HAKO Sweepmaster B800 R User manual

Instruction Manual
Sweepmaster B800 R (6400.20)

2
Preface
Dear Customer,
We are certain that the excellent quali-
ties of the vehicle will justify the faith
you have shown in us through your pur-
chase.
Please read the Chapter "Safety Infor-
mation" prior to starting the vehicle to
ensure it is operated and used safely.
Your safety, and that of others, basical-
ly lies in your ability to control and oper-
ate the vehicle. Before using the
equipment for the first time, read this
original manual thoroughly, act accord-
ing to the information contained and
keep it in a safe place for future refer-
ence or subsequent owners. The oper-
ating manual contains all the most
important information regarding opera-
tion, maintenance and service.
Throughout this operating manual, sec-
tions which concern safety are indicat-
ed by corresponding warning symbols.
Should you have any questions in re-
spect of the vehicle or operating manu-
al, your authorized Hako dealer is
available to provide help at any time.
We would like to point out, explicitly,
that you cannot base any legal claims
on the information contained in this
manual. Please note that only original
spare parts should be used for any nec-
essary maintenance and repair work.
Only original spare parts can guarantee
long, reliable operation of your ma-
chine. Subject to modification as re-
quired by technical advancement.
Valid as of: April 2014
Hako GmbH
D-23843 Bad Oldesloe
Hamburger Straße 209-239
Telephone [phone]
Intended use
The Sweepmaster is a sweeper de-
signed for industrial/ commercial use
and serves to clean up dry and wet re-
fuse from indoor and outdoor areas
such as production plants, warehouses,
car parks, parking blocks, pedestrian
precincts, market squares, railway sta-
tions and filling stations. The Sweep-
master can clean all types of industrial
floors, concrete, asphalt and tar, paving
and interlocking stone paving. It is not
permitted to drive the machine on public
roads for motor traffic.
Any use beyond this is regarded as im-
proper use. The manufacturer is not
considered liable for any damage re-
sulting from improper use; the user is
solely responsible for all the risks.
Intended use also includes maintaining
and observing the operating, mainte-
nance and repair conditions prescribed
by the manufacturer.
The Sweepmaster may only be operat-
ed, serviced and repaired by personnel
who are familiar with the work involved
and are aware of the risks. It is essential
to observe the applicable accident pre-
vention regulations as well as any other
generally accepted industrial health and
Introduction

3
safety directives.
Based on the conception, design and
construction of the model introduced
onto the market by us, the machine
complies with the applicable basic safe-
ty and health requirements stipulated in
the EC Directive (refer to Declaration of
Conformity). This declaration is no lon-
ger considered valid in the event of
modifications to the machine not autho-
rized by us. The manufacturer is not
deemed liable for any damage resulting
from unauthorized modifications to the
machine.
Notes on warranty
The terms defined in the purchase
agreement apply. Claims for compen-
sation related to damage are excluded
from the terms of warranty when the
damage is the result of failure to ob-
serve regulations concerning service
and maintenance. Maintenance work
must be performed by authorized Hako
service centers and confirmed in the
“Maintenance Report” which serves as
a warranty logbook.
The following are excluded from the
terms of warranty: wear and tear
through overuse, defective fuses, im-
proper handling and use or unauthor-
ized modifications. Claims under the
terms of warranty are also annulled
when damage occurs to the vehicle re-
sulting from the use of parts or accesso-
ries not explicitly approved by us or
from failure to observe maintenance
regulations.
Acceptance of the machine
Inspect the vehicle immediately on de-
livery for signs of transport damage.
Replacement will be made when the
damage is confirmed by the carrier im-
mediately and the damage report is
sent to us together with the consign-
ment note.
Introduction

4
Disposal of the machine
Render the machine inoperable. It must
not represent a potential source of dan-
ger for children.
Dispose of the machine according to
the applicable local regulations. For fur-
ther information on handling and recy-
cling, please contact your authorized
Hako dealer where you purchased the
machine.
Used batteries with the recycling sym-
bol contain reusable commodities.
However, the heavy metals contained
also represent a major risk to human
health and to the environment. Never
open or damage batteries. Never touch,
inhale or swallow the content matter of
batteries. Health hazard! Do not allow
batteries to pollute the environment.
There is a risk of contaminating the
ground and water! In accordance with
the symbol with the crossed out bin,
these batteries must not be disposed of
in domestic waste. The return and recy-
cling of old batteries must be agreed on
with the authorized Hako dealer in ac-
cordance with the Battery Act § 6 and
§8.
Introduction

5
Preface. . . . . . . . . . . . . . . . . . 2
Intended use. . . . . . . . . . . . . . 2
Notes on warranty . . . . . . . . . 3
Acceptance of the machine . . 3
Disposal of the machine. . . . . 4
1 Safety Information . . . . . . . . 6
1.1 Safety and warning symbols . 6
1.2 General information . . . . . . . . 7
1.3 Operating information. . . . . . . 8
1.4 Maintenance information . . . 10
1.5 Particular risks . . . . . . . . . . . 11
1.6 Environmental protection . . . 12
1.7 Labels on the vehicle . . . . . . 13
2 Operation . . . . . . . . . . . . . . 17
2.1 Overview . . . . . . . . . . . . . . . 17
2.2 Function description . . . . . . . 18
2.2.1 Special equipment . . . . . . . . 19
2.2.2 Spare part requirements. . . . 19
2.3 Operating panel . . . . . . . . . . 20
2.4 Operating elements on the ve-
hicle . . . . . . . . . . . . . . . . . . . 23
3 Operation . . . . . . . . . . . . . . 28
3.1 Unpacking . . . . . . . . . . . . . . 28
3.2 Before starting up for the first
time . . . . . . . . . . . . . . . . . . . 29
3.2.1 Initial instruction . . . . . . . . . . 29
3.2.2 Initial battery charge. . . . . . . 29
3.3 Adjusting the driver's seat . . 30
3.4 Switching the vehicle on. . . . 31
3.5 Stopping and switching off the
vehicle . . . . . . . . . . . . . . . . . 32
3.6 Sweeping operation . . . . . . . 33
3.7 Charging batteries . . . . . . . . 35
3.8 Operating the shaking device 37
3.9 Emptying the dirt hoppers . . 38
3.10 Fault location . . . . . . . . . . . . 39
3.11 Loading and transporting . . . 40
4 Technical Data . . . . . . . . . . 41
5 Maintenance and Service . 43
5.1 Hako system maintenance. . 43
5.2 Maintenance report . . . . . . . 44
5.3 Maintenance plan. . . . . . . . . 45
5.4 Battery system . . . . . . . . . . . 49
5.4.1 Removing the batteries . . . . 50
5.4.2 Inserting the batteries. . . . . . 50
5.4.3 Battery care . . . . . . . . . . . . . 50
5.4.4 Setting the battery type . . . . 51
5.5 Side brooms . . . . . . . . . . . . . 52
5.5.1 Changing the side brooms . . 53
5.5.2 Setting the sweeping pattern 53
5.6 Cylindrical broom . . . . . . . . . 54
5.6.1 Cleaning the broom space . . 55
5.6.2 Setting the sweeping pattern 55
5.6.3 Changing the cylindrical broom
56
5.6.4 Changing the sealing strips in
the broom space . . . . . . . . . 57
5.6.5 Changing the seals on the dirt
hoppers . . . . . . . . . . . . . . . . 58
5.7 Vacuuming dust . . . . . . . . . . 59
5.7.1 Shaking the panel air filter . . 60
5.7.2 Checking the panel air filter and
seal. . . . . . . . . . . . . . . . . . . . 60
5.7.3 Cleaning the panel air filter . 60
5.8 Drive belt . . . . . . . . . . . . . . . 61
5.8.1 Changing the drive belt . . . . 61
5.9 Electrical installation. . . . . . . 62
5.9.1 Fuses . . . . . . . . . . . . . . . . . . 62
5.9.2 Relays . . . . . . . . . . . . . . . . . 62
EC Declaration of Conformity
63
Table of Contents

6
Safety Information
1 Safety Information
1.1 Safety and warning symbols
All sections related to personal safety,
safety of the vehicle and environmental
protection are assigned the following
symbols throughout the operating man-
ual:
Symbol Risks to Definition
Safety information persons
or property
Safety information on preventing hazardous situations
caused by failure to follow instructions or prescribed
working procedures accurately or at all.
Note the machine Important information on handling the machine in
order to maintain its functionality.
Ecological hazard the environment Ecological hazard through the use of substances
which represent a potential risk to health and the
environment.

7
Safety Information
1.2 General information
• In addition to the information provid-
ed in this operating manual, all the
legally applicable health and safety
provisions must be observed.
• Before starting up the vehicle for the
first time, read the operating manual
supplied with it thoroughly as well as
any separate manuals provided with
additional or attachment equipment
and observe all the information dur-
ing work.
• The machine may only be operated,
serviced and repaired by personnel
trained by Hako technical experts.
• Particular attention should be paid to
the information regarding safety.
Technical expertise is the key to pre-
venting errors when operating the
equipment and ensuring trouble-free
operation.
• The operating manual must always
be kept at the operating location of
the vehicle and, as a result, should
be kept in a safe place on the vehi-
cle.
• If the equipment is sold or rented out,
these documents should be trans-
ferred to the new owner/ operator.
The transfer should be confirmed!
• The warning labels attached to the
equipment provide important infor-
mation concerning safe operation.
Labels which are illegible or missing
must be replaced.
• Original spare parts must be used to
ensure safety.
• It is forbidden to move into the haz-
ard area represented by the vehicle.
• A mobile phone may only be used
when the vehicle has been stopped.

8
Safety Information
1.3 Operating information
• The vehicle is not suitable for clear-
ing up fluids, dust or substances
which are hazardous to health, in-
flammable or explosive. No burning
items may be swept up, such as
glowing cigarettes. It is also forbid-
den to sweep up wood dusts, e.g.
beech and oak dust - health hazard!
• The vehicle must not be driven
through puddles of water when oper-
ating in vacuum-sweeping mode.
• Before starting up the vehicle for the
first time, the battery to be used must
be fully charged according to the
prescribed initial battery charge pro-
cess. Hako assumes no liability for
damage to batteries resulting from
failing to complete the initial battery
charge process.
• The vehicle and its equipment must
be checked in terms of perfect work-
ing condition and operational safety
before being put to use. Clear any
faults immediately! The vehicle must
not be used if it is not in a proper
working condition.
• Before putting the vehicle into opera-
tion, adjust the driver's seat so that
you have a perfect view of the front
and rear path of travel and working
area!
• For safety reasons, the driver's seat
is equipped with a seat contact
switch. The vehicle can only be start-
ed when the operator is sitting on the
driver's seat. The function of the seat
contact switch must not be by-
passed.
• The seat contact switch is monitored
electronically. Any attempt at manip-
ulation can lead to the vehicle being
automatically locked against use.
• Always switch off all the drives be-
fore switching the vehicle on.
• The vehicle must only be started, put
into motion and stopped from the
seat.
• Ensure there is sufficient ventilation
when sweeping in closed spaces
(dust).
• The driving speed must always be
adapted to the ambient conditions
and load status.
Three-wheel vehicles are less stable
than four-wheel vehicles, therefore:
avoid sudden steering movements
when driving at higher speeds, tak-
ing corners at too high a speed could
cause the vehicle to tip. Only use the
vehicles on level surfaces, never on
gradients. Drive up and down in-
clines in straight lines. When driving
up, down or across slopes, avoid
turning corners suddenly or in jerks.
There is a risk of tipping when in an
inclined position!
• Do not drive the vehicle on slopes
with a gradient steeper than the limit
gradient indicated on the vehicle.
• The approved gross total weight and
permissible axle loads must never
be exceeded. Check the fill level of
the dirt hopper at frequent intervals.
• Only put the vehicle into operation
when the seat console is closed and
locked and the shaking device lever
has been pushed in.
• Before starting work, the operator
must be fully familiar with all adjust-
ment, operating and control ele-
ments as well as their respective
function. It is too late to do this when
the vehicle is actually in operation!
• Always wear heavy duty, non-slip
footwear when working with the vehi-
cle.
• The vehicle may only be driven on
and the equipment used on those
surfaces which have been approved

9
Safety Information
by the contractor or person appoint-
ed by him.
• Adapt your manner of driving ac-
cording to the local characteristics.
• It is forbidden to use the vehicle in
potentially explosive atmospheres.
• When using the vehicle, it is essen-
tial to pay attention to third parties,
especially children.
• It is forbidden to transport people on
the vehicle.
• Drive away immediately after switch-
ing on the cylindrical broom, other-
wise the broom may leave
impressions on the contact surface.
• Never leave the vehicle unattended
while it is in operation.
• Remove the key from the key switch
to prevent unauthorized use of the
vehicle.
• Never leave the batteries in a dis-
charged state but recharge them as
soon as possible.
• The filter may only be shaken when
the dirt hopper has been closed.
• Never exceed the max. load capacity
of the hoppers! This could increase
the stopping distance. Caution, par-
ticularly when sweeping up iron fil-
ings for example!
• Only empty the contents of the dirt
hopper from a low height in order to
avoid causing dust. Where appropri-
ate, pay attention to the wind direc-
tion and evade clouds of dust. Health
hazard!
• When transporting the vehicle, the
vehicle must be switched off and the
side broom raised.
• The Sweepmaster is designed for
use on level ground with a maximum
gradient of 12%.
• Steps or curbs with a maximum
height of 4 cm can be driven over.
• It is forbidden to manipulate switches
and safety equipment.

10
Safety Information
1.4 Maintenance information
• The maintenance work and mainte-
nance intervals prescribed in the op-
erating manual must be adhered to.
• Operating personnel must complete
the necessary daily and weekly
maintenance work. All other mainte-
nance work must be completed at
your nearest Hako service center.
• Pay attention to any rotating parts
before starting cleaning and mainte-
nance work. They represent a risk of
crushing!
• The vehicle must be inspected by a
recognized technical expert in re-
spect of operational safety, within
the terms of the applicable accident
prevention laws, at reasonable inter-
vals (we recommend at least once a
year) and following modification or
repairs.
• Spare parts must comply with the
minimum technical requirements
stipulated by the manufacturer! This
is ensured by the use of original
spare parts.
• When completing any maintenance
and repair work, switch the machine
off via the key switch to prevent the
drive being started up inadvertently.
• Suitable tools must be used for
cleaning and maintenance work.
• If the seat console must be raised to
complete work, it must be held in
place by the safety support to pre-
vent it accidentally falling or slam-
ming shut.
• It is not permitted to clean the vehicle
with a pressure washer or steam
blaster.
• The dirt hoppers must be cleaned
regularly to prevent the accumula-
tion of bacteria.
• It is not permitted to use aggressive,
corrosive cleaning agents.
• Let the machine dry thoroughly after
cleaning, e.g. over the weekend.
• When transporting the vehicle, the
vehicle must be switched off.
• If the Sweepmaster is jacked up with
a jack, it must be properly supported.
• No persons may be on the Sweep-
master when it is jacked or raised.
• When changing wheels, the vehicle
must be additionally secured from
rolling away by placing wheel chocks
against the wheels.
Always change wheels on level, sol-
id ground, where possible.
• Do not remove or replace tires or re-
pair one on a rim. Always go to a
proper workshop for work on tires
and rims because they have special-
ly trained personnel and special
safety tools.
• Do not carry out any welding, drilling,
sawing or grinding work on frame
parts. Damaged parts may only be
replaced by specialist workshops ap-
proved by Hako.

11
Safety Information
1.5 Particular risks
Electronics
• In the case of defects in the electrical
installation, always switch the vehi-
cle off and clear the fault.
• Work on the electrical installation
may only be carried out by electri-
cians who have received the neces-
sary training and in accordance with
the electrical engineering regula-
tions.
• The vehicle's electrical equipment
must be inspected/checked at regu-
lar intervals. Defects, such as loose
connection, loose nuts of conductive
bolts, electrical components and
damaged cables, must be rectified
immediately.
• Observe the information in the oper-
ating manual provided by the battery
manufacturer.
• Always disconnect the battery cable
when working on the electrical instal-
lation.
• Only use original fuses with the pre-
scribed amperage. Using fuses
which are too powerful could dam-
age the electrical installation and
lead to fires.
• Pay attention that the insulation on
the charger cable shows no signs of
damage and is not damaged during
the charging process. The cable
must not rub against anything. If the
insulation is defective, do not use the
on-board charger.
• To prevent current leaks, always
keep batteries clean and dry and
protect them from soiling by metallic
dust, for example.
• Never lay any metallic objects or
tools on batteries. Risk of short cir-
cuit and deflagration!
• Ensure sufficient ventilation in the
charging area when charging the
batteries. Otherwise there is a risk of
explosion!
• Batteries must not be connected or
disconnected when switched on.
• After finishing work on the batteries,
wash your hands thoroughly.
Health risks
• The shaking device to clean the pan-
el air filter may only be activated
when the dirt hoppers are in the ma-
chine.
• It is forbidden to eat, drink and
smoke in battery charging rooms.
Safety equipment
• Never operate the Sweepmaster
without the seat console being
closed (safety equipment)!

12
Safety Information
1.6 Environmental protection
• A certain factual expertise is re-
quired in order to use substances
which could represent a risk to
health and the environment.
• Always observe legal regulations
and local directives when disposing
of cleaning agents, refer to the Water
Resources Act.
• Used batteries bearing the recycling
symbol must not be disposed of in
household waste, refer to the Sec-
tion "Disposal".

13
Safety Information
1.7 Labels on the vehicle
The following safety and warning labels
are attached to the vehicle where easily
legible. Missing or illegible labels must
be replaced immediately.
Company logo (front chassis / rear cov-
er panel) (Fig. 1/1 and (Fig. 2/7)
Rating plate (under the foot mat)
(Fig. 1/2)
Shaking device label (Fig. 1/3)
Read and observe the operating manu-
al (Fig. 1/4)
Bypass label (Fig. 1/5)
Rotating parts label (Fig. 1/6)
High-pressure washer label (Fig. 1/7)
Noise emission and gradient label
(Fig. 1/8)

14
Safety Information
Fig.1
5
12
6
7
3
48

15
Safety Information
Side broom label (Fig. 2/1)
Brake label (Fig. 2/2)
Folding apron label (Fig. 2/3)
Parking brake label (Fig. 2/4)
Maintenance-free batteries label
(Fig. 2/5)
Cylindrical broom label (Fig. 2/6)

16
Safety Information
Fig.2
2
7
1
3
4
5
6

17
Operation
2 Operation
2.1 Overview
1 Operating panel
2 Steering column
3 Pedals
4 Side broom
5Drive
6 Larger debris flap
7 Sealing strips, broom space
8 Cylindrical broom
9 Dirt hoppers
10 Panel air filter
11 Seat console
12 Driver's seat
13 Flashing light (option)
Fig.3
1
2
3
4567 8
9
10
11
12
13

18
Operation
2.2 Function description
The Sweepmaster is a sweeper exclu-
sively designed for sweeping up dry
and wet waste from floor surfaces as in
production plants, warehouses, car
parks and pedestrian precincts.
Side broom, right
The side broom (Fig. 3/4) sweeps the
dirt from corners and edges in front of
the cylindrical broom. The side broom
can be lowered and raised using a hand
lever. The sweeping pattern can be ad-
justed. It is driven by the central motor
via a drive belt.
Cylindrical broom
The cylindrical broom (Fig. 3/8) sweeps
the dirt according to the overhead
throwing principle into the dirt hoppers
(Fig. 3/9). In the case of larger debris,
the folding apron (Fig. 3/6) can be
opened. The sweeping pattern of the
cylindrical broom and the sealing strips
(Fig. 3/7) in the broom space can be ad-
justed. It is driven by the central motor
via a drive belt.
Filter system
The fine dust swirled up by the cylindri-
cal broom is forced into the panel air fil-
ter (Fig. 3/10) by a suction turbine and
is filtered out. The particulate matter
settles on the outside of the filter ribs
and drops into the two dirt hoppers
(Fig. 3/9). The panel air filter can be
cleaned by means of the shaking de-
vice. The suction turbine is driven by
the central motor.
Dirt hopper
The refuse is ejected into the two dirt
hoppers (Fig. 3/9) via the cylindrical
broom and the panel air filter. The fill
quantity is approx. 25 kg per dirt hop-
per.
Drive
The Sweepmaster is equipped with a
continuously variable adjustment elec-
tric drive (Fig. 3/5).

19
Operation
Seat console
The seat console (Fig. 3/11) can be piv-
oted up for maintenance work. The seat
console is provided with a safety sup-
port.
Driver's seat
The driver's seat (Fig. 3/12) is adjust-
able and equipped with a seat contact
switch.
Operating panel
The most important operating elements
are arranged within reach of the opera-
tor. The operating panel (Fig. 3/1) is lo-
cated on the steering column (Fig. 3/2).
The pedals (Fig. 3/3) are assigned the
functions service brake, parking brake
and accelerator.
Battery system
The Sweepmaster is equipped with
maintenance-free batteries and an inte-
grated charger. The batteries are moni-
tored by a total discharge signal
transducer.
2.2.1 Special equipment
The basic vehicle can be upgraded by
adding various special equipment. The
order numbers for these components
are listed in the table.
Flashing light
It is possible to install an optional flash-
ing light on the seat console. The holder
for the flashing light is inserted in the
seat console and fixed in place with a
screw. The plug for the electrical con-
nection is in the cable duct of the seat
contact switch.
Side broom, left
The side broom left option can only be
supplied ex works and cannot be retro-
fitted.
2.2.2 Spare part requirements
Special equipment Order no.:
Flashing light 640060
Side broom, left 640050
Spare part Order no.:
Universal cylindrical
broom
01136350
Side broom PES
(indoors)
01270920
Side broom PA
(outdoors)
01270970

20
Operation
2.3 Operating panel
1 Key switch
2 Charge control indicator
3 Charge status indicator
4 Operating hour counter
5 Sweeping functions switch
6 Drive direction switch
7 Steering
8Horn
9 Side broom lever
Fig.4
5
B
3
6
7
8
9
4
C
2
A
1