Tornado Karcher BR 530 BAT User manual

5.959-398 A2005839 06/03
BR 530 BAT BD 530 BAT
BR 53/40 W BD 53/40 W
www.karcher.com
!

Operating Instructions Page 3
Spare Parts List Page 35
Notice d’instructions Page 12
Liste des pièces de rechange Page 35
Instrucciones de servicio Página 23
Liste des pièces de rechange Página 35
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English 5.959-398
Importantinformation
For your safety
Before using this appliance for the first time, please read
andpay attentionto theseOperating Instructions,and the
enclosedleaflet“SafetyInformation”.
Guarantee
The terms of the guarantee that is applicable in each
country have been published by our authorized sales
companies.Anyfaultthatoccurswithyourapplianceduring
theguaranteeperiodwillberepairedfreeofcharge,provided
that it has been caused by a material or manufacturing
defect. Guarantee claims should be addressed to your
dealer or the nearest authorized customer service depot,
andsupportedbydocumentaryevidence ofpurchase.
Protection of the environment
Pleasedisposeofpackaging
in an environmentally friendly manner
Thepackagingmaterialscanberecycled.Please
do not dispose of the packaging with domestic
refuse but have it recycled.
Please dispose of old units
in an environmentally friendly manner
Old units contain valuable recyclable materials
which should be reclaimed. Batteries, oil and
similar substances must not pollute the
environment. Please therefore dispose of old units via
suitable collection systems.
General Information
TheFloorCleanersareintendedforusewith24Vd.c.They
arepoweredby2x12Vbatteriesconnectedinseries.Only
included in supply kit for BAT Package units. (For other
models – see section “Battery Types and Chargers”.)
Thefloorcleanershavebeendesignedsothattheusercan
easily recognize and operate all functions. The operating
console contains all the switches and indicators, the
functions of which are represented by symbols.
Contents
IMPORTANTINFORMATION .................................. 3
For your safety..............................................................3
Guarantee ....................................................................3
Be environmentally aware! ..........................................3
General Information .....................................................3
UNITDIAGRAM ...................................................... 4
OPERATION ........................................................... 5
Preparation for commissioning...................................5
Commissioning and notes on use .............................5
Shut-down procedure ..................................................6
BATTERIES ............................................................ 7
Hazard warnings..........................................................7
Charge battery
Battery types ................................................................. 7
CAREANDMAINTENANCE ................................... 8
Maintenance schedule ................................................8
Sub-zero temperature protection.................................8
Maintenance agreement..............................................8
Transporting the Unit ...................................................8
Replace the squeegee blades....................................8
Replacing the disc brush ............................................8
Replacing the brush rollers .........................................8
Recommended cleaning agents ................................8
Accessories .................................................................9
TECHNICALSPECIFICATIONS............................ 10
TROUBLESHOOTING........................................... 11
BD530BAT BD 53/40W BR530BAT BR 53/40W

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English
5.959-398
1 Pushhandlewith hand leverforbrush
operation
2 Controlpanel
3 Adjustinglever“Suctionbar”
4 Drainhosedirtywater
5 Suctionturbine
6 Ratingplate
7 Suctionhose
8 Connectionfor suctionhose
9 Suctionbar
10 Star knobs “Fixing of suction bar”
12 Brush rollers (BR 530 BAT/BR 53/40 W)
Disc brushes * (BD 530 BAT/BD 53/40 W)
13 Cleaninghead
14 Runninggear
15 Handle
16 Lockingdevice
17 Fuses and electronics *
18 Batterycharger**
19 Batteries **
20 Reservoircatch
21 Dirty-waterreservoir
22 Fresh-waterreservoir
23 Cover
* notshown
** only included in supply kit for BAT Package units
Controlpanel
24 Meteringdetergentsolution
25 Batterychargingcontrolindicator
26 Switch suction turbine
27 Switchbrushoperation
Unit diagram

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English 5.959-398
Commissioning and notes on use
Selectionofthecorrectbrushesforthecleaningtask:
In the Chapter “Accessories” you will find a selection of
variousscrubbingbrushes,paddrivingdiscsandpadswith
application notes, which enable you to make the correct
selection for adapting to the particular cleaning task.
Fill with detergent solution
– Openreservoircover.
– It is best to fill the fresh-water reservoir with a water
hose, max. 60 °C.
– Add detergent appropriate to the cleaning task (see
Chapter“Recommendeddetergents”).
– Do not fill the fresh-water reservoir higher than one
hand’swidthbelow the rim ofthereservoir opening.
– Before taking into use close the reservoir cover.
– Foam-limitingdetergentsaretobeaddedwithappropriate
metering.
Operation
Preparation for commissioning
a) After removing the packing wrapping the unit is still
standingatfirstonitswoodenpallet.Thesideplanksof
the packing are used to construct a ramp.
b) Openthe reservoircatch–turnthe socket-headscrew
with the supplied key and tip up the reservoir.
c) Obtain batteries (only included in supply kit for BAT
Packageunits)–seeChapter“Batterytypesandcharging
devices”
d) The batteries must be installed and connected by
a specialist.
Asshowninthesketchthebatteries
are placed in the trough and the
connecting cable is connected
(greasethepoles).
Theconnectingcableisclampedon
tothefreebatterypoles,(+)and(–).
Caution:makesurethepolarityis
correct! Connect red cable to (+)
pole, black cable to (–) pole. Close reservoir again.
Charge the batteries before taking the unit into
operation!
e) Fastenthepushhandlewiththe4screwssuppliedand
fit the protective caps.
f) Attach drain hose to plugs on the push handle.
g) Move the unit off the pallet:
Preparation(seesketch):
Whentheunitisreceivedthesupplieddiscbrushisnot
yet installed in the cleaning head.
Installitbeforecommissioning–seeChapter“Careand
Maintenance”.
Forvariousdiscbrushes–seeChapter“Accessories”.
BR 530 BAT / BR 53/40 W
On delivery the brush rollers are already fitted.
Forexchangeofbrushrollers–seeChapter“Careand
Maintenance”.
Fordifferingbrushrollers–seeChapter“Accessories”.
k) Park the unit; for this purpose press the push handle
downwards.Inthecleaningheadthelockingleverfolds
downwards and holds the unit in its idle position. To
release again simply push the unit forwards.
Makea rampfromthelong,side boardsof thepacking
by laying them on the pallet. Secure the boards with
nails.Laytheshorterboardsundertherampforsupport.
Removewoodenskirting.
Raise the cleaning head and draw out the cardboard
coverandboard.
Theunitcan now be moveddownwardson the ramp.
h) Install suction bar
Installsuppliedsuctionbarinthesuction-barcarrierand
tighten the star knobs.Pushthesuctionhoseontothe
connection to the suction bar.
i) Install disc brush and brush rollers
BD 530 BAT / BD 53/40 W
Pallet Wooden skirting
Cardboard cover / Board
Ramp arranged from the
side boards

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English
5.959-398
Startingthework
– Closereservoircover.
– Turn on the switches for brush operation and suction
operation.
Note:Thechargingcontrollampsshowthechargingstate
of the battery.
Ifthebrushmotordoesnotrunafterswitchingiton,relieve
the strain on the brush head by drawing back the unit.
Runninggear
Down:Transportation
Up:Cleaning
– Raise the unit slightly with the handle.
– Pull out the locking device.
– Swiveltherunninggear into the desired position.
– Engage the locking device.
Driving to the place of work
– Swiveldownthe running gearandlock.
– Push the unit to the place of work.
Cleaning
– Swivel up the running gear and lock.
– Cleantheunit.
Adjustforwardspeed
(only BD 530 BAT / BD 53/40 W)
Slowerspeed(–)
– rotate towards left
Greaterspeed(+)
–rotate towardsright
Important: Before brush removal,
turnspeeddown
Settingthewaterflowrate
– Openupthe meteringforthe detergent solution.
Note:Theselectionofthepositiondependsonthetypeand
degree of the accumulation of dirt on the floor covering.
Loweringthe suction bar
– Raise the suction bar with the foot, locking releases
itself and the suction bar is lowered.
Note: The suction bar adapts autonomously to the floor
circumstances and does not require special adjustment.
The inclination of the suction bar is adjusted at the
works for normal, common floor coverings. Any setting
changes can be made on the suction bar suspension.
Switching on the brush head
– Pushtheunitforwardswiththepushhandleandactivate
thehandlever–thebrushesswitchthemselveson,and
the work can be started.
Importantnote:Donotlettheunitrunwhilststandingstill,
inorder toavoiddamaging thefloor.
Shut-down procedure
– Close off the metering of the detergent solution.
– Movetheunit1–2mforwardsinordertosuckupresidual
water.
– Turn off the switches for brush operation and suction
operation.
– Raise suction bar.
– Swiveldownthe running gearandlock.
Important: After terminating work it is essential that the
disc brushes and the brush rollers are relieved of strain
(dangerofdeformingthebrushes).
– Drainawaydirtywater(observelocalregulations!).
– Before long periods of no use, empty and clean the
fresh-waterreservoir.Forthispurpose,undothelocking
knob with an appropriate tool (e.g. a coin).
– Unloadbatteries.

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English 5.959-398
BATTERIES
The unit contains circuitry that provides protection
against over-discharging the batteries; i.e., when the
minimum permissible battery capacity has been
reached,thebrushmotorsandtheturbineareswitched
off. In this case the battery charge indicator on the
operating console flashes red.
Pushthescrubbertothechargingstationandrechargethe
battery.
Never use battery chargers in the rain, in areas with
high humidity or in damp rooms!
Hazard warnings
Naked flames, activities that might generate sparks,
and smoking is strictly forbidden in the vicinity of
batteries or in a charging room (DANGER OF
EXPLOSION!).
Any cuts or abrasions should not be allowed to come
into contact with lead; always wash hands thoroughly
after working on batteries.
Neverdeposittoolsorsimilarobjectsontopofbatteries;
i.e., on terminals and cell connections (DANGER OF
SHORT CIRCUIT AND EXPLOSION!).
The following information applies to batteries
that are NOT maintenance-free:
Always add distilled water about one hour before the
charging process is due to end. Check that the acid
content is correct. The batteries are marked
correspondingly. Adding water to a discharged battery
can cause acid to escape.
Observe whether bubbles form in all the cells when
charginghasbeencompleted.Measuretheaciddensity
of each cell every 4 weeks.
Batteries should only be charged with the unit cover
opened (DANGER OF EXPLOSION!).
Always use chemically pure battery acid (as per VDE
0510) with a density of 1.28 kg/L.
Use only distilled or desalinated water (VDE 0510) to
dilute the sulphuric acid.
Never use any additives (so-called enhancing agents)
otherwise the guarantee will be void. Take special
care when handling battery acid (danger of injury and/
or damage to clothing!), use protective goggles, and
observe relevant regulations! If any acid touches skin
or clothing, rinse immediately with plenty of water.
Please dispose of battery or rechargeable
battery in an environmentally friendly manner
Batteries and rechargeable batteries contain
substances which must not pollute the
environment. Please therefore dispose of
batteries via suitable collection systems.
Charge battery
BR/BD530BAT/BR/BD53/40W
Openthereservoircatch–turnthesocket-headscrewwith
the supplied key and tip up the reservoir.
Important:Beforetippingupthereservoirpleasepullaway
the suction hose on the suction bar (Danger of snapped
hose!).
Clamp the charging device to the batteries and switch on,
ensurecorrectpolarity!Onaverage,chargingtakes10–
15 hours. The charging devices recommended by us
(suited to the batteries being used!) are electronically
regulatedandterminatethechargingprocessautomatically.
Battery types
Thefollowingtypesofbattery aresuitableforusewith this
cleaner:
Batteries:
Manufacturer Designation Capacity Voltage Kärcher
Order No.
SONNENSCHEIN 12 V / 70 Ah
maintenance-free 70 Ah 12 V -
DETA * 12 V GIS 80
low-maintenance 80 Ah 12 V 6.654-097
12 V GIV 75 DT
maintenance-free 75 Ah 12 V 6.654-093
* Recommended by manufacturer

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5.959-398
CARE AND MAINTENANCE
Thebatteryplugmustbedisconnectedbeforecleaning
and servicing the unit, or replacing any components.
– The unit should be tested at least once per year by
KÄRCHER or a qualified person; e.g., for damage, leaks,
and for correct functioning of the control devices.
Maintenance schedule
Daily,andafter eachuse:
– Drain off dirty water.
– Rinseoutdirty-water tank.
– Checkthefluffstraineronthesuctionconnectionofthe
suctionturbine.
– Run finger along the squeegee blades to ascertain
condition,andreplace/turnroundifrequired.
– Checkbrushes forwear, andreplaceifrequired.
– Cleantheexterioroftheunit;donotuseahigh-pressure
cleaner.
Monthly:
– Checkbrushes forwear, andreplaceifrequired.
– Checksqueegee blades;disassemble andturn round/
replaceifrequired.
– Check battery terminals for oxidation; brush over
terminals, and smear with grease. Check that the
connecting cable is firmly attached.
– Check tank cover seals for leakage, and replace if
required.
– Overall cleaning of the inside and outside is
recommended,and prolongs thelife oftheappliance.
Annually:
– Arrangefortheprescribedinspectiontobecarriedoutby
aserviceengineer.
Sub-zero temperature protection
If there is a danger of freezing temperatures, activate the
pumpuntilnomorewaterisdischarged.Thesafestprocedure
isto store theappliance inaroom protectedfromfreezing
temperatures.
Maintenance agreement
A maintenance agreement can be concluded with the
responsibleKÄRCHER SalesOffice.
Transporting the Unit
When loaded onto a transport vehicle, the unit must be
secured by straps or ropes to prevent movement during
transit.
Brushheadmustalwaysbeintheraisedposition,otherwise
thebrushescouldbecomedeformed. This would result in
the brushes running out-of-true, and to subsequent
destructionofthe bearings.
For transportation of the unit it is recommended that you
take the disc brushes and the brush rollers out of the
cleaninghead.
Replace the squeegee blades
Inthecourseoftimethesqueegeebladesofthesuctionbar
becomeworn andmustthen bereplaced:
– Undostarknobsinorderthatthedeflectorrollersandthe
squeegeebladescanberemoved.
– Fit the new squeegee blades and tighten up the star
knobsagain.
Replacing the disc brush
BD 530 BAT, BD 53/40 W
– Turn the positive drive to slow speed (–).
– Raise the disc brush slightly, turn it anti-clockwise by
approx. 45° and detach it by pulling it downwards.
– To attach the replacement brush, reverse the above
procedure.
– Turn the positive drive to the required speed (+).
Replacing the brush rollers
BR 530 BAT, BR 53/40 W
– Undo the star knob screws. Remove the side bearing
cover.
– Withdrawthebrushrollers from the side.
– Wheninsertingthenewbrushrollers,turnthemslightly
so that it is easier for them to join with the driver.
– Finallyreplacethebearingcoversandclosethemagain
with the star knob screws.
Recommended cleaning agents
Cleaningagentscanbeobtainedfromyourdealer,quoting
theappropriateordernumber.
– Use only cleaning agents that contain no solvents,
hydrochloricacid norhydrofluoric acid.
– Donotusecleaningagentsthatgeneratelargeamountsof
foam,astheycouldcausedamagetothesuctionturbine
orothercomponents.
Recommended for: Part No.
Routine cleaning
(including alkali-sensitive surfaces) RM 746 6.291-462
Removal of greasy dirt deposits RM 69 ASF 6.291-523
PVC surface stripping RM 752 6.291-466
Linoleum surface stripping RM 754 6.291-425
Sanitary cleaner RM 25 ASF 6.291-252
Disinfectant cleaner RM 732 6.291-382

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English 5.959-398
Accessories
The following table gives details of the various accessories that are available for use with this unit. Accessories can be
obtainedfromyourlocaldealer,quotingtheappropriatepartnumber.
BD 530 BAT / BD 53/40 W Part No.
BD 530
BAT
Part No.
BD 53/40 W Quant Quantity required by unit
Disc brush, white for slightly dirty or delicate
surfaces 6.906-054 6.905-864 1 1
Disc brush, grit
(hard, grey) for very dirty floors 6.906-055 6.905-865 1 1
Disc brush, black (soft) for polishing 6.906-056 6.905-866 1 1
Cleaning pad base for fitting cleaning pads 6.906-078 6.906-075 1 1
Cleaning pad, black for very dirty floors 6.369-022 6.369-015 5 1
Cleaning pad, green for medium dirty floors 6.369-023 6.369-016 5 1
Cleaning pad, red for slightly dirty floors 6.369-024 6.369-017 5 1
BR 530 BAT / BR 53/40 W Part No.
BR 530
BAT
Part No.
BR 53/40 W Quant Quantity required by unit
Brush drum, white
(standard) for routine cleaning, also for medium to very dirty floors 5.762-169 5.762-208 1 2
Brush drum, black (soft) for polishing, and for routine
cleaning of delicate surfaces 5.762-172 5.762-211 1 2
Brush drum, red
(high/low) for scrubbing uneven patterned surfaces
(safety/non-slip tiles, etc.)
5.762-170 5.762-209 1 2
Brush drum, grey (hard) for thorough cleaning of very
dirty floors, and for surface
stripping
(e.g., waxes, acrylates)
5.762-171 5.762-210 1 2
Pad roller shaft for mounting roller pads 4.762-184 4.762-214 1 2
Roller pad (red) for slightly contaminated
floors 6.369-453 20 60 (80-BR 53/40 W)
Roller pad (green) for normally contaminated
floors 6.369-452 20 60 (80-BR 53/40 W)
Roller pad (yellow) for polishing 6.369-451 20 60
(80-BR 53/40 W)
Roller pad (white) for fine polishing 6.369-388 20 60
(80-BR 53/40 W)
BD 530 BAT / BR 530 BAT
BD 53/40 W / BR 53/40 W
One-sided rubber strips
Part No.
BD 530 BAT/
BR 530 BAT
BD 53/40 W/
BR 53/40 W
Quant Quantity required by unit
Rubber lip, blue standard 6.273-185 pair 1 pair
Rubber lip, brown oil-resistant 6.273-168 pair 1 pair
Suction bar straight standard 4.777-027 1 1
Suction bar curved standard 4.777-028 1 1
Reversible rubber strips (only for suction bars 4.777-047 and 4.777-054)
Suction bar straight standard 4.777-047 1 1
Suction bar curved standard 4.777-054 1 1
Rubber lip, blue standard 6.273-229 1 1
Rubber lip, brown oil-resistant 6.273-207 1 1

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English
5.959-398
TECHNICAL SPECIFICATIONS
BR530BAT(BR53/40W*)
Power
Nominalvoltage .................................................... 24 V
Battery capacity........................................... 75AH(5h)
Powerconsumption.............................. 1200(1560*)W
Suctionmotor .................................................... 500W
Brushmotor ....................................................... 600W
Suction
Air flow.................................................................30 l/s
Negativepressure ..........................................140mbar
Brushrollers
Length................................................... 460(530*)mm
Diameter ........................................................... 96 mm
Brushspeed................................................ 15001/min
DimensionsandWeight
Effective cleaning width ........................ 460(530*)mm
Theoreticalarearating.......................1840(2120*)m²/h
Containervolumes,freshwater ...............................40 l
Containervolumes,dirtywater ................................40 l
Totalweight ............................................ 150 (155*)kg
Soundpressurelevel(EN60704-1) ............... 70 dB(A)
BD530BAT(BD53/40W*)
Power
Nominalvoltage .................................................... 24 V
Battery capacity........................................... 75Ah(5h)
Powerconsumption.............................. 1200(1560*)W
Suctionmotor .................................................... 500W
Brushmotor ....................................................... 600W
Suction
Air flow.................................................................30 l/s
Negativepressure ..........................................140mbar
Discbrush
Diameter ............................................... 460(530*)mm
Brushspeed.................................................. 1401/min
DimensionsandWeight
Effective cleaning width ........................ 460(530*)mm
Theoreticalarearating.......................1840(2120*)m²/h
Containervolumes,freshwater ...............................40 l
Containervolumes,dirtywater ................................40 l
Totalweight ............................................ 150 (155*)kg
Soundpressurelevel(EN60704-1) ............... 70 dB(A)

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English 5.959-398
TROUBLESHOOTING
All tests and other work to be carried out on electrical components should be performed by a suitably qualified expert.
Please contact Kärcher Customer Service in the case of more complex problems.
Problem Possible causes Clearance
Cleaner cannot be started Fuse defective Clear cause of damage, replace fuse
Battery run down Charge battery
Plug or connector on battery
loose Check and connect
No or not enough detergent
solution on the floor Fresh-water reservoir empty Fill up
Water feed blocked Check hoses and coupling for
blockage
Not enough suction or
unsatisfactory vacuuming
results from floor
Fuse defective Clear cause of damage, replace fuse
Seal on cover contaminated or
damaged Clean or replace
Fluff strainer blocked Clean
Rubber lips on suction bar
contaminated or worn Clean or replace
Suction hose blocked Clean
Suction turbine defective Call Customer Service
Inadequate cleaning results Brushes worn down Replace
Brushes not suited to application Install other brushes – see Chapter
“Accessories”
Brushes have jammed,
Indicator light illuminated Foreign object has penetrated Undo connection to the battery. Clear away foreign object and connect
battery again.
Brushes do not rotate Fuse defective Clear cause of damage, replace fuse
Toothed belt torn
(BR 530 BAT, BR 53/40 W) Call Customer Service
Brush motor defective Call Customer Service
Worm drive defective
(BD 530 BAT, BD 53/40 W) Call Customer Service
Switch defective Call Customer Service

6.388-549.0
5.059-011.0
7.306-119.0
5.382-594.0
5.380-209.0
6.368-076.0
7.303-065.0
5.321-509.0
5.442-930.0
6.630-005.0
6.682-395.0
6.310-128.0
6.310-128.0
4.172-016.0
6.321-154.0
7.343-300.0
6.343-132.0
7.311-224.0
7.343-300.0
7.303-139.0
6.310-129.0
7.312-003.0
B
(standard/ standard/
standard/)
2
(ölfest/ oil resistent/
resistant à l'huile/)
3
B
7.644-040.0
6.644-277.0
7.644-006.0
7.644-018.0
6.362-089.0
4.034-107.0
12.2002
6.390-733.0 3
6.390-610.0 2
BR 53/40 W B TO*USA
1.127-881.0
4.777-027.0
4.777-028.0
6.273-185.0 2
6.273-168.0 3
A
6.390-166.0 2
6.390-730.0 3
BR 53 / 40
5.762-208.0 (weiss/ white/ blanc/)
5.762-209.0 (rot/ red/ rouge/)
5.762-210.0 (grau 0,6/ grey 0,6/ gris 0,6)
5.762-263.0 (grau 1,0/ grey 1,0/ gris 1,0)
5.762-211.0 (schwarz/ black/ noir/)
A
6.435-356.0
6.435-301.0
5.115-608.0
7.343-004.0
4.777-047.0
4.777-054.0
6.273-207.0 3
6.273-229.0 2
5.128-339.0
6.321-001.0
6.435-061.0