Operating Instructions: Intermediate Pressure Attachment

REINEX Hochdrucktechnik GmbH - Geraer Str.
7 - 07973 Greiz
Operating Instructions
acc. to VDMA 24414
for the
Intermediate Pressure Attachment
Citytrac 4200
Attachment no.: MDA 500-0099-13
REINEX Hochdrucktechnik GmbH, Gewerbegebiet Geraer Str. 7, D-07973 Greiz, Tel. 03661/6285-0, Fax 03661/628519
0
REINEX Hochdrucktechnik GmbH - Geraer Str. 7 - 07973 Greiz
Contents Page
1. Applicability 2
2. Technical data 3
3. Description of device 4
3.1. Attachment 4
3.2. Function 4
4. Initial commissioning and operation 5
5. Device fitting with the setting-down device 7
6. Winter operation 9
6.1. Frost protection 9
7. Decommissioning 9
8. Recommissioning 10
9. Notes on maintenance 10
10. Errors 11
11. Checks 11
12. Prevention of accidents, danger analysis 12
13. General regulations and notes 13
13.1. Guarantee 13
13.2. Regulations for the base vehicle 13
14. Service 14
15. Index of enclosures 14
1
1. Applicability
This device is only authorised for the designated usage in compliance with the relevant
technical standards and the notes on safety in these operating instructions, in particular
sections 3.2 and 12.
With the accessories authorised by us as the manufacturer, the device is suitable for many
cleaning task in the community area when used with water:
- in combination with washing brushes

- service work in parks (watering parks and lawns)
- diverse application possibilities of the device combination
with low-pressure spray bar
- surface cleaning when using a spray bar
- fertilising when using an additive (Dosatron)
- bringing out brine
With the aid of a special pump it is possible to fill containers with a large feed quantity and to
operate work devices with a small feed quantity.
The feed quantity of the pump adapts itself to the relevant pressure conditions.
Since the vehicle has convenient proportions it is very maneouvrable and can thus be used on
narrow streets with gateways, in parks, pedestrian precincts, sports grounds and similar areas.
Any application of the unit which does not conform to the safety instructions and technical
specifications is prohibited. Any misuse lies under the responsibility of the owner, user or
operator.
Moreover, the producer´s operating and maintenance instructions must be applied by all
means.
The device must only be used, maintained and repaired by persons who are familiar with the
device and who have been instructed as to the dangers.
2
2. Technical data
- Machine type MDA 500
Pump type Kappa 100

feed quantity
hydraulic motor 40 l/min
hydraulic pressure 160 bar
output 10,5 KW
feed quantity
water pump approx. 90 l/min
water pressure 40 bar
Pump type ACE

feed quantity
hydraulic motor 15 l/min
hydraulic pressure 60 bar
feed quantity
water pump 60 l/min
water pressure 6 bar
- dimensions L x W x H (mm) 1500 x 1100 x 800
- filling quantity of barrel (l) 500
- empty weight (t) 0.15
- useful load
(with filled barrel 500l) (t) 0.65
3
3. Description of device
3.1. Attachment
The attachment is a combined unit, which can be mounted on a carrier vehicle Hako Citytrac
4200 or Hako Citymaster 1200. The attachment is screwed onto the tipper floor with 4 screws.
Prerequisite for the carrier vehicle is the equipping with a hydraulic unit (required hydraulic
output, see point 2) and the fitting of a crawling speed when using a spray bar.
The attachment consists of the components:
– hollow profile base frame with mountings for parking supports
– water barrel made from glass fibre reinforced plastic
– spray bar attachment
– spring tension reel
– rear slide-in frame with intermediate pressure pump unit
– rear slide-in frame with low-pressure pump unit
The base frame is designed in such a way that only one rear slide-in frame can be mounted,
that is, the attachment can be used either as intermediate pressure or as low pressure unit.
When using the attachment as intermediate pressure unit, it is also possible to bring out brine.
3.2. Function
Dependent on which rear slide-in is mounted, the attachment can be utilised as intermediate or
low pressure unit. The required water pressure is created with a pump and lies against the ball
cocks. The drive is carried out hydraulically via a toothed wheel motor. To enlarge the usable
liquid volume, the container is connected with the tank of the carrier vehicle with a hose.
When filling with the filling device, the water is first guided into the 500 l container of the
attachment and runs from there into the water tank of the carrier vehicle.
The suction line of the pump is connected to the water tank of the vehicle. During operation
of the pump, water is fed out of the vehicle tank. At the same time this quantity is fed from
the attachment container via the connection hose until this container is empty.
A shut-off cock and a suction filter are located in the suction line. The suction filter can be
removed for cleaning without problems if the shut-off cock is closed. A further ball cock is for
emptying the barrel.
An overflow valve is fitted to each pump, where the water pressure can be set.
With closed ball cocks to the consumer and opened suction line, the pressure water is pumped
over the overflow valve and guided back into the container.
4
CAUTION! Avoid a dry run of the pump.
On each pump unit there are two pressure outlets to the consumer
– spring tension reel
– attached spray bar.
A shut-off cock is fitted in each pressure line.
4. Initial commissioning and operation
- fix and lock the attachment on the tipper floor with the aid of 4 screws M10
- connect the hydraulic hoses to the relevant vehicle couplings
- connect the connection line between the container and the suction line to the
water tank of the carrier vehicle
- fit the front attachment to the coupling triangle
- connect the front attachment with the pressure connection at the pump
- plug in the coding plug into the electric socket
- close all cocks
- fill the container via the filling device with clean water
- check the suction filter for cleanliness
- open suction cock
- start the vehicle motor
- switching on the hydraulic unit starts the pump operating
To work with the individual consumers, the relevant ball cock must be opened.
CAUTION!
When mounting the low pressure unit, care must be taken that the setting for the feed
quantity of the hydraulic unit at the carrier vehicle is correct.
Pump type ACE-low pressure pump

Set the hydraulic unit to a feed quantity of 15 l/min. A flow limiting valve is fitted in the
pressure line to the pump motor.
This valve protects the water pump against a speed which is too high.
If the oil flow is too high, the pressure line is closed so that the pump is switched off.
5
Caution, danger of accident
– Water supply lines and hydraulic lines must be absolutely tight and must be checked
again.
– A dry run of the pump must be avoided.
– Open ball cocks when the spray unit is under control.
Caution ! The equipment must only be operated, maintained and repaired by persons
who are familiar with it und who have been instructed as to the dangers.
Please take care that the backflow lines are connected correctly.
If the coupling is not connected properly, the backpressure cone is not
pushed back and a back pressure is created in the backflow lines, which
causes the sealing ring at the shaft of the hydraulic motor to be pushed out.
The attachment is finished as combination attachment, that is, it is possible to fit different
pump units at the base frame.
1. Intermediate pressure unit

– Connect to the front work cycle, the connection lines must be guided at the attachment to
the front through the tunnel underneath the cab.
– Mount the unit at the base frame with 2 bolts and hang the lower mountings at the rear of
the carrier vehicle.
2. Low-pressure unit
– Connect to the couplings of the rear work cycle
– Mount the unit at the base frame with 2 screws M20.
Exchanging the pump unit:

When exchanging the pump units with each other, the required connection lines (water,
hydraulic) must be released.
Removing the intermediate pressure unit:

– Remove the connection bolt Ø 20 at the frame.
– Lift the frame, pull it to the back and set it down.
Removing the low-pressure unit:

– Remove the hexagon screws M20, hold the frame tight for this.
– Pull the frame out downwards and set it down.
Mounting is carried out in reverse order.
6
CAUTION!
Peculiarity when checking the oil level at the vehicle.
The oil level dipstick is located underneath the tipper bridge, which must be tipped for this.
The following must be noted or carried out at the vehicle:
– with the intermediate pressure unit, remove the bottom plugs at the vehicle
– with the low-pressure unit, release the retaining screws M20
– release the couplings of the water hoses at the water tank of the vehicle
– tip the tipper bridge as far as the hydraulic hoses allow
– tip the attachment only with empty container
CAUTION!
At the tipper cylinder, the full stroke is not possible.
5. Device fitting with the setting-down device
CAUTION !
The mounting of the device must only be carried out if the motor is switched off!
The mounting and dismounting of the device on the carrier vehicle can be carried out with a
setting-down device in form of setting-down supports.
These setting-down supports are pushed into the frame and the hydraulic hoses are coupled on
or off.
The connection hoses for the intermediate pressure unit must be pulled forward, together with
the hose for the front attachment, through the mounting support at the tipper and through the
vehicle tunnel.
Set down the unit only on an even surface on firm ground (concrete), as
otherwise there is a danger of tilting!
Disassembly of the assembly only with empty container!
7
Hose guide for tank pooling in the center at the front mount tipper.
(see photo)
8
6. Winter operation
ATTENTION, ACCIDENT HAZARD!

When the unit is frozen all safety devices are blocked!
Before the unit is switched on, please make sure that it has thawed completely! Exclude
damage caused by frost, e.g. cracks in elements delivering water. If a frozen unit is switched
on, heavy damage to the pump may be the result.
ATTENTION, ACCIDENT HAZARD!

Sometimes, ice pieces remain in the pressure hose. When the pressure is increased, they
shoot out of the hose with high speed.
6.1. Frost protection
The following measures can prevent frost damage:
Emptying the complete unit:

- open the outlet ball cock and empty the water container, open outlet cock pump.
- it is essential that the filler hose between pressure regulation valve and water container
is emptied for reasons of safety by pulling the hose off.
- disposal is carried out with the hose hanging down.
Potential damages caused by frost can only be avoided when the unit is emptied entirely!
The emptying of the unit can be assisted with compressed air.
Filling the unit with a chemical antifreeze agent (down to -30°C) is another possibility to
make the unit frost-resistant.
7. Decommissioning
When decommissioning over a longer period, the low pressure equipment must be kept
protected against frost and, if necessary, must be filled with a frost protection agent.
9
8. Recommissioning
Prior to each recommissioning, the entire pressure system must be check as to satisfactory
condition, especially the hose lines and spray units.
Any existing faults must be eliminated.
The pressure system must be rinsed through with clear water at idling speed prior to
commencing work.
9. Notes on maintenance
Maintenance and repairs are always to be carried out with switched off device!
Maintenance periods:
The first maintenance should be done after the 50 hours of operation, the following ones
every 100 hoursof operation.
Fixing the unit:

Make sure that all bolts and pressure hoses are fixed.
Basic vehicle:
See operating and maintenance instructions by the producer.
Hydraulic unit:
see separate operating and maintenance regulations of the vehicle manufacturer
Water pump:
see separate operating instructions
Option: hose wind-up

see separate operating instructions
Water container:
Fill only with clean, filtered water!
When using water from the main system, let the water run until it is clear before filling.
Clean the water container annually with a jet pistol and let the waste water run off.
10
Water filter:
The water filter must be cleaned according to requirement, however, at least once a week.
It is essential that faulty filter inserts (sieves) are renewed!
Cleaning of the filter in the inlet of the water pump can also be carried out with the water tank
filled, by closing the ball cock between the tank and the filter.
After cleaning the filter, the ball cock must be opened again.
Heavily soiled filter impair the suction behaviour of the water pump and can therefore lead to
damage of the water pump.
Oil – hydraulic system:

The oil level of the hydraulic aggregate should be checked every 100 operating hours. If
necessary, fill up oil.
10. Errors
– see separate operating instructions in the appendix (pumps)
11. Checks
Liquids sprayers must be checked as to their work safe condition by the manufacturer or by a
specialist
- prior to the initial commissioning
- after modification or repairs of parts, which influence the safety
- after an interruption in operation for more than 6 months
- however, at least every 12 months.
„Specialists„ are persons who have sufficient knowledge in the area of liquids sprayers due to
their technical training and experience and who are sufficiently familiar with the specific
government regulations for work safety, regulations for the prevention of accidents and the
guidelines of technology (i.e. DIN sheets) so that they are able to evaluate the work safe
condition of liquids sprayers.
The result of the check must be recorded in writing.
11
12. Prevention of accidents, danger analysis
Regulations for the user:
- The equipment must only be operated by persons who are familiar with its operation.
- The maximum pressure according to the type plate must never be exceeded.
- The notes on assembly and the mounting guidelines according to DIN 2066 must be
complied with when connecting the pressure hoses.
- Hoses must be arranged in such a way that they cannot be damaged.
- Hoses must only be repaired by the manufacturer – if the operator wants to repair
hoses himself he must obtain the authorisation of the trade organisation.
- The low-pressure device must be checked for operating safety at least every 12 months
by a specialist (fitter). The result must be recorded in writing.
- Unauthorised alterations to the equipment exclude liability of the manufacturer for

damages resulting from this.
- The jet of liquids must not be directed onto electrical units.
- Damaged or leaking hose lines must be exchanged.
- The device must be checked as to proper condition prior to every commissioning

(sight check).
12
13. General regulations and notes
13.1. Guarantee
Our conditions are the basis for the guarantee. The guarantee starts at the day of delivery and
includes a period of 12 months.
Damage caused by
– wear
– ignorance of the given instructions
– improper use and
– strangers
is excluded from the guarantee.
The guarantee expires when repairs and other interferences have been carried out by persons
who have not been authorized by us.
Moreover, the operator loses any rights of guarantee if he retrofits the unit with other than the
original pieces and if he adds supplements or carries out changes.
During the period of guarantee, transport costs (from the customer to the producer and back)
are at the customer´s expense.
13.2. Regulations for the base vehicle
The admissible total weight and the axis load must not be exceeded.
The equipment guidelines of the vehicle manufacturer guidelines and basic notes for the
operation of the equipment must be complied with.
Note:
The travelling speed must be adjusted to the highway and traffic conditions in each case,
whereby the influence of the device during braking, negotiating bends etc. must be
considered.
The operator is responsible for compliance with the legal regulations of StVO and StVZO, the
regulations for work protection and the prevention of accidents of the relevant trade
organisation, as well as the operating instructions of the device manufacturer.
13
14. Service
Service address of the manufacturer:
REINEX Hochdrucktechnik GmbH

Gewerbegebiet Geraer Straße 7
D-07973 Greiz
Phone: 0049 3661/6285-0

Fax: 0049 3661/628519
Service is carried out through the trader networks of the Hako-Werke.
15. Index of enclosures:
- Enclosure 1: Operating instructions intermediate pressure pump
- Enclosure 2: Operating instructions hose wind-up
- Enclosure 3: Tank amalgamation
- Enclosure 4: Spare parts list
- Enclosure 5: Hydraulic diagram, electric diagram
- Enclosure 6: Acceptance protocol
- Enclosure 7: EC conformity declaration
14
Enclosure 1
15
16
17
Enclosure 2
18
19
20
Enclosure 3
21
22
23
24
25
26
27
28
29
Enclosure 4
Spare parts list MD attachment
Pos. Teil-Nummer Bezeichnung Stück

1 8020002015 Pump high pressure KAPPA 100 1
2 6040001010 Overflow valve DS/2 1
3 6010001110 Filter 1 1/2“ 1
4 6010001112 Filter sieve for 02070050 1
5 8020003009 Intermediate flange 1
6 5073004050 Motor hydraulic 1
7 6020001005 Ball cock low-pressure 1“ 2
8 6020001006 Ball cock low-pressure 3/4“ stainless steel 1
9 7080010010 Hose reel with stroke 1
10 8040003013 Hose DN 12 10m
11 6060002015 Hose liner with retaining nut 1
12 8030003005 pistol 1
13 6020002020 Ball cock low-pressure 1/2“ stainless steel 1
14 7050000205 Check valve „York“ 1 1/4“ 1
15 6050000105 Coupling low-pressure Storz-C 1 1/4“ AG 1
16 6050000150 Coupling low-pressure, blind coupling 1
17 8040002005 Hose „Heliflex“ 2,9m
18 8040002005 Hose „Heliflex“ 4,1m
19 8040002005 Hose „Heliflex“ 1,0m
20 8040002005 Hose „Heliflex“ 0,18m
21 6060001028 Hose liner 1" 3
22 6050003009 Kamlok-Coupling V-part, IG 1
23 6050003005 Kamlok-Coupling M-part, IG 1
24 6050003011 Kamlok-Coupling V-part, AG 1
25 6050003007 Kamlok-Coupling M-part, AG 1
26 8030003310 Angle plastic 90° 1“ IG-AG 1
27 6070001006 Clamping jaw collar 8
28 5020003050 Ventilaiting and air axhaust valve 1
29 6060001010 Hose liner 1/2" 2
30 5050001185 Verschraubung, gerade 1“ IG-AG 1
31 5073001012 Swivel cylinder 1
32 7070002501 Locking nut 3/8“ for nozzle 9
33 7070002012 Nozzle flat jet 6504 9
34 8010000010 dipstick for spray bar 2
35 6070004048 pipe clamp 2
30
31
32
33
34
35
36
37
Enclosure 5
38
39
40
Enclosure 6
41
Enclosure 7
42

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REINEX Hochdrucktechnik GmbH - Geraer Str.

acc. to VDMA 24414

Intermediate Pressure Attachment

Attachment no.: MDA 500-0099-13

4. Initial commissioning and operation 5

5. Device fitting with the setting-down device 7

6.1. Frost protection 9

12. Prevention of accidents, danger analysis 12

13. General regulations and notes 13

13.2. Regulations for the base vehicle 13

15. Index of enclosures 14

- in combination with washing brushes

- Machine type MDA 500

Pump type Kappa 100

Pump type ACE

- dimensions L x W x H (mm) 1500 x 1100 x 800

- filling quantity of barrel (l) 500

- empty weight (t) 0.15

CAUTION! Avoid a dry run of the pump.

A shut-off cock is fitted in each pressure line.

4. Initial commissioning and operation

Pump type ACE-low pressure pump

Caution, danger of accident

1. Intermediate pressure unit

Exchanging the pump unit:

Removing the intermediate pressure unit:

Removing the low-pressure unit:

Mounting is carried out in reverse order.

5. Device fitting with the setting-down device

ATTENTION, ACCIDENT HAZARD!

ATTENTION, ACCIDENT HAZARD!

6.1. Frost protection

The following measures can prevent frost damage:

Emptying the complete unit:

The emptying of the unit can be assisted with compressed air.

Fixing the unit:

Option: hose wind-up

Oil – hydraulic system:

– see separate operating instructions in the appendix (pumps)

The result of the check must be recorded in writing.

12. Prevention of accidents, danger analysis

Regulations for the user:

- Hoses must be arranged in such a way that they cannot be damaged.

- Unauthorised alterations to the equipment exclude liability of the manufacturer for

- The jet of liquids must not be directed onto electrical units.

- Damaged or leaking hose lines must be exchanged.

- The device must be checked as to proper condition prior to every commissioning

13. General regulations and notes

13.2. Regulations for the base vehicle

Service address of the manufacturer:

REINEX Hochdrucktechnik GmbH

Phone: 0049 3661/6285-0

Service is carried out through the trader networks of the Hako-Werke.

15. Index of enclosures:

- Enclosure 1: Operating instructions intermediate pressure pump

- Enclosure 2: Operating instructions hose wind-up

- Enclosure 3: Tank amalgamation

- Enclosure 4: Spare parts list