Kärcher BR 100 R Service Manual
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Kärcher BR 100 R Service Manual

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Service Manual

BR/BD 100/250 R / RI
BR/BD 120/250 R / RI
1.480- . . .
5.906-252.0
Service Manual 08.2007

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Summary of Contents for Kärcher BR 100 R

  • Page 1: Service Manual

    Service Manual BR/BD 100/250 R / RI BR/BD 120/250 R / RI 1.480- . . . 5.906-252.0 Service Manual 08.2007...
  • Page 2 BR/BD 100/250 R BP / RI Service Manual 08.2007 Page 2 / 171...
  • Page 3 BR/BD 100/250 R BP / RI Foreword Foreword Good servicing and maintenance requires comprehensive, practical training and clearly organised documents. This is why we offer all servicing engineers regular basic training and further qualification courses for the whole product range. In addition, we compile service manuals for the main units which can be used as instructions to start with and as a reference work later on.

  • Page 4: Table Of Contents

    Contents BR/BD 100/250 R BP / RI Contents Equipment features ................... 7-11 Technical features (BR/BD 100/250 R) ..............7 Technical features (BR/BD 100/250 RI) ..............8 Technical features (BR/BD 120/250 R, BR/BD 120/250 RI) ........8 View from the left-hand side ..................9 View from the right-hand side ................
  • Page 5 BR/BD 100/250 R BP / RI Contents Contents Basic settings and service procedures ............78-116 Test mode (head CPU from version 1.2) 5.1.1 Access to the test mode (with program switch S9, position 1) ......78 5.1.2 Access to the test mode (with program switch S9, position 2) ......79 5.1.2.1 Current measurement with switching on/off function ..........
  • Page 6 Contents BR/BD 100/250 R BP / RI Contents Troubleshooting ..................117-146 Troubleshooting without displays ............117-120 6.1.1 Unit won’t start ..................... 121 6.1.2 Water volume too low .................. 122-123 6.1.3 Suction performance too low / dirty water tank overflows ......124-125 Troubleshooting with displays ..............

  • Page 7: Equipment Features

    BR/BD 100/250 R BP / RI Equipment features 1.1 Technical features (BR/BD 100/250 R / BP) Battery Water system – 36 volt block battery, 630 Ah, low maintenance – Fresh water tanks on left and right sides of the with filling system. unit.

  • Page 8: Technical Features (Br/Bd 100/250 Ri)

    Equipment features BR/BD 100/250 R BP / RI 1.2 Technical features (BR/BD 100/250 RI) General information Drive system – The BR/BD 100/250 RI has an additional pre- – Wheel-hub motor (3000 watts). sweeping unit with suction function. – Wheel-hub motor tyres, oil resistant (=BR/BD –...

  • Page 9: View From The Left-Hand Side

    BR/BD 100/250 R BP / RI Equipment features 1.4 View from the left-hand side Fresh water filler opening Water filter Cover, dirty water tank Electromagnetic brake (Y1) Dirty water tank 10 Front wheel, wheel hub motor (M1) Fresh water tank, left 11 Recess for headlight (optional) Brush head, BR version 12 Seat...

  • Page 10: View From The Right-Hand Side

    Equipment features BR/BD 100/250 R BP / RI 1.5 View from the right-hand side Wing screw, steering column adjustment (max 2 cm) Steering column Deflection roller, both sides Brake pedal Drive pedal Side sealing strip, with spring pressure Brush head, BD version Fresh water tank, right Cover, dirty water tank Service Manual 08.2007...

  • Page 11: Rear View

    BR/BD 100/250 R BP / RI Equipment features 1.6 Rear view Cover, dirty water tank Deflection roller, suction beam Drain hose, dirty water tank Support roller for suction beam Connection suction hose, suction beam Suction beam, straight design Cleaning opening, dirty water tank Drain hose, fresh water tank Service Manual 08.2007 Page 11 / 171...

  • Page 12: Technical Features

    Technical features BR/BD 100/250 R BP / RI 2.1 Wheel hub motor (M1) Ram protector Note: Front wheel, wheel hub motor (M1) The freewheeling lever (4) must be pulled Carbon brush cover outwards to the outside so that the unit can Freewheeling lever, wheel hub motor (M1) be moved in the neutral position.

  • Page 13: Brush Head

    BR/BD 100/250 R BP / RI Technical features 2.2 Brush head Note: The springs (14) protect and relieve the lifting motor (15) of the brush head. Brush head (BR version) Brush head (BD version) Brush drive assembly cover plate Brush head support bracket (BR version) Deflection roller Spring for mounting plate with sealing strip Mounting plate for sealing strip, with...

  • Page 14: Suction Beam

    Technical features BR/BD 100/250 R BP / RI Suction beam Drain hose, dirty water tank 12 Wing screws (2x), for fixing the suction beam Cleaning opening, dirty water tank 13 Connection, suction hose Deflection roller with star grip for repla- cing/turning the rubber strips Suction beam, straight design Rubber strip...

  • Page 15: Suction Motor

    BR/BD 100/250 R BP / RI Technical features 2.4 Suction motor (M4) Mounting plate, right-hand fresh water Suction motor (M4) tank The suction motor (3) (EC = electronically con- Seat trolled) generates a vacuum in the dirty water tank, with which the dirty water is drawn in from Suction motor (M4, EC Longlife) the suction beam.

  • Page 16: Water System

    Technical features BR/BD 100/250 R BP / RI 2.5 Water system Water filter The water filter (2) is located on the front left- hand side under the fresh water tank. It filters the fresh water to protect the water pump. Water filter Water pump (M5) and Cleaning agent mete- ring pump (M6)
  • Page 17 BR/BD 100/250 R BP / RI Technical features 2.5 Water system Filling-level meter (B2) The filling-level meter (2) is located under the instrument panel and signals when the fresh water has to be topped up. The level meter (2) shows the current fresh water level in the display by means of bars (10 bars = maximum fresh water level).
  • Page 18 Technical features BR/BD 100/250 R BP / RI 2.5 Water system Connecting plug (X99) square, metering valve (Y2) Battery voltage 24 volt (+). Pin 1 Pin 2 24 volt if water pump ON. 0 volt if water pump OFF. Earth 0 volt. Pin 3 Pin 4 Control voltage for servo motor:...

  • Page 19: Dirty Water Tank With Recycling System (Optional)

    BR/BD 100/250 R BP / RI Technical features 2.6 Dirty water tank with recycling function (optional) Recycling mode (optional) The lever (10) for recycling mode is located on the left next to the driver’s seat. The lever (10) can be used to switch the recycling mode ON /OFF.

  • Page 20: Control Panel

    Technical features BR/BD 100/250 R BP / RI 2.7 Control panel WBD spray suction tool (optional) 13 Info-Mode switch, rotary and pusch ON/OFF button function Pre-sweeper (optional) ON/OFF 14 Pushbutton, horn (S3) Service mode indicator light 15 Program switch (S9) Chemical container empty indicator light 16 Direction of travel changeover switch (S2)

  • Page 21: Program Switch

    BR/BD 100/250 R BP / RI Technical features 2.8 Program switch (S9) Driving (without cleaning functions) Note: Wet scrubbing (with suction) The program switch (S9) has 8 switching Wet scrubbing (without suction) positions. The hand cleaning (7) position is Suction (without scrubbing mode) optional and the corresponding manual Polishing (without suction) suction set can be retrofitted.

  • Page 22: Seat Sensor (S10) And Distribution Box (Ext.x1)

    Technical features BR/BD 100/250 R BP / RI Seat sensor (S10) and Distribution box (EXT.X1) Seat sensor (S10) The seat sensor (S10) is integrated in the seat (1) and is not accessible. Note: The seat sensor (S10) is activated as soon as a weight of 5 kg or more is applied.

  • Page 23: Battery (Low-Maintenance) With Filling System

    BR/BD 100/250 R BP / RI Technical features 2.10 Battery (low-maintenance) with filling system – – – – – – – – – – – – – – – – – – – All the unit’s electrical components are connec- Connection cable, seat sensor (S10) ted with the block battery (6.654-136) through Connection cable with battery (–)

  • Page 24: Battery Charger

    Technical features BR/BD 100/250 R BP / RI 2.11 Battery charger Operating instructions: Connect charging cable with the battery. Note battery polarity! Plug mains plug into plug socket. Switch on unit; (Euro plug 230V/50Hz; CE plug 400V/50Hz). Green LED (HL) lit = unit charging; Green LED (NL) lit = recharging mode;...

  • Page 25: Side Brush (Optional)

    BR/BD 100/250 R BP / RI Technical features 2.12 Side brush (optional) Side brush suspension Headlight (optional) Spring, side brush suspension (optional) Side brush (optional) Side brush motors (M10) and (M11, optional) Side brush suspension (optional) Lifting motor (M40), side brush Bowden cable deflection pully (optional) Bowden cable side brush suspension (optional)

  • Page 26: Pre-Sweeper Unit (Only Br/Bd 100/250 Ri)

    Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit (BR/BD 100/250 RI only) Pre-sweeper unit Side brush, LH Side brush motor, RH Side brush, RH Transport roller (2x) Debris container (LH/RH) Service Manual 08.2007 Page 26 / 171...
  • Page 27 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, view from the front / side brush Pre-sweeper unit Side brush, LH Side brush motor (M41), LH Bracket, side brush motor suspension Side brush motor (M42), RH Side brush, RH Service Manual 08.2007 Page 27 / 171...
  • Page 28 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, side view Front wheel, wheel hub motor (M1) Cover, main brush Sealing lip, side Transport roller Side brush, RH Bracket, side brush motor suspension Side brush, LH Service Manual 08.2007 Page 28 / 171...
  • Page 29 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, side view Filter case cover Handwheel, filter locking system Filter case housing Service Manual 08.2007 Page 29 / 171...
  • Page 30 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, parallelogram (adjustment) 200 mm (7.88 in) Adjust parallelism The hexagonal rods (2, 3) are used to align and adjust the pre-sweeper unit. The nuts (1, 4) are used to lock the rods in place. The setting is correct when the sweeping unit is adjusted parallel to the floor.
  • Page 31 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, parallelogram (adjustment) 55 mm (2.17 in) Adjust parallelism If the adjusting rods of the parallelogram have been adjusted to a length of 200 mm (7.88 in), there is a distance of 55 mm (2.17 in) between the frame of the base unit (1) and the pre-sweeping unit (2).
  • Page 32 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, control panel Key switch (S0) Switch, pre-sweeper unit (S6) Filter shaker indicator lamp ON/OFF Push button, horn (S3) Display, Warning- and information module Program switch (S9) (A0) EMERGENCY-STOP push button (S1) Indicator lamp, Pre-sweeper ON/OFF 10 Direction of travel changeover switch Information button, rotary and keying...
  • Page 33 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, housing cover open Impeller fan housing Drive belt, fan Fan motor (M13) Bowden cables raise/lower main brush Bowden cables raise/lower side brush Lifting motor, main brush and side brush Bowden cable, course-dirt flap Printed circuit board (A4/1), lifting module Printed circuit board (A3/1), cleaning...
  • Page 34 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, debris container Debris container, RH The pre-sweeper unit is equipped with two de- bris containers. The debris containers are atta- ched on the LH and RH side of the pre-sweeper unit.
  • Page 35 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, housing cover open Housing cover, pre-sweeper unit Electrical box Filter case Round filter Handwheel, filter locking system Impeller fan housing Fan motor Service Manual 08.2007 Page 35 / 171...
  • Page 36 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, round filter with retainer Filter case If the round filter is blocked it must be removed from the filter case. Round filter – Loosen retaining screws (3). Retaining screws (2x), retainer plate –...
  • Page 37 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, motor, filter shaker Filter case Filter shaker motor (M14) Service Manual 08.2007 Page 37 / 171...
  • Page 38 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, impeller fan system Impeller fan housing Drive belt, fan Fan motor (M13) Service Manual 08.2007 Page 38 / 171...
  • Page 39 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, lifting motor/ main brush / side brush Lifting motor (M40), main brush and side brush Bowden cables raise/lower side brush Bowden cables raise/lower main brush Service Manual 08.2007 Page 39 / 171...
  • Page 40 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, motor main brush Motor (M12), main brush Drive shaft, motor Tension roller Drive belt Pulley Tension spring, tension roller Service Manual 08.2007 Page 40 / 171...
  • Page 41 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, retainer LH / main brush Adjust-/locknut, Bowden cabel Adjust-/locknut, Bowden cabel Bowden cables, raise/lower main brush Drive belt, main brush Pulley, main brush Rocker arm, main brush retainer Tension spring, tension roller Tension roller Service Manual 08.2007 Page 41 / 171...
  • Page 42 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, retainer LH / main brush Rocker arm, main brush retainer The vibration damper (5) prevents the main brush from rocking by rubbing on the debris container. Tension spring Tension roller Hollow screw with internal spring Main brush rocker arm vibration damper Pulley, main brush...
  • Page 43 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, retainer RH / main brush Rocker arm, main brush retainer Retainer centering arbor Centering arbor Main brush Bowden cable raise/lower main brush Service Manual 08.2007 Page 43 / 171...
  • Page 44 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, sealing strip 1-3 mm (0.039 in - 0.118 in) Mounting plate, small, sealing strip The sealing strip (2) is mounted and its height adjusted using the retaining screws (5x, arrow). Sealing strip, side The distance between the floor and sealing strip Mounting plate, large, sealing strip...
  • Page 45 BR/BD 100/250 R BP / RI Technical features 2.13 Pre-sweeper unit, coarse dirt flap Side brush, LH Coarse-dirt flap Sealing lip, front Side brush, RH Return spring, coarse dirt flap Service Manual 08.2007 Page 45 / 171...
  • Page 46 Technical features BR/BD 100/250 R BP / RI 2.13 Pre-sweeper unit, pedal arrangement Drive pedal Brake pedal Steering column Coarse-dirt flap pedal Service Manual 08.2007 Page 46 / 171...

  • Page 47: Unit Functions

    BR/BD 100/250 R BP / RI Unit functions Functional diagram Cover, dirty water tank 13 Brush head (BR version) Cleaning agent tank with level switch 14 Coarse dirt container (BR version) (FULL/EMPTY), (optional) 15 Switchover valve to recycling mode Fresh water tank (optional) Water filter, fresh water 16 Recycling water hose to switchover valve...

  • Page 48: Brush Head Mounting Parts

    Unit functions BR/BD 100/250 R BP / RI 3.1.1 Brush head mounting parts 5, 9 The brush head (BR-version) is fastened with Rear suspension, brush head the guides (5, 9) in the lower hole (11) of the Lifting motor - brush head (M20) bracket (12).

  • Page 49: Brush System - Contact Pressure Adjustment

    BR/BD 100/250 R BP / RI Unit functions 3.1.2 Brush system - contact pressure adjustment Contact pressure adjustment The brush contact pressure is adjusted by the lifting motor (M20). If the required contact pres- sure is set at the display (adjustable using the operator menu, see Chapter 3.3), the electronics automatically evaluates the brush motors’...

  • Page 50: Functional Diagram (Only Br/Bd 100/250 Ri)

    Unit functions BR/BD 100/250 R BP / RI 3.1.3 Pre-sweeper unit functional diagram (BR/BD 100/250 RI only) Fan motor Filter impeller fan and housing Main brush (over-throw principle) Lifting module (A4/1) Side brush motor, LH Side brush, LH Side brush, RH Transport roller (1x left, 1x right) Side brush motor, RH 10 Debris container (LH/RH)
  • Page 51 BR/BD 100/250 R BP / RI Unit functions 3.1.3 Pre-sweeper unit functional diagram (BR/BD 100/250 RI only) Fan motor Note: Filter impeller fan and housing The parallelogram (9) of the mainframe Lifting module (A4/1) connection allows on uneven floors a maximum deflection of 15 cm (5.91 in) Side brush motor, RH Side brush, RH...

  • Page 52: Operator And Service Program Overview

    Unit functions BR/BD 100/250 R BP / RI Operator and service program overview Operator functions: The overview describes the operator functions with the corresponding processes and access to the information menu. The manufacture set- tings for the operator functions are shown in the chart.

  • Page 53: Operator Functions

    BR/BD 100/250 R BP / RI Unit functions Operator functions For operator For service technician Bedienerfunktionen Test-Modus Setup menu – Drives – System parameters Drive (without cleaning – Lifting motors – Driving module parameters functions) – Calibration – Cleaning module parameters Wet scrubbing –...

  • Page 54: Initial Operation And Information Menu

    Unit functions BR/BD 100/250 R BP / RI 3.3.1.1 Initial operation and information menu Switch program switch (S8) to position „1“ Switch on key sw itch (SO) Main relay (K1) switched off Display Shutdown soon Error display? Display Self-test o.k.? Error display Display Shutdown...

  • Page 55: Initial Operation And Information Menu (Head Cpu Up To Version 1.1)

    BR/BD 100/250 R BP / RI Unit functions 3.3.1.2 Initial operation and information menu Switch program switch to Pos.8 Initial startup Switch on key switch (SO) Display Main relay (K1) self-diagnosis switches off Display Self-test Active operator functions: shutdown takes o.k.? a few seconds - Drive...

  • Page 56: Driving

    Unit functions BR/BD 100/250 R BP / RI 3.3.2.1 Driving (without cleaning functions) Initial operation Display Battery: E..F Water/C: E..F Shutdown procedure Switch program switch to Pos 1 (no cleaning components active) Drive motor (M1) ready Driver`s seat occu- pied? (seat sensor S10) Travel direction switch a (S2)

  • Page 57: Driving (Head Cpu From Version 1.2)

    BR/BD 100/250 R BP / RI Unit functions 3.3.2.2 Driving (without cleaning functions) Initial startup Display Battery: E..F Water/C: E..F Shutdown procedure Drive motor (M1) ready Driver`s seat occupied? (Seat sensor S10) Direction of travel switch (S2) (forwards/reverse) Drive pedal pressed? (Magnetic sensor B1) Drive motor (M1) Drive motor (M1)

  • Page 58: Wet Scrubbing (With Suction)

    Unit functions BR/BD 100/250 R BP / RI 3.3.3 Wet scrubbing (with suction) Display Initial startup Battery: E..F Water/C: E..F Shutdown procedure Switch program switch to Pos. 2 - Suction motor (M4) „ON“, lifting motor suction beam (M30) lowers suction beam if direction of travel switch (S2) switched to forwards - If driving operation active (M1) - Lifting motor lowers brush head (M20) - Brush motors (M2, M3) start...

  • Page 59: Wet Scrubbing (Without Suction)

    BR/BD 100/250 R BP / RI Unit functions 3.3.4 Wet scrubbing (without suction) Display Initial startup Battery: E..F Water/C: E..F Shutdown procedure Switch program switch to Pos. 3 - Chemical pump (M6) (OPTIONAL) „ON“ - With driving operation active (M1) - Lifting motor lowers brush head (M20) - Brush motors (M2, M3) start - Water metering valve (Y2) opens...

  • Page 60: Suction (Without Scrubbing Mode)

    Unit functions BR/BD 100/250 R BP / RI 3.3.5 Suction (without scrubbing mode) Initial startup Display Battery: E..F Shutdown procedure Water/C: E..F Switch program switch to Pos. 4 - Suction motor (M4) „ON“ - Lifting motor suction beam (M30) lowers suction beam, if direction of travel switch (S2) switched to forwards Display Battery:...

  • Page 61: Polishing (Without Suction)

    BR/BD 100/250 R BP / RI Unit functions 3.3.6 Polishing (without suction) Initial startup Display Battery: E..F Shutdown procedure Water/C: E..F Switch program switch to Pos. 5 - If the drive motor (M1) is active the lifting motor lowers the brush head (M20) -Start brush motors (M2, M3) Display Battery:...

  • Page 62: Polishing (With Suction)

    Unit functions BR/BD 100/250 R BP / RI 3.3.7 Polishing (with suction) Initial startup Display Battery: E..F Shutdown procedure Water/C: E..F Switch program switch to Pos. 6 - Suction motor (M4) „ON“, suction beam lifting motor (M30) lowers suction beam, if direction of travel switch (S2) switched into forwards direction - If drive motor active (M1) - Lifting motor lowers the brush head (M20) - Start brush motors (M2, M3)

  • Page 63: Hand Cleaning With Wall-Ceiling-Floor Tool (Optional)

    BR/BD 100/250 R BP / RI Unit functions 3.3.8 Hand cleaning with wall-ceiling-floor tool (optional) Display Initial startup Battery: E..F Water/C: E..F Shutdown procedure Switch program switch to Pos. 7 (empty field) - Suction motor „ON“ - LED manual vacuuming / suction motor (green) active - LED-brake (red) active - Driving motor inactive Service Manual 08.2007...

  • Page 64: Manufacture Settings - Operator Functions

    Unit functions BR/BD 100/250 R BP / RI 3.3.9 Operator functions - manufacture settings PROCESS SWITCH MENU, BR 100/250 R Manufacture Settings - Dated 12/04 Processing / setting Adjustable process Bar display, Bar display, Notes program switch (S9) parameters Manufacture MIN/MAX setting 1.

  • Page 65: Modular Electronic Control Circuits

    BR/BD 100/250 R BP / RI Modular Electronic Control Circuits Modular Electronic Control Circuits Module networking – Operating system FILTER INFO/ MASTER – Sequence of machine events SHAKER USERPANEL MODULE – Error diagnosis/Debugging MODULE Expansible, serial network cable (Bus) CLEANING- TRACTION LIFT CHARGING...

  • Page 66: Modular System Br/Bd 100/250 R

    Modular Electronic Control Circuits BR/BD 100/250 R BP / RI Modular system BR/BD 100/250 R KOPF-CPU MASTER-MODULE CPU-MODULE X4/OUT X3/IN X2/OUT X7/IN CLEANMODUL FAHRMODUL CLEANING-MODULE TRACTION-MODULE MODULE DE MODULE DE MOTEUR NETTOYAGE X8/OUT X1/IN X3/IN X3/OUT HUBMODUL ZUBEHÖRMODUL LIFTING-MODULE ACCESSORY-MODULE MODULE DE MOTEUR MODULE DE COURSE...

  • Page 67: Modular System Br/Bd 100/250 R With Side Brush (Optional)

    BR/BD 100/250 R BP / RI Modular Electronic Control Circuits Modular system BR/BD 100/250 R with side brush (optional) KOPF-CPU MASTER-MODULE CPU-MODULE X4/OUT X3/IN X7/IN X2/OUT FAHRMODUL CLEANMODUL TRACTION-MODULE CLEANING-MODULE MODULE DE MOTEUR MODULE DE NETTOYAGE ZUBEHÖR-SEITENBESEN ACCESSORIES-SIDE BROOM X8/OUT X1/IN ACCESSOIRES-GENET A BALAIS DE COTE...

  • Page 68: Modular System Br/Bd 100/250 Ri

    Modular Electronic Control Circuits BR/BD 100/250 R BP / RI Modular system BR/BD 100/250 RI KOPF-CPU MASTER-MODULE CPU-MODULE X4/OUT X3/IN A4/1 X7/IN X3/OUT X2/OUT CLEANMODUL HUBMODUL FAHRMODUL CLEANING-MODULE LIFTING-MODULE TRACTION-MODULE MODULE DE MODULE DE MOTEUR MODULE DE MOTEUR NETTOYAGE DE COURSE X8/OUT X2/IN X1/IN...

  • Page 69: Emergency Operation (Driving) Using The Example Of The Br/Bd 100/250 R

    BR/BD 100/250 R BP / RI Modular Electronic Control Circuits Emergency operation (driving) using the example of the BR/BD 100/250 R KOPF-CPU MASTER-MODULE CPU-MODULE X4/OUT X3/IN X7/IN X2/OUT CLEANMODUL FAHRMODUL CLEANING-MODULE TRACTION-MODULE MODULE DE MODULE DE MOTEUR NETTOYAGE X8/OUT X1/IN X3/IN X3/OUT HUBMODUL...

  • Page 70: Control Panel (View From Below) With Warning And Information Module (A0) And Head Cpu Module (A1)

    Modular Electronic Control Circuits BR/BD 100/250 R BP / RI Control panel (view from below) with Warning and information module (A0) and Head CPU module (A1) Warning and information module (A0) Note: Ribbon cable (W201, 34-pin) If the head CPU module (A1) is replaced, it EMERGENCY-STOP push button (S1) is necessary to calibrate the accelerator Direction of travel changeover switch...

  • Page 71: Lifting Module (A4) And Accessories Module (A5)

    BR/BD 100/250 R BP / RI Modular Electronic Control Circuits Lifting module (A4) and Accessories module (A5) Lifting module (A4) Accessories module (A5) (optional) Terminal strip (X10/A5), working light Terminal strips (not available /used) Programming plug (X1/A4) Horn (H1) Terminal strip (X3/A4) 10 Fan, electronics compartment (M7) Terminal strip (X2/A5) 11 Terminal strip (X4/A4)

  • Page 72: Driving Module (A2) And Cleaning Module (A3)

    Modular Electronic Control Circuits BR/BD 100/250 R BP / RI Driving module (A2) and Cleaning module (A3) Service Manual 08.2007 Page 72 / 171...
  • Page 73 BR/BD 100/250 R BP / RI Modular Electronic Control Circuits Driving module (A2) and Cleaning module (A3) Driving module (A2) Terminal strip (X5/A2) Terminal strip (X4/A2) Terminal strip (X3/A2) Terminal strip (X7/A3) Terminal strip (X2/A3) Cleaning module (A3) Terminal strip (X1/A3) Terminal strip (X3/A3), not used 24 Fuse (F1), brown Terminal strip (X4/A3)

  • Page 74: Lifting Module (A4/1) (Optional) And Cleaning Module (A3/1) (Optional)

    Modular Electronic Control Circuits BR/BD 100/250 R BP / RI Lifting module (A4/1) (optional) and Cleaning module (A3/1) (optional) Service Manual 08.2007 Page 74 / 171...

  • Page 75: Lifting Module (A4/1) (Optional) And Cleaning Module (A3/1) (Optional)

    BR/BD 100/250 R BP / RI Modular Electronic Control Circuits Lifting module (A4/1) (optional) and cleaning module (A3/1) (optional) Lifting module (A4/1), (optional) Cleaning module (A3/1), (optional) Terminal strip (X7/A3/1) 11 Connecting terminal (X6/A3/1), battery positive cleaning module (F3) Terminal strip (X2/A3/1) 12 Battery - negative post (Support point) Terminal strip (X1/A3/1) 13 Printed circuit board - cleaning module...

  • Page 76: Service Module (A9)

    Modular Electronic Control Circuits BR/BD 100/250 R BP / RI 4.9 Service module (A9) Service module (A9) The service module (A9) can be used to diagno- se a unit to find errors and faults. It is used for parameterisation, display adjust- ment and for downloading the firmware.
  • Page 77 BR/BD 100/250 R BP / RI Modular Electronic Control Circuits 4.9 Service module (A9) Connection in module group KOPF-CPU MASTER-MODULE SERVICE-PC/ CPU-MODULE LAPTOP X4/OUT X3/IN X7/IN X2/OUT CLEANMODUL FAHRMODUL SERVICEMODUL CLEANING-MODULE TRACTION-MODULE SERVICE-MODULE MODULE DE MODULE DE MOTEUR MODULE DE NETTOYAGE SERVICE X8/OUT...

  • Page 78: Basic Settings And Service Procedures

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.1.1 Access to the test mode (with program switch S9, position 1) Requirements - Unit switched off - Program switch (S9) in Pos 1 (Drive) - Key switch (SO) in „O“ position - Hold i-button inch function Main relay (K1) - Switch on key switch (SO)

  • Page 79: Access To The Test Mode (With Program Switch S9, Position 2)

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.1.2 Access to the test mode (with program switch S9, position 2) Requirements - Unit switched off - Program switch (S9) in Pos 2 (wet scrubbing with vacuuming) - Key switch (SO) in „O“ position - Hold i-button inch function Main relay (K1) - Switch on key switch (SO)

  • Page 80: Current Measurement With Switching On/Off Function

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.1.2.1 Current measurement with switching on/off function Requirements - Unit is ready for service in test mode - Program switch (S9) in Pos 2 wet scrub with vacuuming (orPos 1 Drive) - Above the rotary function I button the display is Suction motor on/off Display Suction motor...

  • Page 81: Access To The Test Mode (With Program Switch S9, Position 3)

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.1.3 Access to the test mode (with program switch S9, position 3) Requirements - Unit switched off - Program switch (S9) in Pos 3 (wet scrub without vacuuming) - Key switch (SO) in „O“ position - Hold i-button inch function Main relay (K1) - Switch on key switch (SO)

  • Page 82: Access To The Test Mode (With Program Switch S9, Position 4)

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.1.4 Access to the test mode (with program switch S9, position 4) This access is only possible in the following unit versions. - BR-100/250 R with pre-sweeper and side brush - BR-100/250 R with side brush It is inactive in BR 100/250 R basic unit.

  • Page 83: Access To The Test Mode (With Program Switch S9, Position 5)

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.1.5 Access to the test mode (with program switch S9, position 5) Requirements - Unit switched off - Program switch (S9) in Pos 5 (polish) - Key switch (SO) in „O“ position - Hold i-button inch function Main relay (K1) - Switch on key switch (SO)

  • Page 84: Accelerator Pedal Calibration

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.1.5.1 Accelerator pedal calibration Requirements – Unit is ready for service in test mode – Program switch (S9) in Pos 5 Polish – Above the rotary function I-button the Calibrate accelerator pedal? display is active Display Calibrate accelerator pedal?

  • Page 85: Illuminated Symbol Test

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.1.5.2 Illuminated symbol test Requirements – Unit is ready for service in test mode – Program switch (S9) in Pos 5 Polish – Above the rotary function I-button, the Illuminated symbol test display is active Display Illuminated symbol test...

  • Page 86: Service-Operator Menu

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.1.5.3 Service-operator menu Requirements – Unit is ready for service in test mode – Program switch (S9) in Pos 5 Polish – Above the rotary function I-button the call up service/operator menu? display is active Operating notes: If the i-button is not pressed Display...

  • Page 87: Test Mode (Head Cpu Up To Version 1.1)

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.2.1 Access to the test mode Requirements - Unit switched off - Program switch in Pos 1 (drive) - Key switch (SO) in „O“ position -Keep I-button Key function depressed and switch on key switch (SO) Main relay (K1)

  • Page 88: Test Mode - Drive Units

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.2.2 Test mode - drive units Access to Display TEST-MODE TESTER-MODE (see chapter 5.2.1) drives >3s Display TESTER-MODE drives flashing Program switch S9 Condition Drive units LED- LED- Position No. (On/Off) Service Service...

  • Page 89: Test Mode - Lifting Motors

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.2.3 Test mode - lifting motors Access to TEST-MODE (see chapter 5.2.1) Key: Info button Display TESTER-MODE linear actuators Inching mode >3s Display TESTER-MODE linear actuators (flashing) Switch program switch (S9) to Switch program switch (S9) to Switch program switch (S9) to Switch program switch (S9) to...

  • Page 90: Test Mode - Calibration

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.2.4 Test mode - calibration Access to TEST-MODE (see chapter 5.2.1) Display TESTER-MODE adjustment >3sec Display TESTER-MODE adjustment (flashing) Switch program switch (S9) to Switch program switch (S9) to Switch program switch (S9) to Pos 1 Drive Pos 2 Scrub-Vacuum...

  • Page 91: Setup Menu (Head Cpu From Version 1.2)

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.3 Setup menu 5.3.1.1 Access to the setup menu Initial operation takes place in accordance with 3.3.1 Display Battery: E..F Water/C: E..F Switch program selection Press i-button 3 times switch to Pos.

  • Page 92: System Menu And Driving Module Parameters

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.3 Setup menu 5.3.1.2 System menu and driving module parameters Cleaning modul parameters Access to the setup menu and lifting modul parameters (See chapter 5.3.1.1) (See chapter 5.3.1.3) Note: If the i-button is not pressed within 30 seconds the program automatically switches to Battery: E..F...

  • Page 93: Cleaning Module And Lifting Module Parameters

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.3 Setup menu 5.3.1.3 Cleaning module and lifting module parameters 5.2.b Access to the setup menu (See chapter 5.3.1.1) Note: If the i-button is not pressed within 30 seconds the program automatically switches to Battery: E..F Water/C: E..F...

  • Page 94: Setup Menu (Head Cpu Up To Version 1.1)

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.3 Setup menu 5.3.2.1 Access to the setup menu Requirements - Unit switched off - Program switch in Pos. 8 - Key switch (SO) in „O“ position -Keep I-button function Main relay K1 depressed and switch switches off...

  • Page 95: Access To The Setup Menu

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.3 Setup menu 5.3.2.1 Access to the setup menu Display SETUP MENU Activate module (continuation) parameter setup? >3s System parameters and driving module Display (See Chapter 5.3.2.2) Activate module parameter setup (flashing) Lifting module...

  • Page 96: System Menu And Driving Module Parameters

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.3 Setup menu 5.3.2.2 System menu and driving module parameters Access to Display Activate module SETUP MENU parameter setup (See Chapter 5.3.2.1) (flashing) Access to Lifting module (See Chapter SETUP MENU 5.3.2.3) (See Chapter 5.3.2.1)

  • Page 97: Cleaning Module And Lifting Module Parameters

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.3 Setup menu 5.3.2.3 Cleaning module and lifting module parameters Access to Display Activate module SETUP MENU parameter setup (See Chapter 5.2.1) (flashing) System parameters and drive module (See Chapter 5.2.2) Display Parameter menu lifting module...

  • Page 98: Save Changed Adjustable Parameters

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.3 Setup menu 5.3.3 Save changed adjustable parameters Display Display (from chapter 5.2.2/chapter 5.2.3), for example Battery: E..F Lanuage selection: 0 Water/C: E..F 0 = German 1 = Engl. Last used adjustable parameter is displayed Parameter value rigid...

  • Page 99: Load Backup Operating Hours Counter

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.3 Setup menu 5.3.4 Load backup operating hours counter Note: If the CPU has been changed the operating hours counter reading must be loaded back from the clean module (A3) (saved operating hours counter).

  • Page 100: Manufacture Settings - Module Parameters

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.3 Setup menu 5.3.5 Module parameter manufacture settings Head CPU version: from 1.2 Drive module version: up to 1.2 Setup valid for: Clean module version: from 1.2 Lift module version: up to 1.0 Accessory module version: up to 1.0...
  • Page 101 BR/BD 100/250 R BP / RI Basic settings and service procedures 5.3 Setup menu 5.3.5 Module parameter manufacture settings PARAMETER-SETUP, sequence and factory settings BR 100/250R(I) - State 2005/05/20 Module Parameter presentation in Factory setting min:step:max Notes Order Service Development display access access...
  • Page 102 Basic settings and service procedures BR/BD 100/250 R BP / RI 5.3 Setup menu 5.3.5 Module parameter - manufacture settings Subsequent installation of options - 5. Accelerator pedal calibration note If it is necessary to calibrate the accelerator pedal, (e.g. due to replacement of a defective drive sensor (B1)), from HEAD-CPU (A1) Version 1.2 Note: this function is no longer in the setup menu but...

  • Page 103: Steering

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.4.1 Steering Steering column The steering column pipe (4) with internal stee- ring rod (16) is fixed to the base frame (8) with four retaining screws (9). The steering movement of the steering wheel is transferred through the toothed wheel (16) to the toothed ring (12) and steering head (13).

  • Page 104: Lifting Motor - Suction Beam (M30)

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.4.2 Lifting motor - suction beam (M30) Adjust microswitch (S30, S31) If the suction beam does not reach its upper or lower limit positions or if there is no lifting move- ment, the microswitch (S30, S31) settings must be checked first before the complete lifting motor (M30) is replaced.

  • Page 105: Lifting Motor - Brush Head (M20)

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.4.3 Lifting motor - brush head (M20) Adjust lifting motor - brush head (M20) Note: The limit position of the lifting motor (7) is determined by the electrical current limiter. The lifting motor’s shut-off function (7) via microswitches can be activated/deactivated using the system parameters (Chapter 5.3).
  • Page 106 Grundeinstellungen und Servicearbeiten BR/BD 100/250 R BP / RI 5.4.3 Hubmotor Bürstenkopf (M20) Obere Obere v1 > v2 Endstellung Endstellung (S20 offen) (S21 ge- schaltet) Hubmotor (Regelgeschwindigkeit v1) Hubmotor (Regelgeschwindigkeit v2) Untere Untere Endstellung Endstellung (S21offen) (S20 geschaltet) Bürstenkopfabsenkung - Funktionsprinzip Bürstenwalzen oben Funktion der Mikroschalter Umschaltpunkt Regelgeschwindigkeit...

  • Page 107: Maintenance Work To The Brush Head

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.4.4 Brush head - maintenance work Replace brush roller (BR version) – Remove the wing nuts (1) and (5) and pull off the mouting plate (4). – Pull out the brush (2) and check for wear, re- place if necessary.

  • Page 108: Check Brush Rollers For Foreign Bodies

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.4.4 Brush head - maintenance work Check brush rollers for foreign matter and remove If the foreign matter is stick on the brush roller, this can impair the cleaning result. –...

  • Page 109: Remove Brush Head

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.4.4 Brush head - maintenance work – Press the EMERGENCY STOP switch (S1) and switch off the key switch (S0). – Loosen the adjusting screws (Item 6, page 104). –...

  • Page 110: Drive Sensor (B1)

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.4.5 Drive sensor (B1) Floor panel Adjust drive sensor (B1) Retaining screws (2x), drive sensor – Remove the retaining screws of the floor panel (1) and remove the floor panel. Drive sensor (B1) –...

  • Page 111: Wheel Hub Motor Tyres (M1)

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.4.6 Wheel hub motor tyres (M1) Check/replace carbon brushes – Remove carbon brush cover (2). – Remove the retaining screw (6) from the carbon brush (5). – Pull out the carbon brush (5). –...

  • Page 112: Wheel Hub Motor Tyres (M1)

    Basic settings and service procedures BR/BD 100/250 R BP / RI 5.4.6 Wheel hub motor tyres (M1) Replace the tyres – Secure the machine against rolling away. – Remove ram protector. Note: The wheel hub motor (M1) must not be dismantled/removed to change the tyre.

  • Page 113: Magnet Brake (Y1)

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.4.7 Magnet brake (Y1) Remove and check the electromagnetic brake (Y1) The electromagnetic brake (1) is correctly adju- sted in the factory. Depending on the load and operating time, it may be necessary to readjust the brake.
  • Page 114 Basic settings and service procedures BR/BD 100/250 R BP / RI 5.4.7 Magnet brake (Y1) Check electromagnetic brake (Y1) with mounting plate The installation of the magnet brake (Y1) is illu- strated with the mounting plate (1). – Bolt the magnet coil (3) with the brake disk (9) onto the mounting plate (1) by using three mounting screws (refer to page 113, item 3).

  • Page 115: Rear Wheel Brake

    BR/BD 100/250 R BP / RI Basic settings and service procedures 5.4.8 Rear wheel brake Adjust the rear wheel brake Note: The wheels must brake uniformly and symmetrically when the foot brake is pressed. The rear wheel brakes can be adjusted separa- tely on both sides if necessary.

  • Page 116: Replacement Times

    Basic settings and service procedures BR/BD 100/250 R BP / RI Replacement intervals Component Replacement time in minutes Battery with crane or fork lift Floor tool Brush roller bearing Brush rollers Brush drive belt Brush motor carbon brushes Brush motor Transmission (brush drive assembly) Suction beam Rubber strip...

  • Page 117: Troubleshooting

    BR/BD 100/250 R BP / RI Troubleshooting Troubleshooting without displays Note: The troubleshooting test mode function is described in Chapter 5.1. Faults not shown on the Behebung display Unit won't start – Insert/check/replace central battery plug (X1) (see Chapter 6.1.1). –...
  • Page 118 Troubleshooting BR/BD 100/250 R BP / RI Troubleshooting without displays Faults not shown on the Solution display No or too little cleaning agent – Check hose to brush head/remove blockage/kink. supplied – Check/replace fuse (F3). – Test chemical tank float switch (optional) (S12) using test mode/replace.
  • Page 119 BR/BD 100/250 R BP / RI Troubleshooting Troubleshooting without displays Faults not shown on the Solution display Suction beam cannot be – Check/replace fuse (F4). raised/lowered – Lifting mechanism blocked. – Test microswitch (S30, S31) using test mode/replace. – Test program selector switch (S9) test mode/replace. –...
  • Page 120 Troubleshooting BR/BD 100/250 R BP / RI Troubleshooting without displays Faults not shown on the Solution display Device raises dust/does not – Check/replace side brush and main brush. vacuum – Check direction of rotation of the main brush/properly connect electrical connecting cables (plus/minus). (only for RI version with –...

  • Page 121: Unit Won't Start

    BR/BD 100/250 R BP / RI Troubleshooting 6.1.1 Unit won’t start Insert/check/replace the central plug (X1) Check central plug (2), replace defective plug. Check/replace key switch (S0). – Pull off top section of the central plug (2). – Turn key switch (4) to „0“ position. –...

  • Page 122: Water Volume Too Low

    Troubleshooting BR/BD 100/250 R BP / RI 6.1.2 Water volume too low Fill fresh water tank – Open the cover of the fresh water tank and fill with fresh water and cleaning agent. Check/clean/replace water filter – Remove the water filter housing (2) . –...

  • Page 123: Water Volume Too Low

    BR/BD 100/250 R BP / RI Troubleshooting 6.1.2 Water volume too low Check/clean/replace fresh water distributi- on pipe The fresh water distribution pipe (1) is located in front of the front brush roller. It must be turned so that the holes face upwards. Fresh water distribution pipe, view from below Fresh water distribution pipe Fresh water distribution pipe...

  • Page 124: Suction Performance Too Low / Dirty Water Tank Overflows

    Troubleshooting BR/BD 100/250 R BP / RI 6.1.3 Suction performance too low / dirty water tank overflows Check/replace suction hose – Check the suction hose (5) for leaks and blok- kages, clean/replace if necessary. Check/adjust the suction beam setting – Loosen knurled grips (2). –...

  • Page 125: Suction Performance Too Low / Dirty Water Tank Overflows

    BR/BD 100/250 R BP / RI Troubleshooting 6.1.3 Suction performance too low / dirty water tank overflows Suction performance too low Check/clean/replace the seal on the cover of the dirty water tank Check the seal (1) at the dirty water tank for damage and dirt, clean/replace if necessary.

  • Page 126: Troubleshooting With Displays

    Troubleshooting BR/BD 100/250 R BP / RI Troubleshooting with displays Note If a fault signal occurs, reset the key switch fault signal re-occurs, read off the error code (S0). Before the key switch (S0) is switched in accordance with the error group (Chapter back on, wait for approx 10 seconds in order 6.2.1 –...
  • Page 127 BR/BD 100/250 R BP / RI Troubleshooting Troubleshooting with displays Structure of error messages Display format:*) <Process> restricted <Module abbreviation><Clone>/<Code> – 1 (Consecutive No.) 1..9 – 2 0..9 (Error class) 0..1 (Problem level) – Drive – – Load – The machine can contain several –...
  • Page 128 Troubleshooting BR/BD 100/250 R BP / RI Troubleshooting with displays Module clones (BR/BD 100/250 R/I) – Clones and their order are detected during the self-test. – If several clones of a module are available (e.g. A3 and A3/1), the clone order according to the modular system chapter (Chap 4.1-4.3) must be adhered to for correct machine function.

  • Page 129: Troubleshooting With Displays

    BR/BD 100/250 R BP / RI Troubleshooting Troubleshooting with displays Procedure: Note: – When a fault display appears, a key switch Frequently, a single event can cause faults reset should first be performed. Before the key from many modules! switch is switched on again, wait for a time of approx.

  • Page 130: Driving Module Error Messages (A2)

    Troubleshooting BR/BD 100/250 R BP / RI 6.2.1 Drive module (A2) error messages Module involved: Module clone: Only a drive module is currently generally used Display code: F1/xxx for faults/warnings of drive module Module Fault Display code Action classification Irreparable me- F1/001 1.
  • Page 131 BR/BD 100/250 R BP / RI Troubleshooting 6.2.1 Drive module (A2) error messages Module Fault Display code Action classification Error when F1/101 1. Change menu in parameter setup. storing setup 2. Change the setup of drive module (A2). parameters in the 3.
  • Page 132 Troubleshooting BR/BD 100/250 R BP / RI 6.2.1 Drive module (A2) error messages Module Fault Display code Action classification Motor protection Driving 1. Switch off key switch (S0). is activated motor is 2. Cool drive motor (M1) for at least 15 minutes. hot! 3.
  • Page 133 BR/BD 100/250 R BP / RI Troubleshooting 6.2.1 Drive module (A2) error messages Module Fault Display code Action classification Drive module Is protection 1. Perform key switch (S0) reset. (A2) registers open? 2. Check module, module may be defective. external relay EMER- drop (K1) GENCY...

  • Page 134: Accessories Module Error Messages (A5)

    Troubleshooting BR/BD 100/250 R BP / RI 6.2.2 Accessories module (A5) error messages Module involved: Module clone: 1 accessory module is currently generally only used Display code: Z1/xxx for faults/warnings of accessories module Module Fault Display code Action classification Irreparable me- Z1/001 1.
  • Page 135 BR/BD 100/250 R BP / RI Troubleshooting 6.2.2 Accessories module (A5) error messages Fault Display code Action Module classification Cable break or Z1/511 1. Check supply lines to the connected consumers short circuit at A5/X6, or X10 for consistency, short circuits or A5/X6, or X10 loose plug connections.

  • Page 136: Lifting Module (A4) And Cleaning Module (A3) Error Messages

    Troubleshooting BR/BD 100/250 R BP / RI 6.2.3 Lifting module (A4) and Cleaning module (A3) error messages Module involved: A3, A4 Module clone: Currently up to 2 lift modules and up to 2 cleaning modules are optionally possible. Display code: Hy/xxx for errors/warnings xxx of lift module y=(1, 2) Cy/xxx for errors/ warnings xxx of cleaning module y=(1, 2) C1 = Cleaning module clone A3 for scrubbing and vacuuming...
  • Page 137 BR/BD 100/250 R BP / RI Troubleshooting 6.2.3 Lifting module (A4) and Cleaning module (A3) error messages Module Fault Display code Action classification Error when Hy/101 1. Change menu in parameter setup. storing 2. Change to the setup of lift module (A4). setup parameters 3.
  • Page 138 Troubleshooting BR/BD 100/250 R BP / RI 6.2.3 Lifting module (A4) and Cleaning module (A3) error messages Module Fault Display code Action classification Short circuit or Hy/131 1. Disconnect lifting motor A4/X5-2,6. overload on A4/ 2. Perform key switch (S0) reset. If the error is X5-2/6 and/ replaced by another, then search for short circuit or A4/X4-2/6...
  • Page 139 BR/BD 100/250 R BP / RI Troubleshooting 6.2.3 Lifting module (A4) and Cleaning module (A3) error messages Module Fault Display code Action classification Cable break H1/142 Equipment version: Lifting motor - BR/BD 100/250 R suction beam 1. Disconnect lifting motor (M30) at A4/X4-2, 6. (M30) 2.
  • Page 140 Troubleshooting BR/BD 100/250 R BP / RI 6.2.3 Lifting module (A4) and Cleaning module (A3) error messages Module Fault Display code Action classification Power electronic Controls are 1. Switch off key switch (S0). unit for lifting too hot! Let control unit cool for at least 5 minutes. module (A3) is Cool off! 3.
  • Page 141 BR/BD 100/250 R BP / RI Troubleshooting 6.2.4 Head CPU (A1) error messages Module involved: Head CPU (A1) Module clone: There is only this bus master Display code: F1/xxx for faults/warnings of head CPU Module Fault Display code Action classification Actuator main K1/021 1.

  • Page 142: Head Cpu (A1) Error Messages

    Troubleshooting BR/BD 100/250 R BP / RI 6.2.4 Head CPU (A1) error messages Module Fault Display code Action classification No drive module K1/113 1. Couple drive module (A2) directly with the head (A2) found for CPU (A1). emergency 2. If fault remains, replace A2. operation Incorrect module K1/114...
  • Page 143 BR/BD 100/250 R BP / RI Troubleshooting 6.2.4 Head CPU (A1) error messages Module Fault Display code Action classification Forward and K1/163 1. Check function of travel direction switch (S2) (*) reverse operation and contact bonding. are present at the 2.

  • Page 144: Error Memory

    Troubleshooting BR/BD 100/250 R BP / RI 6.3 Error memory 6.3.1 Module error codes – Display pattern User messages Displays Displays A user message is an unformatted message dis- german englisch play. Sitzschalter seat switch User messages allow the operator to analyze unterbrochen! open! unacceptable machine conditions or operating...
  • Page 145 BR/BD 100/250 R BP / RI Troubleshooting 6.3 Error memory 6.3.1 Module error codes – Display pattern Display pattern of significant errors Error number: Module description :*) Head CPU module (A1) = 0 5 main errors are defined for each module (refer to Drive module (A2) = 1 chapter 6.3.2).

  • Page 146: Significant Errors (Head Cpu Module A1)

    Troubleshooting BR/BD 100/250 R BP / RI 6.3 Error memory 6.3.2 Significant errors (Head CPU module A1) Brief description/ Synonymous Potential causes Description Error Error description Run time of module number error No status query / K1/173 – Defective bus drivers. A1 has not received an –...

  • Page 147: Significant Errors (Drive Module A2)

    BR/BD 100/250 R BP / RI Troubleshooting 6.3 Error memory 6.3.3 Significant errors (Drive module A2) Brief description/ Synonymous Potential causes Description Error Error description Run time of module number error Short circuit drive F1/131 – Short-circuiting drive motor (M1). motor (M1) –...

  • Page 148: Significant Errors (Cleaning Module A3)

    Troubleshooting BR/BD 100/250 R BP / RI 6.3 Error memory 6.3.4 Significant errors (Cleaning module A3) Brief description/ Synonymous Potential causes Description Error Error description Run time of module number error Short circuit, brush C1/131 – Short circuit of brush motor(M2). motor (M2) C2/131 –...

  • Page 149: Significant Errors (Lifting Module A4)

    BR/BD 100/250 R BP / RI Troubleshooting 6.3 Error memory 6.3.5 Significant errors (Lifting module A4) Brief description/ Synonymous Potential causes Description Error Error description Run time of module number error Short circuit lifting H1/131 – Short circuit lifting motor. motor (M20, M30, M40) H2/131 –...

  • Page 150: Significant Errors (Accessories Module A5)

    Troubleshooting BR/BD 100/250 R BP / RI 6.3 Error memory 6.3.6 Significant errors (Accessories module A5) Brief description/ Synonymous Potential causes Description Error Error description Run time of module number error Module supply is not Z1/122 – Voltage drop in DC/DC conver- between 12V..14V / ter during operation.

  • Page 151: Maintenance Work

    BR/BD 100/250 R BP / RI Maintenance work Maintenance work Maintenance operations after working hours every every every every 1000 hours hours hours hours Check the battery poles for oxidation. Check the secure attachment of the battery connections. Check the acid level of the batteries (only for low- maintenance batteries).

  • Page 152: Maintenance Work

    Maintenance work BR/BD 100/250 R BP / RI Maintenance work Maintenance operations after working hours every every every every 1000 hours hours hours hours Test the functioning of the seat contact system: – Key switch to position „1“ – Select a driving direction –...

  • Page 153: Circuit Diagrams

    BR/BD 100/250 R BP / RI Circuit diagrams Circuit diagram 0.088-734.0 , Head CPU (A1) Service Manual 08.2007 Page 153 / 171...

  • Page 154: Circuit Diagram 0.088-876.0 , Head Cpu (A1)

    Circuit diagrams BR/BD 100/250 R BP / RI Circuit diagram 0.088-876.0 , Head CPU (A1) Service Manual 08.2007 Page 154 / 171...

  • Page 155: Circuit Diagram

    BR/BD 100/250 R BP / RI Circuit diagrams Circuit diagram 0.088-734.0 , 0.088-876.0 Driving module (A2) Service Manual 08.2007 Page 155 / 171...

  • Page 156: Circuit Diagram

    Circuit diagrams BR/BD 100/250 R BP / RI Circuit diagram 0.088-734.0 , 0.088-876.0 Cleaning module (A3) Service Manual 08.2007 Page 156 / 171...

  • Page 157: Circuit Diagram

    BR/BD 100/250 R BP / RI Circuit diagrams Circuit diagram 0.088-734.0 , 0.088-876.0 Cleaning module - Pre-sweeper unit (A3/1) Service Manual 08.2007 Page 157 / 171...

  • Page 158: Lifting Module (A4)

    Circuit diagrams BR/BD 100/250 R BP / RI Circuit diagram 0.088-734.0 , 0.088-876.0 Lifting module (A4) Service Manual 08.2007 Page 158 / 171...

  • Page 159: Circuit Diagram

    BR/BD 100/250 R BP / RI Circuit diagrams Circuit diagram 0.088-734.0 , 0.088-876.0 Lifting module - Side brush (A4/1) Service Manual 08.2007 Page 159 / 171...

  • Page 160: Lifting Module - Pre-Sweeper Unit (A4/2)

    Circuit diagrams BR/BD 100/250 R BP / RI Circuit diagram 0.088-734.0 , 0.088-876.0 Lifting module - Pre-sweeper unit (A4/2) Service Manual 08.2007 Page 160 / 171...

  • Page 161: Circuit Diagram 0.088-734.0

    BR/BD 100/250 R BP / RI Circuit diagrams Circuit diagram 0.088-734.0 , 0.088-876.0 Accessory module (A5) Service Manual 08.2007 Page 161 / 171...

  • Page 162: Listing

    Circuit diagrams BR/BD 100/250 R BP / RI 8.10 Circuit diagram 0.088-734.0 , 0.088-876.0 Listing A0 Warning-Info module (only 0.088-734.0) M14 Motor filter cleaning (Option) A1 Head CPU M20 Lifting motor, Brush head A2 Driving module M30 Lifting motor, Suction beam A3 Cleaning module M40 Lifting motor, Side brush (Option) A3/1Cleaning module - Pre-sweeper unit...

  • Page 163: Technical Specifications

    BR/BD 100/250 R BP / RI Technical features Technical specifications Unit type Unit No. Circuit diagram Operating Spare parts instructions list BR 100/250 R BP 1.480-111.0 0.088-734.0 5.961-388.0 5.970-364.0 0.088-876.0 BR 100/250 R BP Pack 1.480-121.0 0.088-734.0 5.961-388.0 5.970-364.0 0.088-876.0 BD 100/250 R BP 1.480-211.0 0.088-734.0...

  • Page 164: Special Tools

    Technical features BR/BD 100/250 R BP / RI 10 Special tools Steering wheel extraction tool 2.860-166.0 Cable set for tests on the modular controls 4.822-417.0 Mounting plate for brake adjustment 5.116-199.0 Multimeter 6.803-022.0 Torque wrench 2 - 25 Nm 6.815-090.0 Extraction tool for modular plugs (Molex) 6.816-086.0 Scope of supply - service package (chapter 4.9)

  • Page 165: Index

    BR/BD 100/250 R BP / RI Index 12 Index Brush drive assembly cover plate ....13 Brush head (BD version) ..... 10, 13, 107 Access to the setup menu ....94, 95 Brush head (BR version) ... 9, 13, 47, 48, 108 Access to the setup menu ......
  • Page 166 Index BR/BD 100/250 R BP / RI 12 Index Check/replace Coarse dirt container (BR version) ..13, 47 EMERGENCY OFF switch (S1) ....121 Coarse-dirt flap .......... 45 Check/replace float switch (S11) ..... 125 Coarse-dirt flap pedal ......... 46 Check/replace fuse (F1) ......121 Connecting plug (X1) with the Check/replace key switch (S0) ....
  • Page 167 BR/BD 100/250 R BP / RI Index 12 Index Dirty water tank overflows ....... 125 Filter for recycling mode (optional) ..... 47 Dirty water tank with Filter impeller fan and housing ....50, 51 recycling function (optional) ....... 19 Filter mounting plate ......... 125 Discharge lug ..........
  • Page 168 Index BR/BD 100/250 R BP / RI 12 Index Info-Mode switch, rotary and Microswitch (S20), brush head lowered ... 105 pusch button function ......... 20 Microswitch (S20) cam ......105 Information button, rotary and Microswitch (S21), brush head raised ..105 keying function ...........
  • Page 169 BR/BD 100/250 R BP / RI Index 12 Index cleaning module ......... 33 Retaining screws, motor ......107 Printed circuit board (A4/1), lifting module .. 33 Retaining screws, steering column ..103 Printed circuit board - cleaning module (A3/1), Return spring, coarse dirt flap ....45 (optional) ............
  • Page 170 Index BR/BD 100/250 R BP / RI 12 Index Spring, brush head ........13 Terminal strip (X12/A3) ....... 73 Spring for mounting plate with sealing strip 13 Terminal strip (X12/A3/1) ......75 Spring, lifting motor (M30) ....14, 104 Terminal strip (X2/A2) ......... 73 Springs, suction beam ........
  • Page 171 BR/BD 100/250 R BP / RI Index 12 Index Warning and information module (A0) ..70 Warning code ........... 126 Warning messages ........126 Water connection ........109 Water distribution tube ........ 47 Water filter ..........9, 16 Water filter, fresh water ....... 47 Water filter with housing ......

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