Kärcher KM 150/500 R Bp Sweeper

General Safety Instructions

Read and comply with these original instructions prior to the initial operation of your appliance and store them for later use or subsequent owners.

Before first start-up: It is definitely necessary to read the safety indications no. 5.956-250!

Safety Instructions:

• Your sales outlet should be informed about any transit damage noted when unpacking the product.
• Warning and information plates on the machine provide important directions for safe operation.
• In addition to the information contained in the operating instructions, all statutory safety and accident prevention regulations must be observed.
• The appliance must not be operated by children, young persons or persons who have not been instructed accordingly.
• It is strictly prohibited to take co-passengers.
• Ride-on appliances may only be started after the operator has occupied the driver's seat.
• Please remove the ignition key, when not in use, to avoid unauthorised use of the appliance.
• Never leave the machine unattended so long as the engine is running. The operator may leave the appliance only when the engine has come to a standstill, the appliance has been protected against accidental movement, if necessary, by applying the immobilization brake and the ignition key has been removed.

Unloading tips:

• Risk of injury, risk of damage! Observe the weight of the appliance when you load it!
• Weight (without batteries): 1398 kg*
• Weight (with batteries): 2690 kg* (* If upgrade kits are installed, the weight is respectively higher.)
• Do not use a forklift.
• Use a suitable ramp or a crane to load the appliance!
• Observe when using a ramp: Ground clearance 70 mm.
• If the machine is delivered on a pallet, you must create an unloading ramp using the boards provided. Instructions for this procedure are on page 2. Important instruction: every board must be attached with at least 2 screws.

Drive mode:

• Risk of injury, risk of damage!
• Danger of tipping if gradient is too high. The gradient in the direction of travel should not exceed 12%.
• Danger of tipping when driving round bends at high speed. Drive slowly when cornering.
• Danger of tipping on unstable ground. Only use the machine on sound surfaces.
• Danger of tipping with excessive sideways tilt. The gradient perpendicular to the direction of travel should not exceed 10%.
• It is important to follow all safety instructions, rules and regulations applicable for driving motor vehicles.
• The operator must use the appliance properly. He must consider the local conditions and must pay attention to third parties, in particular children, when working with the appliance.
• The appliance may only be used by persons who have been instructed in handling the appliance or have proven qualification and expertise in operating the appliance or have been explicitly assigned the task of handling the appliance.

Battery-operated machines:

• Note: Warranty claims will be entertained only if you use batteries and chargers recommended by Kärcher.
• Always follow the instructions of the battery manufacturer and the charger manufacturer. Please follow the statutory requirements for handling and disposing batteries.
• Never leave the batteries in a discharged state; recharge them as soon as possible.
• Always keep the batteries clean and dry to avoid creep currents. Protect the batteries and avoid contact with impurities such as metal dust.
• Do not place tools or similar items on the battery. Risk of short-circuit and explosion.
• Do not work with open flames, generate sparks or smoke in the vicinity of a battery or a battery charging room. Danger of explosion.
• Do not touch hot parts of the machine such as the drive motor (risk of burns).
• Be careful while handling battery acid. Follow the respective safety instructions!
• Used batteries are to be disposed according to the EC guideline 91/157 EWG in an environment-friendly manner.

Accessories and Spare Parts:

• Only use accessories and spare parts which have been approved by the manufacturer. The exclusive use of original accessories and original spare parts ensures that the appliance can be operated safely and trouble free.
• At the end of the operating instructions you will find a selected list of spare parts that are often required.
• For additional information about spare parts, please go to the Service section at www.kaercher.com.

Symbols on the Machine

• Risk of burns on account of hot surfaces! Allow the exhaust to cool down sufficiently before starting work on the machine. Always use appropriate gloves while working on the device.
• Risk of getting squeezed on account of getting jammed between vehicle parts.
• Risk of injury on account of moving parts. Do not reach in.
• Risk of fire. Do not vacuum up any burning or glowing objects.
• Chain pick-up / crane point
• Intake points for the jack
• Brush roller adjustment
• Maximum decline of ground when driving with the waste container raised. The gradient in the direction of travel should not exceed 12%.
• Caution! Rotating brush (watch for rotation direction).
• Beware of dangerous electrical current!
• Risk of damage! Do not rinse out the dust filter.

Symbols in the Operating Instructions

• Danger: Warns about immediate danger which can lead to severe injuries or death.
• Warning: Warns about possible danger which could lead to severe injuries or death.
• Caution: Points out a possibly dangerous situation which can lead to light injuries or property damage.

Function

The sweeper operates using the sweep-shovel principle.

• The rotating roller brush moves the dirt directly into the waste container.
• The side brush cleans the corners and edges of the surface and moves dirt and debris into the path of the roller brush.
• The fine dust is sucked in via the dust filter through the suction blower.

Proper Use

This sweeper has been designed to sweep dirt and debris from indoor as well as outdoor surfaces.

• The machine with working equipment must be checked to ensure that it is in proper working order and is operating safely prior to use. Otherwise, the appliance must not be used.
• Use this sweeper only as directed in these operating instructions.
• The machine is not suitable for vacuuming dust which endangers health.
• The machine may not be modified.
• Never vacuum up explosive liquids, combustible gases or undiluted acids and solvents. This includes petrol, paint thinner or heating oil which can generate explosive fumes or mixtures upon contact with the suction air. Acetone, undiluted acids and solvents must also be avoided as they can harm the materials on the machine.
• Do not sweep/vacuum up any burning or glowing objects.
• The machine is only suitable for use on the types of surfaces specified in the operating instructions.
• The machine may only be operated on the surfaces approved by the company or its authorised representatives.
• The machine may not be used or stored in hazardous areas. It is not allowed to use the appliance in hazardous locations.
• General: Keep highly-flammable substances away from the appliance (danger of explosion/fire).

Suitable Surfaces

• Risk of injury! Verify the stability of the ground prior to driving on it.
• Asphalt
• Industrial floor
• Screed
• Concrete
• Paving stones

Caution: Risk of damage! Do not sweep up straps, strings or wires as these may wrap around the brush roller.

Environmental Protection

The packaging material can be recycled. Please do not throw the packaging material into household waste; please send it for recycling.

Old appliances contain valuable materials that can be recycled; these should be sent for recycling. Batteries, oil, and similar substances must not enter the environment. Please dispose of your old appliances using appropriate collection systems.

Notes about the ingredients (REACH): You will find current information about the ingredients at: www.kaercher.com/REACH

Operating and Functional Elements

Illustration of sweeper

1 Cabin door (option), 2 Lashing point (4x), 3 Protective roof (option), 4 Beacon lamp, 5 Windshield wiper (option), 6 Lock of appliance hood, 7 Operating field, 8 Steering wheel, 9 Ignition lock, 10 Parking brake, 11 Pedals, 12 Seat (with seat contact switch), 13 Battery socket, 14 Battery set (2 x 24 V, 700 Ah), 15 Rear wheel, 16 Engine cover, 17 Brush roller adjustment, 18 Lighting system (optional), 19 Waste container, 20 Side brushes, 21 Front wheel, 22 Roller brush access.

Operating field

1 Function keys, 2 Programme switch, 3 Ventilation opening (option), 4 Multifunction display, 5 Fuse box - work station, 6 Ignition lock.

Function keys

1 Work lights on/off, 2 Beacon lamp on/off, 3 Filter dedusting, 4 Horn, 5 Blinker switch, 6 Suction blower, 7 Open/close container lid, 8 Raise/lower waste container.

Ignition switch

1 Ignition key. Position 0: Switch off engine. Position 1: Ignition on. Position 2: Start the engine.

Indicator lamps and display

1 Battery capacity, 2 Battery control lamp, 3 Control lamp operating state, 4 Indicator lamp for position lights, 5 Indicator lamp (not connected), 6 Indicator lamp for dipper, 7 Indicator lamp (not connected), 8 Indicator lamp - forward driving direction, 9 Indicator lamp - reverse driving direction, 10 Operating hour counter.

Pedals

1 Drive pedal, 2 Brake pedal, 3 Parking brake.

Before Startup

Lock/ release parking brake

• Loosen parking brake; press brake pedal at the same time.
• Activate the parking brake; press brake pedal at the same time.

Moving sweeper without engaging self-propulsion

• Open engine cover.
• Turn the freewheel lever of the hydraulic pump (red) by 180° (anti-clockwise). Use special tools.
• Note: The special tool (red screwdriver) is located in a holder in the vehicle frame, next to the freewheel.

Caution: Do not move the machine for long distances without engaging self-propulsion; a speed of 10 km/h should not be exceeded.

• Return the freewheel lever into its original position.

Moving sweeper by engaging self-propulsion

• If the freewheel lever of the hydraulic pump was opened to move the appliance, this must be turned back anti-clockwise all the way to its stop. Use special tools.

Start up

General notes

• Park the sweeper on an even surface.
• Remove ignition key.
• Lock parking brake.

Inspection and maintenance work

Daily before starting operations

• Check battery charging status; charge batteries if required (see Chapter "Charging the batteries").
• Check the sweeping roller and the side brush for wear and wrapped belts.
• Check the wheels for tied up belts.
• Check function of all operator control elements.
• Check appliance for damages.
• Clean the dust filter with the filter cleaning button.
• Note: For description, see section on Care and maintenance.

Safety notes regarding the batteries

Please observe the following warning notes when handling batteries:

• Observe the directions on the battery, in the instructions for use and in the vehicle operating instructions!
• 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!
• Beware of dangerous electrical current!
• Risk of explosion! Do not put tools or similar on the battery, i.e. on the terminal poles and cell connectors.
• Risk of injury! Ensure that wounds never come into contact with lead. Always clean your hands after having worked with batteries.
• Risk of fire and explosion! Smoking and naked flames are strictly prohibited. Rooms where batteries are charged must have good ventilation because highly explosive gas is emitted during charging.
• Danger of causticization!

Charge the batteries

Charge the batteries before commissioning the machine.

• Danger of injury! Comply with safety regulations on the handling of batteries. Observe the directions provided by the manufacturer of the charger. Please read and follow the included operating instructions by the battery manufacturer and follow them.
• Charge the battery only with an appropriate charger.
• Rooms where batteries are charged must have good ventilation because highly explosive gas is emitted during charging.
• Danger of chemical burns. Adding water to the battery in its discharged state can cause the acid to leak! Use safety glasses while handling battery acid and follow the safety instructions to avoid personal injury or damage to clothes. Should the acid spray on to the skin or clothes, rinse immediately with lots of water.

Caution: Risk of damage. Use only distilled or desalinated water (VDE 0510) for filling the battery. Do not add any substances (so-called performance improving agents), else warranty claims will not be entertained.

Recommended batteries, chargers:

• Battery set 48 V, 700 Ah, (low-maintenance)*: Order number 6.654-280.0 (Appliance requires 2 batteries)
• Charger 48 V, 80 A: 6.654-281.0

The use of other batteries and chargers is not recommended and should be discussed with Kärcher customer service.

• Pull the battery plug from the machine and connect it to the plug of the charger.
• Connect the plug of the charger to a proper socket of 16 A, the charger will charge automatically.
• Always keep both motor covers open during the charging process.
• Note: When the batteries are charged, first remove the charger from the mains and then disconnect it from the batteries.

Check fluid level in the battery and adjust if required

Caution: Please read and follow the included operating instructions by the battery manufacturer and follow them.

Check charging status of battery

• Display of the battery capacity in the green range: Battery is charged.
• Display of the battery capacity in the yellow range: Battery is halfway discharged.
• Display of the battery capacity in the red range: Battery is almost discharged. The sweeping mode will be shortly switched off automatically.
• Indicator lamp glows red: Battery is discharged. The sweeping mode will be terminated automatically (the sweeping aggregates cannot be taken into operation until the battery is charged).
• Drive the machine directly to the charging station; avoid any steep gradients in the process.
• Charge battery.

Operation

Adjusting driver's seat

• Pull seat adjustment lever outwards.
• Slide seat, release lever and lock in place.
• Check that the seat is properly locked in position by attempting to move it backwards and forwards.

Programme selection

1 Transport drive, 2 Sweeping with sweep roller, 3 Sweeping using roller brush and side brushes.

Starting the machine

Note: The machine is equipped with a seat contact switch. If the driver's seat is vacated, the machine is switched off.

• Sit on the driver's seat.
• Bring the direction selector switch into the middle position.
• Lock parking brake.
• Insert the ignition key into the ignition switch.
• Turn the ignition key to position "I". The appliance is now ready for operation.
• Turn the ignition key to position "II". The appliance can now be driven.

Note: The display of the battery capacity will show the actual charge status after about 10 seconds.

Drive the machine

• Set programme selection switch to "Transport drive".
• Press brake pedal and keep it depressed.
• Release parking brake.

Drive forward

• Set the travel direction switch to "forward".
• Press accelerator pedal down slowly.

Reverse drive

• Danger: Risk of injury! While reversing, ensure that there is nobody in the way, ask them to move if somebody is around.
• Caution: Risk of damage! Only use the direction switch when the machine is standing still.
• Set the travel direction switch to "backwards".
• Press accelerator pedal down slowly.

Driving method

The accelerator pedal can be used to vary the driving speed infinitely. Avoid pressing the pedal suddenly as this may damage the hydraulic system.

Brakes

• Release the accelerator pedal, the machine brakes automatically and stops.
• Note: The braking effect can be supported by pressing the brake pedal.

Driving over obstacles

Driving over fixed obstacles which are 70 mm high or less:

• Drive forwards slowly and carefully.

Driving over fixed obstacles which are more than 70 mm high:

• Only drive over these obstacles using a suitable ramp.

Caution: Do not sweep up packing strips, wire or similar objects as this may damage the sweeping mechanism.

Note: To achieve an optimum cleaning result, the driving speed should be adjusted to take specific situations into account.

Note: During operation, the dust filter should be shaken off and cleaned at regular intervals.

Sweeping mode

Sweeping dry floors

• Switch on the blower.
• Set the programme switch to sweep with sweeping brush when cleaning surfaces.
• Set the programme switch to sweep with sweeping brush and side brush when cleaning edges.

Sweeping damp or wet floors

• Switch off the blower.
• Set the programme switch to sweep with sweeping brush when cleaning surfaces.
• Set the programme switch to sweep with sweeping brush and side brush when cleaning edges.

Emptying waste container

• Danger: Risk of injury! When emptying the waste container, care should be taken to ensure that no persons or animals are within its swivelling range.
• Danger of crushing. Never reach into the rod assembly for the drainage mechanism. Stay away from the area under the raised container.
• Danger of tipping. Place the machine on an even surface during emptying.

Set programme selection switch to "Transport drive".

• Raise waste container.
• Slowly drive towards the collection container.
• Lock parking brake.
• Open the container door: Press the left side of the switch and empty the waste container.
• Close the container door: Press the right side of the switch (approximately 2 seconds), until the unit is tilted to the end position.
• Release parking brake.
• Drive away the collection container slowly.
• Lower the waste container up to the end-position.

Turn off the appliance

• Press brake pedal and keep it depressed.
• Lock parking brake.
• Turn ignition key to "0" and remove it.

Transport

• Danger: Risk of injury and damage! Observe the weight of the appliance when you transport it.
• Turn ignition key to "0" and remove it.
• Lock parking brake.
• Secure the appliance at the lashing points (4x) using tension belts, ropes or chains.
• Secure the wheels of the machine with wheel chocks.
• When transporting in vehicles, secure the appliance according to the guidelines from slipping and tipping over.

Storage

• Danger: Risk of injury and damage! Note the weight of the appliance in case of storage.

Shutdown

If the sweeper is going to be out of service for a longer time period, observe the following points:

• Park the sweeper on an even surface.
• Set programme selection switch to "Transport drive".
• Turn ignition key to "0" and remove it.
• Lock the sweeper to ensure that it does not roll off.
• Clean the inside and outside of the sweeper.
• Park the machine in a safe and dry place.
• Remove the battery plug from machine.
• Charge battery and recharge it approx. every 2 months.

Maintenance and care

General notes

Caution: Risk of damage! Do not rinse out the dust filter.

• First switch off the appliance, remove the key and remove the battery plug or disconnect the battery before performing any cleaning or maintenance tasks on the appliance, replacing parts or switching over to another function.
• Maintenance work may only be carried out by approved customer service outlets or experts in this field who are familiar with the respective safety regulations.
• Mobile appliances used for commercial purposes are subject to safety inspections according to VDE 0701.
• Park the sweeper on an even surface.
• Turn ignition key to "0" and remove it.
• Lock parking brake.

Cleaning

Caution: Risk of damage! Do not clean the appliance with a water hose or high-pressure water jet (danger of short circuits or other damage).

Cleaning the inside of the machine

• Danger: Risk of injury! Wear dust mask and protective goggles.
• Clean machine with a cloth.
• Blow through machine with compressed air.

External cleaning of the appliance

Clean the machine with a damp cloth which has been soaked in mild detergent.

Note: Do not use aggressive cleaning agents.

Maintenance intervals

See inspection checklist 5.950-648.0!

Note: The elapsed-time counter shows the timing of the maintenance intervals.

Maintenance by the customer

Note: Where maintenance is carried out by the customer, all service and maintenance work must be undertaken by a qualified specialist. If required, a specialised Kärcher dealer may be contacted at any time.

Daily maintenance:

• Check the sweeping roller and the side brush for wear and wrapped belts.
• Check function of all operator control elements.
• Check appliance for damages.

Weekly maintenance:

• Clean the hydraulic oil cooler.
• Check hydraulic unit.
• Check the hydraulic oil level.
• Check brake fluid status.

Maintenance Works

Preparation:

• Park the sweeper on an even surface.
• Turn ignition key to "0" and remove it.
• Lock parking brake.

General notes on safety

Danger: Risk of injury! Always apply the safety bar when the waste container is raised.

• Fold the safety rod for the high emptying up and insert it into the holder (secured).

Replace batteries

The batteries can only be exchanged as a set. The exchange has to be performed by trained personnel.

• Due to the heavy weight (each battery pack weighs 545 kg), the replacement must be performed by means of a crane.
• When removing the battery, disconnect the negative terminal wire first.
• Fasten the crane chains in the four eyelets of the battery set and carefully lift out the batteries.
• Note: Prior to that, remove the side panels.

Check hydraulic oil level and refill hydraulic oil

Note: The waste container must not be raised.

• Open engine cover.

Check hydraulic oil level in the looking glass.

• The oil level must lie between "MIN" and "MAX" marking.
• Add hydraulic oil if the oil level is below the "MIN" marking.
• Loosen the closing cap of the oil filling opening.
• Clean the filling area.
• Refill hydraulic oil.
• Oil grade: see Technical Data
• Replace and tighten the closing cap of the oil filling opening.

Note: If the pressure gauge shows an increased hydraulic oil pressure, the hydraulic oil filter must be replaced by Kärcher customer service.

Check hydraulic unit

• Lock parking brake.
• Start the motor.

Only Kärcher Customer Service is authorised to carry out maintenance tasks on the hydraulic unit.

• Check all hydraulic hoses and connections and ensure that they are leak-proof.

Checking roller brush

• Turn the ignition key to position "I".
• Raise the waste container up to the end-position.
• Turn the ignition key to 0 position.
• Lock parking brake.
• Use the safety bar for emptying from a height.
• Remove belts or cords from roller brush.
• Remove the safety bar.
• Insert the ignition key into the ignition switch.
• Turn the ignition key to position "I".
• Lower the waste container up to the end-position.
• Switch off engine.

Replacing roller brush

• Open the side covers using a key.
• Unscrew the wingnuts from the holding plate side seals and remove the holding plate.
• Flip the side seal out.
• Uncscrew the retaining screw of the roller brush intake, and swing the intake to the outside.
• Pull out roller brush.

Installation position of roller brush in direction of travel (top view)

Note: When installing the new roller brush, ensure correct positioning of the bristle assembly.

• Install new roller brush. The nuts of the roller brush must be inserted on the notches of the opposite crank.

Note: Once the new roller brush has been installed, the sweeping track must readjusted.

Check and adjust roller brush sweeping track

• Check tyre pressure.
• Switch off suction blower.
• Drive sweeper on to a smooth, even surface covered with a visible layer of dust or chalk.
• Set the programme switch to sweep with roller brush.
• Set programme selection switch to "Transport drive".
• Drive machine backwards.
• Check sweeping mirror.

The width of the sweeping track should lie between 40-50 mm.

• Set the sweeping track using the two adjusting screws.
• Check sweeping mirror.

Adjust the side seals

• Drive the waste container up and secure it with the safety rod.
• Danger: Risk of injury! Always apply the safety bar when the waste container is raised.
• Fold the safety rod for the high emptying up and insert it into the holder (secured).

Adjusting the sweeping track:

• Adjust the sweeping track position by adjusting the adjustment screw.
• Check sweeping mirror.

Check and adjust sweeping track of the side-brush

• The side-brushes lift up.
• Drive sweeper on to a smooth, even surface covered with a visible layer of dust or chalk.
• Set the programme switch to sweep with roller brush and side brush.
• Screw in the holding plates.
• Repeat the procedure on the other side of the appliance.
• The side-brushes lift up.
• Set programme selection to "Drive".
• Drive machine backwards.
• Check sweeping mirror.

Manually clean the dust filter

• Clean the dust filter with the filter cleaning button.

Replacing dust filter

• Warning: Empty waste container before replacing dust filter. Wear a dust mask when working around the dust filter. Observe safety regulations on the handling of fine particulate material.
• Open the lock, remove the star grip screw to do this.
• Fold cover forwards.
• Open filter cap.
• Fold the filter vibrator forward.
• Replace the dust filter.
• Close the filter cover.

Changing the headlight bulb (option)

• Unscrew the head lamps.
• Take out the head lamps and pull out the plug.
• Note: Note the positions of the plugs.
• Dismantle the head lamps.
• Dismantle the head lamp casing and hold it horizontally because the lamp unit is not fastened.
• Unlock the bracket and take out the bulb.
• Insert new bulb.
• Reinstall in reverse sequence.

Changing the blinker bulb (option)

Note: Remove the glass of the direction-indicator lamp from its casing to replace the bulb.

Replacing fuses

• Open the fuse holder.
• Check the fuses.
• Replace defective fuses.
• Note: The fuse FU 01 (main fuse) is located on the electronics casing. The fuses FU 14, FU 15 and FU 16 are located in the electronics casing. Attention: Opening of electronics casing and replacing of fuses only by customer service.

EC Declaration of Conformity

We hereby declare that the machine described below complies with the relevant basic safety and health requirements of the EU Directives, both in its basic design and construction as well as in the version put into circulation by us. This declaration shall cease to be valid if the machine is modified without our prior approval.

Product: Sweeper

Type: 1.186-xxx

Relevant EU Directives: 2006/42/EC (+2009/127/EC), 2004/108/EC, 2000/14/EC

Applied harmonized standards: EN 55012: 2007 + A1: 2009, EN 61000-6-2: 2005, EN 60335-1, EN 60335-2-29: 2004+A2: 2010, EN 60335-2-72, EN 61000-3-2:2006+A1:2009+A2: 2009, EN 61000-3-3:2008, EN 62233: 2008

Applied conformity evaluation method: 2000/14/EC: Appendix V

Sound power level dB(A): Measured: 94, Guaranteed: 97

The undersigned act on behalf and under the power of attorney of the company management.

H. Jenner, CEO

S. Reiser, Head of Approbation

Authorised Documentation Representative: S. Reiser

Alfred Kärcher GmbH Co. KG, Alfred-Kärcher-Str. 28-40, 71364 Winnenden (Germany), Phone: +49 7195 14-0, Fax: +49 7195 14-2212

Winnenden, 2012/04/01

Warranty

The warranty terms published by the relevant sales company are applicable in each country. Kärcher will repair potential failures of your appliance within the warranty period free of charge, provided that such failure is caused by faulty material or defects in manufacturing. In the event of a warranty claim please contact your dealer or the nearest authorized Customer Service centre. Please submit the proof of purchase.

Troubleshooting

Technical specifications

Machine data

Electrical system

Hydraulic system

Oil quantity in hydraulic tank

Waste container

Roller brush

Side brushes

Solid rubber tyres

Brake

Filter and vacuum system

Working conditions

Values determined as per EN 60335-2-72

Noise emission

Machine vibrations

Dimensions and weights

Subject to technical modifications!