Ammann ARR 1585 Trench Roller Workshop Manual 3005094 PDF

ARR 1585 TRENCH ROLLER HATZ 2G40 EU Stage V / U.S. EPA Tier 4f

WORKSHOP MANUAL EDITION 07/2021 EN Product Identification Number 3005094 -

Preface Information, specifications, and recommended instructions for the assembly and disassembly of individual machine components or parts contained in this publication represent basic and final information at the time of the printing of this publication. Print errors, technical modifications and modifications of images are reserved. All dimensions and weights are approximate and, therefore, not binding.

Ammann Czech Republic a.s. reserves the right to perform modifications at any time with no 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.

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 ARR 1585

1

Contents CONTENTS........................................................................................................................................................2 1

2

3

INTRODUCTION ......................................................................................................................................5 1.1

About this workshop manual......................................................................................................................................................................... 9

1.1.1

Who is the workshop manual intended for............................................................................................................................................... 9

1.1.2

Purpose.................................................................................................................................................................................................................. 9

1.1.3

Applicability of the workshop manual........................................................................................................................................................ 9

1.1.4

Validity of the workshop manual.................................................................................................................................................................. 9

SAFETY MEASURES AND INSTRUCTIONS..........................................................................................11 2.1

Safety rules..........................................................................................................................................................................................................12

2.2

Environmental and hygiene principles.....................................................................................................................................................15

2.3

Fire prevention...................................................................................................................................................................................................16

2.4

Claim conditions and disclaimer of liability............................................................................................................................................16

SPECIFICATION MANUAL.....................................................................................................................17 3.1

Machine description........................................................................................................................................................................................18

3.2

Dimensioned drawing of the machine.....................................................................................................................................................20

3.3

Technical data....................................................................................................................................................................................................21

4

SPECIFICATION OF OPERATING FLUIDS.............................................................................................23

5

FRAME....................................................................................................................................................29

2

5.1

Description of basic elements......................................................................................................................................................................31

5.4

Mechanical parts...............................................................................................................................................................................................32

5.4.1

Gas strut replacement.....................................................................................................................................................................................32

5.4.2

Bonnet replacement........................................................................................................................................................................................33

5.4.2.1

Bonnet hinge replacement...........................................................................................................................................................................37

5.4.3

Sensor replacement.........................................................................................................................................................................................38

5.4.4

Beacon replacement........................................................................................................................................................................................41

5.4.5

Replacement of bonnet stops, the rubber block on the control cover and the control unit................................................44

5.5

Fuel tank...............................................................................................................................................................................................................47

5.5.1

Fuel level indicator lamp................................................................................................................................................................................47

5.5.2

Fuel replenishment..........................................................................................................................................................................................47

5.5.3

Fuel draining.......................................................................................................................................................................................................47

5.5.3.1

Method 1.............................................................................................................................................................................................................47

5.5.3.2

Method 2.............................................................................................................................................................................................................48

5.5.4

Fuel tank cleaning............................................................................................................................................................................................49

5.5.5

Fuel filter replacement....................................................................................................................................................................................50

5.6

Hydraulic tank....................................................................................................................................................................................................51

5.6.1

Checking the hydraulic oil level..................................................................................................................................................................51

5.6.2

Hydraulic oil replenishment..........................................................................................................................................................................51

5.6.3

Hydraulic oil draining......................................................................................................................................................................................52

5.6.4

Hydraulic oil filter cleaning...........................................................................................................................................................................53

5.7

Rubber-metal element replacement.........................................................................................................................................................54

ARR 1585

WORKSHOP MANUAL 6

7

8

CAB AND PLATFORM............................................................................................................................57 6.1

Control and indication elements................................................................................................................................................................58

6.1.1

Display unit.........................................................................................................................................................................................................60

6.1.1.1

Indicator lamps..................................................................................................................................................................................................60

6.1.3

Infrared remote control..................................................................................................................................................................................62

6.1.3.1

Layout...................................................................................................................................................................................................................62

6.1.3.4

Handling..............................................................................................................................................................................................................62

6.1.3.5

Near and remote machine halt....................................................................................................................................................................69

6.1.4

Cable remote control.......................................................................................................................................................................................70

6.1.4.1

Layout...................................................................................................................................................................................................................70

6.1.4.4

Handling .............................................................................................................................................................................................................70

6.1.5

Manual control...................................................................................................................................................................................................71

6.1.5.1

Layout...................................................................................................................................................................................................................71

6.1.5.4

Handling..............................................................................................................................................................................................................71

6.3.4

Dashboard...........................................................................................................................................................................................................71

6.3.4.2

N1 connector / cable harness.......................................................................................................................................................................71

6.4

Mechanical parts...............................................................................................................................................................................................72

6.4.1

Replacement of the remote control battery...........................................................................................................................................72

6.4.2

Replacement of the display unit.................................................................................................................................................................76

6.4.3

Replacement of the control unit.................................................................................................................................................................78

FRONT DRUM.........................................................................................................................................81 7.2

Hydraulic parts...................................................................................................................................................................................................82

7.2.1

Description of basic elements......................................................................................................................................................................82

7.2.2

Hydraulic valve, vibration and travel valves............................................................................................................................................82

7.4.2

Drum removal....................................................................................................................................................................................................85

7.4.4

Replacement of the travel hydraulic motor............................................................................................................................................86

7.4.5

Drum installation..............................................................................................................................................................................................89

7.4.6

Scraper replacement.......................................................................................................................................................................................89

REAR DRUM...........................................................................................................................................91 8.2

Hydraulic parts...................................................................................................................................................................................................92

8.4

Mechanical parts...............................................................................................................................................................................................92

9 FRONT AXLE (NOT INCLUDED IN THE MACHINE EQUIPMENT)........................................................93 10 REAR AXLE (NOT INCLUDED IN THE MACHINE EQUIPMENT)...........................................................95 11

12

13

TRAVEL...................................................................................................................................................97 11.2

Hydraulic parts...................................................................................................................................................................................................98

11.2.1

Pump replacement...........................................................................................................................................................................................98

VIBRATION...........................................................................................................................................103 12.2

Hydraulic parts................................................................................................................................................................................................ 104

12.2.1

Vibration hydraulic motor replacement................................................................................................................................................ 104

12.2.2

Vibrator removal............................................................................................................................................................................................ 107

STEERING.............................................................................................................................................109 13.4

Mechanical parts............................................................................................................................................................................................ 110

13.4.1

Replacement of steering valves................................................................................................................................................................ 110

13.4.2

Replacement of coils on the steering valves....................................................................................................................................... 110

ARR 1585

3

Contents 14

15

17

18

COOLING..............................................................................................................................................113 14.4

Mechanical parts............................................................................................................................................................................................ 114

14.4.1

Replacement of the cooling propeller on the vibration pump..................................................................................................... 114

ENGINE.................................................................................................................................................117 15.1

Description of basic elements................................................................................................................................................................... 118

15.4

Mechanical parts............................................................................................................................................................................................ 120

15.4.1

Adjustment of the engine speed connecting rod............................................................................................................................. 120

15.4.2

Air filter replacement.................................................................................................................................................................................... 124

15.4.3

Battery replacement..................................................................................................................................................................................... 126

15.4.4

Stop solenoid replacement........................................................................................................................................................................ 131

15.4.5

Voltage regulator replacement................................................................................................................................................................. 134

15.4.6

Fuel filter replacement................................................................................................................................................................................. 138

15.4.7

Engine oil level inspection......................................................................................................................................................................... 138

15.4.8

Engine oil replenishment............................................................................................................................................................................ 138

15.4.9

Engine oil draining........................................................................................................................................................................................ 139

15.4.10

Air suction filter inspection........................................................................................................................................................................ 139

15.4.11

Air suction filter cartridge replacement................................................................................................................................................ 140

GENERAL PROCEDURES.....................................................................................................................143 17.2

Electrical installation..................................................................................................................................................................................... 144

17.2.2

Preparation for welding work.................................................................................................................................................................... 144

17.2.3

Starting the battery by means of another battery (jumping)....................................................................................................... 144

17.2.4

Charging the battery with a charger...................................................................................................................................................... 145

17.2.5

Long-term storage........................................................................................................................................................................................ 145

17.2.6

Battery replacement..................................................................................................................................................................................... 145

TROUBLESHOOTING...........................................................................................................................147 18.1

19

4

Error diagnostics............................................................................................................................................................................................ 148

APPENDICES........................................................................................................................................149 19.2

Wiring diagram............................................................................................................................................................................................... 150

19.4

Hydraulic diagram......................................................................................................................................................................................... 154

19.4.1

Hydraulic diagram of ARR 1585-M.......................................................................................................................................................... 154

19.4.2

Hydraulic diagram of ARR 1585-M/MIC/MC......................................................................................................................................... 156

19.7

Check of the screw connections for tightening.................................................................................................................................. 161

19.x

List of spare parts specified in the publication................................................................................................................................... 163

ARR 1585

WORKSHOP MANUAL

1 Introduction

ARR 1585

5

1

Introduction

The workshop manual is divided into separate chapters and contains technical and maintenance data, instructions for adjustment and instructions for the use of special tools, jigs and aids.

The main purpose of this manual is to provide basic information for disassembly, assembly and service repairs of the main subassemblies of the machine.

Labelling of machine subassemblies in this manual corresponds to the spare parts catalogue.

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

The manufacturer constantly improves its products on the basis of operational experience and the latest findings. Due to development, the manufacturer reserves the right to change the images, descriptions, procedures and designs presented in this manual.

Before disassembly, it is recommended to always mark the removed parts for their reassembly and blank off all holes of individual parts of the hydraulic system in order to prevent contamination of the hydraulic circuits.

When mounting individual parts on the machine, tighten individual screws or nuts according to the table of tightening torques (see the appendix), unless specified otherwise in the text.

When handling the parts, use a crane and slings with adequate load capacity. Weights of individual parts are listed in the electronic spare parts catalogue.

During work, always follow the safety instructions and measures given in Chapter 2.

6

ARR 1585

WORKSHOP MANUAL SAFETY NOTICES AND SIGNS: The notice warns of a serious risk of personal injury or other personal hazards.

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

The notice warns of the necessity of environmental protection.

! CAUTION!

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

FRONT

RIGHT

LEFT

REAR 558023en

ARR 1585

7

1

8

Introduction

ARR 1585

WORKSHOP MANUAL 1.1

About this workshop manual

This workshop manual is a supplementary document for dealers of ARS vibration rollers. It is a document of Ammann and its subsidiaries in other countries.

1.1.1

Who is the workshop manual intended for

This workshop manual is intended for service technicians in the field and a workshop who are authorised by the user to perform servicing and maintenance.

1.1.2

Purpose

The purpose of this workshop manual is to provide instructions for optimal use and safe operation of the roller, while ensuring the following processes: •

Maintenance

•

Repairs

1.1.3

Applicability of the workshop manual

This workshop manual applies to the following rollers: ARR 1585 The roller has a variety of optional equipment, which we can install according to your needs. For this reason, some pictures or descriptions in this workshop manual may differ from your roller.

1.1.4

Validity of the workshop manual

Never remove any chapters from this manual. Missing pages – especially the Safety chapter – must be immediately replaced in case of a loss.

ARR 1585

9

10

ARR 1585

WORKSHOP MANUAL

2 Safety measures and instructions

ARR 1585

11

2

Safety measures and instructions

2.1

Safety rules

These safety rules must be followed by all persons involved in machine repairs!

•

Repairs of this machine may be carried out only by qualified, professionally trained and experienced workers or by the Service personnel of our dealers.

•

Always use our workshop manual when performing repairs. Individual chapters contain special instructions regarding assembly work.

•

Before putting the machine into operation, familiarize yourself with the machine controls according to the Operating Manual and make sure you have well understood all the equipment of your machine.

•

Do not use the machine if you do not fully understand all operating and control elements and if you do not know exactly how the machine works.

•

Familiarize yourself with the area where you work.

•

Do not carry out any alterations or modifications to the machine, as this may affect the safety of the machine.

•

Original parts and accessories have been designed specifically for this machine.

•

Installation and use of spare parts that are not supplied or authorized by the machine manufacturer may have a negative impact on the operational characteristics and safe operation of the machine.

•

It is forbidden to remove components of individual parts during the warranty period. If you fail to comply with this prohibition, the warranty of the damaged component will not be recognized.

Safety measures for machine repairs and inspection •

Wear work clothes and footwear.

•

Use gloves when handling oil, fuel and coolant.

•

When handling the battery, protect your eyes with goggles or a shield.

•

Place the machine on a level and firm surface before performing repairs. Secure the machine against rolling.

•

Secure the machine and drum frame against relative rotation with a lock pin and rod.

•

Before starting work, remove the key from the ignition, disconnect the batteries and allow hot parts to cool.

•

Attach a “machine out of order” sign to the steering wheel and leave it there for the duration of the work.

•

Properly wash the entire machine. In the case of steam cleaning, avoid aiming the steam flow directly at electrical components and insulating material or cover them beforehand.

•

When removing, installing and repairing individual groups, maintain absolute cleanliness of all parts. Protect removed parts against dirt.

•

Clean the surface of removed parts and create a corresponding dust-free work environment with the necessary storage area.

•

Handle cleaning agents with caution. Do not use petrol or other flammable substances for cleaning!

•

Dry the cleaned parts and immediately coat them with anti-corrosion oil – never install corroded parts!

•

Tools, lifting equipment, securing elements, supports and other auxiliary equipment must be in a good, working condition.

•

Lifting equipment and slings (ropes, chains) must have adequate load capacity and be intact.

•

Ensure sufficient air supply when starting the machine indoors.

•

Before putting the machine into operation, make sure there are no persons on the machine or in its dangerous proximity. Use the audible warning signal when putting the machine into operation, always before starting the engine and after each break, before the machine starts moving. Persons located on the machine and in its dangerous proximity must leave the machine and the area after the audible warning signal.

•

Do not adjust the machine in operation.

•

When performing necessary work on a running engine (adjustment), avoid contact with hot and rotating parts of the machine.

Work performed when the engine is running (adjustment) must be carried out in the presence of another person who has immediate access to emergency shut-down and who is continuously in contact with the person performing the adjustment, so that the engine can be immediately switched off if necessary.

•

Only use prescribed kinds of engine, transmission and hydraulic oil and coolant.

12

ARR 1585

WORKSHOP MANUAL Safety measures for work on hydraulic circuits •

Before disassembly, make sure the hydraulic circuits are depressurized. Hydraulic oil leaking under pressure may damage your skin and cause serious injury.

•

Before disassembly, mark the parts, hoses and pipes.

•

Do not put hydraulic pumps and motors into operation without oil.

•

Work with hot oil may result in scalding.

•

Do not heat the oil to temperatures above 160 °C – the oil or its vapours may ignite.

•

When removing hydraulic components, always blank off the hose ends and outlets of the components.

•

Use lint-free cloth when wiping and cleaning hydraulic parts.

•

When assembling parts, use hydraulic oil as a slip agent – not grease.

•

Before installation, carefully clean the fittings and flush and blow compressed air through hoses and pipes.

•

Only use new seals.

•

Fill new aggregates with hydraulic oil before installation.

•

After a hydraulic aggregate replacement, flush the hydraulic circuit and clean the hydraulic tank.

•

Replace the oil filter element.

•

Fill the hydraulic circuit with clean oil of prescribed viscosity, only when the engine is off!

•

Wipe any overflowed oil.

•

Check the connections for any leaks before the system pressurizes.

•

Check all connections after finishing all work.

•

Do not adjust safety valves.

•

After finishing work, reinstall all protective elements.

Check after putting into operation •

Oil level in the hydraulic tank.

•

Check the charge pressure of replaced hydraulic pumps and the pressure of safety valves.

•

Perform the measurement at 40 °C (104 °F).

Safety measures for work on the fuel system Petrol and diesel mixtures (winter fuel) are as flammable as petrol.

-

Do not refuel in enclosed spaces.

-

Wipe any overflowed fuel.

-

Do not smoke and do not use an open flame while working on the fuel system! There is a risk of fire!

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13

2

Safety measures and instructions

Safety measures for work on the electrical system •

Disconnect the battery when repairing the charging circuit to prevent accidental short circuits.

•

Before removal, disconnect the cable from the negative terminal (-) and then from the positive terminal (+).

•

Do not disconnect the batteries when the engine is running.

•

Connect the negative battery terminal to the ground and the positive terminal to the “B+” alternator output. The opposite connection would destroy the whole semiconductor equipment.

•

When starting using an auxiliary external power supply, do not disconnect this power supply until the machine battery is connected. Pay attention to the starting voltage of the auxiliary external power supply (for 24 V).

•

Do not put the alternator into idle operation, i.e. with a disconnected wire from the “B+” terminal and connected “D+” terminal.

•

Do not check the presence of voltage in the wire by sparking against the machine frame.

•

Do not perform any activities generating sparks.

•

Use protective rubber gloves and eye protection when handling batteries.

•

Protect your skin and clothes against being splashed by the electrolyte or lead particles.

•

In case of eye contact with the electrolyte, immediately flush the affected eye thoroughly with running water for several minutes.

Then, seek medical treatment as soon as possible.

•

If the electrolyte comes in contact with skin or clothing, remove the clothes, immediately wash the affected areas with soapy water or a solution of baking soda and water and seek medical treatment.

•

In case of ingestion of electrolyte, drink the maximum possible amount of milk, magnesium oxide dissolved in water or at least water and immediately seek medical treatment.

•

Never fill the cells with distilled water, unless it is followed by work with the machine or recharging outside the machine. It would otherwise cause excessive battery self-discharge.

•

Never add acid (H2SO4)!

•

Do not turn over the batteries to avoid electrolyte flowing out of the degassing vents.

•

In case of acid (electrolyte) spillage, wash the affected area with water and neutralize with lime.

•

The charging process releases hydrogen, which forms an explosive, easily combustible mixture with air. Do not smoke or use open flame or lights in the vicinity.

Welding work on the machine •

Before performing welding work on the machine using an electric arc, disconnect all elements containing semiconductors from the electrical system, including the machine electronics: -

ground the power supply as well as the repaired machine,

-

protect the power supply against moisture,

-

place the ground terminal in close proximity to the weld joint,

-

When performing welding work on suspended parts or machine, it is necessary to prevent current from reaching the lifting equipment by insulating the point of current transition or using non-conductive slings (hemp rope).

Sealing •

Use new seals for all installation.

•

Seal kits are obtained as spare parts.

Tightening torques •

In order to apply the correct tightening torque, use a torque spanner.

•

Fastening screws and nuts of used quality shall be tightened according to the respective tables.

•

The screw quality is indicated on the screw head.

•

Different tightening torques are specified in the respective chapters.

•

Threaded joints of hydraulic circuits shall be tightened according to the tables.

•

The presented tightening torques apply to non-lubricated threads.

•

Only use new self-locking nuts.

14

ARR 1585

WORKSHOP MANUAL 2.2

Environmental and hygiene principles

When repairing the machines, observe general principles of health and environmental protection as well as laws and regulations related to this issue and being in force within the territory where the machine is used.

Hygienic principles •

Petroleum products, fillings of cooling systems, battery fillings and paints, including thinners, are harmful substances that can cause severe injuries when in contact with body organs.

•

It is therefore necessary to strictly follow safety and hygiene instructions of products and use personal protective equipment when handling these substances.

•

Workers coming into contact with the above products when repairing the machine are obliged to follow general principles of their own health protection and comply with safety and hygiene manuals of the manufacturers of the products.

In particular we draw your attention to the following: -

protect your eyes and skin while working with the batteries

-

protect your skin while handling petroleum products, paints and coolants

-

wash your hands properly after finishing the work and before eating, treat your hands with a suitable reparation cream

-

when handling the cooling system, follow the instructions given in the manuals supplied with the machine

•

Always store petroleum products, refrigerants, batteries and paints including organic thinners as well as cleaners and preserving agents in original and properly labelled containers. These materials are not allowed to be stored in unlabelled bottles or in any other containers considering the possible risk of confusion. Possible confusion with foodstuffs or beverages is very dangerous.

•

If by accident the skin, eyes or mucous membrane is stained or if you breathe in the vapours of such products, apply immediately the principles of the first aid. In case of accidental ingestion of these products, immediately seek medical help.

Environmental measures •

Discarded operating fluids of individual systems of the machine and also some of its parts become hazardous wastes with dangerous properties for the environment.

This category of waste products includes in particular: -

organic and synthetic lubricating materials, oils and fuels

-

coolants

-

battery cartridges and batteries

-

cleaning and preservative agents

-

all dismounted filters and filter elements

-

all used and discarded hydraulic or fuel hoses, rubber-metals and other parts of the machine contaminated by the above mentioned products.

•

It is necessary to treat the above mentioned materials and parts after they have been discarded in accordance with relevant national regulations valid for protection of individual parts of the environment and in compliance with health protection regulations.

•

When disassembling hydraulic, fuel and cooling systems and their units. Escape of fluids into the ground has to be prevented by using suitable vessels placed underneath and by plugging of the holes.

•

In case of leakage, the affected area must be immediately dried with the use of sawdust, Vapex, etc.

•

The affected soil must be removed to prevent further leakage. The contaminated soil and absorbent should then be handed over for further safe disposal.

ARR 1585

15

2

Safety measures and instructions

2.3

Fire prevention

•

The oil change point must be located so that it cannot interfere in the explosion or fire hazard area.

•

It must be identified by the tables and signs with “No smoking” signs and signs prohibiting the use of naked fire.

•

The handling area must be dimensioned so that it can capture a volume of the flammable liquid equal to the capacity of the biggest transport container.

•

It must be equipped with portable fire extinguishers.

•

For handling the oil and diesel fuel, use such vessels as metal barrels, jerry cans, sheet-metal cans.

•

The transport containers must be properly closed during storage.

•

Vessels must be with only one outlet, stored always with the outlet up and secured against the outflow and drains.

•

Vessels must be marked by non-removable writing showing the contents and the flammable liquid class.

Special tools, jigs – see relevant chapters of the manual

2.4

Claim conditions and disclaimer of liability

1. Warranty rules •

Regular inspections and correct operation of the equipment

•

Products have been registered at the service portal

•

The equipment is operated by a trained operator

•

Following parts are excluded from warranty: part subject to wear and tear, including, without limitation, rubber washers/wheels, belts, scrapers, sweepers, filters, grease, fluids, conveyor parts, chains, foundation boards, compacting rods, auger elements, bearings, fuel and consumables.

•

A warranty for 12 months / 1,000 hours is provided to batteries. Then batteries are included in parts subject to wear and tear and are excluded from the warranty.

•

Hydraulic hoses can be purchased from local dealers and charged as an expense to Ammann.

2. Procedure for raising a claim •

In case of raising a warranty claim, the owner/user shall immediately submit the manufacturer a completed warranty claim and images of the fault. The owner/user shall also send a proof of regular maintenance before sending the warranty claim or together with it at the latest.

•

Ammann recommends that you send a proof of regular maintenance regularly.

•

The document can be sent in various ways (e.g. via the service portal, service application). The document shall contain a machine serial number and a serial number of the original maintenance kit of Ammann. This information can be provided either typed, or scanned according to the selected manner of handover.

3. Breach •

16

If a dealer breaches obligations stated in points 1) and 2), any warranty claims will be rejected.

ARR 1585

WORKSHOP MANUAL

3 Specification manual

ARR 1585

17

3

Specification manual

3.1

Machine description

The Rammax 1585 trench roller is a roller specially designed for trench compacting. The unlimited side clearance of the roller drums allows compacting in very narrow, tight trenches right up to the trench walls.

Please fill in the following data: (see Pin label, Label of the Hatz engine) Type of machine ................................................................................................................

Machine application The wet, clayey soils found in sewer construction, pipeline construction, road foundations and construction backfilling, etc., are the areas of application for this modern trench roller.

In hazardous construction site applications, it is possible for the operator to control the machine from a safe distance with no personal risk.

Only use the Rammax 1585 roller for driving on and compacting of non-cohesive (loose) materials.

Product Identification Number ................................................................................................................

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

Type of engine ................................................................................................................

Serial number of the engine

ARR 1585-M is equipped with manual control.

ARR 1585-MI is equipped with manual and infrared remote control.

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

ARR 1585-MC is equipped with manual control and cable control.

ARR 1585-MIC is equipped with manual control, infrared remote control and cable control.

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

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.

18

ARR 1585

WORKSHOP 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

4145

1 2 3 4 5 6 7

AMMANN CZECH REPUBLIC a.s.

549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145 CZECH REPUBLIC

8

DESIGNATION TYPE

VERSION

PRODUCT IDENTIFICATION NUMBER

NOMINAL POWER

ENGINE EMISSIONS

OPERATING MASS

FRONT AXLE LOAD

MAXIMUM MASS

REAR AXLE LOAD

SHIPPING MASS

YEAR OF CONSTRUCTION MODEL YEAR

MADE IN CZECH REPUBLIC

9 10 11 12 13 4145

Name plate location

558019

ARR 1585

19

3

Specification manual

3.2

Dimensioned drawing of the machine

D E A

C

C

F

G

B 556247A

mm (in)

A

B

C

D

E

F

G

1520

-

1230

500

850

1780

630

(59,8)

-

(48,4)

(19,7)

(33,5)

(70,1)

(24,8)

1520

850

1230

500

850

1780

-

(59,8)

(33,5)

(48,4)

(19,7)

(33,5)

(70,1)

-

630 ARR 1585 Tier 4 Final 850

20

ARR 1585

WORKSHOP MANUAL 3.3

Technical data ARR 1585 EU Stage V / U.S. EPA Tier 4f 630

850

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

kg (lb)

1305 (2880)

1395 (3080)

Operating load of EN 500-1+A1 (CECE) on front axis

kg (lb)

655 (1440)

700 (1540)

Operating load of EN 500-1+A1 (CECE) on rear axis

kg (lb)

650 (1430)

695 (1530)

Weight of half fluid capacities

kg (lb)

10 (20)

10 (20)

Operating weight of ISO 6016

kg (lb)

1315 (2900)

1405 (3100)

Maximum weight with accessories

kg (lb)

1315 (2900)

1405 (3100)

km/h (MPH)

2.5 (1.6)

2.5 (1.6)

1.1 (0.7)

1.1 (0.7)

Driving characteristics Maximum transport speed Working speed Climbing ability without vibration

%

30

30

Climbing ability with vibration

%

25

25

Theoretical climbing ability of machine

%

40

40

Lateral static stability

%

53

72

Lateral stability during driving without vibration

%

20

25

Lateral stability during driving with vibration

%

10

15

Type of drive

-

Hydrostatic

Number of driving axles

-

2

Type of steering

-

skid

Steering control

-

Hydraulic

Steering

Engine Manufacturer

-

Hatz

Type

-

2G40

kW (HP)

13.2 (18)

Number of cylinders

-

2

Cylinder capacity

cm (cu in)

997 (61)

Nominal speed

min (RPM)

2550

Average fuel consumption

Power according to ISO 3046-1

3

-1

l/h (gal US/h)

2 (0.5)

Engines complies with emission regulations

-

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

Cooling system of engine

-

air cooling

Operating

-

Hydrostatic

Parking

-

Mechanical multiple-disc

Frequency I

Hz (VPM)

30 (1800)

Amplitude I

mm (in)

2.4 (0.094)

Fuel

l (gal US)

24 (6.3)

Engine (oil filling)

l (gal US)

2.5 (0.7)

Hydraulic system

l (gal US)

53 (14)

Brakes

Vibration

Fluid capacities

ARR 1585

21

3

Specification manual ARR 1585 EU Stage V / U.S. EPA Tier 4f 630

850

Wiring Voltage

V

12

Battery capacity

Ah

77

Measured sound power level A, LpA at the operator's position *

dB

75

Uncertainty KpA *

dB

2

Guaranteed sound power level A, LWA **

dB

106

Declared sound pressure level A, LpA at the operator's place (platform) *

m/s2 (ft/s2)

3.7 (12.1)

Measured sound power level A, LWA

m/s2 (ft/s2)

4.4 (14.4)

Noise and vibration emissions

* measured according the EN 500-4 ** measured according the DIRECTIVE 2000/14/EC

22

ARR 1585

WORKSHOP MANUAL

4 Specification of operating fluids

ARR 1585

23

4

Specification of operating fluids

4.2.1

Engine oil 2412

Engine oil is specified by its performance and viscosity classifications.

Performance classification according to API (AMERICAN PETROLEUM INSTITUTE) ACEA (ASSOTIATION DES CONSTRUCTEURS EUROPÉENS DE AUTOMOBILE)

°F

°C

122

50

104

40

86

30

68

20

50

10

32

0

14

-10

-4

-20

-22

-30

NOTE Exceeding of the lower temperature limit does not damage the engine, it may only cause starting problems.

It is suitable to use general-purpose multi-grade oil in order that oil need not be exchanged because of ambient temperature changes.

For easier start at temperatures below 0 °C (32 °F), SAE 10W-30 oil is recommended by the engine manufacturer.

20W20

15W40

All season - SAE 15W-40

10W40

Permitted oil according to ACEA E2, B3, A3

10W30

Permitted oil according to API CG-4/SJ

5W40

To determine SAE (Society of Automotive Engineers) viscosity class, the ambient temperature and type of operation in place of usage of the machine are decisive.

5W30

Viscosity classification

556243 Exceeding the upper temperature limit must not last for long, taking into consideration reduced lubricating properties of oil.

24

ARR 1585

WORKSHOP MANUAL 4.2.2

Fuel

Diesel is used as fuel: •

CEN EN 590

•

DIN 51601 - DK

•

BS 2869 A1, A2

•

ASTM D975 - 1D, 2D

Therefore use winter Diesel fuel at outdoor temperatures below 0 °C (32 °F).

Mixing diesel with special additives is prohibited.

ARR 1585

Use of biofuel (Diesel fuel) Using the fuel mixture under the trade name of Bionafta is in principle approved by the engine manufacturer for the engine on the machine if it conforms to the specifications under EN 14214 or ASTM D6751. Up to 5 % portion of biodiesel is accepted.

Before using Bionafta on the machine, make sure that it is supplied by a reputable supplier who supplies fuels corresponding to the above-mentioned standards.

Always ask the supplier of Bionafta for information concerning the condition under which it can be used.

Guarantee for the engine will be rejected when using Bionafta not conforming to the above-mentioned standards and if the fuel system or engine is damaged as a result of using improper Bionafta!

When using Bionafta, power can be reduced by up to 12% depending on the used mixture of Bionafta. Therefore, do not adjust the engine or the setting of the injection pump for increasing the power in any case. Never mix the fuel mixture at the place of use.

Bionafta has a higher cloud point at a low ambient temperature, which leads to the creation of wax crystals in the fuel resulting in the fuel filter clogging.

When using Bionafta, it is necessary to shorten the intervals of the engine oil exchange and replacement of an oil filter and fuel filter.

When changing over to Bionafta, the action of Bionafta releases corrosion and impurities created on the fuel tank internal walls. Impurities are brought by the fuel to the filter catching them and the filter must be replaced afterwards.

Bionafta has a higher ability to absorb atmospheric moisture, which results in the condensation of atmospheric moisture on the internal walls of the tank and a higher content of water in the fuel and the need for more frequent discharging of water from the fuel filter separators. The possibility of the occurrence of the problem increases in cold weather.

If Bionafta (Biodiesel) is used all the year round, it is necessary to clean the fuel system under the engine operation with a clean diesel fuel for at least 30 minutes before parking the machine for longer than 3 months. Further, it is necessary to drain off the fuel tank, clean it, and either fill it with diesel fuel or minimise the occurrence of moisture and limit the microbiological growth inside the tank. Consult the measures with the fuel supplier.

25

4

Specification of operating fluids

4.2.3

Hydraulic oil

4.2.4

Gear oil

2158

For use in the hydraulic system of the machine, only high-quality hydraulic oils of output class according to ISO VG 46 HLP (equal to DIN51524-2 HLP).

2186

Use high-quality oils corresponding to API GL-4 or MIL-L-2105 C to lubricate the drum gearbox.

Standardly refill the machines with hydraulic oil of kinematic viscosity 46 mm2/s at the temperature of 40 °C (104 °F) ISO VG 46.

This oil is the most suitable one to use in the broadest range of ambient temperatures.

4.2.5

Lubricating grease

Synthetic hydraulic oil Hydraulic system can be filled with synthetic oil, that is completely degradable by microorganisms found in water and soil in case of leak. Hydraulic oil on the basis of HE ester, HEES category according to ISO 15380, can only be used.

0787

For lubrication of the machine, lubricants must be used according to: ISO 2137 DIN 51 502

When changing over from mineral oil to synthetic or when mixing oils of different brands, always consult the procedure with the oil manufacturer or dealer!

26

ARR 1585

WORKSHOP MANUAL 4.3

Fills

Fills of...

Type of fill

Engine

Engine oil according to chapter 3.2.1

Quantity l (gal US)

Brand

2.5 (0.7) 2412

Fuel tank

Diesel according to chapter 3.2.2

24 (6.3)

Hydrostatic system

Hydraulic oil according to chapter 3.2.3

53 (14) 2158

Drum gearbox

Gearbox oil according to chapter 3.2.4

1 (0.26) 2186

Vibrator bearings

Plastic grease according to chapter 3.2.5

lifelong filling 0787

ARR 1585

27

28

ARR 1585

WORKSHOP MANUAL

5 Frame

ARR 1585

29

5

Frame

1

2

3

6 7

4

5

8

9

12 11

11 10

10

17 13 16 14

15

558025

30

ARR 1585

WORKSHOP MANUAL 5.1

Description of basic elements

1.

One-point lifting lug

2.

Infrared sensor

3.

Engine

4.

Air filter

5.

Battery

6.

Hydraulic oil tank

7.

Control panel cover

8.

Safety bar

9.

Hydraulic pump

10.

Drums

11.

Scrapers

12.

Hydraulic oil filter

13.

Fuel tank

14.

Fan

15.

Oil filter

16.

Fuel filter

17.

Warning light beacon

ARR 1585

31

5

Frame

5.4

Mechanical parts

5.4.1

Gas strut replacement

Remove the screws of the gas strut attachment and take out the strut.

558064

558065

32

ARR 1585

WORKSHOP MANUAL 5.4.2

Bonnet replacement

Removal Remove the screws of the gas strut attachment and take out the strut.

558064 Secure the bonnet against tilting back.

Remove the attachment of the safety cable.

558066 Remove the cover on the upper side of the machine.

588067

ARR 1585

33

5

Frame

Remove the cable ties.

558068

558069 Disconnect the connector of the beacon from the control unit.

558070

34

ARR 1585

WORKSHOP MANUAL Close the bonnet.

Remove the screws of the bonnet attachment and put the bonnet aside.

Note: The bonnet weight is about 60 kg (132 lb).

558071

558072

ARR 1585

35

5

Frame

Installation Put the bonnet carefully on the machine frame.

Mount the screws of the bonnet attachment.

Note: The bonnet weight is about 60 kg (132 lb).

558072

558071 Connect the connector of the beacon to the control unit.

558073 Attach the beacon cable using cable ties.

558074 36

ARR 1585

WORKSHOP MANUAL Mount the safety cable.

558066 Mount the gas strut.

558064

5.4.2.1 Bonnet hinge replacement Removal Remove the bonnet (Chapter 5.4.2).

Remove the screws of the attachment of the bonnet hinges.

Put the hinges aside.

558088 Installation Mount the screws of the attachment of the bonnet hinges.

Mount the bonnet (Chapter 5.4.2).

558088 ARR 1585

37

5

Frame

5.4.3

Sensor replacement

Remove the sensor cover.

558096 Remove the cable ties.

558099 Disconnect the connector from the control unit.

558100

38

ARR 1585

WORKSHOP MANUAL Remove the sensor and put aside.

558101

558102 Run the cable of the new sensor through the opening in the frame.

558103 Insert the seal ring.

558104 ARR 1585

39

5

Frame

Insert the green ball.

558105 Mount the sensor.

558106

558107 Mount the sensor cover.

558096 40

ARR 1585

WORKSHOP MANUAL 5.4.4

Beacon replacement

Removal Open the bonnet.

Remove the cover on the upper side of the machine.

588067 Remove the cable ties.

558068

558069 Disconnect the connector of the beacon from the control unit.

558070 ARR 1585

41

5

Frame

Remove the beacon cover.

558075 Put the cover and the seal aside.,

558076 Take out the beacon.

558077

42

ARR 1585

WORKSHOP MANUAL Installation Mount the sensor.

Note: Align the rubber seal with the screw holes.

558078

558079 Open the bonnet.

Connect the connector of the beacon to the control unit.

Fasten the cable using cable ties.

558070 Mount the cover on the upper side of the machine.

588067 ARR 1585

43

5

Frame

5.4.5

Replacement of bonnet stops, the rubber block on the control cover and the control unit

Bonnet stop I Remove the screws of the bonnet stops.

558080 Mount the new bonnet stop.

558081

558080

44

ARR 1585

WORKSHOP MANUAL Bonnet stop II Remove the bonnet stop.

558082

558083 Mount the new bonnet stop.

558084

558082 ARR 1585

558083 45

5

Frame

Rubber block on the control cover Remove the rubber block.

558085

558086 Mount the new rubber block.

558087

558085 46

558086 ARR 1585

WORKSHOP MANUAL 5.5

Fuel tank

5.5.1

Fuel level indicator lamp

Open the engine bonnet.

Check the fuel level in the inspection hole.

If needed, fill the fuel tank with fuel up to the lower edge of the filler neck.

The tank volume is 24 l (6.3 gal US).,

558063

5.5.2

Fuel replenishment

Fill the fuel tank with fuel up to the lower edge of the filler neck.

Do not smoke while working!

558120 Catch the drained fuel.

5.5.3

Fuel draining

5.5.3.1 Method 1 Remove the drain plug.

Collect the drained fuel in a prepared container.

The fuel tank volume is 24 l (6.3 gal US).

558089 ARR 1585

47

5

Frame

5.5.3.2 Method 2 Remove the hose from the fuel filter.

558090 Run the hose through the opening in the frame.

558091 Drain the fuel into a prepared container.

The fuel tank volume is ca. 24 l (6.3 gal US).

558092

48

ARR 1585

WORKSHOP MANUAL 5.5.4

Fuel tank cleaning

Remove the filler neck.

558093 Remove the fuel drain plug.

Drain the fuel into a prepared container and rinse the tank.

The fuel tank volume is 24 l (6.3 gal US).

558089

ARR 1585

49

5

Frame

5.5.5

Fuel filter replacement

Removal Remove the hoses from the fuel filter.

Plug the hoses.

558094 Remove the bracket with the fuel filter.

558095 Installation Mount the bracket with the fuel filter.

558095 Mount the hoses to the fuel filter.

558094 50

ARR 1585

WORKSHOP MANUAL 5.6

Hydraulic tank

5.6.1

Checking the hydraulic oil level

Check the hydraulic oil level always when the engine is cold but running.

Put the machine on a flat terrain.

Let the engine run at idle.

Check the oil level in the inspection hole.

The ideal hydraulic oil level is when the gauge is half-full.

556281 5.6.2

Hydraulic oil replenishment

Remove the plug of the hydraulic tank (1).

Refill the required quantity of hydraulic oil.

Replace the plug.

1

558015

Always lubricate the O-ring before screwing it in place.

Check the oil when it is cooled down.

Stop the oil soaking into the ground.

ARR 1585

51

5

Frame

5.6.3

Hydraulic oil draining

Remove the sensor cover of the machine remote control.

558096 Remove the hydraulic oil filler plug.

558097 Remove the hydraulic oil drain plug.

558098

52

ARR 1585

WORKSHOP MANUAL 5.6.4

Hydraulic oil filter cleaning

Drain the hydraulic oil (Chapter 5.6.3).

Remove the filter housing.

558121 Remove the filter cartridge and replace with a new one.

558122 Mount the cartridge back.

558123

ARR 1585

53

5

Frame

5.7

Rubber-metal element replacement

Remove the screws of all rubber-metal elements.

558156 Hang the machine frame on the crane and lift the frame carefully.

When lifting, take care not to damage the hydraulic hoses.

558157

558158

558159 54

ARR 1585

WORKSHOP MANUAL Remove the rubber-metal elements and replace with new ones.

558160

558161 Lower the machine frame carefully.

When mounting the rubber-metal elements, proceed from front to back.

Secure the screws with the Loxeal 83-54 adhesive.

558162

1

2

3 4 558163

ARR 1585

558164 55

56

ARR 1585

WORKSHOP MANUAL

6 Cab and platform

ARR 1585

57

6

Cab and platform

6.1

Control and indication elements

3

5 4 1 6

7

2 558003 1. Manual control 2. Engine speed lever 3. Ignition box 4. Cable remote control connector 5. Display unit 6. Remote control switch 7. Emergency brake button

58

ARR 1585

8

558004 8. Infrared remote control

9. Cable remote control

9

556271A ARR 1585

59

6

Cab and platform

6.1.1

Display unit

6.1.1.1 Indicator lamps

-

1

-

+

3

2

4

+

Charging indicator lamp (1)

h

RAM13

The indication lamp goes on after the key in the ignition box is switched into the position "I" and goes out after the engine starts. If the indicator lamp turns on during operation or does not turn off after starting, immediately perform the following check.

•

Turn off the engine.

•

Check the V-belt of the engine for damage and loosening.

1/10

5 556245

If the battery charging indicator lamp is still on after this check, contact an authorized service centre of Ammann.

Engine oil pressure indicator lamp (2) RAM14

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

If the engine oil pressure indicator lamp turns on during operation or does not turn off after the starting, immediately stop the machine and the engine.

•

Check the engine for oil leaks and correct oil level.

•

If the oil level in the engine is correct, contact an authorized service centre of Ammann.

Note: The machine is equipped with an automatic shutdown system.

If the oil pressure drops below the limit value, the oil pressure indicator lamp turns on. It lights up for 4 seconds and then the machine turns off.

Coolant temperature indicator lamp (3) RAM15

The machine is equipped with an air-cooled diesel engine. The indicator lamp has no function.

Machine inclination indicator lamp (4) RAM16

When the machine is dangerously inclined, the indicator lamp lights up and the engine automatically stops. The engine cannot be started until the machine inclination is lowered.

60

ARR 1585

WORKSHOP MANUAL Display (5) The display shows three different machine functions: Engine hour counter

556034 Function code display The display shows control unit commands as a code.

A list of all codes can be found at the end of this publication.

556037 Error code display The display shows machine faults as a code.

A list of all codes can be found at the end of this publication.

556036

ARR 1585

61

6

Cab and platform

6.1.3

Infrared remote control

6.1.3.1 Layout

3

1

1

1. Control levers 2. Start / Stop

0

3. Forward/backward vibration 4. Working speed / Transport speed

5

5. Warning horn switch

Start

4

2

Stop

558050

6.1.3.4 Handling Using the infrared remote control, the machine can be controlled from a safe distance.

The maximum range is 20 m.

The infrared remote control is powered by solar cells. No batteries are required.

The infrared remote control is equipped with an internal emergency switch, which protects the battery from deep discharge.

This emergency switch disconnects the battery from other circuits if the battery voltage drops below 3.1 V. Once the battery voltage exceeds 3.5 V, other circuits will reconnect.

When the battery is discharged, expose the infrared remote control to sunlight for at least 10 minutes.

Dust and dirt on the surface of the solar cells lower the light efficiency and thus also the energy efficiency. Dirty solar cells may be the cause for empty batteries of the infrared remote control.

Dirty solar cells, therefore, should be cleaned immediately.

Replace any damaged rubbers protecting the control elements of the infrared remote control to prevent damage of the internal electronics caused by dirt or humidity.

When the protective valve is damaged, contact your dealer immediately to prevent damage of the internal electronics due to dirt or humidity.

Damaged solar cells of the infrared remote control must be replaced. The battery of the transmitter cannot be recharged without solar cells.

62

ARR 1585

WORKSHOP MANUAL The infrared remote control is located in the compartment on the upper side of the machine.

It contains the following transmission elements: •

solar cells,

•

infrared diodes for data transmission and safe distance measurement.

Clean the transmission elements before starting.

Keep the solar cells clean during operation.

558007 Risk of injury due to obstructed bottom part of the cover!

Before and during the operation with the infrared remote control, make sure the entire bottom part of the cover remains completely exposed throughout the whole operation.

The operator must not cover the bottom part of the cover, not even partially.

Proper carrying and use of the infrared remote control Ensure correct positioning.

Proper function requires direct visual contact between the manual infrared remote control and the infrared sensor on the machine.

ARR 1585

63

6

Cab and platform

Proper use of the infrared remote control

The infrared sensor must always be in the area of effect of the infrared remote control.

The range of the infrared remote control is 30° in the vertical plane and 40° in the horizontal plane.

40°

558026

20°

10°

558027

20°

10°

558028

20° 10°

20° 10°

558029 64

558030 ARR 1585

WORKSHOP MANUAL Improper use of the infrared remote control

During the operation of the machine, it is forbidden to use the infrared remote control without direct visual contact between the infrared remote control and the infrared sensor on the machine.

The range of the infrared remote control is 30° in the vertical plane and 40° in the horizontal plane.

40°

558031

20° 20° 10°

10°

558033

558032

20° 10°

20° 10°

558034

558035

20° 20°

10° 10°

558036 ARR 1585

558037 65

6

Cab and platform

During operation, aim the infrared remote control in the direction of the machine only.

The infrared remote control can lean on the operator's body.

556198

556199

The side and front diodes of the infrared remote control must not be covered (e.g. by fingers, hand, foreign objects or dirt).

556200

556203 66

ARR 1585

WORKSHOP MANUAL

Do not aim the transmitter at reflective objects (large surfaces, light objects, other machinery, etc.).

Do not use the infrared remote control in the protected 2 m zone or if there is insufficient visual contact between the machine and the operator or the infrared remote control, unless stated otherwise. For optimum comfort, adjust the strap to the correct length.

556201

556202

The infrared remote control is provided with a protective cover. This cover reduces risk of inadvertent covering of the side and front diodes with hands or fingers of the operator. Do not remove the cover from the infrared remote control.

558060

ARR 1585

67

6

Cab and platform

Protected zone and safe zone when using the infrared remote control

556168

68

ARR 1585

WORKSHOP MANUAL 6.1.3.5 Near and remote machine halt •

The near and remote machine halt function is an electronic safety feature designed to prevent the loss of visual contact between the operator and the machine and excessive proximity of the operator to the machine.

•

A machine equipped with infrared remote control contains infrared sensors determining the safe distance of the operator from the working machine. This creates a protected zone and a safe zone.

•

The protected zone is within 2 m from the infrared sensors.

•

The safe zone is an area marked in grey located at a distance of 2–20 m; when using the infrared remote control, see Fig. 556168.

•

When using the infrared remote control, the operator is allowed to move only within the safety zone.

•

If the operator leaves the safe zone, the machine halts. The engine keeps running, but all other functions are disabled. In order to reactivate the machine, the operator must be located in the safe zone according to specific conditions and when controlling via the infrared remote control (2–20 m).

The infrared sensors do not react to people approaching the machine, only to the infrared remote control.

During the operation of the machine, do not enter the protected zone of two metres.

The border of the protected 2 m zone might be deformed by the deflection of rays of the infrared remote control or insufficient direct visual contact.

Do not use the infrared remote control in the protected 2 m zone or if the visual contact is insufficient between the machine and the operator or the infrared remote control unless stated otherwise.

Operate the machine exclusively from the area in grey, i.e. from the safe zone. Outside the safe zone, the control switches of control elements do not correspond to directions of machine movements.

ARR 1585

69

6

Cab and platform

6.1.4

Cable remote control

6.1.4.1 Layout

4

1

4

1

1. Control buttons 2. Start 3. Stop 4. Vibration buttons 5. Working/transport speed button

1

5

1 2

3

556253

6.1.4.4 Handling Operate the machine exclusively from the area in grey. There, you are within the effective range of the safety bar. Make sure that both your legs are always behind the safety bar – its effective range is limited.

Do not use vibration on steep slopes or in the case of a large tilt angle.

Do not use vibration in buildings and on unstable grounds.

556252

Danger to life caused by machine slipping or falling!

70

ARR 1585

WORKSHOP MANUAL 6.1.5

Manual control

6.1.5.1 Layout

1

2

3

3

1. Working/transport speed switching lever 2. Vibration lever 3. Control levers 4. Engine speed lever 5. Remote control switch 6. Emergency brake button

5

4

6 558006

6.1.5.4 Handling Operate the machine exclusively from the area in grey. There, you are within the effective range of the safety bar. Make sure that both your legs are always behind the safety bar – its effective range is limited.

Do not use vibration on steep slopes or in the case of a large tilt angle.

Do not use vibration in buildings and on unstable grounds.

556251

Danger to life caused by machine slipping or falling!

6.3.4

Dashboard

6.3.4.2 N1 connector / cable harness 18 6 19 20 21

Make sure there is no water or dirt on the N1 connector.

23

11

15

27 26

14

3

10

28

16 4

2

9 22

17 29

1

7 8

5

13 12

25 24

558119 ARR 1585

71

6

Cab and platform

6.4

Mechanical parts

6.4.1

Replacement of the remote control battery

Removal Remove the protective cover.

558124

558125 Remove the rubber gaskets.

558126 Remove the screws.

558127 72

ARR 1585

WORKSHOP MANUAL Open the top of the remote control.

558128 Remove the cable tie.

558129 Remove the battery.

558130 Disconnect the connector.

558131 ARR 1585

73

6

Cab and platform

Installation Connect the connector.

558131 Mount the battery.

558130 Run the fastening strip through the opening under the connector.

Attach the connector using a fastening strip.

Shorten the fastening strip.

558132 Mount the top of the control using the screws.

558127 74

ARR 1585

WORKSHOP MANUAL Mount the rubber gaskets.

558126 Mount the protective cover.

558124

ARR 1585

75

6

Cab and platform

6.4.2

Replacement of the display unit

Removal Remove the dashboard cover.

558115 Disconnect the display connectors.

558116 Disconnect the connector of the ignition box.

558117 Remove the display unit.

558133 76

ARR 1585

WORKSHOP MANUAL Installation Mount the display unit.

558133 Connect the display connectors.

558116 Connect the connector of the ignition box.

558117 Remove the dashboard cover.

558115 ARR 1585

77

6

Cab and platform

6.4.3

Replacement of the control unit

Removal Disconnect the battery.

558134

558135 Disconnect the connectors.

558109 78

558110 ARR 1585

WORKSHOP MANUAL Remove the screws of the metal plate of the control unit.

Put the control unit aside.

558111

558112

ARR 1585

79

6

Cab and platform

Installation Install the control unit on the metal plate.

Mount the metal plate of the control unit into the machine frame.

558111 Connect the connectors.

558108

558110

Connect the battery.

558134 80

558135 ARR 1585

WORKSHOP MANUAL

7 Front drum

ARR 1585

81

7

Front drum

7.2

Hydraulic parts

7.2.1

Description of basic elements

Wiring diagram of hydraulic valve hoses

34

7

3

1

60

A

31

61 33

6

4

2

B

62

2

C

558177

A. Hydraulic vibration and travel speed valve B. Hydraulic travel valve – left side C. Hydraulic travel valve – right side

7.2.2

Hydraulic valve, vibration and travel valves

Remove the metal plate.

558113 82

ARR 1585

WORKSHOP MANUAL Remove the dashboard covers.

558114

558115 Disconnect the connectors of the display and of the ignition box.

558116

558117 ARR 1585

83

7

Front drum

Remove the dashboard cover.

558118 Remove the handles of the control levers.

558136 Disconnect the connectors of the emergency brake button and of the remote control switch.

Mark the connectors.

558137

84

ARR 1585

WORKSHOP MANUAL 7.4.2

Drum removal

Remove the screws and put the scraper aside.

558138 Support the machine frame.

558139 Remove the drum screws.

558140 Hang the drum on the crane and put the drum aside.

Drum weight 61 kg.

558141 ARR 1585

85

7

Front drum

7.4.4

Replacement of the travel hydraulic motor

Removal Remove the drum (Chapter 7.4.2).

Support the hydraulic motor and protect it from falling.

558142 Remove the screws of the hydraulic motor attachment.

558143 Put the hydraulic motor aside carefully.

558144 Installation Insert the seal.

Replace the damaged seal.

558145 86

ARR 1585

WORKSHOP MANUAL Secure the hydraulic motor using 4 screws.

558146

558147 Mount the hydraulic motor using the remaining screws.

Secure the screws with the Loxeal 83-54 adhesive.

558148

558149 ARR 1585

87

7

Front drum

Remove 4 screws that secured the hydraulic motor.

558150

558151 Secure the screws with the Loxeal 83-54 adhesive.

558152

Mount the hydraulic motor using 4 screws.

558150 88

558151 ARR 1585

WORKSHOP MANUAL 7.4.5

Drum installation

Put the drum on the travel hydraulic motor.

Mount the drum using the screws.

Secure the screws with the Loxeal 83-54 adhesive.

558153

7.4.6

Scraper replacement

Remove the screws and put the scraper aside.

558138 Mount the scraper using the screws.

Secure the screws with the Loxeal 83-54 adhesive.

558154 Adjust the gap between the scraper and the drum of ca. 8 mm.

558155 ARR 1585

89

90

ARR 1585

WORKSHOP MANUAL

8 Rear drum

ARR 1585

91

8

Rear drum

8.2

Hydraulic parts

Hydraulic parts (Chapter 7.2)

8.4

Mechanical parts

Mechanical parts (Chapter 7.4)

92

ARR 1585

WORKSHOP MANUAL

9 Front axle (not included in the machine equipment)

ARR 1585

93

94

ARR 1585

WORKSHOP MANUAL

10 Rear axle (not included in the machine equipment)

ARR 1585

95

96

ARR 1585

WORKSHOP MANUAL

11 Travel

ARR 1585

97

11

Travel

11.2

Hydraulic parts

11.2.1 Pump replacement Removal Remove the cover of the remote control compartment.

588067 Remove the metal plate with the control unit (Chapter 6.4.3).

Remove the cooling propeller (Chapter 14.4.1).

Remove the propeller cover.

558165

558166

98

ARR 1585

WORKSHOP MANUAL Remove the hydraulic hoses from the pump.

Plug the hoses.

558167

558168 Remove the pump.

558169 Take out the pump and put it aside.

558170 ARR 1585

99

11

Travel

Installation Mount the pump using the screws.

Secure the screws with the Loxeal 83-54 adhesive.

558171 Mount the hydraulic hoses.

33 34 31

32

558172

558173 Insert the cover of the cooling propeller.

558174 100

ARR 1585

WORKSHOP MANUAL Mount the cooling propeller (Chapter 14.4.1).

558175 Mount the propeller cover using the screws.

558176

ARR 1585

101

102

ARR 1585

WORKSHOP MANUAL

12 Vibration

ARR 1585

103

12

Vibration

12.2

Hydraulic parts

12.2.1 Vibration hydraulic motor replacement Removal Remove the cover of the hydraulic motor.

558178 Remove the cable ties.

558179 Remove the hydraulic hoses.

558180 Plug the hoses using hydraulic plugs.

558181 104

ARR 1585

WORKSHOP MANUAL Remove the screws of the hydraulic motor.

558182 Take out the hydraulic motor and put it aside.

558183 Installation Insert the new seal if the old one is damaged.

558184 Insert the hydraulic motor.

558185 ARR 1585

105

12

Vibration

Mount the travel hydraulic motor using the screws.

Secure the screws with the Loxeal 83-54 adhesive.

558182 Remove the hydraulic plugs.

558181 Connect the hoses to the vibration hydraulic motor.

558180 Mount the cover of the hydraulic motor.

558178 106

ARR 1585

WORKSHOP MANUAL 12.2.2 Vibrator removal Remove the vibration hydraulic motor (Chapter 12.2.1).

Remove the screws of the vibrator cover.

558186 Remove the cover using the forcing-off screws.

558187 Take out the eccentric of the vibration unit.

Eccentric weight 36 kg.

Lubricate and mount the bearings.

558188

558189 ARR 1585

107

12

Vibration

Press the vibrator cover using the screws.

558190 Mount the cover using the screws.

Secure the screws with the Loxeal 83-54 adhesive.

Mount the vibration hydraulic motor (Chapter 12.2.1).

558191

108

ARR 1585

WORKSHOP MANUAL

13 Steering

ARR 1585

109

13

Steering

13.4

Mechanical parts

13.4.1 Replacement of steering valves Steering valves replacement (Chapter 7.2.2).

13.4.2 Replacement of coils on the steering valves Removal Remove the coil nut.

558192 Remove the screw of the connector attachment.

558193 Disconnect the connector.

558194 110

ARR 1585

WORKSHOP MANUAL Remove the coil.

558195

558196 Installation Mount the coil.

Insert the seal ring.

558197 Mount the nut.

558198 ARR 1585

111

13

Steering

Insert the seal and connect the connector.

558199 Mount the screw to attach the connector.

558200

112

ARR 1585

WORKSHOP MANUAL

14 Cooling

ARR 1585

113

14

Cooling

14.4

Mechanical parts

14.4.1 Replacement of the cooling propeller on the vibration pump Removal Remove the nut of the first propeller.

558201 Put the propeller aside.

558202 Remove the second propeller.

558203 Installation Mount the second propeller on an intermediate piece.

558204 114

ARR 1585

WORKSHOP MANUAL Mount the nut.

558205 Mount the second propeller on the shaft.

558206 Put the first propeller on the shaft.

558207

ARR 1585

115

14

Cooling

Mount the first propeller.

Secure the nut with Loxeal 83-54.

558208

558209

116

ARR 1585

WORKSHOP MANUAL

15 Engine

ARR 1585

117

15

Engine

558261

15.1

Description of basic elements

1.

Fuel hose (fuel pump – injection pump)

18.

Engine oil line

2.

Air deflector

19.

Exhaust piping

3.

Engine oil dipstick

20.

Fuel injection pump

4.

Fuel return line

21.

Connecting rod of the engine shutdown

5.

Injector

22.

Speed control lever

6.

Lifting lug

23.

Fuel pump

7.

Starter

24.

Engine oil filter

8.

Air suction

25.

Engine oil drain plug

9.

Air intake inlet pipe

26.

Engine cover

10.

Nameplate

27.

Air duct cover

11.

Glowing plug

28.

Connector

12.

Air cleaner in the oil bath

29.

Voltage regulator

13.

Oil pressure switch

30.

Engine bracket

14.

Waterproof plug

31.

Crankshaft, power take-off

15.

Engine oil filler plug

32.

Fuel line (fuel filter, pump)

16.

Fuel pressure line

33.

Fuel filter

17.

Cylinder head cover

118

ARR 1585

WORKSHOP MANUAL Technical data Engine type

Dimensions 2G40

Working principle

Air-cooled, four-stroke diesel engine

Combustion process

Direct injection

Number of cylinders

2

Bore/stroke

mm

Engine displacement

cm

3

92/75 997 2.5 without oil tank

Lubricating oil change volume (with filter)

l

Difference between the “max.” and “min.” oil level

l

0.8

Engine oil pressure

bar

1 bar at 900 rpm

3.0 with oil tank

Engine oil consumption (after engine running-in)

1% fuel consumption at full power

Engine rotation direction

Counter-clockwise

Valve clearance at 10–30 °C

mm

0.10

Weight (including fuel tank, air filter, exhaust muffler and electric starter)

kg

106

Battery capacity

ARR 1585

Amp/h

max. 12 V / 88 Ah – 24 V / 88 Ah

119

15

Engine

15.4

Mechanical parts

15.4.1 Adjustment of the engine speed connecting rod Removal Remove the screws.

558210 Loosen the screws of the gas cable attachment in the bracket.

558211 Take out the cable from the bracket.

558212 Remove the cable tie.

558213 120

ARR 1585

WORKSHOP MANUAL Run the cable through the frame into the rear of the machine.

558214 Remove the gas control lever head.

558215 Loosen the screws.

558216 Take out the gas cable.

558217 ARR 1585

121

15

Engine

Installation Run the gas cable from the rear of the machine to the front.

558218

558219

558220 Mount the gas cable into the holder.

558221 122

ARR 1585

WORKSHOP MANUAL Mount the holder using the screws.

558210 Mount the cable in the rear of the machine.

558216 Mount the head of the gas control lever.

558215

ARR 1585

123

15

Engine

15.4.2 Air filter replacement Removal Loosen the hose clamps.

558222

558223 Loosen the clamp of the air filter bracket attachment.

558224

558225 124

ARR 1585

WORKSHOP MANUAL Remove the filter from the air suction hoses and put the filter aside.

558226 Installation Put the filter into the bracket and connect the suction hoses.

558227 Attach the filter in the bracket using the clamp.

558228

Attach the suction hoses using the clamps.

558222 ARR 1585

558223 125

15

Engine

15.4.3 Battery replacement Removal Disconnect the battery.

558134

558135 Remove the screws of the battery cover.

558229

558230 126

ARR 1585

WORKSHOP MANUAL Disconnect the horn connectors. Mark the connectors.

558231 Remove the screws of the air filter bracket and take out the bracket.

558232 Remove the connectors from the battery cover.

558233 Take out the battery cover.

558234 ARR 1585

127

15

Engine

Disconnect the overflow hose.

558235 Take out the battery and put it aside.

558236 Installation Insert the battery into the machine.

Connect the overflow hose.

558235 Mount the connectors on the battery cover.

558233 128

ARR 1585

WORKSHOP MANUAL Mount the air filter bracket.

558232 Connect the horn connectors.

558231 Mount the battery cover.

558229

558230 ARR 1585

129

15

Engine

Connect the battery.

558135

558134

130

ARR 1585

WORKSHOP MANUAL 15.4.4 Stop solenoid replacement Removal Remove the cable ties.

558237 Disconnect the connector.

558238 Remove the connector from the bracket.

558239 Remove the lock.

558240 ARR 1585

131

15

Engine

Remove the screws of the stop solenoid.

558241 Take out the stop solenoid and put aside.

558242 Installation Mount the stop solenoid.

558243 Mount the connector on the bracket.

558244 132

ARR 1585

WORKSHOP MANUAL Connect the connector.

558245 Secure the connecting rod.

558246 Attach the cable using the cable tie.

558247

ARR 1585

133

15

Engine

15.4.5 Voltage regulator replacement Removal Remove the screws.

558248

558249

558250

Remove the screws of the regulator wiring.

558251 134

558252 ARR 1585

WORKSHOP MANUAL Disconnect the connectors.

558253 Remove the cable ties.

558254 Disconnect the connector and remove the cover.

558255

ARR 1585

135

15

Engine

Installation Mount the regulator wiring using the screws.

558256 Fit the cover into the frame.

558257 Mount the cover using screws.

558248

558249 136

558250 ARR 1585

WORKSHOP MANUAL Connect the connector.

558255 Attach the wiring cables using cable ties.

558254 Connect the connectors.

558258 Mount the connectors on the bracket.

558259 ARR 1585

137

15

Engine

15.4.6 Fuel filter replacement Fuel filter replacement (Chapter 5.5.5).

15.4.7 Engine oil level inspection Take out the oil dipstick, wipe it, insert fully back and take it out again to read out the oil level.

Keep the level within the range of gauge marks imprinted in the dipstick. The lower mark shows the lowest possible oil level, the upper mark indicates the highest.

Replenish the oil as required.

Check the oil when it is cooled down.

556280

15.4.8 Engine oil replenishment Replenish the engine oil through the filler neck.

Check the engine for leaks and remove the cause.

Note: The total volume of oil in the engine is 2.5 litres (0.7 US gal).

Do not use the engine unless the oil level in the engine is correct.

Replenish the same oil type according to Chapter 3.2.1.

558014

Stop the oil soaking into the ground.

138

ARR 1585

WORKSHOP MANUAL 15.4.9 Engine oil draining The engine oil drain plug (1) is located under the chassis at the front of the machine.

Place a vessel under the drain plug.

Remove the clip (2) of the oil drain hose (3).

Remove the plug (1).

The oil starts to automatically flow out.

556081

Caution! There is a risk of scalding when draining hot oil.

Let the oil cool down below 50 °C (122 °F).

Follow the fire-fighting measures.

Catch the drained oil and do not let it soak into the ground.

Used oil and filters are environmentally hazardous waste – hand it over for disposal.

15.4.10 Air suction filter inspection If the red ring appears on the contamination indicator (1) during operation of the machine, you must replace the cartridge.

The manufacturer does not recommend cleaning the cartridges due to the possibility of reducing the filtration capacity by up to 40% and damaging the cartridge.

1

558042

ARR 1585

139

15

Engine

15.4.11 Air suction filter cartridge replacement Loosen the clamps and remove the air filter cover.

558260 Remove the air filter main cartridge.

556273 Replace the air filter safety cartridge.

556274 Mount a new main cartridge.

556275 140

ARR 1585

WORKSHOP MANUAL Note: If the machine is used in a very dusty terrain, the filter must be checked daily for clogging.

When replacing the cartridges, make sure that no dirt gets into the suction hose.

Check that the suction hole is not dirty, and clean if required.

Do not clean the filter’s inner space with pressure air to prevent dust from entering the engine intake manifold.

Use original cartridges, only.

Take care not to splash water into the air filter.

Replace the vacuum valve immediately if it is damaged!

NEVER operate the machine with the filter body or lid damaged.

ARR 1585

558016

141

142

ARR 1585

WORKSHOP MANUAL

17 General procedures

ARR 1585

143

17

General procedures

17.2

Electrical installation

17.2.2 Preparation for welding work

17.2.3 Starting the battery by means of another battery (jumping) Attach the red cable to the (+) clamps of both batteries.

Connect one end of the green or black cable to the (-) clamps of both batteries.

Press the starter. Let the engine run.

Welding work on a roller with an installed battery may damage the machine control device!

Completely remove the battery before welding work on the roller.

Place grounding cables of the welding equipment as near to the point of welding as possible. The grounding point must be free of paint.

Wait until the engine evenly rotates at idle speed and disconnect the cables form the clamps.

Start with the (-) clamp.

Battery poles and clamps must be clean. If they show a coat of sulphate (whitish or greenish), they must be loosened and cleaned.

Danger of injury!

Incorrectly welded castings may result in material cracks.

Welding of castings is prohibited!

144

ARR 1585

WORKSHOP MANUAL 17.2.4 Charging the battery with a charger

17.2.5 Long-term storage

Disconnect the battery from the clamps.

In case of prolonged downtime of more than two weeks, remove the battery cable from the negative battery pole.

Connect the charger.

Follow the instructions for use of the charger manufacturer.

When reconnecting the battery, start with the (+) terminal.

17.2.6 Battery replacement Battery replacement (Chapter 15.4.3).

Battery poles and clamps must be clean. If they show a coat of sulphate (whitish or greenish), they must be loosened and cleaned.

ARR 1585

145

146

ARR 1585

WORKSHOP MANUAL

18 Troubleshooting

ARR 1585

147

18

Troubleshooting

18.1

Error diagnostics

This chapter states possible causes of faults and their troubleshooting according to symptoms of the faults. Although it is not expressly mentioned, respect that cabling may always be a possible cause of an electric failure.

According to our experience, faults are mostly caused by the cable harness or connection of connectors.

It is a good idea to first check the machine for worn cables and loose or defective connectors.

148

ARR 1585

WORKSHOP MANUAL

19 Appendices

ARR 1585

149

19

Appendices

19.2

Wiring diagram

Legend: A2 A3 F1 G1 G2 M1 S21 Y20 Y20.1

150

Regulator Display / Control panel Fuse Battery Alternator Starter Oil pressure switch Shut-off valve solenoid Shut-off valve solenoid

ARR 1585

WORKSHOP MANUAL

G1 BATTERY / G1

-

F1

+

30 A

12V 77AH

ALTERNATOR / G2 G2

31

G

M

30

S21

X8:A

1

X2:A

X8:B

A

2

Y20.1 1

1

X8:C

X2:B

2

5

X4:1

X4:5

6

X4:2

X4:6

7

X4:3

X4:7

8

X4:4

X4:8

X2:C

4

3

2

1

B

REGULATOR

Y20 SHUT-OFF SOLENOID VALVE

2 + 12V

A2

OIL PRESSURE SWITCH

X3:1

50

X3:2

M1

STARTER / M1

C - 12V

A3 DISPLAY CONTROL PANEL

42603en

ARR 1585

151

19

Appendices

Wiring diagram Legend: A1 A2 A3 A4 C1 F1 G1 G2 H1 M1 S1 S11 S12 S21 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y20 Y20.1

152

Control unit Regulator Display / Control panel Remote control Interference filter Fuse Battery Alternator Horn Starter Switch box Emergency brake button Switch of control Oil pressure switch Drive left - forward Drive left - backward Drive right - forward Drive right - backward Front vibration Rear vibration Fast travel Shut-off valve solenoid Shut-off valve solenoid

ARR 1585

WORKSHOP MANUAL

G1

F1

+

30 A

12V 77AH

X60

1

G2 25

13

28

2

3

6

22

DRIVE LEFT - BACKWARD

1

Y2

X1:7

2

23

7

24

DRIVE RIGHT - FORWARD

1

Y3

X1:8

2

X1:9

Y5

X1:10

1

2

FRONT VIBRATION

1

2

X1:11

Y7

X1:12

2

FAST TRAVEL

1

2

1

2

1

2

SHUT-OFF VALVE SOLENOID

OIL PRESSURE SWITCH

X8:C

Y20

X8:A

Y20.1

X8:B

S11

X7:1 A2

X7:2

10

14

5

20 18

27

A4 REMOTE CONTROL

1 2 3

X6:2

X5:2

X6:3

X5:3

X2:C

B C

S12

X1:16

A4

A3

REZ.

X1:19

X1:17

X1:15

X4:17

X4:15

19

X1:14 X1:20 X1:18

15

X1:21

17

X4:19

21 X5:1

19

X4:21

21

X6:1

X1:24

A

12

X1:5

X1:27

X2:B

11

A1

S21

X1:23

A1

Y6

1

X2:A

9

29

REAR VIBRATION

X1:22

- 12V

CONTROL UNIT

Y4

1

+ 12V

8 16

DRIVE RIGHT - REVERSE

2 X1:3

17

15

1

A3 2 3

CONTROL PANEL

30

X1:6

50

1

Y1

X1:28

S1

DRIVE LEFT - FORWARD

X1:25

X3:1

2

26

A2 REGULATOR

4 X1:13

G

ALTERNATOR / G2

X3:2

X1:4

C1

50

15/54

H1

HORN

31

X1:1

M1

M

30

STARTER / M1

X1:2

-

X1:26

BATTERY / G1

42604en

ARR 1585

153

19

Appendices

19.4

Hydraulic diagram

19.4.1 Hydraulic diagram of ARR 1585-M Legend: 1 Diesel engine 2 Hydraulic pump 4 Suction filter 5 Oil tank 6 High-pressure filter 7 Valve (vibration / fast movement) 8 Valve (left movement) 9 Valve (right movement) 10 Safety valve 11 Gear motor 12 Release brake 13 Hydraulic drive

154

ARR 1585

ARR 1585

B1

Pos 6: DN12

4

260

T

6

Pos 3: DN10 Suction hose

7

2

8

3cm3

T

Pos 9: DN10

Pos 60: DN16 Engine oil draining

A

B

290

R

P

Pos 2: DN10

M

n = 2700 min-1

Pos 33: DN10

Pos 30: DN12

8.6cm3

Pos 5: DN10

Pos 61: DN16

3cm3

Pos 11: DN6

5

P

A2

5

Pos 10: DN6

Rohr

Rohr

12

201.4cm3

201.4cm3

1

B

A

P

Pos 2: DN10

10

Pos 2: DN10

Pos 8: DN10

Rohr

A1

12

11

11cm3

13

Pos 12: DN6

Pos 62: DN16

B

A

T

290

Pos 31: DN10

P

9

WORKSHOP MANUAL

Pos 4: DN10

Rohr

Pos 1: DN10

Pos 34: DN10 Pos 32: DN10

Pos 7: DN12

10516384en

155

19

Appendices

19.4.2 Hydraulic diagram of ARR 1585-M/MIC/MC Legend: 1 Diesel engine 2 Hydraulic pump 4 Suction filter 5 Oil tank 6 High-pressure filter 7 Valve (vibration / fast movement) 8 Valve (left movement) 9 Valve (right movement) 10 Hydraulic shut-off valve 11 Gear motor 12 Release brake 13 Hydraulic drive

156

ARR 1585

ARR 1585

B1

Pos 6: DN12

4

260

T

6

Pos 3: DN10 Suction hose

7

2

8

3cm3

T

Pos 9: DN10

Pos 60: DN16 Engine oil draining

A

B

290

R

P

Pos 2: DN10

M

n = 2700 min-1

Pos 33: DN10

Pos 30: DN12

8.6cm3

Pos 5: DN10

Pos 61: DN16

3cm3

Pos 11: DN6

5

P

A2

5

Pos 10: DN6

Rohr

Rohr

12

201.4cm3

201.4cm3

1

B

A

P

Pos 2: DN10

10

Pos 2: DN10

Pos 8: DN10

Rohr

A1

12

11

11cm3

13

Pos 12: DN6

Pos 62: DN16

B

A

T

290

Pos 31: DN10

P

9

WORKSHOP MANUAL

Pos 4: DN10

Rohr

Pos 1: DN10

Pos 34: DN10 Pos 32: DN10

Pos 7: DN12

10516384en

157

19

Appendices

19.6

Workshop jigs

19.6.1 Special tools Vibrometer Order number: 4-9103000068

557W131 Revolution counter Order number: 2-90000030

557D665 Pressure measuring set Order number: 4-8300610003

557W132 Infrared thermometer Order number: 1286491

557W133 158

ARR 1585

WORKSHOP MANUAL Battery tester Order number: 1294747

557W134 Fuse tester Order number: 1294760

557W135 Solenoid tester Order number: 1-10300477

557D666 Hand crimp tool Order number: 1251168

557W137 ARR 1585

159

19

Appendices

Hand crimp tool (Deutsch) Order number: 1271787

557W138 Sensor for monitoring of particles in hydraulic oil Order number: 4-760211

557W139

160

ARR 1585

WORKSHOP MANUAL 19.7 •

Check of the screw connections for tightening

Check that the main screw connections are not loose (wheel nuts, attachment of axles, hydraulic connections of the engine and attached units). Use torque spanners for tightening.

Tightening torque For screws 8.8 (8G) Thread

Nm

Tightening torque

For screws 10.9 (10K)

For screws 8.8 (8G)

For screws 10.9 (10K)

lb ft

Nm

lb ft

Thread

Nm

lb ft

Nm

lb ft

M6

10

7.4

14

10.3

M18×1.5

220

162.2

312

230.1

M8

24

25.0

34

25.0

M20

390

287.6

550

405.6

M8×1

19

14.0

27

19.9

M20×1.5

312

230.1

440

324.5

M10

48

35.4

67

49.4

M22

530

390.9

745

549.4

M10×1.25

38

28.0

54

39.8

M22×1.5

425

313.4

590

435.1

M12

83

61.2

117

86.2

M24

675

497.8

950

700.6

M12×1.25

66

48.7

94

69.3

M24×2

540

398.2

760

560.5

M14

132

97.3

185

136.4

M27

995

733.8

1400

1032.5

M14×1.5

106

78.2

148

109.1

M27×2

795

586.3

1120

826.0

M16

200

147.5

285

210.2

M30

1,350

995.7

1,900

1,401.3

M30×2

1,080

796.5

1,520

1,121.0

M16×1.5

160

118.0

228

168.1

M18

275

202.8

390

287.6

Values given in the table are tightening torques for dry threads (friction coefficient = 0.14). The values are not applicable to lubricated threads.

Table of tightening torques of cap nuts with sealing O-rings – hoses Tightening torque values of cap nuts with O-rings – hoses Nm

lb ft

Spanner size

Thread

Pipe

Nominal

Min

Max

Nominal

Min

Max

14

12×1.5

6

20

15

25

15

11

18

17

14×1.5

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

16×1.5

22

18×1.5

24

20×1.5

27

22×1.5

30

24×1.5

32

26×1.5

36 41 46 50 50

ARR 1585

30×2 36×2

8 10 10 12 12 14 15

20 22 25 28

42×2

30

240

210

270

177

155

199

45×2

35

290

255

325

214

188

240

330

280

380

243

207

280

52×2

38 42

161

19

Appendices

Table of tightening torque values for necks with tightening edges or with flat gaskets

Table of tightening torques for plugs with flat gaskets

Neck tightening torques

Plug tightening 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

10×1

25

18

10×1

13

10

12×1.5

30

22

12×1.5

30

22

14×1.5

50

37

14×1.5

40

30

16×1.5

60

44

16×1.5

60

44

18×1.5

60

44

18×1.5

70

52

20×1.5

140

103

20×1.5

90

66

22×1.5

140

103

22×1.5

100

74

26×1.5

220

162

26×1.5

120

89

27×1.5

250

184

27×1.5

150

111

33×1.5

400

295

33×1.5

250

184

42×1.5

600

443

42×1.5

400

295

48×1.5

800

590

48×1.5

500

369

M-G

M-G

M-G

282N221T

162

282N222T

ARR 1585

WORKSHOP MANUAL 19.x

List of spare parts specified in the publication Chapter

ARR 1585

Spare part

Order number

163

19

Appendices Notes

164

ARR 1585

WORKSHOP MANUAL Notes

ARR 1585

165

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Materials and specification data are subject to change without notice.

Book ID: 4-P08000-EN | © Ammann Group