Kärcher BR 55/60 WP Operating and installation instructions

Service Information International 02.2003
BR/BD 55/60 WP
1.384- . . .
ServiceInformation
(English) 5.905-882

BR/BD 55/60 WP Technical Features
Service Information International 02.2003 Page 2 / 25
Drive
– Powersuppliedby4maintenance-freeorlow-
maintenance 6-volt batteries.
– Drive by a DC motor with differential gear.
– 2 drive wheels at the front, 2 steering wheels
at the back.
– Complete base frame made of plastic.
Brush system
– Brush head with 2 brush rollers (BR version)
or 2 disc brushes (BD version).
– Brushrollers/discbrushersareconter-rotating.
– Thebrushheadisloweredwiththepedal.The
brush drive assembly is switched on at the
same time. Press the pedal down to raise the
brushheadandswitchthebrushdriveassem-
blyoff.Ifthedrivesystemisswitchedoffwhile
operating the machine (brush head lowered
andbrushesrotating),thebrushescontinueto
run on for approx. 2 - 5 seconds until they are
automatically switched off (after-running time
can be adjusted).
– Brush contact pressure can be adjusted with
the lever.
– The brushes can be changed without tools.
Water system
– Integrated fresh and waste water tank (tank-
in-tank system).
– Whenthewastewatertankisfull,themechan-
ical float closes the suction intake in the tank
lid.
– Thewatertankjustisrestingonthebaseframe
where it is held with 2 screws.
– No water pump, the water flows to the brush
head by the force of gravity.
– Thequantityoffreshwatercanbeadjustedby
a metering valve according to the amount of
dirt.
– When the machine comes to a standstill, a
waterstop valveinterrupts thesupply offresh
water to the brush head.
Suction system
– Suctionbeam leverislowered byalever.The
suction motor starts at the same time. If the
suction beam is raised, the suction motor
switchesoffagainautomatically(after-running
time approx. 10 seconds).
– Standard suction motor with carbon brushes
(option: long-life suction motor).
– Suction beam from BR/BD 750.
– Operation possible with straight and curved
suction beam.
– Suction beam can be adjusted in pivot angle
and inclination positions without any tools.
– Rubberstripcanberaplacedwithoutanytools.
Electric components
– The electric components are located behind
thebatterychargerorunderthecontrolpanel.
– IftheEMERGENCYSTOP buttonispressed,
themachineisbrakedandswitchedOFFcom-
pletely.

Page 3 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
View from the front
1 Screw cap, fresh water drain
2 Fresh water tank
3 Drive wheel
4 Tank locking device
5 Brush head (BR version)
6 Cover, suction channel
7 Tanklid
1
2
3
5
7
4
6

Page 4 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
View from behind
1 Tanklid
2 Lever, to raise and lower the suction beam
3 Water flow control
4 Water level display, fresh water
5 Brush head (BR version)
6 Coarse dirt container
7 Drive wheel
8 Hand lever, increase/decrease brush head
contact pressure
9 Foot lever, raise/lower brush head
10 Support roller
11 Suction beam
12 Deflection roller
13 Charge state display
red LED: Fault in charging procedure.
Batteries or battery charger
defect.
green LED: Batteries are charged.
yellow LED: Batteries are being charged.
nodisplay: No mains voltage available.
Battery not connected.
14 Battery charger U1
(only in the PACKAGE version)
15 Suction hose
16 Drain hose
17 Guidehandle
18 Drive lever forwards/reverse
19 ControlpanelA2
1
2
3
4
5
6
7
8
9
10
12
11
13
14
15
16
17
19
18

Page 5 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Waste water tank
1 Cover, waste water tank
2 Seal, fresh water tank inlet
3 Suction channel, air outlet
4 Fastening screws, suction channel cover
5 Float, mechanical
6 Suctiontube,wastewaterfromsuctionbeam
7 Waste water tank
8 Air intake with fluff strainer, suction motor
9 Tank inlet, fresh water
10 Suction channel, air inlet
11 Suction channel
Cover lifted
View from above, after removing
the suction channel cover
1
2
4
5
6
7
3
9
8
10
11
3

Page 6 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Brush head (BR version)
Electric connection
TheterminalstripEXT-X2islocatedontopofthe
brush head. The M1 and M2 brush motors are
connected at this location.
Terminal strip EXT-X2, electrical connection for the
brush motors
Brush head mounting
1 Brush head (BR version)
2 Supporting frame, brush head
3 Screws (4x), brush head fastening
Coarse dirt container
Thecoarsedirtcontainerrideslooseonthebrush
head.
Coarse dirt and impurities are trapped in the
coarse dirt container.
Coarse dirt container
Suspension
Thebrushhead(1)ismountedonthesupporting
frame (2) and held in place with four srews (3).
1
2
3
3 3
Terminal strip EXT-X1
The terminal strip EXT-X1 is located next to the
batteriesattheleftside.Itismountedonametal
plateandinsertedinthechasis.Thetractionmotor
M3,thebrushheadmicroswitchS7andthewater
pump M4 (option) are connected there.

Page 7 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Brush drive assembly (cover removed)
1 Drive motor, rear brush roller
2 Brush roller
3 Toothedbelt
4 Motor fastening screws and toothed belt
5 Guide shoe
3
1
4
2
5

Page 8 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Battery
1 Battery G1 (4 x 6 volt = 24 volt)
2 Fuse, battery (F1)
3 Positive battery post
4 Wire connector
5 Insulatingnut
6 Lock nut
Note
Theinsulatingnut (5)must befittedin such
a way that the lower shoulder fits exactly in
the hole of the wire connector (4). If fitted
withoutsufficientcare,thisshoulderbreaks
off so that the main fuse F1 (2) is bridged
and thus out of use. Tighten the insulating
nut (5) with a wrench hand-tight and then
lock with the lock nut (6).
1
2
–+
2
3
4
6
5

Page 9 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Suction beam
1 Mounting plate, suction beam
2 Wing nut, to adjust the inclination of the
suction beam
3 Screw,forfasteningthedeflectionrollerand
rubber strips
4 Deflection roller
5 Support roller
6 Star knob, for fastening the suction beam
7 Rubber strip
8 Retainer for the rubber strips
9 Bowden cable, raise/lower suction beam
10 Suction hose
1
4
5
6
7
10
9
8
3
2

Page 10 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
1 Controlpanel A2
2 Control lamp (red) lights up when the bat-
tery is discharged (deep-discharge protec-
tion)
3 Display
4 "Info" button to illustrate the messages into
thedisplay
5 EMERGENCY STOP button S2. Switches
offallfunctionsimmediatelyandbrakesthe
machine. Turn to reset
6 Key switch S1
Control panel
7 Control lamp (red) lights up when the suc-
tion motor is running
8 "Settings"button
– Switchesthesuctionmotoronwhen
theaccessorykit"Wall/Floor/Ceiling"
nozzle is fitted.
– Changesthemachinesettingswhen
usedtogetherwith the"Info" button.
9 Controllamp(red) lightsup whenthe brush
motor is in overload
1
2
3
4
5
6
7
8
9

Page 11 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Display messages
Acces to the operating menu
The user can query the basic settings of the
machine with the operating menu.
1. Switch the machine ON with the key switch.
The basic message "battery" appears.
2. Use the Info button to access the following
information:
Message on the display Explanations
Battery: Basicdisplayshowing the currentbatterycharge.
8 blocks = 100%
CleanSpdFwd=60% Shows the adjusted cleaning speed for
forwards as % of maximum speed.
Press the "Settings" button to change this value.
The new value is only stored if the machine is
then operated for at least 5 seconds (drive
motor on). If the value is changed with the
machine at a standstill, the display changes
back to the basic display within 6 - 8 seconds
without storing the value. Even when the
machine is switched off with the key switch, the
change is still not stored. It is important to
operated the machine for at least 5 seconds!
CleanSpdRev=60% Shows the adjusted cleaning speed for reverse
as % of maximum speed.
The setting can be changed as in
CleanSpdFwd.
Hours 1h23m Shows the current operating hours in hours (h)
and minutes (m).
Speed _ _ mph Shows the current speed in miles per hours.
Alfred Kärcher Shows the manufacturer's name.
BR/BD55/60 2.12 Shows the installed software version.

Page 12 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Drive control (control panel removed)
1 Magnet sensor for drive control B1
2 Toothed segment
3 Shaft with magnet
4 Sideplate
5 Retaining bracket
6 Return spring
7 Toothedwheel
4
5
7
3
2
1
6

Page 13 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Control panel, back side
1 MultipleplugX10
2 MultipleplugX9
3 MultipleplugX7
4 PlugX7A
5 Key switch S1
6 EMERGENCY STOP switch S2
7 MultipleplugX8
8 Control panel module A2
9 Microprocessor
1
2
4
65
7
8
9
3

Page 14 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Electronic control circuits
1 Fuse F4
2 Connection brush motor M1/M2 (+)
3 Connection 24 volt (+)
4 Connection ground (-)
5 Connection drive motor M3 (+)
5 Connection drive motor M3 (-)
7 Connection suction motor M5 (+)
8 MainrelayK1
9 Panel
10 PlugX4A
11 MultipleplugX4
12 MultipleplugX3
13 MultipleplugX2
14 MultipleplugX1
15 Fuse F2
16 Fuse F3
17 Cover power module A1
Theelectroniccontrolcircuitsarelocatedbehind
the panel on the back side of the unit.
Thepanelcanbehingeddownwithallsegments
by unscrewing the fastening screws.
1
2345
678
9
10
11
1213
14
15
16
17

Page 15 / 25
BR/BD 55/60 WP Machine functions
Service Information International 02.2003
Function diagram
1 Fluff strainer
2 Suction channel in the tank lid
3 Float, mechanical
4 Tanklid
5 Suction hose
6 Drain hose, waste water
7 Suction beam
8 Screw cap, fresh water drain
9 Meteringvalve
10 Inlet supply hose, fresh water
11 Brush head (BR version)
12 Brush motor
13 Drive belt
14 Brush rollers (2x)
15 Water distribution tube
16 Fresh water tank
17 Waste water tank
18 Filler neck fresh water and cleaning agent,
max. filling level fresh water tank
19 Suction motor
123 4
5
6
7
8910111213
14
15
16
17
18
19

BR/BD 55/60 WP Basic settings and servicing
Page 16 / 25
Service Information International 02.2003
Setup-Menu
Access to the set-up menu
With the set-up menu, the user can change the
basic settings of the machine.
1. Switchthe machine OFF withthe key switch.
2. Press the buttons "Info" and "Settings" at the
same time. Switch the machine ON with the
key switch.Hold the two buttons until "SET-UP
MENU" appears in the display.
3. All the factorysettings can be changed with
the "Settings" button.
4. Press the "Info" button for access to the
following information.
Message on the display Explanations
SETUP-MENUE Display program for set values.
english Shows the adjusted language version.
Possible settings: German or English.
Factory setting: German.
ReverseClean=OFF Shows whether the suction motor is switch on
or off when reversing.
Possible settings: ON or OFF.
Factory setting: OFF.
Debug-Mode=OFF The debug mode can be used to call
additional operating data in the ON setting
(see page 18).
Possible settings: ON or OFF.
Factory setting: OFF.
LowBattery=22.0V Shows the adjusted deep-discharge
protection.
Possible settings for 22 - 22.8 volt.
Factory setting 22 volt for maintenance-free
batteries.

BR/BD 55/60 WP Basic settings and servicing
Page 17 / 25
Service Information International 02.2003
Setup-Menu
Message on the display Explanations
I_MB_MAX= 68A Shows the adjusted overload protection for the
brush motors.
Possible settings: from 40 - 80 A.
Factory setting: 68 A.
Brush_Delay= 4s Shows the switch-off delay for the brushes
after the machine stops.
Possible settings: 2 - 5 sec.
Factory setting: 4 sec.
SETUP exit? If this is confirmed by pressing "Settings", then
the changed settings are stored.
The settings are not stored if the machine is
switched OFF with the key switch beforehand.

BR/BD 55/60 WP Basic settings and servicing
Page 18 / 25
Service Information International 02.2003
Debug-Mode
Access the debug menu
Withthe debug menu, the user can call
additional information.
1. Inthe set-up mode, call the "Debug mode"
message.
2. Press the "Settings" button to switch the
debug mode ON.
3. Carry on switching the "Info" button until
the message "SET-UP exit?" appears in
the display.
4. Press "Settings" to confirm.
5. Press "Info" to access the following
information:
Message on the display Explanations
Battery Shows the current battery voltage.
CleanSpdFwd=60% Shows the adjusted cleaning speed for
forwards as % of maximum speed.
CleanSpdRev=60% Shows the adjusted cleaning speed for
reverse as % of maximum speed.
Hours 1h23m Shows the current operating hours in hours (h)
and minutes (m).
Speed.: 0.0mph Shows the current travelling speed in mph.
Alfred Kärcher Indicates the manufacturer.
BR/BD55/60 2.12 Indicates the installed software version.
Pxxx Ixx Bxxx Txxx Display for additional electronic functions:
Electronic information only
Current consumption brush motors in A
(0 -150)
Current consumption drive motor in A (0-50)
Speed value (0-255)A
12345 value of 250 to
255 must appear when the driving lever is
pushed to max. limitstop.

BR/BD 55/60 WP Basic settings and servicing
Page 19 / 25
Service Information International 02.2003
Message on the display Explanations
Sxxx vxxx Pxxx cx sx Just electronic information
+=xxx mV–=xxxxmV Just electronic information
nax blx rdx bcx Additional electronic information:
After-running time brush motors
0 - 5 seconds depending on the "Brush delay"
setting
Magnet sensor drive control
0 = closed
1 = open
Battery voltage
0 = voltage > deep-discharge protection
1 = voltage < deep discharge protection or
EMERGENCYSTOP switch pressed
EMERGENCYSTOP switch
0 = not pressed
1 = pressed
To leave the debug mode, switchthe machine
off with the key switch. The debug mode
changes automatically to the OFF setting.
Debug-Mode

BR/BD 55/60 WP Basic settings and servicing
Page 20 / 25
Service Information International 02.2003
Replace brush rollers
Replace brush rollers (BR version)
– Unscrew wing nuts (4).
– Remove the cover plate (3).
– Pullthebrushroller(2)outandcheckforwear,
replace if necessary.
– Push the new brush roller onto the opposite
motor bearing and mount the cover plate (3).
Adjusting screw scrubbing pattern
Adjust scrubbing pattern
– On a flat floor surface, cover an area the size
ofthe brushhead (1)withchalkandmove the
machine over it.
– Lower the brush head (1) and let the brushes
work for approx. 3 seconds.
– Liftthebrush head(1) andmove themachine
back.
– Use the setting screws (4) to adjust the brush
rollers to obtain a parallel scrubbing pattern.
– When lowered, the brush head (1) lies with
bothbrushrollersevenlyonthefloor.Noother
setting is possible.
1 Brush head (BR version)
2 Brush roller
3 Cover plate
4 Wing nuts
5 Adjusting screw, scrubbing pattern
Scrubbing pattern on floor coated with chalk
Basic settings and servicing
Scrubbing pattern
The scrubbing pattern must be parallel and uni-
form in width.
3
4
4
1
2
15