Ammann ARS 122 Single Drum Roller Operating Manual 0059-0062 PDF

Operating manual

ARS 122 Cummins

C

Book ID: 6-P06286CU-EN

ARS122 Single drum roller Cummins BS III

Operating manual Edition 07/2018 EN From serial no. 0059-0062 Original operating manual

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

With kind regards,

Ammann India Private Limited | Block No 157 | At – Ditasan | P.O. Jagudan | State Highway | Mehsana | Gujarat - 382710 | India +91 2762 285344 / 45 / 46 | Fax +91 2762 285359 | Email : info.ain@ammann-group.com | www.ammann-group.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 spareparts.machines@ammann-group.com, helpline: +41 62 916 66 66; should you need further information, contact support.machines@ammann-group.com, hotline: +420 776 667 775.

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.

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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 possible damages to the machine or its parts.

The notice warns of the necessity of environmental protection.

! WARNING !

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

FRONT

LEFT

RIGHT

REAR

ARS 122

282N100Ten

3

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

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

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

4

ARS 122

OPERATING MANUAL 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 & signs used on the Machine ..................................................................................................................................................25

2.2.6.

Hand Signals.............................................................................................................................................................................................................28

2.3. Ecological & Hygienic Principles..........................................................................................................31 2.3.1.

Hygienic Principles.................................................................................................................................................................................................31

2.3.2.

Ecological Principles .............................................................................................................................................................................................31

2.4. Preservation & Storage.........................................................................................................................32 2.4.1.

Short-term preservation & storage for the period of 1 - 2 months.......................................................................................................32

2.4.2.

Machine preservation & storage for the period over 2 months.............................................................................................................32

2.5. Machine disposal upon its life termination.........................................................................................33 2.6. Machine Description.............................................................................................................................34 2.7. Controlling and operation of the machine..........................................................................................35 2.8. How to Control and Use the Machine...................................................................................................41 2.8.1.

Start the Engine ......................................................................................................................................................................................................41

2.8.2.

Travel & Reversing..................................................................................................................................................................................................43

2.8.3.

Travel with vibration..............................................................................................................................................................................................45

2.8.4.

Emergency stop of the Machine.......................................................................................................................................................................46

2.8.5.

Stop the Machine & the Engine.........................................................................................................................................................................47

2.8.6.

Machine Shutdown................................................................................................................................................................................................48

2.8.7.

Platform & Bonnet raising and lowering........................................................................................................................................................49

2.8.8.

Ballasting of tyres with liquid.............................................................................................................................................................................51

2.9. Machine Transportation........................................................................................................................53 2.9.1.

Machine transportation by its own axle.........................................................................................................................................................53

2.9.2.

Machine transportation by public road..........................................................................................................................................................53

2.9.3.

How to load the machine....................................................................................................................................................................................54

2.9.3.1. Loading the machine using a ramp.................................................................................................................................................................54 2.9.4.

Towing of Machine.................................................................................................................................................................................................56

2.10. Special Conditions for the Machine Application.................................................................................62 2.10.1. Vibration driving on compacted and hard materials.................................................................................................................................62 2.10.2. Machine use under heavy climatic conditions ............................................................................................................................................62 2.10.2.1. Machine operation under low temperatures ..............................................................................................................................................62 2.10.2.2. Machine operation under high temperatures and humidity ................................................................................................................63 2.10.2.3. Operating the Machine at high altitudes ......................................................................................................................................................63 2.10.2.4. Machine operation at extremely dusty environment ...............................................................................................................................63

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Content 3.

MAINTENANCE MANUAL.....................................................................................................................67

3.1. Special Conditions for the Machine Application.................................................................................69 3.1.1.

Safety during Machine Maintenance..............................................................................................................................................................69

3.1.2.

Fire precautions when refilling .........................................................................................................................................................................69

3.1.3.

Ecological & Hygienic Principles........................................................................................................................................................................70

3.2. Specification of fluids............................................................................................................................71 3.2.1.

Engine Oil..................................................................................................................................................................................................................71

3.2.2.

Fuel...............................................................................................................................................................................................................................72

3.2.3.

Cooling Liquid..........................................................................................................................................................................................................72

3.2.4.

Hydraulic Oil.............................................................................................................................................................................................................73

3.2.5.

Gearbox Oil...............................................................................................................................................................................................................74

3.2.6.

Lubricating Grease.................................................................................................................................................................................................74

3.3. Refills......................................................................................................................................................75 3.4. Lubrication & Maintenance Table.........................................................................................................76 3.5. Lubrication and service plan................................................................................................................78 3.6. Individual Operations of Maintenance................................................................................................79 Every 20 Hours of Operation or Daily..................................................................................................80 3.6.1.

Check the oil amount in engine........................................................................................................................................................................80

3.6.2.

Check the amount of cooling liquid in the System....................................................................................................................................81

3.6.3.

Check the amount of oil inside hydraulic tank.............................................................................................................................................82

3.6.4.

Crankcase breather................................................................................................................................................................................................83

3.6.5.

Check fan condition...............................................................................................................................................................................................84

3.6.6.

Check engine belt...................................................................................................................................................................................................84

3.6.7.

Check engine air intake........................................................................................................................................................................................85

3.6.8.

Check the amount of fuel....................................................................................................................................................................................86

3.6.9.

How to clean water separator............................................................................................................................................................................87

3.6.10. Check the alarm & control devices...................................................................................................................................................................88

Every 100 Hours ....................................................................................................................................89 3.6.11. Check tire pressure.................................................................................................................................................................................................89

Every 250 Hours or Once in 3 Months .................................................................................................90 3.6.12. How to replace oil in the engine.......................................................................................................................................................................90 3.6.13. Check the fixing of the engine...........................................................................................................................................................................93 3.6.14. Battery check............................................................................................................................................................................................................94 3.6.15. Check the function of Air Filter Vacuum Switch..........................................................................................................................................95 3.6.16. Machine Lubrication..............................................................................................................................................................................................96 3.6.17. How to check oil inside vibrator........................................................................................................................................................................98 3.6.18. How to check oil in gearboxes...........................................................................................................................................................................99

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ARS 122

OPERATING MANUAL Every 500 Hours or Once in 6 Months................................................................................................100 3.6.19. Replacement of fuel filter of the engine...................................................................................................................................................... 100 3.6.20. Cooling liquid inspection.................................................................................................................................................................................. 102 3.6.21. Check of wiring .................................................................................................................................................................................................... 102 3.6.22. Exchanging cleaner element of air cleaner................................................................................................................................................ 103 3.6.23. Check if wheel bolts are tightened................................................................................................................................................................ 105 3.6.24. Change oil in the gearboxes............................................................................................................................................................................ 105

Every 1000 Hours or Once in Year.......................................................................................................107 3.6.25. Check, adjust valve clearance.......................................................................................................................................................................... 107 3.6.26. How to check tightening pulley and belt of the engine........................................................................................................................ 107 3.6.27. Inspect the damping system........................................................................................................................................................................... 109 3.6.28. How to clean fuel tank....................................................................................................................................................................................... 110

Every 2000 Hours or Every 2 Years.....................................................................................................111 3.6.29. How to change oil in the vibrator.................................................................................................................................................................. 111 3.6.30. How to change hydraulic oil and filter......................................................................................................................................................... 112 3.6.31. How to change engine coolant...................................................................................................................................................................... 116

Maintenance - As Needed...................................................................................................................118 3.6.32. How to clean engine cooler and hydraulic oil........................................................................................................................................... 118 3.6.33. How to deaerate fuel system........................................................................................................................................................................... 119 3.6.34. How to adjust the scrapers............................................................................................................................................................................... 121 3.6.35. How to clean the Machine................................................................................................................................................................................ 122 3.6.36. Check bolted connections................................................................................................................................................................................ 122

3.7. Defects..................................................................................................................................................125 3.8. Appendixes..........................................................................................................................................126 3.8.1. Wiring Diagram....................................................................................................................................................................................................... 126 3.8.2.

ARS 122

Hydraulic Diagram................................................................................................................................................................................................ 128

7

8

ARS 122

SPECIFICATION MANUAL

1. SPECIFICATION MANUAL ARS 122 (Cummins BS III)

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 thick- ness (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 thick- ness 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 PD roller with a padfoot 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 ................................................................................................................

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

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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 ESN 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 BS III

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 padfoot segments

kg (lb.)

1750 (3860)

Weight of tyre filling 0°C

kg (lb.)

1120 (2469)

-

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

Type of steering

-

Joint

Steering control

-

Hydraulic

Linear hydraulic motors

-

2

Manufacturer

-

Cummins

Type

-

4BTAA3.9-C99

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

Driving characteristics Number of speeds

Steering

Engine

ARS 122

13

1.3.

Technical Data ARS 122 Cummins BS III

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)

Drum gearbox

l (gal US)

1.9 (0.5)

Routine operation fuel consumption

Axle Maximum tyre pressure

Brakes

Vibration

Fluid capacities

14

ARS 122

SPECIFICATION MANUAL ARS 122 Cummins BS III Wiring Voltage

V

12

Battery capacity

Ah

150

Optional equipment Padfoot drum shell kit Ammann Traction Optimiser Working speed increase kit (increase up to 7 km/h) Hard canopy Self Standing tractor Tyres Tyre ballast -25 °C Warning Beacon Fire Extiguisher Service Kit for 500 h Bio Degradable Hydraulic oil Tool Kit Set of Documentation

ARS 122

15

SPECIFICATION MANUAL Notes

16

ARS 122

SPECIFICATION MANUAL Notes

ARS 122

17

18

ARS 122

OPERATING INSTRUCTIONS

2. OPERATING INSTRUCTIONS ARS 122 (Cummins BS III)

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 degreasers.

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

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 extiguisher 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

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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 1x 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.)

••

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.

••

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.

••

••

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

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.

••

••

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.).

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.

••

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.

••

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 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.

••

••

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

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.

••

Driver must follow the Machine run while in operation and record any malfunctions found into the diagnostic logbook.

••

Keep the Machine fitted with specified accessories and outfit.

••

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.

••

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:

••

••

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.

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OPERATING INSTRUCTIONS 2.2.5. Safety labels & signs used on the Machine

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25

2.2.

Safety Instructions

Safety labels & 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.)

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.)

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.)

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.)

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.)

6

Read the Manual

Read the Operating Manual before starting the Machine.

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

7

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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ARS 122

OPERATING INSTRUCTIONS 8

Battery Disconnector

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.)

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.)

14.

Platform & Cab Lifting

(Symbol placed on left side of rear frame)

15

Clamp Hazard

Risk area with clamp hazard.

(Symbols placed from inside on the left door.)

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27

2.2.

Safety 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.

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ARS 122

OPERATING 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

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29

2.2.

Safety 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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ARS 122

2.3.

Ecological & 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 incl. 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.

2.3.2. Ecological Principles ••

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 incl. 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.

ARS 122

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.

31

2.4.

Preservation & Storage

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

2.4.2. Machine preservation & 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 spec. 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 headlamps, exterior back mirrors and other elements of external wiring via spraying with special agent and wrapping in PE 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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ARS 122

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.

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33

2.6.

Machine Description

1 - Front Frame

11 - Engine

2 - Drum

12 - Hydraulic Oil Cooler

3 - Scraper

13 - Engine Coolant Cooler

4 - Articulated Joint

14 - Driver´s Control Stand

5 - Rear Frame

15 - Travel Pump

6 - Axle

16 - Vibration Pump

7 - Fuel Tank

17 - Exhaust Muffler

8 - Battery

18 - Air Filter

9 - Hydraulic Tank

19 - Hydr. Oil Pressure Filter

10 - Bonnet

20 - Charge Air Cooler 21 - Steering Pump

34

ARS 122

2.7.

Controlling and operation of the machine

Dashboard

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35

2.7.

Controlling and operation of the machine

Dashboard & Control Panel 1 - Steering Wheel 2 - Travel Controller 2A - Vibration Switch 3 - TOTAL STOP pushbutton 4 - Travelling Speed Controller (Selector) 5 - Throttle Controller 6 - Ignition Box 7 - Spare 8 - Charging Port 9 - Operated-Hours Counter 12 - Engine Lubrication Control Lamp 13 - Battery Charge Control Lamp 14 - Brake Alarm Indicator 15 - Engine Overheating Indicator 16 - Fuel level gauge 17 - Air Filter Fouling Indicator 18 - Hydraulic Oil Filter Fouling Indicator 19 - Vibration ON Indicator 20 - Hydraulic Oil Overheating Indicator 21 - Vibration amplitude selector switch 22 - Turn Indicator Switch 23 - Headlights Switch 24 - Rear lights Switch 25 - Alarm Horn Pushbutton 26 - Fuse Block 27 - Hazard Switch 28 - Passing Beam Switch

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ARS 122

OPERATING INSTRUCTIONS Steering Wheel (1) Travel Speed Controller (4)

Used for Machine steering.

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

With the Controller turned ON (“Rabbit” indicator light will glow). The Machine is capable to reach max. Speed with pulling force reduced and climbing ability decreased.

NOTE: With the controller switched off the operating speed mode is set. The Machine reaches max. pulling force and climbing ability.

NEVER switch ON the controller during occupational use of the Machine.

Do NOT switch OFF the controller at high speed. Abrupt slowdown will occur together with impact within the hydraulic system. Turn OFF the controller with the Machine at rest or at low speed!

You may switch ON the controller, i.e. travel speed, when driving the Machine on a formation level.

You may turn ON the controller with the Machine loaded.

With pulling force not sufficient, switch OFF the travel speed controller.

Travel Controller (2) Use this controller to adjust direction & speed of the driving. Driving speed corresponds to the degree the controller deflects from idle (neutral) position. At the same time the controller is used as driving brake of the Machine.

The controller is arrested in set position. When shifted to its centre position the parking brake is enabled, i.e. the control lamp (14) lights up. Vibration Switch (2A) is located at the controller handle, and is used to switch ON/OFF the vibration after moving controller handle from neutral.

Engine starting is possible in idle position only.

It is forbidden to quickly increase and decrease engine speed. It can damage the engine!

It is forbidden to vibrate on the spot!

(Vibrator bearings are not lubricated during vibration at the halt.)

TOTAL STOP pushbutton (3)

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

Throttle (5) Move the throttle downward to increase the speed from idling one to maximal rpm.

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

Ignition Box (6) It has three positions - ”0”, ”I”, ”II”. When in”0” pos. all the consumers with fuses will be connected; in”I” pos.other consumers will be connected; cushion fuse ”II” is used for Machine starting. Turn the key to”0” pos. to stop the Machine, remove the key in this position.

! CAUTION !

Brake off in arrow direction before starting the engine.

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

It is forbidden to use the emergency brake for turning off the engine during normal operation of the machine!

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

When the key is taken out, please close the ignition box cap to protect the ignition box against water & dirt penetration.

37

2.7.

Controlling and operation of the machine Spare (7)

Ammann Traction Optimizer (ATO)- Optional (7)

Engine Lubrication Control Lamp (12)

Switch the ignition box key to position ”I”, and the control lamp lights up and then goes off after starting the engine. The lamp lighted signals engine lubrication is insufficient.

For driving forward It is primarily used to restrict drum slipage on slope and on surfaces with low adhesive. In ATO on mode torque of drum is reduced as compared to wheels by lowering displacement of drum drive motor, In the same condition vibration is allowed.

Unless it goes off, look for the failure!

Using this mode on flat surfaces improves working speed (near to 7 km/h).

Battery Charge Control Lamp (13)

Note: Driving machine backwards with this mode switched on will reduce driving performance.

If the roller is equipped with the switch for increasing working speed, the ATO system will not be used on the machine.

Switch the key on the ignition box (6) to“I” pos. and the control lamp must light up and go off after starting the engine.

Unless it goes off, look for the failure!

Working speed increase kit (Advanced ATO)Optional (7) Position 0- Basic mode, basic working speeds, full traction.

Position 1 (For driving forward)- With this position on, machine is switched to ATO mode (refer above).

Position 2 (For driving backward)- In this mode torque of both rear wheels is reduced as compared to drum by reducing wheel drive motor’s displacement resulting in limiting slipage of wheels, in same condition vibration is allowed. Is Used for improving machine performance on slopes when moving backward Using this mode on flat surfaces improves working speed (near to 7 km/h) in both forward and reverse direction, depending on mode used.

Brake Alarm Indicator (14)

With this indicator lighted up the Machine broken is signalled.

Engine overheating control lamp (15)

When the engine temperature reaches the highest allowable level, the engine overheating control lamp goes ON an audible warning is given.

Charging socket (8) used for Mobile Charging.

Operated-Hours Counter (9)

When battery charge indicator (13) goes off the counter starts reading the hours. Reading the number of hours does not depend on engine rpm.

fuel level gauge (16)

When the fuel level drops down to min. 45 l (12 gal) , it shows the lower level of diesel in tank.

Air Filter Fouling Indicator (17)

When this indicator lights up the filter elements are fouled above their limit.

! CAUTION !

Carry out regular maintenance per hours worked out!

38

Replace the elements at once!

ARS 122

OPERATING INSTRUCTIONS Headlights Switch (23)

Indicator of hydraulic oil filter (18)

This indicator lighted up under hydraulic oil operating temperature of 50 - 60 °C (122 - 140 °F) signals the filter element is clogged with dirt.

Rear Headlights Switch (24)

Replace the elements at once!

Alarm Horn Pushbutton (25)

Vibration ON Indicator (19)

Fuse Block (26) Fuse

(F1) -20 A

Head Light, Number plate Light, Turn indicators, Horn, Beacon (Optional)

Fuse

(F2) -7.5 A

Bonnet Fox Light

Fuse

(F3) -15 A

(Upper Fuse) Engine, Reverse horn, Reverse light, Break, Break light

Fuse

(F4) -7.5 A

travel, vibration, vibration switching control lamp

Fuse

(F5) - 7.5 A

Break indicator lamp, Engine lubrication lamp, Charge control lamp, Hydraulic oil filter fouling lamp, Engine filter fouling lamp, Hour meter, Engine overheating lamp, Hydraulic fluid overheating lamp, Fuel level indicator

Fuse

(F6) -15 A

Reserved

Vibration amplitude selector switch (21)

Fuse

(F7) - 7.5A

Reserved

- Small amplitude and high frequency are switched ON.

Fuse

(F8) - 7.5A

Reserved

With this indicator lighted up the vibration switch (2A) is ON. When set speed is reached the Machine starts vibrating with the amplitude preset via vibration Preselector (21).

Hydraulic fluid overheating warning indicator (20) When the fluid temperatures reaches the highest allowable level the overheating warning lamp goes ON, an audible warning is given.

- High amplitude and low frequency switched ON. Before the machine starts moving, use the switch to set the required amplitude. Before changing the amplitude, first stop the machine, use the switch to change the amplitude and then start moving the machine again.

It is forbidden to vibrator on the spot!

It is forbidden to change the vibration amplitude while driving.

Replace fuses with those of identical value ONLY!!!

Hazard Switch (27)

Turn Indicator Switch (22) Passing Beam Switch (28)

Indicator lamp on will signal traffic-indicator light are ON.

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39

2.7.

Controlling and operation of the machine

Driver Seat Seat adjustment elements:

Backrest angle adjustment – lift the lever (1) to setting up of the backrest.

Longitudinal move of the Seat – lift the lever (2) and move the seat in longitudinal direction forward – backward.

1

2

Seat firmness adjustment – Rotate lever (1) clockwise or anticlockwise to set the weight of operator

1

Battery Cut-off switch Use cut-off switch to disconnect Battery from the system.

Use cut-off switch to disconnect the Battery following the drive end!

Switch OFF the disconnector ALWAYS when washing the Machine!

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ARS 122

2.8.

How to Control and Use the Machine

2.8.1. Start the Engine

Before you start the engine, please turn ON the horn for warning purposes.

Confirm nobody is endangered due to the engine started!

Note: Unless engine starts even after 3 attempts made – check the fuel system. Upon starting, watch the colour of exhaust gases – the absence of blue or white fume indicates the fuel supply is insufficient.

How to start the engine: ••

Make additional fuel pumping via hand feed pump at the engine (upon long term Machine shutdown).

••

Switch ON battery disconnector.

••

Switch ignition box (6) key to pos. ”l” – engine lubrication lamps go ON (12), along with brake lamp (14), and charge control lamp (13).

••

Set the throttle controller (5) to slightly increased speed (1/4 of controller stroke).

••

Switch ignition box key to pos.”ll” and start the engine (keep the key in pos. ”ll” only until the engine starts).

••

When started, use the control lamps to monitor the engine function.

••

When started, let the motor run at idle rpm of 750-950 min-1 for a period of 3-5 minutes.

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41

2.8.

How to Control and Use the Machine Do NOT start for more than 30 sec. Make another starting attempt only after 2 minutes, and unless the motor starts even after 3 attempts, carry out troubleshooting.

Charge control lamp and lubrication lamp must go off when the engine starts.

Lubrication lamp must go off within 15 sec.

Sharp speed increase or decrease is inadmissible – hazard of engine damage.

When started let the engine run at idle rpm of 750-950 min–1 for a period of 3-5 minutes.

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!

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

! CAUTION !

Starting will be interlocked: When the controller (2) is in idle (neutral) position.

42

How to start using starter cables via another machine

Make sure the starting voltage of a booststarting power supply is 12 V. Follow unconditionally the sequence of operations given below!

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

2. Connect second (+) pole end of the cable to (+) pole of battery of the machine used to boost-start.

3. Connect one (–) pole end of the cable to (–) pole of battery in the vehicle used to boost-start.

4. Connect second (–) pole end of the cable to a section of the started Machine fix-connected to the engine (or to the cylinder block itself )

! 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.

ARS 122

OPERATING INSTRUCTIONS Do NOT connect (–) pole of the cable to (–) pole of discharged battery of the started Machine! Hazard of strong sparking when starting, followed by an explosion of gases generated by battery.

Non-insulated sections of the starter cables’ clamps may 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.

NEVER bend yourself over the battery hazard of electrolyte burn!

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

NEVER verify voltage presence within a conductor via sparking through the Machine frame!

How to start at low temperature.

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

Observe strictly safety & hygienic instructions of manufacturer when using starter filling. Non-observance of these instructions may lead to engine or property damage, health and life hazards to people present.

NEVER use volatile, easily ignitable refill when starting inside tunnels or mines.

Always ask for safety guidelines when using starter refills under these conditions.

2.8.2. Travel & Reversing

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 found there!

••

Turn OFF the travelling speed controller (4) – i.e. switched to operating speed.

••

Use throttle controller (5) to adjust engine rpm required, i.e. ca 1800.min–1 (RPM).

••

Confirm vibration switch (2A) is not ON, control lamp (19) is off.

••

Deflect travel controller (2) from idle (neutral) pos. to a required direction – small deflection of the controller = slow speed and vice versa. Following travel controller (2) deflection the brake indicator lamp (14) will go off.

••

Reversing – shift the controller (2) in opposite direction via its idle position.

Turn ON the controller (4) – transport speed - you may do so while driving the Machine by an adjusted terrain (formation level) “Rabbit” symbol will light up.

Turn the controller ON only with the Machine not idle.

In case of lack of pulling force, switch OFF the transport speed controller.

NEVER switch OFF the controller (4) at high speed due to high slowdown along with impact within hydraulic system. Turn OFF the controller (4) at low speed or with the Machine at rest!

Engage operating speed via turning OFF controller (4) before driving by steep incline!

Do NOT apply throttle (5) to control Machine velocity.

NEVER drive in cross direction at the hillsides of high slope! Drive perpendicular to a hillside!

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43

2.8.

How to Control and Use the Machine

OK

OK

C

44

ARS 122

OPERATING INSTRUCTIONS 2.8.3. Travel with vibration ••

Turn OFF controller (4), thus switching to operating speed mode.

••

Use Pre-selector (21) to select vibration amplitude.

••

Use throttle controller (5) to adjust maximal speed.

••

Start moving the Machine and turn ON the switch (2A) to start the vibrations - control lamp (19) lights up – runner begins vibrating.

••

Press and relieve button (2A) to stop the vibration.

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It is forbidden to vibrate on the spot!

It is forbidden to change the vibration amplitude while driving.

45

2.8.

How to Control and Use the Machine

2.8.4. Emergency stop of the Machine Apply in the event when engine is unable to stop via ignition key or when Machine is unable to stop via switching the travel controller to neutral.

••

46

••

Before new engine start, please shift controller (2) to ”N” position and turn pressbutton (3) according to arrow direction.

••

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

Do NOT apply emergency brake during normal operation just to shut off the engine.

Press TOTAL STOP (3) (emergency brake) - the engine stops and the Machine stops moving.

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OPERATING INSTRUCTIONS 2.8.5. Stop the Machine & the Engine ••

Use switch (2A) to turn OFF the vibration – control lamp (19) goes off.

••

Use controller (2) to stop the Machine – parking brake is enabled; lamp (14) lights up.

••

Use controller (5) to lower the speed to engine idle.

••

Switch ignition box key (6) to pos. “0” and take it out – close the ignition box cap.

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

47

2.8.

How to Control and Use the Machine

2.8.6. 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.

48

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.

ARS 122

OPERATING INSTRUCTIONS 2.8.7. Platform & Bonnet raising and lowering Lifting and lowering platform must be done only while the platform is empty.

Danger of injury!

••

Release platform nuts.

••

Open the cover on the left side under the platform. Take out the pump control lever (1).

Lifting: ••

Close the valve (2), insert the control lever (1) into the pump and simultaneously lift the platform and bonnet by pumping.

••

Lock the platform in position using the valve (3).

3

ARS 122

49

2.8.

••

How to Control and Use the Machine

Lock the lifted bonnet using the valve (4).

4

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 platfom and bonnet lifting hydraulic circuit is open, the platform or bonnet may fall. Danger of injury!

Lowering: ••

Unlock the platform using the valve (3).

3

••

Unlock the bonnet using the valve (4).

4

••

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

After lowering, tighten the Platform using screws.

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OPERATING INSTRUCTIONS 2.8.8. 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)

A filler neck can be ordered as a replacement part under number 4-5325190009.

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.

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2.8.

How to Control and Use the Machine

••

Mount the hose from the filling equipment (a tank located above, pump, etc.) on 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.

••

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

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.

••

Unscrew the removable valve insert and let the solution flow out.

The solution can spurt out after unscrewing the valve insert.

••

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.

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.

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2.9.

Machine Transportation

OPERATING INSTRUCTIONS

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.

Transport speed – you may switch ON collector (4) when crossing with the Machine by finished road.

In case of long transportation distances, please make 1-hour cooling breaks every 2 hours. Non-observance of this advice will put in jeopardy of Machine damage that the manufacturer will in no and any circumstances bear responsibility for.

Follow those safety measures specified for the work site when shifting the Machine.

2.9.2. Machine transportation by public road

The basic construction of the Machine is NOT fitted for transportation by its own axle using public road. This type of transportation is prohibited.

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

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 Section 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 via the clamps (tieoffs) (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 via land routes.

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

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Fixing the Machine on the carrier.

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1

2

2 2

1

2

53

2.9.

Machine Transportation

2.9.3. How to load the machine ••

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.

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, antislip surface and must be stored on a flat surface. We recommend that you adhere to regulation BGR 233.

••

Maximum permissible incline of the ramp is 30%.

C

MAX MAX 30 30 % %

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.

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

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OPERATING INSTRUCTIONS 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).

Do NOT enter underneath hanging load!

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.

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2.9.

Machine Transportation

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 ) 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!

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OPERATING INSTRUCTIONS Short-circuiting the travel pump: ••

Switch off the engine. Use the disconnector to disconnect the batteries.

••

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.

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.

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2.9.

••

Machine Transportation

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).

5

4

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ARS 122

OPERATING INSTRUCTIONS ••

Install the another end of hose (3) provided in toolkit on Tconnector (5)

••

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

3 5

••

Close the safety valve (9).

••

Turn on the battery disconnector (6).

••

Switch the key to the “I” position.

••

Operate the lever in the manual pump (7).

••

Monitor the brake indicator (8) 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 frow movement of the lever).

7

6

9 280159 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.

How to put into initial state: ••

Open the safety 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.

6 9 280160

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59

••

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.

••

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

3 5

••

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

••

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

5

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OPERATING INSTRUCTIONS ••

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

••

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

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

2.10.2. Machine use under heavy 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 ca 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.

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OPERATING INSTRUCTIONS 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.

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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.

63

Notes

64

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OPERATING INSTRUCTIONS Notes

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66

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MAINTENANCE MANUAL

3. MAINTENANCE MANUAL ARS 122 (Cummins BS lll)

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68

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3.1.

Special Conditions for the Machine Application

3.1.1. Safety during Machine Maintenance

3.1.2. Fire precautions when refilling

Lubrication, maintenance & 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 & 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 & flammability number.

••

Together with retightening 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!

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69

3.1.

Special Conditions for the Machine Application

3.1.3. Ecological & Hygienic Principles

Ecological Principles

When operating and maintaining the machines a User must follow general health & environment protection principles along with the acts, public notices & 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, plus painting materials (coating compositions) incl. 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 follow safety & hygienic instructions of these products’ manufacturers.

Please note the following in particular: --

Protect your Eyes & skin when handling the Battery

--

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

--

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

--

Observe machine operating instructions when handling its cooling systems.

••

ALWAYS store oil products, refilling of cooling systems and Battery plus paints incl. Organic thinners and also the cleaning & preserving agents in their genuine original properly identified packages. Never 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.

70

This waste product category includes the following: --

Organic or synthetic lubricants, oils and fuels

--

Brake fluids

--

Cooling liquids

--

Battery charges and Battery themselves.

--

Cleaning & preserving agents

--

All the dismantled filters & filter elements

--

All the worn & discarded hydraulic hoses & fuel hose, metal rubbers and other elements of the Machine fouled by the abovementioned 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.

ARS 122

3.2.

Specification of fluids

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

Performance Classification under API (AMETICAN PETROLEUM INSTITUTE) CCMC (COMMITE 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.

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

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

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.

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71

3.2.

Specification of fluids

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.

--

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”).

NEVER use fuels (like bio Diesel oil, mixed bio Diesel oil, LFO, and alike) other than those Diesel oils specified above.

72

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.

NEVER 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.

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MAINTENANCE MANUAL 3.2.4. Hydraulic Oil 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.

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

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

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.

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3.2.

Specification of fluids

3.2.5. Gearbox Oil

3.2.6. Lubricating Grease

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

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

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

--

ISO 6743/9 CCEB 2

--

DIN 51 502 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).

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ARS 122

3.3.

Refills Refill Amount l (gal US)

Section

Refill Type

Engine

Engine oil per Section 3.2.1

10.9 (2.9)

Fuel Tank

Diesel oil per Section 3.2.2.

410 (108.3)

Hydrualic System

Hydraulic oil per Section 3.2.4.

90 (23.8)

Axle Gearboxes

Gearbox oil per Section 3.2.5.

2x1.9 (2x0.24)

Front Gearbox

Gearbox oil per Section 3.2.5.

1.9 (0.24)

Joint bearing & steering cylinders

Plastic lubricant, refer to Section 3.2.6.

as required

Engine Cooling System

Permanent anti-freeze liquid per Section 3.2.3.

20 (5.3)

Vibratory Free Axle

Motor oil as motor

8 (2.1)

battery

Distilled water

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Brand

as required

75

3.4.

Lubrication & Maintenance Table

Every 20 hours of operation or daily 3.6.1.

Check the oil amount in engine

3.6.2.

Check the amount of cooling liquid in the engine

3.6.3.

Check the amount of oil inside hydraulic tank

3.6.4.

Crankcase Breather

3.6.5.

Check fan condition

3.6.6.

Check engine belt

3.6.7.

Check engine air intake

3.6.8.

Check the amount of fuel

3.6.9.

How to clean air separator

3.6.10.

Check the alarm & control devices

Every 100 Hours 3.6.11.

Check tire pressure

Every 250 Hours or Once in 3 Months 3.6.12.

How to replace oil in the engine

3.6.13.

Check the fixing of the engine

3.6.14.

Battery check

3.6.15.

Check the function of Air Filter Vacuum Switch

3.6.16.

Machine Lubrication

3.6.17.

How to check oil inside vibrator

3.6.18.

How to check oil in gearboxes

Every 500 Hours or Once in 6 Months

76

3.6.19.

Replacement of fuel filters of the engine

3.6.20.

Cooling liquid inspection

3.6.21.

Check of wiring

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MAINTENANCE MANUAL 3.6.22.

Exchanging cleaner elements of air cleaner

3.6.23.

Check if wheel bolts are tightened *

3.6.24.

Change oil in the Front and Rear gearboxes *

Every 1000 Hours or Once a Year 3.6.25.

Check, adjust valve clearance

3.6.26.

How to check tightening pulley and belt of the engine

3.6.27.

Inspect the damping system

3.6.28.

How to clean fuel tank

Every 2000 Hours or Every 2 Years 3.6.29.

How to change oil in the vibrator

3.6.30.

How to change hydraulic oil and filter

3.6.31.

How to change engine coolant

Maintenance - As Needed 3.6.32.

How to clean engine cooler and hydraulic oil

3.6.33.

How to deaerate fuel system

3.6.34.

How to adjust the scrapers

3.6.35.

How to clean the Machine

3.6.36.

Check bolted connections

* First after 150 hours

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77

3.5.

78

Lubrication and service plan

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3.6.

Individual Operations of Maintenance

Carry out lubrication & maintenance on regular basis and repeatedly in intervals according to daily reading on the hours of operation counter.

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.

Follow the instructions given in the manual for operation and maintenance of the engine!

Disassembled or loose bolts, plugs, threaded connections of hydraulics etc. should be tightened with torque according to tables in chapter 3.6.36., 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 self-motion, ALWAYS with the engine turned OFF, key removed from the ignition box, and wiring cut OFF (unless otherwise required).

After the first 150 hours of working with a new machine (or after machine general overhaul), make the following operations: 3.6.23.

Check if wheel bolts are tightened

3.6.24.

The first oil exchange in Front and Rear gearboxes

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3.6.

Individual Operations of Maintenance Every 20 Hours of Operation or Daily

3.6.1. Check the oil amount in engine ••

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

••

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

••

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

••

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

••

Always replenish with oil of identical type. Use oils under Section 3.2.1.

••

Check the motor tightness, repair any cause of leakage.

••

Inspect the engine if no damaged or missing parts exist within the motor, and whether no appearance changes have occurred.

NEVER use the engine unless there is proper oil level inside the engine.

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MAINTENANCE MANUAL 3.6.2. Check the amount of cooling liquid in the System ••

Check visually the level.

••

Add via filler neck (1).

Remove the filler plug only after the engine coolant temperature falls below 50 °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.

The level may not drop below the level gauge eyesight.

Replenish with coolant consisting of antifreeze agents of identical base per Section 3.2.3.

NEVER 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.

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81

3.6.

Individual Operations of Maintenance

3.6.3. Check the amount of oil inside hydraulic tank ••

Check the level.

••

Refill with oil if required.

NOTE In case of high loss of oil, repair the cause of hydraulic system leakage.

••

The hydraulic tank lid is provided with a seal.

••

To fill up the hydraulic circuit, use the hydraulic unit.

! CAUTION !

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

Hydraulic unit 230 V Ordering number: 1251998 Hydraulic unit 110 V Ordering number: 1255297

••

82

Connect the hydraulic unit to the quick-coupling in the space under the platform.

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MAINTENANCE MANUAL 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 tank through the filler neck (1) with the specified oil type up to the bottom of the strainer in the filler neck.

3.6.4. Crankcase breather ••

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

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3.6.

Individual Operations of Maintenance

3.6.5. Check fan condition ••

Check visually the fan. If damaged (e.g. missing parts of materials, cracks, shape changes etc.) replace the fan.

3.6.6. Check engine belt ••

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

••

Any cracks perpendiculars to belt width are no damage.

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.

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MAINTENANCE MANUAL 3.6.7. Check engine air intake ••

Check if suction rubber hose leading from the filter is not damaged and if tightening clamps are not missing.

••

Inspect the gasket between the bonnet and air filter. Replace impaired gasket with the new one if required.

NEVER operated the Machine with damaged gasket between the bonnet and air filter, or the connection not tight.

••

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

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

NEVER operate the Machine with dust valve damaged.

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85

3.6.

Individual Operations of Maintenance

3.6.8. Check the amount of fuel ••

Check the level of the diesel in tank with gauge

••

Replenish following the cleaning of filler cap (3) and filler neck (2) via a strainer up until the lower edge of the filler neck.

NOTE: As soon as the fuel pointer reaches near empty line on fuel gauge make up the fuel immediately. Fuel tank capacity is 410 l (108 gal US). The fuel tank equals to ca 34 hours of Machine operation.

NO smoking while at work!

Observe fire precautions!

Fuel tank is not drained fully. To empty fully you must carry out rather arduous deaeration of the entire fuel system.

Use ONLY clean and recommended fuel under Section 3.2.2.

NEVER refill fuel with the engine running.

Do NOT replenish fuel in closed areas.

Prevent fuel from spilling on the ground.

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MAINTENANCE MANUAL 3.6.9. How to clean water separator ••

Prepare a receptacle to drain the sediment into.

••

Turn the separator valve (1) clockwise by 4 revolutions until the valve gets extended by ca 25 mm (1”) downward.

••

Drain the fuel till it starts flowing out pure. Press the valve upward and screw it.

If you drained more than 6 cl (2ozs) of fuel, then make up the fuel in fuel filter in line with Section 3.6.20., or deaeration per Section 3.6.34. In this way you will avoid problems of difficult engine starting.

Observe fire precautions!

NO smoking while at work!

Do NOT drain the separator with the engine running.

Collect the fuel with sediment drained in a proper vessel.

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87

3.6.

Individual Operations of Maintenance

3.6.10. Check the alarm & control devices ••

Turn ON the switches (22), (23), (24), (25), (27), (28), confirm the horn, headlamps and indicator function well.

••

Turn the ignition box key 6 into position “I”. Lamps (12), (13), (14) will light up.

••

Following engine starting “II” the lamps (12), (13) must go off.

••

Start the engine, press (3) TOTAL STOP - engine stalling must occur, pilot lamps go ON.

When in operation, please check continuously the board instruments and indicator lamps.

Repair instantly any failures signalled!

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MAINTENANCE MANUAL Every 100 Hours 3.6.11. Check tire pressure ! NOTE !

Rotate tyres so that valves are at top positions.

••

Check pressure at cold tires using a pressure gauge.

••

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

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89

3.6.

Individual Operations of Maintenance Every 250 Hours or Once in 3 Months

3.6.12. How to replace oil in the engine ••

Prepare an appropriate vessel of capacity 20 L.

••

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

••

Clean the surface round the oil filter head. Dismantle the filter.

••

Clean the contact surface designed for filter gasket.

••

Take a new filter, fill it with pure engine oil – 10.9 l (2.9 gal US).

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MAINTENANCE MANUAL ••

Apply oil on the gasket.

••

Install the filter and hand-tighten securely.

••

Reinstall the plug again. Use 80 Nm (59 lb. ft.) torque.

••

Refill the engine via filler neck (1).

••

Replenish the oil up to the dipstick upper Hole. Oil refilling makes 10.9 l (2.9 gal US).

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3.6.

Individual Operations of Maintenance

NOTE ••

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

Check the tightness of drain plug and filter.

••

Stop the engine and wait 3 minutes until oil descents into the crankcase sump. Then check the oil level using dipstick.

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). Beware of possible scalding when draining hot oil.

Observe fire precautions!

! CAUTION !

Replace oil every 3 months at the latest even though 250 hours of operation have not been reached. Replace oil in an interval that comes first.

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

Use recommended oil only. Refer to Section 3.2.1.

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

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

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

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MAINTENANCE MANUAL 3.6.13. Check the fixing of the engine ••

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

Engine front metal rubbers

Engine rear metal rubbers

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93

3.6.

Individual Operations of Maintenance

3.6.14. Battery check ••

Stop the engine and disconnect the electric system using the isolating master switch.

••

Clean the surface of batteries.

••

Check the condition of poles and terminals (1) and clean them. Apply a thin layer of grease on the terminals.

MAINTENANCE-FREE BATTERY •

In case of a maintenance-free battery (the battery has no freely accessible plugs), only the no-load voltage on terminals is checked. The batteries cannot be replenished. If the no-load voltage is 12.6 V and more, the battery is fully charged.

If the no-load voltage is below 12.4 V, the battery should be charged immediately. 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.

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.

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 batteries that do not work for their disposal.

94

Keep the batteries dry and clean.

Do NOT disconnect battery while the engine runs.

When handling with the battery, always follow 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 eye contact with electrolyte immediately flush affected eye with large amounts of 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.

During skin contact with electrolyte, remove clothing, including shoes, flush affected points as soon as possible with soap water or solution of soda and water.

Get prompt medical attention.

Do NOT eat, drink or smoke while at work!

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

Do NOT check a wire is energized by touching Machine frame.

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.

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MAINTENANCE MANUAL 3.6.15. Check the function of Air Filter Vacuum Switch ••

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

••

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

••

Cover shortly Air Filter Suction Hole on the engine bonnet.

••

Indicator lamp (17) for Air Filter fouling should light.

••

Check the following unless it lights up : Vacuum switch (1) Bulb inside the indicator lamp (17). Confirm the contact, supply cable.

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95

3.6.

Individual Operations of Maintenance

3.6.16. Machine Lubrication ••

Remove greasing nipple caps.

••

Put on gradually the greasing nipple of high pressure press and grease till the old grease begins to flow out.

••

Reinstall the greasing nipple caps again.

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

Linear Hydraulic Cylinder for Steering King pins 2 x

Rear pins 2 x

Linear Hydraulic Cylinder for Tilting the Bonnet Upper pivots 2 x

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MAINTENANCE MANUAL Lower pivots 2 x

Linear Hydraulic Motor for Tilting Operator platform

Bonnet Hinges

Platform Front Pivots Pivots 2 x

Use ONLY recommended lube greases.

Refer to Section 3.2.6.

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97

3.6.

Individual Operations of Maintenance

3.6.17. How to check oil inside vibrator ••

Stop in such a way that the axle plugs on the left side are in the position as per fig.

••

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

••

Replenish oil with the filler cap (2) unscrewed.

••

Wipe the plugs and reinstall.

Check the oil only after it cools down.

Refill with identical type of oil.

Observe fire precautions!

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MAINTENANCE MANUAL 3.6.18. How to check oil in gearboxes 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 via filler plug (1), if required.

••

Wipe the plugs and reinstall.

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 via filler plug (2), if required.

••

Wipe the plugs and reinstall.

••

Confirm the tightness of gearboxes.

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

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

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99

3.6.

Individual Operations of Maintenance Every 500 Hours or Once in 6 Months

The set of filters after 500 M/c hrs, can be ordered from engine spare part catalogue. For the list of all spare parts, see the engine spare part catalogue publication.

3.6.19. Replacement of fuel filter of the engine ••

Clean the head of the fuel filter (1) and the fuel filter with the water separator (2); dismantle the filters.

••

Clean the contact area of the fuel filter (1).

••

Fill up the fuel filter (1) with clean fuel.

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MAINTENANCE MANUAL ••

Apply oil over the sealing ring.

••

Mount the fuel filter (1) and tighten firmly by hand.

••

Carry out the same procedure for the fuel filter with the water separator (2).

NO smoking while at work!

Observe fire precautions!

Use original filters specified.

Do NOT tighten the filters with force.

Collect any fuel flowing out.

Hand over for disposal the filters used.

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101

3.6.

Individual Operations of Maintenance

3.6.20. Cooling liquid inspection ••

Use refractometer to check the concentration of antifreezing agent in the cooling liquid.

••

Add with antifreezing agent per Section 3.2.3.

3.6.21. Check of wiring ••

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.

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MAINTENANCE MANUAL 3.6.22. Exchanging cleaner element of air cleaner The air cleaner contain the main and safety elements. Replace the cartridges always when the indicator lamp (17) lights up, however at the latest after 500 M/c hrs.

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

••

Lift the bonnet to the limit position. (See Operating instructions, chapter 2.8.7.).

••

Remove the lid.

••

Replace the main (Primary) cartridge.

••

Replace the safety cartridge.

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103

3.6.

Individual Operations of Maintenance

••

Clean the inside of the cleaner and contact surface in order that the engine inlet pipe does not get blocked. Check connections and piping for any untightness and clogging of the engine inlet opening on the bonnet (e.g. by leaves).

••

Insert the safety element.

••

Mount the new main element. Check whether the both cartriges fits correctly and whether are sealing.

••

Remove the dust valve, clean it and mount it back.

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

Use original elements only.

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

In case of absorbing water, exchange main element. Dry the cleaner body.

Replace defective vacuum valve immediately!

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

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MAINTENANCE MANUAL 3.6.23. Check if wheel bolts are tightened ••

Confirm the wheel bolts are tightened. Use torque spanner.

••

The torque is 285 Nm (210 lb. ft.)

! CAUTION !

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

3.6.24. Change oil in the gearboxes.

Rear Gearbox ••

Stop the Machine in such a way the plugs (1) & (2) of gearboxes of both the wheels are in position as per fig. Place an appropriate receptacle underneath the plugs and Dismount both the plugs and let oil drain out.

••

After draining complete oil, Drive the machine forward so that the plugs are in position according to fig. Through the plug (1) fill 1.9 l of recommended oil. Check the level in hole (2) (the oil flows out slightly). Reinstall the plugs (1) & (2).

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105

3.6.

Individual Operations of Maintenance

Front Gearbox ••

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

•

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

••

After draining complete oil, reinstall plug (3) back. Use filler plug (2) & (1) to refill the recommended oil 1.9l. Check the level in hole (1) & (2) (the oil flows out slightly from hole (1).

Reinstall the plugs (1) and (2), replace any plug gasket damaged.

Change oil after driving for first 150 engine hours.

Change oil while oil is hot

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

Observe fire precautions!

Avoid oil to leak into the ground.

Used oil is environmentally hazardous waste hand it over for disposal.

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MAINTENANCE MANUAL Every 1000 Hours or Once in Year 3.6.25. Check, adjust valve clearance •

Call Cummins service department to adjust the engine valves – for contact points, please refer to Engine Operation and Maintenance Manual.

3.6.26. How to check tightening pulley and belt of the engine ••

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 43 Nm (32 lb. ft.) torque.

••

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

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107

3.6.

Individual Operations of Maintenance

••

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.

••

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.

••

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.).

••

Reinstall the belt back.

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MAINTENANCE MANUAL 3.6.27. Inspect the damping system ••

Check the condition of metal rubber (cracks, fissures), cohesiveness of metal with rubber. Replace any damaged one

••

Confirm the bolts and nuts are tightened properly.

Rubber metals of the drum, LH side.

Rubber metals of the drum, RH side

Front metal rubber of driver control stand.

Rear metal rubbers of driver control stand.

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109

3.6.

Individual Operations of Maintenance

3.6.28. How to clean fuel tank ••

Unscrew the drain plug and let fuel to flow out into a receptacle installed.

••

Flush the tank with clean fuel.

••

Screw on the plug again.

••

When fouled to a greater extent, remove the battery and tank cap. Inspect and clean the tank’s inner area. Insert the new sealing tape between the lid and the tank.

••

Mount the lid back.

••

Mount the battery.

NOTE When aeration of engine fuel system occurs you must deaerate it under Section 3.6.35.

Carry out cleaning when there is minimal fuel in the tank.

With the tank used up, ca 45 l [12 gal US] of fuel will remain in the tank.

Observe fire precautions!

NO smoking while at work!!!

Follow the environmental regulations when cleaning.

Avoid fuel leaking into the ground.

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MAINTENANCE MANUAL Every 2000 Hours or Every 2 Years 3.6.29. How to change oil in the vibrator ••

Position the cylinder so the drain plug (3) is in its lowest position, and on the opposite the filler plug (1) in its highest position.

••

Put a proper receptacle underneath the drain point.

••

Unscrew all the plugs and let oil to flow out.

••

When draining is completed reinstall the drain plug.

••

Use filler hole (1) to refill with recommended oil up to the edge of inspection hole (2) - 8 l (2.1 gal US).

••

Reinstall the remaining plugs.

Change oil while oil is hot.

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

Observe fire precautions!

Avoid oil to leak into the ground.

Used oil is environmentally hazardous waste – Hand it over for disposal.

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111

3.6.

Individual Operations of Maintenance

3.6.30. How to change hydraulic oil and filter

Change oil before season starts, or following a rather long Machine shutdown.

Drain oil while oil is hot.

••

Unscrew drain plug. Let oil flow out into a vessel installed – total amount of oil that flows out is round 60 l (15.9 gal US).

Mount the plug back.

••

Dismantle the cover.

••

Remove the suction hose.

••

Remove the lid. Remove the suction basket from the suction pipe. Replace the suction basket.

••

Inspect the interior of the tank. When the bottom is dirty, clean and rinse the tank with the new oil. Mount the lid back. Use the new sealing tape.

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MAINTENANCE MANUAL How to replace pressure filter element

Replace ALWAYS : - Together with oil exchange - When pressure filter lamp 18 lights up due to oil operating temperature reaching 50 - 60 °C (122 - 140 °F).

••

Remove filter vessel (2). Replace filter element.

••

Clean thoroughly the filter vessel.

••

Clean the bottom of filtration block contact surface.

••

Check the condition of sealing rings, apply the rings with clean oil.

••

Insert new element into the filter vessel, and screw on back again.

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113

3.6.

Individual Operations of Maintenance

Filling the hydraulic circuit: ••

Fill using the hydraulic unit.

••

Put the quick-release coupling of the hydraulic unit on the quick-release coupling on the right side of the frame under the operator platform.

••

Fill up the tank with oil to the maximum level and disconnect the hydraulic unit.

••

Start the engine, increase its speed to confirm the tightness of filter, temperature sensor, suction hose & cap. Check oil level in oil gauge.

Checking the oil temperature sensor ••

Remove the sensor 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.

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MAINTENANCE MANUAL Alternate filling through the oil tank filler

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

When using this filling method, reduce the next change interval to the half, i.e.

1000 hours or 1 year.

••

Fill the tank through the filler neck with the specified oil type up to the bottom of the strainer in the filler neck.

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 will be shorter.

Do NOT open hydraulic tank uselessly!

Use NO chemical cleaning agents & those means (like clouts) that slip fibres.

Refill oil per Section 3.2.4.

Use only the original filter elements under Spare Parts Catalogue.

Keep clean while at work. Avoid fouling the system with materials that may cause damage to crucial sets and units!

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. Clean & rinse hydraulic tank prior to installing a new unit.

Observe fire precautions!

Collect drained oil, and do NOT let it soak in the ground. Blind all the holes with plugs following the disconnection of hydraulic circuits.

Used oil & filter elements are environmentally hazardous waste – Hand it over for disposal.

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115

3.6.

Individual Operations of Maintenance

3.6.31. How to change engine coolant

Make it with the engine operation stopped or following the heating of the liquid to 50 °C (122 °F) with the engine running.

••

Remove overpressure plug (1) at the expansion tank to open the cooling system.

Do NOT open the overpressure plug before cooling liquid temperature drops below 50 °C (122 °F). Danger of water splashing when opening the overpressure plug and getting scalded.

••

Open the drain cock at the cooler’s bottom chamber. Let the liquid flow out into the receptacles installed. The amount drained is ca 20 l (5.3 gal US).

••

Confirm no damaged hoses or missing hose clamps exist within the engine cooling system. Check the condition of the cooler for any damage, leaks or whether the cooling gills are fouled with slag & mill scale. Clean and repair if required.

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MAINTENANCE MANUAL ••

Close the drain cock and refill the cooling system with new coolant at the ratio of 50 % of water + 50 % of antifreeze.

••

Fill up to the water gauge top level. 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 expansion vessel cap and close the bleed valve. Start the engine and let the motor heat up to 80 °C (175 °F). Stop the engine and check no cooling liquid leaks. Confirm water gauge level.

NOTE: When making the change, please 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 again the motor. Then drain the water. Repeat this till water is clean.

Refill with cooling liquid under Section 3.2.3!

Follow the instructions of antifreeze manufacturer when changing!

Wear gloves to protect your hands!

Wear safety glasses or face shield to protect your eyes!

Hand over used liquid for its safe disposal per the regulations given!

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117

3.6.

Individual Operations of Maintenance Maintenance - As Needed

3.6.32. How to clean engine cooler and hydraulic oil ••

No regular cleaning interval is possible to establish due to different operating conditions.

••

Perform daily cleaning when working within extremely dusty environment. Fouling 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). Clean from the direction of the fan.

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

In case of cooler fouled with crude oil products find out the cause of fouling!

Follow 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!

NEVER use banned cleaning agents!

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MAINTENANCE MANUAL 3.6.33. How to deaerate fuel system Deaerate the fuel system prior to 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.

Deaerate low-pressure piping & filters: ••

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

••

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

••

Tighten air relief screw. The torque figure is 9 Nm (7 lb. ft.).

When using engine starter to aerate, then do not start for over 30 s. Wait 2 minutes in between the starts. Engine may start when aerating, therefore safety precautions must be followed.

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119

3.6.

Individual Operations of Maintenance

Deareate high-pressure piping and the injectors: ••

When you have carried out the previous operations and the engine has not started, please deaerate the high-pressure piping.

••

Switch 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 HP piping.

••

Deaerate till motor runs regularly.

••

Tighten the loosened connections with 38 Nm (28 lb. ft.) torque.

Attention, high fuel pressure inside HP piping. Hazard of skin injury and serious implications.

NEVER make deaeration with hot engine.

Danger of fuel flowing over hot exhaust manifold causing fire.

Open fire FORBIDDEN while working on fuel system!

NO smoking!

Collect any leaking fuel!

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MAINTENANCE MANUAL 3.6.34. How to adjust the scrapers Scraper designed for smooth drum ••

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

! 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 dismantle the scraper (3) and move it by one hole towards the drum.

Scrapers designed for padfoot drum.

••

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

Rear scrapers at the padfoot 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.

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121

3.6.

Individual Operations of Maintenance

3.6.35. How to clean the Machine

3.6.36. Check bolted connections

Machine cleaning

••

Check regularly whether some bolted connections are loosened.

••

Tighten with torque spanners.

••

Clean the Machine to get rid of major dirtiness following a work completion.

••

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.

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.

NEVER use aggressive and easily ignitable cleaning agents (e.g. gasoline or easily ignitable materials).

Follow 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 forbidden cleaning agents!

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.

122

ARS 122

MAINTENANCE MANUAL 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

ARS 122

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

123

3.6.

Individual Operations of Maintenance

Table of torques for nozzles (necks) with sealing edge, or with gasket

Table of torques for plugs with gasket

Plug torques

Nozzle torques G -M

Nm

lb. ft.

G -M

Nm

lb. ft.

G 1/8

25

18

G 1/8

15

11

G 1/4

40

30

G 1/4

33

24

G 3/8

95

70

G 3/8

70

52

G 1/2

130

96

G 1/2

90

66

G 3/4

250

184

G 3/4

150

111

G1

400

295

G1

220

162

G 11/4

600

443

G 11/4

600

443

G 11/2

800

590

G 11/2

800

590

10 x 1

25

18

10 x 1

13

10

12 x 1.5

30

22

12 x 1.5

30

22

14 x 1.5

50

37

14 x 1.5

40

30

16 x 1.5

60

44

16 x 1.5

60

44

70

52

18 x 1.5

60

44

18 x 1.5

20 x 1.5

140

103

20 x 1.5

90

66

22 x 1.5

140

103

22 x 1.5

100

74

26 x1.5

220

162

26 x1.5

120

89

27 x 1.5

250

184

27 x 1.5

150

111

33 x 1.5

400

295

33 x 1.5

250

184

42 x 1.5

600

443

42 x 1.5

400

295

48 x 1.5

800

590

48 x 1.5

500

369

124

ARS 122

3.7.

Defects

Normally, any defects are caused due to a wrong operation of the Machine. Consequently, read once more the instructions given in Operation & Maintenance Manual for the Machine and the Engine when any malfunction occurs. Unless you are able to define the cause of failure, please contact service department or manufacturer.

Troubleshooting in the area of hydraulics and wiring requires knowledge in the field of hydraulics and electrics. Therefore, please confide any repairs necessary to a service department of manufacturer.

ARS 122

125

3.8.

Appendixes

3.8.1. Wiring Diagram

G1 Battery

S3 Hazard

G3 Alternator

S4 Work light

M1 Engine starter

S5 Turn indicator

K2 Start relay

S6 Horn button

Q1 Master switch

S7 Neutral gear switch

K1 Starter relay

S8 Fast travel switch

K3 Break relay

S9 Vibration switch (In the travel controller)

K4 Vibration relay

S10 Vibration switch (movement of travel controller)

K5 Travel Relay

S11 Vibration change over switch

F 1-8 Safety fuses

S12 Break pressure switch

E 1,2 Front headlights

S13 Engine lubrication pressure switch

E3 No plate light

S14 Air filter clogging switch

E 4,5 Rear head light

S15 Hydraulic fluid filter clogging switch

E9 Left front direction light

S16 Hydraulic fluid overheating switch

E10 Left rear direction light

S17 Engine overheating switch

E11 Right rear direction light

S18 Warning beacon switch

E12 Right front direction light

S19 Backup alarm switch

E15 Warning Beacon

S20 Emergency break pushbutton

A1 Flasher

S21 Passing beam switch

H1 Horn

S22 Mobile charger

H2 Switch vibration pilot lamp

P1 Hour meter

H3 Break pilot lamp

P2 Fuel gauge meter

H4 Engine lubrication pilot lamp

X Connection connector

H5 Recharging pilot lamp

B3 Fuel level sensor

H6 Air filter clogging pilot lamp

Y1 Engine stop solenoid valve

H7 hydraulic filter clogging pilot lamp

Y2 Break valve solenoid valve

H8 Engine overheating pilot lamp

Y3 Fast travel speed solenoid valve – Left wheel

H9 Hydraulic fluid overheating pilot lamp

Y4 Fast travel speed solenoid valve – Right wheel

H11 Back up alarm

Y5 Fast travel speed solenoid valve – Drum

S1 Ignition switch

Y6 Vibration 1 solenoid valve

S2 Headlight

Y7 Vibration 2 solenoid valve

126

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MAINTENANCE MANUAL

ARS 122

127

3.8.

Appendixes

3.8.2.

Hydraulic Diagram

1.

Travel Pump

2.

Vibration Pump

3.

Steering Pump

4.

Travel Motor

5.

Vibration Motor

6.

Steering Unit

7.

Steering Cylinders

8.

Flow divider

9.

Block Brakes

10.

Drum Drive Motor

11.

Hydraulic Tank

12.

Suction Strainer

13.

Filler Breather

14.

Return Block

15.

ROC

16.

Hydraulic Filter

17.

Steering Wheel

18.

Minimess Coupling

19.

Platform Lifting Cylinder

20.

Bonnet Lifting Cylinder

21.

Needle Valve

22.

Relief Valve

23.

Hand Pump

128

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MAINTENANCE MANUAL

ARS 122

129

3.8.

Appendixes Notes

130

ARS 122

MAINTENANCE MANUAL Notes

ARS 122

131

Ammann Schweiz AG Eisenbahnstrasse 25 CH-4901 Langenthal Phone +41 62 916 61 61

www.ammann-group.com