HAKO Sweepmaster P1200 RH Service Manual Download Page 26 | Manualshive

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Service Manual

Hako GmbH

Technical Service (KUD) 23843 Bad Oldesloe

Edition: 05/2014

Confidential - For internal use only!

4 Drive

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Summary of Contents for Sweepmaster P1200 RH

Page 1: ...ual 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 ...

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 Jonas 1200 V Sweepmaster P 1200 RH Jonas 1200 D Sweepmaster D 1200 RH Jonas 1200 E Sweepmaster B 1200 RH P means petrol gasoline D means diesel and B stays for battery model The LP driven machines ar...

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 Sweeping Mark Distance 15 3 2 2 Side Brush 16 3 3 Dirt Hopper ABBA System 18 3 4 Dirt Hopper Lift Out System 20 3 5 Filter 21 3 5 1 Change and Clean Cartridge Filter 21 3 5 2 Suction Fan Flap 21 3 6 St...

Page 4: ...1 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 Pump 37 5 3 Brief Description of Work Hydraulic 38 6 ELECTRICAL SYSTEM 39 6 1 Safety Information 40 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...

Page 5: ...ve 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 MAINTENANCE 56 7 1 Gasoline Version Service Intervals 57 7 2 Diesel Version Service Intervals 59 7 3 E Version Service Intervals 61 ...

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

Page 7: ...m 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 is drawn in by suction fan and separated by the filter system 4 Clean air only is taken out into the environment Disposal of dirt is realized via high dump system directly into a standard dustbin ...

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: ...00 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 speed km h 0 4 0 4 0 4 Wheel speed at max velocity rpm 58 58 58 Max sweeping speed recommended 4 0 km h km h 9 0 9 0 8 0 Sweeping width with w o side broom mm 850 1 150 850 1 150 850 1 150 Sweeping ...

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 broom Diameter mm 600 600 600 Speed rpm 85 85 85 Standard bristling PA PA PE Dirt hopper Hopper volume l 130 130 130 Wheels Front wheel drive solid rubber 4 00 4 4 00 4 4 00 4 Rear wheels pneumatic 4 ...

Page 11: ...umers 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 Mobiloil DTE 15 M DTE 15 M DTE 15 M Tank capacity l 22 22 13 Electrical system Starter battery V Ah 12 74 12 45 24 Generator A 13 13 Total output kW 3 10 Output of drive motor kW 1 10 Output of hydraulic...

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: ...internal 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 under tension The tension must not exceed the tension of the valve neutral spring hydraulic broom valve ...

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 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 1 2 3 4 5 ...

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 should amount to 50 5 mm that of the Jonas 1200 V D to 70 10 mm Note Exceeding the specified width has a negative effect on the service life of the cylindrical broom The distances between marks reduc...

Page 16: ...at 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 brush between the 9 and 1 o clock position Adjusting parallelism Loosen l h half bearing of torsion shaft Adjust parallelism with stop screw Half bearing Torsion shaft Stop screw ...

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: ...orner 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 filter passage to direct air flow position Change over by pulling the knob on the dashboard Use switch S12 at the control wire below the dashboard to actuate the jolter motor Note Driven by a V belt the ...

Page 22: ...Edition 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 Representation of the Jonas 980 Carrier plate changed no cover plate ...

Page 23: ...sloe 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 do not match tighten nut until next split pin hole Torque 32 Nm ...

Page 24: ...Confidential 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 nut by 5 Nm If split pin holes do not match tighten nut until next split pin hole ...

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 idling speed 1 550 50 rpm Capacity 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 ...

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 pressure gas hose F4 17 90 angular piece I D 5 8 hose x 3 8 NPT m CA 55M 500 4 Mixer complete 2 1 16 air cleaner connection 65 0004 4614 Hose clamp 50 70mm Champion RC 12 YC 0 3mm spark plug gap E 10 01...

Page 30: ...00 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 control screw see Fig 6 7 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 Vanguard Twin V o...

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: ...ne 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 Compression ratio 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 ...

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: ...e 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 Due to automatic return to zero position the machine is dynamically slowed down and self retaining against unwanted rolling of the machine Should moving of the machine be necessary when engine stands ...

Page 36: ...eed 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 mechanically shifted to forward A or reverse mode B a fluid circulation into the specific direction is generated and depending on the drive motor resistance a driving pressure builds up in the circuit After t...

Page 37: ...0 bar Bypass Ventil 2 Umdrehungen zum Öffnen Anschluß vorwärts Stopfen für Meß punkt Speisedruck Anschluß rückwärts DBV rückwärts 130 bar Speisepumpe Einlass Port forward By pass valve 2 turns for opening Pressure limiting valve forward 160bar Plug for feed pressure measuring point Feed pump inlet Port reverse Pressure limiting valve reverse 130bar ...

Page 38: ...ted 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 for which the upper partial valve has to be switched upwards by the broom cylinder operating lever while simultaneously the hopper lever allows switching of the lower partial valve upwards Then the fl...

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: ...ty 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 connected Do not use the charger unit for emergency starting Disconnect battery before re charging or electro welding at the machine ...

Page 41: ...nual 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 D variant ...

Page 42: ...A 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 glowing control voltage D 10A 10A F13 Fuse LPG V post heating control voltage D 10A 10A F14 Main fuse for pre glowing D not assigned 30A K1 Seat contact controller K2 Engine release relay K3 Starter ...

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: ...10 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 F15 Fuse for brake lights 7 5A F16 Fuse for jolter pulse relay 35A F18 Fuse for broom cylinder motor 63A F19 Fuse for main motor 63A H4 Warning horn 63A K1 Main contactor for drive controller K2 Rel...

Page 45: ...esloe 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 Diagram Wiring of Seat contact controller for Jonas 1200 V D ...

Page 46: ...more 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 outputs PIN 5 8 are switched off The controller proceeds to a self test directly after switching on ignition ON by first switching briefly on and off the PIN5 output and reading back via PIN9 input f...

Page 47: ...Manual 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 type SEM1 ...

Page 48: ...ensor 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 Contactor activation Current sensor Setpoint 3 Driving Self test Power controller of drive motor Current for contactor activation 4 Continuously Temperature of power unit Battery voltage Additionally th...

Page 49: ...T 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 Error in the driving switch wiring 5 NO FIELD CURR Error in the connection to field winding or in the current detection 5 HIGH FIELD CUR Error in the connection to field winding or in the current det...

Page 50: ...e 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 broom relay is switched OFF PIN4 at plug A is no longer grounded The blower fan is switched OFF PIN1 at plug D is no longer grounded The warning horn is activated PIN1 at plug A is grounded To reset...

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: ...harge 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 battery setting made in the factory 6 7 1 LDS Setting Mode In order to create the setting conditions switch on the machine and connect the configuration input of the LDS to battery plus To do so conne...

Page 53: ...chnical 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 setting disconnect A B again ...

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 value by 0 01 V Z or hold depressed for continued incrementing 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...

Page 55: ...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 In the display three digits for the discharge profile discharged value are flashing set to 1 73 V Z in the factory Press the right button to increment the discharged value by 0 01 V Z or hold depressed for continued incrementing After the charged value has been attained display re sta...

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 pump X X X X Check service and parking brake adjust if required X X X X Check inflation pressure X X X X Check sweeping track mark and adjust if required X X X X Check broom apron and adjust or chan...

Page 58: ...X 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 fixing screws brake steering lifting up disposal and tighten if required X Check brake system X Check steering function X Check LPG system for leaking and CO setting X Test drive and function test of ...

Page 59: ...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 pump X X X X Check service and parking brake adjust if required X X X X Check inflation pressure 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 ...

Page 60: ...nd 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 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 X ...

Page 61: ...ng 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 adjust if required X X X X Basic cleaning of the plate filter X X Test drive and function test X X X X Check battery X X X Check tension of steering chain and adjust if required X X Check thread of w...

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 X Check and eventually change the carbon brushes from the drive motor broom motor and central motor each 1000h ...

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