Ammann ARS 122 Single Drum Roller Workshop Manual PDF

Workshop manual

ARS 122 Cummins

Book ID: 4-P07286CU-EN

ARS 122 Single drum roller Cummins BSIII

Workshop manual Edition 08/2017 EN From Serial No.A1N00286C17080001

Preface Information, specifications and recommended instructions for the assembly and disassembly of Individual components and parts of the machine 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 a.s. reserves the right to perform modifications without obligation to inform the machine user. If you identify any differences between the machine operated by you and the informatio n contained in this publication, contact your local dealer.

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

Ammann India Private Limited | Block No 157 | At Ditasan | P.O Jagudan | Mehsana | Gujarat – 382710 | India Phone + 91 2762 285344 | Fax + 91 2762 285359 | info.ain@ammann-group.com | www.ammann-group.com

ARS 122

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Contents

WORKSHOP MANUAL__

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

Introduction...................................................................................................3

2.

Repair safety instructions..................................................................................6

3.

Machine description........................................................................................12

4.

Specification manual.......................................................................................14

5.

Specification of fluids......................................................................................21

6.

Lubrication and Maintenance Chart.....................................................................26

7.

Removing the engine.......................................................................................30

8.

Drum Dismounting..........................................................................................46

9.

Articulated joint............................................................................................71

10.

Removal of pumps, cento clutch........................................................................82

11.

Steering cylinders...........................................................................................91

12.

Controls.......................................................................................................95

13.

The driver‘s station assembly............................................................................97

14.

Electrical installation......................................................................................99

15.

Assembly of segments....................................................................................105

16.

Disassembly of wheel.....................................................................................111

17.

Removal of hydraulic motors...........................................................................114

18.

Disassembly of level gauge..............................................................................121

19.

Disassembly of the floater...............................................................................123

20.

Electric installation.......................................................................................125

21.

Hydraulic Diagram.........................................................................................129

22.

Tightening of bolted connections......................................................................132

23.

Measuring points in the hydraulic circuit ............................................................135

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WORKSHOP MANUAL__

1. Introduction

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WORKSHOP MANUAL__ 1. Introduction This Service Manual splits into separate chapters, it includes technical data and assembly data, adjusting guidelines, and instr uctions to use special tools, jigs and aids.

The major purpose of this Workshop Manual is to provide basic information on disassembly, assembly and service repairs of the Machine’s main groups.

Machine group identification in this Manual corresponds to the Spare Parts Catalogue.

In order to ensure the smooth operation of AMMANN compaction equipment, use for repairs only the original spare parts supplied by AMMANN. Before the assembly, itself, we recommend to always mark the parts disassembled, and this due their reassembly, and to blind all the holes of individual parts of the hydraulic system so to prevent any contamination of the hydraulic circuits.

When you install individual parts into the Machine, please tighten individual bolts or nuts as per the torque tables (Annex) Unless otherwise stated in the text.

ALWAYS observe safety instructions and precautions mentioned in Chapter 2.

Manufacturer improves continuously his products based on operation experience and latest knowledge. Consequently, Manufac turer reserves the possibility of changes depending on development, and this against the illustrations, descriptions, procedures or design patterns given in this Manual.

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__

2. Repair safety instructions

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WORKSHOP MANUAL__ 2.

Repair safety instructions

The following safety instructions must be observed by all repairing the machine!

• •

•

Repairs may be carried out by skilled, trained and experienced personnel only and/or by Ammann SERVICE and dealers.

When performing repairs, always use our shop manual. Special instructions for the assembly work are given in individual chapte rs of the manual.

Before putting the machine into operation acquaint yourselves with the machine control as given in the “Operating instructions and make sure that you understand well all outfit of the machine.

• • •

Do not use the machine if you do not fully understand all controls and until you know how the machine works.

•

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

•

Installation and usage of spare parts not supplied by the manufacturer of the machine or not authorized by him can have negati

Know the area where you will work.

Do not make any redesign or modifications on the machine because you could decrease safety of the equipment.

ve effects on operational characteristics and safety operation of the machine.

Safety precautions when repairing and inspecting the equipment 

Wear work clothe and boots.

  

Use gloves when handling oils, fuel or coolant.

Protect your eyes with goggles or a shield when handling the battery.

Place the equipment on a flat and firm surface before starting repair. Secure the equipment against spontaneous movement.

  

Secure the frame of the equipment and the drum against mutual rotation using a safety pin and a draw bar.



Wash the equipment thoroughly. If you use steam, do not expose electrical components and insulation directly to stem jet, or e

Before starting work remove the ignition key, disconnect the batteries and let hot parts cool down.

Attach a warning note “Equipment out of work“ to the steering wheel and leave it there for the duration of service work. lse cover them beforehand.



Keep all parts absolutely clean when dismantling, mounting, and servicing each assembly. Protect removed parts from getting soiled.

      

Clean the surface of dismantled parts and provide for adequately dust-free working conditions and a needed lay-off area.

 

Do not adjust moving equipment.



Use only prescribed makes of motor, gear and hydraulic oils and coolants.

Be careful when handling cleaning agents. Do not use petrol or other easy inflammable materials for cleaning.

Dry the cleaned parts and immediately cover with anticorrosive protective oil- never install corroded parts!

Tools, hoists, safety equipment of the supports, and other additional items must be serviceable and in good condition.

Use hoists and fasteners (ropes, chains) that have sufficient carrying capacity and are in good condition.

Make sure that there is enough fresh air supply when starting up the equipment in an enclosed area.

Before placing the equipment into operation make sure there nobody on the equipment or close by. The start of the equipment must always be announced with an audible alarm, also after any pause in operation before the equipment is restarted. Persons present on the equipment and dangerously close by must leave the equipment after such alarm has been sounded.

When working (adjusting) on the running engine, avoid touching hot and rotating parts. During work on the running engine, another person must be present that can easily access the emergency switch and must be in contact at all times with the person performing the adjustment, to be able to switch off the engine immediately when necessary.

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WORKSHOP MANUAL__ Safety instructions for work on hydraulic circuits •

make sure that no hydraulic circuit is under pressure before dismantling it. Hydraulic oil leaks under pressure may injure your skin and cause a serious injury.

•

Mark all parts, hoses and pipes before removing them.

•

Do not operate hydraulic generators and hydraulic motors without oil.

•

There is danger of being scalded when handling hot oil.

•

Do not warm oil to temperatures above 160 °C - oil or its fumes may ignite.

•

For cleaning and wiping hydraulic parts use such textiles that do not leave lint.

•

When reassembling parts use hydraulic oil - not grease - as lubricants.

•

Clean screws and bolts carefully before installation, wash hoses and pipes and blow them off using compressed air.

•

Always use new packing in seals.

•

Fill new aggregates with hydraulic oil before installation.

•

Rinse hydraulic circuit after replacing the hydraulic device, clean the hydraulic tank as well.

•

Replace the oil filter cartridge.

•

Fill the hydraulic circuit with pure oil of the prescribed viscosity, but only when the engine has been stopped!

•

Wipe off overflow oil.

•

Check connections for tightness, whether they leak oil, before applying pressure to the system.

•

Do not adjust safety valves.

•

After all work has been finished, recheck all connections and replace all safety elements

•

After finishing the work install again all protective elements.

After putting the machine into operation, check •

Oil level in the hydraulic tank.

•

Check up filling pressure in hydraulic generators in case they are replaced as well as pressure in safety valves.

•

Carry out the measurement at temperature of 40 °C (104 °F).

Safety instruction for work on the fuel system Mixtures of petrol and diesel (winter fuel) are as inflammable as petrol.

-

Do not refuel in closed areas.

-

Wipe off overflowed fuel.

-

Do not smoke when working on the fuel system and do not use naked light! There is a danger of fire!

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WORKSHOP MANUAL__ Safety instruction for work on electrical wiring •

Disconnect the battery when carrying out any repair in the charging circuit to avoid incidental short-circuits.

•

When dismantling, first disconnect the cable from the negative pole (-), then from the positive one (+).

•

Do not disconnect batteries when the engine is running!

• Connect the “minus“ pole of the battery to the chassis and the “plus“ pole to lead “B+“ from the alternator. In case of the Reverse connection the whole semiconductor device could get destroyed.

•

When starting with auxiliary external supply, do not disconnect such supply sooner than the battery of the machine is connected. Watch out starting voltage of the auxiliary external supply (for 12 V).

•

Do not put the alternator into noload run, i. e. with the wire disconnected from the “+“ terminal and connected “D+“ terminal.

•

Do not check the presence of voltage in the wire by sparking it on the chassis of the equipment.

•

Do not do anything that produces sparks.

•

When handling batteries, use protective rubber gloves and goggles.

•

Protect your skin and clothes from stains by electrolyte or lead particles.

•

When electrolyte gets into your eye, rinse it with a stream of water for a few minutes.

Then see a doctor as soon as possible.

•

When electrolyte stains your skin or clothes, take off your clothes, wash the stained area with soap water or with a solution of baking soda and water and see a doctor.

•

After taking electrolyte incidentally, drink as much milk or water as possible or a solution of magnesia and immediately see a doctor.

•

Never pour distilled water into the cells unless the operation of the machine or charging outside the equipment follows.

In such case the battery would self discharge increasingly.

•

Never add sulfuric acid (H2SO4)!

•

Do not overturn the batteries because electrolyte could run out of the degassing holes of the battery.

•

If acid (electrolyte) is spilled, rinse the place with water and neutralize it with lime.

•

When the batteries are being charged, hydrogen is released and it makes mixed with air, an explosive, easily combustible mixture. Do not use open flame and do not smoke.

Welding on the machine •

Before starting arc welding, disconnect all parts with semiconductors from electrical wiring, inclusive of machine electronics:

•

it is necessary to earth both the supply and the machine that is being repaired,

•

secure the supply against moisture,

•

place ground terminal close to the welded joint.

•

when parts are welded or when the machine is in the suspended position, it is necessary to insulate the point of current transfer to avoid current entering the hoist, or to use a non-conducting rope.

Seals •

Always use new packing.

•

You will receive packing kits as spares.

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WORKSHOP MANUAL__ Tightening torque •

Use a torque key for the right tightening torque.

•

Fastening bolts and nuts of the given quality are tightened according to the table.

•

Quality of the bolt is shown visibly on the bolt head.

•

Tightening torque is given in tables.

•

Thread joints of hydraulic circuits are tightened according to tables.

•

The given tightening torque is valid for not oiled bolt thread.

•

Use new self-locking nuts only.

Environmental measures and health precautions When repairing the machine, keep general principles of health protection and environment protection as well, and observe laws, regulations, and guidelines related to these problems as applicable to the territory where the equipment is used.

Principles of hygiene •

Oil products, coolants, battery acids, and paints including thinners can be harmful to your health and they can injure your organs seriously.

•

It is necessary to observe consistently safety and health instructions enclosed with the products and to use personal protective aids when handling them.

•

Personnel in contact with these products during servicing are obliged to observe general principles of their health protection and keep in mind safety and health guidelines as given by manufacturers of such products, especially the following: -

protection of eyes and skin when working with batteries,

-

protection of the skin when handling oil products, paint, and cooling liquids,

-

workers should wash their hands properly after finishing their work and apply proper healing hand lotions,

-

when working with the cooling system it is necessary to observe instruction manuals supplied with the machine.

•

Oil products, coolants, batteries, and paint including organic thinners as well as cleaners and preservatives should be always stored in their original packages properly labeled. Do not store such materials in unlabelled bottles and other vessels because there is a danger of confusion. Confusion of food or drinks is especially dangerous.

•

If the skin or eyes are by chance stained or fumes are breathed, apply immediately first aid. In case of incidental consumption of such products see your doctor immediately.

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WORKSHOP MANUAL__ Ecological precautions •

Contents of machine systems and some parts of the machine can produce, when no longer in use, represent great risks to the environment.

The following products especially belong to this category: -

both organic and synthetic lubricating materials, oils and fuel,

-

coolants,

-

battery acids and batteries themselves,

-

cleaning agents and preservatives,

-

all removed filters and filter elements,

-

all used and discarded hydraulic and fuel hoses, rubber - metals and the other elements stained with the above products.

•

The above parts and materials must be handled, after they had been discarded, in accordance with valid national regulations on environmental protection and according to directions concerning health protection.

•

When hydraulic liquids, fuel, cooling systems and their aggregates are being removed it is necessary to prevent their infiltration into the ground by using retaining vessels and by plugging the holes.

•

After leaks the place must be immediately dried with sawdust, Vapex, and such.

•

The contaminated earth must be removed to prevent further leakage. Then the soil and absorbing material must be disposed of safely.

Fire precautions •

The place where oil is being changed must not situated in an area where there is danger of explosion or fire.

•

Notices showing that smoking and open flame are not allowed must be installed there.

•

The handling area must have sufficient dimensions to capture the amount of inflammable liquid equal to the volume of the largest vessel or the transport package.

•

Portable fire-extinguishers must be available.

•

Oil and oil products should be handled in special vessels, e. g. metal barrels, cans, tin cans.

•

Transport vessels must be properly closed when stored.

•

The vessels should have one hole and should be always stored with the hole up and they must be secured against leakage.

•

The vessels must be labeled with indelible inscriptions showing their contents and burning power class.

THE STANDARD TOOLS FOR MAINTENANCE AND ADJUSTMENT ACCORDING TO THE NORM ISO 4510-1 THE SPECIAL TOOLS, ASSEMBLY JIGS SEE APPROPRIATE CHAPTERS OF THE WORKSHOP MANUAL.

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WORKSHOP MANUAL__

3. Machine description

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WORKSHOP MANUAL__ 3. 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

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WORKSHOP MANUAL__

4. Specification manual

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WORKSHOP MANUAL__ 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 -15 °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, airports), hydraulic construction (earth dams) and civil engineering (industrial areas, ports etc.).

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

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

Modifications The single drum vibratory roller ARS 122 D with the smooth drum is suitable for compaction of all kinds of soil. It can be employed at compaction of clayey soils up to the layer thickness (compacted) of 25 cm (9,8 in), loam soils up to the layer thickness of 40 cm (15,7 in), mixed soils up to the layer thickness of 50 cm (19,7 in), sandy soils and rockfills 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 drum (synchronous kneading and vibrating effect) is suitable for the compaction of clay soils up to a layer thickness (after compaction) of 30 cm (11.8 in), loam soils up to a layer thickness of 40 cm (15.7 in), and mixed soils up to a layer thickness of 50 cm (19.7 in).

ARS 122

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.

15

WORKSHOP 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

1 0 . Year of Construction

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

1

2

Serial number ESN of the CUMMINS engine

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WORKSHOP MANUAL__ Dimension Chart

mm (in) ARS 122

ARS 122 (PD Shell Kit)

ARS 122

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)

2820

1500

1640

450

415

2375

5460

25

2130

2260

(111.0) (59.1)

(64.6)

(17.7)

(16.3) (119.3) (93.5)

(215)

(1.0)

(83.9)

(89)

3030

17

WORKSHOP MANUAL__ Technical Data 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

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WORKSHOP MANUAL__ 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

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WORKSHOP MANUAL__ ARS 122 Cummins BS III Wiring Voltage

V

12

Battery capacity

Ah

150

Optional equipment Padfoot drum shell kit Ammann Traction Optimizer Working speed increase kit (increase up to 7 km/h) Hard canopy Self Standing tractor Tyres Tyre ballast -25 °C Warning Beacon

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WORKSHOP MANUAL__

5. Specification of fluids

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WORKSHOP MANUAL__ 5.1.

Motor Oil 2412

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

°F

°C

122

50

104

40

86

30

68

20

50

10

32

0

14

-10

-4

-20

-22

-30

-40

-40

Performance Classification under API (AMETICAN PETROLEUM INSTITUTE) CCMC (COMMITE OF COMMON MARKET AUTOMOBILE CONSTRUCTORS) ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE AUTOMOBILE)

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

15W-40 15W-40

Viscosity Classification

Note: Exceeding low temperature limit will not lead to any motor 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. Motor manufacturer recommends using SAE 10W-30 oil to make starting at freezing temperatures (below 0 °C, 32 °F) easier.

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.

5W-30

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

10W-30 10W-30

ACEA: E-5

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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WORKSHOP MANUAL__

5.2.

Fuel

5.4.

Hydraulic Oil 2158

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

-

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.

Use only quality hydraulic oils of power class per ISO 6743/ HV for the Machine’s hydraulic system (corresponds to DIN 51524 Section 2 HVLP; CETOP RP 91 H).

Normally the machines are filled at manufacturer with hydraulic oil of cinematic 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.

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

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.

5.3.

Cooling Liquid 2152

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 propylene antifreeze agents as well to refill the cooling system.

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

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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WORKSHOP MANUAL__ 5.5.

Gearbox Oil 2186

Use quality oil corresponding to API GL5 to lubricate the uncoupled axle gearbox and axle drive ge ar-boxes.

SAE 80W/140 viscosity for ambient temperature of +20 °C to +45 °C (68 °F - 113 °F).

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

5.6.

Lubricating Grease 0787

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

ISO 6743/9 CCEB 2

-

DIN 51 502 KP2K-30

-

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

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WORKSHOP MANUAL__ 5.7.

Refills

Section

Refill Type

Refill Amount

Brand

l (gal US) 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

ARS 122

as required

25

WORKSHOP MANUAL__

6. Lubrication and Maintenance Chart

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26

WORKSHOP MANUAL__ 6. Lubrication and Maintenance Chart 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 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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WORKSHOP 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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WORKSHOP MANUAL__

LUBRICATION AND SERVICE PLAN CHECK LUBRICATE EXCHANGE 2000 1000 500 250

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Filterset500h/4-760012

Filterset2000h/4-760110

20

Engine oil:

SAE 15W/40

API CF-4/SG

Hydraulic fluid:

ISO VG 68

ISO 6743/HV

Grease:

ISO 6743/9

CCEB 2

Gear oil:

SAE 80W/90; API GL-5; MIL-L2105 C SAE 80W/140; API GL-5; MIL-L-

29

WORKSHOP MANUAL__

7. Removing the engine

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__ Technical data Motor oils and lubricating grease

Amount [l gal]

Engine oil - API CE; SAE 15W/40

11.2 (2.96)

Coolant fluid in engine - anti-freeze liquid

24 (6.3)

Lubricating grease - ISO 6743/9 CCEB 2, DIN 51 502 KP2K-30

as required

Coolant is a mixture consisting of treated demineralized or distilled water and antifreeze ethylene glycol. Coolant can be also prepared from a propylene glycol antifreeze. Minimum portion of the ethylene glycol or propylene glycol antifreeze in the coolant is 50 %.

Temperature limits of coolant at different contents of ethylene glycol or propylene glycol in the liquids used are given in the following table. antifreeze with ethylene glycol

antifreeze with propylene glycol

50 % = –37 °C [–34 °F]

50 % = –33 °C [–27 °F]

60 % = –54 °C [–65 °F]

60 % = –49 °C [–56 °F]

68 % = –71 °C [–96 °F]

68 % = –63 °C [–82 °F]

Water for preparation of the coolant should be used according to the criteria given in the following table: Water quality

min.

max.

pH factor at 20 °C [68 °F]

6.5

8.5

3 Content of chlorides (mg/dm)

-

100

Content of sulfates (mg/dm) 3

-

100

Total hardness (°dGH)

3

12

Liquids: The liquids used must contain anticorrosive additives protecting all materials in the cooling system including rubber and the head gasket. Liquids should not be mixed together with those of other marks. They must correspond to testing criteria as given in ASTM 4985. Do not use a greater portion of the frost proof cooling agent in coolant than 50 % if it is not necessary.

Never use proportion greater than 68 %.

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WORKSHOP MANUAL__ Disassembly and assembly of the engine Preparatory set-up Preparatory activities and both dismantling and assembly of the engine should be performed in accordance with the first chapter „Safety Instructions“. Ecological measures and HEALTH principles must be kept as well.

Dismantling of the hood Lift the hood, support by fixture no.1 in lifted position.

Disconnect electrical wiring.

1

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35

WORKSHOP MANUAL__ Press out pins from piston ends in lifting hydraulic motors, secure by fixture no. 2.

Install fixture no. 3, lower the hood, support.

3

Remove hinges.

Attach hooks of fixture no. 3.

3

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WORKSHOP MANUAL__ Set hood aside using fixture no. 3.

Removing the cooler Loosen pouring throat, drain coolant.

Drain coolant into a ready container.

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WORKSHOP MANUAL__ 27

Disconnect hoses (123-26), (123-27) and rubber elbow (123-35).

Remove hoses (300-78), (300-79) to the hydraulic oil radiator, plug up outlets.

35

83 84

Remove holders (123-8).

8

Note: When remounting use Loctite 577 to secure the screws.

Loosen bolts (123-53).

Note: When remounting use Loctite 577 to secure the screws.

53

Suspend radiator by hooks, set aside.

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WORKSHOP MANUAL__ Removing the exhaust and air filter Loosen clamp screws (133-23) at the turbocharger.

23

Remove four bolts on the air filter holder.

Disconnect wiring to filter sensor, set filter aside.

Loosen clamp on exhaust pipe (133-14).

14

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WORKSHOP MANUAL__ Remove bolts of exhaust pipe holder.

Set muffler aside.

Plug up outlets.

Dismantling of the engine Disconnect all wires – ground strip, starter wires, alternator wires, water temperature and oil pressure sensor RPM meter, and injection pump solenoid.

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WORKSHOP MANUAL__ Disconnect the throttle cable.

Disconnect intake and overflow of fuel.

Lift the cabin using hydraulic lift, then use crane to unload the piston of the lifting hydraulic motor using fixture no.1.

1

Remove cover of hydraulic tank.

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WORKSHOP MANUAL__ Remove suction hose (334-51) from hydraulic tank to steering pump.

51

Plug up outlet.

Disconnect hoses from pumps, plug up.

Remove bolts.

Set aside rubber wall (471-1).

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WORKSHOP MANUAL__ Remove bolts (103-48) from flange (103-12).

48

12

Suspend pumps on crane.

Slide out of the clutch (103-86), support.

86

Remove nuts of front engine rubber mountings (103-64).

64

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WORKSHOP MANUAL__ Remove nuts of rear rubber mountings (103-64).

64 Suspend engine on the crane by hooks.

Extract, set aside to the appropriate stand.

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WORKSHOP MANUAL__ Fixtures no. 1 Installation – 64-281-126

no. 2 Installation – 64-303-342

no. 3 Handling – 65-281-091

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WORKSHOP MANUAL__

8. Drum Dismounting

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__ Technical data Description The vibrating drum with carriers is fixed on both sides in the front frame by means of metal rubber parts of the prescribed strength.

The vibrating effect is generated by two pairs of cams on both sides of the drum. The cams are interconnected using a shaft. The cams are driven by a hydraulic motor – the drum left side. The drum is driven by a hydraulic motor – right side.

Vibrating roller service fluids

l (gal US)

Drum – vibrator housing – engine oil – API CD EP; SAE 15 W/40

8.0 (2.1)

Reducer – engine oil – API GL-5 SAE 80 W/90 for an ambient temperature of -10 °C to +30 °C (14 °F to 86 °F)

3.5 (0,92)

SAE 80 W/140 for an ambient temperature of +20 °C to +45 °C (68 °F to 113 °F) Lubricating grease – ISO 6743/9 CCEB 2, DIN 51 502 KP2K-30

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as required

51

WORKSHOP MANUAL__ Drum Dismounting Jack up, e.g. using a hydraulic lifting device, the drum frame so that the drum touches the ground lightly. Place it on fixed supports on both sides.

Remove the cover of vibration hydraulic motor.

Dismount the vibration hydraulic motor hoses collars.

Screw four bolts on vibration hydraulic motor off.

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WORKSHOP MANUAL__ Remove hydraulic motor and set aside on the side of the frame.

Remove holders of hoses on rear crossbeam of the frame.

Remove holders of hoses of the travel hydraulic motor.

Place a catch basin underneath the travel hydraulic motor.

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WORKSHOP MANUAL__ Dismount the travel hydraulic motor hoses.

Plug up outlets of hoses and the hydraulic motor.

Fasten the hoses behind the mirror arm to the cab.

Disconnect the electrical installation from the travel hydraulic motor (sensor, solenoid).

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WORKSHOP MANUAL__ Unscrew the dummy plugs (54-18) in the front cross beam, mount the lifting eyes.

18

Suspend crossbeam on the crane.

Remove bolts (54-10) and (54-11) on both sides, set crossbeam aside.

10 Loosen connecting bolts (5-37) of the frame and the bracket on the left side, and (35-18) on the right side.

37

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WORKSHOP MANUAL__ Slide off rubber mounting using fixture bolts no. 3.

3

Tighten rubber mounting by 8–10 mm (0.3to0.4 in).

After having removed bolts that connect the frame of the drum, remove spacers.

Roll the drum from the frame.

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WORKSHOP MANUAL__ Install drain plug in the left lid in lower position.

Use fixtures no. 4 to prevent movement.

4 Unscrew drain plug from the lid of the vibrator, drain oil to catch basin.

Discharged amount: 8 l (2.1 gal U.S.).

Turn bracket (5-2) and remove bolts (5-39) one after the other.

The remaining two bolts in the horizontal axis to be removed first after mounting the bracket to the fixture.

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2

57

WORKSHOP MANUAL__ Place console (5-2) vertically and using fixture no. 5 attach to the crane.

5

2

Remove last two bolts (5-39).

39

39

39

Remove console together with the vibrator plate from the drum – set aside. Remove fixture bolts no.3. one after the other.

3

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58

WORKSHOP MANUAL__ Remove screws (5-44), remove bracket (5-2) from rubber mountings.

2

Vibrator plate to be rotated and placed on the rubber mounting.

Remove safety plate (5-31).

31

Place fixture no. 6 on nut (5-30).

6

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WORKSHOP MANUAL__ Remove nut (5-30) and plate (5-31).

30

Turn vibrator plate (5-3) with hub (5-9) upside down – support it.

31

3

9

Remove bolts (5-42).

42

42

42

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WORKSHOP MANUAL__ Insert fixture bolts no. 7 in the hole, by stepwise tightening remove hub (5-9). If necessary use fixture no. 7 Note Bolts (3 pieces) are part of fixture no. 7 as position (2).

7

Press out bearing (5-28), seal (5-22) and ring (5-23) from the hub.

23 22

28

Vibration plate assembly When mounting, follow the same procedure as when dismounting in the reverse order.

Press on the bearing outer ring (5-28), turn, mount the outer ring of another bearing, and press on the rubber seal (5-22) using fixture no. 8.

28 22 28

Mount (when replacing) the O-ring (5-26) and the ring (5-13) preheated to 90 °C (194 °F) on the vibration plate shaft. Mount the inner part of bearing (5-28) – preheat it to 90 to 110 °C (194 to 230 °F).

28 26

13

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61

WORKSHOP MANUAL__ Fill the bearings with the lubricating grease and mount the hub (5-29).

29

Mount the inner part of bearing (5-28) – preheat it to 90 to 110 °C.

28

Mount the plate (5-31) and nut (5-30).

30

31

Tighten it using fixture no. 6 (tap on the fixture when tightening).

6

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WORKSHOP MANUAL__ Check the nut tightening for a torque of 70 to 80 Nm using fixture no. 9.

9

Right side dismounting Turn the drum to position according to the Fig.

Using fixture no. 5 suspend console (35-1) on the crane.

5

1

Dismount the screws (35-14).

14

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63

WORKSHOP MANUAL__ Set the console (35-1) with the driver (35-2) aside.

1

2 Dismounting of vibrators Dismount the screws (5-38) – hang the cover (5-8) on fixture no. 10; using three screws in the process openings “A”, push the cover away from the drum face.

A

A

10 8

38

A Remove the cover.

8 10

Remove the vibrator using the same fixture.

10

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WORKSHOP MANUAL__ Dismount the screws (5-40), remove the cover (5-10), dismount the retaining ring (20-18), press out the bearing outer rings (20-19) from the covers (5-8), (5-10) and dismount the connecting shaft (20-5).

40 10

5

19

When dismounting the covers (5-7) and (5-10) and the vibrator on the left side of the drum, follow the same procedure!

7

Preheat the bearing inner rings (20-19) to 90 to 110 °C (194 to 230 °F) and dismount them from the shafts.

19

19

Remove the ring halves (20-7) and dismount the free cam (20-2).

The fixed cam (20-1) can be removed by cutting the cam body at its thinnest point or use a new shaft (20-3), (20-4) with the cam (20-1).

3,4 2

7 1

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WORKSHOP MANUAL__ Assembly of the vibrator If new parts are used when mounting the vibrator – heat the cam (20-1) to a temperature of 250 to 350 °C (482 to 662 °F) and place it on fixture support no. 11; push the shaft (20-3), (20-4) with a key (20-11) into it.

5 11 1 11

Press case (20-8) into eccentric (20-2) using fixture no. 12, calibrate it.

2

8

Other operations of the mounting for both sides of the drum are identical; follow them in the order reverse to the order of dismounting.

19

When mounting the bearing outer rings (20-19) into the covers (5-7), (5-8), and (5-10), observe the pairing with the bearing inner rings!

7,8 Mount the circlip (20-17). When mounting the connecting shaft (20-5), it is necessary to observe the right position of the vibrators against each other – this is secured by the groove “A” on both ends of the shaft facing the pins (20-12) in shafts (20-3) and (20-4).

A

17

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5

66

WORKSHOP MANUAL__ Strike the pins (20-12) into both shafts (20-3), (20-4) and secure their position by means of fixture no. 13.

3,4

12

After mounting the covers (5-7), (5-8), test the axial clearance (1.5 – 2.5 mm) of the bearings of both vibrators using fixture no. 14.

14 For replacement of vibration hydraulic motors (5-35), hub must be heated up to 200 °C, and slid on the output shaft of the hydraulic motor. The guide pin on the spline must move freely to full stop and must not be forced.

35

Use Loctite-243 to glue bolts (5-14) of hydraulic motor (5-35).

Tighten the bolts to a torque of 110 Nm.

14

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WORKSHOP MANUAL__ Fixtures no. 3 Installation - 64-281-062

no. 4

Handling - 92-644-128

no. 5 Handling - 65-288-087

no. 6 Installation - 64-322072

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WORKSHOP MANUAL__ no. 7 Installation - 92-632-119

1 2

no. 8 Installation - 64-281-095

no. 9 Control - 64-281-100

no. 10

Installation - 64-298-222

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WORKSHOP MANUAL__ no. 11

Installation - 64-303-263

no. 12

Installation - 64-298-219

no. 13

Installation - 64-298-220

no. 14

Control - 64-298-221

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WORKSHOP MANUAL__

9. Articulated joint

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__

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WORKSHOP MANUAL__ Description

2

The joint connecting the drum frame with the rear frame is equipped with a large-size bearing 1 with cross rollers allowing for the frame to swing in the vertical plane, and two vertical pins 2 allowing for steering angle in the horizontal plane.

1

2

Place the machine on firm ground, support the frame in front.

Support frame in the rear.

Remove plates (373-3).

3

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WORKSHOP MANUAL__ Use fixture no. 1 to press out pins (373-1) out of the ends of pistons of the steering cylinder (373-6).

1

6

Remove hose clamps on the drum frame.

Remove clamping of hoses on the hinge and the rear frame.

Remove cover of vibration hydraulic motor.

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WORKSHOP MANUAL__ Remove vibration hydraulic motor.

Slide hydraulic motor from the drum, set aside.

Suspend drum with the frame using fixture no. 2. Use two twinhooks because of the weight.

2

Remove bolts (63-40).

40 40 40

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WORKSHOP MANUAL__ Set aside the drum with front frame on the right side outside the machine. Secure the drum with appropriate stands.

Place hoist under frame plate (63-2). Remove bolts (63-37).

37 2

When reassembling tight the bolts (63-37) in the order according to the Fig. Tight it with torque 117 Nm, safe the screws by Loctite 243. Always use new bolts according to the Spare parts catalogue.

11 2

8

5 15

14

12

4

3 7

9

Put plate (63-2) aside.

2

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77

WORKSHOP MANUAL__ Loosen bolts (63-38).

38

When reassembling tight the bolts (63-38) with torque 117 Nm according to the Fig. Safe the screws by Loctite 243. Always use new bolts according to the Spare parts catalogue.

17

8

5

13

9

12

3 18

2

14 4

6

Place fixture no. 3 under the upper bolt, suspend on crane using fixture no. 4.

3

Set bearing aside.

4

Loosen nuts and remove nuts (63-25) using fixture wrench no. 5.

The nut reassemble torque: 200 Nm

5 ASC246A

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WORKSHOP MANUAL__ Remove clamps of the pin, press out the pins (63-12) using jack, see Fig.

12

12

Use crane to set hub (63-3) aside.

3

Remove covers (63-10), (63-11), and spreaders (63-13).

11

10 13

Press out bearings (63-24) using fixture no. 6.

24

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WORKSHOP MANUAL__ Fixtures no.1 Installation - 92-632-122

no.2 Handling - 92-645-202

no.3 Handling - 65-281-201

no.4 Handling - 64-298-222

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WORKSHOP MANUAL__ no.5 Installation - 92-655-095

no.6 Installation - 92-631-006

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WORKSHOP MANUAL__

10. Removal of pumps, cento clutch

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82

WORKSHOP MANUAL__ Lift the cabin using hydraulic lift, then use crane to unload the piston of the lifting hydraulic motor using fixture no.1.

Remove and set rubber wall aside.

Remove hose clamps.

Disconnect wires to hydraulic generators.

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WORKSHOP MANUAL__ Remove hoses from hydraulic generators.

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84

WORKSHOP MANUAL__ Plug outlets of hydraulic generators and hose ends.

Remove bolts of gear pump. Put gear pump aside.

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85

WORKSHOP MANUAL__ Suspend vibration hydraulic generator on the crane, remove bolts connecting both hydraulic generators.

Slide out and set aside.

Suspend travel hydraulic generator on the crane.

Remove bolts (103-48) from flange (103-12).

48 12

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86

WORKSHOP MANUAL__ Slide out of clutch (103-86).

86

Set hydro generator with flange aside.

8 Remove bolts T1 of “A“ segment.

A T1

Remove bolts T2, pull down the coupling segment (103-86) from the hydraulic generator shaft, remove bolts T1 and segment„B“.

T1

B T2

86

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WORKSHOP MANUAL__ Remove screws of hydraulic pump from flange (103-12).

12

Clutch Install„A“ segments to the balance-wheel. Center the segments using fixture No. 2. Lubricate T1 bolts under the head with grease, tighten them by means of the torque as given in the table. Check their position after tightening.

2

T1

Assembly clutch

A A

A

Fix flange (103-12) on the flange of the travel hydraulic generator and coupling (103-86) with„B“ segments. Tighten T2 bolts of coupling (103-86) by means of the torque as given in the table, see next page.

12

T1 T2 B

86 When installing coupling (103-86), define axial clearance between the balance-wheel face and the elastic element of clutch.

Measure the distance „a“ from the face of the balance-wheel box.

a

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WORKSHOP MANUAL__ Measure distance „b“ from the elastic element face to the seating area of flange (103-12).

Difference in the distances a - b = 1 to 3 mm.

b

Colored (e. g. blue color) material is deposited on the thread of the supplied countersunk hexagonal screws. Such material includes a film of adhesive and prevents its releasing. The time of hardening of such adhesive material after screwing the bolts is 4 to 5 hours at the ambient temperature of 20 °C. The operation of the machine should not start before this time period has elapsed. Full hardening is finished after 24 hours. At higher temperatures the hardening can be faster, e. g. 15 minutes at 70 °C (heating performed by a hot air fan). Temperature stability of the bolts is between -80 to +90 °C (-112to +194 °F) and they can be used three times at maximum. The adhesive material is sometimes wiped off and it is deposited between the head of the bolt and the segment. This is not a defect, rather advantage - both areas will adhere to each other better. If original supplied bolts are not available, both the bored thread and bolt must be carefully degreased and a layer of Loctite or Omnifit should be applied to them.

Spring washers are not allowed!

The tandem of hydraulic generators including the connection of hydraulic hoses and electrical wiring should be installed using a crane in the opposite way.

Tightening torque T 1 bolt

155 to 165 Nm

T 2 bolt

120 Nm

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WORKSHOP MANUAL__ Fixtures No.1 - 64-281-099 - Handling

No.2 - 64-298-290 - Assembly

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90

WORKSHOP MANUAL__

11. Steering cylinders

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WORKSHOP MANUAL__ Removal from the machine Place the machine on firm flat ground. Set steering to its maximum turn and lift the cabin for easier access. Place a tray under the dismounted hydraulic motor. Disconnect hoses and plug them up. Remove shims (373-1) and press out pins (373-2) from the ends using fixture No. 3. Push the piston rod in after the piston rod pin has been pressed out. Remove the linear hydraulic motor from the machine using hoist, sliding it out through the rear frame opening towards the drum.

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WORKSHOP MANUAL__ Removal of linear hydraulic motor – replacement of seals Place a receptacle under the hydraulic motor, plug openings.

Use fixture no. 1 to remove the cover (1), pull out the piston rod (2) with piston (3), remove the nut (4) and the piston. Slide the cover (1).

Grease sliding faces, watch out for damage to sliding faces. Install parts with new seals after straightening out the seals. At least 15 minutes should elapse between the installation of new seals and the completion of assembly of the linear hydraulic motor. Use fixture No.2 for the installation of the piston rod with the piston in the cylinder body. Tighten threaded joints with torque specified in the table.

4

66 6

3

1

2

Assembly sealing material kits Item No.

Description

1

Sealing

2

Collar

3

Scraping ring

4

Guiding band

5

Guiding band

6

Ring

7

Ring

1

5

4 3

7 6

6

2

Note!

The respective sealing material may be ordered as a kit from the cylinder manufacturer specifying manufacturing number of the equipment.

TIGHTENING TORQUE TABLE Hydraulic cylinder 90/45-400

Connection of piston rod

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Connection of cylinder body, cover

Thread

Tighting torque Nm [lb ft]

Thread

Tighting torque Nm [lb ft]

M 32x2

140 [103]

M 95 x1.5

200 [183]

93

WORKSHOP MANUAL__ Fixtures No.1 - 92-655-112 - Installation (wrench for removal of lid of hydraulic cylinders 90/45)

No.2 - Assembly - 92-644-031 (for assembly of piston to hydr. cylinder)

No.3 - Assembly - 92-633-122 (for pressing pin)

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94

WORKSHOP MANUAL__

12. Controls

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95

WORKSHOP MANUAL__ Removing and reassembling steering Remove screws (187-18), screw out the steering wheel with steering rod.

Accelerator control removal and reassembly Disconnect the accelerator cable. Loosen the nuts (187-23), remove the gas lever (187-8). When removing the accelerator cable, remove it also at the injection pump lever of the engine.

Lubricate new cable with grease.

Removing and reassembling travel control Raise the dust cover, remove the screws, disconnect the wiring.

Remove the travel control.

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WORKSHOP MANUAL__

13. The driver’s station assembly

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97

WORKSHOP MANUAL__ Lifting, lowering and keeping the cabin or platform in the raised position must only be performed with an empty cabin or platform.

Platform Loosen nuts of the driver‘s station.

Fold the station using the lifting hydraulic motor.

Disconnect the cable on the injection pump (3), drain partially the cooling fluid, disconnect heater hoses (1), (2), electrical cables, remove power steering assembly underneath the cabin, disconnect anchor chain, lower the cabin, hook up the hoist by the eyelets on the cabin roof and lay it aside.

Assemble in reverse order, add coolin

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2

1

3

98

WORKSHOP MANUAL__

14. Electrical installation

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99

WORKSHOP MANUAL__ Fuse Block 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 Fuse (F7) - 7.5A Reserved Fuse (F8) - 7.5A Reserved

Replace fuses with those of identical value ONLY!!!

Accumulator cutoff switch Use cutoff switch to disconnect accumulator from the frame.

While working on electrical wiring, disconnect always the battery!

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WORKSHOP MANUAL__ Electrical wiring – location of elements

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WORKSHOP MANUAL__

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102

WORKSHOP MANUAL__

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103

WORKSHOP MANUAL__ Battery

Alternator

The batteries are factory-filled with acid with a density of 1.28 g/ml and sufficiently charged for immediate use. In case of insufficient starting power, recharging is necessary.

•

The alternator is the source of electrical energy.

•

A semiconductor voltage regulator is part of the alternator to maintain output voltage within limits while the revolutions, load and ambient temperature vary.

Charging

•

Regulated voltage is measured on terminal +B.

•

The battery must be recharged if the static voltage drops below 12.5 V as a result of a long storage period. The static voltage should be checked upon the expiry of 2 to 4 quarters after the date of production. If the static voltage is lower than 12.5 V, the battery must be recharged before further storage to the level from 12.7 to 12.8 V. The measurement of static voltage is performed by means of a digital multimeter.

The measurement must be performed under the temperature of approx. 20 °C.

•

The alternator must be always connected to the battery – positive battery to +B. It is not allowed to disconnect the battery while the engine is running.

•

Avoid shorts in the alternator circuit. While repairing wiring or welding on the machine, disconnect the alternator. When starting with an external source, it is not permitted to disconnect this source before the battery is not on. The alternator must not be run unloaded with cable removed from terminal ”+B” and the terminal ”+D” connected.

•

Ensure the adequate ventilation of the working areas.

•

•

Use only suitable direct-current chargers.

•

Connect the plus pole of the battery with the plus output of the charger; similarly, connect the minus pole.

A burnt out indicator bulb of charging must be replaced immediately. Without this bulb the alternator excitation doesn’t function. When washing the engine, prevent water from entering the ventilation openings on the alternator.

•

Turn on the charge only after the connecting the battery and turn it off only after the battery has been recharged.

NOTE: When welding on the machine disconnect the alternator leads from terminals ”+B” and ”+D”, and electrical devices containing semiconductors. Disconnect battery when repairing other electrical devices.

•

Recommended charging current: 1/10 of the battery capacity in amperes (Ah).

•

If the acid temperature exceeds 55 °C, interrupt the charging.

•

The battery is fully charged if the charging voltage does not increase in the course of two hours.

Starter

•

After the charging has been completed, always measure the static voltage (no sooner than 1 hour after the end of charging).

•

Correct operation of the starter is preconditioned by correct and fully charged batteries.

•

The starter has been designed for a short period operation of less than 5 seconds.

•

When the engine starts, stop starting, otherwise the pinion and/or the bearing may be damaged.

•

Cables must be tight, insulation not damaged.

•

The starter body is part of the circuit. Keep contact faces on the engine clean and protected against corrosion.

•

Remove the protective cover of the plus pole only in the machine when connecting the pole terminal and put it on the pole of the dismounted battery in order to prevent short-circuits.

Should the starter be inoperative, look for breaks between the battery and the starter, the engine and the starter, or the chassis and batteries.

•

Check the crown of the flywheel and the pinion for wear, and apply grease at the same time.

•

Clean the poles and grease the terminal poles lightly.

•

•

Fasten the plus poles first and make sure that the terminals are attached firmly.

During repair or every 2 years remove the starter, check the commutator, brush springs, and the breaker contacts.

•

•

Keep at least one vent hole free.

The brushes must sit with a 3/4 surface on the commutator ring, and must be easily sliding. The contact areas of the breaker mustn’t be burnt, and must make contact for the entire flat part.

Dismounting •

When dismounting the battery, disconnect the cable from the negative (-) pole first, then from the positive (+) pole.

Do not disconnect the battery when the engine is running.

Mounting •

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15. Assembly of segments

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WORKSHOP MANUAL__ Place the machine on a firm and flat ground.

Clean thoroughly the surface of the drum.

First segment Suspend the first segment across the openings in the lugs on both sides of the machine.

Place it on the drum.

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WORKSHOP MANUAL__ Use four clamps to fix on each side. Before tightening even up segment edges with the edge of the drum.

Second segment Drive the Machine slowly forward by about 2,4 m (7,88 ft).

Suspend the second segment across the openings in the lugs in the same way as the first segment.

Position the second segment so that there is a gap between the segment ends of about 26 mm (1,02 in).

26(1,02)

While checking the clamps so that they wouldn’t interfere with the drum frame.

Connect segments using material (560-10), (560-13), (560-16).

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WORKSHOP MANUAL__ Dismount the clamps on both sides of the machine.

The second nuts (560-13) are used to cover the thread. Distribute the overlap evenly within 6 mm (0.24 in) range.

6 (0.24in)

Mount the scrapers from both sides of the frame. Check out whether the segment lugs fits into the holes between the scrapers. Secure the screws (560-8) with Loctite 243 adhesive.

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WORKSHOP MANUAL__ How to install the segments onto the Drum’s surface With the bolted M20 8G connections tightened at torque 390 Nm (287,6 lb ft), operate the Machine with low or high vibration switched ON and with travel speed 1 set in time interval of two minutes, stop the Machine, confirm bolted connections are tightened. Following that, operate the Machine in minimal time interval of 1 hour, you may adjust travel speed within 1-3 range, and then check again bolted connections are tightened.

Check continuously bolted connections during Machine drive.

When driving the Roller in the above mentioned process NEVER use high or low vibration frequency on the surface already being compacted, hard subsurface or frozen surface.

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16. Disassembly of wheel

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WORKSHOP MANUAL__ Hoist the rear frame of the machine, insert supports.

Remove bolts (45-8) and washers (45-11).

11

8

Remove tire with the disk, set aside, to use of fixture no. 1.

1

Install tire with the disk supplied in the set with the tamping drum. Tighten with torque - see chapter Check the tightening of bolted connections.

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112

WORKSHOP MANUAL__ Fixtures No.1 - 64-331-056 - Handling (for removal of the wheel)

1

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17. Removal of hydraulic motors

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WORKSHOP MANUAL__ Removal of hood hydraulic motors Lift the hood, support by fixture no.1 in lifted position.

Disconnect electrical wiring.

1

1

Press out pins from piston ends in lifting hydraulic motors, secure by fixture no. 2.

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WORKSHOP MANUAL__ Install fixture no. 3, lower the hood, support.

3

Remove hinges.

Attach hooks of fixture no. 3.

3

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WORKSHOP MANUAL__ Set hood aside using fixture no. 3.

Remove shims, press out pins from piston ends. Using lifting hydraulic motor remove from equipment, remove hydraulic lock.

Removal of cabin hydraulic motor from equipment Lift cabin, support using fixture No. 4, place receptacle under the hydraulic motor, press piston rod in the cylinder, remove hydraulic motor with bracket from the equipment, press out pin, remove hydraulic lock.

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WORKSHOP MANUAL__ Removal of linear hydraulic motor – replacement of seals Place a receptacle under the hydraulic motor, plug openings.

Drill out safety pin from the face of the front lid (1) (bend lid 1 safety) depending on the type of the linear hydraulic motor. Using fixture wrench No. 5, 6 (depending on the type of the linear hydraulic motor) remove lid (1), slide piston rod (2) with piston (3), remove nut (4) and the piston. Slide lid (1).

4

3

6

1

2

Replace the seals. Before mounting the seals, immerse them in oil.

Item No.

Description

1

Sealing

2

Collar

3

Scraping ring

4

Guiding band

5

Ring

6

Ring

1

1

5

1

5

6

6

2

4

4

3

Assembly of the linear hydraulic motor Sliding surfaces should be lubricated – observe that the surface of the piston rod is not damaged. New seals should be straightened out. Wait at least 15 minutes before complete assembly of the hydraulic motor after new seals have been installed. For assembly of piston rod with the piston in the cylinder use fixture No. 7. Threads to be tightened with torque according to the table.

Assembly reverse order. Replace seals (25).

Note!

Proper seal sets for the linear hydraulic motor may be ordered from the equipment manufacturer indicating the S/N of the equipment.

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WORKSHOP MANUAL__ Fixtures No. 1 - 64-281-126 - Assembly (hood support)

No. 2 - 64-303-342 - Assembly (securing the bonnet lifting cylinders)

No. 3 - 65-281-091 - Handling (lifting eyes for assembly of bonnet)

No. 4 - 64-281-099 - Handling (cabin support)

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WORKSHOP MANUAL__ No. 5 - Assembly - 92-655-110 (spanner for disassembly of cover 1)

No. 6 - Assembly - 92-655-112 (spanner for disassembly of cover 1)

No. 7 - Assembly - 92-644-031 (for installation of piston to hydraulic cylinder)

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18. Disassembly of level gauge

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121

WORKSHOP MANUAL__ Remove cover of hydraulic tank.

Remove cover of level gauge.

Loosen bolts attaching the level gauge.

Disconnect and remove wiring.

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WORKSHOP MANUAL__

19. Disassembly of the floater

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123

WORKSHOP MANUAL__ Loosen clamp on the cover of the floater, tilt cover.

Disconnect wiring.

Loosen connecting bolts.

Remove floater.

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20. Electric installation

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The electric installation consists of two accumulator batteries, an alternator and other control and indicating devices.

Operation voltage is 12 V. The minus pole of the accu-batteries is connected to the machine frame through a disconnecter.

The disconnecter connects or disconnects supplying of the machine electric system.

In addition to the basic ”car-electricity”of the machine, there are used electronic elements, some circuits are protected by diodes, and some instruments include e.g. thyristors.

A hydraulic lock (ATC) is controlled by a control unit (SUSMIK) located below the instrument panel. Therefore welding works are prohibited on the machine, without disconnecting all sensitive parts from the power supply and/or their dismantling, if possible, in advance. For example, data inside the SUSMIK equipment can be erased by welding close to it.

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WORKSHOP MANUAL__ Wiring diagram (the diagram represents the machine with maximum number of control elements and accessories)

Key: G1

Battery

S8

Fast travel switch

G3

Alternator

S9

Vibration switch (In the travel controller)

M1

Engine starter

S10 Vibration switch (movement of travel controller)

K2

Start relay

S11 Vibration change over switch

Q1

Master switch

S12

K1

Starter relay

S13 Engine lubrication pressure switch

K3

Break relay

S14 Air filter clogging switch

K4

Vibration relay

S15

K5

Travel Relay

switch

F 1-8

Safety fuses

S16 Hydraulic fluid overheating switch

E 1,2

Front headlights

S17 Engine overheating switch

E3

No plate light

S18 Warning beacon switch

Break pressure switch

Hydraulic fluid filter clogging

E 4,5 Rear head light

S19 Backup alarm switch

E9

Left front direction light

S20 Emergency break pushbutton

E10

Left rear direction light

S21

Passing beam switch

E11

Right rear direction light

S22

Mobile charger

E12

Right front direction light

P1

Hour meter

E15

Warning Beacon

P2

Fuel gauge meter

A1

Flasher

X

Connection connector

H1

Horn

B3

Fuel level sensor

H2

Switch vibration pilot lamp

Y1

Engine stop solenoid valve

H3

Break pilot lamp

Y2

Break valve solenoid valve

H4

Engine lubrication pilot lamp

Y3

Fast travel speed solenoid valve – Left wheel

H5

Recharging pilot lamp

Y4

Fast travel speed solenoid valve – Right wheel

H6

Air filter clogging pilot lamp

Y5

Fast travel speed solenoid valve – Drum

H7

hydraulic filter clogging pilot lamp

Y6

Vibration 1 solenoid valve

H8

Engine overheating pilot lamp

Y7

Vibration 2 solenoid valve

H9

Hydraulic fluid overheating pilot lamp

H11

Back up alarm

S1

Ignition switch

S2

Headlight

S3

Hazard

S4

Work light

S5

Turn indicator

S6

Horn button

S7

Neutral gear switch

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21. Hydraulic Diagram

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WORKSHOP MANUAL__ Hydraulic Diagram Legend: 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

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22. Tightening of bolted connections

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WORKSHOP MANUAL__ •

Confirm regularly that no loosening of bolted connections has occurred.

•

Use the torque spanners to do the tightening.

TIGHTENING MOMENT

TIGHTENING MOMENT

For the screws 8,8 (8G)

For the screws 10,9 (10K)

Worm

Nm

lb-ft

Nm

lb-ft

M6

10

7.4

14

10.3

For the screws 8,8 (8G)

For the screws 10,9 (10K)

Worm

Nm

lb-ft

Nm

lb-ft

M18x1.5

220

162.2

312

230.1

M8

24

25.0

34

25.0

M20

390

287.6

550

405.6

M8x1

19

14.0

27

19.9

M20x1.5

312

230.1

440

324.5

M10

48

35.4

67

49.4

M22

530

390.9

745

549.4

M10x1.25

38

28.0

54

39.8

M22x1.5

425

313.4

590

435.1

M12

83

61.2

117

86.2

M24

675

497.8

950

700.6

M12x1.25

66

48.7

94

69.3

M24x2

540

398.2

760

560.5

M14

132

97.3

185

136.4

M27

995

733.8

1400

1032.5

M14x1.5

106

78.2

148

109.1

M27x2

795

586.3

1120

826.0

M16

200

147.5

285

210.2

M30

1350

995.7

1900

1401.3

M30x2

1080

796.5

1520

1121.0

M16x1.5

160

118.0

228

168.1

M18

275

202.8

390

287.6

The figures given in the chart are torques at dry thread (with coefficient of friction = 0,14). These figures do not apply to a lubricated thread.

Tightening moments for the sliding nuts with the tightening circle„O“ - hoses Nm

lb ft

Size spanner

Worm

Hose

Nominal

Min

Max

Nominal

Min

Max

14

12 x 1.5

6

20

15

25

15

11

18

17

14 x 1.5

8

38

30

45

28

22

33

45

38

52

33

28

38

51

43

58

38

32

43

58

50

65

43

37

48

74

60

88

55

44

65

8

19

16 x 1.5

22

18 x 1.5

24

20 x 1.5

27

22 x 1.5

30

24 x 1.5

16

74

60

88

55

44

65

32

26 x 1.5

18

105

85

125

77

63

92

36

30 x 2

135

115

155

100

85

114

166

140

192

122

103

142

41 46 50 50

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36 x 2

10 10 12 12 14 15

20 22 25 28

42 x 2

30

240

210

270

177

155

199

45 x 2

35

290

255

325

214

188

240

330

280

380

243

207

280

52 x 2

38 42

133

WORKSHOP MANUAL__ Chart showing the torques for necks with sealing edge. or with flat gasket

Chart showing the torques for plugs with flat gasket

Tightening moments for the necks

Tightening moments for the plugs

G -M

Nm

lb ft

G -M

Nm

lb ft

G 1/8

25

18

G 1/8

15

11

G 1/4

40

30

G 1/4

33

24

G 3/8

95

70

G 3/8

70

52

G 1/2

130

96

G 1/2

90

66

G 3/4

250

184

G 3/4

150

111

G1

400

295

G1

220

162

G 11/4

600

443

G 11/4

600

443

G 11/2

800

590

G 11/2

800

590

10 x 1

25

18

10 x 1

13

10

12 x 1.5

30

22

12 x 1.5

30

22

14 x 1.5

50

37

14 x 1.5

40

30

16 x 1.5

60

44

16 x 1.5

60

44

18 x 1.5

60

44

18 x 1.5

70

52

20 x 1.5

140

103

20 x 1.5

90

66

22 x 1.5

140

103

22 x 1.5

100

74

26 x1.5

220

162

26 x1.5

120

89

27 x 1.5

250

184

27 x 1.5

150

111

33 x 1.5

400

295

33 x 1.5

250

184

42 x 1.5

600

443

42 x 1.5

400

295

48 x 1.5

800

590

48 x 1.5

500

369

M-G

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23. Measuring points in the hydraulic circuit

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WORKSHOP MANUAL__ Measuring couplings must be mounted on individual components. Before mounting and measuring. lift the cab/bonnet and secure it with the ball valve in the lifted position.

Steering circuit pressure Remove the quick-coupling.

280D01 Mount the measuring coupling (M22x1.5).

Working pressure in the steering circuit is 140 bars.

280D02 Refilling pressure The measuring point is located on the brake block.

Refilling pressure is 25 bars.

280D03 Travel circuit pressure Mount the measuring coupling (M12x1.5) on the travel pump (top view).

To drive to the front to the right (1) and to drive to the rear to the left (2) of the travel pump.

Working pressure in the travel circuit is 365 bars.

Note: The following conditions on the drive to the front/rear must be adhered to: Use the accelerator control to set the engine speed (to ca. 1800 RPM) and using the travel control. select the required direction of travel (for the purposes of measuring pressures leave the machine braked).

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2 122

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WORKSHOP MANUAL__ Vibration circuit pressure Mount the measuring coupling (1) on the vibration pump (M12x1.5).

Working pressure in the vibration circuit is 330 bars.

Note: The following conditions on vibration must be adhered to. Use the accelerator control to set the engine speed (to ca. 1800 RPM) and using the travel control. select the required direction of travel and turn on vibration.

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WORKSHOP MANUAL__ Notes

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WORKSHOP MANUAL__ Notes

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WORKSHOP MANUAL__

Ammann Unternehmungen Eisenbahnstrasse 25 CH-4901 Langenthal Phone +41 62 916 61 61 www.ammann-group.com

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