Ammann ARS 122 Single Drum Roller Operating Manual 0063 PDF

ARS 122 SINGLE DRUM ROLLER CUMMINS 4BTAA3.9C BSIII / EU Stage IIIA / US EPA Tier 3

C

OPERATING MANUAL EDITION 09/2019 EN From Serial No. 0063-

ARS122 Single drum roller Cummins BSIII

Operating manual Edition 09/2019 EN From serial no. 0063Original operating manual

iv

ARS 122

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. All spare parts are available from your dealers or can be ordered at Toll-Free number : 1800 258 2233 for Ammann India Sales, Service and Spares.

These instructions must always be kept available on the equipment.

ARS 122

1

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

Ammann 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.

2

ARS 122

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 a serious risk of personal injury or other personal hazards.

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

ARS 122

282N100Ten

3

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................................................................................................................19

2.1. Dewaxing and Inspection of a Newly Supplied Machine...................................................................20 2.2. Safety Instructions................................................................................................................................21 2.2.1.

Safety measures to operate the machine .....................................................................................................................................................21

2.2.1.1.

How to start the compaction work........................................................................................................................................................21

2.2.1.2.

Work safety secured by User....................................................................................................................................................................21

2.2.2.

Driver Qualification Requirements...................................................................................................................................................................22

2.2.3.

Driver’s Duties..........................................................................................................................................................................................................23

2.2.4.

Forbidden activities - safety and guarantee.................................................................................................................................................24

2.2.5.

Safety labels and signs used on the machine ..............................................................................................................................................25

2.2.6.

Hand Signals.............................................................................................................................................................................................................29

2.3. Ecological and Hygienic Principles......................................................................................................32 2.3.1.

Hygienic Principles.................................................................................................................................................................................................32

2.3.2.

Ecological Principles .............................................................................................................................................................................................32

2.4. Preservation and Storage.....................................................................................................................33 2.4.1.

Short-term preservation and storage for the period of 1 - 2 months..................................................................................................33

2.4.2.

Machine preservation and storage for the period over 2 months........................................................................................................33

2.5. Machine Disposal upon its Life Termination.......................................................................................34 2.6. Machine Description.............................................................................................................................35 2.6.1.

Chassis........................................................................................................................................................................................................................35

2.6.2.

Electrical.....................................................................................................................................................................................................................36

2.6.2.1.

Hydraulic components...............................................................................................................................................................................38

2.7. Controlling and Operation of the Machine.........................................................................................40 2.7.1.

Dashboard and Control Panel............................................................................................................................................................................40

2.7.1.1.

Instrument cluster indications (17)........................................................................................................................................................43

2.7.2.

Driver’s seat...............................................................................................................................................................................................................45

2.7.3.

Battery cut-off switch............................................................................................................................................................................................45

2.8. How to Control and Use the Machine...................................................................................................46 2.8.1.

Starting the engine ...............................................................................................................................................................................................46

2.8.1.1.

Normal Starting............................................................................................................................................................................................46

2.8.1.2.

Starting engine with jumper cables through different battery .................................................................................................47

2.8.1.3.

Starting engine at low temperature......................................................................................................................................................47

2.8.2.

Travel and reversing...............................................................................................................................................................................................48

2.8.3.

Working / Moving on slopes...............................................................................................................................................................................49

2.8.4.

Travel with vibration..............................................................................................................................................................................................50

2.8.5.

Emergency stop of the machine.......................................................................................................................................................................51

2.8.6.

Stopping the machine .........................................................................................................................................................................................52

2.8.7.

Machine Shutdown................................................................................................................................................................................................53

2.8.8.

Cab control’s and accessories (Optional)........................................................................................................................................................54

2.8.9.

Platform/Bonnet raising and lowering...........................................................................................................................................................58

2.8.10. Ballasting of tyres with liquid.............................................................................................................................................................................60

OPERATING MANUAL 2.9. Machine Transportation........................................................................................................................62 2.9.1.

Machine transportation by its own axle.........................................................................................................................................................62

2.9.2.

Machine transportation by public road..........................................................................................................................................................62

2.9.3.

Loading the machine by crane..........................................................................................................................................................................63

2.9.3.1.

2.9.4.

Loading the machine using a ramp.......................................................................................................................................................63

Towing of machine.................................................................................................................................................................................................65

2.10. Special Conditions for the Machine Application.................................................................................71 2.10.1. Vibration driving on compacted and hard surface....................................................................................................................................71 2.10.2. Machine use under extreme climatic conditions .......................................................................................................................................71 2.10.2.1. Machine operation under low temperatures ....................................................................................................................................71 2.10.2.2. Machine operation under high temperatures and humidity ......................................................................................................72 2.10.2.3. Operating the machine at high altitudes ...........................................................................................................................................72 2.10.2.4. Machine operation at extremely dusty environment ....................................................................................................................72

3.

MAINTENANCE MANUAL.....................................................................................................................53

3.1. Special Conditions for the Machine Application.................................................................................54 3.1.1.

Safety during machine maintenance..............................................................................................................................................................54

3.1.2.

Fire precautions when refilling .........................................................................................................................................................................54

3.1.3.

Ecological and hygienic principles...................................................................................................................................................................55

3.2. Specification of Fluids...........................................................................................................................56 3.2.1.

Engine oil...................................................................................................................................................................................................................56

3.2.2.

Fuel...............................................................................................................................................................................................................................57

3.2.3.

Cooling liquid...........................................................................................................................................................................................................57

3.2.4.

Hydraulic oil..............................................................................................................................................................................................................58

3.2.5.

Gearbox oil................................................................................................................................................................................................................59

3.2.6.

Lubricating grease..................................................................................................................................................................................................59

3.2.7.

Screen washer liquid.............................................................................................................................................................................................59

3.2.8.

Air-conditioning filling..........................................................................................................................................................................................59

3.2.9.

Drum cooling liquid...............................................................................................................................................................................................59

3.3. Refills......................................................................................................................................................60 3.4. Lubrication and Maintenance Table.....................................................................................................61 3.5. Lubrication and service plan................................................................................................................63 3.6. Individual Operations of Maintenance................................................................................................64 Every 20 Hours of Operation................................................................................................................65 3.6.1.

Engine oil level check and restoration............................................................................................................................................................65

3.6.2.

Coolant level check and restoration................................................................................................................................................................66

3.6.3.

Hydraulic oil level check and restoration.......................................................................................................................................................67

3.6.4.

Crankcase breather tube......................................................................................................................................................................................68

3.6.5.

Fan condition check...............................................................................................................................................................................................69

3.6.6.

Engine fan belt inspection...................................................................................................................................................................................69

3.6.7.

Engine air intake system inspection................................................................................................................................................................70

3.6.8.

Fuel level check and refilling..............................................................................................................................................................................71

3.6.9.

Drain water from water in fuel separator.......................................................................................................................................................72

3.6.10. Alarm and control devices check......................................................................................................................................................................73 3.6.11. Tyre pressure check................................................................................................................................................................................................74

Table of Content Every 150 hours of operation...............................................................................................................75 3.6.12. Oil level check in drive gearboxes....................................................................................................................................................................75

Every 250 hours of operation...............................................................................................................76 3.6.13. Replacement of fuel filters (mud strainer and water separator)............................................................................................................76 3.6.14. Engine oil and oil filter replacement................................................................................................................................................................78 3.6.15. Engine mounts and fasteners inspection......................................................................................................................................................81 3.6.16. Battery check............................................................................................................................................................................................................82 3.6.17. Air filter vacuum switch function check.........................................................................................................................................................83 3.6.18. Machine lubrication...............................................................................................................................................................................................84 3.6.19. Vibrator assembly oil level check......................................................................................................................................................................87

Every 500 hours of operation...............................................................................................................88 3.6.20. Hydraulic oil filter replacement.........................................................................................................................................................................88 3.6.21. Wiring check.............................................................................................................................................................................................................89 3.6.22. Air filter of the air conditioning system replacement................................................................................................................................89 3.6.23. Wheel bolts tightening check............................................................................................................................................................................90 3.6.24. Cab ventilation and heating filters replacement.........................................................................................................................................91

Every 1000 hours of operation.............................................................................................................92 3.6.25. Air filter element replacement...........................................................................................................................................................................92 3.6.26. Engine valve clearance adjustment.................................................................................................................................................................94 3.6.27. Engine pulley and belt tension check.............................................................................................................................................................94 3.6.28. Air conditioner compressor mounting check..............................................................................................................................................96 3.6.29. Drive gearboxes oil change.................................................................................................................................................................................96 3.6.30. Vibration damping pad condition inspection..............................................................................................................................................98 3.6.31. Fuel tank cleaning..................................................................................................................................................................................................99

Every 2000 hours of operation...........................................................................................................100 3.6.32. Vibrator casing oil change................................................................................................................................................................................ 100 3.6.33. Hydraulic oil, suction line filter cartridge and strainer replacement................................................................................................. 101 3.6.34. Coolant change.................................................................................................................................................................................................... 105 3.6.35. Air conditioning system cleaning.................................................................................................................................................................. 107

Maintenance - As Needed...................................................................................................................108 3.6.36. Coolant, oil and air cooler cleaning............................................................................................................................................................... 108 3.6.37. Bleeding air from fuel system.......................................................................................................................................................................... 109 3.6.38. Scraper adjustment............................................................................................................................................................................................. 111 3.6.39. Drum cooling mixture (Optional).................................................................................................................................................................. 112 3.6.40. Machine Cleaning................................................................................................................................................................................................ 113 3.6.41. Screwed connections check............................................................................................................................................................................ 113

3.7. Schematics...........................................................................................................................................116 3.7.1.

Electrical schematic............................................................................................................................................................................................. 116

3.7.2.

Hydraulic schematic............................................................................................................................................................................................ 117

3.8. General Information............................................................................................................................118 3.8.1.

Acronyms and Abbreviations.......................................................................................................................................................................... 118

OPERATING MANUAL

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ARS 122

SPECIFICATION MANUAL

1. SPECIFICATION MANUAL ARS 122 (Cummins BSIII)

ARS 122

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 (5 °F) to +45 °C (113 °F).

The vibratory rollers of ARS 122 line are especially suitable for use at mid and large compaction jobs of highway construction (construction of highways, railways and airports), hydraulic construction (earth dams) and civil engineering (industrial areas, ports etc.).

Modifications The single drum vibratory roller ARS 122 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 122 compactor with a pad-foot shell kit (synchronous kneading and vibrating effect) 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).

Please fill in the following data: (Refer to nameplate and rating plate for Cummins engine) Type of machine ................................................................................................................

PIN (Serial number of the machine) ................................................................................................................

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

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

Serial number of the engine ................................................................................................................

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

10

ARS 122

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)

1

2

Serial number of the Cummins engine

ARS 122

11

1.2.

Dimension Chart

Dimensional diagram for ARS 122 machine

mm (in)

A

D

D1

G

G1

H

H1

L

T

W

W1

2820

1500

-

450

415

3030

2375

5460

25

2130

2260

(111.0)

(59.1)

(-)

(17.7)

(16.3)

(119.3)

(93.5)

(215)

(1.0)

(83.9)

(89)

ARS 122 (PD

2820

1500

1640

450

415

3030

2375

5460

25

2130

2260

Shell Kit)

(111.0)

(59.1)

(64.6)

(17.7)

(16.3)

(119.3)

(93.5)

(215)

(1.0)

(83.9)

(89)

ARS 122

12

ARS 122

1.3.

Technical Data

SPECIFICATION MANUAL ARS 122 Cummins BSIII

Weight Operating weight

kg (lb.)

11200 (24692)

Operating load on front axis

kg (lb.)

6300 (13889)

Operating load on rear axis

kg (lb.)

4900 (10800)

Weight of half fluid capacities

kg (lb.)

170 (375)

Static linear load of front drum

kg/cm (lb./in)

29.6 (25.69)

Weight of canopy posts (Version without ROPS)

kg (lb.)

60 (132)

Weight of two pad-foot segments

kg (lb.)

1750 (3860)

Weight of tyre filling 0°C

kg (lb.)

1120 (2469)

Operating weight of ISO 6016 with cab, ROPS

kg (lb)

10290 (22690)

Maximum weight with the cab, ROPS, accessories, weighing

kg (lb)

11990 (26430)

Maximum permitted weight according to ROPS

kg (lb)

18500 (40790)

kg/cm (lb/in)

24,9 (139,4)

Cab weight

kg (lb)

220 (490)

Weight of ROPS

kg (lb)

230 (510)

Weight of sheet roof on ROPS

kg (lb)

140 (310)

Weight of canopy

kg (lb)

60 (130)

Weight of canopy posts (version without ROPS)

kg (lb)

60 (130)

Weight of 2 pad-foot segments

kg (lb)

1700 (3750)

-

1+1

Maximum transport speed

km/h (MPH)

10.3 (6.4)

Working speed

km/h (MPH)

5 (3.2)

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

-

2

Oscillation angle

°

±10

Angle of steering

°

±36

-

Joint

Static linear load of front drum

Driving characteristics Number of speeds

Steering Type of steering

ARS 122

13

1.3.

Technical Data ARS 122 Cummins BSIII

Steering control

-

Hydraulic

No. of steering cylinders

-

2

Manufacturer

-

Cummins

Type

-

4BTAA3.9-C

Power according to DIN 6271

kW (HP)

74 (99)

Power according to ISO 3046/1

kW (HP)

74 (99)

Number of cylinders

-

4

Cylinder capacity

cm3 (cu in)

3900 (238)

Nominal speed

min-1 (RPM)

2200

Maximum torque

Nm/rpm

410/1500

l/h (gal US/h)

11 (2.42)

Engines complies with emission regulations

-

Bharat stage-III

cooling system of engine

-

Liquid

MPa (PSI)

0.16 (23.2)

Pattern of tyres

-

R-3 Diamond Tread

Number of tyres

-

2

Number of rear wheels

-

2

Size of tyres

-

23.1x26´´

Type of tyres

-

Tubeless

Operating

-

Hydrostatic

Parking

-

Multiple-disc spring brake

Emergency

-

Multiple-disc spring brake

Frequency I

Hz (VPM)

32 (1920)

Frequency II

Hz (VPM)

35 (2100)

Amplitude I

mm (in)

1.85 (0.072)

Amplitude II

mm (in)

0.9 (0.035)

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)

10.9 (2.9)

Cooling system

l (gal US)

20 (5.28)

Hydraulic system

l (gal US)

90 (23.78)

Drum vibrator

l (gal US)

8 (2.11)

Wheel gearbox

l (gal US)

2x1.9 (2x0.5)

Engine

Routine operation fuel consumption

Axle Maximum tyre pressure

Brakes

Vibration

Fluid capacities

14

ARS 122

SPECIFICATION MANUAL ARS 122 Cummins BSIII Drum gearbox

l (gal US)

1.9 (0.5)

kg

1.2

Voltage

V

12

Battery capacity

Ah

150

Air conditioner coolant (Air conditioning unit is optional)

Wiring

Optional equipment Pad-foot drum shell kit Ammann traction optimiser Working speed increase kit (increase up to 7 km/h) Hard canopy self standing Tractor Tyres Warning beacon Fire extinguisher Tool kit Set of documentation Cabin (HVAC) ROPS Compaction measuring system ACE

ARS 122

15

Notes

16

ARS 122

SPECIFICATION MANUAL Notes

ARS 122

17

18

ARS 122

OPERATING INSTRUCTIONS

2. OPERATING INSTRUCTIONS ARS 122 (Cummins BSIII)

ARS 122

19

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, please carry out dewaxing, wash away the preserving agents using high pressure stream of hot water added with standard de greasers.

All relevant ecological principles must be adhered to.

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

20

ARS 122

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 perform 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 performs 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 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.

Prior 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 driver 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. The work procedure specifies inter alia:

•

-

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 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 122

21

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.

•

Only the one who with the approval of machine User learns to drive under a direct & constant supervision of professional lector or trainer in order to gain preliminary practice, may drive with no driving licence obtained so far.

•

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).

•

22

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

ARS 122

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 follow 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.)

NEVER 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.

•

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 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 or to cut out the wiring.

•

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

•

Prior to commencing 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 staff in charge, and if possible, alert all the persons threatened by such hazard.

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, please 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. work clothing, safety shoes. 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 platform and bonnet, please confirm there is enough space for lifting, with no electric lines present. Before dropping the platform and 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:

•

•

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 work commencements please 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 staff 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 follow 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.

•

Prior to 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 (uneasy to oversee) sites the operation start may begin only after a period necessary to exit endangered area elapses.

ARS 122

•

-

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.

23

2.2.

Safety Instructions

2.2.4. Forbidden activities - safety and guarantee

•

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 via signalling carried out by duly instructed person.

It is forbidden to: •

Vibrating on the spot. When it is vibrated on the spot, 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.

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

•

•

Using the machine when any operating fluid level is low.

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

•

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

•

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

•

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

•

Leave machine driver seat with the machine running.

•

Wilful repair of the engine – Except common changes of operating fluids and filters, only the Cummins 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.

•

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.

•

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.

•

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.

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

•

•

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

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

•

•

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.

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

•

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, overcompacted) 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 fixed.

•

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

•

Start the machine operation and use the machine with some of the safeguard equipment (emergency brake, hydraulic locks, etc.) removed or damaged.

•

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.

•

24

! CAUTION !

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

ARS 122

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

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25

2.2.

Safety Instructions

Safety labels and signs used on the machine 1

Clamp Hazard

Risk area with clamp hazard. (Symbols placed left and right on the rear cross arm of the front frame.)

2941bz

2

Burn Hazard

Danger of burn. Do NOT touch hot parts of the machine unless you made certain of their being cooled down sufficiently. (Symbols placed from inside on the left door.)

2586bz

3

Injury Hazard

Risk of injury and winding around. NEVER touch rotating parts while engine is running. (Symbol placed on the left side of the cooler.)

2409bz

4

Cooling Liquid

Scalding hazard. Do NOT open expansion tank lid until liquid cools down below 50 °C (122 °F). (Symbol placed on the expansion tank.)

2939

3227bz

5

Adjust while at rest

Risk of injury or being caught by the rotating parts of the machine. Make NO adjustments or maintenance work when the engine is running. (Symbol placed from inside on the left 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

7

26

Machine Max Height

Pay attention when passing through a location with height limit. (Symbol placed on the left side underneath the cab on the frame.)

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OPERATING INSTRUCTIONS 8

Battery Disconnector

I O

2493

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

9

Rigging Diagram

Use rigging of sufficient loading capacity when lifting the machine. Secure machine joints before slinging. (Symbol placed on LH door.)

10

Sling Positions

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

11

Disconnect Alternator

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

2668bz

12

Ear Protectors

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

13.

Electric Devices

Cover electric instruments when washing the machine (Symbol placed on the left side of the cooler.)

2225bz

14.

Platform and Cab Lifting

(Symbol placed on left side of rear frame)

3164

3164

15

Clamp Hazard

Risk area with clamp hazard.

(Symbols placed from inside on the left door.)

3753bz

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27

2.2.

Safety Instructions

16.

Injury hazard

Keep safety distance from rotating pulley and belt.

(Symbol located on both side of radiator bracket.)

17.

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.)

18.

Cooling liquid

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

19.

Machine under maintenance

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

20.

Lashing points

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

21.

Lifting points

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

28

ARS 122

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

Beware 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

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29

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

30

ARS 122

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

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31

2.3.

Ecological and Hygienic Principles During machine operation or storage the User must observe 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.

2.3.1. Hygienic 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 conform 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,

-

Accumulator refills and the accumulators themselves,

-

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 fouled with the aforementioned products.

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

We point in particular to :

-

Oils

-

Eye & skin protections while handling the accumulators

-

Batteries

-

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

-

Tyres (optional)

-

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

-

While handling the cooling systems follow instructions given in the Manuals supplied together with the machine.

•

Always store oil products or accumulator refills and painting materials including organic thinners along with cleaning & preservation agents inside their original packages labelled properly. Do NOT admit to 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 of these products, get prompt medical attention.

•

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

32

2.3.2. Ecological Principles

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 122

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

•

•

For the machine shutdown the identical principles like with short-term preservation will apply.

•

In addition we recommend the following:

•

•

Wash & clean carefully the entire machine. Before machine parking and shutdown in order to make its preservation & storage, please 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:

-

Remove the accumulators, check their condition and store in a cool, dry room (recharge the accumulators on regular basis),

-

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

-

Repair those spots with paint impaired,

-

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

-

-

Confirm water fillings have been drained,

Paint rubber elements with specific preservation agent to protect them,

-

Check cooling liquid has its antifreeze characteristics required,

-

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

-

Check the accumulator charging conditions, recharge if required,

-

Apply chrome-plated piston rods with preservation grease,

-

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

-

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

-

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

-

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

-

Protect head lamps, exterior back mirrors and other elements of external wiring via 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.

NEVER start the engine during storage!

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

Prior to restoration of the machine service, please wash the preservation agents using high pressure stream of hot water added with standard degreasers for Use along with ecological principles.

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

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33

2.5.

Machine Disposal upon its Life Termination

User will be liable to follow national waste or environmental laws and regulations 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.

34

ARS 122

2.6.

Machine Description

OPERATING INSTRUCTIONS

2.6.1. Chassis

1.

Front Frame

12.

Hydraulic Oil Cooler

2.

Drum

13.

Engine Coolant Cooler

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

22.

Canopy

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35

2.6.

Machine Description

2.6.2. Electrical Engine oil pressure sensor (1).

Location: On left side of the engine

1

Coolant temperature sensor (2) Location: Connected left side of T-joint (installed above the engine).

2

Alternator (3) Location: On left side of the engine

3

Starter motor (4) Location: On right side of the engine

4

36

ARS 122

OPERATING INSTRUCTIONS Hydraulic oil temperature sensor (5) Location: Installed on hydraulic block right side of the machine.

5

Hydraulic oil filter clogging indicator sensor (6) Location: Sensor is integrated part of hydraulic oil filter head.

Installed on right side of the machine wall below the operator platform.

6

Air filter clogging indicator sensor (7) Location: Air density sensor is mounted on air filter front, it can be accessed by lifting the bonnet.

7

Brake pressure sensor (8) Location: Installed on brake block, on right side of machine below the hydraulic oil tank.

8

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37

2.6.

Machine Description

2.6.2.1. Hydraulic components Hydraulic oil filter (1) Location: Installed on right side wall of rear frame below the operator’s platform, can be accessed by lifting the operator’s platform.

1

Fuel filter cum water separator (2) Location: Installed on right side of the engine case towards down, It can be accessed from below the machine

2

Fuel filter (3) Location: Installed on top right side of the engine case, It can be accessed by lifting the bonnet.

3

Engine oil filter (4) Location: Installed on left side of the engine case, It can be accessed by lifting the bonnet.

4

38

ARS 122

OPERATING INSTRUCTIONS Travel pump (4) Vibration pump (5) Steering pump (6)

4

5 6

Hydraulic block (7) Location: Installed right side of the machine below the hydraulic oil tank, it can be accessed by lifting the bonnet.

7

Brake block (8) Location: Installed on right side of the machine wall near to the hydraulic block, it can be accessed by lifting the bonnet.

ARS 122

8

39

2.7.

Controlling and Operation of the Machine

2.7.1. Dashboard and Control Panel

17

11

10

0

13

14 15

7 15A 8 15A

5 7.5A

6 15A

4 7.5A

1 20A

12

2 15A 3 15A

!

16 5 1

16

9

2

2A

7

8

3 6 4

1

40

-

Steering wheel

10

-

Ignition box

-

Turn indicator selector switch

2

-

Travel controller

11

2A

-

Vibration switch

12

-

Fuse block

3

-

Emergency brake pushbutton

13

-

Hazard switch

4

-

Travelling speed controller (Selector)

14

-

Rear lights switch

-

Vibration amplitude selector switch

5

-

Engine speed control lever

15

6

-

Charging socket

16

-

Spare

7

-

Horn switch

17

-

Digital cluster

8

-

Low beam selector switch

9

-

High beam selector switch

ARS 122

OPERATING INSTRUCTIONS Steering wheel (1) Used for steering a machine.

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

Travel speed controller (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) and vice versa in work mode (Tortoise).

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.

Travel controller (2) Use this controller to control direction and speed of the machine. Driving speed corresponds to the degree the controller deflects from idle (neutral) position. At the same time the controller is used as service brake of the machine. The controller is hold in set position. When shifted to it’s centre position the parking brake is enabled and indicated with parking brake indicator light turned ON in the cluster (17).

2445

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

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

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.)

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

Charging socket (6)

12 V

Mobile charging socket 12 V.

Emergency brake push button (3) 2582

Press this button to stop and brake the roller, and to shut off the engine.

Horn push button (7) When switch is pressed horn will blow and on releasing switch horn will be OFF.

! CAUTION !

Before starting the engine, turn the button (3) in arrow direction for brake off the machine Low beam selector switch (8)

Use only in case of emergency during a failure when the Roller is unable to stop through resetting the travel actuator.

It is not permitted to use the emergency brake for turning off the engine during normal operation of the machine!

ARS 122

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.

41

2.7.

Controlling and Operation of the Machine High beam selector switch (9)

On pressing switch, high beam light will set ON and on releasing switch it will set OFF.

Note!

High beam has interlock with headlamp, till headlamp is not turned ON, high beam will not be ON.

Ignition box (10) Ignition Box has three positions:

Fuse box (12) 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

Hazard switch (13)

- Position “0” (OFF) - Position “I” (ON)

Enables hazard light ON or OFF when required.

- Position “II” (START) It is used to check any error signal, to start or to stop the engine.

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.

Rear lights switch (14) It is used to turn ON/OFF rear lights.

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 press emergency break pushbutton (3).

Vibration amplitude selector switch (15) This 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).

Spare (16)

Turn indicator switch (11) Used to set ON or OFF respective turn indicator signal lamps.

42

ARS 122

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 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.

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

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 turn indicator switch.

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43

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)

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!

44

ARS 122

OPERATING INSTRUCTIONS 2.7.2. Driver’s seat Driver’s seat can be adjusted in following ways Longitudinal adjustment – Pull lever (1) little outward and move the seat in forward or backward as per requirement.

Release the lever to lock the desired seat position.

Backrest adjustment - As per requirement lift the lever (2) to set backrest position.

Seat belt (3) - Provided to safeguard driver in case of impact

2

1

All the seat adjustments must be done before starting driving!

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

3

Seat firmness adjustment – Rotate lever (4) clockwise or anticlockwise to set the weight of operator

4 2.7.3. Battery cut-off switch Use cut-off switch (5) to connect or disconnect battery from the system.

5

Use cut-off switch (5) to disconnect the Battery at the end of work shift!

Disconnect battery when long stops are foreseen!

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45

2.8.

How to Control and Use the Machine

2.8.1. Starting the engine

Do NOT hold key (10) 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!

2.8.1.1. Normal Starting •

Set the battery cut-off switch to “ON” position.

•

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 (10) 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 (33) and battery charging (19) lamps.

•

Further turn the key (10) to “II” position to start the engine (hold the key (10) in position ”ll” only until the engine starts).

•

Once the engine started, release key (10) immediately, key (10) 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 750-950 min-1 for a period of 3-5 minutes.

•

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

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.

Before start the engine make audio signal by horn for warning purposes. Confirm nobody is endangered due to the engine started!

19

33

10

10

5 7.5A

0

23

I

7 15A 8 15A

4 7.5A

6 15A

1 20A

2 15A

3 15A

!

II

2

5

F N R

46

ARS 122

OPERATING INSTRUCTIONS 2.8.1.2. Starting engine with jumper cables through different battery

2.8.1.3. Starting engine at low temperature •

Starting at ambient temperature below 0°C (32°F) will require different way of starting with the use of starter filling:

1. Connect one (+) pole (1) of jumper cable to (+) pole of discharged battery and second (+) pole (2) to (+) pole of external battery.

•

Adjust the throttle to half-speed, and when starting the engine a second person will inject measured quantity of starter filling into the air filter.

2. Connect one (-) pole (3) of jumper cable to (-) pole of pole of external battery and second (-) pole (4) 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 booststarting 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 122

47

2.8.

How to Control and Use the Machine

2.8.2. Travel and reversing 33

20

0

7 15A 8 15A

5 7.5A

6 15A

4 7.5A

1 20A

2 15A 3 15A

!

2

2A

5 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 1800 min-1.

•

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 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.

48

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 122

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!

OK

OK

C

ARS 122

49

2.8.

How to Control and Use the Machine

2.8.4. Travel with vibration 32

20

0

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

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) will light depending on amplitude selected and drum begins vibrating.

•

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

It is not permitted to vibrate when machine is standstill!

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

50

ARS 122

OPERATING INSTRUCTIONS 2.8.5. Emergency stop of the machine

10

0

5 7.5A

6 15A

7 15A 8 15A

4 7.5A

1 20A

2 15A

3 15A

!

2

5

F N R 3

•

Press emergency brake push button (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 (10) to “0“ position and then proceed to starting.

Apply emergency stop in the event when machine is un­able to stop through shifting the travel control lever to neutral or in case of uncon­trolled behaviour of the machine.

ARS 122

51

2.8.

How to Control and Use the Machine

2.8.6. Stopping the machine 33

20

10

32

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 3

•

Press switch (2A) and the vibration will turn OFF, 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 (10) to “0“ position - Engine will shut off, take out key – close the ignition box cap.

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

52

ARS 122

OPERATING INSTRUCTIONS 2.8.7. Machine Shutdown •

Stop the machine.

•

Cut off battery disconnector.

•

Clean the machine (scraper, tyres).

•

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

•

Confirm tyres have sufficient pressure.

•

Put Scotch blocks to the wheels and uncoupled-axle.

•

Lock the instrument covers or and the door beneath driver control stand.

ARS 122

Stop 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.

53

2.8.

How to Control and Use the Machine

2.8.8. Cab control’s and accessories (Optional)

36

A

35

A

34

54

31

-

Screen washer ON-OFF switch

32

-

Fan switch

33

-

Rear wiper switch

34

-

Front wiper switch

35

-

Cab light

36

-

Air vents

33

32

31

ARS 122

OPERATING INSTRUCTIONS

40 44 42

41 43

37

39

38

38

37

-

Heater valve

38

-

Heater vents

39

-

Screen washer tank

40

-

Cab ventilation filter

41

-

Front wiper

42

-

Rear wiper

43

-

Seat

44

-

Headlights

! ATTENTION !

Do not try to operate the heater valve (37) while driving.

ARS 122

55

2.8.

How to Control and Use the Machine

Screen Washer Tank (39) Two pumps integrated inside the tank are used to wash the windscreen and rear screen.

Driver Seat (43) Seat adjustment elements: Backrest angle adjustment – lift the lever to setting up of the backrest.

43

Seat firmness adjustment (2) –push the lever to the driver’s weight between 50 - 130 kg.

Longitudinal Move of the Seat (1) – lift the lever and move the seat in longitudinal direction forward – backward.

2

1 45 - Air-conditioning switch (OPTION) 46 - Air conditioning blower speed selector (OPTION) 47 - Air recirculation switch

46 45

47 56

ARS 122

OPERATING INSTRUCTIONS Locker (3) Designed for first-aid kit etc.

3

ARS 122

57

2.8.

How to Control and Use the Machine

2.8.9. Platform/Bonnet raising and lowering

1

Lifting and lowering platform must be done only while the platform is empty.

Danger of injury!

1 •

Remove the nuts (1) and release platform.

•

Open the battery cut toff door on the left side under the platform. Take out the pumping lever (2).

2

Lifting: •

Close the valve (3), insert the pumping lever (2) into the pump and simultaneously lift the platform and bonnet by pumping.

3

•

Lock the platform in position using the platform valve (4).

4

58

ARS 122

OPERATING INSTRUCTIONS •

Lock the lifted bonnet using the bonnet valve (5).

5 When working on the platform and bonnet lifting hydraulic circuit, the platform and bonnet must be secured by valves (2), (3), (4). By releasing the valves when the platform and bonnet lifting hydraulic circuit is open, the platform or bonnet may fall. Danger of injury!

Lowering: •

Unlock the platform using the platform valve (3).

4

•

Unlock the bonnet using the valve bonnet (4).

5

•

Lower the platform and bonnet by opening the valve (2).

After lowering, tighten the platform using nuts.

ARS 122

3

59

2.8.

How to Control and Use the Machine

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

Ballasting of tyres with liquid of up to 0 °F Water

Anti Corit 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 The inner space of the tyre is filled with the solution of water and 34% calcium chloride CaCl2.

Water

Anti Corit 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 in the extreme upper position. Secure the drum with blocks on both sides.

•

Unscrew the removable valve insert and screw on the filler neck.

396344 •

A filler neck can be ordered as a replacement part. Refer Spare parts manual for filler neck part number.

4-322839 60

ARS 122

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.

396346 •

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.

The solution can spurt out after unscrewing the valve insert.

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 122

61

2.9.

Machine Transportation

2.9.1. Machine transportation by its own axle •

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 public road 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.

62

Fixing the machine on the carrier.

C

1

2

2 2

1

2

ARS 122

OPERATING INSTRUCTIONS 2.9.3. Loading the machine by crane •

Use loading platform or crane loading 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.

2.9.3.1. Loading the machine using a ramp •

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

•

Maximum permissible incline of the ramp is 30%.

C

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 122

63

2.9.

Machine Transportation

How to lock the joint: •

Unlock and pull out the journal (1).

•

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

1

3

Do NOT enter underneath hanging load!

2

1

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

Follow 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.

64

ARS 122

OPERATING INSTRUCTIONS 2.9.4. Towing of machine •

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

•

A struck machine can be towed for a short distance 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.

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

When towing, please use undamaged towing cable or pull rod of sufficient loading capacity 1.5 higher than the weight of hauled machine. It is forbidden to use a chain for hauling.

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

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

Smooth and constant movement must be maintained in towing. The towing speed must not exceed 1 km/hour (0.62 mph).

The machine should only be towed for the shortest possible distance – to extricate the machine if it gets stuck or is blocking traffic in case of breakdown. Do not tow the machine for a longer distance than 300 m (0.19 mi).

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

When hauling downhill with the help of cable it will be necessary to attach next hauling machine to the rear part of the machine broken. In this way it will be possible to avoid uncontrolled motion of the machine damaged. if the engine does not work, or there is a defect in the hydraulic system, you must release the brake of the machine and short-circuit the hydraulic circuit of the travel. Then the machine can be towed)

3753bz

ARS 122

2

1

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!

The platform and the bonnet must be lowered before the brake is released.

Do not touch hot parts of the machine, burn hazard!

65

2.9.

Machine Transportation

Short-circuiting the travel pump: •

Switch off the engine. Use the disconnector (6) to disconnect the batteries.

6

•

Slacken the locking nuts (2) on the Travel pump by turning them anticlockwise by a half-turn.

•

Screw the screws (1) clockwise towards the springs. If an increased resistance is felt, screw the screw in the spring by a half-turn.

•

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

1

1 2

2

280165

2

1 280166 How to brake off:

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

•

Put a vessel under the machine to collect the leaking fluids.

Avoid leakage of oil to the soil.

66

ARS 122

OPERATING INSTRUCTIONS •

Disconnect the hose (1) from Brake Block Connector (2).

2

1

•

Install one end of hose (3) provided in toolkit on Brake Block Connector (2).

2

3

•

Put a vessel under the machine to collect the leaking fluids.

Avoid leakage of oil to the soil.

•

Disconnect the hose (4) from T- connector (5).

4

ARS 122

5

67

Machine Transportation

Close the flow control valve (9).

•

Turn ON the battery disconnector (6).

•

Switch the ignition key (10) to the “I” position.

•

Operate the lever in the manual pump (7).

•

Monitor the parking brake indicator (33) until it is off with the key switched on. The cylinder is with released brakes and machine towing is possible.

•

If wiring is not operational, operate the lever in the manual pump using at least 30 full strokes (one stroke = to and fro movement of the lever).

Due to leakages, the pressure in the brake can drop during the towing.

Check the drum or tyres in the towed machine for the occurrence of braking or skidding. In such a case, interrupt towing and re-operate the lever in the manual Pump.

When towing is completed, please secure the wheels and drum with scotch blocks (cotters) and put into initial state.

3

5

9

7

6

33 10

!

0

I

II

7 15A 8 15A

•

5 7.5A

Take away the vessel collecting the leaking fluid underneath the machine.

6 15A

•

4 7.5A

Install the another end of hose (3) provided in toolkit on T- connector (5)

1 20A

•

2 15A 3 15A

2.9.

How to put into initial state: •

Open the flow control valve (9).

•

Remove the key out of the ignition box. Disconnect the battery with the disconnector (6).

•

Insert the manual pump lever in the holder under the driver‘s stand.

9

68

6

ARS 122

OPERATING INSTRUCTIONS •

Put a vessel under the machine to collect the leaking fluids.

Avoid leakage of oil to the soil.

•

Slacken the locking nuts (2) on the travel pump.

•

Slacken the screws (1) by turning them anticlockwise endto-end.

•

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

1

1 2

2

280165 •

Disconnect the hose (3) From T- connector (5)

5

4

•

Install the hose (4) on T- connector (5)

•

Take away the vessel collecting the leaking fluid underneath the machine.

ARS 122

4

5

69

2.9.

•

Machine Transportation

Put a vessel under the machine to collect the leaking fluids.

Avoid leakage of oil to the soil.

•

Disconnect the hose (3) From Brake block connector (2)

2

3

•

Install the hose (1) on Brake Block connector (2)

•

Take away the vessel collecting the leaking fluid underneath the machine.

2

1

•

70

Check the hydraulic oil level in the reservoir. If necessary, replenish oil according to chapter 3.6.3

ARS 122

2.10. Special Conditions for the Machine Application 2.10.1. Vibration driving on compacted and hard surface

2.10.2. Machine use under extreme climatic conditions

During vibration driving a loss of contact between the runner and the compacted material (so called vibro-stroke) may occur due to the impact of high level of sub grade material compaction, or due to vibration driving on hard materials (e.g. stony loose material). This state will show through the increased vibration energy transfer to the machine frame and Driver control stand. Increase travel velocity or change machine vibration parameters (applying lower amplitude) to partially remove this effect. Higher vibration energy transfer to the Driver control stand may also be expected when increasing the level of sub grade material compaction.

2.10.2.1. Machine operation under low temperatures

Note When vibration driving on a different sub grade material than stated in ”Specifications Manual”- Hygienic Data, then the emission figures of vibration acceleration will be different.

In case it is urgent to operate the machine under the conditions with the potential of Operator exposed to higher vibrations, then the machine User is liable to adapt the operating procedures so as to avoid driver’s health hazard.

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 perform fast compaction of non-frozen materials (ahead of earth becoming frozen through).

Make the machine ready for operation under 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 runner gearbox with the one recommended for a given range of gearbox temperatures.

•

Use winter fuel.

•

Confirm the battery are charged.

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

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

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

NEVER 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, please exchange oil in the hydraulic system with HV 46 viscosity class oil.

And with HV 32 class oil (e.g. BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.) at ambient temperatures below –13°C (9°F).

NEVER start the machine below –23°C (–9°F) with no preheating of fillings mode.

ARS 122

71

2.10. Special Conditions for the Machine Application 2.10.2.2. Machine operation under high temperatures and humidity

2.10.2.3. Operating the machine at high altitudes

Engine power will lower with air temperature or humidity increasing. Since both of the factors that lower engine performance are independent on each other, their effects can be described as follows:

Engine power will decrease with the altitude rising. This is given by the reduced atmospheric pressure and induction air specific mass.

-

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

-

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

Any engine (cooling liquid) operating temperature over 100°C (212°F) may damage the engine.

At high temperatures when hydraulic oil temp is constantly round 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 operating under extreme temperatures when cooling liquid or hydraulic oil temperatures reach max. Limit temperatures, you may remove fender aprons of the bonnet to increase cooling capacity of the machine cooling system, and hence improve hot air removal from the engine bay.

72

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

! CAUTION !

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

2.10.2.4. Machine operation at extremely dusty environment

Cut short the intervals of cleaning and replacement of air filter elements when operating under extremely dusty conditions; shorten the intervals of cleaning the engine cooler, hydraulics, or of replacing Cabin dust filter.

ARS 122

OPERATING INSTRUCTIONS Notes

ARS 122

73

74

ARS 122

MAINTENANCE MANUAL

3. MAINTENANCE MANUAL ARS 122 (Cummins BSlll)

ARS 122

75

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 at the machine split into the following Danger Numbers:

•

By trained specialists

Danger Number II – Diesel Oil

•

In line with safety instructions given in the Vibrating Roller 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

Place the oil exchange point where it does not interfere with explosion / fire hazard areas.

•

Label with tables and No smoking and No open fire signs.

•

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

•

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

•

With the wiring disconnected and the ignition key removed

•

Fit it with portable fire extinguishers.

•

On the cooled down parts of the machine

•

•

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

Use containers like metal barrels, jerri cans, tin cans to handle the oils, diesel oil.

•

•

Using proper undamaged tools

Confirm the shipping containers are properly closed during storage.

•

Replacing with new original parts per the Spare Parts Catalogue

•

•

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 purring out or dripping.

•

•

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

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

•

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

•

Following the heating of operation fillings (danger of burns).

Use recommended refills only.

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

76

ARS 122

MAINTENANCE MANUAL 3.1.3. Ecological and hygienic principles

Ecological principles

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

Once disposed of (dismantled, refilled) the fillings of the machine’s individual systems and some of its parts become waste with hazardous properties in terms of the environment.

Hygienic principles •

•

Oil products Battery refilling, painting materials (coating compositions) including thinners are materials causing health hazards. Workers that come into contact with these products during machine operation or maintenance must observe general principles of health self-protection and obey safety and hygienic instructions of these products’ manufacturers.

Please note the following in particular: -

Protect your eyes and 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

-

Observe machine operating instructions when handling its cooling systems.

•

ALWAYS store oil products, refilling of cooling systems and Battery plus paints including Organic thinners and also the cleaning and preserving agents in their genuine original properly identified packages. Do not store these materials in unlabelled bottles or other vessels due to exchange hazard.

Especially hazardous is the potential 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 122

This waste product category includes the following: -

Organic or synthetic lubricants, oils and fuels

-

Brake fluids

-

Cooling liquids

-

Battery charges and battery themselves.

-

Cleaning and preserving agents

-

All the dismantled filters and filter elements

-

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

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.

77

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

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. 125 hours or 3 months.

Use engine oil of SG or SH classification due to lubricating the valve tappets.

5W - 30

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

10W - 30

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

15W - 40

Note:

282N224T

78

ARS 122

MAINTENANCE MANUAL 3.2.2. Fuel

3.2.3. Cooling liquid

Use some of the following Diesel fuels to run the engine.

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 antifreeze agents as well to refill the cooling system.

2152

-

CEN EN 590

-

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

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 122

Use treated, demineralized or distilled water to prepare the cooling liquid.

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 anti-corrosion characteristics.

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

79

3.2.

Specification of Fluids

3.2.4. Hydraulic oil

Synthetic hydraulic oil 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).

Normally 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.

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

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

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.

80

ARS 122

MAINTENANCE MANUAL 3.2.5. Gearbox oil

3.2.6. Lubricating grease 2186

Use quality oil corresponding to API GL-5 to lubricate the uncoupled axle gearbox and axle drive gearboxes.

SAE 85W/140 viscosity for ambient temperature of +20°C to +45°C (68°F - 113°F).

0787

Use grease plastic type that contains lithium to lubricate the machine under: -

ISO 6743/9 CCEB 2

-

DIN 51502 KP2K-30

-

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

Operating temperature of oil must NOT exceed 85°C - 90°C (185°F - 194°F).

3.2.7. Screen washer liquid Use water (down to 0 °C) and an agent designed for motor vehicle screen washers (may be mineral water, as is free from salts) to refill washer system tank.

2260

Replace water with antifreeze at temperatures below 0 °C or (32 °F).

3.2.8. Air-conditioning filling Mixture: 1.2 kg of coolant Halocarbon 134a

2441

0.2 L of oil PAG 150 0.005 L of contrast medium

3.2.9. Drum cooling liquid Mixture:

2152

331 L of water 7 L Rust inhibitor

ARS 122

81

3.3.

Refills Section

Engine

Refill Type

Engine oil per Section 3.2.1

Refill Amount L (gal US)

Brand

10.9 (2.9) 2412

Fuel Tank

Diesel oil per Section 3.2.2

410 (108.3)

Hydraulic System

Hydraulic oil per Section 3.2.4

90 (23.8) 2158

Wheel Gearboxes

Gearbox oil per Section 3.2.5

2x1.9 (2x0.24) 2186

Drum Gearbox

Gearbox oil per Section 3.2.5

1.9 (0.24) 2186

Joint bearing and steering cylinders

Plastic lubricant, refer to Section 3.2.6

as required 0787

Engine Cooling System

Permanent anti-freeze liquid per Section 3.2.3

20 (5.3) 2152

Drum vibrator housing

Same as engine oil, per Section 3.2.1

8 (2.1) 2412

Screen Washer

Water and anti freezing agent. The ratio as per outdoor temperature

as required 2260

Mixture: Air-conditioning

1.2 kg of coolant Halocarbon 134a 0.2 L of oil PAG 150

2441

0.005 L of contrast medium Mixture: Drum cooling liquid

331 L of water 7 L Rust inhibitor

82

2152

ARS 122

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

Crank case breather tube

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

3.6.11

Tyre pressure check

First 150 hours of operation 3.6.23

Wheel bolts tightening check

3.6.29

Oil change in drive gearboxes

Every 150 hours of operation 3.6.12

Oil level check in drive gearboxes

Every 250 hours of operation 3.6.13

Replacement of fuel filters (mud strainer and water separator)

3.6.14

Engine oil and oil filter replacement

3.6.15

Engine mounts and fasteners inspection

3.6.16

Battery check

3.6.17

Air filter vacuum switch function check

3.6.18

Machine lubrication

3.6.19

Vibrator assembly oil level check

First 500 hours of operation 3.6.32

ARS 122

Vibrator casing oil change

83

3.4

Lubrication and Maintenance Table

Every 500 hours of operation 3.6.20

Hydraulic oil filter replacement

3.6.21

Wiring check

3.6.22

Air conditioning system air filter replacement

3.6.23

Wheel bolts tightening check

3.6.24

Cab ventilation and heating filters replacement

Every 1000 hours of operation 3.6.25

Air filter elements replacement

3.6.26

Engine valve clearance adjustment

3.6.27

Engine pulley and belt tension check

3.6.28

Air conditioning compressor mounting check

3.6.29

Drive gearboxes oil change

3.6.30

Vibration damping pad condition inspection

3.6.31

Fuel tank cleaning

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

Engine coolant change

3.6.35

Air conditioning system cleaning

Maintenance - As Needed

84

3.6.36

Coolant, oil and air cooler cleaning

3.6.37

Bleeding air from fuel system

3.6.38

Scraper adjustment

3.6.39

Drum cooling mixture (Optional)

3.6.40

Machine cleaning

3.6.41

Screwed connections check

ARS 122

3.5.

Lubrication and service plan

MAINTENANCE MANUAL

LUBRICATION AND SERVICE PLAN 2000 h 1000 h 500 h 250 h 150 h

Engine Filters

Strainer

20 h

Hyd. Filter

LEGEND CHECK LUBRICATE EXCHANGE

Engine oil

Grease

Hydraulic fluid

Gear oil

First after 500 hrs. in vibrator

First after 150 hrs.

1457174

ARS 122

85

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 of operation counter (1).

!

1

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, threaded connections of hydraulics etc. should be tightened with torque according to tables in Section 3.6.41. unless a different value is listed for the particular operation.

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

86

ARS 122

MAINTENANCE MANUAL Every 20 Hours of Operation 3.6.1. Engine oil level check and restoration •

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

•

Pull out the oil dipstick (2), wipe it off and insert it back down to the stop and pull out again to read the oil level.

2

•

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

•

Refill oil through oil filler following a removal of oil filler plug (3). Wait for 1 minute until the level gets stable and then check again.

•

Always add with oil of identical type. Use specified engine oil as per Section 3.2.1.

•

Inspect filler cap (3) for leakage and tightness, repair if necesary.

•

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 122

3

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.

87

3.6.

Individual Operations of Maintenance

3.6.2. Coolant level check and restoration •

Open the bonnet and access the radiator (refer to Section 2.8.9).

•

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).

1

2

Remove the filler plug only after the engine coolant temperature falls below 5°C (120°F). Any attempt to remove filler plug at high temperature may cause operator to be scalded with steam or cooling liquid due to inner overpressure.

OK

OK

282N205T

The level may not drop below the level gauge eyesight.

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

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

Do NOT refill hot engine with cold liquid.

The casts of the engine may get damaged.

When some higher leak occurs, check the cooling system and repair its 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.

88

ARS 122

MAINTENANCE MANUAL 3.6.3. Hydraulic oil level check and restoration •

Open the bonnet and access the radiator (refer to Section 2.8.9).

•

Check the all level through sight glass (3) when engine cooled down to atmospheric temperature.

•

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

3

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 (4).

4

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 (5) in the space under the platform.

ARS 122

5

89

3.6.

Individual Operations of Maintenance

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

CAUTION! Fill the hydraulic circuit through the filler neck only in emergency! When this filling method is used, it is necessary to reduce the next change interval to half, i.e. 1000 hours or 1 year.

•

Fill the hydraulic tank with the specified hydraulic oil through filler neck (1) up to the bottom of the strainer in the filler neck.

1 280196

3.6.4. Crankcase breather tube •

Inspect the crankcase breather hose (2) to make sure it is not clogged with deposits, chips, or in winter season frozen with ice.

2

90

ARS 122

MAINTENANCE MANUAL 3.6.5. Fan condition check •

Visually check the fan (3). If damaged (e.g. missing parts of materials, cracks, shape changes etc.), Replace the fan.

3

3.6.6. Engine fan belt inspection •

4

Visually check the belt (4) for intersecting cracks or any damage.

28054 •

Any cracks perpendicular to the belt width are permitted.

When longitudinal cracks occur 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 122

91

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, if required.

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.

92

ARS 122

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 (4) 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.

4

!

•

Check and clean filler cap and stainer of fuel tank before start the refuelling.

•

Refuel the tank with the specified fuel through filler neck (5) up to the bottom of the strainer in the filler neck (6).

5

6

280121

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 Section 3.2.2.

Do not add fuel with the engine running.

Do not carry out filling process in closed areas.

Avoid fuel spillage on 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 122

93

3.6.

Individual Operations of Maintenance

3.6.9. Drain water from water in fuel separator •

Shut off the engine and place a container under the fuel water separator (1) for drain water and sediment.

•

Use your hand and turn the drain valve (2) counterclockwise approximately 4 turns until the valve drops down 25 mm (1”) and draining occurs.

1

2 •

Let the sediment flow out, till the pure fuel starts flowing out. Lift the valve and turn clockwise to install back to its position.

278N109T

Observe fire precautions!

NO smoking while at work!

Do NOT drain the separator with the engine running.

Drain water and sediment daily!

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

If you drained more than 6 cl (2ozs) of fuel, then add up the fuel in fuel filter as per Section 3.6.13. or bleed per Section 3.6.37. In this way you will avoid problems of difficult engine starting.

Collect the fuel with sediment drained in a proper container.

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

Obey local environmental laws while disposing drained fuel.

94

ARS 122

MAINTENANCE MANUAL 3.6.10. Alarm and control devices check Connect the battery with battery disconnector (6) and turn the ignition key (10) to ON (“I”) position; •

All lamps will illuminate for around 3 sec.

•

Lamps (19), (23) & (33) will remain lit up after 3 seconds.

•

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 travel controller (2) moved from neutral position.

•

Start the engine, press emergency brake push button (3) engine stalling must occur, pilot lamps go ON.

6

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

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

11

19

33

10 I

0

7 15A 8 15A

5 7.5A

6 15A

4 7.5A

1 20A

14

2 15A 3 15A

!

13

II

23

9

15 5

2

7

8 2A

3

ARS 122

95

3.6.

Individual Operations of Maintenance

3.6.11. Tyre pressure check •

Check pressure at cold tyre using a pressure gauge.

•

Maintain 160 kPa (23.2 PSI) pressure in your tires.

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

96

ARS 122

MAINTENANCE MANUAL Every 150 hours of operation 3.6.12. Oil level check in drive gearboxes

1

Rear Gearbox •

Stop the machine in such a way the plugs (1) & (2) of gearboxes of both of the wheels are in position as per fig.

•

Wipe the spot round the check plug (2), unscrew the plug and check the oil level. The level must be as high as the inspection hole or flow out slightly.

•

Refill with oil through filler plug (1), if required.

•

Wipe and install back plugs (1) & (2).

2

28075B Front Gearbox •

Clean the spot round the inspection plug (1). Unscrew the plug and check the oil level. The level must reach up to the hole or flow out slightly.

•

Refill with oil through filler plug (2), if required.

•

Wipe and install back plugs (1) & (2).

•

Confirm the tightness of gearboxes.

2

1 28040

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

NOTE! Plugs are located on the static section of the gearbox – they do not turn while driving.

ARS 122

97

3.6.

Individual Operations of Maintenance Every 250 hours of operation

3.6.13. Replacement of fuel filters (mud strainer and water separator) •

Clean the head of the fuel filter (1).

•

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

•

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

1

282N129T •

Fill up the new filter with clean fuel.

282N160T •

Apply oil over the sealing ring of new filter.

282N131T 98

ARS 122

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 122

99

3.6.

Individual Operations of Maintenance

3.6.14. Engine oil and oil filter replacement Replacing Engine Oil •

Set OFF the engine and remove ignition key.

•

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

•

Place a container of capacity about 15 L below the 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 Replacing Engine Oil Filter •

Loosen the oil filter (2) using filter wrench and remove with hands.

2

•

Clean the filter head surface on which filter cartridge rests.

282N129T •

Take a new filter and fill it with clean engine oil.

396248 100

ARS 122

MAINTENANCE MANUAL •

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).

•

Fill the engine with clean lubricating engine oil through filler neck (1) up to the dipstick upper hole. Total capacity of sump is 10.9 L (2.9 gal US).

3

•

After the oil replaced start the engine for 2 - 3 minutes.

Check the tightness of drain plug and filter.

Lower Hole

•

Stop the engine and wait 3 minutes until oil descents into the crankcase sump. Then check the oil level using dipstick, if found below lower hole add more oil.

•

Install dipstick back to its position.

ARS 122

Upper Hole

101

3.6.

Individual Operations of Maintenance Drain oil when it is hot, following the operation end, or heat the running engine until the cooling liquid temperature reaches 60°C (140°F). Must know the possible scalding when draining hot oil.

Obey fire precautions!

! CAUTION !

Replace engine oil every 3 months or 250 hours of operation whichever comes first.

Use recommended filters only. Refer to Specification Manual or Spare Parts Catalogue of machine.

Use recommended oil only. Refer to Section 3.2.1.

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

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.

NOTE! For further details on engine maintenance refer “Operating Manual” for diesel engine supplied with machine.

102

ARS 122

MAINTENANCE MANUAL 3.6.15. Engine mounts and fasteners inspection •

Confirm the condition of metal rubbers (cracks, fissures), coherence of metal with rubber, tightness of bolts and nuts.

Engine mount front rubbers

280770 Engine mount rear rubbers

ARS 122

103

3.6.

Individual Operations of Maintenance

3.6.16. 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.

104

1

1

Do not turn the accumulators upside down; the electrolyte may pour down from the degassing plugs.

When there is electrolyte spillage, rinse the affected place with water, and neutralize with lime.

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 122

MAINTENANCE MANUAL 3.6.17. Air filter vacuum switch function check •

Remove the engine air intake cover, or the pre-filter (2).

•

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

•

Cover air suction hole (3) on the engine bonnet with impermeable material for a short while.

•

2

3

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

!

27 •

Check the following in case air filter clogging 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.

1

ARS 122

105

3.6.

Individual Operations of Maintenance

3.6.18. 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.

•

Reinstall the greasing nipple caps again.

3

1

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

2

280768

Linear Hydraulic Cylinder for Steering King pins (4) 2 x

280765 Rear pins (5) 2 x

280766 Linear Hydraulic Cylinder for Tilting the Bonnet Upper pivots (6) 2 x

280767 106

ARS 122

MAINTENANCE MANUAL Lower pivots (7) 2 x

280380 Linear hydraulic motor for tilting operator platform Lower pin (8)

280630 Bonnet hinges Pins (9) 2×

9

9

Platform front pivots (10) Pivots 2 x

Use only recommended lube greases.

Refer to Section 3.2.6.

280168 ARS 122

107

3.6.

Individual Operations of Maintenance

Cabin door hinges Pins (11)

Note: It applies only to the machine with cabin.

280778

108

ARS 122

MAINTENANCE MANUAL 3.6.19. 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 inspection/level plug (1).

•

Unscrew the inspection/level plug (1) and check the oil level. The level must reach to the inspection hole (1) or flow out slightly. If oil level is correct, install the inspection/level plug (1) back to its position.

•

If oil dose not start oozing out from the inspection hole (1), proceed with oil addition.

Oil addition: •

With plug (1) open, unscrew and open plug (2) and start adding the specified oil through the filler hole till oil starts flowing out from the inspection hole.

•

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

1 261082 261060

Check the oil level only when oil at atmospheric temperature.

Refill with identical type of oil as per Section 3.2.1.

Avoid oil spillage on ground, it is environmentally hazardous!

ARS 122

109

3.6.

Individual Operations of Maintenance Every 500 hours of operation

3.6.20. Hydraulic oil filter replacement •

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 (4) with filter wrench, then remove by hands.

•

Take new filter cartridge and fill it with hydraulic oil as recommended in Section 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.

4

!

28

Check the oil level only when oil at atmospheric temperature.

Refill with identical type of oil as per Section 3.2.1.

110

ARS 122

MAINTENANCE MANUAL 3.6.21. Wiring check •

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

•

Replace damaged parts. Use only original spare parts.

3.6.22. Air filter of the air conditioning system replacement •

Disassemble cover grating (1).

•

Remove the filter and replace with new one.

1 277101

NOTE! It applies only for machines with cab.

ARS 122

111

3.6.

Individual Operations of Maintenance

3.6.23. Wheel bolts tightening check •

Confirm the wheel mounting bolts (2) are tightened.

•

Use torque wrench and tighten the nuts with torque 285 Nm (210 lb. ft.).

2

CAUTION! Check the wheel screws for tightening after the first 150 hrs. of machine operation.

112

ARS 122

MAINTENANCE MANUAL 3.6.24. Cab ventilation and heating filters replacement Cab: •

Dismantle cover grating (2).

2 268138 •

Remove air filter (3) and replace with new one.

3

268139 Heating: •

Remove grate (4) from either side

•

Remove old filters and replace with new one.

4

277035A

NOTE! It applies only for machines with cab.

ARS 122

113

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 Section 2.8.9).

•

Unlock and remove the lid (1).

!

27

1

•

Pull out primary filter element (2).

2

•

Pull out secondary filter element (3).

3

114

ARS 122

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

5

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.

NOTE! Remove and clean dust valve (5), if necessary.

ARS 122

115

3.6.

Individual Operations of Maintenance

3.6.26. Engine valve clearance adjustment •

Call Cummins service department to adjust the engine valves – for contact information refer to “Engine Operation and Maintenance Manual”.

3.6.27. Engine pulley and belt tension check •

With the engine running inspect visually any vibrations of the fan pulley.

•

Stop the engine!

•

Confirm the stop of tensioner arm dose NOT contact bump stop of the bush. Replace the belt if it makes a contact. When the arm stops continue to contact bump stop of the bush, replace the tensioner. Confirm the cap screw is tightened with torque 43 Nm (32 lb. ft.).

28054A •

Lift the belt tightening pulley using a lever with a square end of 12 mm and remove the belt.

28055 116

ARS 122

MAINTENANCE MANUAL •

Carry out visual inspection of the belt, track any damage made cracks across the belt width are not considered damage. When longitudinal cracks occur on the belt, or the belt has its edges frayed, or parts of the material are ripped out, then the belt must be replaced.

OK OK

282N116T •

With the belt removed, check to confirm the stop of the tensioner arm comes into contact with the bump stop of the bush. Unless so, replace the tensioner.

28056 •

Check the pulley (arm) does not deflects from the vertical axis. Maximal deflection allowed is 3 mm (0.12 inch). Inspect the tensioner pulley along with the arm to make sure there are no fissures over there.

•

Check axial clearance of fan pulley. This clearance may not exceed 0.15 mm (0.006 in.).

28057 •

Reinstall the belt back.

28058 ARS 122

117

3.6.

Individual Operations of Maintenance

3.6.28. Air conditioner compressor mounting check.

•

Check the strength of the compressor attachment and the compressor bracket. Make sure that the belt does not spin. If necessary, tighten the screws.

•

Make visual check of the belt, monitor any of its damage.

280103

3.6.29. Drive gearboxes oil change Rear gearbox •

Stop the machine in such a way the plugs (1) & (2) of gearboxes of both the wheels are in position as per figure (A).

•

Place an appropriate container below the plugs and dismount both the plugs and let oil drain out.

A

1

2 •

After draining complete oil, drive the machine forward so that the plugs are in position as per figure (B). Now open the plug (2) and fill 1.9 L with specified oil.

•

Check the level in hole (2) (the oil flows out slightly). Install the plugs (1) & (2) back.

B

1

2

118

ARS 122

MAINTENANCE MANUAL Front Gearbox •

Wipe the spots round the plugs. Place an appropriate container below the drain plug (3), unscrew it and let the oil drain out.

3

•

Unscrew the plug (1) also and let oil drain out of it also.

•

After draining complete oil, reinstall plug (3) back. Use filler plugs (1) & (2) to refill the specified oil 1.9 L. Check the level in holes (1) & (2) (the oil flows out slightly from hole (1). Install the plugs (1) & (2) back, replace plug gasket if damaged.

2

1

Do not touch gearbox or its adjacent sections when these are hot.

Obey fire precautions!

Change oil after driving for first 150 engine hours.

Change oil while oil is hot

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

Obey local environmental laws while disposing drained fuel.

ARS 122

119

3.6.

Individual Operations of Maintenance

3.6.30. 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

•

Confirm the damper fasteners are tightened properly.

1 1

Dampers (1) of the drum, LH side.

Dampers (2) 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

120

ARS 122

MAINTENANCE MANUAL 3.6.31. 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 (1) 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 (2)

•

With battery disconnected, first disconnect the negative (-) terminal and then positive (+) terminal of the battery (2).

•

Loosen the clamp nuts (3).

•

Remove the battery (2) and place it a side.

•

Loosen and remove the all nuts (5) of tank cap (4).

•

Remove the tank cap (4). Inspect and clean the tank’s inner area.

•

Insert the new sealing tape between the tank cap (4) and the tank.

•

Install the tank cap (4), battery (2) and its connections back.

•

Fill the tank with fuel

Obey fire precautions!

NO smoking while at work!

1

3

5

2

3

4

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 per Section 3.6.37.

ARS 122

121

3.6.

Individual Operations of Maintenance Every 2000 hours of operation

3.6.32. Vibrator casing oil change •

Place the machine horizontally on a solid and flat surface so that the drain plug on the left side of the drum (3) is in the lowest position and the filler plug (1) in the highest position.

•

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

•

Unscrew the plugs (1), (2) and then (3) and let the oil 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 the specified oil as per Section 3.2.1.

•

Clean and install back the remaining drain plugs.

1

2

3 238032

Do NOT touch hot sections, danger of scalding!

Obey fire precautions!

Check the oil level only when oil at atmospheric temperature.

Refill with identical type of oil as per Section 3.2.1.

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.

122

ARS 122

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 (5).

•

Make an arrangement to collect drained oil to container.

•

Remove drain plug (4) and open valve (5) 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 (4) back and close valve (5).

4

5

Replacing hydraulic oil strainer •

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

•

Remove screws (6) to remove cover (7).

7 6

•

Remove the suction hose (8).

•

Remove the screws (10) then remove lid (9).

•

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 (9) back and secure with screws (10).

•

Install suction hose (8) back.

•

Install cover (7) back and secure with screws (6).

8 10

9

Drain oil while oil is warm!

ARS 122

123

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 specified in Section 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.

124

ARS 122

MAINTENANCE MANUAL Refilling the hydraulic circuit •

Carryout refilling using the hydraulic unit (3).

•

Use the specified oil as per section 3.2.4.

3 1251998 •

Connect quick-release coupling of the hydraulic unit with quick-release coupling (4) on the right side of the frame below the operator platform.

4

•

Start filling oil till oil level reaches half in level indicator (5), 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.

•

5

Check oil level in gauge (5), add oil if level drops after engine starting.

Checking the oil temperature sensor •

Remove the sensor (6) 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 122

6

125

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.

126

ARS 122

MAINTENANCE MANUAL 3.6.34. Coolant change

1

Open the bonnet and access the expansion tank cap (1).

Remove pressure cap (1) of the expansion tank to help coolant flow out.

•

Arrange a container of capacity about 20 L (5.3 gal US)

•

Open the drain valve (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 122

127

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 specified as per Section 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.

128

NOTE! When making the change, do flush the system with mixture of water and soda (sodium carbonate) at the ratio of 0,5 kg (1.1 lb.) of soda per 23 L ( 6.0 gal) of water in line with instructions of CUMMINS “Engine Operating Manual” supplied. Refill the system with this mixture and heat up to 80°C (176°F) with the engine running – do NOT install the expansion vessel cap. Turn OFF the engine and drain the water. Refill with clean water and heat up with the engine running. Then drain the water. Repeat this process till the water is cleaned.

ARS 122

MAINTENANCE MANUAL 3.6.35. Air conditioning system cleaning •

Replace the filter-dryer (3).

•

Have the functional check of individual components, wiring checking and air conditioning system cleaning (removal of mould and bacteria) performed by an authorised company.

•

In case of work in a highly dusty environment, have the check performed in shorter intervals.

3

277102

ARS 122

129

3.6.

Individual Operations of Maintenance Maintenance - As Needed

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 show in lowered cooling performance along with increased temperatures of engine cooling liquid and that of hydraulic oil.

•

Clean with compressed air or pressure water (steam).

•

Direct pressurised air or water stream on cooler surface from fan side.

Do NOT use cleaners of excessively high pressure to prevent cooler honeycombs 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!

130

ARS 122

MAINTENANCE MANUAL 3.6.37. Bleeding air 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 and filters: •

Loosen air relief screw at the fuel filter (1).

•

Use fuel feed pump (2) until clean fuel flows out with no air bubbles.

•

Tighten air relief screw with torque value 9 Nm (7 lb. ft.).

1

2

Do not start the engine for over 30 seconds, when using engine starter to bleed the fuel systemate. Wait 2 minutes in between the starts.

Obey the safety precautions at the time of bleeding!

ARS 122

131

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 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!

132

ARS 122

MAINTENANCE MANUAL 3.6.38. Scraper adjustment

2

Scraper designed for smooth drum •

Loosen bolt (1) and shift the holder (2) towards or away form the the drum making the distance between scraper and drum equal to 15 mm (0.6 in.).

1

! CAUTION !

When the chance to displace the scrapers in slotted holes of holders (2) following the wear and tear of scraper (3) is exhausted, you must disassemble the scraper (3) and move it by one hole towards the drum.

3

280219

Scrapers designed for pad foot drum.

•

Loosen bolt (1) and move individual scrapper (2) towards the drum at the distance of 25 mm (1 in.).

1 1

2 282N220T

Rear scrapers at the pad foot drum are longer. When replacing worn and torn scrapers, use rear once to replace the front once, and replace the rear once with new once.

When only a small gap has been set between the scrapers and drums a contact between scraper and drum may occur when turning the machine.

ARS 122

133

3.6.

Individual Operations of Maintenance

3.6.39. Drum cooling mixture (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 (1) will be at minimum height from ground. In this position hole (1) will be level and drain hole (2) will be filling hole.

2

Now open plug (1) gradually, if liquid oozing from it, level is correct. If not, open the plug (2) and start adding mixture from hole (2) till it oozes from hole (1), then install both plugs back.

Fill the mixture according to Section 3.2.9.

To reach specified level, 338 L of mixture will be required.

134

1

ARS 122

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 work with the engine shut off.

Do NOT 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!

Thread

Nm

M6 M8

For bolts 10.9 (10K)

lb ft

Nm

lb ft

10

7.4

14

10.,3

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 122

135

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

136

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 122

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 Nm

lb. ft.

G 1/8

15

11

G 1/4

33

24

70

G 3/8

70

52

130

96

G 1/2

90

66

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

G -M

Nm

lb. ft.

G 1/8

25

18

G 1/4

40

30

G 3/8

95

G 1/2 G 3/4

G -M

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 122

282N222T

137

3.7.

Schematics

3.7.1.

Electrical schematic

Call AMMANN service personnel to consult on Electrical system.

138

ARS 122

MAINTENANCE MANUAL 3.7.2. Hydraulic schematic Call AMMANN service personnel to consult on Hydraulic system.

ARS 122

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3.8.

General Information

3.8.1. Acronyms and Abbreviations The following list contains some of the acronyms and abbreviations used in this manual.

140

0

C

Celsius

0

F

Fahreinheit

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 metre

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 Optimizer

min-1

Revolutions per minute

Hrs

Hours

cl

Centilitre

HVAC

Heating, ventilation and air conditioning ARS 122

MAINTENANCE MANUAL Notes

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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