Ammann AV 130 X Tandem Roller Cummins Tier 3 Operating Manual PDF

Operating manual

AV 130 X Cummins Tier 3

E

© 8 / 2007

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

Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to inform the machine user. If you identify any differences between the machine operated by you and the information contained in this publication, contact your local dealer.

Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic a.s.

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AV 130 X

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

With kind regards,

Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují

+ 420 491 476 111 | Fax + 420 491 470 215 | info@ammann-group.cz | www.ammann-group.cz

This manual consists of: I. Specification manual

II. Operating instructions

III. Maintenance manual

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

Subsequent faults due to improper operating are avoided.

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

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

Spare parts must meet AMMANN technical specifications. These requirements are fulfilled if only original AMMANN spare parts are used.

These instructions must always be kept available on the equipment.

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AV 130 X

Operating Manual

! NOTICE !

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

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Content Content 1.

........................................................................................................................................................ 6

SPECIFICATION MANUAL ......................................................................................................................... 11

1.1. Basic specification ................................................................................................................................... 12 1.1.1.

1.1.2.

1.1.3.

Machine description ....................................................................................................................................... 12 Area of use ...................................................................................................................................................... 12 Machine design .............................................................................................................................................. 12

1.2. Machine dimension scheme .................................................................................................................... 14 1.3. Technical data .......................................................................................................................................... 16 1.3.1. Weights ........................................................................................................................................................... 16 1.3.2. Riding characteristics ..................................................................................................................................... 16 1.3.3. Vibration .......................................................................................................................................................... 16 1.3.4. Engine ............................................................................................................................................................. 17 1.3.5. The Brakes ...................................................................................................................................................... 17 1.3.6. Steering ........................................................................................................................................................... 17 1.3.7. Travel hydrostatic drive ................................................................................................................................... 18 1.3.8. Vibration hydrostatic drive ............................................................................................................................... 18 1.3.9. Hydraulic generator drive gearbox .................................................................................................................. 18 1.3.10. Fills .................................................................................................................................................................. 18 1.3.11. Watering .......................................................................................................................................................... 19 1.3.12. Electrical installation ....................................................................................................................................... 19 1.3.13. Hygienic parameters ...................................................................................................................................... 19 1.3.14. Auxiliary devices, Option ................................................................................................................................. 20

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AV 130 X

Operating Manual 2.

OPERATING INSTRUCTIONS .................................................................................................................... 23

2.1. Receiving Inspection & Dewaxing of New Machine .............................................................................. 24 2.2. Major Safety Precautions ........................................................................................................................ 25 2.2.1. Safety Measures during Machine Operation .................................................................................................. 25 2.2.1.1. Compaction Work Commencement .............................................................................................................. 25 2.2.1.2. Work Safety Secured by User ......................................................................................................................... 25 2.2.2. ROPS Cab ...................................................................................................................................................... 26 2.2.3. Reguirements on Driver’s Qualification ......................................................................................................... 26 2.2.4. Driver’s Liabilities ........................................................................................................................................... 26 2.2.5. Banned Operations ........................................................................................................................................ 28 2.2.6. Hand Signals .................................................................................................................................................. 29 2.2.7. Safety Markings & Signs Used on the Machine ............................................................................................. 32

2.3. Ecological & Hygienic Principles ............................................................................................................ 36 2.3.1.

2.3.2.

Hygienic Principles ......................................................................................................................................... 36 Ecological Principles ...................................................................................................................................... 36

2.4. Preservation & Storage ............................................................................................................................ 37 2.4.1.

2.4.2.

Short-Term Preservation & Storage for the Period of 1 ÷ 2 Months ............................................................... 37 Machine Preservation & Storage for the Period Over 2 Months Long ............................................................ 37

2.5. Machine Disposal Following Its Life Termination .................................................................................. 38 2.6. Machine Description ................................................................................................................................ 39 2.7. Controls & Control Apparatuses .............................................................................................................. 40 2.8. Machine Control ....................................................................................................................................... 53 2.8.1.

2.8.2.

2.8.3.

2.8.4.

2.8.5.

2.8.6.

2.8.7.

Engine Start ..................................................................................................................................................... 53 Drive ................................................................................................................................................................ 55 Emergency Stop .............................................................................................................................................. 58 Sprinkling ........................................................................................................................................................ 59 Machine Parking, Shutdown ........................................................................................................................... 59 How to tilt the bonnet ...................................................................................................................................... 60 Troubleshooting according to flashing codes ............................................................................................... 61

2.9. How to transport the Roller ..................................................................................................................... 62 2.9.1.

Loading the Roller .......................................................................................................................................... 63

2.10. Special Conditions for the Machine Use ................................................................................................ 64 2.10.1. Machine Towing .............................................................................................................................................. 64 2.10.2. Vibrations on compacted and hard materials ................................................................................................ 67 2.10.3. Work at higher temperatures and moisture ................................................................................................... 67 2.10.4. Work at higher altitudes .................................................................................................................................. 67 2.10.5. Work at very dusty environment ...................................................................................................................... 67

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Content 3.

MAINTENANCE MANUAL .......................................................................................................................... 71

3.1. Safety Standards at Lubrication and Maintenance ............................................................................... 73 3.1.1. Safety during maintenance ............................................................................................................................. 73 3.1.2. Fire safety during changing contents ............................................................................................................. 73 3.1.3. Environmental and health regulations ........................................................................................................... 74 3.1.3.1. Health regulations .......................................................................................................................................... 74 3.1.3.2. Environmental principles ................................................................................................................................ 74

3.2. Specification of fluids .............................................................................................................................. 75 3.2.1.

3.2.2.

3.2.3.

3.2.4.

3.2.5.

3.2.6.

3.2.7.

Engine oil ........................................................................................................................................................ 75 Fuel ................................................................................................................................................................. 76 Coolant ............................................................................................................................................................ 76 Hydraulic oil .................................................................................................................................................... 77 Gearbox oil ...................................................................................................................................................... 78 Lubricating grease .......................................................................................................................................... 78 Windshield washer liquid ............................................................................................................................... 78

3.3. Fills

....................................................................................................................................................... 79

3.4. Lubrication and Maintenance Chart ....................................................................................................... 80 3.5. Lubrication Chart ...................................................................................................................................... 82 3.6. Individual Operations of Maintenance ................................................................................................... 83 Every 20 Hours or Daily ............................................................................................................................ 84 3.6.1. Checking the amount of oil in the engine ...................................................................................................... 84 3.6.2. Checking cooling liquid of the engine ............................................................................................................ 85 3.6.3. Hydraulic tank oil level checking ..................................................................................................................... 86 3.6.4. Crankcase breather tube ................................................................................................................................ 87 3.6.5. Checking the condition of the ventilator and belt ........................................................................................... 88 3.6.6. Checking the vacuum valve of the air cleaner ................................................................................................ 89 3.6.7. Fuel level checking ......................................................................................................................................... 90 3.6.8. Watering tank filling ........................................................................................................................................ 91 3.6.9. Cleaning the water separator ......................................................................................................................... 92 3.6.10. Warning and control devices checking .......................................................................................................... 93

Every 250 Hours or Once in 3 Months ..................................................................................................... 95 3.6.11. Air intake cooler, intake piping ........................................................................................................................ 95 3.6.12. Checking the cooling circuit of the engine ..................................................................................................... 96 3.6.13. Checking the engine belt ................................................................................................................................ 97 3.6.14. Checking battery ............................................................................................................................................. 98 3.6.15. Air filter vacuum switch function checking .................................................................................................... 100 3.6.16. Joint bearings, pins ...................................................................................................................................... 102 3.6.17. Checking oil in gearboxes ............................................................................................................................ 104 3.6.18. Watering filter and sprinkler screens ........................................................................................................... 105

Every 500 Hours or Once in 6 Month ..................................................................................................... 106 3.6.19. Engine oil exchange ..................................................................................................................................... 106 3.6.20. Engine fuel filter exchange ........................................................................................................................... 109 3.6.21. Checking cooling liquid ................................................................................................................................. 111

Every 1000 Hours or Once a Year .......................................................................................................... 112 3.6.22. How to check tightening pulley and belt of the engine ................................................................................. 112 3.6.23. Exchanging oil in gearboxes ........................................................................................................................ 114 3.6.24. Damping system checking - drum and cabin .............................................................................................. 116 3.6.25. Fuel tank cleaning ........................................................................................................................................ 118 3.6.26. Water tank cleaning ...................................................................................................................................... 120

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Operating Manual Every 2000 Hours or Every 2 Years ........................................................................................................ 121 3.6.27. Vibrations system oil exchange ................................................................................................................... 121 3.6.28. How to replace hydraulic oil and filters ........................................................................................................ 122 3.6.29. Exchanging the engine cooling liquid .......................................................................................................... 126 3.6.30. Checking torsion vibration damper of the engine ........................................................................................ 128 3.6.31. Exchanging cleaner elements of air cleaner ............................................................................................... 129

Maintenance - As Needed ...................................................................................................................... 131 3.6.32. Cleaning the engine radiator and hydraulic oil ............................................................................................ 131 3.6.33. Water discharge from watering circuit before winter season ...................................................................... 132 3.6.34. Cleaning the air cleaner of cabin ventilation ................................................................................................ 134 3.6.35. Cleaning the machine .................................................................................................................................. 135 3.6.36. Adjustment of scrapers ................................................................................................................................ 136 3.6.37. Checking and tightening bolted joints .......................................................................................................... 138

3.7. Defects ..................................................................................................................................................... 141 3.8. Appendixes ............................................................................................................................................. 142 Wiring scheme AV 130 X ............................................................................................................................................ 142 Hydraulic Diagram AV 130 X ....................................................................................................................................... 146

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Operating Manual

1. SPECIFICATION MANUAL AV 130 X

AV 130 X

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1.1.

Basic specification

1.1.1. Machine description

1.1.3. Machine design

The tandem vibration rollers AV 130 X are equipped with a hinged frame. Each of both drums has its own separate hydraulic circuit for the drive of travel and vibration. The hinged connection of the front and rear frames with two vertical axes enables the steering and offset of drums (crabbing). The concept of frames, cabs, and drum suspension enable the compacting operations close to kerbs or walls and the turning seat of the driver facilitates a good control of the machine in both directions. The distribution of weight on the front and rear drums, as well as equal centrifugal forces of the front and rear vibrator prevent the forming of tracks in the compacted ground even with the use of crabbing. The ergonomic cab with the integrated ROPS (roll-over protective structure) is located in the middle of the machine.

The designing of the machine respected the requirements of the international standards for hygiene, ergonomics, and safety at work. The machine complies with the conditions for being marked with the CE symbol.

Machine’s production label – CE

1.1.2. Area of use The rollers can be used for compaction of asphalt compositions to the layer thickness (after compaction) of 160 mm (6,3 in), hydraulic cemented compositions to the layer thickness of 250 mm (9,8 in), composed earth to the layer thickness of 350 mm (13,8 in), sand and gravel materials to the layer thickness of 450 mm (17,7 in).

The rollers are not convenient for compaction of rockfill, aluminous and clayey materials.

The machines of these series are engineered for operations under the conditions due to the CSN IEC 721-2-1 (038900) : WT, WDr, MWDr (i.e. temper climate zone, hot dry zone or warm dry zone with limited temperature scope from –7 °C (19,4 °F) to +45 °C (113 °F) of ambient temperature.)

The machine does not comply with the conditions for being marked with the “CE” symbol and it is equipped with a name plate without “CE“.

Machine’s production label

To the machine can be mounted the individual auxiliary device, so called cutter, for cutting or re-compaction of the road constructional borders of asphalt compositions.

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AV 130 X

Specification Manual Placing of the production label

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

3

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

2 Type of machine ......................................................................................

1

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

1

- Production label

2

- Machine frame number

3

- Label of the ROPS cabin

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

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

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

Cummins engine serial number

AV 130 X

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1.2.

14

Machine dimension scheme

A

D

H1

H2

K1

K2

L

O

mm

3525

1350

3060

2390

360

770

4875

62

in

138,8

53,1

120,5

94,1

14,2

30,3

191,9

2,4

R1

R2

R3

S

W1

W2

W3

mm

6130

4670

5770

20

2100

2222

160

in

241

184

227

0,8

82,7

87,5

6,3

AV 130 X

Specification Manual

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1.3.

Technical data

1.3.1. Weights Working weight (maximum) with the ISO 6016

kg (lb)

13620 (30026)

front drum

kg (lb)

7025 (15487)

rear drum

kg (lb)

6595 (14539)

The ISO 6016 weight is the weight of the machine with full fuel and lubricant tanks, full sprinkling tank, and an operator (75 kg /165 lb/). The weight data may differ from the above-mentioned in the case of further requirements of the customers for make, equipment, and accessories of the machine.

1.3.2. Riding characteristics Travel speed infinitely variable in both directions

km/h (MPH)

0 – 11,4 (7,1)

Oscillation angle of frames in vertical plane

±°

6

Steering angle of both frames in horizontal plane

±°

35

Drum offset

±mm

160

Machine theoretical gradeability

%

40

Transversal static stability

°

33

1.3.3. Vibration Drive hydrostatic. Vibration driver two-level, circle undirected vibration Frequency

Hz (VPM)

42/55 (2520/3300)

Frequency CE

Hz (VPM)

42/50 (2520/3000)

Nominal amplitude

mm (in)

0,8/0,4 (0,03/0,016)

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AV 130 X

Specification Manual 1.3.4. Engine Manufacturer

Cummins

Engine type

QSB4.5-C130

Number of cylinders

4

Perforation

mm (in)

102 (4,0)

Stroke

mm (in)

138 (5,43)

3

Stroke volume

cm (cu in)

4500 (275)

Engine output due to ISO 3046/1

kW (HP)

97 (130)

Nominal revolutions

min-1 (RPM)

2300

Max. operating revolutions of the engine

min-1 (RPM)

2300

Maximum torsional moment

Nm (ft lb)

512 (376)

Specific fuel consumption under nominal output

g/kWh

233

Fuel consumption under normal operation/hour

l (gal US)

max. 10,1/2,7

Engine fulfills requirements of

Dir. 97/68/EU Stage 3 EPA/CARB 40 CFR Part 89 Tier 3

1.3.5. The Brakes The service brake is a part of the hydrostatic system of travel.

The parking and emergency multiple-disc brakes integrated in the travel reducers controlled by springs by means of hydraulic brake lifting.

1.3.6. Steering The roller steering set consists of: Power steering hydraulic generator Power steering Hydraulic system unit 2 straight-line hydraulic motors of turning Straight-line crabbing hydraulic motor

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1.3.

Technical Data

1.3.7. Travel hydrostatic drive The roller travel drive set consists of: Piston regulating hydraulic generator with the electro-hydraulic control – for each drum, 2 travel hydraulic motors Control units Differential lock with a separate hydrostatic circuit of each drum Travel level sensors

1.3.8. Vibration hydrostatic drive The roller vibration drive set consists of: Piston regulating hydraulic generator with the electro-hydraulic control – for each drum, 2 vibration hydraulic motors.

1.3.9. Hydraulic generator drive gearbox The gearbox on the engine ensures the drive of both tandem hydraulic generators for the travel drive and vibration of the front and rear drum.

1.3.10. Fills Engine (oil fill)

l (gal US)

11,6 (3,1)

Cooling system

l (gal US)

21 (5,5)

Fuel

l (gal US)

210 (55,5)

Hydraulic system

l (gal US)

60 (15,9)

Drum vibrator

l (gal US)

2x19 (2x5)

Drum drive reducer

l (gal US)

2x3 (0,8)

Gearbox pump driven

l (gal US)

1,8 (0,48)

Sprinkling tank

l (gal US)

2,75 (0,72)

Watering tank

l (gal US)

1000 (264)

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AV 130 X

Specification Manual 1.3.11. Watering The drum watering system consists of: 2 water pumps (1 stand-by pump) with a filter in front of the pumps Nozzles with integrated filters and valves The controller of watering interval depending on the distance covered in the travel control unit

1.3.12. Electrical installation Electric set voltage

V

12

Accumulator – capacity

Ah

135

1.3.13. Hygienic parameters The machine with cab: Noise : The acoustic pressure level influencing the driver:

L pA= 82 dB (A)

Guaranteed sound power level

L WA = 108 dB (A)

Vibrations : Vibrations acceleration nominal equivalent value : - transferred to the body

aw < 0,5 m.s-2 (vector sum)

- transferred to the hands

a w < 2,5 m.s-2 (vector sum)

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1.3.

Technical Data

1.3.14. Auxiliary devices, Option Edge cutter and compactor Device weight

kg (lb)

100 (220)

Max. thickness of the cut layer

mm (in)

100 (3,94)

Max. thickness of the compacted layer

mm (in)

95 (3,74)

Cutting disc diameter

mm (in)

400 (15,75)

Compacting disc diameter

mm (in)

390 (15,36)

Infra thermometer Serves for bitumen surface temperature measurement.

Additional light of cab/canopy It is used for lighting the drums surface, the sprinkling nozzles, and the area around the machine under reduced visibility conditions.

Warning beacon

Hinged scrapers Scrapers are pressed down to the drum by the gas pressure springs and can be hinged away from the drum.

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Specification Manual

Notes:

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AV 130 X

2. OPERATING INSTRUCTIONS AV 130 X

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2.1.

•

Receiving Inspection & Dewaxing of New Machine

Check the Machine per transport documents. See if some parts of the Machine are damaged due to their transportation or are missing. Inform the shipper about any abnormalities.

Carry out overall dewaxing of the Machine before restoring its operation.

Wash the Machine with high pressure stream of hot water added with normal degreasing agents while adhering to ecological principals.

Perform dewaxing and washing of the Machine at places provided with intercepting cesspools (sumps) to trap rinsing water or dewaxing agents.

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AV 130 X

2.2.

Major Safety Precautions

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

2.2.1.1. Compaction Work Commencement •

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

•

He must verify and mark: -

utility lines

-

underground areas (direction, depth)

-

seepage or escape of hazardous materials

-

soil bearing capacity, slope of travelling plane

-

other obstractions incl. their removal.

Operating instructions 2.2.1.2.Work Safety Secured by User •

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

•

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

•

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

•

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

•

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

•

He shall provide for regular inspection of operation, technical condition, regular machine maintenance in cycles per the Lubrication and Maintenance Manual.

In cases of failing technical condition of the Machine to such an extent it poses hazard to safety of operation, persons, property or causes damage or impairs the environment, then the Machine must be put out of operation until a defect is repaired.

•

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

•

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

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

•

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

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

-

precautions for any natural disaster hazards

•

-

requirements on work performance while observing job safety principles

He shall provide for fire extinguisher to undergo regular inspections.

•

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

•

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

•

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

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

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2.2.

Major Safety Precautions

2.2.2. ROPS Cab

2.2.4. Driver’s Liabilities

•

•

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

•

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

2.2.3. Reguirements on Driver’s Qualification

•

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

•

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

•

•

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

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

•

•

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

•

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

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

•

•

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

•

Driving the Roller alone may be performed by an employee mentally and physically fit, over 18 years old, who is:

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

•

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

or

•

b) assigned by Constructional Supplier to operate (carry out maintenance) and is evidently trained and acquainted with, or owns professional competence to operate and drive under special regulations (machinist licence, etc.).

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

•

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

•

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

•

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

The ROPS cab must not be deformed and must not show signs of corrosion, cracks or breaks. It must be fixedly connected to the machine frame. No additional adjustments of the cab may be performed without approval of the manufacturer as such adjustments can cause a reduction in its strength. The screwed connections must comply with the specification and must be tightened to the specified torque, must be neither damaged nor deformed, and must not show signs of corrosion.

a) assigned by machine manufacturer for the assembly, testing and presentation of the Machine, for training the drivers, whereas he/she must be made familiar with safety work regulations in force at the workplace

•

26

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

AV 130 X

Operating instructions •

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

•

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

•

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

•

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

•

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

•

Respect Code of Practice or instructions of a person responsible.

•

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

•

•

Upon completion or stop of the Machine operation during which driver leaves the Machine, he/she must make measures against unauthorized use of the Machine or against spontaneous starting the engine.

Remove key from the ignition box, disconnect the wiring via disconnector, lock the cabin, engine bonnet.

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

•

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

•

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

•

Driver shall use personal protective equipment (PPE) – work clothing, safety shoes, the clothing shall not be too loose, impaired, hair protected with proper head piece. During maintenance (lubrication, refilling, replacement of working media) your hands must be protected with proper gloves. Use proper muffs when using Machine with no cabin or with open windows.

•

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

•

Maintain the Machine free of oil dirt or flammable materials. Keep the drive’s stand, foot rests and runner areas clean.

AV 130 X

•

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

try to leave with the Machine a hazardous zone

-

do not leave driver’s stand

-

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

OBSERVE THESE SAFETY ADVICES IN THE MANUAL:

Adhere to safety advice in any case – life hazard.

Adhere to safety advice – risk of injury.

Follow ecological regulations.

! WARNING ! Follow the markings.

27

2.2.

Major Safety Precautions secured through some other way like for instance via signaling by duly instructed person.

2.2.5. Banned Operations Banned are the following •

To use the Machine following ingestion of alcoholic beverages or dopes.

•

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

•

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

•

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

•

•

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

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

•

To control the Machine in some other way than stated in Operating instructions.

•

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

•

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

•

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

•

To operate the Machine unless driver control stand fixed properly.

•

To operate the Machine when engine bay cover is open.

•

To move and transport persons on the Machine.

•

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

•

To operate the Machine at places impossible to see from driver’s stand, and where hazard to people or property could occur unless work safety has been

28

•

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

•

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

•

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

•

To leave driver’s cockpit of the Machine when the Machine is running.

•

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

•

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

•

Leave unsecured Machine – move away from the Machine without having prevented its misuse.

•

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

•

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

•

Start the engine through some other way than given in the Operating instructions.

•

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

•

Lay away material or other objects on the Machine.

•

Remove dirt while the Machine is running.

•

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

•

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

•

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

•

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

•

Let the engine run inside confined spaces.

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Operating instructions 2.2.6. Hand Signals Signals given by Machine assistant operator unless driver visually contains the rolling space or working space or working equipment, tool.

SIGNALS FOR GENERAL COMMANDS

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

Attention Both arms sideways raised horizontally – palms forward.

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

SIGNALS FOR DRIVE

Departure with the Machine One arm erected – bent with open palm, long motion of ante brachium in the direction of required motion, second arm akimbo.

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29

2.2.

Major Safety Precautions

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

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

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

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

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

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

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

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31

2.2.

Major Safety Precautions

2.2.7. Safety Markings & Signs Used on the Machine 1.

Read Operation Manual!

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

2.

Service Manual

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

3.

Pinch Points

Maintain safety distance away from the Machine. Hazard of being clamped by the Machine between front and rear frame (symbols located to the left and right on the front frame underneath the cabin)

4.

Hazardous Area

Maintain safe distance (Symbol located to the left and right on the rear frame near steering joint.)

Keep a safe distance from the cutter and compactor if in operation. (The symbol is located at the right front yoke)

5.

Injury Hazard

Keep safety distance away from rotating cooling fan (Symbol located to the right within engine bay.)

6.

Injury Hazard

Keep safety distance away from rotating pulley and belt (Symbol located to the right, within engine bay.)

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Operating instructions 7.

Adjust at Rest

Carry out adjustment or maintenance with engine stopped. (Symbol located to the left, within engine bay.)

8.

Risk of burn

Do NOT touch Machine’s hot parts unless you made certain these are cooled down sufficiently.. (Symbol located on the rear wall of engine bay, and on the LH side of rear frame overhead the exhaust.)

9.

Cooling Liquid

Cooling liquid is hazardous to health. Scald hazard hot cooling liquid when being replaced. Read Operation Manual! (Symbol located near Cooler inside engine bay.)

10. Explosion Hazard

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

11.

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

Disconnect the Wiring

12. Cover the Electric Instruments

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

33

2.2.

Major Safety Precautions

13. Max Machine Height

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

14. Lifting & Rigging Plan

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

15. Lifting Points

Use only these points to lift the Machine (Symbols located along both sides of the frames overhead the runner.)

16. Switch ON Safety Belt!

Switch ON safety belt before driving! (Symbol located in front of cabin windscreen.)

17. Bonnet Lifting

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

18. Emergency Exit

Symbol located near LH door window

19. First Aid Box

Designation for First Aid Box (Symbol located inside cabin behind seat)

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Operating instructions 20. Noise Emitted

External noise of the Machine (Symbol located on the LH side of the frame)

21. Jacking point

Place to install hand jack or fixed support of the Machine (Symbol located on the front and rear frames along both sides)

22. Sling Points

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

23. Pinch Points

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

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35

2.3.

Ecological & Hygienic Principles When operating and storage the machines a User will be liable to observe general principles of health and environmental protection, laws and regulations that relate to the given issue and are in force within a territory where the Machine is used.

2.3.2. Ecological Principles •

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

•

This category of waste products includes in particular: -

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

-

Cooling liquids,

-

Accumulator fillings and the accumulators themselves,

-

Cleaning & preservation agents,

-

All filters and filter elements dismantled,

-

All used and discarded hydraulic hoses or fuel hoses, metal rubbers and other Machine’s elements, foulded with the abovementioned products.

2.3.1. Hygienic Principles •

•

•

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

We call your attention to the following in particular: -

Eye and skin protection when handling accumulators

-

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

-

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

-

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

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

•

Upon skin, mucosa, eye contacts or inhalation of vapor, immediately apply the principles of first aid.

Upon accidental use of these products get prompt medical attention.

•

When operating the Machine with no cabin provided, or with cabin windows opened, always use ear defenders (muffs) of proper type and version.

36

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

•

Manufacturer and manufacturer-accredited contracting service organizations or dealers take back the following used materials or parts free of charge: Oils Accumulators

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2.4.

Preservation & Storage

2.4.1. Short-Term Preservation & Storage for the Period of 1 ÷ 2 Months •

•

•

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

In addition:

Operating instructions 2.4.2. Machine Preservation & Storage for the Period Over 2 Months Long To park the Machine the same principles will apply like at short-term preservation.

In addition it is recommended to: •

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

•

Support the runner frame so the damping system shows minimal sag,

-

Repair those spots with damaged paint,

•

-

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

Protect rubber elements through painting with spec. preservation agent,

•

-

Confirm water fillings are drained,

Inflate the tires to a pressure required, and protect them from direct sunlight,

-

Check that cooling liquid has antifreezing characteristics required,

•

Apply preservation grease over the chromed surfaces of the piston rods,

-

Check the state of accumulator charges, recharge them if necessary,

•

Preserve the Machine via spraying with special agent, and this at places of possible corrosion origin,

-

Apply preservative grease over the chromed surfaces of piston rods,

•

Blind the engine suction and discharge ports with double PE foil, and tighten this foil thoroughly with adhesive tape,

-

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

•

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

•

Preserve the engine per Manufacturer’s Instruction Manual – mark visibly the engine has been preserved.

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

! WARNING !

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

NEVER start the engine in course of storage!

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

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

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

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37

2.5.

Machine Disposal Following Its Life Termination

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

the specialized companies with respective authorization to deal professionally with these operations,

•

the Machine manufacturer or manufacturer-appointed accredited contracting service organizations put in charge by manufacturer.

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

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2.6.

Machine Description

Operating instructions

1 - Front Frame 2 - Rear Frame 3 - Front Runner 4 - Rear Runner 5 - Engine 6 - Hydrogenerator for travel (roll) and vibration of front runner 7 - Hydrogenerator for travel and vibration of rear runner 8 - Hydromotor for travel 9 - Hydromotor for vibration 10 - Steering Joint 11 - Hydraulics Tank 12 - Batteries 13 - Cabin with integrated ROPS 14 - Fuel Tank 15 - Sprinkling Tank 16 - Sprinkling Jets 17 - Scrapers 18 - Air Filter

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39

2.7.

Controls & Control Apparatuses

Dashboard & Control Panels 1 - Ignition Box

13 - Runner Vibration ON (front - rear - both)

2 - Accelerator Control

14 - Cluster

3 - Travel (Roll) Control

15 - Cluster

4 - Speed Selector

16 - Engine diagnostics

5 - Vibration Switch

17 - Switches

6 - CRAB Switch – Front Runner Right*

18 - Integrated Switchover

7 - CRAB Switch – Front Runner Left*

19 - Lamp Switches

8 - RAMP Switch

20 - Lamps

9 - Interval Sprinkling Control

21 - Steering Wheel Adjustment

10 - Sprinkling Switch

22 - Seat Turning Pedal

11 - TOTAL STOP

23 - Thermometer (option)

12 - Amplitude Selection

*

40

When Roller is fitted with trimmer, then button 6 functions as – downward trimmer, button 7 – upward trimmer.

Trimmer control is wired in the Travel Control on such side of the seat which corresponds to installation of trimmer on the Machine.

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Operating instructions Ignition Box 1 Ignition box 1 has three positions “0-I-II“. When in position ”0” the cylinder’s el. circuit is OFF. In pos. ”I” the LEDS for left or right cluster light on and then go off following 3 sec. Brake alarm indicators, neutral indicator, charge control lamp continue to light. Fuel indicator, water indicator and motohour indicator signal the actual status. When In pos. ”II” the engine is started.

NOTE: The key is the same for the cab door, the disconnecting switch cover, and the engine oil gauge cover.

Accelerator Control 2 It is used to adjust combustion engine speed from idling to maximal.

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41

2.7.

Controls & Control Apparatuses

Travel (Roll) Control 3 It is used as driving brake and also as parking brake. After pulling towards driver, then swinging forward or backward up to the stop the Roller will start moving at a speed set by preselector 4. Shifting the Control to neutral the speed will lower down to stop (driving brake). When with the Control back in locked (arrested) position to the right, the Roller is braked with parking brake.

NOTE Roller is able to be stopped instantly when swiftly shifting the Control within 1 second interval via neutral to the opposite position – the engine will keep running. Enable the travel back again first by shifting the Control to neutral and then to a chosen direction of running.

! WARNING !

Roller will be braked only when with the Control in locked position to the right!

Speed Preselector 4 Used for smooth selection of speed from „0“ to max.

Vibration ON/OFF Switch 5 Press the button to switch ON the vibration, press again the button to switch OFF the vibration.

CRAB 6, 7 Mode Switch Use switch 6 right and switch 7 left to adjust CRAB (widened trace).

RAMP 8 Switch It is used to switch ON slow running down and slow starting to move of the Machine at Machine reversing.

Interval Sprinkling Control 9 Turn from left to right to continuously control the sprinkling cycle of runners on the moving Machine depending on a distance travelled. The Cycle Control is operable when the Sprinkling Pump Switch on Panel 17 is ON. Sprinkling Pushbutton 10 Press sprinkling button and while kept pressed the runners will be sprinkled even with the Machine being stationary.

TOTAL STOP Pushbutton 11 Press down the STOP button the Roller and the engine will stop. Following the stop the Roller is braked.

NOTE: With the emergency brake STOP button pressed the engine will be unable to start!

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Operating instructions Amplitude Selection 12 To select low and high amplitude (low, high vibration)

Vibration ON 13 It is used to switch ON vibration of front or rear runner, or of both of them.

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43

2.7.

Controls & Control Apparatuses

CLUSTER LEFT 14

FUEL CONTENTS GAUGE - Red LED starts flashing when emptied to minimum.

MOTOHOUR COUNTER

BRAKE – signals braked Roller

SEAT SWITCH – lights when driver gets up from seat.

HYDRAULIC OIL FILTER – signals when fouled and replacement required.

BATTERY CHARGING – signals battery recharging. Lights when key 1 is turned ON. It must go off when engine is started.

AIR FILTER – signals it is fouled and needs replacement.

ENGINE OIL PRESSURE – not wired.

ENGINE OVERHEATED – not wired.

DIRECTION INDICATORS – signals indicators switched ON.

44

NEUTRAL – signals Travel Control in locked positions NEUTRAL.

HYDRAULIC OIL TEMP - signals max. temp admissible.

VIBRATION – lights when vibration switch 5 on Travel Control is ON.

HYDRAULIC OIL LEVEL – not wired.

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Operating instructions CLUSTER RIGHT 15 LEVEL INSIDE SPRINKLING TANKS. Red LED starts flashing when emptied to minimum.

COOLING LIQUID LEVEL – signals low level.

AIR CONDITIONER - signals Air Conditioner is ON.

CRAB - signals position of front runner for widened trace.

RAMP - signals slow running down and slow acceleration.

ASC - signals differential lock engaged (with split runners only).

WATER IN FUEL - signals water of separator of fuel filter and filtering. As per engine specification.

ENGINE PREHEATER - signals engine warming up before cold start. As per engine specification.

SPREADER - signals spreader function (optional).

ANTISTALL - signals function is ON (engine relief – automat. change of hydr. transmission).

SPRINKLING PUMP - signals pump run.

CONSTANT SPEED - signals adjusted constant speed on slope.

ALARM LIGHTS - signals alarm lights are ON.

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45

2.7.

Controls & Control Apparatuses ENGINE DIAGNOSTICS 16 – Use the connector to connect ECM (Electronic Control Module) and diagnostics trouble.

Note ECM processes engine function data and controls the engine. Sensors pick up information on engine function and malfunctions and transfer it to ECM. The control module analyses input and returns commands for the engine to function properly. Malfunctions and other data is identified and stored in ECM memory.

This data will be transferred after connecting a service device (notebook) to connector 16.

SWITCH PANEL 17

Engine Max. RMP

Vibration MAN/AUT – In MAN position the vibration can be turned ON even with stationary Roller.

In AUT position the vibration is automatically switched ON/OFF at low speed.

Constant Speed/ Antistall – alternative option between constant speed e.g. during reversing on slope or antistall.

Sprinkling Pump – switch over to enable one of two pumps that sprinkle both of the runners.

Spreader – Optional.

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Operating instructions

Engine diagnostics switch 17C

Troubleshooting switch 17D

In case of a malfunction of the engine, clutch the diagnostics switch to identify the defect on the basis of flashing code on signal lamp (A).

The switch is in the middle position.

Note Signal lamp (A) or (B) will go on in case of an engine malfunction, depending on severity of the defect. After activating switch (C), the will start flashing the code of the first defect see chapter 2.8.7.

If both pilot lamps indicating defects (yellow – B and red – A) go on after pressing the switch when the ignition box is on that means no defects have been identified by engine ECM.

AV 130 X

Turn it continuously any direction (+ forward or - backward) to find defects according to flashing codes of signal lamps A or B. In the event that the engine maximum speed switch is switched off, it is possible to select, using the switch 17D, an idle engine speed within the range of 650 to 1200 RPM by repeated switching in the switch 17D. By switching in the upper half of the switch 17D, the idle engine speed is reduced. By switching in the lower half of the switch 17, the idle engine speed is increased. The selected speed is stored into the memory of the engine computer and it is set to the last pre-selected value with a new start. Within the factory setting, the idle engine speed is set to 900 RPM and the machine parameters are adjusted at this setting.

47

2.7.

Controls & Control Apparatuses

COMBINED SWITCHOVER 18 – direction indicators, fender lights, dimmed lights, distance/dimmed lights switchove, light alarm, horn.

HEADLIGHT SWITCHES 19

Rear Lights

Lighting for runner – lights located on the roof

Alarm Lights

Beacon

LEDs 20

Dimmed/Distance Lights

Stop engine - signal lamp (A) – Stop the engine as soon as possible if this red lamp goes on.

Engine warning - signal lamp (B) – This yellow lamp indicates a defect - the engine must be checked.

Engine heating (E)

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Operating instructions Fuses - following Cover removal:

From the Left: F1 - 20 A

Front, Rear Lights

F2 - 10 A

Dome Lights, Light Switches

F3 - 10 (20)A Direction Indicators, Horn, Beacon, Additional Lights, Assembly socket F4 - 5 A

Clusters, Engine control indicators

F5 - 10 A

Travel Electronics, Engine STOP Magnet, Backing Horn

F6 - 15 A

Sprinkling

F7 - 7,5 A

Vibration, CRAB (Trimmer)

F8 - 1 A

Diagnostic socket

Connector - to check and adjust Control Unit parameters

Inspection Lamp Socket - 12 V

Fuses - behind accumulator disconnector door F9 - 7,5 A

radio

F10 - 30A

engine power supply

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49

2.7.

Controls & Control Apparatuses

Fuses - after lifting off the panel

From the Left: F11 - 15 A

Wipers + Window Washers

F12 - 15 A

Fans

F13 - 5 A

Fan Control

F14 - 10 A

Air Conditioner

Location of controls and cabin accessories

Window Washer Switch 1

4

6

3

2

1

Rear Wiper Switch 2

6 5 6

6 Front Wiper Switch 3

Fan Switch 4

7

Cabin Light 5 Ventilation Nozzles 6 - to control direction and intensity of warm and cold air circulation.

Heater Control 7

50

AV 130 X

Operating instructions Driver’s Seat incl. safety switch – refer to chapter DRIVE for details Seat Adjustment: 1

Seat position

2

Arm rest position and folding

3

Seat rotation

4

Seat traverse

5

Seat cushion rigidity per driver’s weight indicator

6

Seat height adjustment through grasping the seat and slowly lifting to adjust seat height to another higher position where it becomes locked (click sound). When lifted to its highest position the seat will descend back to its lowest position.

3

2

6 1

4

5

! WARNING !

Adjust seat BEFORE driving!

Driver MUST be fastened when driving!

Operation Manual stowage box

Steering Wheel Adjustment 21 Releasing the lever.

When released the lever can be locked in any position.

Turning the workplace 22 - depress the pedal to turn the workplace to each side. With pedal released it becomes locked in one of 4 positions.

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51

2.7.

Controls & Control Apparatuses

Window Washer Tank Refill with clean soft water – best if distilled – incl. purifying and degreasing agent.

! WARNING !

Before winter season, please fill the tank with antifreezing agent or drain it!

Cabin Ventilation Air Filter Contains replaceable element where dirt from intake air is trapped.

Plug for beacon

52

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2.8.

Machine Control

Operating instructions

2.8.1. Engine Start Start up the engine from the driver control stand only!

Before starting the engine turn ON the horn for warning purposes and confirm nobody is in danger due to the engine started!

Before starting up the engine, check levels of oil in the engine and hydraulic tank, cooling liquid in the cooling circuit and fuel in the fuel tank every day. Check of tightening of some machine parts, their wear and presence.

•

Switch ON the battery disconnector.

•

Check the neutral position of the travel control - the neutral indicator will light (the engine cannot be started if another position is geared - the procedure would be interlocked).

•

Check whether the emergency brake STOP button 11 is not pressed.

•

After turning the key on to the position I, the indicator lights of both combined instruments (with the exception of engine lubrication indicator light and cooling liquid temperature indicator light which are off) light up and go out after a short while. The indicator lights of charging, neutral position, brake, and WTS – engine heating will remain lighted up.

•

Wait until the WTS indicator lamp (E) goes out.

•

Switch over the switch 2 to the position MIN. (idle sped) and start up the engine (hold the key in the position “ll” only until the engine is started up).

•

Start for up to 30 seconds. If the engine does not start, wait for a 2 minutes and start again. If the engine does not start up after 2 tries, search for a problem.

•

After starting up, check correct engine operation by indicators.

•

Let the engine run at idle speed of 900 rpm after starting up. Check speed specified on the display.

NOTE: When not succeeding with the start, turn the key back to position „0“. Unless engine starts even after 3 trials – check the fuel system. When starting, please watch exhaust gas color - absence of blue or white fume indicates the fuel supply is insufficient.

If not started within 5 seconds of turning the key on, an audible alarm is activated. If not started within another 2 seconds, the key must be turned back to the “O” position before new starting.

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If upon the starting the following indicator lamps light up: charging, lubricating, engine overheating, hydraulic oil overheating, air filter, hydraulic system, and cooling liquid level, and they do not go out within 5 seconds, an audible alarm is activated and the engine stops after two minutes.

The engine will still be running if the indicators lamps of the air filter and the hydraulic system are on signaling that the replacement is necessary.

53

2.8.

Machine Control

! WARNING !

HOW TO START VIA STARTING CABLES FROM ANOTHER MACHINE

Starting becomes interlocked: -

when TOTAL STOP button is pressed

! WARNING !

-

when both Travel Controls is not in locked NEUTRAL position.

Starting voltage of boost starter power supply shall be of 12 V.

-

If the engine speed switch is not in the position MIN.

Follow unconditionally the undermentioned sequence of operations!

-

If the operator is not siting on the seat.

Do NOT start for over 30 sec. Repeat starting only after 2 minutes.

Following the start the battery charging LED must go off.

When started up, please let the engine run idle at increased idling of 1500 RPM for a period of 3÷5 min.

Do NOT let the engine run idle for more than 10 minutes – longer idling will cause fouling of injectors, sticking of piston rings, seizure of valves!

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

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

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

4. Connect second end of cable (–) pole to such section of the started Machine which is fix-connected with the engine (or with the engine block).

Unless liquid temperature reaches min.

60 °C the engine will not be sufficiently lubricated – do not load the engine with full capacity!

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Operating instructions 2.8.2. Drive Use acoustic alarm to inform about the Machine starting to move, and wait long enough so any persons present within Machine vicinity (space underneath the Machine) can leave the area in time!

Before starting to move, please confirm the space in front as well as behind the Machine is free and that no persons or obstructions are present within this area!

! WARNING !

Before starting to move the driver must sit on the seat otherwise the Machine will not move! If driver gets up from the seat in course of the Roller drive, then the Roller will stop and get braked after a while.

•

Adjust engine max. rpm via Control 2, or press „MAX RPM” (optional). Select vibration of runner 13 (front rear - both) and choose amplitude 12. Select vibration mode MAN or AUT. Start moving the Roller via Travel Control 3 forward or backward up to the stop – brake LED and neutral LED will go off. Use selector 4 to adjust the speed. Use switch 5 to turn ON vibration LED will light.

NOTE: When AUT function is ON the Roller will start vibrating after having started to move at given speed. If you require to vibrate a bit on the spot, please switch to MAN. Keep the travel controller pulled up; upon the release into the locked “Neutral” position, the vibration will turn off.

! WARNING !

If, when the engine is running, the following indicator lamps light up: charging, lubricating, hydraulic oil overheating, air filter, hydraulic system, and low cooling liquid level, and they do not go out within 5 sec., an audible alarm is activated and the engine stops after two minutes. The engine will still be running only if the indicators lamps of the air filter and the hydraulic system are on signaling that the replacement is necessary.

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55

2.8.

•

Machine Control

Constant speed Use switch A on panel 17 to adjust Constant speed, in this way you will maintain set speed when ascending or descending (e.g. when working on slope).

•

ANTISTALL Use switch 8 to turn OFF the RAMP if switched ON. Turn ON B switch on panel 17. After overcoming an obstruction switch it OFF!

! WARNING !

Use ANTISTALL function during engine max. rpm only!

NOTE: Use Antistall in case of emergency when during enormous load the engine rpm drops (engine is choking), e.g. when moving up the low-loading trailer, etc.

•

CRAB Press right button 6 on the Travel Control to tilt the front runner (front frame with runner in steering joint) to the right by 161 mm. Press left button 7 to tilt the runner to the left.

NOTE: While in CRAB mode the Roller is able to be turned.

When Roller is fitted with trimmer, then button 6 functions as – downward trimmer, button 7 – upward trimmer.

Trimmer control is wired in the Travel Control on such side of the seat which corresponds to installation of trimmer on the Machine.

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Operating instructions •

RAMP Use the switch to adjust RAMP (slow running down and accelerating).

NOTE: Forming of waves across compacted surface during reversing will be prevented.

! WARNING !

With the RAMP switch ON the running down will be longer when stopping or reversing of the Machine! To stop the Roller instantly you must swiftly shift the Travel Control via NEUTRAL to its opposite position – the displacement must take less than 1 second – the Roller will stop at once. RAMP function will turn OFF. The function will be enabled again when Travel Control returns to “N” and RAMP button is pressed.

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2.8.

Machine Control

2.8.3. Emergency Stop ! WARNING !

Use in case of failure when the Machine is impossible to stop via driving brake or parking brake control or switching OFF the engine with key.

•

Press TOTAL STOP button – the Machine will stop (brake) and the engine will turn OFF.

•

Turn the button in arrow direction to brake off.

! WARNING !

Before starting the engine make sure the Travel Control is in Neutral, and emergency brake button is released.

Do NOT apply emergency brake to stop the Machine or switch OFF the engine when in normal operation.

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Operating instructions 2.8.4. Sprinkling •

To turn ON, please use switch on panel 17 for both of the runners. Use potentiometer 9 to adjust cycling interval.

•

With button 10 pressed the sprinkling is enabled on stationary Roller.

! WARNING !

Sprinkling switch on panel 17 enables one of the two pumps. Alter regularly the pump operation every 100 motohours to ensure proper function and uniform wear of both of the pumps.

2.8.5. Machine Parking, Shutdown •

Park the Machine on flat and solid surface in place with no natural disaster hazard (landslide, potential flooding, etc.)

•

Clean the Machine to remove dirt (scrapers and runners).

•

Make overall inspection of the Machine and repair any defects hat have occurred during operation.

•

Switch OFF accumulator disconnector, lock the cabin and engine cover.

When Roller stops do NOT turn OFF the engine instantly from its full load, but let it run for another 3÷5 min. at idle rpm of 900. The engine together with turbocharger will cool down evenly.

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59

2.8.

Machine Control

2.8.6. How to tilt the bonnet •

Stop the Roller in straight direction, switch OFF the engine.

•

Remove lever for lifting.

•

Insert it into the pump. Release the valve by turning to the right up to the stop, to not apply force to tighten, lift the bonnet via pumping.

! WARNING !

While lifting, please check the bonnet for its possible collision with Machine’s front section – Roller must be positioned for straight direction of running.

•

When lifted, use valve to lock hydraulic cylinder against descending. Release before start.

•

Turn the valve to the left until you feel valve spring resistance, then the cabin starts descending. Confirm safe touchdown of the bonnet.

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Operating instructions 2.8.7. Troubleshooting according to flashing codes •

In case of engine fault, either stop engine red signal lamp (A) or engine warning yellow lamp (B) will light up.

•

Before troubleshooting stop the engine and turn the ignition key to ”I” position.

•

Press button (C) to activate error code. The lighting signal lamp will start flashing in the code corresponding to the defect and it repeat twice in the same sequence.

•

Press button (D) to move to the next error. You can search for error codes stored in ECM index using symbols of switch (D): upper symbol forward or bottom symbol backward.

Example of flashing error code

NOTE: If only one defect is identified, its error code will be signaled repeatedly even if you press switch (D) in either direction.

After the signal lamp (A) goes on, stop operation and engine while keeping safety at work!

Do not start the engine before the defect has been repaired!

! WARNING !

If signal lamp (B) lights up, repair the defect as soon as possible!

Flashing code consists of three digits.

Example: code 123 signal lamp Yellow lamp (B) will flash, red lamp (A) will flash the code after 1-2 sec.

Number 1: red will flash once, then pauses for 1-2 sec.

Number 2: red will flash twice, then pauses for 1-2 sec.

Number 3: red will flash thrice.

When the number has finished flashing in red, a yellow lamp will appear again. The three – digit code will repeat in the same sequence. Press button (D) to move to the next error.

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2.9.

•

How to transport the Roller

The Roller may travel along its own axle when moving between workplaces outside highways.

Observe safety precautions specified for a workplace when being shifted (displaced).

The rigging points are front and rear mounting lugs, front holes and slings in side pieces of Runner frame.

No persons shall be found on the Machine, driver control stand or carrier’s loading area during transportation of the Machine.

! WARNING !

Basic version of the Machine (low-end machine) is not fitted for transportation via a highway along its own axle, and this transport is forbidden.

•

Roller will be transported via highway on a carrier of corresponding load capacity.

When moving onto a carrier we recommend to switch ON the ANTISTALL function.

The transportation carrier shall be braked and mechanically locked with wedges 2 against undesired movement when loading and unloading.

An employee that guides the Machine shall communicate with driver via specified intercommunication signals, REFER to CHAPTER 2.2.6., he/ she must stay constantly on one spot out of reach of the Machine and off the carrier.

He/she must be within driver’s field of view (in visual contact) over the entire period of loading and unloading the Machine.

When loading on to a carrier and unloading from it all the persons aside from Machine driver shall remove as far as not to be hit by any falling of the Machine.

During transportation the Machine shall be fastened to the carrier via a tie-off 1 in rigging points!

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Operating instructions 2.9.1. Loading the Roller •

Roller is fitted with mounting lugs to load it with crane.

•

Use pin 1 and safety pin (lock) 2 to secure the joint before loading.

1

2

Do NOT step under the hanging load!

Observe provisions in force when loading and unloading.

Use adequate, intact rigging of sufficient load capacity.

Use proper crane of sufficient load capacity.

When slinging, use only those mounting lugs on the Machine that are designed for this purpose.

Slinging may only be carried out by trained slinger.

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2.10. Special Conditions for the Machine Use 2.10.1. Machine Towing Mounting lugs are fitted in the frame to tow the Roller.

! WARNING !

Sunk (blocked) Roller can be recovered for a short distance when engine is running, and the drive and steering are operable. Driver on towed Roller must drive the Roller in towed direction.

Unless engine is functional or if there is a defect within hydraulic system (failed pump of hydromotor), then the Roller has to be braked off and hydraulic circuit short-circuited. No person may stay on the towed Machine.

Following the release of brake and short-circuiting of hydraulic circuit for Travel all the brakes will be disabled!

Secure the Roller against starting to move before you release the brake.

How to release the brake: •

Open the bonnet, lock in lifted position, refer to the Section called Bonnet Lifting. Turn the valve in LH direction up to its stop.

•

Disconnect hose 1 in its snap joint connector 2 and let it hang loosely. Remove the hose 3 from its clamp, and connect it into the snap joint connector 2.

2 3

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1

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Operating instructions •

In the engine compartment,

you must use an appropriate tool to press down the buttons of both travel pumps in order to short-circuit the hydraulic loop.

•

Turn valve 1 in RH direction down to its stop, connect the battery disconnector 2. Now do the pumping to brake off the Roller – after moving the lever for about 20 times – please, check on your dashboard for the brake release.

2

1

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2.10. Special Conditions for the Machine Use •

Switch the key in the ignition box to position I and confirm the brake indicator lamp went off. Now the Roller has been braked off and made ready for towing.

! WARNING !

When towing a pressure drop in the brakes may occur due to any leakage.

Check that brakes are not heated when towing. If LED lights up you must finally pump the brakes.

When towing is completed put the Machine into its original condition. Before this you must secure the Roller against starting to move.

•

Put the hoses to their original condition. Unlock the bonnet lifting hydraulic cylinders, and drop the bonnet.

Those pushbuttons of the pumps’ short circuiting loop will return to their initial position once the engine is started.

Use intact hauling ropes or towing bars of sufficient load capacity 1,5 higher than the weight of towed Machine.

NEVER use chain for towing purposes.

When towing down the slope it will be necessary to connect another towing machine to the rear section of the broken Machine. In this way it will be possible to avoid uncontrolled motion of broken Machine.

Minimal displacement from straight angle of towing must be maintained. Maximal deflection is possible at an angle up to 30°. It is necessary to keep continuous motion when towing. Do NOT exceed towing speed over 2 km/hour (1.2 mph). Do NOT tow at distance over 300 m (0.19 mi).

Towing machine should correspond with its size to the broken machine. It must have sufficient pulling power (capacity), weight and brake effect.

66

Do NOT start the engine when towing the Machine.

NOTE These are general requirements for safe towing of damaged Machine under normal conditions. All the different situations that may occur while towing shall be consulted with dealer.

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Operating instructions 2.10.2. Vibrations on compacted and hard materials With the increasing extent of compaction of background material when rolling (traveling) with vibration a so called vibro-stroke may occur.

The same applies to a drive with vibration on hard materials. This condition will show in increased transfer of vibrations to the Machine frame and to driver control stand. It may partially be removed through increasing the travel speed or changing Machine vibration parameters (apply lower amplitude).

2.10.4. Work at higher altitudes The Machine can be operated at up to 3000 m (10,000 ft) altitude. Engine power will drop with the increased altitude. Such drop is due to a reduced atmospheric pressure and lowered specific mass of intake air.

2.10.5. Work at very dusty environment Cut short the cycles of cleaning the engine cooler, hydraulics, cabin ventilation filter.

NOTE: When making vibrations on a different background material the equivalent figures for vibration acceleration will differ from those declared in “Specification Manual”.

! WARNING !

When it is required to work with the Machine under conditions where it can be that operators are exposed to vibrations to a greater degree, then Machine User will be liable to adjust working practices so as to avoid injury to driver’s health.

2.10.3. Work at higher temperatures and moisture Engine power will decrease with increasing air temperature or moisture. Since both of the factors that lower the engine capacity are mutually independent, it is possible to describe their impact as follows: •

every 10 °C (18 °F) of increased temp means decline of power by up to 4 % (at constant humidity)

•

every 10 % of increased relative humidity means power decline by up to 2 % (at constant temp).

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Notes:

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Operating instructions

Notes:

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3. MAINTENANCE MANUAL AV 130 X (Cummins tier 3)

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3.1.

Safety Standards at Lubrication and Maintenance

3.1.1.

Safety during maintenance

3.1.2.

Lubrication, maintenance and adjustment process: •

use qualified personnel.

•

according to safety instructions in the Operating manual for the vibration roller.

•

according to intervals in the lubrication table according to working hours.

•

on the Machine located on flat solid surface, secured against self-motion (with scotch blocks) and this always with the engine OFF, key removed from ignition, and with the wiring disconnected.

•

with the machine parts cooled off.

•

after cleaning the machine , the lubricating and maintenance points, and spots to be repaired.

•

with proper undamaged tools.

•

by replacing parts with new original ones. The manufacturer cannot be responsible for damages caused by using different units or parts.

•

under proper illumination of the machine when working at reduced visibility or at night

•

in case the work involves removing covers and safety cartridges, reassemble them after completing the work

•

retighten bolts with applicable torque and check tightness of the joints.

•

pay attention not to get burnt after heating up fluids use recommended fills.

•

Fire safety during changing contents

From fire safety point of view, inflammable liquids used in the machine are classified into following classes: II. class of fire danger - Diesel IV. class of fire danger - mineral oils, lubrication greases

•

The location of oil change operation must not conflict with places subject to explosion or fire hazard.

•

It must be marked by tables and signs prohibiting smoking and open flame.

•

The manipulation area must be of such design and dimensions so that it can contain the amount of inflammable liquid equal to the content of the largest tank or transport package.

•

The site must be equipped with portable fire extinguishers.

•

Metal barrels, canisters or tin cans should be used for handling oils or Diesel fuel.

•

Transport containers must be duly closed while being stored.

•

The containers must have one opening, they must always be stored with the opening upside and secured against leaks.

•

The containers must be marked by permanent signs showing the content and the class of fire danger.

Operations performed while the engine is running (adjusting) must be performed with another person present. This person must have immediate access to the emergency stop and must be in permanent communication contact with the adjusting person so that the engine can be stopped immediately, if necessary.

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3.1.

Safety Standards at Lubrication and Maintenance

3.1.3.

Environmental and health regulations

3.1.3.2. Environmental principles Contents of specific machine systems and some of its parts are wastes dangerous to the environment after when discarded (disassembly, changing contents).

During operation and maintenance of the machines the user must follow general principles of health and environment protection, and laws, notices and regulations relating to this subject, applicable in the territory.

3.1.3.1. Health regulations •

•

•

Oil products, contents of cooling systems and batteries, and paints including thinners are materials injurious to health. The workers coming into contact with these products when operating and maintaining the machine must follow general principles of health protection and safety and health instructions by manufacturers of these products.

Especially the following items belong to this category of waste products: -

organic and synthetic grease, oils and fuel

-

hydraulic brake fluids

-

coolants

-

battery contents and batteries as such

We especially draw attention to:

-

contents of air-conditioning systems

-

eyes and skin protection when working with batteries

-

cleaning and preservatives

-

fill tires

-

skin protection when working with oil products, painting compounds and coolants

-

all removed filters and filter cartridges

-

proper washing of hands after work and before meals. Treat your hands with proper skin cream

-

-

follow instructions in the operator’s manual when working with cooling systems.

all used and discarded hydraulic and fuel hoses, rubberized metal pieces, and other machine elements contaminated by the above-mentioned products.

Store oil products, coolants and battery acids, painting compounds including organic thinners and cleaning and preservation agents always in their original, properly marked containers. Avoid storing these materials in unmarked bottles or other containers because of risk of possible substitutions. Possible substitution of food and beverages is particularly dangerous.

•

In case of accidental staining skin, mucous membranes, eyes, or in case of inhaling fumes, immediately apply first aid . In case of accidental ingestion of these products seek out medical help immediately.

•

Always use proper type and design of ear-protectors when working with the machine without cabin or with open windows.

74

•

After discarding, these materials must be treated in compliance with applicable national regulations for the protection of specific segments of the environment, and in compliance with health protection regulations.

AV 130 X

3.2.

Specification of fluids

3.2.1.

Engine oil

Maintenance manual

Engine oil is specified by its performance and viscosity classifications.

Performance classification according to API (AMERICAN PETROLEUM INSTITUTE) CCMC (COMMITE of COMMON MARKET AUTOMOBILE CONSTRUCTORS).

ACEA (ASSOTIATION DES CONSTRUCTEURS EUROPÉENS DE AUTOMOBILE)

Viscosity classification To determine SAE (Society of Automotive Engineers) viscosity class, the ambient temperature and type of operation in place of usage of the machine are decisive.

Permitted oil according to API: CH-4/SJ; CI-4 CCMC: DHD1 ACEA: E-5 All season - SAE 15W-40 (e.g. Valvoline, Premium Blue,).

NOTE Exceeding of the lower temperature limit does not damage the engine, it may only cause starting problems.

It is suitable to use general-purpose multi-grade oil in order that oil need not be exchanged because of ambient temperature changes.

! WARNING !

Exceeding the upper temperature limit must not last for long, taking into consideration reduced lubricating properties of oil.

When using oil according to API CF-4/ SH, the exchange interval should be cut to one half, i.e. 125 hours or 3 months.

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3.2.

Specification of fluids

3.2.2.

Fuel

Diesel is used as fuel:

3.2.3.

Coolant

Use coolant consisting of 50 % water 50% ethyl glycol of frost-resistant agent (for temperatures vicinity by –36 ° C (-33 °F) use the coolant even in zones where temperatures do not fall below 0 °C (32 °F). The coolant is not only protecting the cooling system against frost but increases also the boiling point. Inhibitors contained in the antifreeze protect parts of the engine cooling system and extend their life. Propylene antifreeze may also be used as coolants.

·

CEN EN 590 or DIN/EN 590 (draft)

·

DIN 51 601 (February, 1986)

·

BS 2869 (1988): A1 and A2

·

ASTM D 975-88: 2-D

·

VV-F-800C: DF-A, DF-1 and DF-2

·

NATO code F-54 and F-75

Use modified demineralized or destilled water for this mixture.

! WARNING !

The following antifreeze may be used:

Therefore use winter Diesel fuel at outdoor temperatures below 0 °C (32 °F).

Special Diesel fuel with additives intended for very low temperatures must be used at outdoor temperatures below 15 °C (5 °F) (”super Diesel”).

It is strictly required to use above specified brands of diesel fuel only. Usage of different fuel (like Bio – fuels,or Light heating oils of any kind) is strictly PROHIBITED.

SUNOCO - PERMANENT ANTIFREEZE SHELL - Glycoshell AF 511 S TEXACO - HAVOLINE Antifreeze Coolant/AFC CASTROL - ANTIFREEZE MB

! WARNING !

Do not use more than 50% of antifreeze in the coolant, unless absolutely necessary.

Never use a ratio higher than 68%.

Antifreeze is manufactured in different bases.

Their mutual mixing is not recommended. Anti-corrosive properties may be lost when mixing different types of coolants.

Nitric amines dangerous to health are formed when mixing the nitride-base antifreeze and the amine-base agent.

Check the ratio of antifreeze in the coolant before wintertime using a refract meter (hydrometer).

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Maintenance manual Synthetic hydraulic oil

3.2.4.

Hydraulic oil

For use in the hydraulic system of the machine, only highquality hydraulic oils of output class according to ISO 6743/HV (equal to DIN 51524 part 3 HVLP; CETOP RP 91 H).

Hydraulic system can be filled with synthetic oil, such as PANOLIN - HLP Synth. 15/22/32/68 that is completely degradable by microorganisms found in water and soil in case of leak.

! WARNING !

Manufactured by

Sort of oil

Output class on ISO 6743/HV

HV (HVLP)

Viscosity class on ISO 6743/4, DIN 51519

VG 68

Viscosity class on CETOP RP 91H

HV 68

AGIP

AGIP ARNICA 68

AVIA

AVILUB HVI 68

BP

BARTRAN HV 68

CASTROL

HYSPIN AWH 68

CHEVRON

EP 68 HV

ELF

HYDRELF 68

ESSO

UNIVIS N 68

FINA

HYDRAN HV 68

FUCHS

RENOLIN MR 68 HV

MOBIL

MOBIL DTE 16

ÖMV

HLP - M 68

SHELL

TELLUS T 68

TEXACO

RANDO OIL HD CZ 68

TOTAL

EQUIVIS ZS 68

Water content (condensation water) in oil must not exceed the limit of 0,1%.

Operating fluid must be checked by taking samples in regular intervals - see the chart.

When filling older machines with synthetic oil, the residual limit of mineral oils must not exceed 8% of the total fill.

When filling biologically degradable oils, mixing with up to 2% of the total tank content is allowed.

When changing over from mineral oil to synthetic or when mixing oils of different brands, always consult the procedure with the oil manufacturer or dealer!

Interval of taking samples

Common opera tion

Extreme conditions

1. check

500 h

250 h

2. check

1000 h

500 h

1000 h or once a year

500 h or once a year

subsequent checks

! WARNING !

At high ambient temperatures, when the oil temperature reaches continual 90 °C (194 °F), we recommend replacing the oil with one of kinetic viscosity 100 mm 2/s HV 100 (BP BARTRAN HV 100; ESSO UNIVIS N 100, etc.).

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3.2.

Specification of fluids

3.2.5.

Gearbox oil

3.2.6.

Use high quality oils complying with API GL-5 or EP or MILL-2105 C for lubricating the drum gearbox and axle (wheels) drive gearboxes.

Viscosity SAE 90 EP, SAE 85W-90 EP for outdoor temperature range -5 °C ÷ +35 °C (23 °F ÷ 95 °F).

Lubricating grease

Plastic grease containing lithium in compliance with NLGI-2 regulation (Mobilplex EP-1, Retinax A, Alvania, Grease No 3 etc.) must be used to grease the machine.

ISO 6743/9 CCEB 2 DIN 51 502 KP2K-30 (Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, Grease No 3 etc.).

Mineral oil

Lubricant type

CLP DIN 51517

3.2.7.

Kinematic viscosity [mm2/s] 40°C

220

110

Ambient temperature

-5 ÷ +35 °C

-15 ÷ +25 °C

Degol BG220

Degol BG100

BP - MACH

Energol GR-XP 220

Energol GR-XP 100

CASTROL

Alpha MW 220 SP 220

Alpha MW 100 SP 100

TOTAL

Car ter EP 220

Car ter EP 100

DEA

Falkon CPL 220

Falkon CPL 1500

ESO

Spar tan EP 220

Spar tan EP 100

FUCHS

Renolin CLP 220 Plus

Renolin CLP 100 Plus

MOBIL

Mobilgear 630 Mobilgear XMP 220

Mobilgear 627 Mobilgear XMP 100

AGIP

Agip Blasia 220

Agip Blasia 100

CHEVRON

Gear Compound EP 220

Gear Compound EP 100

SHELL

Shell Omala Oil 220

Shell Omala Oil 100

OPTIMOL

Ultra 220 Optigear BM 220

Ultra 100 Optigear BM 100

ARAL

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Windshield washer liquid

Water (at temperatures down to 0°C) and windshield washer agent are used as fills in the washer can.

! WARNING !

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

AV 130 X

3.3.

Fills

Maintenance manual

Fills of...

Type of fill

Quantity l (gal US)

Engine

Engine oil according to chapter 3.2.1.

11,6 (3,1)

Fuel tank

Diesel according to chapter 3.2.2.

210 (55,5)

Engine cooling system coolant

All year round - anti-freeze liquid according to chapter 3.2.3.

21 (5,5)

Hydrostatic system

Hydraulic oil according to chapter 3.2.4.

60 (15,8)

Brand

1,8 (0,47)

Pump driven gearbox Gearbox oil according to chapter 3.2.5.

2 x 3 (0,8)

Drum gearbox Vibrating drums

Engine oil according to chapter 3.2.1.

2 x 19 (5)

Joint bearings - joint and steering cylinder

Plastic grease according to chapter 3.2.6.

as required

Batter y

Distilled water

as required

Windshield washers

Water and antifreeze - ratio according to outdoor temperature o chapter 3.2.7.

2,75 (0,72)

Water tank

Water

1000 (264)

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3.4.

80

Lubrication and Maintenance Chart

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Maintenance manual

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3.5.

82

Lubrication Chart

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3.6.

Individual Operations of Maintenance

Maintenance manual

Ensure regular and repetitive lubrication and maintenance at intervals according to daily reading of the working hours counter.

Disassembled or loose bolts, plugs, threaded connections of hydraulics etc. should be tightened with torque according to tables in chapter 3.6.37., unless a different value is listed for the particular operation.

! WARNING !

Inspect the Machine is placed on flat, paved surface, and secured against self-motion (scotch blocks), and this ALWAYS with engine switched OFF, key removed from ignition, and wiring disconnected (unless otherwise required).

After the first 200 hours of working with a new machine (or after machine general overhaul), make the following operations:

3.6.23. The first oil exchange in drum gearbox and gearbox pumps drive

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83

3.6.

Individual Operations of Maintenance Every 20 Hours or Daily

3.6.1.

Checking the amount of oil in the engine

•

Wait approx. cca 5 min. until oil runs down to the engine sump.

•

Take out the oil dipstick, wipe it, insert fully back and take it out again to read out the oil level.

•

Keep the level within the range of gauge marks pressed in the dipstick. The lower mark L (Low) marks the lowest possible oil level, the upper mark H (High) the highest one.

•

Refill oil after removing the filler plug through the oil filler. Wait approx. 1 min until the level is stable and check again.

! WARNING !

The amount of oil between the dipstick marks is 0.95 litre (1.0 US Quart).

•

Refill the identical type of oil. Use oils according to chapter 3.2.1.

•

Check the engine for leakage, repair possible causes.

•

Check the engine for damaged and missing parts and for changes in appearance.

! WARNING !

Do not use the engine unless the oil level in the engine is correct.

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AV 130 X

Maintenance manual 3.6.2.

Checking cooling liquid of the engine

•

Let cooling liquid cool down to less than 50 °C (120 °F).

•

Check visually the level.

•

Refill coolant through the filler (1).

1

! WARNING !

The level must not fall below the level indicator eyesight.

Refill only cooling liquids containing the frost-resistant agents on the identical basis, according to chapter 3.2.3.

Do not add additives eliminating untightness of the cooling system to the engine cooling liquid!

Do not refill cold cooling liquid into hot engine. Engine castings might get damaged.

In case of larger losses, find the location of cooling system leaks and repair the cause.

Dismantle the filling plug only when the temperature of engine cooling liquid falls to less than 50 °C (120 °F). If you open it at higher temperatures, you risk scalding by steam or by cooling liquid due to the inner overpressure.

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3.6.

Individual Operations of Maintenance

3.6.3.

Hydraulic tank oil level checking

•

Check the level.

•

Fill up oil through the screen upon unscrewing the plug (1) or by means of the filling equipment through the filling quick-coupling device (2).

1

2

! WARNING !

Keep the level within the range of the upper and lower edge of both the oil level indicators.

Oil level must always be visible in the lower oil level indicator!

Fill up with oil as specified in Chapter 3.2.4.

In case of large oil leaks, find out the cause of leakage of hydraulic system (leakage of screwed connections of hoses, hydraulic generators, hydraulic motors, etc.) and remedy the defects.

The engine shutdown in the case of oil leakage protects the hydraulic system of the machine and ensures thus the ecofriendly operation of the machine as not the whole content of the hydraulic tank but only a very small quantity escape.

The engine can be started up only after the oil filling up.

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Maintenance manual 3.6.4.

•

Crankcase breather tube

Inspect the breather tube for sludge, debris, or ice the tube.

NOTE •

Inspect the tube more frequently in icy conditions.

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87

3.6.

Individual Operations of Maintenance

3.6.5.

Checking the condition of the ventilator and belt

•

Check the ventilator visually. In case of any damage (e.g. missing parts of the material, cracks, changes in shape etc.) replace the ventilator.

•

Lift the belt-tensioning pulley using the lever and remove the belt.

•

Check visually the belt, search for its damage. Cracks perpendicular to the belt are not defects.

In case any lengthwise cracks appear on the belt or its edges are frayed or its parts torn out, it is necessary to exchange the belt.

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Maintenance manual 3.6.6.

•

Checking the vacuum valve of the air cleaner

Clean the exit slit and remove the trapped dust by pushing.

NOTE •

Collected dust is stored in the dust valve and automatically emptied during the machine operation.

•

If the machine is equipped with air pre-filter (optional), clean it daily.

! WARNING !

Do not operate the machine if the dust valve is damaged.

When air filter vacuum valve is damaged, please replace it with a new one of identical type!

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3.6.

Individual Operations of Maintenance

3.6.7.

Fuel level checking

•

Check the fuel level on the left combined instrument signaled by light-emitting diodes (LED) and fuel up in case of not sufficient level.

•

The minimum fuel level is signaled by interrupted flashing of the red LED.

•

Clean the fuel tank cap (1) and filler neck (2).

1

2

•

Unlock the fuel tank cap lock, turn the cap, and remove it.

•

Fill the tank up to the lower margin of the filler neck through the screen.

NOTE The fuel tank volume amounts to 210 l (55.5 gal US). The fuel tank volume is sufficient for approximately 27 operating hours of machine.

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

! WARNING !

Do not run the tank dry.

Use only clean recommended fuel as specified in Chapter 3.2.2.

Do not fuel up when the engine is running.

Do not fuel up in closed rooms.

90

Do not pour fuel into other containers.

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Maintenance manual 3.6.8.

Watering tank filling

•

Check the water level on the right combined instrument signaled by light-emitting diodes (LED) and fill up water in case of not sufficient level.

•

The minimum quantity of water is signaled by the interrupted flashing of red LED.

•

Perform this before starting the engine – the machine must stand on a solid flat surface.

•

Open the tank cap (1) and fill up clean water through the screen (2).

1

2

! WARNING !

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

Follow the instructions as specified in Chapter 3.6.33.

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91

3.6.

Individual Operations of Maintenance

3.6.9.

Cleaning the water separator

•

Prepare a vessel for draining the settling.

•

Turn the separator valve clockwise by 4 rotations until it shifts down by approx. 25 mm (1”). Let fuel drain until clean fuel starts to drain.

•

Then push the valve up and screw it in.

1

! WARNING !

If more than 6 cl (2 ozs) of fuel has been, drained off, fuel up to the pre-filter using a manual pump 1.

Do not smoke nor use open fire when working.

Do not drain the separator under running engine.

Catch the drained fuel with sediments to a suitable container.

92

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Maintenance manual 3.6.10. Warning and control devices checking •

Turn the ignition box key into I position:

•

The lighting function is checked automatically on the left and right combined instrument by the indicator lights lightening up.

•

Afterwards, all the indicator lights go out on the right combined instrument and the indicator lights on left combined instrument remain lighted up:

•

Travel controller zero position indicator light

•

Brake indicator light

•

Charging indicator light

•

Furthermore, test the function of the switches of lamps (19), the integrated control switch of lamps and horn (18).

! WARNING !

Upon turning on the front head-lamps, the intensity of light of the indicator lights is automatically reduced.

•

Start the engine:

•

The indicator lights on the left combined instrument must go out: -

Charging indicator light

! WARNING !

Should the engine not start within 10 seconds upon turning on the instruments (turning the ignition box key into I position), the engine defect is signaled.

•

Drive the machine away:

•

The indicator lights on the left combined instrument must go out.

-

Travel controller zero position indicator light

-

Brake indicator light

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93

3.6.

Individual Operations of Maintenance

•

TOTAL STOP function:

•

When the machine is at standstill, verify the function TOTAL STOP (11).

•

After pressing the button 11, the engine turns off.

•

Afterwards, the indicator lights on the left combined instrument remain lighted up: -

Travel controller zero position indicator light (if the travel controller is in zero position)

-

Brake indicator light

-

Charging indicator light

During the machine running, check the instruments and indicator lights.

Immediately remedy the signaled defects!

Advise the engine start by audible signal!

Before starting the engine ensure that nobody is endangered by the engine starting!

Before driving the machine away, give the audible signal and wait for a sufficient time so that the present persons could leave in time the vicinity of the machine (the area under machine)!

Ensure that the area in front of and behind the machine is free and no persons are present there!

94

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Maintenance manual Every 250 Hours or Once in 3 Months

3.6.11. Air intake cooler, intake piping •

Check the leakage of the intake piping of the engine,

air cooler, and turbo-blower.

•

Check for any damage of the rubber hose of the inlet piping leading from the filter, and for missing clamping clips.

! WARNING !

Do not work with the machine, if the rubber hoses or intake piping connections are damaged.

•

Check whether the oil cooler gills and the engine radiator gills are not clogged. In case of clogged gills clean them for instance by blowing the radiators through with pressure air (steam or warm water) according to chapter 3.6.32.

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95

3.6.

Individual Operations of Maintenance

3.6.12. Checking the cooling circuit of the engine •

Check tightness of the cooling circuit. Check the circuit for damaged hoses and for missing hose clips.

•

Check whether the oil cooler gills and the engine radiator gills are not clogged. In case of clogged gills clean them for instance by blowing the radiators through with pressure air (steam or warm water) according to chapter 3.6.32.

96

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Maintenance manual 3.6.13. Checking the engine belt •

Lift the belt-tensioning pulley using the lever and remove the belt.

•

Check visually the belt, search for its damage. Cracks perpendicular to the belt are not defects.

In case any lengthwise cracks appear on the belt or its edges are frayed or its parts torn out, it is necessary to exchange the belt.

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97

3.6.

Individual Operations of Maintenance

3.6.14. Checking battery •

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

•

Clean the surface of battery.

•

Check the condition of poles and terminals (1) and clean them. Slightly wipe terminals with grease.

•

Check the level of electrolyte after opening plugs of the battery cells (2) - the level of electrolyte in all cells should be 5 - 15 mm (0.2-0.6 in) above the plates, or to the lower edge of the gauge in the battery cells. Refill the cells whose electrolyte level is lower, than 5 mm (0.2 in) above the plates, with distilled water.

2 1

•

98

Measure electrolyte density in the individual cells using a refractometer or hydrometer.

AV 130 X

Maintenance manual •

Compare measured values with the chart.

Density in g/cm3

in °Be (Beume)

20 °C 68 °F

Tro pic

20 °C 68 °F

Tro pic

Pro perly charged

1,28

1,23

32°

27°

Half-Charged

1,2

1,12

24°

16°

Recharge

1,12

1,08

16°

11°

NOTE •

Check the level using a glass tube.

•

Should the machine not be used during winter period - for couple of weeks, dismantle the battery and store it away from frosts. Check battery and charge level before and during storage.

In case of an eye injured by electrolyte immediately wash the eye with flowing water for couple of minutes. Then seek medical advice.

In case of ingestion of electrolyte drink maximum possible amount of milk, water or mixture of magnesium oxide with water.

In case of staining your skin with electrolyte take off your clothes and shoes, wash injured spots with soap water or with solution of soda and water as soon as possible. Then seek medical advice.

Do not eat, drink and smoke during operation!

Wash your hands and face carefully with soap and water after finishing you work!

! WARNING !

Keep the battery dry and clean.

Close battery after checking.

Refill battery with distilled water only never with acid.

Refill distilled water immediately before working with the machine or before recharging the battery.

Recharge insufficiently charged battery.

Recharge battery dismantled from the machine.

Open the plugs before recharging.

Do not disconnect the battery under running engine.

Always follow the instructions of the manufacturer, when working with the battery.

Use protective gloves and eye protection equipment when working with the battery.

Wear suitable dress to protect your skin against staining with electrolyte.

AV 130 X

Do not test whether wires are alive by touching the frame of the machine.

Disconnect the battery to avoid short-circuit when repairing it or manipulating with wires and electric equipment in the circuit of electric system.

Disconnect the minus pole wire first when disconnecting the battery. Connect the plus pole wire first when connecting the battery.

In case of contact of both poles of the battery the short-circuit may cause explosion of the battery.

Do not turn battery upside down to avoid draining of electrolyte from venting of the plugs.

In case of spilling electrolyte wash such a place with water and neutralise with lime.

Dispose of old damaged battery.

99

3.6.

Individual Operations of Maintenance

3.6.15. Air filter vacuum switch function checking •

Stop the engine speed on the increased level of approximately 1500 1/min (RPM).

•

Dismount the engine intake cover.

•

For a short time, cover the intake hole of the air filter.

•

Upon covering, the indicator light of the air filter clogging must light up.

100

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Maintenance manual •

If it does not light up, check: Vacuum switch, contact and lead-in cable.

! WARNING !

Always perform the checking when cleaning the pre-filter of intake air!

Do not use thin paper for covering – avoid the intake hole clogging!

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101

3.6.

Individual Operations of Maintenance

3.6.16. Joint bearings, pins •

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

•

Remove the caps on the grease nipples.

•

Successively mount the grease nipple of pressure lubricator and continue greasing until the old grease starts to drain out.

•

Return the grease nipple caps.

Steering upper bearing 2x lower bearing 2x

bearing 4x

Steering hydraulic cylinders front pins 3x rear pins 3x

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Maintenance manual

Hydraulic cylinders of bonnet lifting upper pins 2x

lower pins 2x

Door hinges pins pins 8 x

! WARNING !

Use only recommended lubricating greases, see chapter 3.2.6.

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103

3.6.

Individual Operations of Maintenance

3.6.17. Checking oil in gearboxes

2

Drum gearbox •

Clean the area around the checking plug (1).

•

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

•

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

•

Clean the plugs and mount again.

•

Check tightness of the gearboxes.

•

Refill the identical type of oil - see chapter 3.2.5.

1

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

Gear box - pumps drive •

Check the oil level on the check gauge of the plug.

•

Unscrew the plug, wipe the gauge, and insert it back into the opening.

•

After removing, check the oil level on the gauge.

•

Measure the oil filling after its unscrewing.

•

If required, fill up oil to the upper gauge mark.

•

Fill up the same oil type, see Chapters 3.2.5. and 3.3.

! WARNING !

Keep the oil level on the upper mark!

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

104

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Maintenance manual 3.6.18. Watering filter and sprinkler screens •

Shut off the water feed by means of a valve.

•

Dismount the watering filter vessel (1), remove the screen (2), and clean it.

1

2

•

Dismount and clean the screens (3) of jet.

3

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105

3.6.

Individual Operations of Maintenance

Every 500 Hours or Once in 6 Month

3.6.19. Engine oil exchange •

Stop the engine.

•

Prepare a suitable container with the capacity of approximately 20 l.

•

Dismantle the drain plug and let oil drain.

•

Clean the area around the oil filter head. Dismantle the filter.

•

Clean the contact area of the filter sealing.

•

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

106

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Maintenance manual •

Wipe the sealing with oil.

•

Mount the filter and tighten firmly with hand.

•

Check the drain plug sealing replace it, if damaged.

•

Check the engine sump thread and clean the contact area of the sealing.

•

Mount the plug back. Tightening torque is 80 Nm (59 ft-lb).

•

Fill the engine through the filler.

•

Refill oil to the upper oil level mark (H). Oil charge is 11.6 l (3.1 gal US).

NOTE •

After refilling, start the engine for 2 - 3 min. Check tightness of drain plug and filter.

•

Stop the engine, wait for approx. 15 min. until oil runs down to the engine sump. Then check the level with oil dipstick.

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107

3.6.

Individual Operations of Maintenance

! WARNING !

Drain oil after stopping the operation, when it is warm. Alternatively, warm engine up until the temperature of cooling liquid reaches 60 °C (140 °F).

Beware of scalding when draining hot oil. Let oil cool down to less than 60 °C (140 °F).

Follow the fire safety measures!

Exchange oil after 6 months at the latest, if 500 hours of operation have not been reached by that time.

Exchange oil in the interval that comes first.

Collect drained oil; do not let it soak into the ground.

Use recommended filters - see the specifications manual or Spare parts catalogue.

Used oil and filters are environmentally dangerous waste - have them liquidated.

Use recommended oil - see chapter 3.2.1. and 3.3.

Do not tighten the filter too tight, the thread and sealing might get damaged.

108

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Maintenance manual 3.6.20. Engine fuel filter exchange •

Stop the engine.

•

Clean the head of the fuel filter 1 and pre-filter 2, dismount the filter.

2

1

•

Clean the contact area of the filter.

•

Fill the filter with clean fuel.

•

Wipe the sealing ring with oil.

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109

3.6.

•

Individual Operations of Maintenance

Mount the filter and tighten firmly with hand.

! WARNING !

Use original specified filters.

Do not tighten by force.

Do not smoke nor use open fire when working!

Collect leaking fuel.

Store used filters in a separate container and dispose of them.

110

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Maintenance manual 3.6.21. Checking cooling liquid •

Check the concentration of anti-freeze agent in cooling liquid using a refractometer.

! WARNING !

Check the cooling liquid always before winter season. In case the concentration measured is not sufficient for -36 °C (-33 °F), adjust it by adding frost-resistant agent into cooling liquid or exchange cooling liquid.

Add anti-freeze agent according to chapter 3.2.3.

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111

3.6.

Individual Operations of Maintenance Every 1000 Hours or Once a Year

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

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

•

Stop the engine!

•

Confirm the stop of tensioner arm does NOT contact bump stop of the bush. Replace the belt if it makes a contact. When the arm stops continue to contact bump stop of the bush, replace the tensioner.

•

Lift the belt tightening pulley using a lever with a square end of 10 mm (3/8 in) and remove the belt.

•

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

112

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Maintenance manual •

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

•

Check axial clearance of fan pulley. This clearance may not exceed 0,15 mm (0.006 in).

•

Reinstall the belt back.

In case any lengthwise cracks appear on the belt or its edges are frayed or its parts torn out, it is necessary to exchange the belt.

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113

3.6.

Individual Operations of Maintenance

3.6.23. Exchanging oil in gearboxes

1

Drum gearbox •

Clean the area around plugs.

•

Put appropriate vessel under the drain plug (3) cca 4 l.

•

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

•

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

•

Refill recommended oil through the filling plug (1).

•

Check oil level in the checking opening (2). The oil level must reach the lower edge of the opening or slightly flow out.

•

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

•

Fill up the same oil type, see Chapters 3.2.5.

2

3

! WARNING !

Perform the first oil exchange after reaching 200 operation hours.

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

Avoid leakage of oil to the soil.

Gear box – pump drive •

Clean the surroundings of the plugs.

•

Place a suitable vessel under the drain plug cca 3 l.

•

Unscrew the plug and let oil flow out.

•

Upon discharging, remount the drain plug.

114

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Maintenance manual •

Pour in the recommended oil through the filler plug.

•

Check the oil level on the check gauge of the plug. Do not screw the plug into the opening when measuring.

Avoid leakage of oil to the soil.

•

If required, fill up oil to the upper gauge mark.

•

Fill up the same oil type, see Chapters 3.2.5. and 3.3.

! WARNING !

Perform the first oil exchange after 200 engine hours.

Keep the oil level on the upper mark!

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115

3.6.

Individual Operations of Maintenance

3.6.24. Damping system checking drum and cabin •

Check the condition of rubber-metal components, bond between metal and rubber.

Damping system of drums, left and right side 2x 10.

Rubber-metal components of the driver’s working place 4x.

Rubber-metal components of the engine 3x.

116

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Maintenance manual Rubber-metal components of the cooler supports 6x.

Rubber-metal components of the battery carrier 4x.

! WARNING !

Replace the damaged parts.

Check the tightening of screws and nuts.

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117

3.6.

Individual Operations of Maintenance

3.6.25. Fuel tank cleaning •

Stop the engine and disconnect the machine electrical equipment.

•

Perform the cleaning at a time when there is a minimum amount of fuel in the tank – only the red LED of the minimum fuel level is flashing.

•

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

•

Dismount the cleaning cap.

•

Wash out the tank with clean fuel and remove impurities.

•

Remount the drain plug and cap – check the sealing.

•

Clean the screen in the filler neck.

NOTE Upon the tank running out of fuel, there will remain approximately 25 l [6.6 US gal] in the tank.

118

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Maintenance manual

Follow the fire fighting measures!

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

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

Comply with the sanitary principles.

Follow the environmental protection regulations!

Prevent oil leakage to the ground.

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119

3.6.

Individual Operations of Maintenance

3.6.26. Water tank cleaning •

Stop the engine and disconnect the machine electrical equipment.

•

Dismount the caps of the filler necks of the tank.

•

Open the drain holes of the tank.

•

Wash out the tank by water jet.

•

Clean the screens in the filler necks.

! WARNING !

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

Follow the instructions as specified in Chapter 3.6.33.

120

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Maintenance manual Every 2000 Hours or Every 2 Years

3.6.27. Vibrations system oil exchange •

Move the roller so that the plug (2) was at the lowest position and the inspection plug (1) is at the highest position, see the figure.

1

•

Place a suitable vessel ca. 20 l under the draining place (2).

2

•

Unscrew all the plugs and let oil flow out.

•

Move the roller so that the plugs are in the position see the figure.

•

Using the opening (2), fill recommended oil up to the edge of the inspection opening (1).

•

Mount the plugs (1) and (2).

•

Fill up the same oil type, see Chapters 3.2.1. and 3.3.

2

1 ! WARNING !

Change the oil when it is warm.

Let the drained oil cool down below 60 °C (140 °F).

Prevent oil leakage to the ground.

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121

3.6.

Individual Operations of Maintenance

3.6.28. How to replace hydraulic oil and filters •

Stop the engine, disconnect the wiring.

•

Unscrew drain plug and let oil pour down into the tank set up cca 65 I.

•

Dismantle the accumulator (1), accumulator holder (2) and hydraulic tank lid (3).

1

•

Inspect tank’s interior. When dirt is present at the bottom, please carry out thorough cleaning and flush the tank with new clean oil.

•

Dismantle the suction strainer (4) from the suction pipe. Wash the suction strainer and blow the strainer with pressure air from inside.

•

Check the condition of the suction strainer; replace the strainer in case of damaged filter part.

•

Mount back the tank lid – check the gasket.

•

Mount back accumulator holder and accumulator.

2 3

! WARNING !

Carry out oil replacement before season starts, or following a long-term machine shutdown. Clean together a suction basket.

4

Drain oil when cooled down below 60°C (140 °F).

Adhere to fire precautions!

With hydraulic circuits disconnected, please blind all the openings with plugs.

Catch the oil being drained, and do not let it leak into ground.

Used oil is ecologically hazardous waste - hand it over for disposal.

122

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Maintenance manual How to check oil temperature sensor •

Dismantle oil temperature sensor in the area behind accumulator, and clean its contact.

•

Dip the sensor in water of 100 °C (212 °F), check its proper function on the associated LH apparatus – hydraulic oil level LED will light up, refer to the Figure.

Unless oil temperature sensor is functional, replace it with a new one of identical type!

How to fill hydraulic circuit: •

Fill via filling device of following parameters: min. pressure of 6 MPa (870 PSI) filtering capability 3 to 10 µm

•

Remove filling end piece cap, and put filling device quick-coupler onto the quick-coupler.

•

Fill the hydraulic circuit till clean oil starts pouring down from the tank via its drain plug. Collect oil in clean tank.

•

When reading ca 15 l (4 gal US) mount the drain plug back – inspect the gasket.

•

Refill oil in the tank up to its max. level and then detach filling equipment.

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123

3.6.

•

Individual Operations of Maintenance

Order your filling equipment at your machine manufacturer or dealer.

Alternate filling via oil tank filler •

When this method is used, please reduce next exchange interval down to one half, i.e. 1000 hours or 1 year.

•

Oil filler cap is sealed. With the seal damaged during guarantee period the guarantee will no longer exist!

•

Use filler neck to fill the tank with specified type of oil up to the bottom of the screen inside the filler neck.

NOTE When filling via tank filler a large portion of used oil along with dirt will remain within, and the hydraulic unit life will be reduced.

! WARNING !

Do NOT open hydraulic tank uselessly!

Use filler neck to fill hydraulic circuit ONLY as an emergency solution, and with this filling method, please lower the next exchange interval to one half, i.e. 1000 hour or 1 year!

When filler neck seal is broken during guarantee period the machine guarantee will cease to exit!

With the circuit filled, please confirm the hydraulic oil level LED does not light!

Start the engine, and with the speed increased, you must test machine functions so to fill up the circuits!

Confirm tightness of filter, temperature sensor, suction hose and the lid!

Replace oil and filter element always when destruction of internal parts of the units (hydromotors, hydrogenerators) has occurred, or following a major overhaul of the hydraulic system!

Clean and flush the hydraulic tank, at the same time replace filter element and this always before new unit is installed!

Do housekeeping during work, and prevent system contaminated with materials that may cause damage to major units!

NEVER use any chemical cleaning agents to clean the hydraulic tank!

Use only those materials with no fibre-slip!

ALWAYS fill hydraulic tank with oil under Section 3.2.4.!

Observe fire and hygienic precautions!

124

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Maintenance manual How to replace pressure filter element •

Dismantle filter container.

•

Replace filter element.

•

Clean thoroughly filter container.

•

Clean from the bottom the filtration block contact face.

•

Check the condition of sealing rings, and apply clean oil on the rings.

•

Insert new element into the filter container and screw back.

! WARNING !

Carry out the replacement ALWAYS during oil exchange or when pressure filter LED lights when oil operating pressure reaches 50 - 60 °C (122 - 140 °F).

Use ONLY original filtration elements per Spare Part Catalogue.

Used filter elements become ecologically hazardous waste – hand them over for disposal.

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125

3.6.

Individual Operations of Maintenance

3.6.29. Exchanging the engine cooling liquid •

Stop the engine.

•

Open cooling system by removing pressure plug on the equalizer reservoir.

! WARNING !

Exchange the coolant after operation of the machine or after warming the coolant (by running the engine) to 80 °C (176 °C).

Do not dismantle the pressure plug before the temperature of cooling liquid falls lower than to 50 °C (122 °C). Beware of gushing of the coolant and scalding when opening the pressure plug.

•

Dismantle the drain plug in the cooler lower chamber.

Let liquid drain into prepared vessels. The quantity drained is approximately 21 l (5.5 US gal).

NOTE Check cooling system for defective hoses and missing hose clips. Check the condition of the cooler - search for defects, leaks and cooling gills blocked with impurities.

Clean and repair it, if necessary.

126

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Maintenance manual •

Assembly the drain plug and fill cooling system with new cooling liquid with ratio of 50% of water + 50% of anti-freeze agent.

Follow the instructions of the manufacturer of anti-freeze fluid when changing coolant!

Protect your hands with gloves!

Use safety glasses or safety shield!

•

Fill it up to the upper edge of the level indicator . After filling, wait for approx. 2-3 minutes until air goes off and the circuit is filled. The maximum filling rate is 20 l/min [5,2 gal US/min]. Close the equalizer reservoir with the pressure plug.

! WARNING !

Use cooling liquid according to chapter 3.2.3!

•

Start the engine and wait until the temperature reaches 80 °C (175 °F). Check during your waiting for any leakage of cooling liquid.

•

Stop the engine.

•

Check the level on the indicator. If the level is low, refill cooling liquid to maximum.

Do not dismantle the pressure plug before the temperature of cooling liquid falls lower than to 50 °C (122 °C). Beware of gushing of the coolant and scalding when opening the pressure plug!

Collect used liquid and have it safely disposed according to valid regulations!

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127

3.6.

Individual Operations of Maintenance

3.6.30. Checking torsion vibration damper of the engine •

Check the silicone part 3 for whether it is higher or lower than 3.18 mm (1/8 in) above the level of metal parts 1 and 2. If the limit is exceeded, exchange torsion vibration damper.

•

Check visually whether the torsion vibration damper is not moving forward. Check th vibration damper for evidence of fluids loss, dents and wobble.

1 3

2

! WARNING !

With time, the flexible silicone filling of the damper gets rigid and no longer works properly. Non-working damper may cause considerable damage to the engine.

128

AV 130 X

Maintenance manual 3.6.31. Exchanging cleaner elements of air cleaner NOTE The air cleaner contains the main and safety elements.

! WARNING !

If signal lamp lights up, the both elements must be exchanged.

•

Lift the bonnet to the limit position. (See Operating instructions, chapter 2.8.6.)

•

Remove the lid (1).

1

•

Carefully remove the main element (2).

2

•

After remove the safety element (3).

3

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129

3.6.

Individual Operations of Maintenance

•

Clean the inside of the cleaner and contact surface in order that the engine inlet pipe does not get blocked.

Check connections and piping for any untightness and clogging of the engine inlet opening on the bonnet (e.g. by leaves).

•

Insert the new safety element.

•

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

•

Remove the dust valve 1, clean it and mount it back.

! WARNING !

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

Replace both elements after 1 year of service at the latest.

Use original elements only.

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

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

Replace defective vacuum valve immediately!

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

130

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Maintenance manual Maintenance - As Needed

3.6.32. Cleaning the engine radiator and hydraulic oil •

Due to variable working conditions it is not possible to determine any fixed interval of cleaning.

•

In case of work in very dusty conditions clean the radiator daily. Clogged radiators will result in lower cooling capacity and increasing temperatures of engine cooling liquid and hydraulic oil.

•

Dismount the engine intake cover.

•

Clean it using pressure air or pressure water (steam).

Cleaning direction is from the ventilator side.

! WARNING !

Do not use cleaner with too high pressure so as not to damage radiator honeycombs.

In case of contamination of the radiator by oil products, use a cleaning agent and proceed according to the manufacturer’s instructions! Find the cause of contamination!

Follow environmental standards and regulations when cleaning the machine!

Clean the machine in a site equipped with an intercepting system for cleaning agents so that the soil and water sources are not contaminated!

Do not use forbidden cleaning agents!

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131

3.6.

Individual Operations of Maintenance

3.6.33. Water discharge from watering circuit before winter season •

Before the winter season, it is necessary to drain water from the watering circuit in order to avoid possible damaging of the individual components due to freezing.

Water discharge from the watering circuit procedure: •

Dismount both the drain caps of the water twincompartment tank for watering. Keep the drain caps at a safe place.

•

The volume of the full tank amounts to 1000 l.

•

Dismount and clean the vessel with the watering filter.

Keep the vessel with the filter at a safe place.

•

Let the valve of the water feed from the tank open.

132

AV 130 X

Maintenance manual •

Dismount the hoses of displacement of water (2) and (3) from the pumps.

2 3

•

Dismount at least one sprinkler of each pipe on the front and rear side of the machine. Keep the sprinklers at a safe place.

•

Turn on the watering pumps for the period of 20 seconds ensuring thus their dewatering.

•

After the winter season, follow the reverse process; properly clean individual parts at first.

! WARNING !

Timely discharge of water from the sprinkling circuit prevents possible damages the manufacturer is not responsible for!

When winter season ends, fill the tanks with water in line with Section 3.6.8.

AV 130 X

133

3.6.

Individual Operations of Maintenance

3.6.34. Cleaning the air cleaner of cabin ventilation •

Dismantle the cover grill.

•

Take out cleaning element.

•

Carefully beat out the element and wash it in a detergent solution. If you damage the cleaning element or you are not able to clean it properly, replace it with a new one.

! WARNING !

Clean it once in a month. In case you work in very dusty conditions, make the interval shorter.

134

AV 130 X

Maintenance manual 3.6.35. Cleaning the machine •

Clean the machine from major impurities after finishing your work.

•

Perform overall cleaning regularly at least once in a week. When working in cohesive soils, cement and lime stabilisation’s, the overall cleaning must be performed daily.

! WARNING !

Blind all openings into which the cleaning agent might penetrate (e.g. engine inlet opening) prior to pressure water washing. Remove these blinders after washing the machine.

Do not expose electric parts or insulation material to direct water or steam flow.

Always cover such materials (inside of the alternator etc.).

Disconnect the isolating master switch.

Work with stopped engine.

Do not use aggressive and highly inflammable cleaning agents (e.g. petrol or highly inflammable materials).

Follow environmental standards and regulations when cleaning the machine!

Clean the machine in a site equipped with an intercepting system for cleaning agents so that the soil and water sources are not contaminated!

Do not use forbidden cleaning agents!

AV 130 X

135

3.6.

Individual Operations of Maintenance

3.6.36. Adjustment of scrapers ADJUSTABLE SCRAPERS (STANDARD) •

The machine is equipped with four adjustable scrapers.

2 1

Setting of scrapers: •

Slacken two screws on both sides of the scraper at point (1) and (2) and by moving the scraper in the ovalshaped hole set up the correct function of the blade (3).

•

If the scraper is set in the oval-shaped hole at the maximum and the blade is worn-out, remove the blade and replace with a new one.

3

Blade replacement: •

Dismount the screws (4) and remove the blade (3) with strips (5).

•

Follow the above-mentioned steps in reverse order when mounting a new blade.

4 ! WARNING !

Correct setting of scrapers ensures perfect cleaning of the drum during the machine operation!

Set up the correct function of the scraper upon the replacement of the blade!

136

5 3

AV 130 X

Maintenance manual HINGED SCRAPERS (OPTION) •

The machine is equipped with four hinged scrapers.

1

The scrapers setting: •

In position (1), the scraper is set in the transport position.

•

In position (2), the scraper is set in the service position.

•

In the service position, the scraper blade (3) is pushed by means of the gas struts (4) to the drum body.

2 1

4

3

Replacement of the blade: •

In case of excessive wear and tear of the blade, set the scraper to position (1), dismount screws (5), and remove the blade (3) with strip (6).

•

When mounting a new blade, follow the steps in the reverse order.

•

At the same time, always check the correct function of the gas struts.

! WARNING !

5

6

3

Only the correct function of the gas struts and the timely replacement of the wornout scraper blade will ensure perfect cleaning of the drum!

AV 130 X

137

3.6.

Individual Operations of Maintenance

3.6.37. Checking and tightening bolted joints •

Check regularly for loosened bolted joints.

•

Use torque wrenches to tighten them.

TIGHTENING MOMENT For the screws 8,8 (8G)

For the screws 10,9 (10K)

Worm

Nm

lb-ft

Nm

lb-ft

M6

10

7,4

14

10,3

M8

24

25,0

34

25,0

M8x1

19

14,0

27

19,9

M10

48

35,4

67

49,4

M10x1,25

38

28,0

54

39,8

M12

83

61,2

117

86,2

M12x1,25

66

48,7

94

69,3

M14

132

97,3

185

136,4

M14x1,5

106

78,2

148

109,1

M16

200

147,5

285

210,2

M16x1,5

160

118,0

228

168,1

M18

275

202,8

390

287,6

M18x1,5

220

162,2

312

230,1

M20

390

287,6

550

405,6

M20x1,5

312

230,1

440

324,5

M22

530

390,9

745

549,4

M22x1,5

425

313,4

590

435,1

M24

675

497,8

950

700,6

M24x2

540

398,2

760

560,5

M27

995

733,8

1400

1032,5

M27x2

795

586,3

1120

826,0

M30

1350

995,7

1900

1401,3

M30x2

1080

796,5

1520

1121,0

138

The values given in the chart are torques used for dry threads (friction factor 0.14). These values are not applicable for lubricated threads.

AV 130 X

Maintenance manual Table of insert nuts tightening moments of the hoses with sealing “O” ring

Torques for cap nuts with O-ring – hoses Nm

Spanner size

lb-ft

Thread

Tube

Nominal

Min

Max

Nominal

Min

Max

14

M12x1.5

6

20

15

25

15

11

18

17

M14x1.5

8

38

30

45

28

22

33

19

M16x1.5

8

45

38

52

33

28

38

51

43

58

38

32

43

10 22

M18x1.5

10 12

24

M20x1.5

12

58

50

65

43

37

48

27

M22x1.5

14

74

60

88

55

44

65

15 30

M24x1.5

16

74

60

88

55

44

65

32

M26x1.5

18

105

85

125

77

63

92

36

M30x2

20

135

115

155

100

85

114

166

140

192

122

103

142

22 41

M36x2

46

25 28

50

M42x2

30

240

210

270

177

155

199

50

M45x2

35

290

255

325

214

188

240

M52x2

38

330

280

380

243

207

280

42

AV 130 X

139

3.6.

Individual Operations of Maintenance

Table of tightening moments for necks with tightening edge, or with flat packing

Table of tightening moments for plugs with flat packing

Plug torques

Nozzle torques

140

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

G 1"

400

295

G 1"

220

162

G 11/4"

600

443

G 11/4"

600

443

G 11/2"

800

590

G 11/2"

800

590

M 10 x 1

25

18

M 10 x 1

13

10

M 12 x 1,5

30

22

M 12 x 1,5

30

22

M 14 x 1,5

50

37

M 14 x 1,5

40

30

M 16 x 1,5

60

44

M 16 x 1,5

60

44

M 18 x 1,5

60

44

M 18 x 1,5

70

52

M 20 x 1,5

140

103

M 20 x 1,5

90

66

M 22 x 1,5

140

103

M 22 x 1,5

100

74

M 26 x 1,5

220

162

M 26 x 1,5

120

89

M 27 x 1,5

250

184

M 27 x 1,5

150

111

M 33 x 1,5

400

295

M 33 x 1,5

250

184

M 42 x 1,5

600

443

M 42 x 1,5

400

295

M 48 x 1,5

800

590

M 48 x 1,5

500

369

AV 130 X

3.7.

Defects

Maintenance manual

! WARNING !

Usually, defects are caused by incorrect operation of the machine. Therefore, in case of any troubles read again properly through the instructions given in the operation and maintenance manual for the machine and engine. If you cannot identify the cause, contact a service department of an authorized dealer or the manufacturer.

! WARNING !

Troubleshooting in hydraulic and electric systems requires knowledge of these systems; therefore a service department of an authorized dealer or the manufacturer should be called to solve these problems.

AV 130 X

141

3.8.

Appendixes

Wiring scheme AV 130 X Legend: A1

Flasher unit for direction indicator lamps

M7 M8

Rear screen washer

A2

Left combined instrument

M9-11

Fans

A3

Right combined instrument

Q1

Battery cut off switch

A4

Travel electronics

R1

A5

Travel controller

Watering interval potentiometer

Windscreen washer

B1

Fuel level float

R2

Speed potentiometer

B2

Cooling liquid level sensor

R3-5

Resistory

B3

Water tank pressure sensor

R6

Engine preheating

B5

Drum speed sensor

R8

Engine speed control

C1

Noise suppressing filter

S1

Ignition box

E1, 2

Front side lamps

S2

Combined switch

E3, 4

Rear lamps

S2.1

Switch of side and headlamps Main / passing beams control switch

S28

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

S29

Right (yellow) button on the left travel lever – CRAB to the right

S30

Left (yellow) button on the right travel lever – CRAB to the left or the cutter upwards

S31

Right (yellow) button on the right travel lever – CRAB to the right or the cutter downwards

S32

Windscreen wiper control switch

S33

Rear screen wiper switch

S34

Washers double push-button

S35

Fan control switch

S36

Air-conditioning switch (option)

E5, 6

Front head-lamps

E7, 8

Rear head-lamps

S2.2

E9, 10

Left direction indicator lamps

S2.3

Headlight flasher switch

S2.4

Loud horn button

S37

Engine idle speed switch

S2.5

Direction indicator lamps control switch

S38

Engine diagnostic switch

S39

Trouble shooting switch

S3

Rear head-lamps switch

V1-12

Light-emitting diode (LED)

S4

Warning lamps switch

X1

Mounting socket

S5

Front additional-lamps switch (option)

X2

Diagnostic socket

X3-4

Connection terminals

S6

Warning beacon switch (option)

X5-62

Interface connector (X60 – unused) Engine diagnostic

E11,12 Right direction indicator lamps E13,14 Additional front head-lamps (option) E15,16 Additional rear head-lamps (option) E17

Warning beacon (option)

E18,19 Brake lamps E20

Cab light

F1-16

Fuses

S7

Brake pressure switch

X63

G1

Battery

S8

X64-69 Connector J1939

G2

Alternator

Hydraulic system filter clogging switch

S9

Air filter clogging switch

S12

Hydraulic oil overheating switch

S13

CRAB position switch

S14

Reverse horn switch

S15

Neutral gear switch

S16

Emergency brake button

S18

Y1

Valve of cooling fan engine

Y3

Brake valve

Y4

Valve - front runner forward drive

Y5

Valve – front runner backward drive

Y6

Valve - back runner forward drive

Constant speed or stalling switch

Y7

Valve – back runner backward drive

S19

Vibration automatics switch

Y8

Smooth start and stop button

Rear drum vibration small amplitude valve

Y9

Rear drum vibration large amplitude valve

H1

Passing beams indicator light

H2

Main beams indicator light

H3

Loud horn

H4

Audible warning device

H5

Reverse horns (option)

H6

Stop engine warning lamp (red)

H7

Engine defect warning lamp (yellow)

H8

WTS (Wait To Start) indicator lamp (white) –engine preheating

S20 S21

Seat switch

K1

Contactor

S22

Vibration button (red) on the left travel lever

Y10

Front drum vibration small amplitude valve

S23

Vibration button (red) on the right travel lever

Y11

Front drum vibration large amplitude valve

S24

Watering button

Y12

Valve of CRAB to the left

S25

Watering pumps control switch

Y13

Valve of CRAB to the right

Y14

Pressure relief valve

S26

Vibration control switch – front / both / rest drum

Y15

Valve of the cutter upwards (option)

S27

Vibration amplitude control switch

Y16

Valve of the cutter downwards (option)

K2-17

Auxiliary relay

K18

Preheating relay

M1

Engine starter

M2

Watering motor

M3

Watering motor

M4

Windscreen wiper

M5

Left rear screen wiper

M6

Right rear screen wiper

142

AV 130 X

Maintenance manual

AV 130 X

143

3.8.

Appendixes

Wiring scheme AV 130 X Legend: A1

Flasher unit for direction indicator lamps

M7 M8

Rear screen washer

A2

Left combined instrument

M9-11

Fans

A3

Right combined instrument

Q1

Battery cut off switch

A4

Travel electronics

R1

A5

Travel controller

Watering interval potentiometer

Windscreen washer

B1

Fuel level float

R2

Speed potentiometer

B2

Cooling liquid level sensor

R3-5

Resistory

B3

Water tank pressure sensor

R6

Engine preheating

B5

Drum speed sensor

R8

Engine speed control

C1

Noise suppressing filter

S1

Ignition box

E1, 2

Front side lamps

S2

Combined switch

E3, 4

Rear lamps

S2.1

Switch of side and headlamps Main / passing beams control switch

S28

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

S29

Right (yellow) button on the left travel lever – CRAB to the right

S30

Left (yellow) button on the right travel lever – CRAB to the left or the cutter upwards

S31

Right (yellow) button on the right travel lever – CRAB to the right or the cutter downwards

S32

Windscreen wiper control switch

S33

Rear screen wiper switch

S34

Washers double push-button

S35

Fan control switch

S36

Air-conditioning switch (option)

E5, 6

Front head-lamps

E7, 8

Rear head-lamps

S2.2

E9, 10

Left direction indicator lamps

S2.3

Headlight flasher switch

S2.4

Loud horn button

S37

Engine idle speed switch

S2.5

Direction indicator lamps control switch

S38

Engine diagnostic switch

S39

Trouble shooting switch

S3

Rear head-lamps switch

V1-12

Light-emitting diode (LED)

S4

Warning lamps switch

X1

Mounting socket

S5

Front additional-lamps switch (option)

X2

Diagnostic socket

X3-4

Connection terminals

S6

Warning beacon switch (option)

X5-62

Interface connector (X60 – unused) Engine diagnostic

E11,12 Right direction indicator lamps E13,14 Additional front head-lamps (option) E15,16 Additional rear head-lamps (option) E17

Warning beacon (option)

E18,19 Brake lamps E20

Cab light

F1-16

Fuses

S7

Brake pressure switch

X63

G1

Battery

S8

X64-69 Connector J1939

G2

Alternator

Hydraulic system filter clogging switch

S9

Air filter clogging switch

S12

Hydraulic oil overheating switch

S13

CRAB position switch

S14

Reverse horn switch

S15

Neutral gear switch

S16

Emergency brake button

S18

Y1

Valve of cooling fan engine

Y3

Brake valve

Y4

Valve - front runner forward drive

Y5

Valve – front runner backward drive

Y6

Valve - back runner forward drive

Constant speed or stalling switch

Y7

Valve – back runner backward drive

S19

Vibration automatics switch

Y8

Smooth start and stop button

Rear drum vibration small amplitude valve

Y9

Rear drum vibration large amplitude valve

H1

Passing beams indicator light

H2

Main beams indicator light

H3

Loud horn

H4

Audible warning device

H5

Reverse horns (option)

H6

Stop engine warning lamp (red)

H7

Engine defect warning lamp (yellow)

H8

WTS (Wait To Start) indicator lamp (white) –engine preheating

S20 S21

Seat switch

K1

Contactor

S22

Vibration button (red) on the left travel lever

Y10

Front drum vibration small amplitude valve

S23

Vibration button (red) on the right travel lever

Y11

Front drum vibration large amplitude valve

S24

Watering button

Y12

Valve of CRAB to the left

S25

Watering pumps control switch

Y13

Valve of CRAB to the right

Y14

Pressure relief valve

S26

Vibration control switch – front / both / rest drum

Y15

Valve of the cutter upwards (option)

S27

Vibration amplitude control switch

Y16

Valve of the cutter downwards (option)

K2-17

Auxiliary relay

K18

Preheating relay

M1

Engine starter

M2

Watering motor

M3

Watering motor

M4

Windscreen wiper

M5

Left rear screen wiper

M6

Right rear screen wiper

144

AV 130 X

Maintenance manual

AV 130 X

145

3.8.

Appendixes

Hydraulic Diagram AV 130 X Legend:

1.

Travel and vibration pump

2.

Steering pump

3.

Travel hydraulic motor

4.

Travel hydraulic motor

5.

Vibration hydraulic motor

6.

Fan hydraulic motor

7.

Steering hydraulic motor

8.

Crab hydraulic motor

9.

Cutter hydraulic motor (option)

10.

Lifting hydraulic motor

12.

Power steering

13.

Combined cooler

14.

Hydraulic tank

15.

Control unit

16.

Thermoregulator

17.

Non-return valve

18.

Intake strainer

19.

Filler neck

20.

Safety unit

21.

Hand pump

22.

Temperature switch

23.

Oil level indicator

24.

Ball valve

25.

Filling quick coupler

146

AV 130 X

Maintenance manual

AV 130 X

147

3.8.

Appendixes

Notes:

148

AV 130 X

Maintenance manual

Notes:

AV 130 X

149

Notes: