Ammann ARX 91 Tandem Roller Workshop Manual 4102225 PDF

Workshop manual

ARX 91 Cummins

Book ID: 4-P08410CU-EN

ARX 91 Articulated tandem roller Cummins BS III

Workshop manual Edition 04/2017 EN From Serial No. 4102225

Preface Information, specification or recommended instructions to assemble or disassemble individual parts of sections of the Machine as included in this publication represent basic and final information at the time this publication has been printed. Any printing errors, technical alterations or illustration changes are reserved. All the dimensions and weights are approximate and therefore unbinding.

Ammann India Pvt Ltd. reserves the right to make changes any time with no obligation to inform Machine User. In the event any differences are found between the Machine used by you and the data given Any reprinting or dissemination of any type shall be preconditioned by a written consent from Ammann India Pvt Ltd.

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

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Contents

WORKSHOP MANUAL__

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

INTRODUCTION .......................................................................................... 4

2.

SAFETY PRECAUTIONS AND INSTRUCTIONS .......................................................... 7

3.

4.

2.1.

Safety Regulations ......................................................................................................... 8

2.2.

Ecological measures & hygienic principles .......................................................................... 12

2.3.

Fire measures ................................................................................................................... 13

SPECIFICATION MANUAL ............................................................................... 14 3.1.

Basic specification ........................................................................................................ 15

3.2.

Machine dimension scheme ........................................................................................... 17

3.3.

Technical data ............................................................................................................. 18

MEDIA SPECIFICATION .................................................................................. 20 4.1.

Engine oil ................................................................................................................. 21

4.2.

Fuel ............................................................................................................................ 22

4.3.

Cooling liquid ............................................................................................................ 23

4.4.

Hydraulic oil .................................................................................................................. 23

4.5.

Gearbox oil .................................................................................................................... 23

4.6.

Lube grease ................................................................................................................ 23

4.7.

Drum cooling liquid ..................................................................................................... 23

4.8.

Media ..................................................................................................................... 24

5.

LUBRICATION AND MAINTENANCE CHART .......................................................... 25

6.

DRUM ........................................................................................................ 29

7.

8.

6.1.

Disassembly of hydraulic motor for vibrations ....................................................................... 31

6.2.

How to remove hydraulic motor for travel ................................................................................. 34

6.3.

How to remove reducer ......................................................................................................... 36

6.4.

Front drum removal ............................................................................................................ 37

6.5

Replace drum’s metal rubbers ........................................................................................ 48

KNUCKLE STEERING ................................................................................... 50 7.1.

How to remove steering joint ............................................................................................. 53

7.2.

How to change steering joint bearings ............................................................................... 57

7.3.

Remove rotator’s bearings .................................................................................................. 61

HYDRAULICS.............................................................................................. 62 8.1.

Remove cooling hydraulic motor ......................................................................................... 63

8.2.

How to remove gear pump for steering ................................................................................ 66

8.3.

How to remove tandem pumps of vibration and travel ............................................................. 70

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WORKSHOP MANUAL__ 9.

REMOVING HYDROMOTORS FOR STEERING……………………………………………………………………………….77 9.1.

Remove hydraulic cylinders for steering ............................................................................. 79

9.2.

Remove sealants of hydraulic cylinders for steering ................................................................ 80

10. BONNET REMOVAL ..................................................................................... 84 11. ENGINE REMOVAL ....................................................................................... 88 12. REMOVAL OF COOLERS ..................................................................................105 13. CABIN ................................................................................................... 114 13.1.

Seat Switch .................................................................................................................. 116

13.2.

Position sensor for neutral and parking brake ......................................................................... 118

13.3.

LH side control panel, backing horn sensor ............................................................................ 118

13.4.

Seat Platform .................................................................................................................... 120

13.5.

Power-Assisted Steering ....................................................................................................... 123

14. WIRING……………………………………………………….…………………………………………………………………………….125 14.1.

Fuses .......................................................................................................................... 126

14.2.

Accumulator ................................................................................................................. 127

14.3.

Alternator .................................................................................................................... 128

14.4.

Starter ........................................................................................................................130

14.5.

Layout of wiring elements within the Machine ........................................................................ 133

15. ANNEXES……….……………………………………………………………..………………………………………………………….135 15.1.

Measuring the relief pressures of hydraulic circuit....................................................................136

15.2.

Vibration frequency adjustment ......................................................................................... 138

15.3.

Adjust pulse sensors ........................................................................................................139

15.4.

Wiring Diagram .............................................................................................................. 141

15.5.

Hydraulics Diagram .........................................................................................................144

15.6.

Check bolted connections are tightened................................................................................146

15.7.

List of figures ................................................................................................................ 148

15.8.

Hand Signals ................................................................................................................. 151

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WORKSHOP MANUAL__

1. Introduction

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

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

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

In order to ensure the smooth operation of AMMANN compaction equipment, use for repairs only the original spare parts supplied by AMMANN. Before the dismounting, we recommend you to mark the parts disassembled keeping in mind the way how they will be put back and to blind all holes of the hydraulic system to prevent contamination of hydraulic circuits.

During assembling the parts to the machine, tighten each bolt or nut according to the tightening torque table (Chapter appendices.) if it is not stipulated otherwise in the text.

Always follow safety regulations and measures shown in Chapter 2.

The manufacturer is continuously improving his products on the basis of operational experience and latest developments.

He, there-fore, retains the right to make changes, on the basis of research and development, as compared with Figures, descriptions, procedures and designs given in this manual.

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WORKSHOP MANUAL__ 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.

! CAUTION !

This Manual uses the terms like RH, LH, in the front, in the rear. These indicate the sides of the Machine viewed during forward drive.

FRONT

RIGHT

LEFT

REAR 401101en

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WORKSHOP MANUAL__

2. Safety Precautions and Instructions

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WORKSHOP MANUAL__ 2.1

Safety Regulations

The following safety regulations shall be observed by all and anybody who repair the Machine!

•

Only the skilled, competent, trained and experienced personnel and/or dealer or Service Center of Ammann Company may repair this Machine.

•

ALWAYS use our Workshop Manual during the repairs. Special instructions concerning assembly work are given in individual Chapters.

•

Before putting the Machine into operation, please read Driver’s Manual thoroughly to make yourself familiar with the Machine control, and make sure you understand well all the equipment of your Machine before putting the Machine into operation.

•

Do NOT use the Machine unless you fully understand all the controls and control elements, and until your know exactly how the Machine operates.

•

Make yourself familiar with the location where you will work.

•

NEVER remodel or adapt the Machine since if doing so you might impair Machine safety.

•

Original parts and accessories have been designed specifically for this Machine.

•

Mounting or using spare parts not supplied by the Machine manufacturer or not authorized thereby, might affect negatively operating characteristics and safe operation of the Machine.

Safety precautions during Machine repair or inspection •

Wear protective clothing and shoes.

•

Use protective gloves when handling oil, fuel, coolant.

•

Protect your eyes with safety glasses or shield when handling the battery.

•

Park the Machine on flat and paved surface before you commence any Machine repair. Secure the Machine against any self-motion.

•

Before any work commencement remove the key from ignition box, disconnect the battery and let the hot parts to cool down.

•

Attach “Machine OFF Operation” warning label to the steering wheel and keep it there throughout the repair time.

•

Wash the complete Machine properly. When using steam, do not expose electric components and insulation material to the direct steam flow, or cover them first.

•

When using detergents, please be careful. Do NOT use gasoline or other flammable materials for cleaning purposes!

•

Observe absolute cleanliness of all parts during disassembly, assembly and service repair work. Protect disassembled parts against any dirt.

•

Clean the surface of parts disassembled, and provide for adequate dust-free environment along with the storage area required.

•

Clean and dry the parts, then apply anticorrosive protective oil instantly – NEVER assemble corroded parts!

•

Tools, hoists, protective means, supports or other auxiliaries shall be in their operable (available) condition and in good order.

•

Use hoists and rigging (cables, chains) of sufficient loading capacity, and intact.

•

Provide for adequate air supply when starting in closed areas.

•

Before running the Machine, please make sure no persons are present on the Machine or within its hazardous reach.

Use sound signal to warn the Machine is started and this always before starting the Machine and after each rest, before setting the Machine into motion. Following the sound signal any persons present on the Machine or within hazardous reach of the Machine must leave the Machine and the area. In addition, it is necessary to use sound, light and hand signals according to the Annex – chapter called Hand Signals.

•

NEVER adjust the Machine in motion.

•

During urgent work on the engine running (any adjustments) please avoid any contact with hot or rotating parts of the Machine. Any work performed while the engine is running (e.g. adjustments) shall be done under the presence of another person that has immediate access to the emergency switching OFF along with continuous provision of communication with the person making the adjustment so engine can be turned OFF instantly if required.

•

Use only the required types of engine oil, transmission oil, hydraulic oil, and cooling liquid.

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WORKSHOP MANUAL__ Safety precautions during work on hydraulic circuits •

Check hydraulic circuits are pressure less before you disassemble them. Hydraulic oil that leaks under pressure may cause serious skin injury..

•

Mark parts, hoses, pipes before their dismantling.

•

Do NOT operate hydroelectric generators, hydraulic motors with no oil.

•

Scald hazard exists when handling hot oil.

•

Do NOT heat oil over 160 °C – oil or its vapours may flame up.

•

Use fabric with no fiber slip when wiping and cleaning hydraulic parts.

•

Use hydraulic oil – and not any lube grease – as slip agent during parts assembly work.

•

Clean thoroughly the bolting before assembly work, flush and blow out with air the hoses and pipes.

•

It is important that you ALWAYS use new gaskets.

•

Fill new sets (units) with hydraulic oil before their assembly.

•

Following hydraulic set replaced, flush the hydraulic circuit, and clean hydraulic tank.

•

Replace oil filter element.

•

Fill hydraulic circuit with clean oil of required viscosity, only with the engine at standstill!

•

Wipe any oil spilled over.

•

Confirm connections are tight with no oil leaks before system gets pressurized.

•

Check all the connections upon completion of all the work.

•

Do NOT adjust the relief valves.

•

Reinstall all the protective elements upon work completion.

Check the following once the Machine is in operation •

Oil level in hydraulic tank

•

Check boost pressure of hydroelectric generators when these are replaces, and relief valve pressure.

•

Measure always at 40 °C (104 °F) temperature.

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WORKSHOP MANUAL__ Safety precautions during work on fuel system Mixtures of gasoline and diesel oil (winter fuel) are of equal flammability like gasoline..

•

Do NOT fill up the tank in closed areas.

•

Wipe any fuel spilled over.

•

NEVER use open fire or smoke when working on fuel system! Fire hazard!

Safety precautions during work on wiring •

Disconnect battery when repairing the charging circuit so to exclude any casual short circuits.

•

Before disassembly work, first disconnect cable from negative pole (-), then from positive pole (+).

•

Do NOT disconnect batteries with the engine running!

•

Connect battery with “negative” pole to the frame, and “positive” pole to the alternator outlet “B+”. Inverse connection would cause the entire semiconductor device destroyed.

•

When starting with auxiliary external power supply NEVER disconnect such power supply before Machine battery is connected.

•

Do NOT run idle the alternator, i.e. with the conductor disconnected from “B+” terminal, and the “D+” terminal connected.

•

NEVER check voltage presence in a conductor through sparking against Machine frame.

•

Do NOT carry out any operations during which sparking will occur.

•

Use rubber gloves and eye protectors when handling the batteries.

•

Protect your skin and clothing against any stain caused by electrolyte or lead particles..

•

If electrolyte contacts your eyes, immediately flush eyes with large amounts of water for several minutes. Get prompt medical attention.

•

If skin or clothing are stained with electrolyte, remove contaminated clothing, immediately flush with large amounts of soap water or cooking soda-water solution. Get prompt medical attention.

•

If electrolyte is ingested, give as much milk as possible or calcined magnesia dissolved in water, or just water, and get prompt medical attention.

•

NEVER top up cells with distilled water unless any work with the Machine or recharging outside the Machine will follow.

Increased self-discharging of the battery would occur.

•

NEVER replenish the acid (H2SO4)!

•

Do NOT turn the batteries over, electrolyte might pour out from the degassing holes of the battery.

•

When acid (electrolyte) is spilled, flush the hit spot with water, and neutralize with lime.

•

When recharging the batteries the hydrogen gets released and mixed with air it forms explosive flammable mixture. Do NOT handle near open fire, or smoke nearby.

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WORKSHOP MANUAL__ Welding work on the Machine Before conducting any welding work using electric arc on the Machine, please disconnect all the semiconductorcontaining elements from the wiring: •

Engine alternator,

•

Moto-hour counter,

•

All electronic elements on the Machine,

•

Ground the power supply and also Machine being repaired,

•

Secure power supply against any moisture,

•

Locate earthing terminal in close proximity to a weld joint.

•

Insulate el. current crossing point or use non-conducting rigging (hemp cable) when welding the parts or with the Machine in its suspended position, and this due to the potential of el. current penetrating the lifting equipment.

Gaskets •

Use new gaskets during any and all assembly work.

•

Gasket sets are available as spare parts.

Tightening torques •

Use torque spanners to observe the tightening torques.

•

Tighten attachment bolts and nuts of used quality according to the respective Table (refer to Annex).

•

Bolt quality identification is shown on bolt head.

•

Different tightening torques have been stated in relevant chapters.

•

Threaded joints of hydraulic circuits shall be tightened according to the Tables.

•

Tightening torques mentioned shall apply to screw threads not greased.

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WORKSHOP MANUAL__ 2.2

Ecological measures & hygienic principles

When repairing the Machine, follow general principles of health protection and environmental protection along with laws, public notices and regulations related to these issues, and valid within the territory where the Machine is used.

Hygienic principles •

Oil products, cooling system media, battery media, and painting materials incl. thinners are health hazardous materials, and when hitting the body organs these may cause serious bodily harm.

•

Consequently, when coming into contact with these products, observe thoroughly product safety and hygiene manuals, wear Personal Protective Equipment.

•

Personnel coming into contact with these products during Machine repair shall be liable to adhere to general principles of one’s own health protection, and follow safety and hygiene manuals of these products’ manufacturers.

Please adhere to the following in particular: -

Protect eyes and skin during battery handling

-

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

-

Wash your hands properly upon work completion or before meal, treat your hands with appropriate repair cream

-

When handling the cooling system, observe instructions given in the Manuals supplied together with the Machine.

•

Always store oil products, cooling system media and battery media, and painting systems incl. organic diluents, detergents and preventives in their original properly identified packages. Do NOT admit storing of these materials in unidentified bottles or other vessels with regard to the hazard of mistaken exchange. Particularly hazardous is the potential of being exchanged for consumables or drinks.

•

If skin, mucosa or eyes get accidentally stained, or vapours are inhaled, immediately apply first aid principles. If ingesting such products accidentally, please get prompt medical attention.

Ecological measures •

Media of Machine’s individual systems, and some of its parts, when discarded, become waste of risky character against the environment.

This category of waste products includes the following in particular: -

Organic and synthetic lube materials, oils and fuels

-

Coolants

-

Battery media and batteries

-

Detergents and preservatives

-

All dismountable filters and filter elements

-

All used or discarded hydraulic and fuel hoses, metal rubbers and other elements of the Machine, contaminated with the aforementioned products.

•

The given materials and parts, once discarded, shall be handled in line with relevant national regulations to protect individual element of the environment and in accord with the health regulations.

•

When dismantling hydraulic, fuel, or cooling systems and their units, please avoid any liquid leaking into ground and this by means of a putting a base layer underneath retention vessels, and plugging the openings.

•

If a leak occurs, use sawdust, Vapex or others to dry a place affected.

•

Remove soil hit so to prevent any further seepage. Hand over contaminated soil and absorbent for their next safe disposal.

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WORKSHOP MANUAL__ 2.3 •

Fire measures

In terms of fire hazard the flammable liquids used in the Machine have been divided into classes of risk: IInd class of risk -

Diesel oil IVtnd class of risk

-

Mineral oils

-

Lubricating greases

-

Antifreeze

Oil exchange point •

Oil exchange point shall be located so not to interfere with the explosion or fire hazard areas.

•

Such point shall be labelled with “No Smoking” and “No Use of Open Flame“ notice boards and signs.

•

Equip oil exchange point with portable fire extinguishers.

•

Dimension the handling area so to catch flammable liquid amount equal to the capacity of biggest vessel or shipping container.

•

To handle oil, diesel oil, please use vessels like metal drums, jerry cans, tin cans.

•

Make sure shipping containers are properly closed during their storage.

•

Vessels shall have one opening, and stored always with the opening at the top, and secured against any leakage (flowing out) or dripping.

•

Vessels shall be labelled with indelible inscription that states their content and flammability class.

Part of Machine’s equipment will be: •

Vibration Roller Operation Manual

•

Spare Parts Catalogue

•

Catalogue of spare parts for the engine used

•

Engine Operation and Maintenance Manual depending on engine used

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WORKSHOP MANUAL__

3. Specification manual

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WORKSHOP MANUAL__ 3.1

Basic specification

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

Machine application

Please fill in the following data: (see Pin label, Label of the CUMMINS engine) Type of machine ................................................................................................................

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

PIN (Serial number of the machine)

The roller is suitable for compacting the asphalt mixtures up to a layer thickness (after compaction) of 150 mm (5.9 in), hydraulically consolidated mixtures up to a layer thickness of 220 mm (8.7 in), mixed soils up to a layer thickness of 320 mm (12.6 in), and sand and gravel materials up to a layer thickness of 420 mm (16.5 in).

Production year

The roller is not suitable for the compaction of rock fill and loam and clay materials.

The machine is intended 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 dealer.

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

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

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

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

The data mentioned in the table refer always when you contact the dealer or manufacturer.

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

1 - Name – always mentioned only in the English version 2 - Pin 3 - Type 4 –Operating Mass 5 -Maximum Mass 6 - Rated power 7 – Shipping Mass 8 - Front axle load 9 - Rear axle load 10- Year of manufacture

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WORKSHOP MANUAL__ Placing of the production label 1 - Pin label 2 - Serial number

1

2

Cummins engine serial number

401603

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WORKSHOP MANUAL__ 3.2

Machine dimension scheme

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

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WORKSHOP MANUAL__ 3.3 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

%

17

Turning radius inner (edge)

mm (in)

4650 (183)

Turning radius outer (contour)

mm (in)

6350 (250)

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 motors

-

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 (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

Operating

-

Hydrostatic

Parking

-

Mechanical multiple-disc

Emergency

-

Mechanical multiple-disc

Driving characteristics

Steering

Engine

-1

Brakes

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WORKSHOP MANUAL__ ARX 91 Vibration 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

67

Centrifugal force II

kN

78

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 reducer

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

Watering

Fluid capacities

Wiring

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

Optional equipment Beacon Crab Steering Compaction meter Cutter/final compaction device Infrared thermometer *

measured according the EN 500-4

** measured according the DIRECTIVE 2000/14/EC *** measured according the EN 1032+A1 on the gravel base under the vibration travel)

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WORKSHOP MANUAL__

4. Media specification

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WORKSHOP MANUAL__ 4.1

Engine oil

Viscosity Diagram 2412

Engine oil has been specified as per its performance classification and viscosity classification.

Performance classification under

°F

°C

122

50

104

40

86

30

68

20

50

10

32

0

14

‐10

‐4

‐20

‐22

‐30

‐40

‐40

CCMC (COMMITE OF COMMON MARKET AUTOMOBILE CON- STRUCTORS) ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE AUTOMOBILE)

Viscosity classification 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.

15W - 40

API (AMETICAN PETROLEUM INSTITUTE)

The use of admissible oil under API: CH-4/SJ; CI-4

API CI-4 oil is recommended as especially appropriate. All the year round: SAE 15W-40, refer to Fig.

5W - 30

ACEA: E-5

10W - 30

CCMC DHD-1

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.

282N224T

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

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.

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WORKSHOP MANUAL__ 4.2

Fuel

Diesel oil is used as the engine fuel:

Use of biofuel (Diesel fuel)

•

Using the fuel mixture under the trade name of Bionafta 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.

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”).

Before using Bionafta on the machine, make sure that it is sup- plied by a reputable supplier who supplies fuels corresponding to the above-mentioned standards.

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

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

! CAUTION !

When using Bionafta, power can be reduced by up to 12% depending on the used mixture of Bionafta.

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.

Bionafta 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 Bionafta, 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 Bionafta, the action of Bionafta 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.

Bionafta 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 oc- currence of the problem increases in cold weather.

If Bionafta (Biodiesel) 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 minimize the occurrence of moisture and limit the microbiological growth inside the tank. Consult the measures with the fuel supplier.

ARX 91

22

WORKSHOP MANUAL__ 4.5. Gearbox oil

4.3. Cooling liquid

2186

2152

Fill the engine cooling system with cooling liquid comprising 50% of ethylene glycol anti freezing mixture and 50% of Water

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

Do NOT use earthy (hard) water with higher content of calcium, magnesium which brings calculus formation , with higher con- tent of chlorides and sulphates which causes corrosion.

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).

Refer to CUMMINS Engine Operation and Maintenance Manual CUMMINS. Max content of compounds of calcium and magnesium is 170 milligrams - hardness of water.

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

Max content of compounds of chlorine is 40 milligrams. Max content of compounds of sulphur is 100 milligrams.

Do Not use the portion of antifreeze cooling agent in cooling liquid higher than 50% (Point of congelation is 36 °C [-34 °F], boiling point is 110 °C [228 °F] unless badly required.

NEVER use the portion over 68%!

We do Not recommend to manually blend antifreeze agents.Mixing Various types of cooling liquid may causes loss of anti coorrosion properties.

4.6. Lube grease 0787

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

check the portion of antifreeze cooling agent in cooing liquid with refractometer always before winter season starts.

4.7. Drum cooling liquid

When mixing antifreeze cooling agent based on nitrides with the agent based on amines the health hazardous nitroamines will form.

Mixture ARX 91: 62 l (16.4 GalUS) of water 1 l (0.26 GalUS) Anticorit SKR 40

4.4. Hydraulic oil 2158

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.

Hydraulic oil synthetic type 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!

ARX 91

23

WORKSHOP MANUAL__ 4.8

Media

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.

208 (55)

Hydraulic system

Hydraulic oil under Section 3.2.4.

70 (18.5) 2158

Drum bearings, caliper bearings, kingpins, suspensions Cooling system

Lube grease under Section 3.2.6.

As required 0787

Coolant under Section 3.2.3.

24 (6.36) 2152

Vibration drum ARX 91

Engine oil under Section 3.2.1..

2x10 (2x2.64) 2412

Drum drive reducer

Gearbox oil according to chapter 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 (16.4) 2152

ARX 91

24

WORKSHOP MANUAL__

5. Lubrication & Maintenance Chart

ARX 91

25

5. Lubrication and Maintenance Chart

WORKSHOP MANUAL__

Every 20 hours of operation or daily 3.6.1.

Engine oil level check

3.6.2.

Engine cooling liquid 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

Every 250 hours of operation or 3 months 3.6.31.

Engine oil in gearboxes*

3.6.11.

Engine oil exchange

3.6.12.

Inspect engine induction manifold

3.6.13.

Inspect engine cooling circuit

3.6.14.

Checking oil in gearboxes

3.6.15.

Inspect the battery

3.6.16.

Air filter sensor check

3.6.17.

Watering filter cleaning

3.6.18.

Machine lubrication

Every 500 hours of operation or 6 months 3.6.19.

Engine fuel filter and water separator exchange

3.6.20.

Engine cooling liquid level check

3.6.21.

Replace air filter elements

3.6.22.

Check of wiring

3.6.24.

Vibrations system oil exchange **

Every 1000 hours of operation or 1 year 3.6.23.

Inspect engine belt

3.6.24.

Vibrations system oil exchange

ARX 91

26

WORKSHOP MANUAL__ 3.6.25.

Inspect the silencing system

3.6.26.

Fuel tank cleaning

3.6.27.

Water tank cleaning

3.6.28.

engine oil filter

3.6.29.

Hydraulic oil filter

3.6.30.

Replace Fuses

Every 1500 hours of operation or 1.5 years 3.6.31.

Exchanging oil in gearboxes

Every 2000 hours of operation or 2 years 3.6.32.

Checking and adjusting valve clearance

3.6.33.

Engine coolant exchange

3.6.34.

Replace hydraulic oil and filters

Maintenance as required

*

3.6.35.

Deaerating (venting) the fuel system

3.6.36.

Cleaning the water separator

3.6.37.

Cleaning of coolers

3.6.38.

Drain water from sprinkling circuit before winter season

3.6.39.

Adjustment of scrapers

3.6.40.

Machine cleaning

3.6.41.

Check the tightening of bolted connections

First after 250 motohours.

** First after 500 motohours.

ARX 91

27

WORKSHOP MANUAL__

LUBRICATION AND SERVICE PLAN ARX 91 CONTROL LUBRICATE EXCHANGE

2000 1500 1000 500 250

Service set : 4 ‐760008

20

ARX 91

ENGINE OIL :

SAE 15W/40

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

HYDRALUIC OIL :

ISO VG 68

ISO 6743/HV

GREASE :

ISO 6743/9

CCEB 2

TRANSMISSION OIL :

SAE 80W/90 SAE 85W/140

API GL-5 API GL-5

28

WORKSHOP MANUAL__

6. Drum

ARX 91

29

WORKSHOP MANUAL__ 1_02389A_B

ARX 91

30

WORKSHOP MANUAL__ 6.1

Disassembly of hydraulic motor for vibrations

Disassembly process is identical for LH side of front drum and RH side of rear drum.

Put oil vessel underneath hydraulic motor for vibration.

401D021 Remove hoses step by step, blind hoses and outlets of hydraulic motor.

401D022 Remove hydraulic motor out from drum flange.

Note Tighten the bolts with 83 Nm (61.22 lb ft) torque during reinstallation.

Glue with Loxeal 58-11.

401D023 Take off plastic segment of clutch 26B.

26B

401D024

ARX 91

31

WORKSHOP MANUAL__ Check, replace “O“ ring.

42

401D025 Remove hub of clutch 26B. Reassembly tightening torque is 35 Nm (25.81 lb ft).

26B

401D026 Remove lock ring.

Note Lock ring is part of the clutch. Install the clutch (26B) to the new vibration hydro motor.

401D028 When mounting hydraulic motor for vibration, please measure the distance from cover face 23 to clutch 26 (hub A).

A

B 26

26

39 ARX 91

401D250

32

WORKSHOP MANUAL__ Adjust dimension X from clutch 26 face (hub B) to hydraulic motor face so to maintain 4±0,2 mm clearance between hub A and hub B.

26

34

39

CAUTION Before you measure, please make final fitting of the vibrator until it stops in bearing 7 placed in flange 11 on the opposite side.

ARX 91

X

A

B 401D251

33

WORKSHOP MANUAL__ 6.2

How to remove hydraulic motor for travel

Note The process is identical for RH side of front drum and LH side of rear drum.

Put oil vessel underneath hydraulic motor for travel, drain reducer oil .

401D029

Remove rpm sensor connection.

Remove step by step, blind hoses and outlets of hydraulic motor.

401D032

Remove hydraulic motor for travel.

Note Tighten the bolts with 200 Nm (147.51 lb ft) torque during reinstallation.

401D033

ARX 91

34

WORKSHOP MANUAL__ Check sealing “O” ring during reassembly.

401D034

ARX 91

35

WORKSHOP MANUAL__ 6.3

How to remove reducer

Remove hydraulic motor hoses, and disconnect rpm sensor connector.

Remove the brake release of reducer.

401D035 Hang RH bracket onto the crane, and remove step by step the bolts for attaching to the frame and to the cross member.

Note While reinstalling, tighten the bolts to the frame with 675 Nm (497.85 lb ft) torque, and to the cross beam with 390 Nm (287.65 lb ft) torque. Glue the screws using Novadurit ZV115.

401D036

46

Remove step by step the bolts for reducer 46.

Note Tighten the bolts with 200 Nm (147.51 lb ft) torque during reinstallation.

401D037

Install jig No 1, hang onto crane (refer to section 15.7. List of jigs).

Take out aux. transmission 25 incl. travel hydraulic motor.

Remove travel hydraulic motor.

Tighten the bolts with 83 Nm (61.22 lb ft) torque during reinstallation.

1

401D520

ARX 91

36

WORKSHOP MANUAL__ 6.4 Front drum removal The removal process is identical for front as well as rear drum.

Lift the Machine a bit on its LH and RH side using a hand jack so drum touches the ground lightly, then put the supports under.

401D040

Mark drum position along both sides due to its reassembly.

401D041

Secure the Drum against any motion (jig No. 2 refer to section 15.7. List of jigs).

2 2

402D022

Disconnect hydraulic hoses from hydraulic motor for vibrations, refer to Chapter 4.1, and deaerated.

Blind vent with 1/2“ hose incl. blank flange.

401D042

ARX 91

37

WORKSHOP MANUAL__ Disconnect sprinkling hose.

401D043 Remove clamps.

401D044 Disconnect wiring of front headlamps on LH side.

401D045 Hang the ramp onto the crane.

401D046

ARX 91

38

WORKSHOP MANUAL__ Remove cross beam incl. scrapers, and this on both sides.

Note Tighten the bolts with 390 Nm (287.65 lb ft) torque during reinstallation.

Hang LH bracket onto the crane, and slacken bolts for fixing to the frame.

Note Tighten the bolts with 675 Nm (497.85 lb ft) torque during reinstallation. Glue the screws using Novadurit ZV115.

Slacken bolts for fixing to the drum.

Note Tighten the bolts with 200 Nm (147.51 lb ft) torque during reinstallation.

401D048 Put the bracket away.

401D050

ARX 91

39

WORKSHOP MANUAL__ On drum’s RH side, please disconnect hydraulic hoses from hydraulic motor for travel incl. reducer brake and rpm sensor, refer to Chapter 4.2.

Hang RH bracket and slacken the bolts for fixing to the frame.

Note Tighten the bolts with 675 Nm (497.85 lb ft) torque during reinstallation. Glue the screws using Novadurit ZV115.

Slacken bolts for fixing to the reducer.

Note Tighten the bolts with 200 Nm (147.51 lb ft) torque during reinstallation.

401D052 Put the bracket away.

401D053

Hang hydraulic hoses of hydraulic motor for vibrations.

ARX 91

40

WORKSHOP MANUAL__ Hang hydraulic hoses for travel hydraulic motor.

401D055 How to remove RH – travel drive

3 Roll the drum out from frame. Fix the clamp (jig No. 3) of 2000kg (4409 lb) loading capacity.

401D056 Erect drum with its LH side standing on the ground.

401D057 Remove carrier with reducer.

Note Tighten the bolts with 83 Nm (61.22 lb ft) torque during reinstallation.

401D058

ARX 91

41

WORKSHOP MANUAL__ Mount the lifting lugs (jig No. 4 refer to section 15.7. List of jigs) into the reducer holes, hang and put away.

401D059 401D055 Mark carrier position against drum on the metal rubbers.

401D060 Mark on the carrier.

401D061 Remove bolts 43 for flange 47

47 43

401D521

ARX 91

42

WORKSHOP MANUAL__ Use 2 bolts to push off the flange (use bolts, pos. 54).

401D063 Screw on the lifting lugs, use crane to remove the flange.

401D064 Remove lock ring.

401D065 Use puller to remove bearing.

Note When reassembling, please clean contact surfaces and apply sealer Loxeal 58-11. Tighten the flange with 83 Nm (61.22 lb ft) torque.

Following the installation of hydraulic motor, please fill reducer with 2,5 L (0.66 US gal) of gearbox oil. Engine bolts and “O“ rings are supplied together with reducer.

401D066

ARX 91

43

WORKSHOP MANUAL__ Dismantle the vibration drive side Erect drum with its RH side on the ground, put something under it.

401D067 Remove hydraulic motor for vibrations.

Note Tighten the bolts with 83 Nm (61.22 lb ft) torque during reinstallation.

401D068 Remove bolts of cover 47.

Note Tighten the bolts with 48 Nm (35.40 lb ft) torque during reinstallation.

47

401D071 Push off and remove the cover.

401D072

ARX 91

44

WORKSHOP MANUAL__ Remove bolts of glange, pos. 10, use two bolts 54 to push it off (mark flange position against drum).

5

Pull out flange 10 with damper plate 2 (use jig No. 5 refer to section 15.7. List of jigs).

2

5

10

401D522

Remove the rotator Heat the bolt 16 to 150°C (302°F) temperature following the re- lease of securing cement (mastic).

Remove bolt 16 by means of jig No.6 refer to section 15.7.

List of jigs).

When reassembling, use Novadurit ZV115 to glue the thread. Tightening torque – 1400 Nm (1032.58 lb ft)

6 16 401D523

Following the removal of screw 16, let the assembly unit to cool down. Position the damper plate unit by means of flange 10 un- der on the supports L = 205 mm. Use press to press out flange 10 by means of jig No. 7 (refer to section 15.7. List of jigs).

7

205

10

401D524

Remove lock ring 47 out from flange 10, press out the bearing 7.

47

7

10

401D271

ARX 91

45

WORKSHOP MANUAL__ Position damper plate 2 onto the L-80 supports, press out the bearing with the use of jig No. 8 (refer to section 15.7. List of jigs).

8

42

80

2

401D525

Install lifting lug (jig No. 4 refer to section 15.7. List of jigs). Pull out complete vibration exciter unit.

4

Note Remove hub of clutch 26A after vibrator is pulled out.

401D074

Use puller to remove inner ring of bearing 7 incl. ring of pos. 43. Take off (detach) 2 halves of ring, pos. 24.

24 7

Note Vibrator, i.e. shaft 17 complete with pressed on (fixed) excenters 18, 19 is one-piece unit.

43 401D075

Caution When reassembling the flange 10 assembly (drum in erected position – drive reducer 25 down) fit fi- xed the vibrator into the bearing inside flange 11, mount flange 10 incl. bearing 7, screw on lifting lug into the thread, and pull vibrator to check axial clearance of 1÷2 mm.

ARX 91

46

WORKSHOP MANUAL__ Before mounting hydraulic motor for vibrations, please measure the distance from cover face 23 to clutch 26 (hub A).

A

B 26

26

23

Adjust dimension X from face of clutch 26 (hub B) to the face of hydraulic motor 34 so to observe 4±0,2 mm (0.16 ± 0.008 in) clearance between hubs A and B.

26

401D250

34

26

X

A

B 401D251

ARX 91

47

WORKSHOP MANUAL__ 6.5

Replace drum’s metal rubbers

LH side Note The procedure is identical for front and rear drum.

Lift a bit the frame to remove pre-stressing of metal rubbers.

401D076 Slacken metal rubber fastener 6 to the damper plate 2.

6 2 401D077 Slacken metal rubber 6 to the metal sheet 9.

6

9

401D078 Slacken bolts for metal sheet, pos. 9, to take up the clearance.

Note Tighten the bolts with 200 Nm (147.51 lb ft) torque during reinstallation.

9

401D079

ARX 91

48

WORKSHOP MANUAL__ Use appropriate lever to loosen metal rubbers.

When reassembling, please tighten the bolts 53 for metal rubbers with 83 Nm (61.28 lb ft). torque.

53

401D080 RH side: Lift a bit the frame to remove metal rubber pre-stressing.

401D081 Remove bolts to fix metal rubbers.

401D082 Take up the clearance to remove metal rubbers, and this between drum face and carrier, use hydraulic hand jack.

When reassembling, please tighten metal rubbers’ bolts with 83 Nm (61.28 lb ft). torque.

401D083

ARX 91

49

WORKSHOP MANUAL__

7. Knuckle Steering

ARX 91

50

WORKSHOP MANUAL__

65_07461A_A

ARX 91

51

WORKSHOP MANUAL__

4‐03563A_050

ARX 91

52

WORKSHOP MANUAL__ 7.1

How to remove steering joint

Support the rear and front frame on both sides.

401D084 Remove gibs 10.

10

401D085 Press out hydraulic cylinder eyebolts.

401D086 Remove hydraulic cylinders from brackets, place them under the Roller frame. Do NOT remove hydraulic hoses.

401D087

ARX 91

53

WORKSHOP MANUAL__ Mark the position, and remove hose holder underneath the front frame on the steering joint.

401D090 Unlock the pads and remove upper and lower yoke for rear king pin.

401D091

ARX 91

54

WORKSHOP MANUAL__ Note Mark yokes for the purpose of reassembly.

Remove bonnet, refer to chapter named “Bonnet Removal”.

401D092 Remove greasing nipples for bearing, pass the rope through under the joint’s bearing, hang with the help of shortening chain /-RUD.

401D096 Adjust chain length to balance suspended rear frame, shift it backward by ca 8-10 cm (4-5 in) for the need of subsequent steering ring removal.

6000kg Use rigging of min 6000 kg (13228 lb) loading capacity - chain 4hook able to adjust the length of individual strands.

8‐10cm 4‐5in 401D097

Put anything underneath the frame.

401D252

ARX 91

55

WORKSHOP MANUAL__ Put adequate hoisting apparatus (hydraulic platform truck) underneath the steering joint’s arm).

401D253 Unlock the pads, remove upper and lower yoke for the front king pin.

When reassembling, please tighten the bolts with 390 Nm (287.6 lb ft) torque.

401D098 Move out with the arm removed for next disassembly.

401D254

ARX 91

56

WORKSHOP MANUAL__ 7.2

How to change steering joint bearings.

Remove the covers on both sides.

401D099 Tap (pound) to drive pin 7 out from the eye of joint’s arm 3.

Note Bearing together with pin may slip out due to tolerances when pin is ejected.

7

3

401D100

Turn joint’s arm 3, knock the bearing 31 back into the arm’s eye.

31

3 401D102

Fit jig No. 9 (refer to section 15.7. List of jigs) onto the outer ring of bearing 31.

31

9

401D526

ARX 91

57

WORKSHOP MANUAL__ Draw off the bearing.

401D103 Take out pin 7 and press out bearing 31 on the other side.

7

31

401D104

Before reassembling, please clean contact surfaces. New bearings make de-preservation and lubricate with lube grease.

401D105 When reassembling, please replace the dust bellows.

38

401D106

ARX 91

58

WORKSHOP MANUAL__ Lubricate pin and covers.

Fit in the bearing – not to its stop.

401D108 Turn the arm, and fit in the bearing from the other side.

401D109 Turn the arm and fit the bearing down to its stop.

401D110

ARX 91

59

WORKSHOP MANUAL__ Apply sealant (caulking compound) onto the contact surfaces.

401D111 Mount the cover.

401D112

ARX 91

60

WORKSHOP MANUAL__ 7.3

Remove rotator’s bearings

Use appropriate hoist (platform truck) to support and then remove the rotator. Slacken bolts 22 from the inside of rear frame.

22

402D178 Remove bearing.

401D114 When assembling new bearing, please locate its position in the rotator so that the bearing’s marked hole will point against the gap in upper part of bearing’s contact surface in the rear frame.

401D115

401D116

ARX 91

61

WORKSHOP MANUAL__

8. Hydraulics

ARX 91

62

WORKSHOP MANUAL__

370_09764A

8.1

Remove cooling hydraulic motor

Remove shaft nut.

401D531

ARX 91

63

WORKSHOP MANUAL__ Disconnect connector.

401D498 Remove hose pipe from the hydraulic motor.

401D499 Remove hydraulic motor-frame mount.

401D429 Use lever to release cooling air blower from hydraulic motor shaft.

Pay attention when air cooling blower is being released so to avoid any damage to the blades.

401D430

ARX 91

64

WORKSHOP MANUAL__

105_08471A_B

ARX 91

65

WORKSHOP MANUAL__ 8.2

How to remove gear pump for steering

Remove the step.

401D422 Remove battery terminals.

401D423 Remove battery mount.

401D424 Remove hose pipes from steering pump’s top.

401D425

ARX 91

66

WORKSHOP MANUAL__ Remove flange from under steering pump.

401D426 Remove pump from engine.

Note Check “O” rings when you reinstall or replace the pump.

401D427 Shift the pump out from engine.

401D428

ARX 91

67

WORKSHOP MANUAL__

ARX 91

68

WORKSHOP MANUAL__

ARX 91

69

WORKSHOP MANUAL__

6

7

8.3 How to remove tandem pumps of vibration and travel Use Scotch blocks to secure the Machine against any motion, switch off the master switch.

Cut off joining strips for pipe hoses and wiring if required.

401D401 Put drip pan underneath the pump, blind pump hoses and ports following the removal.

ARX 91

70

WORKSHOP MANUAL__ Mark and disconnect electromagnets’ connectors from underneath the pumps. For vibration (low/high amplitude), travel (forward/backward). Refer to wiring.

401D402 Remove hoses from underneath the pump.

401D403 Remove pipe hoses from pump’s side and its top.

401D404

401D405

ARX 91

71

WORKSHOP MANUAL__ Remove pipe hoses off the frame’s area.

401D406 Remove pump flange.

401D132

Sling pump onto the lifting equipment of sufficient loading capacity.

401D407 Remove pump from drive housing.

401D408

ARX 91

72

WORKSHOP MANUAL__ Lower the pump under the frame.

401D134 Remove pipe from its holder.

401D409 Remove oil filter holder.

401D410 Remove steering block.

401D411

ARX 91

73

WORKSHOP MANUAL__ Remove oil filter from its holder.

401D012 Swing it out from engine compartment.

401D413 Close fuel valves, remove pipe hoses.

401D414 Throw pipe hoses from gear pump over to upstream the valves.

401D415

ARX 91

74

WORKSHOP MANUAL__ Remove 2 pipe hoses from steering block, and blind it.

401D416 401D012 Remove steering block from engine compartment.

401D417 From top of the pump, please mark and disconnect the connectors for electromagnets.

For vibration (low amplitude, high amplitude), travel (forward, backward). Refer to wiring.

401D418 Remove pipe hose from pump’s top.

401D419

ARX 91

75

WORKSHOP MANUAL__ Remove pipe hose from pump’s side.

401D420 Remove pipe hose from pump’s bottom.

Sling pump onto the lifting equipment of sufficient loading capacity.

Remove pump form drive housing.

Lower it below the frame.

401D421

ARX 91

76

WORKSHOP MANUAL__

9. Removing hydromotors for steering

ARX 91

77

WORKSHOP MANUAL__

65_07461A_A

ARX 91

78

WORKSHOP MANUAL__ 9.1 Remove hydraulic cylinders for steering Remove shims 10.

10

401D085 Press out eyebolts for hydraulic cylinder. Take hydraulic cylinders for steering and crab out from the brackets.

Remove hydraulic hoses connection.

Note Removal shall be designed only for those hydraulic cylinders required to be repaired or replaced.

401D086

ARX 91

79

WORKSHOP MANUAL__ 9.2 Remove sealants of hydraulic cylinders for steering Hydraulic cylinder

1

4

5

3

1 - cylinder body 2 - piston rod 3 - piston 4 - nut 5 - cover

2 401D257 Set of sealants Pos.

Name

1

Sealing

2

Collar

3

Oil control ring

4

Guide band

5

Ring

6

Ring

1

5

1

1

5

6

6

4

2

3

4 401D258

Caution: Order from the manufacturer the relevant sealants in the set for the “PčH” used, mention your Machine’s serial No.

The following procedure is common for the abovementioned hydraulic motors.

Unlock the cover of hydraulic motor for steering.

348D5499

ARX 91

80

WORKSHOP MANUAL__ User hook spanner to remove the cover for hydraulic motor for steering.

348D5522 Take it out.

348D5523 Take out the piston of hydraulic motor for steering.

348D5524 Remove the nut and replace damaged piston seal and lid. The piston and the lid mount back.

348D5525

ARX 91

81

WORKSHOP MANUAL__ Assemble the nut, glue the thread with Novadurit ZV115 and secure twice for 180 °.

401D540 Install jig No. 10 (refer to section 15.7. List of jigs) into the body of hydraulic motor for steering.

10

401D527 Insert the piston.

348D5530 Remove jig from hydraulic motor for steering.

348D5531

ARX 91

82

WORKSHOP MANUAL__ Install hydraulic cylinder cover.

348D5500 Lock the cover.

348D5501

ARX 91

83

WORKSHOP MANUAL__

10. Bonnet Removal

ARX 91

84

WORKSHOP MANUAL__

ARX 91

85

WORKSHOP MANUAL__ CAUTION When removing the bonnet, please position the Machine for straight-ahead driving (with no wheel lock) to avoid collision between bonnet and cabin, Remove plugs on both sides.

401D431 Mount lifting lugs, sling bonnet onto the crane.

401D432 Remove bonnet fixing on both sides, put the bonnet by.

401D433

ARX 91

86

How to remove hydraulic cylinders (plungers) for bonnet lifting

WORKSHOP MANUAL__

Remove bonnet, refer to Section named “How to remove bonnet“.

Remove packing piece.

401D500 Drive out the piston rod eyelet’s pin.

Lay lifting arm and hydraulic cylinder onto the Roller frame, support the piston rod to avoid surface damaged.

401D501 Remove safety ring and grease nipple.

401D502 Bring hydraulic cylinder out from the pin carefully with the help of lever.

Remove pipe hose from hydraulic cylinder.

401D503

ARX 91

87

WORKSHOP MANUAL__

11.

ARX 91

Engine Removal

88

WORKSHOP MANUAL__

105_08471A_B

ARX 91

89

WORKSHOP MANUAL__

135_08856A

ARX 91

90

WORKSHOP MANUAL__

Put drip pan underneath the engine, blind pipe hoses and ports of the pumps following the removal.

Drain engine oil, remove joining strips if required.

Use Scotch blocks to secure the Machine against any motion, disconnect the master switch.

Remove bonnet, refer to Section named “How to remove bon- net”.

401D497

Remove radiator, refer to Section named “How to remove radiator”.

Remove the step.

401D422 Remove battery terminals.

401D423 Remove battery mount.

ARX 91

401D424

91

WORKSHOP MANUAL__ Remove turbo charger cover.

401D461 Remove exhaust pipe hose from turbo charger, lift off.

401D462

401D463 Remove heater pipe hose.

401D464

ARX 91

92

WORKSHOP MANUAL__ Disconnect alternator wiring.

401D465 Disconnect starter wiring.

401D466 Disconnect earth connection.

401D467 Remove pipe hose from steering pump top.

Note Check and eventually replace packing “O“ rings.

401D425

ARX 91

93

WORKSHOP MANUAL__ Remove flange from the steering pump bottom.

401D426

Remove pipe hose leading to thermo-controller.

401D468 Remove hose clamp.

401D469 Remove fuel gauge wiring.

401D470

ARX 91

94

WORKSHOP MANUAL__ Remove sensor for hydraulics filter clogged

401D471 Disconnect connector.

401D472 Remove hydraulics filter hoses.

401D473 Remove hose from its clip.

401D474

ARX 91

95

WORKSHOP MANUAL__ Remove oil filter holder.

401D475 Dismount pipe from steering block.

401D476 Remove pipe hose for braking off rear aux. transmission.

401D477 Remove steering block, lift off.

401D478

ARX 91

96

WORKSHOP MANUAL__ Close valves, Remove pipe hose from fuel tank.

401D479 Remove hose holder.

401D480 Disconnect connector for engine rpm sensor.

401D481 Mark and disconnect from pump top the vibration electromagnet connectors (low amplitude, high amplitude), travel (forward, backward). Refer to wiring.

401D418

ARX 91

97

WORKSHOP MANUAL__ Remove pipe hose from second pump’s top.

401D419 Remove pipe hose from second pump’s side.

401D420

Remove pipe hose from second pump’s bottom.

401D421

Remove pipe hose from first pump’s top.

401D482

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98

WORKSHOP MANUAL__ Remove pipe hose from first pump’s side.

401D483 Mark and disconnect from pump bottom the vibration electro- magnet connectors (low amplitude, high amplitude), travel (for- ward, backward). Refer to wiring.

401D402 Remove pipe hoses from pump bottom.

401D403 Disconnect fuse connector.

401D484

ARX 91

99

WORKSHOP MANUAL__ Disconnect two cables from connector.

401D485 Remove and disconnect connectors on the engine.

401D486 Remove earth connection.

401D487 Remove engine glowing device.

401D488

ARX 91

100

WORKSHOP MANUAL__ Remove holder with filter.

401D489 Remove pipe hoses from holder.

401D490 Take out pipe houses from engine compartment.

401D491 Remove engine’s rubber mountings (3x).

401D492

ARX 91

101

WORKSHOP MANUAL__

401D493

401D494

Sling engine onto the lifting equipment with loading capacity of 700 kg (1543 lb), take out, put aside. Lay the engine on pedestal of sufficient loading capacity.

401D495

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102

WORKSHOP MANUAL__ Sling pumps onto the lifting equipment of sufficient loading capacity.

Remove pumps.

402D181 Put them aside.

401D190 Hang gearbox on lifting equipment of sufficient loading capacity.

Remove gearbox.

401D516

401D517

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103

WORKSHOP MANUAL__

Remove clutch hub.

Note Tighten with 86 Nm (63.43 lb ft) torque during reinstallation.

401D193 Remove flange (22).

Note Glue the thread with Novadurit ZV115 during reinstallation.

22

Tightening torque is 49 Nm (36.14 lb ft).

401D518

ARX 91

104

WORKSHOP MANUAL__

12. Removal of Coolers

ARX 91

105

WORKSHOP MANUAL__

125_09077A_B

ARX 91

106

WORKSHOP MANUAL__ Remove bonnet, refer to Section called “How to remove bonnet”.

Drain cooling liquid.

401D434

Put drip pan under radiator.

401D435

Remove piping from radiator, blind the ports.

401D436

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107

WORKSHOP MANUAL__ Disconnect connectors of sensor for filter element clogged.

401D438 Remove clip for air inlet towards turbo charger, blind the port.

401D439 Remove the mount for adapter 3 leading to fuel tank.

3

401D440 Remove air filter, blind the port.

401D441

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108

WORKSHOP MANUAL__ Remove air filter holder.

401D442 Remove step by step water and hydraulics pipe hoses plus piping mount.

401D443 Remove overflow hose.

401D444

ARX 91

109

WORKSHOP MANUAL__ Remove hose clips.

401D445

401D446 Disconnect connector, and remove pipe hoses from cooling hydraulic motor.

401D447 Remove piping clamp.

401D448

ARX 91

110

WORKSHOP MANUAL__ Remove hose from controller.

401D449 Disconnect connectors for thermal sensor.

401D450 Remove cooling liquid pipe hose from cooler.

401D451 Remove grid.

401D452

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111

WORKSHOP MANUAL__ Remove bolts for middle rubber mountings, on both sides.

401D453 Install jigs No. 12 (refer to section 15.7. List of jigs), hang On to crane.

12

12

401D454 Remove nuts for other rubber mountings.

401D455 Remove cooler holder.

401D456

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112

WORKSHOP MANUAL__ Shift out the cooler and lay it on engine.

401D457 Detach hooks, pass jigs through under the frame, sling onto the crane.

401D458 Remove pipe hose and piping from cooler.

401D459 Put cooler aside.

401D460

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113

WORKSHOP MANUAL__

13.

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Cabin

114

WORKSHOP MANUAL__ Seat

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115

WORKSHOP MANUAL__ 13.1 Seat Switch Remove three bolts from under so to take out seat upholstery.

401D222 Take out seat upholstery.

401D223

Fold up the seat.

401D224

Replace seat switch after having drilled off 2 rivets.

401D225

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116

WORKSHOP MANUAL__ Travel Control

185‐1_04423A

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117

WORKSHOP MANUAL__ 13.2

Position sensor for neutral and parking brake

Replace neutral and parking brake switch 23. Once replaced, ad- just gap X to 1,5 mm between balance arm 7 and switch 23.

X

23

7

401D226

13.3 LH side control panel, backing horn sensor Remove four bolts to release LH panel cover.

401D227 Replace backing horn switch 23, potentiometer for sprinkling interval control 47, travel controller position sensor 22, and emergency brake switch 43.

43

47

With the back run horn switch 23 replaced, please adjust the gap to 1,5 mm between arm 5 and switch 23.

5

Note Apply the identical method to replace speed selector on the RH control panel. Removal of back run switch, sprinkling interval control

23

22 401D228

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118

WORKSHOP MANUAL__ Platform

155‐03977A

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119

WORKSHOP MANUAL__ 13.4

Seat Platform

Remove four bolts that fix the seat to the bed.

401D229 Remove rotator arrest pedals 5 on both sides.

5 401D230 Take seat off the rotator.

401D231 Lift off to the side onto the cab floor.

401D232

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120

WORKSHOP MANUAL__ Remove bearing journal nut 44.

44

401D233 Remove spring 33, take off arrest 4, take out journal 19, replace bearing.

19 4

33

ARX 91

401D234

121

WORKSHOP MANUAL__ Power-Assisted Steering

185_04686A

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122

WORKSHOP MANUAL__ 13.5 Power-Assisted Steering Remove dashboard.

Screw off and take off the lever to adjust steering wheel position.

401D236 Pull down dust bellow from steering column.

401D237

Disconnect connector.

401D238

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123

WORKSHOP MANUAL__ Remove connection of hoses for power-assisted steering hydraulics.

401D239 When remounting tighten the hoses and necks using the torque according to the picture.

400A296

20 100Nm (74 lb ft)

19 100Nm (74 lb ft)

48 90Nm (66 lb ft)

58 70Nm (52 lb ft)

61 90Nm (66 lb ft)

24

12 35Nm (26 lb ft)

46 70Nm (52 lb ft)

59

401A541

Remove four bolts that connect steering wheel columns with power-assisted steering, remove power-assisted steering.

When reassembling glue bolts using Loxeal and tighten them with the torque 30 Nm (22 lb ft).

401D240

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124

WORKSHOP MANUAL__

14. Wiring

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125

WORKSHOP MANUAL__ 14.1

Fuses

Cut-out box It contains F1 - F8 fuses.

F1 - 15 A Head Light F2 - 20 A Horn, traffic – indicator lights F3 - 15 Work light, Charger F4 - 5 A Clusters F5 - 10 A travel electronics, backing horn, brake lights F6 - 15 A sprinkling F7 – 7.5 A vibrations F8 - 15 A Spare

Always replace the fuses with the ones of identical value!

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126

WORKSHOP MANUAL__ 14.2

Accumulator

Treatment while in operation

Storage accumulator has been located in the Machine’s rear frame.

The charging system that operates properly will keep the accumulator near its fully charged condition. The controlled voltage level moves within 13 - 14 V limits.

Putting into operation

With the voltage level adjusted like that, please check the electrolyte level after 3 months. During summer season, check 1x a week. Battery overcharging will be indicated by high loss of electrolyte. Electrolyte density will lower with insufficient charging. Self-discharging current of the battery makes 1 % of its capacity, daily.

Electrolyte max temperature when charging is 40 °C. If required, cool with air or water bath, or lower the charging current, or stop charging.

The charging currents lower than those stated in the Table are beneficial for the battery. The charging time will be extended. When charging, let the filling holes clear of any obstructions. Once charging is completed, please check electrolyte height and density. Make up and adjust density to 1,28 g.cm-3 if required. Screw in the plugs, and after round 2 hours of degassing, please rinse battery surface with water, wipe dry.

Charging Table (Example) Type

Capacity

Charging

L100

100 Ah

10 A

Recharge the battery with the current of 0,1 of total capacity up until having reached the fully charged symbol.

Keep the accumulator batteries clean, properly fixed, the fixing device shall not cripple the accumulator block. Battery terminals must be properly tightened.

Electrolyte aerosol forms sulphates across the surface of terminals’ metal parts. Clean off such sulphates. Protect cleaned metal parts with thin layer of preservation jelly or oil.

Recharge the batteries following 2 months of out of operation.

Safety regulations Charging Symbols Battery is considered fully charged when all its cells produce gas intensively, and the electrolyte shows 1,28 g.cm-3 density in all the cells. Each cell’s voltage reaches 2,5 - 2,7 V. The cumulative value for 6 cells is 14,4 V at the terminal pins.

Check full charge condition following next two hours, and the voltage and density values measured do not vary compared to those given. Discharge condition is given by 1,12 g.cm-3 density.

Instantaneous charging condition is given by the values refer to the Table.

Charge level in %

Electrolyte density in g/cu.cm

100

1,28

70

1,23

50

1,20

20

1,15

Handle the batteries and electrolyte with adequate care. Wear gloves and safety glasses (face shield).

Skin stained with electrolyte: Immediately flush with water and neutralize with soap or soda. When charging, the oxygen hydrogen get released from and electrolyte on electrodes, forming explosive mixture. It is therefore forbidden to handle open fire near the battery when charging Is being performed. Even a spark generated when terminal is disconnected or loosened with the charging circuit connected, may cause such explosion.

When removing, please first disconnect the negative (–) pole cable, followed by positive (+) one. NEVER disconnect the battery with the engine running.

The data apply at electrolyte temperature of 27 °C. At the temperature lowered by 15 °C the density measured will be higher by 0,01g.cm-3. When replenishing the electrolyte the density measuring will be of prevailing character only after 10 to 30 minutes of charging depending on current magnitude during electrolyte intensive gassing. Fill up the level using distilled water before recharging or before work, and this to 5-10 mm height above the separators.

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127

WORKSHOP MANUAL__ 14.3 Alternator Alternator is used as the electric power supply.

In the alternator there is semiconductor voltage controller integrated, and it keeps output voltage within its certain range at variable rpm, variable load, and at variable ambient temperature.

Controlled voltage alters on +B terminal.

Cooling is provided via own fan with the direction of rotation marked thereon.

Alternator shall always operate with the accumulator battery connected – positive battery pole connected to +B terminal. NEVER disconnect battery during operation.

Avoid any short circuits within the alternator vicinity.

Disconnect alternator leads from the mains when wiring is to be repaired or welding carried out. When starting via auxiliary external power supply, please NEVER disconnect such power supply before battery is connected. Alternator may NEVER run idle, i.e. with the wire disconnected from “+B” terminal, and “+D” terminal connected.

Immediately replace recharging indicator lamp burned, alternator excitation will not be provided for with the charging indicator lamp not working. Avoid any water or dirt penetrating the alternator via vent holes when washing the engine compartment.

This inspection is of informative character. Only the checking with measurable load using engine bench can be considered as binding.

The prerequisites of correct operation are: ‐

Wiring integrity

‐

Proper electric connections alternator, regulator, battery

‐

Sufficient tension of drive belt – radial force affecting the alternator shaft via belt pull shall be of max 800 N along pulley’s axis.

on

terminals

of

If alternator or regulator fails then not only insufficient recharging but also overcharging of the battery may occur.

During normal workshop inspection of the entire power supply system, when we do not expect any malfunction, the checking of control voltage or of how indicator lamp reacts to increased rpm, will be enough. When connecting the voltmeter to “B+” terminal the regulated voltage must move within the mean rpm band ranging from 13 - 14 V.

Note During welding work on the Machine you must disconnect alternator – wires from “+B” and “+D” terminals – and electric units or instruments with semiconductor elements. Disconnect alternator when repairing other electric equipment.

Informative inspection of alternator on the Machine

W A

B+

B‐

V

REG.

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128

WORKSHOP MANUAL__ FINDING ANY ALTERNATOR – REGULATOR DEFECT Checking alternator–regulator set – engine bench -

Remove regulator subsystem along with brush holder from the alternator, and replace (install) this subsystem with a guaranteed sound regulator.

Check regulated voltage using the engine bench.

Checking alternator with no regulator – engine bench •

Remove controller subsystem together with brush holder, and fix modified brush holder to the alternator. Modified brush holder has one lead of the brush connected to frame, and the second lead of the brush has a wire soldered and this wire has a socket for connector to be connected to D+ terminal, and this wire continues for ca 20 cm length to make short-time excitation from B+ terminal.

•

Fix and connect the alternator to the engine bench where voltmeter, ammeter, ballast resistor, speedometer and battery are connected. Refer to the Fig.

•

Move the alternator to ca 1500 min-1.

•

Excite the alternator – apply the end of free wire connected to the brushes and D+ terminal for 2-3 sec. to the B+ terminal. Unless excitation is possible the alternator is defective.

•

Check alternator characteristics.

Unless any failure is found with alternator, then malfunction has to be looked for within the regulator.

The failure cause may also be a bad contact between alternator frame and Vehicle frame, or false earth connection of alternator.

Voltage controller It is integrated voltage controller. Alternator excitation circuit is connected between DF an D+ terminals of the controller.

The controller 2itself has been connected with the brush holder, and the entire subsystem is fixed to the alternator with 2 bolts. Its interconnection is made through three soldered circuits (B-, DF, D+) and cable terminated with socket 6,3 to be slipped onto alternator’s “+D” connector. Controller is of throwaway type.

LIST OF POSSIBLE DEFECTS Symptoms of no battery charging Defective controller

Replace controller

Defective rotor – earth short circuit of winding

Replace rotor

Charging indicator lamp is Defective stator – earth short circuit ON while engine is running Failed diode within block

Replace stator Replace failed diode

Loosened soldered connections on diode pins or stator leads

Clean, re-solder

Indicator lamp failed

Replace lamp

Bad connection on +D terminal, or possibly on Recharging indicator lamp battery terminals does not go ON following Defective rotor – winding broken off ignition turned ON. Brush is hanging in its holder Rotor rings contaminated

Clean the connections, tighten Replace rotor Release brush, clean, or replace Clean

Symptoms of battery overcharging Defective earth connection within charging system circuit

Clean earth spots, tighten: controller - alternator, battery – body, body - engine

Defective controller

Replace

Auxiliary diode failed

Replace

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129

WORKSHOP MANUAL__ 14.4 Starter

Check the idling – on the Machine

Operation & Maintenance •

Proper operation of the starter is appropriate and fully charged batteries.

based

on

•

Starter has been designed for short term operation.

Continuous starting shall not last over 5 seconds.

•

Once engine starts, stop starting – risk of damage to starter motor pinion and starter bearing.

•

Feeder cables must have cable heads perfectly tightened, insulation not disrupted.

•

Starter frame forms part of electric circuit, please keep con- tact surfaces on the engine metallic clean, protect against corrosion.

•

Starter does not work, search for its defect within disrupted line between batteries and starter, between engine frame and starter, or between engine frame and batteries.

•

Check the flywheel ring gear and bevel pinion if not worn out. Lubricate with grease when inspecting.

•

Operations during engine repair or 1x per 2 years: Remove Machine starter. Check collector, brushes, brush springs, and switch contact surfaces.

Make sure 3/4 of brush surface will contact the collector, and brushes are easy to slide. Contact surfaces of switch contacts must not be burnt, and must contact each other with their en- tire surface.

Check the starter in such position when bevel pinion does not gear with the gear ring even when extended.

When starter circuit is switched ON the bevel pinion must protrude and spin. Unloaded starter may operate for max ten seconds. For detail description of the checking, please refer to the paragraph na- med “Informative Inspection of Starter”. Values measured must comply with those in the Table.

Finding starter failures Connect “30” terminal of the starter to the well charged battery, connect ammeter with long measuring range to the circuit. Refer to wiring diagram. Do NOT start (please, supply current to “50” terminal). Current value when running idle shall not exceed 120 A (peak at instantaneous deflection will not be taken into account).

The starter must run quietly. Bevel pinion must protrude continuously and return to its home position.

When bevel pinion is protruded it should not spin right on the face of the cap ring. Starter runout, when sensor is disconnected from the power supply, may last eight seconds only. Check pressure of brush springs and their condition. Brushes must be seated on collector with at atleast 2/3 of their surface, and must be able to move inside the chambers. Armature must have visible axial clearance of max 1,3 mm. When turning a bit the bevel pinion in the direction of starter rotation the overrunning clutch must slip lightly. When you are experienced enough, the no-lo- ad checking will do for workshop evaluation. However we recommend to test on engine bench.

А V

50

30

401D286

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130

WORKSHOP MANUAL__ Starter troubleshooting Defect

Starter does not rotate when switched ON

Starter runs idle

Starter does not go OFF – remains in mesh. Immediately disconnect battery (earth pole)!

Starter does not bring pinion into mesh

Pinion mills the flywheel

Starter can be heard to engage bevel pinion but does not turn the engine over

ARX 91

Cause

Remedy

Broken wire to switch’s terminal “30“

Repair wire

Broken wire to switch’s terminal “50“

Repair wire

Ignition box failed

Replace ignition box

Contacts burnt (pitting)

Replace contacts or complete cap (always together with contacts of the

Broken winding for starter switch

Replace starter switch

Starter is short-circuited (weak pull, runs hot)

Replace starter switch

Anchor of the switch remains hanging

Release, clean and apply oil

Damaged protruding (disengaging) mechanism

Replace, or repair

Bevel pinion jams on the shaft

Repair (sometimes shaft alignment is necessary)

Ignition box failed

Replace ignition box

Caked contacts of starter switch

Replace contacts (together with contacts of bridges and/or whole

Seized bevel pinion on shaft

Replace pinion bearing. Eliminate sharp edges on shaft, clean (check for shaft un- true running)

Damaged flywheel ring gear

Repair damaged ring gear and/or replace (find out the cause)

Broken protruding (disengaging) spring

Replace spring

Damaged pinion gearing

Replace pinion (find out the cause)

Discharged battery

Recharge battery

Damaged overrunning clutch – it slips (broken bushing)

Replace

Burnt contacts of starter switch

Replace

131

WORKSHOP MANUAL__

Defect

No reliable operation of starter. Low performance

Cause

Remedy

Battery insufficiently charged

Recharge battery

Dirty or loosened connections in feeder cables (brush-contact

Clean, tighten properly

Malfunctions of battery (normally slow deterioration of starting

Repair battery failure

Damaged starter brushes

Replace brushes (normally collector is necessary to repair)

Dirty and burnt and/or unsoldered collector (commutator)

Broken or heated brush springs

Replace spring

Short circuit to armature

Replace armature

Part of excitation coils has been disconnected (disrupted)

Replace respective pair of coils

Starter switch failed (contact resistance)

Starter operates with noise

Starter heats excessively, low performance

ARX 91

Clean with petrol or alcohol. When collector is burnt or daze emerges between col- lector bars (strong sparking during operation), please disassemble starter, and do machining on the collector. Mill out insulation, polish the collector. If required, solder again and/or replace armature (anchor).

Replace ignition box

Stator excitation winding disrupted on the lead to starter switch terminal

Solder again at the pin (outlet) point

Starter loosened within its flange

Tighten bolts

Armature loosened (seized in bearings) Repair Mechanical defect (various)

Repair defects

Broken cap (max. noise)

Repair, replace cap

Short circuit within excitation circuit

Eliminate short circuit, and/or replace relevant pair of coils

132

WORKSHOP MANUAL__ 14.5

Layout of wiring elements within the Machine

S28 S29

Description of the parts in individual Figures as per the wiring diagram legend.

S30 S31 S23

S22

View A

S15

107209B

S14

V7 V8

V5 V6

A5

107209A

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133

WORKSHOP MANUAL__ View B

S1

107209B View C

Y9 Y8

Y6

Y11

Y10

Y5

Y4

107209C

Y7

View D Y15

Y16

Y12

Y13

Y3

Y14

1‐2mm

S7

401D514 View E

S40, S41

401D519

ARX 91

134

WORKSHOP MANUAL__

15. Annexes

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135

WORKSHOP MANUAL__ 15.1

Measuring the relief pressures of hydraulic circuit

6

7

Pump 6 – Travel Pump 7 – Vibration

ARX 91

136

WORKSHOP MANUAL__ PUMP - 6 Forward drive – pump’s top 300 bar

401D277 Backward drive – pump’s bottom 300 bar

401D278 PUMP 7 High amplitude – pump’s top 350 bar

401D279 Low amplitude – pump’s bottom 350 bar

401D280

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137

WORKSHOP MANUAL__ 15.2

Vibration frequency adjustment

To adjust vibration you must first check and possibly adjust engine’s max rpm, refer to “Engine Removal” chapter.

Check frequency values with the Roller at standstill, and placed on engine bench, or on tyres laid down, or eventually on soft ground, at max engine speed (adjusted to 2290). Locate measuring instrument’s probe onto the drum jacket, switch ON vibration ONLY with the drum measured.

Max total time of vibrator run with drum turning over (bearing no lubrication) is 2 minutes!!!

401D275

Or you may place the measuring instrument’s probe onto the damper plate. When measuring in this way you may read (pick up) vibrator frequency during Machine drive.

401D276 Use Allen screws 1 (low amplitude) and 2 (high amplitude) to adjust the frequency, and this after having slackened the lock nut (counter-nut) of the vibration pump 6 (for front drum), 7 (for rear drum) with the engine turned OFF. Slacken (CCW turning) to increase the frequency, and vice versa. Start the engine a check again the set value with the engine running.

Vibration frequency set values Amplitude

low

55 –0.5Hz

Amplitude

high

42 –0.5Hz

1

Adjust vibration frequency with the engine turned OFF!

2

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138

WORKSHOP MANUAL__ 15.3

Adjust pulse sensors

Adjust again pulse sensor ALWAYS when you replace the sensor of hydraulic motor for travel.

Pulse sensor of KPPG13408 type.

1 – Use spanner 1/2 inches to adjust the sensor

1

2 – Use spanner 11/16 inches to tighten the sensor

2

380D0213 Open-end nut wrench 1 (1/2 in) to adjust the sensor.

Barrel (tubular box) spanner 2 (11/16 in) to tighten the sensor.

2

1

380D0214 Location of pulse sensor on the Machine (front drum – right side).

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139

WORKSHOP MANUAL__ Observe the following procedure to adjust the sensors: Install pulse sensor (1) down to the stop in the hydraulic motor for vibration and travel, until it touches magnetic ring (2).

380D0222

Rotate pulse sensor by 1/2 - 1 turn in backward direction so that clearance will occur between pulse sensor and magnetic ring. Such clearance may not exceed 1,52 mm (0,060 in), refer to the Fig.

Tighten the sensor by the nut with wrench 2 using 13 Nm (9,58 ft lb) torque. When tightened, please check sensor position as per the hydraulic motor axis, refer to the Fig. above, and adjust with spanner 1.

1

2

401D269

ARX 91

140

WORKSHOP MANUAL__ 15.4 Wiring Diagram Legend: A 1 Flasher A 2 Cluster A 4 Travel electronics A 5 Travel controller

S 2.5 Direction indicator control S 3 Rear head lamp S 4 Warning lamp S 5 travel speed S 6 Warning beacons S 7 Break pressure

A 6 Impulse relay (Opt)

S 8 Hydraulic system filter clogging

Q 1 Battery cut-off switch

S 9 Air filter clogging

F 1–8 Fuses

S 10 Engine lubrication pressure

G 1 Battery G 2 Alternator R 1 Water interval potentiometer R 2 Speed potentiometer R 3, 4 Resistor

S 11 Engine over heating S 12 Hydraulic oil over heating S 13 CRAB position (Opt) S 14 Reverse horn S 15 Neutral gear S 16 Emergency brake button

V 1-8 Diode

S 19 Vibration automatic

X Connector

S 20 Smooth start & smooth stop button

X 2 Diagnostic socket

S 21 Seat switch

B 1 Fuel level float

S 22 Vibration button (red) on the left travel lever

B 2 Water in fuel filter

S 23 Vibration button (red) on the right travel lever

B 3 Water tank pressure sensor

S 24 Watering button

B 4 Engine speed sensor

S 25 Watering pump control

B 5 Drum speed sensor

S 26 Vibration control

H 3 Loud horn

S 27 Vibration amplitude control

H 5 Reverse horn

S 28 Left (yellow) button on the left travel lever CRAB to

E 2 Number plate light

the left (Opt)

E 3,4 Rear position light

S 29 Right (yellow) button on the left travel lever CRAB to

E 5,6 Front head lamps

the right (Opt)

E 7,8 Work light

S 30 Left (yellow) button on the right travel lever CRAB to

E 9,10 Left direction indicator lamps

the left or the cutter upward (Opt)

E 11,12 Right direction indicator lamps E 17 Warning

S 31 Right (yellow) button on the right travel lever CRAB to

beacons (Opt)

the right or the cutter downward (Opt)

E 18,19 Break lamps

Y 1 Electromagnet of engine stop

E 20,21 Reverse lights

Y 3 Break valve

K 1 Contactor

Y 4 Valve – runner forward drive

K 2 -16 Auxiliary relay

Y 5 Valve – runner backward drive

M 1 Engine starter

Y 6 Travel control valve

M 2 watering motor

Y 8 Front drum selection

M 3 Watering motor

Y 9 Rear drum selection

S 1 Ignition switch

Y 10 Drum low vibration

S 2 Combined switch

Y 11 Drum high vibration

S 2.1 S/W of side & head lamps

Y 12 Valve of CRAB to left

S 2.2 Main/passing beam control

Y 13 Valve of CRAB to right

S 2.3 head light flasher

Y 15 Valve of the cutter upwards (Opt)

S 2.4 Loud horn button

Y 16 valve of the cutter downwards (Opt)

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141

WORKSHOP MANUAL__

27

32

52

ARX 91

142

WORKSHOP MANUAL__

ARX 91

143

WORKSHOP MANUAL__ 15.5 Hydraulics Diagram Legend: 1.

Travel and vibration pump

2.

Fan charge pump

3.

Steering pump

4.

Travel hydraulic motor

5.

Travel hydraulic motor with sensor

6.

Vibration hydraulic motor

7.

Fan hydraulic motor

8.

Loop flushing valve

9.

Steering hydraulic motor

10. Steering unit 11. Hydraulic filter 12. Hydraulic tank 13. ROC 14. Travel control block 15. Vibration selector block 16. Return line manifold 17. Check valve 18. Filler breather 19. Suction strainer 20. Temperature switch 21. Hand pump 22. Relief valve 23. Ball valve 24. Lift cylinder 25. Orifice 26. Cooler line block 27. Check valve

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144

WORKSHOP MANUAL__ 15.6

Check bolted connections are tightened

•

Confirm regularly that no loosening of bolted connections has occurred.

•

Use the torque spanners to do the tightening.

TIGHTENING MOMENT

TIGHTENING MOMENT

For the screws 8,8 (8G)

For the screws 10,9 (10K)

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

Worm

Nm

lb-ft

Nm

lb-ft

M18x1,5

220

162,2

312

230,1

M8

24

25,0

34

25,0

M20

390

287,6

550

405,6

M8x1

19

14,0

27

19,9

M10

48

35,4

67

49,4

M20x1,5

312

230,1

440

324,5

M22

530

390,9

745

549,4

M10x1,25

38

28,0

54

39,8

M22x1,5

425

313,4

590

435,1

M12

83

61,2

117

86,2

M24

675

497,8

950

700,6

M12x1,25

66

48,7

94

69,3

M24x2

540

398,2

760

560,5

M14

132

97,3

185

136,4

M27

995

733,8

1400

1032,5

M14x1,5

106

78,2

148

109,1

M27x2

795

586,3

1120

826,0

M16

200

147,5

285

210,2

M30

1350

995,7

1900

1401,3

M16x1,5

160

118,0

228

168,1

M30x2

1080

796,5

1520

1121,0

M18

275

202,8

390

287,6

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

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

45

38

52

33

28

38

51

43

58

38

32

43

58

50

65

43

37

48

74

60

88

55

44

65

16

74

60

88

55

44

65

18

105

85

125

77

63

92

135

115

155

100

85

114

166

140

192

122

103

142

19

16x1,5

22

18x1,5

24

20x1,5

27

22x1,5

30

24x1,5

32

26x1,5

36 41 46 50 50

ARX 91

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

146

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

Chart showing the torques for plugs with flat gasket

Tightening moments for the necks

Tightening moments for the plugs

G -M

Nm

lb ft

G -M

Nm

lb ft

G 1/8

25

18

G 1/8

15

11

G 1/4

40

30

G 1/4

33

24

G 3/8

95

70

G 3/8

70

52

G 1/2

130

96

G 1/2

90

66

G 3/4

250

184

G 3/4

150

111

G1

400

295

G1

220

162

G 11/4

600

443

G 11/4

600

443

G 11/2

800

590

G 11/2

800

590

10 x 1

25

18

10 x 1

13

10

12 x 1,5

30

22

12 x 1,5

30

22

14 x 1,5

50

37

14 x 1,5

40

30

16 x 1,5

60

44

16 x 1,5

60

44

18 x 1,5

60

44

18 x 1,5

70

52

20 x 1,5

140

103

20 x 1,5

90

66

22 x 1,5

140

103

22 x 1,5

100

74

26 x1,5

220

162

26 x1,5

120

89

27 x 1,5

250

184

27 x 1,5

150

111

33 x 1,5

400

295

33 x 1,5

250

184

42 x 1,5

600

443

42 x 1,5

400

295

48 x 1,5

800

590

48 x 1,5

500

369

M‐G

M‐G

M‐G

282N221T

ARX 91

282N222T

147

WORKSHOP MANUAL__ 15.7 List of figures Group

No.

Name - Use

aplication

1

ND146614

Handling sling

install / remove aux. transmission

2

ND090535

Stop

lock Drum position

3

ND090512

Handling clamp

handle the Drum

4

ND146613

Lifting lug for handling

install / remove vibrator

ND 090506

Lifting hooks

install / remove damper plates with flange and bearing

6

ND 090607

Adapter

install / remove bolt 16

7

ND 090480

Tube Ø 129/ Ø105‐L120

install / remove flange 10

8

ND 090480

Tube Ø139 / Ø115‐L140

install / remove bearing 42

Steering joint - 65

9

ND 142983

Ring

install / remove bearing

Hydraulic cylinder - 70

10

ND 101783

Split ring Ø70

install hydraulic cylinder piston

11

ND 101783

Split ring Ø110

Install hydraulic cylinder piston

12

ND146612

Handling sling

install / remove cooler

Drum - 1

No.

5

radiator - 125

jig No. 1

ND146614 jig No. 2

ND090535

ARX 91

148

WORKSHOP MANUAL__ jig No. 3

ND090512 jig No. 4

ND146613 jig No. 5

ND090506 jig No.6

ND090607

ARX 91

149

WORKSHOP MANUAL__ jig No. 7 jig No. 8

ND090480 jig No. 9

ND142983 jig No. 10 jig No. 11

ND101783 jig No. 12

ND146612

ARX 91

150

WORKSHOP MANUAL__ 15.8

Hand Signals

Signal provided by Machine Operator Assistant unless Operator is able to visually view driving area or working area, or working equipment of the tool.

GENERAL COMMAND SIGNALS Stop One arm upright with open palm in Operator’s direction, second arm akimbo.

STOP Sig. 1

Attention Both arms sideways raised horizontally – palms forward.

!

Sig. 2

Attention, Hazard Oscillating motion of both arms with forearms from horizontally sideways raised position into position of arms sideways raised – bent, and back again.

!

Sig. 3

SIGNALS TO DRIVE Depart with the Machine One arm raised – bent with open palm, long motion by forearm in direction of the motion required, second arm akimbo.

Sig. 4

ARX 91

151

WORKSHOP MANUAL__ Slow drive forward – towards me Both arms abreast bent raised with palms towards the body – short oscillating movements by forearm towards the body and back again.

Sig. 5

Slow drive backward – away from me Both arms abreast bent raised with palms away from the body ‐ short oscillating movements by forearm away from the body and back again.

Sig. 6

RH drive Left arm sideways raised, right arm akimbo.

Sig. 7

LH drive Right arm sideways raised, left arm akimbo.

Sig. 8

ARX 91

152

WORKSHOP MANUAL__ Short movement Both arms lifted forward, bent. Indicate distance “X“ between palms, then follows the signal to move.

Sig. 9

Engine start Circular motion by right hand forearm with palm tightly closed.

Sig. 10

Engine cut off Oscillating movement made by right hand sideways raised in front of the body, pointing to the sides.

Sig. 11

ARX 91

153

WORKSHOP MANUAL__ Notes

ARX 91

154

ARX 91

155

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

ARX 91

156