Ammann ARX 91 Tandem Roller Operating Manual 0120 PDF

ARX 91 TANDEM ROLLER CUMMINS QSB3.3C BSIII / EU Stage IIIA / US EPA Tier 3

OPERATING MANUAL EDITION 03/2020 EN From Serial No. 0120-

ARX 91 Articulated tandem roller Cummins BSIII

Operating Manual Edition 03/2020 From Serial No. 0120Original Operating Manual

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

With kind regards,

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

This manual consists of: I. Specification manual

II. Operating instructions

III. Maintenance manual

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

Subsequent faults due to improper operating are avoided.

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

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

In order to ensure the smooth operation of AMMANN compaction equipment, use for repairs only the original spare parts supplied by AMMANN. These instructions must always be kept available on the equipment.

ARX 91

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.

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

2

ARX 91

SYMBOLS OF THE SAFETY NOTICES:

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

RIGHT

LEFT

REAR 401101en

ARX 91

3

Content 1.

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

1.1. Basic Data...............................................................................................................................................10 1.2. Dimension Chart....................................................................................................................................12 1.3. Technical Data........................................................................................................................................13 1.

OPERATION MANUAL...........................................................................................................................17

1.1. Dewaxing and Inspection of a Newly Supplied Machine...................................................................18 1.2. Safety Instructions................................................................................................................................19 1.2.1.

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

1.2.1.1.

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

1.2.1.2.

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

1.2.1.3.

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

1.2.2.

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

1.2.3.

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

1.2.4.

Forbidden activities - safety and guarantee.................................................................................................................................................22

1.2.5.

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

1.2.6.

Hand signals.............................................................................................................................................................................................................28

1.3. Ecological & Hygienic Principles..........................................................................................................31 1.3.1.

Hygienic principles.................................................................................................................................................................................................31

1.3.2.

Ecological principles..............................................................................................................................................................................................31

1.4. Preservation & Storage.........................................................................................................................32 1.4.1.

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

1.4.2.

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

1.5. Machine Disposal Following Its Life Termination...............................................................................34 1.6. Machine Description.............................................................................................................................35 1.7. Controlling and Operation of the Machine.........................................................................................36 1.8. How to Control and Use the Machine...................................................................................................50 1.8.1.

Starting the engine................................................................................................................................................................................................50

1.8.1.1.

1.8.2.

Jump start.......................................................................................................................................................................................................52

Travel and reversing...............................................................................................................................................................................................54

1.8.2.1.

Machine forward travel and reversing:.................................................................................................................................................55

1.8.2.2.

Smooth start & smooth stop function:.................................................................................................................................................55

1.8.3.

Machine forward and reversing with vibrations........................................................................................................................................56

1.8.4.

Emergency stop of the machine.......................................................................................................................................................................58

1.8.5.

Stop the machine and set-off the engine......................................................................................................................................................60

1.8.6.

Machine parking.....................................................................................................................................................................................................61

1.8.7.

Bonnet lifting and lowering................................................................................................................................................................................62

1.8.8.

Sprinkling...................................................................................................................................................................................................................64

1.8.9.

Ammann edge cutter (optional).......................................................................................................................................................................66

1.8.10. Infrared thermometer (optional)......................................................................................................................................................................67 1.8.11. Compaction meter (optional).............................................................................................................................................................................68

4

ARX 91

OPERATING MANUAL 1.9. Machine Transportation........................................................................................................................69 1.9.1.

Machine transportation by its own axle.........................................................................................................................................................69

1.9.2.

Machine transportation by public road..........................................................................................................................................................69

1.9.3.

How to load the machine....................................................................................................................................................................................70

1.9.3.1.

Loading the machine using a ramp.......................................................................................................................................................70

1.9.3.2.

Loading the machine on the transporting vehicle using a crane...............................................................................................71

1.10. Special Conditions to Use the Machine................................................................................................72 1.10.1. Machine towing......................................................................................................................................................................................................72 1.10.1.1. Bypassing the hydrostatic system for towing....................................................................................................................................73 1.10.1.2. Brake off the machine.................................................................................................................................................................................74 1.10.2. How to operate the machine during its running........................................................................................................................................77 1.10.3. Machine operation under low temperatures...............................................................................................................................................77 1.10.4. Machine operation under high temperatures and humidity.................................................................................................................77 1.10.5. Machine operation under high altitudes.......................................................................................................................................................77 1.10.6. Machine operation at extremely dusty environment................................................................................................................................77 1.10.7. Driving with vibrations on compacted and hard materials....................................................................................................................77

1.11. Error Codes and Troubleshooting........................................................................................................78 1.

MAINTENANCE MANUAL.....................................................................................................................81

1.1. Safety and Other Measures for Machine Maintenance......................................................................82 1.1.1.

Safety during machine maintenance..............................................................................................................................................................82

1.1.2.

Fire precautions when refilling..........................................................................................................................................................................82

1.1.3.

Ecological and hygienic principles...................................................................................................................................................................83

1.2. Specification of Fluids...........................................................................................................................84 1.2.1.

Engine oil...................................................................................................................................................................................................................84

1.2.2.

Fuel...............................................................................................................................................................................................................................85

1.2.3.

Cooling liquid...........................................................................................................................................................................................................86

1.2.4.

Hydraulic oil .............................................................................................................................................................................................................86

1.2.5.

Gearbox oil................................................................................................................................................................................................................86

1.2.6.

Lubrication grease .................................................................................................................................................................................................86

1.2.7.

Drum cooling liquid...............................................................................................................................................................................................86

1.3. Refills......................................................................................................................................................87 1.4. Lubrication and Maintenance Chart....................................................................................................88 1.5. Lubrication and Service Plan................................................................................................................90 1.6. Lubrication and Maintenance Operations...........................................................................................91 Every 20 hours of operation.................................................................................................................92 1.6.1.

Engine oil level check............................................................................................................................................................................................92

1.6.2.

Engine coolant level check and refilling.........................................................................................................................................................93

1.6.3.

Check the fan belt...................................................................................................................................................................................................94

1.6.4.

Crankcase breather................................................................................................................................................................................................94

1.6.5.

Air filter dust valve check.....................................................................................................................................................................................95

1.6.6.

Inspect fan condition............................................................................................................................................................................................95

1.6.7.

Fuel level check........................................................................................................................................................................................................96

1.6.8.

Hydraulic tank oil level check.............................................................................................................................................................................97

1.6.9.

Water tank refilling.................................................................................................................................................................................................97

1.6.10. Inspect alarm and control devices....................................................................................................................................................................98

ARX 91

5

Content Every 250 hours of operation.............................................................................................................100 1.6.11. Replacing engine oil........................................................................................................................................................................................... 100 1.6.11.1. Replacing engine oil filter...................................................................................................................................................................... 100 1.6.12. Inspect engine induction manifold............................................................................................................................................................... 103 1.6.13. Inspect engine cooling circuit......................................................................................................................................................................... 104 1.6.14. Checking oil level in gearboxes...................................................................................................................................................................... 105 1.6.15. Inspect the battery.............................................................................................................................................................................................. 105 1.6.16. Air filter sensor function check....................................................................................................................................................................... 107 1.6.17. Sprinkling water filter cleaning....................................................................................................................................................................... 108 1.6.18. Machine lubrication............................................................................................................................................................................................ 109

Every 500 hours of operation.............................................................................................................111 1.6.19. Replacement of fuel filter and water separator........................................................................................................................................ 111 1.6.20. Coolant level check............................................................................................................................................................................................. 113 1.6.21. Check of wiring..................................................................................................................................................................................................... 113

Every 1000 hours of operation...........................................................................................................114 1.6.22. Inspect engine belt............................................................................................................................................................................................. 114 1.6.23. Vibration systems oil exchange...................................................................................................................................................................... 115 1.6.24. Inspect the Vibration damper system.......................................................................................................................................................... 116 1.6.25. Fuel tank cleaning............................................................................................................................................................................................... 118 1.6.26. Water tank cleaning............................................................................................................................................................................................ 119 1.6.27. Exchanging oil in gearboxes............................................................................................................................................................................ 120 1.6.28. Replace air filter elements................................................................................................................................................................................ 121

Every 2000 hours of operation...........................................................................................................123 1.6.29. Checking and adjusting valve clearance..................................................................................................................................................... 123 1.6.30. Engine coolant exchange................................................................................................................................................................................. 123 1.6.31. Replace hydraulic oil and filters ..................................................................................................................................................................... 127

Maintenance as required....................................................................................................................131 1.6.32. Cleaning of coolers.............................................................................................................................................................................................. 131 1.6.33. De-aerating (venting) the fuel system......................................................................................................................................................... 132 1.6.34. Draining the water from water separator................................................................................................................................................... 132 1.6.35. Drain water from sprinkling circuit before winter season..................................................................................................................... 133 1.6.36. Adjustment of scrapers...................................................................................................................................................................................... 135 1.6.37. Drum cooling mixture........................................................................................................................................................................................ 136 1.6.38. Machine cleaning ............................................................................................................................................................................................... 137 1.6.39. Check the tightening of bolted connections............................................................................................................................................. 137

1.7. Defects..................................................................................................................................................140 1.8. Schematics...........................................................................................................................................141

6

1.8.1.

Electrical schematic............................................................................................................................................................................................. 141

1.8.2.

Hydraulic schematic............................................................................................................................................................................................ 142

ARX 91

OPERATING MANUAL

ARX 91

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8

ARX 91

SPECIFICATION MANUAL

1. SPECIFICATION MANUAL ARX 91 (Cummins BSlll)

ARX 91

9

1.1.

Basic Data

Machine description Tandem roller with an articulated frame with two smooth steel driven vibrating drums.

Please fill in the following data:

Machine application

Type of machine

ARX 91 rollers are intended for medium and large-sized compaction works in transport construction (roads and motorways, airfields) and building construction (industrial zones, etc.).

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

Rollers are suitable for compacting the asphalt mixtures up to a layer thickness (after compaction) of 140 mm (5.5 in), hydraulically consolidated mixtures up to a layer thickness of 200 mm (7.9 in), mixed soils up to a layer thickness of 300 mm (11.8 in), and sand and gravel materials up to a layer thickness of 400 mm (15.7 in).

The rollers are not suitable for the compaction of rockfill and loam and clay materials.

The machines of this line are designed for the operation under conditions according to ČSN IEC 721-2-1 (038900): WT, WDr, MWDr (i.e. a moderate climate zone, warm dry or hot dry zone with a limited ambient temperature range from -7 °C (19.4 °F) to +45 °C (113 °F).

The standard type of the machine is not intended for road traffic. For more information, please contact your Local / Nearest Branch office.

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

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

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

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

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

The machine that complies with the requirements as to health protection and safety is identified with a name plate 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

10

ARX 91

SPECIFICATION MANUAL Placing of the Pin label and Serial number on front frame 1

Pin label

2

Serial number

2 1

Serial number on rear frame.

2

Cummins engine serial number

3

ARX 91

11

1.2.

12

Dimension Chart

A

D

H

H1

G1

G

mm

3450

1220

3000

2350

685

290

in

135.8

48

118.1

92.5

26.9

11.4

L

T

W

W1

mm

4720

17

1700

1818

in

185.8

0.67

66.9

71.5

ARX 91

1.3.

Technical Data ARX 91

Weight Operating weight of CECE with platform, rail

kg (lb)

9200 (20283)

Operating load of CECE on front axis

kg (lb)

4645 (10240.5)

Operating load of CECE on rear axis

kg (lb)

4555 (10042)

Static linear load of front drum

kg/cm (lb/in)

27.3 (150.2)

Static linear load of rear drum

kg/cm (lb/in)

26.8 (147.4)

Weight of canopy

kg (lb)

20.5 (45.2)

Weight of canopy post

kg (lb)

113.2 (250)

Maximum transport speed

km/h (MPH)

12 (7.5)

Maximum Working speed

km/h (MPH)

7 (4.34)

Climbing ability without vibration

%

40

Climbing ability with vibration

%

35

Lateral static stability

%

67.4

Lateral stability during driving without vibration

%

25

Lateral stability during driving with vibration

%

15

Turning radius inner (edge)

mm (in)

4650 (183)

Turning radius outer (contour)

mm (in)

6645 (262)

Type of drive

-

Hydrostatic

Number of driving axles

-

2

Oscillation angle

°

± 10

Angle of steering

°

± 35

Type of steering

-

Joint

Steering control

-

Hydraulic

Linear hydraulic cylinders

-

2

Manufacturer

-

Cummins

Type

-

4B3.3TAA-60-C

Power according to DIN 6271

kW (HP)

60 (80)

Power according to ISO 3046/1

kW (HP)

60 (80)

Number of cylinders

-

4

Cylinder capacity

cm3 (cu in)

3300 (199)

Rated speed

min-1 (RPM)

2200

Maximum torque

Nm (ft lb)/rpm

305 (225)/1600

Routine operation fuel consumption

l/h (gal US/h)

8.3 (2.2)

Engines complies with emission regulations

-

EU Stage IIIA , U.S. EPA Tier 3 , CARB Tier 3, Bharat Stage 3

Cooling system of engine

-

Liquid

Driving characteristics

Steering

Engine

ARX 91

13

1.3.

Technical Data ARX 91

Brakes Operating

-

Hydrostatic

Parking

-

Mechanical multiple-disc

Emergency

-

Mechanical multiple-disc

Frequency I

Hz (VPM)

42 (2520)

Frequency II

Hz (VPM)

55 (3300)

Amplitude I

mm (in)

0.7 (0.028)

Amplitude II

mm (in)

0.35 (0.014)

Centrifugal force I

kN

78

Centrifugal force II

kN

67

Type of drive

-

Hydrostatic

Type of watering

-

Pressure

Number of pumps

-

2

Number of filtrations

-

3

Fuel

l (gal US)

200 (52)

Water for drum watering

l (gal US)

1000 (264)

Engine (oil filling)

l (gal US)

7 (1.85)

Cooling system

l (gal US)

25 (6)

Hydraulic system

l (gal US)

52 (13)

Vibrating drum front

l (gal US)

10 (2.6)

Vibrating drum rear

l (gal US)

10 (2.6)

Drum drive gearbox

l (gal US)

2x1.1 (0.3)

Drum cooling liquid

l (gal US)

2x62 (16.1)

Voltage

V

12

Battery capacity

Ah

130

m/s2 (ft/s2)

<0.5 (<1.6)

dBa

92

Vibration

Watering

Fluid capacities

Wiring

Noise and vibration emissions Declared highest weighted effective value of vibration acceleration transmitted to the whole body ** Declared sound pressure level A at the operator's place (platform) *

Optional equipment Warning beacon Edge cutter Infrared thermometer Compaction measuring device

*

measured according the EN 500-4

** measured according the EN 1032+A1 on the gravel base under the vibration travel

14

ARX 91

SPECIFICATION MANUAL Notes

ARX 91

15

16

ARX 91

OPERATION MANUAL

2. OPERATION MANUAL ARX 91 (Cummins BSlll)

ARX 91

17

2.1.

Dewaxing and Inspection of a Newly Supplied Machine

•

Inspect the machine per shipping documents.

•

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

Before machine operation, 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.

18

ARX 91

2.2.

Safety Instructions

OPERATION MANUAL

2.2.1. Safety measures to operate the machine

2.2.1.2. Work safety secured by user

Safety measures given in the individual chapters of Engineering Documentation supplied with the machine shall be added with Safety Precautions in force within a respective country that uses the machine at workplace with regard to work organization, work process and personnel involved.

User shall promptly communicate any damage to the utility lines to their operator, and at same time he make measures to prevent unauthorized persons from entering endangered area.

2.2.1.1. How to start the compaction work •

Constructional Supplier (Machine User) is liable to issue instructions for driver and maintenance before compaction work is started, that will include requirements on work safety provision during machine operation.

•

He must verify and mark: -

utility lines

-

underground areas (direction, depth)

-

seepage or escape of hazardous materials

-

soil bearing capacity, slope of travelling plane

-

other obstructions incl. their removal.

He must make machine driver, who will carry out earth work, familiar with these conditions.

•

He must ensure an employee does not work alone at a workplace. Another worker must always be in sight and within an ear-shot, who in case of accident will provide or call for help unless another effective form of monitoring or communication exists.

2.2.1.3. Work safety secured by user •

User shall provide for the machine to be operated merely under those conditions and only for those purposes it is technically capable for under conditions set by manufacturer and respective standards.

•

He must make sure the use of the Roller (Compactor) is used merely in such a way and at such workplaces where there is no hazard of making damage within nearby facilities, etc.

•

He shall provide for regular inspection of operation, technical condition, regular machine maintenance in cycles per the Lubrication and Maintenance Manual. In cases of failing technical condition of the machine to such an extent it poses hazard to safety of operation, persons, property or causes damage or impairs the environment, then the machine must be put out of operation until a defect is repaired.

•

He must specify who and what tasks may carry out under operation, maintenance or repair of the machine.

•

Any who drives the machine (driver) and anybody who performs machine maintenance or repairs must get familiar with the guidelines given in the Machine Operation Manual.

He must specify Code of Practice (C.O.P.) part of which is work procedure for a given work operation and this work procedure will specify inter alia: -

measures when working under extraordinary conditions (work within protective zones, within extreme slopes, etc.)

-

precautions for any natural disaster hazards

-

requirements on work performance while observing job safety principles

-

technical and organizational measures to secure safety of personnel, workplace and environment.

•

He must make machine driver evidently familiar with the Code of Practice.

He shall provide for fire extinguisher to undergo regular inspections.

•

He must ensure the “Machine Operation Manual” and Operation Logbook are stowed at certain place inside Manual box so always available to the driver.

•

He shall furnish constant supervision by an appointed person during machine operation under traffic on public roads, and he will in particular be liable to release instructions on securing the work safety.

•

He must secure the removal of hazardous materials (fuel, oil, cooling liquid, brake fluid, etc.) from where these are spilled depending on their nature so as to avoid their adverse impact against environment, operation safety and persons’ health.

ARX 91

19

2.2

Safety Instructions

2.2.2. Driver qualification requirements •

Only a driver trained under ISO 7130 and other local and national regulations designed for drivers of this group of machines may operate the Roller (Compactor).

•

With no licence only the one who learns driving the machine for the purpose of getting preliminary practice with the approval of User may drive the machine, and such person has to be under direct and continuous surveillance of professional teacher or trainer.

•

Licence holder is liable to take due care of the licence, and when requested, put it forward to the control authorities.

•

Licence holder can make no registrations, changes or corrections in the licence card.

•

He/she is liable to promptly report his/her licence loss to the authority that issued this licence.

•

Driving the Roller alone may be performed by an employee mentally and physically fit, over 18 years old, who is: a) assigned by machine manufacturer for the assembly, testing and presentation of the machine, for training the drivers, whereas he/she must be made familiar with safety work regulations in force at the workplace or b) assigned by Constructional Supplier to operate (carry out maintenance) and is evidently trained and acquainted with, or owns professional competence to operate and drive under special regulations (machinist licence, etc.).

•

20

Machine driver must undergo training and examination concerning work safety regulations at least 1x every 2 years.

ARX 91

OPERATION MANUAL 2.2.3. Driver’s duties •

•

Before starting to operate the machine the driver will be liable to get familiar with the guidelines given in the documentation delivered with the machine, with safety precautions in particular, and observe these thoroughly. This applies as well to the personnel in charge of maintenance, adjustments and repairs of the machine.

Do not drive the Roller unless made familiar with all the machine functions, working and operating elements, and unless knowing exactly how to control the machine.

•

Follow safety signs located on the machine, and keep them in legible condition. Replace or add those impaired or missing once.

•

Before work commencement the driver must get familiar with the workplace environment, i.e. with the slopes, utility line system, with necessary types of workplace protections with regard to the environment (noise, etc.).

•

When finding out any health hazard, life hazard to persons, hazard to property, failures, during hardware accidents, or when finding symptoms of such hazards during operation, the driver must, unless able to remove such hazard by himself/herself, stop his/her work and secure the machine against undesired starting, communicate this to a person accountable, and depending on chances, notify all the persons exposed to such hazard.

•

Before machine operation startup the driver will be liable to get familiar with the records and operation deviations found out in course of the previous work shift.

•

Before work is started he/she must inspect the machine, its accessories, check up control elements, communication and safety devices, whether these are operable in line with the Manual. When finding out a malfunction that might be hazardous to job safety, and he/she is not able to repair it, then he/she must not start running the machine and instead report such failure to the person accountable.

•

During work with the machine the driver must be fastened with the seat belt. The seat belt and its mounting shall not be damaged!

•

During machine operation observe safety regulations, make no action that might endanger work safety, give full attention to machine steering.

•

Respect Code of Practice or instructions of a person responsible.

•

When rolling (traversing) the machine within a workplace adapt your speed to a terrain condition, to a work performed and weather conditions. Watch permanently the clearance so to avoid collision with any obstruction.

•

Upon completion or stop of the machine operation during which driver leaves the machine, he/she must make measures against unauthorized use of the machine or against spontaneous starting the engine. Remove key from the ignition box, disconnect the wiring via disconnector and engine bonnet.

•

When shutting down the machine on roads the measures under regulations effective on roads shall be taken.

•

When operation is completed, park the machine at a proper parking place (flat, bearing area) so as not to endanger machine stability, not to make the machine interfere with traffic roads, not to expose the machine to falling objects (rock), and where the machine is safe against any natural disaster of other kind (floods, landslides, etc.).

•

The operator must wear ear protectors.

•

When working with the machine is ended all the defects, damage to the machine and any repairs made shall be written down in the Operation Logbook. Upon immediate changing of drivers the driver will be liable to call attention of driver to any facts identified.

•

Driver shall use personal protective equipment (PPE) - work clothing, safety shoes, the clothing shall not be too loose, impaired, hair protected with proper head piece. During maintenance (lubrication and refilling) your hands must be protected with proper gloves. Use proper muffs when using machine.

•

Driver shall maintain the machine equipped with fittings and outfit required.

•

Maintain the machine free of oil dirt or flammable materials.

Keep the drive’s stand, foot rests and runner areas clean.

•

When the machine comes into contact with high voltage observe the following principles:

•

When driver finds any defect during operation he/she must immediately stop the machine, secure it safely against undesired ignition.

•

During operation the driver shall follow the machine run and record any defects found in the Operation Logbook.

-

try to leave with the machine a hazardous zone

-

do not leave driver’s stand

•

Driver shall keep his/her Operation Logbook designed to maintain records about machine handover between the drivers, about the defects or repairs in course of operation, to write down major events during work shift.

-

give warning to others to keep off and not touch the machine.

•

Prior turning on the engine the controls have to be in their zero position, no persons may stay within dangerous reach of the machine.

•

Indicate each machine startup via an acoustic or light signal and this always before igniting the machine engine.

•

Confirm brake function and steering function before starting to run the machine.

•

Following the alarm an operator may start the machine only when all the workers have left the danger area. At close (blind) workplaces it will be possible to start the operation only after a time necessary to leave danger area has elapsed.

ARX 91

21

2.2

Safety Instructions

2.2.4. Forbidden activities - safety and guarantee It is forbidden to: •

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

•

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

•

Using the machine when any operating fluid level is low.

•

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.

•

To work in vibro-stroke mode in the long term!

•

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

•

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

•

Operate the machine in the explosive environment and underground.

•

To use the machine following ingestion of alcoholic beverages or dope.

•

To use the machine if its operation might put its technical condition, safety (life, health) of persons, facilities or objects, or road traffic and its continuity, at risk.

•

Put into operation and use the machine when other persons are within its hazardous reach - exception is training a driver by lector.

•

Put into operation and use the machine when some of its safeguarding device (emergency brake, driving brake, horn, etc.) Has been dismantled or damaged.

•

To roll and compact at such slopes where machine stability would be disrupted (turning over). Machine’s static stability stated will lower by drive’s dynamic effects.

driver’s stand, and where hazard to people or property could occur unless work safety has been secured through some other way like for instance via signalling by duly instructed person.

•

To work with the machine at a protected zone of electric lines or substations.

•

To cross electric cables if these are not properly protected against mechanical damage.

•

To operate the machine under lowered visibility or at night, unless machine’s working area and workplace are illuminated sufficiently.

•

To leave driver’s seat of the machine when the machine is running.

•

Boarding or getting off while on the run, jumping off the machine.

•

Sit or stand on the outside parts of the machine when driving, or stand on the steps.

•

Leave unsecured machine - move away from the machine without having prevented its misuse.

•

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

•

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

•

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

•

Locate some other items (tools, accessories) aside from personal needs at driver’s stand.

•

Lay away material or other objects on the machine.

•

Remove dirt while the machine is running.

•

Perform maintenance, cleaning or repairs with the machine not secured against spontaneous move or accidental start, and when contact of a person with moving parts of the machine is not excluded.

•

Contact of moving parts of the machine with human body or objects and tools held in hands.

•

To roll and compact at such angles of slopes where hazard of soil breaking off (dropping) under the machine exists, or loss of adhesion followed by uncontrolled slip might occur.

•

Smoke or handle open fire when checking or pumping fuels, refilling oils, lubricating the machine, or inspecting the accumulator or making up the accumulator.

•

To control the machine in some other way than stated in driving manual.

•

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

•

To roll and compact per bearing capacity of subsoil at such a distance from the edge of slope or trenches, where hazard of landslide or shoulder breaking off (dropping) together with the machine would occur.

•

Let the engine run inside confined spaces.

•

Perform any adjustments on the machine without the prior consent of the manufacturer.

To roll and compact with vibration at such a distance from the walls, cuts, slopes, where their slip (slide) would happen and the machine covered in.

•

Drive without the seat belt fastened.

•

Shift electrical conductors.

•

Use other than original spare parts.

•

Interfere in the electrical and electronic units in any manner.

•

•

To compact with vibration at such a distance from buildings or facilities and equipment within which the risk of them being damaged due to vibration transfer impact, would occur.

•

To operate the machine unless driver control stand fixed properly.

•

To operate the machine when engine bay cover is open.

•

To move and transport persons on the machine.

•

To operate the machine when within hazardous reach thereof are other machines or transportation means aside from those that operate in mutual concert with the machine.

•

To operate the machine at places impossible to see from

22

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

ARX 91

OPERATION MANUAL 2.2.5. Safety labels & signs used on the machine

B A

15

15

13

17 3

4

21

C

23

21

7

14

3

20

8 20

15

15 4 3

21

10 A

16

3

20

19

21

20

18 9 5 11 B

1

12

6

ARX 91

22

2 3

C

8

3

4

23

2.2

1.

Safety Instructions

Read Operation Manual!

Use Operation Manual to make yourself thoroughly familiar with Roller Control and its Maintenance. (Symbol located the LH side of the Control Console).

2702bz

2.

Service Manual

Stowage box to stow Operation Manual. (Symbol located at the rear on the seat stowage).

2428bz

3.

Clamp hazards

Maintain safety distance away from the machine. Hazard of being clamped by the machine between front and rear frame. (Symbols located near steering joint)

2939

2941bz

4.

Danger zone

Keep a safe distance! (Symbol located on the rear rail, on the left and on the right on the front frame)

2939

2942bz

5.

Injury Hazard

Risk of injury and winding around. NEVER touch rotating Parts while engine in running (Symbol located on the fan cover)

2409bz

24

ARX 91

OPERATION MANUAL

6.

Injury Hazard

Keep safety distance away from rotating pulley and belt.

(Symbol located on the fan cover)

2601bz

7.

Adjust at Rest

Carry out adjustment or maintenance with engine stopped. (Symbol located to the left on the rear frame near the door)

2584bz

2586

8.

Risk of burn

Do NOT touch machine’s hot parts unless you made certain these are cooled down sufficiently. (Symbol located on the fuel tank and on the left of the rear frame above the exhaust)

2586bz

9.

Cooling liquid

Cooling liquid is harmful to health. Read the operating manual! (Symbol located on the cooling liquid tank) 2152bz

10.

Explosion Hazard

Read Operation Manual before Battery maintenance, or when starting via starting cables. (Symbol located to the right on the rear frame) 3017bz

11.

Disconnect alternator

Before welding, please disconnect the wiring, alternator, machine’s electronics and Engine Control Unit. (Symbol located on LH side of the control console)

2668bz

ARX 91

25

2.2

12.

Safety Instructions

Cover the Electric Instruments

When washing the machine, please cover the electric instruments. (Symbol located on the LH side of the control console)

2225bz

13.

Max Machine Height

Pay attention when passing through places with vertical constraint. (Symbol located to the left underneath the Platform on the LH side frame)

10ft/3,05m 3207

14.

(20 283 lb) 9200 kg

Lifting & Rigging Plan Lmin = 6.5 m 2x min 2500 kg (2x min 5512 lb)

Lmin = 6.5 m 2x min 2500 kg (2x min 5512 lb)

15.

Lifting Points

To lift the machine use rigging of sufficient loading capacity. Before lifting, please secure the machine articulation. (Symbol located to the left on the front frame)

Use only these points to lift the machine. (Symbols located along both sides of the frames overhead the drum) 2153bz

Switch ON Safety Belt!

2939

16.

Switch ON safety belt before driving! (Symbol located in front of Operator seat).

2687bz

17.

Bonnet Lifting

(Symbol located to the left on the rear frame near the door)

3201

18.

Cooling liquid

Danger of scalding. Do not open the expansion tank lid until the liquid cools down below 50 °C (122 °F). (Symbol located on the inner side of the bonnet door)

2939

3227bz

26

ARX 91

OPERATION MANUAL

19.

Ear protection

be sure to wear an ear protection. (Symbol located in front of Operator Seat) 2408bz

20.

Jacking point

Place to install hand jack or fixed support of the machine.

(Symbol located on the front and rear frames along both sides) 3208bz

21.

Sling Points

The machine is to be rigged in these points. (Symbols located on the both sides of the frames) 3048bz

22.

Pinch Points

3237

Secure after lifting the hood. (Symbol located on the left side of the fuel tank when the hood is lifted)

2939

3237bz

23.

Lifting the hood - Adjust at standstill

3292

The hood lifting at off engine. (Symbol located on the cover the battery disconnector)

3292bz

ARX 91

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 devices or tool.

SIGNALS FOR GENERAL COMMANDS Stop One arm erected with open palm in the direction of the driver, second arm akimbo.

STOP Sig. 1

Attention Both arms sideways raised horizontally - palms forward.

!

Sig. 2

!

Sig. 3

Attention, Danger Swinging motion of both of the arms with antebrachium from the position of arms sideways raised horizontally to the position of arms sideways raised - arms bending across and back.

SIGNALS FOR DRIVE Departure with the machine One arm erected - bent with open palm, long motion of antebrachium in the direction of required motion, second arm akimbo.

Sig. 4

28

ARX 91

OPERATION MANUAL Low-speed cruising forward - towards me Both arms erected abreast bending across, with palms towards the body - short swinging movements of antebrachium towards the body and backward.

Sig. 5

Low-speed cruising backward - away from me Both arms erected abreast bending across, with palms away from the body - short swinging movements of antebrachium away from the body and back.

Sig. 6

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

Sig. 7

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

Sig. 8

ARX 91

29

2.2

Safety Instructions

Short motion

X

Both arms lifted forward bending across. Mark the „X“ distance between palms, then the motion signal follows.

Sig. 9

Engine start Circular motion of right hand’s antebrachium, with the fist closed.

Sig. 10

Engine cut off Oscillating motion of right hand sideways raised in front of the body to the sides.

Sig. 11

30

ARX 91

2.3.

Ecological & Hygienic Principles

2.3.1. Hygienic principles

2.3.2. Ecological principles •

When operating and storing the machines a user will be liable to observe general principles of health and environmental protection, laws and regulations that relate to the given issue and are in force within a territory where the machine is used.

•

Oil products, cooling system fillings, accumulator fillings, or painting materials incl. thinners are materials that pose health hazard. Workers coming into contact with these products during machine operation or maintenance will be liable to follow general principles of one’s own health protection, and abide by safety and hygienic guidelines of these products’ manufacturers.

The fillings of machine’s individual systems and some of its parts become waste with hazardous properties against the environment when discarded.

This category of waste products includes in particular: -

Organic as well as synthetic lubricating materials, oil or fuels,

-

Cooling liquids,

-

Accumulator fillings and the accumulators themselves,

-

Cleaning & preservation agents,

-

All filters and filter elements dismantled,

-

All used and discarded hydraulic hoses or fuel hoses, metal rubbers and other machine’s elements, fouled with the above mentioned products.

We call your attention to the following in particular: -

Eye and skin protection when handling accumulators

-

Skin protection when handling oil products, painting materials or cooling liquids

-

Washing your hands properly upon work completion or before meals, apply a proper reparation cream on your hands

-

When handling cooling systems, please follow the instructions given in the Manuals supplied with the machine.

•

Always maintain oil products, cooling system and accumulator fillings and painting materials incl. organic thinners and also the cleaning and preserving agents in their original properly designated packages. Do not allow storage of these materials in under signed bottles or other vessels due to the hazard of them being interchanged. Especially hazardous is the possibility of interchanging them with eatables or drinks.

•

Upon skin, mucosa, eye contacts or inhalation of vapour, immediately apply the principles of first aid. Upon accidental use of these products get prompt medical attention.

•

When operating the machine always use ear defenders (muffs) of proper type and version.

ARX 91

Handle the given materials and parts following their disposal in line with the respective national regulations on protection of individual components of environment, and in conformity with health regulations.

31

2.4.

Preservation & Storage

2.4.1. Short-term preservation and storage for the period of 1 - 2 months Wash and clean the entire machine carefully. Before parking the machine for its preservation and storage, please warm up the engine to its operating temperature while running. Park the machine on solid, flat surface at a safe place with no risk of natural disaster (floods, landslides, fire, etc.) to the machine.

In addition: •

repair those damaged spots with paint

•

lubricate all lubricating points, control cables, joints of the controls, etc.

•

confirm water fillings are drained

•

check that cooling liquid has antifreezing characteristics requiered

•

check the state of accumulator charges, recharge them if necessary

•

apply preservative grease over the chormed surfaces of piston rods

•

we recommend to protect the machine against corrosion through spraying the preservation agent (applied spraying), and this in particular in places with potential of corrosion origin.

The machine treated like that will need no special preparation prior to its subsequent putting into operation.

32

ARX 91

OPERATION MANUAL 2.4.2. Machine preservation & storage for the period over 2 months To park the machine the same principles will apply like at shortterm preservation.

In addition it is recommended to: •

dismantle the accumulators, check their condition, and store in a cool, dry room (recharge the accumulators regularly)

•

support the runner frame so the damping system shows minimal sag

•

protect rubber elements through painting with spec. preservation agent

•

inflate surface tyres to a pressure required and protect them from direct sunlight.

•

preserve the machine via spraying with special agent, and this at places of possible corrosion origin

•

blind the engine suction and discharge ports with double pe foil, and tighten this foil thoroughly with adhesive tape

•

protect the headlamps, external back mirrors and other elements of external wiring through spraying a special agent and wrapping into polythene foil

•

preserve the engine per manufacturer’s instruction manual - mark visibly the engine has been preserved.

After 6 months we recommend to inspect the condition of preservation and renew if required.

NEVER start the engine in course of storage!

In case of machine storage under field conditions, please check the parking place whether not exposed to the hazard of flooding, and that danger of any other type is not present!

Prior to restoration of machine operation, please wash the preservation agents away with the use of high pressure stream of hot water incl. addition of normal degreasers while observing the Instructions for Use along with ecological principles.

Carry out the dewaxing (deconservation) and washing of the machine at places equipped with intercepting sumps to trap the rinsing water as well as dewaxing agents.

ARX 91

33

2.5.

Machine Disposal Following Its Life Termination

During machine disposal following its service life the User will be liable to follow national waste and environmental regulations and acts. We recommend to always contact in these cases: •

The specialized companies with respective authorization to deal professionally with these operations

•

The machine manufacturer or manufacturer-appointed accredited contracting service organizations put in charge by manufacturer.

In no event shall Manufacturer be liable for damage to User health or environmental damage that arises from non-observance of the above mentioned note.

34

ARX 91

2.6.

Machine Description

OPERATION MANUAL

21 13 16

11 2

10

12 19

14

19

15

20

17

5

20

7

3 8

9

20 1

4

6 18

20

ARX 91 1 - Front frame 2 - Rear frame 3 - Front drum 4 - Rear drum 5 - Engine 6 - Hydraulic pumps 7 - Travel hydraulic motor 8 - Vibration hydraulic motor 9 - Steering Cylinders 10 - Hydraulics tank 11 - Fuel tank 12 - Sprinkling tank 13 - Platform Railling 14 - Driver’s control stand 15 - Battery 16 - Combined cooler 17 - Air filter 18 - Exhaust pipe 19 - Sprinkling jets 20 - Drum scrapers 21 - Canopy

ARX 91

35

2.7.

Controlling and Operation of the Machine

14

13

22

25

P

24

5

15

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

20

10

18

17

11

19

12

16

21

6 8

23 1 7 3 9

36

4 2

ARX 91

OPERATION MANUAL Dashboard and control panels 1 - Travel control lever 2 - Parking switch 3 - Smooth start / smooth stop toggle switch 4 - Work / Travel mode selector switch 5 - Edge cutter switch * 6 - Vibration ON/OFF push button 7 - Emergency stop push button 8 - Manual sprinkling ON/OFF push button 9 - Sprinkling interval change potentiometer 10 - Sprinkling pump selector switch 11 - Ignition box 12 - Engine throttle lever 13 - Front / both / rear drum vibration selector switch 14 - Vibration amplitude selector switch 15 - Vibration mode (MAN/AUTO) selection switch 16 - Light control combined switch 17 - Hazard lights switch 18 - Work light 19 - Charging point 20 - Beacon ON/OFF switch* 21 - Tilt steering adjustment lever* 22 - Digital cluster 23 - Operator’s seat 24 - Fuse box 25 - Infrared thermometer / Compaction Meter / Infrared & Compaction*

* Optional equipments

ARX 91

37

2.7.

Controlling and Operation of the Machine

22

P

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

5

6 8

1 F

3 4

0

N

R

2

38

ARX 91

OPERATION MANUAL Travel control lever (1) This lever is use to select travel direction and adjust speed.

Travel speed depends on the degree of swing of lever from zero position (0).

Travel control lever has two positions, i.e. “0” and “N” : “0” - zero position - At this position no driving force is applied, but at same time machine is not braked in this position.

“N” - neutral - In this position machine parking brake is enabled.

Neutral position (N) is signalled through lighting up of parking brake indicator lamp on the cluster (22).

Vibration ON/OFF push button (6) & Sprinkling ON/OFF push button (8) are located on the travel control lever.

NOTE! Engine start is possible only in lever neutral position (N).

ing will lit up.

Work / Travel mode selector switch (4) It is use to set machine in work or Travel mode Rabbit: Switch, when set to Rabbit position (“Rabbit” indicator light will glow ON) machine is set in travel mode. In travel mode machine is capable to reach max. speed with pulling force reduced and climbing ability decreased.

Turtle: Switch, when set to Turtle position (“Turtle” indicator light will glow ON) machine is set in work mode. In work mode, machine is able to take max. pulling force and climbing ability with reduced speed.

NEVER turn switch to Rabbit position during occupational use of the machine.

Do NOT turn switch to the Turtle position at high speed, abrupt slowdown will occur together with impact within the hydraulic system. Turn the switch to turtle position with the machine at rest or at low speed!

You may turn switch to Rabbit mode, i.e. travel mode, when driving the machine on a formation level.

You may turn ON the Rabbit mode with the machine loaded, But pulling force will not be sufficient.

Parking switch (2)

Edge cutter switch (5) (optional)

Press this button to enable machine’s parking brake, and indicator lamp on cluster (22) for park-

It is an instantaneous switch, use to lower or lift edge cutter assembly as per requirement.

NOTE! Engine will not stop, on applying parking brake in engine ON condition.

NOTE! Do not lower edge cutter assembly on finished road surface, It will leave the mark.

Vibration ON / OFF push button (6) Push button (6) to start/stop drum vibration. ON/OFF condition of vibrator will be indicated by indicator lamp on cluster (22).

Smooth start / smooth stop ON/OFF switch (3) The switch is use to enable and disable the smooth start & smooth stop function of machine. Enabling this function will prevent generation of “waves” because of sudden braking, and waves being transmitted to compacted surface resulting in wavy road surface.

3128

Press the switch (3) to enable the function, and respective indicator lamp on cluster (22) will light. To disable the function, press switch (3) again and respective indicator lamp will off.

NOTE! In machine neutral and/or travel mode, vibration will not start with activation of button (6)

Do not turn ON vibration when machine is almost standstill.

In this mode the machine stopping distance is longer than usual!

ARX 91

39

2.7.

Controlling and Operation of the Machine

14

13 P

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

15

10 11 12

16 8

7

9

40

ARX 91

OPERATION MANUAL Emergency stop push button (7)

Engine throttle lever (12) It is used to set engine speed to min or max.

2582

Press this button to stop machine completely in case of uncontrolled behaviour of machine. When pressed, machine will stop on the spot and engine will shut off.

To release emergency stop, rotate push button clockwise.

Manual sprinkling push button (8) It is used when sprinkling potentiometer at “0” position or got damaged.

Push and hold Sprinkling button (8) on the control lever to start water sprinkling manually. Indicator lamp on cluster (22) will lit up. Sprinkling will stope once release the button (8).

Drum vibration selector switch (13) 3179

Machine allows operator to start vibration with specific drum individually or with both drums at a time.

The selector switch has three positions: Left - only front drum vibration Centre - both drums’ vibration Right - only rear drum vibration

Sprinkling interval change potentiometer (9)

Vibration amplitude selector switch (14)

3186

2682

The selector switch has three positions:

Turning the potentiometer (9) clockwise will reduce stop interval of water sprinkling and vice versa.

Left - Vibration low amplitude

There will be no sprinkling with potentiometer at MIN or at extreme anticlockwise position.

Right - Vibration high amplitude

Centre - Vibration OFF

MAN / AUT vibration mode selector switch (15)

Water pump selector switch (10) 3181

Machine is equipped with two water pumps, one as service and other as standby.

Toggle switch (10) allows selection of any one water pump among two.

3180

It is used to select vibration manual or automatic mode.

MAN - Manual mode, vibrations can be switched ON even with slow machine speed.

AUT - It lets vibration start or stop automatically.

In auto mode, vibration will start when machine reaches and continuous speed of 1.2 kmph

Ignition switch (11)

Light control combination switch (16)

Ignition switch has three positions of “0-I-II“. The key can be inserted in and removed out in OFF (0) position only.

It is used to ON/OFF Position light, Low or High beam, turn indicator lights and horn.

Turning a key clockwise enable the ON (I) position and then START (II) position at which engine will start.

Indicator lamps on cluster (22) light up to signal Low or High beam ON.

Protect ignition switch with cover once the key is removed.

ARX 91

Indicator lamp on cluster (22) lights up to signal turn-indicator lights are ON.

41

2.7.

Controlling and Operation of the Machine

P

24 15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

20

18

17 19

42

ARX 91

OPERATION MANUAL Hazard lights switch (17) 596191

Beacon switch (20) (optional)

It is used to set ON or OFF hazard lights.

It is used to set ON or OFF Beacon light.

Fuse box (24) Work light switch(18) Work lights can be set ON-OFF with switch (18).

Reading from left to right •

F1 - 15A

Head Light

•

F2 - 20A

Horn, traffic-indicator lights

•

F3 - 15A

Work light, Charger

•

F4 - 5A

Cluster

•

F5 - 10A

Travel electronics, reverse horn, brake lights

•

F6 - 15A

Sprinkling

•

F7 - 7.5A

Vibrations, CRAB* and Edge cutter*

•

F8 - 15A

Spare

* Fuse for optional equipments, may or may not be present

Charging socket (19) •

Charging socket 12 V.

ARX 91

43

2.7.

Controlling and Operation of the Machine

22

P rpm

Cluster (22)

Fuel level indicator It indicates current fuel level in the tank, when reaches to minimum level, displayed on the LCD with red mark on bargraph.

AMN25

Parking brake indicator lamp AMN1

Glowing indicator will indicate that parking brake has been enabled.

Seat switch indicator lamp AMN2

Counter of engine-hours actually worked AMN26

The engine hours on the counter represent the period for which the machine has been running.

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

Not applicable

Hydraulic oil filter clogging indicator Flashing indicator (amber) with an acoustic alarm in engine running condition indicates suction line hydraulic oil filter is clogged.

AMN3

Stop the machine and proceed to replace the filter!

44

ARX 91

OPERATION MANUAL Turn indicator, left

Battery recharging indicator

Flashing indicator will signal left turn-indicators are ON, or hazard has been set ON.

AMN4

It indicates battery charging status. When ignition key is turned to ON (“I”) position the indicator lamp should light up (red) and it must go OFF after starting an engine.

These can be set ON or OFF by combination switch (16).

Turn indicator, right

In case indicator lamp is still glowing after engine start, stop the machine and check for possible causes of warning indicator!

Flashing indicator will signal right turn-indicators are ON, or hazard has been set ON. These can be set ON or OFF by combination switch (16).

Air filter clogging indicator Flashing indicator (amber) with an acoustic alarm in engine running condition indicates, filter elements are clogged.

AMN5

Neutral indicator lamp AMN9

Lit up (green) when travel control lever is in neutral (N).

To start the engine, travel control lever (1) must be in neutral position (N)!

Stop the machine and proceed to replace the filter elements instantly!

Vibration ON/OFF indicator AMN10

Hydraulic oil high temperature indicator

Engine oil low pressure indicator Flashing indicator (red) with an acoustic alarm in engine running condition indicates engine oil pressure is insufficient.

AMN6

Stop the machine and check for possible causes of warning indicator!

Engine high temperature indicator AMN7

heated.

Flashing indicator (red) with an acoustic alarm in engine running condition indicates engine is over-

Light will turn ON (red) when vibration starts, and will be OFF with vibration OFF.

AMN11

heated.

Flashing indicator (red) with an acoustic alarm in engine running condition indicate hydraulic oil is over

Stop the machine and check for possible causes of warning indicator!

Low beam ON/OFF indicator Lit up (green) if headlight low beam is ON

High beam ON/OFF indicator

Stop the machine and check for possible causes of warning indicator!

ARX 91

Lit up (blue) if headlight high beam is ON

45

2.7.

Controlling and Operation of the Machine

22

P rpm

Water level in sprinkling tank indicator Water level in tank will be indicated by glowing LED’s on bar graph. Red LED’s will indicate water tank is near to empty.

AMN27

Sprinkling pump indicator lamp AMN22

Smooth start and smooth stop ON/OFF indicator AMN16

Lit up (amber) lamp indicates smooth start and stop function is active and vice versa.

Glowing (green) Indicator indicates sprinkling pump is set ON.

CRAB mode indicator lamp AMN15

Not applicable.

Flashing indicator indicates an error within machine electronic control system.

If flashing is observed, stop the machine and call authorised service personnel to have error diagnosed and resolved!

Water level in water separator indicator Flashing indicator (amber) with an acoustic alarm in engine running condition indicates excessive water accumulated in water separator filter.

AMN18

Stop the machine and drain water from water separator filter!

46

ARX 91

OPERATION MANUAL Steering wheel positioning (21)

21

Release lever (A) to position the steering wheel in the direction away from the column axis towards a dashboard.

A

400125 The lever (A), when shifted out, can be arrested in any position.

A

400126 Operator seat adjustment:

1

1. Arm support and lifting 2. Seat turning 3. Seat sliding 4. Seat springing stiffness according to operator’s weight.

2

5. Backrest position

Adjust seat before start driving!

Seat belt must be fastened while driving!

4

3

5

400253 ARX 91

47

2.7.

Controlling and Operation of the Machine

How to swivel operator’s seat: P

Press and hold pedal (1), seat will be unlocked and can be swivel freely in either directions, once desired position is achieved release the pedal. Seat will be locked in this position.

0

1

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

Operator’s seat can be swivel about steering column, within the range of 56°.

1

MAN

2

AUT

1

MAX 56°

Do not adjust seat location while machine is running!

48

ARX 91

OPERATION MANUAL Electronic control unit (30) Located at left side of steering column in bottom compartment.

It is provided with inbuilt socket to connect diagnostic connector.

30

Hand pump tommy bar (31) Located behind the operater seat in tool box compartment.

Use to operate handpump to lift the bonnet.

31

Battery disconnector (32) Located on left hand side of machine before rear drum Use to disconnect the battery from the machine.

“0“

“I“

Position “0“ - Battery disconnected.

Position “I“ - Battery connected.

Whenever long stops are foreseen, disconnect battery with disconnector

401678 Hand pump (33) Located on left hand side of machine before rear drum It is use to lift a bonnet with the help of tommy bar.

32

33

ARX 91

49

2.8.

How to Control and Use the Machine

2.8.1. Starting the engine

22

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

P

11

16

1 1

7

0

N

2

50

ARX 91

OPERATION MANUAL How to start the engine: -

Switch ON the battery disconnector (A).

-

Insert key in the ignition box (11) in “0” position and switch over to “I” position.

-

All indicator lamps on cluster (22) will light up except CRAB mode and Sprinkling pump indicator lamps.

-

With that the parking brake, recharging and neutral indicator lamps on cluster (22) will remain ON also that time engine oil low pressure indicator lamp start flashing.

-

If you leave the key in ”I“ position for over 5 seconds then the acoustic alarm will switch ON - to warn operator about the battery discharged (acoustic alarm will turn OFF once engine is started). Unless it is started within 2 minutes, please get your key back to “0” position before starting the engine again.

-

Use alarm horn on combined switch (16) to signal engine starting.

-

Turn the key to position “II” to start the engine.

-

On cluster (22), following the starting, recharging indicator lamp shall go OFF.

-

Once the machine has started to move the neutral lamp and brake lamp will go OFF.

A

Machine will not start unless following conditions are fulfilled: -

travel control lever (1) is at neutral position (N)

-

emergency brake (7) is set OFF.

-

parking brake (2) is set OFF.

Check all liquid levels in machine daily before engine starting. Confirm no loosened or missing part or parts exist on the machine.

Do NOT attempt to start the engine for over 30 seconds. Wait 2 minutes before attempting next start.

Following the engine start let the engine run at idle rpm for 3 - 5 min.

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

Do NOT let the engine run idle for over 10 minutes - any idling longer than that may cause fouling of injectors, piston rings, or valves to get seized!

Unless oil temperature reaches min. 60 °C, the engine will not be lubricated sufficiently - do not load the engine fully!

ARX 91

Operate horn to signal the engine starting and ensure nobody is endangered by starting the engine!

NOTE! If battery recharging indicator lamp or hydraulic oil overheating indicator lamp will remain lit up with the engine running then the acoustic warning alarm will go ON. With air filter clogging indicator lamp or hydraulic oil filter lamp lit up, acoustic warning alarm will go ON, but engine will continue running.

51

2.8.

How to Control and Use the Machine

2.8.1.1. Jump start

-

4 0

52

12

V

+

1

+

12

0

-

2

V

3

ARX 91

OPERATION MANUAL 1. Connect one end of +ve cable to +ve terminal of discharged battery and other to +ve terminal of source battery of the machine used to boost-start.

2. Connect one end of -ve cable to -ve terminal of source battery and other to such part of breakdown machine which is fix-wired with the engine (or to the cylinder block itself ).

Do not connect (-) terminal of cable to (-) terminal of discharged battery of the machine being started!

There is risk of strong sparking in course of starting followed by explosion of battery-generated gas.

Make sure the non-insulated parts of the battery jump cable clamps do NOT contact each other!

Make sure the jump cable connected to (+) pole of the battery does NOT come into contact with electrically conductive parts of the machine - danger of short circuit!

Rule out any presence of flammable sources (open flame, burning cigarettes, etc.)

Do NOT confirm voltage presence in a wire through sparking via machine frame!

Starting voltage from external power source shall be the voltage of 12V. When machine started, disconnect the battery jump cables in reverse order.

ARX 91

53

2.8.

How to Control and Use the Machine

2.8.2. Travel and reversing

22

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

P

12

1 1

0

N

3 4

54

ARX 91

OPERATION MANUAL 2.8.2.1. Machine forward travel and reversing: Select travel direction: •

In engine running condition. Set engine rpm to max via engine throttle lever (12)

•

Shifting travel control lever (1) from Neutral (N) position to zero (0) position

•

Now gradual shifting of travel control lever (1) in forward direction will move the machine forward and vice versa.

Travel speed control: •

Travel speed will vary with deflection of travel control lever (1) from zero position (0) in either direction.

•

Travel speed can continuously be altered within the range of MIN to MAX, In both work (turtle) and travel (rabbit) mode controlled by switch (4).

Before starting to move the machine, please check the area in front and behind of the machine is clear from persons or obstructions! Ensure no one is near the machine less than 10 ft. from all sides.

Operator must operate machine with sitting on the drivers seat!

NOTE! The instantaneous stopping of the machine by means of travel control lever (1) applies to all travel modes of the machine.

Shift the travel control lever (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the machine - the engine will continue to run.

2.8.2.2. Smooth start & smooth stop function: •

The function enable the machine to move or stop smoothly without jerks, thereby preventing formation of waves and being transmitted on road surface under compaction during machine in operation.

•

Press push button (3) to set ON/OFF smooth start and smooth stop function, indicator lamp on cluster (22) will lit up If this function is set ON.

•

Gradually moving travel control lever (1) forth and back via position (0) will change machine moving direction and speed withoutsetting OFF the function.

•

Moving travel control lever (1) to neutral (N) position in engine running condition will set OFF the function.

In this mode the machine stopping dis­tance is longer than usual!

NOTE! One can switch on the function during machine travel.

ARX 91

55

2.8.

How to Control and Use the Machine

2.8.3. Machine forward and reversing with vibrations

22

14

13 P

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

15

12

6

1 1

0

N

4

56

ARX 91

OPERATION MANUAL In engine ON condition, set engine rpm to max. with engine throttle lever (12), and control machine travel direction and/or speed by travel control lever (1).

Set machine to work mode with switch (4).

Use switch (13) to set ON the vibration of only front or both or only rear drum.

Vibration amplitude can be set to high or low by switch (14).

Vibration can be set to manual (MAN) or automatic (AUT) mode by switch (15).

Vibration manual (MAN) mode: After selection of drum to be vibrated, vibrating amplitude and vibration manual mode, move travel control lever (1) from its neutral (N) position and press button (6) to start vibration.

In vibration ON condition, respective lamp on cluster (22) will lit up.

Press button (6) again to set OFF vibration from ON condition.

Vibration automatic (AUT) mode: After selection of drum to be vibrated, vibrating amplitude and vibration auto mode, move travel control lever (1) from its neutral (N) position and press button (6) to set vibration ON. Respective indicator lamp lit up on cluster (22).

Vibration will automatically start with machine speed above 1.5 km/hr.

Vibration will automatically stop if machine speed falls below 1.5 km/hr.

NOTE! Vibration will not start if • vibration amplitude selector switch is set to 0.

• travel control lever (1) set to neutral (N) position.

• machine not in work mode

In vibration manual mode vibration can be started even on machine almost stationary, with travel control lever (1) in slightly deflected from (0) position.

MA 25% X MAX 15%

NOTE! Vibration will be stopped If travel control lever (1) set to neutral (N) position from any other position.

For the maximum permissible slope gradient when driving uphill and across the slope gradient, see figures.

The values given are lower depending on adhesive conditions and the machine instantaneous weight!

ARX 91

MAX 35%

57

2.8.

How to Control and Use the Machine

2.8.4. Emergency stop of the machine

22

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

P

11 12

6

1 7

58

ARX 91

OPERATION MANUAL Activation: In case of uncontrolled behaviour of machine press emergency stop push-button (7) and the machine will stop instantly, with engine turned OFF and the acoustic alarm will start.

Releasing emergency stop: Turn the emergency stop push-button (7) in clockwise direction to release the emergency stop and acoustic alarm will set OFF. On cluster (22) the parking brake indicator lamp and neutral indicator lamp will remain ON. Shift travel control lever (1) to neutral (N) position, the machine can be started again in this position.

Apply emergency stop in the event of failure where the engine is unable to stop via ignition key, or through shifting the travel control lever (1) to position (0).

Do NOT apply the emergency break during the normal operation of the machine just to shutoff the engine.

ARX 91

59

2.8.

How to Control and Use the Machine

2.8.5. Stop the machine and set-off the engine Press button (6) on travel control lever (1) to set OFF the vibration If already ON, respective indicator lamp on cluster (22) will go OFF. Move the control lever (1) to neutral (N) position to stop the machine.

Use engine throttle lever (12) to set engine rpm to min.

Turn ignition key (11) anticlockwise to position “0“ - Engine will shutoff, take key out and close the ignition box cap.

Do not stop hot engine instantly but keep it running idle for 3 minutes. The engine and turbocharger will get cooled down slowly and evenly!

After the machine shutdown, make sure that the battery disconnector switch is OFF.

60

ARX 91

OPERATION MANUAL 2.8.6. Machine parking Shut down the machine on flat and solid surface at a point with no potential of natural hazard (landslides, possible flooding, etc.)

After the engine stop, before leaving the machine, please disconnect battery with disconnector (1).

Clean the machine to remove dirt (scrapers and drums).

Make overall inspection of the machine and repair any defects that have occurred during operation.

Lock the machine covers.

1

ARX 91

61

2.8.

How to Control and Use the Machine

2.8.7. Bonnet lifting and lowering In machine stand still and engine off and at atmospheric temperature.

•

Open left door (1) with provided key.

•

Take out the hand pump lever (2) from tool box compartment behind the operator seat.

1

2

Make sure valve (4) is open.

4

Lifting :Before start to lift the bonnet, rotate flow control valve (3) clockwise to make sure it is closed.

If valve (3) is not closed, rotate clockwise and close it.

62

3

ARX 91

OPERATION MANUAL •

With valve (4) closed insert one end of pumping lever (2) into the pump and start pumping, after few strokes simultaneously bonnet will start raising.

•

Continue pumping, till bonnet opens as required.

•

Take out pumping lever (2) once bonnet raised to required extent.

“0“

“I“

401678

2

•

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

4

Lowering :•

Open valve (4).

•

Gradually rotate valve (3) counterclockwise to full of its extent, bonnet will also start lowering gradually.

Note: Once bonnet is lowered completely, rotate valve (3) clockwise to full of its extent to close it.

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

Danger of injury!

Do not intervene in engine compartment when engine is hot, wait till engine temperature falls to ambient temp.

Danger of scalding!

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

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

ARX 91

3

63

2.8.

How to Control and Use the Machine

2.8.8. Sprinkling

22

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

P

10

8

9

64

ARX 91

OPERATION MANUAL Sprinkling in auto mode: •

Switch ON any one water pump with switch (10), respective indicator lamp on cluster (22) will lit up.

•

Using the potentiometer (9), change sprinkler ON/OFF interval within the range of MIN - MAX.

•

Sprinkling will be off when potentiometer at position MIN,

•

Sprinkling will continue without stopping when potentiometer at position MAX.

Sprinkling manually: •

Switch ON any one water pump with switch (10), respective indicator lamp on cluster (22) will lit up.

•

Press switch (8) to start sprinkling and hold till required to keep ON, as soon as switch (8) is released sprinkling will stop.

NOTE! Using the sprinkling push button (8), it is possible to start the additional watering of drums in auto mode.

Check water level in the tank before starting of work shift, Water level in the tank displayed on the LCD of Cluster (22) with bargraph.

We recommend to alter the pumps after 100 hours of working, in order to ensure their uniform wear.

ARX 91

65

2.8.

How to Control and Use the Machine

2.8.9. Ammann edge cutter (optional) Edge cutter and compacting discs are optional. These are not parts of standard machine configuration.

Scraper plate location (A).

A

Scraper plate 1 - Name - Always mentioned only in the English version

2

2 - Type

3

3 - Serial number 4 - Maximum weight

TYPE

5 - Year of manufacture

AMMANN INDIA PRIVATE LIMITED BLOCK NO. 157, AT DITASAN, P.O.- JAGUDAN STATE HIGHWAY , MEHSANA- 382710.

GUJARAT , INDIA

4

SERIAL NUMBER

MAXIMUM MASS

DESIGNATION

YEAR OF CONSTRUCTION

MADE IN INDIA

5

1

3459 Activating the edge cutter Set ON any one water pump with switch (11), sprinkling of the disk is connected to the circuit of sprinkling.

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

P

11

Set ON water sprinkling on edge cutter disc with valve (6).

6

66

ARX 91

OPERATION MANUAL Make sure nobody is endangered when the edge cutter is started!

P

Position the machine at the edge of road surface which is to be trimmed or compacted.

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

Press edge cutter switch (5) to set the edge cutter to the required position.

5

The required position is being set while the button is pressed.

After reaching the limit position in either direction, the cutter will stop automatically.

The cutting disc (2) can be replaced by compacting discs (3) mounted on left side of rear frame.

3

2

2.8.10. Infrared thermometer (optional) Located on right hand side of the machine under the front frame near stair case.

Turning ON the ignition key (12) will set ON Infrared thermometer (A).

Thermometer (A) senses the temperature of the asphalt mix being compacted and show on digital display (25) in °C.

401639

25

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

P

ARX 91

67

2.8.

How to Control and Use the Machine

2.8.11. Compaction meter (optional) Located on left hand side of the machine in the front drum.

Compaction meter will set ON with engine start. Operator has to set ICV (Intelligent Compaction Value), frequency and amplitude, as well as jump function and completion of compaction as reference, with which acceleration sensor will compare actual frequency, amplitude and function to show results on display. It improves the compaction efficiency and reduce the operational cost of the machine by reducing over passes of machine.

68

ARX 91

7

2.9.

Machine Transportation

2.9.1. Machine transportation by its own axle •

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

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

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

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

4

2.9.2. Machine transportation by public road •

It is recommended to carry machine on trailer or carrier, instead of driving on road by its own.

1

1

When transporting the machine on a vehicle, Obey the regulations where transportation is being carried out.

3 9

2

When loading and unloading, the vehicle transporting the machine must be braked and mechanically protected against accidental movement using scotch blocks 3.

The machine on the vehicle must be properly tied and mechanically secured against longitudinal and lateral displacement as well as against tipping 1.

The drums must be secured using scotch blocks 2.

ARX 91

69

2.9.

Machine Transportation

2.9.3. How to load the machine Use drive-up ramps (mobile or stationary) or a crane to load the machine on the transporting vehicle.

2.9.3.1. Loading the machine using a ramp Obey all the safety precaution when loading the machine with a ramp. The ramp must have sufficient loading capacity, anti-slip surface and It must be stored on flat surface.

Maximum permissible incline of the ramp is 30 %.

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

Improper handling can cause serious accident and may result in injury or death.

Non-adherence to the specified procedure and warning of the ramp may result in damage to the machine.

70

MAX 30%

ARX 91

OPERATION MANUAL 2.9.3.2. Loading the machine on the transporting vehicle using a crane For loading with crane the machine is fitted with lifting lugs.

9200 kg (20 283 lb) Lmin = 5 m 2x min 2500 kg (2x min 5512 lb)

Lmin = 5 m 2x min 2500 kg (2x min 5512 lb)

How to secure the articulated joint: Align the holes, engage pin (1) and secure pin from falling with pin lock (2).

1

2

NOTICE! When loading and unloading the machine or its parts, it is necessary to obey the related local regulations where machine is being loaded / unloaded.

Before lifting the machine joint must be secured against slight turning.

Observe safety regulations when loading and unloading!

Use the crane of sufficient loading capacity!

Use corresponding and unbroken rigging of sufficient loading capacity!

The machine must be tied to the lifting lugs on the tow machine!

Only a haulier may carry out the lashing of the machine!

Insure no one present beneath the hanging load!

ARX 91

71

2.10. Special Conditions to Use the Machine 2.10.1. Machine towing To provide for towing the machine is equipped with two lugs on front frame and two lugs on rear frame.

•

•

A sunken 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.

If the engine does not work, or there is a defect in the hydraulic system, then you must release the brake of the machine and short-circuit the hydraulic circuit. Then the machine can be towed.

When towed the machine shall be attached with both lugs!

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

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

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

When towing, it is necessary to ensure the continuous movement. Do not exceed a towing speed of more than 2 km/ hour (1.2 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 tow machine shall have sufficient towing force (performance), weight and brake effect.

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

After the brake is released and the hydraulic circuit is short-circuited, all of the brakes are disabled, so before releasing the brake, secure the machine with scotch blocks against movement!

While intervening on breakdown machine, do not touch hot parts of the machine, scalding hazard!

72

ARX 91

OPERATION MANUAL 2.10.1.1. Bypassing the hydrostatic system for towing •

Stop the machine, Set OFF the engine & disconnect the battery with isolator switch.

•

Lift and secure the bonnet in open condition with hydraulic as well as mechanical means (Refer section 2.8.7 for bonnet lifting).

•

First measure and record length of screw (1) outside of lock nut (2)

•

Loosen the lock nut (2) from pressure relief valve fitted on top of the travel pump by turning it anti clockwise completely.

•

With a hex wrench tighten the screw (1) against the spring seat. If an increased resistance is felt, turn the screw one halfturn clockwise.

•

Retighten the nut (2) turning clockwise with a torque of 22 Nm

•

Repeat the same procedure on pressure relief valve on opposite side i.e beneath the pump.

1

2

1

ARX 91

2

73

2.10. Special Conditions to Use the Machine 2.10.1.2. Brake off the machine •

Disconnect the t-connector (3) from connector (4) which connected B1 port of travel control block.

•

Install one end of hose provide in toolkit on connector (4) which connected B1 port of travel control block.

3 4

Before braking off secure the machine with wooden scotch blocks against starting to move!

•

Disconnect the T-connector (6) from elbow (5) on hand pump.

•

Install another end of hose provide in toolkit on connector (5) on hand pump.

5

6 Switch ON the battery disconnector (3).

Lit up parking brake indicator can be seen on cluster.

Turn the bonnet lifting valve to the clockwise , up to its stop, do not tighten with force.

Insert the tommy bar into the pump, start Stroking. Apply at least 30 full strokes (one stroke = one to and fro movement of lever) to pressurize the brake circuit to release spring applied parking brake.

3

With stroking, parking brake will gradually released and can be confirmed with OFF parking brake indicator on cluster.

Now the machine is braked off, and it will be possible to tow it away.

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

Check the drum of the towed machine for the occurrence of braking or skidding. In such a case stop the towing and pump again using the tommy bar.

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

74

Avoid oil spillage on ground, It is environmentally hazardous

ARX 91

OPERATION MANUAL How to put into initial state Gradually rotate valve (1) of hand pump in anti-clockwise direction up to its stop.

1

•

Disconnect the end of hose on elbow (5) on hand pump.

•

Install t-connector (6) on elbow (5) on hand pump.

5

6 •

Disconnect another end of hose provide in toolkit on connector (4) which connected to B1 port of travel control block.

•

Install the t-connector (3) on connector (4) which connected to B1 port of travel control block.

3 4

•

Loosen the lock nut (2) with hexagon head screw then turn the screw (1) counterclockwise with a hexagon socket wrench as far as it will go.

•

Retighten the nut (2) turning clockwise with a torque of 22 Nm.

ARX 91

1

2

75

2.10. Special Conditions to Use the Machine •

Repeat the same procedure on pressure relief valve fitted on opposite side i.e beneath the pump.

1

2

Unlock bonnet via hydraulic cylinder valve.

Gradually turn the bonnet lifting valve to the anti-clockwise, bonnet will also start closing gradually.

Confirm safe touch-down of the bonnet.

Take out the lever and put it in the tool box.

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

Danger of injury!

76

When working on the bonnet lifting hydraulic circuit, the bonnet must be secured by hydraulic cylinder and bonnet lifting valves.

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

ARX 91

OPERATION MANUAL 2.10.2. How to operate the machine during its running Do not load the machine at its full capacity when putting the new machine into operation or following its major overhaul during the first 30 hours!

2.10.3. Machine operation under low temperatures

2.10.5. Machine operation under high altitudes With the altitudes increasing the engine power drops due to lower atmospheric pressure and lower specific weight of intake air.

The engine power is affected by the environment in which the machine is working.

The machine may be used up to a maximum altitude of 3,658 m (12,000 ft).

Compacting during winter season depends on the content of fine particles and water in the soil being compacted. With the temperature dropping below freezing point the soil becomes more solid and harder to compact.

At the temperatures below 0 °C (32 °F) it is possible to compact only dry soils (and stony loose materials), or carry out rapid compaction of non-frozen materials (before soil gets frozen).

Set up the machine for operation at low temperatures: •

Check concentration of engine cooling liquid.

•

Exchange Engine oil for the one recommended for given external temperature range.

•

Use hydraulic oil of corresponding Kinematic viscosity.

•

Use winter diesel oil.

•

Confirm battery has been recharged.

2.10.6. Machine operation at extremely dusty environment While in extremely dusty environment, please cut short the intervals of cleaning and replacing the air filter elements, and cut short the intervals of cleaning the engine coolers.

Recommended interval of cleaning is 1x per week.

A precondition for proper starting at low temperatures is that the battery is OK. The machine can be used at its full capacity only after the Refill have been heated to their operating temperatures.

2.10.7. Driving with vibrations on compacted and hard materials

2.10.4. Machine operation under high temperatures and humidity

During machine travel with vibration the drums may loose contact with the materials being compacted (so called vibro-stroke) due to high level of compaction of the background material or travel with vibration on hard materials. This condition will come to light in the form of increased vibration transfer into machine frame and onto operator’s control stand. The vibro-stroke can partly be eliminated through the increased travel speed.

The engine power lowers with the air temperature and moisture increasing. Due to the fact that both these factors reducing the engine power, are independent on each other, it is possible to describe their impact as follows: -

each 10 °C (18 °F) of temperature rise means power drop by up to 4 % (at constant humidity)

-

each 10 % of RH increase means power drop by up to 2 % (at constant temperature).

It is banned to work in vibro-stroke mode in the long term!

In extreme cases there is machine damage hazard or operator’s health hazard!

At ambient temperatures when hydraulic oil temperature is constantly round 90 °C (194 °F), we recommend to exchange oil for the one with Kinematic viscosity of 100 mm2/s.

ARX 91

77

2.11. Error Codes and Troubleshooting When an error is detected, it is indicated on cluster with blinking of smooth start smooth stop indicator. Frequency of blinking will be different for different errors, refer the below tables for error code and troubleshooting.

Frequency of Blinking

Error name

Frequency of Blinking

Error name

2

Motor speed sensor

6

Vibration on off PB Short

3

Travel Joystick

7

Forward Solenoid

4

Sprinkler Port

8

Reverse Solenoid

5

Smooth Ramp PB Short Error code

Description

Error type

Troubleshooting

Travel Joystick

8000

No signal/open or short circuit

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Sprinkler Potentiometer

8003

No signal/open or short circuit

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Motor speed sensor

8006

No signal/open circuit

MEDIUM

check RC wiring diagram, check the signal Hz in multimeter and connectivity to RC

Vibration switch ON OFF

8008

Open circuit or Short

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Smooth ramp switch

8009

Open circuit or Short

MEDIUM

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

RAMP stop Output

A000

Short circuit to ground or open load - pump forward

MAJOR

check RC wiring diagram for solenoid connection and joystick any loose connection..

Forward Solenoid

A001

No signal/open or short circuit

MAJOR

check RC wiring diagram, check the signal mA in multimeter and connectivity to RC

Backward Solenoid

A002

No signal/open or short circuit

MAJOR

check RC wiring diagram, check the signal mA in multimeter and connectivity to RC

Fault Lamp Active

A003

Error activated

MAJOR

count error blink lamp and refer below for particular error. And check the connection as per error.

Forward Actuator

A011

Open circuit or Short

MAJOR

check RC wiring diagram for solenoid connection and joystick any loose connection

Reverse Actuator

A012

Open circuit or Short

MAJOR

check RC wiring diagram for solenoid connection and joystick any loose connection

can_sendData:buff overflow<chnl>

2030

CAN bus error

MINOR

Minor error, no issue in function.

Power supply too low

9000

Bat power low then expected

MEDIUM check Bat power given to ECU.

EMCY STOP ACTIVE

9014

Start not released

MAJOR

check error by lamp and trouble shoot it.

Brake Output

A007

Open circuit or Short

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Neutal Control Output

A008

Open circuit or Short

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Smooth Ramp Cluster LED Output

A009

Open circuit or Short

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Reverse Indication Output

A010

Open circuit or Short

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Vibration Output

A004

Open circuit or Short

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Sprinkler Output

A005

Open circuit or Short

MAJOR

check RC wiring diagram, check the signal volt in multimeter and connectivity to RC

Error message

78

ARX 91

OPERATION MANUAL Notes

ARX 91

79

80

ARX 91

MAINTENANCE MANUAL

3. MAINTENANCE MANUAL ARX 91 (Cummins BSlll)

ARX 91

81

3.1.

Safety and Other Measures for Machine Maintenance

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.

•

•

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.

•

Fit it with portable fire extinguishers.

•

With the wiring disconnected and the ignition key removed.

•

•

On the cooled down parts of the machine.

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

•

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

•

Confirm the shipping containers are properly closed during storage.

•

Using proper undamaged tools.

•

•

Replacing with new original parts per the spare parts catalogue.

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

•

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

•

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

•

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

•

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

Use recommended refills only.

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

82

ARX 91

MAINTENANCE MANUAL 3.1.3. Ecological and 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

•

This waste product category includes the following -

Organic or synthetic lubricants, oils and fuels

-

Brake fluids

-

Cooling liquids

Please note the following in particular:

-

Battery charges and Battery themselves

-

Protect your Eyes & skin when handling the Battery

-

Cleaning & preserving agents

-

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

-

All the dismantled filters & filter elements

-

-

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

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

-

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 unlabeled 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.

ARX 91

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.

83

3.2.

Specification of Fluids

3.2.1. Engine oil

Viscosity Diagram 2412

Engine oil has been specified as per its performance classification and 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 (AMERICAN PETROLEUM INSTITUTE) CCMC (COMMITTEE OF COMMON MARKET AUTOMOBILE CONSTRUCTORS) ACEA (ASSOCIATION DES CONSTRUCTEUERS EUROPPÉENS DE AUTOMOBILE)

To determine SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) viscosity class the ambient temperature and type of operations at the place where the Machine will be used are decisive.

The use of admissible oil under API:

15W - 40

Viscosity classification

CH-4/SJ; CI-4

CCMC DHD-1 ACEA: E-5

NOTE! Exceeding low temperature limit leads to no engine damage; it may only cause some starting difficulties.

It is convenient to use universal multi- range oils so to avoid any necessity to exchange oil due to ambient temperature.

It is possible to use synthetic engine oils when oils’ performance and viscosity classifications correspond to the recommended mineral oils.

Exchange periods shall be observed at the same intervals like when mineral oils are used.

To perform starting at the temperatures below 0 °C (32 °F) easier the engine manufacturer recommends SAE 10W-30 oil.

5W - 30

All the year round: SAE 15W-40, refer to Fig.

10W - 30

API CI-4 oil is recommended as especially appropriate.

282N224T

Exceeding upper temperature limit, with regard to oil’s reduced capabilities, must not last for some long period.

When using oil under API CG-4/SH the exchange interval must be reduced to half, i.e. 125 hours.

84

ARX 91

MAINTENANCE MANUAL 3.2.2. Fuel Diesel oil is used as the engine fuel: •

EN 590

•

ASTM D6078-78: 1-D and 2-D

•

The ASTM 2D is recommended to use as optimal one.

Fuel viscosity shall be over 1,3 cST at 40 °C (104 °F) to provide for fair characteristics of the liquidity and lubricating of the fuel system components.

At ambient temperatures below 0 °C (32 °F) you must use winter diesel oil. At ambient temperatures below -15 °C (5 °F) it will be necessary to use special diesel oil with additives for these purposes (”engine super diesel oil”).

Use of bio fuel (Diesel fuel) Using the fuel mixture under the trade name of Bio fuel is in principle approved by the engine manufacturer for the engine on the machine if it conforms to the specifications under EN 14214 or ASTM D6751.

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

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

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

CAUTION! When using Bio fuel, power can be reduced by up to 12% depending on the used mixture of Bio fuel.

Therefore, do not adjust the engine or the setting of the injection pump for increasing the power in any case. Never mix the fuel mixture at the place of use.

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

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

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

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

If Bio fuel is used all the year round, it is necessary to clean the fuel system under the engine operation with a clean diesel fuel for at least 30 minutes before parking the machine for longer than 3 months.

Further, it is necessary to drain off the fuel tank, clean it, and either fill it with diesel fuel or minimise the occurrence of moisture and limit the microbiological growth inside the tank. Consult the measures with the fuel supplier.

ARX 91

85

3.2.

Specification of Fluids

3.2.3. Cooling liquid

3.2.4. Hydraulic oil 2158

2152

Engine manufacturer recommends premixed coolant as per standards: - JIS K 2234 Class 2 - SAE J 1034 (e.g Fleetguard ES Compleat EG or PG) Or can use cooling liquid comprising 50% water and 50% antifreeze agent (designed for ambient temperature of up to -36°C [-33°F]) for the engine cooling system even within a climatic zone where temperatures do not drop below 0°C (32°F). The cooling liquid serves not only to protect the cooling system against any freezing, but also to increase boiling temperature.

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

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

Only the quality hydraulic oil of performance class under ISO 6743/ HV (corresponds to DIN 51524 part 3 HVLP; CETOP RP 91 H) shall be used for the Machine’s hydraulic system.

Fill the Machines normally with hydraulic oil that has Kinematic viscosity of 68 mm2/s at 40 °C (104 °F) ISO VG 68. This oil is most appropriate for its use within the widest range of ambient temperatures.

Synthetic hydraulic oil Hydraulic system is able to be filled with synthetic oil which, if any leaks occur, will be degraded with no residues, via the microorganisms found in water and in soil.

Please consult always with oil manufacturer or dealer any switching from mineral oil to synthetic one or mixing the oils of various brands!

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

3.2.5. Gearbox oil 2186

Use high-quality oil corresponding to API GL-5, or EP or MILL-2105 D to lubricate gearbox, pumps and drum reductors.

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

Do NOT use ration over 68%!

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

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

Viscosity SAE 80W/90 for outdoor temperature range -10 °C 30 °C (14 °F - 86 °F).

Viscosity SAE 85W/140 for outdoor temperature range 20 °C 45 °C (68 °F - 113 °F).

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

3.2.6. Lubrication grease 0787

Use plastic lubricant with lithium content to lubricate the Machine under the following standards: ISO 6743/9 CCEB 2 DIN 51 502 KP2K-30

3.2.7. Drum cooling liquid 2152

Mixture ARX 91: 60 l (16 GalUS) of water 2 l (0.5 GalUS) Anticorit SKR 40

86

ARX 91

3.3.

Refills

MAINTENANCE MANUAL

Part

Engine

Medium Type

Engine oil under Section 3.2.1

Medium Amount l (gal US)

Brand

7 (1.85) 2412

Fuel tank

Fuel under Section 3.2.2

200 (52)

Hydraulic system

Hydraulic oil under Section 3.2.4

70 (18.5) 2158

Drum bearings, calliper bearLube grease under Section 3.2.6 ings, king pins, suspensions

As required

Cooling system

24 (6.36)

Coolant under Section 3.2.3

0787

2152

Vibration drum ARX 91

Engine oil under Section 3.2.1

2x10 (2x2.64) 2412

Drum drive gearbox

Gearbox oil according to section 3.2.5

2x1.1 (0.29) 2186

Sprinkling tank

Water

1000 (264) 2567

Drum cooling liquid ARX 91

Liquid under Section 3.2.7

2x62 (16) 2152

ARX 91

87

3.4.

Lubrication and Maintenance Chart

Every 20 hours of operation 3.6.1

Engine oil level check

3.6.2

Engine coolant level check

3.6.3

Inspect the engine belt

3.6.4

Crankcase breather

3.6.5

Air filter dust valve check

3.6.6

Inspect fan condition

3.6.7

Fuel level check

3.6.8

Hydraulic tank oil level check

3.6.9

Water tank refilling

3.6.10

Inspect alarm and control devices

First 150 hours of operation 3.6.29

Exchange oil in drum drive gearboxes

Every 250 hours of operation 3.6.11

Engine oil and filter exchange

3.6.12

Inspect engine induction manifold

3.6.13

Inspect engine cooling circuit

3.6.14

Checking oil level in drum drive gearboxes

3.6.15

Inspect the battery

3.6.16

Air filter sensor function check

3.6.17

Sprinkling water filter cleaning

3.6.18

Machine lubrication

First 500 hours of operation 3.6.23

Vibration systems oil exchange

Every 500 hours of operation

88

3.6.19

Engine fuel filter and water separator exchange

3.6.20

Coolant level check

3.6.21

Check of wiring

ARX 91

MAINTENANCE MANUAL Every 1000 hours of operation 3.6.22

Inspect engine belt

3.6.23

Vibration systems oil exchange

3.6.24

Inspect the vibration dampers

3.6.25

Fuel tank cleaning

3.6.26

Water tank cleaning

3.6.27

Exchange oil in gearboxes

3.6.28

Air filter elements replacement

Every 2000 hours of operation 3.6.29

Checking and adjusting valve clearance

3.6.30

Engine coolant exchange

3.6.31

Replace hydraulic oil and filters

Maintenance as required or on signalling 3.6.32

Cleaning of liquid and air coolers

3.6.33

De-aerating (venting) the fuel system

3.6.34

Drain water from the water separator

3.6.35

Drain water from sprinkling circuit before winter season

3.6.36

Adjustment of scrapers

3.6.38

Machine cleaning

3.6.39

Check the tightening of bolted connections

ARX 91

89

3.5.

Lubrication and Service Plan

LUBRICATION AND SERVICE PLAN ARX 91 CONTROL / CHECK LUBRICATE EXCHANGE

2000 1500 1000 500 250 20

Engine oil:

SAE 15W/40

API CH-4/SJ; CI-4/SK

Hydraulic oil:

ISO VG 68

ISO 6743/HV

Grease:

ISO 6743/9

CCEB 2

Transmission oil:

SAE 85W/140

API GL-5

First after 500 hrs. in vibrator

90

First after 150 hrs.

ARX 91

3.6.

Lubrication and Maintenance Operations

MAINTENANCE MANUAL

Perform regularly the lubrication and maintenance operations of the machine at the repeated intervals as per everyday data reading on the counter of hours actually worked.

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

P

This Manual includes only the basic engine information, others are given in the Engine Operation and Maintenance Manual which is part of documentation supplied with the Machine.

Follow the instructions given in the Engine Operation and Maintenance Manual!

Removed or loose bolts, plugs, threaded joints of the hydraulics, etc. shall be tightened with the torque according to the charts in Section 3.6.39 unless a different value is given with the relevant operation.

Carry out the inspection of the Machine located on flat or solid surface secured against self-motion (scotch blocks), this always with the engine OFF , key removed from ignition box and with the wiring disconnected (unless otherwise required).

ARX 91

91

3.6.

Lubrication and Maintenance Operations Every 20 hours of operation

3.6.1. Engine oil level check •

Stop the engine and wait for 5 minutes until temperature goes down and oil flows down into crankcase sump.

•

Lift the bonnet, (cc).

•

Pull out oil dipstick (1) and wipe off the oil with a waste cloth.

•

Insert oil dipstick (1) completely once again and pull it out.

•

Maintain the level between the division lines stamped on the dipstick.

•

Low division mark (L) shows lowest possible oil level, high division mark H (High) shows the highest level

•

When the oil level is below the “L-division” level, refill the engine oil through oil filler plug (2).

•

When the oil level is above the “F-Division” level, loosen drain cock to drain the excess engine oil and check the oil level once again.

1

400157 •

Refill the oil via filler-neck with the oil filler plug (2) removed.

Wait for 1 minute until the level gets stable and then check again.

•

Check that the oil level is proper and insert level gauge (1) securely.

•

Lowering the bonnet and close it (refer the section 2)

NOTE! Do NOT run the engine unless there is correct oil level in the engine.

For engine oils to use, see Engine oil specification in section 3.2.1.

The amount of oil between Low and High marks is 1.5L (1.6 U.S. Quart).

92

2

Immediately after the engine is stopped, there is a possibility of getting burn with heated parts and oil. Start working after the temperature goes down.

ARX 91

MAINTENANCE MANUAL 3.6.2. Engine coolant level check and refilling Level check •

Visually check the coolant level at the start of the every work shift.

•

Lift the bonnet and access radiator (refer Section 2.8.7).

•

Check coolant level in level indicator, it must seen in between MIN and MAX range.

•

If coolant level found below MIN mark, proceed to add it

Refilling •

Open radiator pressure cap (1) and add coolant till level reaches in between MIN to MAx range.

•

Add coolant as specified in section 3.2.3.

•

Confirm the coolant level and install the radiator pressure cap (1) again.

•

Set OFF the bonnet (refer Section 2.8.7).

1

MAX MIN

Do not remove a pressure cap from a hot engine. Wait until the coolant temperature is below 50 °C before removing the pressure cap. Danger of scalding.

400159

The level must not drop below the level gauge eyesight.

Never use additives with the engine cooling liquid to repair cooling system leakages.

Do not refill hot engine with cold liquid.

The casts of the engine may get damaged.

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

ARX 91

93

3.6.

Lubrication and Maintenance Operations

3.6.3. Check the fan belt •

Do the visual inspection of the belt (2) for intersecting cracks.

•

Cracks perpendicular to the belt width are not considered a damage.

2

When longitudinal cracks occur on the belt, or belt edges are shattered, or pieces of material missing, then the belt must be replaced.

400161

3.6.4. Crankcase breather •

Inspect the crankcase breather hose (3) for cracks, or other particles, that can obstruct the hose.

3

When running the Machine during low temperature period or under low temperature conditions, make the inspections in shorter intervals.

400162 94

ARX 91

MAINTENANCE MANUAL 3.6.5. Air filter dust valve check •

Check the exit slit of air filter vacuum valve (1), press to remove any dust trapped.

1

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

Never operate the Machine with dust valve damaged.

3.6.6. Inspect fan condition •

Check visually the fan (2). If damaged (e.g. broken parts of materials, cracks, shape changes etc.) replace the fan.

2

ARX 91

95

3.6.

Lubrication and Maintenance Operations

3.6.7. Fuel level check •

Check the amount of fuel Displayed on LCD of cluster (22) with bargraph.

•

Minimal amount of fuel is Displayed on the LCD of Cluster (22) With Red mark on bargraph.

P rpm

•

Clean tank filler cap (3) and filler neck (4).

•

Unlock the cap, turn the cap counterclockwise and remove it.

•

Refill the tank up to the bottom edge of filler neck via the strainer.

3 4

NO smoking and no use of open flame when at work.

Do NOT refill fuel while engine is running.

Do NOT use up fully the tank. When used up fully the entire fuel system must be bled, which is rather hard and demanding.

Use only a clean recommended fuel per Section 3.2.2 .

NEVER replenish fuel in confined space.

Fuel must NOT be spilled.

NOTE! Fuel tank capacity is 200 l (52 gal US).

96

ARX 91

MAINTENANCE MANUAL 3.6.8. Hydraulic tank oil level check •

Lift the bonnet.

•

Check oil level in oil gauge(1).

•

Fill up oil via the filling device using quick-coupling (2), proceed as per Section 3.6.31 .

MAX

MIN

Conduct this filling method as emergency one - not recommended by manufacturer!

Oil level shall always be visible in oil gauge!

Refill required oil according to the Section 3.2.4 .

Upon higher loss of oil, find out the cause of hydraulic system leaking (leaks through hose screw joints, screwed fitting of hydroelectric generators or of hydraulic motors, etc.), and repair the defects.

1

2

3.6.9. Water tank refilling •

Check water amount on the cluster. It is displayed on the LCD of cluster (22) With bargraph.

•

If the water level is low, Fill the tank again.

•

Minimal amount of water is Displayed on the LCD of cluster (22) With Red mark on bargraph.

•

Do this process before start the engine.

P rpm

Open the cap (1) and refill with clean water via the strainer (2).

2 Before winter period, drain water from the water tank and sprinkling system!

Proceed according to Section 3.6.35.

1

ARX 91

97

3.6.

Lubrication and Maintenance Operations

3.6.10. Inspect alarm and control devices

P

•

First set to “ON” the battery disconnector.

•

Put the ignition switch to Position “I”, instantly cluster lamps will set ON.

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

Before start the operation do the test to confirm functioning of controls and any error warning if present as follows:

0

•

I

II

Cluster lamps will go OFF after 3 seconds except:-

Neutral indicator lamp

-

Blinking engine low pressure indicator lamp

-

Parking break lamp

-

Battery recharging indicator lamps P rpm

•

In Position “I” also check the function of Combination switch, Hazard light switch & Work light switch.

22

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

NOTE! When lights are switched ON the luminous intensity of indicator lamps on cluster (22) will lower.

P

17

18

16 •

Turn the Ignition key to Position “II”, Engine will start.

•

The indicator lamps on cluster must go OFF: -

Battery recharging indicator lamps

-

The blinking of engine low pressure indicator lamp P

NOTE! If engine is not started within 10 Sec after ignition switch turned ON to Position “I”, acoustic signal will be enabled (to warn operator of the battery possibly discharged).

98

rpm

ARX 91

MAINTENANCE MANUAL Start moving the machine: •

Indicator lamps on cluster will go OFF: -

Indicator lamp for the idle (neutral) of travel controller

-

Parking switch indicator

P P

15 A 20 A 15 A 5A 10 A 15 A 7.5 A 15 A

rpm

Emergency brake push button function: •

Check whether emergency brake works (7).

•

The engine stalling.

•

Then the following indicator lamps on cluster remain ON:

•

-

Parking brake warning lamp

-

Battery charging indicator

7

When travel controller is shifted to neutral position (N) the seat switch indicator lamp goes OFF, and idle indicator lamp lights up. Now you can start the engine again.

Use sound signal to indicate the engine start!

Before engine is started, check there is no hazard of any person if engine is started!

Use sound signal before Machine starts moving and wait long enough to any persons present can leave the area round the Machine (space beneath the Machine) in time!

Make sure the area in front and behind the Machine is free, with no persons present within thereof!

During operation, check continuously the instruments and indicator lamps.

Immediately repair any failures!

P rpm

ARX 91

99

3.6.

Lubrication and Maintenance Operations Every 250 hours of operation

3.6.11. Replacing engine oil •

Arrange a container of capacity about 7 litters (1.85 gal US) , place it below the engine oil drain plug (1).

•

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

•

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

After reaches oil temperature to 50°C (122°F), drain the oil.

1

3.6.11.1. Replacing engine oil filter •

Loosen and remove the old filter from lubrication oil filter head with filter wrench.

•

Clean the gasket surface on the lubrication oil filter head.

•

Clean seating face for filter gasket.

400173 •

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

396248 100

ARX 91

MAINTENANCE MANUAL •

Apply oil on the gasket.

396247 •

Install the new filter and hand-tighten securely.

•

Tighten filter with filter wrench.

396250A Do not overtighten the filter, the thread and gasket can get damaged!

ARX 91

101

3.6.

Lubrication and Maintenance Operations

•

Check the drain plug gasket, replace if damaged.

•

Check the thread and clean seating face for gasket.

•

Reinstall the plug (1).

1

•

Fill new engine oil through filler neck (2).

2

•

Fill up to the dipstick’s top division mark. Total sump capacity is 7 l (1.85 gal US).

•

After oil is changed, start the engine and let it run at higher idle rmp for 2 - 3 min.

•

Stop the engine and wait for approx 3 min until oil descends into the crankcase, then check and ensure the proper oil level.

400178

Drain oil when hot - best upon operation completion.

Use original filters only.

Use recommended oil under Section 3.2.1 only.

To not overtighten the filter, its thread and gasket can get damaged.

102

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

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

ARX 91

MAINTENANCE MANUAL 3.6.12. Inspect engine induction manifold •

Check the pipes and clamps.

Do not operate the Machine if pipes and clamps are damaged!

•

Check tightness of the connection between bonnet and air filter.

•

Replace damaged gasket with new one.

ARX 91

103

3.6.

Lubrication and Maintenance Operations

3.6.13. Inspect engine cooling circuit •

Check and confirm no damaged hoses or missing hose clamps exist within the engine cooling system.

•

Check for damaged hoses and loose or damaged hose clamps. Replace them, if necessary.

•

Check the radiator for leaks, damage, and buildup of dirt.

Clean and repair, as necessary.

400181

104

ARX 91

MAINTENANCE MANUAL 3.6.14. Checking oil level in gearboxes Drum gearbox (valid only for ARX 91) •

Clean the area around the checking plug (1).

•

Prepare a suitable vessel with the volume of approx 1.1 l (0.29 gal us) capacity.

•

Unscrew the plug (1) and check the oil level. The oil level must reach to the checking points or slightly flow out.

•

Refill oil through the filling plug (2), if necessary.

•

Clean the plugs and mount again.

•

Check the gearboxes fittings are tight.

•

Refill the identical type of oil - see section 3.2.5 .

2 1

Do not touch the gearbox and adjacent parts if they are hot.

3.6.15. Inspect the battery •

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

•

Clean the surface of the battery.

•

Inspect the condition of poles and terminals (1). Clean the poles and terminals. Apply thin layer of grease on terminals.

•

If a maintenance free battery is installed on the machine, it is not necessary to check the electrolyte level and the electrolyte is not filled up for the whole service life of the battery. Other tasks prescribed above must be performed.

Consult the battery discharge condition - the lowest permissible voltage level (measures on the battery terminals) under which the battery could be damaged and the charging procedure with the manufacturer.

•

•

Unless the Machine is going to be used during winter season for a couple of months, remove the battery and store it so it is protected against any frost. Carry out inspections of the battery and its recharging before its storage and for the period it is stored.

“0“

“I“

401678

A

Reinstall the step when work on battery is completed.

ARX 91

105

3.6.

Lubrication and Maintenance Operations Use rubber gloves and safety glasses when working with the battery.

Protect your skin with proper clothing against being stained by electrolyte.

Upon eye contact with electrolyte immediately flush eyes with large amounts of water for at least a couple of minutes. Get prompt medical attention.

Upon ingestion of electrolyte drink max amount of milk, water or solution of calcined magnesia in water.

Upon skin contact with electrolyte remove contaminated clothing, including shoes, wash affected spots as soon as possible with soap water or solution of soda and water. Get prompt medical attention.

Do not eat, drink, smoke, while at work!

Having finished the work, please wash your hands and your face thoroughly with water and soap!

Do not try whether wires are energized through contacting Machine frame.

Keep the battery dry and clean.

Recharge the undercharged battery.

Recharge the battery off the Machine.

Never disconnect the battery with the engine running.

Follow the battery manufacturer’s manual when working with the battery!

Disconnect the battery during its repair, or when handling the wires and electric devices within the wiring circuit to avoid any short circuit.

To disconnect the battery you must first disconnect (-) pole of the cable. To connect, first connect (+) pole.

Never make direct conductive connection between the battery’s both poles, short circuit will occur with the risk of battery explosion.

Do not turn the battery upside down, electrolyte may pour down from the degassing plugs.

Flush spilled electrolyte with water, and neutralize with lime.

Hand over the aged battery that does not work, for its disposal.

106

ARX 91

MAINTENANCE MANUAL 3.6.16. Air filter sensor function check •

Adjust the engine rpm to around 1500 rpm.

•

Remove engine pre-cleaner.

•

Cover the air filter suction hole on the engine bonnet.

Inspect always when cleaning the induction air pre-filter!

Do not use thin paper to cover it - beware of intake hole clogged!

•

After covered, the indicator lamp for air filter clogged shall light up.

P rpm

•

Unless indicator lamp goes ON, check the vacuum switch, contacts and feeder cables.

ARX 91

107

3.6.

Lubrication and Maintenance Operations

3.6.17. Sprinkling water filter cleaning •

Close water supply through the valve.

•

Remove sprinkler filter vessel (1), replace the strainer (2) and clean it.

1

2

400262 •

Remove and clean sprinkler strainers (3).

401385

3

400190 108

ARX 91

MAINTENANCE MANUAL 3.6.18. Machine lubrication •

Remove greasing nipple caps.

•

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

•

Reinstall the greasing nipple caps.

Use only the recommended lube greases, refer to Section 3.2.6 .

Steering joint Upper bearings 1 x Lower bearings 1 x Main bearing 4x

Linear hydraulic motors for steering Pins 4x

ARX 91

109

3.6.

Lubrication and Maintenance Operations

Linear hydraulic motors to lift off the bonnet Upper pins 2 x

Lower pins 2 x

Linear hydraulic motor to edge cutter.

Pins 2 x

110

ARX 91

MAINTENANCE MANUAL Every 500 hours of operation 3.6.19. Replacement of fuel filter and water separator •

Close fuel tank valves.

•

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

•

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

•

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

1

400173 •

Fill new filter with clean fuel and lubricate sealing “O” ring with oil. Refer figure A and B.

A •

Screw the filter with hand until the gasket gets seated, and then tighten by another half-turn.

•

Open fuel tank valves.

•

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

B

396250A ARX 91

111

3.6.

Lubrication and Maintenance Operations

Fuel water separator filter: •

Disconnect the connector of water separator sensor.

•

Clean the head of the fuel filter cum water separator (2).

•

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

2

•

Clean the gasket surface on the fuel filter head and remove the O-Ring.

400173 •

Fill the new filter with clean fuel and lubricate the O-Ring with clean lubricating engine oil.

No smoking while at work!

Obey fire precautions!

Use original filters specified in parts manual for machine.

Do not over tighten the filter.

A •

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

•

Now tighten filter body further with filter wrench.

•

Connect the connector of water separator sensor.

•

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

B

Avoid fuel spillage on ground, It is environmentally hazardous.

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

396250A 112

ARX 91

MAINTENANCE MANUAL 3.6.20. Coolant level check •

Check the concentration via refractometer.

Inspect always before winter season.

Unless concentration for -36 °C (-33 °F) has been measured, you must adjust it through adding antifreeze into the cooling system.

Add antifreeze according to Section 3.2.3.

400183

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.

ARX 91

113

3.6.

Lubrication and Maintenance Operations Every 1000 hours of operation

3.6.22. Inspect engine belt •

With the engine running, check visually the pulley of alter nator (1) and crank shaft (2), whether this does not oscillate.

Check the belt tension: •

Use parking brake to secure the Machine.

•

Press with your thumb at the spot where belt length between pulleys is the longest, using 110 N (25 lb) strength.

•

Max slack is 10 mm (0.39 in).

1 2

Check the belt wear: •

Inspect visually the belt.

•

If longitudinal cracks occur on the belt, or belt edges are shattered, or parts of material are extracted, then you must replace the belt.

400161 Belt tension: •

Tighten the belt once you loosen the bolts and via moving a bit the alternator.

Check the belt and take up the slack with the engine OFF!

114

ARX 91

MAINTENANCE MANUAL 3.6.23. Vibration systems oil exchange Valid only for ARX 91 Oil draining: •

Clean the area around the plug.

•

Position the machine so that the plug (1) is in the lowest position.

•

Dismount the plug and let the oil drain to the container with a capacity of 10 l (2.14 US gal).

1 NOTE! Exchange the oil when it is warm.

Let the drained oil cool down to below 50 °C (120 °F).

Do not touch the hot parts of the machine.

Collect the drained oil.

Perform the disposal in accordance with the applicable the regulations.

Oil filling: •

Position the machine so that the plug (1) is in the highest position.

•

Using the filler plug, pour in the recommended oil, see Section 3.3 .

1

NOTE! Follow the same procedure on the rear drum.

Oil level check: •

Check the oil level in the inspection hole (2).

•

The oil level must reach the lower edge of the hole or flow out slightly.

•

Remount the plugs and replace the plug seals.

NOTE! Follow the same procedure on the rear drum.

ARX 91

2

115

3.6.

Lubrication and Maintenance Operations

3.6.24. Inspect the Vibration damper system •

Check the condition of rubber-metal, coherence (bond strength) between metal and rubber.

Replace the damaged once.

Check the bolts and nuts of the following are tightened .

ARX91 Rubber-metal of drums LH side and RH side 2 x 10.

116

ARX 91

MAINTENANCE MANUAL Rubber-metal for the engine 3x.

Rubber-metal components of the cooler supports 6x.

ARX 91

117

3.6.

Lubrication and Maintenance Operations

3.6.25. Fuel tank cleaning •

Perform the cleaning at a time when there is a minimum amount of fuel in the tank, Only show Displayed on the LCD of cluster (22) With Red mark on bargraphg.

P rpm

•

Unscrew the drain plug and let the remaining fuel flow out into the prepared vessel.

•

Dismount the cleaning cap.

•

Wash out the tank with clean fuel and remove impurities.

•

Remount the drain plug and cap - check the sealing.

•

Clean the screen in the filler neck.

NOTE! If there occur air pockets in the engine fuel system, perform the ventilation according to Section 3.6.33.

When the tank is running out of the fuel, there will remain approximately 25 l (12 galUS) in the tank.

Follow the fire fighting measures!

Do not smoke and do not use open fire when working!

Cleaning should be performed in the ventilated areas without a risk of fire.

Comply with the sanitary principles.

Follow the environmental protection regulations!

Prevent oil leakage to the ground.

118

ARX 91

MAINTENANCE MANUAL 3.6.26. Water tank cleaning •

Remove the caps from the filler necks of the tank.

•

Open the drain holes of the tank.

•

Wash out the tank by water jet.

•

Clean the screens in the filler necks.

Before the winter season, discharge water from the water tank!

Follow the instructions as specified in Section 3.6.35.

ARX 91

119

3.6.

Lubrication and Maintenance Operations

3.6.27. Exchanging oil in gearboxes Drum gearbox (valid only for ARX 91) •

Clean the area around plugs.

•

Prepare a suitable vessel with the volume of approximately 1.1 L (0.3 gal US).

•

Put appropriate vessel under the drain plug (3).

•

Unscrew all plugs (1), (2), (3) and let oil drain.

•

Mount the drain plug (3) after draining is finished.

•

Refill recommended oil through the filling plug (2).

•

Check oil level in the checking opening (1). The oil level must reach the lower edge of the opening or slightly flow out.

•

Mount the plugs (1) and (2), replace damaged plug sealings.

•

Fill up the same oil type, see Sections 3.2.5 .

2 1 3

Perform the first oil exchange after reaching 150 operation hours.

Do not touch the gearbox and adjacent parts if they are hot.

Avoid leakage of oil to the soil.

120

ARX 91

MAINTENANCE MANUAL 3.6.28. Replace air filter elements The proper maintenance of air filter and of the entire inlet piping, the rubber parts in particular, will ensure maximal protection of the engine against dust effects, and prolong the life of the element and its efficiency.

The inherent sign of fouled filter is the exhaust pipe that smokes, higher fuel consumption, output loss and engine temperature increased.

Principles of correct filter element replacement: •

Slowly pull out the clogged element as carefully as possible.

•

Always clean the inner bodies of the cleaner in a way to avoid dust penetrating inside the engine feed piping.

•

Clean the seating faces for gasket in the cleaner body.

•

Examine the dust traces in the element removed, any traces would be an indication of its leakage in the filter body.

•

Press the gasket on the new element, whether it is flexible.

•

Make sure the gasket is seated properly.

NEVER use damaged elements!

Do NOT use other elements than those required!

Do NOT remove the elements just for checking purposes!

Do NOT left the filter opened longer than necessarily required!

NEVER operate the Machine with filter body damaged!

How to replace air filter element: Air filter contains the primary and secondary filter elements.

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

P rpm

•

Open the bonnet (refer to Section 2.8.7).

•

Remove filter cap (1)

1

ARX 91

121

3.6.

•

Lubrication and Maintenance Operations

And replace the main filter element (2) from the filter shell.

2

401681 •

Replace the safety element (3) from the filter shell and check it.

•

Replace the safety element always following three replacements of the main element.

3

•

Clean filter’s inner space in such a way to avoid dust penetration into the inner feed piping to the engine..

•

Take off the air filter dust valve (4), clean it and reinstall.

NEVER use compressed air to clean the inner space.

Replace the dust valve immediately if it is damaged!

NOTE! When safety element is damaged, please replace it with the new one of identical type as per identification!

122

4 ARX 91

MAINTENANCE MANUAL Every 2000 hours of operation

3.6.29. Checking and adjusting valve clearance •

Call CUMMINS service department to adjust the engine valves. Next valve adjustment will follow periodically after 2000 hours or after two years - for contact points, please refer to Engine Operation and Maintenance Manual.

3.6.30. Engine coolant exchange How to drain cooling circuit:

Before you drain the coolant from the cooling circuit let the engine run for 5 minutes for the liquid temperature to reach 82°C (180°F) Do not open overpressure plug before coolant temperature drops below 50 °C (122 °F). If you open overpressure plug the liquid may splash out causing scald.

400159

Stop the engine.

•

Open the cooling system by removing the overpressure plug (1) on the expansion tank.

ARX 91

1

123

3.6.

Lubrication and Maintenance Operations

•

Remove the cooling circuit drain plug. Let the liquid pour down into the vessels set up. The drained amount is approx 24 L (6.36 gal U.S.).

•

Check whether pipes within the engine cooling system are not damaged, clips missing. Check the radiator condition whether not damaged, not leaking, and cooling gills not fouled with impurities. Clean and repair the radiator, if required.

400181 Clean the cooling circuit: The process of cleaning the cooling circuit is divided into two parts.

First part: •

Install the drain plug, fill the cooling system with the mixture of the following ratio: 0.5 kg (1 lb) of sodium carbonate and 23 L (6.1 gal US) of water, or agents normally available on this base.

•

When filled, wait for approx 2-3 min until air escapes and the circuit gets filled. Max filling rate is 10 L/min [2.6 gal US/min].

•

Do not close the tank with overpressure plug.

•

Start the engine and let it run for 5 minutes for liquid temperature to reach 82°C (180°F).

Inspect cooling circuit tightness and liquid level on water gauge.

Stop the engine, drain the cooling circuit and reinstall the drain plug.

400217 124

ARX 91

MAINTENANCE MANUAL Second part: •

Fill the cooling circuit with clean water. When filled, wait approx 2-3 min until air escapes and the circuit gets filled.

Max filling rate is 10 L/min (2.6 gal US/min).

•

Do not close the tank with overpressure plug.

•

Start the engine and let it run for 5 minutes for liquid temperature to reach 82°C (180°F).

Inspect cooling circuit tightness and liquid level on water gauge.

400218 •

Stop the engine and drain the cooling circuit.

MAX MIN

NOTE! Repeat this process until clean water flows out.

Fill the cooling circuit •

Install the drain plug, fill the cooling system with new coolant at the ratio of min 50 % water + 50 % antifreeze.

Wear gloves to protect your hands!

Wear safety glasses or face shield to protect your eyes!

Fill with the coolant according to the Section 3.2.3!

To make the change proceed as per the manual from antifreeze producer!

400219

ARX 91

125

3.6.

•

Lubrication and Maintenance Operations

Refill the coolant to max level. When filled wait approx 2-3 min until air escapes and the circuit gets filled. Max filling rate is 10 l/min [2.6 gal US/min]. Close the expansion tank with overpressure plug.

Start the engine and wait until the temperature reaches 82 °C (180 °F). Check during your waiting for any leakage of cooling liquid and check the level on the indicator.

400218 •

Start the engine and let it run for 5 minutes for liquid temperature to reach 82°C (180°F).

MAX

•

Stop the engine.

MIN

•

Check the level height on water gauge.

•

Confirm the coolant level on water gauge is between MIN and MAX.

Do not open the overpressure plug before coolant temperature drops below 50 °C (122 °F). If you open overpressure plug the liquid may splash out causing scald!

Hand over the used liquid for its safe disposal under the regulations!

400159

126

ARX 91

MAINTENANCE MANUAL 3.6.31. Replace hydraulic oil and filters •

Prepare a proper tank of approx 52 l (30 gal US) capacity.

•

Unscrew drain plug and let oil pour down into the tank set up.

•

Disassemble the Battery (1), Battery holder (2) and hydraulic tank lid (3).

•

Inspect tank’s interior. When dirt is present at the bottom, please carry out thorough cleaning and flush the tank with new clean oil.

•

Disassemble the suction strainer (4) from the suction pipe.

Wash the suction strainer and blow the strainer with pressure air from inside.

•

Check the condition of the suction strainer; replace the strainer in case of damaged filter part.

•

Mount back the tank lid - check the gasket.

•

Mount back Battery holder and Battery.

1

2 3

Carry out oil replacement before season starts, or following a long-term machine shutdown. Clean together a suction basket.

Drain oil when cooled down below 50 °C (122 °F).

Adhere to fire precautions!

4

With hydraulic circuits disconnected, please blind all the openings with plugs.

Catch the oil being drained, and do not let it leak into ground.

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

ARX 91

127

3.6.

Lubrication and Maintenance Operations

How to check oil temperature sensor •

Disassemble the oil temperature sensor in the area beneath the Radiator oil cooler and clean its contact.

•

Dip the sensor in water of 100° C (212° F), check its proper function on the Cluster- hydraulic oil level LED will light up, refer to the Figure.

P rpm

How to fill hydraulic circuit: •

Fill the circuit with hydraulic unit.

•

You can order the hydraulic unit from the machine manufacturer.

1251998 •

Remove filling end piece cap, and put filling device quickcoupler onto the quick-coupler (1).

Unless oil temperature sensor is functional, replace it with a new one of identical type!

1

NOTE! The hydraulic unit 230 V is intended for operation in 230-Volt networks, the hydraulic unit 110 V is intended for operation in 110-Volt networks.

128

ARX 91

MAINTENANCE MANUAL •

Fill the hydraulic circuit till clean oil starts pouring down from the tank via its drain plug. Collect oil in clean tank.

•

When reading approx 15 l (4 gal US) mount the drain plug back - inspect the gasket.

•

Refill oil in the tank up to its max. level and then detach filling equipment.

•

Order your filling equipment at your machine manufacturer or dealer.

Alternate filling via oil tank filler •

When this method is used, please reduce next exchange interval down to one half, i.e. 1000 hours or 1 year.

•

Use filler neck (2) to fill the tank with specified type of oil up to the bottom of the screen inside the filler neck.

MAX

MIN

MAX

2 MIN

NOTE! When filling via tank filler a large portion of used oil along with dirt will remain within, and the hydraulic unit life will be reduced.

Do NOT open hydraulic tank uselessly!

Use filler neck to fill hydraulic circuit ONLY as an emergency solution, and with this filling method, please lower the next exchange interval to one half, i.e. 1000 hour or 1 year!

With the circuit filled, please confirm the hydraulic oil level LED does not light!

Start the engine, and with the speed increased, you must test machine functions so to fill up the circuits!

Confirm tightness of filter, temperature sensor, suction hose and the lid!

Replace oil and filter element always when destruction of internal parts of the units (hydromotors, hydrogenerators) has occurred or following a major overhaul of the hydraulic system!

Clean and flush the hydraulic tank, at the same time replace filter element and this always before new unit is installed!

Do housekeeping during work, and prevent system contaminated with materials that may cause damage to major units!

NEVER use any chemical cleaning agents to clean the hydraulic tank!

Use only those materials with no fibre-slip!

ALWAYS fill hydraulic tank with oil under Section 3.2.4 !

Observe fire and hygienic precautions!

ARX 91

129

3.6.

Lubrication and Maintenance Operations

How to replace hydraulic filter •

Remove filter container (1).

•

Replace filter element.

•

Clean thoroughly filter container (1).

1

•

Clean from the bottom the filtration block contact face.

400173 •

Check the condition of sealing rings, and apply clean oil on the rings.

•

Insert new element into the filter container and screw back.

400174

Carry out the replacement ALWAYS during oil exchange or when pressure filter LED lights when oil operating pressure reaches 50 - 60 °C (122 - 140 °F).

Use ONLY original filtration elements per Spare Part Catalogue.

P rpm

Used filter elements become ecologically hazardous waste - hand them over for disposal.

130

ARX 91

MAINTENANCE MANUAL Maintenance as required 3.6.32. Cleaning of coolers •

Due to various working conditions no regular cleaning interval can be set.

•

In case of work in very dusty environment, perform daily cleaning. Cooler fouling will show in a reduced cooling performance and increased temperatures of engine coolant and of hydraulic oil.

•

Remove the engine air intake cover.

•

Clean with compressed air or pressure water (steam). Clean in the direction from the fan side.

Do NOT clean the radiator with too high pressure so to avoid its damage.

When radiator is contaminated with crude oil products, use a cleaner and proceed according to the manufacturer’s manual!

Find out a cause of contamination!

Clean the Machine at a workplace equipped with cleaner collection system to prevent soil contamination and water resource contamination!

NEVER use forbidden cleaners!

ARX 91

131

3.6.

Lubrication and Maintenance Operations

3.6.33. De-aerating (venting) the fuel system De-aerate (vent) the fuel system before the first start: •

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.

2

Low-pressure piping blow-off and filter de-aeration: •

Loosen air relief screw at the fuel filter (1)

•

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

•

Tighten air relief screw.

Do NOT bleed with the hot engine, leaking fuel may cause fire.

Follow safety regulations!

No smoking or use of open flame while at work on fuel system!

Retain any leaking fuel!

3.6.34. Draining the water from water separator •

Amber indicator lamp signal.

•

Turn the separator’s valve when water starts flowing out.

If you drained over 60 cm3 (0.63 quarts) of fuel, replenish fuel into the fuel filter as per the Section named “De-aerating”.

In this way you will avoid problems concerning difficult starting.

No smoking at work.

NEVER drain separator during engine run.

Retain drained fuel incl. its deposit (sediments) in a suitable vessel.

132

ARX 91

MAINTENANCE MANUAL 3.6.35. Drain water from sprinkling circuit before winter season •

Before winter season it will be necessary to drain water from the sprinkling circuit with regard to any potential damage to individual parts because of frost.

How to drain water from the sprinkling circuit: •

Remove sprinkling water tank drain plug. Store the drain plug at a safe place.

•

Tank’s full capacity is 1000 l (264 gal US).

•

Remove and clean the vessel (1) incl. sprinkling filter (2).

Store the vessel complete with filter at a safe place.

1

2

400262 •

Keep the valve for water supply from the tank opened.

•

Detach the water discharge hose from the pump.

•

Detach at least one sprinkler from each pipe on the front and rear sides of the Machine. Store the sprinklers at a safe place.

ARX 91

133

3.6.

•

Lubrication and Maintenance Operations

Switch ON the sprinkling pumps for 20 sec. so these become drained.

401385 •

Dismount and clean the cutter sprinkler strainer.

•

This procedure will guarantee you max drainage of the sprinkling circuit.

•

When all the above mentioned operations are completed, please proceed in reverse steps, clean thoroughly the individual parts, first.

By draining the water from the sprinkling circuit in time you will avoid any potential damage that the manufacturer shall bear no responsibility for!

134

ARX 91

MAINTENANCE MANUAL 3.6.36. Adjustment of scrapers ADJUSTABLE SCRAPERS •

The machine is equipped with four adjustable scrapers.

2 Setting of scrapers: •

•

1

Slacken two screws on both sides of the scraper at point (1) and (2) and by moving the scraper in the oval-shaped hole set up the correct function of the blade (3).

3

If the scraper is set in the oval-shaped hole at the maximum and the blade is worn-out, remove the blade and replace with a new one.

Blade replacement: •

Dismount the screws (4) and remove the blade (3) with strips (5).

•

Follow the above-mentioned steps in reverse order when mounting a new blade.

Correct setting of scrapers ensures perfect cleaning of the drum during the machine operation!

Set up the correct function of the scraper upon the replacement of the blade!

4

3

5

ARX 91

135

3.6.

Lubrication and Maintenance Operations

3.6.37. Drum cooling mixture Cooling mixture 60 L (16 gal us) of water 2 L (0.5 gal us) anticorit skr 40

1

Level check •

Clean the area around the hole.

•

Position the machine so that the plug (1) is in the lowest position.

•

Unscrew the plug (1) and check the cooling mixture level.

•

The cooling mixture level must reach the checking opening or slightly flow out.

•

Remount the plug.

Filling •

Clean the area around plug.

•

Refill recommended cooling mixture through the filling plug (1).

•

The cooling mixture level must reach the lower edge of the opening or slightly flow out.

•

Clean the plugs and mount again.

NOTE! Follow the same procedure on the rear drum.

136

ARX 91

MAINTENANCE MANUAL 3.6.38. Machine cleaning •

When the work is completed clean the Machine to get rid of major impurities.

•

Carry out overall cleaning on regular basis, at least once per week. Total cleaning must be done daily if working on cohesive soils, cement or lime stabilisation.

Disconnect the disconnector.

Carry out the work with the engine stopped.

NEVER use aggressive or easily ignitable cleaners (e.g. Petrol or easily or flash fuels).

Before pressure cleaning with water or steam, please blind all the ports into which a cleaner might penetrate (e.g.

Engine inlet port). With the Machine cleaned remove these blinds.

Do NOT expose electric parts or insulation material to direct water or steam streams. Always cover these materials (alternator’s inner space, etc.).

3.6.39. Check the tightening of bolted connections •

Confirm regularly that no loosening of bolted connections has occurred.

•

Use the torque spanners to do the tightening.

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

M8

24

25.0

34

25.0

M8x1

19

14.0

27

19.9

M10

48

35.4

67

49.4

M10x1.25

38

28.0

54

39.8

M12

83

61.2

117

86.2

M12x1.25

66

48.7

94

69.3

M14

132

97.3

185

136.4

M14x1.5

106

78.2

148

109.1

M16

200

147.5

285

210.2

M16x1.5

160

118.0

228

168.1

M18

275

202.8

390

287.6

M18x1.5

220

162.2

312

230.1

M20

390

287.6

550

405.6

M20x1.5

312

230.1

440

324.5

M22

530

390.9

745

549.4

M22x1.5

425

313.4

590

435.1

M24

675

497.8

950

700.6

M24x2

540

398.2

760

560.5

M27

995

733.8

1400

1032.5

M27x2

795

586.3

1120

826.0

M30

1350

995.7

1900

1401.3

M30x2

1080

796.5

1520

1121.0

The figures given in the chart are torques at dry thread (with coefficient of friction = 0.14). These figures do not apply to a lubricated thread.

Clean the Machine at a workplace equipped with cleaner collection system so to avoid soil or water recourse contaminations!

NEVER use banned cleaners!

ARX 91

137

3.6.

Lubrication and Maintenance Operations

Chart showing the torques for cap nuts with sealing “O” ring - hoses

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

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

138

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

ARX 91

MAINTENANCE 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 x 1.5

220

162

26 x 1.5

120

89

27 x 1.5

250

184

27 x 1.5

150

111

33 x 1.5

400

295

33 x 1.5

250

184

42 x 1.5

600

443

42 x 1.5

400

295

48 x 1.5

800

590

48 x 1.5

500

369

M-G

M-G

M-G

282N221T ARX 91

282N222T 139

3.7.

Defects In most cases the defects are due to operating the machine improperly. Therefore during any failure read thoroughly once more the instructions given in the Machine and Engine Operation and Maintenance Manual. Unless you will be able to specify the cause of a defect, please contact authorized dealer’s or manufacturer’s help desk (service assistance).

The troubleshooting of hydraulics and wiring requires expertise in the field of hydraulics and wiring, so we strongly recommend to hand over the troubleshooting process to the help desk of an authorized dealer or manufacturer.

140

ARX 91

3.8.

Schematics

3.8.1. Electrical schematic Call AMMANN service personnel to consult on Electrical system.

ARX 91

141

3.8.

Schematics

3.8.2. Hydraulic schematic Call AMMANN service personnel to consult on Hydraulic system.

142

ARX 91

MAINTENANCE MANUAL Notes

ARX 91

143

For additional product information and services please visit : www.ammann.com

Materials and specification data are subject to change without notice.

Book ID: 4-P06000-EN | © Ammann Group