Hako
Hako
Hako
No part of this publication may be reproduced, translated or used in any form or by any means
– graphic, electronic or mechanical including photocopying, recording, taping or information
storage or retrieval systems – without prior permission in writing from Hako-Werke GmbH.
The technical data, special equipment (options) as well as the figures in this Operation
Manual are not binding.
Certain special equipment (options) in this Operation Manual may not yet be available at the
time of the delivery.
Subject to modifications.
These operation and maintenance instructions are valid only for the following models/vehicle
versions:
The cover features the vehicle with possible optional equipment.
Hako-Werke GmbH
Hamburger Straße 209-239
D-23843 Bad Oldesloe
Telefon (04531) 806-0
Table of Contents
BuchIVZ.fm I-1
Table of Contents
4 Maintenance.................................................................................................... 4-1
4.1 Introduction ...................................................................................................... 4-1
4.1.1 Accessibility to assemblies .............................................................................. 4-1
4.1.2 Removing the cover ........................................................................................ 4-2
4.2 Fuel system ..................................................................................................... 4-3
4.2.1 Specific safety instructions .............................................................................. 4-3
4.2.2 Specification of diesel fuel ............................................................................... 4-3
4.2.3 Refuelling ........................................................................................................ 4-4
4.2.4 Bleeding the fuel system ................................................................................. 4-6
4.2.5 Fuel filter maintenance .................................................................................... 4-8
4.3 Engine lubrication system ............................................................................... 4-10
4.3.1 Engine oil specification .................................................................................... 4-10
4.3.2 Checking the oil level ...................................................................................... 4-10
4.3.3 Topping up engine oil ...................................................................................... 4-11
4.3.4 Changing the engine oil ................................................................................... 4-12
4.3.5 Changing the engine oil filter ........................................................................... 4-13
4.4 Cooling systems .............................................................................................. 4-14
4.4.1 Specific safety instructions .............................................................................. 4-14
4.4.2 Specification of engine coolant ........................................................................ 4-15
4.4.3 Checking the coolant level / Topping up the coolant level .............................. 4-16
4.4.4 Draining the coolant ........................................................................................ 4-17
4.4.5 Cleaning the cooling ribs ................................................................................. 4-18
4.4.6 Checking the V-ribbed belt .............................................................................. 4-19
4.5 Air filter ............................................................................................................ 4-22
4.5.1 Replacing the filter cartridge ............................................................................ 4-22
I-2 BuchIVZ.fm
Table of Contents
BuchIVZ.fm I-3
Table of Contents
I-4 BuchIVZ.fm
Introduction
1 Introduction
1.1 Notes on this Operation and Maintenance Manual
This operation and maintenance manual contains important information
on how to work safely, correctly and economically with your Citymaster.
Therefore, it aims not only at new operators, but is also a reference for
experienced ones. It helps to avoid dangerous situations, and reduce
repair costs and downtimes. Furthermore, the reliability and the service
life of the vehicle will be increased by following the instructions in the ope-
ration manual. For these reasons, the operation and maintenance manual
must always be kept at hand in the vehicle.
Your own safety, as well as the safety of others, depends to a great extent
on how the vehicle is moved and operated. Therefore, carefully read and
understand this operation and maintenance manual prior to the first drive.
This operation and maintenance manual will help to familiarise yourself
more easily with the vehicle, thereby enabling you to use it more safely
and efficiently.
Prior to the first drive, carefully read Section 2 "Safety Instructions” as
well, in order to be prepared for possible dangerous situations, as it will be
too late for it during operation. As a rule, keep the following in mind:
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the vehicle do not only depend on
your skill, but also on maintenance and service of the vehicle. This is why
regular maintenance and service work is absolutely necessary. Extensive
maintenance and repair work should always be carried out by an expert
with appropriate training. Insist on using original spare parts when perfor-
ming maintenance and repair work. This ensures operating safety and
readiness and condition in accordance with the regulations of your vehicle
and maintains its value.
Your authorised Hako dealer will be pleased to answer further questions
regarding the vehicle or the operation and maintenance manual.
X56b110.fm 1-1
Introduction
1.3 Abbreviations/Symbols
Abbreviation/
Explanation
Symbol
This symbol shows the direction of travel – for better
orientation in figures and graphics.
ADR Work speed control
AWS Superstructure change system
BG Size
Bh Operating hours
EBD Electronic brake effort distribution system
DIN German Industrial Standard
NW Nominal width
o. Abb. not shown
SO Option
Used whenever controls or other components of the
vehicle are installed as an option.
SWV Quickhitch facility
UVV Accident prevention regulations
StVO Road Traffic Regulations of the Federal Republic of
Germany
StVZO Road use registration of the Federal Republic of Ger-
many
1-2 X56b110.fm
Introduction
• Vehicle type:
• Serial no.: WMU _ _ _ _ _ _ _ _ _ _ _ _ _ _
• Hako-article no.:
• Commissioning / date of registration:
• Operating hours / kilometre reading:
• Engine no.:
• Hydraulic pump no.:
• Hydraulic motor no.:
• Front wheel no.:
• Rear axle no.:
• Optional implements:
Please enter the applicable vehicle data in the above list. They will imme-
diately be at hand for all inquiries or spare parts orders.
• Telephone:
X56b110.fm 1-3
Introduction
1-4 X56b110.fm
Introduction
1.6 Implements
The available implements will primarily determine where and how the
vehicle can be used.
The following implements are available:
• Outdoor cleaning:
• Compact sweeper including sweeping unit, suction port and dirt
hopper
• Optional winter service accessories:
• Additional parts for fitting winter service tools
• Snow blade
• Sand and salt spreader on rear
• Pre-sweeper
• Tipping platform in combination with spreader assembly
Bear in mind the following when driving on public roads with implements
fitted.
• The legal regulations of your country, especially those concerning the
use of implements
• The regulations specified in the operation licence or in the vehicle
papers
• The axle loads specified in the operation licence or in the vehicle
papers as well as the gross weight rating
In addition, bear in mind the mandatory regulations relevant to accident
prevention.
X56b110.fm 1-5
Introduction
1.7 Regulations
Driving licence According to the old Driving Licence Act of the Federal Republic of Ger-
many, the driver of the Citymaster used as a machine or other vehicle tool
carrier must be bearer of a driving licence of the following classes:
• Class 2: Motor vehicle of 7.5 tons or more or combination with more
than 3 axles with bearing in mind the total weights of the combination!
• Class 3: Motor vehicle of up to 7.5 tons. Applies for drawbar combina-
tions as well (= Citymaster as tool carrier plus trailer) and including not
more than three axles; (towing a single-axle trailer only is admitted; two
axles with a distance of 100cm and less are considered as one axle.
According to the reformed German Driving Licence Act applicable from
1.1.1999, drivers of the Citymaster used as a machine or other motor
vehicle - tool carrier must be bearer of a driving licence of the following
classes:
• Class C: Motor vehicle of 3.5 tons and more with trailer of up to 750 kg
• Class CE: Motor vehicle of 3. 5 tons and more with trailer of 3.5 tons
and more (but limited to up to a total combination weight as specified by
the manufacturer)
• Classes B and BE: Motor vehicle of up to 3.5 tons and trailer of up to
750 kg (admissible total weight) or trailer of up to the empty weight of
the towing vehicle as long as an admissible total weight of 3.5 tons for
the combination is adhered to.
Equipment The legal regulations of your country may require you to equip your
vehicle with the following (not included in the scope of delivery):
• 1 warning triangle with design certification
• 1 warning light with design certification
• 1 warning vest
• 1 first-aid kit in accordance with the legal regulations of your country
Observe the relevant national regulations in your country.
1-6 X56b110.fm
Introduction
Documents Observe the legal regulations of your country which deal with the docu-
ments required for driving and working with the vehicle, such as driving
licenses, general certifications, vehicle registrations etc.
• Vehicle registration certificate
• Valid driving licence of vehicle driver
Observe the relevant national regulations in your country.
X56b110.fm 1-7
Introduction
A B
Fig. 1:
Vehicle ID on chassis
The Vehicle ID is stamped on the vehicle frame on the front right side
(behind the foothold).
Example:
WMU2X560V4W000001
Fig. 2:
Engine number
The engine number is located on the diving groove engine/gear.
Supplementary is fixed on the toothed belt cover a sticker with „engine
code letter“ and „serial number“.
Example:
CBKA/01176
Fig. 3:
Hydraulic pump
The type label (arrow) is located on the flange connecting the hydraulic
pump to the engine.
Example:
A4VG40 EP1DT1/32R-NAC02F025LT
9602124 252.15.41.10
Identification no. 4420219
Fig. 4:
1-8 X56b110.fm
Introduction
Hydraulic motor
The type label (arrow) is located on the lower side of the hydraulic motor
housing.
Example:
A6VM 80 EP1/63W-VZB017DAT
9604224 262.20.42.75
Identification no. 4465615
Fig. 5:
Rear axle
The rear axle number is stamped on top of the input flange.
Example:
Y 732211
Fig. 6:
Fig. 7:
50 The labels are located at the vehicle rear and at the hopper sides.
Fig. 8:
Hako-Label:
The Hako labels are located under the windscreen wipers, at the lateral
fairing and the hopper rear.
Safety foil
Safety foils (red/white) have been attached at the front under the head-
lights and to the tool box at the rear.
Fig. 9:
X56b110.fm 1-9
Introduction
Burning surfaces
Burning hazard due to heated surfaces of the cooling system. The label is
located at the radiator.
Rotating parts
Risk of injury due to rotating parts of the cooling system. The label is loca-
ted at the radiator.
Fig. 12:
1-10 X56b110.fm
Safety instructions
2 Safety instructions
2.1 Identification of warnings and dangers
Important indications regarding the safety of the operating personnel and
the vehicle are indicated in this operation manual with the following terms
and symbols:
Danger!
Caution!
Important!
Environment!
Failure to observe the instructions identified by this symbol may
result in damage to the environment.
The environment is in danger if environmentally hazardous
material (e.g. waste oil) is not subject to proper use or disposal.
2.2 Warranty
Warranty claims can be made only if the conditions of warranty have been
observed. They are included in the General Conditions of Sales and Deli-
very for vehicles and spare parts manufactured or sold by Hako-Werke
GmbH, Federal Republic of Germany. Furthermore, the instructions in this
operation manual must be observed.
X56b210.fm 2-1
Safety instructions
2-2 X56b210.fm
Safety instructions
X56b210.fm 2-3
Safety instructions
2-4 X56b210.fm
Safety instructions
Danger!
X56b210.fm 2-5
Safety instructions
2-6 X56b210.fm
Safety instructions
• Never get on or off a moving vehicle! Never jump off the vehicle!
• Should the lights of the vehicle not be sufficient for the safe execution of
certain work processes, provide additional lighting of the work area.
• Installed work lights must not be switched on during travel on public
roads. They can be switched on in work operation if users of public
roads are not dazzled.
• Hydrostatic four wheel steering takes time getting used to it. Therefore,
adjust the driving speed to your abilities and the circumstances.
Selection and change of steering mode at vehicle standstill only!
Trailers and implements The below items refer to trailer operation and apply only for Citymaster
being registered as other motor vehicle - tool carrier (For machines, ope-
ration with trailer is prohibited).
• Prior to driving on public roads unhitch the implements which can not
be secured in compliance with the legal regulations of your country.
• Implements, trailers and ballast weights affect handling, as well as the
steering and brake capability of the vehicle! Adapt the handling accor-
dingly!
• Fix the implements and the trailers with the specially required devices
only!
• Secure trailers and implements to prevent them from rolling away!
• Trailer operation is authorised only if the trailer coupling is in normal
position and if the coupling pin is safely locked.
• Hitch the trailer according to the legal regulations of your country.
Check the function of the trailer brake system. Observe the manufac-
turer's instructions.
• Observe the maximum authorised drawbar load and trailer weight on
the trailer coupling!
• Coupling implements requires special care!
• Before uncoupling or coupling hydraulic lines (hydraulic quick couplers)
• Switch off the engine
• Unpressurise hydraulic connections (see page 3-74)
• Operate the vehicle only if all protective facilities have been installed
and are functional, and if all brake, light and hydraulic connections have
been connected!
• Do not exceed the admissible total weights as specified in the type
approval and applicable for the vehicle, for the front and rear axle loads
and the entire combination (vehicle plus trailer or attached implement).
• If optional equipment is installed, all additionally required light installa-
tions, telltales, etc., must be provided for and functional.
X56b210.fm 2-7
Safety instructions
• Mount the implements only if the engine has been stopped and the
drive switched off.
• Especially when driving or working with vehicles provided with a quick-
hitch facility for the implements, make sure that the implement is safely
locked in the quickhitch facility. Check before starting work.
• Make sure hydraulic hoses are connected correctly when connecting
hydraulic cylinders and hydraulic motors.
• Be careful when coupling implements: risk of personal injury due to
crushing and shearing. Make sure nobody is between the vehicle and
the equipment without securing the vehicle and the implement against
movement.
Transport • The vehicle must be towed, loaded and transported only in accordance
with the operation manual!
• For towing the vehicle observe the prescribed transport position, admis-
sible speed and route.
• Safely secure the vehicle on means of transport! Use suitable mounting
points and load-securing devices.
• Restarting after transport must be strictly in accordance with the
operation manual!
2-8 X56b210.fm
Safety instructions
X56b210.fm 2-9
Safety instructions
Gas, dust, steam, smoke • Operate the vehicle only on adequately ventilated premises! Before
starting internal combustion engines or operating fuel-operated heating
systems on enclosed premises, make sure that there is sufficient venti-
lation!
Observe the regulations in force at the respective site!
• Carry out welding, flame-cutting and grinding work on the vehicle only if
this has been expressly authorised. For For example, there may be a
risk of explosion and fire!
• Before carrying out welding, flame-cutting and grinding work, clean the
vehicle and its surroundings from dust and other inflammable
substances, and make sure that the premises are adequately
ventilated – risk of explosions!
2-10 X56b210.fm
Safety instructions
Hydraulics • Work on the hydraulic equipment of the vehicle may be carried out only
by persons with special knowledge and experience in hydraulic
systems!
• Check all lines, hoses and screwed connections regularly for leaks and
obvious damage! Repair any damage and leaks immediately! Splashed
oil may cause injury and fire.
• In accordance with the operation manual/instructions for the respective
assembly, unpressurise all system sections and pressure lines
(hydraulic system) to be opened before carrying out any implementing/
repair work!
• Ensure that no hydraulic connections are interchanged. The fittings,
lengths and quality of the hoses must comply with the technical require-
ments.
Battery • When handling the battery observe the specific safety instructions and
regulations relevant to accident prevention. Batteries contain sulphuric
acid – caustic!
• During charging in particular, but also during normal battery operation,
an oxyhydrogen mixture is formed in the battery cells – risk of
explosion!
• In the case of a frozen battery or an insufficient electrolyte level, do not
try to start with a battery jump cable. The battery can burst or explode.
Tyres • Repair work on tyres and rims may be carried out by skilled personal or
by an authorised workshop only!
• Damaged tyres and/or wrong tyre pressure reduce the operational
safety of the vehicle. Make regular tyre checks for:
• Prescribed tyre pressure
• Damage
• Do not inflate tyres with inflammable gas – risk of explosion!
• Make regular checks of the wheel nuts for tightness, however, after
150 operating hours or 5000 km at the latest. Check the wheel nuts
after 40 km after changing tyres – tighten if necessary!
Axle loads and total weights • Comply with the admissible axle load and total weight values as
specified in the technical data.
X56b210.fm 2-11
Safety instructions
Sweeping unit • Lift the sweeping unit before proceeding to transport rides!
• The operator has to make sure during sweeping operation that no
person stays in the hazard zone of the sweeping unit and that all
objects have been removed from that zone!
Dirt hopper • Fully lower the dirt hopper before proceeding to transport rides!
• A filled dirt hopper significantly affects handling of the vehicle and it is
recommended to adapt the handling accordingly!
• Empty the hopper and install the safety strut whenever working under
the dirt hopper!
• Nobody is allowed to stay in the zone of danger during the lifting or
lowering of the dirt hopper!
• Passenger transport on the dirt hopper is prohibited!
• Make sure that the folding safety strut has safely locked!
• Be seated before starting, riding or stopping the vehicle!
• Check the fan for wearing and unbalanced condition at regular
intervals!
• Access to fan outlet only after opening of hopper flap or dismounting of
maintenance cover; exhaust air flow is directed to the bottom!
• Mind hot parts of the exhaust system accessible after lifting-out of the
hopper!
2-12 X56b210.fm
Operation Operation
Pos. Description
1 Additional turn indicator (right)
2 Auxiliary headlight for low beam, high beam headlight (right) (option)
3 Working light (front, option))
39
4 Numberplate bracket (front)
18 38
5 Auxiliary headlight for low beam, high beam headlight (left)
6 Additional turn indicator (left)
19 37
7 Wiper
8 Turn indicator (left)
21
9 High beam headlight (left)
36 20
11 10 Low beam headlight (left)
11 Quickhitch facility for implements
10 9 8 12 23-pole socket
16 15 14
12 13 Not used
14 Low beam headlight (right)
15 High beam headlight (right
16 Turn indicator (right)
17 Access (right)
18 Rearview mirror (right)
19 Door handle / door lock (right)
20 Side turn indicator (right)
21 Radiator cover
25 26 33 34
Positionen 25, 26, 33, 34, 36, 37, 38, 39, siehe nächste Seite
Fig. 13:
3-2 X56b310.fm
Operation Operation
Pos. Description
27
38 Rearview mirror (left)
39 Rotating beacon
40 Rotating beacon (option)
22
30
29
Fig. 14:
3-4 X56b310.fm
Operation Operation
Pos. Description
61 47 61 60 61
Vehicle doors
41 Handle (left)
42 Lock for sliding window (left)
43 Door opener/lock (left)
44 Door opener/lock (right)
45 Lock for sliding window (right)
64 46 Handle (right)
46
Operator's compartment controls
47 Steering wheel for power steering
57 45 48 Passenger's seat
62
49 Three-point seat belt
59
41 50 Seat belt – buckle
56
54 55 51 Storage compartment for tool kit, warning triangle and first-aid kit (behind passenger's seat)
44
42 52 Storage compartment for operation manual (behind passenger's seat), control device
53 Operator's seat
43 54 Brake pedal (service brake)
63 48 55 Accelerator pedal
56 Leg room air vent (left)
53
57 Lever on steering column (left) for steering column adjustment..............................................................................
50 52 58 Ignition switch
58
49 59 3 pole socket
49
60 Combined switch on steering column (right) for wiper, washer system, headlights on and off,
headlight flasher and horn, direction indicator
66
61 Heater nozzle – windscreen
65
62 Leg room air nozzle (right)
63 Parking brake lever
Controls between the seats
64 Drive lever FORWARD/NEUTRAL/REVERSE
65 Rotary switch - 3-stage blower
51 67 68 69 71
66 Recirculated air control lever
72
67 Rotary switch (hot/cold)
68 Radio/transceiver installation area
69 Tachograph (option)
70 Not used
71 Fuse box
72 Towing operation switch (lockable)
73 Not used
74 Not used
Fig. 15:
3-6 X56b310.fm
Operation Operation
Pos. Description
80 81 82 83 84 85 86 87 88 89 90 91
Controls in the roof area
75 Not used
76 Interior light
79
77 Sun visor (left/right)
78 Handles (left/right)
79 Roof console
80 Telltale - direction indicator (tractor vehicle, green)
81 Telltale - direction indicator (trailer, green)
82 Telltale – high beam (blue)
83 Warning light - battery charging, alternator (red)
92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 84 Warning light - engine oil pressure (red)
85 Telltale - engine preheater (yellow)
86 Warning light – brake fluid level (red)
87 Not used
88 Not used
89 Not used
90 Telltale – rear fog light (yellow)
91 Telltale – window heating and mirror heating (option, green)
92 Tip switch – working mode/transport mode
93 Telltale – working mode (orange)
94 Telltale – transport mode (green)
95 Not used
96 Faster winter service in transport mode (option)
97 Tip switch – differential lock (green)
98 Rocker switch – rotating beacon (yellow)
99 Tip switch – front wheel steering/four wheel steering (green)
100 Telltale – four wheel steering (green)
77 77
101 Telltale – front wheel steering (green)
78 78 102 Not used
76
103 Not used
104 Not used
105 Tip switch – heated windscreen / heated outside rearview mirror (green)
106 Not used
Fig. 16:
3-8 X56b310.fm
Operation Operation
Pos. Description
107 108 109 110 111 112 113 113 A 115 116
Centre console controls
107 Superstructure
108 Tip switch - superstructure headlight ON/OFF (green
109 Toggle switch - front working headlight ON/OFF (SO)
114
110 Tip switch - rear fog light ON/OFF (green)
111 Toggle switch - warning flasher ON/OFF (red)
117 119
112 Control light On-Board-Diagnosis-System (OBD)
139
Fig. 17:
3-10 X56b310.fm
Operation Operation
Pos. Designation
145
154
Fig. 18:
3-12 X56b310.fm
Operation
Operation
3.3.2 Taking the vehicle into service for the first time
Important information • The vehicle may be taken into service by authorised personnel only –
see also section "Regulations” of this operation manual
• The operators must have read and understood this operation manual
before taking the vehicle into service
• The vehicle may only be used in technically perfect condition in accor-
dance with its designated use and the instructions set out in the
operation manual, and only by persons who are fully aware of the risks
involved in operating the vehicle
• Go through the "Start-up” check list in the following section
Running-in period Handle the vehicle carefully during its first 100 operating hours.
The future performance and service life of the vehicle are heavily depen-
dent on the observance of the following recommendations during the run-
ning-in period.
• Do not overload the vehicle, but at the same time do not drive too
cautiously either, otherwise the vehicle will never reach its proper
operating temperature
• Do not run the engine at high revolutions for extended periods
• Increase the load gradually whilst varying the engine revolutions
• Strictly follow the maintenance plans (see page 4-63)
X56b320.fm 3-13
Operation
Start-up check list Check the following points before taking the vehicle into service or starting
the engine:
No
Question
.
3-14 X56b320.fm
Operation
Operation check list After starting the engine and during operation, check and observe the fol-
lowing points:
No
Question
.
X56b320.fm 3-15
Operation
Parking check list Check and observe the following points when parking the vehicle:
No
Question
.
3-16 X56b320.fm
Operation
82 blue High beam • When the high beam is switched on (lever 60)
• When the headlight flasher is activated (lever 60)
83 Red Battery charging, • When the ignition is switched on but goes out when
alternator the engine has been started
• The V-belt for the alternator, or the charging circuit
of the alternator is faulty if the telltale lights with the
engine running.
The battery is no longer charged page (see page
4-19)
84 Red Engine oil pres- • When the ignition is switched on but goes out when
sure the engine has been started
• When the engine oil pressure is too low
Caution!
X56b320.fm 3-17
Operation
86 Red Brake warning • When the brake fluid level in the brake system tank
light is too low
Danger!
The brake warning light goes off when the brake fluid level is again in the
admissible range and/or the malfunction of the brake system has been
corrected.
3-18 X56b320.fm
Operation
Colou
Ref. no. Symbol Function Lights:
r
88 not used
89 not used
90 Yellow Rear fog light • When the rear fog light is switched on (tip switch
126)
91 Green Windscreen hea- • When the windscreen heating and the mirror
ting and mirror heating (option) is switched on (tip switch 105)
heating (option)
101 Green Front wheel stee- • When the front wheel steering is switched on (tip
ring switch 99) only in working mode (tip switch 92)
100 Green Four wheel stee- • When the four wheel steering is switched on (tip
ring switch 99) only in working mode (tip switch 92)
• Flashes during the synchronisation until the
process is completed
• Flashes when the rear axle is locked
112 Yellow OBD • Flashes when there is a malfunction of the exhaust
(On-Board-Dia- gas aftertreatment system
gnosis) (Drive on carefully and consult an authorised
workshop without delay!)
117 Red Axle load • When admissible axle load is exceeded
118 Red Parking brake • When parking brake lever 63 of the parking brake
is pulled
Caution!
X56b320.fm 3-19
Operation
Fig. 19:
Operating parameters in the top area of the multifunction display:
Operating parame-
Symbol Unit: Remarks:
ter:
Operating parame-
Symbol Unit: Remarks:
ter:
Time h:min -
Date Day, -
month
Service information h Displays the operating hours until the
next service time
3-20 X56b320.fm
Operation
Operating parame-
Symbol Unit: Remarks:
ter:
Coolant temperature °C -
Time Hours / -
minutes
Clear water l -
Brush h -
X56b320.fm 3-21
Operation
Important!
3-22 X56b320.fm
Operation
Changes:
B
Reset
Settings
Fig. 20:
Menu 1
Menu 2 Menu 3
Contrast:
9
+
_ Year: 03 Language:
Brightness Month: 07 English
Day:
Day: 03 Unit:
10
Brightness Hour: 15 Kilometres
Night: Minute: 10
5
MFA_Menue.eps
X56b320.fm 3-23
Operation
3.4.3 Speedometer
Function:
132 Indicates the current driving speed in kph (kilometres per hour) and mph
(miles per hour).
Important!
The speedometer has been set at the factory to the tyre size fitted
on the vehicle at delivery. If the vehicle is fitted with a different tyre
size, the speedometer must be set accordingly by an authorised
Hako workshop!
Fig. 21:
Important!
Posi-
Function Power consumer
1 tion
2
0 Ignition OFF/parking posi- Parking light, cigarette lighter,
(Stop) tion interior lighting, rotating beacon,
0 Insert or remove the igni- hazard warning light
(Stop) tion key
1 Ignition ON / driving posi- All telltales and warning lights
tion (except 85) light for about.
58 2 seconds
Warning light 87 lights if parking
Fig. 22:
brake 63is applied
System check All telltales and warning lights
light for approx. 3 seconds
Warning lights 84, 83 light
Engine preheating Telltale 85 (preheating) lights,
(below 5 °C approx. engine is preheated until telltale
20 seconds) goes off
All functions are operational
2 Starts the engine Starter is actuated
Telltales and warning lights must
go off
3-24 X56b320.fm
Operation
3.4.5 Brakes
General information Brake lining wear depends very much on:
• Conditions of use, e.g. short or long distance travel
• Flat land, mountains
• Driving style
Therefore it may be necessary to have the brake linings also checked bet-
ween the specified maintenance intervals by your authorised Hako work-
shop.
Danger!
Power brakes The power brakes work with negative pressure which is generated only
while the engine is running.
Danger!
X56b320.fm 3-25
Operation
Danger!
Danger!
63
The brake power of the parking brake depends on the rear
Fig. 23: wheel with the lowest friction factor. When the vehicle is parked
on a slope with one rear wheel placed on solid and dry ground
while the other rear wheel is placed on ice or snow, the
maximum brake power is determined by the friction factor
between the wheel and the ice. Prevent the vehicle from rolling
away!
Accident hazard!
When parking the vehicle on a slope, additionally switch on
four wheel drive
When parking the vehicle on a slope, use chocks as well!
Important!
The parking brake lever acts via a pull cable on a separate brake
drum on the gearbox shaft.
3-26 X56b320.fm
Operation
Brake pedal
Function
• Brakes the vehicle
Actuation of service brake
Press brake pedal 54 depending on the desired braking effect
Important!
54
When the vehicle is fully loaded, a higher braking pressure is requi-
red for braking.
Fig. 24: Pedal travel and foot power to be applied increase
The maximum achievable braking effect of a loaded vehicle
is reduced as compared to an unloaded vehicle
Danger!
X56b320.fm 3-27
Operation
3.4.6 Steering
Danger!
Important!
Do not lock the steering wheel in fully for more than 15 seconds. A conti-
nuous full lock causes the servo pump to heat the hydraulic oil quite stron-
gly. This can damage the servo steering system.
Every full lock while standing is also noticeable by noise because of the
strong load on the servo pump. In addition, the idle speed of the engine is
reduced for a short time.
Steering column adjustment The height and inclination of the steering wheel and steering column 47
can be adjusted to each driver.
Adjust the steering column as follows before starting to drive
47
Steering column adjustment
Height Pull up lever 57 Height of steering column 47
adjustable
Inclina- Push down lever 57 Inclination of steering wheel 47
tion adjustable
57
Fig. 25:
3-28 X56b320.fm
Operation
Danger!
Important!
Important!
Fig. 27:
X56b320.fm 3-29
Operation
3-30 X56b320.fm
Operation
Fig. 29:
67
Fig. 30:
Cruise control Tip switch 129 allows riding the vehicle at constant driving speed. Adjust
the desired speed (2kph min.) with the accelerator pedal and press the
switch to accept it.
Controlng is interrupted by actuation of the brake or by pressing the tip
129 switch. Pressing the tip switch 129 to re-set the adjusted driving speed.
Danger!
X56b320.fm 3-31
Operation
Accelerator pedal
Different drive modes are possible depending on work performed. The
standard mode of the vehicle is the automotive drive mode. Accelerator
pedal 55 regulates the engine revolutions of the diesel engine as follows:
Accelerator pedal Effect
• Press pedal down Engine speed, driving speed increases
• Release pedal slowly Engine speed, driving speed decreases
55
• Release pedal fully The braking effect of the hydrostatic drive
and the diesel engine takes effect
Fig. 32:
Important!
Drive lever
Danger!
Function:
• Selection of forward or backward driving direction
67 • Continuous selection of speed range
V
Important!
0 The engine will not start when drive lever 67 is not in neutral posi-
tion.
R
Fig. 33:
3-32 X56b320.fm
Operation
Drive range selector The hydrostatic drive in the production version allows for two drive modes.
The Transport and Working modes are preselected with switch 92. For
the possible driving speeds in the different drive modes (see page 5-2).
In working mode, the driving speed (0 to 15 kph) allows for precisely
adapting the driving speed to the application with higher driving torque.
The result is uniform and smooth performance.
In transport mode, a higher driving speed (0 to 50 kph) is possible with a
smaller driving torque.
Important!
The engine speed is constant working mode. The driving speed will
regulated over the accelerator pedal.
In the case of cold hydraulic oil (<30^C) or soiled pressure filter, the
top speed limit is no longer reached.
Multifunctional display:
- An additional thermometer is displayed (hydraulic oil <30°C)
- Traction drive pressure filter soiled (hydraulic oil >30°C and soiled
pressure filter)
X56b320.fm 3-33
Operation
Operation
Important!
3-34 X56b340.fm
Operation
Headlights
Important!
When the ignition is switched off with the low beam or high beam
lights on – key in ignition switch 58 in position 0 – only the parking
light remains on!
60
Low beam/high beam/headlight flasher
2
Headlight beam adjustment To prevent dazzling other drivers, the headlight setting can be adjusted or
changed for high load conditions.
Check the headlight setting after every weight change!
Headlight beam adjustment 130 does not affect the setting of the
auxiliary headlights (option).
The basic setting of the headlights must always be performed by
your authorised Hako workshop. Headlight beam adjustment 130
must be in basic position (0) for this adjustment!
X56b340.fm 3-35
Operation
60
Turn indicators
L
LEFT Press combined Telltale 80 flashes, in trailer
(L) switch 60 to the front operation, telltale 81 also
0 flashes
RIGHT Pull combined switch 60 Telltale 80 flashes, in trailer
R (R) to the rear operation, telltale 81 also
flashes
Fig. 39: OFF Combined switch 60 in Telltales 80 and 81 go off
() centre position
Caution!
60
Horn
Fig. 40:
3-36 X56b340.fm
Operation
Fig. 41:
Caution!
Important!
The rear fog light lights only with the low beam or high beam swit-
ched on, but not the parking light.
The rear fog light can also be switched off by switching off the
lights. When the lights are switched on again, the rear fog light also
has to be switched on again.
111
Hazard warning system
0 ON Press rocker switch 111 on Telltale in rocker switch flashes
(1) symbol
1 OFF Press upper half of rocker Telltale off
(0) switch 111
Fig. 42:
X56b340.fm 3-37
Operation
98 Rotating beacon
0 ON Press rocker switch 98 on Telltale in rocker switch on
(1) symbol
OFF Press upper half of rocker Telltale in rocker switch off
1 (0) switch 98
Fig. 43:
Important!
Follow the legal regulations of your country, which may require you
not to switch on the rotating beacon on public roads unless the road
is within the vehicle’s working range and the vehicle represents an
obstruction to the normal flow of traffic when working.
Observe the relevant national regulations in your country.
Fig. 44:
Important!
The working lights light only with the low beam or high beam swit-
ched on, but not the parking light. The working lights can also be
switched off by switching off the lights.
The working lights must only be used when the vehicle is working,
and only if blinding of drivers of vehicles on publicroads is not
expected.
3-38 X56b340.fm
Operation
Auxiliary headlight change- When working with implements covering the lower light systems, e.g. win-
over switch ter use with snow plough, auxiliary headlights are required. A change-over
switch 108 on the instrument panel can be used to switch from the lower
main headlights and direction indicators to the auxiliary headlights and
upper direction indicators.
Important!
The headlight beam adjustment 130 does not adjust the auxiliary
headlights.
Interior light
76 Interior light
0
OFF Set rocker switch of interior Interior light off
(0) light 76 to centre position (0)
X56b340.fm 3-39
Operation
60 Wiper
2. 1. 0 Combined switch 60 in Wiper OFF
0. home position
3. Turn combined switch 60 Interval switching
1
B to the 1st position
2 Turn combined switch 60 Slow
further to the 2nd position
Fig. 47:
3 Turn combined switch 60 Fast
further to the 3rd position
Fig. 48:
Important!
The reservoir for the windscreen washer unit is located behind the
passenger's seat (see page 4-46)!
3-40 X56b340.fm
Operation
Danger!
Important!
65
A Temperature setting
Fig. 49:
1st step Turn rotary switch 65 clockwise to Fan runs at 1st speed
0 position 1
2nd Turn rotary switch 65 further clock- Fan runs at 2nd
1. step wise to position 2 speed
3rd Turn rotary switch 65 further clock- Fan runs at 3rd speed
2. wise to position 3
3. step
Fig. 50:
X56b340.fm 3-41
Operation
Important!
Fig. 52:
Switch the heated windscreen/outside rearview mirror off again
when the windows/outside rearview mirrors are free. High current
consumption!
After approx. 10 minutes, the heated windscreen/outside rearview
mirror are switched off automatically (time lag relay).
91
Fig. 53:
3-42 X56b340.fm
Operation
Operation
Danger!
Fig. 54: The driver seat has been equipped with a seat contact switch. In
case of excessive seat springing adjustment, travel drive cannot be
activated!
Use handwheel D to continuously adjust the seat suspension to the
operator's weight (possible ranges from 50 – 130 kg).
- Driving is only possible when the seat contact switch (driver’s
seat) is actuated.
- Acceleration is only possible when the seat contact switch
(driver’s seat) is actuated.
- Getting up from the driver’s seat (under 18kph) causes the vehicle
to stop.
- If the driver is not on the driver’s seat and the accelerator is pres-
sed or the hand throttle is actuated, the „SEAT CONTACT
SWITCH“ message appears in the vehicle’s multifunctional display.
Backrest adjustment E
Sit down on the operator’s seat
• Press your back lightly against the backrest and pull up lever E at the
same time
• Release lever E and let the backrest engage
X56b342.fm 3-43
Operation
Danger!
3-44 X56b342.fm
Operation
The three-point seat belts are for the operator's and passenger's safety.
Fasten your seat belt before driving as follows
Fig. 56:
Important!
Clean the belt strap with lukewarm water only, do not use solvents!
X56b342.fm 3-45
Operation
Danger!
Important!
The doors can be unlocked and locked only with the door key from
the outside.
42
Fig. 58:
3-46 X56b342.fm
Operation
Important!
Bear in mind the legal regulations of your country and the tacho-
graph manufacturer's instructions!
69
Fig. 59:
X56b342.fm 3-47
Operation
Danger!
Function:
Cigarette lighter and socket for hand lamp etc.
Operation:
When using as cigarette lighter:
Press in cigarette lighter 132
Cigarette lighter 132 returns to its initial position after a couple of
132 seconds and can be pulled out to light a cigarette
When using as socket
Pull out cigarette lighter 132 and keep it elsewhere
Fig. 60: The opening serves as a 12 V socket, max. 10 A
Important!
3 pole socket for superstruc- Socket 59 is located at the left of the centre console below the ashtray.
ture equipment
• Socket for additional equipment
59
Fig. 61:
3-48 X56b342.fm
Operation
12
Fig. 62:
154
Fig. 63:
• Sockets behind the cab 145 (23-polig) for superstructur
145
Fig. 64:
X56b342.fm 3-49
Operation
Operation
Important!
All controls must be within easy reach. You must be able to move
the brake and accelerator pedals to their limit positions!
Danger!
3-50 X56b330.fm
Operation
Caution!
Important!
In the cold season, use oil which is suitable for the temperature
(see page 4-62)
X56b330.fm 3-51
Operation
Service brake
Danger!
The brake lights at the rear of the vehicle do not light up when
the
• Parking brake is applied
When driving on public roads and during work operation, use
the brake pedal 54 to brake the vehicle, so that the brake
lights light up.
Dirt accumulation in the area of the brake pedal can result in
brake malfunctions –
Accident hazard!
Always keep the brake pedal 54 in a clean condition!
Before moving off, press down the brake pedal 54 to check that
• After a maximum of half the pedal travel and high power applied there
is a firm resistance to be felt
• The brake lights lights when the brake pedal is pressed down
After moving off, check in the rearview mirror that no-one will be hinde-
red by a brake manoeuvre
Check the brake action at low speed
Lighting
Functional check: Check all lights on the vehicle and trailer (see page
3-34)
3-52 X56b330.fm
Operation
Caution!
Make sure you have released the parking brake - driving with
the parking brake applied overheats the parking brake and
causes its failure!
Important!
Fig. 66:
The vehicle starts to move only when the operator is sitting on the
operator's seat (seat contact switch)
3.5.5 Driving
The driving speed can be continuously adjusted with accelerator pedal 55.
Depending on the tyres, the maximum speed on even ground is reached
at engine revolutions of 2700 to 2900 rpm. This means that after the acce-
leration phase, accelerator pedal 55 can be released somewhat when dri-
ving on level ground without reducing the driving speed.
This actively contributes to noise reduction as well as reduction of the fuel
consumption.
To achieve maximum acceleration or the maximum speed when driving
55
on an incline, full throttle must be used so that the diesel engine operates
at its rated horsepower at approx. 3100 rpm.
X56b330.fm 3-53
Operation
Important!
Danger!
3-54 X56b330.fm
Operation
Caution!
Differential lock tip switch [97] Switch on the differential lock of the rear axle with tip switch 97.
97 Differential lock
ON Press tip switch 97 on symbol
(1)
OFF Release tip switch 97
1
Important!
Fig. 68: The differential lock can be switched on while driving, but only if the
wheels are not spinning, i.e. as long as the wheels turn with ground
contact and only while driving straight ahead.
The differential lock engages only after the occurrence of low speed
differences at the wheels of rear axle (e.g. when cornering).
The differential lock is active only as long as the tip switch is pres-
sed.
Driving on firm ground with the differential lock switched on increa-
ses tyre wear.
Never use the differential lock longer than necessary.
X56b330.fm 3-55
Operation
Caution!
The vehicle may not be towed with the engine running when
drive lever 67 is not in neutral position and switch 72 was not
pressed!
Towing could damage the hydrostatic drive!
With the engine running:
The vehicle may be towed at a maximum speed of 10 kph and
over a maximum distance of 10 km!
With the engine at a standstill:
The vehicle may be towed at a maximum speed of 5 kph and
over a maximum distance of 2 km!
3-56 X56b330.fm
Operation
Towing operation switch Towing operation switch 72 is located on the right of the cab rear panel
below the fuse box cover
72 A Towing operation
1
ON Push lock A downwards and press rocker switch 72 on the
(1) upper half
X56b330.fm 3-57
Bedienung
Operation
Steering Hydrostatic front wheel steering with selectable four-wheel steering is sup-
plied by a separate steering pump.
Fan drive The fan for engine cooling is supplied by a separate hydraulic pump.
3-58 X56b350.fm
Operation
Danger!
X56b350.fm 3-59
Operation
ECO-Mode (SO)
Eco operating mode is activated by pressing the Eco button (127). The en-
gine speed is reduced to 1600 rpm. The blue symbol lights up constantly
127 following activation. When Eco mode is active, the Tip Up/Down button (A)
has no function.
The brush and fan speeds (128) are limited (potentiometer settings above
the limit value have no effect).
128 When Eco mode is switched off, the engine speed is increased to 1900
rpm. The brush and fan speeds are again aligned to the set potentiometer
value (no limit).
129 In the case of cold oil (when switching to Work mode, the engine remains
at 1100 rpm), no power is supplied to the ECO switch and, as a result, its
functionality is disabled (the switch does not even light up).When the oil is
warm, the function is enabled.
Eco mode must not be switched on when Winter Service is activated.
Danger!
3-60 X56b350.fm
Operation
After switching Eco mode off, the speed changes from 1600
rpm to 1900 rpm resulting in an acceleration from 7 kph to 13
kph.
0 Tip
switch Effect
138
1 1 • Fan drive ON, clean water pump ON, water valve ON,
LOWER suction port, LOWER sweeper/implement carrier
and brush drives ON
0 • Fan drive OFF, clean water pump OFF, water valve OFF,
LIFT suction port, LIFT sweeper/implement carrier and
Fig. 72:
brush drives OFF
Important!
Fan is running only after dirt hopper has been lowered and the hop-
per flap closed.
Fig. 73:
11
Fig. 74:
X56b350.fm 3-61
Operation
26 26A
Fig. 75:
Tip switch for suction nozzle flap
113A Tip
0 switch Effect
113A
Fig. 76:
3-62 X56b350.fm
Operation
Joystick
Effect
136
• Lift left sweeping brush
25B
Joystick
Effect
137
• Lift right sweeping brush
X56b350.fm 3-63
Operation
Potentio-
meter Effect
121
0 - 10 • Left sweeping brush is pressed down
Potentio-
meter Effect
121 122 122
Fig. 79: 0 - 10 • Right sweeping brush is pressed down
Potentio-
meter Effect
123
0 - 10 • Left brush drive supplied with hydraulic fluid
Potentio-
meter Effect
123 124 124
Fig. 80: 0 - 10 • Right brush drive supplied with hydraulic
Clean water pump switch
116
Switch
Effect
0 116
2 • Second clean water pump switched ON
1 1 • Clean water pump switched ON
0 • Clean water pump switched OFF
Fig. 81:
3-64 X56b350.fm
Operation
3.6.7 Superstructure
The superstructure 23 holds the clean water tanks, the dirt hopper and the
tool box.
The superstructure has been equipped with an automatic folding safety
strut 32.
The clean water tank 23A is located below the dirt hopper and holds 350
litres. The clean water pump 23B delivers the clean water to the spray
nozzles at the sweeping brushes and to the pipe at the suction port.
Danger!
Raised superstructure!
Risk of injury!
Check safety strut 32 before working under the superstruc-
ture!
Stay clear of the lifting or lowering superstructure
Working with the superstructure
32
23
23A
23B
Abb. 82:
X56b350.fm 3-65
Operation
Bottom flap
Befor cleaning the dirt hopper, opening the bottom flap inside the dirt hop-
per by means of lever 1 is required
Use tip switch 119 to lift the dirt hopper until top limit position
Turn handle 4 counterclockwise by 1/4 - (open lock direction)- flap is
unlocked
Plug the lever extension 3 which is stored inside the cabin onto lever 1
1 2 3 Press the locking plate 2 and pull lever downwards
If bottom flap is closed, use handle 4 to lock. Tirn handle 4 clockwise 1/
4 - (clock lock direction) - the safety pin 5 catches audible - flap is lok-
ked
Important!
When closing the bottom flap, press locking plate again and make
sure that the lever engages behind the locking plate.
119
3-66 X56b350.fm
Operation
Dirt hopper
The dirt is drawn into the dirt hopper by a fan. Speed of the fan drive 24C
120 119
is continuously controlled by the potentiometer 125.
For emptying and cleaning:
0 0 Use tip switch 120 to open and close the flap 24A of the dirt hopper 24
and lift or lower it with tip switch 119. The lever 24B is used to open the
bottom flap of the dirt hopper.
1 1
Caution!
Tip switch
Effect
119
1 • Lower dirt hopper
0 • Lift dirt hopper
Potentio-
meter Effect
125
0 - 10 • Fan drive is supplied with hydraulic fluid
125 Important!
The fan runs only if hopper flap is closed and after lowering of the
dirt hopper.
24C
Fig. 84:
X56b350.fm 3-67
Operation
Joystick
Effect
137
• Lower snow plow
137
• Lift snow plow
Fig. 85:
• Swivel snow plow to the left
An additional switch (96) on the roof panel means that the winter service
function can now be activated in Transport mode.
The switch must be unlocked to switch the function on and off.
The snow flake icon appears in the multifunctional display.
Important!
96 • Switch ECO mode off when the Faster Winter Service function is
activated.
• To start the engine, the Faster Winter Service function must be
switched off. (Start lock).
• If a brush system is attached when Faster Winter Service is in
operation, it is detected by the control unit and the working
functions are switched off. Error 73 appears in the multifunctional
display. The power supply relay for the control devices (joysticks,
Hako button and quick emptying) is deactivated while this status
continues.
3-68 X56b350.fm
Operation
Important!
125
Potentio-
meter Effect
124
0 - 10 • Cylindrical broom drive supplied with
Joystick
Effect
137
• Lower cylindrical broom
• Upon lowering, the cylindrical broom drive is switched on
• Lift the cylindrical broom
137
• Upon lifting, the cylindrical broom drive is switched off
• Swivel the cylindrical broom to the left
Fig. 86:
X56b350.fm 3-69
Operation
Potentio-
125 meter Effect
125
0 - 10 • Spreader cylinder drive supplied with hydraulic fluid
Tip
switch Effect
138
1 • Spreader cylinder drive switched ON
0 • Spreader cylinder drive switched OFF
138
Fig. 88:
3-70 X56b350.fm
Operation
Weed Brush(SO)
113 The weed brush is intended for use when more intensive cleaning is
necessary, e.g. in cases where roadside and path curbs are overgrown
with weeds or moss because they have not been cleaned for a long time.
The weed brush must be installed on the right-hand side of the sweeping
unit. The existing brush is simply replaced by the weed brush.
The angle of the weed brush head is adjusted by means of two buttons, in
longitudinal direction by button 113 and in lateral direction by button 139.
Button
Action
113
1 • Activate weed brush adjustment in longitudinal direction
(left/right)
0 • Deactivate weed brush adjustment in longitudinal direction
(left/right)
Button
Action
139
1 • Activate weed brush adjustment in lateral direction (front/
rear)
0 • Deactivate weed brush adjustment in lateral direction (front/
rear)
139
113
0
139
0
X56b350.fm 3-71
Operation
3.6.9 Implements
If not otherwise provided by the manufacturer, operate the implements in
the work stage only! Mount and operate only implements approved by
Hako Werke GmbH! The following information refers to implements such
as e.g. snow plow or cylindrical broom.
Danger!
Danger!
Staying below the minimum load of the rear axle with attached
implement may cause critical driving situations, especially when
abruptly braking.
Accident hazard!
Observe a minimum load on the rear axle!
Do not exceed axle loads and admissible total weight!
12
D
3-72 X56b350.fm
Operation
11
Fig. 89:
X56b350.fm 3-73
Operation
Hydraulic connections
Important!
3-74 X56b350.fm
Operation
Operate implement
Danger!
Important!
X56b350.fm 3-75
Operation
3-76 X56b350.fm
Maintenance
Maintenance
4 Maintenance
4.1 Introduction
Before carrying out service and maintenance work, always read, under-
stand and follow the instructions given in
• Section 2 "SAFETY INSTRUCTIONS” of this operation manual
• The instructions in the operation manuals of the implement equipment
manufacturers
Daily and weekly service and maintenance work can be performed by a
specially trained operator. All other maintenance work must be carried out
by trained and qualified mechanics only.
All warranty claims become obsolete in case of nonobservance and the
resulting damage!
For the repair and maintenance of the Citymaster, our wide network of
contract dealers and workshops with trained specialists, modern equip-
ment and all necessary special tools is available. Here you can obtain
advice from specialists as well as fast and effective help.
The maintenance plans (see page 4-63) state when the maintenance
work mentioned below must be carried out.
X56b510.fm 4-1
Maintenance
Fig. 92:
4-2 X56b510.fm
Maintenance
Environment!
Use a suitable container to collect any spilt fuel and dispose of it
according to local or national environment protection regulati-
ons!
Winter operation
With decreasing outside temperatures, the flow property of the diesel fuel
is reduced by the formation of paraffin. The use of "summer diesel fuel"
can cause malfunctions. Therefore, more cold-resistant "winter diesel
fuel" is available in Germany which - depending on the fuel brand - is still
safe to operate between -15°C and -22°C.
With night temperatures below - 25°C, diesel fuel can become so viscous
that the engine does not start any more. We therefore recommend parking
the vehicle in a heated room.
Fuel additives (flow improvers) and similar agents may not be added to
the diesel fuel!
PME fuel (biodegradable diesel The vehicle cannot be operated with PME fuels (Plant MethylEster).
fuel) PME fuels have not been tested and approved by Hako-Werke GmbH.
They may have a negative effect on the safety of the vehicle. Hako-Werke
GmbH assumes no liability for resulting damage.
1. Euro Standard
2. Cetan number = measure for the ignition capability of the diesel fuel
X56b510.fm 4-3
Maintenance
4.2.3 Refuelling
Danger!
Environment!
Use a suitable container to collect any spilt fuel and dispose of it
according to local or national environment protection regulati-
ons!
Important!
Never run the fuel tank completely empty, otherwise dirt is drawn
into the fuel system.
The fuel system does not bleed automatically.
4-4 X56b510.fm
Maintenance
Open the tank flap and unlock lockable tank lock as applicable
Immerse the nozzle of the fuel pump as deep as possible in the tank to
prevent splashing or spilling diesel fuel
After refuelling, replace the tank lock and turn it to the right until it audi-
bly locks into place
Lock the tank lock and close the tank flap as applicable
Caution!
Environment!
Cleaning the fuel tank Use a suitable container to collect any spilt fuel and dispose of it
according to local or national environment protection regulati-
ons!
Important!
Drain the condensation water from the fuel tank at regular intervals,
at the latest every 600 operating hours or at the latest every
year.
Deposits of dirt particles and water in the tank cannot be entirely avoided.
The fuel tank should therefore be cleaned occasionally, particularly before
winter operation.
Clean the fuel tank when the fuel level in the tank is as low as possible!
Clean the fuel tank as follows:
Place a drip pan under the fuel tank
Open the tank lock
Remove the drain plug (see figure 96)
Flush out the fuel tank with fuel, several times if necessary
Turn in the drain plug with a new sealing ring
Fill the tank
Check the drain plug for tightness
Bleed the fuel system as required (see page 4-6)
Fig. 95:
X56b510.fm 4-5
Maintenance
Danger!
When spilt fuel runs on hot engine parts or on the exhaust pipe
Risk of fire!
Never bleed the fuel system when the engine is hot!
Important!
B Environment!
A
Use a suitable container to collect any spilt fuel and dispose of it
according to local or national environment protection regulati-
ons!
Fig. 96:
4-6 X56b510.fm
Maintenance
• Check seals F and G for damage and correct seat and replace, if
necessary
F G
• Place filter cover A on filter housing E. Make sure that the centring
A pins fit into the recesses (arrows) in filter cover A
X56b510.fm 4-7
Maintenance
Environment!
Use a suitable container to collect any spilt fuel and dispose of it
according to local or national environment protection regulati-
ons!
Important!
Fig. 97:
4-8 X56b510.fm
Maintenance
F G
• Place filter cover A on filter housing E. Make sure that the centring
A pins fit into the recesses (arrows) in filter cover A
Fig. 98:
X56b510.fm 4-9
Maintenance
Caution!
Caution!
MAX
MIN Engines always consume oil, even under normal conditions. Oil
A
consumption can reach up to 0.5% of the fuel consumption,
depending on driving style and operating conditions. Oil
consumption can be even higher during the first operating hours!
Therefore:
Check the engine oil level every 10 operating hours or
every day (preferably before you start working) with the oil
dipstick!
Engine oil dipstick A is located on the left side of the vehicle behind the
fuel tank and is accessible from the outside.
Important!
The topping up volume between MIN and MAX on the oil dip stick is
about 0.5 l engine oil.
4-10 X56b510.fm
Maintenance
Caution!
Environment!
Collect the drained engine oil in a suitable container and dispose
of it according to local or national environment protection regula-
tions!
Fig. 101:
X56b510.fm 4-11
Maintenance
Danger!
Environment!
Collect the drained engine oil in a suitable container and dispose
of it according to local or national environment protection regula-
tions!
Keep waste oil safely away from children!
Important!
Change the engine oil and the engine oil filter for the first time
after 50 operating hours as well as after the first 300 operating
hours, then every 300 operating hours, at the latest every year.
Specification (see page 4-62)!
10 l
Fig. 102:
4-12 X56b510.fm
Maintenance
Danger!
Environment!
Use a suitable container to collect any spilt engine oil.
Dispose of used oil and filters according to local or national envi-
ronment protection regulations!
Keep waste oil and used filters away from children!
Important!
Change the engine oil and the engine oil filter for the first time
after 50 operating hours as well as after the first 300 operating
hours, then every 300 operating hours, at the latest every year
(see page 4-62)
X56b510.fm 4-13
Maintenance
Danger!
Never open the radiator and never drain coolant if the engine is
warm, since the cooling system is under high pressure –
Risk of burns!
Wait at least 10 minutes after switching off the engine!
Wear protective gloves and clothing
Always start by actuating the safety valve in the cap of the
expansion tank. To do this: Open the cap to the first notch
and allow the pressure to escape.
• The coolant agent and the coolant are detrimental to health! Therefore,
store the coolant agent in the original container especially safe from
children!
• Dirt on the cooling ribs reduces the radiator’s heat dissipation capacity!
Therefore:
Clean the outside of the radiator at regular intervals. Cleaning inter-
vals (see page 4-63)
In dusty or dirty work conditions, clean more frequently than indicated
in the maintenance plans
• An insufficient coolant level reduces the heat dissipation capacity as
well, and can lead to engine damage! Therefore:
Check the coolant level at regular intervals (see page 4-63).
If coolant must be added frequently, check the cooling system for lea-
kage and/or contact your authorised workshop!
Never fill in cold water/coolant if the engine is warm!
After filling the radiator, test run the engine and check the coolant
level again after switching off the engine
• The use of the wrong coolant can severely damage the engine and
Fig. 104: radiator. Therefore:
Use only G 12 plus and/or an additive with the specification TL-VW
774 F as a coolant additive, since it already contains an anticorrosion
agent (see page 4-62)
Do not use radiator cleaning compounds if an antifreeze compound
has been added to the coolant – otherwise this causes sludge to form,
which can damage the engine
Environment!
Use a suitable container to collect the any spilt coolant and dis-
pose of it according to local or national environment protection
regulations!
4-14 X56b510.fm
Maintenance
X56b510.fm 4-15
Maintenance
Important!
Check the coolant level for the first time after 50 operating hours
as well as after the first 300 operating hours as well as regularly
every 300 operating hours . We recommend checking the oil level
before starting the engine.
A warning message on the multifunction instrument is displayed if
the coolant level is too low.
4-16 X56b510.fm
Maintenance
Important!
Replace the coolant every two years at the latest (see page 4-62)!
X56b510.fm 4-17
Maintenance
Caution!
Fig. 107:
4-18 X56b510.fm
Maintenance
Danger!
Risk of injury!
Switch off the engine before carrying out maintenance work in
the engine compartment!
Caution!
If the belt tension of the alternator is too low or the V-ribbed belt is torn,
this is also signalled by warning light 83 on the instrument panel.
Check the V-ribbed belt for the alternator and the coolant pump for the first
time after 50 operating hours as well as after the first 300 operating
hours as well as regularly every 300 operating hours.
83 Change the V-ribbed belt and the tensioning pulley every 600 operating
hours!
Fig. 108:
Check new V-belts after approx. 15 minutes operating time.
Regular checks can prevent premature wear of the V-belts.
C
B
Important!
Proceed as follows:
• Park vehicle on even ground and secure against rolling away
• Switch off the engine, pull the ignition key
• Remove screws B and cover plate C
Fig. 109: • Check condition and tension of V-ribbed belt A
Have V-ribbed belt and/or tensioning pulley replaced by your authori-
sed Hako workshop!
A
Fig. 110:
X56b510.fm 4-19
Maintenance
a b
Fig. 111:
c • Wear on flanks (ribs are pointed d, new ribs have a trapezoidal shape
d
c) and fibres are visible at the base of the ribs (brighter spots e)
Fig. 112:
g
Fig. 113:
Fig. 114:
j iI j
Fig. 115:
4-20 X56b510.fm
Maintenance
Check the toothed belt for the first time after 300 operating
hours, then every 300 operating hours for dirt, damage and
correct tension!
Change the toothed belt every 1200 operating hours!
The toothed belt may only be changed in authorised work-
shops!
X56b510.fm 4-21
Maintenance
Maintenance
Caution!
Important!
Fig. 116:
4-22 X56b520.fm
Maintenance
Important!
The hydraulic oil tank is located on the left side of the vehicle below
the tipper. The oil level can be checked in the sight glass.
• Check and top up, if necessary, the hydraulic oil level weekly.
• Change the hydraulic oil for the first time after 1200 operating
hours, at the latest every three years!
• Change the hydraulic oil filter for the first time after
50 operating hours as well as regularly every 1200 operating
hours, at the latest according to the fouling indicator!
• Maintenance intervals for the hydraulic system (see page 4-63).
Environment!
Collect drained or spilt hydraulic oil in a suitable container and
dispose of it according to local or national environment protec-
tion regulations!
X56b520.fm 4-23
Maintenance
Important!
If the hydraulic oil level is too low, this is also signalled by a warning
message in the multifunction display
Proceed as follows:
• Park vehicle on even ground and secure against rolling away
• Switch off the engine, pull the ignition key
A • Retract all hydraulic cylinders
• Switch off the engine
When all the oil has returned to the hydraulic oil tank:
• Check the oil level at sight glass A
If the oil level is lower than in fig. 118/A:
• Top up the hydraulic oil
Fig. 117:
Caution!
The lock of the filter housing for the hydraulic oil is made of
plastic material.
Be careful when opening or closing the filter housing – risk of
breakage!
Do not tilt the lock, as this could damage the thread!
Do not top up the hydraulic oil unless the engine is switched off. Other-
wise, hydraulic oil will run out of the filler opening on the hydraulic tank.
Top up as follows:
• Park vehicle on even ground and secure against rolling away
• Retract all hydraulic cylinders
• Switch off the engine
• Apply parking brake
B When all the oil has returned to the hydraulic oil tank:
• Clean the area around the filler opening with a cloth
A
• Unscrew screw plug B (SW 32) of the return filter
• Slowly top up hydraulic oil
• Check the hydraulic oil level in sight glass A (see page 4-24)
• Top up if necessary and check again
Fig. 118:
• Screw in screw plug B
4-24 X56b520.fm
Maintenance
Danger!
Important!
Also change the filter element of the return filter whenever hydraulic
oil is changed (see page 4-27).
Proceed as follows:
D
B • Warm up the vehicle and park it on level ground
E • Retract all hydraulic cylinders (not the fift cylinder)
• Switch off the engine
F • Unscrew screw plug B of the return filter
• Position a suitable container to collect the oil as it drains (see page
4-62)
• Unscrew oil drain plug C on the underside of the hydraulic oil tank
The oil drains into the container
• Remove complete filter element D with filter pot E
• Clean filter pot E
A
• Flush out the hydraulic oil tank with a little fresh hydraulic oil
• Install filter pot E and new filter element D
• Fit oil drain plug C with a new sealing ring
• Fill in fresh hydraulic oil up to the middle of sight glass A
C
X56035.eps • Make sure O-ring F on screw plug B is in perfect condition and
replace, if necessary
• Screw in screw plug B
Fig. 119: • Starting the engine
• At a low engine speed: Move all the equipment that can be moved
hydraulically, as far as it will go several times
• Retract all hydraulic cylinders again
• Switch off the engine
When all the oil has returned to the hydraulic oil tank:
• Check the hydraulic oil level in sight glass A (see page 4-24)
• Top up if necessary and check again
X56b520.fm 4-25
Maintenance
Important information for the • Use only the biodegradable hydraulic fluids approved by Hako-Werke
use of biodegradable oil GmbH (see page 4-62). Always contact Hako-Werke GmbH for the use
of other, not recommended products. In addition, ask the oil supplier for
a written declaration of guarantee. This guarantee is applicable to
damage occurring on the hydraulic components, which can be proved
to be due to the hydraulic fluid.
• When topping up or changing the oil, use only biodegradable oil of the
same type. In order to avoid misunderstandings, a label providing clear
information is located on the hydraulic oil tank (next to the filler inlet)
regarding the type of oil currently used! Replace missing labels!
The joint use of two different biodegradable oils can affect the quality of
one of the oil types. Therefore, make sure the remaining amount of
initial hydraulic fluid in the hydraulic system does not exceed 8 % when
changing biodegradable oil (manufacturer indications).
• Do not top up with mineral oil – the content of mineral oil should not
exceed 2 % by weight in order to avoid foaming problems and to ensure
biological degradability.
• When running the vehicle with biodegradable oil, the same oil and filter
replacement intervals are valid as for mineral oil (see page 4-63).
The condensation water in the hydraulic oil tank must be drained every
600 operating hours, but in any case before the cold season starts. The
water content should not exceed 0.1 % by weight.
• The instructions in this operation manual concerning environmental
protection are also valid for the use of biodegradable oil.
• If additional hydraulic implements are mounted or operated, use the
same type of biodegradable oil for these implements to avoid mixtures
in the hydraulic system.
4-26 X56b520.fm
Maintenance
X56b520.fm 4-27
Maintenance
Important!
4-28 X56b520.fm
Maintenance
Environment!
Collect drained oil and dispose of this oil and the filter element
according to local and national environment protection regulati-
ons.
Fig. 123:
X56b520.fm 4-29
Maintenance
Fig. 124:
4-30 X56b520.fm
Maintenance
Maintenance
4.7 Gearbox
Maintenance of these components is limited to checking oil levels and
changing the oil at the prescribed intervals (see page 4-63).
Danger!
Caution!
The gearboxes of the Hako are filled with different types of oil
depending on their function. Therefore, do not attempt to correct
oil levels yourself, since an incorrect oil could cause consi-
derable damage. Always go to your authorised workshop when
you notice leaks!
Environment!
Collect drained or spilt gearbox oil in a suitable container and
dispose of it according to local or national environment protec-
tion regulations!
Important!
Only use new sealing rings for oil filler and drain plugs. Drain oil
only after running the vehicle for a longer period of time!
Important!
The inspection, filler and drain plugs of the individual gearboxes are
best accessible from the underside of the vehicle.
Only use new sealing rings for oil filler and drain plugs. Drain oil
only after running the vehicle for a longer period of time!
First oil change after 50 operating hours.
Check the oil level every 300 operating hours.
Then change the oil every 1200 operating hours, at the latest
every four years.
X56b530.fm 4-31
Maintenance
Checking oil levels Park vehicle on even ground and secure against rolling away
Switch off the engine, pull the ignition key
Clean and turn out oil filler plugs E
When the oil levels are below the rims of the oil filler plugs E or are no lon-
ger visible:
Top up oil, specification (see page 4-62)
Screw in oil filler plugs E with new sealing rings to make oil-tight seals
Changing oil Run the vehicle until warm before changing the oil so that the old oil is
fluid by heating and can be completely drained.
Place suitable oil container underneath oil drain plugs A
Clean and unscrew oil filler plugs E and oil drain plugs A
Drain old oil completely
Screw in oil drain plugs A with new sealing rings to make oil-tight seals
Top up fresh oil at the oil filler plugs E until oil just overflows, specifica-
tion and capacity (see page 4-62)
Check the oil levels again after a couple of minutes and add oil as
required
Screw in oil filler plugs E with new sealing rings to make oil-tight seals,
tightening moment 35 + 3 Nm
4-32 X56b530.fm
Maintenance
4.8 Axles
Maintenance of these components is limited to checking oil levels and
changing the oil at the prescribed intervals (see page 4-63).
Danger!
Environment!
Collect drained or spilt gearbox oil in a suitable container and
dispose of it according to local or national environment protec-
tion regulations!
Important!
Only use new sealing rings for oil filler and drain plugs. Drain oil
only after running the vehicle for a longer period of time!
First oil change after 50 operating hours.
Check the oil level every 300 operating hours.
Then change the oil every 1200 operating hours, at the latest
every four years.
X56b530.fm 4-33
Maintenance
Checking oil levels Park vehicle on even ground and secure against rolling away
Switch off the engine, pull the ignition key
Clean and turn out oil filler plugs E
If the oil levels are below the rim of the oil filler plugs E or are no longer
visible:
Top up oil, specification (see page 4-62)
Screw in oil filler plugs E with new sealing rings to make oil-tight seals
Changing oil Run the vehicle until warm before changing the oil so that the old oil is
fluid by heating and can be completely drained.
Place suitable oil container underneath oil drain plugs A
Clean and unscrew oil filler plugs E and oil drain plugs A
Drain old oil completely
Screw in oil drain plugs A with new sealing rings to make oil-tight seals
Top up fresh oil at the oil filler plugs E until oil just overflows, specifica-
tion and capacity (see page 4-62)
Check the oil levels again after a couple of minutes and add oil as
required
Screw in oil filler plugs E with new sealing rings to make oil-tight seals
4-34 X56b530.fm
Maintenance
Fig. 125:
X56b530.fm 4-35
Maintenance
Avoid brake fluid contact with the paintwork of the vehicle as it may dis-
solve the paint.
Danger!
Environment!
Collect drained or spilt brake fluid in a suitable container and dis-
pose of it according to local or national environment protection
regulations!
Important!
4-36 X56b530.fm
Maintenance
Fig. 126:
Caution!
MAX Soiling of the brake fluid could cause failure of the brake system!
Ensure absolute cleanliness when working on the brake
A MIN system!
Important!
X56b530.fm 4-37
Maintenance
25F
25A
Fig. 129:
4-38 X56b530.fm
Maintenance
26A
26C
26
X56b530.fm 4-39
Maintenance
4.12 Superstructure
Danger!
Lifted superstructure!
Danger of injury!
Before start working under the superstructure check function
of the foldable safety strut 32!
Do not stay under the superstructure while it is lifted or lowe-
red!
27A
Fig. 131:
4-40 X56b530.fm
Maintenance
Caution!
Fill the clear water tank 23A through the opening 23D. Filing level is moni-
tored by the sensor 23C and shown on multi-function display 126. The
pump 23B delivers clear water to the spray nozzles at the sweeping unit
and to the handheld suction hose.
Open valve 23E for emptying the clear water tank. Check the filter sieve
23F for clogging at daily intervals and clean if required
A second pump is optionally available to ensure dust binding in the suc-
tion pipe. This pump will be mounted next to pump 23B.
23D
23C
32
23A
23E 23B
23F
Fig. 132:
X56b530.fm 4-41
Maintenance
Caution!
4.12.4 Fan
For easy fan cleaning, a water connection is fitted underneath the fan.
Switch on the fan and connect a water hose to the connection 24F.
24F
24D
24A
24E
Fig. 133:
4-42 X56b530.fm
Maintenance
Danger!
Environment!
Have old tyres disposed of by your authorised Hako workshop
according to local or national environment protection regulati-
ons!
Important!
X56b530.fm 4-43
Maintenance
Weekly checks Carry out the following maintenance work every week:
• Check the tyre pressure (when the tyres are cold)
• Check the tyres and rims for damage (cracks, ageing, etc.) – also on
the inside
• Remove foreign bodies from the tyre tread
• Remove traces of oil and grease from the tyres
• Check the wheel nuts for firm seating
• Check the tyres for wear and measure the tread depth
• When the tyre wear differs very much:
Check or have the track checked and change the wheels diagonally:
front right with rear left, and front left with rear right.
Caution!
All repair work on tyres and rims may only be carried out by
authorised specialist workshops
The wheels are heavy and can damage the threads on the
wheel studs if they are handled incorrectly!
Use suitable assembly tools, such as covering sleeves for the
studs, a jack etc.
Fig. 134:
4-44 X56b530.fm
Maintenance
Fig. 135:
X56b530.fm 4-45
Maintenance
Caution!
If sufficient antifreeze has not been added, the washer fluid can
freeze and cause severe damage to the motor of the windscreen
wash unit.
When mixing the washer fluid with the additive or antifreeze,
observe the correct mixing ratio. Refer to the manufacturer's
instructions on the packing of the additive or antifreeze.
The washer tank is located in the cab behind the driver's seat.
Park vehicle on even ground and secure against rolling away
Switch off the engine, pull the ignition key
Fold the backrest of the driver's seat forward (see page 3-43)
Open washer tank cover A and fill up the tank
A
Important!
Daily checks Check level of windscreen washer unit and top up, if necessary
Weekly checks Check the condition of the wiper blades. When soiled or damaged, they
can considerably affect visibility
Remove grease, dirt and tar from the windscreen at regular intervals.
This increases the service life of the wiper blades considerably.
Check the nozzles of the windscreen washer unit to see whether the
water jet is correct. Use a needle to clear any nozzle blockages.
4-46 X56b530.fm
Maintenance
Maintenance
• When connecting the battery make sure the poles are not reversed,
otherwise sensitive electric components will be damaged
• When re-connecting the battery first connect the positive terminal,
then the negative terminal!
• After every maintenance involving disconnecting the battery, make sure
that the clamps are firmly seated on the terminals after connection!
X56b540.fm 4-47
Maintenance
Danger!
Caution!
Important!
4-48 X56b540.fm
Maintenance
F F
Press tension spring F together with your fingers and remove light bulb
G
Hold new light bulb G on lamp socket - do not touch glass piece - and
insert it in the headlight
G Check the locking device which ensures the correct position of the light
bulb G in the headlight, see figure
Fit tension spring F, sealing cap E and cable plug D in reverse order
X56b540.fm 4-49
Maintenance
MC262-097
F F
Press tension spring F together with your fingers and remove light bulb
G
Hold new light bulb G on lamp socket - do not touch glass piece - and
insert it in the headlight
Check the locking device which ensures the correct position of the light
G
bulb G in the headlight, see figure
Fit tension spring F, sealing cap E and cable plug D in reverse order
4-50 X56b540.fm
Maintenance
Important!
The light bulb can be changed without removing the turn indicator.
The turn indicator has been dismantled in our illustration for a better
J explanation.
X56b540.fm 4-51
Maintenance
Rear lights
P O N M
M N O Q
To change the light bulbs of the auxiliary headlights and working light:
Remove lamp cover
Unscrew lamp cover or lamp reflector with a screwdriver for recessed-
head screws
Press tension screw down and to the side - see figure - hold lamp by
the socket and pull it out
On the auxiliary headlight, pull off lamp cable and connect new lamp
with cable
Refasten tension spring and than install lamp again
4-52 X56b540.fm
Maintenance
Interior light
MC262-103
Rotating bacon
X56b540.fm 4-53
Maintenance
Electronic control units To avoid work which could permanently damage the installed control units
or cause malfunctions, observe the following rules:
• When performing welding work on the chassis:
• Disconnect first the negative terminal, then the positive terminal and
connect the cables with each other
• Disconnect the central electric system, remove the central electric
system when performing welding work near the central electronic
system
• Attach ground terminal of the welding equipment as close as possible
to the area to be welded
• Do not lay the cable of the welding equipment parallel to the vehicle
cable
• Do not disconnect the connections of the control units while the engine
is running or the control units are switched on
• Remove control units if temperatures above 80°C could be generated
during the work
• Disconnect the battery leads from the central electric system prior to
the removal of the engine starter relay
4-54 X56b540.fm
Maintenance
X56b540.fm 4-55
Maintenance
Environment!
Only use authorised washing places for cleaning the vehicle!
4-56 X56b540.fm
Maintenance
Exterior of the vehicle Wash your vehicle at regular intervals with water and a mild cleaning
agent.
How often the vehicle has to be washed depends on the following factors:
• Area of usage of the vehicle
• Driving on roads spread with salt
• Parking under trees where resin can drip on the vehicle
Cleaning plastic parts Clean the outside plastic parts in the same manner as the vehicle. If the
dirt cannot be removed in this manner, we recommend special cleaning
agents for plastic materials. You can use these also for plastic parts inside
the vehicle.
Do not use paint cleaners or products containing solvents, methanol or
hydrocarbon.
Cleaning glass surfaces Use special glass cleaning agents and clean cloths to prevent scratches
and dullness.
X56b540.fm 4-57
Maintenance
Engine compartment
Danger!
Caution!
When cleaning the engine using a water jet or steam jet, do not
point the jet directly at electrical plug and socket connections
and sensors, such as the oil pressure switch.
Otherwise, liquid penetrating such units can lead to corrosion
and failure of the measuring function!
Clean sweeping unit Proceed to the cleaning works described in the following at least at daily
intervals and yet more often in case of heavy soiling.
Do not use steam or high-pressure cleaning equipment. Do not direct
water jet on electric or electronic parts.
Switch on fan by Hako key 138
Place water hose in suction port 26 (see page 4-39) and open water
Have the water jet sucked through into the dirt hopper until suction port
and pipe are clean
Switch off fan
Clean sweeping unit outside
Clean filter sieve on the clear Clean filter sieve 23F on the clear water tank at daily intervals (see
water tank page 4-41)
Clean recirculation water sup- Clean recirculation water supply at daily intervals (see page 3-62)
ply
4-58 X56b540.fm
Maintenance
Empty and clean dirt hopper Take the vehicle to suitable place for cleaning. Back the vehicle at the
place of disposal, slow down to standstill and engage parking brake.
Use tip switch 120 to open the dirt hopper flap and use a water hose to
clean the fan grid top and bottom. Use tip switch 119 to lift and empty
the dirt hopper (see page 3-65). Set engine to increased idling speed
before emptying the dirt hopper!
Open the dirt hopper bottom flap (see page 3-66). Clean dirt hopper
inside thoroughly by water hose. Close bottom flap again.
Open valve of the separate soiled water tank (see page 4-42) and tho-
roughly clean the soiled water tank by water hose.
Close valve and fill separate soiled water tank with water. switch on
recirculation system with tip-switch 115 and let water run until clear
water comes out of the suction port.
Lower dirt hopper and close hopper flap.
Switch on fan and connect water hose to fan fitting (see page 4-42).
Clean fan by water pressure
Clean dirt hopper outside, especially: dirt hopper, inlet of clear water
tank, toolbox, suction pipe and soiled water tank with valve.
Clean working place.
X56b540.fm 4-59
Maintenance
Maintenance
Delivery
50 1st Inspection
300 A
600 A+B
900 A
1200 A, B + C
1500 A+D
1800 A+B
2100 A
2400 A, B, C + E
2700 A
3000 A, B, D + F
3300 A
3600 A, B, + C
3900 A
4-60 X56b550.fm
Maintenance
4200 A+B
4500 A+D
4800 A, B, C + E
5100 A
5400 A+B
5700 A
6000 A, B, C, D+ F
6300 A
6600 A+B
6900 A
7200 A, B, C + E
7500 A+D
7800 A+B
8100 A
8400 A, B + C
8700 A
9000 A, B, D + F
X56b550.fm 4-61
Maintenance
Maintenance
SAE 5W-30
4.3 l,
according to VW 507 00
VW turbodiesel engine Engine oil year-round of which about 0.3 l
for
in the oil filter
multigrade oils
G12 according to TL-
VW 774
Engine cooling, heating Coolant min. 40% to -25°C year-round 12.0 l
max. 60% to -40°C
+ water
Hydraulic oil HVLP
46 Hydraulic oil DTE 15M,
year-round
as per DIN 51524 Mobil DTE 10 Excel 46
Hydraulic oil tank part 3 58 l
Panolin HLP SYNTH 46
Biodegradable oil
Plantosyn 3268 ECO year-round
on ester basis
Aral Vitamin EHF 46
Reduction gearbox and 1.15 l
transfer gearbox SAE 85 W-90
Hypoid gearbox oil year-round
MIL-L-2105; API - GL5
Differential on rear axle 2.5 l each
Lubrication points Grease DIN 51825, KP 2N-20 year-round as required
DEA Paragon EP 2;
Multipurpose
Cardan shafts Shell Alvania EP 2; year-round as required
grease
Retinax MS / LX
Battery terminals Acid-proof grease year-round as required
Paint preservative Anticorrosion agent Förch L 250 black year-round about 1 l
Fuel tank Diesel fuel DIN EN 590, min 49 CZ year-round 50 l
Brake system Brake fluid DOT 5.1 - FMVSS 116 year-round 2.0 l
Windscreen washer unit Cleaning agent Water + antifreeze year-round 1.5 l
a. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
4-62 X56b555.fm
4.18 Maintenance plan (overview)
Maintenance
X56b560.fm
Work descriptiona
Explanation of symbols: Check or clean/top up At the latest
A
B
C
D
afterc
daily
Change
weekly
Lubricate
Ref. no. in
lubrication plan
1st inspection
2nd inspection
after 50 hoursb
after 300 hoursb
every 300 hours
every 600 hours
every 1200 hours
every 1500 hours
every 1800 hours
Maintenance work
Maintenance work
Oils and filters, engine/machine fluids (Hako-Service):
• Engine oil level 1
• Engine oil 2 Every year
• Engine oil filter 3 Every year
• Check engine coolant d 6 Every 2 years
• Antifreeze 6 Every 2 years
• Control fuel tank (drain) 15
• Change fuel filter 15 Every year
• Change air filter inserte, clean air filter housing According to
21 indicating instru-
ment
• Breather filter of vacuum valves Every 3 years
• Gearbox oil in rear and front axle differentials 24, 10 Every 4 years
• Gearbox oil in reduction gearbox 8 Every 4 years
• Brake fluid of service brake 25 Every 2 years
• Hydraulic oil 16, 17 Every 3 years
• Hydraulic oil filter inserte (return filter) Following indi-
16 cation, if neces-
saryt
• Pressure filter, drive e Following indi-
5 cation, if neces-
sary
• Breather filter of hydraulic oil tank 19
• Windscreen washer fluid d 22
• Battery:
Check acid level and charging condition, clean and grease battery 20
terminals
Maintenance
4-63
4-64
Work descriptiona
Explanation of symbols: Check or clean/top up At the latest
A
B
C
D
afterc
daily
Change
weekly
Lubricate
Ref. no. in
lubrication plan
1st inspection
2nd inspection
after 50 hoursb
after 300 hoursb
every 300 hours
every 600 hours
every 1200 hours
every 1500 hours
every 1800 hours
Maintenance work
Maintenance work
Maintenance
X56b560.fm
Work descriptiona
X56b560.fm
Explanation of symbols: Check or clean/top up At the latest
A
B
C
D
afterc
daily
Change
weekly
Lubricate
Ref. no. in
lubrication plan
1st inspection
2nd inspection
after 50 hoursb
after 300 hoursb
every 300 hours
every 600 hours
every 1200 hours
every 1500 hours
every 1800 hours
Maintenance work
Maintenance work
Inspection work (Hako-Service):
• Download the entries for the engine electronics as well as the entries for
the hydrostat control unit, steering control unit and work hydraulics control
unit, evaluate them, clear any faults and complete a software update, if
necessary.
• Toothed belt of engine control 4
• V-ribbed belt 26
• Check condition and function of automatic belt tensioner and replace, if 26
necessary
• Check alternator for soiling and clean alternator
• Check and clean radiator for charge air, water and hydraulic oilf 7
• Clean and check the brake linings and drums. Replace if necessary
• Check brake hoses; replace, if necessary Every 5 years
• Check parking brake function; have re-adjusted if necessary
• Check wheel (damage, air pressure, tread depth)
• Change high-pressure hoses of drive system Every 3000
hours or every
five years
• Change hydraulic hoses (except high-pressure hoses of drive system) Every 5 years
• Check the function of the hand pump on the sweepings container
• Check the backlash of the differential gear pinion and crown wheel
• Change the air filter vacuum valves
• Change the cab air filter
• Change the wheel bearings (front and rear axles)
• Change the hand brake sealing ring every 2400
hours
• Change the steering links of the rear and front axles every 3000
hours
Maintenance
4-65
4-66
Work descriptiona
Explanation of symbols: Check or clean/top up At the latest
A
B
C
D
afterc
daily
Change
weekly
Lubricate
Ref. no. in
1st inspection
lubrication plan
2nd inspection
after 50 hoursb
after 300 hoursb
every 300 hours
every 600 hours
every 1200 hours
every 1500 hours
every 1800 hours
Maintenance work
Maintenance work
Maintenance
X56b560.fm
Work descriptiona
X56b560.fm
Explanation of symbols: Check or clean/top up At the latest
A
B
C
D
afterc
daily
Change
weekly
Lubricate
Ref. no. in
lubrication plan
1st inspection
2nd inspection
after 50 hoursb
after 300 hoursb
every 300 hours
every 600 hours
every 1200 hours
every 1500 hours
every 1800 hours
Maintenance work
Maintenance work
Functional check, leakage check (Hako-Service):
Check pipes and hose lines and screw connections for firm seating, leakage and chaffing marks and damage
• Air intake line (air filter - turbocharger - charge-air cooler - engine)
• Engine lubrication (engine – filter) 2, 3
• Exhaust system
And after
• Fuel lines 15
repairs
• Cooling system (engine oil cooler, radiator, heating) 7, 6
• Service and parking brake
• Steering system
• Gearbox, axles 8, 10, 24
i
• Functional check of work hydraulics
• Lift cylinder of front and rear power lift (option)
And after
• Tilt cylinder of tipper
repairs
• Electrical system (light system, heater fan, horn, wiper, etc.)
• Check headlight setting, adjust, if necessary
• Check cables for chafe marks and damage
• Check cable and earth connections
• Technical inspection as required according to the regulations of your country N1: For the first time after 36 months, thereafter every 24 months
N2: After every 12 months
a. For service and maintenance work on the diesel engine/implement, please also refer to the operation and maintenance manual of the engine/implement manufacturer.
b. Performance of the work after the first 50 and 300 operating hours by an authorised workshop is required for the acceptance of guarantee claims
c. Maintenance after maximum time as from the day of the initial registration!
d. Check antifreeze in addition in autumn or at temperatures below 4°C
e. Replace filter insert according to the maintenance display on the multifunction display!
f. It may be necessary to clean the cooler more frequently depending on operation and dust conditions.
g. Retighten wheel nuts after 50 km or 10 operating hours after changing a wheel
h. Observe lubrication for the implements and superstructure equipment (e.g. snow plough) according to manufacturer's information!
i. Switching of all consumer axes with pressure measurement at the control blocks
Maintenance
4-67
4.19 Lubrication plan
4-68
2 1 3 5 6 7 8
Maintenance
4
9
Maintenance
10
N13-0754
26
X56077
25
24
23 22 21 20 19 18 17 16 15
X56b570.fm
32 32
X56b570.fm
31
27 31
27
30
33
33 30
28 29
29 28
33 33
34
34
35 35
Maintenance
4-69
Maintenance
4-70 X56b570.fm
Specifications
Specifications
5 Specifications
5.1 Frame
Torsionally flexible, welded ladder frame, offset and inclined at the front
part of the frame. Four-point ball joints for superstructure
5.2 Engine
X56b610.fm 5-1
Specifications
5.3 Cooling
Combined water, hydraulic oil and charge-air cooler, fan control via visco-
sity clutch, AC condenser (option) fitted in front.
5.5 Steering
Steering is provided by hydrostatic single-circuit steering without feedback
(power steering system with purely hydraulic transmission). Both axles
have steering cylinders, so that four-wheel steering is possible in working
mode. In transport mode, only front wheel steering can be activated. The
switch-over is performed by a latching 4/2-way valve. This valve is activa-
ted by an electronic control unit.
Steering Citymaster
5-2 X56b610.fm
Specifications
5.6 Tyres
Tyres Standard Wide base tyre Winter tyre*
Basic vehicle in standard version without options with tyres 215/70 R15
without driver with full tanks
X56b610.fm 5-3
Specifications
5.8 Brakes
The vehicle brake system is designed as a servo power boosted hydraulic
two-circuit brake system with brake power control on the rear axle. The
parking brake acts as a drum brake on the transfer gearbox to the rear
axle.
Service brake
5.9 Cab
Cab
Seats: 2
Driver's seat: Suspended seat. Air suspension (option)
Passenger's seat: Unsprung, suspended seat (option)
Heating / airconditioning: Warm water heating with 3-stage fan,
manually operated air conditioning
system (option)
Standard equipment: Three-point seat belts
Windscreen heating
Optional equipment Mirror heating (option)
Glass roof vent (option)
Radio (option)
Tachograph (option)
Sweeping unit
Brushes (piece/diameter) 2 / 900 mm
Speed Brushes 120 +/- 5 1/min
Dirt hopper
Speed Suction fan 1500 - 3000 1/min
Suction tube diameter 200 mm
Dirt hopper (cubic capacity) 1850 l
Clean water (cubic capacity) 330 l
Recirculation system 300 l
5-4 X56b610.fm
Specifications
K
E G
L
L1
Abb. 139:
W
Dimensions with tyresa in mm 215/70 R15
A Front track width 1033
Fig. 140:
X56b610.fm 5-5
Specifications
5.13 Vibration
Effective acceleration value for the upper extremities of the body < 2.5 m/s2
Effective acceleration value for the body < 0.5 m/s2
Tightening torques in Nm
Screw dimensions
8.8 10.9 12.9
M4 3 4 5
M5 5,5 8 10
M6 10 14 16
M8 23 34 40
M10 46 67 79
M12 79 115 135
M14 125 185 220
M16 195 290 340
M18 280 400 470
M20 395 560 660
M22 540 760 890
M24 680 970 1150
M27 1000 1450 1700
M30 1350 1950 2300
5-6 X56b610.fm
Specifications
Specifications
X56bEP1.fm 5-7
Specifications
Fuses
71
Rated
Termi-
No. current Protected circuit
nal
(A)
F 14 F 31 F 48
F4 10 A 56 Low beam, right
F 13 F 30 F 47 F5 10 A 56 High beam auxiliary headlight, left (option)
F 12 F 29 F 46 F6 10 A 56 High beam auxiliary headlight, right (option)
F 11 F 28 F 45
F7 10 A 56 Low beam auxiliary headlight, left (option)
F 10 F 27 F 44
F8 10 A 56 Low beam auxiliary headlight, right (option)
F9 F 26 F 43
F9 5A 56 Rear fog light
F8 F 25 F 42
F7 F 24 F 41
F10 7.5 A 58 Left parking light
F6 F 23 F 40 F11 7.5 A 58 Right parking light
F5 F 22 F 39 F12 5A 58 Lighting speedometer, operation unit, switch light,
F4 F 21 F 38 relay front working light
F3 F 20 F 37 F13 15 A X Front working light (option)
F2 F 19 F 36 F14 20 A AFM Clear water pump, Hako-key green, joystick
F1 F 18 F 35 oeration brush lower/swivel
F15 Reserve
F16 15 A X Wiper/wash system, horn
X56_sicherungen.eps
F17 15 A 15 Turn indicators
Fig. 141: F18 15 A X 13 pole trailer socket
F19 5A X Operation unit, hydrostatic control unit
F20 15 A X Headlight flasher
F21 5A AFM Steering control unit – electronic
F22 20 A AFM Steering control unit - load circuit, differential lock,
tip switch ADR
F23 15 A X 3 pole socket in centre console
F24 5A X Working light back (option)
F25 10 A X Joysticks, reversing camera/monitor, tip switch dirt
hopper, tip switch dirt hopper flap, rough material
flap
F26 5A X Work hydraulics control unit - electronic
F27 10 A 15 Reversing light, reversing buzzer
F28 5A 15 Radio, transceiver, tachograph
F29 5A 15 Lighting, switch, tip switch, transducers, sensors in
cab
5-8 X56bEP1.fm
Specifications
Rated
Termi-
No. current Protected circuit
nal
(A)
30 Continuous- Plus
15 Supply for ignition ON
X Supply for ignition ON, no supply during starting
58 Supply with the parking light switched on
56 Supply with the low beam and high beam light switched on
AFM Supply with working mode active
HRM Supply via relay K36.5 (J317)
X56bEP1.fm 5-9
Specifications
K 34.2
Relay no. Relay switching function
K 22.1
K 35.7 K 37.1
K22.1 Fresh water pump (option, rotary broom)
K35.7 Rear fog light
K 38.1 K 36.5
K 34.3 K 36.1
K 35.2
K35.2 Switch-over relay for parking light, left
X56E4_relais.eps
Fig. 142:
5-10 X56bEP1.fm
Hako-Cargo 2000
Changes Due to Machine Directive 2006/42/EC Clean ahead
Hako-Werke GmbH Reference was made to the following Name of the authorized person who
Hamburger Straße 209-239 standards and/or norms and/or techni- compiles technical documents for
D-23843 Bad Oldesloe cal specifications to ensure proper im- Hako:
plementation of the safety and health
declares that the products requirements in the EC Directive: Ludger Lüttel
Kehrmaschinen
Power sweeper
Balayeuses
Poliermaschinen
Schrubbautomaten
Polishers
Scrubbers
Lustreuses
Autolaveuses
Außenreinigungs-
Maschinen
Machines for
outdoor cleaning
Machines pour
l´entretien des
surfaces urbaines
Mehrzweck-
maschinen
Multi-purpose
machines
Machines
Polyvalentes
Hako-Werke GmbH
Hauptverwaltung
Hamburger Straße 209-239
D-23843 Bad Oldesloe
Clean ahead Telefon (04531) 806-0 · Telefax (04531) 806-338
E-Mail: info@ hako.com
Internet: www.hako.com