The Hako Jonas 1200 D is a powerful diesel-powered sweeper designed for efficient cleaning of large areas. It features a high-dump hopper for easy dirt disposal, a robust cylindrical broom and side brush for effective dirt collection, and a powerful suction system with a large filter surface for clean air exhaust. This machine is ideal for cleaning parking lots, industrial facilities, and other large outdoor spaces.
Service Manual
(6300.10 / 6300.20 / 6300.30)
Training
Troubleshooting
Adjustments
Components/Suppliers
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Service Manual
From may 2014 the machine names are changed. The „old“ name Jonas for sit-on sweepers is changed into Sweepmaster for all sweepers. The differentiation which machine is it exactly is done by the 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.
P means petrol-/gasoline-, D means diesel- and B stays for battery-model. The LP driven machines are still an option and didn´t have an own name. The R means, it´s a sit-on machine and the H stays for high dump.
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Service Manual
JONAS 1200 V / D / E ......................................................................................................... FEHLER! TEXTMARKE NICHT DEFINIERT.
1.0 OPERATION ..................................................................................................................................................................................... 6
1.1 Scheme of Operation ...................................................................................................................................................................................................................... 7
2.0 TECHNICAL DATA ........................................................................................................................................................................... 8
3.0 DESIGN AND 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 Steering.......................................................................................................................................................................................................................................... 22
3.7 V/D-Version Travelling Drive ....................................................................................................................................................................................................... 23
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
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Service Manual
3.8 E-Version Travelling Drive ........................................................................................................................................................................................................... 24
3.8.1 Bearing Plate ........................................................................................................................................................................................................................... 24
3.8.2 Change Brushes ...................................................................................................................................................................................................................... 25
4 DRIVE .............................................................................................................................................................................................. 26
4.1 V-Version Engine .......................................................................................................................................................................................................................... 27
4.1.1 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
6.4.1 Circuit Diagram ........................................................................................................................................................................................................................ 45
6.4.2 Logic ........................................................................................................................................................................................................................................ 46
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Service Manual
6.5 Drive 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
7.2
Gasoline-Version Service Intervals ..................................................................................................................................................................................... 57
Diesel-Version Service Intervals .......................................................................................................................................................................................... 59
7.3 E-Version Service Intervals .................................................................................................................................................................................................. 61
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Service Manual
Hako GmbH
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Service Manual
1.1 Scheme of Operation
Functional details:
The side brush (1) removes dirt from 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.
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Hako GmbH
Service Manual
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Service Manual
Dimensions and weights
Length incl. side broom
Width w/o side broom
Width with 1 side broom
Width with 2 side brooms
Height above driver seat
Turning radius
Empty weight
Adm. total weight
Riding and sweeping performance
Forward driving speed
Wheel speed at max. velocity
Reverse driving speed
Wheel speed at max. velocity
Max. sweeping speed (recommended: 4.0 km/h)
Sweeping width with/w/o side broom
Sweeping width with 2 side brooms
Theor. sweeping performance with 1 / 2 side broom(s)
Climbing ability
Filter system
Filter surface
Plate filter
Hako GmbH km/h rpm km/h rpm km/h mm mm m²/h
% mm mm mm mm mm mm kg kg m² qty.
Jonas 1200V
1,998
1,142
1,142
1,142
1,520
3300
763
1,056
0 – 9
156
0 – 4
58
9.0
850 / 1,150
1,470
10,300 / 13,200
18
4.8
1
Jonas 1200D
1,998
1,142
1,142
1,142
1,520
3300
784
1,074
0 – 9
156
0 – 4
58
9.0
850 / 1,150
1,470
10,300 / 13,200
18
4.8
1
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Jonas 1200E
1,998
1,142
1,142
1,142
1,520
3300
1,105
1,395
0 - 8
139
0 - 4
58
8.0
850 / 1,150
1,470
9,200 / 11,700
16
4.8
1
Edition: 05/2014
Service Manual
Cylindrical broom
Length / diameter
Wear limit
Speed
Distance between sweeping marks
Qty. of bristles
Standard bristling
Sealing strip ground clearance (broom compartm.) left / right / rear front
Side broom
Diameter
Speed
Standard bristling
Dirt hopper
Hopper volume
Wheels
Front wheel drive (solid rubber)
Rear wheels (pneumatic)
Inflation pressure
Optional rear wheel option (solid rubber) (Standard E)
Hako GmbH mm mm rpm mm qty. mm mm mm rpm l bar
Jonas 1200V
800 / 430
350
500
±
20
70 + 10
12 V-shape
PA
1 / 1 / 4
0
600
85
PA
130
4.00-4
4.00-8
6
4.00-8
Jonas 1200D
800 / 430
350
500
±
20
70 + 10
12 V-shape
PA
1 / 1 / 4
0
600
85
PA
130
4.00-4
4.00-8
6
4.00-8
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Jonas 1200E
800 / 430
350
500
±
20
50 + 5
12 V-shape
PES
1 / 1 / 4
0
600
85
PE
130
4.00-4
4.00-8
Edition: 05/2014
Service Manual
Engine
Manufacturer
Type
Work cycles / quantity of cylinders
Capacity
Power (at 2,550 rpm)
Service speed (all consumers on)
Fuel tank capacity
Consumption
Engine oil / filling
Spark plug cm³ kW rpm l l/h
Type / l
Jonas 1200V
Briggs&Stratton
Vanguard V-Twin
4-stroke / 2
480
8.2
2,550 + 50
25
2.5
15W-40 / 1.5
Champion RC 12
YC
Jonas 1200D
Lombardini
LDW 502
4-stroke / 2
505
6.3
2,550 + 50
25
1.25
15W-40 / 1.5
Jonas 1200E
Hydraulic system
Hydraulic fluid (e.g. Mobiloil)
Tank capacity
Electrical system
Starter battery
Generator
Total output
Output of drive motor
Output of hydraulic drive
Noise emission value
Sound pressure level acc. to DIN IEC 60335-2-72
Sound power level acc. to DIN IEC 60335-2-72
Hako GmbH l
V / Ah
A kW kW kW dB(A) dB(A)
DTE 15 M
22
12 / 74
13
78
94
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DTE 15 M
22
12 / 45
13
79
95
DTE 15 M
13
(24 / )
3.10
1.10
2 x 1.00
71
88
Edition: 05/2014
Service Manual
Hako GmbH
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Service Manual
3.1 Operation Elements
Mitnehmer Feder
Carrier spring
Mitnehmer Welle
Carrier shaft
Hydraulikventil
Hydraulic valve
The spring connected to the side broom lever should be slightly under tension. The tension must not exceed the tension of the valveneutral-spring (hydraulic broom valve).
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3.2 Cylindrical Broom and Side Brush
3.2.1 Cylindrical Broom
3.2.1.1 Replace Cylindrical Broom
Dismounting:
• Lower broom
• Remove l-h lateral cover
• Loosen star-shape knob (2) to remove l-h broom arm (1)
•
Open both knobs (3+5) and remove lateral plate (4); pull out the cylindrical broom
Mounting:
Proceed in inverse order
Note:
Twist broom while inserting until it audibly catches in the driving tooth
3
2
1
4
5
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3.2.1.2 Check Sweeping Mark Distance
•
Take machine to level concrete or asphalt ground
(check inflation pressure of machines equipped with pneumatic tyres and correct pressure if required)
• Switch on cylindrical broom and let it run briefly while vehicle is standing
•
Lift up and switch off the cylindrical broom, forward machine a short distance and 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 reduce as the cylinder broom diameter reduces due to bristle wearing.
3.2.1.3 Adjust Sweeping Mark Distance
Adjust the sweeping mark distance by turning the hand wheel located under the engine compartment cover. The “mark pin” indicates wear limit of the cylindrical broom.
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Adjusting parallelism
•
Loosen l-h half-bearing of torsion shaft
• Adjust parallelism with stop screw
Half-bearing
Torsion shaft
Stop screw
3.2.2 Side broom
Provide for side brush inclination such that 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
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Height adjustment
Roll for Bowden cable
Inclination of 5° fixed
Hako GmbH
Return spring
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3.3 Dirt Hopper ABBA System
Cyl. broom shift wheel
Hako GmbH
Cable cord for cyl. broom
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Tracking of the Dirt Hopper
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3.4 Dirt Hopper Lift-Out System
Hako GmbH
The ball head (ABBA system) catches here
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3.5 Filter
3.5.1 Change and Clean Cartridge Filter
• Stop engine and pull key
•
Open seat hood
• Remove filter case cover
•
Loosen and remove wing screws at the corner 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 fan constantly runs as soon as the engine (V/D) / central motor (E) is running.
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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
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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
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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
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3.8.2 Change Brushes
Loose this 4 screws
Hako GmbH
Carbon brushes
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Hako GmbH
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4.1 V-Version Engine
4.1.1 Engine
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Air-cooled, 2-cylinder, 4-stroke petrol engine with 11.93 kW at 3,600 rpm with electrical starter
Manufacturer:
Type:
Briggs & Stratton
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:
Capacity:
Output at nominal speed:
Torque at 2,400 rpm:
1,550 ± 50 rpm
480 ccm
8.2 kW
33.1 Nm
Maintenance and repair of the drive units according to manufacturer’s prescriptions
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Service Manual
4.1.2 LPG Version
Construction scheme
42 3540 1200/1201
Electr. shut-off valve
63 0483 1040 Fitting, straight
M 10x1 (m) x 1/4“NPT
Engine
Oil hose, genuine
B & Str hose
Del. by HAKO
CO – 1 Cobra evapor./press. controller
Outg. press. -1.3mbar
(orange spring)
61 0016 0100
Safety valves and meas. connections for evaporator
65 0001 1016
Hose clamp
62 2223 0600
Low-pressure hose
E 10-01-230
Relay LSS 230
Champion
RC 12 YC
0.3mm spark plug gap
Fitting D8 S, C8 LL = Del. by KARG
Pipe, compl. 96113253, del. by HAKO
Oil hose
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
Oil filter
62 3061 0620 Hose DIN 4815/4
∅
5/16“; 5/16“ SAE flare 90° x
3/8“SAE flare
Air hose – 90498 155
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
54 3865 0000
Overpressure safety control dev.
(tested)
63 0000 0444 bulkhead fitting
Engine
LPG plug 90510975
(del. by HAKO)
85 3158 5315
Cylinder connection fitting (5/16“)
62 5059 0060
Hose
∅
50 x 50 lg.
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Service Manual
1) Check position of gas cylinder for liquid discharge; base plate protrudes the cylinder collar opening.
2) The LPG system is to be checked for leakage by pressure test
3) Check throttle for central position
See Fig. 7
4) For correct CO measurement, the following is required: a) Insert exhaust gas measurement probe for at least 300 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 oil filter
Hako GmbH
Adjust to or check mixture control screw for 12.7mm clearance
62 5059 0060
Hose 50 lg. Set throttle to neutral (central) position
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Air hose (Hako)
90490970
Hose clamp A 40 – 60
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Service Manual
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Service Manual
4.2 D-Version Engine
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Water-cooled, 2-cylinder 4-stroke diesel engine 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:
Bore:
Stroke:
Compression ratio:
Output at nominal speed:
Torque at 2,000 rpm:
505 ccm
72 mm
62
22.8: 1
8.2 KW
28 Nm
Maintenance and repair of the drive units according to manufacturer’s prescriptions
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Hako GmbH
Service Manual
Technical Service (KUD) 23843 Bad Oldesloe
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Service Manual
5.1 General
Hydraulic units are maintenance-free.
Maintenance reduces to oil and filter change in the sense of system cleaning.
Regular inspection and periodic maintenance precludes premature failure.
5.2 Brief Description of V/D Travel Drive
The 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 still, open the bypass valve of the pump.
Pump pressure is assured by two pressure-limiting vales (bidirectional). They are set to 160bar (forward) and 130 bar (reverse).
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5.2.1 Hydraulic Diagram V/D-Version Driving
Forward
Drive pump 10ccm/U
Drive motor
160ccm/U
Reverse
As soon as the engine runs, the feed pump delivers hydraulic fluid into the driving circuit. The fluid is available in the complete circuit and comes in at the pressure-limiting valves (forward and reverse) as well as at the feed 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 this pressure attains the
160bar (forward) or the 130bar (reverse), the pressure-limiting valve opens accordingly and protects driving.
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5.2.2 Drive Pump
Pressure-limiting valve, forward
160bar
By-pass valve
2 turns for opening zum Öffnen
Plug for feed pressure, measuring point
Port, reverse
Pressure-limiting valve, reverse
130bar
Hako GmbH
Feed pump, inlet
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5.3 Brief Description of Work Hydraulic
Work hydraulic is responsible for supply of the side brushes and the lifting cylinder of the hopper lift-out system.
Side broom speed shift optional
Side broom 1
2 nd side broom, optional
A gear pump (driven by V-belt) delivers hydraulic fluid from the tank to the combined control valve. As long as no specific function is set, the fluid flows back into the tank. For operation of side brush, the “upper” partial valve is shifted 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 fluid flows from the pump through the “upper” to the “lower” and then to the piston side of the lifting cylinder. The hopper is then lifted-out. For lowering, actuation of the hopper lever to the other side (valve switched downwards) is sufficient.
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Hako GmbH
Service Manual
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Service Manual
6.1 Safety Information
• 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
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6.2 View on V/D-Version Fuse Box
Lighting,
OPTIONAL
Optional LPG equipment displaced
Hako GmbH
Jonas 1200 D variant
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Service Manual
F11
F12
F13
F14
K1
K2
K3
K4
K5
K6
K7
K8
A1
Pos
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
Description
Pre-fuse for key switch
Fuse for K1 control voltage
Fuse for K1/K5 control voltage
Fuse for horn / pilot lamps
Fuse for lighting, permanent plus
Fuse for lighting, switched plus
Fuse for parking / rear light, left-hand
Fuse for parking / rear light, right-hand
Fuse for jolter motor
Fuse for direction indicator, left-hand
Fuse for direction indicator, right-hand
Fuse LPG (V) / pre-glowing control voltage (D)
Fuse LPG (V) / post-heating control voltage (D)
Main fuse for pre-glowing (D)
Seat contact controller
Engine release relay
Starter relay
Time relay for pick-up delay / filter monitoring
Pulse relay for jolting
Relay for lighting
Flashing relay
Pre-glowing relay (D)
LPG switch unit (V)
Hako GmbH
V-version
15A
5A
10A
10A
15A
10A
5A
5A
35A
5A
5A
10A
10A not assigned
Optional
Optional not assigned
Optional
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D-version
15A
5A
10A
10A
15A
10A
5A
5A
35A
5A
5A
10A
10A
30A
Optional
Optional not assigned
Service Manual
6.3 View on E-Version Fuse Box rear front
Lighting
OPTIONAL
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Service Manual
K4
K7
K8
K9
K10
X19
F12
F13
F14
F15
F16
F18
F19
H4
K1
K2
K3
Pos
A1
F1
F2
F3
F4
F5
F6
F7
F8
F10
F11
Hako GmbH
Description
Drive controller
Main fuse for drive controller
Fuse for start lock
Fuse for drive controller, switched plus
Fuse for LDS
Fuse for horn
Fuse for side brush motor, left-hand (optional)
Fuse for jolter activation
Fuse for vacuumer (optional)
Fuse for lighting, permanent plus
Fuse for lighting, switched plus
Fuse for parking / rear light, left-hand
Fuse for parking / rear light, right-hand
Fuse for flasher relay
Fuse for brake lights
Fuse for jolter pulse relay
Fuse for broom cylinder motor
Fuse for main motor
Warning horn
Main contactor for drive controller
Release of main motor
Relay of broom cylinder./ motor
Relay for main motor
Time relay for pick-up delay / filter monitoring
Pulse relay for jolting
Relay for working floodlight
Flasher relay
Plug configuration LDS
V-machine
160A
15A
10A
5A
7,5A
2A
5A
30A
10A
10A
5A
5A
10A
7,5A
35A
63A
63A
63A
Optional
Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
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
Hako GmbH
Wiring of Seat contact controller for Jonas 1200 V/D
Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
6.4.2 Logic
Starting/Driving Safety Function
After ignition ON, 12V apply to PIN1 while simultaneously ground applies to PIN4 (seat contact closed) and the PIN8 output is connected. Voltage then applies to relay K2 (motor release). If, at the same time, 12V apply to PIN7 (accelerator pedal in neutral position), the PIN5 output will be connected. This allows supplying the relay K3 (starter) with current. If the seat contact is interrupted for 3 seconds or more (voltage at PIN4 to 12V), PIN8 output releases. This interrupts voltage supply to the release relay Riding (K2). If no voltage applies to the PIN4 input for 2 seconds or 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, followed by the PIN8 output. Should feedback to PIN9 be incorrect (internal error, external error: short-circuit behind plus), both outputs switch off.
Input Monitoring Safety Function
The PIN7 (neutral switch) and PIN4 (seat contact switch) inputs are permanently monitored. Should they be connected for 6 hours or longer (PIN4 ground; PIN7 12V) with simultaneous connection of PIN8 output, the next start trial will be inhibited. Actuation of the seat contact switch is required before resetting is available (even if neutral switch was the cause).
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
6.5 Drive Controller
The drive controller used in the E variant is a ZAPI controller of the type SEM1
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
Some monitoring functions are realized via the controller.
Four sections are supervised:
1) Upon switching ON (key switch ON)
-
Self-test of controller
-
Current sensor
-
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 the drive controller monitors some safety functions of the machine electric.
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
6.5.1 Error Messages
Errors are displayed via LED.
5
5
5
6
6
6
7
1
2
2
3
3
3
4
4
5
Flashing code Error message
1
1
LOGIC FAILURE #1
WATCH DOG
EEPROM KO
INCORRECT START
FORW + BACK
CAPACITOR CHARGE
VMN NOT OK
VFIELD NOT OK
VACC NOT OK
PEDAL WIRE KO
NO FIELD CURR
HIGH FIELD CUR
STBY I HIGH
I=0 EVER
CONTACTOR DRIVER
COIL SHORTED
CONTACTOR CLOSED
TH PROTECTION
Hako GmbH
Description
Error in the current monitoring at the main contactor
Error in the logic and/or program
Error in the area of the EEPROM
Error in the start sequence
Both travel drive directions apply simultaneously
Error in the power unit
Error during test of the drive motor power controller (armature circuit))
Error of the field voltage
Error of the accelerator pedal signal (potentiometer)
Error in the driving switch wiring
Error in the connection to field winding or in the current detection
Error in the connection to field winding or in the current detection
Error in the armature current detection
Error in the armature current detection
Error in the contactor activation
Contactor coil short-circuited
Error at main contactor contact
Controller temperature exceeding limits (<70°C or > -10°C)
Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
6.5.2 Machine Safety Functions
Main broom function
The PIN4 at plug A is only grounded if the following input signals are sended:
The key lock have to be switched “ON”; Signal on PIN2 at plug A have to be “HIGH”
The seat contact switch have to be activated; or max. 3 sec. Deactivated. Signal on PIN5 at plug A have to be “HIGH”
The LDS have to send a signal that the battery is not “LOW”. Signal on PIN8 at plug A have to be “LOW”
Monitoring of start sequence
Driving will only be activated if firstly the key lock is “ON” and the seat switch is activated. PIN2 and PIN5 at plug A have to be “HIGH”.
Then a travel direction can be applied, by a “HIGH” signal at either PIN4 or PIN6 at plug B. Only if this sequence 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 the warning, the key lock have to be switched “OFF” and then “ON” again
Monitoring of seat switch
If the input at PIN 5 at plug A is “HIGH” for longer then 6 h 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
The driving speed is reduced to half speed. Internal signal in the drive controller.
To reset this, the key lock have to be switched “OFF” and “ON” again and then the seat switch have to be switched “ON” and “OFF”
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
6.6 Electric Drive Motor
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
6.7 Low Discharge Signal Sender (LDS)
Function of the low discharge signal sender is to safely protect the battery from low discharge while making full use of existing capacities.
Before taking the battery-powered machine into operation, set the low discharge 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, connect the plug X19 at the fuse box to the contact underneath it. Now, programming of the LDS is possible.
Note:
After setting, make sure to disconnect the plugged contact again!
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
6.7.2 LDS Programming
In order to invoke the programming level, press the left button “
▲
“ and hold depressed until display flashes. Then release button.
Set battery type:
04
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 been attained, press the left button”
▲ once.
“
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
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-starts automatically with 1.50 V/Z.
After the desired discharged value of the profile has been attained, press the left button”
▲
“ once.
Terminate configuration mode by pressing the left button. Display then shows charge state.
After setting make sure to separate connection of plug contact in the dashboard.
Setting parameter:
7401 4 x 6 V / 240 Ah GiV mainten.-free
7408 24V / 420Ah EPzS low-mainten.
2,04
2,04
1,76
1,73
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Hako GmbH
Service Manual
Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
7.1 Gasoline-Version Service Intervals
Service intervals
Change engine oil (type: SAE 15 W-40)
Change engine oil filter
Clean gasoline filter
Change gasoline filter
Check engine speed
Check sealings at filter system
Visual check of V-belts
Change hydraulic filter
Check hydraulic oil level
Check optical condition of machine
Change air filter; main element
Change air filter; saftey element
Check spark plug, replace if required
Check neutral centering of drive pump
Check service and parking brake, adjust if required
Check inflation pressure
Check sweeping track mark and adjust if required
Check broom apron and adjust or change if required
Check V-belt for wearing and correct tension and adjust if required
Basic cleaning of the plate filter
Test drive and function test
Check battery
Check tension of steering chain and adjust if required
Check thread of wheels
Change plate filter
Hako GmbH
X
X
X
X
X
X
X
X
X
X every
125 h
X
X
X
X
X
X once after 50h
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X every
500 h
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X every
250 h
X
X
X
X
X
X
X
X
X
X
Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
Check lifting-up disposal function (2-hand-operation)
Check hydraulic hoses and replace if required
Check cables and plugged connections for damage and tight fit
Change hydraulic oil
Change ring filter (dust filter)
Engine; adjust valves
Engine, change valve cover seal
Safety checks
Check fixing screws (brake, steering, lifting-up disposal) and tighten if required
Check brake system
Check steering function
Check LPG system for leaking and CO setting
Test drive and function test of safety relevant items
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
7.2 Diesel-Version Service Intervals
Service intervals
Change engine oil (type: SAE 15 W-40)
Change engine oil filter
Clean fuel filter
Check engine speed
Check sealings at filter system
Visual check of V-belts
Change hydraulic filter
Check hydraulic oil level
Check optical condition of machine
Change air filter; main element
Change air filter; saftey element
Check spark plug, replace if required
Check neutral centering of drive pump
Check service and parking brake, adjust if required
Check inflation pressure
Check sweeping track mark and adjust if required
Check broom apron and adjust or change if required
Check V-belt for wearing and correct tension and adjust if required
Basic cleaning of the plate filter
Test drive and function test
Check battery
Check tension of steering chain and adjust if required
Check thread of wheels
Change plate filter
Check lifting-up disposal function (2-hand-operation)
Hako GmbH
X
X
X
X
X
X
X
X
X
X every
125 h
X
X
X once after 50h
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X every
500 h
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X every
250 h
X
X
X
X
X
X
X
X
X
X
Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
Check hydraulic hoses and replace if required
Check cables and plugged connections for damage and tight fit
Change hydraulic oil
Change fuel filter
Change ring filter (dust filter)
Engine; adjust valves
Engine, change valve cover seal
Safety checks
Check fixing screws (brake, steering, lifting-up disposal) and tighten if required
Check brake system
Check steering function
Test drive and function test of safety relevant items
X
X
X
X
X
X
X
X
X
X
X
X
X
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
Service Manual
7.3 E-Version Service Intervals
Service intervals
Check sealings at filter system
Check wheel speed
Check broom speed
Visual check of V-belts
Change hydraulic filter
Check hydraulic oil level
Check optical condition of machine
Check service and parking brake, adjust if required
Check sweeping track mark and adjust if required
Check broom apron and adjust or change if required
Check V-belt for wearing and correct tension and adjust if required
Basic cleaning of the plate filter
Test drive and function test
Check battery
Check tension of steering chain and adjust if required
Check thread of wheels
Change plate filter
Check lifting-up disposal function (2-hand-operation)
Check hydraulic hoses and replace if required
Check cables and plugged connections for damage and tight fit
Change hydraulic oil
Change ring filter (dust filter)
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
X every
125 h
X
X
X
X
X
X
X
X
X once after 50h
X
X
X
X
X
X
X
X
X
X
X
X
X
Edition: 05/2014
X
X
X
X
X
X
X
X
X every
500 h
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X every
250 h
X
X
X
X
X
X
X
X
X
X
Service Manual
Safety checks
Check fixing screws (brake, steering, lifting-up disposal) and tighten if required
Check brake system
Check steering function
Test drive and function test of safety relevant items
Check, and eventually change, the carbon brushes from the drive motor, broom motor and central motor each 1000h.
X
X
X
X
Hako GmbH Technical Service (KUD) 23843 Bad Oldesloe
Confidential - For internal use only!
Edition: 05/2014
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Diesel engine
High-dump hopper
Cylindrical broom
Side brush
Suction system
Large filter surface
Continuous speed control
130 l dirt hopper volume
4.8 m² filter surface
The sweeping width of the Jonas 1200 D with one side broom is 850 mm, and 1150 mm with two side brooms.
It has a 505 ccm Lombardini LDW 502 engine.
The recommended maximum sweeping speed is 4.0 km/h.
How to wire the D1200RH?
Specific wiring diagrams for the D1200RH model are unavailable. However, relevant electrical system information includes fuse box views for V/D versions, a seat contact controller circuit diagram and logic description for the Jonas 1200 V/D, and drive controller information (fault codes, safety functions) for the E variant. Consult specific electrical diagrams or a qualified technician for detailed wiring instructions.
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