Ammann ARS 121 Single Drum Roller Operating Manual 0101 PDF

ARS 121 SINGLE DRUM ROLLER ASHOK LEYLAND BSIII / EU STAGE IIIA / US EPA Tier 3

OPERATING MANUAL EDITION 11/2019 EN From Serial No. 0101

ARS121 Single drum roller Ashok Leyland BSIII

Operating manual Edition 11/2019 EN From serial no. 0101 Original operating manual

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

With kind regards,

Ammann India Private Limited | Block No 157 | At – Ditasan | P.O. Jagudan | State Highway | Mehsana | Gujarat - 382710 | India +91 2762 285344 / 45 / 46 | Fax +91 2762 285359 | Email : info.ain@ammann.com | www.ammann.com

This manual consists of: I. Specification manual

II. Operating instructions

III. Maintenance manual

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

Subsequent faults due to improper operating are avoided.

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

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

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

These instructions must always be kept available on the equipment.

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

Ammann India Pvt. Ltd. Reserves the right to perform modifications without obligation to inform the machine user. If you identify any differences between the machine operated by you and the information contained in this publication, contact your local dealer / Nearest branch office.

Reproduction or copying of any kind is prohibited without the written permission of Ammann India Pvt. Ltd.

OPERATING MANUAL SYMBOLS OF THE SAFETY NOTICES IN THE OPERATION MANUAL:

The notice warns of a serious risk of personal injury or other personal hazards.

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

The notice warns of the necessity of environmental protection.

! WARNING !

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

FRONT

LEFT

RIGHT

REAR

282N100Ten

Table of Content 1.

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

1.1. Basic Data...............................................................................................................................................10 1.2. Dimension Chart....................................................................................................................................12 1.3. Technical Data........................................................................................................................................13 2.

OPERATING INSTRUCTIONS................................................................................................................17

2.1. Dewaxing and Inspection of a Newly Supplied Machine...................................................................18 2.2. Safety Instructions................................................................................................................................19 2.2.1.

Safety measures to operate the machine .....................................................................................................................................................19

2.2.1.1.

How to start the compaction work........................................................................................................................................................19

2.2.1.2.

Work safety secured by user.....................................................................................................................................................................19

2.2.2.

Driver qualification requirements.....................................................................................................................................................................20

2.2.3.

Driver’s duties...........................................................................................................................................................................................................21

2.2.4.

Not permitted activities - safety and guarantee..........................................................................................................................................22

2.2.5.

Safety labels and signs used on the machine ..............................................................................................................................................23

2.2.6.

Hand signals.............................................................................................................................................................................................................27

2.3. Ecological and Hygienic Principles......................................................................................................30 2.3.1.

Hygienic principles.................................................................................................................................................................................................30

2.3.2.

Ecological principles .............................................................................................................................................................................................30

2.4. Preservation and Storage.....................................................................................................................31 2.4.1.

Short-term preservation and storage for the period of 1 - 2 months..................................................................................................31

2.4.2.

Machine preservation and storage for the period over 2 months........................................................................................................31

2.5. Machine Disposal upon Its Life Termination.......................................................................................32 2.6. Machine Description.............................................................................................................................33 2.6.1.

Chassis........................................................................................................................................................................................................................33

2.6.2.

Electrical.....................................................................................................................................................................................................................34

2.6.2.1.

Hydraulic components...............................................................................................................................................................................36

2.7. Controlling and Operation of the Machine.........................................................................................38 2.7.1.

Dashboard.................................................................................................................................................................................................................38

2.7.1.1.

Instrument cluster indications (17)........................................................................................................................................................41

2.7.2.

Driver’s seat...............................................................................................................................................................................................................43

2.7.3.

Battery cut-off switch............................................................................................................................................................................................43

2.8. How to Control and Use the Machine...................................................................................................44 2.8.1.

Starting the engine ...............................................................................................................................................................................................44

2.8.1.1.

How to start using jumper cables through different battery ......................................................................................................45

2.8.2.

Travel and reversing...............................................................................................................................................................................................46

2.8.3.

Working / Moving on slopes...............................................................................................................................................................................47

2.8.4.

Travel with vibration..............................................................................................................................................................................................48

2.8.5.

Emergency stop of the machine.......................................................................................................................................................................49

2.8.6.

Stopping the machine .........................................................................................................................................................................................50

2.8.7.

Shutting down engine and machine...............................................................................................................................................................51

2.8.8.

Bonnet lifting and lowering................................................................................................................................................................................52

2.8.9.

Ballasting of tyres with liquid.............................................................................................................................................................................54

2.9. Machine Transportation........................................................................................................................56 2.9.1.

Machine transportation by its own..................................................................................................................................................................56

2.9.2.

Machine transportation by carrier....................................................................................................................................................................56

OPERATING MANUAL 2.9.2.1.

Loading the machine by crane................................................................................................................................................................57

2.9.2.2.

Loading the machine using a ramp.......................................................................................................................................................57

2.9.2.3.

How to lock the steering joint.................................................................................................................................................................58

2.9.3.

Towing of machine.................................................................................................................................................................................................59

2.9.3.1.

Bypassing the hydrostatic system..........................................................................................................................................................60

2.9.3.2.

Deactivating the bypass function..........................................................................................................................................................60

2.9.3.3.

Parking brake disable, 3 radial screw system.....................................................................................................................................61

2.9.3.4.

Parking brakes enable................................................................................................................................................................................62

2.10. Special Conditions for the Machine Application.................................................................................63 2.10.1. Vibration driving on compacted and hard materials.................................................................................................................................63 2.10.2. Machine use under extreme climatic conditions .......................................................................................................................................63 2.10.2.1. Machine operation at low temperatures.............................................................................................................................................63 2.10.2.2. Machine operation under high temperatures and humidity.......................................................................................................64 2.10.2.3. Operating the machine at high altitudes............................................................................................................................................64 2.10.2.4. Machine operating at extremely dusty environment ....................................................................................................................64

3.

MAINTENANCE MANUAL.....................................................................................................................69

3.1. Special Conditions for the Machine Application.................................................................................70 3.1.1.

Safety during machine maintenance..............................................................................................................................................................70

3.1.2.

Fire precautions when refilling .........................................................................................................................................................................70

3.1.3.

Ecological and hygienic principles...................................................................................................................................................................71

3.2. Specification of Fluids...........................................................................................................................72 3.2.1.

Engine oil...................................................................................................................................................................................................................72

3.2.2.

Fuel...............................................................................................................................................................................................................................73

3.2.3.

Cooling liquid...........................................................................................................................................................................................................73

3.2.4.

Hydraulic oil..............................................................................................................................................................................................................74

3.2.5.

Lubricating grease..................................................................................................................................................................................................74

3.2.6.

Axle - Differential and epicyclic gearbox oil..................................................................................................................................................75

3.2.7.

Drum cooling liquid...............................................................................................................................................................................................75

3.3. Refills......................................................................................................................................................76 3.4. Lubrication and Maintenance Table.....................................................................................................77 3.5. Lubrication and Service Plan................................................................................................................79 3.6. Individual Operations of Maintenance................................................................................................80 Every 20 hours of operation.................................................................................................................81 3.6.1.

Engine oil level check and restoration............................................................................................................................................................81

3.6.2.

Coolant level check and restoration................................................................................................................................................................82

3.6.3.

Hydraulic oil level check and restoration.......................................................................................................................................................83

3.6.4.

Crankcase breather inspection..........................................................................................................................................................................84

3.6.5.

Fan condition check...............................................................................................................................................................................................85

3.6.6.

Engine fan belt inspection...................................................................................................................................................................................85

3.6.7.

Engine air intake system inspection................................................................................................................................................................86

3.6.8.

Fuel level check and refilling..............................................................................................................................................................................87

3.6.9.

Drain fuel filter cum water separator...............................................................................................................................................................88

3.6.10. Alarm and control devices check......................................................................................................................................................................89

Every 150 hours of operation...............................................................................................................90 3.6.11. Tyre pressure check................................................................................................................................................................................................90

Table of Content Every 250 hours of operation...............................................................................................................91 3.6.12. Engine mounts and fasteners inspection......................................................................................................................................................91 3.6.13. Replacement of fuel filter (mud filter).............................................................................................................................................................92 3.6.14. Battery check............................................................................................................................................................................................................94 3.6.15. Air filter vacuum switch function check.........................................................................................................................................................95 3.6.16. Machine lubrication...............................................................................................................................................................................................96 3.6.17. Vibrator assembly oil level check......................................................................................................................................................................98 3.6.18. Axle - Epicyclic gearboxes oil level check......................................................................................................................................................99 3.6.19. Axle - Differential gearboxes gearbox oil level check............................................................................................................................. 100

Every 500 hours of operation.............................................................................................................101 3.6.20. Engine oil change................................................................................................................................................................................................ 101 3.6.20.1. Engine oil filter replacement................................................................................................................................................................. 101 3.6.21. Fuel filter cum water separator replacement............................................................................................................................................. 104 3.6.22. Coolant level check............................................................................................................................................................................................. 106 3.6.23. Wiring check.......................................................................................................................................................................................................... 106 3.6.24. Wheel bolts tightening check......................................................................................................................................................................... 107

Every 1000 hours of operation...........................................................................................................108 3.6.25. Air filter element replacement........................................................................................................................................................................ 108 3.6.26. Engine valve clearance adjustment.............................................................................................................................................................. 110 3.6.27. Engine fan belt tension check......................................................................................................................................................................... 110 3.6.28. Vibration damping pad condition inspection........................................................................................................................................... 112 3.6.29. Fuel tank cleaning............................................................................................................................................................................................... 113

Every 1500 hours of operation...........................................................................................................114 3.6.30. Axle - Differential oil change........................................................................................................................................................................... 114 3.6.31. Axle - Epicyclic gearbox oil change............................................................................................................................................................... 115

Every 2000 hours of operation...........................................................................................................116 3.6.32. Vibrator casing oil change................................................................................................................................................................................ 116 3.6.33. Hydraulic oil, suction line filter cartridge and strainer replacement................................................................................................. 117 3.6.34. Coolant change.................................................................................................................................................................................................... 121

Maintenance - As needed....................................................................................................................123 3.6.35. Drum cooling liquid (optional)....................................................................................................................................................................... 123 3.6.36. Coolant, oil and air cooler cleaning............................................................................................................................................................... 124 3.6.37. Air purging from fuel system........................................................................................................................................................................... 125 3.6.38. Scraper adjustment............................................................................................................................................................................................. 127 3.6.39. Battery charging................................................................................................................................................................................................... 128 3.6.40. Machine Cleaning................................................................................................................................................................................................ 129 3.6.41. Screwed connections check............................................................................................................................................................................ 129

3.7. Schematics...........................................................................................................................................132 3.7.1.

Electrical schematic............................................................................................................................................................................................. 132

3.7.2.

Hydraulic schematic............................................................................................................................................................................................ 133

3.8. General Information............................................................................................................................134 3.8.1.

Acronyms and abbreviations........................................................................................................................................................................... 134

OPERATING MANUAL

8

ARS 121

SPECIFICATION MANUAL

1. SPECIFICATION MANUAL ARS 121 (Ashok Leyland BSIII)

ARS 121

9

1.1.

Basic Data

Application range The rollers are designated for operation under conditions as according to IEC 721-2-1 (038900): WT, WDr, MWDr (i.e. moderate, warm dry, hot dry) with temperature limits from -10 °C (14 °F) to +45 °C (113 °F).

The rollers of ARS 121 line are especially suitable for use at midand large compaction jobs of highway construction (construction of highways, railways and airports), hydraulic construction (earth dams) and civil engineering (industrial areas, ports etc.).

Please fill in the following data: Type of machine ................................................................................................................

PIN (Serial number of the machine)

Modifications The single drum roller ARS 121 with the smooth drum is suitable for compaction of all kinds of soil. It can be employed at compaction of clayey soils up to the layer thickness (compacted) of 25 cm (9.8 in), loam soils up to the layer thickness of 40 cm (15.7 in), mixed soils up to the layer thickness of 50 cm (19.7 in), sandy soils and rock fills up to the layer thickness of 80 cm (31.4 in), gravels up to the layer thickness of 60 cm (23.6 in). Maximal allowed grain size is up to 2/3 of total layer thickness. The roller is suitable for compaction of stabilized soils as well.

ARS 121 compactor with a pad-foot shell kit is suitable for compaction of clay soil up to a layer thickness of 40 cm (14.7 in), and mixed soil up to a layer thickness of 50 cm (19.7 in).

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

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

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

Serial number of the engine (See the nameplate or label plate of the engine) ................................................................................................................

Make sure above information is filled by commissioning engineer once commissioning is completed.

10

ARS 121

SPECIFICATION MANUAL PIN label 1. Designation–always mentioned only in the English version 2. PIN 3. Type 4. Operating mass 5. Maximum mass 6. Nominal power 7. Shipping mass 8. Front axle load 9. Rear axle load 10. Year of construction

PIN label (1), S/N (2)

2

1

2

Serial number details (A) of the engine

A

ARS 121

11

1.2.

Dimension Chart

Dimensional diagram for ARS 121 machine

D G

T A

L

H

W W1 mm (in) ARS 121

12

A

D

G

H

L

T

W

W1

2820

1500

465

3075

5560

25

2130

2260

(111.0)

(59.1)

(18.3)

(121.1)

(218.9)

(1.0)

(83.9)

(89)

ARS 121

1.3.

Technical Data

SPECIFICATION MANUAL ARS 121 Ashok Leyland BS III

Weight Operating weight

kg (lb.)

11100 (24471)

Operating load on front axis

kg (lb.)

6200 (13669)

Operating load on rear axis

kg (lb.)

4900 (10802.5)

Weight of half fluid capacities

kg (lb.)

170 (375)

Static linear load of front drum

kg/cm (lb./in)

29.1 (162.9)

Weight of canopy

kg (lb.)

40 (88)

Weight of canopy posts

kg (lb.)

90 (198)

Weight of tyre filling 0°C

kg (lb.)

710 (1566)

-

1+1

Maximum transport speed

km/h (MPH)

11 (6.83)

Working speed

km/h (MPH)

6 (3.73)

Climbing ability

%

40

Climbing ability with vibration

%

30

Lateral static stability

%

72.65

Lateral stability during driving without vibration

%

25

Lateral stability during driving with vibration

%

15

Maximum gradient when towing machine on slope

%

60

Turning radius inner (edge)

mm (in)

3210 (126.4)

Turning radius outer (contour)

mm (in)

5575 (219.5)

Front approach slope

%

58

Rear approach slope

%

53

Type of drive

-

Hydrostatic

Number of driving axles

-

1

Oscillation angle

°

±10

Angle of steering

°

±36

Manufacturer

-

Ashok Leyland

Type

-

ALHT4CTIC3

Power according to DIN 6271

kW (HP)

74.3 (99.6)

Power according to ISO 3046/1

kW (HP)

74.3 (99.6)

Number of cylinders

-

4

Cylinder capacity

cc (cu in)

3900 (238)

Nominal speed

min-1 (rpm)

2200

Maximum torque

Nm/rpm

390/1400-1600

l/h (gal US/h)

10.3 (2.72)

Engines complies with emission regulations

-

Bharat stage-III

Cooling system of engine

-

Liquid

Driving characteristics Number of speeds

Engine

Routine operation fuel consumption

ARS 121

13

1.3.

Technical Data ARS 121 Ashok Leyland BS III

Steering Type of steering

-

Joint

Steering control

-

Hydraulic

Linear hydraulic cylinders

-

2

MPa (PSI)

0.16 (23.2)

Pattern of tyres

-

UK 5 Diamond

Number of tyres

-

2

Number of rear wheels

-

2

Size of tyres

-

23.1 x 26”

Type of tyres

-

Tubeless

Operating

-

Hydrostatic

Parking

-

Spring applied hydraulically released

Emergency

-

Spring applied hydraulically released

Frequency I

Hz (RPM)

35 (2100)

Frequency II

Hz (RPM)

32 (1920)

Amplitude I

mm (in)

0.9 (0.035)

Amplitude II

mm (in)

1.85 (0.1073)

Centrifugal force I

kN

275

Centrifugal force II

kN

160

Type of drive

-

Hydrostatic

Fuel

l (gal US)

410 (108.31)

Engine (oil filling)

l (gal US)

10 (2.6)

Cooling system

l (gal US)

20 (5.28)

Hydraulic system

l (gal US)

90 (23.77)

Drum vibrator

l (gal US)

8 (2.11)

Voltage

V

12

Battery capacity

Ah

150

Axle Maximum tyre pressure

Brakes

Vibration

Fluid capacities

Wiring

Optional equipments Tyre inflation system Tool set Canopy Canopy frame Service kits machines

14

ARS 121

SPECIFICATION MANUAL Notes

ARS 121

15

16

ARS 121

OPERATING INSTRUCTIONS

2. OPERATING INSTRUCTIONS ARS 121 (Ashok Leyland BSIII)

ARS 121

17

2.1.

Dewaxing and Inspection of a Newly Supplied Machine

•

Inspect the machine per shipping documents.

•

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

Before machine operation, do carry out dewaxing, wash away the preserving agents using high pressure stream of hot water added with standard degreasers.

All relevant ecological principles must be adhered to.

Do the dewaxing & washing of the machine at places equipped with intercepting sumps to catch rinsing water & dewaxing agents.

18

ARS 121

2.2.

Safety Instructions

OPERATING INSTRUCTIONS

2.2.1. Safety measures to operate the machine

2.2.1.2. Work safety secured by user

Safety measures stated in the individual sections of the Engineering documentation supplied together with the machine shall be supplemented with those safety precautions in force within a respective country where the machine will be used, and within a workplace, with regard to human resource management, work process and personnel.

•

User must ensure the machine will be operated only under those conditions, and solely for those purposes the machine is technically eligible for under the conditions specified by manufacturer and respective standards.

•

User must promptly report any damage of the utility lines to their operator, and at the same time do measures to prevent admittance except on business to the danger area.

2.2.1.1. How to start the compaction work

•

User shall provide for use of vibration roller only in such a way and at such sites where there is no hazard of damage to nearby premises and others.

•

User shall ensure that a worker does NOT work alone at the site, and that another worker is ALWAYS in sight and within ear-shot to provide or call for aid unless other effective form of supervision or communication is available.

•

User must ensure surveillance designate worker at work machinery in the working condition on public communication, which be in capacity issue instructions to reservation labour protection.

•

User must secure regular inspection of the operations, operating condition, regular machine maintenance in intervals under the lubrication & maintenance manual. In case of nonconforming operating condition of the machine to the extent it becomes hazardous and detrimental to the environment, then the machine must be discarded until the defect gets repaired.

•

User shall specify who and what tasks may be carried out during operation, maintenance and repairs of the machine.

•

The one who drives the machine (driver) and anybody who does maintenance and repairs of the machine must be made familiar with those instructions given in the machine Operating manual.

•

User must ensure the ”machine Operating manual” and the Operation Logbook are stored at a specific place to be always available to the other driver.

•

•

Supplier of building work (machine user) shall be liable to provide instructions for driver and maintenance department. These instructions include the requirements to secure occupational safety while operating the machine.

Before the compaction work the Supplier of building work (machine user) must verify the following: -

Utility lines

-

Underground areas (direction, depth)

-

Seepage or escape of hazardous materials

-

Soil bearing capacity, slope of traverse plane

-

Other barriers and obstructions, along with specifying the measures to ensure work safety.

•

Supplier of building work (machine user) must then make familiar with these conditions a machine user who will carry out the earthwork.

•

Supplier of building work (machine user) shall define technological process part of which is the work procedure designed for a given job. In addition the work procedure specifies below measures: -

Measures for work under extraordinary conditions (work within protective zones, under extreme slopes etc.)

-

Measures against any natural disasters

-

Requirements for job execution while observing job safety principles

•

Technical and organisational measures to secure safety of workers, site and environment.

User shall make the fire extinguisher (If available) to undergo regular inspections.

•

User must provide for disposal of hazardous materials (fuel, oil, coolant, and alike) away from their leakage point in order to avoid their adverse environmental impact, adverse effect on operation safety and health.

•

Supplier of building work (machine user) must evidently make machine driver familiar with the technological process (job description).

ARS 121

19

2.2.

Safety Instructions

2.2.2. Driver qualification requirements •

Only a driver trained under local and national regulations and standards designed for drivers of this group of machines may operate the roller.

•

No one, even somebody who has trained to drive under a direct & constant supervision of professional lector or trainer, cant drive without authorised driving licence (driving without authorised driving license may be punishable offence in country where machine is being drove, before start driving the machine ensure operator must have driving license).

•

Licence holder is liable to duly keep the licence in custody and if requested he/she must put it forward to the control authorities.

•

Licence holder may NOT make any recordings, changes or corrections to the licence.

•

Driver is liable to promptly report any loss of his/her licence to the authority that had issued the licence.

•

Only a person mentally and physically competent, over 18 years old may drive the Roller alone if : a) Charged by the machine manufacturer to assemble, test and demonstrate the machine, or to train drivers, whereas he/she must be made familiar with the occupational safety regulations in force at the site, or b) Appointed by Supplier of building work to operate (carry out maintenance), and evidently trained and acquainted with, or if, under specific regulations, he/she owns professional competence to operate and drive (engine operator’s licence, and alike).

•

20

Machine driver must undergo training at least once every 2 years, and pass exams concerning work safety regulations.

ARS 121

OPERATING INSTRUCTIONS 2.2.3. Driver’s duties •

•

Before starting machine operation driver must get familiar with the instructions given in the documentation supplied with the machine, with safety measures in particular, and obey these guidelines thoroughly. This applies also to a personnel in charge of machine maintenance, adjustments and repairs. (Unless you understand some sections of the manual, please contact your dealer or manufacturer.)

Do NOT drive roller unless fully made familiar with the entire machine’s functions, operating and handling elements, and until you know precisely how to operate the machine.

•

Obey safety signed located on the machine, and keep them in legible condition.

•

Before to starting work, driver must get familiar with the site environment, i.e. any barriers, slopes, utility lines, necessary site protections in terms of the surrounding environment (noise, vibrations, etc.).

•

When finding any health hazard, life hazard, danger to persons, property, finding any failures, or when there is an accident of technical facilities, or when finding any symptoms of such hazards during operation, then the driver must, unless able to clear away such danger by himself/herself, stop the work and secure the machine against any undesirable starting ON, report to a operation in charge, and if possible, alert all the persons threatened by such hazard.

•

Before starting to run the machine, driver is liable to get familiar with the records and any operating deviations found out in course of previous working shift.

•

Before starting the work do inspect the machine, fittings, check the control elements, communication & safety equipment, whether these are functional and enabled according to the manual. When finding any defect hazardous to job safety and unable to be repaired by driver, then the driver may not start the machine but instead communicate the failure to a authority accountable.

•

When driver finds a defect during operation, he/she must stop the machine immediately, and secure safely against any undesired starting ON.

•

Driver must obey the machine run while in operation and record any malfunctions found, into the diagnostic logbook.

•

Driver must keep diagnostic logbook designed to make records on handing in and handing over the machine between the drivers, and on any defects and repairs during operation, and to document major events during an operating shift.

•

Before starting the engine check the controllers are in gauge zero; no persons may remain within danger range of the machine.

•

Make sound or light signal to communicate each start up of the machine, and this always before you start machine engine.

•

Confirm the functions of the brake and steering before machine operation start up.

•

Following an alarm the operator may start the machine only when all workers leave the danger area. At blind (difficult to oversee) areas the operation start may begin only after a period necessary to exit endangered area elapses.

•

When operating the machine the safety regulations must be adhered to, no activity, hazardous to work safety can be carried out, commit yourself fully to machine driving. Always sit on the seat when driving the machine.

•

Respect job description or instructions of an employee

ARS 121

accountable.

•

When moving with the machine at the site you must adapt the speed to the terrain condition, work in progress, and weather conditions. Watch continuously the clearance height to avoid collision with any obstruction.

•

Upon completion or stop of the machine operation during which driver leaves the machine, he/she must first make measures against unauthorized use of the machine and its spontaneous start. Remove key from the ignition box, lock the vandal guard and disconnect the battery supply.

•

Upon operation completion park the machine at an appropriate station (flat, good bearing surface) in order not to threaten machine stability, intervene with traffic roads, expose the machine to the falling objects (rock), and where no natural disasters of other type (floods, landslides, etc.) are not a threat to the machine.

•

When parking the machine on communications over land, do carry out measures under the regulations effective for communications over land. Label the machine properly.

•

When working with the machine is completed, please write down in the operation logbook any machine defects and its damage including repairs made. During immediate change of drivers it is a duty to directly draw changing driver’s attention to any matters found out.

•

Driver must wear personal protective equipment, i.e. Goggles, work clothing, safety shoes, in case of open cabins face and hair masks. The clothing must NOT be too loose or damaged, hair protected with proper head piece. Hands protected with proper gloves during maintenance work (lubricating, replacing of operating media).

•

Driver at the machine must use ear protection effective within noise level of round 90 dB.

•

Keep the machine fitted with specified accessories and outfit.

•

Keep clean driver control stand, climbing steps and walkway surfaces.

•

Before lifting the bonnet, please confirm there is enough space for lifting, with no electric lines present. Before dropping the bonnet confirm nobody will be endangered with this operation.

•

In case the machine would come into contact with high voltage the following principles must be adhered to:

•

-

Try to escape with the machine from the hazardous area

-

Do NOT leave driver control stand

-

Give warning to others not to approach and contact the machine.

Maintain the machine free of oil dirt and flammable materials.

21

2.2.

Safety Instructions

2.2.4. Not permitted activities - safety and guarantee It is not permitted to:

fixed.

•

Operate the machine with its bonnet lifted.

•

Operate the machine when there are other machines or conveyances within the danger area of the machine except for those working in mutual interaction with the machine.

•

Operate the machine at a location unable to be seen from driver control stand, and where hazard to persons or property may occur unless work safety is secured in some other way e.g. Indirectly through signalling carried out by duly instructed person.

•

Operate the machine within protective zone of electric lines and substations.

•

Pass over the electric cables unless these are properly protected against mechanical damage.

•

Operate the machine under reduced visibility or at night unless the working area of the machine or the site is sufficiently illuminated.

•

Turn ON drum vibration in stand still condition, when does so, bearings of the vibrator are not lubricated.

•

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

•

Changing the vibration amplitude when driving – It is always necessary to stop and only then set a different amplitude.

•

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

•

Using the machine when any operating fluid level is lower than specified.

•

Quickly increase and decrease engine speed, It can damage the engine.

•

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

•

Leave machine driver seat with the engine running.

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

•

Abandon unsecured machine, i.e. move away from the machine without preventing its misuse.

•

Disable safeguarding, protecting or locking systems, or alter their parameters.

•

Use the machine with leaking oil, fuel, coolant or other fillings.

•

•

Use the machine after drinking alcohol and ingestion of narcotics.

•

•

Use the machine in case its operation might deteriorate its operating condition, cause safety hazard (life, health) to persons, buildings and other property, or to road traffic and its continuity.

Start the engine in some other way than given in the engine manual.

•

Place, aside from personal needs, so other things (tools, accessories) at the driver Control Stand.

Start the machine and use it when other persons are within the hazardous vicinity of the machine. Exempted is driver training by lector.

•

Put any materials or other object on the machine.

•

Remove any dirt while the machine is running.

•

Carry out maintenance, cleaning or repairs unless the machine is secured against self-motion and accidental start, or unless contact between worker and moving parts of the machine is excluded.

•

Touch moving parts of the machine with your body and objects or tools held in your hands.

•

Smoke or handle open fire while inspecting or refilling the fuels, changing, replenishing oil, lubricating the machine, or checking and refilling the battery.

•

Carry the rags soaked with flammable materials on the machine (inside engine bay, cab), or carry flammable liquids in free vessels.

•

Let the engine run inside confined areas. Exhaust gases are dangerous to life.

•

•

Start the machine operation and use the machine with some of the safeguard equipment (emergency brake, hydraulic locks, etc.) not functioning.

•

Move and compact at such banks at which machine stability would be broken (overturn). machine static stability specified gets reduced by the dynamic effects of the drive.

•

Move and compact at such angles of slopes at which the hazard of earth breaking off together with the machine could occur, or adhesion lost followed by uncontrollable breakaway.

•

Control the machine in a way other than stated in this manual.

•

Move and compact with vibration per soil bearing capacity at such distance from the slope edge or excavation edges to avoid the hazard of material sliding down or shoulder breaking off together with the machine.

•

Move or compact with vibration at such distance from walls, cuts or slopes so as to avoid the hazard of their collapsing and backfilling the machine.

•

Driving with vibration on hard (frozen, concrete, over compacted) surface or on bedrock. There is a danger of damage to the machine.

•

Compact with vibration at such distance from the buildings or premises and facilities within which a hazard of their being damaged due to vibration energy transfer could occur.

•

Move or transport persons on the machine.

•

Operate the machine unless driver control stand is properly

22

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

ARS 121

OPERATING INSTRUCTIONS 2.2.5. Safety labels and signs used on the machine

9

6

14 3

4 13

16

10

7

18

20

11

7

21

8

1

19

19

20

A 2 15

5 17

12

A

ARS 121

23

2.2.

Safety Instructions

Safety labels and signs used on the machine 1

Clamp hazard

Risk area with clamp hazard. (Symbols placed to left and right underneath of the operator’s platform on the frame.)

2941bz

2

Burn hazard

Danger of burn. Do NOT touch hot parts of the machine until it cools down. (Symbols placed from inside on the LH side lateral door.)

2586bz

3

Risk of injury

Risk of injury and entanglement hazard. Keep away from the fan when the engine is running. (Symbol placed on the both side of the cooler fan cover.)

2409bz

4

Scalding hazard

Scalding hazard with hot coolant. Do NOT open expansion tank pressure cap until liquid cools down below 50 °C (122 °F). (Symbol placed on the both side of the cooler fan cover.)

2939

3227bz

5

Adjust while at rest

Risk of injury. Stop the engine and remove the key before doing maintenance or repair work. (Symbols placed from inside on the LH side lateral door.)

2584bz

6

Read the manual

Read the operating manual before starting the machine.

(Symbol placed on the left side of the control panel.)

2702bz

24

ARS 121

OPERATING INSTRUCTIONS

7

Danger zone

Keep a safe distance from the machine as long as the engine is running. (Symbol located at rear side of machine on fuel tank and on the both side of the front frame)

8

Injury hazard

Keep safety distance from rotating pulley and belt.

(Symbol located on both side of radiator bracket.)

9

Machine under maintenance

Danger! Machine under maintenance, Do NOT start the machine. (Symbol hung on the steering wheel)

10

Explosion hazard

Read the operating manual before battery maintenance, or when starting engine by jumper cables. (Symbol located on the fuel tank cover right side underneath the battery.)

11

Machine max height

Pay attention when machine is passing through a location with height limit. (Symbol placed on the left side underneath the operator’s platform on the frame.)

12

Battery disconnector

I O

2493

In case of failure or following a work completion, Set battery disconnector to ”0” position. (Symbol placed on the panel behind LH side lateral door.)

13

Cooling liquid

Cooling liquid is harmful to health. Read the operating manual! (Symbol located on the radiator expansion tank)

14

Ear protectors

When the machine has no cab, or operates with open windows, must use ear protection. (Symbol placed at centre on steering column.)

ARS 121

25

2.2.

15

Safety Instructions

Disconnect alternator

Before welding disconnect the battery terminals and alternator connections of the machine. (Symbol placed from inside on the LH side lateral door.)

2668bz

16

Electric devices

Cover electric instruments when washing the machine (Symbol placed both side on the front face of the intercooler.)

2225bz

17

Crush hazard

Risk area with crush hazard. (Symbols placed from inside on the left door.)

3753bz

18

Rigging diagram

Use rigging with sufficient loading capacity when lifting the machine. Secure machine joints before slinging.

(Symbols placed to left and right underneath of the operator’s platform on the frame.)

19

Lifting points

Lifting the machine at these points. (Symbols placed on both sides of the front frames.)

20

Lashing points

The machine is to be rigged in these points. (Symbols located on the both sides of the frames.)

21

Platform & cab lifting

(Symbol placed on left side of rear frame) 3164

3164

26

ARS 121

OPERATING INSTRUCTIONS 2.2.6. Hand signals Signals given by machine Operator Assistant when Operator is unable to cover visually moving working space or utility device or tool.

General command signals Stop One arm rose with open palm in the direction of Operator, the other arm akimbo.

STOP Sig. 1

ATTENTION! Both arms sideways raised horizontally – palms forward.

!

Sig. 2

!

Sig. 3

Be careful of danger Oscillating motion of both fore-arms from the position of arms sideways raised horizontally to a position of arms sideways raised – in huddled-up way and back.

Signals to drive Drive away with the machine One arm erected – bent with open palm, long motion of forearm in the direction of required motion, second arm akimbo.

Sig. 4

ARS 121

27

2.2.

Safety Instructions

Slow forward drive – to me Both arms stretched upward abreast huddled up, with palms towards the body; short oscillating motions of fore-arms towards the body and back.

Sig. 5

Slow backward- drive - away from me Both arms stretched upward abreast huddled up, with palms away from the body – short oscillating motions of fore-arms away from the body and back.

Sig. 6

Driving on the right Left arm sideways raised, right arm akimbo.

Sig. 7

Driving on the left Right arm sideways raised, left arm akimbo.

Sig. 8

28

ARS 121

OPERATING INSTRUCTIONS Short motion

X

Both arms lifted forward huddled-up. Mark the distance “X“ between the palms, then the motion signal follows.

Sig. 9

Engine start Circular motion of right hand’s fore-arm with fist.

Sig. 10

Engine shut down Oscillating motion of right hand sideways rose in front of the body a moving to the sides.

Sig. 11

During machine operation or storage, the user must be obeyed general principles of occupational safety and environmental protection along with laws, public notices or regulations related to these issues and in force within a territory where the machine is used.

ARS 121

29

2.3.

Ecological and Hygienic Principles

2.3.1. Hygienic principles

2.3.2. Ecological principles

•

•

Oil products, refrigerants of cooling systems, alternator, refills or painting materials like thinners are health hazard materials. Workers coming into contact with these products during machine operation or maintenance will be liable to adhere to general principles of their own occupational safety and adhere to the safety & hygienic manuals of the manufacturers of these products.

Refills for the machine’s individual systems and some of its parts become waste having hazardous properties against the environment following their disposal.

This waste product category includes in particular: -

Organic or synthetic lubrication materials, oils and fuels,

-

Cooling liquids,

-

Battery refills and the battery itself,

-

Tyre fillings

-

Cleaning & preservation agents,

-

All the filters & filter elements removed,

-

All the used and discarded hydraulic & fuel hoses, metalrubbers and other elements of the machine clogged with the above mentioned products.

We point in particular to: -

Eye & skin protections while handling the batteries

-

Skin protection while handling the oil products, painting materials or cooling liquids

-

Washing your hands properly upon work completion or before taking meal. Treat your hands with appropriate reparable cream.

-

While handling the cooling systems liquid, obey the instructions given in the manuals supplied together with the coolant.

•

Always store oil products or battery refills and painting materials including organic thinners along with cleaning & preservation agents inside their original packages labelled properly. Do NOT store these materials in unlabelled bottles or other containers due to their exchange hazard. Especially hazardous is the potential of being exchanged for consumables or drinks.

•

Should your skin, mucosa, eyes be stained incidentally, or vapours inhaled, then immediately apply first aid principals.

In case of accidental ingestion or consumption of these products, get prompt medical attention.

•

When handling the machine then use always ear protections of suitable type and construction.

30

Producer and contractual service organizations accredited by him or branch office take back the following materials or parts free of charge: -

Oils

-

Batteries

-

Tyres (optional)

Following the disposal of the above mentioned materials and parts make sure these are handled in line with the respective national environmental regulations and health regulations.

ARS 121

2.4.

Preservation and Storage

OPERATING INSTRUCTIONS

2.4.1. Short-term preservation and storage for the period of 1 - 2 months

2.4.2. Machine preservation and storage for the period over 2 months

•

•

•

•

Wash & clean carefully the entire machine. Before machine parking and shutdown in order to make its preservation & storage, heat the running engine up to its operating temperature. Park the machine on fixed, flat surface at a safe place with no potential of machine damage caused by natural disaster (floods, landslides, fire, etc.).

In addition:

For the machine shutdown the identical principles like with short-term preservation will apply, In addition we recommend the following: -

Remove the battery, check it’s condition and store in a cool, dry room (recharge the battery on regular basis)

-

Bottom on the roller (front) frame so the damping system has minimal deflection (flexure),

-

Paint rubber elements with specific preservative agent to protect them,

-

Inflate the tyres to a specified pressure, and protect them from direct sunlight,

-

Repair those spots with paint impaired,

-

Lubricate all lubricating points, control cables, joints of the controllers, etc.,

-

Confirm water fillings have been drained,

-

Check cooling liquid has its antifreeze characteristics required,

-

Apply chrome-plated piston rods with preservation grease,

-

Check the battery charging conditions, recharge if required,

-

Spray the machine with special agent and this at places with possible corrosion origin,

-

Apply preservation grease over the chrome-plated surfaces of the piston rods,

-

Blind engine air intake and exhaust with double polythene foil and fix it carefully with adhesive tape,

-

We recommend to spray preservation agent (applied through spraying) to protect your machine against corrosion, and this particularly in places with corrosion hazard.

-

Protect head lamps, exterior back mirrors and other elements of external wiring through spraying with special agent and wrapping in polythene foil

-

Preserve the engine per manufacturer’s manual. Install a visible label informing the engine has been conserved.

Machine treated like that will need no special set-up before its subsequent putting into operation.

CAUTION! Following 6 months we recommend to inspect preservation condition and renew it if necessary.

Do NOT start the engine during storage!

When the machine is stored under field conditions, make sure that such stand is not exposed to any deluge hazard caused by floods, or that no other type of hazard occurs within this area!

Before restoration of the machine service, do wash the preservative agents using high pressure stream of hot water added with standard degreasers for use along with ecological principles.

De-wax and wash the machine at the locations provided with intercepting sumps to catch rinsing water and dewaxing agents.

ARS 121

31

2.5.

Machine Disposal upon Its Life Termination

User will be liable to obey national waste or environmental laws and regulations where the machine is being used when carrying out machine disposal. We therefore recommend to always consulting: •

Licensed industrial waste products disposing companies,

•

Machine manufacturer or by them appointed and certified contractual service companies.

Manufacturer bears no responsibility for any damage to health of the users or environmental damage caused by breach of the above mentioned notice.

32

ARS 121

2.6.

Machine Description

OPERATING INSTRUCTIONS

2.6.1. Chassis

9

14

18

20 17

13

10

12

2

8

5 1

3 3

4 19

21

15 16

6

11

1.

Front frame

12.

Hydraulic oil cooler

2.

Drum

13.

Radiator

3.

Scraper

14.

Driver´s control stand

4.

Articulated joint

15.

Travel pump

5.

Rear frame

16.

Vibration pump

6.

Axle

17.

Exhaust muffler

7.

Fuel tank

18.

Air filter

8.

Battery

19.

Hydraulic oil pressure filter

9.

Hydraulic tank

20.

Charge air cooler

10.

Bonnet

21.

Steering pump

11.

Engine

ARS 121

7

33

2.6.

Machine Description

2.6.2. Electrical Engine oil pressure sensor (A).

Location: On left side of engine

A

Coolant temperature sensor (B) Location: On left side of engine

B

Alternator (C) Location: On left side of engine

C

Starter motor (D) Location: On right side of engine

D

34

ARS 121

OPERATING INSTRUCTIONS Hydraulic oil temperature sensor (A) Location: Mounted on hydraulic block beneath hydraulic oil tank on right side of machine.

A

Hydraulic oil filter clogging indicator sensor (B) Location: Sensor is integral part of hyd. oil filter head.

B

Air filter clogging indicator sensor (C) Location: Air density sensor is mounted on air filter front & can be access after lifting the bonnet

C

Brake pressure sensor (D) Location: Mounted on brake block, on right side of machine beneath the hydraulic oil tank.

D

ARS 121

35

2.6.

Machine Description

2.6.2.1. Hydraulic components Hydraulic oil filter (A) Location: Mounted on right side wall of rear frame, underneath of operator’s platform. To access one need to open operator platform.

A

Fuel filter cum water separator (B) Location: Mounted on right side of engine, can be accessed by lifting the bonnet.

B

Fuel filter (C) Location: Mounted on left side wall of rear frame, beneath engine, It can be accessed from underneath of machine

C

Travel pump (D) Vibration pump (E)

F

D

Steering pump (F)

E

36

ARS 121

OPERATING INSTRUCTIONS Hydraulic block (A) Location: Mounted beneath the hydraulic oil tank, on right hand side of machine, can be accessed after lifting the bonnet.

B

A

Brake block (B) Location: Mounted beneath the hydraulic oil tank, on right hand side of machine, can be accessed after lifting the bonnet.

ARS 121

37

2.7.

Controlling and Operation of the Machine

2.7.1. Dashboard

10

17

6

!

15

12

7

7 15A 8 15A

5 7.5A

6 15A

4 7.5A

1 20A

14

2 15A 3 15A

7

9

16 2

5

13

11

2A

1 F N R

3

STOP

4

38

8 12V

1

-

Steering wheel

9

-

Vibration amplitude selector switch

2

-

Travel controller

10

-

Turn indicator selector switch

2A

-

Vibration switch

11

-

Headlights switch

3

-

Engine stop pull cable

12

-

Rear lights switch

4

-

Travel or work mode selector switch

13

-

Horn push button

5

-

Engine throttle lever

14

-

Fuse block

6

-

Ignition switch

15

-

Hazard switch

7

-

Spare

16

-

High beam selector switch

8

-

Charging port

17

-

Digital cluster

ARS 121

OPERATING INSTRUCTIONS Steering wheel (1) Used to steer a machine in desired direction.

With respect to safe steering, do adjust optimal speed (1800 Min–1) when driving without vibrations.

Travel or work mode selector switch (4)

Machine is provided with Travel and Work mode option. On engine starting, selected mode is indicated on cluster (17).

Travel mode (Rabbit) - In this mode the machine is capable to reach max. speed with minimum possible torque (i.e pulling force reduced and climbing ability decreased) & vice versa in Work mode (Tortoise).

Travel controller (2)

Do NOT shift machine operating modes during Its occupational use, sudden pressure change will occur within the hydraulic system.

Shift machine operating modes with the machine at rest or at low speed!

With pulling force not sufficient, shift to work mode.

2445

Use this controller to control direction & speed of the machine.

Driving speed corresponds to the distance of the controller deflects from idle (neutral) position. At the same time the controller is used as service brake of the machine. When shifted to its centre position the parking brake is enabled, & is indicated with parking brake indicator light turned ON in the cluster (17).

Vibration Switch (2A) is located at the controller handle and is used to switch ON/OFF the vibration when machine is moving.

Engine starting is possible in neutral position only.

It is not permitted to quickly increase and decrease engine speed. It can damage the engine!

It is not permitted to start vibration in machine standstill condition! (Vibrator bearings are not lubricated during vibration at the halt.)

Engine speed control lever (5) Move the lever downward to increase the speed from idling to maximal rpm.

With respect to safe steering, do adjust optimal speed (1800. Min–1) when driving without vibrations.

Ignition box (6) Ignition Box has three positions: -

Position “0” (OFF)

-

Position “I” (ON)

-

Position “II” (START)

It is used to check any error signal, to start or to stop the engine.

STOP

Engine stop / Emergency stop pull cable (3)

To shut-off the engine pull this cable.

Also In case of emergency or uncontrolled machine behaviour to stop and brake the roller and to shut off the engine pull this cable.

Use emergency stop function only in case of emergency, when the roller is unable to stop through resetting the travel controller.

The key can be inserted and removed in “0” position only. Turn key to “I” position, all cluster lamps will lit up for 3 secs. and buzzer will sound for 2 sec.. After 3 secs. lamps turns OFF except engine oil pressure, parking brake and battery charging lamps.

Further turn the key to “II” position to start the engine.

Once the engine started, release key immediately, key will return to the “I” position by itself.

Remove the key from the ignition box when leaving the machine!

When the key is taken out, close the ignition box cap to protect the ignition box from dirt, particles or other unwanted material.

NOTE! Turning the key to”0” position will not stop the engine, to stop the engine pull engine stop cable (3).

ARS 121

39

2.7.

Controlling and Operation of the Machine Spare (7)

Charging socket (8)

12 V

Mobile charging socket 12 V.

Vibration amplitude selector switch (9) 2244

-

Fuse box (14) Fuse

(F1) -20A

Head light, registration plate lamp,

Fuse

(F2) -15A

Hazard , Horn,

Fuse

(F3) -15A

Engine stop, Turn indicators, Emergency stop, Break light, Reverse horn, Vibration switching control , Reverse light,

Fuse

(F4) -7.5A

Travel,

Fuse

(F5) -7.5A

Instrument cluster,

Fuse

(F6) -15A

Work light, Charger, Beacon (Optional),

Fuse

(F7) - 15A

Reserved,

Fuse

(F8) - 15A

Reserved

T his switch allows operator to select small amplitude and high frequency or High amplitude and low frequency.

Whatever the mode selected is indicated on cluster (17).

Replace blown fuses with fuses of same rating only!

It is not permitted to start vibration when machine is stand still!

It is not permitted to change the vibration amplitude while machine is in motion.

Hazard switch (15) 596191

Enables hazard light ON or OFF when required.

Turn indicator switch (10) Passing light (High) beam switch (16)

A228404

Used to set ON or OFF respective turn indicator signal lamps.

On pressing switch, high beam light will be ON & on releasing switch it will set OFF. Headlights (Low beam) switch (11)

It is 3 position switch, at zero position it is in OFF condition, a push turns position lights ON and at 3rd position headlamp low beam will be ON.

NOTE! High beam has interlock with headlamp, Till headlamp is not turned ON, high beam will not be ON

Rear lights switch (12) It is used to set ON or OFF rear lights

Horn push button (13) When switch is pressed horn will blow and on releasing switch horn will be OFF.

40

ARS 121

OPERATING INSTRUCTIONS 2.7.1.1. Instrument cluster indications (17)

34

35

18

33

19

32

20

31

21

30

22

36

!

29 28

23

37

24 27

25

26

Battery recharging indicator (19)

Fuel level indicator (36) AMN25

AMN4

Number of visible bars (36) indicates fuel level in tank. More the numbers of bars visible on display, more the fuel quantity and vise versa.

When the fuel level goes below 40 L first two (horizontal) bars will start blinking.

When switching ON the ignition key over to “I” position, the indicator lamp shall set ON and after the engine start it must go OFF. It signals battery recharging status.

In case indicator lamp (19) doesn’t goes OFF on starting engine, Indicates defect in battery charging circuit!

Check fuel level before starting work everyday.

Machine worked-hours indicator (37) AMN10

AMN26

The engine hours on the display shows the period for which the engine has been running.

The engine hours counting does not depend on the engine speed. (Use the engine hours for the machine maintenance interval determination.)

High amplitude low frequency vibration indicator (20)

A lit Indicator lamp will signal the high amplitude low frequency vibration is selected.

High beam lights Indicator (21)

Right turn indicator (18)

A flashing indicator lamp will signal traffic that machine is going to turn right.

High beam light’s selection can be confirmed with illuminating indicator (21).

It can be set ON by switch (10).

ARS 121

41

2.7.

Controlling and Operation of the Machine Rear work light indicator (22)

Hydraulic oil overheated indicator (29) AMN11

It indicates rear work light ON/OFF status.

Engine oil pressure indicator (23)

When the hydraulic oil temperature reaches the highest allowable level, the hydraulic oil overheated indicator (29) will be ON with an acoustic warning.

AMN6

Stop the machine and check oil level, If found OK, get root cause somewhere else!

In case engine oil pressure falls, indicator (23) will lit up and stay ON with an acoustic warning.

Do not operate engine without sufficient oil pressure. If indicator stays lit for longer than 5 seconds under normal operating conditions, stop the engine and check the cause.

Position light indicator (30) Lit lamp (30) indicates position lights are ON

Low beam indicator (31)

Engine overheated indicator (24) AMN7

When the engine temperature reaches the highest allowable level, the engine overheating indicator (24) will be ON with an acoustic warning.

Beacon light indicator (25) (Optional)

Lighting indicator (31) indicates the low beam lights are ON.

Low amplitude indicator (32)

high

frequency

vibration

Lighting indicator (32) indicates that vibration with low amplitude and high frequency is selected.

If beacon is set ON, lamp (25) will lit.

Parking brake indicator (33) Work mode selection indicator (Tortoise) (26) Lighting indicator (26) confirms machine in work mode.

Air filter clogged indicator (27)0

AMN1

The lit indicator (33) indicates the parking brake has been enabled.

Left turn indicator (34)

AMN5

Lit up indicator (27) with acoustic warning indicates, filter elements are clogged.

Immediately replace the air filter element!

A flashing indicator lamp will signal traffic that machine is going to turn left. It can be set ON by switch (10).

Travel mode selection indicator (Rabbit) (26) Lighting indicator (34) confirms machine in travel mode.

Hydraulic oil pressure filter clogged indicator (28) AMN3

Lit up indicator (28) with acoustic warning indicates, filter cartridge is clogged.

Immediately replace the filter cartridge!

42

ARS 121

OPERATING INSTRUCTIONS 2.7.2. Driver’s seat

B

Driver’s seat can be adjusted in following ways Longitudinal adjustment – Press lever (A) and move seat in forward or backward as per requirement.

Backrest adjustment - As per requirement backrest (B) can be swing forward or backward.

A

Seat belt (C) - Provided to safeguard driver in case of impact

All the seat adjustments must be done before starting driving!

While driving, not applying seat belt is punishable offence, be aware of local legislations!

C

2.7.3. Battery cut-off switch Use cut-off switch to connect or disconnect battery from the system.

B

Use cut-off switch to disconnect the Battery at the end of work shift!

Disconnect battery when long stops are foreseen!

ARS 121

43

2.8.

How to Control and Use the Machine

2.8.1. Starting the engine 19

33

6

6

5 7.5A

0

23

I

7 15A 8 15A

4 7.5A

6 15A

1 20A

2 15A

3 15A

!

II

2

F N R

STOP

12V

How to start the engine: •

Connect battery with battery cut-off switch.

•

Make sure that the engine throttle lever (5) is at top end (i.e Idle speed).

•

Ignition box has three positions:-

Position “0” (OFF)

-

Position “I” (ON)

-

Position “II” (START)

•

Insert key (6) to ignition box and turn to “I” position, all cluster lamps will lit up for 3 secs. and buzzer will sound for 2 secs.. After 3 secs. lamps will go OFF except engine oil pressure (23), parking brake (22) and battery charging (19) lamps.

•

Further turn the key (6) to “II” position to start the engine (hold the key (6) in position ”ll” only until the engine starts).

•

Once the engine started, release key (6) immediately, key (6) will return to the “I” position by itself.

•

Make sure travel controller (2) at neutral and signal (33) is lighting.

•

When started, refer the control lamps to monitor various functions.

•

When started, let the engine run at idle rpm of 800 (± 50) min-1 for a period of 3-5 minutes.

•

Unless coolant temp. reaches min. 60°C (140°F) the engine will not be lubricated sufficiently enough – do NOT run the engine at full capacity!

Before start the engine make audio signal by horn for warning purposes.

Confirm nobody is endangered due to the engine started!

44

Do NOT hold key (6) in position “II” for more than 30 sec. Make another starting attempt only after 2 minutes and if the engine doesn’t starts even after 3 attempts, carry out troubleshooting.

Battery charging indicator lamp (19) and engine oil pressure lamp (23) must go off when the engine starts.

Do NOT let the engine run idle for over 10 minutes – running idle for longer period will cause injectors clogged, piston rings gummed, valves seized!

CAUTION! Starting is interlocked with machine in neutral i.e Engine won’t start if travel controller (2) is not at neutral position.

NOTE! Make additional fuel pumping by hand feed pump on the engine when engine doesn’t start after several attempts, after the machine is at rest for long time.

If engine doesn’t starts even after 3 attempts – check the fuel system.

For engine related troubleshooting refer engine operating manual provided separately with machine.

ARS 121

OPERATING INSTRUCTIONS 2.8.1.1. How to start using jumper cables through different battery 1. Connect one (+) pole of jumper cable to (+) pole of discharged battery and second (+) pole to (+) pole of external battery.

How to start at low temperature •

Starting at ambient temperature below 0°C and upto-15°C cold start aid “Thermostat” has to be fitted in the intake manifold.

•

Turn the ignition switch to “II” position and hold. When the coolant temperature decreases below 0°C, starting aid is preheated automatically by the engine coolant temperature sensing.

•

Confirm the coolant temp. not shown in cluster.

•

After reaching at specific temperature of coolant unhold the “II“ position to start the engine.

2. Connect one (-) pole of jumper cable to (-) pole of discharged battery and second (-) pole to discharged vehicle.

Do NOT connect (–) pole of the jumper cable to (–) pole of discharged battery!

Hazard of strong sparking when starting, followed by an explosion of gases generated by battery.

Non insulated sections of the starter cables or their clamps must NOT contact each other!

Make sure starter cable connected to (+) pole of battery does NOT come into contact with electrically conductive parts of the machine – short-circuit hazard.

Do NOT bend yourself over the battery hazard of electrolyte burn!

Exclude presence of any flammable sources (free flame, smoking cigarettes, and alike).

Do NOT check voltage presence within a conductor through sparking through the machine frame!

Make sure the starting voltage of a boost-starting power supply is 12 V. Obey unconditionally the sequence of operations given below!

CAUTION! When started, disconnect the starter cables in reverse order.

When aided by starter unit with no batteries connected, do not disconnect the unit before the machine battery is connected.

+

1

2

12

0

v

12

v

0

+ -

4

3

396N034 ARS 121

45

2.8.

How to Control and Use the Machine

2.8.2. Travel and reversing 33

20

7 15A 8 15A

5 7.5A

6 15A

4 7.5A

1 20A

2 15A 3 15A

!

2

5

2A

1

F N R

3

4

Use acoustic alarm to communicate drive away of the machine and wait long enough so the persons present may leave in time the adjacent area of the machine (area under the machine)!

Before drive away you must confirm the area in front of and behind the machine is free and that no persons are present there!

Once engine is started machine can be moved as mentioned below: •

Make proper selection between Work or Travel mode with switch (4) .

•

Shift the engine throttle lever (5) to bottom most position to run engine at max. rpm (2300 ± 50 at idle).

•

At machine standstill, confirm vibration is OFF.

•

Forward: Gradually shift travel controller (2) from neutral position to forward – small deflection of the travel controller = slow speed and vice versa. Once travel controller (2) is moved put from neutral position the parking brake indicator lamp (33) will go off.

•

Reverse: for reversing, gradually shift the travel controller (2) in backward direction by its idle position.

46

STOP

12V

Set ON the travel mode with switch (4) – while driving on the road for machine transfer purpose. “Rabbit” symbol will light up. Set ON the travel mode only with the machine not idle.

In case of lack of pulling force on terrains or while working on site, switch to “work” mode.

Do NOT shift to work mode from travel mode at high speed, It will create impact within hydraulic system due to high slowdown. Shift to work mode from travel mode at low speed or with the machine at rest!

Do NOT control the machine speed by engine throttle lever (5) position.

ARS 121

OPERATING INSTRUCTIONS 2.8.3. Working / Moving on slopes Do NOT drive in cross direction at the hillsides of high slope! Possibility of machine roll-over, Drive perpendicular to a hillside!

ARS 121

OK

OK

47

2.8.

How to Control and Use the Machine

2.8.4. Travel with vibration 32

20

7 15A 8 15A

5 7.5A

6 15A

4 7.5A

1 20A

2 15A 3 15A

!

9 2

5

2A

1

F N R

STOP

4

•

Put engine rpm at high by engine throttle lever (5).

•

Set machine to work mode (Tortoise) by switch (4), selected mode can be confirmed on instrument cluster.

•

Use switch (9) for high or low vibration amplitude.

•

Start moving the machine and push switch (2A) to set ON vibration. Indicator lamp (20) or (32) lits up depending on amplitude selected & drum begins vibrating.

•

To stop the vibration, press and release button (2A).

12V

It is not permitted to vibrate when machine is standstill!

It is not permitted to change the vibration amplitude while driving.

48

ARS 121

OPERATING INSTRUCTIONS 2.8.5. Emergency stop of the machine

6

5 7.5A

7 15A 8 15A

6 15A

4 7.5A

1 20A

2 15A

3 15A

!

2

5

F N R 3

STOP

12V

•

Pull total stop cable (3) - the engine will shut down and the machine stops moving.

•

Before next start of engine, shift travel controller (2) to neutral position and engine throttle lever (5) to min.

•

Switch key (6) to “0“ position and then proceed to starting.

Apply in the event when machine is unable to stop through switching the travel controller to neutral or in case of uncontrolled behaviour of the machine.

ARS 121

49

2.8.

How to Control and Use the Machine

2.8.6. Stopping the machine 33

20

32

6

0 7 15A 8 15A

5 7.5A

6 15A

4 7.5A

1 20A

2 15A 3 15A

!

2

5

2A

F N R 1

STOP

12V

•

Press switch (2A) and turn OFF the vibration, if previously ON – vibration indicator lamp (20) or (32) will go off.

•

Gradually move travel controller (2) to neutral position to stop the machine – parking brake is enabled; lamp (33) lights up.

•

Move the engine throttle lever (5) towards minimum position to lower the engine RPM.

•

Switch key (6) to “0“ position - Engine will shut off, take key out – close the ignition box cap.

Do NOT stop hot engine instantly, instead let it idle for a period of 3 minutes.

50

ARS 121

OPERATING INSTRUCTIONS 2.8.7. Shutting down engine and machine •

Followed by machine stoppage, to shutdown engine pull total stop cable (1), engine will shut down.

•

Switch ignition key (6) from position “1” to position “0” - take key out key and close the ignition box cap.

•

Disconnect battery by isolator switch (2), if long stop is fore seen or work shift is finished.

•

Clean the machine, especially scrapers & tyres.

•

Make overall inspection of the machine and repair any defects caused during operation.

•

Safeguard machine rolling by putting scotch blocks to the wheels.

•

Lock the instrument panel cover and the door beneath driver platform.

1

6

6

0

5 7.5A

I

7 15A 8 15A

6 15A

1 20A

2 15A

4 7.5A

3 15A

!

II

F N R 1 STOP

12V

Park the machine on flat, paved surface.

Confirm no natural hazard (landslide potential of deluge due to any floods, etc.) exists at the location where the machine is parked and shut down.

Do NOT stop hot engine instantly, instead let it run in idle speed for a period of 3 minutes to get it cooled down gradually.

2

NOTE! Engine will not shut off by turning ignition key to OFF position, It is possible only by pulling total stop cable (1).

ARS 121

51

2.8.

How to Control and Use the Machine

2.8.8. Bonnet lifting and lowering •

Open left door (1) with provided key.

1

•

Take out the pumping lever (2) hooked to platform.

2

Lifting: •

Turn valve (3) in clockwise direction to close it.

•

Insert one end of pumping lever (2) into the pump and start pumping, simultaneously bonnet will start raising.

•

Continue pumping till bonnet opens to required extent.

•

Close valve (4) on left side of machine to safeguard bonnet from falling.

3

2

4

52

ARS 121

OPERATING INSTRUCTIONS Lowering: •

Open valve (4).

4

•

Gradually turn valve (3) anti clockwise to full of its extent, bonnet will also start closing gradually.

3

Lifting and lowering the bonnet must be done only while no personnel is on or in the working area of bonnet.

Danger of injury!

When working on the bonnet lifting hydraulic circuit, the bonnet must be secured by valves (3) & (4).

In addition, when bonnet is to be kept open for long duration, It must be held open additionally by mechanical means!

ARS 121

53

2.8.

How to Control and Use the Machine

2.8.9. Ballasting of tyres with liquid It is used for lowering the machine centre of gravity. The mixing ratios for individual temperature per one tyre are given in the table.

Ballasting of tyres with liquid of up to 0°F (-180C) Water

Anticorit SKR40

Added weight

(l) [gal US]

(kg) [lb]

(kg) [lb]

345 (91)

10 (22)

355 (782.6)

Ballasting of tyres with liquid of up to -25°F (-31.70C) The inner space of the tyre is filled with the solution of water and Anticorit SKR40.

Water

Anticorit SKR40

Added weight

(l) [gal US]

(kg) [lb]

(kg) [lb]

185 (48,87)

265 (584.2)

450 (992)

Filling procedure: •

Move the machine to a firm base. The filling valves should be at the extreme upper position. Secure the drum with blocks on both sides.

•

Remove the removable insert valve and keep it aside.

54

ARS 121

OPERATING INSTRUCTIONS •

Connect the filling hose from the filling equipment (a tank has pump with pressure gauge mounted on it.) to the filler neck and fill the tyres with the solution.

•

During the filling, air escapes from the tyre through the side opening from the filler neck. The tyre is sufficiently filled (at 75%) when the solution starts flowing out through the opening.

•

Disconnect the filler neck, fit the insert valve back on, and inflate the tyre to a pressure of 160 kPa (23.2 PSI).

396345 Draining procedure: •

Move the machine to a firm base. The filling valves should be in the extreme lower position. Secure the drum with blocks on both sides.

•

Slowly uninstall the insert valve and remove it to let solution flow out.

•

As soon as the solution does not flow out due to a decrease in pressure, screw on the filler neck and inflate the tyre to a pressure of 160 kPa (23.2 PSI).

•

After the tyre has been inflated, remove the filler neck and screw the valve insert back on.

396346

The solution can spurt out after unscrewing the valve insert. It can cause injury to your hands and eyes.

Protect your eyes with glasses (face shield) and your hands with rubber gloves!

Wash away spilled solution with clean water. Solution may never come into contact with metal parts and wiring.

Avoid solution spillage on ground, as It is environmentally hazardous.

Obey the local environmental laws while disposing used solution.

ARS 121

55

2.9.

Machine Transportation

2.9.1. Machine transportation by its own •

Move the roller by its own axle when moving within a working site outside public roads.

If machine travels on road from one working site to another, It must be driven in travel mode, set ON with switch (4).

In case of long transportation distance 1-hour cooling breaks at intervals of 2-hours are preferred, if not obeyed, could result in damage to machine or its components, In such case manufacturer will not responsible for any of resulting loss or damage.

Obey the safety instruction for moving the machine to work site.

2.9.2. Machine transportation by carrier The basic construction of the machine is not fit for transportation by its own axle using public road. This type of transportation is not permitted.

When driving onto the carrier, we recommend to put rubber bands or wooden planks, etc. under the drum.

Make sure the carrier designed for the transport is braked when loading and unloading, as well as mechanically locked against undesired moves using the scotch blocks (2).

A person that guides the machine must communicate with the driver using specified intercommunication signals, (refer to chapter 2.2.6.), this guiding person must always stay at one place outside the reach of the machine and outside the carrier. Guiding person must remain within driver’s field of sight (in visual contact) throughout the entire period of driving the machine onto the carrier and driving down from the carrier.

When driving onto and down from the carrier all the persons aside from machine driver must go away as far as to avoid being hit by a falling machine.

Fix the machine to the carrier through the clamps (tie-offs) (1) at the rigging points! By rigging points we mean front & rear slings, front & rear pulling hitches, and sling holes in the runner frame sidewalls.

Adhere to the motor vehicle construction and use regulations when transporting through land routes.

No persons may stay on the machine, driver control stand or carrier loading area during machine transportation.

56

1

1 2

2

2

ARS 121

OPERATING INSTRUCTIONS 2.9.2.1. Loading the machine by crane •

Use loading platform or bridge crane of sufficient capacity to load the machine onto the carrier.

•

When loading with crane the roller is fitted with slings (lifting eyes)-refer to the fig. for slinging method.

•

Before lifting the roller, please lock the machine joint against being turned slightly.

While loading the machine with crane, make sure steering joint is locked.

2.9.2.2. Loading the machine using a ramp •

When loading the machine using a ramp, all safety regulations related to loading of the machine valid in the place of loading must be adhered to. The ramp must have appropriate loading capacity, anti slip surface and must be stored on a flat surface. We recommend that you must adhere to local regulation where machine is being loaded.

•

Maximum permissible incline of the ramp is 30%.

MAX MAX 30 30 % %

Pay increased attention when loading the machine. Improper handling can cause serious injury or death.

Do NOT enter beneath the hanging load!

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

When loading the machine, a second person must be present to signal approach onto the ramp. See the list of hand signals in chapter 2.2.6.

ARS 121

57

2.9.

Machine Transportation

2.9.2.3. How to lock the steering joint •

Align front frame with rear frame.

•

Unlock and pull out the journal (1)

•

Fold down the arm (2), lock with the journal (1) and secure with safety lock (3).

1

3

2

1

Do NOT check hole alignment with finger while aligning holes by moving machine

Upon completion of loading, return the safety arm back to its initial position.

Obey provisions in force when loading/ unloading.

Apply adequate, intact rigging of sufficient loading capacity.

Use only those lifting eyes (mounting lugs) on the machine designed specifically for slinging.

Only a trained slinger may carry out the slinging.

58

ARS 121

OPERATING INSTRUCTIONS 2.9.3. Towing of machine •

The machine is provided with two towing lugs (1) on the front frame and with two towing lugs (2) on the rear frame.

•

The machine may only be towed with low speed 1 km/h (16.7 m/min). The maximum towing distance is 300 m.

•

If the engine is running and the travel drive and steering are working, the operator on the towed machine must steer the machine in the towing direction.

•

If the diesel engine fails, the machine can only be steered in a restricted way and with a high amount of force at the steering wheel.

2

1

Before start towing, make sure hydrostatic system is bypassed as given in chapter 2.9.3.1.

The machine must be fastened using both lugs during pulling or towing!

When towing the machine use undamaged towing cable or pull rod of sufficient loading capacity 1.5 higher than the weight of hauled machine. It is not permitted to use a chain for towing.

It will be necessary to maintain minimal deflection from direct angle of towing.

Max deflection will be possible within angle of up to 30°.

The machine should only be towed for the shortest possible distance (max.

300 m.) – to extricate the machine if it gets stuck or is blocking traffic in case of breakdown.

The towing machine shall fit with its size the machine broken. It shall have sufficient towing force (performance), weight and brake effect.

When towing downhill with the help of cable it will be necessary to attach next towing machine to the rear part of the machine broken. In this way it will be possible to avoid uncontrolled motion of the damaged machine.

ARS 121

No person may stay on the towed machine!

After the brake is released and the hydraulic circuit is short-circuited, all of the brakes are disabled!

Before releasing the brake, secure the machine with wooden scotch blocks against motion!

Do NOT touch hot parts of the machine.

Danger of burning!

59

2.9.

Machine Transportation

2.9.3.1. Bypassing the hydrostatic system •

Switch off the engine & disconnect the battery with isolator switch.

•

First measure and record length of both screws (1) outside of check nut (2).

•

Loosen the lock nuts (2) on both the sides of travel pump by turning them anti clockwise completely.

•

With hex wrench, screw both the screws (1) clockwise towards the springs till stuck to spring seat.

•

Tighten the lock nuts (2) with a torque of 22 Nm.

1

1

2

2

Secure the machine with wheel chock before disconnecting travel pump.

2 Before disconnecting the travel pump put a tray (3) under the machine to avoid spillage of oil to the soil.

1

2.9.3.2. Deactivating the bypass function •

To deactivate bypass function do the steps under ‘Bypassing the hydrostatic system’ in reverse order.

3

60

ARS 121

OPERATING INSTRUCTIONS 2.9.3.3.

Parking brake disable, 3 radial screw system

A

1

2

B 3

C

Obey the below instructions: •

Unscrew the six grub screws (1) from the 3 positions (A, B, C) on both sides of the axle, keeping firmly locked the special screws (2).

•

Screw in the brake release bolts (3), at least 1/2 turn at a time, in sequence of A, B, C on both sides until the Braking torque drops off sharply (4-5 turns).

Before releasing the parking brake, secure machine with mechanical locking.

Add warning symbol on ignition lock or on steering wheel, failure to obey can result in serious injury or death.

ARS 121

61

2.9.

Machine Transportation

2.9.3.4. Parking brakes enable

A

4

1

2

B 3

C

Obey the below instructions: •

Apply a pressure of 13 bar to the feeding port (4) of parking brake.

•

Remove the all 6 grub screws (1), on locations A, B & C, keeping firmly locked the special screws (2).

•

Unscrew all the brake release bolts (3) on both sides until the end of stroke has been reached. (Operate gradually to avoid that the brake piston is put crosswise to the cylinder and locks itself, the piston must move without arranged crosswise to the cylinder.)

•

It is recommended to loosen the screw (3) of about 1/2 turn at a time working in sequence (A, B, C).

•

Release the pressure at the brakes port (4).

•

Assemble the lock screws (1) to the bolts (2).

•

Lock the bolts (2) then tighten the lock screws (1) to the specified torque on both sides.

•

The parking brake is enable now and the wheels are locked.

•

Check that the parking brake is working properly before using the machine again!

Apply mechanical lock for all four wheels to prevent the machine from moving.

Failure to obey can result in serious injury or death.

62

ARS 121

2.10. Special Conditions for the Machine Application

OPERATING INSTRUCTIONS

2.10.1. Vibration driving on compacted and hard materials

2.10.2. Machine use under extreme climatic conditions

When operating the machine with vibration on hard materials (e.g. stony loose material), or with high level of compacting the base material, there can be even loss of contact between the drum and the material compacted (so called vibro-hit).

This state will show in the increased vibration transfer into the machine frame and onto the Driver’s control stand. Its partial elimination is possible through increasing the travel speed or changing the machine vibration parameters (with the use of lower amplitude).

2.10.2.1. Machine operation at low temperatures

When it is necessary to operate the machine under conditions where the operator might be exposed to higher vibrations, then the machine operator will be liable to adjust the work procedures so as to prevent any injury to Driver’s health.

Compacting during winter season depends on fine particle contents and water contents within a soil under compaction. With the temperature going down below freezing point the earth becomes more solid and harder to compact.

When compacting at the temperatures below 0°C (32°F) is required, you may compact dry soils (or stony loose materials) or do fast compaction of non-frozen materials (ahead of earth becoming frozen through).

Make the machine ready for operation at low temperatures: •

Check the engine coolant concentration.

•

Exchange oil in the engine with the one recommended for a given range of low ambient temps.

•

Apply hydraulic oil of corresponding Kinematic viscosity.

•

Change oil in axle differential and epicyclic gearbox with the one recommended for a given range of gearbox temperatures.

•

Use winter fuel.

•

Use cold start aid “Thermostat”.

•

Confirm the battery is charged.

Good condition of battery is the prerequisite of good starting under low temperatures. Warm up the battery to temperature 20°C (68°F) (through removing battery and storing it in a dry warm room) to lower limit temp for starting by 4 to 5°C (39.2 to 41°F).

Driving machine with vibration on hard (frozen, concrete, over-compacted) surface or on bedrock is not permitted.

There is a risk of damage to the machine.

NOTE! When driving the machine with vibrations on a different base material than stated in “Specification Manual”. The emission figure for vibration acceleration will be different - “Noise and vibration emissions”.

Danger of engine damaged when engine (liquid cooled) operating temperature remains constantly below 60°C (140°F).

NOTE! Cold start aid “Thermostat” must be installed in the intake manifold when operating the machine below 0°C and upto-15°C temperature.

Use the machine at its full power only after heating the fillings to their operating temperatures (coolers possible to be partially covered as well).

Do NOT start the machine at ambient temperatures below +2°C (36°F) when the hydraulic system is filled with HV 100 oil.

When starting at ambient temperatures below –8°C (18°F) is required for a period of one month or more, do exchange oil in the hydraulic system with HV 46 viscosity class oil.

Do NOT start the machine below –7°C (19°F) without cold start aid (Thermostat).

ARS 121

63

2.10. Special Conditions for the Machine Application 2.10.2.2. Machine operation under high temperatures and humidity Engine power will lower with increase in air temperature or increase in humidity. Since both of the factors that lower engine performance are independent on each other, their effects can be described as follows: -

With every 10°C (50°F) of increased in air temp. the power will drop by up to 4 % (at constant humidity)

-

With every 10 % of increased in relative humidity the power will drop by up to 2 % (at constant temperature).

2.10.2.3. Operating the machine at high altitudes Engine power will decrease with the altitude rising. This is because of the reduced atmospheric pressure and induction air specific mass.

When black smoke is generated by the engine at high altitudes (above 1500 m), do contact your engine manufacturer service department to make adjustment to fuel injection pump to fit these operating conditions.

CAUTION! Engine power will be affected by the environment where the machine is operating, as per chapters 2.10.2.1 & 2.10.2.3.

Danger of engine damage if any engine (liquid cooled) operating constantly at temperature over 100°C (212°F).

At high temperatures when hydraulic oil temp. is constantly staying at 90°C (194°F), we recommend to exchange hydraulic oil with denser one of 100 mm2/s Kinematic viscosity class (BP BARTRAN HV 100, ESSO UNIVIS N100, etc.)

CAUTION! When hydraulic system is filled with oil class: HV 46, then oil max. limit temperature is 80°C (144°F).

HV 32, then oil max. limit temperature is 70°C (158°F).

When machine is operating under extreme temperature, the hydraulic oil or coolant temperature will reach to the max limit. In that situation you must remove fender aprons of the bonnet to increase cooling capacity of machine.

64

2.10.2.4. Machine operating at extremely dusty environment

Shorten the intervals of cleaning and replacement of air filter elements when operating the machine under extremely dusty conditions; Also shorten the intervals for cleaning the engine cooler, hydraulic oil cooler, and of replacing cabin dust filter.

ARS 121

OPERATING INSTRUCTIONS Notes

ARS 121

65

Notes

66

ARS 121

OPERATING INSTRUCTIONS

ARS 121

67

68

ARS 121

MAINTENANCE MANUAL

3. MAINTENANCE MANUAL ARS 121 (Ashok Leyland BSlll)

ARS 121

69

3.1.

Special Conditions for the Machine Application

3.1.1. Safety during machine maintenance

3.1.2. Fire precautions when refilling

Lubrication, maintenance and adjustments must be carried out:

•

In terms of fire safety, the flammable liquids applied to the machine split into the following Danger Numbers:

By trained specialists

-

Danger Number II – Diesel Oil

•

In line with safety instructions given in the Operation Manual

-

Danger Number IV - Mineral Oils, Lubricating Greases.

•

According to the time intervals as stated in lubrication table following the hours of actual operation

•

Carry out oil exchange activity where there is no danger of fire.

•

With the machine located on a flat fixed surface secured against self-motion by wedges and If necessary with the steering joint locked.

•

Label with no smoking & no open fire signs.

•

Design the size of handling area so it can catch the amount of flammable liquid equal to the capacity of the largest vessel or shipping container.

•

•

With the battery disconnected and the ignition key removed

•

On the cooled down parts of the machine

•

Have portable fire extinguisher. Installed on machine.

•

Following the cleaning of the machine of lubrication points, maintenance points and of repair points

•

Use containers like metal barrels, Jerry cans, Tin cans to handle the oils, Diesel oil.

•

Using proper undamaged tools

•

•

Replacing with new original parts as per the spare parts catalogue

Confirm the shipping containers are properly closed during storage.

•

•

With sufficient lighting of the entire machine when under lowered visibility or at night

Make sure the containers have one hole and are stored with their hole up and secured against their contents dripping out.

•

With the guards (covers) and safety elements reinstalled upon work completion, if dismantled before.

•

Label the containers with indelible inscription specifying the content & flammability number.

•

Together with re tightening bolted connections – using proper torque and checking tightness of the connections

•

When machine at ambient temperature with recommended refills only.

Confirm all safeguard equipment functions are OK once adjustments or maintenance are completed!

70

ARS 121

MAINTENANCE MANUAL 3.1.3. Ecological and hygienic principles

Ecological principles

When operating and maintaining the machines a user must obey general health & environment protection principles along with the acts, public notices & regulations related to these issues and effective within the territory where a machine is used.

This waste product category includes the following:

Hygienic principles •

•

Oil products, Battery refilling, painting materials including thinners are materials could be dangerous to health. Workers those come into contact with these products during machine operation or maintenance must obey general principles of health self-protection and obey safety & hygienic instructions of these products’ manufacturers.

-

Organic or synthetic lubricants, oils and fuels

-

Brake fluids

-

Cooling liquids

-

Battery charges and Battery Itself.

-

Cleaning & preserving agents

-

All the used filters & filter elements

-

All the worn & discarded hydraulic hoses & fuel hose, metal rubbers and other elements of the machine clogged by the above mentioned products.

Please note the following in particular: -

Protect your Eyes & Skin when handling the Battery

-

Protect your skin when handling oil products, painting materials and cooling liquids

-

Wash your hands upon work completion and before taking meals; treat your hands with reparation (recovery) cream

-

Obey machine operating instructions when handling its cooling systems.

•

Always store oil products, refills of cooling system, battery, paints including organic thinners and also the cleaning & preserving agents in their genuine original properly identified packages. Do not store these materials in unlabelled bottles or other vessels due to danger of exchange. Especially danger of the possibility of being mistaken with eatables or beverages.

•

Upon skin, mucosa or eye contacts or vapour inhalation, you must apply first aid measures instantly. During accidental ingestion of these products you must call for prompt medical attention.

•

Use always ear protectors (muffs) of proper type and construction when operating the machine.

ARS 121

Following the disposal of the given materials and parts these must be handled under the respective National Environmental Policy Regulations, and in line with Health Regulations.

71

3.2.

Specification of Fluids

3.2.1. Engine oil 2412

Engine oil shall be specified per its performance classification & viscosity classification.

Performance classification under API (AMERICAN PETROLEUM INSTITUTE) CCMC (COMMITTEE OF COMMON MARKET AUTOMOBILE CONSTRUCTORS) ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE AUTOMOBILE) Viscosity classification Ambient temperature and type of operation where the machine is used will be decisive to determine SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) viscosity class.

°F

°C

122

50

104

40

86

30

68

20

50

10

32

0

14

-10

-4

-20

-22

-30

-40

-40

Admissible oils applied compliant to API: CF-4/SG; CG-4/SH CCMC DH1 ACEA: E-5

5W - 30

NOTE! Exceeding low temperature limit will not lead to any engine damage, it may only cause some problems when starting the machine.

It is rather convenient to use multigrade oils so as to avoid oil replacement due to ambient temperature changes.

10W - 30

Exceeding max temperature limit may not last for a longer time due to the lowered lubricating capabilities of oil.

When using synthetic oil due to operating conditions (low ambient temperature) the same change intervals like with mineral oils must be maintained.

When using oil under API CD/SF you must cut the change interval by half, i.e.

250 hours or 3 months.

15W - 40

Year round SAE 15W-40 (e.g. Leypower, Valvoline, Premium Blue)

282N224T

72

ARS 121

MAINTENANCE MANUAL 3.2.2. Fuel

3.2.3. Cooling liquid

Below are the some recommended fuel oils:

Engine manufacturer recommends premixed coolant as per standards:

-

CEN EN 590

-

ASTM D 975-88: 1-D & 2-D

Engine manufacturer recommend diesel fuel as per ISO 1460 : 2017 standard. According to this standard, fuel can have max sulphur content 50 mg per kg and max 200 gm of water per kg

2152

-

JIS K 2234 Class 2

-

SAE J 1034

(e.g Leypower coolant 5000) Or can use cooling liquid comprising 50% water and 50% antifreeze agent (designed for ambient temperature of up to -36°C [-33°F]) for the engine cooling system even within a climatic zone where temperatures do not drop below 0°C (32°F). The cooling liquid serves not only to protect the cooling system against any freezing, but also to increase boiling temperature.

The inhibitors contained within the antifreeze protect parts of the engine cooling system. You may use Ethylene glycol or Propylene glycol antifreeze agents as well to refill the cooling system.

Good quality of water is important for cooling system performance. Excessive levels of calcium and magnesium contribute to scaling problems and excessive levels of chlorides and sulphates cause cooling system corrosion.

The engine manufacturer recommends the use of fully formulated coolant. Ethylene glycol or Propylene glycol.

Use winter Diesel oil with ambient temperatures below 0°C (32°F). Use special type of Diesel oil with additives designed for the conditions with ambient temperatures less than -15°C (5°F) (”Super Diesel oil”).

Do NOT use fuels (like bio Diesel oil, mixed bio Diesel oil, LFO, and alike) other than those Diesel oils specified above.

ARS 121

Do NOT use the portion of antifreeze cooling agent within cooling liquid, over 50 % unless absolutely necessary to do so.

Do NOT use ration over 68%!

Antifreeze agents are made variously based, we do not recommend their mutual mixing. Blending various types of cooling liquids may lead to loss of anticorrosion characteristics.

Use refractometer (densimeter) to check the portion of antifreeze cooling agent in cooling liquid before winter period begins.

73

3.2.

Specification of Fluids

3.2.4. Hydraulic oil

3.2.5. Lubricating grease 0787

2158

Use only quality hydraulic oils of power class per ISO 6743/ HM for the machine’s hydraulic system (corresponds to DIN 51524 Section 2 HLP).

Usually the machines are filled at manufacturer with hydraulic oil of kinematic viscosity of 68 mm2/s at 40°C (104°F) ISO VG 68.

This oil is the most suitable one to be used within the widest range of ambient temperatures.

Use grease plastic type that contains lithium, some are listed below: -

ISO 6743/9 CCEB 2

-

DIN 51502 KP2K-30

-

(Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, Grease No 3, and alike).

When at high ambient temperatures with oil temperature constantly reaching 90°C (194°F) we recommend to replace with oil of Kinematic viscosity 100 mm2/s HM 100.

Synthetic hydraulic oil You can fill the hydraulic system with synthetic oil which, when making any leaks, becomes degraded through microorganisms found in water and in soil.

Please consult any transition from mineral oil to synthetic oil, or mixing oils of various brands with oil manufacturer or dealer!

74

ARS 121

MAINTENANCE MANUAL 3.2.6. Axle - Differential and epicyclic gearbox oil Use quality oil corresponding to 85W140 API GL-5 to lubricate the axle differential gearbox and axle Epicyclic gearboxes.

3.2.7. Drum cooling liquid Mixture: 360 L of water 7 L Rust inhibitor

NOTE! Drum is not filled with cooling liquid while leaving factory, It is to be filled as per requirement.

ARS 121

75

3.3.

Refills

Section

Refill Type

Refill Amount L (gal US)

Engine

Engine oil per chapter 3.2.1

9.5 (2.5)

Brand

2412

Fuel tank

Diesel oil per chapter 3.2.2

410 (108.3)

Hydraulic system

Hydraulic oil per chapter 3.2.4

90 (23.8) 2158

Axle epicyclic gearboxes

Gearbox oil per chapter 3.2.6

2x1.3 (2x0.34) 2186

Axle differential

Axle differential oil per chapter 3.2.6

14.5 (3.9) 2186

Joint bearing and hydraulic cylinders

Plastic lubricant, refer to chapter 3.2.5

as required 0787

Engine cooling system

Permanent anti-freeze liquid per chapter 3.2.3

20 (5.3) 2152

Drum vibrator housing

Same as engine oil, per chapter 3.2.1

8 (2.1) 2412

Drum cooling liquid

Mixture according to chapter 3.2.7

367 (97) 2152

Battery

Distilled water

as required AMN4

76

ARS 121

3.4.

Lubrication and Maintenance Table

MAINTENANCE MANUAL

Every 20 hours of operation 3.6.1

Engine oil level check and restoration

3.6.2

Coolant level check and restoration

3.6.3

Hydraulic oil level check and restoration

3.6.4

Crankcase breather inspection

3.6.5

Fan condition check

3.6.6

Engine fan belt inspection

3.6.7

Engine air intake system inspection

3.6.8

Fuel level check and refilling

3.6.9

Drain water from water in fuel separator

3.6.10

Alarm and control devices check

First 150 hours of operation 3.6.24

Wheel bolts tightening check

3.6.30

Axle - Differential oil change

3.6.31

Axle - Epicyclic gear box oil change

Every 150 hours of operation 3.6.11

Tyre pressure check

Every 250 hours of operation 3.6.12

Engine mounts and fasteners inspection

3.6.13

Replacement of fuel filter (mud strainer)

3.6.14

Battery check

3.6.15

Air filter vacuum switch function check

3.6.16

Machine lubrication

3.6.17

Vibrator assembly oil level check

3.6.18

Axle - Epicyclic gearboxes oil level check

3.6.19

Axle - Differential gearbox oil level check

First 500 hours of operation 3.6.32

Vibrator casing oil change

Every 500 hours of operation 3.6.20

ARS 121

Engine oil change

77

3.4

Lubrication and Maintenance Table

3.6.20.1

Engine oil filter replacement

3.6.21

Fuel filter cum water separator replacement

3.6.22

Coolant level check

3.6.23

Wiring check

3.6.24

Wheel bolts tightening check

Every 1000 hours of operation 3.6.25

Air filter elements replacement

3.6.26

Engine valve clearance adjustment

3.6.27

Engine fan belt tension check

3.6.28

Vibration damping pad condition inspection

3.6.29

Fuel tank cleaning

Every 1500 hours of operation 3.6.30

Axle - Differential oil change

3.6.31

Axle - Epicyclic gear box oil change

Every 2000 hours of operation 3.6.32

Vibrator casing oil change

3.6.33

Hydraulic oil, suction line filter cartridge and strainer replacement

3.6.34

Coolant change

Maintenance - As needed 3.6.35

Drum cooling liquid

3.6.36

Coolant, oil and air cooler cleaning

3.6.37

Air purging from fuel system

3.6.38

Scraper adjustment

3.6.39

Battery charging

3.6.40

Machine cleaning

3.6.41

Screwed connections check

NOTE! More frequent attention will be necessary in case machine working under adverse conditions, the regular maintenance periods, therefore, should be altered to suit the local conditions.

78

ARS 121

3.5.

ARS 121

Lubrication and Service Plan

MAINTENANCE MANUAL

79

3.6.

Individual Operations of Maintenance

Carry out lubrication and maintenance on regular basis and repeatedly in intervals according to daily reading on the hours counter (38) on the cluster.

!

38

This manual includes only basic information on the engine; the rest is provided in the operation and maintenance manual of the engine, which is a part of documentation supplied with the machine.

Obey the instructions given in the engine operation and maintenance manual provided with machine for maintenance of the engine!

Disassembled or loose bolts, plugs, hydraulic threaded connections etc. Should be tightened with torque according to tables in chapter 3.6.38. Unless a different value is listed for the particular operation.

Carry out the maintenance with the machine parked on a flat, paved surface, and secured against selfmotion, always with the engine set OFF, key removed from the ignition box and battery disconnected (unless otherwise required).

80

ARS 121

MAINTENANCE MANUAL Every 20 hours of operation 1

3.6.1. Engine oil level check and restoration •

Stop the engine and wait for 5 minutes until all oil flows down to crankcase sump.

•

Pull out the oil dipstick (1), wipe it off and insert it back down to the stop and pull out again to read the oil level.

•

Maintain the level within the range of holes stamped on the dipstick. The lower hole indicates the lowest permissible oil level, the upper hole indicates the highest one.

LOW FULL

•

Refill oil through oil filler following a removal of oil filler plug (2). Wait for 1 minute until the level gets stable and then check again.

2

•

Always add oil of identical type. Use oils under Section 3.2.1.

•

Inspect cap (2) for leakage and tightness, repair if found any leakage.

•

Inspect the engine or any damaged or missing parts, if found any get it repaired.

Do NOT operate the engine unless there is proper oil level inside the engine.

ARS 121

Avoid oil spillage on ground, as it is environmentally hazardous.

Obey local environmental laws while disposing used oil or hand it over to supplier for disposal.

81

3.6.

Individual Operations of Maintenance

3.6.2. Coolant level check and restoration •

Open the bonnet and access the radiator (refer to chapter 2.8.8).

•

Check visually the level in level indicator (2).

•

Liquid level must be seen in level indicator.

•

If coolant level not seen in level indicator, add coolant through filler neck (1).

Remove the pressure cap only after the engine coolant temperature falls below 50°C (120°F). Any attempt to remove pressure cap at high temperature may cause operator to be scalded with spurted steam or hot liquid coolant.

1

2

OK

OK

282N205T

The level must not drop below the level gauge eyesight.

Add coolant consisting of antifreeze agents of identical base per Section 3.2.3.

Do NOT use additives with the engine cooling liquid to repair cooling system leakages.

Do NOT refill hot engine with cold liquid.

The casts of the engine may get damaged.

In case of loss of high amount of coolant find out and repair cause.

Avoid oil spillage on ground, as it is environmentally hazardous.

Obey local environmental laws while disposing used oil or hand it over to supplier for disposal.

82

ARS 121

MAINTENANCE MANUAL 3.6.3. Hydraulic oil level check and restoration •

Open the bonnet and access the radiator (refer to chapter 2.8.8).

•

Check the all level through sight glass (1) when engine is cooled down to atmospheric temperature.

•

Oil must be seen in sight glass, If not refill tank with oil.

1

Danger to machine!

In case of loss of high amount of oil, find out and repair cause.

•

The hydraulic tank lid is provided with a seal.

•

To fill up the hydraulic circuit, use the hydraulic pump unit (2).

2

CAUTION! If the hydraulic circuit is filled in a different way than using the hydraulic pump unit, the guarantee will expire.

1251998 •

Connect the hydraulic unit to the quick-coupling (3) in the space under the operator’s platform.

3

ARS 121

83

3.6.

Individual Operations of Maintenance

Alternative filling through the filler neck of the tank in the space under the bonnet

4

CAUTION! Fill the hydraulic circuit through the filler neck only in emergency!

•

Add specified oil to the tank through the filler neck (4) up to the bottom of the strainer in the filler neck.

Avoid oil spillage on ground, as it is environmentally hazardous.

Obey local environmental laws while disposing used oil or hand it over to supplier for disposal.

3.6.4. Crankcase breather inspection •

Inspect the crankcase breather hose (5) to make sure it is that there and not clogged with deposits, chips or in winter season with ice.

5

84

ARS 121

MAINTENANCE MANUAL 3.6.5. Fan condition check •

Check visually the fan (1). If damaged (e.g. broken, cracks, shape changes etc.) replace the fan.

1

3.6.6. Engine fan belt inspection •

Make visual check of the belt (2) for torn, wear, thinning, cracks etc.

2

•

Transverse cracks are permitted. In case longitudinal cracks seen on the belt or frayed (shattered) belt edges exist or any torn off parts of material are seen, then the belt must be replaced.

OK OK

282N116T

ARS 121

85

3.6.

Individual Operations of Maintenance

3.6.7. Engine air intake system inspection •

1

Check and make sure suction rubber hose leading from the filter is not damaged and tightening clamps (1) are not missing.

1

•

Inspect the gasket (2) between the bonnet and air filter.

Replace damaged gasket with the new one.

2

•

Check the exit slit of air filter vacuum valve (3), press to remove any dust trapped.

3

Do NOT operate the machine with damaged gasket between the bonnet and air filter or the connection not tight.

Do NOT operate the machine with dust valve damaged.

NOTE! The dust caught inside dust valve gets emptied automatically during machine operation.

86

ARS 121

MAINTENANCE MANUAL 3.6.8. Fuel level check and refilling •

Check the level of the diesel in tank on the Instrument cluster screen.

•

Number of visible bargraphs (3) indicates fuel level.

•

More the number of bargraphs, higher the fuel level in tank and vice-versa.

•

Flashing bars indicates fuel tank nearing to empty, to avoid sudden stop immediately refuel the tank only after stopping the engine.

3

!

•

Add fuel, following remove and cleaning of filler cap (1) through filler neck (2) through a strainer up until the lower edge of the filler neck (2).

1

2

No smoking while at work!

Obey fire precautions!

If fuel tank is fully empty, bleed the fuel system.

Use only clean and recommended fuel under chapter 3.2.2.

Do NOT add fuel while the engine is running.

Do NOT carryout filling process in closed areas.

Avoid fuel spillage on the ground, as it is environmentally hazardous.

NOTE! As soon as emptying condition of tank is indicated on cluster, add fuel immediately. To fill completely emptied fuel tank, it will require 410 L (108 gal US) of fuel.

ARS 121

87

3.6.

Individual Operations of Maintenance

3.6.9. Drain fuel filter cum water separator •

Prepare a receptacle to drain the sediment into.

•

Turn the drain cap at the bottom of filter (1) in counterclockwise direction till it gets separated.

1

•

Let the sediment flow out, till the pure fuel starts flowing out. Reinstall cap back to its position

278N109T

Obey fire precautions!

No smoking while at work!

Do NOT drain the separator with the engine running.

Drain water daily.

Drain cap should be hand tightened fully, do not use any spanner to tighten drain cap.

Collect the fuel with sediment drained in a proper vessel.

Avoid fuel spillage on ground, as it is environmentally hazardous.

Obey local environmental laws while disposing drained fuel.

88

ARS 121

MAINTENANCE MANUAL 3.6.10. Alarm and control devices check

When in operation, please monitor instrument cluster continuously for warning signals.

With battery connected, the ignition key (6) set to ON (“I”) position; •

All lamps will flash for around 3 sec., Later lamps (19), (23) & (33) will remain lit up.

•

Set ON the switches (10), (11), (12), (13), (15), (16) and confirm the turn lights, head lamp high or low beam, work lamps, horn, and hazard lights functions.

•

Lamps (19) & (23) must go off after starting engine.

•

Lamp 33 will go off with drive lever (2) moved from neutral position.

10

19

33

15

5 7.5A

6 15A

4 7.5A

1 20A

2 15A 3 15A

6

6

23

I

7

7 15A 8 15A

!

7 14

If seen any warning signal, find and repair cause immediately!

12

16

11

2

5

II

13

2A

F N R 3

STOP

12V

ARS 121

89

3.6.

Individual Operations of Maintenance Every 150 hours of operation

3.6.11. Tyre pressure check •

Check pressure at cold tyre using a pressure gauge.

•

Maintain 160 kPa (23.2 PSI) pressure in tires.

NOTE! Turn tyres so that valves (1) are at top positions.

90

1

ARS 121

MAINTENANCE MANUAL Every 250 hours of operation

A

3.6.12. Engine mounts and fasteners inspection •

Confirm the condition of engine mounts (A) must be free from cracks and/or fissures, adherence of metal with rubber, tightness of nuts (B) of both front and rear engine mounts.

B

B

A

ARS 121

91

3.6.

Individual Operations of Maintenance

3.6.13. Replacement of fuel filter (mud filter) •

Clean the head of the fuel filter (1).

•

Loosen filter body with filter wrench, then remove with hands.

1

•

Clean the filter head area in contact with filter body, make sure no traces of old gasket left behind there.

282N129T •

Fill up the new filter with clean fuel.

282N160T •

Apply oil over the sealing ring of new filter.

282N131T 92

ARS 121

MAINTENANCE MANUAL •

Position new fuel filter (1) and tighten firmly by hand till it touches filter head.

•

Now tighten filter body further with filter wrench.

•

Start and run the engine for 2-3 minutes then set it OFF and ensure no fuel leakage from filter assembly.

396250A

No smoking while at work!

Obey fire precautions!

Use original filters specified in parts manual for machine.

Do NOT over tighten the filter.

Avoid fuel spillage on ground, It is environmentally hazardous.

Obey local regulations while disposing used filter or hand it over to dealer for disposal.

ARS 121

93

3.6.

Individual Operations of Maintenance

3.6.14. Battery check Lead acid battery •

Stop the engine and disconnect the electric system using the isolator switch.

•

Open the bonnet and access the battery.

•

Clean the surface of battery.

•

Check the condition of terminals (1) and clean them. Apply petroleum jelly on the terminals to prevent it from corrosion and to ensure smooth start.

Maintenance-free battery •

In case of a maintenance-free battery (the battery has no freely accessible plugs), only the no-load voltage on terminals is checked. If no-load voltage is 12.6 V and more, the battery is fully charged. If no-load voltage is below 12.4 V, the battery should be charged immediately. After the battery is charged, leave it to stand for 2–3 hours and then measure the voltage again. It is recommended to be mounted 24 hours after charging.

Keep the battery dry and clean.

Do NOT disconnect battery while the engine runs.

When handling the battery, always obey battery Manufacturer’s Manual!

Use rubber gloves and eye protection aids when handling the battery.

Use proper clothing to protect your skin against any electrolyte stain.

When there is direct contact of any body part with electrolyte immediately flush affected body part with water for a few minutes. Get prompt medical attention.

When there is electrolyte ingestion, drink max amount of milk, water or solution of calcined magnesia in water.

Do NOT eat, drink or smoke while at work!

After work is completed, wash your hands and face thoroughly with water and soap!

Disconnect the battery before its repair, or when about to handle the wires and electric devices within the wiring circuit so to avoid a short circuit.

When disconnecting the battery, please disconnect cable with (-) pole first. When connecting, you must connect (+) pole first.

Making direct conductive connection between battery’s both poles you will cause a short circuit with battery explosion hazard.

94

1

Do NOT turn the battery upside down; the electrolyte may pour down from the degassing plugs.

Hand over old battery to supplier for disposal.

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

ARS 121

MAINTENANCE MANUAL 3.6.15. Air filter vacuum switch function check •

Remove the engine air pre cleaner (A).

•

Set up the engine speed to about 2000 min-1.

•

Cover air suction hole (B) on the engine bonnet with impermeable material for a short while.

•

Indicator lamp (27) for air filter clogging should light.

A

B

!

27 •

Check the following In case air filter fouling indicator (27) fails to lit in above test: -

Vacuum switch (1) and it’s electrical connection.

-

Bulb inside the indicator lamp (27) and it’s connection to cluster.

ARS 121

1

95

3.6.

Individual Operations of Maintenance

3.6.16. Machine lubrication •

Remove greasing nipple caps.

•

Connect delivery end of high pressure greasing gun to machine greasing nipple and start greasing till grease oozes out of greasing nipple.

•

1

3

Reinstall the greasing nipple caps again.

Steering joint Upper bearing (1) Lower bearing (2) Bearing (3) 4x

2

Steering cylinders King pins (4) 2x

4

4

Rear pins (5) 2x

5

Bonnet lifting cylinders Upper pivots (6) 2x

6

96

6

ARS 121

MAINTENANCE MANUAL Lower pivots (1) 2x

1

1

Bonnet hinges (2)

2

2

Platform front pivots (3) Pivots 2 x

3 3

Use only recommended lube greases.

Refer to chapter 3.2.5.

ARS 121

97

3.6.

Individual Operations of Maintenance

3.6.17. Vibrator assembly oil level check 2

Level check: •

Stop the machine in such a way that the filler plug (2) on the left side of drum is at top.

•

Clean the area round of the level plug (1). Unscrew the plug (1) and remove it gradually, If oil starts oozing out the level is ok, install plug (1) back, If not, proceed with oil addition.

Oil addition: •

With plug (1) open, unscrew and open plug (2) and start adding oil through hole for plug (2) till oil starts flowing out of hole for plug (1).

•

Clean and install plugs (1) & (2) back and tighten with specified torque.

1

Check the oil level only when oil at atmospheric temperature.

Refill with identical type of oil as per chapter 3.2.1.

Avoid oil spillage on ground, it is environmentally hazardous!

98

ARS 121

MAINTENANCE MANUAL 3.6.18. Axle - Epicyclic gearboxes oil level check •

Position the machine in such a way the plug (1) of the axle gearbox is horizontal as in image.

•

Wipe the area round the plug (1), unscrew the plug gradually and then remove.

•

The oil must be present till the bottom of hole for plug (1).

•

If oil level not seen up to the mark, add recommended oil as per chapter 3.2.6 through same hole with the help of funnel.

•

Wipe the plug and install back with specified torque.

•

Repeat the procedure with gearbox on opposite side.

1

Do NOT touch gearbox and its adjacent parts when these are hot.

Avoid oil spillage on ground, it is environmentally hazardous.

ARS 121

99

3.6.

Individual Operations of Maintenance

3.6.19. Axle - Differential gearboxes gearbox oil level check Obey the below instructions: •

Place a container of capacity about 1 L under plug (1) to collect leaking oil.

•

Unscrew the filler and level plug (1), If oil starts oozing, level is ok, If not add some oil to restore level.

•

With funnel add specified oil as in chapter 3.2.6 upto the bottom of the fill plug hole (1).

•

Clean and install back the plug (1).

•

Tighten the plug to the prescribed torque.

1

Do NOT touch axle and its adjacent parts when are hot.

Avoid oil spillage on ground, it is environmentally hazardous

100

ARS 121

MAINTENANCE MANUAL Every 500 hours of operation 3.6.20. Engine oil change •

Set OFF the engine and remove ignition key.

•

Wait till engine coolant temp reaches 500 C (122 F)

•

Arrange a container of capacity about 15 L, place it beneath engine oil drain plug (1).

•

Remove engine oil drain plug (1) and let oil to flow out.

•

After draining complete oil, install drain plug (1) back and tighten it with 80 Nm (59 lb. ft.) torque.

1

3.6.20.1. Engine oil filter replacement •

Loosen the old filter using filter wrench and remove with hands.

2

•

Clean the filter head surface on which filter cartridge rests.

282N129T •

Take a new filter, fill it with clean engine oil

396248 ARS 121

101

3.6.

•

Individual Operations of Maintenance

Apply oil on the gasket.

282N131T •

Install the new filter and hand-tighten securely.

•

Tighten filter with filter wrench.

396250A •

Fill new engine oil through filler neck (1).

•

It will take about 10 l (2.6 gal US) of oil to fill till required level

2

•

Confirm oil level with dipstick, oil level must be seen in between full and low level marks on dipstick.

•

If oil level found less than required, add some oil again.

•

Install dipstick back to its position once correct oil level is reached.

•

Now start the engine, allow it to run in idle rpm for 2 to 3 mins. and shut it off.

•

Wait for 5 minutes until oil descents into the crankcase sump. Then check the oil level using dipstick, If found below low level mark, add some oil.

•

LOW FULL

Install dipstick back to its position.

102

ARS 121

MAINTENANCE MANUAL Drain oil when it is hot, i.e after 20 mins. of engine shutdown or when the cooling liquid temperature reaches 50°C (122°F).

Be careful of possible scalding when draining hot oil.

Collect drained oil and do not leave it to soak in the ground.

Used oil and filters are environmentally hazardous. Obey local regulations to dispose these or hand it over to supplier for disposal.

CAUTION! Replace engine oil every 6 months or 500 hours of operation whichever comes first.

Use recommended filters only. Refer to specification manual of engine or Spare Parts Catalogue of machine.

Use recommended oil only. Refer to chapter 3.2.1.

Do NOT over tighten the filter, Its thread or gasket may get damage.

NOTE! With the oil replaced, start the engine for 2 - 3 minutes. Check the drain plug and filter for leakages.

For further details on engine maintenance refer operating manual for diesel engine supplied with machine.

ARS 121

103

3.6.

Individual Operations of Maintenance

3.6.21. Fuel filter cum water separator replacement •

Clean the head of the fuel filter cum water separator (1).

•

Loosen filter body with filter wrench, then unscrew and remove with hands.

1

•

Clean the filter head area in contact with filter body, make sure no traces of old gasket left behind there.

282N129T •

Fill up the new filter with clean fuel.

282N160T •

Apply oil over the sealing ring of new filter.

282N131T 104

ARS 121

MAINTENANCE MANUAL •

Position new fuel filter cum water separator (1) and tighten firmly by hand till it touches filter head.

•

Now tighten filter body further with filter wrench.

•

Start the engine and ensure no fuel leakage around the sealing rubber ring and filter assembly

396250A

No smoking while at work!

Obey fire precautions!

Use original filters specified in parts manual for machine.

Do NOT over tighten the filter.

Avoid fuel spillage on ground, It is environmentally hazardous.

Obey local regulations while disposing used filter or hand it over to dealer for disposal.

ARS 121

105

3.6.

Individual Operations of Maintenance

3.6.22. Coolant level check •

Open the bonnet to access the radiator (refer to chapter 2.8.8).

•

Check coolant level through sight glass (B), coolant must be seen through it.

•

If not seen, open pressure cap (A) and add coolant till it is seen in sight glass.

•

Add coolant as recommended in chapter 3.2.3.

A

B

Do NOT open pressure cap of radiator when engine is too hot, danger of scalding, wait till coolant temperature falls to 500 C (1220 F).

NOTE! Coolant level must be checked after 15 to 20 mins. of engine shutdown or when coolant is at 500 C (1220 F).

3.6.23. Wiring check •

Check for any damage to cables, connectors, protective hoses and their fastening, especially near of hot surfaces and moving parts of the machine including the engine.

•

Replace damaged parts, use only original spare parts.

106

ARS 121

MAINTENANCE MANUAL 3.6.24. Wheel bolts tightening check •

Confirm the wheel mounting bolts (1) tightening.

•

Use torque wrench and tighten the nuts with torque 500 Nm (368.8 lb. ft.).

1

CAUTION! Check the wheel nuts for tightness after the first 150 hrs. of machine operation.

ARS 121

107

3.6.

Individual Operations of Maintenance Every 1000 hours of operation

3.6.25. Air filter element replacement Air filter contains the primary and secondary filter elements.

Replace the both filter elements after every 1000 hrs of operation or with air filter clogging indicator lamp (27) lights up.

The manufacturer does not recommend cleaning the cartridges because of reduction of filtration capacity of the cartridges due to the cleaning.

•

Open the bonnet (refer to chapter 2.8.8).

•

Unlock and remove the lid (1).

!

27

1

•

Pull out primary filter element (2).

2

•

Pull out secondary filter element (3).

3

108

ARS 121

MAINTENANCE MANUAL •

Clean the inside of the air filter body with cloth in order that dust does not enter engine through inlet pipe.

•

Check air suction line connections and piping for any lose connection or leakage, repair immediately if found any to avoid entry of foreign particles in to the engine.

•

Install new secondary and then primary filter elements.

•

Check whether the both cartridges locked on their places.

•

Install air filter cover (1) back to its position and lock it.

1

Do NOT clean the inside of the cleaner by pressurised air; dust might get into the engine inlet piping.

Use original filter cartridge only, specified in parts manual for machine.

When washing the machine, make sure water cannot enter into the air cleaner.

In case filter element got wet, exchange main element. Dry the cleaner body.

Replace defective vacuum valve immediately!

Do NOT operate the machine with damaged cleaner body or cover.

ARS 121

109

3.6.

Individual Operations of Maintenance

3.6.26. Engine valve clearance adjustment •

Call Ashok Leyland service department to assign personnel to adjust the engine valves – for contact information, please refer Engine Operation and Maintenance manual supplied with machine.

3.6.27. Engine fan belt tension check •

Press with thumb at the centre spot (2) where belt length between pulleys is the longest.

•

Monitor belt deflection, it should not be more than 15 mm (0.5 in.), If more proceed with increasing belt tension.

•

To increase belt tension first loosen nut (3) then tighten nut (4) till required belt tension is achieved.

•

Tighten both nuts (3) & (4) after adjusting belt tension.

2

4

3

Visual check of the belt condition •

Carry out visual inspection of the belt for any cracks across the belt width and along length, transverse cracks are acceptable but longitudinal are not.

•

If belt has its edges frayed or parts of the material are ripped out, then the belt must be replaced.

OK OK

282N116T 110

ARS 121

MAINTENANCE MANUAL Replacing the fan belt •

Loosen nut (2) so as to move alternator by 1 to 2 in. towards fan pulley.

•

Now belt is slack and can be removed.

•

Check pulley grooves for wear/damage and replace the pulley if required.

•

Clean the pulley grooves.

•

Check alignment of the pulleys.

•

Mount the new belt over pulleys and ensure the belt ribs are seated in the respective pulley grooves.

•

Adjust nuts (3) and (4) so as to swivel the alternator away from engine to increase the fan belt tension.

•

Tighten nuts (3) & (4) after belt tension setting.

•

Run the engine for 3 to 5 min with the applied tension to allow the belt to seat in the respective pulley grooves properly.

•

Stop the engine, check belt tension again and reset if necessary.

2 1

4

3

Belt must be tensioned properly as too tight belt will exert excess tension on pulleys and resulting in bearing failure before their designed life and too slack belt will generate much heat due to friction and may fail before its designed life.

Check alignment of the pulleys, misalignment of pulleys will produce noise and shorten the belt life.

ARS 121

111

3.6.

Individual Operations of Maintenance

3.6.28. Vibration damping pad condition inspection •

•

Check the condition of damper (1) (cracks, fissures), cohesiveness of metal with rubber, Replace immediately if found any one damage

1

1

Confirm the damper fasteners are tightened properly.

Dampers of the drum, LH side.

Dampers (1) of the drum, RH side 1

1

Front metal rubber (2) of operator’s platform.

2

Rear metal rubbers (3) of operator’s platform.

3

3

112

ARS 121

MAINTENANCE MANUAL 3.6.29. Fuel tank cleaning •

Carryout fuel tank cleaning activity when fuel in tank is about to finish.

•

Arrange clean capacious container of capacity to accommodate fuel available in tank.

•

Loosen and remove the drain plug (A) beneath the frame on which battery is mounted and let fuel to flow out into a receptacle installed.

•

Flush the tank with clean fuel.

•

Install drain plug again.

•

Open the bonnet and access the battery (B)

•

With battery disconnected, first disconnect the negative (-) terminal and then positive (+) terminal of the battery (B).

•

Loosen the clamp nuts (C).

•

Remove the battery (B) and place it a side.

•

Loosen and remove the all nuts (E) of tank cap (D).

•

Remove the tank cap (D). Inspect and clean the tank’s inner area.

•

Insert the new sealing tape between the tank cap (D) and the tank.

•

Install the tank cap (D), battery (B) and its connections back.

•

Fill the tank with fuel

Obey fire precautions!

NO smoking while at work!

A

B

C

E

C

D

Avoid fuel spillage on the ground, It is environmentally hazardous.

Obey the local environmental regulations while disposing clothes or materials soaked with fuel oil.

NOTE! When fuel system emptied completely air entrapped in system must be removed as stated in chapter 3.6.37.

ARS 121

113

3.6.

Individual Operations of Maintenance Every 1500 hours of operation 3

3.6.30. Axle - Differential oil change

1

Obey the below instructions: •

Park the machine on levelled ground and secure with wheel chocks.

•

Place container of capacity about 15 L under plug (2) to collect drained oil.

•

Unscrew the filler plug (1) for easy out flow of oil.

•

Remove drain plug (2), oil will start draining.

•

After draining complete oil, clean drain plug (2) and install it back.

•

Clean the breather plug (3) and the surrounding area.

•

Fill to the bottom of the fill plug hole (1) with the specified oil as in chapter 3.2.6.

•

Wait till complete oil flow out of the axle.

•

Clean and install back the plug (1).

•

Tighten the plug to the specified torque.

2

Risk of violent oil ejection, obey carefully all the safety procedures indicated in this manual.

To check the oil level, drain & fill the oil the axle must be horizontal.

Avoid oil spillage on ground, as it is environmentally hazardous.

Obey local environmental laws while disposing used oil or hand it over to supplier for disposal.

114

ARS 121

MAINTENANCE MANUAL 3.6.31. Axle - Epicyclic gearbox oil change Follow below Instructions: •

Park the machine in a way so as to position plug (1) horizontally.

•

Partially unscrew plug (1) to release possible pressure.

•

Move machine to bring the plug (1) closer to ground, as in image B.

•

Place a container of approx. capacity 3 L beneath plug (1).

•

Remove plug (1) and let the complete (1.3 L) oil flow out of the casing.

•

Move machine to bring plug (1) to position as in image (A).

•

Fill specified oil as in chapter 3.2.6 to the bottom of the fill plug hole with funnel.

•

1.3 l of oil will be required to fill each side gearbox.

•

Tighten the plug (1) to the torque 80 Nm.

•

Repeat same procedure on gearbox on opposite side.

A 1

B

1

To check the oil level, drain & fill oil the axle must be horizontal.

1 Avoid oil spillage on ground, as it is environmentally hazardous.

Obey local environmental laws while disposing used oil or hand it over to supplier for disposal.

ARS 121

115

3.6.

Individual Operations of Maintenance Every 2000 hours of operation

1

3.6.32. Vibrator casing oil change •

Park machine so as to bring the drain plug (3) nearer to ground & the filler plug (1) at highest possible distance from ground.

•

Place a container of capacity 8 L underneath the drain plug (3).

•

Unscrew the plugs (1), (2) and then (3) and let oil to flow out completely.

•

Clean and install the drain plug (3) back.

•

Fill oil through hole (1) till it flows out of hole for plug (2).

•

Use oil recommended in chapter 3.2.1.

•

Clean and install back the remaining drain plugs.

2 3

Do NOT touch hot sections, danger of scalding.

Obey fire precautions!

Change oil while oil is warm!

Avoid oil spillage on ground, as it is environmentally hazardous.

Obey local environmental laws while disposing used oil or hand it over to supplier for disposal.

116

ARS 121

MAINTENANCE MANUAL 3.6.33. Hydraulic oil, suction line filter cartridge and strainer replacement Draining hydraulic oil •

Open the bonnet and access hydraulic oil tank drain valve (B).

•

Make an arrangement to collect drained oil to container.

•

Remove drain plug (A) and open valve (B) to let oil flow out into a vessel installed – total amount of oil that flows out is round 60 L (15.9 gal US).

•

Clean and install plug (A) back & close valve (B).

A B

Replacing hydraulic oil strainer •

Stop the engine and let the oil temperature decrease to ambient temperature.

•

Remove screws (C) to remove cover (D).

D C

•

Remove the suction hose (E).

•

Remove the screws (G) then remove lid (F).

•

Replace strainer.

•

Inspect the interior of the tank, If the bottom is dirty, clean and rinse the tank with the new oil.

•

Install the lid (F) back and secure with screws (G).

•

Install suction hose (E) back.

•

Install cover (D) back and secure with screws (C).

E G

F

Drain oil while oil is warm!

ARS 121

117

3.6.

Individual Operations of Maintenance

Replacing suction line filter cartridge •

Stop the engine and let the oil temperature decrease to ambient temperature.

•

Place a container to collect oil leaking while replacing cartridge.

•

Loosen filter body (2) with filter wrench, then remove by hands.

•

Take new filter cartridge and fill it with hydraulic oil as recommended in chapter 3.2.4.

•

Clean the filter head bottom surface in contact with filter body.

•

Apply oil to sealing ring.

•

Position new filter cartridge and hand tighten as much possible.

•

Further tighten 3/4th turn with filter wrench.

•

Also replace hydraulic oil filter cartridge (2), in response with lighting signal (28) on cluster.

2

!

28

Always replace strainer and suction line filter cartridge together with oil exchange.

118

ARS 121

MAINTENANCE MANUAL Refilling the hydraulic circuit •

Carryout refilling using the hydraulic unit (A).

•

Use oil recommended in chapter 3.2.4.

A

1251998 •

Connect quick-release coupling of the hydraulic unit with quick-release coupling (1) on the right side of the frame under the operator platform.

1

•

Start filling oil till oil level reaches half in level indicator (2), then disconnect the hydraulic unit.

•

Start the engine, increase its speed and allow it to run for 2-3 mins.

•

Stop the engine and check oil filter and suction hose areas for signs of oil leakage. Repair immediately if found any leakage.

•

Check oil level in gauge (2), add oil if level drops after engine starting.

2

Checking the oil temperature sensor •

Remove the sensor (3) and clean the contact.

•

Immerse the sensor in warm oil of a known temperature and read the temperature on the hydraulic oil thermometer. If the sensor operation is incorrect, replace the sensor with a new one.

ARS 121

3

119

3.6.

Individual Operations of Maintenance

Alternate filling through the oil tank filler •

Open the bonnet and access hydraulic oil tank.

•

Open filler cap (1) with hands.

•

Fill clean oil to through the filler neck up to the bottom of the strainer in the filler neck.

•

Install cap (1) back and tighten with hands

1

Obey fire precautions.

Do NOT open hydraulic tank cap unnecessarily!

Use no chemical cleaning agents & those means (like clouts) that slip fibres.

Use only the original filter elements under Spare Parts Catalogue.

Exchange oil and filter element always when internal parts of units (hydraulic motors, hydroelectric pumps) have been damaged or following a major overhaul of hydraulic system.

Avoid oil spillage on ground, as it is environmentally hazardous.

Used oil & filter cartridges are environmentally hazardous waste – Obey local environmental regulations while disposing them or hand it over to dealer for disposal.

NOTE! When the tank is filled through the tank neck, a large portion of the old dirty oil will remain in the circuit and the life cycle of the hydraulic units may be reduce.

120

ARS 121

MAINTENANCE MANUAL 3.6.34. Coolant change Open the bonnet and access the expansion tank cap (1).

1

Remove pressure cap (1) of the expansion tank to help coolant out flow.

•

Arrange a container of capacity about 20 L (5.3 gal US)

•

Open the drain cap (2) at the bottom of radiator and make coolant to flow into container by some means.

2

•

Check visually the condition of the radiator for any damage, leaks or whether the cooling fins are clogged with slag & mill scale. Clean and repair if required.

•

Confirm no damaged hoses or missing hose clamps exist within the engine cooling system.

282N206T

Do NOT open the pressure cap before coolant temperature drops below 50°C (122°F), danger of spurting of hot coolant and getting scalded.

OK

OK

Make it after 20 minutes of engine operation stopped or following the heating of the liquid to 50°C (122°F) with the engine running.

282N205T ARS 121

121

3.6.

•

Individual Operations of Maintenance

Close the drain cap and refill the cooling system with new coolant at the ratio of 50 % of water + 50 % of antifreeze or premixed coolant directly through filler neck (1).

282N207T •

Fill till liquid level seen at top of level indicator (2). Adequate filling speed is 19 L/min [5 gal US/min]. When the system is filled up you must wait 2-3 minutes to let the bleeding come about. Screw on the pressure cap and close the bleed valve.

Start the engine and let the engine heat up to 80°C (175°F).

Stop the engine and check for cooling liquid leaks. Confirm liquid level in level gauge (2), add if required.

1

2

Wear gloves, safety goggles and face shield to protect yourself!

Refill with cooling liquid recommended under chapter 3.2.3.

Additionally obey instructions of antifreeze manufacturer while replacing!

Avoid liquid spillage on ground, it is environmentally hazardous.

Obey local environmental laws while disposing used coolant or hand it over to supplier for disposal.

122

ARS 121

MAINTENANCE MANUAL Maintenance - As needed 3.6.35. Drum cooling liquid (optional) Drum cooling mixture is a lifetime charge and it is not changed.

To check and maintain mixture level in drum, position the machine in such a way that plug (A) will be at minimum height from ground. In this position hole (A) will be level & drain hole (B) will be filling hole.

B A

Now open plug (A) gradually, if liquid oozing from it, level is correct. If not, open the plug (B) and start adding mixture from hole (B) till it oozes from hole (A), then install both plugs back.

Fill the mixture according to chapter 3.2.7.

To reach specified level, 307 L of mixture will be required.

ARS 121

123

3.6.

Individual Operations of Maintenance

3.6.36. Coolant, oil and air cooler cleaning •

No regular cleaning interval is possible to establish due to different operating conditions.

•

Do daily cleaning when working within extremely dusty environment. Clogging of coolers will result in lowered cooling performance along with increased temperatures of engine cooling liquid and that of hydraulic oil.

•

Clean with compressed air or pressurised water stream.

•

Direct pressurised air or water stream on cooler surface from fan side.

Do NOT use cleaners of excessively high pressure to prevent cooler fins being damaged.

In case of cooler clogged with crude oil products find out the cause of clogging!

Obey the ecological standards and regulations when cleaning!

Clean the machine at a workplace equipped with cleaning agent intercepting system to avoid contamination of soil and water resources!

Do NOT use those cleaning agents which are not permitted!

124

ARS 121

MAINTENANCE MANUAL 3.6.37. Air purging from fuel system Remove the air from the fuel system before a first start of the engine upon: •

Fuel filters not refilled with fuel – when replacing the filters

•

Fuel pump replacement

•

Replacement of high-pressure piping, injector

•

Long-term shutdown of the machine

•

Fuel pumped out from the tank

Remove the air from low-pressure piping & filters: •

Loosen air relief screw (1) on the fuel pump.

1

•

Turn fuel feed pump knob (2) counterclockwise until it gets open.

•

Start pumping fuel feed pump (2) until continuous stream of fuel (without air bubbles) spurt out from banjo (1).

•

Tighten banjo (1) with torque 9 Nm (7 lb. ft.).

2

Avoid oil spillage on ground, as it is environmentally hazardous.

ARS 121

125

3.6.

Individual Operations of Maintenance

Remove the air from high-pressure piping and the injectors: •

When you have carried out the operations before and the engine has not started, bleed the high-pressure piping.

•

Set the ignition box key to position ”ON” to energize engine “Stop” solenoid valve.

•

Loosen one or more nuts on the injectors and then swing the engine to force the air out from High Pressure piping.

•

Remove the air from till engine runs regularly.

•

Tighten the loosened connections with 38 Nm (28 lb. ft.) torque.

396N052

Attention, high fuel pressure inside HP piping. Hazard of skin injury and serious implications.

Do NOT operate on hot engine. Danger of fuel flowing over hot exhaust manifold causing fire.

Open fire is not permitted while working on fuel system!

NO smoking!

Collect any leaking fuel!

126

ARS 121

MAINTENANCE MANUAL 3.6.38. Scraper adjustment Scraper designed for smooth drum •

Loosen all bolts (1) and shift the holder (2) towards or away form the drum making the distance between scraper and drum equal to 15 mm (0.6 in.).

•

Add “In machine at stop condition” at beginning

•

Tighten all bolts (1) after desired setting is done.

ARS 121

2 1

127

3.6.

Individual Operations of Maintenance

3.6.39. Battery charging •

Only use chargers with an appropriate rated voltage. Check that charger is strong enough to charge the battery, not too strong to charge with excessive current.

•

Read and obey the instructions from user guide for battery charger.

•

Ensure ventilation holes on battery cover are not clogged and gases can escape freely.

•

Connect positive terminal (+) of the battery to the positive terminal of the charger.

•

Connect negative terminal (-) of the battery to the negative terminal of the charger.

•

Switch ON the charger only after connecting the battery.

•

Charge the battery with current corresponding to one tenth of the battery capacity.

•

After charging, first turn off the charger and then disconnect the cables from the battery.

•

The battery is fully charged, if: -

Electric current and voltage remain constant in the case of voltage controlled chargers,

-

The charging voltage in the case of current controlled chargers does not increase within two hours, the automatic charger turns off or switches to maintain charge.

Use rubber gloves and eye protection devices when handling battery.

Use suitable clothing to protect your skin against contact with the electrolyte.

In case of contact of battery electrolyte with body part, immediately flush the affected body part with running water for several minutes. Then seek medical advice.

After ingestion of the electrolyte drink large quantity of water.

Do NOT turn the battery upside down, the electrolyte can flow out.

Obey local environmental regulations or handover inoperative battery to supplier for disposal.

When working with the battery, always obey battery manufacturers instructions.

Do NOT charge a frozen battery or battery with a temperature above 450 C. Stop charging if battery is hot or leaking.

Do NOT make direct conductive connection between both poles of the battery to avoid a short circuit and a risk of explosion of the battery.

128

ARS 121

MAINTENANCE MANUAL 3.6.40. Machine Cleaning

3.6.41. Screwed connections check

•

Clean the machine to get rid of major dirtiness following a work completion.

•

Check regularly whether some bolted connections are loosened.

•

Make overall cleaning on general basis at least once every week. When working on cohesive soils, soil cement or lime stabilization, please make overall cleaning on daily basis.

•

Tighten with torque spanners.

TORQUE For bolts 8.8 (8G)

Blind all the holes where a cleaning agent could enter (e.g. Engine suction port) before compressed cleaning with water or steam. Remove these blinds upon machine cleaning completion.

Do NOT expose electric parts or insulation material to direct stream of water or steam. ALWAYS cover these materials (internal space of alternator, etc.).

Wear gloves to protect your hands!

Wear safety glasses or face shield to protect your eyes!

Disconnect battery cut off switch.

Conduct cleaning with the engine shut off.

Use aggressive and easily ignitable cleaning agents (e.g. Gasoline or easily ignitable materials).

Obey ecological standards and regulations when cleaning!

Clean the machine at a workplace equipped with cleaning agent intercepting system to avoid contamination of soil and water resources!

Do NOT use those cleaning agents which are not permitted!

For bolts 10.9 (10K)

Thread

Nm

lb ft

Nm

lb ft

M6

10

7.4

14

10.,3

M8

24

25.0

34

25.0

M8x1

19

14.0

27

19.9

M10

48

35.4

67

49.4

M10x1.25

38

28.0

54

39.8

M12

83

61.2

117

86.2

M12x1.25

66

48.7

94

69.3

M14

132

97.3

185

136.4

M14x1.5

106

78.2

148

109.1

M16

200

147.5

285

210.2

M16x1.5

160

118.0

228

168.1

M18

275

202.8

390

287.6

M18x1.5

220

162.2

312

230.1

M20

390

287.6

550

405.6

M20x1.5

312

230.1

440

324.5

M22

530

390.9

745

549.4

M22x1.5

425

313.4

590

435.1

M24

675

497.8

950

700.6

M24x2

540

398.2

760

560.5

M27

995

733.8

1400

1032.5

M27x2

795

586.3

1120

826.0

M30

1350

995.7

1900

1401.3

M30x2

1080

796.5

1520

1121.0

The figures given in the Table are torques at dry thread (at coefficient of friction = 0.14). The figures do not apply to lubricated thread.

ARS 121

129

3.6.

Individual Operations of Maintenance

Table of torques for cap nuts with sealing O-ring – hoses

Torques for cap nuts with O-ring – hoses Nm

lb. ft.

Spanner size

Thread

Tube

Nominal

Min

Max

Nominal

Min

Max

14

12x1.5

6

20

15

25

15

11

18

17

14x1.5

8

38

30

45

28

22

33

19

16x1.5

45

38

52

33

28

38

22

18x1.5

51

43

58

38

32

43

24

20x1.5

58

50

65

43

37

48

27

22x1.5

74

60

88

55

44

65

30

24x1.5

16

74

60

88

55

44

65

32

26x1.5

18

105

85

125

77

63

92

135

115

155

100

85

114

166

140

192

122

103

142

36 41 46 50 50

130

30x2 36x2

8 10 10 12 12 14 15

20 22 25 28

42x2

30

240

210

270

177

155

199

45x2

35

290

255

325

214

188

240

330

280

380

243

207

280

52x2

38 42

ARS 121

MAINTENANCE MANUAL Table of torques for nozzles (necks) with sealing edge, or with gasket

Table of torques for plugs with gasket

Plug torques

Nozzle torques G -M

Nm

lb. ft.

G -M

Nm

lb. ft.

G 1/8

25

18

G 1/8

15

11

G 1/4

40

30

G 1/4

33

24

G 3/8

95

70

G 3/8

70

52

G 1/2

130

96

G 1/2

90

66

G 3/4

250

184

G 3/4

150

111

G1

400

295

G1

220

162

G 11/4

600

443

G 11/4

600

443

G 11/2

800

590

G 11/2

800

590

10 x 1

25

18

10 x 1

13

10

12 x 1.5

30

22

12 x 1.5

30

22

14 x 1.5

50

37

14 x 1.5

40

30

16 x 1.5

60

44

16 x 1.5

60

44

70

52

18 x 1.5

60

44

18 x 1.5

20 x 1.5

140

103

20 x 1.5

90

66

22 x 1.5

140

103

22 x 1.5

100

74

26 x1.5

220

162

26 x1.5

120

89

27 x 1.5

250

184

27 x 1.5

150

111

33 x 1.5

400

295

33 x 1.5

250

184

42 x 1.5

600

443

42 x 1.5

400

295

48 x 1.5

800

590

48 x 1.5

500

369

M-G

M-G

M-G

282N221T

ARS 121

282N222T

131

3.7.

Schematics

3.7.1. Electrical schematic Call AMMANN service personnel to consult on Electrical system.

132

ARS 121

MAINTENANCE MANUAL 3.7.2. Hydraulic schematic Call AMMANN service personnel to consult on Hydraulic system.

ARS 121

133

3.8.

General Information

3.8.1. Acronyms and abbreviations The following list contains some of the acronyms and abbreviations used in this manual.

134

0

C

Celsius

0

F

Fahrenheit

cm

Centimetre

S/N

Serial number

PIN

Product Identification Number

kg

Kilogram

lb

Pound

ROPS

Roll Over Protection System

kW

kilowatt

HP

Horse power

cm3

Cubic centimetre

in3

cubic inch

N.m

newton meter

rpm

Revolutions per minute

l/h

Litre per hour

MPA

Megapascal

psi

Pounds per square inch

Hz

Hertz

VPM

Vibrations per minute

KN

KiloNewton

gal (U.S)

Gallon, United States

V

Volt

Ah

Ampere-hour

Km/h

Kilometre hour

RH

Right hand side

LH

Left hand side

ATO

Ammann Traction Optimiser

min-1

Revolutions per minute

Hrs

Hours

cl

Centilitre

ARS 121

MAINTENANCE MANUAL Notes

ARS 121

135

For additional product information and services please visit : www.ammann.com

Materials and specification data are subject to change without notice.

Book ID: 4-P06000-EN | © Ammann Group