HAKO Fleet-Recorder User manual

Assembly Manual
Fleet-Recorder (5305.00)

2
Foreword
The installation procedures described
in this assembly manual should only be
undertaken by a Hako service centre or
a workshop authorised by Hako.
Members of staff with the required level
of training and expertise are only
guaranteed in the said workshops.
This assembly manual may be used
only in conjunction with the machine's
operating manual.
Safety instructions
With regard to handling and operation,
please observe the general safety regu-
lations of the corresponding machine in
the relevant operating manual.
Place the machine on a level surface
and hold it with the parking brake.
Disconnect the battery plug.
We would expressly advise you that no
legal claims may be asserted based on
the contents of these instructions. In the
case of necessary repair work, please
make sure that only original spare parts
are used. Only original spare parts
guarantee constant and reliable opera-
tional readiness of your machine. We
reserve the right to make changes in
the interests of further technical
development.
Valid as from: January 2016
Hako GmbH
23843 Bad Oldesloe, Germany
Hamburger Str. 209-239
Phone [phone]
This assembly manual applies to all
variants of the
Scrubmaster B75 R and
Scrubmaster B115 R.
Introduction

3
Fleet-Recorder Scrubmaster B75 R
1 Fleet-Recorder
Scrubmaster B75 R
1.1 Parts list
1 Fleet-Recorder
2I-Button-Reader
3 User key
4 Antenna
5Buzzer
6 Label
Parts not displayed:
1x W77 cable loom
1x fuse insert
1x O-ring
Fig. 1
4
2
5
1
3
6

4
Fleet-Recorder Scrubmaster B75 R
1.2 Installing the Fleet-Recorder
Scrubmaster B75 R
Caution
Prior to installation, place the
machine on a level surface, se-
cure it against rolling away and
disconnect the battery plug!
Make all the electrical connec-
tions according to the circuit
diagram of the respective
machine variant.
1.2.1 Installing the I-Button-Reader
1. Use the extractor to disassemble the
steering wheel.
2. Disassemble the control panel.
3. Cut into the film in the area of the
right-hand hole on the rear of the
control panel (Fig. 2/1).
4. Install the I-Button-Reader.
5. Connect the plug of the
I-Button-Reader to the 4-pole plug
B20/X1 of the existing W60 cable
loom (Fig. 2/2).
6. Reinstall the control panel and the
steering wheel.
7. Position the RFID lock sticker under-
neath the I-Button-Reader. Fig. 2
2
3
3
1

5
Fleet-Recorder Scrubmaster B75 R
1.2.2 Installing the antenna and the
Fleet-Recorder
1. Clean the surface of the seat con-
sole to the right of the driver's seat.
2. Use the sticker to fix the antenna at
a distance of 140 mm to the rear wall
(Fig. 3/1).
3. Route the antenna cable through the
ventilation slots of the seat console
(Fig. 3/2).
4. Route the cable in a protective tube
along the seat contact switch cable
into the electronics compartment
(Fig. 3/3).
5. Attach the Fleet-Recorder (Fig. 3/4)
to the holder using an O-ring
(Fig. 3/5).
6. Connect the antenna cable to the
GPS and the GSM connections of
the Fleet-Recorder (Fig. 3/6)
according to the labelling.
Fig. 3
1
23
140 +2
4 56

6
Fleet-Recorder Scrubmaster B75 R
1.2.3 Installing the buzzer
The connection lines of the
buzzer are sensitive to tension
stress!
Use cable ties at a distance
of > 50 mm to the buzzer.
Run the antenna cable (Fig. 4/1) in a
loop and fix it together with the P20
buzzer (Fig. 4/2) using cable ties
(Fig. 4/3).
1.2.4 Installing the W77 cable loom
1. Insert the 6-pole plug A01/X3 of the
W77 cable loom into the diagnosis
slot of control A01 (Fig. 4/4).
2. Connect the plug of the P20 buzzer
to the plug of the W77 cable loom
(Fig. 4/5).
3. Connect the 4-pole plug X78 of the
W77 cable loom to the same named
plug of the W60 cable loom.
4. Connect the plug of the
Fleet-Recorder A20/X1 to the
12-pole plug of the W77 cable loom.
5. To connect to the key switch,
connect plug X102 of the W77 cable
loom to the same named plug of the
W3 cable loom.
Fig. 4
1
2
3
A
View A
4
5
6
6

7
Fleet-Recorder Scrubmaster B75 R
6. Establish earth connection with X41.
7. Use cable ties to fix the W77 cable
loom to the chassis (Fig. 4/6).
8. Establish a connection to fuse F20
(Fig. 5/1). Insert the fuse insert 5A
into the fuse holder (Fig. 5/2).
9. Plug connector XK01/A1 is not
connected. Fix the plug connector to
the W3 cable loom using cable ties
(Fig. 5/3).
10.Plug connectors X106 and X107 are
not connected. Run the lines of the
plug connectors in loops and fix
them to the W77 cable loom using
cable ties (Fig. 5/4).
1.3 Putting into service
The machine specific settings for
putting the Fleet-Recorder into service
are carried out by the technical
customer service.
Fig. 5
1
2
3
4

8
Fleet-Recorder Scrubmaster B75 R
1.4 Schematic diagram of the W77 cable loom (Scrubmaster B75 R)
A20/X1
B20
P20
X102
X78
W60
F20
A1/X3 W3
X41/B6

9
Fleet-Recorder Scrubmaster B115 R
2 Fleet-Recorder
Scrubmaster B115 R
2.1 Parts list
1 Fleet-Recorder
2I-Button-Reader
3 User key
4 Antenna
5Buzzer
6 Label
7Plate
8 Holder
Parts not displayed:
1x W77 cable loom
1x W78 cable loom
1x W79 cable loom
1x fuse insert
1x O-ring
2x sheet-metal screw
Fig. 6
4
2
5
1
3
6
8
7

10
Fleet-Recorder Scrubmaster B115 R
2.2 Installing the
Fleet-Recorder B115 R
Caution
Prior to installation, place the
machine on a level surface, se-
cure it against rolling away and
disconnect the battery plug!
Make all the electrical connec-
tions according to the circuit
diagram of the respective
machine variant.
2.2.1 Installing the I-Button-Reader
1. Disassemble the control panel on
the left-hand side (Fig. 7/1).
2. Cut into the film in the area of the top
left hole on the rear of the control
panel (Fig. 7/2).
3. Install the I-Button-Reader.
4. Connect the plug of the
I-Button-Reader to the 4-pole plug
B20/X1 of the W78 cable loom
(Fig. 7/3).
5. Attach the cable end of the
I-Button-Reader to the available
cable loom using cable ties.
6. Route the W78 cable loom on the left
of the steering column downwards.
7. Re-install the control panel. Fig. 7
1
2
3
4

11
Fleet-Recorder Scrubmaster B115 R
8. Position the RFID lock sticker under-
neath the I-Button-Reader (Fig. 7/4).
2.2.2 Routing the W78 cable loom
1. Disassemble the hood of the
steering column (Fig. 8/1) and the
brake pedal (Fig. 8/2).
2. Route the W78 cable loom (Fig. 8/3)
laterally along the inside of the
steering column and fix it using cable
ties (Fig. 8/4).
3. Run the W78 cable loom in front of
the brake pedal (Fig. 8/5) and route it
into the electronics compartment.
4. In the electronics compartment,
route the W78 cable loom through
the available cable ties (Fig. 8/6).
Fig. 8
1
2
3
4
5
6

12
Fleet-Recorder Scrubmaster B115 R
2.2.3 Installing the antenna
Prior to installing the antenna, remove
the batteries.
Caution
Only use suitable lifting
equipment to remove/insert
batteries!
1. Install the plate at the rear wall of the
seat shell using two sheet-metal
screws according to the sketch
(Fig. 9/1).
2. Clean the adhesive surface and use
the sticker to fix the antenna to the
plate (Fig. 9/2).
3. Guide the antenna cable through the
hole in the centre of the seal shell
(Fig. 9/3).
4. Route the antenna cable along the
seat contact switch cable (Fig. 9/4).
5. Route the antenna cable at the
bottom of the battery compartment
through the available cable ties into
the electronics compartment
(Fig. 9/5).
6. Use cable ties to fix the antenna
cable along the route.
Fig. 9
34
5
1
2

13
Fleet-Recorder Scrubmaster B115 R
2.2.4 Installing the Fleet-Recorder
1. Attach the holder for the
Fleet-Recorder in the electronics
compartment using the available
screws and washers (Fig. 10/1).
2. Fix the Fleet-Recorder to the holder
using the O-ring (Fig. 10/2).
3. Connect the antenna cable to the
GPS and the GSM connections of
the Fleet-Recorder (Fig. 10/3)
according to the labelling.
4. Run the cable of the Fleet-Recorder
back into the electronics compart-
ment.
Fig. 10
1
2
3

14
Fleet-Recorder Scrubmaster B115 R
2.2.5 Connections of the W79 cable
loom
1. Connections for the variant with
on-board charger and relay K01:
- Connect XK01/A1 to the second
connection of K01/A1 (Fig. 11/1).
- X102 is not connected.
- Ring cable lug of connection
K01/K1 (Fig. 11/2).
- Ring cable lug of connection
K01/K3 (Fig. 11/3)
- Connect the plug X4/B6 to the plug
of the W77 cable loom (Fig. 11/4).
2. Connections for the variant
without on-board charger:
- Connect X102 to plug K01/A/1.
- XK01A1 is not connected.
3. Attach fuse holder F20 from the W79
cable loom on the right next to fuse
holder F7 (Fig. 11/5).
4. Insert fuse insert 5A into the fuse
holder (Fig. 11/6) and affix the
sticker (Fig. 11/7).
Fig. 11
2
1
3
4
5
6
7

15
Fleet-Recorder Scrubmaster B115 R
2.2.6 Installing the buzzer
The connection lines of the
buzzer are sensitive to tension
stress!
Use cable ties at a distance
of > 50 mm to the buzzer.
Run the cable of the P20 buzzer in a
loop and fix it to the W77 cable loom
using cable ties (Fig. 12/1).
2.2.7 Connections of the W77 cable
loom
1. Insert the 6-pole plug A01/X3 of the
W77 cable loom into the diagnosis
slot of the control (Fig. 12/1).
2. Connect the plug of the P20 buzzer
to the plug of the W77 cable loom.
3. Connect the plug A20/X1 of the
Fleet-Recorder to the 12-pole plug of
the W77 cable loom (Fig. 12/2).
4. Connect the 4-pole plug X78 of the
W77 cable loom to the plug of the
W78 cable loom.
5. Establish a connection to fuse F20
(Fig. 12/3).
Fig. 12
2
3
1
1

16
Fleet-Recorder Scrubmaster B115 R
6. Connect the plug connector X106 to
plug G02/x1 of the W2 cable loom
and fix it using cable ties (Fig. 13/1).
7. Connect the plug connector X107 to
X1 of the charger G02 (Fig. 13/2).
2.3 Putting into service
The machine specific settings for
putting the Fleet-Recorder into service
are carried out by the technical custom-
er service.
Fig. 13
2
1

17
Fleet-Recorder Scrubmaster B115 R
2.4 Schematic diagram of the W77 cable loom (Scrubmaster B115 R)
A20/X1
B20
P20
X102
X78
W78
F20
A01/X3
X41/B6
XK01A1
X106
X107

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Hako GmbH · Hamburger Str. 209-239 · D-23843 Bad Oldesloe
Fon [phone] · Fax [phone]
88-10-3060 - 3288-04