HAKO Hakomatic B 1100 Service Booklet
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HAKO Hakomatic B 1100 Service Booklet

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Service-Handbuch
Service Booklet
Hakomatic B 1100
(7580.02)(7580.35)
Hakomatic B 1050
(7580.12/22)(7580.16/26)(7580.15)
Schulung/Training
Fehlersuche/Trouble Shooting
Einstelldaten/Adjustments
Hako GmbH
Vertraulich – nur für den internen Gebrauch
.
Technisches Produktmanagement
.
D-23840 Bad Oldesloe
For internal use only!
.
.
Stand 04/2012
Foil 1

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  • Page 1 Service-Handbuch Service Booklet Hakomatic B 1100 (7580.02)(7580.35) Hakomatic B 1050 (7580.12/22)(7580.16/26)(7580.15) Schulung/Training Fehlersuche/Trouble Shooting Einstelldaten/Adjustments Hako GmbH Technisches Produktmanagement D-23840 Bad Oldesloe Stand 04/2012 Vertraulich – nur für den internen Gebrauch For internal use only! Foil 1...

  • Page 2: Table Of Contents

    Contents 1 Remarks 2 General 2.1 Settings 2.2 Brief Description 2.2.1 Switch Off Suction/Recovery Tank Filled Up 2.2.2 Initial Position Of Machine/Release, Lock Functions 3 Check Settings For Machine Type, TSG And Options, Display And Delete Last Error 3.1 Check And Set Machine Type 3.2 Check And Set Options 3.3 Check And Set TSG 3.4 TSG Error 3211...

  • Page 3: Module

    Contents 5 Specific Customer Settings (Display Of Last Error And Selection Of Water Stage, Cleaning Agent, SWA, Side Brush, Filter) PPV 5.1 PPV1 5.2 PPV2 5.3 PPV3 5.4 PPV4 5.5 PPV5 (B 1100 only) 5.6 PPV6 (B 1100 only) 5.7 PPV7 (B 1100 only) 5.8 PPV8 (B 1100 only) 6 Setting Of Modules 6.1 Module 1...
  • Page 4 Contents 9 Drive Controllers 9.1 SEVCON Controller (Diagnostic LED) 9.1.1 Signal Measurement On Controller (SEVCON) 9.2 ATECH / ZAPI Controller 9.2.1 Automatic Monitoring Of Components 9.2.2 Error Messages Displayed Via LED 9.2.3 Explanations For Displayed Error Messages 9.3 Drive Motor Hakomatic B1050 (Amer) 9.3.1 Tyre replacement 9.3.2 Check / replacement of carbon brushes 9.3.3 Diagnostic LED for drive control unit (Italsea)

  • Page 5: Remarks

    1. Remarks This document is structured so as to allow and seek continuous extension. You thus receive the documents with the 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.
  • Page 6 1. Remarks Caution : • Before working at the machine, disconnect voltage supply (pull battery plug) except for the purpose of voltage and current measurement. • When replacing stripe fuses, only loosen screws. Do not remove them completely - short-circuit hazard. Make sure to fully and evenly insert new blade fuses under the screws.

  • Page 7: General

    2. General The Hakomatic B 1100 and the Hakomatic B1050 are equipped with a service indication in the hourmeter display. Upon switching the key switch ON, a 4-digit code describing the software version (e.g. 3.018), is displayed for about 3 seconds, followed by another 4-digit code signalling the last error which again is followed by the hourmeter indication.

  • Page 8: Settings

    2.1 Settings Settings on the control electronics/panel which have to be set and checked on each machine: In contrast to the Hakomatic B1100, scope of performance of the Hakomatic B1050 is reduced and does not feature all the options available in the Hakomatic B1100. The Hakomatic B1050PB (Plate Brush aggregate) has the side scrub unit optionally available only;...
  • Page 9 2.1 Settings Settings which may be set via operator panel according to customer requirements:  Display of last (remedied) error upon switching machine ON  Selection of water stage upon start of cleaning  Cleaning agent ON in addition to switching water ON (B1100 & B1100 PB 1230 only) ...
  • Page 10 2.1 Settings Settings at Module 1:  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 operator panel coding Foil 10...

  • Page 11: Brief Description

    2.2 Brief Description Machine control is effectuated via the following electronics:  Control electronics  Module 1  Module 3 (for pre-sweeper, side broom and side brush, 3rd brush options)  Operator panel  Cleaning agent dosage /SWA operator panel (B1100 only) ...
  • Page 12 Upon occurrence of a defect on the drive 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 combined cleaning may be switched arbitrarily such that the selected function is activated.
  • Page 13 2.2 Brief Description The machine is equipped with a seat switch. Activation of this switch is required before switching key switch on since otherwise sweeping and scrubbing functions (even in combination) are locked. If the seat switch is not activated, suction can only be activated for the „Hand suction hose“...

  • Page 14: Switch Off Suction/Recovery Tank Filled Up

    2.2.1 Switch Off Suction / Recovery Tank Filled Up The suction function is either stopped by the operator via button actuation or automatically upon the „recovery tank filled up“ signal. Switching off by operator:  Squeegee is lifted up  Suction motors switch off delayed (15 seconds) Switching off after tank filled up: ...

  • Page 15: Initial Position Of Machine/Release, Lock Functions

    2.2.2 Initial Position/Release, Lock Functions When turned ON and the seat switch closed, all units of the machine are set to „initial position“. This means that the control electronic triggers all units (lifting elements and motors). Lifting elements will be lifting up as long as they are not switched off by the micro- switch controlling the upper limit position and integrated in the lifting element.
  • Page 16 2.2.2 Initial Position/Release, Lock Functions Before operation of the pre-sweeper (B1100 & B1100 PB 1230 only), the hood is to be closed and the dirt hopper correctly inserted. The hood and the dirt hopper are monitored each by a switch (NC switch) being serially connected. As soon as the switch opens, the LED in the standard operator panel lights to signal „open hood“...
  • Page 17 2.2.2 Initial Position/Release, Lock Functions Activation of the „Brushes“ function causes lowering of the brush head to the so-called central position. The lifting element does not attain the lower limit position before cleaning with increased ground pressure. The brush head lifting element thus has 3 micro-switches integrated, one each for the upper, the central and the lower limit position.

  • Page 18: Check Settings For Machine Type, Tsg And Options, Display And Delete Last Error

    3. Machine Type Settings Check settings for machine 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 replacement. Foil 18...
  • Page 19 3. Machine Type Settings The picture shows the Hakomatic 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. B1050 PB & CB & PB 1230 Foil 19...
  • Page 20 3. Machine Type Settings Entry into programming 1. Switch off machine by key switch 2. Simultaneously press "G" and "H" and hold depressed, then switch on key switch 3. Hold depressed both buttons as long as the software version is displayed then release buttons Display of set machine type then appears automatically.
  • Page 21 3. Machine Type Settings Software version, automatic change to next 4020 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 and reset Foil 21...
  • Page 22 3. Machine Type Settings Control electronics A1.X2 B1100 B1050 PB/CB B1050PB 1230 B1100-PB 1230 Foil 22...

  • Page 23: Check And Set Machine Type

    3.1 Check And Set Machine Type 1. Make sure to have the correct machine type set. Use the Dip switch A on the control electronics for setting (see foil 22) 2. For the B1100 machine, the bars no. 1, 2, 4 are to set in bottom and the bar no. 3 in top position.

  • Page 24: Check And Set Options

    3.2 Check And Set Options 1. Setting each option in the machine is required at the Dip switch B (see p. 22) on the control electronics. 2. The Dip switches are assigned as follows: Cleaning agent dosage (B1100 &B1100PB 1230) (set = “ON”) (set = “ON”) SWA (B1100 only) (set = “ON”)

  • Page 25: Check And Set Tsg

    3.3 Check And Set 1. The TSG has to be set in any case to 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.
  • Page 26 3.3 Check And Set “1” means ON; “0” means OFF The addition “foreign” indicates batteries which are not delivered by Hako. Reset voltage for the TSG: approx. 38.5V. This voltage is required to reset the TSG capacity to 100%. Caution: 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.
  • Page 27 3.3 Check And Set GiS and GiV are Grid plate batteries, PzS and PzV are Tubular plate 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 used: GiS = FF GiV = GF-Y;...

  • Page 28: Tsg Error 3211

    3.4 TSG Error 3211 TSG - Remarks on the error 3211 The controller receives data from the TSG module in serial form and transmission of a telegram takes one second. The 3211 error occurs when two telegrams with the same contents are not received within 5 seconds and this equally is the case if there is no transmission at all.

  • Page 29: View And Delete Last Appeared Error In The Display

    3.5 View And Delete Last Error View 1. Press “N” button three times; then a 4-digit error code with blinking dots appears (last error occurred and remedied) 2. Quit programme by switching OFF key switch (do not switch OFF key switch when proceeding to point “Delete”) Delete 1.
  • Page 30 4. Programming Different 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 the icon on the operator panel) Foil 30...
  • Page 31 4. Programming Different Procedures Check 1. Switch off machine by key switch 2. Simultaneously press "N" and "O" buttons and hold depressed, then switch on key switch 3. Hold both buttons depressed as long as the software version appears in the display then release both buttons 4.

  • Page 32: Programme Functions

    4.1 Programme Functions Precondition for functioning of the following programmes is that “Brushes” and/or “Suction" and/or “Sweep” are ON. All programmes allow normal cleaning and suction in ‘forward' accelerator position; for the 'Neutral' and 'Reverse‘ accelerator positions, however, differences apply and are listed in the following table. Programme Accelerator Function according to code...
  • Page 33 4.1 Programme Functions Programme Accelerator Function according to code position/ accelerator position/direction switch Direction Brush head Squeegee Broom switch + Water (B1100 only) Neutral Brushes and Lift squeegee Broom remains water ON Reverse Brushes and Lift squeegee Broom remains water ON Neutral Brushes and Suction remains...
  • Page 34 4.1 Programme Functions Programme Accelerator Function according to code position/ accelerator position/direction switch Direction Brush head Squeegee Broom switch + Water (B1100 only) Neutral Brushes and Lift squeegee Broom off and water OFF, lifted up lift brush head Reverse Brushes and Lift squeegee Broom off and water OFF,...
  • Page 35 4.1 Programme Functions Programme Accelerator Function according to code position/ accelerator position/direction switch Direction 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 brushes to avoid (B 1100 only) the brushes from...
  • Page 36 Programme Functions When the selected function 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” only means ‘switched OFF’, ‘lifted’ is additionally indicated Foil 36...

  • Page 37: Specific Customer Settings

    5. Specific Customer Settings (Display of last error and selection of water 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 the position of buttons which is decisive and not the icon on the operator panel.
  • Page 38 5. Specific Customer Settings Entry into programming 1. Switch off machine by key switch 2. Simultaneously press ”G" and "O" buttons and hold depressed, then switch on key switch 3. Hold both buttons depressed as long as the software version appears in the display, then release both buttons Then the programmed settings for the following points are displayed automatically: ...
  • Page 39 5. Specific Customer Settings (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 scrub/suct Water stage Error display Foil 39...

  • Page 40: Ppv1

    5.1 PPV1 (Display Of Last Error) 1. Select desired setting by “L” and “N” buttons 2. The corresponding bar starts blinking 3. Use “M” button to move the bar up and down = 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 displayed 4.

  • Page 41: Ppv2

    5.2 PPV2 (Water stage Upon Start of cleaning) 1. Select desired setting by “L” and “N” buttons 2. The corresponding bar starts blinking 3. Use “M” button to move the bar up and down = ON = last selected stage is set Down = OFF = always the medium stage is set 4.

  • Page 42: Ppv3

    5.3 PPV3 (Cleaning Agent / Waterstage) 1. Select desired setting by “L” and “N” buttons 2. The corresponding bar starts blinking 3. Use “M” button to move the bar up and down B1100 = ON = Cleaning agent is equally switched on Down = OFF = Cleaning agent is not switched on &...

  • Page 43: Ppv4

    5.4 PPV4 (Switch Over to SWA / Side broom - side brush) 1. Select desired setting by “L” and “N” buttons 2. The corresponding bar starts blinking Use “M” button to move the bar up and down B1100 = ON = Switching to dirty water recycling (SWA) Down = OFF = Switching to clear water B1050 = ON = Switching on side broom / brush together...

  • Page 44: Ppv5 (B 1100 Only)

    5.5 PPV5 (Side Brush Upon Switching On Scrubbing) (B1100 only) 1. Select desired setting by “L” and “N” buttons 2. The corresponding bar starts blinking 3. Use “M” button to move the bar up and down = ON = side brush is equally switched on Down = OFF = side brush is not switched on 4.

  • Page 45: Ppv6 (B 1100 Only)

    5.6 PPV6 (Filter Shaking) (B 1100 & B1100 PB 1230) 1. Select desired setting by “L” and “N” buttons 2. The corresponding bar starts blinking 3. Use “M” button to move the bar up and down = ON = Filter shaking as long as button is depressed Down = OFF = Filter shaking after switching on by button 3 times in intervals 4.

  • Page 46: Ppv7 (B 1100 Only)

    5.7 PPV7 (Filter Suction Upon Switching On Sweeping Mode) (B 1100 & B1100 PB 1230) 1. Select desired setting by “L” and “N” buttons 2. The corresponding bar starts blinking 3. Use “M” button to move the bar up and down = ON = Filter suction is equally switched on Down = OFF = Filter suction is not switched on 4.

  • Page 47: Ppv8 (B 1100 Only)

    5.8 PPV8 (Automatic Filter Shaking After Sweeping) (B 1100 & B1100 PB 1230) 1. Select desired setting by “L” and “N” buttons 2. The corresponding bar starts blinking 3. Use “M” button to move the bar up and down = ON = after a 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.

  • Page 48: Setting Of Modules

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

  • Page 49: Module

    6.1 Module 1 As they have an influence 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-breaker values: Brush head:...

  • Page 50: Module 3

    6.2 Module 3 As they have an influence on the module coding and the load value of the electronic circuit breakers for the pre-sweeper / side broom / side brush lifting 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)

  • Page 51: Settings Of Can Operator Panels (B 1100 Only)

    7. Operator Panel Settings (B 1100 only) The Code A and B operator panels (pre-sweeper / side brush and 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 panel of the machine.

  • Page 52: Water Pump

    8. Water Pump 8.1 Water Amounts For checking function of the water pump, voltage for each of the stages can be measured at Module 1 (A5:X2:6+7). When using a True RMS device, having water in the tank and ensuring that suction turbine is OFF, the values from the following table shall be obtained: When using other than the indicated measuring devices, values may vary since measured voltage is pulsed.
  • Page 53 8. Water Pump Hakomatic B1100 / B1050PB Hakomatic without with B1050CB Option Tool Sidebrush Sidebrush Hakomatic B1050 Stage 1: xx V ca. 1,3 l/min ca. 2,7 l/min ca. 1,3 l/min ca. 1,0 l/min Stage 2: ca. 5,7 V ca. 2,2 l/min ca. 3,3 l/min ca.

  • Page 54: Standstill Detection For Water Pump

    Standstill Detection For Water Pump Automatic standstill detection for water pump: The electronics offer a possibility for water pump protection if delivery of pump is blocked. When the pump takes in water from the tank but cannot deliver it to the brushes, a pressure builds up downstream the pump.

  • Page 55: Drive Controllers

    Drive Controller 9.1 SEVCON Controller (Diagnostic LED) The light-emitting diodes (LED) are directly located on the electronics LED indication Malfunction Remark Drive controller Voltage supply interrupted without function Check fuses and wiring Drive controller is Drive controller function operable okay 2 signals Wrong start sequence Check accelerator and direction...
  • Page 56 9.1 SEVCON Controller LED indication Malfunction Remark 4 signals Output transistors do Check wiring to drive motor not connect or no and drive motor. connection to drive motor Check direction switch and direction contactors on drive controller; if okay but signals still present, replace drive controller 5 signals...
  • Page 57 SEVCON Controller LED indication Malfunction Remark 6 signals Accelerator or cable Check accelerator and wiring, connection interrupted plugged 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 of drive...

  • Page 58: Signal Measurement On Controller (Sevcon)

    9.1.1 Signal Measurement at the Drive Controller (SEVCON) During test of the drive controller, the following points should be checked since faultless operation of the drive controller is not possible without the described signals applying accordingly. The drive controller is designated by A6 in the circuit diagram and is supplied with 36 V even though some of the signals are 24-Volts signals.
  • Page 59 9.1.1 Signal Measurement at the Drive Controller (SEVCON) 5. Cabling between accelerator potentiometer and drive controller okay? Voltage measurement: Green at A6-X51:8 (approx. 8.6V) at A6-X51:9 (0-5V depending on potentiometer position) Yellow at A6-X51:3 (approx. 0V) Measured to battery minus Resistance measurement (with machine switched off and potentiometer disconnected): Between green and red: approx.
  • Page 60 9.1.1 Signal Measurement at the Drive Controller (SEVCON) 6. Is connection between A6:X51:3 and A1:X4:3&4 okay? Is battery minus equally connected to A1:X4:3&4? 7. Is battery minus applying at A1:X3:1 after closing of key switch and seat contact switch? Battery minus equally at S54:1? Is 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 switch.
  • Page 61 9.1.1 Signal Measurement at the Drive Controller (SEVCON) 11. Are 24V applying at A1:X8:2 after “forward” ride selected? 12. Is jumper in A1:X8 between Pin 1 and 3 and 5 okay? 13. Do switches S53 (direction) and S54 (potentiometer) operate faultlessly? 14.
  • Page 62 9.1.1 Signal Measurement at the Drive Controller (SEVCON) 17. Is cabling between drive controller and drive motor 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.

  • Page 63: Atech / Zapi Controller

    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 Foil 63...
  • Page 64 9.2 ZAPI Controller Description of control connections of the ZAPI controller Speed reduction 1; active if no positive voltage is applying Emergency inversion acc. to Europ. standard; active if a pos. voltage is applying Tiller micro switch; active if a pos. voltage is applying Activation of neg.

  • Page 65: Automatic Monitoring Of Components

    9.2.1 ZAPI Controller 9.2.1 Automatic Monitoring of the Components The micro-processor effectuates evaluation of basic controller functions. This evaluation concerns: •Check upon switching key switch ON: Watch Dog, current sensor, power MOS FET, contactor activation (contactor driver), direction switch, potentiometer connections, EEPROM) •Check in standstill: Watch Dog, current, power MOS FET, contactor activation (contactor driver), potentiometer connections)

  • Page 66: Error Messages Displayed Via Led

    9.2.2 ZAPI Controller 9.2.2 Error Codes Displayed Via The LED Blinks Message State* Remark WATCH-DOG Error on electronics 2/3/4/5) EEPROM Error on electronics (EEprom) INCORRECT START Direction actuated upon switching ON (or incorrect connection of IR) VMN LOW MOSFET short-circuited VMN HIGH Diodes short-circuited or direction contactor stuck VACC NOT OK...

  • Page 67: Explanations For Displayed Error Messages

    9.2.3 ZAPI Controller 9.2.3 Explanations On Displayed Error Messages 1) WATCH-DOG Test during rest state as well as during ride; internal self-test of hard- and software; replace controller in case of fault alarm! 2) EEPROM PAR. KO Error in the memory area containing values of the setting parameters. System switches off. 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.
  • Page 68 9.2.3 ZAPI Controller 4) EEPROM DATA KO Data of the memory area controlling the hourmeter counter are corrupted. If alarm disappears after having 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 concerning the programmable parameters and the saved alarms.
  • Page 69 9.2.3 ZAPI Controller 6) INCORRECT START Corrupted order of sequence of start conditions. The system only starts if, depending on SAFETY SWITCH 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) Direction or tiller micro-switch stuck.
  • Page 70 9.2.3 ZAPI Controller 7) VMN LOW Test in rest state and during ride up to VMN synchronised for 80%; Voltage at VMN terminal normally equals 50% Vbatt if contactors are open. If this voltage is insufficient (< 30% VBatt), an alarm will 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 terminal, switch on, fault disappears)
  • Page 71 9.2.3 ZAPI Controller 8) VMN HIGH Test in rest state; Voltage at VMN terminal normally equals 50% Vbatt if contactors are open. If this voltage is excessive (> 70% VBatt), an alarm will be output. Possible causes : a) One of the direction contactors is permanently 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, Fault disappears, repair motor)
  • Page 72 9.2.3 ZAPI Controller 9) VACC NOT OK Test in rest state; An alarm is displayed if the potentiometer voltage is higher than 1V, related to the saved minimum value. Possible causes: a) One of the wires at the potentiometer or inductive sensor is broken. b) Potentiometer or inductive sensor ist defective.
  • Page 73 9.2.3 ZAPI Controller 11) HIGH CURRENT Test in rest state - contactor open; If measured current is >50A, an alarm will be output and the system switches off. 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.
  • Page 74 9.2.3 ZAPI Controller 13) TEMPERATURE This message indicates that temperatures has exceeded 76°C. Maximum current is reduced by steps down to zero with a temperature of 86°C. Possible causes: a) If the alarm is output directly after switching the system 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 installation and fastening screws)
  • Page 75 9.2.3 ZAPI Controller 15) DRIVER 1 KO If voltage at the NT1 terminal (A11) does not correspond to the desired value, an alarm is output and the system switches off. Possible causes: a) Wire at the NT1 terminal (A11) broken or coil of the direction contactor for reverse ride is defective.
  • Page 76 9.2.3 ZAPI Controller 17) DRIVER 2 KO If voltage at the NT2 terminal (A4) does not correspond to the desired value, an alarm is output and the system switches off. Possible causes: a) Wire at the NT2 terminal (A4) broken or coil of the direction contactor for forward ride is defective.
  • Page 77 9.2.3 ZAPI Controller 19) DRIVER SHORTED (only with H0 STANDARD TRACT.) If voltage at the NT1 terminal (A11) does not correspond to the desired value, an alarm is output and the system switches off. Possible causes: a) Wire at the NT1 terminal (A11) broken or coil of the direction contactor for forward or reverse ride is defective.
  • Page 78 9.2.3 ZAPI Controller When does error occur? 1st test result 2nd test Result Error --> --> Forward direction contactor In forward direction closes for 0.3 seconds and For 0.3 seconds, a voltage only then opens applies to the coil of the forward direction contactor -->...
  • Page 79 9.2.3 ZAPI Controller The NO contact of the forward 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 contactor (TA) Clean NC contact of the reverse direction contactor (TI)
  • Page 80 9.2.3 ZAPI Controller The NC contact of the forward 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 NO contact of the reverse direction contactor (TI) Clean NC contact of the forward direction contactor (TA)
  • Page 81 9.2.3 ZAPI Controller 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 motor connection Foil 81...
  • Page 82 9.2.3 ZAPI Controller The forward direction contactor is correctly activated but does not close. - contactor coil defective, measure resistance by ohmmeter - contact is mechanically blocked - nominal voltage of contactor coil is higher than the battery voltage The reverse direction contactor is correctly activated but does not close. - contactor coil defective, measure resistance by ohmmeter - contact is mechanically blocked - nominal voltage of contactor coil is higher than the battery voltage...
  • Page 83 9.2.3 ZAPI Controller 21) POSITION HANDLE If, upon switching ON, the tiller micro-switch has already been actuated, an error is output (only if SAFETY SWITCH is programmed to HANDLE). Possible causes: a) Tiller micro-switch stuck b) Incorrect operation 22) INVERSION If, upon switching ON, the emergency inversion switch (deadman) has been pressed, an alarm is output.

  • Page 84: Drive Motor Hakomatic B1050 (Amer)

    9.3 Drive Motor B1050 (Amer) 9.3.1 Tyre replacement Screw the 4 pullers two by two (at 180°) in the bracket until the hub is removed (Tool Unscrew the 4 screws of the hub PN 03502210) Warning! Lift up the machine so that the Warning! Remove the 4 pullers tyre is not touching the ground after this operation...
  • Page 85 9.3 Drive Motor B1050 (Amer) Unscrew the 6 screws M6x30 Replace the old tyre and re-assemble Remove the tightening torque 16Nm ±10% the new tyre with the hub without the plastic hub cover plastic hub cover Torque screw 16 Nm ± 10% Foil 85...
  • Page 86 9.3 Drive Motor B1050 (Amer) Warning! Check the radial position of the Install the wheel on the MTR11 by using hub with the inner disc during the a plastic mallet mounting Tire puller kit (Tool PN 03502210) Foil 86...
  • Page 87 9.3 Drive Motor B1050 (Amer) Mount the plastic cover hub manualy Screw the 4 screws M8x20 tightening torque screw 22 Nm ±10% Foil 87...

  • Page 88: Check / Replacement Of Carbon Brushes

    9.3.2 Drive Motor B1050 (Amer) Check (every 1000 hours) and replacement (max. 1500 hours) of the carbon brushes •the wear out limit of the carbon brushes is 12 mm Remove the 4 screws M6x20. Unscrew the 2 nuts. tightening torque 9.5Nm -10% +20% After remove the terminal board cover.

  • Page 89: Diagnostic Led For Drive Control Unit (Italsea)

    9.3.3 Diagnostic LED for Drive control unit (Italsea) Display / Flashes Alarm What To Do Alarm A1 Forward switch closed at Put the speed reference to zero and open the FORWARD switch ON power-on Forward switch Alarm A2 Backward switch closed at Put the speed reference to zero and open the BACHWARD switch ON power on...
  • Page 90 9.3.3 Diagnostic LED for Drive control unit (Italsea) Display / Flashes Alarm What To Do Alarm A9 Undervoltage Check battery charging level Undervoltage Alarm A10 Overvoltage Battery voltage higher than 45V: check the battery Overvoltage Check the Motor working current Alarm A11 Overload protection Armature: I...

  • Page 91: Error Table With Information On Service Display

    10. Error Table With Information On Service Display Error code in Malfunction Remark the display 1.2.5.2. Thermal switch Wire broken since NC activation? Brush motor Measure operating current (approx. 12 A 1); 2); 3); 4); 5) for a motor when operated without in- creased pressure and on Fama Famin) Motor overload due to unfavourable floor- brush-combination and/or permanent...
  • Page 92 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 1.2.6.1. Blocking protection Check 35 A fuse Brush motor Measure operating current (approx. 12 A (right and left) for a motor when operated without in- 1);...
  • Page 93 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 1.2.6.3. Electronic circuit-breaker Jammed? Lifting element stopped by Brush lifting element limit stop before being switched off by 1); 2); 3); 4); 5) micro-switch? Check coding of Module 1 Measure operating current (approx.
  • Page 94 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 1.3.6.2. Blocking protection Jammed? Lifting element stopped by Lifting element limit stop before being switched off by Side brush micro-switch? Check coding of 1); 2) Module 3 Code D Measure operating current (approx.
  • Page 95 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 2.2.5.1. Thermal switch Thermal switch of Broom or Side brush Broom (and thermal motor opened or cabling faulty? switch Side brush Jammed? Measure operating current Motor if new version (approx.
  • Page 96 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 2.2.6.1. Blocking protection Jammed? Check 35 A fuse broom Measure operating 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.
  • Page 97 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 2.3.5.1. Thermal switch side Side broom setting okay? broom left / right Jammed? Measure operating current 1); 3); 5) (max. 2.5 A after approx. 10 minutes run) 2.3.6.1.
  • Page 98 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 2.3.6.4. Blocking protection Jammed? Does lifting element moves up lifting element side to dead stop before being switched off broom by micro switch? 3.1.6.1. Fuse Check 10 A / 80 V fuse.
  • Page 99 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 3.1.6.2. Fuse Check all fuses F1(10 A / 80 V) Module 3 Code A and F4-F7, check motors for filter ( for pre-sweeper) suction (F6 = 20A/80V), 1);...
  • Page 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) Foil 100...
  • Page 101 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 3.1.6.6. Fuse Check all fuses (F4 - F7 (5 A / 80 V)) Module 3 Code D and F1 (10 A / 80 V), check water valve (for side brush) Side brush 1);...
  • Page 102 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 3.2.1.1. TSG defective Measure approximate battery voltage on 1); 2); 3); 4); 5) control electronics A1.X2 PIN 1 and 4 even with the machine being switched off; if not okay, check cable connection up to battery plug;...
  • Page 103 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 3.4.5.1. Thermal switch of Is travel drive smooth? Parking brake drive motor setting okay? Longer uphill rides 1); 2); 3); 4); 5) effectuated? Interrupted wire since NC activation? Measure operating current (approx.
  • Page 104 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 4.1.3.1. Module 1 no Check fuse F1 (2 A / 32 V); check response (timeout) CAN bus; check contacts and connectors; check resistance (2 x 120 W) 1);...
  • Page 105 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 4.3.2.3. Module 3 Code C CAN bus connected? Check fuse F3 not recognised (2 A / 32 V); check contacts and (for 3rd brush) connectors; module coding okay? 4);...
  • Page 106 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 4.3.3.1. Module 3 Code A CAN bus connected? Check fuse F3 no response; timeout (2 A / 32 V); check contacts and (for pre-sweeper) connectors; module coding okay? 1);...
  • Page 107 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 4.3.3.4. Module 3 Code D CAN bus connected? Check fuse F3 no response; timeout (2 A / 32 V); check contacts and ( for side brush) connectors;...
  • Page 108 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 4.5.2.2. CAN operator panel Check CAN bus to Cleaning agent/SWA Code B not recognised operator panel; check contacts and connectors; check resistance (120 W); (for Cleaning agent/ SWA) 1);...
  • Page 109 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 4.5.3.2. CAN operator panel Check CAN bus to Cleaning agent/SWA Code B no response; operator panel; check contacts and connectors; check resistance (120 W); timeout (60 W due to parallel connection) (for Cleaning agent / SWA) 1);...
  • Page 110 10. Error Table With Information On Service Display Error code in Malfunction Remark the display 4.6.2.1. CAN bus error Check CAN bus cabling between control (no response - electronics and modules; check contacts and connectors; check resistance (120 W) timeout) (60 W due to parallel connection) 1);...
  • Page 111 10. Error Table With Information On Service Display Error code 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 available (see chapter 3)? All modules connected...
  • Page 112 3) - Hakomatic B 1050 WZB 4) - Hakomatic B 1050 TB 1230 5) - Hakomatic B 1100 TB 1230 Current values for cleaning units always depend on the condition of broom and brushes as well as on the type of floor.

  • Page 113: Notes

    11. Notes Foil 113...
  • Page 114 11. Notes Foil 114...
  • Page 115 11. Notes Foil 115...
  • Page 116 11. Notes Foil 116...

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