HAKO Sweepmaster P800 User manual

Instruction Manual
Sweepmaster P800 (6404.10)
Sweepmaster B800 (6404.20)

2
Introduction
Preface
Dear customer,
We hope that the excellent qualities of
the machine justify the faith you have
shown in us by purchasing the product.
Your safety, and that of others, is de-
pendent on your ability to control the
machine. Please read this original man-
ual before using the machine for the
first time, act according to the informa-
tion contained and keep it in a safe
place for future reference or subse-
quent owners. In order to ensure that
you can work with the machine safely,
please read the chapter on safety be-
fore starting it up.
The operating manual contains all the
important information you need to oper-
ate, maintain and service the machine.
Sectionsofthisoperatingmanualwhich
arerelevant to safetyaremarked bythe
hazard label. If you have any questions
with regard to the machine or operating
manual, you can contact your Hako ser-
vice partner at any time.
We would like to emphasize that no le-
gal claims can be asserted in respect of
any work described in this manual. En-
sure only original spare parts are used
should any repairs be necessary. Only
such original spare parts warrant that
theequipment is reliably readytouse at
all times. We reserve the right to make
technical improvements.
Valid from: April 2014
Hako GmbH
D-23843 Bad Oldesloe
Hamburger Straße 209-239
Telephone [phone]
Intended use
The Sweepmaster is a manually operat-
ed sweeper for industrial/commercial
use and serves to clean up dry and wet
waste from indoor and outdoor areas
suchasproductionplants,warehouses,
car parks, parking blocks, pedestrian
precincts, market squares, railway sta-
tions and filling stations. The Sweep-
master can clean all types of industrial
floor, concrete, asphalt and tar, paving
and interlocking stone paving. It is not
permitted for use on public roads with
motor traffic. The Sweepmaster B800
can be upgraded with a carpet kit so it
can also be used to clean dry waste
from carpets.
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.
Introduction

3
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. The applica-
ble accident prevention laws must be
observed and any generally accepted
health and safety directives must be
maintained.
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 directives (refer to the Declara-
tion of Conformity). The EC Declaration
of Conformity is no longer considered
valid in the event of modifications to the
machine not authorized by us. The
manufacturer is not deemed liable for
any damage resulting from unauthor-
ized modifications to the machine.
Information on the warranty
As a fundamental rule, the regulations
in the purchase agreement apply.
There are no rights to claims for com-
pensation under the terms of warranty
when the damage is a resultof failure to
observe the stipulations concerning
serviceandmaintenance. Maintenance
work must be completed by an author-
izedHakoservicecenterand confirmed
in the “maintenance logbook”; this
servesasproofofrightstoclaimsunder
the terms of warranty.
The following are excluded from the
termsofwarranty:normalwearandtear
and damage caused by overuse, defec-
tive fuses, improper handling or unau-
thorized modifications. Claims under
the terms of warranty are also annulled
whendamageoccurstothemachine as
the result of the use of parts and acces-
soriesnotexplicitlyapproved byusorto
failure to observe maintenance proce-
dures.
Handover of the machine
Inspect the machine immediately on
delivery for signs of transport damage.
Replacement will be made when confir-
mation is provided immediately by the
freight carrier with regard to the
damage and the damage report is sent
toour authorized salespartner together
with the consignment note.
Introduction

4
Disposing of the machine
Renderthe machine inoperable.Itmust
not represent a source of risks to chil-
dren. Dispose of the machine in accord-
ance with the applicable local
regulations.
For further information on disposal and
recycling, contact the authorized Hako
dealer where you purchased the ma-
chine.
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 con-
tent matter of batteries. Health hazard!
Do not allow batteries to pollute the en-
vironment. There is a risk of contami-
nating the ground and water! In
accordance with the symbol with the
crossed out bin, these batteries must
not be disposed of in domestic waste.
Thereturnand recyclingofold batteries
must be agreed on with the authorized
Hako dealer in accordance with the Bat-
tery Act § 6 and § 8.
Introduction

5
Contents
Introduction . . . . . . . . . . . . . 2
Preface. . . . . . . . . . . . . . . . . . 2
Information on the warranty . . 2
Intended use. . . . . . . . . . . . . . 3
Handover of the machine. . . . 3
Disposing of the machine. . . . 4
Disposing of batteries. . . . . . . 4
1 Safety Information . . . . . . . . 7
1.1 Safety and warning symbols . 7
1.2 General information . . . . . . . . 8
1.3 Operating information. . . . . . . 8
1.4 Maintenance information . . . 10
1.5 Particular risks . . . . . . . . . . . 11
1.6 Environmental protection . . . 11
1.7 Labels on the machine. . . . . 12
2 Starting Up . . . . . . . . . . . . . 16
2.1 Before starting up
for the first time. . . . . . . . . . . 16
2.1.1 Unpacking . . . . . . . . . . . . . . 16
2.1.2 Refueling the engine
(only Sweepmaster P800) . . 17
2.1.3 Checking the oil level
(only Sweepmaster P800) . . 17
2.1.4 Connecting the batteries
(only Sweepmaster B800) . . 17
2.1.5 Initial battery charge
(only Sweepmaster B800) . . 17
2.1.6 Instruction. . . . . . . . . . . . . . . 18
2.2 Before starting up each day . 18
3 Operation . . . . . . . . . . . . . . 19
3.1 Method of operation . . . . . . . 19
3.2 Operating
and indicator elements. . . . . 20
3.2.1 Operating elements . . . . . . . 20
3.2.2 Operating panel . . . . . . . . . . 24
3.3 Operation . . . . . . . . . . . . . . . 26
3.3.1 Switching on. . . . . . . . . . . . . 26
3.3.2 Accelerating . . . . . . . . . . . . . 27
3.3.3 Stopping. . . . . . . . . . . . . . . . 27
3.3.4 Vacuumsweeping. . . . . . . . . 27
3.3.5 Switching off. . . . . . . . . . . . . 28
3.3.6 After finishing work. . . . . . . . 29
3.3.7 Loading and transportation . 29
3.4 Function faults . . . . . . . . . . . 30
3.5 Options. . . . . . . . . . . . . . . . . 30
4 Technical Data . . . . . . . . . . 31
5 Maintenance and
Service . . . . . . . . . . . . . . . . 33
5.1 Hako system maintenance. . 33
5.2 Maintenance report . . . . . . . 34
5.3 Maintenance Plan . . . . . . . . 35
5.4 Engine . . . . . . . . . . . . . . . . . 38
5.4.1 Checking
the engine oil level . . . . . . . . 39
5.4.2 Refilling engine oil . . . . . . . . 39
5.4.3 Changing/Draining
the engine oil change. . . . . . 39
5.4.4 Disassembling the air filter. . 40
5.4.5 Cleaning the air filter . . . . . . 40
5.4.6 Installing the air filter . . . . . . 40
5.5 Battery system . . . . . . . . . . . 41
5.5.1 Charging batteries . . . . . . . . 42
5.5.2 Total discharge signal
transducer (TSG) . . . . . . . . . 42
5.5.3 Servicing the drive batteries. 42
5.5.4 Removing batteries . . . . . . . 42
5.5.5 Inserting batteries. . . . . . . . . 43
5.5.6 Disposing of batteries. . . . . . 43
5.6 Drives. . . . . . . . . . . . . . . . . . 44
5.6.1 Adjusting the drive belt. . . . . 45

6
Contents
5.7 Side brush . . . . . . . . . . . . . . 47
5.7.1 Side brush wear,
readjustment . . . . . . . . . . . . 48
5.7.2 Changing the side brush . . . 48
5.8 Rotary brush. . . . . . . . . . . . . 49
5.8.1 Cleaning the brush space . . 50
5.8.2 Changing the rotary brush . . 50
5.8.3 Setting the sweeping pattern 51
5.8.4 Changing the sealing strips . 51
5.9 Dirt hoppers . . . . . . . . . . . . . 54
5.9.1 Removing a dirt hopper . . . . 55
5.9.2 Emptying the dirt hopper . . . 55
5.9.3 Inserting the dirt hoppers . . . 55
5.9.4 Changing the seals . . . . . . . 55
5.10 Dust vacuum . . . . . . . . . . . . 56
5.10.1 Clearing dust deposits
from panel air filter
during operation . . . . . . . . . . 57
5.10.2 Removing the panel air filter 57
5.10.3 Cleaning the panel
air filter thoroughly . . . . . . . . 57
5.10.4 Replacing the sealing strips . 57
5.10.5 Inserting panel air filters. . . . 58
5.10.6 Checking the suction turbine 58
5.10.7 Checking
the filter system for leaks . . . 58
5.11 Special equipment . . . . . . . . 59
Notes. . . . . . . . . . . . . . . . . . 60
EC Declaration
of Conformity . . . . . . . . . . . 61

7
Safety Information
1 Safety Information
1.1 Safety and warning symbols
The following warning symbols appear
in the operating manual in those
sectionsinwhich yoursafety, thesafety
of the machine and environment could
be affected:
Symbol Damage to ... Definition
Safety information persons
or property Safety symbol to indicate dangerous situations arising throughfailuretofollowinstructionsorprescribedwork
procedures precisely or through ignoring them
altogether.
Note the machine Important information on handling the machine to
maintain its functioning ability.
Risk to environment the environment Risks to the environment through using substances
which represent a risk to health and the environment.

8
Safety Information
1.2 General information
• In addition to the information
providedin thisoperating manual,all
the legally applicable health and
safety provisions must be observed.
• Before starting up the machine for
the first time, read the operating
manualsuppliedwithitthoroughlyas
well as any separate manuals
provided with additional or
attachment devices and observe all
the information during work.
• The equipment may only be
operated, serviced and repaired by
personnel trained by Hako technical
experts.
• This vehicle is not intended to be
used by persons (including children)
with limited physical or mental capa-
bilities or persons without sufficient
experience and ability.
• Particular attention should be paid to
the information regarding safety.
Technical expertise is the key to
preventingerrorswhenoperatingthe
machine and ensuring trouble-free
operation.
• The operating manual must always
be kept at the operating location of
the machine and, as a result, should
kept in a safe place on the
equipment.
• Iftheequipmentissoldorrentedout,
these documents should be
transferred to the new owner/
operator. The transfer should be
confirmed!
• The warning labels attached to the
machine provide important
information concerning safe
operation.
Illegible or missing labels must be
replaced by new ones.
• For reasons of safety, always use
original spare parts.
1.3 Operating information
• The machine is not suitable for
clearing up fluids, dust or
substanceswhichrepresentahealth
hazard, are inflammable or
explosive. No burning items may be
cleared up, e.g. glowing cigarettes.
In addition, it is forbidden to clean up
wood dust, e.g. beech and oak dust
- health hazard!
• When the machine is in
vacuumsweeping mode, it must not
be driven through puddles of water.
• Before starting the machine up for
the first time, the battery to be used
must be fully charged, properly, by
implementing the initial battery
charge routine (only Sweepmaster
B800). Hako assumes no liability for
damage to the battery caused by a
fault when the battery is charged for
the first time.
• The machine together with the
workingequipmentmustbechecked
in terms of proper condition and
operational safety each time prior to
use. Clear any faults immediately!
Themachinemustnotbeusedwhen
not in a sound condition.
• Only start the machine when the

9
Safety Information
hood is closed and locked and the
lever of the shaking device has been
pushed in.
• Before starting work, the operator
must be fully familiar with all
adjustment, operating and control
elements as well as their respective
function! It is too late to do this when
the machine is actually in operation!
• Always wear heavy duty, non-slip
footwear when working with the
machine.
• The machine may only be used on
those surfaces which have been
approvedbythecontractororperson
appointed by him.
• The manner of driving must be
adapted to the local conditions.
• It is forbidden to use the machine in
potentially explosive atmospheres.
• Do not let the engine run indoors!
Risk of poisoning (only
Sweepmaster P800)! Ensure
sufficient ventilation when working
indoors.
• When using the machine, it is
essential to pay attention to third
parties, especially children.
• Pay attention to hot parts of the
engine, risk of burns.
• It is prohibited to transport
passengers.
• Accelerate the machine immediately
after switching on the rotary brush,
otherwiseimprintsof the brushcould
be produced on the floor.
• Neverleavethemachineunattended
as long as the engine is running.
• Remove the ignition key to prevent
unauthorized use of the machine.
• Never leave batteries in a
discharged state but recharge them
as soon as possible (only
Sweepmaster B800).
• When transporting the machine,
switch the engine off and raise the
side brush.
• The Sweepmaster P800 can be
used on surfaces with a maximum
gradient of 10%.
• The Sweepmaster B800 can be
used on surfaces with a maximum
gradient of 10% (for maximally 3
minutes).
• Steps or curbs up to a maximum of
4 cm can be driven over.
• Itisforbiddentomanipulateswitches
and safety equipment.

10
Safety Information
1.4 Maintenance information
• The maintenance work and
maintenance intervals prescribed in
the operating manual must be
adhered to.
• Operating personnel must complete
the necessary daily and weekly
maintenance work. All other
maintenance work must be
completed at your nearest Hako
service center.
• The machinemust be inspected by a
recognized technical expert in
respect of operational safety, within
the terms of the applicable accident
prevention laws, at reasonable
intervals (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.
• The machine must be switched off
prior to cleaning or servicing it or to
replacing parts.
• Suitable tools must be used for
cleaning and maintenance work.
• When working with the hood raised,
it must be opened up fully to prevent
it from accidentally dropping or
slamming shut.
• When working on the electrical
system, always disconnect the
battery cable (only Sweepmaster
B800).
• Batteries may only be handled and
changed by properly skilled
maintenance personnel (only
Sweepmaster B800).
• Pay attention that the insulation of
the charger cable is not damaged
and cannot be damaged during the
charging process. The cable must
not chafe against anything. In the
case of defective insulation, do not
use the on-board charger (only
Sweepmaster B800).
• Check the exhaust system at regular
intervals (only Sweepmaster P800).
• It is not permitted to clean the
machine with a pressure washer or
steam blaster.
• It is not permitted to use aggressive
and corrosive cleaning agents.
• Allow the machine to dry properly
after being cleaned, e.g. over the
weekend.
• Donotcarryoutanywelding, drilling,
sawingorgrindingwork on the frame
sections. Damaged parts may only
be changed at an authorized Hako
service center.

11
Safety Information
1.5 Particular risks
Refueling
(only Sweepmaster P800)
• Take the utmost care when handling
fuel: Increased risk of fire! Never
refuel near open flames or
incendiary sparks! Never smoke
when refueling!
• Never refuel indoors!
• Before refueling, switch off the
engine and remove the ignition key.
• Wipe up spilled fuel immediately!
Batteries (only Sweepmaster B800)
• To prevent creeping currents,
always keep the batteries clean and
dry, protect from soiling such as by
metal dust.
• Never lay any metallic objects or
tools on batteries. Risk of short
circuit and deflagration!
• When charging the batteries, there
must be sufficient ventilation in the
charging area. Otherwise, there is a
risk of explosion!
• Batteries must not be connected or
disconnected when conducting
electricity.
• Wash your hands thoroughly after
working on batteries.
Information on the power plug
(only Sweepmaster B800)
• Only take hold of the power plug and
power cable when your hands are
dry.
• Never insert the power plug in the
socket if the base is wet or damp.
• Never immerse the power cable or
power plug in water or other fluids
clean them in running water. Risk of
electric shock!
• Dry any power plugs and power ca-
bles which have become damp with
adryclothbeforeconnectingthemin
power sockets.
• Pay attention that the power socket
is dry.
• We recommended the use of splash-
proof power sockets complying with
DIN VDE 0620-1.
• Pay attention that no water or fluids
can get on to live machine parts. If
water should penetrate to such
parts, disconnect the power plug im-
mediately and have the vehicle
checked at an authorized Hako ser-
vice center.
• Thepowerconnectioncablemustbe
inspected for signs of damage at
regular intervals. If damage is de-
tected, the cable must be replace pri-
or to further use.
Health hazard
• The shaking device for cleaning the
panel air filter may only be actuated
when the dirt hoppers are in the
machine and have been raised.
• It is forbidden to eat, drink and
smoke in battery charging rooms.
Safety equipment
• Never operate the Sweepmaster
without the hood being closed and
locked (safety equipment)!
• Do not open the hood when the
engine is running!

12
Safety Information
1.6 Environmental protection
• Sufficient factual knowledge is
required in order to use substances
which could represent a risk to
health and the environment, e.g oil
and lubricants.
• Observe the applicable laws and
local regulations when disposing of
waste and cleaning agents, also
refer to the Water Resources Act.
• Observe the applicable laws and
local regulations when disposing of
waste oil (only Sweepmaster P800).
• Used batteries with the recycling
symbol must not be disposed of in
household waste, refer to paragraph
”Disposing of the machine”.

13
Safety Information
1.7 Labels on the machine
The following safety and warning labels
are attached to the machine where
easily legible.
Missing or illegible labels must
be replaced immediately.
Choke (Fig. 1/1)
(only Sweepmaster P800)
Lock, dirt hopper
(Fig. 1/2)
Company logo (Fig. 1/3)
Fig. 1
2
3
1

14
Safety Information
Fig. 2
2
3
1
5
4
6

15
Safety Information
Bypass flap (Fig. 2/1)
Only use maintenance-free batteries
(Fig. 2/2)
(only Sweepmaster B800)
Wear compensator for rotary brush
(Fig. 2/3)
Rating plate (Fig. 2/4)
Wear compensator for side brush
(Fig. 2/5)
Oil label (Fig. 2/6)
(only Sweepmaster P800)
Engine oil, only use SAE 15 W 40 .
Folding apron (Fig. 3/1)
Parking brake (Fig. 3/2)
Shaking device (Fig. 3/3)

16
Safety Information
Fig. 3
Read and observe the operating
manual (Fig. 3/4)
Lower/Raise side brush (Fig. 3/5)
1
2
3
4
5

17
Safety Information
2StartingUp
2.1 Before starting up for the first
time
2.1.1 Unpacking
Remove the packaging, open the
fastening straps and take the
Sweepmaster from the pallet. For
reasons of packaging, the handlebar of
the Sweepmaster is pivoted forwards.
First of all, pivot the handlebar to its
operating position.
Pivoting the handlebar to its
operating position
1. Loosen the wing bolts (Fig. 4/1) on
the right and left sides of the
handlebar (Fig. 4/2) a few
revolutions until the handlebar
(Fig. 4/2) can be straightened up.
2. Pivot the handlebar (Fig. 4/2)
towardstherear and setit to aheight
convenient for the user.
3. Tighten the wing bolts (Fig. 4/1) on
the right and left sides of the
handlebar (Fig. 4/2).
Fig. 4
12

18
Safety Information
2.1.2 Refueling the machine
(only Sweepmaster P800)
Unscrew the fuel tank cap
(Fig. 7/7) and fill approx. 2.5 l gasoline.
Screw the fuel tank cap back on.
Only refuel the machine when
the engine has cooled down.
Otherwise, any spilled
gasoline can evaporate if it
lands on hot machine parts.
Healthhazardthroughinhaling
vapors!
Refueling must not be carried
out in closed rooms.
Refueling may only be carried
out when the engine is
switched off! Remove the
ignition key.
It is forbidden to smoke or use
fire when refueling or working
on or near components
containing fuel.
Wipe up any spilled fuel!
Wipeupspilledfuelwithacloth
and dispose of the cloth
according to the applicable
environmental laws.
2.1.3 Checking the oil level
(only Sweepmaster P800)
Engine oil is filled at the factory. As a
precaution, however, check the oil level
again on site, refer to Section 5.4.1.
2.1.4 Connecting the batteries
(only Sweepmaster B800)
Before starting up for the first time,
connect the positive cable of the device
as illustrated in Figure 5 to the positive
pole (Fig. 5/1) of the batteries in the
device.
2.1.5 Initial battery charge
(only Sweepmaster B800)
Before starting up the machine for the
first time, the batteries used must be
fully charged by completing the initial
battery charge, refer to Section 5.5.1.
Hakoassumesnoliabilityfordamageto
the battery resulting fromfailing tocarry
out the initial battery charge properly.
Risk of explosion! When
charging the batteries, there
must be sufficient ventilation in
the charging area.
Fig. 5
1

19
Safety Information
2.1.6 Instruction
Operators must receive instruction
before putting the machine into service.
Only technicians from your local,
authorized Hako dealer are allowed to
provide initial instruction on how to use
the machine. The manufacturing plant
notifies the dealer immediately after
delivering the machine and the dealer
will contact you to arrange a date for
providing the initial instruction.
2.2 Before starting up each day
Carry out the following checks before
starting the machine:
1. Check the parking space for signs of
leaks.
2. Only Sweepmaster P800: Check the
engine oil level with the dipstick and
refill, if necessary; refer to Section
5.4.2.
3. Only Sweepmaster P800: Check the
fuel supply and refill fuel, if
necessary, refer to refer to
paragraph 2.1.2.
4. Only Sweepmaster B800: Check the
charge status of the batteries and
recharge, if necessary.
5. Checkthe fill level of thedirthoppers
and empty them, if necessary.
6. Check the levels of wear on the
rotary brush and side brush.
7. Check the ergonomic position of the
handlebar and readjust it, if
necessary.

20
Safety Information
3Operation
3.1 Method of operation
The Sweepmaster is a manually
operated sweeper machine with a drive
for the dry cleaning of hard floors and
carpets.
Theside brush(Fig. 6/4), locatedonthe
right-hand side of the machine, sweeps
the dirt away from corners and edges
into the path of the rotary brush
(Fig. 6/3). The rotary brush (Fig. 6/3)
sweepsthe dirt into the two dirthoppers
(Fig. 6/2) using the overhead throw
method. The particulate matter
(depicted gray in Fig. 6) is forced
against the panel air filter (Fig. 6/1) by
thesuctionturbine(Fig. 6/5)andfiltered
out there. Only dust-free air is fed back
into the ambient air.
Fig. 6
1 Panel air filter
2 Dirt hoppers
3 Rotary brush
4 Side brushes
5 Suction turbine
Sweepmaster P800
The Sweepmaster P800 is equipped
with a gasoline engine and is filled with
approx. 2.5 l gasoline.
Sweepmaster B800
To charge the batteries, the
Sweepmaster B800 is equipped with a
corresponding, fully automatic on-
board charger. To protect the battery
against total discharge, the
Sweepmaster B800 is provided with a
total discharge signal transducer (TSG)
which indicates the battery status
during the charging process and
discharging.
4321
5