Table of Contents
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Summary of Contents for HAKO Sweepmaster P 1200 RH
- Page 1 Service Manual Sweepmaster P/D/B 1200 RH (6300.10 / 6300.20 / 6300.30) Training Troubleshooting Adjustments Components/Suppliers Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
- Page 2 (close to the old Hakomatics). In this training manual are the old names used. Here a comparison of the „old“ and „new“ names for this machine. Jonas 1200 V Sweepmaster P 1200 RH Jonas 1200 D Sweepmaster D 1200 RH...
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Page 3: Table Of Contents
3.5 Filter ................................................21 3.5.1 Change and Clean Cartridge Filter ......................................21 3.5.2 Suction Fan Flap ............................................. 21 3.6 Steering................................................22 3.7 V/D-Version Travelling Drive ........................................23 Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 4 6.2 View on V/D-Version Fuse Box ........................................41 6.3 View on E-Version Fuse Box ........................................43 6.4 Seat Contact Controller..........................................45 6.4.1 Circuit Diagram ............................................45 6.4.2 Logic ................................................ 46 Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
- Page 5 6.7.1 LDS Setting Mode ........................................... 52 6.6.2 LDS Programming ........................................... 54 MAINTENANCE ....................................56 Gasoline-Version Service Intervals ..................................... 57 Diesel-Version Service Intervals ......................................59 E-Version Service Intervals ........................................61 Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 6: Operation
Service Manual 1.0 Operation Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 7: Scheme Of Operation
(4). Clean air only is taken out into the environment. Disposal of dirt is realized via high-dump system directly into a standard dustbin. Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe... -
Page 8: Technical Data
Service Manual 2.0 Technical Data Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 9 Theor. sweeping performance with 1 / 2 side broom(s) m²/h 10,300 / 13,200 10,300 / 13,200 9,200 / 11,700 Climbing ability Filter system Filter surface m² Plate filter qty. Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
- Page 10 Front wheel drive (solid rubber) 4.00-4 4.00-4 4.00-4 Rear wheels (pneumatic) 4.00-8 4.00-8 Inflation pressure Optional rear wheel option (solid rubber) (Standard E) 4.00-8 4.00-8 4.00-8 Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
- Page 11 2 x 1.00 Noise emission value Sound pressure level acc. to DIN IEC 60335-2-72 dB(A) Sound power level acc. to DIN IEC 60335-2-72 dB(A) Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 12: Design And Mechanics
Service Manual 3.0 Design and Mechanics Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 13: Operation Elements
Hydraulikventil Hydraulic valve The spring connected to the side broom lever should be slightly under tension. The tension must not exceed the tension of the valve- neutral-spring (hydraulic broom valve). Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014... -
Page 14: Cylindrical Broom And Side Brush
• Open both knobs (3+5) and remove lateral plate (4); Twist broom while inserting until it audibly catches pull out the cylindrical broom in the driving tooth Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 15: Check Sweeping Mark Distance
3.2.1.3 Adjust Sweeping Mark Distance Adjust the sweeping mark distance by turning the hand wheel located under the engine compartment cover. The “mark pin” indicates wear limit of the cylindrical broom. Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014... -
Page 16: Side Brush
Seen in direction of travel, the floor contact surface of the r-h side brush should be between the 11 and 3 o’clock position. l-h side brush between the 9 and 1 o’clock position Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 17 Service Manual Height adjustment Roll for Bowden cable Inclination of 5° fixed Return spring Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 18: Dirt Hopper Abba System
Service Manual 3.3 Dirt Hopper ABBA System Cyl. broom shift wheel Cable cord for cyl. broom Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 19 Service Manual Tracking of the Dirt Hopper Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 20: Dirt Hopper Lift-Out System
Service Manual 3.4 Dirt Hopper Lift-Out System The ball head (ABBA system) catches here Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 21: Filter
• Use switch (S12) at the control wire below the dashboard to actuate the jolter motor. Note: Driven by a V-belt, the fan constantly runs as soon as the engine (V/D) / central motor (E) is running. Hako GmbH Technical Service (KUD) -
Page 22: Steering
0.2mm remains between the coil spaces (feeler gauge) Representation of the Jonas 980! Carrier plate changed, no cover plate Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 23: V/D-Version Travelling Drive
- Tighten nut by 5 Nm - If split pin holes do not match tighten nut until next split pin hole Torque 32 Nm Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 24: E-Version Travelling Drive
- Swing wheel by 90° - Tighten lower nut by 5 Nm - If split pin holes do not match tighten nut until next split pin hole Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 25: Change Brushes
Service Manual 3.8.2 Change Brushes Loose this 4 screws Carbon brushes Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 26: Drive
Service Manual 4 Drive Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 27: V-Version Engine
Service Manual 4.1 V-Version Engine 4.1.1 Engine Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 28 480 ccm Output at nominal speed: 8.2 kW Torque at 2,400 rpm: 33.1 Nm Maintenance and repair of the drive units according to manufacturer’s prescriptions Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 29: Lpg Version
42 3540 1200/1201 Fitting D8 S, C8 LL = Del. by KARG 54 3865 0000 Overpressure safety Electr. shut-off valve Pipe, compl. 96113253, del. by HAKO control dev. 63 0483 1040 Fitting, straight (tested) M 10x1 (m) x 1/4“NPT Oil filter... - Page 30 Fig. 6 If required, remove pipe adapter, measurement probe and bridge of seat contact switch. Re-install connection of seat contact switch and secure by shrinking hose Air hose (Hako) 62 5059 0060 Adjust to or check mixture control...
- Page 31 Service Manual Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 32: D-Version Engine
Service Manual 4.2 D-Version Engine Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 33 22.8: 1 Output at nominal speed: 8.2 KW Torque at 2,000 rpm: 28 Nm Maintenance and repair of the drive units according to manufacturer’s prescriptions Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 34: Hydraulic System
Service Manual 5 Hydraulic System Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 35: General
Should moving of the machine be necessary when engine stands still, open the bypass valve of the pump. Pump pressure is assured by two pressure-limiting vales (bidirectional). They are set to 160bar (forward) and 130 bar (reverse). Hako GmbH Technical Service (KUD) -
Page 36: Hydraulic Diagram V/D-Version Driving
After this pressure attains the 160bar (forward) or the 130bar (reverse), the pressure-limiting valve opens accordingly and protects driving. Hako GmbH Technical Service (KUD) -
Page 37: Drive Pump
By-pass valve Bypass-Ventil 2 turns for opening 2 Umdrehungen zum Öffnen Pressure-limiting DBV rückwärts valve, reverse 130 bar 130bar Feed pump, Speisepumpe inlet Einlass Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 38: Brief Description Of Work Hydraulic
“upper” to the “lower” and then to the piston side of the lifting cylinder. The hopper is then lifted-out. For lowering, actuation of the hopper lever to the other side (valve switched downwards) is sufficient. Hako GmbH Technical Service (KUD) -
Page 39: Electrical System
Service Manual 6 Electrical System Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 40: Safety Information
Information for AC generator • Let engine run only with the battery connected. • Do not use the charger unit for emergency starting • Disconnect battery before re-charging or electro-welding at the machine Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014... -
Page 41: View On V/D-Version Fuse Box
Service Manual 6.2 View on V/D-Version Fuse Box Optional LPG equipment displaced Lighting, OPTIONAL Jonas 1200 D variant Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 42 Pulse relay for jolting Relay for lighting Optional Optional Flashing relay Optional Optional Pre-glowing relay (D) not assigned LPG switch unit (V) Optional not assigned Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 43: View On E-Version Fuse Box
Service Manual 6.3 View on E-Version Fuse Box rear front Lighting OPTIONAL Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 44 Relay for main motor Time relay for pick-up delay / filter monitoring Pulse relay for jolting Relay for working floodlight Optional Flasher relay Plug configuration LDS Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 45: Seat Contact Controller
6.4 Seat Contact Controller The S2 seat contact switch is monitored via the K1 relay which has implemented several logic functions. 6.4.1 Circuit Diagram Wiring of Seat contact controller for Jonas 1200 V/D Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014... -
Page 46: Logic
(PIN4 ground; PIN7 12V) with simultaneous connection of PIN8 output, the next start trial will be inhibited. Actuation of the seat contact switch is required before resetting is available (even if neutral switch was the cause). Hako GmbH Technical Service (KUD) -
Page 47: Drive Controller
Service Manual 6.5 Drive Controller The drive controller used in the E variant is a ZAPI controller of the type SEM1 Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 48 Current for contactor activation 4) Continuously Temperature of power unit Battery voltage Additionally the drive controller monitors some safety functions of the machine electric. Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 49: Error Messages
Error in the contactor activation COIL SHORTED Contactor coil short-circuited CONTACTOR CLOSED Error at main contactor contact TH PROTECTION Controller temperature exceeding limits (<70°C or > -10°C) Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 50: Machine Safety Functions
The driving speed is reduced to half speed. Internal signal in the drive controller. To reset this, the key lock have to be switched “OFF” and “ON” again and then the seat switch have to be switched “ON” and “OFF” Hako GmbH Technical Service (KUD) -
Page 51: Electric Drive Motor
Service Manual 6.6 Electric Drive Motor Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 52: Low Discharge Signal Sender (Lds)
To do so, connect the plug X19 at the fuse box to the contact underneath it. Now, programming of the LDS is possible. Note: After setting, make sure to disconnect the plugged contact again! Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe... - Page 53 Service Manual Connect plug X19 contact (A) and tab connector (B) Proceed to LDS setting as described under 6.7.2 After LDS setting, disconnect (A)+(B) again Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 54: Lds Programming
After the 2.30 V/Z value has been attained, display re-starts automatically with 1.80 V/Z. /• After the desired charged value of the profile has been attained, press the left button”▲ “ once. Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 55 "Charged" profile "Discharge" profile 7401 4 x 6 V / 240 Ah GiV mainten.-free 2,04 1,76 7408 24V / 420Ah EPzS low-mainten. 2,04 1,73 Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 56: Maintenance
Service Manual 7 Maintenance Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! -
Page 57: Gasoline-Version Service Intervals
Basic cleaning of the plate filter Test drive and function test Check battery Check tension of steering chain and adjust if required Check thread of wheels Change plate filter Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 58 Check fixing screws (brake, steering, lifting-up disposal) and tighten if required Check brake system Check steering function Check LPG system for leaking and CO setting Test drive and function test of safety relevant items Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 59: Diesel-Version Service Intervals
Test drive and function test Check battery Check tension of steering chain and adjust if required Check thread of wheels Change plate filter Check lifting-up disposal function (2-hand-operation) Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 60 Check fixing screws (brake, steering, lifting-up disposal) and tighten if required Check brake system Check steering function Test drive and function test of safety relevant items Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only!
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Page 61: E-Version Service Intervals
Check hydraulic hoses and replace if required Check cables and plugged connections for damage and tight fit Change hydraulic oil Change ring filter (dust filter) Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014 Confidential - For internal use only! - Page 62 Check steering function Test drive and function test of safety relevant items Check, and eventually change, the carbon brushes from the drive motor, broom motor and central motor each 1000h. Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe Edition: 05/2014...
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