Kärcher BD 50/50 C Bp Classic User manual

English 9.808-230.0 Rev. 01 (03/20) 1
BD 50/50 C Bp Classic
BD 43/25 C Bp Classic
BD 50/60 C Ep Classic
BD 43/35 C Ep Classic
Service Manual

2 English 9.808-230.0 Rev. 01 (03/20)
Contents
Contents 2
Preface 5
Safety instructions 5
Symbols on the machine 6
Hazard levels 7
Description in this service manual 7
Service groups 7
Functional group structure 7
Textual description 7
Technical Features 8
Intended use 8
Field of application 8
Safety installations 9
Type plate 9
Transport 10
Transport position 10
Overview of the appliance 11
Front view 11
View from behind 12
Operator console 13
AC Service group control panel 14
010 Safety information 14
020 Overview 14
Operator console 14
030 Function 14
040 Service activities 15
ACBP Uninstall / install control panel board 15
ACBR Uninstall/ install safety switch 15
ACPW Uninstall / install programme selector switch 16
ACSS Uninstall/ install switch brush motor 17
050 Maintenance and inspection 18
060 Error diagnosis 18
ACPP Check programme selector switch 18
070 Peculiarities/ others 18
AD Service group water system 19
010 Safety information 19
020 Overview 19
Water system 19
030 Function 20
040 Service activities 20
ADSA Uninstall / install waste water drain hose 20
ADSC Uninstall / install float 21
ADSI Uninstall / install seal float 21
ADWD Uninstall / install water dosing valve 22
050 Maintenance and inspection 23
060 Error diagnosis 23
070 Peculiarities/ others 23
AE Service group tank system 24
010 Safety information 24
020 Overview 24
Tank system 24

English 9.808-230.0 Rev. 01 (03/20) 3
030 Function 25
040 Service activities 25
AEAA Lay the device on its side for maintenance work 25
AESD Uninstall / install seal of the cover of the waste water tank 26
050 Maintenance and inspection 26
060 Error diagnosis 26
070 Peculiarities/ others 26
AF Service group suction system 27
010 Safety information 27
020 Overview 27
Suction system 27
030 Function 28
040 Service activities 28
AFAR Uninstall/ install deflection rollers suction bar 28
AFAS Uninstalling/installing suspension of the suction bar 29
AFES Uninstall/ install end pieces suction bar 29
AFHS Uninstall / install lever suction bar lifting device 30
AFKS Uninstall / install sliding contacts of the suction turbine30
AFRR Uninstalling/installing support roller of the vacuum bar 31
AFSB Uninstall/ install suction bar 31
AFSD Uninstall / install suction turbine 32
Uninstalling/ installing AFSE suction hose 36
050 Maintenance and inspection 36
AFSL Uninstall/ install suction lips 36
060 Error diagnosis 36
070 Peculiarities/ others 36
AG service group energy supply 37
010 Safety information 37
020 Overview 37
Energy supply 37
030 Function 37
040 Service activities 38
AGBS Uninstall / install batteries 38
050 Maintenance and inspection 38
Recommended batteries 38
Insert batteries and connect 39
060 Error diagnosis 39
070 Peculiarities/ others 39
AH Service group electrics 40
010 Safety information 40
020 Overview 40
Electrical system 40
030 Function 40
040 Service activities 41
AHBM Uninstall / install capacitor 41
AHHF Uninstall / install master fuse 43
AHKB Uninstall / install cable harness 44
AHNK Uninstall / install power cable 45
AHSJ Uninstall / install start electronics 47
050 Maintenance and inspection 49
060 Error diagnosis 49
070 Peculiarities/ others 50
Safety test after working on electrical components 50
AK Service group cleaning head 51
010 Safety information 51
020 Overview 51
Cleaning head 51

4 English 9.808-230.0 Rev. 01 (03/20)
030 Function 52
040 Service activities 52
AKAT Uninstall / install contact roller brush plate 52
AKBE Uninstall / install disc brush 53
AKBS Uninstall / install bracket disc replacement 53
AKBT Uninstall / install spring bracket disc replacement 54
AKBW Uninstall/ install cleaning head 54
AKKE Uninstall / install sliding contacts brush motor 55
AKMG Uninstall / install brush motor 56
AKMK Uninstall / install ball bearing brush motor 56
AKMW Uninstall / install shaft seal brush motor 58
AKRE Uninstall / install deflector roller 58
AKSA Uninstall / install retainer disc brush 58
AKSE Uninstall / install splash guard 59
050 Maintenance and inspection 59
060 Error diagnosis 59
070 Peculiarities/ others 59
AN Service group running gear 60
010 Safety information 60
020 Overview 60
Chassis 60
030 Function 60
040 Service activities 61
ANRA Install/uninstall wheel axle 61
ANRD Uninstall / install wheels 61
ANTP Uninstall / install transport wheel 62
050 Maintenance and inspection 62
060 Error diagnosis 62
070 Peculiarities/ others 62
Faults 63
Faults with display 63
Faults without display on the console 63
Measurements at the control panel 64
Technical Documentation 65
Technical specifications 65
Special tools 67
Expected run times / load changes with regular load 67
Start-up circuit 68
Circuit diagram 69
Board design 71
Cable harness 72

English 9.808-230.0 Rev. 01 (03/20) 5
Good service work requires extensive and practice-orient-
ed training as well as well-structured training materials.
Hence we offer regular basic and advanced training pro-
grammes covering the entire product range for all service
engineers.
In addition to this, we also prepare service manuals for im-
portant appliances - these can be initially used as instruc-
tion 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 address these
citing the following subject to:
[email protected]
The responsible product specialist will take care of your is-
sue.
Copying and duplication of texts and diagrams as well
as third-party access to this information is permitted
only with the explicit permission of the company:
Alfred Kärcher GmbH & Co. KG
Postfach 160
71349 Winnenden (Germany)
www.kaercher.com
Service and maintenance tasks may only be performed by
qualified and specially trained specialists.
Observe safety information in the chapters!
–Warning and information plates on the machine provide
important directions for safe operation.
–The device may only be operated when the cover and
all lids are closed.
–The appliance must only be operated on surfaces that
do not exceed the max. permitted incline (see "Techni-
cal Specifications").
DANGER
–Risk of explosion! Do not put tools or similar on the bat-
tery, i.e. on the terminal poles and cell connectors.
–Riskofinjury.Ensurethatwoundsnevercomeintocon-
tact with lead. Always clean your hands after having
worked with batteries.
–Risk of injury! When loading or unloading the machine,
it may only be operated on gradients up to the maxi-
mum value (see "Technical Specifications"). Drive
slowly.
–Risk of injury! Set the programme selector switch to
"OFF" and pull the mains plug of the charger prior to
performing any work on the appliance.
몇WARNING
Danger of causticization!
–Adding water to the battery in its discharged state can
cause the acid to leak.
–Use safety glasses while handling battery acid and fol-
low the safety instructions to avoid personal injury or
damage to clothes.
–Shouldthe acid spray on to the skin or clothes, rinseim-
mediately with lots of water.
몇CAUTION
–Risk of damage by electrostatic discharge (ESD)! Take
suitable measures for discharging electrostatic charge
prior to performing work on the appliance electronics.
–When the batteries are installed and removed, the sta-
bility of the appliance can be compromised; ensure a
safe stance.
ATTENTION
Risk of damage!
–Use only distilled or desalinated water (EN 50272-T3)
for filling the battery.
–Do not add any substances (so-called performance im-
proving agents), else warranty claims will not be enter-
tained.
–Replace batteries with the same battery type only.
Preface
Subject: Fall 119210
Safety instructions

6 English 9.808-230.0 Rev. 01 (03/20)
Please observe the following warning notes when handling
batteries:
** option
Observe the directions on the battery, in the in-
structions for use and in the vehicle operating in-
structions!
Wear an eye shield!
Keep away children from acid and batteries!
Risk of explosion!
Fire, sparks, open light, and smoking not allowed!
Danger of causticization!
First aid!
Warning note!
Disposal!
Do not throw the battery in the dustbin!
Symbols on the machine
Battery socket
Lashing point
Mop holder **
Filling level fresh water tank 25%
Bow brush change
Vacuum bar lowering lever
Drain outlet fresh water tank
Dirt water discharge hose

English 9.808-230.0 Rev. 01 (03/20) 7
DANGER
Foran immediate danger which can leadto severe injuries
or death.
몇WARNING
For a possibly dangerous situation which could lead to se-
vere injuries or death.
몇CAUTION
Forapossiblydangeroussituationwhich can leadtominor
injuries or property damage.
ATTENTION
Pointer to a possibly dangerous situation, which can lead
to property damage.
Note
Indicates useful tips and important information.
Example:
Install/uninstall ANRA wheel axle
Observe the allocation of service groups to the appliance
components in the overview diagram in Chapter "Overview
over the service and functional groups".
Instruction
Preparatory operations
1
2 Key numerical
A
B Key alphanumerical
–Enumeration / General list
Safety note
Pointer to hazards, sources of errors.
Hazard levels
Description in this service manual
Service groups
AN RA Install/uninstall wheel axle
Service group Component Activity
Functional group structure
010 Safety instructions
020 Overview
030 Function
040 Service activities
050 Maintenance and inspection
060 Error diagnosis
070 Peculiarities/ others
080 - 100 Not assigned
Textual description

8 English 9.808-230.0 Rev. 01 (03/20)
The scrubbing vacuum cleaner is used for the wet cleaning
of level floors.
–The device can be easily adjusted to the respective
cleaning task by adjusting the water volume and the de-
tergent volume.
The detergent dosing unit can be adjusted via the addi-
tion in the tank.
–The device is equipped with a fresh water and a waste
water tank. These allow an effective cleaning with a
long usage life.
–Homebase system
Different options are offered to carry along, for exam-
ple, a mop, cloths or detergent bottles.
–The appliance may only be used for the cleaning of
hard surfaces that are not sensitive to moisture and pol-
ishing operations.
–The appliance is not suited for the cleaning of frozen
grounds (e.g. in cold stores).
–The appliance may only be equipped with original ac-
cessories and spare parts.
–The appliance is not suited for the use in potentially ex-
plosive environments.
–The machine should not be used to suck in inflammable
gases, undiluted acids or solvents.
This includes petrol, thinning agents or hot oil that can
form an explosive mixture when it comes in contact with
sucked air. Do not use acetone, undiluted acids and
solvents as they are aggressive towards the materials
from which the appliance is made.
–The machine has been approved for use on surfaces
with max. gradients as listed under "Technical Specifi-
cations".
This service manual describes the following appliances:
Technical Features
Intended use
Field of application
Appliance type Part number Power supply
BD 50/50 C Bp Classic 1.127-001.0 24 V
Battery-operated
Bp variant:
BD 50/60 C Ep Classic 1.127-002.0 230 V
Mains-operated
Ep variant
BD 50/60 C Ep Classic 1.127-003.0 120 V
Mains-operated
Ep variant
BD 43/35 C Ep Classic 1.515-401.0 230 V
Mains-operated
Ep variant
BD 43/25 C Bp Classic 1.515-400-0 24 V
Battery-operated
Bp variant:

English 9.808-230.0 Rev. 01 (03/20) 9
Safety devices serve to protect the user and must not be
rendered in operational or their functions bypassed.
Observe safety information in the chapters!
1 Nameplate
The type plate is located on the right inside of the fresh wa-
ter tank.
1 Appliance description
2 Serial number
3 Maximum climbing ability
4 Year of manufacture
5 Part number
6 Specifications
7 Bar code. Contains part and serial number.
8 Address of manufacturer
9 IP rating/ protection class
Safety installations
Type plate

10 English 9.808-230.0 Rev. 01 (03/20)
몇CAUTION
Risk of personal injury or damage! Mind the weight of the
appliance during transport.
When transporting in vehicles, secure the appliance ac-
cording to the guidelines from slipping and tipping over.
1 Cover waste water tank
2 Eyelet points
Open the cover of the waste water tank.
Fasten the appliance using the enclosed fasteners:
Note
Use a suitable base.
1 Bearing wheel
2 Wheel
Tilt the device backwards on the push handle until the
transport wheel touches the ground.
Push the machine to the place where it is to be used.
Transport
Transport position

English 9.808-230.0 Rev. 01 (03/20) 11
1 Safety button
2 Dirt water drain hose
3 Holding rail for home base
4 Fresh water tank
5 Fresh water tank lock
6 Cleaning head
7 Splash guard
8 Disc brush
9 Scraper roller
10 Fresh water reservoir filler neck
11 Cover waste water tank
12 Storage surface for cleaning set "Home base box“
Overview of the appliance
Front view

12 English 9.808-230.0 Rev. 01 (03/20)
1 Holding rail for home base
2 waste water tank
3 Handle disc replacement
4 Fresh water level display
5 Height adjustment of suction bar
6 Star handle screw
7 Scraper roller of suction bar
8 Suction lips
9 Support roller, suction bar
10 Rotary handle to incline the vacuum bar
11 Wing nuts for fastening the vacuum bar
12 Vacuum bar *
13 Suction hose
14 Water quantity regulator
15 Bp variant:
Main connector
Ep variant
Mains cable with mains plug
16 Lever suction bar lift
17 Operator console
18 Push handle
* not included in the delivery
View from behind

English 9.808-230.0 Rev. 01 (03/20) 13
Diagram
Bp variant:
1 OFF
Device is switched off
2 Display
3 Normal mode
Wet clean the floor and vacuum up dirt water.
4 Intense mode
Wet clean the floor and allow the detergent to react.
5 Vacuum mode
Suck in the dirt fleet.
6 Program selection switch
Diagram
Ep variant
1 OFF
Device is switched off
2 Normal mode
Wet clean the floor and vacuum up dirt water.
3 Indicator light voltage supply
4 Intense mode
Wet clean the floor and allow the detergent to react.
5 Vacuum mode
Suck in the dirt fleet.
6 Program selection switch
Operator console

14 English 9.808-230.0 Rev. 01 (03/20)
Observe general safety information!
Service and maintenance tasks may only be performed by
qualified and specially trained specialists.
몇CAUTION
Risk of damage by electrostatic discharge (ESD)! Take
suitable measures for discharging electrostatic charge pri-
or to performing work on the appliance electronics.
Note
Bp variant:
Battery display
The charging state of the batteries is shown via the display
in the control panel.
AC Service group control panel
010 Safety information
020 Overview
Operator console
ACBP Uninstall / install control panel board
ACBR Uninstall/ install safety switch
ACPW Uninstall / install programme selector switch
ACSS Uninstall/ install switch brush motor
030 Function
Number of bars / display Battery voltage
6 > 23,9 V
5 23,4 V...23,9 V
4 23,1 V...23,4 V
3 22,8 V...23,1 V
2 22,4 V...22,8 V
1 22,1 V...22,4 V
0 20,8 V...22,1 V
LOW BAT < 20,8 V

English 9.808-230.0 Rev. 01 (03/20) 15
Note
Unless otherwise described, the installation takes place in
reverse order.
Note
Bp variant:
Remove the main connector.
ACPW Uninstall / install programme selector switch
Mark power cables.
Separate the electric connectors.
Loosen the mounting nuts.
Remove the connecting cable.
Dismount connection cables.
Remove control panel board.
Installation information
Observe the plug arrangement during installation.
Mind correct installation of the lines.
Pin assignment
1 Safety button
2 Screws
Unscrew the screws.
Remove the safety switches
Installation information
Pay attention to the correct fitting position during reinstal-
lation.
040 Service activities
ACBP Uninstall / install control panel board
1 Operating panel board A1
2 Electric socket plug connections
3 Nuts
4 Connection cables
Operating panel
board
Program selection switch
Red Green
Brown -
Blue Yellow
Black White
ACBR Uninstall/ install safety switch

16 English 9.808-230.0 Rev. 01 (03/20)
Remove the main connector.
1 Screws
2 Bottom part push handle
Unscrew the screws on both sides of the appliance.
1 Screws
2 Bottom part push handle
Unscrew the screws.
1 Bottom part push handle
2 Screw
3 Cable connector
4 Top part push handle
Secure the bottom part of the push handle on the de-
vice using a screw.
Secure the top part of the push handle to the bottom
part of the push handle using a cable tie.
1 Screws
Pull off the rotary knob of the programme selector
switch.
Unscrew the screws.
ACPW Uninstall / install programme selector switch

English 9.808-230.0 Rev. 01 (03/20) 17
Diagram
Bp variant:
Separate the electric connectors.
Remove the programme selector switch.
Diagram
Ep variant
Mark power cables.
Separate the electric connectors.
Remove the programme selector switch.
Installation information
Observe the connection diagram.
Remove the main connector.
ACPW Uninstall / install programme selector switch
Note
Only loosen the top part of the push handle.
Separate the electric connectors.
Remove the brush motor switch.
Installation information
Mind correct installation of the lines.
1 Electric connectors
2 Program selection switch S1
1 Electric socket plug connec-
tions
2 Program selection switch S1
ACSS Uninstall/ install switch brush motor
1 Bottom part push handle
2 Switch brush motor S2
3 Electric socket plug connections
4 Cable guides

18 English 9.808-230.0 Rev. 01 (03/20)
Service group does not contain any maintenance and in-
spection points.
For detailed fault diagnosis see:
Faults
Diagram
Ep variant
1 Axle
A Front view, axle in OFF position
B View from above
C Connection diagram
Plugging chart subject to the programme selector switch
position.
The service group does not contain any peculiarities.
050 Maintenance and inspection
060 Error diagnosis
ACPP Check programme selector switch
0° Off
34° Scrubbing and vacuuming
68° Scrubbing
102° Vacuuming
070 Peculiarities/ others

English 9.808-230.0 Rev. 01 (03/20) 19
Observe general safety information!
Service and maintenance tasks may only be performed by
qualified and specially trained specialists.
AD Service group water system
010 Safety information
020 Overview
Water system
ADSA Uninstall / install waste water drain hose
ADSC Uninstall / install float
ADSI Uninstall / install seal float
ADWD Uninstall / install water dosing valve

20 English 9.808-230.0 Rev. 01 (03/20)
1 Water quantity regulator
2 Square
3 Water dosing valve
4 Water channel
A View from above
The inflow of the water volume is adjusted via the regulat-
ing knob water value.
The square connects the regulating knob water volume
with the water dosing valve.
Depending on the position of the regulating knob water vol-
ume, the water dosing valve is opened or closed.
The set water volume flows through the water channel to
the outlet onto the disc brush.
When the regulating knob water volume is completely
opened, the supplied water volume varies between 2.2 l/
min with a full and 0.9 l/min with an almost empty fresh wa-
ter tank.
Upon ending the work, the water dosing valve must be
closed.
Note
Unless otherwise described, the installation takes place in
reverse order.
Remove the waste water tank.
1 waste water tank
2 Hose clip
3 Dirt water drain hose
Loosen the hose clip.
Remove waste water drain hose.
Installation information
Secure the hose clip in a way that it does not touch the
fresh water tank.
030 Function
040 Service activities
ADSA Uninstall / install waste water drain hose