HAKO Scrubmaster B 115 R Installation and operation manual

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Scrubmaster B 115 R
(7090.11/21/35/41/51/81/91)
Service-Handbuch
Service Booklet
Hako GmbH .Technisches Produktmanagement . D-23840 Bad Oldesloe .Stand 09/2014
Vertraulich –nur für den internen Gebrauch .For internal use only!
Schulung/Training
Fehlersuche/Troubleshooting
Einstelldaten/Adjustments

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Contents
1 Information 6
2 General Information 7
2.1 Settings 9
2.1.1 Connection with the Diagnosis-Computer 11
2.1.2 Flashing of the control unit 13
2.1.3 Connection schemes with the different interfaces 15
2.2 Short Description 16
2.2.1 Deactivating Vacuuming / Dirty Water Tank Full 17
2.2.2 Home Position of the Machine 18
2.2.3 Seat Contact Switch (3.6.6.4.) 19
2.2.4 Introduction to Programming 21
2.2.5 Reset Last Error Which Occurred in the Start Screen 25
3 Technical Data 26

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Contents
4 Maintenance Intervals 29
4.1 Hako System Maintenance (Customer) 30
4.2 Hako System Maintenance I 31
4.3 Hako System Maintenance II 32
4.4 Hako System Maintenance S 33
5 Cleaning Programs 34
6 Machine Settings 37
6.1 Basic Settings 37
6.1.1 Machine Type 37
6.1.2 Cleaning Units 39
6.1.3 Battery Setting 41
6.1.4 Charger 44
6.2 Settings On Customer Request (PPV) 46

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Contents
7 Mechanical Components 51
7.1 Squeegee 51
7.2 Disk Brush Head 56
7.3 Cylindrical Brush Head 56
7.3.1 Adjustment cylindrical brush head 57
7.4 Brush Head Lifting Unit 59
7.4.1 Potentiometer in the Brush Head Lifting Unit 62
8 Water Pump 63
8.1 Water Quantities 64
8.2 Water Pump Standstill Recognition 65
9 Drive Control Units 66
9.1 ATECH / ZAPI Drive control unit (DC-Motor) 67
9.1.1 Automatic Monitoring of Components 69
9.1.2 Diagnosis LED for Drive Module (ZAPI) 70
9.1.3 Explanations of Error Messages 71
9.2 DMC (AC-Motor) 88
9.2.1 Description of the connectors 88
9.2.2 Error-Codes on the DMC Control unit (AC Motor) 90

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Contents
10 Error Reference Chart with Information on Service Display 96
10.1 Service Counter 3.3.1.1. 101
11 Brakes 103
11.1 Adjustment of Brake (DC-Motor) 104
11.2 Brake of the AC Motor 105
12 Options 106
12.1 Silence Kit 107
12.2 Acoustic Warning Signal 110
12.3 Chemical Dosage 111
12.4 Scrubbing-Vacuum Tool 123
13 Real-Time Clock (RTC) 128
14 Notes 131

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Attention:
•All work on the vehicle may only be completed after disconnection of the power
supply (disconnect the battery plug) with the exception of the current and voltage
measurements.
•When changing high current fuses, only loosen the screws. Never unscrew the
screws completely, otherwise there is a risk of short circuit.
Insert the new high current fuses fully, i.e. evenly under the screws.
•Following repairs, the starting current and operating current must be measured in
order to discover any potential faults.
•The legally binding, generally applicable safety and accident prevention
regulations must be observed when performing any work on the vehicles.
1. Information

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as part of a restyling of the Hako brand names, the name of the scrubber-driers has
been changed from "Hakomatic" to "Scrubmaster". In this document both names are
used equally, because this document is also valid for machines which have been
introduced in the market before the renaming
The Scrubmaster B115 R is equipped with a service indicator in the operating hour
counter display. After switching the key switch on, a four-character code appears for
approx. 3 seconds in the display which indicates the software version (e.g. 1.001),
possibly another four-character code which indicates the last fault which has occurred
followed by the operating hour counter.
As soon as a fault occurs, the open-ended wrench lights up in the display and the
machine beeps. The current diagnostic code (four-character alphanumeric code in
the service indicator) appears with flashing points between the characters. Only
when these criteria are fulfilled is the error currently pending!
There is no diagnostic code which contains a "ZERO".
2. General Information

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B115 R
The Scrubmaster B115 R is available with working widths between 65 cm and 90 cm.
The 7090.35/41/51 models require an external charger; the 7090.11/21/81/91 models
are equipped with an integrated charger.
The 7090.51 model is equipped with a 65 cm disk brush unit; the 7090.11/35 models
are equipped with a 75 cm disk brush unit. The 7090.21/41 models are provided with a
cylindrical brush unit with a working width of 70 cm.
The working width of the disk brush unit (7090.81) is 90 cm and working width of the
cylindrical brush unit (7090.91) is 85 cm.
The chargers are provided with a separate operating manual enclosed with the device
and which contains descriptions of the operating and fault conditions of the charger.
2. General Information

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The relevant settings can be defined in the machine's Configuration menu. The
diagnostics connector with order number PN 03006790 is required in order to define
these settings.
The settings to be defined include:
•Machine type / Cleaning unit
•TSG (total discharge signal transducer) / Battery type
•Options
•Deletion of the display of the last error on completion of repairs
•Programmable program versions (PPV)
•Fixed program versions (FPV), cleaning programs
These settings can also be entered via the diagnostics system using a service PC. In
this case, a PC with min. 1x USB 2.0 and 1x RS232 port, the diagnostic cable PN
03502110 and CAN interface PN 03501750 (alternative the service interface PN
03502430) represent the hardware required. Windows XP or Windows 7 must be
installed as the operating system on the PC. The diagnostics software required for the
Scrubmaster B115R is contained on the current Hako Diagnosis CD-ROM (85-00-
2144).
2.1 Settings

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A new machine control unit is delivered from spares stock without machine software.
Only the Boot-loader is pre-installed on the control module.
This can be recognized by the jumping “F” in the hour meter display of the dashboard,
after the control module is mechanically and electrically installed in the machine and
the keyswitch is switched “on”.
Therefore, after mechanical and electrical installation of the control module, the
machine software must be flashed on the control module.
This requires the same preconditions (hard- and software), like for the diagnosis of the
machine.
2.1 Settings

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2.1.1 Connection with the
Diagnosis-Computer
To activate the control unit PN 01273590 for a Scrubmaster B115 R after a
replacement, the following components are necessary:
•up to date Hako Diagnosis software (DVD 85-00-2144/xx)
•Service computer (e.g. CF19 Hako order No. 03501860, english keyboard)
•Interface PN 03501750* (as Software-License) or 03502430** (as Software-
License and USB to RS232 (COM) converter) –works only at the B115 R as a
converter USB to RS232
•B90CL-serial-connect-cable (Diagnosis cabel) PN 03502110***
•Diagnosis plug PN 03006790
Connection schemes with the two different Interfaces see chapter 2.1.3

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Please download the up to datet diagnosis software (HakoDiagnose) as folder or
as zip-file (810MB) from e.g. the FTP-server:
Link: ftp://217.7.18.253
Benutzername / user name: Hako-Kunden
Kennwort / Pass word: N3GRBX6M7PCT
Alternative please download the latest revision of the diagnosis software from Hako-
Download server. For information regarding the access to this download server,
please ask Mrs. Maike Christiansen under e-mail: [e-mail]
To install the diagnosis software on a service computer:
1) Delete the folder "C:\HakoDiagnose" and „C:\MDT“ from the Harddisk of your
Service computer. Then delete the old desktop shortcuts.
2) Copy the folder "HakoDiagnose" to your Hard disk "C:\"
3) Open the folder "C:\HakoDiagnose\Runtime V1.XX.YYYY\" and run the programm
"setup.exe"; Confirm all checkboxes
2.1.1 Connection with the
Diagnosis-Computer

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To flash the B115 R control unit:
- Install the control unit PN 01273950 complete in a machine. Activate the back up
battery by removing the insulating strip between the button cell CR2032 and the
battery holder on the back oft he pcb (PN 01273590)
- Connect the Interface (*/**) to a free USB port of your service-computer.
- Connect the control unit to the service PC with the known devices (SIE-Interface -
PN 03501750* (or PN 03502430**) at a USB port. The D-SUB9 connector of the
B90CL-serialconnect-cable - PN 03502110*** is connected to the RS232 port of
the computer, if the Interface * is used. In case the Interface ** is used, connect
the DSUB9 connector of the Diagnosis cable with the D-Sub9 connector of the
Interface **, that is marked with "RS232". The Molex 6-Pin connector is pluged
into connector X3 of the machine control unit.
- Switch on the power of the machine.
- Run the Hako Diagnosis Software. Select the button "HAKO", then the button
"Scrubmaster B115 R / Hakomatic B115 R". This will start the flashing tool for the
Scrubmaster B115 R. The flash-tool looks for a (brand new) control unit.
2.1.2 Flashing of the control unit

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- Follow the instructions, key in the Hako-serial and do not disconnect the cable and /
or switch off the computer or the machine before the job is completed.
-The settings for options, battery type and parameter you can change by using the
buttons on the operating panel with pluged diagnosis plug. Please follow the
Service Booklet.
-
•SIE-Interface - PN 03501750 - at a USB port is required as a license dongle for
the software
** SIE-Interface - PN 03502430 - at a USB port is required as a license dongle for
the software and as a converter USB to RS232 (COM)
*** B90CL-serial-connect-cable - PN 03502110- is the communication cable between
the control unit PN 01273950 and the RS232 port of the computer. The
communication connector on the control unit PN 01273950 is connector X3.
2.1.2 Flashing of the control unit

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2.1.3 Connection schemes with
different interfaces
Configuration (1) with Interface PN 03501750 *:
Configuration (2) with Interface PN 03502430 **:

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The vehicle is controlled by means of the following electronics:
•Central electronics system (A1)
•Operating and indicator panel (A2)
•Drive control (A4)
The control electronics (A1) assumes all the control and monitoring tasks in the
vehicle except for the driving functions.
No special diagnostic code appears in the display should a drive control error occur
because the drive control is provided with a separate diagnostics display (blink code
via the LED on the drive control) (see Chapter 9).
It is possible to switch between the buttons controlling scrubbing and vacuuming and
the green Hakomatic button for combined cleaning as required so that the function
selected at any moment is activated. On pressing the "Boost" button, the brush
pressure is increased and the water quantity is set to its maximum level, as long as
this button is depressed.
The hand-operated tool can only be used when the parking brake is applied and the
seat contact switch is open.
2.2 Short Description

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Vacuuming is switched off manually by the operator using the corresponding button or
automatically when the “Dirty water tank full” signal is received in order to protect the
suction turbines.
Deactivation by the operator:
•Squeegee is raised
•Suction motor switches off after a delay (15 second)
Deactivation due to full tank:
•The “Dirty water tank full” switch opens as soon as the tank is full
•If the switch remains open longer than 3 seconds (splashing protection), the
squeegee is raised and the suction motor is switched off after a delay (15 seconds).
2.2.1 Deactivating Vacuuming /
Dirty Water Tank Full

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After switching the machine on, all the components are set to their "home position"
when the seat contact switch is actuated (closed).
The lifting elements are raised as long as they have not been switched off by the
microswitch monitoring the top end position integrated in the lifting element.
The motors are switched off and the LED indicators in the cleaning component
operating panel go out.
The lifting unit for the brush head has an integrated position detector controlled via a
potentiometer.
When disassembled, the spindle of the lift element must not be turned, otherwise the
positioning of the lift elements is disadjusted.
2.2.2 Home Position of the Machine

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The seat contact switch is connected to the control electronics A1 at A1:X9.8+18.
The control electronics (A1) reacts to the opening of the seat contact switch with a 2-
second delay. This means: if the contact is opened for longer than 2 seconds during
operation, the motors stop and the brush head and squeegee are raised.
If the switch is closed again within the 2 seconds, the machine continues to operate
without any interruption.
If an attempt is made to switch the machine on without the seat contact switch being
closed or the switch is open for longer than 2 seconds, all the machine's functions
(driving and clean) are inhibited.
If the seat contact switch remains closed or opened for longer than 6 hours without an
interruption, all the machine's functions are deactivated. The service code 3.6.6.4.
appears in the operating hour counter. It is only possible to drive at this point. If the
key switch is switched off and on again without the seat contact switch being opened
or closed, the driving function is deactivated too.
2.2.3 Seat Contact Switch (3.6.6.4.)

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To reactivate the machine functions after the “seat contact switch manipulation” was
triggered, the control system needs to recognize a change in switch position
(ON-OFF-ON or OFF-ON-OFF).
Sear contact closed means, the operator is on the seat;
Seat contact open means, no operator is on the seat.
When the seat contact switch is closed, the hour meter in the display is constant on,
while it is blinking, when the switch is open.
The drive control is provided with its own diagnosis and self-test.
Therefore, the function of the drive control is inhibited when the machine is switched
on if the drive potentiometer is not in its neutral position or is not detected as being in
neutral.
The same occurs after the seat contact switch has been opened and is closed again.
Even when the seat contact switch is closed, the drive potentiometer must be in
neutral, or rather: detected as being in neutral by the drive control.
If the drive control detects the drive potentiometer as not being in neutral, it initiates
flashing signals (LED) on the drive control.
2.2.3 Seat Contact Switch (3.6.6.4.)