1. BR VARIO Toothed belt 6.348-383/ -401 No. 2003-003 ... Bulletins/2003-003e.pdf · LED iluminates. - If the brush is overloaded, the battery monitor LED flashes. - All other unit

1. BR VARIOToothed belt 6.348-383/ -401

International Service InformationNo. 2003-003 dated 27.03.2003

Classification Level IV

Nr. 2003-003 vom 25.03.2003

Note: The toothed belts 6.348-320/ -321 have been switched over to the better CXPIII quality from serial number 23 881.

The old toothed belts can be replaced with the new toothed belts.

Toothed beltToothed belt

Old version6.348-3206.348-321

New version6.348-3836.348-401

2. BR/D 530 BAT/ XL BATCircuit board 6.682-570


Classification Level III

Nr. 2003-003 vom 25.03.2003

Note: We have already reported on this point in Service Information 2002-034.This point has now been extended.Point 1 in the Service Information 2002-034 is invalid with immediateeffect.

Problem: The suction motor no longer switches on or off because the circuit board6.682-570 has become wet or damp.

Cause: Water can penetrate the switch in the electrical cabinet and drip onto theboard.

The power transistor may burn out if the board becomes wet or damp. This willcause an undefined switching status of the power transistor.

Switch 6.630-005 Circuit board 6.682-570Solution: - The switch has been improved and installed during production. The new

switch differs from the old switch by the switch housing.The old switch housing was blackThe new switch housing is white

- The board circuits have been changed to make the board more insensitiveto dampness. The new layout can be identified by the newly added 1500ohm resistor.

- Ensure that water cannot penetrate the electrical box. The cellular rubbercord 6.273-195 under the control panel must be installed in the bestpossible way.

- The unit must not be sprayed.

Note: The improved board has been installed from the following serial number:for 1.127-351/ -361 from # 59 100for all other BAT models from # 57 622

3. BR/D 530 Traction1.127-474/ -475Traction board 6.682-617



Nr. 2003-003 vom 25.03.2003

Problem: - As soon as the unit is switched on with the key switch, the brush overloadLED iluminates.

- If the brush is overloaded, the battery monitor LED flashes.

- All other unit functions are normal.

Cause: The layout of the traction board 6.682-617 was changed after the initial unitswere built.

Remedial action: If the old traction board model is replaced with the new model, the wiring onconnector X9 must be changed.

The colour-coded connections must be in accordance with the circuit diagramas follows:Wire 1 on terminal X9/4 (yellow)Wire 2 on terminal X9/3 (green)Wire 3 on terminal X9/2 (red)Wire 4 on terminal X9/1 (black)

Note: In the serial number range 45 443 - 47 429 can be 25 units affected.

Old model New model

4. BR/D 530 TractionTraction board 6.682-617



Nr. 2003-003 vom 25.03.2003

Problem: The unit can no longer be driven because the software has not been optimallyadjusted to the drive motor.

Cause: Units up to software version V1.1 may be affected.

Solution: The traction board has been optimised with software version V1.2.

Software version V1.2 has been installed from the following serial number:

BR 530 TBR 530 T XL BAT PACKBD 530 TBD 530 T XL BAT PACK

1.127-3741.127-4741.127-3751.127-475

from # 51 714from # 50 783from # 51 463from # 50 105

Boards offered as a spare part also feature software version V1.2.

5. BR/D 750 BATNotification of changes



Nr. 2003-003 vom 25.03.2003

Note: The unit has undergone some fundamental changes which we should like topoint out. We shall mention only the most important components which havebeen changed.

The changes have been incorporated from serial number 12 135.

The circuit diagram has been changed. See enclosure.circuit diagram 0.088-375 for BR/D 750 BAT PACKcircuit diagram 0.088-545 for BR/D 750 BAT TORNADOcircuit diagram 0.088-475 for BR/D 750 BAT

The safety switch 6.630-128 was void and cannot be re-tooled.

Old: Tank 4.071-122

New: Tank without manual watermetering: 4.071-144

Old: Handle on left 4.321-126 andhandle on right 4.321-132

New: One-part handle, part number4.034-124

Old: Control panel 4.841-113

New: Control panel with +/- button formetering water 4.841-136

Old: Microswitch for brake 6.631-952Microswitch for brush head 6.630-203

New: Microswitch for brake and brushhead 6.630-331Microswitch housing 5.060-998

5. BR/D 750 BATNotification of changes



Nr. 2003-003 vom 25.03.2003

Old: Pump 6.473-416Cover 5.031-215

New: Pump 3.540-032The orifice is no longer required.

Old: Ball valve 6.412-289 - open/closevalve

New: Water valve compl. 4.580-605with electrical metering adjustment viathe dashboard.

Old: Board 6.682-592

New: Board 6.682-677 for electricalmetering adjustment by the watervalve

6. BR/D TRIKECircuit board 6.682-652



Nr. 2003-003 vom 25.03.2003

Note: A new full-transistor circuit board 6.682-652 has been installed in the TRIKE.The circuit board is version V4.0

The change has been implemented from the following serial number:- BD TRIKE from # 23 530- BR TRIKE from # 23 545

The old circuit board 6.682-468/ -550 cannot be replaced with the new circuitboard 6.682-652.

The new circuit diagrams are enclosed:

for BR/D TRIKEfor BR/D TRIKE BAT PACKfor BR/D TRIKE Tornado

0.088-5520.088-5530.088-554

The following has been changed in the Setup menu:

Clean Speed is no longer stored in the Setup menu. The user can now set thespeed himself with the Info button.Setting:- For forward drive: Press Info button until "Clean spd Fwd" is displayed- For reverse drive: Press Info button until "Clean spd Rev" is displayed- Press Forward or Reverse drive button to set the operating speed. The speedis increased for forward drive and reduced for reverse drive.- The data is automatically saved after 5 seconds driving mode. The menuthen changes automatically to the Battery menu. The direction of travel cannotbe changed for as long as the Clean Speed menu is selected.

The following function has been added to the Setup menu:

Menu: REVERSE-ALERET setting option: ON/ OFF - setting ex works: ONIf the standard "ON" setting is actuated, the machine sounds its hornintermittently when reversing.If the "OFF" setting is actuated, the horn is switched off when the machinereverses.

Menu: I-MB-MAX setting option: 40-80 A - setting ex works: 68 AThe overload protection of the brush motor can be set between 40 and 80 A in1 A steps. The overload protection is set to 68 A as standard.

Standby mode has been addedIf an operating break exceeds 30 minutes, the unit switches to standby mode.To switch on the unit again, briefly turn the key switch to "O" and then back to"1".

6. BR/D TRIKECircuit board 6.682-652



Nr. 2003-003 vom 25.03.2003

7. BR/D TRIKEBracket 5.058-670



Nr. 2003-003 vom 25.03.2003

Problem: The protective hose and the connection cable from the drive motor or thebrake may rub against the drive wheel. The worst that can happen is that ashort-circuit may occur if the insulation of the two cables is abraded. If thebrake cable has worn through, the brake will no longer function.

Cause: - The protective hose has not been correctly attached to the cable tie on theunit.

- Cable ties missing

Solution: A new bracket 5.058-670 has been installed from serial number 23 500 forattachment of the protective hose with a cable tie 6.641-464.

Even older units can be retrofitted with the bracket. When attaching theprotective hose, ensure that the steering angle is provided on both sides andthat the cable is not overstretched.

Note: Whenever carrying out a repair, observe this point and, if required, attach thebracket.Units from serial number 11 526 to 23 499 have been manufactured without abracket.

8. BR/D TRIKEBattery charger 6.654-145



Nr. 2003-003 vom 25.03.2003

Note: A new battery charger 6.654-145 has been installed in TRIKE 1.161-203/ -204/-211/ -212 from serial number 23 595. If required, the old battery charger canbe replaced with the new battery charger.

The following part is required for this:Complete battery charger 4.839-324 - 1x

This part number includes all parts required for the replacement.

The characteristic curve of the new battery charger can be switched frommaintenance-free to low maintenance. The battery charger has been set tomaintenance-free batteries as standard. The characteristic curve is indicatedon the sticker:Yellow sticker is for maintenance-freeBlue sticker is for low maintenance

The battery charger is supplied with an operating manual which describes theprocedure for switching over the characteristic curve.

9. BR/D TRIKEBattery 6.654-070



Nr. 2003-003 vom 25.03.2003

Note: Affects only units with low-maintenance wet batteries.

When charging wet batteries, the tank must be opened fully so that the gasescan escape during the charging process. It is not permitted to place the batteryconnectors on the outside to save yourself from opening the tank.

If an accident occurs, KÄRCHER accepts no liability.

Please also inform your dealers and customers.

10. BR 1000 BATToothed belt 6.348-407



Nr. 2003-003 vom 25.03.2003

Problem: The brush roller is no longer driven because the 15 mm wide toothed belt6.348-301 has torn.

Cause: The toothed belt is too narrow for extreme, intermittent loads.

Solution: A 20 mm wide high-performance toothed belt 6.348-407 has been installedfrom serial number 10 946.

The old machines can be retrofitted with the new toothed belt. To do this, thewhole drive must be replaced. This procedure also improves the bearings.

The following parts are required to convert the belt width from 15 mm to 20mm:

DesignationBearingBushingBelt pulleyBelt pulleySynchronising discBelt pulleyBelt pulleyDrive beltToothed beltFeatherkeyFeatherkeyLock washer

Part number4.251-0445.112-5625.625-2675.625-4345.625-4395.626-0025.626-0036.348-2966.348-4077.318-0037.318-0107.343-206

Quantity4x1x1x2x2x1x1x1x2x3x1x4x

From C/W 15 the conversion parts can be ordered under part number 4.251-046. This part number includes all the part numbers listed above.

Note: The toothed belt must run in the middle of the synchronising disc and must notstrike the flange rings. If the toothed belt strikes the flange ring, the tensionroller is not at the correct angle to the synchronising disc.

10. BR 1000 BATToothed belt 6.348-407



Nr. 2003-003 vom 25.03.2003

Documents

1. BR VARIO Toothed belt 6.348-383/ -401 No. 2003-003 ... Bulletins/2003-003e.pdf · LED iluminates. - If the brush is overloaded, the battery monitor LED flashes. - All other unit