AMMANN AP 240 PNEU TYRED ROLLER OPERATING MANUAL 3001217 PDF

ART 240 PNEU TYRED ROLLER DEUTZ TCD3.6 L4 EU Stage IV / U.S. EPA Tier 4f

OPERATING MANUAL EDITION 01/2021 EN Product Identification Number 3001217 -

ES / EU Prohlášení o shodě (Původní ES/EU prohlášení o shodě / Original EC/EU Declaration of conformity / Ursprüngliche EG-/EU-Konformitätserklärung )

EC / EU Declaration of conformity / EG-/EU-Konformitätserklärung (Překlad původního ES/EU prohlášení o shodě /Translation original EC/EU Declaration of conformity / Übersetzung der ursprünglichen EG-/EU-Konformitätserklärung ) Originální ES/EU prohlášení o shodě je dodané s dokumenty během expedice stroje. / The original EC/EU Declaration of Conformity is supplied with documents during expedition of machine. / Das Original der EG-/EU-Konformitätserklärung wird mit den Unterlagen während des Versands der Maschine mitgeliefert.

Výrobce / Manufacturer / Hersteller: Adresa / Address / Adresse: IČ / Identification Number / Ident.-Nr:

Ammann Czech Republic a.s.

Náchodská 145, CZ-549 01 Nové Město nad Metují, Czech Republic 000 08 753

Jméno a adresa osoby pověřené sestavením technické dokumentace podle 2006/42/ES a jméno a adresa osoby, která uchovává technickou dokumentaci podle 2000/14/ES / Name and address of the person authorised to compile the technical file according to 2006/42/EC and name and address of the person, who keeps the technical documentation according to 2000/14/EC / Name und Adresse der mit der Zusammenstellung der technischen Dokumentation beauftragten Person gemäß 2006/42/EG und Name und Adresse der mit der Aufbewahrung der technischen Dokumentation beauftragten Person gemäß 2000/14/EG:

Ing. Radek Ostrý Ammann Czech Republic a.s.

Náchodská 145, CZ-549 01 Nové Město nad Metují, Czech Republic

Popis strojního zařízení / Description of the machinery / Beschreibung der Maschineneinrichtung: Označení / Designation / Bezeichnung:

Pneumatikový válec / Pneu tyred roller / Gummiradwalze

Typ / Type / Typ:

ART 240

Verze / Version / Version: Product Identification Number: Motor / Engine / Motor:

Deutz TCD3.6 L4, vznětový, jmenovitý výkon (ISO 14396): 74,4 kW, jmenovité otáčky: 2000 min-1 / Deutz TCD3.6 L4, Diesel, nominal power (ISO 14396): 74,4 kW, rated speed: 2000 RPM / Deutz TCD3.6 L4, Dieselmotor, Nennleistung (ISO 14396): 74,4 kW, Nenndrehzahl: 2000 min-1

Prohlašujeme, že strojní zařízení splňuje všechna příslušná ustanovení uvedených směrnic / We declare, that the machinery fulfils all the relevant provisions mentioned Directives / Wir erklären, dass die Maschineneinrichtung sämtliche entsprechenden Bestimmungen aufgeführter Richtlinien erfüllt:

Strojní zařízení – směrnice 2006/42/ES / Machinery Directive 2006/42/EC / Maschineneinrichtung – Richtlinie 2006/42/EG Elektromagnetická kompatibilita – směrnice 2014/30/EU / Electromagnetic Compatibility Directive 2014/30/EU / Elektromagnetische Kompatibilität – Richtlinie 2014/30/EU Emise hluku – směrnice 2000/14/ES / Noise Emission Directive 2000/14/EC / Lärmemissionen – Richtlinie 2000/14/EG

Harmonizované technické normy a technické normy použité k posouzení shody / The harmonized technical standards and the technical standards applied to the conformity assessment / Harmonisierte technische Normen und für die Beurteilung der Konformität verwendete Normen:

ČSN EN ISO 12100, ČSN EN 500-1+A1, ČSN EN 500-4, ČSN EN ISO 4413, ČSN EN ISO 4414, ČSN EN 13309

Osoby zúčastněné na posouzení shody / Bodies engaged in the conformity assessment / An der Konformitätsbeurteilung beteiligte Personen:

Notifikovaná osoba č. 1016 / Notified Body No.: 1016 / Notifizierte Stelle Nr.: 1016

Použitý postup posouzení shody / To the conformity assessment applied procedure / Verwendetes Vorgehen der Konformitätsbeurteilung:

Na základě směrnice 2000/14/ES příloha VI / Pursuant to the Noise Emission Directive 2000/14/EC, Annex VI / Aufgrund der Richtlinie 2000/14/EG, Anlage VI

Naměřená hladina akustického výkonu / Measured sound power level / Gemessener Schallleistungspegel: Garantovaná hladina akustického výkonu / Guaranteed sound power level / Garantierter Schallleistungspegel:

LWA = 102 dB

Místo a datum vydání / Place and date of issue / Ort und Datum der Ausgabe:

Nové Město nad Metují,

Státní zkušebna strojů a.s., Třanovského 622/11, 163 04 Praha 6–Řepy, ČR. / The Government Testing Laboratory of Machines J.S.C., Třanovského 622/11, 163 04 Praha 6–Řepy, Czech Republic / Staatliche Prüfstelle für Maschinen AG, Třanovského 622/11, 163 04 Praha 6–Řepy, Tschechische Republik.

LWA = 103 dB

Osoba zmocněná k podpisu za výrobce / Signed by the person entitled to deal in the name of manufacturer / Zeichnungsberechtigter für den Hersteller: Jméno / Name / Name: Funkce / Grade / Stelle: Podpis / Signature / Unterschrift:

Jiří Sychra Logistics Manager CZ / EN / DE

Congratulations on your purchase of an AMMANN road roller. This modern compaction device is characterised by simple operation and maintenance and is the product of many years of AMMANN experience in the field of road roller engineering. In order to avoid faults due to improper operation and maintenance we request that you read this operating manual with great care and keep it for later reference.

With kind regards,

Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují

% + 420 491 476 111 | Fax + 420 491 470 215 | info@ammann.com | www.ammann.com

This instruction manual is a “translation of the original instruction manual” within the meaning of the paragraph 1.7.4.1 of the Directive of the European parliament and of the Council 2006/42/EC of 17 Mai 2006.

This manual consists of: I. Specification manual

II. Operating instructions

III. Maintenance manual

The following explanations serve to familiarise the machinist (operator) with the roller and to support him during handling and maintenance. It is therefore absolutely necessary to provide the operator with these instructions and to ensure that he reads them carefully before using the road roller. This aids training comprehension during the first use of the road roller.

Subsequent faults due to improper operating are avoided.

Adherence to maintenance instructions increases the reliability and lifetime of the machinery. It reduces repair costs and down time.

AMMANN accepts no liability for continued safe functioning of the road roller if it is incorrectly operated and / or operating modes are employed which represent improper use.

In order to ensure the smooth operation of AMMANN compaction equipment, use for repairs only the original spare parts supplied by AMMANN.

These instructions must always be kept available on the equipment.

ART 240

1

Preface Information, specifications, and recommended operation and maintenance instructions contained in this publication are basic and final information at the time of the printing of this publication. Printer’s errors, technical modifications, and modifications of figures are reserved. All dimensions and weights are approximate and, therefore, not binding.

Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to inform the machine user. If you identify any differences between the machine operated by you and the information contained in this publication, contact your local dealer.

Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic a.s.

2

ART 240

SYMBOLS OF THE SAFETY NOTICES: The notice warns of a serious risk of personal injury or other personal hazards.

The notice warns of possible damages to the machine or its parts.

The notice warns of the necessity of environmental protection.

! NOTICE !

As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indicate the sides of the machine moving forward.

REAR RIGHT

LEFT FRONT ART 240

435en 3

Content Content..............................................................................................................................................................4 1

SPECIFICATION MANUAL.......................................................................................................................9

1.1 Basic specification.................................................................................................................................10 1.2 Dimensional diagram of the Machine..................................................................................................12 1.3 Specifications.........................................................................................................................................15

4

ART 240

OPERATING MANUAL 2

OPERATION MANUAL...........................................................................................................................21

2.1 Main Safety Measures...........................................................................................................................23 2.1.1

Safety measures during Machine operation.................................................................................................................................................23

2.1.1.1 Compaction Work Commencement................................................................................................................................................................23 2.1.1.2 Work in the dangerous area................................................................................................................................................................................23 2.1.1.3 Ensurance of safety measures by the owner................................................................................................................................................24 2.1.1.4 ROPS............................................................................................................................................................................................................................24 2.1.2

Requirements for qualification of driver........................................................................................................................................................25

2.1.3

Duties of the driver.................................................................................................................................................................................................26

2.1.4

Forbidden activities – safety and guarantee.................................................................................................................................................27

2.1.5

Safety notices and symbols used on the machine.....................................................................................................................................29

2.1.6

Manual signals.........................................................................................................................................................................................................33

2.2 Ecological and hygienic principles.......................................................................................................36 2.2.1

Hygienic principles.................................................................................................................................................................................................36

2.2.2

Ecological principles..............................................................................................................................................................................................36

2.3 Machine preservation and storage......................................................................................................37 2.3.1

Short-term preservation and storage for a period of 1 – 2 months.....................................................................................................37

2.3.2

Preservation and storage for a period over 2 months...............................................................................................................................37

2.3.3

Dewaxing and inspection of a supplied machine......................................................................................................................................38

2.4 Machine disposal following its life cycle end......................................................................................39 2.5 Machine Description.............................................................................................................................40 2.6 Controls and checking instruments.....................................................................................................42 2.6.1

Power View control.................................................................................................................................................................................................65

2.7 Machine operation and use..................................................................................................................74 2.7.1

Engine start...............................................................................................................................................................................................................75

2.7.2

Drive and reverse drive.........................................................................................................................................................................................79

2.7.3

Stopping the machine and engine..................................................................................................................................................................83

2.7.4

Machine emergency stop....................................................................................................................................................................................85

2.7.5

Machine parking.....................................................................................................................................................................................................87

2.7.6

Watering and scrapers..........................................................................................................................................................................................89

2.7.7

Edge Cutter...............................................................................................................................................................................................................91

2.7.8

Additional weighting of the machine.............................................................................................................................................................92

2.7.9

Opening and closing the dashboard cover...................................................................................................................................................93

2.8 How to transport the Machine..............................................................................................................95 2.8.1.

Machine loading.....................................................................................................................................................................................................96

2.8.1.1 Loading the machine using a ramp.................................................................................................................................................................96 2.8.1.2 Loading the machine using a crane.................................................................................................................................................................97

2.9 Machine work under heavy conditions...............................................................................................98 2.9.1

Machine towing......................................................................................................................................................................................................98

2.9.2

Machine operation during its running-in period..................................................................................................................................... 100

2.9.3

Machine operation at low temperatures.................................................................................................................................................... 100

2.9.4

Machine work under high temperatures and humidity........................................................................................................................ 101

2.9.5

Machine work in high altitudes...................................................................................................................................................................... 101

2.9.6

Work of the machine in the dusty environment...................................................................................................................................... 101

ART 240

5

Content 3

MAINTENANCE MANUAL...................................................................................................................103

3.1 Safety standards and other maintenance regulations ....................................................................105 3.1.1

Safety of machine maintenance..................................................................................................................................................................... 105

3.1.2

Fire precautions during operation media exchanges............................................................................................................................ 105

3.1.3

Ecological and hygienic standards................................................................................................................................................................ 106

3.2 Specification of fluids..........................................................................................................................107 3.2.1

Engine oil................................................................................................................................................................................................................ 107

3.2.2

Fuel............................................................................................................................................................................................................................ 108

3.2.3

Coolant.................................................................................................................................................................................................................... 108

3.2.4

Hydraulic oil........................................................................................................................................................................................................... 109

3.2.5

Oil - planetary gear with torque converter................................................................................................................................................. 109

3.2.6

Transmission oil.................................................................................................................................................................................................... 109

3.2.7

DEF (AdBlue).......................................................................................................................................................................................................... 109

3.2.8

Brake fluid............................................................................................................................................................................................................... 109

3.2.9

Lubricating grease............................................................................................................................................................................................... 110

3.2.10 Screen washer fluid............................................................................................................................................................................................. 110 3.2.11 Air-conditioning filling....................................................................................................................................................................................... 110 3.2.12 Emulsion................................................................................................................................................................................................................. 110

3.3 Media....................................................................................................................................................111 3.4 Lubrication and Maintenance Chart..................................................................................................112 3.5 Lubrication and Service Plan..............................................................................................................115 3.6 Lubrication and Maintenance Operations.........................................................................................116 Every 20 hours of operation (daily)....................................................................................................117 3.6.1

Engine oil level check......................................................................................................................................................................................... 117

3.6.2

Engine cooling liquid level check.................................................................................................................................................................. 118

3.6.3

Fan inspection....................................................................................................................................................................................................... 119

3.6.4

Engine and exhaust pipe intake manifold check..................................................................................................................................... 119

3.6.5

Air filter dust valve check.................................................................................................................................................................................. 120

3.6.6

Hydraulic oil level check.................................................................................................................................................................................... 120

3.6.7

Brake fluid check.................................................................................................................................................................................................. 121

3.6.8

Brake inspection................................................................................................................................................................................................... 122

3.6.9

Water tank refill..................................................................................................................................................................................................... 123

3.6.10 Water separator cleaning.................................................................................................................................................................................. 123 3.6.11 Oil in the gearbox check.................................................................................................................................................................................... 124 3.6.12 Warning and control devices check.............................................................................................................................................................. 125 3.6.13 Inspection of DEF (AdBlue) level.................................................................................................................................................................... 127 3.6.14 Check of the front axle....................................................................................................................................................................................... 129

Every 100 hours of operation (weekly)..............................................................................................130 3.6.15 Tyre pressure check............................................................................................................................................................................................. 130 3.6.16 Check of the oil level in the front axle hydraulic cylinders................................................................................................................... 131

Every 250 hours of operation (3 months)..........................................................................................132 3.6.17 Engine induction manifold and air filter sensor check........................................................................................................................... 132 3.6.18 Machine lubrication............................................................................................................................................................................................ 134

6

ART 240

OPERATING MANUAL Every 500 hours of operation (6 months)..........................................................................................136 3.6.19 Engine oil change................................................................................................................................................................................................ 136 3.6.20 Fuel filters replacement..................................................................................................................................................................................... 138 3.6.21 Air filter elements replacement...................................................................................................................................................................... 140 3.6.22 Engine cooling liquid check............................................................................................................................................................................. 141 3.6.23 Gearbox oil filter replacement........................................................................................................................................................................ 142 3.6.24 Oil in differential and oil in rear axle check................................................................................................................................................ 143 3.6.25 Wiring check.......................................................................................................................................................................................................... 143 3.6.26 Air conditioning coolant check....................................................................................................................................................................... 144 3.6.27 Air filter of the air conditioning system replacement............................................................................................................................. 145 3.6.28 Cab ventilation filter cleaning......................................................................................................................................................................... 145 3.6.29 Replacement of DEF (AdBlue) filter............................................................................................................................................................... 146 3.6.30 Engine belt check................................................................................................................................................................................................ 149

Every 1000 hours of operation (1 year).............................................................................................150 3.6.31 Battery check......................................................................................................................................................................................................... 150 3.6.32 Brake shoes adjustment.................................................................................................................................................................................... 152 3.6.33 KM nuts tightening check and front wheels lubrication....................................................................................................................... 154 3.6.34 Cleaning of the air cooler.................................................................................................................................................................................. 155 3.6.35 Air conditioning compressor mounting check......................................................................................................................................... 155 3.6.36 Gearbox oil change............................................................................................................................................................................................. 156 3.6.37 Oil in differential change................................................................................................................................................................................... 157 3.6.38 Air drier replacement......................................................................................................................................................................................... 158

Every 2000 hours of operation (2 years)............................................................................................159 3.6.39 Oil in rear axle change........................................................................................................................................................................................ 159 3.6.40 Hydraulic oil and filter change........................................................................................................................................................................ 161 3.6.41 Oil in front axle hydraulic cylinders change............................................................................................................................................... 164 3.6.42 Brake fluid change............................................................................................................................................................................................... 165 3.6.43 Air conditioning system check........................................................................................................................................................................ 167

Every 6000 hours of operation (4 years)............................................................................................168 3.6.44 Engine cooling liquid change......................................................................................................................................................................... 168

Maintenance if required......................................................................................................................170 3.6.45 Water from separator draining........................................................................................................................................................................ 170 3.6.46 Fuel system venting............................................................................................................................................................................................ 171 3.6.47 Coolers cleaning................................................................................................................................................................................................... 172 3.6.48 Regeneration of clogged catalyst SCR (Selective Catalytic Reduction)........................................................................................... 173 3.6.49 Refilling the oil level in the front axle hydraulic cylinders.................................................................................................................... 174 3.6.50 Sprinkling filter cleaning................................................................................................................................................................................... 176 3.6.51 Brush scrapers cleaning..................................................................................................................................................................................... 177 3.6.52 Check of wheel nuts for tightening............................................................................................................................................................... 177 3.6.53 Machine cleaning................................................................................................................................................................................................ 178 3.6.54 Air collector inspection...................................................................................................................................................................................... 179 3.6.55 Charging of the battery..................................................................................................................................................................................... 180 3.6.56 Screw connection tightening check............................................................................................................................................................. 181

3.7 Defects..................................................................................................................................................183

ART 240

7

Content 3.8 Annexes................................................................................................................................................184 Wiring Diagram..................................................................................................................................................................................................................... 184 Wiring diagram Aftertreatment...................................................................................................................................................................................... 190 Hydraulics Diagram............................................................................................................................................................................................................. 192 Air Distribution...................................................................................................................................................................................................................... 194 Table of spare parts.............................................................................................................................................................................................................. 196

8

ART 240

SPECIFICATION MANUAL

1 SPECIFICATION MANUAL ART 240 (Deutz Tier 4 Final)

ART 240

9

1.1

Basic specification

Machine description Pneu tyred roller with a rigid frame with a front steerable isostatic axle and rear drive axle. Each axle is mounted with four smooth tyres.

Please fill in the following data: (see Pin label, Label of the Deutz engine)

Type of machine

Machine application The roller is intended for medium and large-sized compaction works in transport construction (roads and motorways, railways, airfields) and building construction (industrial zones, etc.).

The roller is suitable for compacting the asphalt mixtures up to a layer thickness (after compaction) of 120 mm, hydraulically consolidated mixtures up to a layer thickness of 150 mm, loam and clay soils up to a layer thickness of 150 mm, mixed soils up to a layer thickness of 200 mm, and sand and gravel materials up to a layer thickness of 250 mm.

................................................................................................................

Product Identification Number

................................................................................................................

Production year ................................................................................................................

Type of engine

The roller is not suitable for the compaction of rockfill.

The machines are designed for operation in arid, temperate and cold climates according to EN 60721-2-1:2014 with a limited temperature range from -15 °C (5 °F) to +45 °C (113 °F) and a maximum absolute humidity of 25 g.m-3.

................................................................................................................

The standard type of the machine is not intended for road traffic. For more information, please contact your dealer.

................................................................................................................

Serial number of the engine

Please refer to the data in the table below always when approaching the dealer or the manufacturer.

10

ART 240

SPECIFICATION MANUAL The machine that complies with the requirements as to health protection and safety is identified with a name plate with CE marking.

1. Name – always mentioned only in the English version 2. Type 3. Product identification number 4. Rated power 5. Operating weight 6. Maximum weight 7. Shipping weight 8. Version 9. Engine emissions 10.Front axle load 11.Rear axle load 12.Year of manufacture 13.Model year Name plate location 1 - Name plate 2 - Machine frame number

4145

1

AMMANN CZECH REPUBLIC a.s.

549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145 CZECH REPUBLIC

2

8

DESIGNATION TYPE

3

VERSION

PRODUCT IDENTIFICATION NUMBER

4 5 6

NOMINAL POWER

ENGINE EMISSIONS

OPERATING MASS

FRONT AXLE LOAD

MAXIMUM MASS

REAR AXLE LOAD

SHIPPING MASS

YEAR OF CONSTRUCTION MODEL YEAR

7

MADE IN CZECH REPUBLIC

9 10 11 12 13 4145

2

1 AP001 Engine name plate location

264003

ART 240

11

Dimensional diagram of the Machine

G*

G

H1

1.2

A L

435001

12

A

G

G*

H

H1

L

L1

W

W1

W2

mm

3780

280

250

3130

2380

5030

5780

1986

2100

2310

(in)

(148.8)

(11.0)

(9.8)

(123.2)

(93.7)

(198.0)

(227.6)

(78.2)

(82.7)

(90.9)

ART 240

H

SPECIFICATION MANUAL

W W1

435002

A

G

G*

H

H1

L

L1

W

W1

W2

mm

3780

280

250

3130

2380

5030

5780

1986

2100

2310

(in)

(148.8)

(11.0)

(9.8)

(123.2)

(93.7)

(198.0)

(227.6)

(78.2)

(82.7)

(90.9)

ART 240

13

1.2

Dimensional diagram of the Machine

L1

W2

435003

14

A

G

G*

H

H1

L

L1

W

W1

W2

mm

3780

280

250

3130

2380

5030

5780

1986

2100

2310

(in)

(148.8)

(11.0)

(9.8)

(123.2)

(93.7)

(198.0)

(227.6)

(78.2)

(82.7)

(90.9) ART 240

1.3

Specifications

SPECIFICATION MANUAL ART 240 EU Stage IV / U.S. EPA Tier 4f

Weight Operating weight of EN 500-1+A1 (CECE) with cab, ROPS

kg (lb)

9700 (21380)

Operating weight of EN 500-1+A1 (CECE) with cab

kg (lb)

9400 (20720)

Operating weight of EN 500-1+A1 (CECE) with platform, rail

kg (lb)

9120 (20110)

Weight of half fluid capacities

kg (lb)

300 (660)

Operating weight of ISO 6016 with cab, ROPS

kg (lb)

9800 (21610)

Maximum weight with the cab, ROPS, accessories, weighing

kg (lb)

24000 (52910)

Maximum permitted weight according to ROPS

kg (lb)

24000 (52910)

Weight of empty ballast tanks

kg (lb)

1100 (2430)

Balance weight 6 t

kg (lb)

6280 (13850)

Weight of ballast tanks filled with concrete

kg (lb)

2800 (6170)

Weight of ballast in frame – water

kg (lb)

3000 (6610)

Weight of ballast in frame – sand

kg (lb)

4500 (9920)

Weight of ballast in the frame – scrap up to the total machine weight

kg (lb)

24000 (52910)

Cab weight

kg (lb)

320 (710)

Weight of ROPS

kg (lb)

300 (660)

Weight of ROPS/FOPS (CNH design)

kg (lb)

530 (1170)

Weight of sheet roof on ROPS

kg (lb)

230 (510)

Weight of canopy

kg (lb)

50 (110)

Weight of canopy posts (version without ROPS)

kg (lb)

60 (130)

Weight of wheel insulation

kg (lb)

120 (260)

Weight of Ammann edge cutter

kg (lb)

150 (330)

-

3

Maximum transport speed

km/h (MPH)

0-19 (0-11.8)

Working speed 1

km/h (MPH)

0-5 (0-3.1)

Working speed 2

km/h (MPH)

0-11 (0-6.8)

Working speed 3

km/h (MPH)

0-19 (0-11.8)

Climbing ability

%

25

Lateral static stability

%

25

Lateral stability during driving

%

10

Turning radius inner (edge) left

mm (in)

6200 (244.1)

Turning radius inner (edge) right

mm (in)

6100 (240.2)

Turning radius outer (contour) left

mm (in)

10000 (393.7)

Turning radius outer (contour) right

Driving characteristics Number of speeds

mm (in)

8800 (346.5)

Type of drive

-

Hydrodynamic

Type of gearbox

-

Three-stage reversing

Number of driving axles

-

1

Number of driven wheels

-

4

Oscillation angle

°

3

Angle of steering

°

32

Steering Type of steering

-

Two-point suspension

Steering control

-

Hydraulic power steering

Linear hydraulic motors

-

1

ART 240

15

1.3

Specifications ART 240 EU Stage IV / U.S. EPA Tier 4f

Engine Manufacturer Type

-

Deutz

-

TCD3.6 L4

kW (HP)

74.4 (100)

Number of cylinders

-

4

Cylinder capacity

cm (cu in)

3621 (221)

Nominal speed

min (RPM)

2000

Power according to ISO 14396

Maximum torque

3

-1

Nm/rpm

410/1600

l/h (gal US/h)

10 (2.6)

Engines complies with emission regulations

-

EU Stage IV, U.S. EPA Tier 4 Final

Cooling system of engine

-

Liquid

Maximum tyre pressure

MPa (PSI)

0.75 (108.8)

Minimum tyre pressure

MPa (PSI)

0.2 (29)

Pattern of tyres

-

COM HL.

Number of tyres

-

8

Number of front wheels

-

4

Number of rear wheels

-

4

Size of tyres

-

11.00x20´´

Type of tyres

-

Tube Type

Operating

-

drum

Parking

-

Mechanical disc

Emergency

-

Mechanical disc

Type of watering

-

Pressure

Number of pumps

-

1

Fuel

l (gal US)

250 (66)

Water for tyre watering

l (gal US)

390 (103)

Engine (oil filling)

l (gal US)

9.5 (2.5)

Average fuel consumption

Axle

Brakes

Watering

Fluid capacities

Cooling system

l (gal US)

20.5 (5.4)

Gearbox oil

l (gal US)

21.5 (5.7)

Differential oil

l (gal US)

6 (1.6)

Oil in front axle disengaging

l (gal US)

6 (1.6)

End gear oil

l (gal US)

2x5.2 (2x1.37)

Hydraulic system oil

l (gal US)

22 (5.8)

Front wheel hydraulic system oil

l (gal US)

6 (1.6)

Brake fluid

l (gal US)

1.75 (0.5)

DEF Tank

l (gal US)

22 (5.8)

Spraying emulsion

l (gal US)

60 (15.9)

Voltage

V

24

Battery capacity

Ah

2x55

Wiring

16

ART 240

SPECIFICATION MANUAL ART 240 EU Stage IV / U.S. EPA Tier 4f

Noise and vibration emissions Measured sound power level A, LpA at the operator's position (cab) *

dB

79

Uncertainty KpA *

dB

2

Guaranteed sound power level A, LWA **

dB

103

Declared highest weighted effective value of vibration acceleration transmitted to the whole body (cab) ***

m/s2 (ft/s2)

<0.5 (<1.6)

Declared total value of vibration acceleration transmitted to hands (cab) ***

m/s2 (ft/s2)

<2.5 (<8.2)

* measured according the EN 500-4 ** measured according the DIRECTIVE 2000/14/EC *** measured according the EN 1032+A1 on the gravel base under the vibration travel

Optional equipment Cab with ventilation and heating Sun protection foil for windows ROPS protection ROPS canopy (mounted to ROPS) Cab FOPS protection (mounted to ROPS) Air conditioning Preparation for radio (box, 2 loudspeakers, antenna) (only cab versions) Radio Preparation for Telematic Water ballastable frame (welded) Ballast 3,000 kg – „Easy load“ blocks Ballast 6,000 kg – „Easy load“ blocks Ballast (frame filled with iron) for 1 ton – max. 8.6 tons Thermal aprons Edge cutter 4+4 radial tyres (8 pcs) Spare wheel with a diagonal or radial tyre Hinged wheel scrapers Cocoa scrapers instead of standard ones Emulsion sprinkling Ammann Traction Control (inter-axle differential) Air pre-filter Towing equipment, front Reversing light Warning beacon (rotating warning light) Back-up alarm Protective propeller grid Chock blocs First service kit for the first 500 h (engine filters, air filters) Set of filters, 500 h Wheel spanner Toolkit Ammann Special paint schema Certificate of Origin Set of documentation - printed hardcopy ART 240

17

Notes

18

ART 240

SPECIFICATION MANUAL Notes

ART 240

19

20

ART 240

OPERATION MANUAL

2 OPERATION MANUAL ART 240 (Deutz Tier 4 Final)

ART 240

21

22

ART 240

2.1

Main Safety Measures

2.1.1

Safety measures during Machine operation

Safety measures stated in individual sections of Technical Documentation supplied with the Machine shall be added with the safety measures in force in the country the Machine is used at a work site, and this with regard to work organization, working process and the personnel.

2.1.1.1 Compaction Work Commencement Construction work supplier (Machine operator) is liable to give such instructions for driver and maintenance personnel which will include the requirements to secure job safety during Machine operation.

•

OPERATION MANUAL 2.1.1.2 Work in the dangerous area Any damage of engineering technical services must be immediately communicated to their owner, and at the same time the precautions preventing entry of unauthorized persons to the endangered area must be carried out.

The workman must not work alone on such working place where there is not any another workman in view or within calling distance that if necessary would be able to provide help or to call for help in case the efficient form of control or connection is not ensured.

Construction work supplier must check and mark the following: -

Utility lines

-

Underground areas (direction, depth)

-

Toxic material seepage and escape

-

Soil bearing capacity, travel plane slope

-

Other barriers incl. their removal

He/she shall make Machine driver who will carry out the ground work, familiar with such condition.

•

He/she shall set forth the technological procedure part of which is the work process for given labour activity, and such technological procedure will inter alia include: -

Precautions during work under extraordinary conditions (work within protection zones, in extreme slopes, etc.)

-

Precautions for the sake of natural disaster hazard

-

Requirements to carry out work while adhering to work safety principles

-

Technical and organizational measures to provide for safety of employees, workplace and environment

He/she must make Machine driver evidently familiar with the technological procedure!

ART 240

23

2.1

Major Safety Precautions

2.1.1.3 Ensurance of safety measures by the owner •

•

•

•

The owner must ensure that the machine is operated only in such conditions and only for such purposes to which the machine is technically capable according to conditions specified by the manufacturer and relevant standards.

He must ensure that the roller is used only in such manner and on such working places without a danger to damage the close structures, sections, etc.

He must ensure a regular inspection of operation and technical conditions, regular maintenance of the machine in intervals specified in the manuals for greasing and maintenance work. In case the technical condition of the machine does not meet the requirements to such extent it endangers safety of operation, people and property or it causes a damage and impairment to the environment, the machine must be put out of service until the defects are removed.

He must specify who is allowed to carry out operation, maintenance and repairs of the machine as well as what activities can be carried out during the operation, maintenance and repair of the machine.

•

The person (driver) who drives the machine and each person carrying out maintenance and repair of the machine must be acquainted with instructions specified in the operation manual of the machine.

•

He must ensure that ”Operation manual of the machine” and operational book are kept on specified place to be at disposal for the driver all the time.

•

He must assign a workman for permanent supervision over the machine work during its operation on public roads and especially he is obliged to issue instructions to ensure safety of works.

•

He must ensure that dangerous substances (such as fuel, oils, coolant, break fluid, etc. must be removed from places of leakage according to their nature to prevent from their adverse impact to the environment, safety of operation and health of people.

24

2.1.1.4 ROPS The following precautions shall be observed while the protection frame ROPS is used: •

The machine frame must not be damaged (broken, bent, etc.) in the place of connection.

•

The ROPS frame itself must not show the marks from corrosion, damage through cracks or splits.

•

ROPS frame must not be loose during the machine operation.

•

All bolted connections must meet the specifications requirements and must be tightened to the moment specified.

•

Bolts and nuts must not be damaged, distorted and they must not show the marks from corrosion.

•

None additional modifications can be carried out on the ROPS frame without the approval of the manufacturer because they can result in decrease of its strength (e.g. openings, welding, etc.).

•

Weight of the machine with the protective frame must not exceed the permitted weight for which ROPS was approved.

ART 240

OPERATION MANUAL 2.1.2

Requirements for qualification of driver

•

Only a driver trained to ISO 7130 and other local and international regulations and standards designed for drivers of this class, may operate the Roller.

•

Only a person learning to drive under a direct and constant supervision by a professional lector or trainer in order to get a preliminary practice, may drive the Machine with no certificate of competency, with the approval by Machine Operator.

•

Holder of the competency (licence) will be liable to duly keep the licence, and submit it, as requested, to the control authorities.

•

Holder of the competency shall not make any entries, changes or corrections in the licence.

•

Holder shall report immediately his/her licence loss to the one who issued such licence.

•

Person mentally competent and physically fit person, over 18 years old may drive the Roller individually if: a) Authorized by Machine manufacturer, for the assembly work, testing and demonstrate the Machine, or eventually for training the drivers whereas he/she must have been made familiar with the work safety regulations effective in the workplace; or b) Assigned by construction work supplier to operate (carry out maintenance), trained and drilled with conclusive evidence, or eventually owning professional competency to operate and drive under special regulations (machinist certificate, or others).

•

Machine driver shall be trained min. 1x every 2 years and examined in regulations to provide for occupational safety.

ART 240

25

2.1

Major Safety Precautions

2.1.3

Duties of the driver

•

•

Before Machine operation starts the driver shall be liable to get familiar with the instructions given in the documentation supplied together with the Machine, with the safety measures in particular, and observe these thoroughly. This applies also to the personnel in charge of maintenance, adjustments and repairs of the Machine.

Do not drive the Roller unless fully made familiar with all the Machine’s functions, working elements and operation elements, and until knowing exactly how to control the Machine.

•

Follow the safety symbols placed on the Machine and keep these in legible condition.

•

Before work is started, get familiar with the work site environment, i.e. with any barriers, slopes, utility line system, necessary types of workplace protection with respect to the environment (noise, vibrations, etc.).

•

When you find out any hazard to health or life of persons, property hazard, failure, or upon technology equipment accident, or when finding any symptoms of such hazards in course of operation, then the driver, unless able to eliminate such hazard by himself/herself, must stop the work and secure the machine against any undesirable start; please attach “MACHINE REPAIR” warning sign onto steering wheel as depicted in Section called “Safety signs used on the machine“, report this to the person in charge, and if possible, notify all persons exposed to such danger.

•

Observe safety regulations during Machine operation, carry out no activity that would jeopardise work safety, pay full attention to Machine steering.

•

Respect the technological procedure or the instructions by a person accountable.

•

When rolling in the workplace, adapt the rolling speed to the terrain condition, work carried out and weather conditions. Watch continuously the clearance so to avoid any collision with a barrier.

•

Upon completion or stop of the Machine operation during which driver leaves the Machine, adopt measures against any unauthorized use of the Machine and its spontaneous start. Remove key from ignition box, turn ON the parking brake switch, lock the cab, (dashboard cover in the Machine with no cab), engine bonnet, use disconnector to cut off wiring.

•

With the Machine parked on a road or highway, take measures in line with regulations valid for roads and highways.

•

Having finished the operation, park the Machine at a proper place (flat, bearing area) so to avoid Machine stability endangered, Machine interfering with traffic roads, Machine exposed to falling objects (rock), and where exposed to no other disaster of different kind (floods, landslides or others.).

•

When working with the Machine is completed, record in the Operation Logbook any Machine defects, damage or repairs made. During immediate switching of drivers there is the duty to notify directly the switching driver of the facts found.

•

Before starting Machine operation, get familiar with the records and operating deviations found out in course of previous work shift.

•

•

Inspect the Machine and its accessories before work is started, check controllers, communication and safety equipment, whether these are able to work as per the Manual. If having found any defect that might endanger work safety and unable to repair by yourself, do NOT start the Machine, and report such defect to a person in charge.

Driver must use Personal Protective Equipment - work clothing, safety shoes, the clothing shall not be too loose, damaged, hairs protected with proper head piece. During maintenance (lubricating, replacing operating media) make sure hands are protected with appropriate gloves.

•

With the Machine that has no cab, or when driving with 3rd gear, use ear protection.

•

Maintain the Machine fitted with the required equipment accessories and outfit.

•

Keep the Machine free of any oil dirt or flammable materials.

Keep driver’s control stand, climbing irons, walkway (stepon) surfaces clean.

•

In case Machine comes into contact with high voltage, please adhere to the following principles:

•

Fasten your seat belt when working with the Machine. Make sure the seat belt and its mounting are not damaged!

•

If finding any defect during operation, stop the Machine instantly, lock safely against any undesired starting.

•

Follow Machine run during its operation, and record any defects found in the Operation Logbook.

•

Keep Operating Logbook designed to make Machine acceptance and handover records between drivers, records about defects and repairs during operation, evidence of major events during a work shit.

•

Before starting the engine the controllers must be in their zero position, no persons may stay within hazardous reach of the Machine.

•

Use sound or light signal everytime the Machine is put into operation, and this always before starting Machine engine.

•

Before driving, make up air reservoir to 8 bar (116 PSI) pressure in order to brake off the Machine.

•

Before starting Machine operation, check the function of brakes and steering.

•

Following a warning signal the operator may start the Machine only when all the employees left a danger area. Concerning (blind) workplaces unable to overlook properly, put the Machine into operation only after the elapse of the time required to leave danger area.

26

-

Try to move with the Machine away from the hazardous area

-

Do not leave driver’s control stand

-

Give warning signal to others not to come near or touch the Machine.

ART 240

OPERATION MANUAL 2.1.4

Forbidden activities – safety and guarantee

The following is forbidden:

•

To operate the Machine under reduced visibility and at night unless Machine’s working area and the site have sufficient lighting.

•

To change driver’s position at the control stand from the left to the right and vice versa while driving.

•

Leave Machine driver’s position with the Machine running.

•

Filling the hydraulic circuit during the guarantee period in a different way than using the hydraulic unit.

•

Using the machine in case of an evident defect of the machine.

•

To leave unsecured Machine - move away from the Machine without preventing it from being misused.

•

Using the machine when any operating fluid level is low.

•

•

Wilful repair of the engine – Except common changes of operating fluids and filters, only the Deutz service department can intervene in the engine, in particular in peripheral components of the engine – alternator, starter, thermostat, electrical installation of the engine.

To disable safety system, protective system and locking system or change their parameters.

•

To use the Machine with oil, fuel, cooling liquid or other media leaking therefrom.

•

To start the engine in some other way than stated in the Operation Manual

•

Using the emergency brake for turning off the engine during normal operation of the machine.

•

To locate other items (tools, instruments) at driver’s control stand aside from items of personal needs.

•

Operate the machine in potentially explosive atmospheres (ATEX) and underground areas.

•

To lay away any material or other objects onto the Machine

•

To use the Machine following ingestion of alcoholic beverages or narcotic substances.

•

To remove any dirt or waste while the Machine is in operation

•

To use the Machine that would mean a threat to its technical condition, safety (life, health) of persons, sites, facilities and things, or eventually of road traffic and its continuity.

•

To carry out maintenance, cleaning or repairs with the Machine not secured against its self-motion and accidental starting, and unless contact between operator and moving parts of the Machine is excluded.

•

To put into operation and use the Machine if other people are staying within its hazardous reach - except for training a driver by lector.

•

To touch moving parts of the Machine with human body or objects and tools held in hands.

•

Putting the machine into operation and using the machine when a safety device (emergency brake, hydraulic locks, etc.) has been removed or damaged.

•

To smoke and handle open fire when checking or filling in fuels, changing or filling up oils, lubricating Machine, and when inspecting battery and filing up battery

•

To travel and compact in such banks where Machine stability would be impaired (overturn). The mentioned static stability of the Machine lowers by dynamic effects of travel.

•

To carry rags soaked with flammable materials on the Machine (inside engine compartment), and flammable liquids stored in free vessels.

•

To travel and compact in such gradients of slopes where hazard of ground torn off along with the Machine would occur, or loss of adhesion followed by uncontrolled skid.

•

Leave the engine running in enclosed, unventilated areas.

Exhaust fumes are dangerous to life.

•

Drive with open doors.

•

To control the Machine in some other way different from that stated in the Operation Manual.

•

Perform any adjustments on the machine without the prior consent of the manufacturer.

•

To travel and compact according to the soil bearing capacity at such distance from the edge of a slope, excavated trenches so to avoid any hazard of material fall (slide) or shoulder torn off along with the Machine.

•

Drive without the seat belt fastened.

•

Shift electrical conductors.

•

Use other than original spare parts.

•

Interfere in the electrical and electronic units in any manner.

•

To travel and compact at such distance from the walls, cuts, slopes so to avoid any hazard of their sliding and covering the Machine.

•

To displace and transport people on the Machine.

•

To operate the Machine within the hazardous range of which there are other machines or transport vehicles except for those that operate in mutual coordination with the Machine.

•

To operate the Machine in places invisible from driver’s post and where hazard to the persons or property might occur unless work safety is secured another way, i.e. implicitly through signalling by a person duly instructed – refer to the Section named Hand Signals.

•

To operate the Machine within protective zone of electric line system and substations, and of gas.

•

To drive over electric cables unless these are properly protected against any mechanical damage.

ART 240

THE ADDITIONAL WEIGHT consists of 4 pcs and is mounted as option from the bottom of the Machine frame at Manufacturer. It is therefore considered to be the integral part of the Machine. Any handling of this weight is hazardous and is banned.

Please do not hesitate to contact your dealer, if required!

Breaching these provisions can influence the judgement of a possible complaint and effectiveness of the engine guarantee period.

27

2.1

Major Safety Precautions

A

B

7

13

C

12 18

25

12

24

20

25

11 22

18

15

16

15

23

C 9 26

27 12 25

12

25 18

16

28 15

15 10

10

3

A

8 14 6

4

21

17

5

1

B 2

19 435032C

28

ART 240

OPERATION MANUAL 2.1.5 1.

Safety notices and symbols used on the machine

Scalding hazard

There is a risk of scalding. Do not open the lid until the liquid cools down below 50 °C (122 °F).

2939

3227bz

2.

Accident hazard

There is a risk of an accident. Do not touch rotating parts while the machine is in operation. There is a risk of burns.

Do not touch hot parts of the machine unless you make sure that they have cooled down sufficiently.

3322bz

3.

Coolant is hazardous for health.

Read the Operation Manual!

Coolant 2152

4.

Switch off the engine

Before starting any maintenance or repair of the machine, switch off the engine and remove the key out of the ignition box.

2939

2584bz

5.

Washing the machine with water

Hazardous situation. Prevent water from entering electric and electronic parts of the machine as it may result in damage of the equipment and personal injury. Read the Operation Manual!

2225bz

2939

6.

Read the Operation Manual

Use the Operation Manual to get familiar with operation and maintenance of the machine!

2702bz

ART 240

29

2.1 7.

Major Safety Precautions Operation Manual

Box for inserting the Operation Manual of the machine.

2428bz

8.

Welding on machine

Prior to any welding operations, disconnect the battery, alternator, control units and other electronic components of the machine. Read the Operation Manual!

2668bz

9.

There is a risk of explosion during handling of the batter.

Read Operation Manual!

Explosion hazard

3017bz

Safety belt

Lock the safety belt before starting the machine.

2939

10.

2687bz

11.

24 t

Lifting diagram

(52910 lb)

L min

ROPS

ROPS

Lmin= 4m Lmin= 8m Lmin= 4m + Lmin= 13ft Lmin= 26ft l = 1,95m

2x 12 000 kg (2x 26455 lb)

Lmin= 13ft + l = 6,4ft

ROZPĚRA l = 1,95 m THE BRACE l = 6,4 ft DIE SPREIZE l = 1,95 m VOLEA l = 1,95 m

L min

To lift the machine, use binding means of sufficient loading capacity, refer to the chapter Machine loading. Before lifting, lock the articulation of the machine.

2x 12 000 kg (2x 26455 lb)

CADENAS PARA AGARRE EN LA PLATAFORMA PARA TRANSPORTE

3715

3715bz

12.

Lifting point

Only use these points for hanging the machine.

2153bz

3045

13.

Guaranteed sound power level

L WA

103dB

3045bz

14.

Dangerous noise level! Use hearing protection.

Hearing protection

2408bz

30

ART 240

OPERATION MANUAL 15.

Tie-down attachment point

Tie-down the machine during transport at these points only.

3048bz

16.

Danger zone

There is a risk of an accident. Keep a safe distance from the edge cutter and compactor in operation.

2939

3352bz

3407

17.

Machine braking

Engage a gear before going downhill! Read the Operation Manual!

3407bz

18.

Danger zone

Keep safe distance from the machine.

2939

2942bz

19.

Engine start

Switch the parking brake on before starting the engine.

P

0

3236bz

20.

3983

Battery switch

Switch the battery off no sooner than 120 seconds after switching off the engine. Keeping of the time limit is necessary for saving the data in the engine control unit.

1.

2.

2 min

3.

0

3983bz

21.

Inflating of tyres

0 I 3397

3397

ART 240

31

2.1 22.

Major Safety Precautions Maximum Machine Height 3,13 m/10,27 ft

Pay attention when passing through places with vertical limitations.

3757bz

23.

3881

Battery switch

Switch the battery off no sooner than 120 seconds after switching off the engine. Keeping of the time limit is necessary for saving the data in the engine control unit.

120 sec

0

3881bz

24.

Additional loading by water

3404

3239

25.

Tyre pressure 200-750 kPa 29-109 PSI 3239

3686

26.

Refuelling

D

< 15 ppm S < 15 mg/kg S

3686

27.

Hydraulic oil level

2158bz

28.

Draining operating liquids

3634

3634

29.

Machine service and maintenance

Do not start the machine. Post this tag on the machine before starting a repair or maintenance activity. Read the Operation Manual!

2775

2775bz

32

ART 240

OPERATION MANUAL 2.1.6

Manual signals

•

Signals given by an assistant operator if the operator cannot see the travelling or working area or machine work devices.

•

The following principles must be followed: -

Only a limited number of signals must be used for communication purposes.

-

The signals must clearly distinguishable to prevent any misunderstanding.

-

Manual signals can only be used in cases when the environment conditions enable clear communication between persons.

-

Manual signals must be as similar as possible to intuitive gestures.

-

Single-hand signals can be given by either hand.

EXAMPLES OF COMMUNICATION SIGNALS: Engine start

Sig. 10 Engine shut-down

Sig. 11 Stop

STOP Sig. 1 ART 240

33

2.1

Major Safety Precautions

Watch out

!

Sig. 2

!

Sig. 3

Watch out, danger

Drive

Sig. 4 Slow driving forward - towards me

Sig. 5 34

ART 240

OPERATION MANUAL Slow driving backward - away from me

Sig. 6 Driving to the right

Sig. 7 Driving to the left

Sig. 8 Short-distance drive

Sig. 9 ART 240

35

2.2

Ecological and hygienic principles 2.2.2 •

When operating and storing the Machine the User shall be liable to adhere to the general principles of health and environment protection, as well as the laws, regulations, and rules related to this issue, and effective within the territory where the Machine will be used.

2.2.1 •

Observe the following in particular: -

Eye and skin protection when handling the batteries,

-

Skin protection when handling oil products, coating compositions and cooling liquids,

-

Wash your hands thoroughly upon work completion and before meal, treat your hands with proper tissue cream,

-

When handling the cooling systems, please observe instructions given in the Operation Manual supplied with the Machine.

•

Always store oil products, cooling system media, battery media and coating compositions incl. organic thinners, and the cleaning and preservation agents as well, in their original properly marked packages. Admit no storage of these materials in unidentified bottles or other vessels with regard to the risk of being interchanged. Especially hazardous is the potential of interchanging for eatables or drinks.

•

If skin, mucosa or eyes are stained accidentally, or vapours inhaled, promptly apply the first air principles. Get prompt medical attention upon accidental ingestion of these products.

36

When discarded, the media for Machine’s individual systems and some of the Machine’s parts will become waste of hazardous properties against the environment.

This waste product category includes the following in particular:

Hygienic principles

Oil products, cooling system media, battery media, and coating compositions incl. thinners are deleterious materials. Persons that come into contact with these products during Machine operation and maintenance shall be liable to follow general principles of own health protection and conform to the safety and hygienic directions from manufacturers of these products.

Ecological principles

•

-

Organic and synthetic lubrication materials, oil and fuels,

-

Cooling liquids,

-

Battery media and the batteries themselves,

-

Tyre media,

-

Cleaning and preservation agents,

-

All filters and filter elements removed,

-

All used and discarded hydraulic and fuel hoses, metal rubbers or other Machine’s elements contaminated by the abovementioned products.

Manufacturer and Manufacturer-accredited contracting service organizations or dealers take back these used materials or parts without cost: -

oils,

-

batteries,

-

tyres.

The mentioned materials and parts, when discarded, shall be handled in line with relevant national regulations to protect individual components of environment, and in conformity with the health protection regulations.

ART 240

2.3

Machine preservation and storage

2.3.1

Short-term preservation and storage for a period of 1 – 2 months

OPERATION MANUAL

2.3.2

Preservation and storage for a period over 2 months

Wash and clean thoroughly the entire Machine. Before shutting down the Machine for preservation and storage, please heat the engine to its operating temperature while running. Park the Machine on paved, flat surface, in safe location with no danger of of damage to the Machine due to natural disasters (floods, landslides, fire origination, etc.).

For machine shut-down, the same principles are applicable as for the short-term preservation.

•

support the machine or mark one of its tyres at the point of its contact with the ground and move the machine so that the marked spot is not in the lowest point; move the machine once a month.

In addition:

•

inflate the tyres to specified pressure and protect them against sun rays; regularly check tyre pressure once a month,

•

remove the accumulators, check their condition and charge them to full and store them in a cold dry room, and recharge them once a month,

•

use a special agent to protect rubber components,

•

apply preservative agent on chromed surfaces of piston rods,

•

preserve the machine by spraying with a special agent, especially at points of possible corrosion (bonnet hinges, fuel tank lid, hose fittings, door locks, switches, etc.),

•

blind the suction and exhaust pipe of the engine with double PE foil and tighten it carefully with sealing tape,

•

protect the headlamps, external rear-view mirrors and other elements of the external wiring by a special agent and wrapping in PE foil,

•

preserve the engine according to the manufacturer‘s manual – place a visible tag that preservation of the engine is in progress,

•

if you are not using a winter fuel, add additives into diesel oil.

•

Repair spots where paint has been impaired,

•

Lubricate all lubricating points, actuator cables (cable assemblies), joints of the actuators, etc.,

•

Check water media have been drained,

•

Confirm cooling liquid has the antifreezing properties required,

•

Check condition of the battery charges; let them be recharged if required,

•

Spread chromated surfaces of piston rods with preservation fat,

•

We recommend to protect your Machine against corrosion through spraying the preservation agent (spray-applied), and this especially in places of corrosion hazard.

The Machine treated like that needs no special preparation (setup) before its subsequent putting into operation.

Fill the fuel tank with fuel to maximum even in the case of a short-time shut-down of the machine (several days) as protection against corrosion on the walls of the fuel tank.

In addition it is recommended to:

Following 6 months we recommend to inspect the condition of preservation and renew it if required.

If storing the Machine under field conditions, please check the parking place is not exposed to any flooding hazard due to deluges, or whether any other type of risk occurs within such area!

NEVER start the engine in course of storage!

Before restoration of the Machine service, please dewax and wash the preservation agents away with high pressure stream of hot water added with normal degreasers while observing Directions for Use along with ecological principles.

Carry out dewaxing and washing of the Machine at places equipped with collection sumps to catch rinsing water and dewaxing agents.

ART 240

37

2.3

Machine preservation and storage

2.3.3

Dewaxing and inspection of a supplied machine

•

Check the Machine according to the shipping documents.

•

Check no parts of the Machine have been damaged during transportation, and that no parts are missing. Inform shipper about any deficiencies.

Before restoration of the Machine service, please dewax and wash the preservation agents away with high pressure stream of hot water added with normal degreasers while observing Directions for Use along with ecological principles.

Carry out dewaxing and washing of the Machine at places equipped with collection sumps to catch rinsing water and dewaxing agents.

38

ART 240

2.4

Machine disposal following its life cycle end

OPERATION MANUAL

Upon Machine disposal following its life cycle end the User shall be liable to follow the national regulations, waste acts and environmental policy acts. We therefore recommend to always contact: •

Specialized companies with relevant authorization to deal with these operations,

•

Machine Manufacturer or Manufacturer-appointed accredited contracting service organization.

Manufacturer bears no responsibility for any damage caused to Users’ health or for any damage to environment due to non-adherence to the aforementioned warning.

ART 240

39

2.5

Machine Description

23 18

14

24

1

19

15

12

17

8 16

5

11

3 20 10

13

4

2

20

7 6

22 21

40

26

25

22 9

21

435004

ART 240

OPERATION MANUAL Tyre roller ART 240 - individual parts of the machine 1. Machine frame 2. Engine 3. Combined cooler for air, hydraulic oil and engine coolant 4. Transmission with hydraulic torque converter 5. Axle drive with differential 6. Reduction gear box 7. Cardan shaft 8. Parking and emergency brake 9. Service brakes (rear wheels only) 10. Front axle with telescopic cylinders 11. Steering pump 12. Air filter 13. Battery 14. Catalyst 15. Catalyst 16. Additional water tank lid* 17. Fuel tank 18. Driver´s post 19. Sprinkling tank 20. Tyre sprinkling 21. Wheels 22. Scrapers 23. Protective frame ROPS 24. DEF tank (AdBlue) 25. Additional weights 26. Discharging additional water ballast*

* - If the water-proof frame for additional weight with water fill is used on the machine, refer to the Specification Manual - Weights.

ART 240

41

2.6

Controls and checking instruments

30

31

34

bar

°C 25

0

50

150

35

32 4

bar

6

2

6

2

14 15 16 17 18 19 20 28

10

0

36

4 8

8 0

bar

10

33 36

DIAC

22 23 24 25 26 21 27

1

2

4

3

5

F8

F7

F6

F5

F4

F3

F2

11

6

F18

F17

F16

F15

F14

F13

F12

F11

F1

29

37 37

10 9 7

8

38

12 13

39

42

40 41

43

44

45

435008

42

ART 240

OPERATION MANUAL Dashboard controls 1. Headlamps switch 2. Rear lights switch 3. Warning lights switch 4. Warning beacon switch (optional) 5. Parking brake switch 6. Differential lock switch (optional) 7. Emulsion sprinkling button (optional) 8. Not assigned 9. Turn indicators switch 10. Emergency brake button 11. Sprinkling cycler 12. Regeneration switch 13. Scraper switch (optional) 14. Neutral indicator lamp 15. Indicator lamp of brake fault 16. Indicator lamp of hydraulic oil overheating 17. Engine pre-heating indicator lamp 18. Indicator lamp for turn signal lights 19. Engine error indicator lamp 20. DEF level indicator lamp (AdBlue) 21. Engine lubrication indication lamp 22. Battery charging indication lamp 23. Parking brake indicator lamp 24. Indicator lamp of hydraulic oil filter clogging 25. Coolant level indicator lamp 26. Tyre sprinkling indicator lamp 27. Regeneration indication lamp 28. Indication lamp of water level in fuel filter 29. Not assigned 30. Power View Display 31. Gearbox oil pressure gauge 32. Brake circuit pressure gauge 33. Acoustic module 34. Gearbox oil thermometer 35. Tyre pressure gauge 36. Active workplace indication 37. Fuses 38. Acoustic signalization of brake fault 39. Tyre inflation 40. Tyre deflation 41. Diagnostic socket 42. Connector CAN-BUS 43. Ignition box 44. Service lamp socket 45. Bonnet lock release

ART 240

43

2.6

Controls and checking instruments

46

3

2

ON

1 OFF

OFF

47

48

47

47

49

52

bar 0

4

bar

50

150

4 8

0

54

°C 25

6

2

50 51

6

2

10

8 0

bar

10

54 F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

1 2 3

53

53 55 56

56 55

57 47

47

435065

44

ART 240

OPERATION MANUAL Controls in the cab ceiling 46. Air conditioning (optional) 47. Blowers 48. Car radio 49. Front screen wiper switch 50. Rear screen wiper switch 51. Screen washer switch 52. Rear-view mirror 53. Steering wheel 54. Drive control 55. Accelerator pedal 56. Brake pedal 57. Heating

ART 240

45

2.6

Controls and checking instruments

bar

4

bar

°C 25

0

50

150

6

2

4 8

0

6

2

10

8 0

bar

10

1

2

3

4

5

F1

F2

F3

F4

F5

F6

F7

F8

F11

F12

F13

F14

F15

F16

F17

F18

DIAC

11

6 10 9

7

12 13

435008A

46

ART 240

OPERATION MANUAL Headlamps switch (1)

Emergency brake button (10)

596303

2582

Rear lights switch (2)

Press the button to stop and brake the machine and to turn off the engine.

591668

Warning lights switch (3) 596191

Use when you cannot stop the machine by changing the control to the neutral position, using the brake pedal or you cannot use the parking brake.

Warning beacon switch (4) – optional 592348 0

I II

Parking brake switch (5)

III

Sprinkler cycling (11)

IV

2659

2703

Turn the switch to the left to put the pump into permanent operation - the tyres are sprinkled constantly.

Turn the switch to any of the four positions to the right to switch on a sprinkling cycle interval.

The operator must always enable the parking brake at machine shut-down!

Position I sprinkling 10 s delay 10 s Position II sprinkling 10 s delay 15 s Position III sprinkling 10 s delay 22 s Position IV sprinkling 10 s delay 33 s

Differential lock switch (6) – optional

The sprinkling indicator lamp (26) is lit only when the pump is running.

596116A

Regeneration button (12) Emulsion sprinkling button (7) - optional

AMN118

It serves for activation of SCR catalyst regeneration.

3499

Switch of direction indicators (9) 595200

Scraper switch (13) - optional 2701

ART 240

47

2.6

Controls and checking instruments

bar

4

bar

50

150

6

2

4 8

0

°C 25

0

10

6

2

14 15 16 17 18 19 20

8 0

bar

10

DIAC

F1

F2

F3

F4

F5

F6

F7

F8

F12

F13

F14

F15

F16

F17

F18

21

F11

22

435008B

48

ART 240

OPERATION MANUAL Neutral indicator lamp (14) 596653

DEF level indicator lamp (AdBlue) (20) AMN128

It indicates the neutral “N” position of both controls.

The indicator lamp indicates low level of DEF (AdBlue). Add DEF (AdBlue).

The indicator lamp indicates quality of DEF (AdBlue).

Before starting the machine, check that both controls are in the neutral position.

Danger in DEF (AdBlue) handling.

Proceed according to the chapter 3.6.13.

Indicator lamp of brake fault (15) 595148

It indicates a drop of air pressure in the circuit below 5.2 bar simultaneously with acoustic signal.

After starting the engine, the indicator lamp is lit until the sufficient pressure in the brake circuit is reached.

Use only DEF according to the specification in Chap.

3.2.7.

Fill DEF (AdBlue) according to Chapter 3.6.13.

When this indicator lamp goes on during driving, shut down the machine. The fault must be removed before the machine can be used again.

Indicator lamp of hydraulic oil overheating (16) 2635

Engine lubrication indication lamp (21) AMN113

It indicates the max. permitted temperature (reduce power, let cool down).

Battery charging indication lamp (22) 2587

Engine heating pilot lamp (17) 589502

The indication lamp goes on after the key in the switch box is switched into the position “I” and goes out after the engine starts.

It signals glowing before engine start at low ambient temperature.

Pilot lamp of headlamps (18) 2489

DIAC

Engine error indicator lamp (19)

3688

If the indicator lamp is flashing, remove the failure displayed on the Power View display or contact your dealer or the authorised service centre Ammann.

ART 240

49

2.6

Controls and checking instruments

bar 0

4

bar

°C 25

50

6

2

4 8

0

150

28

10

6

2

8 0

bar

10

DIAC

F1

F2

F3

F4

F5

F6

F7

F8

F12

F13

F14

F15

F16

F17

F18

27

F11

23 24 25 26

435008F

50

ART 240

OPERATION MANUAL Parking brake indicator lamp (23) 2703

Indication lamp of water level in fuel filter (28) 3540

It indicates that the machine is braked.

The lit indicator lamp indicates water in the fuel filter.

Indicator lamp for hydraulic oil filter fouled (24)

If this indicator is lit, clean the fuel filter!

2276

It signals filter element is clogged.

Immediately replace the cartridge!

Coolant level indicator lamp (25) 3591

When this indicator lamp goes on, add engine coolant immediately. Check that coolant is not leaking fro them cooling system.

Tyre sprinkling indicator lamp (26) 3548

The indicator lamp is lit when the interval sprinkling control is on.

Regeneration indication lamp (27) AMN118

ART 240

51

2.6

Controls and checking instruments

30

31

34

bar 0

°C 25

50

150

35

32 4

bar

6

2 0

36

4 8

6

2

10

8 0

bar

10

33 36

F1

F2

F3

F4

F5

F6

F7

F8

F11

F12

F13

F14

F15

F16

F17

F18

DIAC

435008C

52

ART 240

OPERATION MANUAL Power View Display (30) The multifunctional device displays engine functions and fuel level.

Tyre pressure gauge (35) 2658

The minimum air pressure after deflating of tyres is set to 1.5 - 2 bar.

Gearbox oil pressure gauge (31) sta06

Operating pressure of oil must be between 12.5-15.5 bar.

Active workplace indication (36) It indicates which place (seat) is used for controlling of machine drive.

When pressure drops below 12.5 bar, stop the machine.

If none of the indicator lamps (36) is flashing after the ignition key is switched on in the ignition box, it is possible to start the engine. If the indicator lamps (36) are flashing after the ignition key is switched on in the ignition box, the engine cannot be started because one or both drive controls are not in the N position - the neutral indicator lamp is not lit.

Brake circuit pressure gauge (32) 2657

The white indicator indicates air pressure in the air reservoir - set to max. 8 bar.

The red indicator indicates air pressure during braking - air pressure from the brake cylinder to the brake power assist unit.

Acoustic module (33) It provides acoustic signalization of motor faults.

Gearbox oil thermometer (34) 2185

Operating temperature can be from 80 - 120 °C. The maximum temperature is 120 °C.

ART 240

53

2.6

Controls and checking instruments

bar 0

4

bar

°C 25

50

150

6

2

4 8

0

6

2

10

8 0

bar

10

F7

F6

F5

F4

F3

F2

F8 F18

F17

F16

F15

F14

F13

F12

F11

F1

DIAC

37 37

435008D

54

ART 240

OPERATION MANUAL Fuses (37) Fuse box: Fuse (F1) – 15 A:

mounting socket

Fuse (F2) – 15 A:

rear headlamps

Fuse (F3) – 15 A:

beacon, cabin lights, brake lights

Fuse (F4) – 15 A:

turn indicators

F1

F2

F3 F4

F5

F6 F7

F8

Fuse (F5) – 5 A: Fuse (F6) – 15 A:

front parking lights, instrument lighting, rear lights

Fuse (F7) – 7.5 A:

front headlamps, aftertreatment

Fuse (F8) – 15 A:

aftertreatment

Fuse (F11) – 7.5 A:

horn, drive direction change-over electronics, drive and steering valves, reverse horn, reversing headlamp

Fuse (F12) – 7.5 A:

emergency brake, differential lock, brake

Fuse (F13) – 7.5 A:

gearbox thermometer and manometer, indicator lamps of charging, brake and parking brake failures, of hydraulic filter clogging, hydraulic oil overheating

Fuse (F14) – 1 A:

Power View, engine diagnostics

Fuse (F15) – 15 A:

wipers, screen washers

Fuse (F16) – 7.5 A:

sprinkling, emulsion sprinkling

Fuse (F17) – 20 A:

fans

Fuse (F18) – 15 A:

air drier, scraper

F11 F12 F13 F14 F15 F16 F17 F18

F1

435061

F2

F3

F4

F5

F6

F7

F8

F11 F12

F13

F14

F15

F16

F17

F18

435096 Battery switch fuses: Fuse (F20) – 70 A:

engine pre-heating

Fuse (F21) – 60 A:

main fuse

Fuse (F22) – 15 A:

ECM

Fuse (F23) – 10 A:

fuel pump

Fuse (F24) – 15 A:

air-conditioning

Fuse (F25) – 25 A:

aftertreatment

Fuse (F26):

reserve

Fuse (F27) – 10 A:

car radio

Fuse (F28) – 15 A:

voltage converter 24 V / 12 V

Fuse (F29) – 10 A:

socket 12 V

F26 F27

F22 F23

F21 F24 F25 F28

F20

F29

435036

F22 F23 F24 F25 F26 F27 F21

F28 F29

F20

435097 ART 240

55

2.6

Controls and checking instruments

bar

4

bar

°C 25

0

50

150

6

2

4 8

0

6

2

10

8 0

bar

10

38

39

42

40 41

43

F5

F6

F15

F16

F8

F4 F14

F7

F3 F13

F18

F2 F12

F17

F1 F11

DIAC

44

45

435008E

56

ART 240

OPERATION MANUAL Acoustic signalization of brake fault (38)

Tyre inflation (39) and deflation (40) It serves for inflating or deflating tyres. Pressure levels, refer to tables in Chap. Checking pressure in tyres.

Do not switch both valves into the position ”I” at once!

39

42

40

38

41

43

435033

Diagnostics socket (41) It serves for connecting to engine control unit and for diagnostics of faults or setting of parameters.

Connector CAN-BUS (42) It serves for data bus connection.

Ignition box (43) In the position “0”, the machine lighting and service lamp socket is powered. In the position ”I”, all other appliances are powered.

The spring-loaded position ”II” serves for engine start. The key can be removed in position ”0” only.

Note: The key is identical with the key for the cabin door lock.

Service lamp socket (44) It is used for connecting a service lamp.

Bonnet lock release (45)

44 45 435034 ART 240

57

2.6

Controls and checking instruments

46

2

3

ON

1 OFF

48

OFF

47 47

47

bar 0

4

bar

50

150

4 8

0

50 51

°C 25

6

2

49

6

2

10

8 0

bar

10

F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

1 2 3

F13

DIAC

1 2 3

435065A

58

ART 240

OPERATION MANUAL Air-conditioning (46) - (optional) Air-conditioning switch (A) OFF - Switched off

B

A

ON - Switched on Fan speed switch - air flow control (B) OFF - Switched off 1 - Minimum 2 - Medium 3 - Maximum

431011A Control the air-conditioning switches from the right seat only.

It is advisable to put the air-conditioning system into operation once every 3 weeks.

Blowers (47)

Front screen wiper switch (49) 2260

435037 Rear screen wiper switch (50) 596307

Screen washer switch (51) 596625

Control the screen wiper and washer switches from the right seat only.

ART 240

59

2.6

Controls and checking instruments

2

3

ON

1 OFF

bar 0

4

bar

50

150

4 8

0

54

°C 25

6

2

OFF

6

2

10

8 0

bar

10

54 F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

1 2 3

56

55 56

55

57

435065I

60

ART 240

OPERATION MANUAL Drive control (54) It serves for driving direction setting and for changing gears using the turning handle.

54

position “F” - forward position “N” - neutral position “R” - rearward The control incorporates the horn button and a fuse.

The position of the safety “N” - control locking.

N

D

435066

Accelerator pedal (55) When the engine is started, always only the left accelerator pedal is active. When the right seat is activated using the drive lever, the right pedal is activated automatically. Then, whichever seat is activated using the drive lever, always only the corresponding accelerator pedal is active.

56 55

Brake pedal (56)

435035 Heating (57) Internal air circulation – outside air intake (A) Air temperature control (B)

A

B

C

Blown air intensity (C)

It is forbidden to manipulate with the fan and heating controls during driving.

431016

ART 240

61

2.6

Controls and checking instruments

Driver’ seat 1

Backrest position

2

Longitudinal shift

3

Suspension setting - refer to driver weight indicator

4

Seat height - by grasping the seat and gradual lifting, you can adjust the seat height to a higher position and lock it there. After lifted into the MAX position, the seat drops back to the lowest position.

1

2

MAX 2 1 0

Adjust the seat and fasten your seat belt before driving!

3

4 374006

Document box 2428

The document box is located on the rear wall.

431019 Lockers are under the left and right seat.

374028

62

ART 240

OPERATION MANUAL Air reservoir valve control - for discharging air (condensate) from the air reservoir.

374N026 Fire extinguisher - optional Place to install a holder for fire extinguisher.

The manufacturer recommends that the machine is equipped with a fire extinguisher.

374018 Screen washer reservoir Refill with clear soft water - distilled water best - with cleaning and degreasing agent.

Fill the reservoir with antifreeze mixture or drain it before the winter season starts!

374N159

ART 240

63

2.6

Controls and checking instruments 3881

Battery switch 120 sec

0

3881bz

Switch off the battery disconnector no sooner than 120 seconds after removing the key from the ignition switch.

The time limit must be observed to pump DEF (AdBlue) back into the tank and store the EMR engine data.

By failing to adhere to this time limit you take the risk of damaging the machine, for which the manufacturer bears no responsibility.

64

435038

ART 240

OPERATION MANUAL 2.6.1

Power View control

2

3

1. Display 2. Red LED lights – ENGINE SHUTOFF – engine substantial defect alarm

1

3. Yellow LED lights - WARNING – engine failure alarm, or minimal fuel level in tank alarm 4. Menu selection pushbutton – to enter or exit menu 5. Pushbutton – to move cursor UP – illuminates data on display or moves parameter option to the left or up 6. Pushbutton – to move cursor DOWN – illuminates data on display or moves parameter option to the right or down 7. ENTER pushbutton – selects menu or parameter, or conceals/displays active error code

4

7 5

6

396011B

The red LED is lighting – reduce the engine power, park the machine immediately at a safe place and turn off the engine! Contact your dealer. Do not operate the machine until the failure is removed!

The yellow LED is lighting – warning – engine failure alarm, or minimal fuel level in the tank alarm. Reduce the engine power, park the machine immediately at a safe place and turn off the engine! Remove the failure or contact your dealer. Do not operate the machine until the failure is removed!

If a failure code is displayed, contact your dealer.

ART 240

65

2.6

Controls and checking instruments

NAVIGATION ESSENTIALS When the engine is turned on, the four-parameter screen is displayed (Engine speed, Coolant temperature, Fuel level, DEF level). Press the left or right arrow to display four additional parameters.

0 RPM ENG RPM

28°C COOL TEMP

20% FUEL LEVEL

65% DEF LVL

435098 (Engine oil pressure, Engine load, Electric system voltage, Engine hours counter) Press MENU to display the main menu.

2.92 BAR OIL PRES

37 % LOAD@RPM

28.6 VDC BAT VOLT

10.5 H ENG HRS

435099 GO TO 1-UP DISPLAY - single-parameter display In the main menu, use the cursor (1) to move on an item and press ENTER (2) to enter a submenu.

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

431121 Using the cursor (1), 9 set parameters are displayed one after another (Engine speed, Coolant temperature, Engine oil pressure, Engine load in % at actual engine speed, Electric system voltage, Number of engine hours, Actual consumption, Fuel level, Accelerator position, DEF level).

0

1100

2200

2000 RPM

Press MENU (2) to return to the main menu.

ENG RPM

Note:

COOL TEMP

If the engine is at rest, the battery voltage is indicated. If the engine is running, then roller’s el. system voltage is indicated.

2 66

1

396117 ART 240

OPERATION MANUAL LANGUAGES – menu to select a language Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

2 Use the cursor and select a language, then confirm your selection using the button ENTER (1) and return to the main menu by pressing the button MENU (2).

1

431122

*

ENGLISH FRANÇAIS DEUTSCH ITALIANO ESPAÑOL

2

1

431124

STORED CODES – saved defects, which are not enabled.

Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

Note: The following message will appear on the display: “Requesting fault codes“. Wait until it disappears.

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

1 If the word MORE appears, use the cursor to move to other saved positions. By pressing the button ENTER, return to the main menu.

2

431125

1 of x

FUEL DELIVERY PRESSURE VERY LOW MORE

HIDE

431126 ART 240

67

2.6

Controls and checking instruments

ENGINE CONFIGURATION – menu to browse engine parameters

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

431138 Using the cursor you can move among the parameters.

ENGINE SPEED PT 1

850 RPM < NEXT >

431136 SELECT UNITS – selection of units of measure Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

1

2

431128

Use the cursor to set (1) ENGLISH and the indicated variables appear in PSI units (pressure), °F (temperature).

ENGLISH METRIC Kpa METRIC BAR

After you set METRIC KPA, the displayed variables are in kPA, °C units.

After you set METRIC BAR, the displayed variables are in bar, °C units.

Using the button ENTER (2) confirm the variables and using the button MENU (3) return to the main menu.

3 68

1

2

431129 ART 240

OPERATION MANUAL ADJUST BACKLIGHT – adjustment of the display backlight intensity Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

1

2

431130

Set the backlight intensity using the cursor. By pressing the button MENU, return to the main menu.

ADJUST BACKLIGHT

396028 ADJUST CONTRAST – adjustment of the display contrast Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

1 Set the display contrast using the cursor. By pressing the button MENU, return to the main menu.

2

431131

ADJUST CONTRAST

396032 ART 240

69

2.6

Controls and checking instruments

SOFTWARE VERSION – informs about the software version

ADJUST CONTRAST SOFTWARE VERSION OEM

1

2

431132

OEM – service access

ADJUST CONTRAST SOFTWARE VERSION OEM

431133

ENGINE FAULT SIGNALLING ALARM SIGNALLING The alarm signal indicated with the lighting yellow LED informs about an engine malfunction – warning.

Engine failure alarm, or min fuel level in tank alarm.

Reduce the engine power, park the machine immediately at a safe place and turn off the engine! Remove the failure or contact your dealer. Do not operate the machine until the failure is removed!

A registered failure is indicated on the display through an error code and a description of the failure.

396034

1 of x

WARNING

When more errors are registered, please use the cursor to display the registered failures step by step.

SPN110FMI10 HIGH COOLANT TEMP MORE

HIDE

396036 70

ART 240

OPERATION MANUAL Press ENTER to confirm and hide the display.

1 of 1

WARNING

SPN110FMI10 HIGH COOLANT TEMP HIDE

MORE

396037 Return to the 1-parameter screen with the warning icon for the active failure in the RH corner.

0

1100

2200

2000 RPM ENG RPM

COOL TEMP

396038 Return to the 4-parameter screen with the warning icon for the active failure in the RH corner.

If a failure description and a code appear on the display of the instrument board, contact your dealer if it is impossible to remove the failure.

0 RPM ENG RPM

28°C COOL TEMP

20% FUEL LEVEL

100 ENG HRS

431134

ART 240

71

2.6

Controls and checking instruments

ENGINE CUT OFF ALARM The alarm signal indicated by the red lighting LED informs about a serious failure of the engine – Turn off the engine.

Reduce the engine power, park the machine immediately at a safe place and turn off the engine! Contact your dealer. Do not operate the machine until the failure is removed!

396040 A registered serious failure of the engine is indicated by an error code and a description of the failure on the display with the warning message “SHUT DOWN“. Confirm and hide the display using the button ENTER.

1 of x

SHUTDOWN

SPN110FMI10 HIGH COOLANT TEMP MORE

HIDE

396042 1-parameter display with the warning icon “SHUT DOWN“ in the upper right corner.

0

1100

2200

2000 RPM ENG RPM ENG RPM

COOL TEMP

396043 4-parameter display with the warning icon “SHUT DOWN“ in the upper right corner.

Note Press ENTER to display again the hidden error code for failure.

Press ENTER once again to display either 1 parameter or 4 parameters. The warning icon is displayed until the failure is removed.

0 RPM ENG RPM

28°C COOL TEMP

20% FUEL LEVEL

100 ENG HRS

431135 72

ART 240

OPERATION MANUAL ERROR MESSAGES Error message

Signature

“WAIT TO START PREHEATING” is displayed

The EMR is broadcasting a ‚Wait To Start‘message. Engine manufacturers typically recommend against starting the engine while the EMR is broadcasting this message. Once the EMR stops broadcasting this message,this screen will no longer be displayed on the Power View.

“CANBUS FAILURE” is displayed

The Power View has not received any valid J1939 CAN messages for at least 30 seconds.

“TIMEOUT EMR NOT RESPONDING” is displayed

The Power View sent a request to the EMR for Stored Fault Code (DM2) information, and the EMR did not respond to the request. This message on the PowerView indicates the EMR may not support Stored Fault Code (DM2) functionality over J1939.

“NO STORED CODES” is displayed

The Power View sent a request to the EMR for Stored Fault Code (DM2) information, and the EMR responded. There are zero stored codes.

“NO GAGE DATA” is displayed

The Power View has no record of gages connected to the RS485 bus.

“NO DATA” is displayed in place of a parameter value

The Power View has not received data for the selected parameter for at least 5 seconds.

“NOT SUPPORTED” is displayed in place of a parameter value

The EMR is sending a message that it does not support this parameter.

“DATA ERROR” is displayed in place of a parameter value

The EMR is sending a message that there is a data error with this parameter.

Or (PV101 only) FUEL LEVEL has been selected for display, ANALOG INPUT has been set to FUEL LEVEL, but no Murphy Fuel Sender has been connected to the analog input.

One of the 4-UP quadrants is empty

No parameter has been selected for display in this quadrant.

Display is not readable, either very dim or very dark

The LCD contrast may have been over or under adjusted. Press and hold the MENU key for approximately 5 seconds. This will reset the LCD contrast setting to factory default.

ART 240

73

2.7

Machine operation and use

2

3

ON

1 OFF

OFF

30 bar 0

4

bar

°C 25

50

150

6

2

4 8

0

6

2

10

8 0

54

bar

10

54 F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

1 2 3

5

10

43

435065B

74

ART 240

OPERATION MANUAL 2.7.1

Engine start

Before starting the engine, daily check the level of oil in the engine and hydraulic tank, coolant in the cooling circuit, fuel in the fuel tank, oil in the transmission and the level of brake fluid. Check that there are no loosened, worn or missing parts on the machine.

Start the engine only from the driver’s control stand! Use the alarm horn to signal the engine starting and check that nobody is exposed to risk by starting of the engine!

Note: When the engine is started, always only the left accelerator pedal is active. When the right seat is activated using the drive lever, the right pedal is activated automatically. Then, whichever seat is activated using the drive lever, always only the corresponding accelerator pedal is active.

Start-up procedure: •

Switch on the battery switch.

•

Check that both drive controls (54) are in the neutral position.

•

Check that the parking brake (5) is engaged.

•

Sit down on the seat.

•

Check that the emergency brake (10) is not activated.

•

Insert the key in the ignition box (43) in the position “0” and switch over to the position “I”.

•

The indicator lamps of parking brake, battery charging, neutral position or pre-heating (according to temperature of the environment).

•

Power View (30) is activated (refer to Chapter 2.6.1 Power View device handling).

•

Wait until the pre-heating indicator lamp goes out.

•

Use the alarm horn to indicate the engine starting.

•

Turn the key to the position “II” to start the engine.

•

When the engine has started, the battery charging indicator must go off within 15 s.

Starting is disabled: If the emergency brake (10) is activated.

If the machine is not braked using the parking brake (5).

If both drive controls (54) are not in the neutral position.

Note If the start-up is unsuccessful, turn the key back to the position “I”. If you fail to start the engine even after 3 attempts – check the fuel system.

Do not use the accelerator pedal during engine starting, perform starting at idle speed.

Do NOT start for longer than 30 s. Repeat starting only after 2 minutes.

Once the engine has started, let it idle for 3-5 min, depending on outside temperature, to let the brake system pressurize to 7 bar.

Do not let the engine run on idle for more than 10 min - it could result in damage of the engine!

It is forbidden to start the engine by towing the machine!

ART 240

75

2.7

Machine operation and use

3

4

2

1

-

+ 0

24

V

+

0

12

V

0

12

V

-

435094

76

ART 240

OPERATION MANUAL The start-up procedure using leads from an external power supply:

The voltage of the external power supply must be 24 V. Always follow the undermentioned operation sequence.

1. Connect one end of the (+) pole of the cable to the (+) pole of the discharged battery.

2. Connect the second end of the (+) pole of the cable to the (+) pole.

3. Connect one end of the (-) pole of the cable to the (-) pole of the external accumulator.

4. Connect the second end of the (-) pole of the cable to any part fixed to the engine of the machine being started (or to the engine block itself ).

After starting, disconnect the starting leads in reverse order.

Do not connect the (-) pole of the cable to the (-) pole of the discharged battery of the machine being started! During starting heavy sparking may occur and gases of the charged battery may explode.

Uninsulated parts of clamps of the battery jump cables must not touch each other!

The starting lead connected to the (+) pole of the batteries must not come into contact with electrically conductive parts of the machine – danger of a short circuit!

Do not lean over the batteries – possibility of electrolyte burns!

Remove flammable sources (open flame, burning cigarettes, etc.)

Do not check that the wire is live by sparking on the machine frame!

ART 240

77

2.7

Machine operation and use

2

3

ON

1 OFF

14

36

bar

0

4

bar

50

150

6

2

4 8

0

36

°C 25

6

2

10

8 0

54

bar

10

54 F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

23

F13

DIAC

1 2 3

OFF

1 2 3

5 6

56

55

56

55

435065J

78

ART 240

OPERATION MANUAL 2.7.2

Drive and reverse drive

Check that both travel controls are in the neutral position, the parking brake is activated and the emergency brake is not activated.

Use the warning horn to announce that the engine is starting and wait long enough so that all persons could leave the area around the machine or under the machine in time!

Before moving off, check that the area in front of and behind the machine is empty and that there are no persons or obstructions there!

Setting the machine in motion and stopping: •

Set the drive control (54) safety to the position “D”.

•

At idle engine speed, select the gear 1, 2 or 3 by turning the gear selector on the drive control (54). Use gear 3 for transfer of the machine only.

•

Use the switch (5) to unbrake the machine - the parking brake indicator lamp goes off (23).

•

Use the drive control (54) to select a drive direction, “F” for forward drive or “R” for reverse drive - the indicator lamp of the active workplace (36) lights up and the neutral indicator lamp (14) goes off.

•

Use the accelerator pedal (55) to increase the engine speed, and the machine starts moving in the selected direction.

•

You can slow down the machine either by reducing the engine speed using the accelerator pedal (55) or by braking using the service brake pedal (56).

•

To stop the machine, use the service brake pedal (56).

Reversing: •

Before performing reversing, let the machine stop by itself or press lightly on the service brake pedal (56). When the machine has come to a halt, engage the relevant gear using the drive control (54) and set the machine in motion in the selected direction.

It is forbidden to reverse /i.e. using the travel controller (54), to activate the reversing/ when the machine is moving and when the accelerator pedal (55) is pressed down.

Shifting gears: •

Gear shifting from 1 to 2 or from 2 to 3 during driving can be done by turning the gear selector (54) under load. Gear shifting from 3 to 2 or from 2 to 1 is only permitted at the machine speed corresponding to the gear engaged.

•

When driving uphill, engage a lower gear in time.

If there is a loss of traction, a decrease of tractive force or a significant decrease of the engine speed, engage the lower gear using the travel control (54)! If the machine is equipped with an ATC differential lock function, enable this function using the switch (6)!

ART 240

79

2.7

Machine operation and use

Differential lock use: •

Use differential interlock only when recovering the Machine!

Switch OFF the interlock once heavy conditions are overcome - danger of damage to differential or tires.

It is forbidden to activate the differential lock when the machine is moving!

It is forbidden to use the differential lock under good adhesion conditions and when turning!

Note: When engaging one travel control (54) from ”N” to ”F” or ”R” the ENABLED workplace - signal lamp will light up.

All the commands, i.e. driving direction change, gear control at the driver’s DISABLED point (on the second side) are non-operable!

ENABLED workplace - signal lamp will go OFF with the engine shut off.

2

1

3 N

N

N

NEVER drive downhill with travel controller in “N“ position (idle). The gear engaged during downhill driving must correspond to the gear engaged should there be uphill driving. (the higher the slope gradient the lower the gear).

1

2 3 435023

80

ART 240

OPERATION MANUAL M < 18 t [39690 lb]

M > 18 t [39690 lb]

NEVER drive a Roller over 18 tons of its weight on a slope with gradient over 25 %.

NEVER drive a Roller over 18 tons of its weight with 2nd and 3rd gear engaged on a slope that has gradient over 15 %.

MA 30%X

MAX 25% 435022

For the maximum permissible slope gradient when driving uphill and across the slope gradient, see figures.

The values given are lower depending on adhesive conditions and the machine instantaneous weight!

M – machine weight

MAX 10% 435021 NEVER change steering place - shifting from LH seat to RH one and vice versa while driving. Stop the Roller, brake it a then change the seat!

Unless the engine cooling liquid temperature reaches min 60 °C, do not load the engine at full capacity!

When oil temperature in gearbox rises over 120 °C, stop the work, stop driving and cool gearbox oil down to optimal 80-100 °C in situ at increased engine speed of 1500 rpm. If oil heats up to 120 °C frequently, change the driving manner - shift gears more frequently, clean oil cooler!

Never use parking brake for normal brake application.

When you select direction of running via controller, and after braking off the Machine will start to move slowly even with the engine idling.

While driving, keep the engine at rather high rpm to achieve better controllability of steering the Machine.

ART 240

81

2.7

Machine operation and use

2

3

ON

1 OFF

bar 0

4

bar

°C 25

50

150

6

2

4 8

0

OFF

6

2

10

8 0

54

bar

10

54 F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

1 2 3

5

43

435065D

82

ART 240

OPERATION MANUAL 2.7.3

Stopping the machine and engine

•

Shift the drive control (54) to the neutral position.

•

Activate the parking brake (5).

•

Switch over the key in the ignition box (43) to the position “0” and close the lid of the ignition box.

3881

120 sec

0

Switch off the battery disconnector no sooner than 120 seconds after removing the key from the ignition switch.

The time limit must be observed to pump DEF (AdBlue) back into the tank and store the EMR engine data.

By failing to adhere to this time limit you take the risk of damaging the machine, for which the manufacturer bears no responsibility.

3881bz

Do not stop the hot engine instantly but let it idle for 3 minutes. The engine and the turbocharger will cool down slowly and evenly!

When the engine is in operation, the parking brake of the standing machine must be engaged!

It is forbidden to park the machine on a slope with the incline exceeding 15 %!

ART 240

83

2.7

Machine operation and use

2

3

ON

1 OFF

bar 0

4

bar

°C 25

50

150

6

2

4 8

0

OFF

6

2

10

8 0

54

bar

10

54 F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

1 2 3

5

56

10

56

435065E

84

ART 240

OPERATION MANUAL 2.7.4

Machine emergency stop

To be used if you cannot stop the machine by changing the drive control (54) to the neutral position, using the brake pedal (56) or you cannot use the parking brake (5)!

Activation: •

After pressing the emergency brake button (10), the machine is braked and the engine stops.

Deactivation: •

Shift the drive control (54) to the neutral position.

•

Turn the emergency brake button (10) in the direction of arrows.

•

Activate the parking brake (5).

•

Turn the key in the ignition box into the position “0”; it is possible to start the engine again in this position.

ART 240

85

2.7

Machine operation and use

2

3

ON

1 OFF

bar 0

4

bar

°C 25

50

150

6

2

4 8

0

OFF

6

2

10

8 0

bar

10

F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

1 2 3

5

435065F

86

ART 240

OPERATION MANUAL 2.7.5

Machine parking

•

Stop the machine on a flat and compact surface where there is no potential natural hazard (landslides, possible flooding, etc.)

•

Activate the parking brake (5).

•

Secure the machine with wheel chocks or other suitable means preventing unintended movement.

•

Remove dirt from the machine (scrapers and tyres).

•

Check the whole machine and repair defects arisen during the operation.

•

Check the tyre pressure and inflate to 8 bar.

•

Lock the machine covers and cab.

It is forbidden to park the machine on a slope with the incline exceeding 15 %!

After a longer shut-down of the machine, fill fuel in the filter.

ART 240

87

2.7

Machine operation and use

2

3

ON

1 OFF

bar 0

4

bar

°C 25

50

150

6

2

4 8

0

OFF

6

2

10

8 0

bar

10

F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

1 2 3

11 7

435065G

88

ART 240

OPERATION MANUAL 2.7.6 •

Watering and scrapers

When compacting fresh-laid asphalt coat, please turn ON the sprinkling (11) and set adequate sprinkling interval.

Lift the scrapers during normal compaction work on soil and when driving.

•

Lower the front scrapers (A) and rear scrapers (B).

B A

435095

Emulsion sprinkling •

Hold the emulsion sprinkling button (7), until the entire tire circumference is sprinkled with separation emulsion.

•

The separation emulsion (anti-adhesive agent) ensures the effective separation of tyres and compacted surface.

Advantages of the use of anti-adhesive agent: -

No traces on the compacted surface due to an effective separation effect

-

Extremely low consumption of anti-adhesive agent

-

The surface can be treated at high temperatures

-

The surface does not suffer from rolling much due to a lower water consumption

-

The anti-adhesive agent does not cause the corrosion of rubber tyres

-

The penetration of excessive anti-adhesive agent has no other negative effects

-

The anti-adhesive agent is biologically degradable

ART 240

89

2.7

Machine operation and use

2

3

ON

1 OFF

bar 0

4

bar

°C 25

50

150

6

2

4 8

0

OFF

6

2

10

8 0

bar

10

F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

1 2 3

F13

DIAC

1 2 3

13

435065H

90

ART 240

OPERATION MANUAL 2.7.7

Edge Cutter

•

Press the switch to lower the edge cutter (13) to its end position and vice versa.

•

When operating the edge cutter, switch ON the sprinkler and open the valve near edge cutter disc.

Confirm nobody is in hazard before lowering, lifting.

431037A

Scraper plate location.

431037B Scraper plate 1. Name – always mentioned only in the English version

2

2. Type

3

3. Serial number 3459

4. Maximum weight

TYPE

5. Year of manufacture

AMMANN CZECH REPUBLIC a.s.

Náchodská 145 549 01 NOVÉ MÌSTO NAD METUJÍ CZECH REPUBLIC

4

SERIAL NUMBER

MAXIMUM MASS

DESIGNATION

YEAR OF CONSTRUCTION

MADE IN CZECH REPUBLIC

1

5 3459

ART 240

91

2.7

Machine operation and use

2.7.8

Additional weighting of the machine

•

It is used to increase the weight of the machine and compaction efficiency.

•

Mount the weight evenly in the whole frame. You can also increase the machine weight only in the front or only in the rear part of the frame.

435116 Weight type

Weight kg (lb)

Empty ballast tank

1100 (2430)

Weight 6 t (concrete, steel)

6280 (13850)

Ballast tanks filled with concrete

2800 (6170)

Water

3000 (6610)

Sand

4500 (9920)

Scrap up to the maximum machine weight

24000 (52910)

92

ART 240

OPERATION MANUAL 2.7.9

Opening and closing the dashboard cover

Opening the cover Open the lock plate.

435128 Open the lower half of the cover.

435129 Open the top half of the cover.

435130 Open cover.

435131 ART 240

93

2.7

Machine operation and use

Closing the cover Move the top half of the cover onto the dashboard.

435132

435135 Close the lower half of the cover.

435133 Close the lock plate and lock the cover.

435134 94

ART 240

2.8 •

How to transport the Machine

OPERATION MANUAL

The machine can move on its own between working sites.

When moving, observe the safety measures applicable to the working site.

•

When on the road, the machine should be transported on a vehicle.

When transporting the machine on a vehicle, observe the regulations in force in the given territory.

When loading and unloading, the vehicle transporting the machine must be braked and mechanically protected against accidental movement using scotch blocks (3).

If the Machine has been equipped with differential interlock - then lock in the interlock before running onto the carrier’s platform!

The machine on the vehicle must be properly tied and mechanically secured against longitudinal and lateral displacement as well as against tipping (1). The drums must be secured using scotch blocks (2).

2

3

2

3

1

435017

The manufacturer recommends that the machine should be tied starting from the left rear lashing point. After the machine has been tied, the means of lashing must not be in contact with tyres as such contact could result in damage to the tyre.

ART 240

95

2.8

How to transport the Machine

2.8.1. Machine loading •

Use a loading ramp or crane to load the machine onto the transport vehicle.

2.8.1.1 Loading the machine using a ramp •

When loading the machine using a ramp, all safety regulations related to loading of the machine valid in the place of loading must be adhered to. The ramp must have appropriate loading capacity, antislip surface and must be stored on a flat surface. We recommend that you adhere to regulation BGR 233.

Maximum permissible incline of the ramp is: •

30 % for machines without lower weight;

MAX 30 % 435018 •

25 % for machines with lower weight.

MAX 25 % Non-adherence to the prescribed parameters of the ramp may result in damage to the machine.

When loading the machine, a second person must be present to signal approach onto the ramp. See the list of hand signals in chapter 2.1.6.

435019

Pay increased attention when loading the machine.

Improper handling can cause serious injury or death.

96

ART 240

OPERATION MANUAL 2.8.1.2 Loading the machine using a crane •

When loading with crane the Roller is fitted with lifting lugs.

L min 2x 12 000 kg (2x 26,455 lb)

L min 2x 12 000 kg (2x 26,455 lb)

24 t (52,910 lb)

ROPS

ROPS

Lmin = 4 m

Lmin = 8 m

Lmin = 4 m A = 1,95 m

Lmin = 13 ft

Lmin = 26 ft

Lmin = 13 ft A = 6.4 ft

A

435020

Observe the relevant national safety measures when loading the machine with a crane.

Beware of Roller’s actual mass incl. weight and additional load in ballast spaces of Roller!

Use only the designed lifting lugs intended to tie the ropes.

Binding may only be performed by a binder with a binding certificate.

Use lifting equipment and rigging of sufficient loading capacity.

When using ropes shorter than 8 m (26.3 ft), insert cross bar (A) 1.95 m (6.4 ft) long between the ropes overhead the cab.

Do NOT enter under the hung load!

ART 240

97

2.9

Machine work under heavy conditions

2.9.1

Machine towing

Use a towing device mounted at the front of the machine for towing. The towing device is regarded a special accessory.

If the towing device is not mounted on the machine, towing is prohibited. Transfer the machine using a crane instead. The carrying capacity of a crane and tying means must be higher than the actual service weight of the machine!

•

If the pressure in the brake circuit is 5.2 bar and lower and the engine cannot be used to increase pressure, the machine must be unbraked for towing using a special jig (machine accessories).

374110 •

Remove the floor covers between the seats.

374N058A •

Uninstall the fitting.

374042 98

ART 240

OPERATION MANUAL •

Screw the jig (1), (2) into the spring cylinder (3) to release the grip of the brake shoes on the parking brake disc.

Before releasing the brakes, secure the machine against accidental movement by chocking the wheels!

All the brakes are out of operation!

No persons are allowed to be on the towed machine with the engine out of order.

1

2 3 374N161T

When the engine of the machine being towed is out of order, the steering does not work and the service brake is not fully functional (air pressure cannot be generated).

The parking brake can be unbraked using the jig, so the machine is not braked. Therefore, it is forbidden to use a tow rope for towing the machine, especially downhill; use a tow bar instead!

To tow, use unbroken tow ropes, or tow bar of sufficient loading capacity, 1.5 times higher than the actual weight of the towed machine. It is forbidden to use a chain!

When towing, make sure that persons are in a sufficient distance to prevent their injury in case the rope breaks or the tow device fails.

It is necessary to maintain the minimal angular deviation from the direction of towing. The maximum possible angular deviation is 30°.

Smooth and constant movement must be maintained in towing. Do not exceed the towing speed of more than 2 km/hour (1.2 mph).

Tow the machine as short a distance as possible - in order to recover it after bogging down or to remove it as an obstacle in the case of a failure. Do not tow for a distance exceeding 300 m (0.19 miles).

The size of the towing machine should correspond to the size of the faulty machine to be towed. It must have a sufficient traction power (output), weight, and brake effect.

If the engine is not functional, immediately after towing secure the machine against movement and then uninstall the jig from the parking brake and put the machine into the same condition as before unbraking.

These are the general requirements for safe towing of the damaged machine under standard conditions. Any specific conditions that may occur during towing must be consulted with the machine distributor.

ART 240

99

2.9.

Special conditions of the Machine use

2.9.2

Machine operation during its running-in period

Upon the commencement of the operation of a new machine and during the first 30 hours of operation, do not load the machine at its full capacity.

2.9.3

Machine operation at low temperatures

The compaction in the winter period depends on the content of fine particles and water in the compacted soil. The soil becomes more solid and more difficult to compact with a decreasing temperature below the freezing point.

Dry soils and stony soils can be compacted and non-frozen materials (before the soil freezes up) can be quickly compacted at temperatures below 0 °C (32 °F).

Preparation for works at low temperatures •

Check the concentration of the engine cooling liquid.

•

Exchange the engine oil with the recommended one for the respective low ambient temperatures.

•

Use the hydraulic oil of the corresponding kinematic viscosity.

•

Use the winter fuel.

•

Check the battery charge.

Note Heating the batteries to approximately 20 °C (68 °F) (by removing and storing the batteries in a warm room) will reduce the limiting starting temperature by 4 to 5 °C (39.2 to 41 °F).

The minimum temperature of the engine cooling liquid is 60 °C (140 °F). The maximum temperature is 100 °C (212 °F).

When using the HV 100 oil in the hydraulic system, the machine must not be started at ambient temperatures below +2 °C (36 °F).

100

ART 240

OPERATION MANUAL 2.9.4

Machine work under high temperatures and humidity

2.9.5 •

With altitude growing the atmospheric pressure and specific gravity of intake air decrease, and in connection therewith the engine performance lowers.

•

If engine smokes black in the altitudes of over 1500 m, please contact service department of engine manufacturer (Engine Operation and Maintenance Manual) and this manufacturer will adjust the injection pump accordingly to suit such conditions.

Engine power lowers with growing air temperature and humidity.

•

Every 10 °C of temperature increase means power drop by up to 4 % (at constant humidity),

•

Every 10 % of increased relative humidity means power drop by up to 2 % (at constant temperature).

Machine work in high altitudes

Note •

•

In the environment where hydraulic oil temperature moves constantly round 90 °C (194 °F), we recommend to have hydraulic oil replaced by the oil with HV 100 kinematic viscosity.

For planetary gearbox with hydraulic torque converter within the environment characterized as TROPICAL, we recommend to use oil of SAE 30 viscosity value that corresponds to the performance classification of Caterpillar TO-4.

The engine power is affected by the environment in which the machine is working.

The machine may be used up to a maximum altitude of 3,658 m (12,000 ft).

2.9.6 •

ART 240

Work of the machine in the dusty environment

When working in a very dusty environment, please cut short the intervals for replacement of suction filter elements, cut short the interval for cleaning the coolers, for replacement of cabin’s dust filter, refer to Machine Maintenance Table.

101

Notes

102

ART 240

MAINTENANCE MANUAL

3 MAINTENANCE MANUAL ART 240 (Deutz Tier 4 Final)

ART 240

103

104

ART 240

3.1

Safety standards and other maintenance regulations

3.1.1

Safety of machine maintenance

Carry out lubrication, maintenance and adjustments: •

By professionally trained personnel.

•

In line with safety instructions given in the Operation Manual.

•

According to schedule given in the Lubrication Chart following the hours actually worked.

•

On the machine located on flat solid surface, secured against self-motion (scotch blocks), and this always with the engine OFF, key removed from ignition box, and the wiring cut off.

3.1.2 •

Fire precautions during operation media exchanges

In terms of fire hazard the flammable liquids used on the Machine have been divided into three hazard classes: IInd

Hazard class – Diesel oil

IVth Hazard class – mineral oils, lube greases •

Oil exchange point shall be located so it does not interfere with the explosion or fire hazard area.

•

It shall be identified with notice boards and signs of no smoking and no use of open flame.

•

Only after Machine Repair sign is attached onto steering wheel (the sign is supplied together with machine accessories).

•

Handling area shall be sized so the capture the amount to flammable liquid equal to the capacity of biggest vessel, transport container.

•

On machine parts cooled out.

•

It must be equipped with portable fire extinguishers.

•

After having cleaned the machine, lubrication points and maintenance locations.

•

To handle the oil, Diesel oil, please use such vessels like metal barrels, canisters or sheet-metal cans.

•

Using proper, undamaged tools.

•

Transport containers shall be properly closed when stored.

•

Through replacement with new original parts as per the Spare Parts Catalogue.

•

•

With sufficient lighting of the entire machine in the event of lowered visibility and at night.

Vessels shall have one opening, be stored with the opening on top, and secured against any flowing out or dripping of their content.

•

•

so the guards and safety elements are reinstalled again upon work completion.

Vessels shall be designated with indelible inscription indicating the content and flammability class.

•

through retightening bolted connections – with torque specified, and through checking the connection tightness.

•

with the operation media heated – beware of burns – use recommended media, only.

Upon completion of the adjustment or maintenance, please examine the function of all safeguard equipment!

ART 240

105

3.1

Safety and other measures for machine maintenance

3.1.3

Ecological and hygienic standards

When operating and maintening the machine the owner is obliged to keep the common regulations of health and environment protection and the laws, regulations and promuglations, correlative to this problems and valid in the region of the machine use.

Hygienic standards •

•

•

The petroleum products, cooling systems fills, accumulators, brake liquids and fills and paints including the thinners are harmful materials. Workers that come into contact with these materials during the service and maintenance of the machine, are obliged to keep the common standards of health protection and they must keep the safety and hygienic manuals of the manufacturers of these materials.

Ecological standards

The fills of individual machine systems and also some parts are after blackout (dismounting, changing the fills) the garbage with risk attributes for the environment.

•

To this category of waste products includes: -

organic and synthetic lubricants, oils and fuels,

-

brake fluids,

-

cooling liquids,

We want you to focus your attention mainly on these areas:

-

accumulator filling and accumulators themselves,

-

eyes and skin protection when manipulating with the accumulators,

-

the conditioner systems fillings,

-

skin protection when manipulating with the petroleum products, paints, cooling liquids and brake liquids,

-

cleaning and preservative materials,

-

all dismounted filters and filter inserts,

-

all used and blackouted hydraulic and fuel pipes, rubber steels and other machine parts, contaminated by materials above.

-

proper washing the hands after finishing the work and before the meal, treat the hands using the appropriate regenerating cream,

-

when manipulating with cooling systems, keep the machine manipulating manual instructions.

The petroleum products, cooling systems fills, accumulators fills, brake liquids and paints including the organic thinners and also cleaning and preservative means always store on a original, properly signed covers. Don’t allow storing of these materials in the non-marked vessels and other cans due to danger of exchange. Extremely danger may be the exchange with meal or drinks.

•

In the case of accidental stain of the skin, mucous membranes, eyes or of inhalation of the vapour, apply immediately the first aid. In such case find the emergency first aid.

•

When working with the machine unequipped with the cab, or with opened windows and cab door, always use the ears protections of convenient kind and design.

106

With materials and parts listed we must work after blackout according to the appropriate national regulations for individual environment parts protection and according to the health protection regulations.

ART 240

3.2

Specification of fluids

3.2.1

Engine oil

MAINTENANCE MANUAL

2412

°F 104

°C 40

86

30

68

20

50

10

32

0

14

-10

-4

-20

-22

-30

-40

-40

The engine oil is specified according to the performance and viscosity classification.

Up-to-date list of oils meeting the classification can be found on the website of the manufacturer of Deutz engine (www.deutz. com).

The machine manufacturer uses the oil filling according to the classification DQC IV LA, type Valar Egida FNA104 10W-40.

If a failure occurs as a result of the use of improper classification oil, no warranty claim will be accepted.

20W-50

15W-40

10W-40

10W-30

DQC IV LA

5W-40

DQC III LA

5W-30

Acceptable oils according to DEUTZ QUALITY CONTROL (DQC):

0W-40

With respect to the emission requirements of Tier 4 final, the engine manufacturer requires the use of only such oils that are certified by Deutz.

0W-30

Performance classification

Viscosity classification To determine the viscosity class SAE (Society of Automotive Engineers), the ambient temperature and type of operation where the machine is used are decisive.

Note Exceeding the lower temperature limit does not result in engine damage; it may only cause some starting difficulties.

264029B

It is convenient to use universal multi-grade oils to avoid oil changes due to the ambient temperature.

Exceeding the upper temperature limit may result in a reduction of lubricating properties of oil and extensive oil wear.

When temperatures are below -40 °C, pre-heat the oil before starting the engine.

Reduce the interval of oil replacement to half if any of the following circumstances occurs: - ambient temperature is constantly below -10 °C - oil temperature during operation of the machine is below 60 °C.

ART 240

107

3.2

Specification of fluids 3686

3.2.2

Fuel

D

< 15 ppm S < 15 mg/kg S

3686

Diesel oil is used as fuel for the engine: CEN EN 590 ASTM D 975 Grade 1-D S15 ASTM D 975 Grade 2-D S15

The manufacturer of the engine requires using a fuel with sulphur content not exceeding 0.0015 percent by weight (0.0010 percent by weight for use of the machine in EU).

Any use of a fuel with a higher content of sulphur results in expiration of the warranty for the engine.

At ambient temperatures below 0 °C (32 °F), use winter diesel oil.

Mixing diesel oil with special additives is prohibited.

Refill the cooling circuit with the same or a completely miscible coolant of the required specification.

If the use of a different, immiscible coolant is necessary, the cooling circuit must be completely drained and cleaned with clean water repeatedly, at least 3 times.

However, it is not allowed to use a coolant of a different specification than stated by the engine manufacturer.

The coolant protects the cooling system from freezing, corrosion, cavitation, overheating, etc.

It is forbidden to operate the machine without coolant even for a short time.

It is forbidden to use a coolant of a different than prescribed specification and base. The engine and the cooling system can get damaged and the warranty lost.

Always check the ratio of antifreeze cooling agent in the coolant with a refractometer before the winter season starts.

Water quality Use only water whose properties correspond to values in the table:

3.2.3

Coolant

pH value

2152

The coolant specification must meet requirements of: DQC CB-14 DQC CC-14

min.

max.

6.5

8.5

Chlorine content in mg/l

100

Sulphate content in mg/l

100

Water hardness in mmol/l

3.56

If the water properties do not correspond to the values in the table, the water must be treated.

•

Too low pH value: -

To fill the cooling circuit, use the coolant in the mixing ratio of 50%/50% with high-quality water (thermal protection up to -37 °C).

Change the coolant every 6,000 hours of operation, after 4 years at the latest.

When the thermal protection is required under -37 °C, contact Deutz partners.

Note: The machines are filled with a cooling solution with the Bantleon Avia Antifreeze NG coolant, specification DQC CC-14 at the manufacturer’s during the production.

It is a coolant based on monoethyleneglycol containing silicates.

It does not contain phosphates, nitrates, amines and borates.

There is an Avia NG label placed at the point to fill the coolant into the machine.

108

•

Too high total hardness: -

•

Add dilute sodium hydroxide or caustic potash.

Mix with softened, distilled or desalinated water.

Too high chloride and/or sulphate value: -

Mix with softened, distilled or desalinated water.

Safety instructions: 1) Protect your hands with protective gloves.

2) In case of ingestion immediately seek medical treatment.

3) In case of contact with skin or clothing immediately wash the affected area with clean water.

4) Do not mix different types of coolants. The mixture can cause a chemical reaction with formation of harmful substances.

ART 240

MAINTENANCE MANUAL 3.2.4

Hydraulic oil

3.2.6

Transmission oil

2158

It is necessary to only use high-quality hydraulic oils of the performance class according to ISO 6743/HV (corresponding to DIN 51524 part 3 HVLP; CETOP RP 91 H) in the hydraulic system of the machine.

Fill the machines with a hydraulic oil with the kinematic viscosity 68 mm2/s at the temperature 40 °C (104 °F) ISO VG 68. This oil is most appropriate for its use within the widest range of ambient temperatures.

2186

Axle drive The hypoid axle drive is lubricated by the oil SAE 80W-90H API GL 5 or MIL-L-2105 B/C / LS. Reduction gear Reduction gears are lubricated by the oil SAE 85W-140H API GL 5.

Note: The hydraulic system can be filled with a synthetic oil, which if leakages occur degrades completely by the action of microorganisms living in water and soil.

3.2.7

DEF (AdBlue)

DEF

595426

Please consult always with oil manufacturer or dealer any switching from mineral oil to synthetic one or mixing the oils of various brands.

A liquid additive used for treatment of exhaust gases from Diesel engines.

Specification: DIN 70070, ISO 22241-1, ATSTM D 7821.

Trade name in Europe: AdBlue Trade name in US: DEF - Diesel Exhaust Fluid

3.2.5

Oil - planetary gear with torque converter

Use only DEF (AdBlue) according to the recommended specification!

2186

For the gearbox, use the oil of performance class according to ISO VG 32 (corresponding to DIN 51524 HLP; GM Type C3).

The manufacturer fills the gearbox with the oil Valar OTHP3.

3.2.8

A synthetic oil is suitable for use in the gearbox if it meets the specification above.

Brake fluid

Brake fluid shall meet the international specifications ISO 4925, SAE J 1703 f, DOT 3. It can be mixed with brake fluids of all brands, meeting these specifications. The brake fluid is intended for brake systems operating at ambient temperatures from –50 °C (–58 °F) to 60 °C (140 °F) and at operating temperatures from –50 °C (–58 °F) to 205 °C (400 °F).

Note: A brake fluid meeting the specification DOT 4 can be used in the brake system as well.

ART 240

109

3.2

Specification of fluids

3.2.9

Lubricating grease

3.2.11 Air-conditioning filling 2441

0787

To lubricate the machine you must use plastic grease containing lithium according to: ISO 6743/9 CCEB2

Mixture: 1.2 kg coolant Halocarbon 134a 0.3 l of oil PAG 150

DIN 51 502 KP2K-30 For lubrication of the reduction gear covers, lubricant must be used according to:

0.005 l of contrast medium

ISO 6743/9 BDHB2 DIN 51502 KP2N-25

3.2.12 Emulsion 3499

For sprinkling the tyres, use anti-adhesive emulsion of RHODOSIL EMULSION E1P with water in the mixing ratio of 1.5:100.

3.2.10 Screen washer fluid 2260

The screen washer reservoir can be filled with clean water when temperatures are above 0 °C (32 °F). We recommend using water with added antifreeze washing liquid for car screen washers mixed according to conditions of machine deployment - in CZ Glacidet K.

If there is a risk that temperature drops below 0 °C (32 °F), add an antifreeze agent or discharge water!

110

ART 240

3.3

Media

MAINTENANCE MANUAL

Part

Medium Type

Engine

Engine oil as per Section 3.2.1

Amount of Medium l (gal US)

Brand

9.5 (2.5) 2412

Engine

Cooling liquid as per 3.2.3

20.5 (5.4) 2152 3686

Fuel tank

Diesel oil as per 3.2.2

250 (66)

D

< 15 ppm S < 15 mg/kg S

3686

Hydraulic circuit

Hydraulic oil as per Section 3.2.4

22 (5.8) 2158

Hydraulic cylinders for front wheels

Hydraulic oil as per 3.2.4

6 (1.6) 2158

CLARK transmission

Oil as per Section 3.2.5

21.5 (5.7) 2186

Differential

Gear oil as per Section 3.2.6

6 (1.6) 2186

Speed reduction transmission

Gear oil as per section 3.2.6

2x5.2 (2x1.37) 2186

DEF tank (AdBlue)

Mixture according to Chap. 3.2.7

22 (5.8)

DEF

595426

Brake system

Brake fluid as per Section 3.2.8

1.75 (0.5)

Lubrication according to Lubrication Chart

Plastic lubricant as er Section 3.2.9

If required

Sprayer

Medium as per Section 3.2.10

0787

2.5 (0.66) 2260

Water tank for tyre sprinkling

Water

390 (103) 596128

Air-conditioning

Mixture according to chapter 3.2.11

2441

Additional tank for emulsion sprinkling

Emulsion according to chap. 3.2.12

60 (15.9) 3499

ART 240

111

3.4

Lubrication and Maintenance Chart

Every 20 hours of operation (daily) 3.6.1

Engine oil level check

3.6.2

Engine cooling liquid level check

3.6.3

Fan inspection

3.6.4

Engine and exhaust pipe intake manifold check

3.6.5

Air filter dust valve check

3.6.6

Hydraulic oil level check

3.6.7

Brake fluid check

3.6.8

Brake inspection

3.6.9

Water tank refill

3.6.10

Water separator cleaning

3.6.11

Oil in the gearbox check

3.6.12

Warning and control devices check

3.6.13

Inspection of DEF (AdBlue) level

3.6.14

Check of the front axle

After 50 hours of operation 3.6.52

Check of wheel nuts for tightening *

Every 100 hours of operation (weekly) 3.6.15

Tyre pressure check

3.6.16

Check of the oil level in the front axle hydraulic cylinders

After 100 hours of operation 3.6.23

Gearbox oil filter replacement **

Every 250 hours of operation (3 months) 3.6.17

Engine induction manifold and air filter sensor check

3.6.18

Machine lubrication

After 250 hours of operation

112

3.6.37

Oil in differential change ***

3.6.39

Oil in rear axle change ***

ART 240

MAINTENANCE MANUAL Every 500 hours of operation (6 months) 3.6.19

Engine oil change

3.6.20

Fuel filters replacement

3.6.21

Air filter elements replacement

3.6.22

Engine cooling liquid check

3.6.23

Gearbox oil filter replacement

3.6.24

Oil in differential and oil in rear axle check

3.6.25

Wiring check

3.6.26

Air conditioning coolant check

3.6.27

Air filter of the air conditioning system replacement

3.6.28

Cab ventilation filter cleaning

3.6.29

Replacement of DEF (AdBlue) filter

3.6.30

Engine belt check

Every 1000 hours of operation (1 year) 3.6.31

Battery check

3.6.32

Brake shoes adjustment

3.6.33

KM nuts tightening check and front wheels lubrication

3.6.34

Cleaning of the air cooler

3.6.35

Air conditioning compressor mounting check

3.6.36

Gearbox oil change

3.6.37

Oil in differential change

3.6.38

Air drier replacement

Every 2000 hours of operation (2 years) 3.6.39

Oil in rear axle change

3.6.40

Hydraulic oil and filter change

3.6.41

Oil in front axle hydraulic cylinders change

3.6.42

Brake fluid change

3.6.43

Air conditioning system check

ART 240

113

3.4

Lubrication and Maintenance Chart

Every 6000 hours of operation (4 years) 3.6.44

Engine cooling liquid change

Maintenance if required 3.6.45

Water from separator draining

3.6.46

Fuel system venting

3.6.47

Coolers cleaning

3.6.48

Regeneration of clogged catalyst SCR (Selective Catalytic Reduction)

3.6.49

Refilling the oil level in the front axle hydraulic cylinders

3.6.50

Sprinkling filter cleaning

3.6.51

Brush scrapers cleaning

3.6.52

Check of wheel nuts for tightening

3.6.53

Machine cleaning

3.6.54

Air collector inspection

3.6.55

Charging of the battery

3.6.56

Screw connection tightening check

* First after 50 hours ** First after 100 hours *** First after 250 hours

114

ART 240

3.5

Lubrication and Service Plan

MAINTENANCE MANUAL

LUBRICATION AND SERVICE PLAN INSPECTION LUBRICATE EXCHANGE

2000 2

1000 2

500 1

1

250

Filter set 500 h / 4-760181

Filter set 1000 h / 4-760182

Filter set 2000 h / 4-760183

20

2 1

1

1

3

1

1

3

Engine oil:

DQC III LA, DQC IV LA

1

Fluid for automatic transmission see chapter 3.2.5

2

Transmission oil:

SAE 80W-90H API GL-5

3

Transmission oil:

SAE 85W-140H API GL-5

Hydraulic oil:

ISO VG 68

Grease:

ISO 6743/9 CCEB 2

Grease:

ISO 6743/9 BDHB 2

1 2

ISO 6743/HV

435024en

ART 240

115

3.6

Lubrication and Maintenance Operations

Carry out lubrication and maintenance in regularly repeated intervals as per the everyday data reading on the counter of hours actually worked.

0 RPM ENG RPM

28°C COOL TEMP

20% FUEL LEVEL

100 ENG HRS

396313A This Manual states only the basic information about the engine, other data are given in the Engine Operation and Maintenance Manual which is part of the Documentation supplied with the Machine.

Follow also the instructions given in the engine operation and maintenance manual!

Carry out maintenance with the Machine placed on flat, paved surface, and secured against any self-motion, always with the engine OFF, key removed from ignition box, and with the wiring disconnected (unless otherwise required).

Removed or loose bolts, plugs, threaded joints of the hydraulics, etc. shall be tightened with the torque according to the Tables in Section 3.6.56, unless a different value is given with the relevant operation.

If the exhaust pipe with a flexible part between the engine and the catalytic converter shows any leak or damage, the machine cannot be operated until the defect is fixed.

Following the first 50 hours of operation of the new Machine (after Major Overhaul), please perform the following: 3.6.52 Check of wheel nuts for tightening Following the first 100 hours of operation of the new Machine (following a major overhaul) carry out as per: 3.6.23 Gearbox oil filter replacement Following the first 250 hours of operation of the new Machine (following a major overhaul) carry out as per: 3.6.37 Oil in differential change 3.6.39 Oil in rear axle change 116

ART 240

MAINTENANCE MANUAL Every 20 hours of operation (daily) 3.6.1

Engine oil level check

•

Shut off the engine, wait ca 3 min for oil to descend into crankcase sump.

•

Pull out oil dipstick, wipe it, put it back and pull out again to read oil level.

435101 •

Maintain level between division lines stamped on oil dipstick. Low division mark shows lowest possible oil level, high division mark shows the highest one.

MAX

MIN

409162 •

Replenish oil via filler neck.

435102

Refill oil of identical type, use oils as stated in Section.

3.2.1.

Do NOT run the engine unless there is correct oil level in the engine.

ART 240

117

3.6

Individual Operations of Maintenance

3.6.2

Engine cooling liquid level check

•

Let cooling liquid cool down to less than 50 °C (120 °F).

•

Check visually the level.

•

Refill coolant through the filler (1).

435103

OK

OK

Dismantle the filling plug only when the temperature of engine cooling liquid falls to less than 50 °C (120 °F). If you open it at higher temperatures, you risk scalding by steam or by cooling liquid due to the inner overpressure.

The level must not fall below the level indicator eyesight.

Add only the coolant according to Chapter 3.2.3.

Do not add additives eliminating untightness of the cooling system to the engine cooling liquid!

In case of larger losses, find the location of cooling system leaks and repair the cause.

118

282N205T

ART 240

MAINTENANCE MANUAL 3.6.3 •

Fan inspection

Visually check the fan. If you find, for instance, any missing parts of the material, cracks, deformations, etc. - replace the fan.

435040 •

Visually check the belt. If any longitudinal cracks, smooth, bright flats occur on the belt, or belt’s edges are frayed, or parts of the material are torn out, it is necessary to adjust or replace the belt. Belt tightening every 500 hours.

435041

3.6.4 •

Engine and exhaust pipe intake manifold check

Check the tightness of the engine intake manifold. Make sure that the hoses are not damaged and that the tightening clips are not missing.

435042 •

Check the tightness of the exhaust pipe.

•

Make sure that the tightening clips are not missing.

If the exhaust pipe with a flexible part between the engine and the catalytic converter shows any leak or damage, the machine cannot be operated until the defect is fixed.

435104 ART 240

119

3.6

Individual Operations of Maintenance

3.6.5

Air filter dust valve check

•

Any dust trapped will automatically be emptied during Machine operation. We recommend to occasionally clean the exit slit, press to remove any dust trapped.

Replace the dust valve immediately if it is damaged!

Dust valve Order number: 1-952454 •

Should the Machine be fitted with air pre cleaner, clean the vessel (1) when filled with dirt up to the mark, first unscrew nut (2) and remove cover (3).

435044

2

3 1

374050

3.6.6 •

Hydraulic oil level check

Open oil tank cover. Check and maintain oil level. If the oil level drops under the minimum level, the engine will stop.

Engine can be started only after oil is filled up. Using the hydraulic unit, fill with the same type of oil, see chap.

“How to exchange hydraulic oil and filter”.

435045

120

ART 240

MAINTENANCE MANUAL 3.6.7 •

Brake fluid check

Keep its level between ”MIN” and ”MAX”. Clean filler cap and filler neck before filling up.

435105 •

Check the following when fuel has dropped: -

Pipes and hoses of the system,

-

Connection tightness,

-

brake master cylinder,

-

brake cylinders in rear axle wheels.

Keep brake fluid in its original, well closed containers!

When it is to be used, please follow instructions of brake fluid producer.

Brake fluid will cause damage to painted parts of the Machine.

When filling up, avoid and fluid spilled over the Machine or outside the Machine.

ART 240

121

3.6

Individual Operations of Maintenance

3.6.8

Brake inspection

Inspection of service brake operation Start the machine on a level surface as described in the Operation Manual. Deactivate the parking brake using the switch (5) on the dashboard and press the service brake pedal (56). Set the first speed gear on the drive control (54), select driving direction forward (F) and press the accelerator pedal (55). If the machine stays in place, the service brake is in good condition. If the machine starts moving, stop it using the emergency brake button (10) and turn off the engine.The machine must be put out of operation immediately until the service brake is repaired. After repair or maintenance, check the service brake operation again.

F

1 2 3

N

R

431030

Inspection of parking brake operation Start the machine on a level surface as described in the Operation Manual. Leave the parking brake (5) switch in the braked position. Set the first speed gear on the drive control (54), select driving direction forward (F) and press the accelerator pedal (55). If the machine stays in place, the parking brake is in good condition. If the machine starts moving, stop it using the service brake pedal (56) and turn off the engine. Use wheel chocks to secure the wheels. The machine must be put out of operation immediately until the parking brake is repaired. After repair or maintenance, check the parking brake operation again.

5

10

Inspection of emergency brake operation Start the machine on a level surface as described in the Operation Manual. Deactivate the parking brake using the switch (5) on the dashboard. Set the first speed gear on the drive control (54), select driving direction forward (F). The machine will start moving slowly. Press down the emergency brake button (10).

If the machine stops and the engine turns off, the emergency brake is in good condition. If the machine does not stop and the engine does not turn on, use the service brake (56) to stop the machine, move the travel control (54) to neutral and activate the parking brake using the switch (5). Check the parking brake for operation. The machine must be put out of operation immediately until the emergency brake is repaired. After repair or maintenance, check the emergency brake operation again.

435005

56 55

If the brake operation is not correct, it is not allowed to use the machine; the defect must be corrected!

435035

122

ART 240

MAINTENANCE MANUAL 3.6.9 •

Water tank refill

Open the cap and fill up with clean water.

431048

3.6.10 Water separator cleaning •

This should be performed with the full air pressure in the air reservoir (according to the brake circuit pressure gauge).

Shut OFF engine, switch ON parking brake. Pull drain valve’s chain to confirm valve operation is OK.

374N026

ART 240

123

3.6

Individual Operations of Maintenance

3.6.11 Oil in the gearbox check

Check with the engine idling at oil temperature of 82÷93 °C – best after Machine operation is ended.

•

Open and lift off the cover between pedals on Machine’s floor.

374082 •

Unscrew and pull out dipstick, wipe off and push in again.

Pull it out once more and check oil level – it must reach the upper gauge line.

•

Fill up oil using this neck and screw the oil level gauge back.

374055

124

ART 240

MAINTENANCE MANUAL 3.6.12 Warning and control devices check •

Turn ON the switches to test that lights, warning lamps, traffic indicator lights, flashing beacon.

435025 •

Turn ignition key to position ”I” (confirm travel controllers are in idle position [neutral], parking brake switched ON), pilot lamps for recharging, idle position, parking brake must light up. Check Power View display and horn.

bar

4

bar

°C 25

0

50

150

6

2

4 8

0

6

2

10

8 0

bar

10

F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

I II

435026

0

•

Start the engine, pilot lamp for recharging must go off, check engine oil pressure via the display.

bar

4

bar

°C 25

0

2.92 BAR OIL PRES

37 % LOAD@RPM

28.6 VDC SYS VOLT

3.1 L/HR FUEL RATE

50

150

6

2

4 8

0

6

2

10

8 0

bar

10

F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

I II

435027

0

•

Start the machine as described in the Operation Manual.

When switching off the parking brake switch, check that the brake indicator lamp goes off. When pulling off, check that the corresponding indicator lamp of the activated seat goes on and the neutral position indicator goes off.

bar 0

36

4

bar

°C 25

50

150

6

2

4 8

0

36

6

2

10

8 0

bar

10

F2

F3

F4

F5

F6

F7

F8

F14

F15

F16

F17

F18

F1

F12

F11

F13

DIAC

1 2 3

435028 ART 240

125

3.6 •

Individual Operations of Maintenance

Switch off the engine, check the brake fault indicator lamp.

Press several times on the brake pedal to reduce the pressure to 5.2 bar, according to the pressure gauge - the brake fault indicator must go on and the warning signal must sound.

bar 0

4

bar

°C 25

50

150

6

2

4 8

0

6

2

10

8 0

bar

10

F1

F2

F3

F4

F5

F6

F7

F8

F11

F12

F13

F14

F15

F16

F17

F18

DIAC

1 2 3

I II 0

435029

During operation, check the instruments and indicator lamps continuously.

Use the alarm horn to signal the engine starting and check that nobody is exposed to risk by starting of the engine!

126

ART 240

MAINTENANCE MANUAL 3.6.13 Inspection of DEF (AdBlue) level •

Check the DEF (AdBlue) volume on the screen and refill if necessary.

0 RPM ENG RPM

28°C COOL TEMP

20% FUEL LEVEL

65% DEF LVL

435100 •

Remove the tank cap.

•

Add DEF (AdBlue).

435063

Refill according to the prescribed specification according to Chap. 3.2.7.

Add the necessary volume according to Chap. 3.3.

Fill 10 l (2.64 gal US) of DEF (AdBlue) at least or fill up the tank.

Using other fluids than prescribed will cause irreparable damage of the SCR system.

If incorrect fluid is used, never switch the ignition on or start the engine!

DEF (AdBlue) concentration is monitored by the control unit. When the quality requirements are breached, engine power is reduced.

Refill with the engine off!

Maintain cleanliness. Prevent contamination of the system with surrounding dust.

ART 240

127

3.6

Individual Operations of Maintenance

First aid instructions Inhalation Move the exposed person out to fresh air. Get medical attention if health effects occur. In case of inhalation of decomposition products in a fire, symptoms may be delayed. The exposed person may need to be kept under medical surveillance for 48 hours.

Ingestion Rinse the mouth with water. If material has been swallowed and the exposed person is conscious, give small quantities of water to drink. Get medical attention if health effects occur.

Skin contact Flush contaminated skin with soap water. Remove contaminated clothing and shoes. Get medical attention if health effects occur.

Eye contact Immediately flush eyes with plenty of water, occasionally lifting the upper and lower eyelids. Check for and remove any contact lenses.

Continue rinsing for at least 10 minutes. Get medical attention if irritation occurs.

General Evacuate the victim to a safe place as soon as possible. If unconscious, place in recovery position and get medical attention immediately. If not breathing, if breathing is irregular or if respiratory arrest occurs, provide artificial respiration or oxygen by trained personnel.

Maintain an open airway. Loosen tight clothing such as a collar, tie, belt or waistband. Keep the victim at rest in a well-ventilated area.

Accidental release measures Environmental principles Avoid dispersal of spilt material and runoff and contact with soil, waterways, drains and sewers. Inform the relevant authorities if the product has caused environmental pollution (sewers, waterways, soil or air).

Large spill Stop leak if without risk.

Move containers from the area of spill. Prevent from entering sewers, waterways, basements or confined areas. Absorb with DRY earth, sand or other non-combustible material. Contaminated absorbent poses the same hazard as the spilled product.

Small spill Stop leak if without risk.

Move containers from the area of spill. Absorb with liquid-binding material (sand, diatomite, universal binders, etc.) or use a spill kit.

Storage Keep in the original container or an approved alternative made from a compatible material, kept tightly closed when not in use. Provide sufficient ventilation.

128

ART 240

MAINTENANCE MANUAL 3.6.14 Check of the front axle

Regularly check the condition of the front axle. A failure of the front axle, especially the axle hydraulic suspension system, has an adverse effect on the braking efficiency.

•

Visually check the height of the front of the machine frame above the tyres. The height of the frame side above the wheels should be at least 100 mm on each side.

435123

435124 •

If the height is smaller, visually check the axle for leaks and the condition of the chrome parts of the piston rods – height of the wiped surface (at least 25 mm on each side).

•

If an oil leak is detected, do not operate the machine until the fault has been rectified and the oil has been refilled.

435125

It is forbidden to operate the machine with the wrong amount of front axle charge.

ART 240

129

3.6

Individual Operations of Maintenance Every 100 hours of operation (weekly)

3.6.15 Tyre pressure check •

Check the pressure in tyres inflated as required for operation depending on values in the Table when cold (before driving) at temperatures of 18÷21 °C (64.5÷70 °F).

While inflating, check the tyres visually for damage (local deformation, separation of rubber parts, cracks, breaks).

431053

Contact area and effective load depending on the wheel load and tyre inflation CONTACT AREA (cm2) 11.00-20 / 18 PLY Compactor without pattern

Tyre inflation (bar)

Load per one wheel (kg) 1300

1500

2000

2500

3000

3

409

442

531

605

688

4

385

416

495

570

642

5

358

390

464

537

600

6

334

364

434

507

560

7

311

345

425

496

541

8

292

328

399

463

512

10400

12000

16000

20000

24000

Machine weight (kg)

EFFECTIVE LOAD (kg/cm2) 11.00-20 / 18 PLY Compactor without pattern

Tyre inflation (bar)

Machine weight (kg)

130

Load per one wheel (kg) 1300

1500

2000

2500

3000

3

3.18

3.39

3.77

4.13

4.36

4

3.38

3.61

4.04

4.39

4.67

5

3.63

3.85

4.31

4.66

5.00

6

3.89

4.12

4.61

4.93

5.36

7

4.18

4.35

4.71

5.04

5.55

8

4.45

4.57

5.01

5.40

5.86

10400

12000

16000

20000

24000

ART 240

MAINTENANCE MANUAL 3.6.16 Check of the oil level in the front axle hydraulic cylinders •

Shut down the machine on a flat and solid surface where there is no potential natural hazard (landslides, possible flooding, etc.)

•

Measure the reference dimension of 291 mm on both piston rods of the front axle.

•

If the measured dimension is less than 260 mm, search for the location and cause of the oil leak and rectify the fault.

•

Refill oil according to Chapter 3.6.49.

435126

It is forbidden to operate the machine with the wrong amount of front axle charge.

ART 240

131

3.6

Individual Operations of Maintenance Every 250 hours of operation (3 months)

3.6.17 Engine induction manifold and air filter sensor check •

Check pipe hoses and fixing of clips.

435106

435047 •

Check air filter cuff. Cover suction hole.

435048 •

Start the engine, use the accelerator pedal to increase the engine speed to maximum; error message SPN 107 FMI 0 must be shown on the display.

1 of 1

WARNING

SPN 107

FMI

0

AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED HIDE

431115 132

ART 240

MAINTENANCE MANUAL •

If error message is not shown on the display, inspect the wiring of underpressure switch and the switch.

435049

Do NOT operate the Machine if induction manifold, air filter cuff are damaged!

ART 240

133

3.6

Individual Operations of Maintenance

3.6.18 Machine lubrication •

Lubricate with grease as per Section 3.2.8.

•

Remove floor coverings to make lubrication points accessible.

374018A •

Lubricate pin (1). If lever (2) is overhead the horizontal position when braked, then reposition pin (3) into another hole of pull rod (4).

1 Be careful grease does not get onto active surface of brake disc!

4 2

3 374041A 374041B Shaft joints

374076 Steering pins

374180 134

ART 240

MAINTENANCE MANUAL Door hinges

374078 Cover suspensions.

431063 Edge cutter pins.

431110

ART 240

135

3.6

Individual Operations of Maintenance Every 500 hours of operation (6 months)

The set of filters after 500 operating hours can be ordered under the order number 4-760181. For the list of all spare parts, see the table in the end of this publication.

3.6.19 Engine oil change

Drain oil when it is still hot after operation is ended, or while running, warm up the engine until cooling liquid reaches 60 °C. Observe fire precautions!

Beware of hot oil burn hazard when draining oil. Let oil cool down below 50 °C.

431054 •

Remove drain plug and let oil flow out into a vessel of ca 10 l (2.64 US gal) capacity. Reinstall drain plug. Apply 80 Nm (59 lb ft) torque to tighten.

•

Clean oil filter and its vicinity. Remove filter.

435107 •

Apply oil slightly across filter gasket.

Oil filter Ordering number: 5-0020003

396247 136

ART 240

MAINTENANCE MANUAL •

Clean contact surface for filter gasket. Screw the filter and tighten with the torque of 15–17 Nm.

Do not tighten excessively the filter, its thread and gasket may get damaged.

Note: Refer to Engine Operation and Maintenance Manual for the special spanner required.

•

435107

Use filler neck to fill the engine – medium amount is 9.5 l (2.5 US gal).

435102 •

Fill to upper gauge line of the dipstick.

•

When exchanged, start the engine for 2 - 3 min. Check tightness of drain plug and filter. Stop the engine and wait for 5 min. until oil flows down to crankcase sump. Then use dipstick to confirm oil level.

Exchange oil after 6 months at the latest even though 500 hours have not been actually operated. Exchange oil within interval that occurs as first.

Use recommended filters, refer to Catalogue of Spare Parts.

Use oil as per Section 3.2.1.

435101

Drain oil into catch vessels.

Spent oil and filter are ecological waste – hand over for disposal.

ART 240

137

3.6

Individual Operations of Maintenance

3.6.20 Fuel filters replacement Fuel filter •

Clean and remove fuel filter.

435108 •

Clean contact surface for the filter.

396249 •

Apply oil over the sealing ring at the new filter.

Fuel filter Ordering number: 1238008

396247 •

Mount the filter and tighten firmly by hand – tightening torque 10–12 Nm.

396250A 138

ART 240

MAINTENANCE MANUAL Fuel pre-filter •

Disconnect the connector of water separator sensor and proceed in the same way like in the previous text. Connect the sensor connector.

Note •

If the filters are not filled with the fuel while replacing them, refuel; see chapter “Cleaning the water separator on the fuel filter”.

Fuel filter Ordering number: 1229401

431065

Use original filters required.

No smoking at work!

Do NOT tighten the filters with force.

Retain any fuel flowing out.

Store used filters inside separate container, and hand over for their disposal.

ART 240

139

3.6

Individual Operations of Maintenance

3.6.21 Air filter elements replacement Note: The air filter contains a main element and a safety element. Replace the main element when the error message SPN 107 FMI 0 is shown on the display but not later than after 500 engine hours. Replace the safety element after every third replacement of the main element.

Manufacturer does not recommend any cleaning of the element due to lowered filtration capacity by up to 40 % and due to potential of damaging the element when being cleaned.

•

1 of 1

WARNING

SPN 107

FMI

0

AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED HIDE

431115

Slacken the clips and take off the lid.

431076 •

Take out the main element.

Filter set Order number: 1229388

431077 •

Take out the safety element.

•

Replace the safety element after every third replacement of the main element.

•

Clean the internal area of the filter and of the contact surface so that no dust is taken into the supply piping towards the engine. Insert the new safety element and the new main element.

431078 140

ART 240

MAINTENANCE MANUAL •

Take off dust valve, clean it and reinstall.

Dust valve Order number: 1-952454

NEVER clean inner space of the filter with pressure air to avoid any dust penetrating into engine induction manifold.

Use original elements, only.

When washing the Machine be careful not to splash water into air filter.

Replace the dust valve immediately if it is damaged!

Do NOT operate Machine with filter body damaged or filter cover damaged.

In case of work in a very dusty environment, shorten the cleaning intervals.

435044

3.6.22 Engine cooling liquid check •

Inspect cooling liquid concentration with the refractometer using cold engine.

435103

Check always before winter season. Unless concentration for ambient temperatures of -36 °C (-33 °F) is found, adjust it or exchange cooling liquid according to Section 3.2.3.

ART 240

141

3.6

Individual Operations of Maintenance

3.6.23 Gearbox oil filter replacement

First carry out after 100 hours.

•

Open the cover in the floor.

374082 •

Unscrew oil filter, collect oil flowing out. Apply oil over new filter’s packing ring. Screw on the new filter and tighten with 27 – 34 Nm (20 – 25 lb ft) torque.

Oil filter Ordering number: 4-9502000402

431067

Do NOT tighten with force, danger of threads and gasket damaged.

Let gearbox cool down below 50 °C before replacing.

Spent filter is ecologically hazardous waste, hand over for disposal.

142

ART 240

MAINTENANCE MANUAL 3.6.24 Oil in differential and oil in rear axle check •

Clean and unscrew inspection plug for differential. Check oil level is up to inspection hole.

•

If it is required to fill up the oil, proceed according to Chapter 3.6.37 Axle drive oil change.

•

Tighten the plug with 80÷90 Nm (59÷66.4 lb ft).

374090 •

Clean and remove plug on rear side of down gear housing, and check if level reaches up to the inspection hole or flows out slightly.

•

If it is required to fill up the oil, proceed according to Chapter 3.6.39 Rear axle oil change.

374085

3.6.25 Wiring check •

Check for any damage to cables, connectors, protective hoses, and their fastening, especially if in the vicinity of hot surfaces and moving parts of the machine including the engine. Replace damaged parts. Use only original spare parts.

ART 240

143

3.6

Individual Operations of Maintenance

3.6.26 Air conditioning coolant check •

Lift the bonnet.

431089 •

Check the filter dehydrator sight hole while the air conditioning system is on and the engine is running at idle speed.

431090 •

The liquid flowing in the sight hole must be transparent.

OK

402D285 •

Fogging or foam indicates the lack of coolant and, thus, decreased unit functionality. Check the hoses, their connections, and the compressor for coolant leaks.

•

To remove any defects, call an authorised service company.

402D284 144

ART 240

MAINTENANCE MANUAL 3.6.27 Air filter of the air conditioning system replacement •

Remove the cover grille on both sides.

374K03 •

Replace both filter elements.

•

Beat the elements gently and wash them in a detergent solution. Should any element be damaged or should it not be possible to remove dirt, replace it with a new one.

•

In case of work in a highly dusty environment, shorten the intervals of cleaning.

Filter Ordering number: 4-16481

374K04

3.6.28 Cab ventilation filter cleaning •

Remove the cover (1). Remove the filter cartridge (2) (filtration of sucked air outside the cab), replace with a new cartridge.

Filter cartridge Order number: 4-5351010189

1 431099

2

431100 ART 240

145

3.6

Individual Operations of Maintenance

3.6.29 Replacement of DEF (AdBlue) filter

Keep clean.

Provide sufficient ventilation.

In case of insufficient ventilation, wear suitable respiratory equipment.

Recommended: organic fumes filter (A type), ammonia filter (K type).

Wear suitable chemical resisting, impervious gloves.

Wear goggles intended for splash water protection.

Avoid contact with skin. Wear suitable protective clothing.

•

Turn off the engine.

•

Put a reservoir under the filter.

•

Remove the lid.

4090240 •

Pull out the levelling item.

4090241 146

ART 240

MAINTENANCE MANUAL •

Remove the insert.

4090242

4090243 •

Check the thread and clean the seating face.

4090244 •

Wipe the sealing with oil.

•

Insert a new filter.

Filter cartridge Order number: 1391087

4090245 ART 240

147

3.6 •

Individual Operations of Maintenance

Insert a new levelling item.

4090246 •

Put back the lid.

•

Tightening torque 22.5 ± 2.5 Nm (16.6 ± 1.8 lb ft).

4090247

Only use an original filter.

Do NOT overtighten the filter, its thread and gasket may get damaged.

Dispose used filters in compliance with regulations.

148

ART 240

MAINTENANCE MANUAL 3.6.30 Engine belt check •

With the engine running, check visually the pulley of alternator, cooling air blower, crank shaft, to confirm these do not oscillate.

•

Stop the engine!

•

Lift the belt-tensioning pulley and remove the belt.

431044 •

Perform the visual inspection of the belt for any damage.

Cracks perpendicular to the width of the belt are not a defect. If there are longitudinal cracks on the belt or the belt edges are ragged or any parts of material are torn out, it is necessary to replace the belt.

264057 •

Remount the belt.

•

Check the belt for correct tension. Apply the force 400± 50 N, the belt sag must not be visible.

Check the tension accurately using the fixture that you can order from the engine manufacturer Deutz; it is specified in the engine operating instructions supplied on CD.

ART 240

149

3.6

Individual Operations of Maintenance Every 1000 hours of operation (1 year)

The set of filters after 1000 operating hours can be ordered under the order number 4-760182. For the list of all spare parts, see the table in the end of this publication.

3.6.31 Battery check •

Use isolating switch to disconnect storage batteries.

435038 •

Open the cover.

374017 •

Clean the surface of batteries.

•

Check the condition of poles and terminals (1). Clean battery poles and terminals. Apply a thin layer of grease to terminals (make sure that the contact is good).

1

1 431062 150

ART 240

MAINTENANCE MANUAL MAINTENANCE-FREE BATTERY •

In case of a maintenance-free battery (the battery has no freely accessible plugs), only the no-load voltage on terminals is checked. The batteries cannot be replenished. If the no-load voltage is 12.6 V and more, the battery is fully charged. If the no-load voltage is below 12.4 V, the battery should be charged immediately. It is recommended to be mounted 24 hours after charging.

Note: The no-load voltage is the voltage measured at the terminals of the battery which was at rest for at least 12 hours – was neither charged nor discharged.

Unless the Machine is going to be used during severe frosts, remove storage batteries and store them so to be protected against any frost. While stored, inspect their charging condition 1x per month and recharge.

Keep storage batteries dry and clean.

NEVER disconnect storage battery with the engine running. Always follow storage battery manufacturer’s manual when working with the storage battery!

Use rubber gloves and safety glasses when handling storage battery.

Protect your skin with proper clothing against being stained by electrolyte.

Upon eye contact with electrolyte immediately flush eyes with large amounts of water for at least a couple of minutes. Get prompt medical attention.

Upon ingestion of electrolyte drink max amount of milk, water or solution of calcined magnesia in water. Get prompt medical attention.

Upon skin contact with electrolyte remove contaminated clothing, including shoes, wash affected spots as soon as possible with soap water or solution of soda and water. Get prompt medical attention.

Do not eat, drink, smoke, while at work!

Upon work completion, please wash your hands and your face thoroughly with water and soap!

Do NOT attempt to confirm a wire is energized through contacting Machine frame.

Disconnect storage battery before its repair or when handling wires or electric equipment within wiring circuit to avoid any short-circuit.

To disconnect storage battery you must first disconnect (–) pole of the cable. To connect, first connect (+) pole.

NEVER attempt to make direct conductive connection between storage battery’s both poles, short circuit will occur with the risk of storage battery explosion.

Do not turn storage battery upside down, electrolyte may pour down from the degassing plugs.

Flush with water and neutralize with lime the spot affected with spilled electrolyte.

Hand over the aged storage battery that does not work, for its disposal.

ART 240

151

3.6

Individual Operations of Maintenance

3.6.32 Brake shoes adjustment

Brake off the Roller before wheel removal.

•

•

Lift a bit the Machine onto the rear lugs of the frame so the rear wheels do not touch the ground. Chock the rear part of Machine frame. Secure front wheels with Scotch blocks on both sides.

435030

Remove the tire inflation and deflation hoses (1). Remove the nuts (2) and remove the rear wheels.

2

1 431092 •

Remove step by step the brake drums. When removal is complicated, use forcing-off screws M12-60 of min. 8G strength, into holes (1) of brake drum (2). Confirm there are no scratches or cracks across drum’s internal diameter.

1

1

2

1

•

1

374N121

Check thickness, uneven wear or contamination of lining (1).

1

2

1 374N122

152

ART 240

MAINTENANCE MANUAL

If, while checking, you find lining thickness is 4 mm (0.16”) or smaller, please check lining after next 500 operating hours.

Replace lining always when thickness reaches min value of 2 mm (0.08”).

Replace all brake clips at one time to maintain uniform braking!

Always replace adjusting mechanism defected with new one.

When replacing, use original brake clips only!

With brake shoe lining replaced the brake efficiency will lower and stopping distance will get longer. Adapt driving mode and braking mode to this case!

•

Check brake cylinder for any leakage of brake fluid.

374N123 •

When checking is completed reinstall the drums. Turn brake drum with its adjustment hole pointing downward towards adjusting wheel. Rotate adjusting wheel (1) until brake clips lean against brake drum (brake drum unable to rotate). Turn a bit the adjusting screw backward by only such turn so the brake clips get released (brake drum able to rotate freely).

1 374N121A Carry out brake clip adjustment during: Insufficient brake efficiency (long step of brake pedal) Replacement of worn clips for new ones Following the installation of new brake drum or after brake drum’s inner diameter is machined (refer to Workshop Service Manual).

•

Before installing wheels onto the brake drums following the brake repair, please point the brake drum bolts against holes in the wheels using an appropriate lever so to avoid damage of bolt threads, reinstall wheels, tighten wheel nuts with 400 Nm (295 lb ft) torque.

ART 240

153

3.6

Individual Operations of Maintenance

3.6.33 KM nuts tightening check and front wheels lubrication •

Check the tightening of KM nuts of front wheels applying a torque of 250 Nm.

374072C •

Lubricate with grease as per Section 3.2.9.

-

External bearings of front wheels

374072B -

Internal bearings of front wheels

374075 •

In order to grease the inner and outer bearings of front axle wheels thoroughly, the lubricating grease must be pressed out around the flange.

430023 154

ART 240

MAINTENANCE MANUAL 3.6.34 Cleaning of the air cooler •

Remove both of the plugs of the air cooler and drain the accumulated condensate.

•

Clean the plugs and mount again.

435053

435054

3.6.35 Air conditioning compressor mounting check •

Check the strength of the compressor attachment and the compressor bracket. Make sure that the belt does not spin. If necessary, tighten the screws.

431101

ART 240

155

3.6

Individual Operations of Maintenance

3.6.36 Gearbox oil change

Drain oil when operation has ended after cooling down to 50 °C, or while driving you wait until oil warms up.

Beware of burn hazard when draining hot oil .

•

Remove the plug, drain the oil into the prepared vessel of 21.5 l (5.7 gal US) and at the same time replace the filter according to chap. Replace the oil filter of the gearbox CLARK.

•

Open the cover underneath control panel.

431054A

431112 •

Pour the amount of 21.5 l (5.7 gal US) through a hole after having pulled out check dipstick, up to FULL mark. Start the engine and while idling, check oil level to confirm it reaches up to ADD mark. With oil warmed up to 82÷93 °C, please check and fill up to FULL if required.

431113 Observe fire precautions!

Use recommended oils according to Section 3.2.5.

Drain oil into collection vessels.

Spent oil is ecological waste – hand over for disposal.

156

ART 240

MAINTENANCE MANUAL 3.6.37 Oil in differential change

First carry out after 250 hours.

•

Drain sprinkling tank, refer to Section called “How to clean sprinkling filter”. Remove the tank.

431015 •

Remove filler plug (1) and inspection plug (2).

1

2

374084A •

Let the oil drain into the prepared vessel.

•

Use hole (1) to pour 6 l (1.58 gal US) of oil according to Section 3.2.6.

•

Check oil level in hole (2). Oil must pour out slightly.

•

Tighten inspection plug (2) with 80÷90 Nm (59÷66 lb ft) torque. Tighten filler plug (1) with 70÷80 Nm (52÷59 lb ft) torque.

374090A

1 Beware of burn hazard when draining hot oil.

2 Drain oil into collection vessels. Spent oil is ecological waste – hand over for disposal.

374084A ART 240

157

3.6

Individual Operations of Maintenance

3.6.38 Air drier replacement •

Remove the floor cover.

431094 •

Remove air drier cartridge. Clean upper part of the body. No dirt may enter the clean air area (non-return valve). Apply oil over the gasket of new drying cartridge. Tighten manually the cartridge – with 15 Nm (11 lb ft) torque.

Drier Ordering number: 1426356 Cartridge Ordering number: 1296325

Spent drying cartridge is ecological waste – hand over for disposal.

158

431114

ART 240

MAINTENANCE MANUAL Every 2000 hours of operation (2 years)

The set of filters after 2000 operating hours can be ordered under the order number 4-760183. For the list of all spare parts, see the table in the end of this publication.

3.6.39 Oil in rear axle change

2

First carry out after 250 hours.

•

Clean and remove drain plugs (1), filling plugs (2) – in both housings.

•

Let the oil drain into the prepared vessel. After draining the oil, mount the plugs (1).

•

Fill 5.2 l (1.4 gal US) of the new oil according to Chapter 3.2.6 into the filler (2) for each housing separately. The oil can run out slightly from the hole (2).

•

Remount the filler plug (2).

1 374085A

Beware of burn hazard when draining hot oil.

Drain oil into collection vessel of 6 l (1.6 gal US) capacity.

Spent oil is ecological waste – hand over for disposal.

ART 240

159

3.6 •

Individual Operations of Maintenance

Remove the housing cover on both speed-reduction transmissions using unloading screws.

Right side

374166 Left side

374167 •

Lubricate the cover with Vaseline according to Chapter 3.2.9.

•

Remount the cover.

374168

160

ART 240

MAINTENANCE MANUAL 3.6.40 Hydraulic oil and filter change

Exchange oil before season or following a long term shutdown of the Machine.

Drain oil when operation has ended after cooling down to 50 °C, or while driving the Machine, wait until oil warms up.

Observe fire precautions!

Beware of burn hazard when draining hot oil.

•

Open the cover and drain 22 l (5.81 US gal) of oil via the valve. When drained, close the valve.

435062 •

Remove the cover.

431083 •

Unscrew filter cap.

431084 ART 240

161

3.6 •

Individual Operations of Maintenance

Replace filter element.

Replace the filter element always after the control lamp of the hydraulic oil filter clogging lights up, if the minimum operation temperature of oil of 50 °C (140 °F) is reached.

Filter cartridge Ordering number: 1229403

•

431085

Replace the breather filter .

Breather filter Ordering number: 1296125

435064 •

Check temperature sensor – remove the sensor. Put in liquid heated to 88 °C (190 °F) temperature and check whether pilot lamp for oil overheating will light up.

Temperature sensor Ordering number: 4-5503580053

Filling the hydraulic circuit: •

Fill using the hydraulic unit.

•

You can order the hydraulic unit from the machine manufacturer.

431086

Hydraulic unit 230 V Ordering number: 1251998 Hydraulic unit 110 V Ordering number: 1255297

NOTE •

The hydraulic unit 230 V is intended for operation in 230Volt networks (Europe), the hydraulic unit 110 V is intended for operation in 110-Volt networks (North America).

162

1251998 ART 240

MAINTENANCE MANUAL •

Slide the quick-coupling of the hydraulic unit on the filling end piece.

•

Fill oil up to max level.

435055

Observe cleanliness during work. Avoid any contamination of the system with materials that might cause damage to the units!

Use only recommended oil according to Section 3.2.4.

Exchange oil and filter always when destruction of internal parts of the units (hydromotors, hydrogenerators) occurs, or following a major repair of hydraulic system.

Fill new unit with oil before its installation. Test the Machine function with the engine running at high speed.

Check tightness.

Blind all holes with plugs when hydraulic circuits are disconnected.

Collect drained oil and do not let it soak into ground.

Spent oil and filters are ecologically hazardous waste – hand it over for disposal.

ART 240

163

3.6

Individual Operations of Maintenance

3.6.41 Oil in front axle hydraulic cylinders change •

Use front lifting lugs to lift a bit the front part of the Roller so its front wheels get relieved by means of crane.

435031 •

Remove cover.

435056 •

Remove fast coupling on the pipe that connects hydraulic cylinders for front axles, put on the hose, and descend the Machine slowly to drain oil into a vessel set up. Screw in the filling quick-coupling, refill the hydraulic cylinders using a filler with new oil to the reference dimension.

431072

Observe fire precautions!

Use recommended oil as per Section 3.2.4.

Spent oil is ecological waste – hand over for disposal.

164

435122 ART 240

MAINTENANCE MANUAL 3.6.42 Brake fluid change

To deaerate, there must be air pressure level inside brake system (air tank). Unless there is air level the system must be filled while the engine is running – follow safety measures during engine start.

Two persons must work together to carry out deaeration.

Pump out brake fluid from the circuit: •

Remove rear wheel according to Section called “How to adjust brake clips”.

•

Slip box end wrench over the hose pipe No. 9.

374N138 •

Slip hose pipe incl. key over the deaeration (air relief ) screw.

374N139 •

Locate hope pipe in the vessel and slacken deaeration screw for brake cylinder. It is possible to always handle the wheel couple simultaneously. Second person is to depress brake pedal repeatedly to force out fluid step by step from all brake cylinders into the vessel. Tighten deaeration screw.

374N140 ART 240

165

3.6 •

Individual Operations of Maintenance

Fill equalizer tank with fluid and keep level above ”MIN” when deaerating.

435105 •

Remove the floor cover.

431094 •

Slacken deaeration screw at the brake master cylinder by 2 turns, and when filled up with fluid, close deaeration screw.

374100 •

Fill tanks with new brake fluid (immerse hose pipe end below level). Slacken deaeration screws. Press brake pedal slowly as long as fluid moves out with air bubbles. Then with the brake pedal pressed, close deaeration screws for brake cylinders, wipe them and install protective caps. Check circuit tightness, level in the tank, and adjust. Reinstall wheels.

Tighten wheel nuts with 400 Nm (295 lb ft) torque.

166

ART 240

MAINTENANCE MANUAL

Keep brake fluid inside original, well closed containers!

When in use, proceed according to brake fluid producer’s instructions.

Brake fluid will damage painted parts of the Machine.

Use recommended brake fluid under Section 3.2.3.

When filling up, avoid fluid spilled over the Machine and off the Machine as well.

Collect brake fluid in the vessel and hand it over for disposal!

3.6.43 Air conditioning system check •

Have the functional check of individual components, wiring checking, and air conditioning system cleaning (removal of mould and bacteria) performed by an authorised company.

•

In case of work in a highly dusty environment, have the check performed in shorter intervals.

ART 240

167

3.6

Individual Operations of Maintenance Every 6000 hours of operation (4 years)

3.6.44 Engine cooling liquid change •

Open cooling system by removing pressure plug on the equaliser reservoir.

435058

OK

OK

Do not dismantle the pressure plug before the temperature of cooling liquid falls lower than to 50 °C (122 °F).

Beware of gushing of the coolant and scalding when opening the pressure plug.

282N205T •

Dismantle the drain plug.

•

The quantity drained is approximately 11.5 l (3 US gal).

431054B NOTE Check cooling system for defective hoses and missing hose clips. Check the condition of the cooler - search for defects, leaks and cooling gills blocked with impurities.

168

ART 240

MAINTENANCE MANUAL •

Fill up the cooling system with the agent Deutz and water in the specified ratio; see chapter 3.2.3.

Cooling agent Ordering number: 1416502 •

Fill it up to the upper line of the watermark. After pouring, wait about 2 to 3 minutes until the air escapes and the circuit is filled. The maximum rate of filling is 11 l/min (3 US gal/min). Close the expansion tank using a pressure cap.

•

Start the engine and wait until the temperature reaches 80 °C (175 °F). While waiting, make sure that the cooling liquid does not leak.

•

Stop the engine.

•

Check the level according to the watermark. If it is low, fill up the cooling liquid to the maximum.

431093

Do not dismantle the pressure plug before the temperature of cooling liquid falls lower than to 50 °C (122 °F).

Beware of gushing of the coolant and scalding when opening the pressure plug.

Use cooling liquid according to chapter 3.2.3!

Protect your hands with gloves!

Use safety glasses or safety shield!

Collect used liquid and have it safely disposed according to valid regulations!

ART 240

169

3.6

Individual Operations of Maintenance Maintenance if required

3.6.45 Water from separator draining •

If error message SPN 97 FMI 12 is shown on the display, clean the water separator of the fuel filter.

1 of 1

WARNING

SPN 97

FMI

12

WATER IN FUEL DETECTED

HIDE

431117 •

Turn the separator’s valve until water starts flowing out.

431075

Do NOT drain separator while engine is hot and running.

Collect drained fuel incl. sediment into a proper vessel.

170

ART 240

MAINTENANCE MANUAL 3.6.46 Fuel system venting Deaerate fuel system before first starting: •

Replacement of the fine filter

•

During fuel pump replacement

•

Upon long term shutdown of the Machine

•

With fuel pumped out from the tank

Filter venting: •

Vent the filter using the bleeder screw.

435109 •

Turn the key in the ignition box to the “I” position to enable the pump. When the clean fuel starts flowing out from the filter, turn the key back to the position “0”.

•

Tighten the bleeder screw.

Do NOT deaerate while engine is hot, leaking fuel may cause fire.

Do NOT smoke!

Collect leaking fuel!

ART 240

171

3.6

Individual Operations of Maintenance

3.6.47 Coolers cleaning •

With regard to the Machine operating in various working environments no regular interval for cleaning can be determined. When working in very dusty environment, carry out cleaning on daily basis. Fouled radiator will cause increased temperature of engine cooling liquid and hydraulic system oil. Clean with pressure air or pressure water (steam) from the side of cooling air blower.

435060

Do NOT use cleaners with too high pressure so to avoid any damage to radiators’ plates.

With radiator contaminated with crude oil products (oil), use cleaning agent and proceed in line with producer’s instructions! Find out the cause of contamination!

When cleaning, please proceed according to ecological standards and regulations!

Perform cleaning at workplaces equipped with cleaning agent collection system to avoid any contamination of soil and water resources!

NEVER use banned cleaning agents!

172

ART 240

MAINTENANCE MANUAL 3.6.48 Regeneration of clogged catalyst SCR (Selective Catalytic Reduction) •

Regeneration is a special engine mode, during which the machine cannot be used.

•

Regeneration is made through dissolution of DEF (AdBlue) crystals in the SCR catalyst.

•

The regeneration is fully controlled by the engine control unit and it is recommended to wait until the regeneration process is completed.

Conditions for start of regeneration

Indication lamp of SCR catalyst clogging

Engine failure indicator lamp

AMN118

Sound signal

Machine reactions

AMN47

Normal operation

No need for regeneration

Off

no

no

No

Crystallisation detection

Machine idle and regeneration button

Flashing slowly 0.5 Hz

no

no

No

Crystallization detection warning

Machine idle and regeneration button

Flashing slowly 0.5 Hz

Lit

Yes

Engine output reduced by 25 %

Crystallization detection switch off

Machine idle and service tools requested

Flashing rapidly 3 Hz

Yes

Output reduced to 50 % + reduction of max. engine speed 1300 rev/min

Flashing

Regeneration conditions: -

Stop the machine at a safe place.

-

Drive control in the brake position

-

Coolant temperature >70 °C

-

Sufficient volume of fuel - ca 20 l (5.3 gal US)

-

Sufficient volume of DEF (AdBlue) (Diesel exhaust fluid) - ca 1 l (0.26 gal US).

Start of regeneration: -

Press the SCR catalyst regeneration button

Progress of regeneration: -

Automatic increase of engine speed (about 1800 rpm).

-

Regeneration duration 40-50 min.

End of regeneration: -

Automatic decrease of engine speed (about 1000 rpm).

-

Regeneration and warning indication lamp switches off.

ART 240

173

3.6

Individual Operations of Maintenance

3.6.49 Refilling the oil level in the front axle hydraulic cylinders •

Shut down the machine on a flat and solid surface where there is no potential natural hazard (landslides, possible flooding, etc.).

•

Remove the front axle cover.

435056 •

Refill the hydraulic cylinders using a filler through the quickcoupling.

431072 •

Refill hydraulic oil to the specified dimension according to the figure. Perform the check on both piston rods and calculate the arithmetic mean of both values.

435122 •

Disconnect the filler and check the quick-coupling on the machine for leaks.

•

Reinstall the cover.

•

If you overfill the hydraulic cylinders, relieve the front axle by supporting the frame with a jack or by hanging it on a crane.

435127 174

ART 240

MAINTENANCE MANUAL •

Remove the quick-coupling on the pipe and push out excess oil by gradual slow lowering.

431072

Follow the fire-fighting measures!

Use only the oil recommended in Chapter 3.2.4.

ART 240

175

3.6

Individual Operations of Maintenance

3.6.50 Sprinkling filter cleaning •

Remove the filter, clean its strainer.

Drain sprinkling tank and system always before ambient temperature lowers below 0 °C (32 °F)!

431018 •

Drain tank.

431097 •

Drain sprinkling pipes at the front and back by slackening the nozzles.

431140

176

ART 240

MAINTENANCE MANUAL 3.6.51 Brush scrapers cleaning •

Check condition of front brushes (1), rear brushes (2) – clean them and repair them.

1 431141

2 431142

3.6.52 Check of wheel nuts for tightening

First carry out after 50 hours.

•

Check the wheel nuts for tightening to 400 Nm (295 lb ft).

431097A

ART 240

177

3.6

Individual Operations of Maintenance

3.6.53 Machine cleaning •

When the work is completed clean the Machine to get rid of major dirt! Carry out overall cleaning on regular basis, at least once per week. When working on cohesive soils, soil cements and lime soil, carry out overall cleaning on daily basis. Pay attention to the function of scrapers!

Before pressure cleaning the Machine with water or steam, please blind all the ports into which a cleaner might penetrate (e.g. engine inlet port, cabin’s ventilation port, etc.). With the Machine cleaned remove these blinds.

Disconnect master switch!

NEVER expose electric parts or insulation material (alternator, electric connections, etc.) to direct stream of pressure water or steam, always cover these locations.

Carry out the work with the engine stopped.

Follow producer’s instructions when using cleaning agents.

NEVER use aggressive or easily ignitable cleaning agents (e.g. petrol and/or incendiary materials easy to ignite).

When cleaning, please proceed according to ecological standards and regulations.

Perform cleaning at workplaces equipped with cleaning agent collection system to avoid any contamination of soil and water resources.

Do NOT use forbidden cleaning agents.

178

ART 240

MAINTENANCE MANUAL 3.6.54 Air collector inspection •

The air collector is a simple pressure vessel serving as a compressed air reservoir for the brake circuit and additional systems of the machine.

Air collector inspection in operation, i.e. tests and examinations are carried out in specialised repair shops, no later than after five years and always when they were suffered damage or the machine broke down.

No modifications, weldings and heat treatments are allowed on the air collector!

•

374202

If the air collector passed prescribed tests, it is necessary to stamp the air collector plate with the test date and the name of the worker who carried out the test. The air collector test must be recorded in the after-repair delivery report of the machine and in the service book delivered with the machine. It is necessary to remove name plates from air collectors, which were put out of service after a fault was detected, and the air collectors must be destroyed to prevent their further use.

ART 240

179

3.6

Individual Operations of Maintenance

3.6.55 Charging of the battery •

Only use chargers with an appropriate rated voltage. Check that the charger is strong enough to charge the battery not too strong to charge with excessive current.

•

Read and observe the operating manual of the charger manufacturer.

•

Check that the ventilation holes in the battery cover are not dirty or clogged and that gases can escape freely.

•

Connect the positive terminal (+) of the battery to the positive terminal of the charger.

•

Connect the negative terminal (-) of the battery to the negative terminal of the charger.

•

Turn on the charger only after connecting the battery.

•

Charge the battery with current corresponding to one tenth of the battery capacity.

•

After charging, first turn off the charger and then disconnect the cables from the battery.

•

The battery is fully charged, if: -

electric current and voltage remain constant in the case of voltage-controlled chargers,

-

the charging voltage in the case of current-controlled chargers does not increase within two hours, the automatic charger turns off or switches to maintaining charge.

Use rubber gloves and eye protection devices when handling the battery.

Use suitable clothing to protect your skin against contact with the electrolyte.

After eye contact with the battery electrolyte, immediately flush the affected eye thoroughly with running water for several minutes. Then seek medical advice.

After ingestion of the electrolyte drink large quantities of milk, water or suspension of magnesium hydroxide in water.

In case of skin contact with electrolyte, remove your clothing and shoes, wash the affected skin immediately with soap and water or with solution of water and soda.

Then seek medical advice.

Do not eat, drink and smoke while working!

After completing the work, wash your hands and face thoroughly with water and soap!

Do not check that a wire is live by touching the machine frame.

When working with the battery always follow instructions of the battery manufacturer!

Never charge a frozen battery or battery with a temperature above 45 °C. Stop charging if the battery is hot or leaking acid.

Check that the ventilation holes in the battery cover are not dirty or clogged and that gases can escape freely. If the ventilation holes are clogged, gases can accumulate inside the battery and irreversibly damage it.

Never make direct conductive connection between both poles of the battery to avoid a short circuit and a risk of explosion of the battery.

Do not turn the battery upside down, the electrolyte can flow out.

If the electrolyte is spilled, wash the affected area with water and neutralize with lime.

Hand over the old inoperative battery for disposal.

180

ART 240

MAINTENANCE MANUAL 3.6.56 Screw connection tightening check •

Check no main bolt connections (wheel nuts, axle mount, hydraulic connection mount, engine mount, mount of units attached to the engine) have been slackened). Use torque spanners to tighten these.

TORQUE For 8.8 (8G) bolts

TORQUE

For 10.9 (10K) bolts

For 8.8 (8G) bolts

For 10.9 (10K) bolts

Thread

Nm

lb ft

Nm

lb ft

Thread

Nm

lb ft

Nm

lb ft

M6

10

7.4

14

10.3

M18x1.5

220

162.2

312

230.1

M8

24

25.0

34

25.0

M20

390

287.6

550

405.6

M8x1

19

14.0

27

19.9

M20x1.5

312

230.1

440

324.5

M10

48

35.4

67

49.4

M22

530

390.9

745

549.4

M10x1.25

38

28.0

54

39.8

M22x1.5

425

313.4

590

435.1

M12

83

61.2

117

86.2

M24

675

497.8

950

700.6

M12x1.25

66

48.7

94

69.3

M24x2

540

398.2

760

560.5

M14

132

97.3

185

136.4

M27

995

733.8

1400

1032.5

M14x1.5

106

78.2

148

109.1

M27x2

795

586.3

1120

826.0

M16

200

147.5

285

210.2

M30

1350

995.7

1900

1401.3

M16x1.5

160

118.0

228

168.1

M30x2

1080

796.5

1520

1121.0

M18

275

202.8

390

287.6

The values given in the Table are torques at dry thread (at coefficient of friction = 0.14). These values DO NOT apply to greased thread.

Chart for torques of cap nuts with “O” sealing ring - hoses Torques of cap nuts with “O“ ring - hoses Nm

lb ft

Spanner size

Thread

Pipe

Nominal

Min

Max

Nominal

Min

Max

14

12x1.5

6

20

15

25

15

11

18

17

14x1.5

8

38

30

45

28

22

33

45

38

52

33

28

38

51

43

58

38

32

43

58

50

65

43

37

48

74

60

88

55

44

65

16

74

60

88

55

44

65

18

105

85

125

77

63

92

135

115

155

100

85

114

166

140

192

122

103

142

19

16x1.5

22

18x1.5

24

20x1.5

27

22x1.5

30

24x1.5

32

26x1.5

36 41 46 50 50

ART 240

30x2 36x2

8 10 10 12 12 14 15

20 22 25 28

42x2

30

240

210

270

177

155

199

45x2

35

290

255

325

214

188

240

330

280

380

243

207

280

52x2

38 42

181

3.6

Individual Operations of Maintenance

Chart for torques of necks with sealing edge or with flat gasket

Chart for torques of plugs with flat gasket

Neck Torques

Plug Torques

G -M

Nm

lb ft

G -M

Nm

lb ft

G 1/8

25

18

G 1/8

15

11

G 1/4

40

30

G 1/4

33

24

G 3/8

95

70

G 3/8

70

52

G 1/2

130

96

G 1/2

90

66

G 3/4

250

184

G 3/4

150

111

G1

400

295

G1

220

162

G 11/4

600

443

G 11/4

600

443

G 11/2

800

590

G 11/2

800

590

10 x 1

25

18

10 x 1

13

10

12 x 1.5

30

22

12 x 1.5

30

22

14 x 1.5

50

37

14 x 1.5

40

30

16 x 1.5

60

44

16 x 1.5

60

44

18 x 1.5

60

44

18 x 1.5

70

52

20 x 1.5

140

103

20 x 1.5

90

66

22 x 1.5

140

103

22 x 1.5

100

74

26 x1.5

220

162

26 x1.5

120

89

27 x 1.5

250

184

27 x 1.5

150

111

33 x 1.5

400

295

33 x 1.5

250

184

42 x 1.5

600

443

42 x 1.5

400

295

48 x 1.5

800

590

48 x 1.5

500

369

M-G

M-G

M-G

282N221T

182

282N222T

ART 240

3.7

Defects

MAINTENANCE MANUAL

Usually, defects are caused by incorrect operation of the machine. Therefore, in case of any troubles read again properly through the instructions given in the operation and maintenance manual for the machine and engine. If you cannot identify the cause, contact a service department of an authorised dealer or the manufacturer.

Troubleshooting in hydraulic and electric systems requires knowledge of these systems; therefore a service department of an authorised dealer or the manufacturer should be called to solve these problems.

ART 240

183

3.8

Annexes

Wiring Diagram Legend: A1 Turn indicator interrupter

H12 Brake indicator lamp

S20 Brake pressure switch

A2 Electronics of steering switching version 102-1

H13 Hydraulic filter clogging indicator lamp

S21 Hydraulic oil filter pressure switch

A3 Multifunctional display Murphy PV-101

H16 Hydraulics overheating indicator lamp

S22 Engine air filter pressure switch

A4 Air dryer

H17 Sprinkling indicator lamp

A5 Air-conditioning (optional)

H19 Coolant indicator lamp

S25 Front screen wiper switch

A6 ECM

H20 Diagnostics indicator lamp

A7 Converter

H21 Oil pressure pilot lamp

A8 Fan speed control

H22 SCR indicator lamp

A10 Acoustic module PVAA20

H23 Regeneration indicator lamp

A12 Voltage converter

H24 Water in fuel pilot lamp

A13 Telematic (optional)

K1-5,10 Auxiliary relays

B1 Accelerator pedal position sensor - left

K11-12 Contactors

B2 Accelerator pedal position sensor - right B3 Gearbox temperature sensor B4 Gearbox lubrication pressure sensor

K6-9 Auxiliary relays (cab) M1 Engine starter M2 Front screen wiper M3 Rear screen wiper M4 Front screen washer

B5 Fuel level float

M5 Rear screen washer

C1 Noise suppressing filter

M6 Sprinkling pump motor

E1 Instrument lighting

M7-9 Fans

E2,3 Front parking lights

M10 Fuel pump

E4,5 Tail lights

M11 Emulsion sprinkling pump motor (optional)

E6,7 Front headlamps E8,9 Rear headlamps E10 Warning beacon (optional) E11,12 Cab lighting E13,14 Brake lights E15-17 Left turn lights E18-20 Right turn lights E21 Reverse searchlights (optional) F1-28 Fuses G1,2 Batteries

P1 Gear box thermometer

S26 Rear screen wiper switch S27 Screen washer double button S28 Emulsion sprinkling button S29 Sprinkler cycling device S30 Fan switch S32 Air-conditioning thermostat (optional) S33 Air-conditioning overpressure fuse (optional) S34 Scraper double button (optional) S36 Water-in-fuel switch S38 Coolant level S39 Regeneration button V1,10,11 Diodes X1-33 Interconnecting connectors X45-47 Interconnecting connectors X34,80 Mounting socket X6.1,6.2 Engine connector (for Deutz X23) X37 Engine diagnostics connector

P2 Gear box lubrication pressure gauge

X38-43 Connectors J1939

Q1 Battery switch

X55,56 Connectors J1939

R1.1-1.4 Engine pre-heating R3,4 Resistor S1 Ignition box S2 Front headlamp switch S3 Rear headlamp switch

G3 Alternator

S4 Warning beacon switch (optional)

H1 Horn

S5 Brake light pressure switch

H2 Reversing alarm

S8 Warning light switch

H3 Turn light indicator lamp

S9 Turn light switch

H4 Neutral indicator lamp

S11 Left gear selector

H5 Right steering indicator lamp

S12 Right gear selector

H6 Left steering indicator lamp

S14 Emergency brake button

H8 Engine pre-heating indicator lamp

S15 Parking brake switch

H9 Battery charging indicator lamp H10 Brake fault indicator lamp

S17 Differential lock indication (optional)

H11 Brake fault acoustic signalization

S19 Brake fault pressure switch

184

S24 Hydraulic oil overheating switch

S16 Differential lock switch (optional)

X51-53 Connectors J1939 X70-80 Multiple connectors (Wago) X84 Connectors J1939 Y1,2 Gear selecting valves electromagnets Y3 Forward drive valve electromagnet Y4 Backward drive valve electromagnet Y5 Brake valve electromagnet Y6.1,6.2 Differential lock valve electromagnets (optional) Y7 Air-conditioning compressor electromagnetic coupling (optional) Y8 Scraper-up valve electromagnet (optional) Y9 Scraper-down valve electromagnet (optional) Y10 Relief valve electromagnet (optional)

ART 240

MAINTENANCE MANUAL

M10

X2:2

86

87

30

X17:7

E2 X35.1:1

X36.1:2

E3 X36.1:1

X22.2:A

E4 X22.2:C

X16:2

X23.2:A

E5 X23.2:C

X17:2

X3:2

E6

X15:2

X2:8

E7

X15:6

X2:9

E8

X16:4

X3:3

1

X3:4

9

Front headlights Rear headlights

E9

Warning beacon

E10

X17:4

X2:7

60A 30

X9:1

F1

X9:2

15A

S2

6 8 1 9

X3:1

15/54

F5

2 3

5A

10

F6 15A

S3

K1

10

15A

S4

1

86

30

87

85

86

30

87

F3

5

9

85

K8

F2

5

X8:2

X20:2

S1

50a

X34

X70

D+ W

X2:5

X

X1.1

X1.2

15A

F21

F22

10A

F27 E1

X35.1:2

G3

X84

X8:7

X2:6

X20:7

X19:1

Y

Tail lights

15A B

X16:6

X15:1

F24

25A

G

Q1

F25

12V 55Ah

Car radio

Front outline lights

Relay

G1

12V 55Ah

Dashboard illumination

F23

X2:1

50

10A

G2

Inspection lamp socket

30

ECU

85

SCR

X11:3

X11:1

X11:2

R1.3 R1.4

M1

31

ECU

Z

K2

70A

K11

F20

M

Fuel pump

K12

R1.1 R1.2

M

Engine glowing

10

15A

X15:7,8

E11

X16:1

Cab light

X17:1 P

X21:1

X8:1

X20:1

E12

S5

X2:10 X2:11

Direction indicator lights

E13 X22.2:B X16:5

X3:5

X23.2:A

E14 X23.2:B X17:5

X3:6

X71

X32:2

E15 X32:1

X2:12

X35.2:2

E16X35.2:1 X15:3

X2:13

X22.1:2

E17X22.1:1 X16:3

X3:7

X36.2:2

E18X36.2:1 15:4

X2:14

H3 7

X33:2

E19 X33:1

X2:15

X73

X23.1:2

E20X23.1:1 X17:3

X3:8

1

S9

2 8

5

S8 6 1 5

3

X15:5

X74

X27:4

X29:4

X16:6

H

7.5A

S12 1 2 3

A C D

X29:3

X27:3

X29:1

X27:1

R

X26:3

Forward travel solenoid Backward travel solenoid

X24:5

X3:9

Y2

X24:7

X3:10

X24:4

Y3

X24:3

X3:11

X24:2

Y4

X24:1

X3:12

H2 X34:1 X17:9

X3:13

X17:10 X34:2

Backing horn

X17:6

Backing light

X17:8

Brake solenoid

IN

Differential lock switch

X25:2

H4

F12 7.5A

X3:16

7

Y6.1

X7:1

X2:40

S17

S15

5 6 1 9

X25:1

S16

5 10

15

X3:19 6

ART 240

X10:19

S14

Y6.2

1 2 3 4 5

R N F

X80

2 X7:2

A2

N

X3:14

E21 Y5

Differential lock solenoid

VP X26:1

X26:2 F

X10:9 PŘF X10:1 PŘR X10:7 PŘ2 X10:3 PŘ1 X10:10 LŘ1 X10:4 LŘ2 X10:8 LŘR X10:2 LŘF

H6

R

H

PŘ LŘ MB MC MA ME + -

H5 Y1

S11

X10:13 X10:14 X10:17 X10:18 X10:16 X10:15 X10:5,6 X10:21,22,23,24

X10:20

1 2 3

N X28:3

F X28:2 R N F

X24:8

A C D

N

VP

X24:6

F11

X28:1 HOUKAČKA

X17:7

Solenoid for speed

15A

-31

10

X2:16

Solenoid for speed

A1 F4

CL

C1

H1

Horn

X72

HOUKAČKA

Brake lights

X22.2:A

7

8

9

10

11

12 13 14

108098_1en

185

3.8

Annexes

Wiring Diagram Legend: A1 Turn indicator interrupter

H12 Brake indicator lamp

S20 Brake pressure switch

A2 Electronics of steering switching version 102-1

H13 Hydraulic filter clogging indicator lamp

S21 Hydraulic oil filter pressure switch

A3 Multifunctional display Murphy PV-101

H16 Hydraulics overheating indicator lamp

S22 Engine air filter pressure switch

A4 Air dryer

H17 Sprinkling indicator lamp

A5 Air-conditioning (optional)

H19 Coolant indicator lamp

S25 Front screen wiper switch

A6 ECM

H20 Diagnostics indicator lamp

A7 Converter

H21 Oil pressure pilot lamp

A8 Fan speed control

H22 SCR indicator lamp

A10 Acoustic module PVAA20

H23 Regeneration indicator lamp

A12 Voltage converter

H24 Water in fuel pilot lamp

A13 Telematic (optional)

K1-5,10 Auxiliary relays

B1 Accelerator pedal position sensor - left

K11-12 Contactors

B2 Accelerator pedal position sensor - right B3 Gearbox temperature sensor B4 Gearbox lubrication pressure sensor

K6-9 Auxiliary relays (cab) M1 Engine starter M2 Front screen wiper M3 Rear screen wiper M4 Front screen washer

B5 Fuel level float

M5 Rear screen washer

C1 Noise suppressing filter

M6 Sprinkling pump motor

E1 Instrument lighting

M7-9 Fans

E2,3 Front parking lights

M10 Fuel pump

E4,5 Tail lights

M11 Emulsion sprinkling pump motor (optional)

E6,7 Front headlamps E8,9 Rear headlamps E10 Warning beacon (optional) E11,12 Cab lighting E13,14 Brake lights E15-17 Left turn lights E18-20 Right turn lights E21 Reverse searchlights (optional) F1-28 Fuses G1,2 Batteries

P1 Gear box thermometer

S26 Rear screen wiper switch S27 Screen washer double button S28 Emulsion sprinkling button S29 Sprinkler cycling device S30 Fan switch S32 Air-conditioning thermostat (optional) S33 Air-conditioning overpressure fuse (optional) S34 Scraper double button (optional) S36 Water-in-fuel switch S38 Coolant level S39 Regeneration button V1,10,11 Diodes X1-33 Interconnecting connectors X45-47 Interconnecting connectors X34,80 Mounting socket X6.1,6.2 Engine connector (for Deutz X23) X37 Engine diagnostics connector

P2 Gear box lubrication pressure gauge

X38-43 Connectors J1939

Q1 Battery switch

X55,56 Connectors J1939

R1.1-1.4 Engine pre-heating R3,4 Resistor S1 Ignition box S2 Front headlamp switch S3 Rear headlamp switch

G3 Alternator

S4 Warning beacon switch (optional)

H1 Horn

S5 Brake light pressure switch

H2 Reversing alarm

S8 Warning light switch

H3 Turn light indicator lamp

S9 Turn light switch

H4 Neutral indicator lamp

S11 Left gear selector

H5 Right steering indicator lamp

S12 Right gear selector

H6 Left steering indicator lamp

S14 Emergency brake button

H8 Engine pre-heating indicator lamp

S15 Parking brake switch

H9 Battery charging indicator lamp H10 Brake fault indicator lamp

S17 Differential lock indication (optional)

H11 Brake fault acoustic signalization

S19 Brake fault pressure switch

186

S24 Hydraulic oil overheating switch

S16 Differential lock switch (optional)

X51-53 Connectors J1939 X70-80 Multiple connectors (Wago) X84 Connectors J1939 Y1,2 Gear selecting valves electromagnets Y3 Forward drive valve electromagnet Y4 Backward drive valve electromagnet Y5 Brake valve electromagnet Y6.1,6.2 Differential lock valve electromagnets (optional) Y7 Air-conditioning compressor electromagnetic coupling (optional) Y8 Scraper-up valve electromagnet (optional) Y9 Scraper-down valve electromagnet (optional) Y10 Relief valve electromagnet (optional)

ART 240

MAINTENANCE MANUAL 1 2 3 4 5

6 X23:3

X2:25

X23:4

X2:26

X23:10

Converter 24V/12V

X47:1

3 4 10

X47:2

X6.2:12 X6.2:74 X6.2:23

Glowing pilot lamp Diagnostics pilot lamp Throttle pedal - left side

A C

X6.2:26

X2:23

X6.2:70

X30:1

X2:27

X6.2:29

X30:2

X2:28

X6.2:20

B1 B

X30:3

X2:30

F

X30:4

X2:31

X30:5

X2:32

X81:1

X3:20

X6.2:30

C

X81:2

X3:21

X6.2:16

B2 B

X81:3

X3:23

X6.2:69

F

X81:4

X3:24

X81:5

X3:25

A

X79

E

X6.2:84 X77

E

Throttle pedal - right side

S36 X2:22

L

Water in fuel switch

X6.2:75

X6.2:59 X6.2:85 X6.2:86 X6.2:82 X6.2:83

Gearbox temperature Gearbox oil pressure Brake failure

X23:12 R4

SCR

R120

B90

F7 7.5A X63:2

SCR

Hydraulic oil filter

F8

X2:39

Sensors

15A

X6.2:34

85

86

87

30

S39

X6.2:32

1

K4

5

X6.2:43

85

86

87

30

X6.2:91 X6.2:71

H23

X6.2:90

H22

X6.2:36

H21

X6.2:54

H24

X6.2:57 X6.2:53

H19

X6.2:37

H8

X6.2:56

H20

X6.2:73 X6.2:64 X X6.2:01

X48:1

X6.2:03

X48:2

X6.2:05

X48:3

K5

X6.2:67

85

86

87

30

F13 7.5A

B3

X2:33

B4

X2:34

S

P S19

X2:35

H10

S

P1

°C

MPa

P S20

X3:26

H12

P

S21

X3:27

H13

S24

X3:15

H16

P2 V1

H11

X9:4

Brake

15

X2:29

X23:7

X23:8

K18

X63:1

X23:1

1

K13 K31

D2.2 K34 K32 K71 K91 K43

X6.2:15

K90

S22 X2:20

K53 K57 K54 K36

X2:21

Engine air filter

P

K37

X6.2:81

Regeneration button

K64 K73 K56

X2:18 X6.2:62

12 13 14

X2:17

K05 K03 K01

S3

S38

12

K67

L

- 2

X2:19

Coolant level

+

1

A6

X6.2:50

K81 K62

X2:4

K20 K29 K70 K26 K23 K74 K12 K15

2

U

Pedal switch-over

11

K3

K84

X6.2:10

t

K16 K30 K75

X2:3

10

X23:11 R120

11

7

9

K69

X6.2:06

S35 1

8

Connector EMR 4

Coolant pilot lamp

K83 K82 K86 K85 K59

X6.2:02 X6.2:04

K50 K10 K06 K04 K02

X23:9

2 9

8

R3

X23:6

6

X47:3 X23:2

Inlet air temperature sensor

7

X23:5

5

Engine harness connector X23

X2:24

H9

X9:3

A B

X84

7 2

A B

B A

X52 6

3

B5 G

X3:28 X3:29

H G A B

A B

A M B F

B

A

A B

X36

X36a

A B

2

4

X38

A B

X3:33

Fuel gauge

TELEMATIC

Y 12

X37

3

1 11

A13

X83

7

Engine diagnostic socket

1 2

X40

Service socket

X45

X40

A B

ART 240

B A

X56

A B

X55

A B

B A

X36

X51

X53

X41

A B

120

A B

X42

120

X43

Hydraulic oil overheating

A4 A5

F14 1A

A3 A2

A3 A6

A1

A B

108098_2en

187

3.8

Annexes

Wiring Diagram Legend: A1 Turn indicator interrupter

H12 Brake indicator lamp

S20 Brake pressure switch

A2 Electronics of steering switching version 102-1

H13 Hydraulic filter clogging indicator lamp

S21 Hydraulic oil filter pressure switch

A3 Multifunctional display Murphy PV-101

H16 Hydraulics overheating indicator lamp

S22 Engine air filter pressure switch

A4 Air dryer

H17 Sprinkling indicator lamp

A5 Air-conditioning (optional)

H19 Coolant indicator lamp

S25 Front screen wiper switch

A6 ECM

H20 Diagnostics indicator lamp

A7 Converter

H21 Oil pressure pilot lamp

A8 Fan speed control

H22 SCR indicator lamp

A10 Acoustic module PVAA20

H23 Regeneration indicator lamp

A12 Voltage converter

H24 Water in fuel pilot lamp

A13 Telematic (optional)

K1-5,10 Auxiliary relays

B1 Accelerator pedal position sensor - left

K11-12 Contactors

B2 Accelerator pedal position sensor - right B3 Gearbox temperature sensor B4 Gearbox lubrication pressure sensor

K6-9 Auxiliary relays (cab) M1 Engine starter M2 Front screen wiper M3 Rear screen wiper M4 Front screen washer

B5 Fuel level float

M5 Rear screen washer

C1 Noise suppressing filter

M6 Sprinkling pump motor

E1 Instrument lighting

M7-9 Fans

E2,3 Front parking lights

M10 Fuel pump

E4,5 Tail lights

M11 Emulsion sprinkling pump motor (optional)

E6,7 Front headlamps E8,9 Rear headlamps E10 Warning beacon (optional) E11,12 Cab lighting E13,14 Brake lights E15-17 Left turn lights E18-20 Right turn lights E21 Reverse searchlights (optional) F1-28 Fuses G1,2 Batteries

P1 Gear box thermometer

S26 Rear screen wiper switch S27 Screen washer double button S28 Emulsion sprinkling button S29 Sprinkler cycling device S30 Fan switch S32 Air-conditioning thermostat (optional) S33 Air-conditioning overpressure fuse (optional) S34 Scraper double button (optional) S36 Water-in-fuel switch S38 Coolant level S39 Regeneration button V1,10,11 Diodes X1-33 Interconnecting connectors X45-47 Interconnecting connectors X34,80 Mounting socket X6.1,6.2 Engine connector (for Deutz X23) X37 Engine diagnostics connector

P2 Gear box lubrication pressure gauge

X38-43 Connectors J1939

Q1 Battery switch

X55,56 Connectors J1939

R1.1-1.4 Engine pre-heating R3,4 Resistor S1 Ignition box S2 Front headlamp switch S3 Rear headlamp switch

G3 Alternator

S4 Warning beacon switch (optional)

H1 Horn

S5 Brake light pressure switch

H2 Reversing alarm

S8 Warning light switch

H3 Turn light indicator lamp

S9 Turn light switch

H4 Neutral indicator lamp

S11 Left gear selector

H5 Right steering indicator lamp

S12 Right gear selector

H6 Left steering indicator lamp

S14 Emergency brake button

H8 Engine pre-heating indicator lamp

S15 Parking brake switch

H9 Battery charging indicator lamp H10 Brake fault indicator lamp

S17 Differential lock indication (optional)

H11 Brake fault acoustic signalization

S19 Brake fault pressure switch

188

S24 Hydraulic oil overheating switch

S16 Differential lock switch (optional)

X51-53 Connectors J1939 X70-80 Multiple connectors (Wago) X84 Connectors J1939 Y1,2 Gear selecting valves electromagnets Y3 Forward drive valve electromagnet Y4 Backward drive valve electromagnet Y5 Brake valve electromagnet Y6.1,6.2 Differential lock valve electromagnets (optional) Y7 Air-conditioning compressor electromagnetic coupling (optional) Y8 Scraper-up valve electromagnet (optional) Y9 Scraper-down valve electromagnet (optional) Y10 Relief valve electromagnet (optional)

ART 240

MAINTENANCE MANUAL B

X22:3

X21:3,4,6

M

X22:6

Front wiper

X21:4

M2 X22:2

7

5

3 1

X23:1 X21:6

M

X23:2

X8:6

X21:1 8 S26 6 5

1

X21:9

M M

Rear screen washer

M3 X23:4

X23:3 X21:8

X20:6

X21:5

X21:7

Front screen washer

15A

S25

X22:4

X8:5 X20:5

Rear wiper

F15

X8:3,4

X20:3,4

X22:1

A

M4

X21:10

M5

X21:11

S27 7

3

1

K9

M11

M

M6

X46:3

0

S1 C

F

7.5A

S2

X12:2

86

85

87

30

X46:1

X45:1

X46:4

X45:4

S28

X2:38 X12:1

Sprinkling

X45:3

Konvekta AG

P S33 P S32

1 2 3

A5

M

Emulsion sprinkling

Y7

M

A/C compressor clutch

X46:2

M

X45:2

1

F16

5

7.5A

X2:36 X2:37

S29

OUT

H17

Edge cutter - up

Y8

Edge cutter - down

Y9

Relief valve

Y10

OR

M9 OR

3 4

1

6

A8

2

A7 2

5

3

S30

L H M

1

X13:1

F17 20A

B

S X3:34

F18

X3:35

15A

X3:30

S34

7 X3:31

X3:18

3

1

V10

A4

X3:32

OR

V11

Air dryer

M

C

M8

X13:2

Fans

M7

M

C

M

C

B4 X31.1

B3

A3

X31.2

B1

B6

A4

A3

A10 R4

A1

A6

120

B4

B3

A10

Mounting socket 12V

X80

F29 10A

12V

24V

GND

GND

A12

F28 15A

Z

108098_3en

ART 240

189

3.8

Annexes

Wiring diagram Aftertreatment Legend A11 Relay box B54 NOx sensor in front of SCR catalytic converter B56 NOx sensor behind SCR catalytic converter B65,78 Exhaust gas temperature B88 Pressure sensor behind DPF module B90 Diesel exhaust fluid sensor F34 Fuse N3 Diesel exhaust fluid tank control R5 Return circuit heating R6 Intake circuit heating R7 Pressure circuit heating X39-70 Interconnecting connectors Y24 Diesel exhaust fluid dosing valve Y31 Diesel exhaust fluid tank heater valve

190

ART 240

X63:1

X39:3

X39:5

X39:8

X39:9

X39:10

X39:13

X39:11

X39:18

X39:16

X39:20

X39:19

X39:21

X39:22

X39:23

X39:24

X39:25

X39:28

X39:29

X39:30

X39:31

X39:32

X39:33

X39:34

X39:35

X39:36

X39:37

X39:39

X39:38

X39 Engine harness

X63:2

X2:39 X2:29

MAINTENANCE MANUAL

8 10 4 12

A9

3 2 11 5 6

Q1/OUT

9

X64:1

F25

X64:2

30A

X65:1 X65:2 X65:3 X65:4

A11

X65:5 X65:6 X65:7 X65:8

Suction circuit heater

Relaybox

Return circuit heater

Pressure circuit heater

X66:1

X67:1

X66:2

X67:2

X66:3

X68:1

X66:4

X68:2

X66:5

X69:1

X66:6

X69:2

R5 R6 R7

X66:7 X66:8

Y31

Urea solution tank heater valve

NOx sensor before SCR catalyst

1

4

2 3 B54 4 1

2 NOx sensor after SCR catalyst

3

B56 4 1

2 Urea solution sensor

4

B90 1 3

Urea solution feeder valve

Exhaust gases temperature

Y24 1

2

2

1

B78

3 Pressure sensor after DPF modul

B88

2

1 Exhaust gases temperature

B65 2

1

212121en

ART 240

191

3.8

Annexes

Hydraulics Diagram 1 Steering pump 3 Steering hydromotor 4 Edge cutter hydromotor 5 Servo-steering 6 Priority valve 7 Logic valve 9 Edge cutter block 10 Non return valve 11 Combined cooler 13 Hydraulic tank 14 Filter + element + switch 15 Filler neck 16 Temperature switch 85±3 °C 18 Fast coupling filling-type 19 Fast coupling measuring-type

192

ART 240

MAINTENANCE MANUAL

200

5 210

210

210

140

P

T

L

R

P

LS

T

L

R Dn10

Dn10

Dn10 80/40-200 Dn8

T

0,6 mm

P

180

160

M

3 P

T

9

Dn8

CF

EF

Dn16

Dn16

7

11

Dn16

5

A

4

Dn12 Dn10

B

210

140

LS

B

Dn8

200

63/32-250

Dn8

A

6

LS

Dn16

10

18

P

Dn16

19 Dn12 Dn25

16

Transmission

i=1.0

16

Deutz 2200 RPM Dn16

1

5 bar

15

14

2,5 bar

-0,03 bar

°C

+0,1 bar

2 bar 16

13 Dn12

ART 240

211649A

193

3.8

Annexes

Air Distribution 1 Compressor 2 Air drier 3 Air filter 4 Air tank 35 l 5 Cooler 6 Brake pedal 7 Diaphragm-type booster 8 Four-way valve 9 Two-way valve 10 Drain tap 11 Solenoid valve 12 Brake pressure gauge 13 Spring cylinder 14 Sensor for filter clogged 15 Pressure switch 16 Coupling T – measuring-type 17 Coupling T – measuring-type 18 Coupling T – measuring-type Option: Central Tyre Inflation System 20 Control valve 21 Non return valve 22 Tyre pressure gauge 23 Rotary-type supply 24 Safety valve Option: Differential lock control 25 Pneumatic distributor 26 Hydraulic cylinder

194

ART 240

ART 240

Dn9

Dn9

Front axle

24

Dn12

23

Dn6 2

1

3

Dn12

24

Dn12

Dn12

20

21

20

3

3

Dn12

Dn12

1

22

21

10

24

23

Dn6

Differential lock control

8

11

15

Dn6

3

5

2

4 1

Dn6

Dn9

2

3

21

4

12

Dn6

Dn6

25

Dn9

22

23

2200 RPM

Deutz

3

16

9 7

17

6

26

63/36/160

Dn9

3

62mbar

360

Dn19

14

Dn4 4

1 Dn18

1

4/23

Dn6

Dn9

5

2

6

13

18

15

MAINTENANCE MANUAL

500±50 kPa

Dn6

Dn6

200 kPa

520 kPa

Dn32

Dn6

Dn6

Rear axle

212182en

195

3.8

Annexes

Table of spare parts Chapter

Spare part

Order number

Every 20 hours of operation (daily) 3.6.5

Dust valve

1-952454

Every 500 hours of operation (6 months) 3.6.21

Dust valve

1-952454

3.6.27

Filter

4-16481

Every 1000 hours of operation (1 year) 3.6.38

Drier

1426356

3.6.38

Cartridge

1296325

Every 2000 hours of operation (2 years) 3.6.40

Filter cartridge

1229403

Every 6000 hours of operation (4 years) 3.6.44

Cooling agent

1416502

Content of the set of filters after 500 operating hours (4-760181)

Chapter

196

Spare part

Number of parts

Order No.

3.6.19

Oil filter

1

5-0020003

3.6.21

Filter set

1

1229388

3.6.23

Oil filter

1

4-9502000402

3.6.28

Filter element

1

4-5351010189

3.6.20

Fuel filter

1

1238008

3.6.20

Fuel filter

1

1229401

3.6.29

Filter element

1

1391087

ART 240

MAINTENANCE MANUAL Content of the set of filters after 1000 operating hours (4-760182)

Chapter

Spare part

Number of parts

Order No.

3.6.19

Oil filter

1

5-0020003

3.6.21

Filter set

1

1229388

3.6.23

Oil filter

1

4-9502000402

3.6.28

Filter element

1

4-5351010189

3.6.20

Fuel filter

1

1238008

3.6.20

Fuel filter

1

1229401

3.6.29

Filter element

1

1391087

3.6.38

Cartridge

1

1296325

Number of parts

Order No.

Content of the set of filters after 2000 operating hours (4-760183)

Chapter

ART 240

Spare part

3.6.19

Oil filter

1

5-0020003

3.6.21

Filter set

1

1229388

3.6.23

Oil filter

1

4-9502000402

3.6.28

Filter element

1

4-5351010189

3.6.20

Fuel filter

1

1238008

3.6.20

Fuel filter

1

1229401

3.6.29

Filter element

1

1391087

3.6.38

Cartridge

1

1296325

3.6.40

Breather filter

1

1296125

3.6.40

Filter element

1

1229403

197

3.8

Annexes Notes

198

ART 240

MAINTENANCE MANUAL Notes

ART 240

199

3.8

Annexes Notes

200

ART 240

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Materials and specification data are subject to change without notice.

Book ID: 4-P06000-EN | © Ammann Group