Kärcher BR 120 RI User Manual (English)

Questions and Answers:

C
Chad StaffordAug 22, 2025
What to do if the suction motor won't run on my Kärcher BR 120 RI Floor Machine?
- S
  Scott LewisAug 22, 2025
  If the suction motor on your Kärcher Floor Machine isn't running, consider these possible solutions: – Ensure the suction beam is not raised. – Check if the dirty water tank is full. – Check and replace fuse (F3) if necessary. – Test and replace the float switch (S12) if necessary, using test mode. – Test and replace the program selector switch (S9) if necessary. – Test and replace the suction motor (M4) if necessary, using test mode. – Check cable connections, removing any defective cables. – Test the cleaning module printed circuit board (A3) and replace if necessary, using test mode.
M
matthew92Aug 25, 2025
What causes poor suction performance in a Kärcher BR 120 RI Floor Machine?
- M
  Mark SalazarAug 25, 2025
  If you're experiencing poor suction performance with your Kärcher Floor Machine, here are some things to check: – Make sure the air intake cover on the dirty water tank isn't blocked; clean it if it is. – Check, clean, or replace the seal on the cover of the dirty water tank. – Clean, turn, or replace the rubber strips on the suction beam. – Check and replace the suction hose if needed. – Check and adjust the suction beam setting. – Test the microswitch (S30, S31) of the lifting motor (M30), adjust or replace if necessary, using test mode.
R
Richard WhiteAug 28, 2025
How to resolve poor cleaning result with Kärcher Floor Machine?
- C
  Cynthia ByrdAug 28, 2025
  To address poor cleaning results with your Kärcher Floor Machine: – Inspect brush rollers for any foreign objects and remove them. – Test and adjust the contact pressure of the brush rollers using test mode. – Check if the suction performance is too low. – Verify that there is sufficient water supply. – Ensure that enough cleaning agent is being supplied.
E
Erica OwensAug 29, 2025
Why is the suction motor not switching off after the after-running time on my Kärcher Floor Machine?
- P
  Philip MartinAug 30, 2025
  If the suction motor on your Kärcher Floor Machine doesn't switch off after the after-running time, consider these possible causes: – The float switch may be blocked or defective (only fully active for dirt container). – The limit switch of the suction beam lifting motor (S20, S21) may be defective; replace it if necessary. – Test the cleaning module printed circuit board (A3) and replace if necessary, using test mode.
S
Susan CastilloAug 31, 2025
Why is the dirty water tank overflowing on my Kärcher BR 120 RI?
- D
  Dakota FigueroaAug 31, 2025
  If the dirty water tank on your Kärcher Floor Machine is overflowing: – Check and replace fuse (F3) if necessary. – Test the dirty water tank float switch (S11) and replace if necessary, using test mode. – Check cable connections and replace defective cables. – Test the cleaning module printed circuit board (S3) and replace if necessary, using test mode.
M
Margaret ThomasSep 2, 2025
What causes noises in the area of the wheel hub motor of Kärcher BR 120 RI?
- L
  Laura McbrideSep 2, 2025
  To address noises in the wheel hub motor area of your Kärcher Floor Machine: – Adjust the castellated nut. – Check and replace the steering bearing if necessary.
J
jennifer52Sep 4, 2025
What to do if there is no or too little cleaning agent supplied by Kärcher BR 120 RI?
- L
  Laura HarrisSep 4, 2025
  If your Kärcher Floor Machine is not supplying enough cleaning agent, try the following: – Check the hose to the brush head for blockages or kinks and remove them. – Check and replace the fuse (F3) if necessary. – Test the chemical tank float switch (optional) (S12) and replace if necessary, using test mode. – Test the program selector switch (S9) and replace if necessary, using test mode. – If equipped, clean the flow meter of the chemical pump (M6) if it's contaminated. – Test the chemical pump (M6) (optional) and replace if necessary, using test mode. – Check cable connections and replace defective connections. – Test the cleaning module printed circuit board (A3) and replace if necessary.
L
Laura MillerSep 6, 2025
What to do if the suction beam cannot be raised or lowered on a Kärcher BR 120 RI?
- J
  Jennifer MorenoSep 6, 2025
  If the suction beam on your Kärcher Floor Machine cannot be raised or lowered: – Check and replace fuse (F4) if necessary. – Ensure the lifting mechanism is not blocked. – Test the microswitch (S30, S31) and replace if necessary, using test mode. – Test the program selector switch (S9) and replace if necessary, using test mode. – Test the lifting motor (M30) and replace if necessary, using test mode. – Check cable connections and replace defective cables. – Test the lifting module printed circuit board (A4) and replace if necessary, using test mode.
N
npenaSep 7, 2025
What to do if the brush head cannot be raised or lowered on a Kärcher Floor Machine?
- S
  Sheila WheelerSep 7, 2025
  If the brush head on your Kärcher Floor Machine cannot be raised or lowered: – Check and replace fuse (F4) if necessary. – Ensure the lifting mechanism is not blocked. – Test the program selector switch (S9) and replace if necessary, using test mode. – Test the lifting motor (M20) and replace if necessary, using test mode. – Test the lifting module printed circuit board (A4) and replace if necessary, using test mode.
R
Robert HunterSep 9, 2025
Why won't the brush motor start on my Kärcher Floor Machine?
- B
  Bradley SnyderSep 9, 2025
  If the brush motor on your Kärcher Floor Machine isn't starting: – Check and replace fuse (F3) if necessary. – Test the brush motor (M2, M3) and replace if necessary, using test mode. – Check cable connections and remove defective cables. – Test the cleaning module printed circuit board (A3) and replace if necessary, using test mode.

Kärcher BR 120 RI Specifications

General

Brand	Kärcher
Model	BR 120 RI
Category	Floor Machine
Language	English

Summary

Service Manual Introduction

Foreword

Introduction to the service manual, emphasizing training and documentation.

Equipment Features

Technical Features BR/BD 100/250 R

Details the technical specifications of the BR/BD 100/250 R model.

Technical Features BR/BD 100/250 RI

Details the technical specifications of the BR/BD 100/250 RI model.

Technical Features BR/BD 120/250 R and RI

Details the technical specifications for the 120/250 R and RI models.

View from the Left-Hand Side

Diagram identifying components from the left side of the machine.

View from the Right-Hand Side

Diagram identifying components from the right side of the machine.

Rear View

Diagram identifying components from the rear of the machine.

Technical Features - Components

Wheel Hub Motor (M1)

Detailed explanation and diagram of the wheel hub motor and its components.

Brush Head

Description and diagrams of the brush head assembly for BR and BD versions.

Suction Beam

Detailed description and diagrams of the suction beam and its components.

Suction Motor (M4)

Details on the suction motor, its function, and location.

Water System

Overview of the water system components, including filters and pumps.

Dirty Water Tank with Recycling Function (Optional)

Details on the optional dirty water tank with recycling capabilities.

Control Panel

Identification and function of all buttons and indicators on the control panel.

Program Switch (S9)

Explanation of the program switch positions and their functions.

Seat Sensor (S10) and Distribution Box (EXT.X1)

Description of the seat sensor safety function and distribution box components.

Battery (Low-Maintenance) with Filling System

Details on the battery system, including filling and connections.

Battery Charger

Information on the battery charger, its operation, and indicator lights.

Side Brush (Optional)

Description of the optional side brush system and its components.

Pre-Sweeper Unit (BR/BD 100/250 RI Only)

Overview of the pre-sweeper unit for the RI version.

Pre-Sweeper Unit: Parallelogram (Adjustment)

Instructions for adjusting the pre-sweeper unit parallelogram for proper parallelism.

Pre-Sweeper Unit: Control Panel

Details on the control panel specific to the pre-sweeper unit.

Pre-Sweeper Unit: Housing Cover Open

Illustration showing the internal components when the housing cover is open.

Pre-Sweeper Unit: Round Filter with Retainer

Instructions on how to remove the round filter from the filter case.

Pre-Sweeper Unit: Motor, Filter Shaker

Details on the filter shaker motor and its location.

Pre-Sweeper Unit: Impeller Fan System

Description of the impeller fan system, including belt and motor.

Pre-Sweeper Unit: Lifting Motor/Main Brush / Side Brush

Details on the lifting motor and Bowden cables for the main and side brushes.

Pre-Sweeper Unit: Motor Main Brush

Description of the main brush motor, drive shaft, belt, and pulley.

Pre-Sweeper Unit: Retainer LH / Main Brush

Diagram and explanation of the retainer and tensioning system for the main brush.

Pre-Sweeper Unit: Sealing Strip

Instructions for adjusting the sealing strip height relative to the floor.

Pre-Sweeper Unit: Coarse Dirt Flap

Description of the coarse dirt flap and its components.

Pre-Sweeper Unit: Pedal Arrangement

Diagram showing the arrangement of the machine's pedals.

Unit Functions

Functional Diagram

Schematic illustrating the functional flow of the machine's systems.

Brush Head Mounting Parts

Details on the mounting components of the brush head for BR and BD versions.

Brush System - Contact Pressure Adjustment

Explanation of how brush contact pressure is adjusted via the lifting motor.

Pre-Sweeper Unit Functional Diagram (BR/BD 100/250 RI Only)

Functional diagram specific to the pre-sweeper unit on the RI model.

Operator and Service Program Overview

Overview of operator functions and the service program availability.

Operator Functions

Description of operator functions, available settings, and test modes.

Initial Operation and Information Menu REVISED

Detailed flowchart for initial operation and accessing the information menu.

Initial Operation and Information Menu ORIGINAL

Flowchart for initial operation and information menu for older versions.

Driving (Without Cleaning Functions) REVISED

Flowchart detailing the driving function without cleaning components active.

Driving (Without Cleaning Functions) ORIGINAL

Flowchart for driving function in older versions.

Wet Scrubbing (With Suction)

Flowchart describing the wet scrubbing operation with suction.

Wet Scrubbing (Without Suction)

Flowchart describing the wet scrubbing operation without suction.

Suction (Without Scrubbing Mode)

Flowchart for the suction-only operation mode.

Polishing (Without Suction)

Flowchart for polishing operation without suction.

Polishing (With Suction)

Flowchart for polishing operation with suction.

Hand Cleaning with Wall-Ceiling-Floor Tool (Optional)

Description of the optional hand cleaning function with accessories.

Operator Functions - Manufacture Settings

Table detailing manufacture settings for operator functions based on program switch.

Modular Electronic Control Circuits

Module Networking

Diagram illustrating the interconnection of various electronic modules.

Modular System BR/BD 100/250 R

Block diagram showing the modular system configuration for the BR/BD 100/250 R.

Modular System BR/BD 100/250 R with Side Brush (Optional)

Block diagram of the modular system with the optional side brush.

Modular System BR/BD 100/250 RI

Block diagram of the modular system for the BR/BD 100/250 RI.

Emergency Operation (Driving) Example

Procedure for emergency driving operation in case of module failure.

Control Panel (View from Below) with Modules

Diagram showing control panel components from below, including CPU and info modules.

Lifting Module (A4) and Accessories Module (A5)

Diagrams and identification of the lifting and accessories modules.

Driving Module (A2) and Cleaning Module (A3)

Diagrams and identification of the driving and cleaning modules.

Optional Lifting (A4/1) and Cleaning (A3/1) Modules

Diagrams and identification of optional lifting and cleaning modules.

Service Module (A9)

Description of the service module for diagnostics, parameterization, and firmware updates.

Basic Settings and Service Procedures

Access to Test Mode (Program Switch S9, Position 1)

Procedure to access the test mode using program switch S9 position 1.

Access to Test Mode (Program Switch S9, Position 2)

Procedure to access the test mode using program switch S9 position 2.

Current Measurement (On/Off Function)

Procedure for measuring current with the on/off function in test mode.

Access to Test Mode (Program Switch S9, Position 3)

Procedure to access the test mode using program switch S9 position 3.

Access to Test Mode (Program Switch S9, Position 4)

Procedure to access the test mode using program switch S9 position 4.

Access to Test Mode (Program Switch S9, Position 5)

Procedure to access the test mode using program switch S9 position 5.

Accelerator Pedal Calibration

Step-by-step guide for calibrating the accelerator pedal.

Illuminated Symbol Test

Procedure for testing all illuminated symbols and LEDs on the display.

Service-Operator Menu

How to access and navigate the service-operator menu for diagnostics and settings.

Access to Test Mode ORIGINAL

Procedure to access the test mode for original software versions.

Test Mode - Drive Units

Tests for the drive units, including motor and pump functions.

Test Mode - Lifting Motors

Tests for the lifting motors, including their movement and limit switch functions.

Test Mode - Calibration

Calibration tests for various machine functions.

Access to Setup Menu REVISED

Procedure to access the setup menu for revised software versions.

System Menu and Driving Module Parameters REVISED

Accessing and adjusting system and driving module parameters.

Cleaning Module and Lifting Module Parameters REVISED

Accessing and adjusting cleaning and lifting module parameters.

Access to Setup Menu ORIGINAL

Procedure to access the setup menu for original software versions.

System Parameters and Driving Module

Navigating system and driving module setup menus.

System Menu and Driving Module Parameters ORIGINAL

Adjusting system and driving module parameters for original software.

Cleaning Module and Lifting Module Parameters ORIGINAL

Adjusting cleaning and lifting module parameters for original software.

Save Changed Adjustable Parameters

Procedure for saving modified adjustable parameters.

Load Backup Operating Hours Counter

Instructions for loading backup operating hours from the cleaning module.

Module Parameter Manufacture Settings

Table of manufacture settings and factory defaults for various modules.

Module Parameter - Manufacture Settings

Details on specific manufacture settings for options like chemical metering and warning lights.

Steering

Description and diagrams of the steering column and head components.

Lifting Motor - Suction Beam (M30)

Procedure for adjusting microswitches and checking the suction beam lifting motor.

Lifting Motor - Brush Head (M20)

Instructions for adjusting the brush head lifting motor and its limit positions.

Brush Head - Maintenance Work

Routine maintenance tasks for the brush head, including roller and belt replacement.

Check Brush Rollers for Foreign Matter

Guidance on checking and removing foreign matter from brush rollers.

Check/Adjust Splash Guard Strips

Instructions for checking and adjusting the splash guard strips.

Check Brush Pattern (BR/BD)

Procedure for checking and adjusting the brush pattern for parallel and symmetrical results.

Adjust Brush Pattern (BR/BD)

Steps to adjust the brush pattern for proper floor contact.

Drive Sensor (B1)

Procedure for adjusting the drive sensor and its automatic calibration.

Wheel Hub Motor Tyres (M1)

Instructions for checking and replacing carbon brushes in the wheel hub motor.

Replace the Tyres

Step-by-step guide for replacing the tires on the wheel hub motor.

Remove and Check Electromagnetic Brake (Y1)

Procedure for removing, checking, and adjusting the electromagnetic brake.

Check and Set Freewheeling Lever (M1)

Instructions for checking and setting the freewheeling lever and brake air gap.

Check Electromagnetic Brake (Y1) with Mounting Plate

Detailed steps for checking and setting the electromagnetic brake air gap.

Rear Wheel Brake

Procedure for adjusting the rear wheel brakes for uniform braking.

Replacement Intervals

Table listing components and their recommended replacement intervals.

Troubleshooting

Troubleshooting Without Displays

Guidance for troubleshooting faults not indicated on the display.

Unit Won't Start

Steps to diagnose and resolve issues when the unit fails to start.

Water Volume Too Low

Troubleshooting steps for low water volume issues.

Suction Performance Too Low / Dirty Water Tank Overflows

Diagnosing and resolving low suction performance and tank overflows.

Troubleshooting With Displays

Interpreting and resolving faults indicated by display messages and error codes.

Structure of Warning Messages

Explanation of the structure and meaning of warning messages displayed by the machine.

Meaning of the 3-Digit Error Code

Decoding the 3-digit error codes for various system functions.

Drive Module (A2) Error Messages

List of error codes and troubleshooting actions for the drive module.

Accessories Module (A5) Error Messages

List of error codes and troubleshooting actions for the accessories module.

Lifting Module (A4) and Cleaning Module (A3) Error Messages

Error messages and troubleshooting for lifting and cleaning modules.

Head CPU (A1) Error Messages

Error messages and troubleshooting actions for the Head CPU module.

Error Memory and Maintenance

Module Error Codes - Display Pattern

Understanding the display patterns for module error codes and significant errors.

Significant Errors (Head CPU Module A1)

Details of significant errors related to the Head CPU module.

Significant Errors (Drive Module A2)

Details of significant errors related to the Drive module.

Significant Errors (Cleaning Module A3)

Details of significant errors related to the Cleaning module.

Significant Errors (Lifting Module A4)

Details of significant errors related to the Lifting module.

Significant Errors (Accessories Module A5)

Details of significant errors related to the Accessories module.

Maintenance Operations After Working Hours

Scheduled maintenance tasks based on working hours.

Additional Instructions for Version RI

Specific maintenance instructions for the RI version of the machine.

Circuit Diagrams

Circuit Diagram 0.088-734.0, Head CPU (A1)

Electrical circuit diagram for the Head CPU module (A1).

Circuit Diagram 0.088-876.0, Head CPU (A1)

Revised electrical circuit diagram for the Head CPU module (A1).

Circuit Diagram for Driving Module (A2)

Circuit diagram for the Driving module (A2).

Circuit Diagram for Cleaning Module (A3)

Circuit diagram for the Cleaning module (A3).

Circuit Diagram for Cleaning Module - Pre-Sweeper Unit (A3/1)

Circuit diagram for the cleaning module of the pre-sweeper unit (A3/1).

Circuit Diagram for Lifting Module (A4)

Circuit diagram for the Lifting module (A4).

Circuit Diagram for Lifting Module - Side Brush (A4/1)

Circuit diagram for the lifting module - side brush (A4/1).

Circuit Diagram for Lifting Module - Pre-Sweeper Unit (A4/2)

Circuit diagram for the lifting module - pre-sweeper unit (A4/2).

Circuit Diagram for Accessory Module (A5)

Circuit diagram for the Accessory module (A5).

Listing of Circuit Diagram Components

List of components and their corresponding circuit diagram references.

Technical Specifications

Technical Specifications Overview

Table of unit types, unit numbers, circuit diagrams, operating instructions, and spare parts.

Special Tools

List of special tools required for maintenance and repair.

Tightening Torques

Specifications for tightening torques of various bolts and nuts.

Related product manuals

Kärcher BR 35/12 C BP

40 pages

Kärcher BR 40/10 C Adv

Kärcher BR 40/25 EP Bp

5 pages

Kärcher BR/BD 530 XL BAT

390 pages

Kärcher BR 120 RI User Manual

Table of Contents