Kärcher BR 30/4 C User manual

English 5.906-434.0 Rev. 00 (12/10) 1
BR 30/4 C
BR 30/4 C Adv
BR 30/4 C Bp Pack
BR 4.300
Service Manual

2 English 5.906-434.0 Rev. 00 (12/10)

English 5.906-434.0 Rev. 00 (12/10) 3
1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Hazard levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Operation and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Vacuuming operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Vacuum bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Cleaning operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Setup and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Front view (BR 30/4 C Adv and BR 30/4 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Front view (BR 30/4 C Bp Pack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Rear view (BR 30/4 C Adv and BR 30/4 C / BR 30/4 C Bp Pack). . . . . . . . . . . 9
4.4 View from below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5.1 Parking/operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5.2 Raising/lowering the vacuum bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5.3 Removing the tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5.4 Insert suction nozzle (BR 30/4 C Adv only) . . . . . . . . . . . . . . . . . . . . . . 13
4.5.5 Water flow schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5.6 Remove the cover from the cleaning head. . . . . . . . . . . . . . . . . . . . . . . 15
4.5.7 Replace the batteries (BR 30/4 C Bp Pack only) . . . . . . . . . . . . . . . . . . 15
4.5.8 LED display on the brush head (BR 30/4 C Bp Pack only) . . . . . . . . . . 16
4.5.9 Displays on the charger (BR 30/4 C Bp Pack only) . . . . . . . . . . . . . . . . 16
4.5.10 Control board (BR 30/4 C Bp Pack only) . . . . . . . . . . . . . . . . . . . . . . . 17
4.5.11 Balance weight (BR 30/4 C Bp Pack only) . . . . . . . . . . . . . . . . . . . . . . 17
5 Basic settings and service procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Removing the appliance components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1.1 Replacing the main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1.2 Replacing the water pump switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1.3 Replacing the brush roller intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.4 Replacing the brush roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.5 Replacing the water distribution bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.6 Replace the vacuum bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.7 Removing the cleaning head housing . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.4 Replacing the water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.9 Voltage measurement on the water pump . . . . . . . . . . . . . . . . . . . . . . . 24
5.1.10 Replacing the toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1.11 Replace the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.12 Replacing the suction turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.13 Remove the parking position release. . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.14 Cleaning the suction channel, the suction pipe and the suction hose . 29
5.1.15 Replace the control board (BR 30/4 C Bp Pack only) . . . . . . . . . . . . . 30
5.1.16 Remove the balance weight (BR 30/4 C Bp Pack only). . . . . . . . . . . . 31

4 English 5.906-434.0 Rev. 00 (12/10)
5.2 Check the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.1 Voltage measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.2 Resistance measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1 Circuit diagram 0.089-099.0 - BR 30/4 C (230V/50-60 Hz), BR 4.300 . . . . . . 34
7.2 Circuit diagram 0.089-149.0 - BR 30/4 C (120 V/60 Hz). . . . . . . . . . . . . . . . . 35
7.3 Circuit diagram 0.089-150.0 - BR 30/4 C (100V/50-60 Hz). . . . . . . . . . . . . . . 36
7.4 Circuit diagram 0.089-305.0 - BR 30/4 C Bp Pack . . . . . . . . . . . . . . . . . . . . . 37
8 Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.1 BR 30/4 C - power models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2 BR 30/4 C Bp Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.3 Exchange times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.4 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9 Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

English 5.906-434.0 Rev. 00 (12/10) 5
Good service work requires extensive and practice-
oriented training as well as well-structured training
materials.
Hence we offer regular basic and advanced training
programmes covering the entire product range for all
service engineers.
In addition to this, we also prepare service manuals
for important appliances - these can be initially used
as instruction guides and later on as reference
guides.
Apart from this, we also regular information about
product enhancements and their servicing.
If you should require supplements, have corrections
or questions regarding this document, please ad-
dress these citing the following subject to:
[email protected]
The responsible product specialist will take care of
your issue.
Copyingand duplicationoftexts anddiagramsas
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
Note
Indicates useful tips and important information about
the product.
The appliance is used for the wet cleaning of level
floors.
A working width of 300 mm and a capacity of 4 l each
of the fresh and dirt water reservoirs enable an effec-
tive cleaning of smaller surfaces.
The power supply operation allows a high capacity
without a restriction of the working time.
–The appliance can be used in a forward motion by
pushing it and backwards by pulling it by the han-
dle.
The fresh water tank must be filled with the correct
mixtureofwateranddetergent prior to operation.The
detergentsolutionflowsto thebrushheadvia a water
pump and is revacuumed by two vacuum bars.
–Content of fresh water tank: 3.7 l
–Content of wastewater reservoir: 3.7 l
The suction turbine (M1) produces a vacuum pres-
sure in the wastewater reservoir, which pulls the
wastewater from the vacuum bar to the wastewater
reservoir.
If the wastewater reservoir is full, the float closes the
suction opening.
The wastewater reservoir can be removed from the
appliance for cleaning purposes.
Note
The suction turbine (M1) does not switch off automat-
ically when the wastewater reservoir is full. Only
when you press the main switch, the suction turbine
(M1) will shut off.
For the appliances BR 30/4 C and BR 30/4 C Bp
Pack, it is possible to lift the suction bar and perform
a wet cleaning only.
The BR 4.300 does not have a suction bar lift.
The vacuum bar can be replaced without the use of
tools.
The switches for the operation of the appliance are lo-
cated in the handle and on top of the housing.
–The main switch (S1) for brushing and vacuuming
operations are located on top of the housing.
–The switch (S2) for the operation of the water
pump (M3) is located in the handle.
Mains models
–230V / 50/60Hz / 16A.
–120V / 60Hz / 15A
–100V / 50/60Hz / 7A
BR 30/4 C Bp Pack
–Two batteries at 25.2 V / 3.3 Ah each
1 Preface
Subject: Case
111410
2 Safety instructions
2.1 Hazard levels
3 Technical Features
3.1 Operation and control
3.2 Water System
3.3 Vacuuming operations
3.4 Vacuum bar
3.5 Electrical system

6 English 5.906-434.0 Rev. 00 (12/10)
The brush contact pressure cannot be adjusted.
The brush roller has a diameter of 60 mm. It rotates
at 1,450 rpm for the mains model and at 1,270 for the
battery model.
BR 30/4 C Adv
To vacuum in corners, a vacuuming nozzle can be at-
tached to the vacuum pipe of this model.
3.6 Cleaning operations

English 5.906-434.0 Rev. 00 (12/10) 7
1 Handle
2 Cable hook
3 Main switch for brushing/vacuuming operations
4 Fresh water tank lock
5 Release, park position
6 Vacuum bar lift pedal
7 Cleaning head
8 Fresh water tank
9 Fresh water level display
10Release of fresh water reservoir
11Dirt water reservoir
12Release, wastewater reservoir
13Carrying handle
14Water pump switch
4 Setup and function
4.1 Front view (BR 30/4 C Adv and BR 30/4 C)

8 English 5.906-434.0 Rev. 00 (12/10)
1 Handle
2 Main switch for brushing/vacuuming operations
3 Fresh water tank lock
4 Release, park position
5 Vacuum bar lift pedal
6 Cleaning head
7 Batteries, 2 x 25.2 VDC
8 Fresh water tank
9 Fresh water level display
10Release of fresh water reservoir
11Dirt water reservoir
12Release, wastewater reservoir
13Carrying handle
14Water pump switch
15Charging station 1
16Charging station 3
17Charger
18Mains cable
19Battery at charging station 4
20Charging station 2
21Battery charge indicator
4.2 Front view (BR 30/4 C Bp Pack)

English 5.906-434.0 Rev. 00 (12/10) 9
1 Handle
2 Cable hook
3 Cable hook, rotating
4 Vacuum nozzle intake
5 Exhaust air cover
6 Suction hose
7 Release, park position
8 Suction tube connection
9 Suction pipe
10Bellow
11Vacuum bar holder (BR 30/4 C Adv only)
12Suction nozzle (BR 30/4 C Adv only)
13Vacuum bar (BR 30/4 C Adv only)
14Suction tube handle (BR 30/4 C Adv only)
4.3 Rear view (BR 30/4 C Adv and BR 30/4 C / BR 30/4 C Bp Pack)

10 English 5.906-434.0 Rev. 00 (12/10)
1 Park roller
2 Space roller
3 Rear vacuum bar
4 Brush roller
5 Front vacuum bar
6 Space roller
The spacer rollers prevent the cleaning head from
scraping on the floor when the brush is worn.
4.4 View from below

English 5.906-434.0 Rev. 00 (12/10) 11
ÎTo operate, the release of the parking position
must be pressed (small arrow) and the appliance
has to be swivelled back simultaneously. The
parking roller submerges into the cleaning head
and the brush roller touches the floor.
1 Pedal position, vacuum bar raised
2 Vacuum bar lift pedal
3 Pedal position, vacuum bar lowered
The vacuum bars can be raised or lowered using the
pedal for the vacuum bar lift.
Note
Turn the appliance off before you activate the suction
bar lift. Otherwise, the brush drive can be triggered.
The BR 4.300 does not have a suction bar lift.
1 Dirt water reservoir
2 Fresh water tank
3 Wastewater inlet opening with seal
4 Suction pipe
5 Funnel for fresh water inlet
6 Suction air channel
7 Suction air stub with seal
ÎThe fresh water reservoir and the wastewater res-
ervoir can be removed to fill, empty and clean the
appliance.
4.5 Function
4.5.1 Parking/operating position
4.5.2 Raising/lowering the vacuum bar
4.5.3 Removing the tanks

12 English 5.906-434.0 Rev. 00 (12/10)
1 Fresh water tank
2 Fresh water tank lock
3 Release of fresh water reservoir
ÎPull on the release and remove the fresh water
reservoir from the appliance toward the front.
ÎTo fill the fresh water tank, open the latch and fill
the fresh water tank with water and detergent.
1 Water outlet valve
2 Tappet
ÎThe water outlet valve is located at the bottom of
the fresh water reservoir.
1Valvepin
2Sieve
ÎWhen inserting it into the appliance, the valve pin
pushes the tappet into the water outlet valve and
the water can flow to the water pump (M2).
ÎThe contaminated sieve can be removed for
cleaning.
1 Spring element
The spring element pushes the wastewater reservoir
down. This will prevent damage to the seal rings dur-
ing the installation of the wastewater reservoir.

English 5.906-434.0 Rev. 00 (12/10) 13
1 Dirt water reservoir
2 Release, wastewater reservoir
ÎPush the release for the wastewater reservoir
down and remove the wastewater reservoir from
the appliance toward the front.
1 Dirt water reservoir
2 Cover dirt water reservoir
3 Air suction opening
4 Wastewater inlet opening
5 Lock, lid
ÎThe lid of the wastewater reservoir houses the air
suction opening and the wastewater inlet opening.
ÎIn order to remove the lid, open the lock and pull
the lid off the wastewater reservoir upwards.
1 Wastewater inlet opening
2 Water separator
3 Cover dirt water reservoir
4Seal
5 Floater seal
6 Locking flap
7 Float
ÎThe floater is located in the lid. This floater closes
up the air suction opening and suctioning is no
longer possible.
ÎThe wastewater reservoir needs to be emptied.
With model BR 30/4 C Adv, a suction nozzle can be
attached to vacuum in corners.
1 Suction pipe holder
2 Suction pipe
ÎRemove the suction pipe from the suction pipe
holder.
4.5.4 Insert suction nozzle (BR 30/4 C Adv only)

14 English 5.906-434.0 Rev. 00 (12/10)
1 Suction nozzle
2 Suction tube connection
3 Suction pipe
ÎPull the suction pipe out of the suction pipe con-
nection toward the top.
1 Suction pipe
2 Suction nozzle
ÎAttach the suction nozzle to the suction pipe.
1 Dirt water reservoir
2 Fresh water tank
3 Rear vacuum bar
4 Cleaning head
5 Brush roller
6 Front vacuum bar
7 Water distribution bar
4.5.5 Water flow schematic

English 5.906-434.0 Rev. 00 (12/10) 15
1 Cover of cleaning head
2 Vacuum bar lift pedal
ÎRemove the cover from the cleaning head toward
the top.
The cover has several hooks that lock into the
cleaning head.
1 Vacuum bar lift pedal
2 Vacuum bar guide
3 Vacuum bar
4 Vacuum bar holder
5 Suction channel
ÎPressthereleaseandpullthedepletedbattery out
of the battery compartment.
ÎInsert the charged batteries into the battery com-
partment and push in until they lock into place.
4.5.6 Remove the cover from the cleaning head 4.5.7 Replace the batteries (BR 30/4 C Bp Pack
only)

16 English 5.906-434.0 Rev. 00 (12/10)
1 LED operating status display, left battery
2 Battery storage
3 Battery compartment
4 Battery
5 LED operating status display, right battery
There are two batteries in the appliance and respec-
tively2LEDoperatingstatusdisplays. Bothcanshow
the colours green, orange and red.
LED green: U= >22.00 V
LED orange: U= >20.00 V
LED red: U= <20.00 V
Both battery voltages are measured after switching
on the appliance. The depleted batteries are added
and the LED assigned tois will illuminate green when
the batteries are fully charged.
The second battery pack is not added until the first
one has been discharged and switched off. If the sec-
ond battery pack is not charged or if the appliance is
operated by battery power only, the respective LED
will light up red immediately after you turn it on.
As soon as the active batteries do not reach the de-
fined voltage level, the LED will switch to orange. If
the batteries have been depleted all the way down to
the deep discharge level, it will be switched off. The
respective LED will now illuminate in red and the sec-
ond battery pack will be switched on/added. Its
charging status will be displayed via the LED as-
signed to it according to its violtage level.
After the second battery pack has been depleted,
both LEDs will light up red; the appliance will auto-
matically switch off after 30 seconds.
1 Red LED charge status display
2 Green LED charge status display
3 Illumination examples for green LED charge sta-
tus display
4 Illumination examples for red LED charge status
display
Every charging station (1-4) has two LED charge sta-
tus display. A red one and a green one. Depending
on the charge status of thebatteries, the LEDs will re-
main illuminated continuously or they will blink.
Blinks green: Battery is being charged.
Continuously illuminated green: Battery is fully
charged.
Blinks red: Batteries defective.
Continuouslyilluminatedred:Thebatteriesaretoo
hot or too cold.
Note
Thechargerchargesthebatteriesbetween0°and45
°C. If the batteries are inserted into the charger while
theyarestill warm, the redLEDwillbeilluminated.As
soon as the batteries have cooled down, the charger
will begin charging and the LED will blink green.
4.5.8 LED display on the brush head (BR 30/4 C
Bp Pack only) 4.5.9 Displays on the charger (BR 30/4 C Bp Pack
only)

English 5.906-434.0 Rev. 00 (12/10) 17
The printed circuit board allows the safe and reliable
operation of the battery-poweredBR 30/4 via voltage
and current measurement.
Battery test
There are two different switch-on criteria.
A After every switch-on, both batteries are checked.
The depleted battery is always activated, unless
its idle voltage is at least 20.5 Volts. A completely
discharged battery is indicated by a red LED im-
mediately and continuously.
Ifbothbatteriesarebelowthis minimumthreshold,
the appliance cannot be started.
B During the discharge, the active batteries are
measured permanently and switched off accord-
ingly to prevent a depth discharge.
Over current switchoff
After switching on the BR 30/4, the electric motor will
start via a startup ramp. This will last approx. 3.8 sec-
onds. This way, startup currents that aretoo high are
prevented. With currents >45 A, the motor will be
switched off. The switch-off is displayed via the two
LED operating status displays. The blink orange. If
the appliance is not shut off, the display will remain
the same until the batteries have been discharged to
20 Volts. In this case, the display changes to red con-
tinuouslight.After30seconds,thecontrolwillshutoff
automatically.
Relay test
When switching on, switching off, or switching from
one battery to another, the printed circuit board is
checked for sticky relays. If a relay sticks, the appli-
ance cannot be started up. The printed circuit board
will give out an error message, both LED operating
status displays blink simultaneously with the colours
red and orange. The blinking of the LED operating
status displays can only be terminated by removing
the batteries.
Exception:
A sticky relay during switch on. Here, the display will
only show up while the ON switch is pressed.
By checking the relays, the switch must be pressed
for 300 ms when turning the appliance on in order to
be able to start operating it. A short tapping will not
suffice.
1 Balance weight, brass disc
2 Wheel, right
Thebrassdiscisinstalledintotherightwheel(viewed
from behind) as a balance weight.
This balance weight is necessary to prevent the ap-
pliance from tipping forward due to the heavy batter-
ies. It als also prevents the brush roller from being
pressed onto the ground in the parking position.
4.5.10Control board (BR 30/4 C Bp Pack only)
4.5.11Balance weight (BR 30/4 C Bp Pack only)

18 English 5.906-434.0 Rev. 00 (12/10)
1 Main switch for brushing/vacuuming operations
1 Housing top
2 Spring element
ÎRemove the wastewater reservoir (see chapter
"Removing the tanks").
ÎLoosen the fastening screws (arrows).
ÎSlide the casing top toward the top.
1 Main switch for brushing/vacuuming operations
2 De-interference capacitor
ÎRemovethe cable plug connectionsfromthe main
switch.
ÎPush the main switch out of the top of the housing.
ÎInstall the new main switch in reverse order.
1 Connector, protective conductor cable
2 Connector, pump
Main switch / check switch
ÎConnect a resistance gauge between the connec-
tion plug 1 and 1a or 2 and 2a.
Target value:
Main switch turned off = >1 MOhm
Main switch turned on = <2 Ohm
Note
For the BR 30/4 Bp, the switch must be pressed for
>300 msec for the appliance to be switched on.
5 Basic settings and service procedures
5.1 Removing the appliance components
5.1.1 Replacing the main switch

English 5.906-434.0 Rev. 00 (12/10) 19
BR 30/4 C Bp Pack
1 Connector, pump
1 Fastening screws (3x), housing cover
2 Covering lid
3 Water pump switch
ÎUnscrew locking screws.
1 Covering lid
2 Water pump switch
ÎRemove the housing cover.
ÎRemove the cable plug connections from the wa-
ter pump switch.
ÎPress the water pump switch out of the housing
cover from the inside out.
ÎInstall the new water pump switch in reverse or-
der.
Check the water pump switch
ÎConnect a resistance gauge between the connec-
tion plug 1 and 1a or 2 and 2a.
Target value:
Water pump switch turned off = >1 MOhm
Water pump switch turned on = <2 MOhm
5.1.2 Replacing the water pump switch

20 English 5.906-434.0 Rev. 00 (12/10)
1 Fastening screws (3x), cover
2Cover
ÎUnscrew locking screws.
ÎRemove cover.
1 Toothed belt disc
2 Outer ball bearing
3 Gear belt
ÎRemove the drive unit from the cleaning head.
1 Towing, brush roller
2 Inner ball bearing
3 Toothed belt disc
4 Outer ball bearing
ÎInstall the new drive unit in reverse order.
5.1.3 Replacing the brush roller intake