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HAKO 6400.20, Instruction Manual

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HAKO 6400.20 Instruction Manual Download Page 49

49

Maintenance and Service

5.4

Battery system

When completing any mainte-

nance and repair work, switch 

the machine off via the key 

switch to prevent the drive be-

ing started up inadvertently!
Only batteries approved by 

Hako may be installed.

Batteries may only be handled 

and changed by properly 

skilled maintenance person-

nel.
Only maintenance-free batter-

ies may be used. 

1 Seat console

2 Safety support

3 Grab handle

4 Batteries

5 Retaining strap

6 Connection diagram

 Fig.17

1

3

4

2

5

6

Summary of Contents for 6400.20

Page 1: ...Instruction Manual Sweepmaster B800 R 6400 20 ...

Page 2: ...pair work Only original spare parts can guarantee long reliable operation of your ma chine Subject to modification as re quired by technical advancement Valid as of April 2014 Hako GmbH D 23843 Bad Oldesloe Hamburger Straße 209 239 Telephone 49 4531 806 0 Intended use The Sweepmaster is a sweeper de signed for industrial commercial use and serves to clean up dry and wet re fuse from indoor and out...

Page 3: ...sult of failure to ob serve regulations concerning service and maintenance Maintenance work must be performed by authorized Hako service centers and confirmed in the Maintenance Report which serves as a warranty logbook The following are excluded from the terms of warranty wear and tear through overuse defective fuses im proper handling and use or unauthor ized modifications Claims under the terms...

Page 4: ...dities However the heavy metals contained also represent a major risk to human health and to the environment Never open or damage batteries Never touch inhale or swallow the content matter of batteries Health hazard Do not allow batteries to pollute the environment There is a risk of contaminating the ground and water In accordance with the symbol with the crossed out bin these batteries must not ...

Page 5: ...ng the shaking device37 3 9 Emptying the dirt hoppers 38 3 10 Fault location 39 3 11 Loading and transporting 40 4 Technical Data 41 5 Maintenance and Service 43 5 1 Hako system maintenance 43 5 2 Maintenance report 44 5 3 Maintenance plan 45 5 4 Battery system 49 5 4 1 Removing the batteries 50 5 4 2 Inserting the batteries 50 5 4 3 Battery care 50 5 4 4 Setting the battery type 51 5 5 Side broom...

Page 6: ...o Definition Safety information persons or property Safety information on preventing hazardous situations caused by failure to follow instructions or prescribed working procedures accurately or at all Note the machine Important information on handling the machine in order to maintain its functionality Ecological hazard the environment Ecological hazard through the use of substances which represent...

Page 7: ...tion regarding safety Technical expertise is the key to pre venting errors when operating the equipment and ensuring trouble free operation The operating manual must always be kept at the operating location of the vehicle and as a result should be kept in a safe place on the vehi cle If the equipment is sold or rented out these documents should be trans ferred to the new owner operator The transfe...

Page 8: ...ion can lead to the vehicle being automatically locked against use Always switch off all the drives be fore switching the vehicle on The vehicle must only be started put into motion and stopped from the seat Ensure there is sufficient ventilation when sweeping in closed spaces dust The driving speed must always be adapted to the ambient conditions and load status Three wheel vehicles are less stab...

Page 9: ... of the vehicle Never leave the batteries in a dis charged state but recharge them as soon as possible The filter may only be shaken when the dirt hopper has been closed Never exceed the max load capacity of the hoppers This could increase the stopping distance Caution par ticularly when sweeping up iron fil ings for example Only empty the contents of the dirt hopper from a low height in order to ...

Page 10: ...for cleaning and maintenance work If the seat console must be raised to complete work it must be held in place by the safety support to pre vent it accidentally falling or slam ming shut It is not permitted to clean the vehicle with a pressure washer or steam blaster The dirt hoppers must be cleaned regularly to prevent the accumula tion of bacteria It is not permitted to use aggressive corrosive ...

Page 11: ... the electrical installation and lead to fires Pay attention that the insulation on the charger cable shows no signs of damage and is not damaged during the charging process The cable must not rub against anything If the insulation is defective do not use the on board charger To prevent current leaks always keep batteries clean and dry and protect them from soiling by metallic dust for example Nev...

Page 12: ... substances which could represent a risk to health and the environment Always observe legal regulations and local directives when disposing of cleaning agents refer to the Water Resources Act Used batteries bearing the recycling symbol must not be disposed of in household waste refer to the Sec tion Disposal ...

Page 13: ...legible labels must be replaced immediately Company logo front chassis rear cov er panel Fig 1 1 and Fig 2 7 Rating plate under the foot mat Fig 1 2 Shaking device label Fig 1 3 Read and observe the operating manu al Fig 1 4 Bypass label Fig 1 5 Rotating parts label Fig 1 6 High pressure washer label Fig 1 7 Noise emission and gradient label Fig 1 8 ...

Page 14: ...14 Safety Information Fig 1 5 1 2 6 7 3 4 8 ...

Page 15: ...15 Safety Information Side broom label Fig 2 1 Brake label Fig 2 2 Folding apron label Fig 2 3 Parking brake label Fig 2 4 Maintenance free batteries label Fig 2 5 Cylindrical broom label Fig 2 6 ...

Page 16: ...16 Safety Information Fig 2 2 7 1 3 4 5 6 ...

Page 17: ...panel 2 Steering column 3 Pedals 4 Side broom 5 Drive 6 Larger debris flap 7 Sealing strips broom space 8 Cylindrical broom 9 Dirt hoppers 10 Panel air filter 11 Seat console 12 Driver s seat 13 Flashing light option Fig 3 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 18: ... folding apron Fig 3 6 can be opened The sweeping pattern of the cylindrical broom and the sealing strips Fig 3 7 in the broom space can be ad justed It is driven by the central motor via a drive belt Filter system The fine dust swirled up by the cylindri cal broom is forced into the panel air fil ter Fig 3 10 by a suction turbine and is filtered out The particulate matter settles on the outside o...

Page 19: ...ies are moni tored by a total discharge signal transducer 2 2 1 Special equipment The basic vehicle can be upgraded by adding various special equipment The order numbers for these components are listed in the table Flashing light It is possible to install an optional flash ing light on the seat console The holder for the flashing light is inserted in the seat console and fixed in place with a scre...

Page 20: ...ating panel 1 Key switch 2 Charge control indicator 3 Charge status indicator 4 Operating hour counter 5 Sweeping functions switch 6 Drive direction switch 7 Steering 8 Horn 9 Side broom lever Fig 4 5 B 3 6 7 8 9 4 C 2 A 1 ...

Page 21: ...dicates an error status refer to the charger operating manual Charge status indicator Fig 4 3 While the vehicle is in operation the ve hicle s electronic system indicates the discharge status of the batteries by means of a red LED Fig 4 3B and three green LEDs Fig 4 3C When all three green LEDs light up the batteries are fully charged As the battery power increasingly discharges the LEDs go out fr...

Page 22: ...ct the driving direc tion Control lever forward forward drive Control lever O neutral position Control lever back reverse drive To change the driving direction stop the vehicle by applying the service brake select the new direction and ac celerate again Steering Fig 4 7 The steering transmission from the steering wheel to the front wheel is per formed by a fork head The small turn ing circle enabl...

Page 23: ...ation 2 4 Operating elements on the vehicle 1 Driver s seat adjustment lever 2 Charger power cable 3 Shaking device lever 4 Accelerator 5 Folding apron pedal 6 Parking brake 7 Service brake Fig 5 2 3 4 5 7 6 1 ...

Page 24: ...celerator Fig 5 4 It serves for the continuously variable regulation of the vehicle speed when driving forward or in reverse Set the driving direction be forehand using the drive direc tion switch If the pedal is released it automatically returns to its zero position and the vehi cle comes to a stop Folding apron pedal Fig 5 5 The pedal is used to open and close the folding apron to sweep up large...

Page 25: ...Operation 1 Bypass flap 2 Adjusting bolt for right hand side broom 3 Adjusting bolt for left hand side broom option 4 Adjusting bolt for cylindrical broom 5 Safety support for seat console Fig 6 2 1 3 4 5 ...

Page 26: ...ig 6 3 This adjusting bolt is used to adjust the sweeping pattern of the left hand side broom Adjusting bolt for cylindrical broom Fig 6 4 This adjusting bolt is used to adjust the sweeping pattern of the cylindrical broom Safety support for seat console Fig 6 5 Only operate the vehicle when the seat console is closed Only open the seat console for mainte nance and repair work Take hold of the han...

Page 27: ...27 Operation Dirt hopper lock Fig 7 1 The lock serves to secure the dirt hop pers To empty the dirt hoppers Fig 7 2 pivot the lock lever Fig 7 1 up and remove the dirt hoppers Fig 7 2 1 ...

Page 28: ...he packaging and tighten ing straps 2 Park the machine by applying the parking brake 3 Remove the wooden chock 4 Remove the rear skirting panel and assemble it under the front one 5 Release the parking brake and push the machine from the pallet Fig 8 ...

Page 29: ...ge a date Practice all the operating steps in an large area of space and only use the machine when you are familiar with its opera tion 3 2 2 Initial battery charge Before starting up the vehicle for the first time the battery to be used must be fully charged according to the pre scribed initial battery charge process Also observe the information in the op erating manual enclosed with the char ger...

Page 30: ...er is seated com fortably and can reach all the operating elements with ease Pull the lever Fig 9 2 upwards and slide the driver s seat to the required seat position The machine is equipped with a seat contact switch The ma chine can only operated when an operator is sitting on the driver s seat Fig 9 2 1 ...

Page 31: ... can only be put into operation when an operator is sitting on the driver s seat The function of the seat contact switch must not be bypassed 1 Make sure that all control levers are at their off or zero position 2 The vehicle s parking brake must be applied Fig 10 1 3 Switch the vehicle on with the key switch Fig 10 2 Fig 10 1 2 ...

Page 32: ...t is insuffi cient you can also apply the service brake Fig 11 2 to de celerate more quickly 2 Apply the parking brake Fig 11 3 to its end position and lock in place 3 Switch off the sweeping functions with the button Fig 11 4 4 Switch the vehicle off with the key switch Fig 11 5 Remove the key when getting off the vehicle to prevent unau thorized use Fig 11 1 2 3 4 5 ...

Page 33: ... operation 1 Charge status indicator 2 Shaking device 3 Dirt hoppers 4 Bypass flap 5 Driver s seat 6 Key switch 7 Drive direction switch 8 Sweeping functions switch 9 Side broom lever 10 Accelerator Fig 12 2 5 6 7 4 1 8 3 9 10 ...

Page 34: ...3 Switch on the sweeping functions with the switch Fig 12 8 4 Lower the side broom using the lever Fig 12 9 5 Actuate the accelerator Fig 12 10 and drive over the area to be cleaned After switching on the sweep ing functions drive off straight away to avoid the risk of the cy lindrical or side broom marking the floor following rotation After sweeping operation 1 Drive to an appropriate service are...

Page 35: ...35 Operation 3 7 Charging batteries 1 Charge status indicator 2 Key switch 3 Power cable 4 Charge control indicator Fig 13 4 2 1 3 ...

Page 36: ...Remove the key 2 Take the power cable Fig 13 3 from the opening and plug it into a power outlet 110 230 VAC 3 While the battery is being charged the charge control indicator Fig 13 4 lights up When all three greed LEDs light up the batteries are fully charged If the key switch is actuated during the charging the charg ing process is interrupted 4 When the charging process is com pleted disconnect ...

Page 37: ... shaking device Pull and push the lever Fig 14 1 in and out quickly several times in suc cession in order to clean the dust from the panel air filter Only operate the shaking de vice when the electric drive is switched off Fig 14 1 ...

Page 38: ...he lock lever Fig 15 1 upwards and remove the dirt hoppers Fig 15 2 Transport the dirt hoppers using the handles Fig 15 3 Risk of injury For reasons of health each dirt hopper should only be filled to a maximum of 25 kg When disposing of refuse ob serve the applicable legal re quirements and local direc tives Fig 15 2 1 3 ...

Page 39: ... Contact Hako service Machine swirls dust Sealing strips on broom space worn Adjust or change the sealing strips Panel air filter soiled Clean the panel air filter Bypass still open Close the bypass Vehicle or sweeping function can not be activated Seat contact switch has tripped The operator must be seated in the seat during oper ation Start sequence not maintained Driver on driver s seat Drive d...

Page 40: ...ake the weight of the machine into ac count when loading refer to Section Technical Data Transporting The vehicle must be properly secured It must not slip or tip during transportation Risk of injury When transported on another vehicle or trailer the machine must be secured against rolling away lash the machine securely at the front and rear Fig 16 ...

Page 41: ...eed rpm 500 Side broom diameter cm 40 Side broom speed rpm 100 Area coverage theoretical with right hand side broom m h 5340 Sweeping speed kph 6 Turning circle cm 155 Dirt hopper volume max load capacity 2x25 kg liter 2x30 Filter surface m 1 4 Battery V Ah 2 x 12 105 Nominal power input drive motor kW 0 75 Gross total weight kg 450 Weight transport mode with battery and driver kg 360 Maximum clim...

Page 42: ...according to DIN EN 60335 2 72 under normal working conditions is dB A 81 Vibration values The weighted effective value of the acceleration established in accordance with ISO 5349 1 to which the upper limbs hand arm are exposed under normal working conditions is m s 2 5 The weighted effective value of the acceleration established in accordance with ISO 2631 1 to which the body feet seat surface is...

Page 43: ...nte nance and repair costs ensures the vehicle has a long ser vice life The Hako system maintenance de scribes the specific technical work nec essary for the individual modules and defines the intervals for the mainte nance tasks Individual parts which must be changed during maintenance tasks are defined and stipulated in spare parts kits Hako system maintenance cus tomer Work to be carried out by...

Page 44: ...erating hours Hako System Maintenance I 625 operating hours Workshop Stamp completed on at _________________ operating hours Hako System Maintenance II 750 operating hours Workshop Stamp completed on at _________________ operating hours Hako System Maintenance I 875 operating hours Workshop Stamp completed on at _________________ operating hours Hako System Maintenance III S 1000 operating hours W...

Page 45: ...shaking device o o Empty the dirt hopper o o Check side broom for signs of wear and damage change if necessary o Check cylindrical broom for signs of wear and damage change if necessary o Check sweeping pattern of side broom adjust if necessary o Check sweeping pattern of cylindrical broom adjust if necessary o Check seals in broom space of cylindrical broom for signs of wear and damage change if ...

Page 46: ...tern of side broom adjust if necessary o Check sweeping pattern of cylindrical broom adjust if necessary o Check seals in broom space of cylindrical broom for signs of wear and damage change if necessary o Check seals of dirt hoppers change if necessary o Check seals of dust vacuum change if necessary o Check the function of the parking brake and service brake o Check dust vacuum clean or change p...

Page 47: ...rized Hako service center Activity Interval Every 250 operating hours All maintenance work in accordance with Hako system maintenance I o Check fan belt adjust belt tension or change fan belt if necessary o Check the visual appearance of the vehicle o Test drive and function test of all safety related components o ...

Page 48: ...brushes of the drive motor and central motor for ease of move ment and signs of wear change of necessary o Check the retaining screws retighten if necessary o Check actuating lever for folding apron cylindrical broom side broom brake pedal parking brake and accelerator spray with oil to ease movement if necessary o Check brake linings and Bowden cables in the brake system for signs of wear change ...

Page 49: ...revent the drive be ing started up inadvertently Only batteries approved by Hako may be installed Batteries may only be handled and changed by properly skilled maintenance person nel Only maintenance free batter ies may be used 1 Seat console 2 Safety support 3 Grab handle 4 Batteries 5 Retaining strap 6 Connection diagram Fig 17 1 3 4 2 5 6 ...

Page 50: ...nce free batteries approved by Hako may be installed and at the intended position 1 Switch the vehicle off using the key switch and secure with the parking brake 2 Open the seat console Fig 17 1 and secure with the safety support Fig 17 2 3 Pick up the batteries Fig 17 4 us ing the grab handle Fig 17 3 and insert them in the vehicle 4 Secure the batteries in place with the retaining strap Fig 17 5...

Page 51: ...t tery types can be setup using the fourfold DIP Switch Fig 18 2 X1 6 X1 7 open X1 6 X1 7 jumper Fig 18 The two settings for GiV are equivalent The DIP setting OFF ON ON OFF is the preferred setting When battery sizes other than 100Ah to 117Ah the on board charger must be adjusted by Hako service technicians DIP1 DIP2 DIP3 DIP4 TYP ON OFF OFF OFF Crown ON ON OFF ON GiS ON OFF ON OFF PzS OFF ON ON ...

Page 52: ... prevent the drive be ing started up inadvertently 1 Seat console 2 Safety support 3 Adjusting bolt side broom right 4 Side broom 5 Retaining screws side broom Side broom left option The work to adjust and change the optional left hand side broom must be completed in the same sequence as for the right hand side broom Fig 19 1 1 2 3 4 5 ...

Page 53: ...he sweeping pat tern mark the floor with chalk 1 Switch the vehicle off using the key switch and secure with the parking brake 2 Open the seat console Fig 19 1 and secure with the safety support Fig 19 2 3 Turn the adjusting bolt Fig 19 3 until the right hand side broom Fig 19 4 touches the ground For the left hand side broom option use the adjusting bolt Fig 20 8 4 Unlock the safety support and c...

Page 54: ...he machine off via the key switch to prevent the drive be ing started up inadvertently 1 Seat console 2 Adjusting bolt for cylindrical broom 3 Dirt hoppers 4 Seals dirt hoppers 5 Broom space 6 Sealing strips broom space 7 Cylindrical broom 8 Adjusting bolt left hand side broom option Fig 20 8 3 1 4 6 7 5 2 ...

Page 55: ...cylindrical broom Fig 20 7 To control the sweeping pat tern mark the floor with chalk 1 Switch the vehicle off using the key switch and secure with the parking brake 2 Open the seat console Fig 20 1 and secure with the safety support 3 Turn the adjusting bolt Fig 20 2 until the cylindrical broom Fig 20 7 touches the ground 4 Unlock the safety support and close the seat console 5 Switch on the vehi...

Page 56: ...g brake 2 Remove the dirt hoppers Fig 21 1 3 Loosen the screws Fig 21 2 and remove the first half shell Fig 21 3 4 Then turn the cylindrical broom shaft Fig 21 4 180º by hand and disas semble the second half shell 5 Assemble the new half shells in the reverse sequence 6 The sweeping pattern must be read justed after changing the cylindrical broom The half shells are illustrated without any bristle...

Page 57: ... a weekly basis and change them in the case of wear 1 Switch the vehicle off using the key switch and secure with the parking brake 2 Remove the screws connecting the sealing strips Fig 22 1 to 3 3 Assemble the new sealing strips and set a distance of 1 2 mm to the floor Fig 22 1 Sealing strip front folding apron 2 Sealing strip rear 3 Sealing strips right and left 2 1 3 ...

Page 58: ...pace and dirt hoppers Check the two seals weekly and change in the case of wear 1 Switch the vehicle off using the key switch and secure with the parking brake 2 Remove the dirt hoppers Fig 23 1 from the vehicle 3 Pull the seals Fig 23 2 from the edges 4 Press new seals onto the edges Fig 23 1 Dirt hoppers 2 Seals 2 1 ...

Page 59: ...ainte nance and repair work switch the machine off via the key switch to prevent the drive be ing started up inadvertently 1 Panel air filter 2 Seal 3 Hood 4 Knurled nuts 5 Locking handle 6 Lever for shaking device 7 Safety support 8 Seat console Fig 24 3 4 5 6 1 2 8 7 ...

Page 60: ...sis and change them in the case of wear 1 Switch the vehicle off using the key switch and secure with the parking brake 2 Open the seat console Fig 24 8 and secure with the safety support Fig 24 7 3 Loosen the knurled nuts Fig 24 4 and locking handle Fig 24 5 and remove the hood Fig 24 3 4 Check the panel air filter Fig 24 1 and seal Fig 24 2 and clean or change them as necessary 5 7 3 Cleaning th...

Page 61: ... the parking brake 2 Open the seat console Fig 25 1 and secure with the safety support Fig 25 2 3 Loosen the tension roller Fig 25 3 and change the drive belt Fig 25 4 for the cylindrical broom 4 Tension the drive belt again using the tension roller Fig 25 3 To access the drive belt of the side broom Fig 25 5 disassemble the cov er Fig 25 7 To access the drive belt of the suction turbine Fig 25 6 ...

Page 62: ...vice 5 9 Electrical installation 5 9 1 Fuses F1 Hydraulic motor 70A F2 Drive motor 50A F3 Key switch 10A 5 9 2 Relays K1 Working mode K2 Drive motor K3A Enable drive mode K3B Enable operating mode Fig 26 F3 F2 K1 F1 K3A B K2 ...

Page 63: ...ve 2006 42 EC and is in accordance with 2004 108 EC Reference was made to the following standards and or norms and or techni cal specifications to ensure proper im plementation of the safety and health requirements in the EC Directives EN 60335 2 72 EN 55012 EN 61000 6 2 Bad Oldesloe 22 04 2014 Dr Rainer Bavendiek Director R D Name of the authorized person who compiles technical documents for Hako...

Page 64: ...zentechnik für eine saubere und schönere Umwelt Advanced Technology for a Cleaner Better Environment Hako GmbH Hamburger Str 209 239 D 23843 Bad Oldesloe 49 4531 806 0 Fax 49 4531 806 338 88 10 2971 3100 09 ...

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