HAKO Citytrac 4200 Installation and operation manual

Service-Handbuch
Service-Booklet
Schulung/Training
Fehlersuche/Trouble Shooting
Einstelldaten/Adjustments
Baukomponenten/Zulieferer
Components/Suppliers
Hako-Werke GmbH
.
Technischer Kundendienst 23843 Bad Oldesloe
.
Stand 03/2009
Vertraulich – nur für den internen Gebrauch
.
For internal use only!
Hako - Citytrac (8010.11 / 8010.12)
Hako - Citymaster (1433.11 / 1433.12)
Hako - Citycleaner (1433.52)

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
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Contents
1.0 Product Description
1.1 Product description 6
1.2 Short operator manual 8
2.0 Technical Data
2.1 Technical data 13
2.2 Overview service 15
3.0 Assembly and Mechanical Design
3.1 Articulated 4-wheel chassis 17
3.1.1 Articulated steering 17
3.1.2 Hydraulic motor 17
3.2 Accelerator 18
3.3 Engine hand throttle 20
4.0 Engine
4.1 Engine identification system 22
4.2 Technical data 22
4.3 Overview of components 23
4.4 Crankshaft housing ventilation 25
4.5 Valve clearance adjustment 26
4.6 Changing the injection pump 28
4.7 Engine shutdown solenoid 29

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
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Status
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5.0 Hydraulic Installations
5.1 Safety regulations 31
5.2 Hydraulic pumps 32
5.2.1 Overview of pump locations 32
5.2.2 Variable displacement pump 33
5.2.3 Technical data 35
5.2.4 Hydraulic pump description 36
5.2.5 Flush valve 37
5.2.6 Gear pump, ZP1 39
5.2.7 Gear pump, ZP2 39
5.3 Traction drive 40
5.3.1 System diagram 40
5.3.2 Differential lock valve 43
5.3.3 Switching valve, working/transport mode 46
5.4 Work hydraulics 50
5.4.1.1 Valve manifold, old 50
5.4.1.2 Valve manifold, new 51
5.4.1.3 Torque, valve manifold 52
5.4.1.4 Measure values solenoid valves 53
5.4.2.1 Valve manifold, system diagram, old 55
5.4.2.2 Valve manifold, system diagram, new 56
5.4.3 Function description, valve manifold 57
5.4.4 Proportional throttle cartridge 60
5.4.5 Functions, system diagram 61
5.4.6 Proportional valve control unit 66
5.4.7 Hydraulic connections for front attachment devices 68
5.4.8 Rear connections 69
5.5 Citycleaner hydraulics 70

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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6.0 Electrical Installations
6.1 Safety information 76
6.2 Basic principles 77
6.3 Fuse box, cab 79
6.4 Fuse box, trailer 81
6.5 Overview of components 82
6.6 Front attachment device connector 84
6.7 Rear attachment device connector 87
6.8 Rear device connector assignment 89
6.9 Switching functions 91
6.10 Controller water regulation 94
6.11 Relay surface pressure 95
7.0 Options
7.1 Multipurpose packet 97
7.1.1 Path-dependent spreading 97
7.1.1.1 Electrical circuit 98
7.1.1.2 Control unit 100
7.1.2 Rear connections 102
7.2 Grass and leaf collector 103
7.3 Workingtime counters / Mileometer 105
7.4 High pressure cleaner 108

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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Hako - Citytrac 4200
Hako - Citymaster 1200
Hako - Citycleaner
Product Description

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
6 of 108
1.0 Product description, Hako – Citytrac 4200 / Citymaster 1200
Citytrac Lawnmower: Citytrac Snow plough and gritting:
Flexible working width, 1.50 and 1.80 m with side ejection Snow clearance with spring-mounted blade, 1.50 and 1.70 m,
rear ejection or mulchmower. Cutting height adjustment 3-10 cm. in combination with hydraulic rollers or combination gritting,
1.20 / 6 m working width
Citytrac Grass-Leaf vacuumunit Citymaster Sweeping:
In combination with lawnmower to collect directly Hydraulically powered suction fan
the grass and leafes. The suction fan is hydraulicly
driven

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
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Status
March 2009
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1.0 Product description, Hako – Citytrac 4200 / Citymaster 1200
Citymaster Hand-held suction hose Citycleaner
Optionally equipped with the strong hand-held suction Wet sweeping unit to clean special outdoor
hose for cleaning gutters and drains surfaces

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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1.2 Short operator manual
1control panel r.h. 1cobination switch, flasher/horn
2control panel l.h. 2rocker switch, suction fan/water pump (mower deck option)
3control console, right 3working lights
4control console, left 4rotating beacon
5control panel, cabin roof 5hazard flasher
6pedals 6pilot lamp, direction indicator
7sun blind 7pilot lamp, coolant temperatur
8auxiliary tools 8pilot lamp, battery charge
9driver seat 9pilot lamp, pre-glowing
10 pilot lamp, oil pressure
11 pilot lamp, low fuel
12 clean water for suction mouth nozzle

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
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Status
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1keypad, lifting, lowering and pivoting front attachments 1heater valve
2speed govenor, engine 2heating, ventilation and a/c (Comfort))
3hourmeter 3rotary switch, fresh air/heater fan
4speed govenor, side brushes 4air flow openings
5ignition lock 5pilot lamp, parking brake
6reset switch for trip hourmeter 6pilot lamp, hydraulic fliud temperatur
7socket 7pilot lamp, dirt hopper lifted
8selector for plough side selection 8switch for implement ground pressure
9plough, r.h. positio 9quick discharge of rear spreader (hydr. circuit 2)
10 plough, l.h. position 10 button for lifting/lowering dirt hopper
11 Reversing signal ON/OFF (option) 11 diving lights /side marker lamps
12 button, windscreen wiper switch and washer
13 interior lighting

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
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Status
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Spezielle Elemente beim
Citycleaner:
1 Tastenfeld Heben und Senken
2 Drehzahlversteller Motor
3 Betriebstsundenzähler
4 Drehzahlversteller für Schrubbaggregat
5 Zündschloß
6 Resettaster für Tagesstunden- / kilometerzähler
7 Steckdose
8 Wahlschalter für hydraulische Zusatzfunktion
9 Wassermenge Schrubbaggregat
10 Andruckverstellung Schrubbaggregat

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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1 2 3 4 5
1opening for windscreen washer reservoir 1coarse particle flap
2parking brake 2differential lock (option)
3lever for recirculation water suction mouth 3brake pedal
4spray water for side brushes 4pedal, reverse ride
5pedal, forward ride

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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Hako - Citytrac 4200
Hako - Citymaster 1200
Hako - Citycleaner
Technical Data

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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13 of 108
2.0 Technical data
Vehicle dimensions CT 4200 DA CM 1200
Length without attachment devices / with
circular brushes
mm 3090 3944
Width without attachment devices mm 1325 1193
Height above cabin without / with beacon lamp mm 1995 / 2200
Wheelbase mm 1430
Track gauge, front mm 998 984
rear mm 998 984
Turning diameter: outer mm 5125 5500
Weight
Unloaden weight acc. to StvZO kg 1400 1800
Gross vehicle weight kg 2500
Axle load
Permissible axle load front kg 1500
rear kg 1500
Engine
Manufacturer Yanmar Co. LTD
Type 4 TNV 88 MHW
Method of operation 4-stroke diesel, direct injection
Output kW 33
Bore / Stroke mm 88 / 90
No. of cylinders / arrangement 4 cylinder / row
Cubic capacity cm
3
2190
Idling speed rpm 1100±50
Operating speed rpm 2450
Max. speed rpm 2750 ±25

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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Valve clearance inlet / outlet (cold) mm 0.20
Air filter cartridge Spare part no.:: 114 – 347
Backup cartridge Spare part no.:: 114 – 348
Fuel system
Tank volume Ltr. Approx. 60
Fuel filter cartridge Spare part no.:: 114 - 033
Driving speed
Transport mode (automotive) forwards kph 0 - 25
reverse kph 0 - 12
Work mode forwards kph 0 - 13
reverse kph 0 - 9
Tyres
Size 26 x 12.00 – 12/8 PR 195 R 14 C
Load bearing capacity kg 750
Air pressure bar 1.5 3.0
Wheel bolt tightening torque Nm 130
Hydraulic system
Traction drive Variable displacement pump, Rexroth A10VG
Hydraulic motors with hydr. diff. lock Sauer Danfoss TMKW 250
2-circuit work hydraulics
Electrical installations
Nominal voltage Volt 12
Starter battery V/Ah 12/74
Three-phase generator V/A 12/80
Starter V/kW 12/2.3
2.2 Overview service

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
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Status
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Interval
Description once 250 500 750 1000
Change engine oil and replace filter 50h x x x x
Check radiator and coolant hoses for leakage 50h x x x x
Check v-belt at engine for condition and tension 50h x x x x
Check suction fan for speed, bearing play and soiling 50h x x x x
Replace fuel filter 50h x x
Replace hydraulic return7suction filter cartridge 50h x x
Check brake and parking brake function 50h x x
Check idling and operation speed 50h x x
Check wheel bolts for tight seating (130Nm) 50h x
Check ball heads of steering cylinder 50h x
Check fresh air intake filter for cabin fan x x x x
Check brake fluid level x x x x
Check wearing plate in dirt hopper x x x x
Clean air cleaner element x x x x
Check exhaust system for damages x x x x
Replace air cleaner element x x x x
Check water separator at fuel system x x x x
Replace safety cartridge of air cleaner x
Check engine air gap inlet/outlet (0,2mm) with cold engine x
Replace diaphragm in valve bonnet of engine ventilation system x
Change hydraulic fluid x
Replace ventilation filter in hydraulic tank x
Change coolant x
Change brake fluid x
Check brake shoes x
Check tires x
Replace bowden cables at engine (1x) and drive pump (2x) x
Articulated joint, check play and rubber damper x

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
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Hako - Citytrac 4200
Hako - Citymaster 1200
Hako - Citycleaner
Assembly and Mechanical
Design

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
17 of 108
3.1 Articulated 4-wheel chassis
3.1.1 Articulated steering
Pendulum articulated joint with shock absorption
Maintenance:
-Grease weekly
-Check condition of rubber stops and for signs of wear
3.1.2 Hydraulic motor
Torque:
Retaining screws 100 Nm
Turn castle nut 350 Nm
further until the next pin
hole

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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Bowden cable, hand throttle
(from cabin)Stop screw forwards pedal
wheel speed 225 rpm
3.2 Accelerator pedal
The following adjustments must be carried out in the sequence described each time
the Bowden cables or couplings have been disassembled.
1. Bowden cable from throttle to accelerator pedal:
•Adjust so that the microswitch on the accelerator pedal is actuated
when the throttle is at the first notch.
•The entire path of travel for the throttle must be free to a point behind
the second notch must be available.
2. Bowden cable from accelerator pedal to drive engine:
•Set the throttle to transport ride (before the first notch).
Use the rear adjusting bolt to set the
engine to 1100 ± 50 rpm.
•Adjust the front adjusting bolt to set
the maximum speed of 2750 rpm.
Attention!
Check each 1000h the complete part
for wearout of bushings
, springs etc.

Citytrac 4200
Citymaster 1200
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Service Documents
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Status
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Bowden cable, engine speed adjustment
Stop screw reverse pedal wheel speed
100 rpm
Throttle
Idling 1100 rpm
Max. speed 2750
3. Bowden cables in the hydraulic pump:
•Raise the front of the machine, set the hand throttle to "Transport mode", actuate the parking brake and secure the machine by
positioning chocks against the rear wheels.
•Disconnect both cables from the accelerator pedal and check that the pedals are parallel.
•Hook in the cables for the forward ride and adjust them so that the pump is not moved when the pedals are in a neutral position.
Adjust the stop screw so that the average of both front wheel speeds is maximally 225 rpm.
•Hook in the cable for reverse ride and adjust until the average speed is 100 rpm
Microswitch
S22
here

Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
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3.3 Engine hand throttle
The throttle serves to adjust the engine speed and select the driving
mode.
Up to first notch:
Engine idling; transport mode (2-wheel, max. 25.0 km/h)
Automotive mode; work hydraulics disabled
Behind first notch:
Engine idling; work mode (4-wheel, max. 12.5 km/h)
Automotive mode; work hydraulics enabled
In front of the second notch:
Preferred speed 2450 rpm; work mode (4-wheel, max. 12.5 km/h)
Automotive mode; work hydraulics enabled
End stop position:
Max. engine speed 2750 ± 25 rpm; work mode (4-wheel,
max. 12.5 km/h)
Automotive mode; work hydraulics enabled
Attention:
The Bowden cable actuates a cam disk on the accelerator pedal and
has no direct connection to the engine.