Kärcher Tornado BR User manual

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BR/BD Trike
5.959-413 A 2001381 12/05

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Operating Instructions BR/BD Trike English
4
Safety notes
Before using the unit, please read and
comply with the operating instructions and
the enclosed brochure “Safety instructions
for brush cleaning units and spray
extraction units”, No. 5.956-251.
It is permitted to operate the unit on
surfaces with no more than a 10 % incline.
The unit may only be operated when the
hood and all covers have been closed.
Safety features
Safety features are intended to protect the
user and must not be disconnected or
bypassed.
Emergency STOP pushbutton
Immediately stops all functions To unlock
the Emergency STOP pushbutton, rotate it
slightly to the right and release.
Safety switch
Switches the drive motor off if the operator
leaves his seat while operating or driving
the unit.
Symbols
The following symbols are used in these
operating instructions:
Danger!
Indicates imminent danger. Non-
compliance with this warning may result in
death or serious injury.
Caution!
Indicates a potentially dangerous
situation. Non-compliance with this warning
may result in slight injury or damage to
property.
Information:
Indicates application tips and
important product information.
Function
The BR/BD Trike is used for wet-cleaning
of level floors. It can easily be adjusted to
a particular cleaning task by setting the
water flow rate, the contact pressure of the
brushes and extraction of dirty water.
An operating width of up to 640 mm
(BR model) or 695 mm (BD model) and an
80 l fresh-water tank and dirty-water tank
enable effective cleaning over a prolonged
period.
The unit is self-propelled; the driving motor
is powered by four batteries.
Information:
The unit can be fitted with various
accessories for a particular cleaning task.
Ask for our catalogue or visit us on the
Internet at www.karcher.com.
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English Operating Instructions BR/BD Trike
5
Appropriate use
Use this unit exclusively in accordance with
the information in these operating
instructions.
– The unit may be used for cleaning non-
moisture-sensitive smooth floors only.
– The unit is not suitable for cleaning
frozen floors (e.g. in cold-storage
depots).
– The unit may be fitted with original
accessories and spare parts only.
– The unit has been developed for
cleaning indoor floors or covered areas.
The use of alternative brushes must be
tested for other application areas.
– The unit has not been designed for
cleaning public highways.
Protection of the
environment, disposal
Do not simply throw packaging into the
household rubbish.
Take the packaging components to the
appropriate collection points for recycling.

Operating Instructions BR/BD Trike English
6
Operating and function controls
1 Manual water control
2Cover
3Seat
4 Fresh/dirty-water tank
5 Recycling filter and pump (optional)*
6 Threaded plug for fresh-water tank
7 Metering equipment
8 Drainage hose for dirty water
9 Clip for attaching the battery cover
10 Suction hose
11 Battery cover
12 Star knobs for attaching the suction bar
13 Suction bar**
14 Star knobs
for inclining the suction bar
15 Batteries
16 Fresh-water drainage tap
17 Brush roller (BR model)
Disc brush (BD model)*
18 Cleaning head
19 Selector switch for recycling/
fresh-water mode (optional)
20 Suction motor
21 Magnet brake for drive motor
22 Front panel
23 Electronics module/printed circuit
board
24 Steering wheel
25 Battery plug connection
* not illustrated
** not supplied with the appliance

English Operating Instructions BR/BD Trike
7
Control console
1 Mains plug for battery charger
(package version)
2Horn
3 Pushbutton for reverse driving
4 Pushbutton for forward driving
5 Pushbutton for information display
(optional)
6 Battery charger monitor
(package version)
7 Display (optional)
8 Battery monitor
9 Emergency STOP pushbutton
10 Key switch
11 Water metering pedal
12 Drive pedal reverse/forwards
13 Manual water control
14 Star knob
for adjusting the brush contact
pressure
15 Pedal for raising/lowering the suction
bar
16 Pedal for raising/lowering the brush
head

Operating Instructions BR/BD Trike English
8
Before switching on
the unit
Batteries
When handling batteries, comply with the
following warning symbols:
Comply with the information on the
battery, in the operating instructions
and in the vehicle operating
instructions.
Wear eye protection
Keep children away from acid and
batteries
Danger of explosion
No naked flames, sparks or naked
lights and no smoking
Risk of chemical burns
First Aid
Warning
Disposal
Do not throw the battery
in the dustbin
Danger of explosion!
Do not place any tools or similar
objects on the battery, i.e. on the terminals
and intercell connectors.
Risk of injury!
Do not bring any wounds into contact
with lead; after working with batteries,
always wash hands.
Inserting and connecting batteries
The batteries are already installed in the
BAT package variant.
Remove the suction hose from the
suction bar.
Unscrew the star knob slightly and
swivel the bracket off.
Remove the battery cover.
Lift up the water tank and cover and
engage the support.
Insert the batteries into the container
flush with the cleaning head.
Grease the terminals and connect to the
enclosed cables.
Caution!
Ensure that the polarity is correct!
Clamp the supplied connection cable to
the remaining free battery terminals (+)
and (–).
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English Operating Instructions BR/BD Trike
9
Unlock the support and swivel back the
water tank and cover.
Insert the battery cover.
Tighten the star knob.
Caution!
Before switching on the unit, charge
the batteries!
Charging the batteries
Information:
The unit features deep-discharge
protection, i.e. if the still permitted minimum
capacity value is reached, the brush motors
and the turbine are switched off. In this
case the battery charge status display on
the control console illuminates red. From
this moment on the unit can only be driven.
Drive the unit directly to the charging
station, avoiding any inclines.
Information:
If using other batteries (e.g. another
manufacturer), the deep-discharge
protection for the particular battery must be
re-adjusted by Kärcher customer service.
Danger of electric shock!
Note power supply system and
fusing –see “Battery charger”.
Never use the battery charger in rain, in
high atmospheric humidity or in damp
rooms!
Information:
The battery charging process lasts
on average 10–15 hours.
The recommended battery chargers (which
correspond to the utilised batteries) are
electronically controlled and end the
charging process automatically.
Charging process BR/BD Trike BAT
Danger of explosion!
Open the hood before charging lead-
acid batteries.
Remove the battery cover.
Lift up the water tank and cover and
engage the support.
Remove the battery connector and
connect to the charger cable.
Switch on battery charger.
After charging the battery:
Switch off the battery charger and
disconnect from the power supply.
Remove the charging cable and connect
to the battery plug connection.
Non-maintenance-free batteries
One hour before the end of the charging
process, add distilled water, ensuring
that the acid level is correct. Batteries
are identified accordingly. At the end of
the charging process all cells must gas.
Risk of injury!
If a discharged battery is refilled
with water, acid may escape!
When handling battery acid, wear
protective goggles and follow the
instructions to prevent injury and damage
to clothing.
Immediately wash off any acid splashes on
the skin or clothing using plenty of water.
Caution!
Use only chemically pure battery acid
(in compliance with VDE 0510),
concentration 1.28 kg/l.
Refill the batteries with distilled or
demineralised water only (VDE 0510).
Do not use additives (so-called enhancing
agents), otherwise any warranty will be
invalidated.
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Operating Instructions BR/BD Trike English
10
Recommended batteries
* not approved for the BAT package variant
Caution!
Use only maintenance-free batteries
with package battery chargers.
Maximum dimensions
The following is to be observed if lead-acid
batteries are used in the BAT variant:
– Lead-acid batteries must be housed in
a battery container (accessory).
– Observe the maximum battery
dimensions.
– The tank must be folded open while
charging lead-acid batteries.
– When charging lead-acid batteries,
comply with the regulations of the
battery manufacturer.
Attaching the steering wheel
Attach the steering wheel and tighten
the clamping screw.
Caution!
The steering wheel must be attached
firmly; observe the minimum insertion
depth of 65 mm.
Manufacturer
Kärcher
order no.
Description
Hagen
6.654-070*
24 V PzS 175 (5)
low-maintenance
Capacity: 175 Ah
Voltage: 4 x 6 V
Hagen
6.654-071
24 V GiV 160 (5)
maintenance-free
Capacity: 160 Ah
Voltage: 4 x 6 V
DETA
6.654-130
24 V GiV 180 DTP
maintenance-free
Capacity: 180 Ah
Voltage: 4 x 6 V
DETA
6.654-089
24 V GiV 160 DT
maintenance-free
Capacity: 160 Ah
Voltage: 4 x 6 V
SONNEN-
SCHEIN*
020 8517 405
low-maintenance
Capacity: 175 Ah
Voltage: 4 x 6 V
SONNEN-
SCHEIN
021 9216 000
maintenance-free
Capacity: 160 Ah
Voltage: 4 x 6 V
Length Width Height
Battery
set (4x)
520 mm 380 mm 290 mm
Single
battery
260 mm 190 mm 290 mm

English Operating Instructions BR/BD Trike
11
Unloading the unit
Risk of injury!
To stop all functions immediately,
press the red Emergency STOP
pushbutton.
Place the long, lateral planks from the
packaging on the pallet and form a ramp.
Secure the planks with nails.
Support the ramp by placing the shorter
planks underneath.
Remove the wooden laths.
Raise the cleaning head with the pedal
and lock it.
Set key switch to “I”.
Press ”Direction-of-travel” pushbutton
and slowly run the unit down the ramp.
Set key switch back to “O”.
Attaching the brushes
BD Trike
Before switching on the unit, the disc
brushes must be attached (see
“Maintenance procedures”).
Attaching the suction bar
Unlock the suction bar pedal.
Insert the suction bar into the suction-
bar suspension device, ensuring that the
profiled sheet is situated over the
suspension device.
Tighten the star knobs.
Check that the traction cable functions
correctly.
Attach the suction hose.
Operation
Risk of injury!
To stop all functions immediately,
press the red Emergency STOP pushbutton.
Driving
Caution!
Get used to your unit by test-driving
it in an open space.
Drive up/down slopes at low speed only.
Information:
The unit has a projecting brush head
on the right side, ensuring a clear view
when cleaning right up to the edge.
Sit on the unit and set the key switch
to “I".
Set the direction of travel with the
“Direction-of-travel” buttons on the
control panel.
Specify the driving speed by depressing
the drive pedal.
To stop the unit: release the drive pedal.
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Operating Instructions BR/BD Trike English
12
Adding detergent
Caution!
Use the recommended detergents
only. If other detergents are used, the
operator increases the risk of malfunctions
and accidents.
Detergents must not contain solvents,
hydrochloric acid or hydrofluoric acid.
Information:
Do not use detergents which foam
vigorously.
Before switching on the unit for the first
time, completely fill the fresh-water tank in
order to vent the water line system.
Working without recycling
If cleaning in hygienic areas (e.g. hospitals,
food companies) and if giving very dirty
floors a basic cleaning.
Open the threaded plug on the fresh-
water tank.
Fill with fresh water (maximum 60 °C)
up to the lower edge of the filler inlet
Add detergent.
Comply with the metering information.
Close the threaded plug on the fresh-
water tank.
Working in recycling mode (optional)
For cleaning slightly to normally dirty floors.
Detergent and setting-up times are
reduced in recycling mode.
When the fresh-water tank is empty and
the dirty-water tank is full, set the rotary
knob to recycling mode.
Information:
Dirty water is filtered before being
reused.
Recycling mode requires a feed pump
which conveys the fresh and recycled water
to the brushes.
If the fresh water goes directly into the dirty-
water tank, recycling mode can be actuated
at the start of the cleaning process.
Recommended detergents
Detergents are available from specialist
outlets.
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Application: Detergents
Maintenance cleaning
(also for alkaline-sensitive
floors)
RM 745
RM 746
Cleaning greasy dirt
deposits
RM 69 ES ASF
RM 69 ASF
Basic cleaning
(stripping) alkaline-
resistant hard floor
coverings
RM 752
Basic cleaning
stripping linoleum
RM 754
Sanitary cleaner RM 25 ASF
Disinfectant cleaner RM 732
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English Operating Instructions BR/BD Trike
13
Setting the water flow rate
Set the maximum water flow rate with
the control knob.
Control the water flow rate by
depressing the metering pedal.
Simultaneous depression of the drive
and metering pedals ensures that
metering is speed-dependent.
Information:
The surface must be cleaned several
times depending on the degree of dirt.
Lowering the suction bar
Unlock the suction bar pedal by gently
pushing it to the right.
The suction bar is lowered and the
suction motor switches on.
Caution!
To clean tiled floors, adjust the
straight suction bar so that it is not at right
angles to the crevices. When the dirty-
water tank is full, the suction turbine
automatically switches off.
Information:
To improve the vacuuming result,
the suction bar can be rotated or tilted
(see “Setting the suction bar”).
Switching on the brush head
Caution!
To prevent damage to the floor, do
not operate the unit on the spot.
Depress the pedal and unlock by
simultaneously tilting it forwards;
the cleaning head is lowered and the
brush motor starts automatically.
Adjust the brush contact pressure with
the star knob.
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Operating Instructions BR/BD Trike English
14
Information:
Start cleaning at a low contact
pressure. Gradually increase the contact
pressure until the desired cleaning result
is obtained.
A correctly set contact pressure reduces
the energy requirement and brush wear.
If the machine stops, the brush motors
stop. If the brush motors overload, the fuse
trips. In this case, the fuse must be
changed (F2, 70 A).
Caution!
The brush contact pressure must not
be set too high for polishing.
Stopping and switching off
the unit
Raise and lock the brush head
To do this, depress the brush head
pedal and lock by simultaneously tilting it
backwards.
The motor switches off automatically.
Move the unit another 1–2 m to extract
any remaining water.
Raise the suction bar.
To do this, depress the suction bar pedal
and lock by gently pushing it to the left.
The suction motor coasts for a further
10 seconds to extract remaining water out
of the suction bar and vacuum channels.
Set the key switch on the control panel
to “O” and remove the key.
Draining the dirty water
Caution!
Observe local regulations for
the treatment of waste water.
Take the drainage hose out of the holder
and place in a suitable receptacle. Drain
off the dirty water by opening the
metering equipment. Then rinse out the
dirty-water tank with fresh water.
Adjusting the suction bar
Rotating the suction bar
To improve the suction result on ceramic
coverings, the suction bar can be rotated by
up to 5°:
Loosen the star knobs.
Rotate the suction bar.
Tighten the star knobs.
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English Operating Instructions BR/BD Trike
15
Tilting the suction bar
If the suction result is unsatisfactory,
the straight suction bar can be tilted.
Loosen the wing nuts.
Tilt the suction bar.
Tighten the wing nuts.
Care and maintenance
Risk of injury!
Before working on the appliance,
always set the key switch to “O”, remove
the key and disconnect the mains plug from
the battery charger.
Drain off and dispose of dirty water and
any residual cleaning liquid.
Maintenance schedule
After work
Caution!
Do not spray the unit with water or
use any aggressive detergents.
Drain off the dirty water.
Rinse out the dirty-water tank with fresh
water.
Clean the outside of the unit with a damp
cloth soaked in a mild detergent
solution.
Check the fluff strainer on the intake
neck of the suction motor and, if
required, clean.
Remove the squeegee blades, check
for wear and, if required, replace.
Check the brushes for wear and,
if required, replace.
Monthly
Check the battery terminals for oxidation
and, if required, lubricate with terminal
grease. Ensure that the connection
cables are secure.
Check that the parking brake functions.
Check the condition of the container
cover seals and, if required, replace.
If non-maintenance-free batteries are
used, check the acid concentration of
the cells.
Clean the brush tunnel.
Annually
Have customer service conduct the
stipulated inspection.
Maintenance procedures
Replacing the squeegee blades
Loosen the star knobs.
Remove the squeegee blades.
Attach the new squeegee blades.
Tighten the star knobs.
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Operating Instructions BR/BD Trike English
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Replacing the roller brushes
Loosen the wing nuts.
Remove the bearing cover.
Remove both roller brushes, insert new
ones (note hexagon fixtures for the roller
brushes).
Attach bearing cover.
Tighten the wing nuts.
Replacing disc brushes
Raise the disc brushes.
Rotate disc brushes by approx. 45° in an
anti-clockwise direction.
Pull down and remove disc brushes.
Insert the new disc brushes in reverse
sequence.
Maintenance agreement
To ensure that the unit operates reliably,
maintenance agreements can be
concluded with the appropriate Kärcher
sales office.
Frost protection
If there is a risk of frost
Drain the fresh-water and dirty-water
tanks.
Put the unit in a room which is protected
from frost.
Transportation
Risk of injury!
The unit may be loaded and
unloaded on max. 10 % inclines only.
If transporting the unit by vehicle, secure
the unit with tension belts/ropes to
prevent it from sliding.
Raise the cleaning head to prevent
damage to the brushes.
BD Trike
Remove the disc brushes from the brush
head.
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English Operating Instructions BR/BD Trike
17
Troubleshooting
Risk of injury!
Before working on the appliance,
always set the key switch to “O”, remove
the key and disconnect the mains plug from
the battery charger.
Drain off and dispose of dirty water and
any residual cleaning liquid.
If faults cannot be rectified with the aid of
this table, contact customer service.
Changing the fuses
The drive control/electronics module is
attached under the front panel. If a fuse has
to be changed, this front panel must be
removed.
Loosen the screws on the housing.
Change the fuse.
Re-attach the front panel.
Information:
The fuse configuration is indicated on
the inside of the front panel.
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Fault Remedial action
Unit cannot be started. Check fuses F1 and F4 and, if required, change.
Check batteries; if required, replace.
Unit does not move. Check fuse F5; if required, replace.
Inadequate water flow rate. Check fresh-water level; if required, top up tank.
Check hoses for blockages; remove any blockages.
Display: “Gas pedal” Set key switch to “O” and then back to “I” without
depressing the gas pedal.
Inadequate suction power. Check fuse F3; if required, replace.
Clean container cover seals and check for leaks;
if required, replace.
Clean the fluff strainer on the intake neck of the suction
motor.
Clean squeegee blades on the suction bar; if required,
replace.
Check suction hose for blockages; remove any
blockages.
Check suction hose for leaks; if required, replace.

Operating Instructions BR/BD Trike English
18
Accessories
Inadequate suction power. Check whether metering equipment on the dirty-water
drainage hose is closed.
Check the setting of the suction bar.
Unsatisfactory cleaning
result.
Adjust contact pressure.
Check brushes for wear; if required, replace.
Brushes do not rotate. Reduce contact pressure.
Check whether the brushes are blocked by foreign
objects; if required, remove foreign objects.
Check fuse F2; if required, replace.
Designation Part no. Description Quantity
Quantity
required
for unit
Brush roller, red (standard) 5.762-130 for maintenance
cleaning of very dirty
floors
12
Brush roller, white (soft) 5.762-131 for polishing and for
maintenance cleaning
of sensitive floors
12
Brush roller orange
(high/low)
5.762-132 for scrubbing of
structured floors
(safety tiles, etc.)
12
Brush roller, green (hard) 5.762-133 for basic cleaning of
very dirty floors and
for removal of coatings
(e.g. wax, acrylates)
12
Brush roller, black (very hard) 5.762-189 1 2
Pad roller shaft 4.762-188 for housing roller pads 1 2
Roller pad (white) 6.369-389 20 80
Roller pad (red) 6.369-456 for cleaning of slightly
dirty floors
20 80
Fault Remedial action

English Operating Instructions BR/BD Trike
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Roller pad (green) 6.369-455 for cleaning of normal
to very dirty floors
20 80
Roller pad (yellow) 6.369-454 for polishing of floors 20 80
Disc brushes, nature 6.958-233 for polishing of floors 1 1
Disc brush, red 6.958-234 for cleaning of slightly or
sensitive floors
11
Disc brush, black grit 6.958-235 for cleaning of very dirty
floors
11
Driving plate 6.906-333 for housing pads 1 1
Disc pad (red) 6.369-003 for cleaning of slightly
dirty floors
51
Disc pad (green) 6.369-002 for cleaning of very dirty
floors
51
Disc pad (black) 6.369-001 for cleaning of very dirty
floors
51
Rubber squeegee, grey 6.273-179 Standard pair 1 pair
Rubber squeegee,
oil-resistant
6.273-180 oil-resistant pair 1 pair
Suction bar, straight 4.777-034 Standard 1 1
Suction bar, curved 4.777-035 Standard 1 1
Battery container 5.039-042 for lead-acid batteries 1 1
Designation Part no. Description Quantity
Quantity
required
for unit

Operating Instructions BR/BD Trike English
20
Technical Specifications
Unit BR BD
Power
Nominal voltage V 24 24
Battery capacity Ah(5h) 160 160
Power consumption W 2200 2300
Driving motor output W 600 600
Suction motor output W 500 500
Brush motor output W 1100 2 x 600
Suction
Suction power, air flow rate l/s 22 22
Suction power, vacuum mbar 115 115
Cleaning brush
Operating width mm 640 695
Diameter, brush roller mm 105 360
Brush speed 1/min 1400 180
Dimensions and weight
Max. driving speed km/h 6 6
Max. gradient % 10 10
Theoretical surface performance m2/h 2880 3150
Volume, fresh/dirt-water tanks l 80/80 80/80
Weight (with/without batteries) kg 300/170 295/165
Noise emission
Average sound pressure level in
compliance with EN 60704
dB(A) 70 70
Vibrations of unit in compliance with ISO 5349 and ISO 2631-1
Upper elements of steering wheel m/s20.39 0.39
Whole seat m/s20.105 0.105