Clean
ing
tec
hnology
• Municipal technology
Citymaster 1600 (1491)
Operating Manual
Issue: 04.2016
Part number: 88-10-3036-3451-01
Introduction
Introduction
Foreword
Dear Customer,
We are certain that the excellent qualities of the vehicle will justify the faith you have shown in us by your
purchase.
To guarantee you safe working with the vehicle, please read the Safety Notes chapter before putting it into
service.
Your own safety, as well as the safety of others, depends essentially on your ability to control the vehicle. Please
read this original operating manual before you use the vehicle for the first time, act accordingly and keep these
instructions for future reference or subsequent users. The operating manual contains all important information for
operation, maintenance and care. We have provided the places in this operating manual concerning your safety
with a danger pictogram. Your authorised Hako dealer is available at all times to answer further questions about
the vehicle or the operating manual.
We would expressly advise you that no legal claims may be asserted based on the contents of this operating
manual. In the case of necessary repair work, please make sure that only original spare parts are used. Spare
parts must be original spare parts to guarantee safety. We reserve the right to make changes in the interests of
further technical development.
Hako GmbH
23843 Bad Oldesloe, Germany
Hamburger Str. 209-239
Phone +49 4531 806-0
Issue:
IndexPart number: Valid as from: 9,N
10 88-10-3036-3009-09 12.2014 149101400500 / 149102400515
11 88-10-3036-3317-00 06.2015 14
12
13 8
2 00-1491-00-13.fm
88-10-3036-3371-00 01.2016 1491
8-10-3036-3451-01 04.2016 14
9101500613 / 149102501803
01600661 / 149102603066
9101600701 / 149102603622
Introduction
Fig. 1:
A
Applications
The Citymaster 1600 is a multi-purpose machine for commercial and municipal use throughout the year. Thanks
to special attachments, the Citymaster 1600 can be used for various applications. The basic vehicle Fig. 1-A
without attachments is described in chapter 1 to 5. The following attachments are described in chapter 6.
• Vacuum sweeping system with the sweeping unit, suction mouth, dirt hopper and trolley
• Lawn mowing system with the front mower
• Sweeping system with the front sweeping machine
• Snow clearing system with the front sweeping machine or a folding snow blade. A roller spreader as rear
attachment. The loading platform is used for holding salt and grit.
• Transport system with the loading platform or trailer operation.
• Wet cleaning system with scrubbing deck, squeegee and trolley.
The Classic vehicle version is equipped with hot water heating. The Comfort vehicle version is equipped in addition with an air conditioner. Your authorised Hako dealer is available to you at all times to answer questions on
further applications.
00-1491-00-13.fm 3
Introduction
Ve h ic l e d a t a
Your vehicle is described clearly by the following data. Please always quote these data in correspondence or
when making a telephone query to your authorised Hako dealer or our company.
• Vehicle type:
• Chassis No.:
• Engine No.:
• Start-up on:
Please enter the data applicable to your vehicle in the list above. The data are immediately available in the case
of enquiries or spare parts orders.
Your nearest authorised Hako dealer
• Address:
• Telephone:
4 00-1491-00-13.fm
Introduction
Intended use
The Citymaster 1600 is a multi-purpose machine intended for commercial and municipal use throughout the year
and with the attachments approved by Hako it is suitable for use in agriculture and forestry, mowing and sweeping, marketplaces and car parks and for snow clearing. Any use extending beyond this is not intended use. The
manufacturer is not liable for any damage resulting from this and the user alone bears the risk. Intended use also
includes compliance with the operating, maintenance and servicing conditions specified by the manufacturer.
The vehicle may be used, maintained and repaired only by persons who are familiar with this work and instructed
about the dangers. The vehicle and its attachments correspond by virtue of their design and construction as well
as in the version distributed by us to the usual health and safety requirements of the EC Directives (see Declaration of Conformity and CoC documents). These documents lose their validity in the event of a modification not
authorised by us. The manufacturer is not deemed liable for any damage resulting from unauthorised modifications to the machine.
Notes on warranty
The terms defined in the purchase agreement apply. Claims for compensation in relation to damage are excluded
from the terms of the warranty when the damage is the result of the failure to observe rules concerning servicing
and maintenance. Maintenance work must be carried out by authorised Hako dealers and confirmed in the “Maintenance Report”, which serves as a warranty logbook. The following are excluded from the terms of warranty:
wear and tear through overuse, defective fuses, improper handling and use and unauthorised modifications.
Claims under the terms of the warranty are also annulled when damage occurs to the vehicle resulting from the
use of parts or accessories not explicitly approved of by us or from failure to observe maintenance rules.
Acceptance of the vehicle
Inspect the vehicle immediately on delivery for signs of transport damage. You will be compensated if the damage is immediately confirmed by the haulage contractor and the damage report is sent to our authorised Hako
dealer together with the consignment note.
Conditions for approval
The Citymaster 1600 is a multi-purpose machine (tractor for use in agriculture or forestry) in terms of the EC
Directive 2003/37/EC. The manufacturer provides an EC Certificate of Conformity and an EC Declaration of Conformity. Based on the EC Certificate of Conformity, the local licensing authorities will produce the registration certificate part 2 (vehicle registration) and part 1 (vehicle registration). For use on public roads, paths and areas the
Citymaster 1600 has to be licensed and display an official license plate. In accordance with the StVZO, in Germany the vehicle must carry a first aid kit, warning triangle and the vehicle type approval when used on public
roads, paths and pedestrian precincts. In Germany the Citymaster 1600 is subject to regular general inspection
according to § 29 StVZO (every 24 months).
Warning
If any modifications or additions are made to the Citymaster 1600, which affect the contents and are
not contained in the registration certificate, it will become void. In consequence the insurance cover
and the vehicle tax will also become void.
To acquire a new registration certificate, the vehicle must be presented to an officially accepted expert to produce
a new report. The modifications have to be included in the registration certificate by the registration authorities. In
the EC Declaration of Conformity the manufacturer declares that the attachments approved by Hako adhere to
the rulings in the EC Directive 2006/42/EC.
In other countries, the corresponding national regulations must be complied with.
00-1491-00-13.fm 5
Introduction
Driving license
According to the driving license law in Germany the Citymaster 1600 may be driven as a multi-purpose machine
(tractor) by drivers with the following classes of driving license:
Class L (Class L is contained in Class B):
Tractors which according to their construction are intended for use in agriculture or forestry and are used for such
purposes, with a maximum speed determined by the construction of not more than 40 km/h and combinations of
these vehicles and trailers, if they are driven at a speed of not more than 25 km/h and, provided the maximum
speed determined by the construction of the traction vehicle is more than 25 km/h, they are identified in the manner specified by § 58 of the Road Traffic Approval Order (StVZO) for a maximum speed of not more than 25 km/
h as well as self-propelled working machines, lift trucks, self-propelled forage wagons and industrial trucks with a
maximum speed determined by their construction of not more than 25 km/h and combinations of these vehicles
and trailers.
In other countries, the corresponding national regulations must be complied with.
Equipment
According to § 53 StVZO the following equipment has to be kept with the vehicle in the Federal republic of Germany (not included in the scope of supply):
• 1 warning triangle of approved type
• 1 warning light of approved type
• 1 warning vest
• 1 first aid kit corresponding at least to the requirements of DIN 13164, Sheet 1 standard. In other countries, the
corresponding national regulations must be complied with.
Required documents
Within the Federal Republic of Germany, the following documents must always be available:
• Approval certificate (Part I) of the vehicle
• Valid driving license of the driver
• Operating manual (kept in the left-hand operating console)
In other countries, the corresponding national regulations must be complied with.
Vehicle inspection
• All occupational accident insurance schemes in the Federal Republic of Germany require a safety inspection
of your vehicle according to BGV D 29, which must be made at least once annually by an expert.
A inspection label should be attached to the vehicle in addition so that the driver knows when the next expert
inspection is due.
• According to § 29 StVZO of the Federal Republic of Germany, a general inspection (HU) must be made
regularly:
• For vehicles of less than / equal to 3.5 t permitted overall weight every 24 months (for vehicles which are
hired commercially without provision of a driver, 12 months apply).
• For vehicles of more than 3.5 t permitted overall weight every 12 months.
In other countries, the corresponding national regulations must be complied with.
6 00-1491-00-13.fm
Table of contents
Introduction ...................................................................................................... 2
Foreword ............................................................................................................ 2
Applications ........................................................................................................ 3
Vehicle data ....................................................................................................... 4
Intended use ...................................................................................................... 5
Notes on warranty .............................................................................................. 5
Acceptance of the vehicle .................................................................................. 5
Conditions for approval ...................................................................................... 5
Driving license .................................................................................................... 6
Equipment .......................................................................................................... 6
Required documents .......................................................................................... 6
Vehicle inspection .............................................................................................. 6
1 Safety Instructions......................................................................................... 10
1.1 Marking of warning and danger symbols ......................................................... 10
1.2 General safety instructions .............................................................................. 11
1.3 Operating safety instructions ........................................................................... 11
1.4 Safety instructions for attachments ................................................................. 12
1.5 Information about special risks ........................................................................ 14
1.6 Safety instructions for maintenance and servicing .......................................... 15
1.7 Environmental protection instructions ............................................................. 18
1.8 Shutting down and disposal ............................................................................ 19
1.9 Labels on the vehicle ...................................................................................... 20
2 Operation ........................................................................................................ 24
2.1 Overviews ....................................................................................................... 24
2.1.1 Front view ........................................................................................................ 25
2.1.2 Rear view ........................................................................................................ 27
2.1.3 Driver's cab ..................................................................................................... 29
2.2 Multifunctional display ..................................................................................... 34
2.2.1 Start screen ..................................................................................................... 34
2.2.2 Menu guidance ................................................................................................ 34
2.2.3 Menu structure ................................................................................................ 35
2.2.4 Normal view ..................................................................................................... 36
2.2.5 Working menu (A menu) ................................................................................. 37
2.2.6 Operating menu (B menu) ............................................................................... 39
2.2.7 Configuration menu (C menu) ......................................................................... 41
2.2.8 Warning and information symbols ................................................................... 45
2.3 Controls in the driver's cab .............................................................................. 47
2.3.1 Steering column control panel ......................................................................... 47
2.3.2 Left-hand control panel ................................................................................... 50
2.3.3 Right-hand control panel ................................................................................. 50
2.3.4 Arm rest control panel ..................................................................................... 53
2.3.5 Roof control panel ........................................................................................... 54
2.3.6 Accelerator pedal ............................................................................................ 55
2.3.7 Brake ............................................................................................................... 55
2.3.8 Coarse material flap ........................................................................................ 55
2.3.9 Driver's seat .................................................................................................... 56
2.3.10 Seat belt .......................................................................................................... 58
2.3.11 Cab heating ..................................................................................................... 59
2.3.12 Air conditioning system ................................................................................... 60
2.3.13 Doors ............................................................................................................... 61
2.4 Operating equipment of the vehicle ................................................................. 62
2.4.1 Auxiliary tool .................................................................................................... 62
2.4.2 Ball cock circulating water ............................................................................... 62
2.4.3 Front tool carrier .............................................................................................. 62
2.4.4 Connections for front attachments .................................................................. 65
88-00-3036-3371-00IVZ.fm 7
Table of contents
2.4.5 Connections for rear attachments ................................................................... 67
3 Starting up ....................................................................................................... 69
3.1 Instruction ........................................................................................................ 69
3.2 Before start-up of the vehicle .......................................................................... 69
3.2.1 Checklist – Before start-up of the vehicle ........................................................ 70
3.3 Starting and driving the vehicle ....................................................................... 73
3.3.1 Starting and driving the vehicle ....................................................................... 74
3.3.2 Troubleshooting ............................................................................................... 77
3.4 Shutting down the vehicle ............................................................................... 78
3.4.1 Shutting down after the end of work ................................................................ 78
3.4.2 Shutting down in work breaks ......................................................................... 78
3.4.3 Shutting down on occurrence of faults ............................................................ 78
3.5 Transporting and towing the vehicle ................................................................ 79
3.5.1 Transporting the vehicle .................................................................................. 79
3.5.2 Towing the vehicle ........................................................................................... 80
3.6 Working with attachments ............................................................................... 81
3.6.1 Hako attachments ........................................................................................... 81
3.6.2 Non-Hako attachments .................................................................................... 81
3.6.3 Ballast .............................................................................................................. 82
4 Technical Data................................................................................................ 85
5 Maintenance and Servicing........................................................................... 88
5.1 Maintenance certificate ................................................................................... 89
5.2 Maintenance plan ............................................................................................ 90
5.3 Panelling and covers ....................................................................................... 96
5.3.1 Opening the engine cover, engine flap and side door ..................................... 96
5.3.2 Removing side cover ....................................................................................... 96
5.3.3 Opening the radiator cover .............................................................................. 96
5.4 Engine ............................................................................................................. 97
5.4.1 Checking the engine oil level ........................................................................... 97
5.5 Fuel system ..................................................................................................... 98
5.5.1 Emptying the water trap .................................................................................. 98
5.6 Diesel particle filter .......................................................................................... 99
5.7 Cooling system ................................................................................................ 100
5.7.1 Cleaning the cooling system ........................................................................... 100
5.7.2 Checking the coolant level .............................................................................. 101
5.8 Air filter ............................................................................................................ 102
5.8.1 Checking the air filter ....................................................................................... 102
5.8.2 Cyclone separator and dust ejection valve ...................................................... 102
5.8.3 Cleaning/changing the air filter ........................................................................ 103
5.9 Hydraulic system ............................................................................................. 104
5.9.1 Important information for using BIO OIL .......................................................... 104
5.9.2 Checking the hydraulic oil level ....................................................................... 105
5.10 Driver's cab ...................................................................................................... 106
5.10.1 Changing the cab air filter ............................................................................... 106
5.11 Wheels ............................................................................................................ 107
5.11.1 Tyre changing .................................................................................................. 107
5.12 Electrical system ............................................................................................. 108
5.12.1 Changing lamps .............................................................................................. 108
5.12.2 Fuses and relays ............................................................................................. 109
5.12.3 Battery ............................................................................................................. 112
5.13 Lubrication plan ............................................................................................... 114
5.14 Cleaning the vehicle ........................................................................................ 115
5.14.1 General notes .................................................................................................. 115
6 Attachments and Options.............................................................................. 117
6.1 Vacuum sweeping system ............................................................................... 118
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Table of contents
6.1.1 Labels on the unit ............................................................................................ 119
6.1.2 Vacuum sweeping system safety instructions ................................................. 119
6.1.3 Mounting ......................................................................................................... 120
6.1.4 Operation ........................................................................................................ 128
6.1.5 Technical data ................................................................................................. 146
6.1.6 Maintenance .................................................................................................... 149
6.1.7 Troubleshooting .............................................................................................. 158
6.1.8 Accessories ..................................................................................................... 158
6.2 Lawn mowing system ...................................................................................... 159
6.2.1 Labels on the unit ............................................................................................ 160
6.2.2 Lawn mowing system safety instructions ........................................................ 160
6.2.3 Mounting ......................................................................................................... 161
6.2.4 Operation ........................................................................................................ 162
6.2.5 Technical data ................................................................................................. 166
6.2.6 Maintenance .................................................................................................... 167
6.2.7 Troubleshooting .............................................................................................. 169
6.2.8 Accessories ..................................................................................................... 169
6.3 Sweeping system ............................................................................................ 170
6.3.1 Labels on the unit ............................................................................................ 171
6.3.2 Sweeping system safety instructions .............................................................. 171
6.3.3 Assembly ......................................................................................................... 172
6.3.4 Operation ........................................................................................................ 173
6.3.5 Technical data ................................................................................................. 176
6.3.6 Maintenance .................................................................................................... 176
6.3.7 Troubleshooting .............................................................................................. 178
6.3.8 Accessories ..................................................................................................... 178
6.4 Snow clearing system ..................................................................................... 179
6.4.1 Labels on the unit ............................................................................................ 180
6.4.2 Snow clearing system safety instructions ........................................................ 180
6.4.3 Assembly ......................................................................................................... 181
6.4.4 Operation ........................................................................................................ 186
6.4.5 Technical data ................................................................................................. 189
6.4.6 Maintenance .................................................................................................... 189
6.4.7 Accessories ..................................................................................................... 189
6.5 Transport system ............................................................................................. 190
6.5.1 Labels on the unit ............................................................................................ 191
6.5.2 Safety instructions ........................................................................................... 191
6.5.3 Assembly ......................................................................................................... 191
6.5.4 Operation ........................................................................................................ 193
6.5.5 Technical data ................................................................................................. 193
6.5.6 Maintenance .................................................................................................... 193
6.5.7 Accessories ..................................................................................................... 193
6.6 Wet cleaning system ....................................................................................... 194
6.6.1 Labels on the unit ............................................................................................ 195
6.6.2 Mounting ......................................................................................................... 195
6.6.3 Operation ........................................................................................................ 201
6.6.4 Technical data ................................................................................................. 209
6.6.5 Maintenance .................................................................................................... 210
6.6.6 Troubleshooting .............................................................................................. 216
6.6.7 Accessories ..................................................................................................... 217
6.7 Options ............................................................................................................ 218
88-00-3036-3371-00IVZ.fm 9
Safety Instructions
1 Safety Instructions
1.1 Marking of warning and danger symbols
Important tasks concerning the safety of the operator and vehicle are named as follows in this operating manual
and emphasised by symbols.
Danger
Indication of a direct danger with high risk, in which death or severe physical injury can occur if it is
not avoided.
Warning
Indication of a possible danger with average risk, in which death or severe physical injury can occur
if it is not avoided.
Caution
Indication of a danger with low risk, in which light to medium severe physical injury or material damage can occur if it is not avoided.
Attention
Attention indicates a hazard that can lead to technical damage when not heeded.
Environmental danger
Environmental danger due to the use of substances from which a health and environmental risk proceeds.
Note
Indication of information that facilitates more effective and economical use of the vehicle.
10 01-1491-00-12.fm
Safety Instructions
1.2 General safety instructions
• Apart from the instructions in this operating manual, the general safety and accident prevention regulations of
the legislation must be taken into account.
• Before the vehicle is put into service, please read carefully the operating manual you receive as well as further
separate instructions for additional implements or attachments and observe them in all aspects in your work.
• The vehicle may be used, maintained and repaired only by persons who have been instructed by Hako
experts.
• This device may not be used by persons (including children) with reduced physical or mental abilities or by
persons without sufficient experience and skills.
• You should pay special attention to the safety instructions. For errors in operating the vehicle can be avoided
and trouble-free operation can be guaranteed only with precise factual knowledge.
• Please hand over these documents as well as the approval documents to the new owner/operator on sale or
rental of the vehicle. Have the hand-over confirmed!
• The labels attached to the vehicle provide important information for safe operation. Renew labels that are no
longer legible or present.
• The approval certificate (Part 1), valid driver's license of the vehicle driver and the operating manual must be
present constantly at the place of use of the vehicle and should therefore be kept carefully in the driver's cab.
• Spare parts must be original spare parts to guarantee safety.
• The Citymaster 1600 is equipped with a safety cab (ROPS – roll-over protection system) according to
86/298/EEC.
1.3 Operating safety instructions
Before putting into service
• Risk of accident! If the steering column is unlocked while driving, it can come unexpectedly out of adjustment.
You can then lose control over the vehicle.
• Risk of accident! Adjust the driver's seat only when the vehicle is stationary. You will otherwise be diverted
from the traffic and could lose control over the vehicle by moving the seat. You could cause an accident by
this.
• Risk of accident! A dirty, damaged seat belt or one stressed or changed in an accident may not offer the
intended protection. You could therefore suffer severe injuries or death in an accident. Please check regularly
that the seat belts are not damaged and not contaminated. Always have damaged seat belts or those stressed
in an accident renewed by an authorised workshop.
• Risk of accident! Good viewing conditions contributing to traffic safety are guaranteed only if all windows are
free of ice, snow and condensation. Make yourself familiar with the correct operation of the heating and ventilation system as well as de-moisturising/defrosting the windows. Maximum heating power and fast thawing of
the windows can be achieved only if the engine has reached its operating temperature.
• There is a risk of accidents when driving with open doors! The doors must remain closed when driving on
public roads and when working.
• Check the vehicle for its correct condition and operating safety before using it. The vehicle must not be used if
it is not in order.
• Before starting work, the operator must familiarize himself with all equipment, operating and actuating
elements as well as with their function. It is too late to do this during operation!
• A warning triangle, a warning light, a warning vest and a first aid kit must be in the vehicle during operation.
• Sturdy and slip-proof shoes must be worn when working with the vehicle.
• This device may not be used by persons (including children) with reduced physical or mental abilities or by
persons without sufficient experience and skills.
• Carrying persons is not permitted!
• Only those surfaces approved by the contractor or its authorised representative for use of the vehicle may be
driven on.
• The vehicle is not suitable for removing dangerous, combustible or explosive liquids, dusts or materials.
• Observe the maximum gradability of the vehicle, see Technical data.
01-1491-00-12.fm 11
Safety Instructions
During operation
• Toxic engine exhaust gases! Inhaling exhaust gases is injurious to health and can lead to unconsciousness
and to death! Never let the engine run in enclosed spaces.
• Danger to life in the danger area of the vehicle! Special caution is required in the area of the articulated
steering, under the raised tipper, in the area of the front and rear attachment and in the area of the trailer.
• Danger of tilting over when driving uphill or downhill and transversely to a slope. Avoid sudden turns when
driving uphill or downhill or across slopes. There is a risk of tilting over in an inclined position! The vehicle
speed must always be adapted to the surrounding conditions and the load condition.
• Danger of tilting due to wrong steering! Note that the steering behaviour of an articulated steered vehicle
differs essentially from that of a car. Sudden steering movements at high speed or too high speeds when
turning can cause the vehicle to tilt over.
• Risk of accident! Note that there is a risk of skidding on unpaved ground or snow and ice. This can lead to
uncontrolled behaviour of the vehicle. Drive correspondingly carefully!
• Risk of accident! Use the cruise control and the speed limiter only when the traffic situation allows!
• For reasons of safety, the vehicle is equipped with a seat contact switch and the function of the seat contact
switch must not be bypassed.
• In the case of restricted vision, especially when reversing the vehicle, it is necessary to have a second person
who gives the driver appropriate signals. The second person must always be in the field of view of the driver.
• When working with the vehicle, pay special attention to third persons, especially children.
• In transport journeys on public roads the working spotlights must be switched off.
Shutting down the vehicle
• Risk of accident! Adopt measures against erroneous starting and unwanted movement. Operate the parking
brake. Switch the engine off and pull out the ignition key.
• Risk of accident! The vehicle must be parked on firm ground. On inclinations secure the vehicle additionally
against rolling away with a wheel chock.
Transporting and towing the vehicle
• Danger to life! Start driving slowly! Make sure that there are no persons in the towing area.
• Risk of injury! The vehicle may be loaded only using suitable loading aids, such as a loading ramp or drive-up
planks.
• Risk of injury! After loading, make sure that the vehicle is secured according to regulations against rolling off
and tilting. Use the wheels for securing the vehicle.
• Tow the vehicle using only suitable towing gear!
• The vehicle may be towed with a towing rope only if the brakes and steering are functioning!
• When the engine is still the steering has only emergency steering properties!
• Secure the vehicle against unintended movement! Lock the parking brake and insert the locking bolt on the
articulated joint. Note that the steering is then blocked!
1.4 Safety instructions for attachments
General
• Danger to life in the danger area of the vehicle! Special caution is required under the raised tipper, in the area
of the front and rear attachment and in the area of the trailer.
• Risk of injury! Put the attachment into service only if all protective devices are attached and in protection
position.
• Risk of injury! Make sure that the attachments are suitable for the set oil volume. An oil volume set too high
can lead to injuries due to a defect of the attachment!
• Risk of injury! High-pressure hoses, fittings and couplings are important for equipment safety. Use only high-
pressure hoses, fittings and couplings recommended by the manufacturer.
• Risk of accident! When connecting attachments to the hydraulic system, ensure that the hydraulic hoses are
connected correctly. Swapping the connections can lead to reverse functioning of the attachment, e.g.
movement to the right rather than the left.
• Risk of accident! Front attachments not correctly fastened to the front tool carrier can drop down while driving.
Always secure the front attachment with the locking devices.
• Risk of accident! You must consult Hako before attaching other attachments not approved by Hako! Check in
the individual case that the relevant axle loads and total weights are complied with.
12 01-1491-00-12.fm
Safety Instructions
• Risk of accident! Handling, steering and braking as well as stability are influenced by attachments, trailers and
the vehicle payload (e.g. full dirt hopper). For this reason, pay attention to adequate steering and braking
capability as well as stability.
• Risk of accident! In Germany, if attachments extend beyond the outer lighting equipment of the vehicle or if the
maximum distances of the outer lighting equipment specified according to StVZO are exceeded, the lighting
equipment of the vehicle must be extended (see Merkblatt StVZO § 30, explanations 11 and 12).
Ballast
• Risk of accident! When attaching other attachments not approved by Hako, consult Hako as to whether the
relevant axle loads and total weights are complied with!
• Risk of accident! The front axle of the working machine must always be loaded with at least 25 % of the empty
weight and the rear axle with at least 37 % of the empty weight of the working machine.
• Risk of accident! The attachment of front and rear attachments must not lead to exceeding the permissible
total weight, the permissible axle load and the tyre load capacity of the working machine!
• Make sure before purchasing the attachment that these requirements are fulfilled by weighing the working
machine attachment combination!
Vacuum sweeping system
• Danger to life in the danger area of the vehicle! Special caution is required under the raised tipper and in the
area of the sweeping unit.
• Danger of tilting over when driving uphill or downhill and transversely to a slope! Avoid sudden turns when
driving uphill or downhill or across slopes. There is a risk of tilting over in an inclined position! The vehicle
speed must always be adapted to the surrounding conditions and the load condition.
• Danger of tilting due to wrong steering! Note that the steering behaviour of an articulated steered vehicle
differs essentially from that of a car. Sudden steering movements at high speed or too high speeds when
turning can cause the vehicle to tilt over.
• Risk of injury! Frequently check the filling level of the dirt hopper. Switch the suction fan off for this! The lid and
the side doors of the dirt hopper must not be opened when the suction fan is running.
• Risk of accident! Make transport journeys only with the sweeping unit raised and secured in the transport
position.
• Risk of accident! Make transport journeys only with a completely lowered dirt hopper!
• Risk of accident! The stability of the vehicle is influenced by a filled dirt hopper. Handling of the vehicle must be
adapted accordingly.
• Risk of accident! Do not exceed the permissible total weight of the vehicle!
• Risk of accident! When the dirt hopper is emptied, the Citymaster 1600 must be on a sufficiently load bearing,
horizontal surface. Driving with the dirt hopper tilted is not permitted.
• When removing blockages in the suction hose or attaching the hand suction hose (optional), switch off the
engine and wait for the suction fan to come to a standstill.
• The sweeping system may be operated only in connection with the Citymaster 1600. The safety regulations for
the Citymaster 1600 must be complied with absolutely.
Lawn mowing system
• Danger to life in the danger area of the vehicle! Special caution is required under the raised tipper and in the
area of the front mower.
• Risk of injury! Make sure that the attachments are suitable for the set oil volume. An oil volume set too high
can lead to injuries due to a defect of the attachment!
• Risk of injury! Always wear protective gloves when changing blades!
• Risk of injury! Immediately renew damaged or highly unbalanced mowing blades to avoid damage to the blade
bearings.
• Risk of injury! Before reinstalling, balance the blades and check them for out of true in height.
• Risk of injury! The V-belt is self-tensioning by spring force. Do not hook tension springs in or out with your bare
hand.
• Risk of injury! Do not exceed the permissible total weight. There is a risk of accidents! Frequently check the
filling level of the dirt hopper. Switch the suction fan off for this! The lid of the dirt hopper must not be opened
when the suction fan is running.
• Risk of injury! Modifying the safety equipment is not permitted.
• Risk of accident! You must consult Hako before attaching other attachments not approved by Hako!
• The lawn mowing system may be put into operation only with the suction nozzles raised! Refer to mounting the
mower on page 161!
01-1491-00-12.fm 13
Safety Instructions
• The lawn mowing system may be operated only in connection with the Citymaster 1600. The safety regula-
tions for the Citymaster 1600 must be complied with absolutely.
Sweeping system
• Danger to life in the danger area of the vehicle! Special caution is required in the area of the articulated
steering, under the raised tipper and in the area of the front sweeping roller.
• Risk of injury! When sweeping with the front sweeping machine, small stones or other parts in the snow can be
thrown out by the rotating sweeping roller.
• Risk of injury! Secure the front sweeping machine against rolling away when mounting it.
• The sweeping system may be operated only in connection with the Citymaster 1600. The safety regulations for
the Citymaster 1600 must be complied with absolutely.
Snow clearing system
• Danger to life in the danger area of the vehicle! Special caution is required in the area of the articulated
steering, under the raised tipper and in the area of the front and rear attachment.
• Risk of accident due to unintended lowering of the attachment! Activate winter operation in the configuration
menu only in connection with an uncoded snow blade. The front lift is then not limited downwards. Winter
operation must be deactivated immediately after use.
• The snow clearing system may be operated only in connection with the Citymaster 1600. The safety regula-
tions for the Citymaster 1600 must be complied with absolutely.
Transport system
• Danger to life in the danger area of the vehicle! Special caution is required in the area of the articulated
steering, under the raised tipper and in the area of the trailer.
• Danger to life due to inadequately secured load! The load must be correctly distributed and fastened on the
loading surface.
• Risk of injury! Modifying the safety equipment is not permitted.
• Risk of accident! Adopt measures against erroneous starting and unwanted movement. Switch the engine off
and pull out the ignition key.
• Risk of accident! You must consult Hako before attaching other attachments not approved by Hako!
• The transport system may be operated only in connection with the Citymaster 1600. The safety regulations for
the Citymaster 1600 must be complied with absolutely.
Wet cleaning system
• Risk of crushing! The squeegee of the CityCleaner weighs more than 25 kg. Body parts may be crushed if the
squeegee falls down or falls over. Always use suitable load-carrying equipment.
• Risk of injury! Wear suitable protective clothing (protective gloves and safety goggles) when using detergents.
• Risk of injury! There is a risk of tilting over if the squeegee is located on the trolley without the scrubbing deck.
Observe the correct assembly and disassembly sequence.
• Risk of injury! Always wear protective gloves when working on the lateral deflectors and brushes.
14 01-1491-00-12.fm
Safety Instructions
1.5 Information about special risks
Exhaust gases
• Toxic engine exhaust gases! Inhaling exhaust gases is injurious to health and can lead to unconsciousness
and to death! Never let the engine run in enclosed spaces.
Re-fuelling the vehicle
• Risk of fire! Diesel fuel is flammable! Take the utmost care when handling fuel. Never refuel close to naked
flames or ignitable sparks. Do not smoke during fuelling. Switch off the engine, pull out the ignition key and
apply the parking brake before fuelling.
Danger areas at the vehicle
• Danger to life in the danger area of the vehicle! Special caution is required in the area of the articulated
steering, under the raised tipper, in the area of the front and rear attachment and in the area of the trailer.
Danger of tilting over
• Danger of tilting over when driving uphill or downhill and transversely to a slope! Avoid sudden turns when
driving uphill or downhill or across slopes. There is a risk of tilting over in an inclined position! The vehicle
speed must always be adapted to the surrounding conditions and the load condition.
• Danger of tilting due to wrong steering! Note that the steering behaviour of an articulated steered vehicle
differs essentially from that of a car. Sudden steering movements at high speed or too high speeds when
turning can cause the vehicle to tilt over.
Unsecured load
• Danger to life due to inadequately secured load! The load must be correctly distributed and fastened on the
loading surface.
Suspended loads
• Danger to life due to suspended loads! Do not stay or work under suspended loads!
Battery
• Danger of explosion due to smoking, fire or open light! Especially when being charged, but also in the normal
use of batteries, batteries emit explosive gases! Avoid smoking, fire, sparks or open light in the vicinity of
batteries!
• Danger of explosion due to sparks! Never place tools or other electrically conductive objects on the battery!
Sparks that can ignite escaping gases arise if the poles are short-circuited.
Always observe the correct order when connecting and disconnecting the battery!
• Disconnecting the battery: First the minus pole and then the plus pole!
• Connecting the battery: First the plus pole and then the minus pole!
• Danger of explosion due to frozen battery or too low acid level! With a frozen battery or if the acid level is too
low, do not attempt to start with a jumper cable, the battery can burst or explode.
• Danger of burns due to battery acid! The special safety and accident prevention regulations must be complied
with when handling the battery. Batteries contain sulphuric acid.
Noise
• Danger of injury due to noise! Sound insulation devices on the vehicle must be in their protection position
during operation. If required, wear hearing protectors!
Hydraulics
• Risk of injury! Hydraulic oil issuing under high pressure can penetrate the skin and cause severe injuries.
Therefore, even with the smallest wounds, consult a doctor since otherwise severe infections can arise!
• Hydraulic pipes must be run and installed correctly! The work may be done only by authorised skilled persons.
Make sure that no connections are mixed up! Fittings, length and quality, especially resistance to pressure and
temperature of hydraulic pipes, must comply with the requirements.
Operating and auxiliary materials
• Risk of injury! Observe the safety regulations applicable for the product when handling oils, greases and other
chemical substances (e.g. battery acid or sulphuric acid)!
• There is a risk of burns and scalds! Caution when handling hot operating and auxiliary materials.
01-1491-00-12.fm 15
Safety Instructions
1.6 Safety instructions for maintenance and servicing
General
• Daily and weekly maintenance work must be done by the operating staff. In all other maintenance work, please
contact your nearest authorised Hako dealer.
• Apart from the regular general inspection (HU), the vehicle, the attachments and the trolley must be
maintained at regular intervals according to BGV, D 29 and be checked at least annually for operationally safe
condition.
• Risk of accident! Adopt measures against erroneous starting and unwanted movement. Operate the parking
brake. Switch the engine off and pull out the ignition key.
• Spare parts must be original spare parts to guarantee safety.
• Use suitable tools for the cleaning and maintenance work.
• Cleaning the electrical and electronic components as well as the engine space with a high-pressure cleaner or
steam cleaner is not allowed.
• Do not perform any welding, drilling, sawing or grinding work on parts of the frame. Damaged parts may be
replaced only by your authorised Hako dealer.
• After cleaning, examine all fuel, engine oil and hydraulic pipes for leaks, abrasion places and damage.
Immediately rectify any damage found!
• Always tighten screw connections loosened in maintenance and repair work.
• If dismantling safety devices is required in equipping, maintenance and repair work, fit and check the safety
devices immediately after completion of the work.
• Perform maintenance and repair work under a jacked up vehicle or attachment only if it is safely and securely
supported (hydraulic cylinders, jacks, etc. alone do not secure a jacked-up vehicle).
Engine
• Toxic engine exhaust gases! Inhaling exhaust gases is injurious to health and can lead to unconsciousness
and to death! Never let the engine run in enclosed spaces.
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and exhaust
system during operation and for some time after. Let the engine cool down.
• Risk of injury due to rotating parts of the cooling system. Injury of limbs or hair or clothing getting caught up.
Switch the engine off and pull out the ignition key.
• If the engine oil pressure warning symbol in the multifunction display lights up with the engine running, there is
a risk of engine damage! Stop the vehicle in the safe range. Turn the engine off immediately and check the oil
level. Have the cause of the inadequate engine oil pressure removed.
• If the diesel particulate filter in the multifunction display lights up red, the vehicle engine must be switched off
immediately. Serious engine damage can be caused if this is not complied with.
Fuel system
• Risk of fire! Diesel fuel is flammable! Take the utmost care when handling fuel. Never refuel close to naked
flames or ignitable sparks. Do not smoke during fuelling. Switch off the engine, pull out the ignition key and
apply the parking brake before fuelling.
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and exhaust
system during operation and for some time after. Let the engine cool down.
• There is a risk of engine damage if the fuel system is run completely empty! Inform an authorised workshop!
Diesel particulate filter
• Danger of fire and burning! The diesel particulate filter gets very hot. Do not grasp in the area of the diesel
particulate filter. Do not park the vehicle in the direct vicinity of flammable substances.
Cooling system
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and exhaust
system during operation and for some time after. Let the engine cool down.
• Risk of scalding from hot coolant! The cooling system is under pressure. If the cooling system cap is opened
with a hot engine there is a risk of scalding. Let the engine cool down.
• Risk of injury due to rotating parts! Injury of limbs or hair or clothing getting caught up. Switch the engine off
and pull out the ignition key.
• The cooling fins are very thin and can be damaged easily.
• Small air bubbles can form when the radiator is filled. Therefore the cooling system must be vented at the
same time. Have this done by an authorised workshop!
16 01-1491-00-12.fm
Safety Instructions
Air filter
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and exhaust
system during operation and for some time after. Let the engine cool down.
• We can assume no liability for cleaned filter inserts. Never let the engine run without a filter insert!
• Only replace the safety cartridge, do not clean it! Never let the engine run without safety cartridge!
Hydraulic system
• Risk of injury from hydraulic oil! Hydraulic oil issuing under high pressure can penetrate the skin and cause
severe injuries. Therefore, even with the smallest wounds, consult a doctor since otherwise severe infections
can arise!
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and exhaust
system during operation and for some time after. Let the engine cool down.
• Work on the hydraulic system of the vehicle may be done only by persons with special knowledge and
experience in hydraulics.
• Regularly check all pipes, hoses and screw connections for leaks and external visible damage. Immediately
rectify damage and leaks. Oil squirting out can cause injuries and fires. Observe the recommended
replacement intervals for hydraulic pipes. With normal requirements 6 years, with increased requirements on
safety 2 years!
• Do not change over hydraulic pipes! Fittings and the length and quality of the hose line must comply with the
requirements.
Air conditioning system
• Risk of injury! The coolant in the air conditioning system is under high pressure. Do not open any parts of the
air conditioning system. Have maintenance work on the air conditioning system done only by authorised
workshops.
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and exhaust
system during operation and for some time after. Let the engine cool down.
Wheels
• Risk of accident! Repair work on tyres and rims may be undertaken only by skilled personnel or authorised
workshops.
• When changing wheels, make sure that the jack is applied to the specified jacking point.
• Damaged tyres and/or incorrect tyre pressure reduce the operating safety of the vehicle. There is a risk of an
accident with tyres with too low or too high tyre pressure!
• Check the wheel nuts regularly for firm seating. After a tyre change check the wheel nuts after 50 km and
tighten them if necessary.
Electrical system
• Danger of explosion due to smoking, fire or open light! Especially when being charged, but also in the normal
use of batteries, batteries emit explosive gases! Avoid smoking, fire, sparks or open light in the vicinity of
batteries!
• Danger of explosion due to sparks! Never place tools or other electrically conductive objects on the battery!
Sparks that can ignite escaping gases arise if the poles are short-circuited,
Always observe the correct order when connecting and disconnecting the battery!
• Disconnecting the battery: First the minus pole and then the plus pole!
• Connecting the battery: First the plus pole and then the minus pole!
• Danger of explosion due to frozen battery or too low acid level! With a frozen battery or if the acid level is too
low, do not attempt to start with a jumper cable, the battery can burst or explode.
• Danger of burns due to battery acid! The special safety and accident prevention regulations must be complied
with when handling the battery. Batteries contain sulphuric acid.
• Work on the electrical system may be done only in accordance with electrical engineering standards by a
specialist trained for this work.
• Regularly inspect/check the electrical equipment of the vehicle. Defects such as loose connections or
scorched cables must be removed immediately.
• Note the operating voltage of the vehicle!
• Use only original fuses. If stronger fuses are used, the electrical system can be destroyed and there can be
fires.
• Welding work on the vehicle may be done only by authorised Hako dealers. Welding work on the vehicle leads
to damage to the control electronics and can impair driving safety.
01-1491-00-12.fm 17
Safety Instructions
Installation of electrical devices
• The vehicle is equipped with electronic components and parts whose function can be influenced by electro-
magnetic emissions of other devices. Such influence can lead to danger to persons and safety-relevant
functions if the following safety instructions are not complied with:
• If electrical and electronic devices and/or components, which also are connected to the vehicle electrical
system, are installed subsequently in the vehicle, the user must examine in his own responsibility whether the
installation causes interference to the vehicle electronics or to other components, a renewed acceptance test
may be necessary.
• Above all it must be ensured that the subsequently installed electrical and electronic components comply with
the EMC Directive 2004/108/EC in the relevant valid edition and bear the CE marking or an E1 approval is
available.
• In addition, the following requirements especially must be fulfilled for the subsequent installation of mobile
communication systems (e.g. radio, telephone):
• Only devices with approval according to the valid national regulations (e.g. BZT approval in the Federal
Republic of Germany) may be installed.
• The device must be installed permanently.
• Operation of portable or mobile devices inside the vehicle is permitted only through a connection to a perma-
nently installed outside antenna.
• The transmitter must be installed in a separate location from the vehicle electronics.
• When installing the antenna, pay attention to correct installation with good ground connection between
antenna and vehicle ground.
1.7 Environmental protection instructions
• Adequate knowledge is required for the safe handling of substances which could represent a risk to health and
the environment.
• Observe the applicable laws and local regulations when disposing of detergents.
• During maintenance work and repairs, operating substances and filters have to be collected in suitable
containers and properly disposed of observing the applicable laws and local regulations.
• Leaked oil, diesel fuel and lubricants etc. must not enter into the soil. Otherwise this would create a serious risk
of groundwater contamination.
• Any contamination from leakages has to be cleared up without delay and disposed of properly. Used filters
usually have to be disposed of as special waste (e.g. fuel filters) depending on the filtered substance.
• Ensure safe and environment-conserving disposal of operating and auxiliary materials. Take up escaping or
spilled operating materials in suitable containers and dispose of them in an environmentally friendly manner.
• Used batteries with the recycling symbol contain reusable commodities. In accordance with the symbol
showing the crossed-out garbage bin, these batteries must not be disposed of in the domestic waste. Return
and recycling have to be arranged with the authorised Hako dealer as required in § 6 and § 8 of the German
battery law (BattG)!
18 01-1491-00-12.fm
Safety Instructions
1.8 Shutting down and disposal
If the end of use of the vehicle or of its components is reached and this is handed over for scrapping, the components must be correctly disposed of. Here the regulations of the competent local authorities must be observed.
The operating materials in the vehicle require special disposal and may not get into the environment. Further
information about disposal is available through the competent local authorities and the authorised Hako dealer.
• Do not dispose of products with the symbol at the end of their life in the domestic waste.
• Recycle used materials with the symbol according to their labelling.
• Recycle packaging materials and do not throw them into the domestic waste.
• Recycle plastics that are identified with statement of the material, such as PPTV20 for example, and do not
throw them into the domestic waste.
• Old batteries contain hazardous materials and must be returned to the distributor, disposed of correctly or
delivered to a collecting point. Do not throw old batteries into the domestic waste.
• Treat operating materials such as oils, hydraulic fluids or fuels as hazardous waste and dispose of them
correctly.
• Have refrigerants disposed of only by specialist firms with expert staff and the required technical equipment.
Refrigerant may under no circumstances get into the atmosphere. Have refrigerants disposed of by an
authorised Hako dealer.
• Observe national regulations.
01-1491-00-12.fm 19
Safety Instructions
G
A
I
A
B
D
E
F
Fig. 2:
F
B
A
D
G
C
C
E
H
H
I
Citymaster 1600
J
J
K
K
1.9 Labels on the vehicle
The following safety and instruction labels are affixed well legibly to the vehicle. Renew missing or illegible labels
immediately.
20 01-1491-00-12.fm
Safety Instructions
Hako company logo Fig. 2-A
The Hako company logo (147 mm x 40 mm) is located on the left and right cover of the engine.
The Hako company logo (220 mm x 60 mm) is located on the windscreen.
Label – High-pressure cleaner Fig. 2-B
The High-pressure cleaner label is located in the driver's cab under the driver's seat.
Label – Noise measurements Fig. 2-C
The Noise measurements label is located in the driver's cab under the driver's seat.
Label – Type plate Fig. 2-D
The Type plate label is located in the driver's cab under the driver's seat.
Label – Tyre pressure Fig. 2-E
The Tyre pressure label is located in the driver's cab under the driver's seat.
Label – Operating manual Fig. 2-F
The Operating manual label is located in the driver's cab on the front bar top right.
Label – Machine type Fig. 2-G
The Machine type label is located on both driver's doors.
Label – Emergency steering Fig. 2-H
The Emergency steering label is located in the driver's cab on the steering column.
Label – Parking brake Fig. 2-I
The Parking brake label is located in the driver's cab on the steering column.
Label – Suction mouth Fig. 2-J
The Suction mouth label is located behind the front tool carrier.
Label – Front tool carrier lowering valve Fig. 2-K
The Front tool carrier lowering valve label is located on the left control panel.
01-1491-00-12.fm 21
Safety Instructions
G
A
B
D
E
F
Fig. 3:
C
F
C
E
C
D
G
A
B
A
22 01-1491-00-12.fm
Safety Instructions
Labels – Danger in articulation area Fig. 3-A
The Danger in articulation area labels are located on the driver's cab at the rear on the left and right.
Label – Safety cab Fig. 3-B
The Safety cab label is located in the driver's cab at the rear in the centre.
Labels – Risk of crushing Fig. 3-C
The Risk of crushing labels are located on the rear wagon on the left and right next to the suction pipe.
Label – Rotating parts Fig. 3-D
The Rotating parts label is located on the rear wagon on the left next to the suction pipe.
Label – High-pressure cleaner Fig. 3-E
The High-pressure cleaner label is located on the rear wagon on the right next to the suction pipe.
Label – Allowed maximum speed Fig. 3-F
Allowed maximum speed of the vehicle in km/h. The Allowed maximum speed label is located at the driver's cab
at the rear on the right.
Label – Air-conditioner Fig. 3-G
The Air-conditioner label is located at the driver's cab at the rear on the right.
01-1491-00-12.fm 23
Operation
14
15
13
12
11
6
7
5
8
9
Fig. 4:
31 2 4
10
2 Operation
2.1 Overviews
The description in chapter 2 contains information on the function and handling of the individual controls on the vehicle. The controls always have
the same item number in all chapters.
24 02-1491-00-11.fm
2.1.1 Front view
Item Designation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Driver's cab
Additional working spotlight (optional) or driving light above (optional)
Direction indicator (front) with side lights
Beacon
Outside mirror (optionally heated)
Windscreen wiper
Doors
Fresh water tank
Fuel tank
Ball cock circulating water
Front attachment connections
Front tool carrier
Working spotlight
Head light
Number plate holder
Operation
02-1491-00-11.fm 25
Operation
Fig. 5:
25
23
16
18
17
19
22
21
20
24
26 27
26 02-1491-00-11.fm
2.1.2 Rear view
Item Designation
16
17
18
19
20
21
22
23
24
25
26
27
7-pin socket for trailer operation
Direction indicator with rear light and brake light
Number plate light
Rear attachment connections
Engine space cover
Circulating water coupling
Hydraulic oil tank
First aid box and warning triangle (optional)
Auxiliary tool
7-pin socket for spreader control cable (optional)
Fog tail light (optional)
Reversing light (optional)
Operation
02-1491-00-11.fm 27
Operation
Fig. 6:
28
42
44
41
43
46
47
37
36
38
39
40
35
41
48
49
34
30
32
29
33
31
45
28 02-1491-00-11.fm
2.1.3 Driver's cab
Item Designation
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Inside roof control panel
Steering wheel
Steering column control panel
Socket for spreader control cable on the steering column
3-pin socket
Steering column
Windscreen wiper system filling opening
Multifunctional display
Forwards accelerator pedal
Reverse accelerator pedal
Door handle
Right arm rest control panel
Right-hand control panel
Seat belt
Socket for spreader control cable on the driver's cab outside
Left-hand control panel
Driver's seat
Brake pedal
Coarse material flap pedal
Foot space air vent
Electrical system cover
Water filter cover
Operation
02-1491-00-11.fm 29
Operation
Fig. 7:
62
63
61
67
5550 51 545352
58 575960
65
64
66
68
56
30 02-1491-00-11.fm
Continued – Driver's cab
Item Designation
Inside roof control panel
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
Air-conditioner switch
Suction fan controller
Heating controller
Air vent
Head light/side light switch
Working spotlight switch
Top driving light switch (optional)
Mirror heating switch (optional)
Fog tail light switch (optional)
Beacon switch
Inside light switch
Steering column control panel
Emergency flasher system switch
Steering column lever
Engine fixed speed button
Windscreen wiper motor/water pump switch
Direction indicator switch/horn button
Preheat control light
Generator control light
Cruise control switch/limiter (optional)
Operation
02-1491-00-11.fm 31
Operation
Fig. 8:
75
69
78
73
72
7980
81
82
83
74
77
70 71
76
84
32 02-1491-00-11.fm
Continued – Driver's cab
Item Designation
Arm rest control panel
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
Turn-push knob for the multifunctional display
Joystick lowering front tool carrier (configuration depending on the attachment)
Joystick raising front tool carrier (configuration depending on the attachment)
Hako button
Armrest tilt star-shaped handle
Right-hand control panel
Fuse box
Raise/lower dirt hopper switch
Cooling system reversing fan switch
Electrical parking brake
Ignition switch
Operating manual shelf
Left-hand control panel
Radio installation space
Fresh water amount at the suction mouth lever
Sweeper fresh water amount lever
Drink holder
Front tool carrier lowering valve
Operation
02-1491-00-11.fm 33
Operation
Fig. 9:
35
Fig. 10:
69
2.2 Multifunctional display
2.2.1 Start screen
Functions and indicators of the vehicle are set and displayed with the mul-
tifunctional display Fig. 9-35.
After the vehicle is switched on, the operating system and data are loaded
and the start screen appears on the display. The version number of the
control unit is shown on the start screen at the bottom left and the version
number of the display software at the bottom right.
2.2.2 Menu guidance
The menu is operated with the turn-push knob Fig. 10-69. The turn-push
knob is located in the right armrest of the driver's seat.
Menus and submenus are selected in the multifunctional display and the
individual menu item values are set or changed with the turn-push knob.
The basic principles in this case are:
• Turn to select a menu item.
• Push to activate a menu item.
• Turn to change a value.
If no setting is made for around two seconds, the cursor jumps back again.
34 02-1491-00-11.fm
2.2.3 Menu structure
Fig. 11:
The menu structure of the multifunctional display is divided into several
levels.
• The information and warning symbols and the most important operating
data are shown in the normal view.
• Operating settings such as the output of the hydraulic oil circuit I/II or
the loading and unloading of the front tool carrier (optional) are made in
the working menu.
• Operating menu (B menu):
The pre-settings for the normal view are made in the operating menu.
• Configuration menu (C menu):
Basic settings such as date, time, units etc., are made in the configuration menu.
Operation
*) according to the option or attachment
02-1491-00-11.fm 35
Operation
Fig. 12:
1
2
3
4
5
6
A
B
C
D
8
2.2.4 Normal view
General structure
The normal view appears automatically after the start screen. The current
vehicle data are displayed in the normal view. The user can determine
partially in the operating menu the vehicle data that are displayed. The
other part of the vehicle data is determined by the vehicle condition
(e.g. current engine speed).
The normal view Fig. 12 is structured as follows:
1 Warning and information symbols
2 Warning and information symbols (left and right)
recognised attachment (centre)
3 Speed, pedal indicator, blinkers, time
4 Attachment parameters (left)
Operating times and operating kilometres (right)
5 Service information (left)
Current engine speed (right)
6 Engine values (left)
Hydraulic values and fresh water level (right)
The vehicle data are displayed as symbols, switches, bar charts or
numbers.
A Symbols
• Example: Fuel supply low
Special feature:
Warning symbols are displayed red or yellow shining or flashing.
Information symbols are displayed green or white.
B On and Off switches
C Bar chart
• Example: Hydraulic circuit I
The bar chart can be set from 0 to 100 %.
Special feature: The range can be restricted for certain parameters.
For example, the suction fan has a setting range of 30 % to 100 %.
D Numbers
• Example: Suction fan run-on (8 seconds)
36 02-1491-00-11.fm
2.2.5 Working menu (A menu)
Fig. 13:
69
Adjustable indications are displayed on entry into the working menu
Fig. 13. All indications are displayed one after the other by pushing the
turn-push knob Fig. 13-69. The operator can change the values in the
current display by turning the turn-push knob.
The following displays are possible according to the attachment/option:
1 Basic vehicle:
• Setting hydraulic circuit I (front attachment), see page 66
• Setting hydraulic circuit II (rear attachment), see page 68
• Loading and unloading the front tool carrier
2 Vacuum sweeping system:
• Switching the fresh water pump on/off, see page 142
• Setting the rotating brush speed, see page 141
• Setting the suction fan speed, see page 142
3 Lawn mowing system:
• Setting hydraulic circuit I (50 litres/minute), see page 163
4 Sweeping system:
• Setting hydraulic circuit I (70 litres/minute), see page 174
5 Wet cleaning system:
• Setting the water supply, see page 207
• Setting the water volume, see page 207
• Setting the brush speed, see page 208
• Setting the suction fan speed, see page 208
• Setting the brush pressure, see page 208
Operation
02-1491-00-11.fm 37
Operation
69
Fig. 14:
A
B
C
Example: Setting the output of hydraulic circuit I
The following example shows how the output of hydraulic circuit I can be
changed in the working menu.
1 The normal view (A) is displayed.
2 Turn the turn-push knob Fig. 14-69: The last active function (B) is
selected. (For example: hydraulic circuit I with maximum 50 litres/
minute to 30 %)
3 Turn the turn-push knob: The current value is changed. (For example,
hydraulic circuit I with 80 %).
Danger
Risk of injury! Make sure that the attachments are suitable for
the set oil volume. An oil volume set too high can lead to injuries due to a defect of the attachment! As a reminder, the setting process is interrupted briefly at 70 %.
The change is made immediately in working travel. If the change is made
in the transport driving mode, it is activated only on changing to the working driving mode.
38 02-1491-00-11.fm
2.2.6 Operating menu (B menu)
D
2
4
6
8
9
10
11
12
1
3
5
7
A
B
C
A
B
C
D
69
Fig. 15:
The displays of the normal view can be combined for the corresponding
requirements in the operating menu Fig. 15. Different functions can be
selected in the fields (A), (B) and (C).
The service information is displayed in the field (D).
Operating data
The distances are displayed in kilometres (km) or miles (mi) depending on
the system setting in the configuration menu. System setting, see page
41.
The displayed counter is reset by pushing the turn-push knob Fig. 15-69
for a long time.
Field A:
1 Operating hours total
2 Operating hours resettable
3 Work hours total
4 Work hours resettable
5 Sweeping kilometres total
6 Sweeping kilometres resettable
7 Distance total
8 Distance resettable
Field B:
9 Fuel supply
10Cooling water temperature
Field C:
11Fresh water supply
12Hydraulic temperature
Service information
If a service information has occurred since the ignition was switched on, a
4-digit code is displayed in field D. If the code is currently active, a red
flashing wrench appears in addition.
Operation
Note
The displayed service information can be hidden after error
rectification by pushing the turn-push knob for a long time.
02-1491-00-11.fm 39
Operation
69
2 sec
Fig. 16:
A
C
D
E
B
Example: Selecting the fuel gauge
The following example explains how to change the operating data display
from cooling water temperature to fuel gauge in the operating menu.
1. In the normal view (A), push the turn-push knob Fig. 16-69 for at least
two seconds. The operating menu is activated. The cursor stands on
the EXIT symbol (B).
2. Turn the turn-push knob and move to the field (C).
3. Push the turn-push knob: Field (C) is activated.
4. Turn the turn-push knob and select the fuel gauge (D).
5. Push the turn-push knob. The new function is taken over.
6. Turn the turn-push knob and exit the operating menu via the EXIT
symbol (E).
40 02-1491-00-11.fm
2.2.7 Configuration menu (C menu)
Fig. 17:
1
2
3
4
5
6
7
8
9
10
Fig. 18:
A B
C
1 ... 6
D
Fig. 19:
A
B
The configuration menu Fig. 17 consists of a table of contents. The menu
items to be changed can be selected in the table of contents. When you
select a menu item, you branch into a sub menu in which you can make
settings.
A condition is that the accelerator pedal is in neutral position.
There are the following menu items in the configuration menu:
1 Driving profile
2 Suction fan settings
3 Winter operation
4 Time/date
5 Service information
6 Front tool carrier
7 Fresh water supply
8 Driving settings
9 System settings
10System information
Operation
Driving profile Fig. 18
A Loading a sweeping program
B Saving the current parameters
C Resetting to defaults
D Selecting storage place for saving or loading
Suction fan settings Fig. 19
A Suction fan after ignition ON
• 0 ... OFF
• 1 ... ON
• 2 ... Last value in ignition OFF
B Suction fan run-on
• 0 to 15 seconds (standard): 8 seconds)
02-1491-00-11.fm 41
Operation
Fig. 20:
B
C
D
A
Fig. 21:
A
B
Fig. 22:
A
B
Fig. 23:
A
B
50
C
Winter operation Fig. 20
Danger
Risk of accident due to unintended lowering of the attachment! Activate winter operation in the configuration menu only
in connection with an uncoded snow blade. The front lift is
then not limited downwards. Winter operation must be deactivated immediately after use.
A Winter operation ON/OFF
• 0 ... OFF (standard)=
• 1 ... ON
B Spreader run-on
• 0 to 4 seconds (standard): 0 seconds)
C Spreader fast emptying ON/OFF
• 0 ... OFF
• 1 ... ON
D Spreader corresponding to the pedal setting
• 0 ... OFF
• 1 ... ON (standard)
Time/date Fig. 21
A Time in hours/minutes
B Date in day/month/year
Service information Fig. 22
The last ten items of service information are displayed with time stamp
Fig. 22-A and error number Fig. 22-B.
If no time stamp is available, the error occurred immediately at ignition ON
or the display was switched off or not ready.
Front tool carrier Fig. 23
A Lower front tool carrier
• 0 ... Automatic OFF
• 1 ... Automatic ON
B Loading and unloading the front tool carrier
• 0 ... Last value
• 1 ... Always floating position
C Front tool oil volume
• 0 ... 50 litres/min
• 1 ... 70 litres/min
42 02-1491-00-11.fm
Fresh water supply Fig. 24
Fig. 24:
B
C
A
Fig. 25:
B
C
D
A
E
Fig. 26:
A
B
Fig. 27:
A
B
C
A Water pump to last set value (standard)
• 0 ... Last value
• 1 ... Always ON
B Water pump for uncoded attachment
• 0 ... Not available
• 1 ... Available
C Water supply for the 3rd rotating brush (optional)
• 0 ... OFF
• 1 ... ON
Driving settings Fig. 25
A Signal tone on flashing
• 0 ... OFF
• 1 ... ON (standard)
B Signal tone on reversing
• 0 ... OFF
• 1 ... ON (standard)
C Tyre type
• see selection list
D Warning tone when driving with raised dirt hopper
• 0 ... OFF
• 1 ... ON (standard)
E Speed reduction in working travel
• Limit value in %
System settings
A Setting units
• km/h (standard)
• mi/h
B Display brightness
• Standard: 80 %
Operation
System information
A Vehicle type
B Recognised attachment
• Example: Sweeping system with two rotating brushes
C Software statuses
02-1491-00-11.fm 43
Operation
69
Fig. 28:
A
E
D
C
F G H
B
I
1 .. 6
J
2 sec
Example: Driving profile setting
The following example explains how to make a setting in the driving and
sweeping program.
1. In the normal view (A), push the turn-push knob Fig. 16-69 for at least
two seconds. The operating menu is activated. The cursor stands on
the EXIT symbol (B).
2. In the operating menu turn the turn-push knob and move to the arrow
symbol (C).
3. In the operating menu push the turn-push knob. The configuration
menu is activated. The cursor stands on the EXIT symbol (D).
4. In the configuration menu turn the turn-push knob and move to the driv-
ing profile menu item (E).
5. In the configuration menu push the turn-push knob. The driving profile
sub-menu is selected. The cursor stands on the EXIT symbol (F).
6. Turn the turn-push knob in the driving profile sub-menu. There are the
following possibilities:
• Loading a sweeping program with the symbol (G)
• Resetting to defaults with the symbol (H)
• Saving the current parameters with the symbol (I)
• Selecting the storage place for loading or saving: 1 to 6 (J)
Use the EXIT symbol to exit the sub menu.
44 02-1491-00-11.fm
2.2.8 Warning and information symbols
Warning symbols
Item Symbol Colour Function Remedy
Operation
1
2
3
4
5
6
7
8
9
10
11
Red Charge control The control light of the generator lights up when
the ignition is switched on, but goes out as soon
as the engine is started. If the control light goes
on when the engine is running, this signals:
Defect on the V-belt of the generator or defect in
the charge circuit of the generator. The battery
is no longer being charged! Immediately stop
the vehicle safely and if necessary notify an
authorised workshop.
Red Engine oil pressure low If the warning symbol appears, there is a risk of
engine damage. Immediately stop the vehicle
safely and check the engine oil level.
Red Cooling water temperature too high If the warning symbol appears, there is a risk of
engine damage. Immediately stop the vehicle
safely and check the engine oil level.
Red Hydraulic oil temperature If the warning symbol appears, there is a risk of
operating failure of the hydraulic system. The
hydraulic oil temperature is too high! Stop the
vehicle safely and switch off all hydraulic units.
Red Parking brake on The warning symbol appears if the parking
brake is on.
Red Hopper overload (optional) Empty the dirt hopper immediately if the warning
symbol appears.
Yellow Engine fault If the warning symbol appears with the engine
running, there is a risk of engine damage. Immediately stop the vehicle safely and if necessary
notify an authorised workshop.
Yellow Fuel supply low If the warning symbol flashes, then refuel with-
out delay. There is a risk of engine damage if
the fuel system is run completely empty! Inform
an authorised workshop!
Yellow Hopper raised As long as the dirt hopper is not in its lower end
position, the warning symbol appears.
Yellow Driver not on driver's seat The warning symbol appears if the driver leaves
the driver's seat during operation.
Yellow Preheat
(see page 48)
There is an engine fault if the warning symbol
flashes. There is a risk of engine damage.
Immediately stop the vehicle safely and notify
an authorised workshop.
02-1491-00-11.fm 45
Operation
N12
Information symbols
Item Symbol Colour Function
12
13
14
15
16
17
18
19
20
21
Green Vehicle blinker
Green Trailer blinker
Green Side and rear lights
White Front tool carrier floating position
White Front tool carrier upper stop
White Transport mode
White Work mode with front tool carrier or unknown attachment
White Winter operation
White Work mode with 2-brush system
White Work mode with 3-brush system
22
23
24
25
26
27
White Work mode with front sweeping machine
White Work mode with front mower
White Work mode with CityCleaner
White Accelerator pedal in neutral position
White Speed level 1 lights up constantly or flashes
White Speed level 2 lights up constantly or flashes
46 02-1491-00-11.fm
2.3 Controls in the driver's cab
Fig. 29:
A
33
29
Fig. 30:
6365
2.3.1 Steering column control panel
Adjusting the steering column
Danger
Risk of accident! If the steering column Fig. 29-33 is unlocked
while driving, it can come unexpectedly out of adjustment.
You can then lose control over the vehicle.
The steering column Fig. 29-33 can be adjusted to the corresponding
driver position with a lever.
• Turn the lever Fig. 29-A counter-clockwise until the steering column is
unlocked.
• Set the required steering column adjustment.
• Turn the lever clockwise until the steering column is locked.
Check that the steering column is locked. To do this, move the steering
wheel Fig. 29-29 in the longitudinal direction.
Setting the fixed engine speed
The fixed engine speed and thus the system output of the vehicle in the
work mode is set with the button Fig. 30-63.
Operation
Stage Rpm Hydraulic circuit I
Litres/minute
1-ECO 1600 50 20
2-STANDARD 2000 50/70 27
3-MAXIMUM 2400 50/70 32
The overview illustrates that sufficient power is available already in the
ECO mode for many applications.
The full hydraulic output is reached as from the Standard speed.
Additional energy is available in the driving mode as well as in hydraulic
circuit II at Maximum. Set the speed corresponding to the requirements.
Operation primarily in the ECO mode lowers consumption and noise. See
pages 66 and 68 for information about setting the hydraulic circuits.
Horn
The horn is switched on and off with the button Fig. 30-65.
Hydraulic circuit II
Litres/minute
• Push the button: Horn ON
• Release the button: Horn OFF
02-1491-00-11.fm 47
Operation
Fig. 31:
A
B
65
61
Fig. 32:
68
A
Switching the emergency flasher system on and off
The emergency flasher system is switched on and off with the switch
Fig. 31-61. The direction indicators Fig. 4-3 and Fig. 5-17 flash. The
emergency flasher system also functions in position P of the ignition
switch.
• Switch in stage I: Emergency flasher system OFF
• Switch in stage II: Emergency flasher system ON
The lamps are monitored. Fast flashing signals a defective lamp.
In the multifunctional display, the flasher information symbol Fig. 31-A
appears, or in trailer operation the trailer operation flasher information
symbol Fig. 31-B.
Direction indicators
The direction indicators Fig. 31-65 and Fig. 4-3 are switched on and off
with the switch Fig. 5-17. The direction indicators also function in position
P of the ignition switch.
• Switch in stage I: Left direction indicator switch ON
• Switch in stage II: Direction indicator switch OFF
• Switch in stage III: Right direction indicator switch ON
The lamps are monitored. Fast flashing signals a defective lamp.
In the multifunctional display, the flasher information symbol Fig. 31-A
appears, or in trailer operation the trailer operation flasher information
symbol Fig. 31-B.
Cruise control and speed limiter (optional)
The cruise control and speed limiter is available only in work mode. The
current speed is set in the first position of the switch Fig. 32-68. In this
case the road speed is controlled so that it is not lower or higher than the
speed set with the cruise control. The cruise control information symbol
Fig. 32-A appears in the multifunctional display. The cruise control is
switched off again in the neutral position of the switch.
If the driver presses the accelerator pedal, the road speed is increased
without the cruise control being deactivated. For reasons of safety, the
cruise control switches off immediately when the brake pedal is operated.
The speed limiter determines the maximum road speed with the accelerator pedal pushed down fully. This serves for convenient control of the road
speed especially at low working speeds. The speed must be set on the
configuration menu. It is activated via the second switch position of the
switch Fig. 32-68.
Danger
Risk of accident! Use the cruise control and the speed limiter
only when the traffic situation allows!
48 02-1491-00-11.fm
Generator control light
Fig. 33:
66
67
Fig. 34:
34
64
6
The control light of the generator Fig. 33-66 lights up when the ignition is
switched on, but goes out as soon as the engine is started. If the control
light goes on when the engine is running, this signals: Defect on the V-belt
of the generator or defect in the charge circuit of the generator. The battery is no longer being charged! Immediately stop the vehicle safely and if
necessary notify an authorised workshop.
Preheat control light
The preheat control light Fig. 33-67 lights up with the ignition switched on.
The engine is preheated until the control light goes out.
If the preheat control light flashes, the preheat procedure has been inter-
rupted and must be repeated.
If the preheat control light flashes when the key in the ignition switch is in
position 1, or during operation slowly or fast, then a fault in the engine
control has occurred.
Operation
Windscreen washer system
The windscreen washer system is used for cleaning the windscreen.
The water sprayed onto the windscreen supports the cleaning effect of the
windscreen wipers Fig. 34-6.
The windscreen washer system is supplied from the water tank
Fig. 34-34. Detergents and antifreeze are added to the water as required.
Note
Do not let the windscreen wipers Fig. 34-6 wipe over dry
windscreens for a longer time. Wiper blades wear prematurely due to this and the wiper motor can overheat! Switch
the windscreen wipers off with dry windscreens.
The windscreen wiper motor and the water pump are switched on and off
with the switch Fig. 34-64.
The switch has three positions:
• Position 1: Functions of the windscreen washer system OFF
• Position 2: Functions of the windscreen washer system ON
(continuous mode)
• Position 3 (pressed briefly): Interval operation ON/OFF
Position 3 (pressed longer): Interval operation ON and water pump ON
02-1491-00-11.fm 49
Operation
Fig. 35:
81
82
75
Fig. 36:
I
II
A
2.3.2 Left-hand control panel
Switching on fresh water for the suction mouth
For binding dust the suction mouth is supplied with water from the circulating water system.
In addition, fresh water can be supplied to the suction mouth as required
with the lever Fig. 35-81 in the left-hand control panel.
Setting the fresh water volume for the sweeping unit
The volume of the fresh water at the spray nozzles is set with the lever
Fig. 35-82 in the left-hand control panel. Set the volume corresponding to
the requirements.
• Light contamination: Reduce fresh water volume with the lever.
• Heavy contamination: Increase fresh water volume with the lever.
Note
Switch the fresh water pump on in the configuration menu
before adjusting the fresh water volume, see page 41.
Note
Make sure that the ball cock for the circulating water is
opened, see page 62.
2.3.3 Right-hand control panel
Raising and lowering the tipper body
The following functions on the tipper body are switched on with the button
Fig. 36-75:
• Button in position I: Tipper body is raised until the button is released.
• Button in position II: Tipper body is lowered until the button is released.
As long as the tipper body is not in its lower end position, the tipper body
raised warning symbol Fig. 36-A appears.
Danger
Danger to life in the danger area of the vehicle! Special caution is required in the area of the raised tipper body.
Note
For reasons of safety, the road speed is limited when the tipper body is raised (hopper or load platform)! With the tipper
body removed, the warning signal and the road speed limitation must be deactivated for normal travel (configuration
menu, vehicle settings, see page 41). Each time the
button Fig. 36-75 is pushed, the warning and safety function
is switched back on automatically.
50 02-1491-00-11.fm
Cooling system reversing fan switch (optional)
76
Fig. 37:
A
77
Fig. 38:
A
45
Should the radiator cover of the cooling system get dirty during sweeping
or mowing, it is possible to clean it with the reversing fan. To do this, press
the switch Fig. 37-76. In this way the reversing fan runs for a certain time
in the reverse direction.
• The reversing fan runs for approx. 10 seconds when the button is
pressed briefly.
• The reversing fan runs for approx. 30 seconds when the button is
pressed longer.
The Reversing fan information symbol Fig. 37-A appears in the multifunc-
tional display.
Operation
Parking brake (electrical) switch
Danger
Risk of accident! Adopt measures against erroneous starting
and unwanted movement. Operate the parking brake. Switch
the engine off and pull out the ignition key.
The parking brake Fig. 38-77 prevents the vehicle from rolling away. If the
vehicle still moves, activation of the parking brake is not possible.
Holding the vehicle with the parking brake:
• Push the brake pedal Fig. 38-45.
• Unlock the parking brake and press the switch Fig. 38-77.
• The warning symbol Fig. 38-A appears in the multifunctional display.
• If the accelerator pedal is deflected with the parking brake locked, a
warning signal sounds.
Releasing the parking brake:
• Press the switch Fig. 38-77. The parking brake is released again.
With the parking brake released the warning light Fig. 38-A goes out.
02-1491-00-11.fm 51
Operation
Fig. 39:
1
2
P
0
A
B
78
67
66
Ignition switch
Warning
• If the engine oil pressure symbol Fig. 39-A in the multifunctional display lights up with the engine
running, there is a risk of engine damage! Stop the vehicle in the safe range. Turn the engine off
immediately and check the oil level. Have the cause of the inadequate engine oil pressure
removed.
Note
• The engine can be started only if the accelerator pedals Fig. 6-36 and Fig. 6-37 are in neutral
position.
• The ignition switch Fig. 8-78 has a start repeating interlock. Switch back to position 0 for a further
start.
• Do not repeat the starting procedure more than 3 times, then let the starter cool down.
• After starting the cold engine, let it warm up with slightly increased idling speed.
• At temperatures below 10 °C, the engine speed is electronically limited to prevent damage to the
hydraulic system. Above 10 °C the permissible engine speed is increased linearly up to 30 °C.
Above 30 °C hydraulic oil temperature, the maximum engine speed is available.
• Do not actuate the accelerator pedal during the starting procedure!
The ignition switch Fig. 8-78 is used for starting the engine and for switch-
ing the electrical system on and off.
• Position P: The emergency flasher light, side lights, beacon, number
plate light, rear fog light (optional) and interior light are functioning. The
key can be pulled out. Position P can be reached from position 0. Push
the key down and then turn it to the left.
• Position 0: The emergency flashing light is functioning. The electrical
system and the engine are switched off. The key can be pulled out.
• Position 1: The electrical system and the engine are switched on.
• The parking brake warning symbol Fig. 39-B in the multifunctional
display may light up.
• The generator control light Fig. 41-66 lights up briefly and goes out
after the engine has started and has sufficient engine speed.
• The preheat control light Fig. 41-67 lights up, the engine is preheated
until the control light goes out.
• Position 2: Start the engine.
• The parking brake warning light may light up.
• Warning lights must go out.
• If the preheat control light flashes when the key in the ignition switch
is in position 1, or during operation slowly or fast, then a fault in the
engine control has occurred. Refer to troubleshooting on page 77 or
contact an authorised Hako dealer.
• If a service information is displayed in the multifunctional display
with a flashing wrench then there is an error. Refer to troubleshooting on page 77 or contact an authorised Hako dealer.
• The ignition switch goes back into position 1.
52 02-1491-00-11.fm
Fig. 40:
C
D
A
B
70
69
72
71
12
11A
11B
2.3.4 Arm rest control panel
Hako button
The Hako button Fig. 40-72 switches from transport mode to work mode
or vice versa and starts automated procedures according to the attachment.
The accelerator pedals must be in the neutral position.
In the multifunctional display, the transport mode Fig. 40-A, or front tool
carrier symbol Fig. 40-B appears.
The vehicle speed is in the:
• transport mode is 0 to 40 km/h
• work mode is 16/20/24 km/h according to selected engine speed
You will find the functional description of the Hako button for attachments
in chapter 6.
Joystick
The front tools are operated with the joystick Fig. 40-70 and the
joystick Fig. 40-71.
The joystick Fig. 40-70 acts on the front tool carrier Fig. 40-12 and on the
hydraulic connections Fig. 40-11A.
• Joystick forwards: Lowering front tool carrier (floating position)
• Joystick back: Raising front tool carrier
• Joystick to the left: the left-hand actuator swings to the left
• Joystick to the right: the left-hand actuator swings to the right
In the multifunctional display, the upper stop information symbol Fig. 40-C
or floating position symbol Fig. 40-D appears.
The joystick Fig. 40-71 acts on the hydraulic connections Fig. 40-11B.
• Joystick to the left: The right-hand actuator swings to the left
• Joystick to the right: The right-hand actuator swings to the right
Operation
Note
• For reasons of safety, lowering the front tool carrier with the
vehicle moving is possible only in the work mode. In the
transport mode, the front tool carrier can be lowered only at
a road speed of <5 km/h.
• If the front tool does not have to be lowered completely,
interrupt the lowering movement by briefly pulling the
joystick back.
• If the movement of the front tool does not agree with the
movement of the joystick, change over the hydraulic
connections.
Turn-push knob
The turn-push knob Fig. 40-69 is located in the right armrest of the driver's
seat. Menus and submenus are selected in the multifunctional display and
the individual menu item values are set or changed with the turn-push
knob, see page 34.
02-1491-00-11.fm 53
Operation
Fig. 41:
A60
59
5554
57
2.3.5 Roof control panel
Working spotlight
The switch Fig. 41-55 switches the working spotlights Fig. 4-13
(or additional working spotlight Fig. 4-2) in the work area on and off.
• Switch in stage I: Working spotlights OFF
• Switch in stage II: Working spotlights (series) ON
• Switch in stage III: Additional working spotlights (optional) ON
Head light and side lights
The switch Fig. 41-54 switches the head light Fig. 4-14, the side lights
Fig. 4-3 and the number plate light Fig. 5-18 on and off. The side lights
also function in position P of the ignition switch.
• Switch in stage I: Head light and side lights OFF
• Switch in stage II: Side lights ON
• Switch in stage III: Head light and side lights ON
With the multifunctional display switched on, the head light and side lights
information symbol Fig. 41-A appears.
Beacon
The beacon Fig. 41-59 is switched on and off with the switch Fig. 4-4.
The beacon also functions in position P of the ignition switch.
• Switch in stage I: Beacon OFF
• Switch in stage II: Beacon ON
Interior lighting
The interior lighting is switched on and off with the switch Fig. 41-60.
• Switch in stage I: Interior lighting OFF
• Switch in stage II: Interior lighting ON
Outside mirror heating (optional)
The switch Fig. 41-57 switches the optional outside mirror heating on and
off.
• Switch in stage I: Outside mirror heating OFF
• Switch in stage II: Outside mirror heating ON
54 02-1491-00-11.fm
2.3.6 Accelerator pedal
Fig. 42:
36
37
N
A
1 2
B
C
Fig. 43:
45
Fig. 44:
46
Accelerator pedal for forwards and reverse
The accelerator pedals Fig. 42-36 for forwards Fig. 42-37 and for reverse
are used for continuously changing the road speed. Push the accelerator
pedal down to increase the driving speed. If you release the accelerator
pedal, it goes back automatically to zero position, the vehicle stops. The
warning symbol Fig. 42-A appears in the multifunctional display.
In forwards gear up to a speed of approx. 15 km/h the vehicle is in speed
level 1, The warning symbol Fig. 42-B appears in the multifunctional dis-
play.
If the temperature of the hydraulic oil is below 15 °C, the vehicle remains
in speed level 1 and the information symbol flashes.
Above a speed of approx. 20 km/h the vehicle is in speed level 2
Fig. 42-C.
This can be delayed depending on the acceleration and the load. In this
case the information symbol flashes.
2.3.7 Brake
When the accelerator pedal is released (forwards or reverse) the vehicle
comes to a stop because of the hydrostatic braking effect. If this braking
effect is not sufficient, the brake Fig. 43-45 must be applied in addition.
Operation
2.3.8 Coarse material flap
Operating the coarse material flap
If there are larger objects or coarse dirt (cans, bottles, leaves, etc.) in front
of the suction mouth, you can open the coarse material flap on the suction
mouth by pressing down on the pedal Fig. 44-46.
The pedal can be locked by shifting it to the right when it is operated.
Pushing and shifting the pedal to the left with your foot will unlock it.
Note
• The coarse material flap pedal Fig. 44-46 cannot be
operated with the suction mouth raised!
• The coarse material flap must be closed again after picking
up the coarse material. Fine sand is not taken up if the
coarse material flap is open.
02-1491-00-11.fm 55
Operation
Fig. 45:
A
D
E
B
C
G
H
44
2.3.9 Driver's seat
Danger
• Risk of accident! Adjust the driver's seat only when the vehicle is stationary. You will otherwise be
diverted from the traffic and could lose control over the vehicle by moving the seat. You could
cause an accident by this.
Warning
• For reasons of safety, the vehicle is equipped with a seat contact switch and the function of the
seat contact switch must not be bypassed.
The driver's seat Fig. 45-44 is air-cushioned. To reach the controls easily,
the right armrest, height and longitudinal setting can be adjusted.
If the driver leaves the driver's seat during operation, then the driver's seat
warning symbol Fig. 45-A in the multifunctional display flashes. The warn-
ing symbol goes out as soon as the driver is back on the driver's seat.
56 02-1491-00-11.fm
Adjusting the armrest
The armrest can be folded and its inclination can be adjusted. Turn the
wheel Fig. 45-B to adjust the inclination. The right armrest can be
unlocked with the lever Fig. 45-C.
Lever for longitudinal adjustment
Adjust the seat in the longitudinal direction with the lever Fig. 45-D.
• Pull lever up = seat unlocked. Set the seat forwards or backwards.
• Let the lever snap back after the adjustment.
Weight adjustment
For optimum suspension, the driver's seat must be adjusted to the weight
of the driver with the knob Fig. 45-E.
• Pull knob up = increase driver's weight
• Pull knob down = decrease driver's weight
The suspension is adjusted optimally if the indicator is in the middle.
Backrest adjustment
Adjust the backrest with the lever Fig. 45-G. You should be on the driver's
seat for the adjustment.
• Pull the lever up with your left hand.
• Move the backrest back (inclined position) by leaning your upper body
back.
• Move the backrest forwards (vertically) by leaning your upper body
forwards.
• Let the lever go when you have reached the optimum position of the
backrest, the lever then snaps back into the desired position.
Spine support adjustment
Turn the wheel Fig. 45-H of the backrest to adjust the spine support.
Operation
02-1491-00-11.fm 57
Operation
C
B
41
Fig. 46:
2.3.10 Seat belt
Danger
Risk of accident! A dirty, damaged seat belt or one stressed or changed in an accident may not offer
the intended protection. You could therefore suffer severe injuries or death in an accident. Please
check regularly that the seat belts are not damaged and not contaminated. Always have damaged
seat belts or those stressed in an accident renewed by an authorised workshop.
The seat belt Fig. 46-41 serves for the safety of the driver. The seat belt
assures complete freedom of movement when pulled slowly. However, it
is blocked in sudden braking. The seat belt can also be blocked when driving over potholes or other bumps in the road.
Putting seat belts on and off
Insert the buckle latch Fig. 46-B into the belt buckle Fig. 46-C until it
snaps in audibly (check by pulling). Tension the seat belt by pulling on the
end. The seat belt must always lie firmly against your pelvis.
Make sure you are sitting upright and the belt runs correctly!
To take off the seat belt hold it firmly and press the red button on the belt
buckle Fig. 46-C. Guide the seat belt slowly up to the reel.
58 02-1491-00-11.fm
2.3.11 Cab heating
Fig. 47:
A
51
52 53
Danger
Risk of accident! Good viewing conditions contributing to traffic safety are guaranteed only if all windows are free of ice, snow and condensation. Make yourself familiar with the correct operation of the
heating and ventilation system as well as de-moisturising/defrosting the windows. Maximum heating
power and fast thawing of the windows can be achieved only if the engine has reached its operating
temperature.
Operation
The vehicle is equipped with cab heating. Two operating conditions can
be selected with the cab heating:
• Ventilation
• Heating
The air flow is transported by a 3-stage suction fan to the air vents
Fig. 47-53 of the windscreen and through the air vents Fig. 6-47 of the
foot well into the driver's cab.
Adjusting the ventilation
The ventilation is set with the controller Fig. 47-51.
• Controller in position 0: Suction fan OFF
• Controller in position 1: Suction fan runs in stage 1
• Controller in position 2: Suction fan runs in stage 2
• Controller in position 3: Suction fan runs in stage 3
Setting the temperature
The temperature is set with the controller Fig. 47-52.
• Setting warmer: Turn the controller counter-clockwise
• Setting colder: Turn the controller clockwise
Cab air filter
The installed cab air filter Fig. 47-A, which is located beneath the number
plate holder Fig. 4-15, filters out largely dust and pollen. A clogged filter
reduces the air supply into the vehicle interior. Therefore please observe
the filter changing intervals, see page 90.
02-1491-00-11.fm 59
Operation
Fig. 48:
50
52
53
51
2.3.12 Air conditioning system
Danger
Risk of injury! The coolant in the air conditioning system is under high pressure. Do not open any
parts of the air conditioning system. Have maintenance work on the air conditioning system done
only by authorised workshops.
The air conditioning system regulates the temperature and humidity of the
vehicle interior and filters unwanted substances out from the air.
The air conditioning system is operational only when the engine is running. It functions optimally only if the side windows are closed.
The air flow is transported by a 3-stage suction fan to the air vents
Fig. 48-53 of the windscreen and through the air vents Fig. 6-47 of the
foot well into the driver's cab.
In warm weather ventilate the vehicle for a short time only. In this way you
accelerate the cooling process and the desired vehicle interior temperature is reached faster.
Observe the recommended setting, otherwise the windows can mist over.
Switch the air conditioning off only briefly and the circulating air on only
briefly.
Switching the air conditioning on
• Switch the air conditioning on with the switch Fig. 48-50. The control
light on the switch goes on.
• Set the air supply on the controller Fig. 48-51.
• Set the temperature with the controller Fig. 48-52 to 18 °C to 22 °C.
60 02-1491-00-11.fm
2.3.13 Doors
Fig. 49:
A
B
C
5
7
Danger
• There is a risk of accidents when driving with open doors Fig. 49-7! The doors must remain closed
when driving on public roads and when working.
• The outside mirrors Fig. 47-5 image reduced in size. The visible objects are closer than they
appear. Thus you can incorrectly estimate the distance from road users driving behind you, e.g.
when changing lanes. There is a risk of accidents! Therefore check the actual distance from road
users driving behind you by glancing over your shoulder.
Opening doors from the outside
To open the doors Fig. 49-7 insert the key in the door lock Fig. 49-A, turn
it counter-clockwise and push it.
Opening doors from the inside
To open the doors pull the lever Fig. 49-B upwards.
Adjusting the side windows
The left and right side windows are opened or closed with the catches
Fig. 49-C. Push the catch up and move the window correspondingly.
Outside mirrors
You have an extended field of view due to the convex outside mirrors
Fig. 49-5.
Adjusting the outside mirrors
Adjust the outside mirrors so that the roadway and the rear work area are
completely visible.
The outside mirrors can be folded down.
Operation
02-1491-00-11.fm 61
Operation
Fig. 50:
24
Fig. 51:
10
Fig. 52:
12
A
B
C
2.4 Operating equipment of the vehicle
2.4.1 Auxiliary tool
The auxiliary tool Fig. 50-24 is located on the driver's cab at the rear on
the right. This auxiliary tool has the following functions:
• For mounting the suction mouth, see page 120.
• For removing coarse dirt from the suction mouth and suction duct, see
page 144.
• For cleaning the dirt hopper, e.g. if leaves clog up the sieves, see page
145.
• As lever for the hand pump of the rear structure (optional). For raising
the dirt hopper/loading platform in the case of an engine failure.
• For releasing the parking brake on the rear axle.
2.4.2 Ball cock circulating water
The circulating water is closed off only with the ball cock Fig. 51-10 for
maintenance purposes. In normal operation the ball cock must be opened!
• Circulating water supply opened: Ball cock in flow direction
• Circulating water supply closed: Ball cock at right angles to the flow
direction
2.4.3 Front tool carrier
The front tool carrier Fig. 52-12 is used for holding an attachment.
Note
Close off the circulating water supply only if there is circulating
water in the dirt hopper and the suction mouth should be
mounted or dismounted, see page 120.
Danger
Risk of accident! Front attachments not correctly fastened to
the front tool carrier can drop down while driving. Always
secure the front attachment with the locking devices
Fig. 52-A and B.
Always secure non-Hako tools with the locking
device Fig. 52-C.
62 02-1491-00-11.fm
Taking up and securing the front tool
III
B
Fig. 53:
12
C
B
A
F
D
E
X1
G
X2 X3
70
1 Drive the vehicle up to the attachment and lower the front tool carrier
with the joystick Fig. 53-70.
2. Bring the locking hook Fig. 53-A into the rear position and the
lever Fig. 53-B into the upper position (II). Pick up the chain Fig. 53-C
and hook in onto the hook Fig. 53-E.
3. Drive under the take-up of the attachment and carefully raise the
attachment with the joystick Fig. 53-70. Raising the front tool carrier is
interrupted if the driver leaves the driver's seat.
4. Bring the locking hook into the front position and the lever into the lower
position (I).
5. Adjusting the movement limiter of the front tool carrier:
• For sweeping hook the chain Fig. 53-C onto the holder Fig. 53-D.
Observe the hooking point Fig. 53-G!
• For attachments with floating position the chain must be hooked onto
the hook Fig. 53-E! (parking position)
6. Check the locking plate Fig. 53-F on the attachment. If necessary,
loosen the screws and shift the locking plate.
The position of the front tool carrier is shown in the multifunctional display.
• Upper end position Fig. 53-X1
• Floating position Fig. 53-X2
• Lowered and fixed Fig. 53-X3
Operation
02-1491-00-11.fm 63
Operation
Fig. 54:
84
Fig. 55:
A
B
II
I
III
A
Fig. 56:
B
C
Adjusting the lowering valve
The lowering valve Fig. 55-84 is used to adjust the lowering speed of the
front tool carrier.
• Turn the lowering valve clockwise = lowering speed lower
• Turn the lowering valve counter-clockwise = lowering speed higher
Adjustable upper link (optional)
The adjustable upper link Fig. 55-A is provided for the fine adjustment of
attachments and for simplified take-up of attachments with conventional
A-frames type 0. Loosen the nut Fig. 55-B and adjust the middle section
with a suitable tool to the required length. Then secure with the nut
Fig. 55-B.
• Turn the middle section clockwise = the front tool carrier inclines to the
front
• Turn the middle section counter-clockwise = the front tool carrier
inclines to the back
Maximum (I): The spindle touches the edges of the long elongated hole.
Minimum (II): both spindles are flush
Standard length (III): The spindle touches the edges of the short elon-
gated hole.
Note
When the sweeping system is used, adjustment to position III
Fig. 55 is required for correct operation of the sweeping unit.
Lift system tipper body (optional)
With the optional lift system tipper body, additional controls for raising or
lowering the tipper body are located on the left side of the rear wagon.
Danger
Risk of crushing! When carrying out work on the tipper body,
always operate the controls in two-handed operation.
• Raise tipper body: Press the button Fig. 56-A and the button
Fig. 56-B simultaneously
• Lower tipper body: Press the button Fig. 56-A and the button
Fig. 56-C simultaneously
64 02-1491-00-11.fm
2.4.4 Connections for front attachments
Fig. 57:
E F
G
A B C
X63
D
12
X
X
The following devices can be operated with the connections for the front
attachments Fig. 57-12:
• X63 = 19-pin socket for front attachments
• A = supply/LS for optional 3-brush system
• B = water connection for sweeping unit spray nozzles
• C = supply/return right-hand actuator
• D = supply/return left-hand actuator
• E = return leakage oil pipe (e.g. for front mower)
• F = supply/return maximum 70 litres/min (hydraulic circuit I)
Setting the output, see page 66.
• G = ball cock for the suction mouth lift system:
• Vacuum sweeping system: Suction mouth lift system can be moved
freely, open the ball cock
• Mowing system: Bring the suction mouth lift system into the upper
position and close the ball cock
• Sweeping system: Bring the suction mouth lift system into the upper
position and close the ball cock
• Snow clearing system: Bring the suction mouth lift system into the
upper position and close the ball cock
• Transport system: Bring the suction mouth lift system into the upper
position and close the ball cock
• Wet cleaning system: Suction mouth lift system can be moved freely,
open the ball cock
Operation
02-1491-00-11.fm 65
Operation
63
Fig. 58:
B
A
69
C
Output setting for hydraulic circuit I
The maximum delivery of hydraulic circuit I is determined by the coding
plugs on the attachment. Two selectable oil flows with a maximum flow of
50 l/min (Fig. 58-A) or 70 l/min (Fig. 58-B) are available for attachments
without coding plugs. The adjustment is made on the configuration menu,
see page 41.
In the working menu, the hydraulic circuit I Fig. 58-A is activated and set
to the required value with the turn-push knob Fig. 58-69. Setting range:
OFF/ON or 0 to 100 % In the setting to 70 l/min the adjustment process
stops initially at 70 % (corresponds to 50 l/min setting), but can be contin-
ued by renewed turning of Fig. 58-69 up to 100 % (70 l/min).
Danger
Risk of injury! Make sure that the attachments are suitable for
the set oil volume. An oil volume set too high can lead to injuries due to a defect of the attachment! As a reminder, the setting process is interrupted briefly at 70 %.
Note
The hydraulic circuit I is switched off if the driver leaves the
driver's seat. The driver switches the hydraulic circuit I back
on with Fig. 58-69 after returning to the driver's seat. In con-
nection with the sweeping unit and the universal hopper, the
brush is restarted by pushing the left joystick to the front!
Note
The delivery of hydraulic circuit I depends to a large extent on
the engine speed set on the tip switch Fig. 58-63. Select the
ECO mode as often as possible in the sense of the most
energy-saving operation of the vehicle.
If the oil flow requested by Fig. 58-69 does not reach the set
value, then the warning Fig. 58-C appears in the multifunc-
tional display. Cancel the adjustment or increase the engine
speed until the warning symbol goes out. Also increase the
engine speed if you require additional power for driving (e.g.
driving uphill or propulsion work in winter service). If the additional power requirement is no longer required, reduce the
power step by step.
66 02-1491-00-11.fm
2.4.5 Connections for rear attachments
Fig. 59:
19
A
C
X65
B
X68
X67
X64
D
The following devices can be operated with the connections for the rear
attachments Fig. 59-19:
• X64 = 7-pin socket for rear attachments
• A = supply/return maximum 35 litres/min (hydraulic circuit II)
Setting the output, see page 68.
• B = supply/return for lift system hydraulic cylinder
• C = dirt hopper circulating water
• D = fresh water for high-pressure cleaner (optional)
• X65 = 7-pin socket for lights
• X68 = 7-pin socket for spreader control cable
• X67 = 7-pin socket for spreader control cable
Operation
02-1491-00-11.fm 67
Operation
Fig. 60:
A
69
Output setting for hydraulic circuit II
The delivery of hydraulic circuit II is in the range between 0 and 32 l/min.
In the working menu, the hydraulic circuit II Fig. 58-A is activated and set
to the required value with the turn-push knob Fig. 60-69. Setting range:
OFF/ON or 0 to 100 %
When the vehicle is used with the sweeping unit and the dirt hopper, the
power range is set automatically with the coding plugs. The maximum
suction power is reached only at standard speed. Operation in the ECO
mode ensures noise and consumption-optimised operation of the sweeping machine.
Danger
Risk of injury! Make sure that the attachments are suitable for
the set oil volume. An oil volume set too high can lead to injuries due to a defect of the attachment!
Note
The hydraulic circuit II is switched off if the driver leaves the
driver's seat. Restarting by Fig. 60-69 is also possible without
the operator on the driver's seat. The driver switches the
hydraulic circuit I back on with Fig. 60-69 after returning to the
driver's seat. In connection with the sweeping unit and the dirt
hopper, hydraulic circuit II remains in operation even when
the driver's seat is left (operation of hand suction hose and
high-pressure cleaner possible).
Note
Note that attachments driven on hydraulic circuit II without the
presence of the operator at the workplace (driver's seat) can
possibly lead to danger to the operator and third parties.
Observe the safety instructions and danger warnings for the
corresponding attachment. Secure the vehicle by operating
the parking brake.
68 02-1491-00-11.fm
3 Starting up
3.1 Instruction
Instruction is required before the first start-up.
The first-time instruction of the Citymaster 1600 may be provided only by
a specialist of your authorised Hako dealer.
This person will be notified immediately after delivery of the vehicle from
the factory and will contact you to make an instruction appointment.
3.2 Before start-up of the vehicle
Danger
• Risk of accident! If the steering column is unlocked while driving, it can come unexpectedly out of
adjustment. You can then lose control over the vehicle.
• Risk of accident! Adjust the driver's seat only when the vehicle is stationary. You will otherwise be
diverted from the traffic and could lose control over the vehicle by moving the seat. You could
cause an accident by this.
• Risk of accident! A dirty, damaged seat belt or one stressed or changed in an accident may not
offer the intended protection. You could therefore suffer severe injuries or death in an accident.
Please check regularly that the seat belts are not damaged and not contaminated. Always have
damaged seat belts or those stressed in an accident renewed by an authorised workshop.
• Risk of accident! Good viewing conditions contributing to traffic safety are guaranteed only if all
windows are free of ice, snow and condensation. Make yourself familiar with the correct operation
of the heating and ventilation system as well as de-moisturising/defrosting the windows. Maximum
heating power and fast thawing of the windows can be achieved only if the engine has reached its
operating temperature.
• There is a risk of accidents when driving with open doors! The doors must remain closed when
driving on public roads and when working.
Warning
• Check the vehicle for its correct condition and operating safety before using it. The vehicle must
not be used if it is not in order.
• Before starting work, the operator must familiarize himself with all equipment, operating and
actuating elements as well as with their function. It is too late to do this during operation!
• A warning triangle, a warning light, a warning vest and a first aid kit must be in the vehicle during
operation.
• Sturdy and slip-proof shoes must be worn when working with the vehicle.
• Carrying persons is not permitted!
• Only those surfaces approved by the contractor or its authorised representative for use of the
vehicle may be driven on.
• The vehicle is not suitable for removing dangerous, combustible or explosive liquids, dusts or
materials.
• Observe the maximum gradability of the vehicle, see Technical data.
Operation
03-1491-00-11.fm 69
Operation
Fig. 61:
A
C
B
Fig. 62:
C
B
A
3.2.1 Checklist – Before start-up of the vehicle
No. Description
1 Checking the engine oil level
2 Checking the coolant level
3 Checking the hydraulic oil level
4 Checking the fuel supply
5 Checking the lighting system
6 Checking the outside mirrors
7 Checking the windscreen washer system
8 Checking the tyre pressure
9 Checking the locking bolt
Note
Start-up of the vehicle also includes setting the operating
data.
Checking the engine oil level
Danger
Caution when handling hot operating and auxiliary materials.
There is a risk of burns and scalds!
Check the engine oil level with the dip stick Fig. 61-A. Refill engine oil if
required. To do this, open the cap Fig. 61-B. Filling volume, see Technical
data on page 87.
If the warning symbol Fig. 61-C appears, there is a risk of engine damage.
Immediately turn off the engine and check the engine oil level.
Checking the coolant level
Danger
Caution when handling hot operating and auxiliary materials.
There is a risk of burns and scalds!
Check the coolant level at the coolant tank Fig. 62-A, if necessary top up
with coolant. To do this, open the cap Fig. 62-B. Filling volume, see Tech-
nical data on page 87.
If the warning symbol Fig. 62-C appears, there is a risk of engine damage.
Immediately turn off the engine and check the coolant level.
70 03-1491-00-11.fm
Checking the hydraulic oil level
Fig. 63:
AB
MIN
MAX
C
Fig. 64:
A
B
Fig. 65:
A
Danger
There is a risk of burns and scalds! Caution when handling
hot operating and auxiliary materials.
Check the hydraulic oil level with the level indicator Fig. 63-A, if necessary
top up hydraulic oil. To do this, open the cap Fig. 63-B. Filling volume, see
Technical data on page 87.
If the warning symbol Fig. 63-C appears, there is a risk of operating failure
of the hydraulic system. Immediately switch the engine off and check the
hydraulic oil level.
Checking the fuel supply
Danger
Risk of fire! Diesel fuel is flammable! Take the utmost care
when handling fuel. Never refuel close to naked flames or
ignitable sparks. Do not smoke during fuelling. Switch off the
engine, pull out the ignition key and apply the parking brake
before fuelling.
The current fuel supply is shown in the multifunctional display. Refuel as
required.
To do this, open the cap Fig. 64-A. Filling volume, see Technical data on
page 87.
If the warning symbol Fig. 64-B appears, then refuel without delay. There
is a risk of engine damage if the fuel system is run completely empty!
Inform an authorised workshop!
Operation
Checking the lighting system
Check all lighting equipment on the vehicle with the switches Fig. 65-A on
the control panel in the roof and the direction indicator in the steering col-
umn.
03-1491-00-11.fm 71
Operation
Fig. 66:
5
Fig. 67:
34
Fig. 68:
A
Fig. 69:
A
Checking the outside mirrors
Adjust the outside mirrors Fig. 66-5. Adjust the outside mirrors so that the
roadway and the rear work area are completely visible.
Checking the windscreen washer system
Fill the windscreen washer system tank Fig. 67-34.
Filling volume: 2.0 litres.
Checking the tyre pressure
Remove the valve cap Fig. 68-A and adjust the tyre pressure with a com-
pressed air unit, see Technical data on page 87.
Checking the locking bolt
Danger
Danger to life in the danger area of the vehicle! Special caution is required in the area of the articulated steering.
Before start-up, loosen the locking bolt Fig. 69-A on the articulated joint
and bring it into the working position. The vehicle cannot be steered with
the locking bolt engaged!
72 03-1491-00-11.fm
3.3 Starting and driving the vehicle
Danger
• Toxic engine exhaust gases! Inhaling exhaust gases is injurious to health and can lead to uncon-
sciousness and to death! Never let the engine run in enclosed spaces.
• Danger to life in the danger area of the vehicle! Special caution is required under the raised tipper,
in the area of the front and rear attachment and in the area of the trailer.
• Danger of tilting over when driving uphill or downhill and transversely to a slope. Avoid sudden
turns when driving uphill or downhill or across slopes. There is a risk of tilting over in an inclined
position! The vehicle speed must always be adapted to the surrounding conditions and the load
condition.
• Danger of tilting due to wrong steering! Note that the steering behaviour of an articulated steered
vehicle differs essentially from that of a car. Sudden steering movements at high speed or too high
speeds when turning can cause the vehicle to tilt over.
• Risk of accident! Note that there is a risk of skidding on unpaved ground or snow and ice. This can
lead to uncontrolled behaviour of the vehicle. Drive correspondingly carefully!
• Risk of accident! Use the cruise control and the speed limiter only when the traffic situation allows!
Warning
• For reasons of safety, the vehicle is equipped with a seat contact switch and the function of the
seat contact switch must not be bypassed. The vehicle may be started, put into motion and
stopped only from the driver's seat. Do not press on the accelerator pedal when starting!
• In the case of restricted vision, especially when reversing the vehicle, it is necessary to have a
second person who gives the driver appropriate signals. The second person must always be in the
field of view of the driver.
• When working with the vehicle, pay special attention to third persons, especially children.
• In transport journeys on public roads the working spotlights must be switched off.
Attention
• If the engine oil pressure warning symbol Fig. 72-A in the multifunctional display lights up with the
engine running, there is a risk of engine damage! Stop the vehicle in the safe area. Turn the
engine off immediately and check the oil level. Have the cause of the inadequate engine oil
pressure removed.
Operation
03-1491-00-11.fm 73
Operation
Fig. 70:
37
36
45
Fig. 71:
A
77
3.3.1 Starting and driving the vehicle
No. Description Reference
1 Accelerator pedal in zero position Page 74
2 Engaging parking brake Page 74
3 Starting engine and releasing parking brake Page 75
4 Starting transport mode Page 75
5 Activating work mode Page 76
6 Setting engine fixed speed for attachments/options Page 76
7 Activating front tool carrier Page 76
Accelerator pedal in zero position
The accelerator pedals Fig. 70-36 and Fig. 70-37 must be in the zero
position to start the engine.
Engaging parking brake
The electrical parking brake Fig. 71-77 stops the vehicle from rolling
away.
• Press the brake pedal Fig. 70-45 until the vehicle stops.
• Unlock the parking brake and press the switch Fig. 71-77.
• The warning symbol Fig. 71-A appears in the multifunctional display.
74 03-1491-00-11.fm
Starting the engine
Fig. 72:
78
A
77
Fig. 73:
A
37
36
1 2
B
C
Start the engine with the ignition switch Fig. 72-78.
• Position 1: Preheat the engine until the control light Fig. 72-A goes out.
• Position 2: Start the engine.
• The ignition switch goes back into position 1.
Note the information on the ignition switch on page 55.
Releasing the parking brake
Press the switch Fig. 72-77. The parking brake is released again. With the
parking brake released the warning light Fig. 71-A goes out.
Starting transport mode
Slowly press down the accelerator pedal Fig. 73-36 or Fig. 73-37 for the
required direction and speed. The vehicle moves away. The correspond-
ing engine speed and the transport mode information symbol Fig. 73-A
appear in the multifunctional display.
The speed in the transport mode is 0 to 40 km/h.
When the accelerator pedal is released (forwards or reverse) the vehicle
comes to a stop quickly because of the hydrostatic braking effect.
Operation
In forwards gear up to a speed of approx. 15 km/h the vehicle is in speed
level 1. The warning symbol Fig. 73-B appears in the multifunctional dis-
play.
If the temperature of the hydraulic oil is below 15 °C, the vehicle remains
in speed level 1 and the information symbol flashes.
Above a speed of approx. 20 km/h the vehicle is in speed level 2
Fig. 73-C.
This can be delayed depending on the acceleration and the load. In this
case the information symbol flashes.
03-1491-00-11.fm 75
Operation
Fig. 74:
72
A
Fig. 75:
63
Fig. 76:
70
X1
X2
X3
Activating work mode
Use the Hako button Fig. 74-72 to change over from the transport mode
to the work mode.
The accelerator pedals must be in the neutral position.
The work mode with front tool carrier information symbol Fig. 74-A
appears in the multifunctional display.
The road speed in the work mode is maximum 16/20/24 km/h according to
the selected engine speed.
Setting the fixed engine speed
The fixed engine speed and thus the system output of the vehicle in the
work mode is set with the button Fig. 75-63.
Stage Rpm Hydraulic circuit I
Litres/minute
1-ECO 1600 50 20
2-Standard 2000 50/70 27
3-Maximum 2400 50/70 32
The overview illustrates that sufficient power is available already in the
ECO mode for many applications.
The full hydraulic output is reached as from the Standard speed.
Additional energy is available in the driving mode as well as in hydraulic
circuit II at Maximum. Set the speed corresponding to the requirements.
Operation primarily in the ECO mode lowers consumption and noise. See
pages 66 and 68 for information about setting the hydraulic circuits.
Activating the front tool carrier
The front tool carrier is activated with the joystick Fig. 76-70. The following
functions are possible for a vehicle without attachment:
Hydraulic circuit II
Litres/minute
• Raising front tool carrier
• Front tool carrier in floating position
• Lower the front tool carrier.
The position of the front tool carrier is shown in the multifunctional display.
Upper end position Fig. 76-X1 / floating position Fig. 76-X2 / lowered and
fixed Fig. 76-X3
Further settings of the joystick, see page 53.
Raising the front tool carrier is interrupted if the driver leaves the driver's
seat.
76 03-1491-00-11.fm
Operation
3.3.2 Troubleshooting
The engine does not start, the starter works audibly. Remedy
The fuel tank was run completely empty. There is a risk of engine damage if the fuel system
is run completely empty! Inform an authorised workshop!
The engine electronics are faulty. The fuel supply is faulty. Do not repeat the starting procedure more than 3
times, then let the starter cool down. If the engine
does not start even after several starting attempts:
inform an authorised workshop!
The engine does not start, the starter is not audible. Remedy
The electrical system voltage is too low because the battery is too weak or empty.
The starter was exposed to too high thermal loading. Let the starter cool down for around 2 minutes. Start
Have starting help applied. If the engine does not
start despite starting help: inform an authorised
workshop!
the engine again. If the engine still does not start:
inform an authorised workshop!
03-1491-00-11.fm 77
Operation
3.4 Shutting down the vehicle
Danger
• Risk of accident! Adopt measures against erroneous starting and unwanted movement. Engage
the parking brake. Switch the engine off and pull out the ignition key.
• Risk of accident! The vehicle must be parked on firm ground. On inclinations secure the vehicle
additionally against rolling away with a wheel chock.
Attention
• Do not switch the engine off in normal operating condition from the high speed range, only in the
case of faults.
• After full load operation, let the engine idle on for 1 to 2 minutes.
• Do not switch the engine off when an attachment is switched on.
3.4.1 Shutting down after the end of work
1. Bring the accelerator pedal back into the neutral position or take your
foot off from the accelerator pedal. The hydrostatic drive brakes to
standstill.
2. Engage the parking brake.
3. Switch the engine off and pull out the ignition key.
4. Close the driver's cab if necessary.
3.4.2 Shutting down in work breaks
The driver must also bring all operating devices into zero position even in
short work breaks before leaving the vehicle. Engage the parking brake
and secure it against unauthorised use.
3.4.3 Shutting down on occurrence of faults
The engine of the Citymaster 1600 must be switched off immediately on
the occurrence of faults. A vehicle left lying on public roads must be
secured with the emergency signal system and warning triangle. If the
electrical system has failed, the vehicle must be secured with the warning
light.
78 03-1491-00-11.fm
3.5 Transporting and towing the vehicle
Fig. 77:
Danger
• Danger to life! Start driving slowly! Make sure that there are no persons in the towing area.
• Risk of injury! The vehicle may be loaded only using suitable loading aids, such as a loading ramp
or drive-up planks.
• Risk of injury! After loading, make sure that the vehicle is secured according to regulations against
rolling off and tilting. Use the wheels for securing the vehicle.
Warning
• Tow the vehicle using only suitable towing gear!
• The vehicle may be towed with a towing rope only if the brakes and steering are functioning!
• When the engine is still the steering has only emergency steering properties!
• Secure the vehicle against unintended movement! Engage the parking brake and insert the
locking bolt on the articulated joint. Note that the steering is then blocked!
Attention
• The towing speed may be at most 2 km/h, the towing time at most 3 minutes and the towing
distance at most 100 m!
3.5.1 Transporting the vehicle
Operation
Securing the vehicle:
• Place a wheel chock diagonally before and behind any front or rear
wheel.
• Additional security by one three-point belt each.
03-1491-00-11.fm 79
Operation
Fig. 78:
C
12
D
A
F
F
C
B
A
B
D
E
G
E
3.5.2 Towing the vehicle
Caution
After completing the towing process, open the ball cock Fig. 78-E again and close the ball
cock Fig. 78-F of the bypass valve again. Set the lever of the hand pump Fig. 78-C to the lower
position again!
The wheels are blocked when the vehicle is at a standstill. Proceed as follows for towing or displacing.
1. The towing eye Fig. 78-A is located in the rear wagon on the right and
must be mounted on the holder Fig. 78-B of the front tool
carrier Fig. 78-12.
2. Turn the lever of the hand pump Fig. 78-D into the upper position.
• upper position = unlock the parking brake
• lower position = raise/lower the dirt hopper
3. Close the ball cock Fig. 78-E to the right of the hand pump (see
symbol).
4. Open the ball cock Fig. 78-F of the bypass valve (see symbol).
5. Insert the auxiliary tool Fig. 78-G in the hand pump Fig. 78-C and
pump so long (approx. 25 times) until the parking brake is unlocked.
80 03-1491-00-11.fm
3.6 Working with attachments
Danger
• Danger to life in the danger area of the vehicle! Special caution is required under the raised tipper,
in the area of the front and rear attachment and in the area of the trailer.
• Risk of injury! Put the attachment into service only if all protective devices are attached and in
protection position.
• Risk of injury! Make sure that the attachments are suitable for the set oil volume. An oil volume set
too high can lead to injuries due to a defect of the attachment!
• Risk of injury! High-pressure hoses, fittings and couplings are important for equipment safety. Use
only high-pressure hoses, fittings and couplings recommended by the manufacturer.
• Risk of accident! When connecting attachments to the hydraulic system, ensure that the hydraulic
hoses are connected correctly. Swapping the connection can lead to reverse functioning of the
attachment, e.g. movement to the right rather than the left.
• Risk of accident! Front attachments not correctly fastened to the front tool carrier can drop down
while driving. Always secure the front attachment with the locking devices.
• Risk of accident! You must consult Hako before attaching other attachments not approved by
Hako! Check in the individual case that the relevant axial loads and total weights are complied
with.
• Risk of accident! Handling, steering and braking as well as stability are influenced by attachments,
trailers and the vehicle payload (e.g. full dirt hopper). For this reason, pay attention to adequate
steering and braking capability as well as stability.
• Risk of accident! In Germany, if attachments extend beyond the outer lighting equipment of the
vehicle or if the maximum distances of the outer lighting equipment specified according to StVZO
are exceeded, the lighting equipment of the vehicle must be repeated (see Merkblatt StVZO § 30,
explanations 11 and 12).
Operation
3.6.1 Hako attachments
You will find the descriptions for the attachment of the vacuum sweeping
system, lawn mowing system, sweeping system, snow clearing system
and transport system as from page 117.
3.6.2 Non-Hako attachments
You will find the description for the attachment of non-Hako attachments
as from page 62.
03-1491-00-11.fm 81
Operation
Fig. 79:
3.6.3 Ballast
Danger
• Risk of accident! When attaching other attachments not approved by Hako, check in the individual
case whether the relevant axle loads and total weights are complied with!
• Risk of accident! The front axle of the working machine must always be loaded with at least 25 %
of the empty weight and the rear axle with at least 37 % of the empty weight of the working
machine.
• Risk of accident! The attachment of front and rear attachments must not lead to exceeding the
permissible total weight, the permissible axle load and the tyre load capacity of the working
machine!
Warning
• Make sure before purchasing the attachment that these requirements are fulfilled by weighing the
working machine attachment combination!
Calculating ballast
You require the following data to calculate the total weight, the axle loads
and the tyre load capacity as well as the required minimum ballast:
Note
All weight data in (kg)
All dimensions in (m)
1) See Citymaster 1600 technical
data.
2) See price list and/or operating
manual of the attachment
3) Dimensioning
• T
(kg) = empty weight of the vehicle (1)
L
• T
(kg) = front axle load of the empty vehicle (1)
V
• T
(kg) = rear axle load of the empty vehicle (1)
H
• G
(kg) = total weight of rear attachment/rear ballast (2)
H
• G
(kg) = total weight of front attachment/front ballast (2)
V
• a (m) = distance between centre of gravity of front attachment (front
ballast) and middle of front axle max. = 1.75 m (2 and 3)
At maximum front ballast 280 kg.
• b (m) = vehicle wheelbase (1 and 3)
• c (m) = 0.941 m
• d (m) = distance between middle of attachment-side fixing point and
centre of gravity of rear attachment/rear ballast max. 0.185 m (2 and 3)
At maximum rear ballast 450 kg.
82 03-1491-00-11.fm
1 Calculation of the minimum front ballast for rear attachments
Enter the value in the table.
2 Calculation of the minimum rear ballast for front attachments
(Value "x" see manufacturer's data, if no information x = 0.45)
Enter the value in the table.
Operation
3 Calculation of the actual front axle load T
If the required minimum front ballast (G
attachment (G
the weight of the minimum front ballast!
), the weight of the front attachment must be increased to
V
V min
V tat
) is not reached with the front
Enter the calculated actual front axle load and the permissible front axle
load stated in the operating manual of the work machine in the table.
4 Calculation of the actual total weight
(If the required minimum rear ballast (G
attachment (G
increased to the weight of the minimum rear ballast!)
), then the weight of the rear attachment must be
H
) is not reached with the rear
H min
Enter the calculated actual total weight and the permissible total weight
stated in the operating manual in the table.
5 Calculation of the actual rear axle load
Enter the calculated actual rear axle load and the permissible rear axle
load stated in the operating manual of the work machine in the table
6 Tyre load capacity
Enter double the value (two tyres) of the permissible tyre load capacity
(see for example documents of the tyre manufacturer) in the table.
03-1491-00-11.fm 83
Operation
Ballast table
The calculated values must be less than or equal to the permissible values!
Actual value according to
calculation
Front/rear minimum ballast
Total weight kg kg
Front axle load kg kg kg
Rear axle load kg kg kg
kg
Permissible value
according to operating
manual
The minimum ballast must be attached to the vehicle as attachment or
ballast weight!
The following accessories are available for ballast:
Accessories Type
Front weight holder for max. 9 ballast weights 344000
Rear weight holder for max. 10 ballast weights 344120
Ballast weight 17 kg 344130
84 03-1491-00-11.fm
4 Technical Data
Fig. 80:
3830
1600
941
1210
975
1964
Technical Data
04-1491-00-11.fm 85
Technical Data
Dimensions
Name Unit
Length mm 3830
Width (with standard tyres) mm 1210
Height (with standard tyres) mm 1970
Wheelbase mm 1600
Tread width (with standard tyres) mm 975
Turning circle inside/outside (DIN EN 15429-1) mm 1290/2760
Weights and loads
Name Unit
Empty weight (deviations according to equipment) kg 1975
Permissible total weight kg 3500
Permissible total combination weight unbraked kg 4250
Permissible total combination weight braked kg 5250
Permissible front axle load kg 1700
Permissible rear axle load kg 2400
Driving speeds and inclination values
Name Unit
Transport mode/work mode forwards km/h 40
Transport mode/work mode reverse km/h 12
Gradability basic vehicle in work mode (forwards/reverse) % 24
Gradability basic vehicle in transport mode (forwards/reverse) % 24
Noise emission values – basic vehicle
The driving noise according to 2009/63/EC Annex VI at 1830 rpm is: 82 dB(A)
Standing noise according to 2009/63/EC Annex VI at 2400 rpm is: 73 dB(A)
Noise at driver's ear according to 2009/76/EC Annex VI is: 79 dB(A)
Vibration values – basic vehicle
The weighted effective value of the acceleration to which the body (feet or seat surface)
is subjected to according to EN 1032 is under the customary conditions of use no more
than: 0.5 m/s2
86 04-1491-00-11.fm
Technical Data
Engine
Manufacturer VW
Type
Number of cylinders 4
Displacement cm3 1968
Power kW 55/2700
Speed rpm 3100
Torque Nm 240/1750
Engine oil filling volume with oil filter litre 4.3
Cooling water volume litre 12
Fuel system
Fuel Diesel
Tank volume litre 52
Hydraulic system
Hydraulic oil HVLP 46
Tank volume litre 45
Tyre pressure
Standard tyres: 225/70 R15C 112R bar 5.0
TDI 2.0l CR CPYA
Wide tyres (optional)
255/65 R16C 109H
320/55-15 123 A8
LT325/60R15
Electrical system
Starter kW 2.0
Nominal voltage Volt 12
Generator Ampere 140
Windscreen washer system
Tank volume litre 2.0
bar
bar
bar
3.0
2.8
2.5
04-1491-00-11.fm 87
Maintenance and Servicing
5 Maintenance and Servicing
General
Before undertaking servicing and maintenance work observe without fail
chapter 1 Safety Instructions in this operating manual.
Compliance with the maintenance work recommended by us gives you
the certainty of always having an operational vehicle available.
Daily and weekly maintenance and repair work can be undertaken by a
driver trained for this, all further Hako system maintenance work may be
undertaken only by trained and qualified personnel.
Please contact your nearest authorised Hako dealer. Any warranty claim
is null and void if this is not complied with and damage results.
Please always state the serial number in all enquiries and spare parts
orders, see the Labels on the vehicle section.
Always have the following work on the vehicle done in an authorised workshop.
• Safety-relevant work
• Maintenance work
• Changes as well as installations and conversions
• Work on electronic components
Hako system maintenance
The Hako system maintenance specifies in single modules the special
technical work to be done and the periods of time for the maintenance
activities. Parts to be replaced for the individual maintenance tasks are
determined and specified in spare parts kits. Hako system maintenance:
• assures the reliable readiness for use of the vehicle (preventive mainte-
nance)
• minimises operating costs, repair costs, costs for maintenance
• assures long life and readiness for use of the vehicle.
Note
Compile the maintenance work by reference to the maintenance plans.
Example: After 2000 operating hours the maintenance work
from the 500, 1000 and 2000 hours maintenance plan must
be performed.
88 05-1491-00-11.fm
5.1 Maintenance certificate
Maintenance and Servicing
Handover
Equipment
Trial run
Handover to customer
Instruction
performed on:
at _________________ operating hours
Hako system maintenance II/S
1000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
3000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
5000 operating hours
Workshop stamp
Hako system maintenance
50 operating hours once
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
1500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
3500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
5500 operating hours
Workshop stamp
Hako system maintenance
250 operating hours once
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
2000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
4000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
6000 operating hours
Workshop stamp
Hako system maintenance I
500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
2500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
4500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
6500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
7000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
9000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
11000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
performed on:
at _________________ operating hours
Hako system maintenance I
7500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
9500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
11500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
performed on:
at _________________ operating hours
Hako system maintenance II/S
8000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
10000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance II/S
12000 operating hours
Workshop stamp
performed on:
at _________________ operating hours
performed on:
at _________________ operating hours
Hako system maintenance I
8500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
10500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
Hako system maintenance I
12500 operating hours
Workshop stamp
performed on:
at _________________ operating hours
05-1491-00-11.fm 89
Maintenance and Servicing
5.2 Maintenance plan
Maintenance plan – daily
Vehicle cleaning
• Vehicle cleaning as required
Engine
• Checking engine oil level, replenishing if necessary
• Checking and if necessary refilling coolant level in coolant tank
• Checking combination radiator and radiator grille for dirt, cleaning with compressed air if necessary
• Checking fuel supply, refuelling if required
• Checking maintenance indicator of the air filter, cleaning filter elements if necessary
Steering
• Checking the emergency steering function
Brake
• Checking the operating and parking brakes for function
Electrical system
• Checking lighting, work functions, horn, etc.
Maintenance plan – weekly
Vehicle cleaning
• Vehicle cleaning as required
Engine
• Checking engine oil level, replenishing if necessary
• Checking and level in coolant tank, refilling if necessary
• Checking combination radiator and radiator grille for dirt, cleaning with compressed air if necessary
• Checking fuel supply, refuelling if required
• Checking maintenance indicator of the air filter, cleaning filter elements if necessary
• Emptying the water trap of the fuel system
Cab
• Checking and the windscreen washing agent level, refilling if necessary
• Checking air conditioning system (optional) for function
• Checking heating for function
Steering
• Checking the emergency steering function
• Checking steering cylinder for play
Brake
• Checking the operating and parking brakes for function
• Braking test
Hydraulics
• Checking and if necessary refilling the hydraulic oil level
Lubrication service (see section 5.13)
• Door hinges (4x)
• Front lifting cylinder (4x), front lift (2x) and upper link (2x)
• Steering cylinder (4x)
Tyres
• Checking the air pressure of the tyres
90 05-1491-00-11.fm
Maintenance and Servicing
Maintenance plan – once after 50 operating hours
Engine
• Changing engine oil
• Changing engine oil filter
• Replacing the fuel filter
• Emptying the water trap of the fuel system
• Checking coolant hoses and radiator
• Checking and coolant level in coolant tank, refilling if necessary
• Checking combination radiator and radiator grille for dirt, cleaning with compressed air if necessary
• Checking engine bearings for damage and cracks
• Checking ribbed V-belt for condition and function
• Checking generator for soiling and cleaning if required
• Checking ECO, standard and maximum speed
• Checking the exhaust system for function and tightness
• Checking the fuel pipes for function and tightness
• Checking air suction pipe for function and tightness
Vehicle control
• Reading and evaluating the service information of the vehicle control system and removing faults if necessary
• Checking the software status, updating if necessary
Electrical system
• Checking horn, lighting and working functions
• Checking cabling for abrasion points and damage
• Checking battery charge condition, cleaning and greasing battery poles
Hydraulics
• Changing the return filter
• Checking the hydraulic oil level, refilling if necessary
• Checking the lifting cylinder of the front power lift for function and tightness
• Checking hydraulic pipes for function and tightness
• Checking the hand pump for function
Chassis and axles
• Checking chassis springs for damage and ease of movement
• Checking shock absorbers for function and tightness
• Checking bearing bushes of the axle suspension for cracks and damage
• Checking buffers for cracks and damage
Steering
• Checking function and ease of movement
• Checking steering cylinder for play
Brake
• Checking the operating brake for function
• Checking the brake fluid
• Checking the brake hoses for damage
• Checking the parking brake for function
Cab
• Checking air conditioning system (optional) for function
• Checking heating for function
• Checking window washing agent
05-1491-00-11.fm 91
Maintenance and Servicing
Maintenance plan continued – once after 50 operating hours
Wheels and tyres
• Tightening the wheel nuts
• Checking tyres for damage and air pressure
Lubrication service (see section 5.13)
• Door hinges (4x)
• Front lifting cylinder (4x), front lift (2x) and upper link (2x)
• Steering cylinder (4x)
Maintenance plan – once after 250 operating hours
Engine
• Changing engine oil
• Changing engine oil filter
• Replacing the fuel filter
• Emptying the water trap of the fuel system
• Checking coolant hoses and radiator
• Checking coolant level in coolant tank, refilling if necessary
• Checking combination radiator and radiator grille for dirt, cleaning with compressed air if necessary
• Checking engine bearings for damage and cracks
• Checking ribbed V-belt and tensioning roller for condition and function, replacing if necessary
• Checking ribbed V-belt and belt tensioner of the generator
• Checking generator for soiling and cleaning if required
• Checking ECO, standard and maximum speed
• Checking the exhaust system for function and tightness
• Checking the fuel pipes for function and tightness
• Checking air suction pipe for function and tightness
Vehicle control
• Reading and evaluating the service information of the vehicle control system and removing faults if necessary
• Checking the software status, updating if necessary
Electrical system
• Checking horn, lighting and working functions
• Checking cabling for abrasion points and damage
• Checking battery charge condition, cleaning and greasing battery poles
Hydraulics
• Checking the hydraulic oil level, refilling if necessary
• Checking the lifting cylinder of the front power lift for function and tightness
• Checking hydraulic pipes for function and tightness
• Checking the hand pump for function
Chassis and axles
• Checking chassis springs for damage and ease of movement
• Checking shock absorbers for function and tightness
• Checking bearing bushes of the axle suspension for cracks and damage
• Checking buffers for cracks and damage
92 05-1491-00-11.fm
Maintenance plan continued – once after 250 operating hours
Steering
• Checking function and ease of movement
• Checking steering cylinder for play
Brake
• Checking the operating brake for function
• Checking the brake fluid
• Checking the brake hoses for damage
• Checking the parking brake for function
Cab
• Checking air conditioning system (optional) for function
• Cleaning the cab air filter
• Checking heating for function
• Checking window washing agent
Wheels and tyres
• Tightening the wheel nuts
• Checking tyres for damage and air pressure
Lubrication service (see section 5.13)
• Door hinges (4x)
• Front lifting cylinder (4x), front lift (2x) and upper link (2x)
• Steering cylinder (4x)
Maintenance and Servicing
Maintenance plan – every 500 operating hours
Engine
• Changing engine oil
• Changing engine oil filter
• Replacing the fuel filter
• Emptying the water trap of the fuel system
• Changing filter insert of the air filter
• Checking coolant hoses and radiator
• Checking coolant level in coolant tank, refilling if necessary
• Checking combination radiator and radiator grille for dirt, cleaning with compressed air if necessary
• Checking engine bearings for damage and cracks
• Checking ribbed V-belt and tensioning roller for condition and function, replacing if necessary
• Checking ribbed V-belt and belt tensioner of the generator
• Checking V-belt for tension and condition
• Checking generator for soiling and cleaning if required
• Checking ECO, standard and maximum speed
• Checking the exhaust system for function and tightness
• Checking the fuel pipes for function and tightness
• Checking air suction pipe for function and tightness
• Performing service regeneration of the diesel particulate filter. Only vehicles with diesel particulate filters!
Vehicle control
• Reading and evaluating the service information of the vehicle control system and removing faults if necessary
• Checking the software status, updating if necessary
05-1491-00-11.fm 93
Maintenance and Servicing
Maintenance plan continued – every 500 operating hours
Electrical system
• Checking horn, lighting and working functions
• Checking cabling for abrasion points and damage
• Checking battery charge condition, cleaning and greasing battery poles
Hydraulics
• Checking the hydraulic oil level, refilling if necessary
• Checking the lifting cylinder of the front power lift for function and tightness
• Checking hydraulic pipes for function and tightness
• Checking the hand pump for function
Chassis and axles
• Checking chassis springs for damage and ease of movement
• Checking shock absorbers for function and tightness
• Checking bearing bushes of the axle suspension for cracks and damage
• Checking buffers for cracks and damage
Steering
• Checking function and ease of movement
• Checking steering cylinder for play
Brake
• Checking the operating brake for function
• Checking the brake fluid
• Checking the brake hoses for damage
• Checking the parking brake for function
Cab
• Checking air conditioning system (optional) for soiling
• Cleaning the cab air filter
• Cleaning the condenser on the cab rear wall with compressed air
• Checking heating for function
• Checking and if necessary refilling the windscreen washing agent level
Wheels and tyres
• Tightening the wheel nuts
• Checking tyres for damage and air pressure
Lubrication service (see section 5.13)
• Door hinges (4x)
• Front lifting cylinder (4x), front lift (2x) and upper link (2x)
• Steering cylinder (4x)
94 05-1491-00-11.fm
Maintenance and Servicing
Maintenance plan – every 1000 operating hours
Engine
• Changing the safety cartridge
Hydraulics
• Checking the hydraulic oil. Taking and sending in a sample
• Changing the hydraulic oil filter
• Changing the venting filter of the hydraulic oil tank
• Checking the hydraulic oil level, refilling if necessary
Cab
• Changing the cab air filter
Maintenance plan – every 2000 operating hours
Bowden cable
• Checking the coarse material flap and suction mouth lift for function, ease of movement and zero point
Maintenance plan – every 2500 operating hours
Engine
• Changing the coolant VW G13
Note:
Even in warm countries, never drive without coolant additive, since the coolant additive protects the engine
against corrosion and increases the boiling point of the cooling water! The coolant additive must be at least
40 % and may be a maximum of 60 %. Use only distilled water for mixing!
• Changing V-belt and V-belt pulleys
• Changing the water pump
• Changing the ribbed V-belt and belt tensioner of the generator
Maintenance plan – every 3000 operating hours
Hydraulics
• Changing hydraulic oil
05-1491-00-11.fm 95
Maintenance and Servicing
Fig. 81:
A DE B
A E
C
DB C
5.3 Panelling and covers
Danger
• Risk of injury! Put the vehicle into service only if all protective devices are attached and in
protection position.
• Danger of burning! Do not touch any parts such as engine block, cooling system and exhaust
system during operation and for some time after.
5.3.1 Opening the engine cover, engine flap and side door
The engine cover Fig. 81-A, the engine flap Fig. 81-B and the side
doors Fig. 81-C are opened with a square key.
5.3.2 Removing side cover
Loosen the mounting screws of the side cover Fig. 81-C and pull the side
cover out to the side.
5.3.3 Opening the radiator cover
Open the lock Fig. 81-E and swing down the radiator cover.
96 05-1491-00-11.fm
5.4 Engine
Fig. 82:
A
MIN
MAX
B
Danger
• Toxic engine exhaust gases! Inhaling exhaust gases is injurious to health and can lead to uncon-
sciousness and to death! Never let the engine run in enclosed spaces.
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and
exhaust system during operation and for some time after. Let the engine cool down.
• Risk of injury due to rotating parts of the cooling system. Injury of limbs or hair or clothing getting
caught up. Switch the engine off and pull out the ignition key.
Attention
• If the engine oil pressure warning symbol Fig. 82-A in the multifunctional display lights up with the
engine running, there is a risk of engine damage! Stop the vehicle in the safe area. Turn the
engine off immediately and check the oil level. Have the cause of the inadequate engine oil
pressure removed.
Environmental danger
• Ensure safe and environment-conserving disposal of operating and auxiliary materials.
Take up escaping or spilled operating materials in suitable containers and dispose of them in an
environmentally friendly manner.
5.4.1 Checking the engine oil level
Check the engine oil level daily and refill as required.
Maintenance and Servicing
1. Place the vehicle on a level surface and hold it with the parking brake.
Switch the engine off and pull out the ignition key. Let the engine cool
down.
Note
The circulating engine oil requires a few minutes to flow back
to the oil sump.
2. Check the engine oil level with the dip stick Fig. 82-B.
3. The engine oil level should lie between the MAX and MIN mark of the
dip stick and may never drop below the MIN mark.
4. Refill engine oil as required and check the engine oil level once again.
Only use branded oils 5W-30 to oil specification VW507.00.
Note
The engine oil level must not be above the MAX mark. There
5. Reinsert the dip stick.
is a risk of damage to the catalytic converter.
05-1491-00-11.fm 97
Maintenance and Servicing
A
B
C
Fig. 83:
5.5 Fuel system
Danger
• Risk of fire! Diesel fuel is flammable! Take the utmost care when handling fuel. Never refuel close
to naked flames or ignitable sparks. Do not smoke during fuelling. Switch off the engine, pull out
the ignition key and engage the parking brake before fuelling.
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and
exhaust system during operation and for some time after. Let the engine cool down.
Attention
• If the fuel system has been run empty, the vehicle must be stopped immediately. Serious engine
damage can be caused if this is not complied with. The fuel system must be vented. Have this
done by an authorised workshop!
Environmental danger
• Ensure safe and environment-conserving disposal of operating and auxiliary materials.
Take up escaping or spilled operating materials in suitable containers and dispose of them in an
environmentally friendly manner.
5.5.1 Emptying the water trap
Check the water trap weekly and drain the condensed water out from the
water trap if required.
1. Place the vehicle on a level surface and hold it with the parking brake.
2. Loosen the clips Fig. 83-A and remove the fuel filter Fig. 83-B from the
3. Place a suitable vessel under the water trap.
4. Open the drain screw Fig. 83-C and collect the condensed water.
5. Close the drain screw again.
Switch the engine off and pull out the ignition key. Let the engine cool
down.
holder.
98 05-1491-00-11.fm
Maintenance and Servicing
Fig. 84:
A
5.6 Diesel particle filter
Danger
• Danger of fire and burning! The diesel particulate filter gets very hot. Do not grasp in the area of
the diesel particulate filter. Do not park the vehicle in the direct vicinity of flammable substances.
Attention
• If the diesel particulate filter symbol Fig. 84-A in the multifunction display lights up red, the vehicle
engine must be switched off immediately. Serious engine damage can be caused if this is not
complied with.
The diesel particulate filter filters damaging soot particles from the engine
exhaust gases. The engine control system automatically initiates cleaning
of the diesel particulate filter.
If the diesel particulate filter is soiled so much that it can no longer be
regenerated by automatic cleaning, then the diesel particulate filter symbol appears in the multifunctional display.
• The diesel particulate filter symbol lights up yellow:
Automatic cleaning could not be performed.
The shift can still be worked up to the end.
Have a service regeneration performed by the Hako service.
• The diesel particulate filter symbol lights up red:
The diesel particulate filter has reached its maximum level.
Immediately stop the vehicle to avoid engine damage!
Have a service regeneration performed by the Hako service.
05-1491-00-11.fm 99
Maintenance and Servicing
Fig. 85:
A
E
D
B E
A
C
D
5.7 Cooling system
Danger
• Danger of burns from hot parts! Do not touch any parts such as engine block, cooling system and
exhaust system during operation and for some time after. Let the engine cool down.
• Risk of scalding from hot coolant! The cooling system is under pressure. If the cooling system cap
is opened with a hot engine there is a risk of scalding. Let the engine cool down.
• Risk of injury due to rotating parts! Injury of limbs or hair or clothing getting caught up. Switch the
engine off and pull out the ignition key.
Attention
• Small air bubbles can form when the radiator is filled. Therefore the cooling system must be
vented at the same time. Have this done by an authorised workshop!
• The cooling fins are very thin and can be damaged easily.
Environmental danger
• Ensure safe and environment-conserving disposal of operating and auxiliary materials.
Take up escaping or spilled operating materials in suitable containers and dispose of them in an
environmentally friendly manner.
5.7.1 Cleaning the cooling system
Check the grille screen Fig. 85-A and the cooling fins of the combination
cooler located behind Fig. 85-B and of the hydraulic oil cooler Fig. 85-C
daily and clean as required.
1. Place the vehicle on a level surface and hold it with the parking brake.
Switch the engine off and pull out the ignition key. Let the engine cool
down.
2. Open the lock Fig. 85-D (see sketch) and swing down the radiator
cover Fig. 85-E.
3. Check the grille screen and the cooling fins of the combination cooler
located behind daily and clean with compressed air or water jet as
required.
100 05-1491-00-11.fm
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