HAKO 7580.02 Service Booklet Download Page 63

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Foil 63

9.2 ZAPI Controller

The ZAPI controller has a diagnostic input. Unless not expressly indicated in the service
documents, modification of the default values and parameters is

not

admitted.

Contactor arrangement

A = Connector for contactor control and control inputs

B = Connector for console or alarm LED

Summary of Contents for 7580.02

Page 1: ...2 7580 16 26 7580 15 Service Handbuch Service Booklet Hako GmbH Technisches Produktmanagement D 23840 Bad Oldesloe Stand 04 2012 Vertraulich nur f r den internen Gebrauch For internal use only Schulun...

Page 2: ...s 15 3 Check Settings For Machine Type TSG And Options Display And Delete Last Error 18 3 1 Check And Set Machine Type 23 3 2 Check And Set Options 24 3 3 Check And Set TSG 25 3 4 TSG Error 3211 28 3...

Page 3: ...PV 37 5 1 PPV1 40 5 2 PPV2 41 5 3 PPV3 42 5 4 PPV4 43 5 5 PPV5 B 1100 only 44 5 6 PPV6 B 1100 only 45 5 7 PPV7 B 1100 only 46 5 8 PPV8 B 1100 only 47 6 Setting Of Modules 48 6 1 Module 1 49 6 2 Module...

Page 4: ...Automatic Monitoring Of Components 65 9 2 2 Error Messages Displayed Via LED 66 9 2 3 Explanations For Displayed Error Messages 67 9 3 Drive Motor Hakomatic B1050 Amer 84 9 3 1 Tyre replacement 84 9 3...

Page 5: ...he annotation that more or revised pages are to follow in future This decision has been taken to allow adding modifications made to the machine equally to the documents as revisions Beyond that this d...

Page 6: ...only loosen screws Do not remove them completely short circuit hazard Make sure to fully and evenly insert new blade fuses under the screws After each repair proceed to starting and service current m...

Page 7: ...version has updated to 4 020 With the software revision 4 026 the Hakomatic B1100 TB 1230 was introduced As soon as a malfunction occurs the red LED signalling a defect lights up and a warning buzzer...

Page 8: ...ylindrical Brush aggregate has the side broom unit optionally available while the pre sweeper dirty water recycling and cleaning agent dosage 99756402 options are available and settable for the Hakoma...

Page 9: ...er ON B1100 B1100 PB 1230 only Switching over to SWA upon switching water ON B1100 only Side brush additionally ON in addition to switching ON scrubbing B1100 and B1050 PB only Side broom additionally...

Page 10: ...Dip switch for electronic circuit breakers Settings at Module 3 Dip switch for electronic circuit breakers and module coding Settings at the additional operator panels B1100 only Dip switch for operat...

Page 11: ...transformer Voltage to the electronics is supplied by the auxiliary voltage module which transforms 36 Volts to 24 Volts As the electronics are the same as integrated in the B910 and B 750R machines t...

Page 12: ...ive controller an error code is not output since this controller has its own diagnostic indicator see chapter 10 The buttons for scrubbing suction scrubbing and suction and the green Hako button for c...

Page 13: ...and on again with the key switch Constant activation of the seat switch is also required Leaving the seat while key switch is ON causes locking of the functions The seat contact switch is 3 seconds de...

Page 14: ...gee is lifted up Suction motors switch off delayed 15 seconds Switching off after tank filled up The switch signalling recovery tank filled up opens as soon as the tank is filled If switch is open for...

Page 15: ...g elements are powered for approx 6 sec every time the machine is switched on During this time a voltage can be measured at the outputs for the lifting elements Motors are off and the cleaning unit LE...

Page 16: ...ually lights if the switch signalling no dirt hopper inserted opens In case of faulty function check the switch and all cable connections and connectors Another safety request is effected by the therm...

Page 17: ...ible only after the brush head had lowered or in other words if the central position micro switch does not switch the brush lowering completed signal is missing and the side brush does not swing out T...

Page 18: ...ne type TSG and options display and delete last error The settings described in this step are to be checked and modified if required Proceed to check and adjustment in particular after electronics rep...

Page 19: ...akomatic B1050 operator panel Position of the programming buttons is identical to those of the Hakomatic B1100 Only the icons differ due to the different functional scope of this machine 3 Machine Typ...

Page 20: ...as long as the software version is displayed then release buttons Display of set machine type then appears automatically Use the N button to proceed to display of set options and display of TSG setti...

Page 21: ...ine Type Settings Software version automatic change to next display Set machine 4 means B 1100 11 means B 1050 13 means B1050 PB 1230 14 means B1100 PB 1230 Set options TSG setting Display last error...

Page 22: ...Foil 22 3 Machine Type Settings Control electronics A1 X2 B C A B1100 B1050 PB CB B1050PB 1230 B1100 PB 1230...

Page 23: ...in bottom position This setting is a prerequisite for display of the cipher 14 For the B1050 machine the bar no 3 is to set in bottom and the bars 1 2 and 4 in top position This setting is a prerequi...

Page 24: ...1100 B1100PB 1230 set ON 2 SWA B1100 only set ON 3 Side brush B1100 B1050PB set ON 4 Tool B1100 suction only set to OFF Tool B1100 PB1230 B1050PB CB set ON and B1050 PB 1230 Spraying and suction 5 Pre...

Page 25: ...the correct battery type 2 When fitting other battery types modify TSG setting as described below by using Dip switch C on the control electronics see p 22 3 Dip switch 4 is to set to 36 V OFF Set the...

Page 26: ...tion as far as maintenance free gel batteries are concerned the difference between Sonnenschein and Deta is no longer made and setting depends on the battery type Setting 6 for GIV batteries and setti...

Page 27: ...batteries GiV and PzV are maintenance free batteries in Gel Technologie GiS and PzS are vented low maintenance batteries with liquid electrolyte For block batteries the following short terms are also...

Page 28: ...the following causes are possible for this error message No voltage supplied to the TSG MK controller A1 X2 1 4 TSG is in auto test mode battery DIP switch set to off off off or on off off 1 2 3 from...

Page 29: ...roceeding to point Delete Delete 1 Press O button and hold depressed as long as the display changes to 0 0 0 0 2 Release button switch key switch OFF and on again 3 The software version appears then a...

Page 30: ...Procedures Programming of different procedures of cleaning functions depending on the direction switch check and set For setting of the B 1050 it is the position of buttons which is decisive and not...

Page 31: ...g the different programmes is possible by pressing the button L down or the button N up 5 The active programme is marked by a dash in front of the cipher 6 Quit programme by switching OFF key switch d...

Page 32: ...or position for the Neutral and Reverse accelerator positions however differences apply and are listed in the following table Programme Accelerator Function according to code position accelerator posi...

Page 33: ...n switch Direction Brush head Squeegee Broom switch Water B1100 only Neutral Brushes and Lift squeegee Broom remains water ON ON 2 Reverse Brushes and Lift squeegee Broom remains water ON ON Neutral B...

Page 34: ...ush head Squeegee Broom switch Water B1100 only Neutral Brushes and Lift squeegee Broom off and water OFF lifted up lift brush head 4 Reverse Brushes and Lift squeegee Broom off and water OFF lifted u...

Page 35: ...ion Brush head Squeegee Broom switch Water B1100 only Neutral Brushes and Lift squeegee Broom OFF and water OFF delay lifted up of 1 second for 6 brushes to avoid B 1100 only the brushes from B1100 be...

Page 36: ...on of water supply brush or suction function or the green Hakomatic button is switched off by changed accelerator position the function related LED blinks ON always means switched ON and lowered OFF o...

Page 37: ...stage cleaning agent SWA side brush filter The settings described in this step can be modified according to customer requirements Factory settings need not be adopted For setting of the B 1050 it is...

Page 38: ...age always medium stage Switch on cleaning agent together with switching ON water yes no B 1100 B1100 PB1230 Water stage for Scrubbing and suction last selected stage always medium stage B1050PB B1050...

Page 39: ...ings this is the Factory setting for the B1100 Currently programmed setting Filter B 1100 only Side brush SWA B 1100 only Side broom brush with scrubbing Cleaning agent B 1100 only water stage at scru...

Page 40: ...nking 3 Use M button to move the bar up and down Up ON Error code of the remedied error will be displayed for 3 seconds after switching on Down OFF Error code of the remedied error will not be display...

Page 41: ...nd N buttons 2 The corresponding bar starts blinking 3 Use M button to move the bar up and down Up ON last selected stage is set Down OFF always the medium stage is set 4 Save setting by pressing the...

Page 42: ...he bar up and down B1100 Up ON Cleaning agent is equally switched on B1100 PB 1230 Down OFF Cleaning agent is not switched on B1050 Up ON Water stage for Scrubbing and suction last selected stage Down...

Page 43: ...n to move the bar up and down B1100 Up ON Switching to dirty water recycling SWA Down OFF Switching to clear water B1050 Up ON Switching on side broom brush together not B1050 PB 1230 with scrubbing D...

Page 44: ...Use M button to move the bar up and down Up ON side brush is equally switched on Down OFF side brush is not switched on 4 Save setting by pressing the green button O button as long as the dot appears...

Page 45: ...move the bar up and down Up ON Filter shaking as long as button is depressed Down OFF Filter shaking after switching on by button 3 times in intervals 4 Save setting by pressing the green button O but...

Page 46: ...to move the bar up and down Up ON Filter suction is equally switched on Down OFF Filter suction is not switched on 4 Save setting by pressing the green button O button as long as the dot appears at th...

Page 47: ...minimum of 2 minutes of sweeping shaking is automatically switched on upon end of sweeping Down OFF shaking is not automatically switched on upon end of sweeping 4 Save setting by pressing the green...

Page 48: ...Foil 48 6 Settings On Module The settings on the modules have an influence on load values of the electronic circuit breakers and the module coding...

Page 49: ...e on the load value of the electronic circuit breakers for the brush head and squeegee lifting elements the Dip switch settings have to be correct on Module 1 Dip switch setting 1 OFF 2 OFF Circuit br...

Page 50: ...ing elements the Dip switch settings have to be correct on Module 3 Modul 3 Code A pre sweeper B 1100 Modul 3 Code C 3rd Brush B 1100 PB 1230 B 1050 TB 1230 B1100 PB 1230 Side broom B 1050 CB only 1 O...

Page 51: ...d Cleaning agent SWA have to be correctly set i e coded on the Dip switch These operator panel are available only in the Hakomatic B1100 B1100 PB 1230 They are located under the right hand operator pa...

Page 52: ...using other than the indicated measuring devices values may vary since measured voltage is pulsed Beyond that the value depends on battery voltage Here measurement was done with charged battery prese...

Page 53: ...V ca 2 9 l min ca 3 9 l min ca 2 9 l min ca 1 0 l min Stage 4 ca 8 9 V ca 3 6 l min ca 4 4 l min ca 3 6 l min ca 1 0 l min Stage 5 ca 12 0 V ca 4 7 l min ca 5 5 l min ca 3 9 l min ca 1 0 l min Stage 6...

Page 54: ...p would continue delivery against this pressure and could be damaged The electronics detects interruption of free delivery of the pump and automatically switches off the pump for 2 seconds After these...

Page 55: ...Check fuses and wiring ON Drive controller is Drive controller function operable okay 2 signals Wrong start sequence Check accelerator and direction switch as well as cabling 3 signals Output transis...

Page 56: ...rive motor Check direction switch and direction contactors on drive controller if okay but signals still present replace drive controller 5 signals Output transistors 160 A fuse blown check defective...

Page 57: ...ed connection eventually loose check direction switch and drive potentiometer switch 7 signals Battery voltage in Measure voltage check sufficient less than connections 13 Volts 8 signals Temperature...

Page 58: ...esignated by A6 in the circuit diagram and is supplied with 36 V even though some of the signals are 24 Volts signals The drive controller is a pulse controller activating the motor by the pulsed volt...

Page 59: ...asurement with machine switched off and potentiometer disconnected Between green and red approx 5 7 kW Reducing to approx 1 8 kW upon actuation Between yellow and red approx 1 8 kW Increasing to appro...

Page 60: ...s connection between A1 X3 1 and S54 1 okay Only when battery minus is applying to S54 potentiometer switch the closed direction contactors can control the potentiometer switch and the S53 direction s...

Page 61: ...hes S53 direction and S54 potentiometer operate faultlessly 14 Is battery minus applying at A6 X51 4 with forward ride being selected potentiometer switch has to close 15 Is battery minus applying at...

Page 62: ...otor okay Please check each cable and their contacts Do two wires contact via crimping short circuit 18 Do direction contactors switch Eventually proceed to activate each of them directly 19 Test with...

Page 63: ...a diagnostic input Unless not expressly indicated in the service documents modification of the default values and parameters is not admitted Contactor arrangement A Connector for contactor control and...

Page 64: ...standard A5 CH connected from key switch A6 IRZ Emergency inversion ZAPI standard active if no positive voltage is applying A7 RV2 Speed reduction 2 active if no positive voltage is applying A8 PT Ac...

Page 65: ...rection switch potentiometer connections EEPROM Check in standstill Watch Dog current power MOS FET contactor activation contactor driver potentiometer connections Check during ride Watch Dog current...

Page 66: ...ring defective 13 7 TEMPERATURE C Temperature 76 C 15 8 DRIVER 1 KO A NT1 driver short circuited 16 8 DRIVER 1 SIC KO A Contactor coil on NT1 short circuited 17 8 DRIVER 2 KO A NT2 driver short circui...

Page 67: ...If error still persists after having switched key switch OFF and ON again replace logic If error disappears mind that the saved parameter values are deleted initial setting 3 EEPROM CONF KO Error in t...

Page 68: ...ing switched key switch OFF and ON again mind that the hourmeter counter is reset to zero then 5 EEPROM OFF LINE Error in the non volatile memory containing those values of the hourmeter counter conce...

Page 69: ...H programming the following order is observed Key switch tiller micro switch direction switch HANDLE Key switch direction switch FREE Key switch seat switch direction switch SEAT Possible causes a Dir...

Page 70: ...be output Possible causes a Main contactor if available does not close or is not connected at all b Short circuit between VMN and Batt terminals metal particle or other disconnect cable at VMN termina...

Page 71: ...ly closed due to mechanical blocking or permanent activation incorrect wiring of contactor coil b Short circuit between field and anchor coil of the motor disconnect cable at VMN terminal switch on Fa...

Page 72: ...the potentiometer or inductive sensor is broken b Potentiometer or inductive sensor ist defective 10 I 0 EVER Test during ride If during ride the current does not exceed a determined minimum value the...

Page 73: ...Current sensor is defective replace controller 12 PEDAL WIRE KO If no voltage can be measured at the Pin NPOT A12 to which the negative potentiometer terminal is connected an alarm is output Possible...

Page 74: ...em ON with a cold controller temperature monitoring is not working correctly replace controller b If the alarm is output shortly after start of operation heat is insufficiently dissipated check instal...

Page 75: ...coil of the direction contactor for reverse ride is defective b Internal driver MOSFET short circuited replace controller 16 DRIVER 1 SIC KO If current load at the contactor driver which activates th...

Page 76: ...coil of the direction contactor for forward ride is defective b Internal driver MOSFET short circuited replace controller 18 DRIVER 2 SIC KO If current load at the contactor driver which activates th...

Page 77: ...Wire at the NT1 terminal A11 broken or coil of the direction contactor for forward or reverse ride is defective b Internal driver MOSFET short circuited replace controller 20 CONTACTOR OPEN Test upon...

Page 78: ...ds a voltage applies to the coil of the forward direction contactor In reverse direction only Reverse direction contactor closes for 0 3 seconds and then opens No For 0 3 seconds a voltage applies to...

Page 79: ...direction contactor TA or the NC contact of the reverse direction contactor TI is soiled or stuck Clean contacts or replace contactor group if required Clean NO contact of the forward direction conta...

Page 80: ...direction contactor TA or the NO contact of the reverse direction contactor TI is soiled or stuck Clean contacts or replace contactor group if required Clean NC contact of the forward direction conta...

Page 81: ...PI Controller A3 Connection to motor interrupted Carbon brushes without contact to collector Fig 1 Connecting cable of carbon brush broken Fig 2 Motor winding defective or motor cable broken Inverted...

Page 82: ...on contactor is correctly activated but does not close coils of contactors are defective measure resistance by ohmmeter contacts are mechanically blocked nominal voltage of contactor coils is higher t...

Page 83: ...is output Possible causes a Micro switch for emergency inversion stuck b Incorrect operation c Incorrect wiring or programming 23 FORW BACK Fault is displayed if two directions are simultaneously act...

Page 84: ...ment Unscrew the 4 screws of the hub Warning Lift up the machine so that the tyre is not touching the ground Screw the 4 pullers two by two at 180 in the bracket until the hub is removed Tool PN 03502...

Page 85: ...e Motor B1050 Amer Remove the plastic hub cover Unscrew the 6 screws M6x30 tightening torque 16Nm 10 Replace the old tyre and re assemble the new tyre with the hub without the plastic hub cover Torque...

Page 86: ...86 9 3 Drive Motor B1050 Amer Install the wheel on the MTR11 by using a plastic mallet Warning Check the radial position of the hub with the inner disc during the mounting Tire puller kit Tool PN 0350...

Page 87: ...Foil 87 9 3 Drive Motor B1050 Amer Screw the 4 screws M8x20 tightening torque screw 22 Nm 10 Mount the plastic cover hub manualy...

Page 88: ...d replacement max 1500 hours of the carbon brushes the wear out limit of the carbon brushes is 12 mm Unscrew the 2 nuts After remove the terminal board cover Remove the 4 screws M6x20 tightening torqu...

Page 89: ...larm A5 Over temperature Alarm A4 Reference OUT of neutral Move the potentiometer to neutral position or if it is in neutral position yet calibrate the speed reference Thermal protection Controllers p...

Page 90: ...lace it Alarm A14 E2PROM FAIL Alarm A15 Field Fault Check the input switch this alarm will reset by power off Input voltage at A6 J2 6 Disable switch ON Alarm A12 Disable ON Alarm A13 KEY OFF Key Off...

Page 91: ...reased pressure and on Fama Famin Motor overload due to unfavourable floor brush combination and or permanent ride with increased ground pressure 1 2 5 5 Thermal switch Wire broken since NC activation...

Page 92: ...3 4 5 creased pressure and on Fama Famin Motor overload due to unfavourable floor brush combination and or permanent ride with increased ground pressure 1 2 6 2 Blocking protection Check 35 A fuse 3r...

Page 93: ...icro switch Check coding of Module 1 Measure operating current approx 3 5A max during lifting 1 3 5 1 Thermal switch Jammed Permanent contact to border Side brush during ride Wire broken since NC 1 2...

Page 94: ...top before being switched off by Side brush micro switch Check coding of 1 2 Module 3 Code D Measure operating current approx 1 2A max during lifting 1 4 6 1 Electronic circuit breaker Jammed Lifting...

Page 95: ...y switch Side brush Jammed Measure operating current Motor if new version approx 9 5 A max on Fama Famin for is fitted broom motor Wrong sweeping track 1 5 width Unfavourable floor brush combination A...

Page 96: ...ing current approx 9 5 A 1 5 on Fama Famin floor Sweeping track adjustment 30 mm 50 mm Unfavourable floor broom combination 2 2 6 2 Blocking protection Jammed Does lifting element moves up lifting ele...

Page 97: ...ating current 1 3 5 max 2 5 A after approx 10 minutes run 2 3 6 1 Blocking protection Side broom setting okay L h side broom Jammed Measure operating current 1 3 5 max 2 5 A after approx 10 minutes ru...

Page 98: ...ement side to dead stop before being switched off broom by micro switch 3 3 1 6 1 Fuse Check 10 A 80 V fuse If code for Module 1 blocking protection of lifting element for 1 2 3 4 5 brush or squeegee...

Page 99: ...V Module 3 Code A and F4 F7 check motors for filter for pre sweeper suction F6 20A 80V 1 3 5 shaking F7 20A 80V r h F4 and l h side broom F5 Caution If old version of side broom motor PN 51 237 is sti...

Page 100: ...Foil 100 10 Error Table With Information On Service Display Error code in Malfunction Remark the display 3 1 6 5 Fuse Check all fuses F1 10 A 80 V Module 3 Code C and F4 F7 5A 80V for 3rd brush 4 5...

Page 101: ...A 80 V Module 3 Code D and F1 10 A 80 V check water valve for side brush Side brush 1 2 3 1 6 7 Fuse Check fuse 7 5 A 32 V Control electronic Check connection to cleaning agent unit 1 2 3 4 5 A7 X2 2...

Page 102: ...electronics A1 X2 PIN 1 and 4 even with the machine being switched off if not okay check cable connection up to battery plug check battery selection setting of Dip switch on control electronics if ok...

Page 103: ...drive motor setting okay Longer uphill rides 1 2 3 4 5 effectuated Interrupted wire since NC activation Measure operating current approx 40 A during cleaning 4 1 2 1 Module 1 not Check fuse F1 2 A 32...

Page 104: ...nse timeout CAN bus check contacts and 1 2 3 4 5 connectors check resistance 2 x 120 W check current supply of Module 1 voltage transformer 4 3 2 1 Module 3 Code A CAN bus connected Check fuse F3 not...

Page 105: ...gnised 2 A 32 V check contacts and for 3rd brush connectors module coding okay 4 5 see chapter 6 2 check current supply of Module 3 voltage transformer 4 3 2 4 Module 3 Code D CAN bus connected Check...

Page 106: ...eout 2 A 32 V check contacts and for pre sweeper connectors module coding okay 1 3 5 see chapter 6 2 check current supply of Module 3 voltage transformer 4 3 3 3 Module 3 Code A CAN bus connected Chec...

Page 107: ...heck contacts and for side brush connectors module coding okay 1 2 see chapter 6 2 check current supply of Module 3 voltage transformer 4 5 2 1 CAN operator panel Check CAN bus to operator panel pre C...

Page 108: ...ts and for Cleaning agent connectors check resistance 120 W SWA 1 5 check module coding see chapter 7 60 W due to parallel connection 4 5 3 1 CAN operator panel Check CAN bus to pre sweeper side Code...

Page 109: ...nse operator panel check contacts and timeout connectors check resistance 120 W for Cleaning agent 60 W due to parallel connection SWA 1 5 Check voltage supply of operator panel voltage transformer 4...

Page 110: ...check resistance 120 W 1 2 3 4 5 60 W due to parallel connection 4 6 3 1 CAN bus error Check CAN bus cabling between control Buserror electronics and modules check contacts 1 2 3 4 5 and connectors ch...

Page 111: ...e in Malfunction Remark the display 4 6 5 1 Wrong machine Check machine setting of Dip switch A type set on control electronics A1 1 2 3 4 5 4 6 5 2 Set option not Too many options set on Dip switch B...

Page 112: ...ng All options set on Dip switch B too many modules see chapter 3 in the machine 1 2 3 4 5 1 Hakomatic B1100 2 Hakomatic B 1050 TB 3 Hakomatic B 1050 WZB 4 Hakomatic B 1050 TB 1230 5 Hakomatic B 1100...

Page 113: ...Foil 113 11 Notes...

Page 114: ...Foil 114 11 Notes...

Page 115: ...Foil 115 11 Notes...

Page 116: ...Foil 116 11 Notes...

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