HAKO 6300.10 Service Manual Download

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Service Manual

Hako GmbH

Technical Service (KUD) 23843 Bad Oldesloe

Edition: 05/2014

Confidential - For internal use only!

Sweepmaster P/D/B 1200 RH

(6300.10 / 6300.20 / 6300.30)

Training
Troubleshooting
Adjustments
Components/Suppliers

Summary of Contents for 6300.10

Page 1: ...al Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only Sweepmaster P D B 1200 RH 6300 10 6300 20 6300 30 Training Troubleshooting Adjustments Componen...

Page 2: ...indication of kind of drive sweeping width and operation concept 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...

Page 3: ...MECHANICS 12 3 1 Operation Elements 13 3 2 Cylindrical Broom and Side Brush 14 3 2 1 Cylindrical Broom 14 3 2 1 1 Replace Cylindrical Broom 14 3 2 1 2 Check Sweeping Mark Distance 15 3 2 1 3 Adjust Sw...

Page 4: ...Engine 27 4 1 2 LPG Version 29 4 2 D Version Engine 32 5 HYDRAULIC SYSTEM 34 5 1 General 35 5 2 Brief Description of V D Travel Drive 35 5 2 1 Hydraulic Diagram V D Version Driving 36 5 2 2 Drive Pum...

Page 5: ...e Controller 47 6 5 1 Error Messages 49 6 5 2 Machine Safety Functions 50 6 6 Electric Drive Motor 51 6 7 Low Discharge Signal Sender LDS 52 6 7 1 LDS Setting Mode 52 6 6 2 LDS Programming 54 7 MAINTE...

Page 6: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 1 0Operation...

Page 7: ...corners and edges and allows enlarging work width and area performance on free surfaces The cylindrical broom 2 collects the dirt to throw it overhead into the dirt hopper 3 The collected fine dust i...

Page 8: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 2 0Technical Data...

Page 9: ...0 Empty weight kg 763 784 1 105 Adm total weight kg 1 056 1 074 1 395 Riding and sweeping performance Forward driving speed km h 0 9 0 9 0 8 Wheel speed at max velocity rpm 156 156 139 Reverse driving...

Page 10: ...10 70 10 50 5 Qty of bristles qty 12 V shape 12 V shape 12 V shape Standard bristling PA PA PES Sealing strip ground clearance broom compartm left right rear mm 1 1 4 1 1 4 1 1 4 front mm 0 0 0 Side b...

Page 11: ...mers on rpm 2 550 50 2 550 50 Fuel tank capacity l 25 25 Consumption l h 2 5 1 25 Engine oil filling Type l 15W 40 1 5 15W 40 1 5 Spark plug Champion RC 12 YC Hydraulic system Hydraulic fluid e g Mobi...

Page 12: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 3 0Design and Mechanics...

Page 13: ...nternal use only 3 1 Operation Elements Mitnehmer Feder Carrier spring Hydraulikventil Hydraulic valve Mitnehmer Welle Carrier shaft The spring connected to the side broom lever should be slightly und...

Page 14: ...2 1 Cylindrical Broom 3 2 1 1 Replace Cylindrical Broom Dismounting Mounting Lower broom Proceed in inverse order Remove l h lateral cover Loosen star shape knob 2 to remove l h broom arm 1 Note Open...

Page 15: ...measure dimensions of sweeping marks With correct adjustment of the cylinder broom the marks left on the ground have to be in parallel The distance between parallel sweeping marks of the Jonas 1200 E...

Page 16: ...t the contact surface covers about 2 3 of the brush circumference 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 b...

Page 17: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only Height adjustment Roll for Bowden cable Return spring Inclination of 5 fixed...

Page 18: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 3 3 Dirt Hopper ABBA System Cyl broom shift wheel Cable cord for cyl broom...

Page 19: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only Tracking of the Dirt Hopper...

Page 20: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 3 4 Dirt Hopper Lift Out System The ball head ABBA system catches here...

Page 21: ...rner points Fold up and hook jolter frame Remove cartridge filter by pulling to top 3 5 2 Suction Fan Flap Before collecting wet dirt or sweeping humid surfaces change over the flap position from filt...

Page 22: ...dition 05 2014 Confidential For internal use only 3 6 Steering Open maintenance flap Compression spring with nut turn jointly until a clearance of 0 2mm remains between the coil spaces feeler gauge Re...

Page 23: ...loe Edition 05 2014 Confidential For internal use only 3 7 V D Version Travelling Drive Tighten nut by 60 Nm with simultaneous swinging of the wheel Loosen nut Tighten nut by 5 Nm If split pin holes d...

Page 24: ...onfidential For internal use only 3 8 E Version Travelling Drive 3 8 1 Bearing Plate Tighten lower nut by 60 Nm with simultaneous swinging of the wheel Loosen lower nut Swing wheel by 90 Tighten lower...

Page 25: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 3 8 2 Change Brushes Loose this 4 screws Carbon brushes...

Page 26: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 4 Drive...

Page 27: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 4 1 V Version Engine 4 1 1 Engine...

Page 28: ...600 rpm with electrical starter Manufacturer Briggs Stratton Type Vanguard V Twin 16HP Nominal speed cyl broom side brush and suction fan being on 2 500 rpm Upper idling speed 2 650 50 rpm Lower idlin...

Page 29: ...Del by HAKO 18812438 63 0490 6060 90 3 8 NPT m x 3 8 SAE F4 19 90 1 2 NPT m x 16mm hose conn 65 0001 4610 Hose clamp Fitting D8 S C8 LL Del by KARG Pipe compl 96113253 del by HAKO 62 2223 1000 low pre...

Page 30: ...0 mm into the tailpipe and secure b Bridge plug at seat contact switch 5 Start engine 6 Take to service temperature in idle run 1 550 50 1 min CO should amount to 0 1 otherwise regulate via mixture co...

Page 31: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only...

Page 32: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 4 2 D Version Engine...

Page 33: ...e with 9 8 kW at 3 600 rpm with electrical starter Manufacturer Lombardini Type LDW 502 Nominal speed cyl broom side brush and suction fan being on 2 550 rpm Capacity 505 ccm Bore 72 mm Stroke 62 Comp...

Page 34: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 5 Hydraulic System...

Page 35: ...machines with IC engines are equipped with hydrostatic travel drives which operate in closed systems Forward and reverse driving speed is continuously controllable by pedal mechanically on the pump D...

Page 36: ...ed pressure valve Since feed pressure adjustment is the lowest this valve opens and the driving circuit features a pressure of 3 8bar 0 2bar when the engine is running When the drive pump is mechanica...

Page 37: ...60 bar Bypass Ventil 2 Umdrehungen zum ffnen Anschlu vorw rts Stopfen f r Me punkt Speisedruck Anschlu r ckw rts DBV r ckw rts 130 bar Speisepumpe Einlass Port forward By pass valve 2 turns for openin...

Page 38: ...ed downwards by actuation of the side broom lever to allow the fluid flowing to the side broom motors for driving them For emptying of the dirt hopper a safety circuit two hand operation is provided f...

Page 39: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 6 Electrical System...

Page 40: ...y Information Caution Before working at the engine and at the electrical system generally disconnect the battery negative pole Information for AC generator Let engine run only with the battery connect...

Page 41: ...ual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 6 2 View on V D Version Fuse Box displaced Lighting OPTIONAL Optional LPG equipment Jonas 1200...

Page 42: ...F8 Fuse for parking rear light right hand 5A 5A F9 Fuse for jolter motor 35A 35A F10 Fuse for direction indicator left hand 5A 5A F11 Fuse for direction indicator right hand 5A 5A F12 Fuse LPG V pre...

Page 43: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 6 3 View on E Version Fuse Box Lighting OPTIONAL rear front...

Page 44: ...0 Fuse for lighting permanent plus 10A F11 Fuse for lighting switched plus 10A F12 Fuse for parking rear light left hand 5A F13 Fuse for parking rear light right hand 5A F14 Fuse for flasher relay 10A...

Page 45: ...sloe Edition 05 2014 Confidential For internal use only 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...

Page 46: ...ore the PIN5 output will be switched off This causes the starter relay K2 to switch off Output Monitoring Safety Function If voltage supply either at the PIN3 logic or at PIN2 supply breaks down both...

Page 47: ...anual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 6 5 Drive Controller The drive controller used in the E variant is a ZAPI controller of the...

Page 48: ...nsor Power controller of drive motor Contactor activation Driving direction signal Setpoint 2 Idle circuit condition ignition ON no function Self test of controller Power controller of drive motor Con...

Page 49: ...OK Error during test of the drive motor power controller armature circuit 3 VFIELD NOT OK Error of the field voltage 4 VACC NOT OK Error of the accelerator pedal signal potentiometer 4 PEDAL WIRE KO...

Page 50: ...is done the travel will be working Monitoring of ignition key If the key lock is ON and the seat switch is deactivated for longer then 3 sec Then the following action is taken The ground for the main...

Page 51: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 6 6 Electric Drive Motor...

Page 52: ...arge signal sender LDS with combined battery charge indication to the battery type used in the machine Use of two battery types is admitted a maintenance free compound battery b low maintenance tray b...

Page 53: ...hnical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 1 Connect plug X19 contact A and tab connector B 2 Proceed to LDS setting as described under 6 7 2 3 After LDS...

Page 54: ...Then release button Set battery type In the display three digits for the discharge profile charged value are flashing set to 2 04 V Z in the factory Press the right button to increment the charged val...

Page 55: ...rofile 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 In the display three digits for the discharge profile discharged value are flashing se...

Page 56: ...Service Manual Hako GmbH Technical Service KUD 23843 Bad Oldesloe Edition 05 2014 Confidential For internal use only 7 Maintenance...

Page 57: ...X X X Check optical condition of machine X X X X Change air filter main element X X X Change air filter saftey element X X Check spark plug replace if required X X X X Check neutral centering of drive...

Page 58: ...Check cables and plugged connections for damage and tight fit X X Change hydraulic oil X Change ring filter dust filter X Engine adjust valves X Engine change valve cover seal X Safety checks Check f...

Page 59: ...Change air filter main element X X X Change air filter saftey element X X Check spark plug replace if required X X X X Check neutral centering of drive pump X X X X Check service and parking brake ad...

Page 60: ...d plugged connections for damage and tight fit X X Change hydraulic oil X Change fuel filter X Change ring filter dust filter X Engine adjust valves X Engine change valve cover seal X Safety checks Ch...

Page 61: ...g brake adjust if required X X X X Check sweeping track mark and adjust if required X X X X Check broom apron and adjust or change if required X X X X Check V belt for wearing and correct tension and...

Page 62: ...only Safety checks Check fixing screws brake steering lifting up disposal and tighten if required X Check brake system X Check steering function X Test drive and function test of safety relevant items...

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