Service-Handbuch
Service-Booklet
Schulung/Training
Fehlersuche/Trouble Shooting
Einstelldaten/Adjustments
Baukomponenten/Zulieferer
Components/Suppliers
Hako-Werke GmbH . Technischer Kundendienst 23843 Bad Oldesloe . Stand 03/2009
Vertraulich – nur für den internen Gebrauch . For internal use only!
Hako - Citytrac (8010.11 / 8010.12)
Hako - Citymaster (1433.11 / 1433.12)
Hako - Citycleaner (1433.52)
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
2 of 108
Contents
1.0 Product Description
1.1 Product description 6
1.2 Short operator manual 8
2.0 Technical Data
2.1 Technical data 13
2.2 Overview service 15
3.0 Assembly and Mechanical Design
3.1 Articulated 4-wheel chassis 17
3.1.1 Articulated steering 17
3.1.2 Hydraulic motor 17
3.2 Accelerator 18
3.3 Engine hand throttle 20
4.0 Engine
4.1 Engine identification system 22
4.2 Technical data 22
4.3 Overview of components 23
4.4 Crankshaft housing ventilation 25
4.5 Valve clearance adjustment 26
4.6 Changing the injection pump 28
4.7 Engine shutdown solenoid 29
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
3 of 108
5.0 Hydraulic Installations
5.1 Safety regulations 31
5.2 Hydraulic pumps 32
5.2.1 Overview of pump locations 32
5.2.2 Variable displacement pump 33
5.2.3 Technical data 35
5.2.4 Hydraulic pump description 36
5.2.5 Flush valve 37
5.2.6 Gear pump, ZP1 39
5.2.7 Gear pump, ZP2 39
5.3 Traction drive 40
5.3.1 System diagram 40
5.3.2 Differential lock valve 43
5.3.3 Switching valve, working/transport mode 46
5.4 Work hydraulics 50
5.4.1.1 Valve manifold, old 50
5.4.1.2 Valve manifold, new 51
5.4.1.3 Torque, valve manifold 52
5.4.1.4 Measure values solenoid valves 53
5.4.2.1 Valve manifold, system diagram, old 55
5.4.2.2 Valve manifold, system diagram, new 56
5.4.3 Function description, valve manifold 57
5.4.4 Proportional throttle cartridge 60
5.4.5 Functions, system diagram 61
5.4.6 Proportional valve control unit 66
5.4.7 Hydraulic connections for front attachment devices 68
5.4.8 Rear connections 69
5.5 Citycleaner hydraulics 70
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
4 of 108
6.0 Electrical Installations
6.1 Safety information 76
6.2 Basic principles 77
6.3 Fuse box, cab 79
6.4 Fuse box, trailer 81
6.5 Overview of components 82
6.6 Front attachment device connector 84
6.7 Rear attachment device connector 87
6.8 Rear device connector assignment 89
6.9 Switching functions 91
6.10 Controller water regulation 94
6.11 Relay surface pressure 95
7.0 Options
7.1 Multipurpose packet 97
7.1.1 Path-dependent spreading 97
7.1.1.1 Electrical circuit 98
7.1.1.2 Control unit 100
7.1.2 Rear connections 102
7.2 Grass and leaf collector 103
7.3 Workingtime counters / Mileometer 105
7.4 High pressure cleaner 108
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
5 of 108
Hako - Citytrac 4200
Hako - Citymaster 1200
Hako - Citycleaner
Product Description
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
6 of 108
1.0 Product description, Hako – Citytrac 4200 / Citymaster 1200
Citytrac Lawnmower: Citytrac Snow plough and gritting:
Flexible working width, 1.50 and 1.80 m with side ejection Snow clearance with spring-mounted blade, 1.50 and 1.70 m,
rear ejection or mulchmower. Cutting height adjustment 3-10 cm. in combination with hydraulic rollers or combination gritting,
1.20 / 6 m working width
Citytrac Grass-Leaf vacuumunit Citymaster Sweeping:
In combination with lawnmower to collect directly Hydraulically powered suction fan
the grass and leafes. The suction fan is hydraulicly
driven
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
7 of 108
1.0 Product description, Hako – Citytrac 4200 / Citymaster 1200
Citymaster Hand-held suction hose Citycleaner
Optionally equipped with the strong hand-held suction Wet sweeping unit to clean special outdoor
hose for cleaning gutters and drains surfaces
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
8 of 108
1.2 Short operator manual
1 control panel r.h. 1 cobination switch, flasher/horn
2 control panel l.h. 2 rocker switch, suction fan/water pump (mower deck option)
3 control console, right 3 working lights
4 control console, left 4 rotating beacon
5 control panel, cabin roof 5 hazard flasher
6 pedals 6 pilot lamp, direction indicator
7 sun blind 7 pilot lamp, coolant temperatur
8 auxiliary tools 8 pilot lamp, battery charge
9 driver seat 9 pilot lamp, pre-glowing
10 pilot lamp, oil pressure
11 pilot lamp, low fuel
12 clean water for suction mouth nozzle
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
9 of 108
1 keypad, lifting, lowering and pivoting front attachments 1 heater valve
2 speed govenor, engine 2 heating, ventilation and a/c (Comfort))
3 hourmeter 3 rotary switch, fresh air/heater fan
4 speed govenor, side brushes 4 air flow openings
5 ignition lock 5 pilot lamp, parking brake
6 reset switch for trip hourmeter 6 pilot lamp, hydraulic fliud temperatur
7 socket 7 pilot lamp, dirt hopper lifted
8 selector for plough side selection 8 switch for implement ground pressure
9 plough, r.h. positio 9 quick discharge of rear spreader (hydr. circuit 2)
10 plough, l.h. position 10 button for lifting/lowering dirt hopper
11 Reversing signal ON/OFF (option) 11 diving lights /side marker lamps
12 button, windscreen wiper switch and washer
13 interior lighting
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
10 of 108
Spezielle Elemente beim
Citycleaner:
1 Tastenfeld Heben und Senken
2 Drehzahlversteller Motor
3 Betriebstsundenzähler
4 Drehzahlversteller für Schrubbaggregat
5 Zündschloß
6 Resettaster für Tagesstunden- / kilometerzähler
7 Steckdose
8 Wahlschalter für hydraulische Zusatzfunktion
9 Wassermenge Schrubbaggregat
10 Andruckverstellung Schrubbaggregat
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
11 of 108
1 2 3 4 5
1 opening for windscreen washer reservoir 1 coarse particle flap
2 parking brake 2 differential lock (option)
3 lever for recirculation water suction mouth 3 brake pedal
4 spray water for side brushes 4 pedal, reverse ride
5 pedal, forward ride
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
12 of 108
Hako - Citytrac 4200
Hako - Citymaster 1200
Hako - Citycleaner
Technical Data
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
13 of 108
2.0 Technical data
Vehicle dimensions CT 4200 DA CM 1200
Length without attachment devices / with
circular brushes
mm 3090 3944
Width without attachment devices mm 1325 1193
Height above cabin without / with beacon lamp mm 1995 / 2200
Wheelbase mm 1430
Track gauge, front mm 998 984
rear mm 998 984
Turning diameter: outer mm 5125 5500
Weight
Unloaden weight acc. to StvZO kg 1400 1800
Gross vehicle weight kg 2500
Axle load
Permissible axle load front kg 1500
rear kg 1500
Engine
Manufacturer Yanmar Co. LTD
Type 4 TNV 88 MHW
Method of operation 4-stroke diesel, direct injection
Output kW 33
Bore / Stroke mm 88 / 90
No. of cylinders / arrangement 4 cylinder / row
Cubic capacity cm
3
2190
Idling speed rpm 1100±50
Operating speed rpm 2450
Max. speed rpm 2750 ±25
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
14 of 108
Valve clearance inlet / outlet (cold) mm 0.20
Air filter cartridge Spare part no.:: 114 – 347
Backup cartridge Spare part no.:: 114 – 348
Fuel system
Tank volume Ltr. Approx. 60
Fuel filter cartridge Spare part no.:: 114 - 033
Driving speed
Transport mode (automotive) forwards kph 0 - 25
reverse kph 0 - 12
Work mode forwards kph 0 - 13
reverse kph 0 - 9
Tyres
Size 26 x 12.00 – 12/8 PR 195 R 14 C
Load bearing capacity kg 750
Air pressure bar 1.5 3.0
Wheel bolt tightening torque Nm 130
Hydraulic system
Traction drive Variable displacement pump, Rexroth A10VG
Hydraulic motors with hydr. diff. lock Sauer Danfoss TMKW 250
2-circuit work hydraulics
Electrical installations
Nominal voltage Volt 12
Starter battery V/Ah 12/74
Three-phase generator V/A 12/80
Starter V/kW 12/2.3
2.2 Overview service
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
15 of 108
Interval
Description
once 250 500 750 1000
Change engine oil and replace filter 50h x x x x
Check radiator and coolant hoses for leakage 50h x x x x
Check v-belt at engine for condition and tension 50h x x x x
Check suction fan for speed, bearing play and soiling 50h x x x x
Replace fuel filter 50h x x
Replace hydraulic return7suction filter cartridge 50h x x
Check brake and parking brake function 50h x x
Check idling and operation speed 50h x x
Check wheel bolts for tight seating (130Nm) 50h x
Check ball heads of steering cylinder 50h x
Check fresh air intake filter for cabin fan x x x x
Check brake fluid level x x x x
Check wearing plate in dirt hopper x x x x
Clean air cleaner element x x x x
Check exhaust system for damages x x x x
Replace air cleaner element x x x x
Check water separator at fuel system x x x x
Replace safety cartridge of air cleaner x
Check engine air gap inlet/outlet (0,2mm) with cold engine x
Replace diaphragm in valve bonnet of engine ventilation system x
Change hydraulic fluid x
Replace ventilation filter in hydraulic tank x
Change coolant x
Change brake fluid x
Check brake shoes x
Check tires x
Replace bowden cables at engine (1x) and drive pump (2x) x
Articulated joint, check play and rubber damper x
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
16 of 108
Hako - Citytrac 4200
Hako - Citymaster 1200
Hako - Citycleaner
Assembly and Mechanical
Design
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
17 of 108
3.1 Articulated 4-wheel chassis
3.1.1 Articulated steering
Pendulum articulated joint with shock absorption
Maintenance:
- Grease weekly
- Check condition of rubber stops and for signs of wear
3.1.2 Hydraulic motor
Torque:
Retaining screws 100 Nm
Turn castle nut 350 Nm
further until the next pin
hole
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
18 of 108
Bowden cable, hand throttle
(from cabin)
Stop screw forwards pedal
wheel speed 225 rpm
3.2 Accelerator pedal
The following adjustments must be carried out in the sequence described each time
the Bowden cables or couplings have been disassembled.
1. Bowden cable from throttle to accelerator pedal:
• Adjust so that the microswitch on the accelerator pedal is actuated
when the throttle is at the first notch.
• The entire path of travel for the throttle must be free to a point behind
the second notch must be available.
2. Bowden cable from accelerator pedal to drive engine:
• Set the throttle to transport ride (before the first notch).
Use the rear adjusting bolt to set the
engine to 1100 ± 50 rpm.
• Adjust the front adjusting bolt to set
the maximum speed of 2750 rpm.
Attention!
Check each 1000h the complete part
for wearout of bushings
,
springs
etc.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
19 of 108
Bowden cable, engine speed adjustment
Stop screw reverse pedal wheel speed
Throttle
Idling 1100 rpm
Max. speed 2750
3. Bowden cables in the hydraulic pump:
• Raise the front of the machine, set the hand throttle to "Transport mode", actuate the parking brake and secure the machine by
positioning chocks against the rear wheels.
• Disconnect both cables from the accelerator pedal and check that the pedals are parallel.
• Hook in the cables for the forward ride and adjust them so that the pump is not moved when the pedals are in a neutral position.
Adjust the stop screw so that the average of both front wheel speeds is maximally 225 rpm.
• Hook in the cable for reverse ride and adjust until the average speed is 100 rpm
Microswitch
S22
here
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
20 of 108
3.3 Engine hand throttle
The throttle serves to adjust the engine speed and select the driving
mode.
Up to first notch:
Engine idling; transport mode (2-wheel, max. 25.0 km/h)
Automotive mode; work hydraulics disabled
Behind first notch:
Engine idling; work mode (4-wheel, max. 12.5 km/h)
Automotive mode; work hydraulics enabled
In front of the second notch:
Preferred speed 2450 rpm; work mode (4-wheel, max. 12.5 km/h)
Automotive mode; work hydraulics enabled
End stop position:
Max. engine speed 2750 ± 25 rpm; work mode (4-wheel,
max. 12.5 km/h)
Automotive mode; work hydraulics enabled
Attention:
The Bowden cable actuates a cam disk on the accelerator pedal and
has no direct connection to the engine.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
21 of 108
Hako – Citytrac 4200
Hako – Citymaster 1200
Hako - Citycleaner
Engine
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
22 of 108
Yanmar 4 TNV 88 (B)M HW
4.1 Engine naming system
4 TNV 88 (B)M HW
No. of Cylinders Model/Series Cylinder Bore Speed Range Hako Plant
4.2 Technical data
Cylinder bore / stroke mm 88 x 90
Cubic capacity cm
3
2.190
Ignition sequence 1 – 3 – 4 – 2 (1st cylinder on flywheel)
Direction of rotation Anticlockwise (viewed from the flywheel side)
Idling speed rpm 1100 ± 50
Max. speed rpm 2750 ± 25 (no load)
Preferred speed rpm 2450
Eingine oil capacity ltr 8,6 (incl. Filter) Mobiloil DELVCAC 15W-40 (o. similar)
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
23 of 108
4.3 Overview of components
Shutdown solenoid
Fuel filter
Dip stick
Oil Pressure switch
Oil filter
Oil filling neck
Thermostat
Coolant pump
Oil cooler
Service cover
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
24 of 108
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
25 of 108
4.4 Crankshaft housing ventilation
Complete the following every 1000 operating hours or every 2 years:
- Check whether any oil or condensate has penetrated between the
membrane and cover.
Membrane cover
Pressure spring
Pressure plate
Membrane
Valve cover
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
26 of 108
4.5 Valve clearance adjustment
The valve clearance must be checked every 1000 operating hours or at least once a year and readjusted, as necessary.
During this maintenance work, check whether the valve caps are set square on the valves or if they
have become misaligned due to wear or infiltration of dirt.
Counternut
Adjusting bolt
Rocker arm
Valve
clearance, cold
0.20 mm
Valve
cap
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
27 of 108
Changing the timing belt Not applicable
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
28 of 108
4.6 Changing the injection pump
Comment:
The pump flange and driving wheel are set up for the engine at the factory. Do not loosen the flange bolts.
Pump driving wheel
Pump flange
Driving wheel nut
Do not
dismantle
Driving wheel nut
Flange bolt
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
29 of 108
4.7 Engine shutdown solenoid
Break-away starting current: 30 Amp. / 1 second
It is switched on for one second by relay K17 via the timer
Holding current: 1 Amp.
In the event of a voltage drop, a spring pulls the
control shaft to "engine shutdown"
(If the shutdown mechanism fails, the engine can be
operated to a restricted level after disassembling
the solenoid with the loss of all safety features.
(In this case, the engine must be switched off by actuating
the injection pump.)
Advanced air heating
Output / Power consumption: 400 Watt / 35 Amp.
Resistance: 0.4 Ohm
From July 2009 the engine will have a preheating by glowplugs.
Connection
Heater wires
Porcelain insulator
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
30 of 108
Hako - Citytrac 4200
Hako - Citymaster 1200
Hako - Citycleaner
Hydraulic Installations
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
31 of 108
5.1 Safety regulations
• The hydraulic system is under high pressure!
High-pressure fluids (fuel, hydraulic oil) escaping at high pressure can penetrate the skin and cause severe injuries. Therefore,
seek medical attention immediately to prevent the possibility of developing a severe infection!
• Use the applicable tools when searching for leaks to prevent the risk of injury!
• Before starting work on the hydraulic system, it must be depressurised and any devices attached must be lowered!
• When working on the hydraulic system, it is essential to switch the engine off and secure the vehicle against rolling away
(parking brake, wheel chock)!
• When connecting hydraulic cylinders and motors, pay strict attention to the method of connecting hydraulic hoses prescribed!
• If connections are swapped, there is a risk of reversed functioning (e.g. raise/lower) - risk of accident!
• Check hydraulic lines at regular intervals and replace them in the event of signs of damage or ageing!
The replacement hoses must fulfil the technical requirements stipulated by the equipment manufacturer!
Dispose of oils, fuel and filters according to the applicable laws!
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
32 of 108
5.2 Hydraulic pumps
5.2.1 Overview of pump location
Hydraulic pump
Gear pump 1
(circuit 1 / mower;
suction fan)
Measuring points:
Drive high pressure forwards
Feed pressure
Drive high pressure backwards
Gear pump 2
(circuit 2 / cylinder functions)
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
33 of 108
5.2.2 Variable displacement pump – Bosch Rexroth A 10VG with pressure cut-off and
pressure-controlled regulation
Pressure control valve
with bypass
Measuring point MB
Pressure-controlled regulation
Measuring point G (feed
pressure)
Feed pressure valve
Measuring point MA
Pressure control valve
with bypass
Set pressure, PS
Pressure cut-off
Transposition
Hydraulic
zero position
Mechanical
zero position
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
34 of 108
Feed pressure adjustment
Comment:
Only check at
operating temperature
Compensating disks
22 bar at
max. speed
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
35 of 108
5.2.3 Technical data and set values
3
2
1
4
Feed volumes / Revolutions cm
3
46
Max. speed:
Higher idling
rpm 2750 ±25
1
Feed pressure at on-load speed bar 22
2+3
High pressure A + B bar 322
4
Pressure cut-off bar 295 + 5
Flushing quantity l/min 11
Pump start-up/Adjusting lever > ° 2
5
DA-regulating valve
6
Starting cadridge
6
5
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
36 of 108
5.2.4 Hydraulic pump description
The swash plate variable displacement pump feeds 0 – 110 l/min, continually adjustable, in both directions. When at high pressure,
both outlets are set to 322 bar (Pos. 2 + 3)(pressure relief valve).
The integrated feed pump supplies a maximum of 30 l/min to compensate for oil leakage, to change a defined quantity of oil for cooling
and for diverse control functions.
The feed pump draws oil from the tank via the suction return flow filter (Pos. 204) and feeds it to the non-return valves which are
integrated in the pressure relive valves (Pos. 2 + 3). The maximum feed pressure is limited to 22 bar by the feed pressure valve
(Pos.1). The non-return valve to which high pressure is not applied enables feed to the variable displacement pump circuit.
At the same time, the feed pressure is generated via the starting cartridge for the mechanical-hydraulic control units.
Depending on the DA - regulating valve (pos.5), actuating the accelerator pedal causes the feed pressure to be supplied to the set
piston which moves the hydraulic pump's pivoting disk in the required direction and angle (feed volume/driving speed).
If the pressure at the hydraulic motors meets with resistance (gradient/obstruction) which causes a pressure increase in excess of
290bar, the overpressure is relieved, by the pressure cut-off valve, to the tank. Cause of this, the pressure will be hold at 290bar. The
function of the pressure cut-off valve is to limit the power of the pump (feed volume x pressure) to the maximum allowed value. The
pressure relief valves (Pos. 2 + 3) are used for safety reasons. Normally they are never activ.
The set feed pressure is measured at measuring points G.
The set cut-off pressure is measured at measuring points MA and MB when the wheels are blocked.
To measure the relive valve pressure, the cut-off valve has to be set to a value over 325bar. Then the relive pressure can be
measured at the points MA and MB.
After this the pressure cut-off valve must be set back to 290bar!
The correct feed pressure is a basic condition for generating high pressure.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
37 of 108
5.2.5 Flush valve
The task of the output valve, which is connected parallel to the high pressure lines from the traction drive, is to supply oil at 11 l/min
from the depressurised high pressure line to the tank. This is necessary to replace the warmed oil in the closed circuit with cold oil.
Flush
valve
B
Flush
valve
A
mA
MB
A
B
Feed pressure control
Discharge pressure control
Hydraulic pump
Hydraulic motor
High pressure valve A
High pressure valve B
Feed pressure pump
11
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
38 of 108
The high pressure (drive pressure) actuates the valve, whereby a connection of the return flow line to the pump is diverted by an
aperture to the quantity control and via a pressure control valve (16 bar) to the tank. The pressure control valve prevents the feed
pressure dropping below 16 bar.
The feed pressure controlled at 22 bar for controlling the switching valve (front/all-wheel drive) and controlling the differential valve is
extracted at connection G on the hydraulic pump.
When rear-wheel drive is switched off, the all-wheel drive valve establishes a connection to the flow and return flow of the wheel
motors to compensate for loss of oil through leakage. When this switch position is set, the feed pressure is approx. 1 – 2 bar lower,
depending on the tolerance and wear of the motors.
In the event of wheel or motor damage evident due to high oil loss, the feed pressure may drop until a functional fault occurs in the
respective system.
In the case of too low a feed pressure and high pressure:
1. Check the towing aid (bypass) for signs of leaks.
2. Check the flush valve for impermissible leaks.
3. Check the wheel motors for impermissible losses due to oil leakage (max. 2.5 l/min per engine at max. speed).
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
39 of 108
5.2.6 Gear pump, ZP 1
Constant gear pump, Sauer / Sundstrand SNP 2/19 (46 l/min)
Hydraulic oil supply for pump circuit 1
(attachment devices, e.g. mower mode, suction fan mode)
5.2.7 Gear pump, ZP 2
Constant gear pump, Sauer / Sundstrand SNP 2/17 (36 l/min)
Hydraulic oil supply for pump circuit 2
(steering, front attachment support, tipping platform / container support, pivot attachment devices; spreading mode; circular
brush mode; suction device support; mulchmower compound circuit)
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
40 of 108
5.3 Traction drive
Hydraulic pump
5.3.1 System diagram
Four-wheel drive on
(Y13 not activated / not energised!)
Differential lock off
(Y11 not activated / not energised!)
Four-wheel
switching valve
Differential
lock valve
Hydraulic
pump
Y11
Y13
l
2,4
16 bar
11l/min
Front axle
Rear axle
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
41 of 108
Four-wheel drive on
(Y13 not activated / not energised)
Differential lock on
(Y11 activated / energised)
Four-wheel
switching valve
Differential
lock valve
Hydraulic pump
Y13
Y11
il
16 bar
11l/min
2,4
Front axle
Rear axle
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
42 of 108
Front-wheel drive on, 25 km/h
(four-wheel drive off)
(Y13 activated / energised)
Differential lock off
(Y11 not activated / not energised)
Four-wheel
switching valve
Differential
lock valve
Hydraulic pump
Y13
Y11
16 bar
11l/min
2,4
Front axle
Rear axle
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
43 of 108
5.3.2 Differential locking valve
The volume flow supplied from the hydraulic pump for forward drive is fed to the differential locking valve (P) (Pos. 216).
When (Y11) is not is its active state, it is possible to bypass the current divider and distribute the current to the wheel motors (A,B,C)
as required.
Comment:
It is only possible to activate the differential lock valve (Y11 energized) in “work ride / four-wheel” mode.
If the differential locking valve is activated (Y11 energized), the solenoid valve interrupts the outflow of the feed pressure to the tank
and the distributing valve is actuated hydraulically.
The differential locking valve is basically comprised of two double-action current dividers, (dividing and accumulating) and a
distributing valve to optionally bypass the current divider.
When activated, the hydromotors are automatically switched parallel and the three outputs of the current divider are supplied with a
load-independent component current, according to the proportions selected.
This ensures that, in the event of unfavourable ground conditions, the maximum pump pressure is applied at the blocked wheel.
Two compensation nozzles, arranged between the outputs A, B and C enable a certain partial compensation and prevent the wheels
distorting.
Part distribution:
A: 50% drive, rear-wheel
B: 25% drive, front right
B: 25% drive, front left
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
44 of 108
Y 11 /
approx. 5.7 Ω
Compensating nozzle D2
Compensating nozzle
D2
A
B
C
X
T
P
D2
D1 at opposit
side of the
block
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
45 of 108
Differential locking valve
Possible faults Possible causes
Diff. locking valve does not switch on No power at the solenoid (coil: approx. 5.7 Ω )
Feed pressure too low or not provided
Aperture in connection X is blocked
Series piston jams
O–ring on series piston is defect
Valve switches – pump is pressurised Consumer is blocked (wheel stands still)
Divider piston jammed
Aperture bore in divider piston blocked
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
46 of 108
5.3.3 Switching valve, work/transport mode
As it progresses, the volume flow from the shut-off unit (output A) to the rear wheel motors is applied to the switching valve (input A).
When in an inactive state (Y13), the volume flow is fed to the rear wheel motors (all-wheel drive).
The two rear motors are connected in series so that the volume flow can be divided as required.
The slower work mode results from distribution of the feed quantity to 4 wheel motors.
When activated (Y13 energised), the solenoid valve switches the feed pressure to the distributing valve and activates it hydraulically.
When at this switch setting (drive on roads), the distributing valve connects the feed side with the outflow side and the feed pressure.
At the same time, a connection from the outflow side of the motors (C), used to exchange the warmed oil, is established to the tank via
an aperture.
The feed (A) to the switching terminal is blocked so that the oil quantity supplied by the pump only needs to be distributed to the two
front motors.
This results in the faster transport mode.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
47 of 108
X
A
P2
P1
B
T
C
A
= Feed/Return flow from differential lock
B = Return flow/Feed from the hydraulic pump
P1 = Feed/Return flow from the hydraulic motor
P2 = Return flow/Feed from the hydraulic motor
X = Feed pressure
T = Tank
C = Outflow
Y 13 /
approx. 6 Ω
d=0.6
d=0.6
D2 Sperre Vorderräder 25% pro Rad D2 Sperre Vorderräder 25% pro Rad
D2 Differential lock front 25% per wheel D2 Differential lock front 25% per wheel
D1 Sperre zwischen Vorder- und Hinterachse, 50% per Achse
D1 Diffential lock between front and rear axle, 50% per axle. View from machine side.
D1
D2
Bei Traktionsproblemen Düse D1 gegen eine Stopfen
M10X1 austauschen.
In case of traction problems, replace the nozzle D1 with a
plug (thread M10X1 mm).
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
48 of 108
Switching valve four-wheel / front-wheel drive
Possible faults Possible causes
Valve does not switch No power at solenoid magnet (coil approx. 6 Ω)
Feed pressure too low or not provided
Aperture d = 0.6 blocked
Solenoid precontrol valve defect
Main control piston jam
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
49 of 108
Faults: In the case of transport mode, the end speed of 25 km/h is not reached
Possible causes:
Engine does not reach the final speed: Air filter is blocked; fuel filter is blocked.
The valve Y13 (wheel motors connected in series) is not energised.
Solution:
Clean the air filter or fuel filter, change them if necessary and check whether the engine reaches the end speed when idling
(2750 rpm +/- 25 rpm (no load applied))
Check the electrical system and clear the fault.
1. Is power applied to Y13?
a) Is the hand throttle in transport mode position?
b) Check fuses F6, F14.
c) Energise Y13 directly; if valve Y13 now switches properly (25 km/h is reached), the electrical test can continue.
d) Contacts on the Y13 connector are in order (no corrosion, contacts fit correctly in the connector; B+ on Pin 1; B- on Pin 2 of X41). Check the resistance of
coils on Y13 (set value: approx. 6 Ω).
e) Switch the relays K1 and K6 through (refer to circuit diagram).
When the electrical system test is completed successfully, without fault clearance:
2. Y13 does not switch mechanically.
Possible cause: Valve Y13 is stiff or jammed.
Solution:
Disassemble Y13 and clean it; in the event of defect mechanical parts, the valve must be replaced (refer to Pages 36 + 37 for details).
Note:
The jamming of valves is caused to 80% by contaminated hydraulic oil. Please filter the hydraulic system using a bypass filter system to clean the hydraulic oil,
otherwise more faults can be expected on other valves!
Note:
When changing the hydraulic oil, it is essential to ensure that the system is only filled with filtered hydraulic oil. To do this,
the filling and filter systems must use filters not in excess of 5µµµµ!
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
50 of 108
5.4 Work hydraulics
5.4.1.1 Valve manifold up to 30.09.2006
M2 :
Measuring connection P2
(at rear of manifold)
Y10 : Lower container (approx. 6 ΩΩΩΩ)
Y7 : Pivot brushes (approx. 6 ΩΩΩΩ)
Y2 : Lower front attachment support
(approx. 6ΩΩΩΩ)
Y12 : Front attachment support
float/lower (approx. 6 ΩΩΩΩ)
Y5 : Proportional valve
side brushes/spreader (approx. 6ΩΩΩΩ)
Y6 : Work hydraulics on
(circulation off) (approx. 6 ΩΩΩΩ)
Pressure control valve : 60 bar
Pressure control valve: 195 bar
M1 : Measuring connection P1
Y 9 :
Raise container
(approx. 6 ΩΩΩΩ)
Y 8 : Pivot brushes up
(approx. 6 ΩΩΩΩ)
Y 3 : Raise front attachment
support (approx. 6 ΩΩΩΩ)
Pressure control valve : 195 bar
Y 4 : CT 4200 mower/
CM 1200 fan
(approx. 6 ΩΩΩΩ)
5.4.1.2 Steuerblock neu ab 30.09.2006:Valve mainfold new from 30.09.2006
M2 Messpunkt Arbeitshydraulik
hinten am Hydraulikblock
M2 measuring point work hydraulic
at rear side of valve mainfold
Fahrtrichtung / Driving direction
M1 Messpunkt Sauggebläse/ Mähwerk
M1 measuring point work
suction fan/ mower deck
Y9 Behälter heben 6Ω
Y9 raise hopper 6Ω
Y8 Besen ausschwenken 6Ω
Y8 Brooms out 6Ω
Y3 Frontaushebung heben 6Ω
Y3 Raise front attachment 6Ω
Y9
Y8
Y3
Y10
Y7
Y2
Y6
Y5
DBV 195 bar Arbeitshydraulik
Pressure relief valve 195 bar work hydraulic
Y5 Proportionalventil Seitenbesen /Steuer 6Ω
Y5 Proportinal valve side bromms/ spreader 6Ω
Y4
M1
Y10 Behälter senke 6Ω
Y10 Lower hopper 6Ω
Y6 Arbeitshydraulik ein
(Umlauf aus) 6Ω
Y6 work hydrauliks on
(circulation off) 6Ω
DBV 60 bar Mähwerkstop
Pressure relief valve 60 bar mower stop
DBV 195 bar Sauggebläse/ Mähwerk
Pressure relief valve 195 bar suction fan/ mower
Y4 CM 1200 Sauggebläse, Y4 CT 4200 Mähwerk
Y4 CM 1200 suction fan,Y4 CT 4200 mower
5.4.1.2 Steuerblock neu ab 30.09.2006:Valve mainfold new from 30.09.2006
Y9 Y10
Y8
Y3
Y7
Y2
Y12
Y6
Y5
Y4
Y7 Besen einschwenken 6Ω
Y7 brooms in 6Ω
Y2 Frontaushebung senken 6Ω
Y2 lower front attachment 6Ω
Y12 Frontaushebung senken/ Schwimmstellung
Y12 Lower front attachment/ floating position
M1
Fahrtrichtung / Driving direction
Y10
Y7
Y2 Y12
Y6
Y5
Y4
DBV 60 bar Mähwerkstop
Pressure relief valve 60 bar
mower stop
DBV 195 bar Sauggebläse/
Mähwerk
Pressure relief valve 195 bar
suction fan/ mower
5.4.1.2 Steuerblock neu ab 30.09.2006:Valve mainfold new from 30.09.2006
Y12 Frontaushebung senken/
Schwimmstellung 6Ω
Y12 Lower front attachment/
floating position 6Ω
DBV
DBV
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
51 of 108
5.4.1.2 Valve manifold, new from 30.09.2006
Stromregelventil
auf Pos. M2 neu
hinzugekommen
Mengenteiler
auf A2 hat
sich hierhin
verschoben
Siehe auch Umrüstsatz 97056907 aus KUD 22 vom 30.08.2006
Current
regulating valve
added at Pos M2
Quantity
divider on A2
has moved
here
Also refer to retrofit kit 97056907 from KUD 22 dated
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
52 of 108
5.4.1.3 Starting moment, valve manifold components
4x each
Ma=5.5 Nm
4.2
4.1
6.
27
Ma=25Nm
9.
27
Ma=25Nm
2.
24
Ma=30Nm
3.
24
Ma=40Nm
10.
24
Ma=30Nm
7.
27
Ma=25Nm
5.2
27
Ma=25Nm
5.1
27
Ma=25Nm
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
53 of 108
5.4.14 Measuring values at individual solenoid valves
Caution: Measuring tolerance of +/- 20% due to diffrent measuring devices
BeschreibungDescription
Spannung (V)
Voltage(V)
Stromstärke (A)
Current flow ( A)
Widerstand
der Spule (ΩΩΩΩ)
Resistance
of the coil (ΩΩΩΩ)
Y2 Hydraulikventil Geräteträger senken
Hydraulic valve front carrier down
12V 2000mA
6Ω
ΩΩ
Ω
Y3 Hydraulikventil Geräteträger heben
Hydraulic valve frontcarrier up
12V 2000mA
6Ω
ΩΩ
Ω
Y4 Hydraulikventil Sauggebläse ein/ Mähwerk ein
Hydraulic valve vacuum fan (suction turbine) on/ mower on
12V 2000mA
6Ω
ΩΩ
Ω
Y5 Proportionalventil Seitenbesen/ Streuer
Proportional valve side brooms/ spreader
4- 6.5V 780- 1060mA
6Ω
ΩΩ
Ω
Y6 Hydraulikventil Umlauf aus; Arbeitshydraulik ein
Hydraulic valve circulation off; work hydraulic on
12V 2000mA
6Ω
ΩΩ
Ω
Y7 Hydraulikventil Besen auf ( Besen ausschwenken)
Hydraulic valve brooms wide ( brooms
12V 2000mA
6Ω
ΩΩ
Ω
Y8 Hydraulikventil
Hydraulic valve
12V 2000mA
6Ω
ΩΩ
Ω
Y9 Hydraulikventil Behälter heben
Hydraulic valve hopper up
12V 2000mA
6Ω
ΩΩ
Ω
Y10 Hydraulikventil Behälter senken
Hydraulic valve hopper down
12V 2000mA
6Ω
ΩΩ
Ω
Y11 Hydraulikventil Differentialsperre ein (Option)
Hydraulic valve diff gear on (option)
12V 2100mA
5.7Ω
ΩΩ
Ω
Y12 Hydraulikventil Geräteträger Schwimmstellung
Hydraulic valve front carrier relaesed
12V 2000mA
6Ω
ΩΩ
Ω
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
54 of 108
BeschreibungDescription
Spannung (V)
Voltage(V)
Stromstärke (A)
Current flow ( A)
Widerstand
der Spule (ΩΩΩΩ)
Resistance
of the coil (ΩΩΩΩ)
Y13 Hydraulikventil Radmotore 2/4 ein (Radmotore ein 25km/h)
Hydraulic valve wheel motors 2/4 on (wheel motor on 25 km/h)
12V 2000mA
6Ω
ΩΩ
Ω
Y16 Hydraulikventil Geräteträger drücken
(Option Citycleaner)
Hydraulic valve front carrier pressure
(Option Citycleaner)
0.95- 2.5V 150- 450mA
6.3ΩΩΩΩ
Y17 Hydraulikventil Geräteträger Schwimmstellung
(Opt.Citycleaner)
Hydraulic valve front carrier released (floating)
(Opt.Citycleaner)
12V 1280mA
9.1ΩΩΩΩ
Y18 Hydraulikventil Umschaltung Druck/ Entlastung
(Opt.Citycleaner)
Hydraulic valve weight/ unweight
(Opt.Citycleaner)
12V 1765mA
6.1ΩΩΩΩ
Y19 Hydraulikventil Vordruck
(Opt.Citycleaner)
Hydraulic valve input pressure
(Opt.Citycleaner)
12V 1825mA
6.2ΩΩΩΩ
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
55 of 108
5.4.2.1 Valve manifold system diagram before 30.09.2006
STEERING
SIDE BRUSHES
MOTOR
FRONT ATTACHMENT
SUPPORT
PIVOTING
CONTAINER
EMPTYING
FAN
MOTOR
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
56 of 108
5.4.2.2 Valve manifold system diagram from 30.09.2006
Additional current regulating valve
STEERING
SIDE BRUSHES
MOTOR
FRONT ATTACHMENT
SUPPORT
PIVOTING
CONTAINER
EMPTYING
FAN MOTOR
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
57 of 108
5.4.3 Valve manifold function description
The oil is fed (46 l/min) from the gear pump ZP1 to connection P1 in the valve manifold. If valve Y4 (Pos.2) is not energised (CT 4200
mower drive; CM 1200 suction fan), the drive is switched off because the combined pressure control/circulation valve (Pos. 5.3.3)
DVPA-2 is opened via the pump side control line and the oil flows either via the bypass or through the oil cooler (Pos.205) and return
flow suction filter (Pos.204), depending on its temperature, back into the hydraulic oil tank. The circulating pressure is approx. 8 bar
with an oil temperature of 50°C. All the measurements for the drive must be taken at measuring point M1.
If valve Y4 (Pos.2) is energised (CT 4200 mower drive, CM 1200 suction fan), the drive is switched on. Y4 switches the connection of
the control line of the pressure control valve to the hydraulic oil tank. The force of the spring in the DBV takes effect and a maximum of
195 bar can be generated (measuring point M1)
Note: If the pressure control valve needs to be replaced, it is essential to set the pressure control valve to the prescribed
pressure (195 bar).
If the drive is switched off (Y4 is no longer energised), the control slide moves from valve Y4 back to its initial position and the
connection of the control line from pressure control valve 5.1 is reconnected to the hydraulic oil tank. The hydraulic oil can then flow
via the pressure control valve again into the hydraulic oil tank. The circulation pressure is approx. 8 bar.
At the same time, the control line to pressure control valve 5.2 is closed by the control slide in Y4, the force of the spring in pressure
control valve 5.2 then takes effect so that pressure control valve 5.2 opens at 60 bar. This ensures that the front attachment device
(CT 4200 mower drive) comes to a stop within 7 seconds (work safety).
Note: If the pressure control valve needs to be replaced, it is essential that the pressure control valve is set to the prescribed
pressure (60 bar). In this case, the pressure control valve 5.1 and 5.2 must be swapped over for the adjustment process.
The oil from the gear pump ZP2 is fed via connection P2 to the valve manifold (approx. 36 l/min) up to the feed quantity distributor
(Pos.7). At this point, a constant 8 l/min. is extracted at connection Z for the steering. A further 28 l/min. are available at connection B
for the remaining functions in the manifold.
If no consumer is switched on (raise/lower front attachment support, pivot front attachment devices,
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
58 of 108
raise/lower loading platform/container), the pressure regulator (Pos. 6) is opened via the control line on the pump side.
The oil then flows back through the open pressure regulator via connection T2 into the hydraulic oil tank.
If proportional valve Y5 (Pos. 9) is activated (energised), a quantity of oil adjustable between 5 and 20 l/min flows to the hydraulic
clutch (Pos. 147 / A3). This additional quantity is also used for those front attachment devices which require an increased quantity of
hydraulic oil (e.g. mulchmower). The pressure regulator (Pos. 6) is closed by Y5 via the control line and shuttle valves (Pos. 8). The
mechanical spring then takes effect against the oil flow and a maximum of 195 bar can be generated before the pressure regulator
(DBV) opens and enables the connection to the hydraulic oil tank.
In order to activate the raise front attachment support / pivot front attachment devices / raise platform/container functions, valve Y6
(Pos.10) is always triggered parallel. The hydraulic oil is fed to the valves (Y2 + Y3, Y7 + Y8, Y9 + Y10) via the connecting valve Y6. In
addition, Y6 also closes the pressure regulator via the control line and shuttle valve (Pos. 8). The mechanical spring then restricts the
flow of oil and a maximum of 195 bar is possible before the pressure regulator (DBV) opens and the connection to the hydraulic oil
tank is enabled (also refer to the description of Y5).
Note: In the event of a fault on the connecting valve Y6 (Pos.10) (electrical/mechanical), the downstream valves (Y2 + Y3
(Pos. 4.1), Y7 + Y8 (Pos. 4.2), Y 9 + Y10 Pos. 4.3)) are not supplied with oil, i.e. following a failure of the work hydraulics,
always check Y6 first.
When the proportional valve Y5 (Pos. 9) is energised, between 5 and 20 litres can be distributed to the consumers in a continuously
variable adjustment. When the maximum quantity of 20 l/min is extracted at the quick-release coupling (Pos. 147) at the front or rear of
the device, only approx. 8 l/min can be used for the following functions (raise/lower front attachment support, pivot front attachment
device, raise/lower loading platform/container).
If these functions only work when the potentiometer has been moved to its lower setting when the maximum quantity is extracted, the
feed quantity of the pump for these functions must be checked and readjusted using the A1 electronics as necessary.
A connection must be produced between the quick-release couplings for the attachment devices (Pos. 147/A3 and 151/B3).
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
59 of 108
If the hand throttle has been pivoted to the stop position of the second notch (preferred speed), the engine speed must be set to
approx. 2450 rpm. A quick-release coupling with a short hose must be connected to one of the quick-release couplings for the "pivot
attachment device" function (Pos. 148 and 150).
A coding plug must be connected for enabling "side brushes spreading mode". When the above speed is set, the potentiometer is fully
open and "pivot attachment device" is actuated, the feed quantity from this line should be between 6 and 8 litres per minute.
In the case of an adaptation, the maximum quantity for the proportional valve must be set to the maximum quantity using the trimming
potentiometer provided on the control unit.
Note: If the A1 electronics are replaced, the minimum quantity must also be set to 5 ± 0.25 litre using the relevant trimming
potentiometer, measured on the flow for the side brushes/spreading mode (Pos.149).
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
60 of 108
5.4.4 Proportional throttle cartridge
Attention:
When disassembling the throttle cartridge, pay attention
that the threaded flange is only turned clockwise to align
the coils.
There must be a gap between the bodies of the coils
and the flange.
Coil resistance: 6.5 Ohm
Threaded flange
Screws
(7 - 9 Nm)
Gap
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
61 of 108
5.4.5 Functions, system diagram
CT 4200 mower off;
CM 1200 suction fan off
(Y4 not connected)
T-oil leakage line to tank
Circulation
approx. 8 bar
Y 4
Mower/Suction fan
Through the valve Y4 is the
tankline of the hydraulic servo
controlled pressure relief valve
195bar open. At the same time
is the pressure relief vale
60bar closed. Therefore the oil
flow is goping directly to the
tank. In the system is only the
circulation pressure of appr.
8bar.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
62 of 108
CT 4200 mower on;
CM 1200 suction fan on
(Y4 connected)
Y 4
T-oil leakage line to tank
Mower/Suction fan
Circulation approx. 8 bar
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
63 of 108
CT 4200 spreader off;
CM 1200 side brushes off
(Y5 not connected)
Y5
M2 circulating pressure approx. 22 bar
cause DBV 6 is not switched
STEERING
SIDE BRUSHES
MOTOR
FRONT ATTACHMENT
SUPPORT
PIVOTING
CONTAINER
EMPTYING
FAN
MOTOR
STEERING
Schematic shows old version
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
64 of 108
CT 4200 spreader on;
CM 1200 side brushes on
(Y5 connected)
195 bar
SIDE BRUSHES
MOTOR
STEERING
FRONT ATTACHMENT
SUPPORT
PIVOTING
FAN
MOTOR
To feed circuit
To feed circuit
Pressure control valve opens
at 195 bar, cause of oil from
interchange valve 8
Schematic shows old version
CONTAINER
EMPTYING
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
65 of 108
Circulation off,
Work hydraulics on
(Y6 and at least one consumer connected)
195 bar
STEERING
SIDE BRUSH
MOTOR
FRONT ATTACHMENT
MOTOR
PIVOTING
CONTAINER
EMPTYING
FAN
MOTOR
To feed
circuit
Pressure control valve opens
at 195 bar, cause of oil from
interchange valve 8
Y6 energised, work hydraulics on
Y9 energised
Schematic shows old version
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
66 of 108
5.4.6 Control unit proportional valve (A1)
;
P
a
r
t
N
u
m
b
e
r
0
0
5
6
2
6
7
0
The control unit regulates a proportional magnet on the quick-release coupling Pos.147 (side brush, spreader, compound circuits,
mulchmower) for the hydraulic quantity.
The current regulation ensures the current flowing through the magnet remains constant even when the power supply fluctuates or the
magnet heats up.
The set value is defined by means of a potentiometer integrated in the circuit. The potentiometer is equipped with an On/Off switch.
The value of the minimum current (min) and maximum current (max) can be adjusted using two trimming potentiometers.
P3 max P2 min
Power supply
12 V to 30 V
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
67 of 108
Setting/Controlling the output current
1. Connect the coding plug for enabling the "side brush spreading mode".
2. Disconnect one of the two cables from the magnet's "MAG" terminal on the control card.
3. Connect the ammeter with a measuring range of 500 – 2500 mA between the "MAG" terminal
and the cable to the coil. Note: Measure the Amp. current in series
4. Switch on the machine ignition, move the throttle to its work mode position.
5. Switch the potentiometer on via the latching point and set to Minimum.
6. Set the minimum current (min) P2 to 780 mA, with the trimming potentiometer, which corresponds to 5 l/min.
7. Set the potentiometer to Maximum.
8. Set the maximum current (max) P3 to 1060 mA with the trimming potentiometer, which corresponds to 20 l/min.
(The magnet current must not exceed 2500 mA because A1 and the coil Y5 could be damaged.)
9. Check the two current values set
10. Disconnect the measuring devices and complete the machine.
---- Do not forget to disconnect the service plug 01144380 ----
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
68 of 108
5.4.7 Hydraulic connections for front attachment devices
1)
Pivot front attachment devices forwards/back
(e.g.: snowblade, brushes)
2)
Pivots front attachment devices forwards/back
(e.g.: snowblade, brushes)
3)
Coding plug for attachment detection/lighting
4)
Proportional regulation (maximum 20 litres) forward
(e.g.: compound circuit mulchmowers, side brush drive
5)
Proportional regulation (maximum 20 litres) back
(e.g.: side brush drive)
6)
Work pump (maximum 46 litres) forward
(e.g.: mowers, brushes)
7)
Work pump reverse
(e.g,: mowers, brushes, mulchmowers)
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
69 of 108
5.4.8 Rear connections
1) Proportional regulation (max 20ltr) forward
(e.g. spreader, suction gras-leaf collector)
2) Proportional regulation return
3) Plug X60
4) Proportional regulation (max 20ltr) forward
(e.g. trailer ext. hydraulic, hopper gras-leaf collector)
5) Proportional regulation return return
6) Plug X64
1
2
3
4
5
6
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
70 of 108
5.5 Citycleaner Hydraulic
View
Rear frame from middle to right side
hydraulic tank
View
Rear
frame in
driving
direction to
hydraulic
valve
block
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
71 of 108
Y 18
Y17
Y 16
Valve block scrubdeck-surface pressure-regulation
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
72 of 108
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
73 of 108
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
74 of 108
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
75 of 108
Hako – Citytrac 4200
Hako – Citymaster 1200
Hako - Citycleaner
Electrical Installations
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
76 of 108
6.1 Safety information
Attention!
• When working on the engine and the electrical installations, always disconnect the battery (minus pole).
Notes on the three-phase generator
• Only allow the engine to run with the battery connected.
• Do not use a charger as a cold start device.
• Disconnect the battery before starting any recharging or electric welding on the device.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
77 of 108
6.2 Basic principles, electrical engineering circuit diagram (terminal plan/wiring diagram)
Circuit and wiring plans are always comprised of the drawings and reference lists.
The reference lists always contain all the machine components.
The letter assignment is organised as follows:
- A electronics, control units
- B sensors, transducers
- C capacitors
- E headlights, lighting, indicators
- F fuses
- G batteries, generators
- H control lamps
- K relays
- M starter, electric motors, stroke elements, pumps
- R resistors, potentiometers, glow plugs
- S switches, buttons
- V diodes
- X connectors, potential distributor
- Y valves, solenoid valves, proportional solenoid valves, magnetic clutches
Every component is identified by a letter and chronological number, e.g.: M1 relates to a starter, M2 a pump, M3 an electric motor, etc.
Plugs and connectors on electronic components are identified by A1; X1 or A1;X2.
Plugs and connectors with several pins are identified by A1; X1:1 or A1; X1:2 etc..
Connectors or potential distributors which are not located on an electronics component are only identified by X1, X2 etc.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
78 of 108
Circuit diagram:
The circuit diagram depicts the connections between the individual components within the entire machine. The functional organisation
of the system can be seen on the circuit diagram.
Wiring diagram:
In addition to the information on the circuit diagram, the wiring diagram illustrates all the components, such as connectors, plugs,
cables, cable harnesses etc., as they are installed in the corresponding machines. Each cable harness is identified by a number. This
number can be used to order the respective cable harness from Hako (e.g. 97-06 415-8). Cable harnesses are produced individually
according to customer orders.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
79 of 108
6.3 Fuse box PCB
F1 : Parking, rear light, right
F2 : Parking, rear left license plate light
F3 : Flashing alarm lamps, interior lighting
F4 : Pre-fuse 58 / 50
F5 : Pre-fuse 15
F6 : Pre-fuse 75
F7 : Control unit controller, seat contact
F8 : Fan condenser (air-conditioning unit)
F9 : 12 V socket, radio terminal 30
F10: Heater fan, controller
Air-conditioning unit
F11: Y6 Circulation off
F12: Operating hour counter, radio terminal 15
F13: Hydraulic valves
F14: Y13 Work mode / all-wheel off
F15: Work circuit control unit, seat contact
F16: Driving lights, front
F17: Windscreen wiping/washing system
F18: Work headlights
F19: Engine control, K1 (75)
F20: Indicators
F21: Wedge plough, spreader, quick emptying
F22: Proportional valve Y4 + Y5
F23: Y11 Diff. lock, water pump
F24: Hazard lights
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
80 of 108
K 1 : Relay voltage 75
K 2 : Control unit, seat contact
K 3 : Relay fan/clutch air-conditioning unit
K 4 : Lock, front attachment support floating
K 5 : Proportional valve connection
K 6 : Work - Transport mode change-over
K 7 : Restart protector, mower (locking)
K 8 : Windscreen wiper interval (option)
K 9 : Enable mower (seat contact B8 > mower switch S5)
K10: Suction fan/mower relay on
K11: Indicator relay
Identification Name Order No.
F1, F2, F3; F19; F21; F22 Fuse link C7.5 A 50-955
F9; F12; F13; F17; F20: F23 Fuse link C10 A 73-363
F10; F16; F18; F24 Fuse link C15 A 73-364
F8; F15 Fuse link C20 A 50-036
F4; F5; F6 Fuse link C30 A 15-206
F14 Fuse link C5 A 90-612
F7; F11 Fuse link C3 A 105-705
K1; K3 Small relay 74-477
K2 Control unit, seat contact 114-118
K4; K5; K6; K7; K9; K10 Relay with snubber resistor 114-117
K11 Indicator transducer 109-274
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
81 of 108
6.4 Fuse box, trailer
Motor,
rig
Motor, right
Cab
Motor, left
Valves
Lighting
F30 = Main fuse
00874760
K12 = Preheating control unit
01144400
K14 = Cooling water level control unit
01081390
K15 = Cooling water level relay
00744770
K16 = Timer, fuel valve
01141150
K17 = Relay, fuel valve
01041700
K19 = Relay, enable starter
00744770
K20 = Relay, dynamo (option)
00744770
K22 = Relay, reversing signal (option)
00744770
R11 = Series resistor, preheating control
unit
19245018
S21 = Limit switch, container/platform
01161460
V20 = Diode, fuel valve
01144370
View of
junction box
-K19, -K20 and -K22 (OPTION)
mounted on junction box lid
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
82 of 108
6.5 Overview of electrical components
Overview machine
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
83 of 108
Frontview cab Look at circuit board A2
Connectors control unit
A1
View steering column
View roof consol (inside cab)
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
84 of 108
6.6 Front attachment device connector X63 7-pin
This connector serves mainly for enabling/disabling certain hydraulic functions
Pins 1 – 5 are provided for this. Pin 6 is for the lighting and Pin 7 is the PE connection.
Connector
Order no.: 114-372
Service plug
Order no.: 114-438
Jumper K10
Device support
Seat contact 0s
Jumper K9
Seat contact 1s
Reserved for machines with front brushes
Connections must not be used for other functions
Pivoting
plough
Mulchmower
(bridged when
mower is available)
(View of pin contacts)
Side lights
mower
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
85 of 108
No jumpers
Operation as Citytrac with mower
• The hydraulic circuit is only activated after switching on the “mower circuit”.
• The attachment switches off automatically when the front attachment support is raised.
• The hydraulic circuit is switched off immediately the driver leaves the seat and must be reactivated
after the seat contact has been closed again by switching it "off and on again".
Jumper, pin 1 to pin 2:
Optional operation as Citymaster or Citytrac (not for mower operation)
• The hydraulic circuit is only activated after switching on the “mower circuit”.
• When the front attachment support is raised, the attachment device runs again (till September 2008).
• The attachment switches off automatically when the front attachment support is raised (from September 2008).
• The hydraulic circuit is switched off one second after the driver leaves the seat and must be reactivated
after the seat contact has been closed again by switching it "off and on again".
Can be used for attachment devices which should continue to run after being raised. Is not currently used by Hako.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
86 of 108
Jumper, pin 4 to pin 7:
Operation as Citymaster or Citytrac with mulchmower (hydraulic compound circuit) or spreader
• This enables the continual operation of the proportional hydraulic circuit.
The connector necessary to implement this bridging function belongs to the scope of delivery of the attachment device.
Jumper pin 1 to pin 2; pin 2 to pin 3 and pin 4 to pin 7:
Operation as CM1200
• The hydraulic circuit is only activated after switching on the “mower circuit“.
• When the front attachment support is raised, the attachment device runs again (till September 2008).
• The attachment switches off automatically when the front attachment support is raised (from September 2008).
• The hydraulic circuit is not switched off when the driver leaves the seat.
• This enables the continual operation of the proportional hydraulic circuit.
There is a connector (cable harness W17) for this jumper which belongs to the functional scope of the brush unit. It is assigned spare
part no. 01161150
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
87 of 108
6.7 Rear attachment device connector X60 13-pin
This connector fulfils several functions. It serves the lighting, coding and power supply.
Pin assignment
1 Drive direction indicator, left (L) 9 Not connected
2 Open at X13:1 10 Power supply for F23
3 Earth (31) 11 Earth (31)
4 Drive direction indicator, right (R) 12 Spreader coding
5 Rear light, right (58R) 13 Not connected
6 Brake lights (54)
7 Rear light, left (58L)
8 Reversing light (option)
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
88 of 108
Jumper, pin
3
to pin 12:
Operation as Citymaster or Citytrac with path depending spreader
• This enables the continual operation of the proportional hydraulic circuit, depending of the way/speed
The connector necessary to implement this bridging function belongs to the scope of delivery of the attachment device.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
89 of 108
6.8 Rear attachment device connector X64 7-pin
This connector fulfils several functions. It serves the lighting, coding and power supply.
Pin assignment
1 Speedometer
2 Power supply for F23
3 Open at X13:2
4 Spreader coding
5 Switch signal S16
6 Rear light, right (58R)
7 Earth (31)
View of the pin contacts
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
90 of 108
Jumper, pin 4 to pin 7:
Operation as Citymaster or Citytrac with grass and leaf vacuum
• This enables the continual operation of the proportional hydraulic circuit.
The connector necessary to implement this bridging function belongs to the scope of delivery of the attachment device. The connector
(grass skip connection cable) to operate the grass-leaf vacuum 8380 has serial no. 97715767.
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
91 of 108
6.9 Switching functions
Work ride/Work mode (e.g. mower on)
1. G1:P (battery+) to fuse F6 (30A) (refer to Point 5 for further circuitry).
2. G1:P (battery+) flows via the fuse F5 (30A) to S1 (key-operated switch) terminal 19. If S1 is connected, B+ flows via terminal 58 to
F19 (7.5A), F7 (3A) and F15 (20A).
3. 3. B+ flows via F7 to K2:3 (seat contact control unit) and B8:2 BN (seat contact switch).
B+ flows via F15 (20A) to K2:1 and K2:2
4. If the seat contact switch B8 is closed, K2 connects relay K9 (enable mower) via Pin 5.
5. B+ flows via fuse F19 ( 7.5A) to K1:86; B- (earth) is connected via X40 and M1:50 to K1:85. Relay K1 is connected. B+ flows via
F6, K1:30, K1:87 to fuse F13 (10A) an on to switch S22 (work ride/work mode switch). B+ flows via the closed switch S22 to relay
K6:86. The relay connects B+ via K6:30 to K6:87 and further to F22 (7.5A) to switch S5 (mower/fan on) and to K7:30. At the same
time, B+ is connected to K7:86 via the open switch S5 (converter). Relay K7 is switched and B+ is connected via K7:30 and K7:87
to K9:30. K9 is switched by the seat contact control unit and seat contact switch. (The seat contact switch must be closed).
Switch S15 (lower device support) connects B+ via S15:1 and S15:2 and diode V8 to relay K4:86. The relay switches back and
enters automatic lock. Simultaneously, solenoid valve Y12 is energised via K4:30 / K4:87 and the brush unit is lowered.
B+ is switched parallel to K10:86 and the mower is enabled. S15 and K10 control the mower/fan is switched off when the device
support is raised and switched on again when lowered.
When the driver leaves the seat, K9 disconnects after 1 second and K7 is released from its lock, i.e. to switch the mower/fan on
again, the seat contact must be closed and switch S5 first turned to zero and then switched on again so that the mower/fan can
start up again.
Attention
!
Important safety function! Never bypass!
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
92 of 108
Fault:
Mower does not start up:
Is Y4 (mower/fan on solenoid valve) energised?
Yes: Measure coil resistance on Y4: should be 5.9 Ohm. If resistance is ok, check whether Y4 is mechanically jammed.
Solution: Clean; replace if necessary.
No: Complete following tests:
Test fuses F5, F19, F7, F15, F6, F22.
Test switches S1, B8 (seat contact) S5, S15, S22.
Test relays K1,K4, K6, K7, K9, K10. Check that B+ is applied at K2 on pins 1, 2, 3;
B- at pin 6. If the seat contact B8 is closed, B- must be connected at pin 4 via X 42 and B8. B+ must now be connected to K9:86
via pin 5. K9 closes.
Fault:
Engine does not start:
Seat contact switch B8 is not actuated.
Fuse F5, F7, F15 or F30 is defect.
Seat contact switch B8 is dedect.
Zero position switch drive pump S20 not actuated.
Fuse F19 defect.
Seat contact switch S20 defect.
Solution:
Actuate seat contact switch B8.
Check fuses F5, F7, F15 and F30, replace as necesarry.
Check seat contact swith B8, replace if necesary. When the driver is seated on the seat, B8 earth (B-) must be swithed through
vom X42 to K2:4.
Check the inputs at K2 are ok, check K2; replace, if necessary.
Check fuse F19; replace as necessary.
Check the input from S20 to K2:7. The zero position switch drive pump S20 must be switched switched trough (B+ from F19 to X36:3,
X34:1 to K2:7, in zero position. Check at relay socket K2.
Are the inputs at K2 ok, check K2 and replace as necessary.
Caution:
The seat contact switch B8 and the zero position switch drive pump S20 has to be bridged only for testing!
If B8 or S20 are bridged longer than 8hours, you cant´t start the engine!
If other test and checks are necessary, it is essential to use the function wiring and circuit diagrams!
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
94 of 108
6.10 Controller water regulation (A5)
O
p
t
i
o
n
C
i
t
y
c
l
e
a
n
e
r
(
6
1
5
0
.
0
0
)
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
95 of 108
6.11 Relais surface pressure (A4
Option
)
Digital input
Power supply
Analog
input
Output prop. valve 1
Ground
Output prop. valve 2
Citytrac 4200
Citymaster 1200
Citycleaner
Service Documents
For internal use only
Status
March 2009
Page
96 of 108
Hako - Citytrac 4200
Hako - Citymaster 1200
Hako - Citycleaner
Options
Loading...