HAKO Scrubmaster B 115 R, Service Booklet

Page 1: ...1 91 Service Handbuch Service Booklet Hako GmbH Technisches Produktmanagement D 23840 Bad Oldesloe Stand 09 2014 Vertraulich nur f r den internen Gebrauch For internal use only Schulung Training Fehle...

Page 2: ...ntrol unit 13 2 1 3 Connection schemes with the different interfaces 15 2 2 Short Description 16 2 2 1 Deactivating Vacuuming Dirty Water Tank Full 17 2 2 2 Home Position of the Machine 18 2 2 3 Seat...

Page 3: ...ko System Maintenance I 31 4 3 Hako System Maintenance II 32 4 4 Hako System Maintenance S 33 5 Cleaning Programs 34 6 Machine Settings 37 6 1 Basic Settings 37 6 1 1 Machine Type 37 6 1 2 Cleaning Un...

Page 4: ...h Head Lifting Unit 62 8 Water Pump 63 8 1 Water Quantities 64 8 2 Water Pump Standstill Recognition 65 9 Drive Control Units 66 9 1 ATECH ZAPI Drive control unit DC Motor 67 9 1 1 Automatic Monitorin...

Page 5: ...10 1 Service Counter 3 3 1 1 101 11 Brakes 103 11 1 Adjustment of Brake DC Motor 104 11 2 Brake of the AC Motor 105 12 Options 106 12 1 Silence Kit 107 12 2 Acoustic Warning Signal 110 12 3 Chemical D...

Page 6: ...the screws Never unscrew the screws completely otherwise there is a risk of short circuit Insert the new high current fuses fully i e evenly under the screws Following repairs the starting current an...

Page 7: ...on a four character code appears for approx 3 seconds in the display which indicates the software version e g 1 001 possibly another four character code which indicates the last fault which has occurr...

Page 8: ...the 7090 11 35 models are equipped with a 75 cm disk brush unit The 7090 21 41 models are provided with a cylindrical brush unit with a working width of 70 cm The working width of the disk brush unit...

Page 9: ...s Programmable program versions PPV Fixed program versions FPV cleaning programs These settings can also be entered via the diagnostics system using a service PC In this case a PC with min 1x USB 2 0...

Page 10: ...e hour meter display of the dashboard after the control module is mechanically and electrically installed in the machine and the keyswitch is switched on Therefore after mechanical and electrical inst...

Page 11: ...software DVD 85 00 2144 xx Service computer e g CF19 Hako order No 03501860 english keyboard Interface PN 03501750 as Software License or 03502430 as Software License and USB to RS232 COM converter wo...

Page 12: ...For information regarding the access to this download server please ask Mrs Maike Christiansen under e mail mchristiansen hako com To install the diagnosis software on a service computer 1 Delete the...

Page 13: ...connector of the B90CL serialconnect cable PN 03502110 is connected to the RS232 port of the computer if the Interface is used In case the Interface is used connect the DSUB9 connector of the Diagnos...

Page 14: ...Please follow the Service Booklet SIE Interface PN 03501750 at a USB port is required as a license dongle for the software SIE Interface PN 03502430 at a USB port is required as a license dongle for...

Page 15: ...Foil 15 2 1 3 Connection schemes with different interfaces Configuration 1 with Interface PN 03501750 Configuration 2 with Interface PN 03502430...

Page 16: ...provided with a separate diagnostics display blink code via the LED on the drive control see Chapter 9 It is possible to switch between the buttons controlling scrubbing and vacuuming and the green Ha...

Page 17: ...activation by the operator Squeegee is raised Suction motor switches off after a delay 15 second Deactivation due to full tank The Dirty water tank full switch opens as soon as the tank is full If the...

Page 18: ...nitoring the top end position integrated in the lifting element The motors are switched off and the LED indicators in the cleaning component operating panel go out The lifting unit for the brush head...

Page 19: ...ion If an attempt is made to switch the machine on without the seat contact switch being closed or the switch is open for longer than 2 seconds all the machine s functions driving and clean are inhibi...

Page 20: ...ontrol is provided with its own diagnosis and self test Therefore the function of the drive control is inhibited when the machine is switched on if the drive potentiometer is not in its neutral positi...

Page 21: ...ion of parameters not described in this manual could lead to machine malfunction Therefore the utmost care must be taken with all alterations to the configuration Introduction to the Configuration Men...

Page 22: ...on the key switch The following display appears in the operating hour counter after approx 3 seconds The start screen of the Configuration menu is now open Press Button 2 to access Chapter 0 of the Co...

Page 23: ...2 3 The Configuration menu is represented by 3 digits Fig 2 4 which describe the individual levels The left hand digit indicates the chapter the middle digit the configuration and right hand digit th...

Page 24: ...After reaching the highest value pressing again calls in the lowest value Press and hold Button 3 for min 3 seconds to save the Content setting selected as long as the diagnostics connector is plugge...

Page 25: ...A1 X3 Press Button 2 six times the last error which occurred is indicated in the display e g Press and hold Button 3 for approx 3 seconds until 0 0 0 0 appears in the display Switch the machine off u...

Page 26: ...Foil 26 3 Technical Data...

Page 27: ...Foil 27 3 Technical Data...

Page 28: ...Foil 28 3 Technical Data...

Page 29: ...he machine Hako System Maintenance I every 250 hours of operation To be performed by qualified personnel of authorised Hako Service Centre in accordance with the machine specific system maintenance in...

Page 30: ...Foil 30 4 1 Hako System Maintenance K The daily and weekly maintenance intervals must be performed by the customer operator...

Page 31: ...Foil 31 4 2 Hako System Maintenance I The following maintenance work must be performed by an authorised Hako Service workshop...

Page 32: ...Foil 32 4 3 Hako System Maintenance II The following maintenance work must be performed by an authorised Hako Service workshop...

Page 33: ...Foil 33 4 4 Hako System Maintenance S Safety Check The following maintenance work must be performed by an authorised Hako Service workshop Only DC motor...

Page 34: ...ter switch S08 provide a 24 V signal for forward drive at input A01 X10 4 and for reversing at input A01 X10 5 If no voltage signal is applied the cleaning units are not activated The reaction of the...

Page 35: ...Yes Yes No No No No No No No No No No No Yes No Yes No No Yes Yes Yes Lift squeegee when drive control is in neutral Lift squeegee when drive control is in reverse Contents Lift brush when drive cont...

Page 36: ...090 11 21 35 41 99 7090 81 91 3 0 3 0 1 x x x 3 0 2 d d d 3 0 3 x x x 3 0 4 x x x 3 0 5 x x x 3 0 6 x x x 3 0 7 x x x 3 0 8 x x x 3 0 9 x x x Refer to FPV table Refer to FPV table Refer to FPV table R...

Page 37: ...garding the machines in the Hakomatic B115R series These types can be set in the Configuration menu To check and change the machine type setting access programming level as described in Chapter 2 2 4...

Page 38: ...er Configuration Contents Description B115 PB650 B115 PB750 CB700 B115 PB900 CB850 99 7090 51 99 7090 11 21 35 41 99 7090 81 91 0 1 Machine Model 0 1 3 Hakomatic B115 650 99 7090 51 x 0 1 5 Hakomatic...

Page 39: ...sh units with working widths of 70 cm and 85 cm are also available This setting is necessary to ensure correct function of the overload limits and the water quantities To check and change the machine...

Page 40: ...on Contents Description B115 PB650 B115 PB750 CB700 B115 PB900 CB850 99 7090 51 99 7090 11 21 35 41 99 7090 81 91 0 2 Cleaning Units 0 2 1 Disk brush 650 mm d 0 2 2 Disk brush 750 mm d 0 2 4 Disk brus...

Page 41: ...um service life of the batteries it is essential to set the battery monitor referred to as TSG to the correct discharge curve Batteries of different construction are available which differ according t...

Page 42: ...V and PzV are sealed absolutely maintenance free gel batteries GiS and PzS are sealed low maintenance batteries with liquid electrolyte AGM batteries are wrapping electrodes with fiberglass separators...

Page 43: ...scription B115 PB650 B115 PB750 CB700 B115 PB900 CB850 99 7090 51 99 7090 11 21 35 41 99 7090 81 91 0 3 Battery Setting 0 3 0 Crown without offset x x x 0 3 1 Crown with offset x x x 0 3 2 GIS foreign...

Page 44: ...n integrated charger This adjustment is necessary so that the TSG can operate correctly To check and change the machine type setting access programming level as described in Chapter 2 2 4 The paramete...

Page 45: ...4 Charger Chart 6 4 Chapter Configuration Contents Description B115 PB650 B115 PB750 CB700 B115 PB900 CB850 99 7090 51 99 7090 11 21 35 41 99 7090 81 91 0 4 Chargers 0 4 0 Charger not available d x x...

Page 46: ...hether the last error which occurred on the machine should be displayed or not when the machine is switched on again To check and change the PPV setting access programming level as described in Chapte...

Page 47: ...ts Description B115 PB650 B115 PB750 CB700 B115 PB900 CB850 99 7090 51 99 7090 11 21 35 41 99 7090 81 91 2 0 Last error indicator after switching on the machine 2 0 0 Deactivate x x x 2 0 1 Activate d...

Page 48: ...5 PB750 CB700 B115 PB900 CB850 99 7090 51 99 7090 11 21 35 41 99 7090 81 91 2 2 Water level when switching on scrubbing and vacuuming 2 2 0 Last setting d d d 2 2 1 Preset level x x x 2 3 Water level...

Page 49: ...B700 B115 PB900 CB850 99 7090 51 99 7090 11 21 35 41 99 7090 81 91 2 6 Water Setting 2 6 0 From last level to first level in circuit d d d 2 6 1 Change direction on reaching max min level ping pong x...

Page 50: ...ter Configuration Contents Description B115 PB650 B115 PB750 CB700 B115 PB900 CB850 99 7090 51 99 7090 11 21 35 41 99 7090 81 91 2 8 Acoustic Alarm Tone Interval menu option only appears when the Acou...

Page 51: ...Foil 51 7 Mechanical Components 7 1 Squeegee Fig 7 1...

Page 52: ...t to adjust the squeegee so that the ends of the sealing strips just make contact with the floor Fig A Fig 7 2 Turn the counternut counterclockwise Distance from sealing strip to floor is reduced in t...

Page 53: ...Foil 53 7 Mechanical Components 7 1 Squeegee Fig 7 2 Fig 7 3...

Page 54: ...or must be adjusted by altering the number of washers Fig 7 1 6 Fig 7 3 on the holder In the case of very smooth floors e g coated screed PVC linoleum etc the number of washers 2 This corresponds to a...

Page 55: ...nts Squeegee connection The drawing Fig 7 4 specifies the dimensions for adjusting of the suspension springs 60 mm and the threaded rods for adjusting the parallel alignment 151 mm of the squeegee con...

Page 56: ...widths are available for the Hakomatic B115R 65 cm 75 cm and 90 cm The two brushes are each driven by a separate motor 7 3 Cylindrical Brush Head Cylindrical brush heads are available for the Hakomat...

Page 57: ...g the adjusting bolt Fig 7 9 1 and check guide II Fig 7 7 with adjusting plate I on both sides Set adjusting plate I between guide II and washer III flat on the slide stone The adjustment is ideal whe...

Page 58: ...Foil 58 7 Mechanical Components 7 3 1 Cylindrical Brush Head Fig 7 9 Fig 7 8 Fig 7 7 1...

Page 59: ...Foil 59 7 Mechanical Components 7 4 Brush Head Lifting Unit...

Page 60: ...Foil 60 7 Mechanical Components 7 4 Brush Head Lifting Unit...

Page 61: ...Foil 61 7 Mechanical Components 7 4 Brush Head Lifting Unit...

Page 62: ...easuring point A1 X19 1 A1 X19 3 2 5V Reference Voltage A1 X19 2 A1 X19 3 0 2 5V 0 2 5V depending on the position of the lifting element Possible faults A1 X19 1 A1 X19 3 less than 2 5V or 0V Short ci...

Page 63: ...th the suction turbines switched off Disk brush Cylindrical brush Level 1 Approx 3 5 V Approx 4 7 V Level 2 Approx 4 2 V Approx 5 2 V Level 3 Approx 5 1 V Approx 5 8 V Level 4 Approx 7 6 V Approx 7 1...

Page 64: ...is specified as follows in the operating manual If power is applied to the pump but the water quantity does not correspond to the information check whether the hoses are clogged or kinked that the sol...

Page 65: ...ushes a pressure builds at the pump Without being protected by the electronic module the pump would deliver against this pressure and could be damaged The electronic module detects the blocked deliver...

Page 66: ...its neutral position or is not detected as being in neutral The same occurs after the seat contact switch has been opened and is closed again Even when the seat contact switch is closed the drive pot...

Page 67: ...e ZAPI drive control unit is equipped with a diagnosis connector Any changes of the factory presetting values and parameters is forbidden Position of connectors A Connector for relay control and contr...

Page 68: ...battery positive active function when pin is free A7 RV2 Speed reduction no 2 input normally close contact toward battery positive reduction is active when pin is free A8 PT Positive contactors outpu...

Page 69: ...switch potentiometer connections EEPROM Check during standstill Watchdog current power MOS FETs contactor drive contactor driver potentiometer connections Check during ride Watchdog current power MOS...

Page 70: ...efective 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 short circ at NT1 17 8 DRIVER 2 KO A NT2 driver short circuited 18 8 DR...

Page 71: ...f Replace logic if error persists after switching key switch off and on If alarm disappears mind the fact that the saved parameter values are deleted basic setting 3 EEPROM CONF KO Error in the memory...

Page 72: ...disappears after switching key switch off and on mind the fact that the hourmeter is reset to zero 5 EEPROM OFF LINE Error in the non volatile memory containing hourmeter values programmable paramete...

Page 73: ...sequence is respected key switch handle micro switch direction switch HANDLE key switch direction switch FREE key switch seat contact switch direction switch SEAT Possible causes a Direction or handl...

Page 74: ...tput Possible causes a Master contactor if fitted does not close or is not connected at all b Short circuit between connection VMN and Batt metal particles or other disconnect cable at connection VMN...

Page 75: ...hanically blocked or permanently driven incorrect wiring of contactor coil b Short circuit between field and armature winding of motor disconnect cable at connection VMN switch on error disappears rep...

Page 76: ...inductive sensor b Potentiometer or the inductive sensor is defective 10 I 0 EVER Test during ride If current does not exceed a determined minimum value during ride an error message appears and the sy...

Page 77: ...ensor is defective replace controller 12 PEDAL WIRE KO If no voltage is measured at pin NPOT A12 to which the negative wire of the potentiometers is connected an alarm is output Possible causes a Wire...

Page 78: ...ON with cold controller temperature monitoring is faulty replace controller b If the alarm is output after relatively short period of operation heat is insufficiently dissipated check installation an...

Page 79: ...f reverse direction contactor is defective b The internal MOSFET driver is short circuited replace controller 16 DRIVER 1 SIC KO If current load at contactor driver controlling the output NT1 A11 is e...

Page 80: ...f forward direction contactor is defective B The internal MOSFET driver is short circuited replace controller 18 DRIVER 2 SIC KO If current load at contactor driver controlling the output NT2 A4 is ex...

Page 81: ...a Wire broken at connection NT1 A11 or coil of forward or reverse direction contactor is defective b The internal MOSFET driver is short circuited replace controller 20 CONTACTOR OPEN Test upon actuat...

Page 82: ...At the forward or reverse direction contactor depending on selected direction a voltage applies to the coil for 0 3 sec In reverse direction only Reverse direction contactor closes for 0 3 sec before...

Page 83: ...ctor TA or the break contact of the reverse direction contactor TI is soiled or blocked Clean contacts or if required replace contactor group Clean the make contact of forward direction contactor TA C...

Page 84: ...actor TA or the make contact of the reverse direction contactor TI is soiled or blocked Clean contacts or if required replace contactor group Clean the make contact of reverse direction contactor TI C...

Page 85: ...No connection to motor Carbon brushes without contact to collector Fig 1 Connection cable of carbon brushes interrupted Fig 2 Motor winding defective or motor cable interrupted Incorrect connection o...

Page 86: ...tly driven but does not close Contactor coils are defective use ohmmeter to measure resistance Contacts are mechanically blocked Nominal voltage of contactor coils higher than battery voltage C1 No vo...

Page 87: ...ible causes a Micro switch for emergency reverse stuck b Incorrect operation c Incorrect wiring or programming 23 FORW BACK An error is displayed if two directions are simultaneously active Possible c...

Page 88: ...the factory preset parameters and values is forbidden Currently only the diagnosis with the blinking codes at the Trip LED is used for the Drive control unit 9 2 1 Description of the connectors M1 M2...

Page 89: ...d activ if B is present A6 alwais at B A7 Input from foot brake switch S10 if B is present machine is decreased to standstill A8 Potentiometer yellow A9 Feedback from Potentiometer RED A10 Control vol...

Page 90: ...Blinking Code Warning Faults ON None lowest Priority Controller operational and OK No action required 1 Handbrake on Handbrake switch closed Release handbrake 2 Voltage getting low Battery voltage ge...

Page 91: ...o cool down Use vehicle within it s specifications 6 Controller hot Thermal cutback allow the controller to cool down Check heat sinking and specifications 7 Adjustments out of range One or more adjus...

Page 92: ...oth forward and reverse selected Recycle both directions and FS1 Check direction switch and wiring 11 decontrol is missing Signal from A1 X10 1 is missing Check wiring and voltage potential Batt B 12...

Page 93: ...el controller voltage rating settings 16 not used 17 Voltage too low Battery voltage too low Check battery capacity charge level controller voltage rating settings 18 High sided Mosfet short circuit H...

Page 94: ...driver or wiring open circuit Check contactor coils and wiring 22 Voltage too high Battery voltage too high normally during braking Reduce braking levels or vehicle Speed defective battery 23 Low side...

Page 95: ...side Mosfet short circuit Low sided Mosfet short circuit before line contactor closed Check motor insulation and line contactor if OK replace controller 28 Wire off detected Sub 0 No wire off detecte...

Page 96: ...4 of brush motors series circuit Inputs A1 X9 1 and 11 power consumption per brush motor max PB 650 30A PB 750 PB 900 CB 700 CB 850 40A 1 2 6 1 Blocking protection brush 1 2 Do brush motors run smooth...

Page 97: ...display and before the operating hour counter remains 5 s or when working unit is ON 3 2 6 6 Backup battery empty Message appears after the Last error display and before the operating hour counter rem...

Page 98: ...ion switch and cabling 3 4 5 1 Drive motor overheated Check thermostatic switch and cabling of drive motor connector X10 input A1 X9 2 and 12 3 6 6 4 Seat switch manipulation The seat contact switch w...

Page 99: ...t A01 operating panel A02 This error only occurs when switching the machine on 4 5 3 5 Operating panel response missing timeout Check connection cable for control unit A01 operating panel A02 This err...

Page 100: ...mation doesn t impair the function of the machine This information is displayed for 5 sec everytime the machine is switched on then the machine can be used as usual You can skip this information by ac...

Page 101: ...tware Click on the tab System of the diagnosis menu and choose Write event Fig 10 1 Then the window for the service interval is opened Fig 10 2 There the Service alert can deactivated with the button...

Page 102: ...Foil 102 10 1 Service Intervall 3 3 1 1 Fig 10 2...

Page 103: ...h on plane ways At a maximum speed of 6 5 km h this means that the maximum stopping distance may be 1 235 m This has to be checked after working on the brake system and during the regular maintenance...

Page 104: ...Foil 104 11 Brakes 11 1 Adjustment of Brake DC Motor...

Page 105: ...ock button 1 is pressed Set the key switch to On Press and hold the Unlock button and at the same time push the vehicle The Unlock button is situated at the front left of the machine viewed in driving...

Page 106: ...12 Options The following options are available for vehicles in the Hakomatic B115R series Silence kit 99 7730 10 Acoustic warning signal 99 7091 00 Chemical dosage 99 7678 45 Scrubbing vacuum tool 99...

Page 107: ...bed in Chapter 2 2 4 Then define the parameter settings as indicated in the table below and save the settings Chapter Configuration Contents Description B115 PB650 B115 PB750 CB700 B115 PB900 CB850 99...

Page 108: ...Foil 108 12 1 Option Silence Kit...

Page 109: ...Foil 109 12 1 Option Silence Kit...

Page 110: ...ated in the table below and save the settings The switching contact of the cable harness is connected to connector X10 on cable harness W3 This is input A01 X9 9 19 on control unit A01 Chapter Configu...

Page 111: ...d in Chapter 2 2 4 Then define the parameter settings as indicated in the table below and save the settings Chapter Configuration Contents Description B115 PB650 B115 PB750 CB700 B115 PB900 CB850 99 7...

Page 112: ...Foil 112 12 3 Option Chemical Dosage...

Page 113: ...Foil 113 12 3 Option Chemical Dosage...

Page 114: ...Foil 114 12 3 Option Chemical Dosage...

Page 115: ...Foil 115 12 3 Option Chemical Dosage...

Page 116: ...Foil 116 12 3 Option Chemical Dosage...

Page 117: ...Foil 117 12 3 Option Chemical Dosage...

Page 118: ...Foil 118 12 3 Option Chemical Dosage...

Page 119: ...Foil 119 12 3 Option Chemical Dosage...

Page 120: ...Foil 120 12 3 Option Chemical Dosage...

Page 121: ...Foil 121 12 3 Option Chemical Dosage...

Page 122: ...Foil 122 12 3 Option Chemical Dosage...

Page 123: ...vel as described in Chapter 2 2 4 Then define the parameter settings as indicated in the table below and save the settings Chapter Configuration Contents Description B115 PB650 B115 PB750 CB700 B115 P...

Page 124: ...Foil 124 12 4 Option Scrubbing Vacuum Tool...

Page 125: ...Foil 125 12 4 Option Scrubbing Vacuum Tool...

Page 126: ...Foil 126 12 4 Option Scrubbing Vacuum Tool...

Page 127: ...Foil 127 12 4 Option Scrubbing Vacuum Tool...

Page 128: ...off the clock is supplied with power from a backup battery on the control electronics Proceed as follows to set the clock e g after changing the battery Plug diagnostics connector PN 03006790 on conn...

Page 129: ...while the key switch is switched on After approx 3 seconds the year setting appears in the operating hour counter In the example 11 for 2011 Release the buttons Then press Button 1 to access the sett...

Page 130: ...onger than one second the value changes automatically at a constant speed If a value is modified the point at the bottom right behind the number disappears After pressing Button 5 for three seconds th...

Page 131: ...Foil 131 14 Notes...

Page 132: ...Foil 132 14 Notes...

Page 133: ...Foil 133 14 Notes...