HAKO 1900 V User manual

Instruction Manual
Hako-Jonas 1900 V/D (6330.10 / 6330.20)

2
Introduction
Preface
Dear customer, It is our desire that the
good characteristics of the Hako-Jonas
1900 should justify the confidence you
demonstrated by making this purchase.
Prior to the first use, read the chapter
"Safety Information” carefully as this will
ensure safe operation of the machine.
Your own safety, as well as the safety of
others, depends to a great extent on
how the machine is moved and opera-
ted. Therefore, this operation and main-
tenance manual must be read and
understood prior to the machine being
used for the first time.
The manual provides valuable informa-
tion about operation, service and
maintenance. The warning symbols as
used in this manual identifies items re-
levant to safety. Please observe the
safety provisions (see chapter "Safety
Information”).
Your authorized Hako dealer will be
pleased to answer further questions re-
garding the machine or the operation
and maintenance manual.
Please be advised explicitly that we
cannot accept any legal issues out of
the contents of this manual.
If repair work has to be performed make
sure that only genuine spare parts are
used; only genuine spare parts may
guarantee a dependable machine.
We reserve the right for technical im-
provement..
Valid as of: Januar 2007
Hako-Werke GmbH as from 2013 Hako GmbH
D-23843 Bad Oldesloe
Hamburger Str. 209-239
Telefon ++49 (04531) 8060
Intended use
The Hako-Jonas 1900 is a sweeping
vehicle conceived exclusively for
sweeping up dry and wet refuse from
areas such as production plants, ware-
houses, car parks and pedestrian pre-
cincts. Any use beyond this is regarded
as improper use. The manufacturer is
not considered liable for any damage
resulting from improper use; the user is
solely responsible for all the risks. The
sweeping vehicle must not be used to
clear up toxic, inflammable or other
substances which represent a potential
risk to health. Intended use also inclu-
des maintaining and observing the ope-
rating, maintenance and repair
conditions prescribed by the manufac-
turer.
The Hako-Jonas 1900 may only be
operated, serviced and repaired by per-
sonnel who are familiar with the work in-
volved and are aware of the risks. The
applicable accident prevention laws
must be observed and any generally
accepted health and safety directives
must be maintained. The manufacturer
is not deemed liable for any damage re-
sulting from unauthorized modifications
to the vehicle.
Notes on warranty
The terms of the sales contract apply.
Damages are not subject to warranty if
they are due to non-compliance with the
maintenance and service provisions.
The maintenance work has to be perfor-
med by an authorized Hako service
center and confirmed in the "Mainte-
nance certificate" which is the warranty
document.
The following is excluded from
warranty: fuses, natural wear, damages
caused by overload, inexpert handling
and unauthorized modification of the
machine. Moreover, any claim for war-
Introduction

3
ranty cannot be accepted if damages of
the machine are caused by fitting parts
or accessories without Hako’s prior and
explicit consent or by non-compliance
with the maintenance instructions.
Acceptance of the machine
Upon arrival, check machine for possi-
ble damages in transit. For refund of
such damage, have the Deutsche Bahn
AG or your freight forwarder confirm
such damage. Mail notification and
waybill to:
Hako GmbH
Hamburger Strasse 209-239
23843 Bad Oldesloe
Conditions for approval
The Hako-Jonas 1900 is an automotive
machine within the terms defined in the
Road Traffic Licensing Regulations
(FZV §2, previously StVZO §18).
On request, the manufacturing plant
can enclose a report with which to ac-
quire the vehicle type approval. This re-
port is used by the local vehicle
registration office to produce a valid ve-
hicle registration license (Vehicle Regi-
stration Certificate, Part 1).
An official license number is not neces-
sary. A general inspection in accordan-
ce with § 29 StVZO (road traffic
licensing regulation) is not required eit-
her because the vehicle is designed for
a top speed under 20 kph. In accordan-
ce with the StVZO, the vehicle must
carry a first-aid kit, warning triangle and
the vehicle registration license when
used on public roads, paths and pede-
strian precincts.
If any attachments or conversions are
made on the Hako-Jonas 1900 1900 V/
D which affect the equipment described
in the vehicle registration license and
are not mentioned in the vehicle regi-
stration license, the license becomes
invalid. To acquire a new vehicle regi-
stration license, the vehicle must be
presented to an officially accepted ex-
pert to produce a new report. The report
becomes the official vehicle registration
license when the vehicle registration of-
fice applies the applicable stamp.
Driving license
In accordance with the provisions on
driving licenses, a person who intends
to drive a motor vehicle constructed
with a top speed in excess of 6 kph on
public roads, paths and pedestrian pre-
cincts, must be in possession of a valid
driving license. Drivers of the Hako-Jo-
nas 1900 require a Class L driving li-
cense (motor vehicles up to 25 kph).
Introduction

4
Table of Content
Preface. . . . . . . . . . . . . . . . . . 2
Intended use . . . . . . . . . . . . . 2
Notes on warranty . . . . . . . . . 2
Acceptance of the machine . . 3
Conditions for approval . . . . . 3
Driving license . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . 3
1 Safety information . . . . . . . . 6
1.1 Safety and Warning Symbols. 6
1.2 General Provisions. . . . . . . . . 7
1.3 Operating information. . . . . . . 8
1.4 Maintenance information . . . . 9
1.5 Particular risks . . . . . . . . . . . 11
1.6 Information for Protection of En-
vironment . . . . . . . . . . . . . . . 12
1.7 Labels on the vehicle . . . . . . 13
2 First Operation . . . . . . . . . . 17
2.1 Instruction. . . . . . . . . . . . . . . 17
2.2 Prior to starting up . . . . . . . . 17
2.3 Starting the vehicle. . . . . . . . 17
2.4 Putting into operation . . . . . . 18
2.4.1 Optimum use of the sweepings
container (RTR system) . . . . 18
2.4.2 Emptying the sweepings
container . . . . . . . . . . . . . . . 19
2.5 Stopping and switching off the
vehicle . . . . . . . . . . . . . . . . . 20
2.6 After completing work. . . . . . 20
2.7 Transporting and towing. . . . 21
3 Operation . . . . . . . . . . . . . . 23
3.1 Method of operation . . . . . . . 23
3.1.1 General information . . . . . . . 23
3.1.2 Sweeping unit. . . . . . . . . . . . 23
3.1.3 Filter system. . . . . . . . . . . . . 24
3.1.4 Agitating device . . . . . . . . . . 24
3.1.5 Engine . . . . . . . . . . . . . . . . . 25
3.1.6 Hydraulic system . . . . . . . . . 25
3.1.7 Brakes and tires . . . . . . . . . . 26
3.1.8 Special equipment . . . . . . . . 26
3.2 Operating elements . . . . . . . 27
3.2.1 Overview . . . . . . . . . . . . . . . 27
3.2.2 Operating panel . . . . . . . . . . 29
3.2.3 Control lamps and indicators 30
4 Technical Data . . . . . . . . . . 37
5 Maintenance and
Service . . . . . . . . . . . . . . . . 42
5.1 Hako system maintenance. . 42
5.2 Proof of Maintenance . . . . . 44
5.3 Maintenance plan. . . . . . . . . 45
5.4 Engine . . . . . . . . . . . . . . . . . 52
5.4.1 Opening the engine bracket . 54
5.4.2 Refilling engine oil . . . . . . . . 54
5.4.3 Changing the engine oil and oil
filter . . . . . . . . . . . . . . . . . . . 55
5.5 Air filter. . . . . . . . . . . . . . . . . 56
5.5.1 Disassembling the main filter 57
5.5.2 Cleaning the main filter . . . . 57
5.5.3 Installing the main filter . . . . 57
5.5.4 Changing the main filter . . . . 57
5.5.5 Changing the safety cartridge57
5.6 Fuel system . . . . . . . . . . . . . 58
5.6.1 Changing the fuel filter . . . . . 58
5.6.2 Venting the fuel system . . . . 58
5.7 Cooling system. . . . . . . . . . . 59
5.7.1 Cleaning the radiator . . . . . . 60
5.7.2 Refilling coolant . . . . . . . . . . 60
5.7.3 Changing the coolant . . . . . . 60
5.8 Hydraulic system . . . . . . . . . 61
5.8.1 Filling hydraulic oil . . . . . . . . 62
5.8.2 Changing the hydraulic oil . . 62
5.8.3 Change hydraulic oil filter. . . 62
5.9 Sweepings container . . . . . . 63
5.9.1 Cleaning the dust filters . . . . 64
5.9.2 Changing the dust filters . . . 64
5.9.3 Emptying the sweepings
container . . . . . . . . . . . . . . . 65
5.10 Side brush . . . . . . . . . . . . . . 66
5.10.1 Adjusting the angle of the side
brush . . . . . . . . . . . . . . . . . . 67
5.10.2 Wear compensator for the side

5
Table of Content
brush . . . . . . . . . . . . . . . . . . 67
5.10.3 Changing the side brush . . . 67
5.11 Rotary brush. . . . . . . . . . . . . 68
5.11.1 Adjusting the rotary brush wear
compensator. . . . . . . . . . . . . 69
5.11.2 Parallel adjustment of the
rotary brush . . . . . . . . . . . . . 69
5.11.3 Changing the rotary brush . . 70
5.11.4 Changing the rotary brush
aprons . . . . . . . . . . . . . . . . . 70
5.11.5 Adjusting the rotary brush
aprons . . . . . . . . . . . . . . . . . 70
5.12 Tires . . . . . . . . . . . . . . . . . . . 71
5.12.1 Checking tire wear . . . . . . . . 71
5.12.2 Disassembling the tires . . . . 71
5.12.3 Fitting tires . . . . . . . . . . . . . . 71
5.13 Brakes . . . . . . . . . . . . . . . . . 71
5.14 Electronics . . . . . . . . . . . . . . 72
5.14.1 Changing the fuses . . . . . . . 72
5.14.2 Changing the battery . . . . . . 72
5.14.3 Electrical installation. . . . . . . 73
5.14.4 Changing the antistatic chain 74
5.15 Lubrication points . . . . . . . . . 75
5.16 Special equipment and spares
requirements . . . . . . . . . . . . 76
EC Declaration of
Conformity . . . . . . . . . . . . . .77

6
Safety information
1 Safety information
1.1 Safety and Warning Symbols
All paragraphs in this manual referring
to your personal safety, the safety of
your machine and the environment pro-
tection are attributed one of the follo-
wing warning symbols:
Symbol Hazardous for ... Description
Safety Provisions persons and goods Safety Provisions in dangerous situation caused by
misuse inaccurate adherence of instructions or pres-
cribed work routine.
CAUTION the machine important information on handling the machine in
order to maintain operability.
Ecological hazard the environment due to use of substances representing an inherent
danger to health of environment

7
Safety information
1.2 General Provisions
• Apart from the provisions contained
in this instruction manual, the gene-
ral safety provisions and the acci-
dent prevention regulations as
imposed by law have to be complied
with.
• Before taking your machine into ope-
ration, carefully read the instruction
manual as well as other separate in-
structions for accessories or atta-
ched implements and comply with all
points mentioned there during work.
• Persons being trained by qualified
Hako technicians only are authori-
sed to operate, service and repair
the machine.
• You are advised to thoroughly study
the safety instructions since precise
knowledge only helps avoiding er-
rors during operation of the machine
and thus guarantee faultless usage
of the machine.
• The operating instructions have to
be at hand at the place of use of the
machine, and therefore have to be
kept readily available at the machi-
ne.
• When selling or letting the machine
for rent, hand out these documents
to the new owner/operator and have
the transfer certified!
• The warning and instruction plates
attached to the machine contain va-
luable advice about safe operation.
Immediately replace incomplete or il-
legible labels.
• As far as safety standards are con-
cerned, spare have to equal genuine
spare parts!

8
Safety information
1.3 Operating information
• Check the operational safety of the
vehicle each time before starting it
up! Clear any faults immediately!
• 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 ve-
hicle.
• The vehicle may only be driven on
and the equipment used on those
surfaces which have been approved
by the contractor or person appoin-
ted by him.
• When using the vehicle, it is essenti-
al to pay attention to third parties, es-
pecially children.
• The vehicle is not suitable for clea-
ring up hazardous, inflammable or
explosive fluids, dust or substances.
• This vehicle must not be used as
dust cleaner equipped with a dust fil-
ter insert (dust collector) to clear up
dust which could represent a hazard
to health.
• It is forbidden to use the vehicle in
potentially explosive atmospheres.
• Remove the ignition key to prevent
unauthorized use of the vehicle.
• The vehicle and its equipment must
be checked in terms of perfect wor-
king condition and operational safety
before being put into use. The vehic-
le 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 function of the seat con-
tact switch must not be bypassed!
• The seat contact switch is monitored
electronically. Any attempt at mani-
pulation can lead to the vehicle being
automatically locked against use.
• Always switch off all the drives befo-
re starting the engine.
• The vehicle must only be started, put
into motion and stopped from the se-
at.
• Do not allow the engine to run in clo-
sed rooms! Risk of poisoning!
• Ensure there is sufficient ventilation
when sweeping in closed spaces
(dust and exhaust fumes).
Risk of poisoning!
• 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, ta-
king corners at too high a speed
could cause the vehicle to tip.
Only use the vehicle on level sur-
faces, never on gradients.
Drive up and down inclines in
straight lines.
When driving up, down or across slo-
pes, avoid turning corners suddenly
or in jerks. There is a risk of tipping
when in an inclined position!
• The vehicle has been conceived for
use on surfaces with a maximum
gradient of 16%.
• The approved gross total weight and
permissible axle loads must never
be exceeded. Check the fill level of
the sweepings container at frequent
intervals.
• Before raising or lowering the
sweepings container, ensure that

9
Safety information
there are no persons, animals or
items in the working area.
• Risk of crushing and shearing.
Before raising or lowering the
sweepings container, ensure that
there is a sufficient safety clearance.
• The sweepings container may only
be raised in the direct vicinity of the
refuse container.
Only empty the sweepings container
on level, solid ground.
• Never sweep when the sweepings
container is in a raised position.
• Pay attention to any persons in the
vicinity when emptying the
sweepings container.
• The filter may only be shaken when
the sweepings container has been
closed.
• Pay attention to hot parts, e.g. coo-
ling water, exhaust manifold, etc.
• Never exceed the max. load capacity
of the container!
• The vehicle may only be driven at
creeping speed when the sweepings
container has been raised. Avoid
any sudden steering movements or
decelerations.
1.4 Maintenance information
• 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.
• The maintenance work and mainte-
nance intervals prescribed in the
operating manual must be adhered
to.
• Suitable tools must be used for cle-
aning and maintenance work.
• 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 mi-
nimum technical requirements stipu-
lated by the manufacturer! This is
ensured by the use of original spare
parts.
• Only use the rotary brushes and side
brushes recommended by the manu-
facturer (refer to Technical Data).
The use of other rotary brushes and
side brushes could impair safety.
• Only use the air and oil filters recom-
mended by the manufacturer (refer
to Technical Data). The use of other
filters could impair safety.
• The vehicle must be switched off pri-
or to cleaning or servicing it or repla-
cing parts.
The ignition key must be removed.
• The sweepings container must be
cleaned regularly to prevent the ac-
cumulation of bacteria.
• The vehicle is splashproof (IPX3).
It is not permitted to clean the vehicle
with a pressure washer or steam bla-
ster.
• The engine must be switched off
when transporting the vehicle.
• If the Hako-Jonas 1900 is jacked up
with a jack, it must be properly sup-
ported.
• No persons may be on the Hako-Jo-
nas 1900 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, so-
lid ground, where possible.
• Do not remove or replace tires or re-
pair one on a rim. Always go to a pro-

10
Safety information
per workshop for work on tires and
rims because they have specially
trained personnel and special safety
tools. Never loosen the screws in the
two-part rims while the wheel is still
mounted on the vehicle and there is
air in the tires. Risk of severe injury!
• 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.
• Only use original fuses. Using fuses
which are too powerful could dama-
ge the electrical installation and lead
to fires.
• Always disconnect the negative pole
of the battery when working on the
electrical installation.
• Never leave the batteries in a di-
scharged state but recharge them as
soon as possible.
• Only refill distilled water.
When the cells are in good condition,
never refill the battery acid.
• To prevent current leaks, always
keep the battery clean and dry, pro-
tect it from soiling by metallic dust,
for example.
• Battery acid is very corrosive (keep
out of reach of children).
Wear protective goggles when con-
trolling the acid level. In the event of
acid splashing in the eyes, rinse
them with water for approx. 15 minu-
tes and seek medical attention im-
mediately.
Always wear appropriate protective
clothing when handling the battery
(e.g. protective gloves, finger stalls).
Never use an open flame (risk of ex-
plosion).
• When installing or removing the bat-
tery or changing it, there is a risk of
crushing and shearing.
• Any fluids (fuel, hydraulic oil) esca-
ping under high pressure can pene-
trate the skin and cause severe
injuries. Seek medical attention im-
mediately in order to prevent the risk
of infection. Take care when draining
hot oil - risk of burns.
• Subject the brake system to a tho-
rough inspection regularly! Adjust-
ments and repairs to the brake
system may only be completed by
specialist service centers approved
by Hako or recognized brake service
workshops.
• Subject the hydraulic system to a
thorough inspection regularly! Adju-
stment and repair work on the hy-
draulic system may only be
performed in specialist Hako work-
shops.
• Check hydraulic lines and hoses re-
gularly for signs of damage and
leaks. Replace damaged lines and
hoses immediately.
• Have the zero alignment of the hy-
draulic pump checked regularly at a
specialist Hako workshop.