT
system).
WDB-Function=OFF Displays the set WDB function (wall-
ceiling-floor nozzle).
RMDosierung=2,5% Displays the set dosing equipment for
detergent (DOSE).
Betr.st. 1h23m Displays the current operating hours in
hours (h) and minutes (m).
Geschw.:_ _km/h Displays the current drive speed in km/
h.
Bürste Displays the current brush contact
pressure. This is only displayed while
the brush motors are running.
Alfred Kärcher Displays the appliance manufacturer.
B80W 3.03 Displays the versions of the integrated
software.

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 4.4.2 Open the setup menu
Î The display shows "B80W". Quickly tap the info button 3 x with-
in one second. The display shows "setup menu".
Î Browse through the setup menu using the rotating function of
the info button.
Î A menu point is modified by tapping the info button. The display
will blink. The setting is changed by rotating the info button and
it is saved by tapping the info button. Once the new setting is
saved, the display will no longer blink.
The user can use the setup menu to modify the basic settings of
Î Keep browsing via the rotating function until you reach the
the appliance.
menu item "SETUP EXIT“. The setup menu is saved and exited
Î Turn off the appliance using the key switch.
by retapping the info button.
Î Switch on the key switch.

Menu Settings Explanation Factory settings

the lan- German Displays the text in German. German english
guage English Displays the text in English.
Reverse On Driving possible with lowered vacuum bar. Suction turbine on during reverse On
clean Off drive.
Driving impossible with lowered vacuum bar. Suction turbine OFF during re-
verse drive.
Brush 0.5 to 5 seconds Switch-off delay to brush stop when machine is standing still. 2 seconds
delay 60 seconds 60 second setting cannot be saved. Only for service work.
Low 20.0 V - 22.8 V Deep discharge protection for low-maintenance and maintenance-free bat- 22.0 V for mainte-
Battery teries nance-free batter-
ies.
I MB 40 A - 80 A Overload protection of the brush motors. 68 A
MAX
FACT On Power, Whisper and Fine Clean can be selected from the operator menu. On with BR
Off Power, Whisper and Fine Clean are not displayed in the operator menu. OFF with BD
Clean On The cleaning speed can be changed in the operator menu. On
Speed edit Off The cleaning speed is not shown in the operator menu and can only be mod-
ified in the setup menu.
Clean 30 - 100 % Displays the cleaning speed during forward drive in % of the max. transport 70%
Speed Fwd speed (6 km/h).
"CleanSpeed Fwd" is only displayed if "Clean Speed Edit" – "Off" was select-
ed in the menu.
Clean 30 - 100 % Displays the cleaning speed during reverse drive in % of the max. transport 70 %
Speed Rev speed (4.5 km/h).
"CleanSpeed Rev" is only displayed if "Clean Speed Edit" – "Off" was select-
ed in the menu.
Water-Edit On The water volume can be changed in the operator menu. On
Off The water volume is not shown in the operator menu and can only be modi-
fied in the setup menu.
Water 0 - 10 Water volume (electrical ball tap). Display appears if "Water Edit ON" is set 5
in the setup menu.
Water-Time 0.5 s - 4.0 s After the water is turned on, the ball tap is fully opened for this time period, 2.0 s
so that the empty hose can be filled as quickly as possible.
RM- On Detergent dosing exists. On
Function Off Detergent dosing does not exist.
RM-Edit On The detergent dose can be changed in the operator menu. On
Off The detergent dose is not shown in the operator menu and can only be set
in the setup menu.
RM- 0-3% Detergent dosing. Display appears if "RM Edit ON" is set in the setup menu. 1,0 %
Dosing
Flashlight On Beacon light (option) switched on during driving. Off
Off Beacon light (option) switched off.
Brake 1 to Appliance is immediately braked. 1
Ramp 4 Appliance is gently braked.
Debug On Access to debug mode during SETUP exit. Off
Mode Off No access to debug mode during SETUP exit.
Load Tap menu item once. Basic settings are saved again.
Defaults
Setup Exit The setup menu is saved and exited by tapping the info button.

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 4.4.3 Open the debug mode
+=xxx mV –=xxx mV Electronic information only
Dxxx Axxx Exxx Sxxx Dxxx = safety sensor distance
Axxx = max. speed at a distance of 150
cm (0...30...60) *0.1 km/h.
Exxx = max. speed at a distance of 30
cm (0...30...60) *0.1 km/h.
You can use the debug mode to call up additional information.
Î Call up the "debug mode" display in the setup menu. Sxxx = nominal value (0-60) *0.1 km/h
Î You can use the info button to set the debug mode to ON.
Î Keep turning the info button until "SETUP exit?" appears on the
display.
Î You can use the info button to confirm the settings.
Î The following information can now be retrieved by using the
info button:

Display on the moni- Explanations

tor
Battery: 26,0V Displays the current battery voltage.
Water Displays the current water volume.
CleanSpdFwd=60% Shows the set cleaning speed during
forward drive in % of the max. value (is
only shown in the display if "Clean
Speed Edit On“ is set up in the setup
menu).
CleanSpdRev=60% Shows the set cleaning speed during
reverse drive in % of the max. value (is
only shown in the display if "Clean
Speed Edit On“ is set up in the setup
menu).
FACT Displays the current brush speed.
WDB-Function=OFF Displays the set WDB function (wall-
ceiling-floor nozzle).
RM-Dosing Shows the set detergent volume (is
only shown in the display if "RM Edit
On“ is set up in the setup menu).
Operating hours 2 h Displays the current operating hours in
10 m hours (h) and minutes (m).
Speed:0.0km/h Displays the current drive speed in km/
h.
Alfred Kärcher Displays the appliance manufacturer.
B80W 3.03 Displays the versions of the integrated
software.
Pxxx Sxxx Vxxx Pxxx Display of additional electronic infor-
mation:
Pxxx = speed value (0-255) With max.
movement of driving lever, a value of
250-255 must be displayed.
Sxxx = nominal speed value 0-61 (*0.1
km/h)
Vxxx = actual speed value 0-61 (*0.1
km/h)
Pxxx = electronic information only 0-
250
Ixxx Bxxx Mxxx Pxxx Ixxx = current pickup drive motor in A
(0-50).
Bxxx = current pickup brush motor in A
(0-255).
Mxxx = electronic information only
Pxxx = electronic information only

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 4.5 Circuit board (A1)

Î Unscrew the fastening screws (see Chapter 4.2, Item 11) and 15 Main relay (K1)
fold the cover plate back. 16 Connection terminal suction turbine (M5) (plus)
17 Plug (X4A), ground on performance circuit board (A2)
1 Connection terminal (X4) (covered), control board (A2) 18 Covering plate
2 Connection terminal (X3), microswitch (S7), detergent pump
(M6), water pump (M4), microswitch (S9), water stop valve (Y1)
3 Connection terminal (X2), main relay (K1) and power supply of
operating panel circuit board (A1)
4 Fuse 7.5 A (F3), water pump (M4)
5 Fuse 3 A (F2), control (A1)
6 Connection terminal (X1), battery charger (U1) (Bp pack only)
7 Circuit board (A1)
8 Fuse 30 A (F4), drive motor (M3)
9 Connection terminal of brush motors (M1 and M2) (plus)
10 Connection terminal 24 V (plus)
11 Connection terminal ground (minus)
12 Collection point ground (minus)
13 Connection terminal drive motor (M3) (plus)
14 Connection terminal drive motor (M3) (minus)

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 4.6 Water filling system (option) 4.8 Drain tap for fresh water

Î The stop valve on the fresh water reservoir must be opened in

order to empty the fresh water reservoir.

Note
Only open the stop valve once there is a suitable water drain under
the drain valve.

4.9 parking brake

The water filling system can be used to fill the fresh water reservoir.
The water hose is connected to the connection neck. Once the
maximum fill level is reached, the built-in floater valve will stop the
water inflow.

1 Connection nozzle
2 Fastening screws (4x), water filling system
3 Water outlet into the tank
4 Float
5 Swimmer valve
The parking brake is used to prevent the appliance from inadvert-
ent movements.
4.7 Water filter
Î Press the pedal for the parking brake down and let it lock.

Note
The stop valve must be closed before opening the water filter.

1 Water filter
2 Locking tap
The brake pushes against the drive wheel.

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 4.11 Cover opened.

The microswitch is used and the indicator lamp for the parking
brake lights up on the operator panel.

1 Pedal for parking brake

2 Brake (on both sides of the appliance)
3 Microswitch (S9), parking brake

4.10 Vacuum bar

1 Plug for filling opening of fresh water

2 Cover
1 Winch, raise/lower vacuum bar 3 Swimmer for foam, mechanical
2 Pickup plate, vacuum bar 4 Dirt water reservoir
3 Wing screw (2x), setting of the inclination 5 Swimmer, electrical
4 Wing screw (2x), setting of the horizontal position 6 Fill opening for fresh water
5 Vacuum bar 7 Lint sieve, suction turbine
6 Support roller (2x) 8 Wastewater from the suction hose
7 Fastening screw (2x)
8 Scraper roller (2x)
9 vacuum lip (2x)
10 vacuum lip mounting (2x)

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 4.12 Battery 4.13 Water stop valve

The water stop valve is located under the tank.

Î Drain the water from the fresh water and wastewater tank.
Î Open the tank cover screw.
Î Tilt the tank backwards.

The servo motor only opens the water stop valve, if the following
conditions are met:
– Water pump switched on.
– Brush head lowered.
Note – Drive operation forward or backward.
The insulation nut must be mounted so that the bottom edge fits ex- If one of the three conditions is not met, the servo motor will close
actly into the boring of the cable shoe of the connecting cable. If it the water stop valve.
is mounted incorrectly, the insulation nut can be damaged. The
fuse is bypassed and ineffective. Tighten the insulation nut finger- Note
tight using a wrench.
The water stop valve is used to avoid water damage by leaking wa-
ter. It is not as sensitive against contamination and leaks as a so-
1 Connection, battery plus terminal
lenoid valve.
2 Battery (G1), 4 x 6 Volts, 180 Ah
3 Central plug (X1)
4 Connection, battery minus terminal
5 Insulation nut
6 Fuse 125 A (F1), battery

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 4.14 Detergent dosing pump (DOSE)

The detergent dosing pump is located behind the battery.

Î Drain the water from the fresh water and wastewater tank.
Î Open the tank cover screw.
Î Tilt the tank backwards.

Pin 1 Battery voltage 24 Volt (+).

Pin 2 24 Volts if the water pump is ON.
0 Volts if the water pump is OFF.
Pin 3 Ground 0 Volts.
Pin 4 Control voltage for servo motor:
1.7-1.9 volts = dosing valve opened to the max.
3.1-3.3 volts = dosing valve opened at min.
0 volts = dosing valve closed.

1 Water stop valve (Y1)

2 Hose for the water pump (M4)
3 Hose to the brush head
4 Connecting coupling
5 Potentiometer
6 Servo motor
7 Connection plug

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 While the brush head is raised, the press spring on the brush head
The flowmeter measures the set water volume, after that the cor- pickup is compressed.
responding volume of detergent is metered in by switching on the
detergent pump.
1 Detergent dosing pump (DOSE)
2 Cover, detergent pump
3 Cap, pump motor
4 Pump outlet
5 Pump input
6 Connection cables, detergent pump
7 Detergent pump (M6)
8 Transport rotor
9 Transport hose
10 Transport rolls
11 Flowmeter
12 Control cable, flowmeter
13 Motor, detergent pump
14 Control board

4.15 Raise/lower brush head If the brush head is lowered, the press spring is decompressed and
presses the brush head onto the floor.

The brush head is switched on and off by lowering and raising it.
Î Raise: Press the pedal downward and lock it towards the right.
Î Lower: Press the pedal downwards; move it to the left and re-
lease it upward.
The brush head will automatically start up as soon as the appliance
is driven forward/backwards.
The desired brush contact pressure is adjusted by means of the lever.
The setting is adjusted in several detents. With each detent, by which
the lever is pressed down, the brush contact pressure is reduced.
Note
Only use the lever while the brush head is lowered. When moving
the lever while the brush head is raised, there can be injuries by the
lever flying upwards.
When the brush head is lowered, the microswitch switches on the
brush motors.
If the brush head is raised, the microswitch turns the brush motors
back off.
1 Foot lever for raising/lowering the brush head
2 Lever for adjusting the brush contact pressure
3 Press spring, compressed
4 Press spring, decompressed
5 Microswitch (S7), brush motors (M1, M2) ON/OFF

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 4.16 Water pump 4.18 Drive

The water pumps is located underneath the detergent dosing

pump (DOSE).

Î Drain the water from the fresh water and wastewater tank.
Î Tilt the tank backwards.

1 Hose from the water filter

2 Water pump (M4)
3 Hose to the flowmeter

4.17 Discharge flag against static electricity

1 Connection cable, drive motor (M3)
2 Drive motor (M3)
3 Differential gear

4.19 Suction turbine

The discharge flag prevents the buildup of static electricity, which

could interrupt or damage the control electronics. The suction turbine is located on the bottom of the folded open
tank.
Note
Î Drain the water from the fresh water and wastewater tank.
Distance between the discharge flag (arrow) and the floor: 5 mm
(0.197 in). Î Open the tank cover screw.
Î Tilt the tank backwards.

1 Exhaust air outlet

2 Suction turbine (M5)

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 4.20 Brush head (BD model) 4.21 Brush head, BR model

The water distribution bar can be pulled out of the front of the brush
head for cleaning.

1 Brush head
2 Cover, belt drive
3 Waste container
4 Lock, bearing lid, left
5 Bearing lid, left
6 Left scraper roller
1 Left mount
7 Water distribution bar
2 Connection terminal, brush motors (M1, M2)
3 Pedal for changing brushes, left
4 Left scraper roller
5 Right scraper roller
6 Top mount
7 Pedal for changing brushes, right
8 Connecting coupling
9 Right mount
10 Hose, distribution of detergent solution
11 Disc brush, right
12 Disc brush, left
13 Detergent outlet for right disc brush
14 Pickup, right disc brush
15 Bow to release the right disc brush
16 Bow to release the left disc brush
17 Pickup, left disc brush
18 Detergent outlet for left disc brush

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 5 Basic settings and service procedures
5.1 Replace filling system 5.2 Setting the vacuum Bar

Î Unscrew locking screws.

Î Remove the filling system from the tank.

To improve the vacuuming result on tiled floors the vacuum bar can
be turned to an oblique position of up to 5°.

Î Release the wing screws.

Î Turn the vacuum bar into the respective horizontal position.
Î Retighten the wing screws.

If the vacuum result is unsatisfactory the inclination of the straight

vacuum bar can be modified.

Î Loosen the wing nuts.

Î Tilt the vacuum bar accordingly.
Î Retighten the wing screws.

1 Wing screws (2x), setting of the tilting position

2 Wing screws (2x), setting of the horizontal position

Î Grease the seal ring when installing the new filling system.

1 Filling system
2 Fastening screws (4x), filling system
3 Fresh water inlet into the fresh water reservoir
4 Float
5 Switch-off valve

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 5.3 Clean/replace the vacuum lips 5.4 Check/replace the support roller on the vacuum
bar.

The support roller is used to prevent the vacuum bar from sucking
itself to the floor and so that the vacuum lips do not bend too much.

Î Loosen the fastening screws.

Î Adjust the support roller in the elongated hole accordingly.
Clean the vacuum lips on the vacuum bar and check for damage/
wear. Turn over/replace if needed. 1 Fastening screw, support wheel
2 Support roller, vacuum bar
Î Loosen the fastening screw.
Î Pull the scraper roller with the metal bushing and the vacuum
5.5 Removing the suction turbine
lip mount off the vacuum bar on both sides.
Î Pull the vacuum lips out of the side of the guide grooves, install
the new vacuum lips in reverse sequence.

Note
The front and rear vacuum lip can also be rotated by 180°.

1 Vacuum lip mounting

2 Metal bushing
3 Scraper roller
4 Fastening screw
5 Vacuum lips (front and rear)
6 Vacuum bar

Î Loosen the hose clip and pull the exhaust air hose off the neck.
Î Disconnect the connecting cable at the connectors.
Î Unscrew locking screws.
Î Remove the suction turbine.
Î Install the new suction turbine in reverse sequence.

1 Hose clip
2 Fastening screws (3x), suction turbine
3 Suction turbine (M5)
4 Connectors on the connecting cables

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 5.6 Remove the drive unit 5.7 Remove the BD brush head

The drive unit consists of a differential gear and an attached drive

motor.

Î Release the screw for locking the tank and swing up the tank.
Î Remove the lid of the connector cover on the brush head.
Î Disconnect the connection plug.
Î Disconnect the connecting coupling of the water supply.

Î Disconnect the connecting cable of the drive motor from the

power supply.
Î Support the drive unit and secure it against falling down.
Î Remove the fastening screws from the left and right bearing
block.
Î Remove the drive unit.
Î Assemble the drive unit in the reverse sequence.

1 Bearing blocks to attach the drive unit

2 Differential gear
3 Fastening screws (2x), left bearing block
4 Fastening screws (2x), right bearing block

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 5.9 Remove the BR brush head

Î Fold the safety locks on the brush head pickups on the left and
right of the brush head up and pull them out of the sides of the
pickups.
Î Fold the safety lock on the brush head pickup on top of the
brush head down and pull them out of the sides of the pickups.
Î The brush head is disconnected from the appliance and can be
removed.
Î Install the new brush head in reverse sequence.
Î To set the brush head, loosen the nuts on the adjusting screw
and align the brush head so that:
both brush heads touch the floor evenly on the BR head.
the brush head on the BD head is aligned parallel to the floor.
Î Retighten the nuts.

1 Connection plug
2 Adjusting screw
3 Nuts
4 Connection coupling, water supply
5 Safety lock, left
6 Safety lock, right
7 Safety lock, top

5.8 Replace the disc brushes on the BD brush head Î Release the screw for locking the tank and swing up the tank.
Î Unscrew the star handle screw of the connection plug cover
(see Chapter 4.20) on the brush head and pull the cover out.
Î Disconnect the connection plug.
Î Disconnect the connecting coupling of the water supply.
Î Fold the safety locks on the brush head pickups on the left and
right of the brush head up and pull them out of the sides of the
pickups.
Î Fold the safety lock on the brush head pickup on top of the
brush head down and pull them out of the sides of the pickups.
Î The brush head is disconnected from the appliance and can be
removed.
Î Install the new brush head in reverse sequence.

1 Safety lock, left

2 Safety lock, top
3 Safety lock, right
Î Raise the brush head.
Î Press the pedal for changing the brushes downward beyond its
resistance.
Î Pull the disc brush out of the side below the cleaning head.
Î Hold the new disc brush under the brush head, push upward
and lock.

1 Pedal for brush exchange (left and right on the brush head)

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 5.10 Replace the brush rollers on the BR brush head 5.11 Replace the drive belt

Î Remove the bearing lid from the brush roller mount (see Chap-
ter 5.10).
Î Unscrew the fastening screws of the drive belt cover and re-
move the drive belt cover.
Î Raise the brush head.
Î Turn the lock of the bearing cover counter-clockwise.
Î Push the bearing lid down and remove.
Î Pull out the brush roller.

Î Loosen the fastening screws of the brush motor.

Î Remove the drive belt.
Î Insert the new brush roller and slide it onto the pickup mandrel. Î Install the new drive belt, tension it and tighten the fastening
Î Reassemble the bearing lid in the reverse sequence. screws on the motor. The V belt tension is determined via the
position of the motor shaft (tensioning by raising the motor, e.g.
1 Lock, bearing lid with a screwdriver, through the elongated hole beneath the mo-
2 Bearing lid tor shaft).
3 Pickup mandrel
Note
The drive belt must be tensioned so that it can be deflected by a
strong thumb press to a max. of 5 mm (arrow) between the motor
shaft and the driven pulley.

1 Fastening screws (9x), drive belt cover

2 Drive belt cover
3 Fastening screws (4x), brush motor
4 Drive belt

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 5.12 Remove the brush drive on the BR brush head 5.13 Clean water filter.

Î Close the stop valve.

Î Unscrew the filter cup.
Î Remove the sieve and rinse it.
Î Assemble in reverse order.
Î Remove the drive belt cover (see Chapter 5.11).
Î Unscrew the fastening screws (arrows) of the brush drive. 1 Filter pot
2 Locking tap

5.14 Adjust drive control

Î Pull the brush drive out of the brush head.

Î Disconnect the connecting cable of the brush motor.
Î Install the new brush drive in reverse sequence.
Brush mirror adjustment
Î Park the brush head on an even surface.
Î Install the new brush rollers.
Î Slightly shake the brush head so that the brush drive with the
brush rollers can adapt to the even surface.
Î Tighten the fastening screws (arrows).
1 Brush drive
If the fault message "Gas>POTI_ZER_MAX" is displayed, the
drive control is not set correctly and the appliance will not run. In
this case, the positioning of the tooth segement and the toothed
gear is incorrect.
Î Unscrew the operating panel.
Î Remove the right and left drive levers.
Î Remove the entire drive control.
Î Unscrew the side plate and readjust the position of the tooth
segment to the toothed wheel by one tooth forward/backwards.
Î Check the drive control and adjust by moving it by one more
tooth if necessary.

1 Shaft with magnet

2 Side plate
3 Toothed gear segment
4 Halting plate
5 Return spring
6 Toothed gear
7 Magnetic sensor for drive control (B1)
8 Microswitch (S6), suction turbine
9 Connection cable, magnetic sensor
10 Connection cables, microswitch (S6)

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 6 Circuit diagram
6.1 Circuit diagram 0.089-050.0 BAT models

26 English 5.906-468.0 Rev. 00 (02/09)

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 6.2 Circuit diagram 0.089-051.0 BAT PACK models

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 6.3 Legend of the electrical components

A1 Control board
A2 Operating panel board
A3 Circuit Board, safety sensor (option)
B1 Magnetic sensor, drive control
B2/B3 Ultrasound sensors, transmitter/receiver (option)
D1 LED (green), suction turbine ON
D2 LED (green), water pump ON
D3 LED (red), brush overload
D4 LED (red), wastewater tank full
D5 LED (red), brake
D6 LED (red), battery
F1 Main switch (125 A)
F2 Fuse, control (3 A)
F3 Fuse, water pump (7.5 A)
F4 Fuse, travel drive (30 A)
G1 Battery (24 V / 180 Ah)
H1 Beacon lamp (option)
K1 Main relay
M1 Brush motor
M2 Brush motor
M3 Drive motor
M4 Water pump
M5 Suction turbine
M6 Detergent dosing pump (DOSE)
S1 Key switch
S2 Emergency-stop button
S6 Microswitch, suction turbine
S7 Microswitch, brush head
S8 Microswitch for detergent (option)
S9 Microswitch, brake
S10 Microswitch, wastewater tank
U1 Battery charger (BAT PACK model only)
V1 Protective diode
Y1 Water stop valve
EXT.X1 Central plug

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 7 Troubleshooting
7.1 Troubleshooting without display

Fault
Appliance cannot be started
Machine does not move
Insufficient water quantity
Insufficient vacuum performance
Insufficient cleaning result
Brushes do not turn
* Remove screws of the electronics system and tilt the electronics cover with charger downwards
Remedy
Stand-by, turn key switch to "0", then set it back to "1".
Check fuse F1 *, F2 *, replace if required. *
Check battery; charge it if required.
Check if the parking brake has been triggered.
Check fresh water level, refill tank if necessary.
Check fresh water filter; clean if required.
(See "Maintenance Tasks").
Check hoses for blockages; clean if required.
Clean the seals between dirt water reservoir and cover and check for tightness, replace if
required.
Clean the fluff filter.
Clean the vacuum lips on the vacuum bar, replace if required
Check suction hose for blockages; clean if required.
Check the suction hose for tightness; replace if required.
Check if the cover on the dirt water discharge hose is closed
Check the setting of the vacuum bar.
Set/ adjust contact pressure.
Check the brushes for wear, replace if required.
Use appropriate brush type for the type of dirt.
Set to "Power Clean" with appliances with brush rollers FACT.
Empty the waste container on the BR head.
Reduce contact pressure.
Check if foreign matters block the brushes; remove foreign matter if required.
If over-current switch in the electronics system has been triggered, turn key switch to "0",
then set it back to "1".

7.2 Troubleshooting with display

Message Cause Remedy

Driving lever active!
Raise brush!
Temperature !!!
Gas pedal !!!
Brush overload!
Battery depleted!
Battery depleted!!!
Refill detergent!
Emergency-STOP!
Gas>POTI_ZER_MAX
The driving lever is not in the centre position during
switch on.
Roller brush lowered and at a standstill.
Overtemperature in the performance electronics
Driving lever fault during operation.
Max. brush power exceeded for more than 5 sec-
onds.
Battery low voltage not reached for more than 60
seconds.
Battery power less than 18 V.
Detergent container is empty.
Emergency STOP button activated.
Drive control not adjusted properly.
Turn off the appliance, move the driving lever to the
centre position and turn on the appliance once
again.
Raise the brush head.
Switch off appliance and let it cool down.
Release the driving lever, switch the appliance off
and back on again. Check the driving lever.
Check/adjust the contact pressure at the brush
head.
Charge battery.
Charge battery.
Install full detergent container.
Release emergency-stop button.
Adjust drive control.

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 8 Specifications

Appliance type Appliance no. Circuit diagram operating instruc- Spare parts list
tions
BR 65/80 W Bp *EU 1.259-120.0 0.089-050.0 5.962-445.0 5.962-558.0
BD 65/80 W Bp *EU 1.259-121.0 0.089-050.0 5.962-445.0 5.962-558.0
BR 65/80 W Bp Pack *EU 1.259-122.0 0.089-051.0 5.962-445.0 5.962-558.0
BD 65/80 W Bp Pack *EU 1.259-123.0 0.089-051.0 5.962-445.0 5.962-558.0
BR 65/80 W Bp DOSE *EU 1.259-124.0 0.089-050.0 5.962-445.0 5.962-558.0
BD 65/80 W Bp DOSE *EU 1.259-125.0 0.089-050.0 5.962-445.0 5.962-558.0
BR 65/80 W Bp Pack DOSE *EU 1.259-126.0 0.089-051.0 5.962-445.0 5.962-558.0
BD 65/80 W Bp Pack DOSE *EU 1.259-127.0 0.089-051.0 5.962-445.0 5.962-558.0

The technical specification sheet and the circuit diagram will be in- The operating instructions and the spare parts list can be request-
cluded in the next version of the spare parts CD (DISIS) and in the ed in paper form with the respective part numbers from our spare
Intranet. parts service department.

9 Special tools

Description Part number

Is not required.

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