Ammann AV 130 X Tandem Roller Operating Manual 4022006 PDF

Operating manual

AV 130 X Cummins

Book ID: 4-P06402CU-EN

AV 130 X Articulated tandem roller Cummins Tier 3

Operating manual Edition 02/2011 EN From Serial No. 4022006 Translation of Original Operating Manual

Místo a datum vydání / Place and date of issue / Ort und Datum der Ausgabe:

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.com | www.ammann-group.com

401100

This manual consists of: I. Specification manual

II. Operating manual

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.

AV 130 X

1

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

Ammann 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.

2

AV 130 X

SYMBOLS OF THE SAFETY NOTICES:

The notice warns of a serious risk of personal injury or other personal hazards.

The notice warns of possible damages to the machine or its parts.

The notice warns of the necessity of environmental protection.

! NOTICE !

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

FRONT

RIGHT

LEFT

REAR 402002en

AV 130 X

3

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

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

1.1. Basic specification.................................................................................................................................10 1.2. Machine dimension scheme.................................................................................................................12 1.3. Technical data........................................................................................................................................14

4

AV 130 X

OPERATING MANUAL 2.

OPERATION MANUAL...........................................................................................................................19

2.1. Major Safety Precautions......................................................................................................................21 2.1.1.

Safety Measures during Machine Operation ...............................................................................................................................................21

2.1.1.1. Compaction Work Commencement ...............................................................................................................................................................21 2.1.1.2. Work Safety Secured by User..............................................................................................................................................................................21 2.1.1.3 Ensurance of safety measures by the owner................................................................................................................................................22 2.1.1.4. ROPS Cab ..................................................................................................................................................................................................................22 2.1.2.

Reguirements on Driver’s Qualification..........................................................................................................................................................23

2.1.3.

Driver’s Liabilities....................................................................................................................................................................................................23

2.1.4.

Banned Operations................................................................................................................................................................................................25

2.1.5.

Safety inscriptions and signs used on the Machine ..................................................................................................................................26

2.1.6.

Hand Signals.............................................................................................................................................................................................................32

2.2. Ecological & Hygienic Principles..........................................................................................................35 2.2.1.

Hygienic Principles . ..............................................................................................................................................................................................35

2.2.2.

Ecological Principles .............................................................................................................................................................................................35

2.3. Preservation and storing of machines.................................................................................................36 2.3.1.

Short-Term Preservation & Storate for the Period of 1 ÷ 2 Months......................................................................................................36

2.3.2.

Preservation & Storage for the Period Over 2 Months Long...................................................................................................................36

2.3.3.

Dewaxing and inspection of the supplied machine..................................................................................................................................37

2.4. Machine Disposal Following Its Life Termination...............................................................................38 2.5. Machine Description.............................................................................................................................39 2.6. Controls & Dashboard Instruments .....................................................................................................40 2.7. Machine control and use.......................................................................................................................62 2.7.1.

Start-up of the engine...........................................................................................................................................................................................63

2.7.2.

Travel and reversing...............................................................................................................................................................................................67

2.7.3.

Emergency stop of the Machine.......................................................................................................................................................................77

2.7.4.

How to stop the Machine and its engine.......................................................................................................................................................77

2.7.5.

Machine parking.....................................................................................................................................................................................................77

2 .7.6.

Bonnet raising and lowering..............................................................................................................................................................................79

2.7.7.

Sprinkling...................................................................................................................................................................................................................81

2.7.8

Ammann edgecutter.............................................................................................................................................................................................82

2.7.9.

Infra thermometer..................................................................................................................................................................................................83

2.8. Machine transport.................................................................................................................................84 2.8.1.

How to load the Machine.....................................................................................................................................................................................85

2.9. Special conditions for using the machine...........................................................................................86 2.9.1.

Machine towing......................................................................................................................................................................................................86

2.9.2.

Operating the machine during initial run period.......................................................................................................................................89

2.9.3.

Operating the Machine at low temperatures...............................................................................................................................................89

2.9.4.

Machine operation at high temperatures and humidity..........................................................................................................................89

2.9.5.

Machine operation at high altitudes...............................................................................................................................................................89

2.9.6.

Work of the machine in the dusty environment.........................................................................................................................................89

2.9.7.

Driving with vibrations on compacted and hard materials....................................................................................................................89

AV 130 X

5

Content 3.

MAINTENANCE MANUAL.....................................................................................................................91

3.1. Safety Standards at Lubrication and Maintenance............................................................................93 3.1.1.

Safety of machine maintenance........................................................................................................................................................................93

3.1.2.

Fire precautions during operation media exchanges...............................................................................................................................93

3.1.3.

Ecological and hygienic principles...................................................................................................................................................................94

3.2. Specification of fluids............................................................................................................................95 3.2.1.

Engine oil...................................................................................................................................................................................................................95

3.2.2.

Fuel...............................................................................................................................................................................................................................96

3.2.3.

Coolant ......................................................................................................................................................................................................................96

3.2.4.

Hydraulic oil..............................................................................................................................................................................................................97

3.2.5.

Gearbox oil................................................................................................................................................................................................................98

3.2.6.

Lubricating grease..................................................................................................................................................................................................98

3.2.7.

Windshield washer liquid....................................................................................................................................................................................98

3.3. Fills..........................................................................................................................................................99 3.4. Lubrication and Maintenance Chart..................................................................................................100 3.5. Lubrication Chart.................................................................................................................................102 3.6. Individual Operations of Maintenance..............................................................................................103 After 20 hours of operation (daily).....................................................................................................104 3.6.1.

Engine oil level check......................................................................................................................................................................................... 104

3.6.2.

Engine cooling liquid level check.................................................................................................................................................................. 105

3.6.3.

Hydraulic tank oil level check.......................................................................................................................................................................... 106

3.6.4.

Crankcase breather tube................................................................................................................................................................................... 106

3.6.5.

Checking the condition of the ventilator and belt.................................................................................................................................. 107

3.6.6.

Checking the vacuum valve of the air cleaner.......................................................................................................................................... 108

3.6.7.

Fuel level check..................................................................................................................................................................................................... 109

3.6.8.

Water tank refilling.............................................................................................................................................................................................. 110

3.6.9.

Cleaning the water separator.......................................................................................................................................................................... 111

3.6.10. Warning and control devices checking....................................................................................................................................................... 112

After 250 hours of operation (3 months)...........................................................................................114 3.6.11. Air intake cooler, intake piping....................................................................................................................................................................... 114 3.6.12. Checking the cooling circuit of the engine................................................................................................................................................ 115 3.6.13. Checking the engine belt................................................................................................................................................................................. 116 3.6.14. Checking battery................................................................................................................................................................................................. 117 3.6.15. Air filter sensor check......................................................................................................................................................................................... 119 3.6.16. Machine lubrication............................................................................................................................................................................................ 120 3.6.17. Checking oil in gearboxes................................................................................................................................................................................ 122 3.6.18. Watering filter cleaning..................................................................................................................................................................................... 123

After 500 hours of operation (6 months)...........................................................................................124 3.6.19. Engine oil exchange............................................................................................................................................................................................ 124 3.6.20. Fuel filter exchange............................................................................................................................................................................................. 127 3.6.21. Engine cooling liquid level check.................................................................................................................................................................. 128 3.6.22. Check of wiring..................................................................................................................................................................................................... 128

6

AV 130 X

OPERATING MANUAL After 1,000 hours of operation (after 1 year)....................................................................................129 3.6.23. How to check tightening pulley and belt of the engine........................................................................................................................ 129 3.6.24. Exchanging oil in gearboxes............................................................................................................................................................................ 131 3.6.25. Damping system checking............................................................................................................................................................................... 133 3.6.26. Fuel tank cleaning............................................................................................................................................................................................... 134 3.6.27. Water tank cleaning............................................................................................................................................................................................ 136

After 2,000 hours of operation (after 2 years)...................................................................................137 3.6.28. Vibrations system oil exchange...................................................................................................................................................................... 137 3.6.29. How to replace hydraulic oil and filters ...................................................................................................................................................... 138 3.6.30. Exchanging the engine cooling liquid......................................................................................................................................................... 142 3.6.31. Exchanging cleaner elements of air cleaner.............................................................................................................................................. 144 3.6.32. Inspect, adjust engine valve clearance........................................................................................................................................................ 145

Maintenance - As Needed...................................................................................................................146 3.6.33. Cleaning of coolers.............................................................................................................................................................................................. 146 3.6.34. Water discharge from watering circuit before winter season ............................................................................................................ 147 3.6.35. Cleaning the air cleaner of cabin ventilation............................................................................................................................................. 149 3.6.36. Cleaning the machine . ..................................................................................................................................................................................... 150 3.6.37. Adjustment of scrapers...................................................................................................................................................................................... 151 3.6.38. Checking and tightening bolted joints........................................................................................................................................................ 153

3.7. Defects..................................................................................................................................................155 3.8. Appendixes .........................................................................................................................................156 Wiring scheme....................................................................................................................................................................................................................... 156 Hydraulic Diagram............................................................................................................................................................................................................... 160

AV 130 X

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8

AV 130 X

SPECIFICATION MANUAL

1. SPECIFICATION MANUAL AV 130 X (Cummins Tier 3)

AV 130 X

9

1.1.

Basic specification

Machine description

Please fill in the following data:

Tandem roller with an articulated frame with two smooth steel driven vibrating drums. Steering using the articulated frame enables the setting of extended track (crabbing).

(see Pin label, Label of the CUMMINS engine) Type of machine

Machine application The AV 130 X vibratory rollers are intended for medium and large-sized compaction works in transport construction (roads and motorways and airfields) and building construction (industrial zones, etc.).

The roller is suitable for compacting the asphalt mixtures up to a layer thickness (after compaction) of 160 mm (6.3 in), hydraulically consolidated mixtures up to a layer thickness of 250 mm (9.8 in), mixed soils up to a layer thickness of 350 mm (13.8 in), and sand and gravel materials up to a layer thickness of 450 mm (17.7 in).

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

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

The standard type of the machine is not intended for road traffic. For more information, please contact your dealer.

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

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

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

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

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

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

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

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

10

3487

1 2 4 5 6 7

AMMANN CZECH REPUBLIC a.s.

549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145 CZECH REPUBLIC

DESIGNATION

TYPE

3

VERSION

SERIAL NUMBER

OPERATING MASS

kg

FRONT AXLE LOAD

kg

MAXIMUM MASS

kg

REAR AXLE LOAD

kg

NOMINAL POWER

kW

YEAR OF CONSTRUCTION

MADE IN CZECH REPUBLIC

8 9 10 3487

AV 130 X

SPECIFICATION MANUAL Placing of the production label 1 - Production label 2 - Machine frame number 3 - Label of the ROPS cabin

3 1

2

402619 Cummins engine serial number

402313

AV 130 X

11

Machine dimension scheme

H

1.2.

T

T D

G

D

A L

402003

12

A

C

D

G

G1

H

mm

3525

160

1350

335

770

3060

in

138,8

6,3

53,1

13,2

30,3

120,5

H1

L

T

W

W1

mm

2390

4875

20

2100

2222

in

94,1

191,9

0,8

82,7

87,5

AV 130 X

G1

H1

SPECIFICATION MANUAL

W

C

W1

402004

AV 130 X

13

1.3.

Technical data

Weight Operating weight of CECE with cab, ROPS

kg (lb)

13030 (28726)

Operating weight of CECE with platform, rail

kg (lb)

12600 (27783)

Operating load of CECE with cab, ROPS on front axis

kg (lb)

6605 (14561)

Operating load of CECE with cab, ROPS on rear axis

kg (lb)

6425 (14164)

Weight of half fluid capacities

kg (lb)

785 (1731)

Operating weight of ISO 6016 with cab, ROPS

kg (lb)

13815 (30457)

Max. weight – cab + ROPS (6016) + accessories + weighing

kg (lb)

14015 (30898)

Maximum permitted weight according to ROPS

kg (lb)

14500 (31967)

Static linear load of front drum

kg/cm (lb/in)

31,45 (173,4)

Static linear load of rear drum

kg/cm (lb/in)

30,59 (168,6)

Cab weight

kg (lb)

700 (1543,5)

Weight of ROPS

kg (lb)

700 (1543,3)

Weight of sheet roof on ROPS

kg (lb)

70 (154,3)

Weight of canopy

kg (lb)

40 (88,2)

Weight of canopy posts (version without ROPS)

kg (lb)

100 (220,5)

Weight of Ammann cutter

kg (lb)

100 (220,5)

Weight of Ammann diagonal cutter

kg (lb)

200 (441)

km/h (MPH)

11,4 (7,1)

Climbing ability without vibration

%

40

Climbing ability with vibration

%

30

Theoretical climbing ability of machine

%

40

Lateral stability during driving with vibration

%

15

Lateral static stability

%

65

Turning radius outer (edge)

mm (in)

4670 (184)

Turning radius outer (contour)

mm (in)

6880 (271)

Type of drive

-

Hydrostatic

Number of driving axles

-

2

Oscillation angle

°

±6

Angle of steering

°

± 34

Type of steering

-

Joint

Steering control

-

Hydraulic

Linear hydraulic motors

-

2+1 (Crab)

Driving characteristics Maximum transport speed

Steering

14

AV 130 X

SPECIFICATION MANUAL Engine Manufacturer

-

Cummins

Type

-

QSB4.5-C130

Power according to DIN 6271

kW (HP)

97 (130)

Power according to ISO 3046/1

kW (HP)

97 (130)

Number of cylinders

-

4

Cylinder capacity

cm3 (cu in)

4500 (275)

Nominal speed

min-1 (RPM)

2300

Maximum torque

Nm (ft lb)/rpm

512 (376)/1600

Routine operation fuel consumption

l/h (gal US/h)

11,6 (3,1)

Engines complies with emission regulations

-

*b

Cooling system of engine

-

Liquid

Operating

-

Hydrostatic

Parking

-

Mechanical multiple-disc

Emergency

-

Mechanical multiple-disc

Small amplitude

mm (in)

0,4 (0,016)

Large amplitude

mm (in)

0,8 (0,03)

Low frequency

Hz (VPM)

42 (2520)

High frequency

Hz (VPM)

55 (3300)

Low centrifugal force

kN

96 / 116

High centrifugal force

kN

135

High frequency CE

Hz (VPM)

50 (3000)

-

Hydrostatic

Type of watering

-

Pressure

Number of pumps

-

2

Number of filtrations

-

3

Fuel

l (gal US)

210 (55,5)

Water for drum watering

l (gal US)

1000 (264)

Engine (oil filling)

l (gal US)

11,6 (3,1)

Cooling system

l (gal US)

21 (5,5)

Hydraulic system

l (gal US)

60 (15,9)

Drum vibrator

l (gal US)

2x19 (5)

Vibrating drum front

l (gal US)

19 (5)

Vibrating drum rear

l (gal US)

19 (5)

Front watering tank

l (gal US)

1000 (264)

Drum gearbox

l (gal US)

2x2,5 (0,67)

Washer tank

l (gal US)

2,75 (0,72)

Pump drive gearbox

l (gal US)

1,8 (0,48)

Brakes

Vibration

Type of drive

Watering

Fluid capacities

AV 130 X

15

1.3.

Technical data

Wiring Voltage

V

12

Battery capacity

Ah

135

Declared value of sound pressure A at operator's place (cab)

dB

82

Guaranteed sound power level A

dB

108

Highest weighted effective value of acceleration of vibrations transmitted to the whole body (cab)

m/s2 (ft/s2)

<0,5 (<1,64)

Total value of acceleration of vibrations transmitted to hands (cab)

m/s2 (ft/s2)

4,7 (15,4)

dBa

92

Noise and vibration emissions

Level of sound pressure affecting operator (platform)

Optional equipment Air-conditioning Installations for radio (antenna, 2 loudspeakers) (only a cab version) Radio with CD Reversing alarm Beacon Additional working headlights Adjustable scrapers Cutter/final compaction device Infrared thermometer Fire extinguisher Ammann set of tools Biologically degradable oil Different colour design (Ammann scheme), max. 2 different colours Special colour design Filters for the first 500 Mh Additional documentation

*b……….97/68/EU Level 3, EPA/CARB 40 CFR Part 89 Tier 3

16

AV 130 X

SPECIFICATION MANUAL Notes

AV 130 X

17

18

AV 130 X

OPERATION MANUAL

2. OPERATION MANUAL AV 130 X (Cummins Tier 3)

AV 130 X

19

20

AV 130 X

2.1.

Major Safety Precautions

2.1.1. Safety Measures Operation

during

Machine

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.

2.1.1.1. Compaction Work Commencement ••

••

OPERATION MANUAL 2.1.1.2. Work Safety Secured by User ••

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 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.

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.

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

--

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

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

AV 130 X

21

2.1.

Major Safety Precautions

2.1.1.3 Ensurance of safety measures by the owner ••

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

••

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

••

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

22

2.1.1.4. ROPS Cab ••

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.

AV 130 X

OPERATION MANUAL 2.1.2. Reguirements on Driver’s Qualification

2.1.3. Driver’s Liabilities

••

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

••

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

••

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

••

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.).

••

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.).

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.

••

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

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

••

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

••

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

••

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.

••

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.

••

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

••

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

••

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

••

Driving the Roller alone may be performed by an employee mentally and physically fit, over 18 years old, who is: a) assigned by machine manufacturer for the assembly, testing and presentation of the Machine, for training the drivers, whereas he/she must be made familiar with safety work regulations in force at the workplace or

••

AV 130 X

23

2.1.

Major Safety Precautions

••

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.

••

In the event that the machine has no cab or when the windows are open, the operator must wear ear protectors.

••

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.

••

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

24

--

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.

AV 130 X

OPERATION MANUAL 2.1.4. Banned Operations

••

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

Banned are the following

••

maszynę eksploatować w środowisku wybuchowym i w podziemiu

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

••

••

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

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

••

••

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.

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

••

Start the engine through some other way than given in the Driving Manual.

••

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

••

Lay away material or other objects on the Machine.

••

Remove dirt while the Machine is running.

••

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

••

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

••

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.

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

••

drive with open doors

••

perform any adjustments on the machine without the prior consent of the manufacturer

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.

••

drive without the seat belt fastened

••

shift electrical conductors

••

To operate the Machine unless driver control stand fixed properly.

••

use other than original spare parts

••

••

To operate the Machine when engine bay cover is open.

interfere in the electrical and electronic units in any manner.

••

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 secured through some other way like for instance via signalling by duly instructed person.

••

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

••

To cross electric cables if these are not properly protectedli 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 or getting off while on the run, jumping off the Machine.

••

••

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 Driving Manual.

••

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

••

••

AV 130 X

25

2.1.

Major Safety Precautions

2.1.5. Safety inscriptions and signs used on the Machine

B A

15

15

13

19

4 21

3

14

17

C

23

21

8

21

3

20

7

21

20

15

15 4 3

21

A 18

4

10

21

21

3

20

21

20

16 24 9 5

11 1 B

C

12

8

6 2

22

25

4 402617

26

AV 130 X

OPERATION MANUAL

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).

2702bz

2.

Service Manual

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

2428

3.

Pinch Points

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

2939

2941bz

4.

Hazardous Area

Maintain safe distance (Symbols located at the left and right on the front frame)

2939

2942bz

Keep a safe distance from the cutter and compactor if in operation (Symbol located on the right front side board).

2939

3352bz

5.

Injury Hazard

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

2939

2409bz

AV 130 X

27

2.1.

6.

Major Safety Precautions

Injury Hazard

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

2601bz

7.

Adjust at Rest

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

2584bz

2586

8.

Risk of burn

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

2586bz

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).

2152bz

10.

Explosion Hazard

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

3017bz

28

AV 130 X

OPERATION MANUAL

11.

Disconnect the Wiring

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

2668bz

12.

Cover the Electric Instruments

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

2225bz

13.

Max Machine Height

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

3,11 m 3149bz

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).

14 500 kg (32 000 lb) Lmin = 5m 2x min 4000 kg (2x min 8820 lb)

Lmin = 5 m 2x min 4000 kg (2x min 8820 lb)

3206

3206bz

15.

Lifting Points

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

2153bz

AV 130 X

29

2.1.

Switch ON Safety Belt!

2939

16.

Major Safety Precautions

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

2687bz

17.

Bonnet Lifting

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

3201

18.

Hearing protectors

2408bz

3035

19.

Noise Emitted

L WA

108dB

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

3035

20.

Jacking point

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

3208bz

30

AV 130 X

OPERATION MANUAL

21.

Sling Points

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

3048bz

22.

3237

Pinch Points

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

2939

3237bz

3292

23.

Lifting the hood

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

3292bz

24.

Cooling liquid

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

2939

3227bz

25.

Injury Hazard 2939

Keep safety distance away from rotating pulley and belt.

(Symbol located in within engine bay) 3333bz

AV 130 X

31

2.1.

Major Safety Precautions

2.1.6. 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.

STOP Sig. 1

Attention Both arms sideways raised horizontally – palms forward.

!

Sig. 2

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

!

Sig. 3

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

Sig. 4

32

AV 130 X

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

Sig. 5

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

Sig. 6

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

Sig. 7

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

Sig. 8

AV 130 X

33

2.1.

Major Safety Precautions

Short motion

X

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

Sig. 9

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

Sig. 10

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

Sig. 11

34

AV 130 X

2.2.

Ecological & Hygienic Principles

2.2.1. Hygienic Principles

2.2.2. Ecological Principles ••

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

••

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

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

This category of waste products includes in particular: --

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

--

Cooling liquids,

--

Accumulator fillings and the accumulators themselves,

--

Cleaning & preservation agents,

--

All filters and filter elements dismantled,

--

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

We call your attention to the following in particular:

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

--

Eye and skin protection when handling accumulators

Oils

--

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

Accumulators

--

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 undesignaged bottles or other vessels due to the hazard of them being interchanged. Especially hazardous is the possibility of interchanging them with eatables or drinks.

••

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

••

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

AV 130 X

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.

35

2.3.

Preservation and storing of machines

2.3.1. Short-Term Preservation & Storate for the Period of 1 ÷ 2 Months

2.3.2. Preservation & Storage for the Period Over 2 Months Long

••

To park the Machine the same principles will apply like at shortterm preservation.

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:

In addition it is recommended to: ••

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

••

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

••

Protect rubber elements through painting with spec. preservation agent,

••

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

••

Repair those spots with damaged paint,

••

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

••

Confirm water fillings are drained,

••

Check that cooling liquid has antifreezing characteristics requiered,

••

••

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

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

••

••

Apply preservative grease over the chormed 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.

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.

36

AV 130 X

OPERATION MANUAL 2.3.3. Dewaxing and inspection of the supplied machine ••

Check the machine against delivery documentation.

••

Check whether any parts were damaged during transport or are missing. Inform the shipper of any discrepancies.

Before starting operations again, wash off conservation ith highpressured hot water with ordinary degreasing means added as directed, while observing environmental rules.

Remove conservation and wash the machine in places with catch basins available to collect rinse water and chemicals.

AV 130 X

37

2.4.

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.

38

AV 130 X

2.5.

Machine Description

OPERATION MANUAL

13 14 2

11 12 15 16

5

16

17

18

8

17 10

3 9

7

4

6 17

1 17

401203

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 - Hydrogeneratorfor 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

AV 130 X

39

2.6.

Controls & Dashboard Instruments

27 15

28

16 25

13

0

22

17

J1939

23

MAN

1 0 WTS

18

2

kg

32 33 29 21 20 24 34 30 31 26 11

AUT

14

IDLE

19 12

35 6

6

5 7

1

5

7

1

8

2

9

3

10

36

402600

40

AV 130 X

OPERATION MANUAL Dashboard and control panels 1 - Travel controls 2 - Speed potentiometer 3 - Pushbutton for mode of soft starting to move and stopping to move 4 - CRAB mode resetting switch 5 - Pushbuttons for CRAB mode – right* 6 - CRAB pushbuttons – left* 7 - Vibration pushbuttons 8 - Emergency brake pushbutton 9 - Sprinkling pushbutton 10 - Sprinkling interval potentiometer 11 - Sprinkling pumps selector switch 12 - Ignition box 13 - Accelerator control 14 - Engine idling 15 - Front / both / rear vibration selector switch 16 - Vibration amplitude selector switch 17 - Vibration mode selection switch (MAN/AUT) 18 - Combined switch 19 -Switch for constant speed and protection against engine overload 20 - Beacon switch (optional) 21 - Alarm lights switch 22 - Additional lights switch (optional) 23 - Switch + indicator lamp for rear lights 24 - lndicator lamps for lights (dipped/distance) 25 - Infrathermometer (optional) 26 - Spreader – Optional 27 - LH cluster 28 - RH cluster 29 - Engine diagnostics 30 - Engine diagnostics switch 31 - Troubleshooting switch 32 - Red lamp (engine diagnostics) 33 - Yellow lamp (engine diagnostics) 34 - Engine heating 35 - Steering wheel position adjustment 36 - Operator seat * If the Machine is equipped with cutter and final compactor then pushbuttons (5) and (6) on the travel control (1) are used to control it, and this on the same side where it has been mounted (optional).

AV 130 X

41

2.7.

Machine basic functions control

27

28

0

J1939

MAN

1 0 WTS

6

kg

AUT

IDLE

6

5 7

1

2

5

7

1

8

2

9

3

1

0

N

402601 42

AV 130 X

OPERATION MANUAL 3317

Steer angle of the drum in CRAB mode – yellow pushbuttons (5) and (6)

Travel controls (1) 2721

3317

These controls are used to adjust travel direction and speed.

Travel speed depends on the degree of swing of travel controls from zero position (0), in dependence on speed potentiometer (2) adjustment.

Press pushbuttons on travel controls (1) to steer in CRAB mode Pushbutton (5) – right Pushbutton (6) – left

Travel controls have two positions, i.e. “N” and “0”:

Indicator lamp on cluster (28) goes ON to signal this function.

“N” - neutral - in this position the Machine parking brake is enabled.

“0” - zero position - the Machine is not braked in this position.

Neutral position (N) is signalled through lighting up of neutral and parking brake indicator lamps on the cluster (2).

Located on the travel control are vibration ON/OFF pushbuttons (7) and pushbuttons (5), (6) to control in CRAB mode.

If the Machine is equipped with cutter and final compactor then pushbuttons (5) and (6) on travel control are used to control it, i.e. those on the same side where it is mounted (optional).

Note If the Machine is equipped with cutter and final compactor then it will be controlled via pushbuttons (5) and (6) on travel control (1), and this on the same side where it has been mounted (optional).

Vibration ON / OFF pushbuttons (7) Press these buttons to turn ON/OFF this function. Indicator lamp on cluster (27) will go ON.

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

Emergency brake (8) pushbutton 2582

Speed potentiometer (2) 2685

Potentiometer is used to smoothly select speed mode within the range from min speed of “turtle” to max speed of “rabbit”.

When adjusting potentiometer speed in any position you may always enable vibration function.

Machine will not move with speed potentiometer set to MIN position.

Switch for the mode of soft starting to move (driveaway) and stopping to move (stopway) (3)

Press this button to enable Machine’s emergency brake, and indicator lamps on cluster (27) for brakes, recharging, neutral will light up.

Engine will stop and stall!

Sprinkling button (9) 3183

Hold down this pushbutton to enable drum additional sprinkling function. Indicator lamp on cluster (28) will light up.

3128

It is used to adjust soft starting to move and stopping to move when stopping and reversing the Machine. In this way the creation of “waves” on compacted surface will be eliminated. Press the switch to enable the function, and indicator lamp on cluster (28) will go ON.

Attention, in this mode the Machine stopping distance is longer!

AV 130 X

43

2.7.

Machine basic functions control

27 15

28

16 13 0

J1939

MAN

1 0 WTS

18

24

2

kg

AUT

IDLE

14

17

11 12

10

402601A 44

AV 130 X

OPERATION MANUAL Drum vibration selector switch (15)

Sprinkling interval potentiometer (10) 3179

3186

Swing the sprinkling potentiometer from „MIN“ to „MAX“ position to control smoothly drum sprinkling intensity.

The selector switch has three positions:

Sprinkling function will not be enabled with the sprinkling potentiometer set to MIN position.

Centre – both drums’ vibration

Left – front drum vibration Right – rear drum vibration

Vibration amplitude selector switch (16)

Pumps sprinkling selector switch (11)

2682

The selector switch has three positions:

3181

One of two drum sprinkling pumps will turn ON, and indicator lamp on cluster (28) will light up.

Adjust sprinkling potentiometer before switching ON the pump!

Left – low amplitude switched ON Centre - OFF Right – high amplitude switched ON

Ignition box (12 ) Ignition box has three positions of „0-I-II“. The key can be inserted and removed in ”0” position only.

Turn a bit the key to RH side to enable first the ”I” position and then ”II” position. ”II” position is used to start the engine.

MAN / AUT vibration mode selector switch (17) 3180

It is used to switch ON vibrations in MAN or AUT mode.

MAN – manual mode, vibrations can be switched ON even with stationary Machine.

Protect ignition box with cover once the key is pulled out.

AUT – automatic mode to switch OFF/ON vibrations Cluster (18) It is used to turn ON/OFF contour lights, dipped lights, distance lights, traffic-indicator lights and horn.

Accelerator control (13) 3004

It is used to adjust combustion engine rpm ranging from idle to max speed. Move the accelerator control towards operator seat to increase the rpm and vice versa. Accelerator control is connected with the engine injection pump control lever via a cable.

IDLE

Indicator lamps (24) light up to signal contour, dipped, and distance lights are ON. Indicator lamp on cluster (27) lights up to signal traffic-indicator lights are ON.

Engine idling (14)

3006

It must be switched ON when starting the engine.

AV 130 X

45

2.7.

Machine basic functions control

27

28 25

13

0

J1939

MAN

1 0

23

2

WTS

22

21 20 24

26

kg

AUT

IDLE

19 12

1

1

2

1

0

N

402601B 46

AV 130 X

OPERATION MANUAL

0

Switch for constant speed and protection against engine overload (19)

3185

Switch + indicator lamp rear lights (23) 591668R

It is used to turn ON/OFF rear lights, indicator lamp in the switch signals this function.

Constant speed function: It is used to maintain constant speed of the Machine when driving on flat surface, uphill, or downhill.

Indicator lamps for (dipped / distance) lights (24)

When control unit is switched ON the indicator lamp on cluster (28) signals this function.

The driving speed corresponds to the degree of swing of travel control (1) from neutral position (0), depending on speed potentiometer (2) adjustment.

591508

These lamps signal dipped or distance lights switched ON.

ANTISTALL function It is used to protect the engine on steep grade or the Machine not to sink in ground.

With the control unit switched ON the indicator lamp on cluster (28) will signal this function. The control unit will automatically lower the power take-off (PTO) through reducing the set speed (rpm of travel hydraulic motor) independently on travel control position. Thus the tractive force (of travel hydraulic motor) will increase - engine will get relieved.

Infrathermometer (25) - (optional) 3044

It will be enabled through the key turned ON in the ignition box (12) and it will measure through temperature sensor for a bitumen surface rolled. The value measured is indicated in C° degrees on display (25).

Spreader – Optional

Adjust engine max rpm by means of accelerator control (13) before turning ON the switch!

When a hard terrain has been overcome, turn OFF the switch!

AMN20

Switch + hazard beacon indicator lamp (20) - (optional) 592348

It is used to switch ON/OFF hazard beacon, indicator lamp in the switch signals this function.

Alarm lights switch (21) AMN24

It is used to turn ON/OFF alarm lights - indicator lamp in the alarm lights switch and on clusters (27) and (28) will flicker to signal this function.

596473

Switch + indicator lamp for cabin’s additional lights (22)

It is used to switch ON/OFF additional lights, indicator lamp in the switch signals this function.

AV 130 X

47

2.7.

Machine basic functions control 27

0

478320

J1939

MAN

1 0

2

WTS

kg

AUT

IDLE

402604 LH cluster (27) Indicator lamp for hydraulic oil pressure filter fouled

Fuel consumption gauge AMN25

It signals current fuel level in the tank, when emptied to min the red LED will flicker.

Check fuel operation.

level

during

AMN3

Indicator lamp ON signals filter element is fouled.

Machine

Immediately replace the filter element!

Counter of motohours actually worked AMN26

Battery recharging indicator lamp AMN4

It will display the number of motohours the engine was running.

With the engine started the counter will begin counting the motohours.

It signals proper function of battery recharging. When switching the key on the ignition box (12) over to “I” position the indicator lamp shall go ON and following the start it must go OFF.

Note Counting the number of motohours does not depend on engine rpm.

Unless indicator lamp goes OFF, find a defect!

Parking brake indicator lamp AMN1

The indicator lamp ON will signal the parking brake has been enabled.

Seat switch indicator lamp AMN2

Indicator lamp will light ON when operator is not sitting on the seat or when emergency brake has been enabled.

48

Indicator lamp lighted ON during engine run will signal a defect. Following 5 seconds the acoustic alarm will start, and after 2 minutes the engine will stall automatically – the Machine will stop and parking brake will be enabled.

Engine can be started once its defect has been repaired!

AV 130 X

OPERATION MANUAL Indicator lamp that the vibration is ON

Indicator lamp for air filter fouled AMN5

AMN10

Indicator lamp ON signals filter element is fouled above a limit admissible.

Stop the Machine and replace the filter element instantly!

Indicator lamp ON will signal the vibration is ON.

Indicator lamp for hydraulic oil temperature AMN11

Indicator lamp signals max hydraulic oil temperature admissible has been exceeded.

Engine lubrication lamp

Stop the Machine and check oil level or find a defect!

AMN6

Not wired

Indicator lamp for engine overheated AMN7

Check hydraulic oil level AMN12

Not wired

Not wired

Indicator lamp for traffic-indicator lights AMN8

Indicator lamp ON will signal traffic-indicator lights are ON, or alarm lights have been turned ON.

Neutral indicator lamp AMN9

Indicator lamp ON will signal the position of travel controls is in neutral (N).

Before starting the engine the travel controls (1) shall be in neutral position (N)!

AV 130 X

49

2.7.

Machine basic functions control 28

0

J1939

MAN

1 0 WTS

2

kg

AUT

IDLE

402605

50

AV 130 X

OPERATION MANUAL RH Cluster (28) Fuel filter indicator lamp Level height in sprinkling tank.

AMN18

Indicator lamp lighted ON signals water presence in fuel filter.

AMN27

It signals the actual level of water in the tank, and when emptied to min the red LED will start to flash.

If this indicator is ON, please clean the fuel filter!

Check water level in the tank during Machine run.

Engine glowing indicator lamp AMN19

Cooling liquid indicator lamp AMN13

Indicator lamp lighted ON during engine run will signal a defect. Following 5 seconds the acoustic alarm will start, and after 2 minutes the engine will stall automatically – the Machine will stop and parking brake will be enabled.

Signals engine warming up before cold start. As per engine specifications.

Spreader indicator lamp AMN20

This indicator lamp signals the spreader is ON (optional).

Air conditioner indicator lamp Indicator lamp to protect against engine overload (ANTISTALL)

AMN14

Indicator lamp signals air conditioner is ON (optional).

AMN21

This indicator lamp signals the ANTISTALL is ON. CRAB mode indicator lamp Sprinkling pump indicator lamp

AMN15

Indicator lamp signals the drum is set to CRAB mode.

AMN22

Indicator lamp signals sprinkling pump is ON. Indicator lamp for soft starting to move and stopping to move AMN16

Indicator lamp ON signals the mode of soft starting to move and stopping to move is ON.

Constant speed indicator lamp AMN23

This indicator lamp signals the constant speed mode is ON. ASC indicator lamp Alarm lights indicator lamp

AMN17

Not connected.

AMN24

This indicator lamp signals alarm lights are ON.

AV 130 X

51

2.7.

Machine basic functions control

0

J1939

MAN

1 0 WTS

32 33

2

kg

AUT

IDLE

29

34

30 31

35

402606

ENGINE DIAGNOSTICS (29) – 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 29.

Engine diagnostics switch (30) 2428

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 (32).

Note Signal lamp (32) or (33) will go on in case of an engine malfunction, depending on severity of the defect. After activating switch (30), the will start flashing the code of the first defect.

If both pilot lamps indicating defects (yellow – 33 and red – 32) go on after pressing the switch when the ignition box is on that means no defects have been identified by engine ECM.

After the signal lamp (32) goes on, stop operation and engine while keeping safety at work!

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

After the signal lamp (33) repair the defect as soon as possible!

52

AV 130 X

OPERATION MANUAL Example of flashing error code Troubleshooting switch (31)

Flashing code consists of three digits.

Example: code 123 signal lamp Yellow lamp (33) will flash, red lamp (32) will flash the code after 1-2 sec.

3007

The switch is in the middle position.

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

Turn it continuously any direction (+ forward or - backward) to find defects according to flashing codes of signal lamps 32 or 33.

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

Turn ON/OFF switch (31) repeatedly to select idle engine speed ranging from 650 to 1200 RPM. By switching in the upper half of the switch (31), the idle engine speed is reduced. By switching in the lower half of the switch (31), 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.

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 (31) to move to the next error.

Note If only one defect is identified, its error code will be signaled repeatedly even if you press switch (31) in either direction.

After the signal lamp (32) goes on, stop operation and engine while keeping safety at work!

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

If signal lamp (33) lights up, repair the defect as soon as possible!

Stop engine - signal lamp (32) 3000

Stop the engine as soon as possible if this red lamp goes on.

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

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

WTS

Engine glowing indicator lamp (34)

3008

Signals engine warming up before cold start. As per engine specification.

Engine warning - signal lamp (33) 3000

This yellow lamp indicates a defect - the engine must be checked.

! WARNING !

Repair the defect as soon as possible!

Troubleshooting according to flashing codes ••

In case of engine fault, either stop engine red signal lamp (32) or engine warning yellow lamp (33) will light up.

••

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

••

Press button (30) 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 (31) to move to the next error. You can search for error codes stored in ECM index using symbols of switch (31) upper symbol forward or bottom symbol backward.

AV 130 X

53

2.7.

Machine basic functions control

Steering wheel positioning (35) It is used to facilitate boarding and leaving the Machine by its operator.

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

A

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

A

400126 Operator seat (36) Seat adjustment: 1

Backrest position

2

Arm support position and lifting

3

Seat turning

4

Seat shifting

5

Seat springing stiffness according to weight indicator.

6

Seat height – grasp the seat and lift slowly to adjust seat height in its next higher position and lock it there. Once lifted to its highest position, the seat will drop back to its lowest position.

3

2 1

6

4 5

400122

Adjust your seat before driving !

Driver must be fastened with the seat belt while driving!

400253 54

AV 130 X

OPERATION MANUAL How to swivel operator’s place: Operator’s place can be swivelled within the range of 40° when accelerator pedal is pressed. Once the pedal is released the operator’s place is locked (arrested) in one of 4 positions.

Seat switch: Seat switch is located in its cushion.

Description of seat switch function: It is used to interlock the engine starting or to stop the Machine if no operator sits on the seat.

Interlocking of engine starting: When operator is not sitting on the seat the Machine cannot be started.

MAX 56°

401223

Machine stopping: If operator stands up from the seat while driving then the Machine will stop following 8 seconds.

Machine starting to move: Its operator must sit down on the seat and shift the travel controls (1) to neutral (N) and then select direction of running.

Do NOT load seat switch with other objects!

Documentation stowage box 2428

The locker for documentation is located on the seat’s rear side.

400123

AV 130 X

55

2.7.

Machine basic functions control

Cut-out box (27) 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

37

401615C Other fuses located on the Machine At battery disconnector F9 - 7,5 A

radio

F10 - 30A

engine power supply

F16 - 125A

engine preheating

F9 F10

F16

402218 Under the cabin lighting cover F11 - 15 A

Wipers + Window Washers

F12 - 15 A

Fans

F13 - 5 A

Fan + Air Conditioner Control

F14 - 10 A

Air Conditioner

401215

400119 56

AV 130 X

OPERATION MANUAL Cabin fuse (38) F15 - 30 A

cabin wiring

Always replace the fuses with the ones of identical value!

38

Diagnostics socket (39)

39

It is used to check and set the control units’ parameters via external computer units (notebook).

Mounting socket (40)

401615D

It is used to connect auxiliary inspection lamp (12V).

Front wiper selector switch (41) 596625

40

44

41 42 43

Three-position selector switch --

Turned OFF

--

Low speed ON

--

High speed ON

Rear wiper selector switch (42) 596307

Three-position selector switch --

Turned OFF

--

Low speed ON

--

High speed ON

401620C

Glass washer switch (43) 2260

Two-position selector switch --

Windscreen washing ON

--

OFF

--

Rear window washing ON

Fan switch (44) 594701

It is used to switch ON cabin fan, its function is signalled via indicator lamp in the switch.

--

OFF

--

High delivery ON

--

Low delivery ON

AV 130 X

57

2.7.

Machine basic functions control

Cabin lighting (45) Ceiling lamp incl. selector switch is located overhead the dashboard.

47

Ventilation nozzles (46) Adjustable nozzles are located on cabin ceiling, please adjust and swivel the dampers to alter the amount and direction of flowing air.

Air-conditioning Swich (47) (Option)

46

45

2441

401620D max

Control tie rod for heating valve (48)

min

50

48

2638

It is used to switch ON the cabin heating.

Make continuous control from MIN position (valve closed) to MAX position (valve fully open) for the amount of liquid flowing to the heating body.

49

Adjust the heating valve before driving!

Hand pump control lever (49)

401622C

It is used to control the hand pump when lifting or letting down the bonnet.

First-aid box stowage place (50)

The Machine shall be equipped with first-aid box!

Extinguisher (51) (OPTION) Place for the installation of a fire extinguisher.

! Attention !

The manufacturer recommends that the machine be equipped with a fire extinguisher.

401703 58

AV 130 X

OPERATION MANUAL Stowage pockets (52) These are used for Operator’s personal items.

52

401622D Anti-dazzle (sun) screen (53) Adjust the anti-dazzle screen through securing it to the fixing on the glass.

400242 Window washer tank (54) Fill with standardly available media.

Fill with antifreeze or drain before winter season starts!

401625 Additional lights (55) Lights located on the Machine cabin (optional).

400258 AV 130 X

59

2.7.

Machine basic functions control

Beacon socket (56) It is used to connect the beacon.

Back mirrors (57) External back mirrors enable to view poorly visible areas.

Maintain these mirrors clean and properly adjusted!

400243 Cabin ventilation air filter (58) It includes replaceable filter element to catch the impurities drawn in from air.

400258A Arm rests on the door (59) Transportation position

400244 Working position

400245 60

AV 130 X

OPERATION MANUAL Battery disconnector (60) It is used to disconnect the battery from the Machine frame.

Position „0“ – Machine wiring disconnected.

„0“

„I“

Position „I“ – Machine wiring connected.

401678 Hand pump (61) It is used to lift or let down the bonnet.

Located on LH side of rear frame.

402218A

AV 130 X

61

2.7.

Machine control and use

27

28

0

J1939

MAN

1 0

2

WTS

kg

AUT

IDLE

14

34 18

12

1

1

8

1

0

N

402601C 62

AV 130 X

OPERATION MANUAL 2.7.1. Start-up of the engine Check daily before engine starting the amount of oil in the engine and hydraulic tank, cooling liquid in the cooling circuit, fuel in fuel tank, water level in water tank. Confirm no loosened, worn or missing parts exist on the Machine.

Start the engine only from the driver’s control stand! Use alarm horn to signal the engine starting and check nobody is endangered by starting the engine!

How to start: --

Switch ON the battery disconnector (60).

--

Insert key in the ignition box (12) in “0” position and switch over to “I” position.

--

All indicator lamps on clusters (27 and 28) will light up.

--

Then on cluster (27) the indicator lamps for brakes, recharging, neutral and WTS (34) will remain ON.

--

Wait until the WTS indicator lamp (34) goes out.

--

If you leave the key in ”I“ position for over 15 seconds then the acoustic alarm will switch ON – to warn operator about the battery discharged (acoustic alarm will turn OFF once engine is started). Unless it is started within 2 minutes, please get your key back to “0” position before starting the engine again.

--

Use alarm horn on combined switch (18) to signal engine starting.

--

Turn on IDLE (14) engine idling switch.

--

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

--

On cluster (27), following the starting, the recharging indicator lamp shall go OFF.

--

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

--

If upon the starting the following indicator lamps light up: charging, 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.

Note If starting is unsuccessful, please turn your key back to ”0“ position. Unless engine starts even after 3 attempts – please check the oil system.

Starting is interlocked: --

unless travel controls (1) are in neutral position (N)

--

unless operator is sitting on the seat

--

emergency brake (8) function is enabled.

Do NOT start the engine for over 30 seconds. Wait 2 minutes before any next starting.

When starting at low temperatures the recharge indicator lamp will remain ON accompanied by a sound alarm – increase engine rpm adequately – the indicator lamp will go OFF. Following the engine start let the engine idle at increased rpm for 3÷5 min.

Steep rpm increase or decrease is inadmissible – it may damage the engine.

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

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

AV 130 X

63

2.7.

Machine control and use

+ 0

12

V

1

12

0

4

+ 2

V

3

402005

64

AV 130 X

OPERATION MANUAL Starting with the use of starting cables from an other machine

Starting voltage from external power source shall be the voltage of 12V. Follow unconditionally the operation sequence below.

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

2/ Connect second end of (+) cable pole to (+) pole.

3/ Connect one end of (–) cable pole to (–) pole of external battery.

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

When started, disconnect the battery jump cables in reverse order.

Do not connect (–) pole cable to (–) pole of discharged battery of the Machine being started! There is risk of strong sparking in course of starting followed by explosion of battery-generated gas.

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

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

Do NOT lean over the battery – risk of electrolyte burn!

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

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

AV 130 X

65

2.7.

Machine control and use

13 0

J1939

MAN

1 0 WTS

2

kg

AUT

IDLE

1

1

2

1

0

N

402601D 66

AV 130 X

OPERATION MANUAL 2.7.2. Travel and reversing Before starting to move, please check the area in front and behind the Machine is clear and with no persons or obstructions present!

Use loud horn to signal engine starting and wait long enough for those persons present to leave the in time the area round the Machine or the area beneath the Machine!

Operator must sit on the seat before the Machine starts moving! If the operator gets up from the seat during the Machine travel then the Machine will stop and brake.

Machine travel and reversation Select travel direction: Start the engine. Adjust max engine rpm via accelerator control (13) Get the Machine moving by shifting travel controls (1) from (N) zero position to (0) neutral position and then by selecting a direction of running.

Shift the controls (1) to opposite direction to change the direction of Machine travel.

Travel speed selection: Travel speed corresponds to the deflection magnitude of travel controls (1) from zero position (0).

Travel speed can continuously be altered using speed potentiometer (2) within the range of MIN (turtle) to MAX (rabbit).

If the speed potentiometer (2) is in MIN position then the Machine is unable to start moving.

Note The instantaneous stopping of the Machine by means of travel controls (1) applies to all travel modes of the Machine.

Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.

AV 130 X

67

2.7.

Machine control and use

28

0

J1939

MAN

1 0 WTS

2

kg

AUT

IDLE

19

1

1

2 3

1

0

N

402601E 68

AV 130 X

OPERATION MANUAL Travel modes of the Machine: ••

RAMP (soft starting to move and stopping to move)

••

CONSTANT SPEED (continuous Machine drive)

••

ANTISTALL (engine protection against overload)

••

CRAB (extended track of the Machine)

Travel in RAMP mode The function of soft starting to move or stopping to move prevents from forming the waves when compacting the bitumen surface during Machine travel.

Attention, in this mode the Machine stopway is longer!

Use speed potentiometer (2) to adjust the speed, and use travel control (1) to adjust travel direction.

Press pushbutton (3) to switch ON/OFF this function, indicator lamp on cluster (28) will light up to signal this function.

Move travel controls (1) to opposite position via (0), and then return it back to (0) position within 1 second interval to stop the Machine – the engine will remain running.

Following the travel controls (1) moved to neutral (N) the function will be OFF! Shift travel controls (1) to neutral (N) position, press pushbutton (3) – the function will become enabled again.

Note You may switch ON the function during Machine travel.

Travel in CONSTANT SPEED mode This function is used to maintain continuous travel while the Machine is ascending or descending.

AMN23

Use speed potentiometer (2) to adjust travel speed and use travel controls (1) to adjust its direction.

Use switch (19) to turn ON/OFF the function, indicator lamp on cluster (28) will light up to signal this function.

Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.

Swivel the travel controls (1) from position (0) and the Machine will start moving.

Note The function can be turned ON during Machine travel.

AV 130 X

69

2.7.

Machine control and use

28

13 0

J1939

MAN

1 0 WTS

2

kg

AUT

IDLE

19

1

1

2 3

1

0

N

402601F 70

AV 130 X

OPERATION MANUAL Travel in ANTISTALL mode AMN21

It is used to protect against engine overload on steep grade or with the Machine sunk.

Control unit will automatically reduce the power take-off through lowering the set rpm (rpm of travel hydraulic motor) independently of travel control position. Thus the pulling power (of the travel hydraulic motor) will increase – the engine will get relieved.

Switch OFF the function of soft starting to move and stopway via switch (3) if this function is turned ON! Before turning ON the switch (19), please use accelerator control (13) to adjust engine’s max rpm!

Use speed potentiometer (2) to adjust travel speed, and use travel controls (1) to adjust its direction.

Use switch (19) to turn ON/OFF this function, the indicator lamp on cluster (28) will light up to signal this function.

Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.

Swivel travel controls (1) from position (0) and the Machine will start moving.

When having overcome a difficult terrain, please turn OFF the switch!

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

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

MAX 40%

402006

MA 25%X

MAX 15%

402007 AV 130 X

71

2.7.

Machine control and use

28

0

J1939

MAN

1 0 WTS

6

2

kg

AUT

IDLE

6

5

5

1

1

2

1

0

N

402601G 72

AV 130 X

OPERATION MANUAL Travel in CRAB mode This function is used to adjust extended track during Machine travel.

Use potentiometer (2) to adjust travel speed, and use travel controls (1) to adjust its direction.

Press pushbuttons (5) and (6) on travel controls (1) to control the Machine in CRAB mode, and at the same you may turn the Machine.

Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.

Swivel travel controls (1) from (0) and the Machine will start moving.

Turning ON: Press button (5) to deflect the front drum to the right and press button (6) to deflect to the left, the indicator lamp on cluster (28) will light up to signal this function.

Max deflection of the front drum to both sides is 160 mm.

Turning OFF: Indicator lamp on cluster (28) will go OFF to signal CRAB mode has been reset.

Note If the Machine is equipped with cutter and final compactor, then pushbuttons (5) and (6) on travel control (1) on the same side where it has been mounted, are used to control it.

Then pushbuttons (5) and (6) on the second travel control (1)) are used to control the Machine in CRAB mode.

Take special care when Machine travels in CRAB mode near constructed facilities so to avoid their damage due to any collision (hitting)!

If necessary, fold the external mirrors!

AV 130 X

73

2.7.

Machine control and use

27 15

16 13 0

J1939

MAN

1 0 WTS

2

kg

AUT

IDLE

17

1

7

7

1

2

1

0

N

402601H 74

AV 130 X

OPERATION MANUAL Machine travel and reversation incl. vibrations Adjust max engine rpm via accelerator control (13), and adjust travel speed via speed potentiometer (2).

Use selector switch of the vibrating drum (15) to choose vibration (front / both / rear), and use vibration amplitude selector switch (16) to choose high or low amplitude.

Vibration manual switching ON/OFF mode (MAN): Use switch (17) to turn ON/OFF this function.

Press button (7) on travel control (1) to switch ON the vibration.

Indicator lamp on cluster (27) lighted up will signal this function.

Press button (7) on travel control (1) again to switch OFF vibration.

Note MAN mode enables to switch ON vibration on stationary Machine, the travel controls (1) shall be in (0) position.

You can switch OFF the vibration by shifting travel controls (1) to neutral (N) position.

Automatic vibration switching ON/OFF mode (AUT): Use switch (17) to turn ON/OFF this function.

Press button (7) on travel control (1) to switch ON vibration.

Indicator lamp lighted up on cluster (27) will signal vibration function.

Vibration will automatically switch ON at travel speed over 0,5 km x hour–1 (0,3 MPH).

Vibration will automatically switch OFF at travel speed below 0,5 km x hour–1 (0,3 MPH).

Automatic vibration function remains enabled even after travel controls (1) have been moved via position (0).

Note Vibration can be switched OFF through shifting travel controls (1) to neutral (N) position.

Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.

Deflect travel controls (1) from position (0) and the Machine will start moving.

The Machine will stop only with the travel controls (1) set to the position.

Upon the Machine shutdown the travel controls (1) shall be in the parking brake position (neutral ”N“)!

AV 130 X

75

2.7.

Machine control and use

27

0

J1939

MAN

1 0 WTS

2

kg

AUT

IDLE

14 12

7

1

7

1

8

2

1

0

N

402601I 76

AV 130 X

OPERATION MANUAL 2.7.3. Emergency stop of the Machine Apply this in the event of failure where the engine is unable to be shut off via the key in the ignition box, or through shifting the travel controls (1) to position (0)!

How to switch ON: Press emergency brake button (8) and the Machine will brake, engine will turn OFF and the acoustic alarm will start.

On cluster (25) the indicator lamps for seat switch, parking brake, recharging will light up.

How to switch OFF: Turn the press button in the direction of arrows and the acoustic alarm will get turned OFF.

On cluster (25) the parking brake indicator lamp and neutral indicator lamp will remain ON. Shift travel controls (1) to neutral (N) position, the Machine can be started again in this position.

Do NOT use emergency brake to stop or switch OFF the engine during normal operation of the Machine!

2.7.4. How to stop the Machine and its engine Press button (7) on travel control (1) to switch OFF vibration, indicator lamp on cluster (27) will go OFF. Stop the Machine through shifting travel controls (1) to neutral (N) position.

Turn on IDLE (14) engine idling switch.

Switch over the key in the ignition box (12) to “0“ position, and tilt back the ignition box lid to close it.

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

Travel controls (1) shall be always in neutral (N) position!

Switch OFF the battery disconnector during Machine shutdown!

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

Following the engine stop, before leaving the Machine, please disconnect its battery disconnector (60).

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

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

Lock the Machine covers and its cabin.

3351

30 sec

0

Switch off the battery disconnector no sooner than 30 seconds after removing the key from the ignition switch.

Keeping of the time limit is necessary for saving the data of the ECM motor.

Do NOT stop hot engine instantly, but instead let it idle for 3 minutes. The engine and turbocharger will cool down slowly and evenly!

3351

AV 130 X

77

2.7.

78

Machine control and use

AV 130 X

OPERATION MANUAL 2 .7.6. Bonnet raising and lowering Stop the Machine, shut off the engine, and disconnect battery disconnector (60).

„0“

„I“

Lift the bonnet with the engine shut off and battery disconnector disconnected!

Check that no persons are under hazard when letting the bonnet down!

Keep your limbs out of the area of the lowering of the bonnet

401678 Lift the bonnet Remove control lever and insert in the hand pump.

Turn the bonnet lifting valve clockwise till the stop, do not tighten the valve with force.

Pump to lift the bonnet.

402220 Once lifted, secure the bonnet.

With the bonnet raised up, do not turn the machine (to the right/left) as this could damage the bonnet and cab!

402240 Let down the bonnet Unlock the bonnet Turn anticlockwise the valve designed to lift the bonnet, the bonnet will start to descend.

Confirm safe touch-down of the bonnet.

Remove control lever and put it inside Machine cabin.

402219 AV 130 X

79

2.7.

Machine control and use

28

0

J1939

MAN

1 0 WTS

2

kg

AUT

IDLE

11

9

10

402601J 80

AV 130 X

OPERATION MANUAL 2.7.7. Sprinkling It is used to sprinkle the Machine drums.

Switch ON one of two sprinkling pumps via sprinkling pumps selector switch (11).

Indicator lamp on cluster (28) will signal the function of switching ON the sprinkling pump.

Green LEDs signal water level in the tank, red LED flashes when emptied to min.

Using the potentiometer of the watering cycle interval (10), set the watering intensity within the range of MIN / MAX. The watering intensity depends on the driving speed; the standing machine performs watering only if the potentiometer (10) is set to MAX. Using the watering button (9), it is possible to switch on the additional watering of drums, e.g. before driving on a compacted bitumen surface.

Check water level in the tank during Machine operation.

We recommend to alter the pumps following 100 motohours in order to ensure their uniform wear.

AV 130 X

81

2.7.

Machine control and use

2.7.8

Ammann edgecutter

(OPTION)

To additional assembly use appropriate manual.

Edge cutter plate location.

401635A Edge cutter plate 1 - Name – always mentioned only in the English version

2

2 - Type

3

3 - Serial number 3459

4 - Maximum weight

TYPE

5 - Year of manufacture

AMMANN CZECH REPUBLIC a.s.

Náchodská 145 549 01 NOVÉ MÌSTO NAD METUJÍ CZECH REPUBLIC

4

SERIAL NUMBER

MAXIMUM MASS

DESIGNATION

YEAR OF CONSTRUCTION

MADE IN CZECH REPUBLIC

5

1

3459 How to activate the cutter Open the valve of disc sprinkling on the edge cutter arm.

401635 Turn the switch of sprinkling (11) on to the position II.. Sprinkling of the disk is connected to the circuit of sprinkling of the front drum.

J1939

MAN

1 0

2

11 82

kg

AUT

IDLE

402614 AV 130 X

OPERATION MANUAL 6

Before starting the scraper, make sure that nobody is endangered.

5

Press button (5), (6) (see up/down symbols on the button) to set the edge cutter to the required position.

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

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

401638 The cutting disc (2) can be replaced for the compacting disc (3).

To replace them, dismantle 6 bolts holding the compacting disc on the rear bracket. Fix the unused cutting disc to the rear right bracket of the drum by two bolts.

3

2

401636

2.7.9. Infra thermometer (OPTION) It is activated by turning on the key in the switch box (12) and it measures the temperature of the bitumen surface being rolled.

401639 The temperature is sensed by a sensor. The measured temperature in °C is indicated on the display (25).

25

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402614A AV 130 X

83

2.8.

••

Machine transport

The Machine may pass by its own axis between its workplaces.

When moving, observe the safety measures applicable to the working site.

••

When on the road, the machine should be transported on a vehicle.

When transporting the machine on a vehicle, observe the regulations in force in the given territory.

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

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

The drums must be secured using scotch blocks 2.

84

1

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1

2 402008

AV 130 X

OPERATION MANUAL 2.8.1. How to load the Machine

14 500 kg (32 000 lb)

Use loading ramps or a crane to load the Machine on its transporting vehicle.

Lmin = 5 m 2x min 4000 kg (2x min 8820 lb)

For loading with crane the Machine is fitted with lifting lugs.

Lmin = 5 m 2x min 4000 kg (2x min 8820 lb)

Before lifting, the Machine joint must be secured against slight turning.

402009 How to secure the joint Use pin 1 and safety pin (lock) 2 to secure the joint before loading.

Observe safety regulations when loading and unloading!

Use the crane of sufficient loading capacity!

Use corresponding and unbroken rigging of sufficient loading capacity!

The Machine must be tied to the lifting lugs on the Machine!

Only a trained person (slinger) may carry out the tying of the Machine!

Keep off the area beneath the hanging load!

AV 130 X

1 2 401647

85

2.9.

Special conditions for using the machine

2.9.1. Machine towing To provide for towing the Machine is equipped with two lugs on front frame, and with two lugs on rear frame.

A Machine sunk can be hauled for a short distance if the engine is running and the travel drive and steering do work.

Operator on towed Machine shall steer the Machine in the direction of hauling.

Unless the engine works, or a defect exists within the hydraulic system, or travel pump is broken, then you must brake off the Machine and short-circuit the hydraulic circuit. No person may stay on the Machine towed!

When braked off and hydraulic circuit for the travel is short-circuited, this means that all the brakes are disabled!

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

Do NOT touch hot parts of the Machine, burn hazard!

402010

2 1 3

How to brake off the Machine:

401248

Lift the bonnet and secure it.

Remove hose (3) away from the clip.

Disconnect hose (1) in quick-coupler (2).

Connect hose (3) into quick-coupler (2) .

In the engine compartment,

401250 You must use an appropriate tool to press down the buttons of both travel pumps in order to short-circuit the hydraulic loop.

Connect battery disconnector (60).

Switch over the key in ignition box to “ I“ position.

Note If the key remains in “I“ position for more than 15 seconds the acoustic alarm will switch ON – to warn operator the battery has been discharged.

401249 86

AV 130 X

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

Insert control lever into the hand pump and start pumping until brake indicator lamp on cluster (27) goes OFF. Now the Machine is braked off, and it will be possible to tow it away.

Due to leakage the pressure in the brakes may lower in course of towing.

Check regularly the Machine brakes do not become hot in course of towing the Machine.

If brake indicator lamp will go ON in course of towing, stop towing the Machine and start pumping until the indicator lamp goes OFF! When towing is completed, secure the Machine with scotch blocks against its driving away, and carry out the application of its brakes!

402220

How to brake the Machine: Turn the bonnet lifting valve to the left, up to its stop, do not tighten with force.

478320 h

Put the hose (1) and (3) to its original condition.

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

Unlock the bonnet

400111K

Turn the bonnet lifting valve to the left, bonnet will start to descend.

Confirm safe touch-down of the bonnet.

Remove control lever (49) and put it back in the Machine cabin.

Make sure that nobody is endangered by the bonnet lowering!

Keep your limbs out of the area of the lowering of the bonnet!

When operating the machine under normal conditions when the hose with the quick coupling (3) is not connected at the point (2), the function of “Emergency Hydraulic Machine Brake Releasing”, the hose with quick coupling (1) must always be connected at the point (2)!!!

No persons may be on the towed roller with a non-functional engine.

After towing the roller away, restore the roller into original condition!

AV 130 X

87

2.9.

Special conditions to use the Machine For towing purposes, use only intact tow-ropes or towing-bars with a sufficient capacity 1.5 times higher than the towed machine weight. It is banned to use chains for towing the machine!

It is necessary to keep the minimum departure from the direct towing angle.

The maximum departure is possible at an angle of 30°.

When towing, it is necessary to ensure the continuous movement. Do not exceed a towing speed of more than 2 km/ hour (1.2 mph). Do not tow the machine for a longer distance than 300 m (0.19 mi).

The size of the towing machine should correspond to the size of the towed machine. It must have a sufficient traction force (power), weight, and brake effect.

Do not start the engine when towing.

When towing downhill using a rope, another towing machine must be connected to the rear part of the damaged machine. Thus it is possible to prevent an uncontrolled movement of the damaged machine.

Note These are general requirements for safe towing of a damaged machine under normal conditions. Please consult with your dealer any and all different situations that may occur while towing the Machine.

88

AV 130 X

OPERATION MANUAL 2.9.2. Operating the machine during initial run period Do NOT load the Machine at its full capacity when putting the new Machine into operation or following its major overhaul during the first 30 hours!

2.9.3. Operating the temperatures

Machine

at

low

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

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

Set up the Machine for operation at low temperatures: ••

Check concentration of engine cooling liquid.

••

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

••

Use hydraulic oil of corresponding cinematic viscosity.

••

Use winter diesel oil.

••

Confirm battery has been recharged.

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

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

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

--

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

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

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

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

2.9.6. Work of the machine in the dusty environment While in very dusty environment, please cut short the intervals of cleaning and replacing the air filter elements; and the replacement intervals of cabin dust filter, and cut short the intervals of cleaning the coolers.

Recommended interval of cleaning is 1x per week.

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

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

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

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

AV 130 X

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MAINTENANCE MANUAL

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

AV 130 X

91

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3.1.

Safety Standards at Lubrication and Maintenance

3.1.1. Safety of machine maintenance Carry out lubrication, maintenance and adjustments:

3.1.2. Fire precautions during operation media exchanges •

In terms of fire hazard the flammable liquids used on the Machine have been divided into three hazard classes:

•

By professionally trained personnel

•

In line with safety instructions given in the Operation Manual

•

According to schedule given in the Lubrication Chart following the hours actually worked

•

•

On the machine located on flat solid surface, secured against self-motion (scotch blocks), and this always with the engine OFF, key removed from ignition box, and the wiring cut off

Oil exchange point shall be located so it does not interfere with the explosion or fire hazard area.

•

It shall be identified with notice boards and signs of no smoking and no use of open flame.

•

On machine parts cooled out

•

•

After having cleaned the machine, lubrication points and maintenance locations

Handling area shall be sized so the capture the amount to flammable liquid equal to the capacity of biggest vessel, transport container.

•

Using proper, undamaged tools

•

It must be equipped with portable fire extinguishers.

•

Through replacement with new original parts as per the Spare Parts Catalogue

•

To handle the oil, Diesel oil, please use such vessels like metal barrels, canisters or sheet-metal cans.

•

With sufficient lighting of the entire machine in the event of lowered visibility and at night

•

Transport containers shall be properly closed when stored.

•

•

so the guards and safety elements are reinstalled again upon work completion

Vessels shall have one opening, be stored with the opening on top, and secured against any flowing out or dripping of their content.

•

through retightening bolted connections – with torque specified, and through checking the connection tightness

•

Vessels shall be designated with indelible inscription indicating the content and flammability class.

•

with the operation media heated – beware of burns – use recommended media, only

IInd

Hazard class – Diesel oil

IVth Hazard class – mineral oils, lube greases

Upon completion of the adjustment or maintenance, please examine the function of all safeguard equipment!

AV 130 X

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3.1.

Safety Standards at Lubrication and Maintenance

3.1.3. Ecological and hygienic principles

3.1.3.2. Ecological principles

When operating or maintaining the Machines the user shall be liable to follow the general principles of health and environment protection according to the laws, ordinances and regulations in individual territories of the Machine use.

The media of Machine’s individual systems, and some of its parts after having been discarded (dismantled, media exchanged) become waste with hazardous properties against the environment.

3.1.3.1. Hygienic principles •

•

Crude oil products, cooling system media, battery media and coating compositions incl. thinners are materials harmful to health. Workers coming into contact with these products during machine operation or maintenance shall be liable to follow the general principles of their own health protection and conform to the safety and hygienic manuals of these products’ manufacturers.

We call your attention to the following in particular: --

Eye protection and skin protection during work with the batteries

--

Skin protection during work with crude oil products, coating compositions or cooling liquids

--

Proper hand washing upon work completion and before any meal; use adequate reparation cream to treat your hands

--

Adherence to the instructions given in this Manual

•

Always store the crude oil products, cooling system media and battery media, and coating compositions incl. organic thinners, and also the cleaners and preserving agents, in the genuine, original and properly labelled packages. Do not admit any storage of these materials in unlabelled bottles or in any other vessels with regard to the hazard of mistaken identification (faulty change).

•

When skin, mucosa, eyes are accidentally stained, or vapours inhaled, immediately apply the first aid principles. In the event of accidental use of these products get prompt medical attention.

•

When working with the Machine in cases where the Machine has platform fitted, cabin windows are left opened, always use ear protectors of adequate type and version.

94

•

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

Organic and synthetic lubricating materials, oils and fuels

--

Brake fluids

--

Cooling liquids

--

Battery media and the batteries themselves

--

Cooling system media

--

Cleaners & preserving agents

--

All dismantled filters and filter elements

--

All used and discarded hydraulic or fuel hoses, rubbermetal and Machine’s other elements, made dirty due to the abovementioned products.

The given materials and parts, when scrapped, shall be handled compliant to the respective national regulations on environmental protection, and in line with the health protection regulations, as well.

AV 130 X

3.2.

Specification of fluids

3.2.1. Engine oil 2412

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 /SK

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.

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

When using oil according to API CG-4/ SH, the exchange interval should be cut to one half, i.e. 250 hours or 3 months.

AV 130 X

400150

95

3.2.

Specification of fluids

3.2.2. Fuel Diesel is used as fuel: CEN EN 590 ASTM D 975-88: 2-D

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.

96

3.2.3. Coolant 2152

Use coolant consisting of 50 % water 50% ethyl glycol of frostresistant 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.

Use modified demineralized or destilled water for this mixture.

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).

AV 130 X

MAINTENANCE MANUAL 3.2.4. Hydraulic oil

Synthetic hydraulic oil 2158

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

Standardly refill the machines with hydraulic oil of kinematic viscosity 68 mm2/s at the temperature of 40 °C (104 °F) ISO VG 68.

This oil is the most suitable one to use in the broadest range of ambient temperatures.

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.

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!

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 mm2/s - HV 100 (BP BARTRAN HV 100; ESSO UNIVIS N 100, etc.).

If you have to start the machine at ambient temperatures lower than – 8 °C (18 °F) for a time period longer than one month, exchange the hydraulic system oil for one having kinematic viscosity of 46 mm2/s – viscosity class HV 46.

At temperatures lower than – 13 °C (9 °C) exchange it for oil having kinematic viscosity of 32 mm2 / s (e. g., BP BARTRAN HV 32; ESSO UNIVIS N 32, and the like).

AV 130 X

97

3.2.

Specification of fluids

3.2.5. Gearbox oil

3.2.6. Lubricating grease 2186

Use high-quality oil corresponding to API GL-5, or EP or MIL-L2105 D to lubricate gearbox, pumps and drum reductors.

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

0787

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.).

3.2.7. Windshield washer liquid 2260

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

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

98

AV 130 X

3.3.

Fills Fills of...

Engine

Type of fill

Engine oil according to chapter 3.2.1.

Quantity l (gal US)

Brand

11,6 (3,1) 2412

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)

Hydraulic system

Hydraulic oil according to chapter 3.2.4.

60 (15,8)

2152

2158

Pump driven gearbox Drum gearbox

Vibrating drums

Gearbox oil according to chapter 3.2.5.

Engine oil according to chapter 3.2.1.

1,8 (0,47) 2 x 2,5 (0,67)

2186

2 x 19 (5) 2412

Joint bearings - joint and steering cylinder

Plastic grease according to chapter 3.2.6.

Battery

Distilled water

as required 0787

as required 2587

Windshield washers

Water tank

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

2,75 (0,72)

Water

1000 (264)

2260

2567

AV 130 X

99

3.4.

Lubrication and Maintenance Chart

After 20 hours of operation (daily) 3.6.1.

Engine oil level check

3.6.2.

Engine cooling liquid level check

3.6.3.

Hydraulic tank oil level check

3.6.4.

Crankcase breather tube

3.6.5.

Checking the condition of the ventilator and belt

3.6.6.

Checking the vacuum valve of the air cleaner

3.6.7.

Fuel level check

3.6.8.

Water tank refilling

3.6.9.

Cleaning the water separator

3.6.10.

Warning and control devices checking

After 250 hours of operation (3 months) 3.6.11.

Air intake cooler, intake piping

3.6.12.

Checking the cooling circuit of the engine

3.6.13.

Checking the engine belt

3.6.14.

Checking battery

3.6.15.

Air filter sensor check

3.6.16.

Machine lubrication

3.6.17.

Checking oil in gearboxes

3.6.18.

Watering filter cleaning

After 500 hours of operation (6 months)

100

3.6.19.

Engine oil exchange

3.6.20.

Fuel filter exchange

3.6.21.

Engine cooling liquid level check

3.6.22.

Check of wiring

AV 130 X

MAINTENANCE MANUAL After 1,000 hours of operation (after 1 year) 3.6.23.

How to check tightening pulley and belt of the engine

3.6.24.

Exchanging oil in gearboxes *

3.6.25.

Damping system checking

3.6.26.

Fuel tank cleaning

3.6.27.

Water tank cleaning

After 2,000 hours of operation (after 2 years) 3.6.28.

Vibrations system oil exchange

3.6.29.

How to replace hydraulic oil and filters

3.6.30.

Exchanging the engine cooling liquid

3.6.31.

Exchanging cleaner elements of air cleaner

3.6.32.

Inspect, adjust engine valve clearance **

Maintenance - As Needed 3.6.33.

Cleaning of coolers

3.6.34.

Water discharge from watering circuit before winter season

3.6.35.

Cleaning the air cleaner of cabin ventilation

3.6.36.

Cleaning the machine

3.6.37.

Adjustment of scrapers

3.6.38.

Checking and tightening bolted joints

* First after 200 hours. ** First after 5000 hours.

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101

3.5.

Lubrication Chart

LUBRICATION PLAN CONTROL LUBRICATE EXCHANGE 2000 1000 500 250 20

Engine oil:

SAE 15W/40

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

Hydraulic oil:

ISO VG 68

ISO 6743/HV

Grease:

ISO 6743/9

CCEB 2

Transmission oil:

SAE 85W/90

API GL-5 402011en

102

AV 130 X

3.6.

Individual Operations of Maintenance

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

0

478320

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MAN

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2

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AUT

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402606A This Manual includes only the basic engine information, others are given in the Engine Operaion and Maintenance Manual which is part of documentation supplied with the Machine.

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

Disassembled or loose bolts, plugs, threaded connections of hydraulics etc. should be tightened with torque according to tables in chapter 3.6.38., unless a different value is listed for the particular operation.

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).

Following the first 200 hours of new Machine operation or after the major overhaul, please carry out the operations under this Section: 3.6.24.

AV 130 X

The first oil exchange in drum gearbox and gearbox pumps drive

103

3.6.

Individual Operations of Maintenance After 20 hours of operation (daily)

3.6.1. Engine oil level check •

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.

402314 •

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.

OK H

H

H

OK L

L

L OK 401305

•

Refill oil after removing the filler plug through the oil filler.

Wait approx. 1 min until the level is stable and check again.

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.

402313A

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

104

AV 130 X

MAINTENANCE MANUAL 3.6.2. Engine cooling liquid level check

1

•

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

•

Check visually the level.

MAX

•

Refill coolant through the filler (1).

MIN

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.

AV 130 X

401307

400159

105

3.6.

Individual Operations of Maintenance

3.6.3. Hydraulic tank oil level check •

Raise the bonnet.

•

Check the level.

•

Fill up oil via the filling device using quick-coupling (1), proceed as per Section 3.6.29..

Tank filler neck cap (2) has been sealed.

If this seal is damaged during guarantee period, then the Machine guarantee will terminate.

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

Oil level must always be visible in the 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.

1

402311

2

402317

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.

402325

400162 106

AV 130 X

MAINTENANCE MANUAL 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.

402316 •

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

402320

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.

400161

AV 130 X

107

3.6.

Individual Operations of Maintenance

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.

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!

108

401316

AV 130 X

MAINTENANCE MANUAL 3.6.7. Fuel level check •

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.

478320 h

400111A •

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

1

2

401318 •

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 18 operating hours of machine.

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

Do not fuel up when the engine is running.

Do not fuel up in closed rooms.

401319

Do not run the tank dry.

Use only clean recommended fuel as specified in Chapter 3.2.2.

Fuel must NOT be spilled.

AV 130 X

109

3.6.

Individual Operations of Maintenance

3.6.8. Water tank refilling •

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.

400112A •

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

1

401322

2

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

Follow the instructions as specified in Chapter 3.6.34.

110

401323

AV 130 X

MAINTENANCE MANUAL 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

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

402315 Do not smoke nor use open fire when working.

Do not drain the separator under running engine.

1

2

3

Catch the drained fuel with sediments to a suitable container.

401402

AV 130 X

111

3.6.

Individual Operations of Maintenance

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

478320 h

400111L •

Furthermore, test the function of the switches of lamps (20-24), the integrated control switch of lamps and horn (18).

0

! WARNING !

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

J1939

MAN

1 0

2

WTS

kg

AUT

IDLE

18 402616 •

Start the engine:

•

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

Charging indicator light

! WARNING !

Should the engine not start within 15 seconds upon turning on the instruments (turning the ignition box key into I position), the engine defect is signaled.

478320 h

400111M •

Drive the machine away:

•

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

--

Travel controller zero position indicator light

--

Brake indicator light

478320 h

400111D 112

AV 130 X

MAINTENANCE MANUAL TOTAL STOP function: •

When the machine is at standstill, verify the function TOTAL STOP (8).

•

After pressing the button (8), the engine turns off.

N

0

8

402601 •

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!

AV 130 X

478320 h

400111L

113

3.6.

Individual Operations of Maintenance

After 250 hours of operation (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.

402321 •

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

402326

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

OK

OK

OK OK 401328 •

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.

OK

402340 114

AV 130 X

MAINTENANCE MANUAL 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.

402326A

402339 •

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.

400181

401329 AV 130 X

115

3.6.

Individual Operations of Maintenance

3.6.13. Checking the engine belt •

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

282N171T •

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

402320

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.

400161

116

AV 130 X

MAINTENANCE MANUAL 3.6.14. Checking battery •

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

•

Clean the surface of battery.

402218 •

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 402327 •

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

400183

AV 130 X

117

3.6.

•

Individual Operations of Maintenance

Compare measured values with the chart.

Density in g/cm

3

Normal temperatures fully charged

in °Be (Beume)

Tropics

Normal temperatures

Tropics

1,28

1,23

32°

27°

semi charged

1,2

1,12

24°

16°

exhausted charge immediately!

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.

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.

118

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!

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

Disconnect the battery to avoid shortcircuit 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.

AV 130 X

MAINTENANCE MANUAL 3.6.15. Air filter sensor check •

Dismount the engine intake cover.

•

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

•

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

402341 •

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

478320 h

400111H •

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

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

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

402332

AV 130 X

119

3.6.

Individual Operations of Maintenance

3.6.16. Machine lubrication •

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

401336

bearing 4x

401337 Steering hydraulic cylinders front pins 3x rear pins 3x

401338

401339 120

AV 130 X

MAINTENANCE MANUAL Hydraulic cylinders of bonnet lifting upper pins 2x

402310 lower pins 2x

402319 Linear hydraulic motor to edge cutter pins 2 x

401635B Door hinges pins pins 8 x

Use only recommended lubricating greases, see chapter 3.2.6.

402323 AV 130 X

121

3.6.

Individual Operations of Maintenance

3.6.17. Checking oil in gearboxes •

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.

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

2 1

402342

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.

402322

Keep the oil level on the upper mark!

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

401347

122

AV 130 X

MAINTENANCE MANUAL 3.6.18. Watering filter cleaning •

Shut off the water feed by means of a valve.

401698 •

Dismount the watering filter vessel (1).

•

Remove the screen (2), and clean it.

1

2

400262 •

Dismount and clean the screens (3) of jet.

401385

3

401397 AV 130 X

123

3.6.

Individual Operations of Maintenance

After 500 hours of operation (6 months) 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.

402334 •

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

402309 •

Clean the contact area of the filter sealing.

400173 •

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

282N130T 124

AV 130 X

MAINTENANCE MANUAL •

Wipe the sealing with oil.

400174 •

Mount the filter and tighten firmly with hand.

401400 •

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.

402313A •

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.

400178 AV 130 X

125

3.6.

Individual Operations of Maintenance 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).

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.

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

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.

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

Follow the fire safety measures!

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

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

126

AV 130 X

MAINTENANCE MANUAL 3.6.20. Fuel filter exchange •

Stop the engine.

•

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

2

1 402315A •

Clean the contact area of the filter.

400173 •

Fill the filter with clean fuel.

282N160T •

Wipe the sealing ring with oil.

400174 AV 130 X

127

3.6.

•

Individual Operations of Maintenance

Mount the filter and tighten firmly with hand.

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.

396250

3.6.21. Engine cooling liquid level check •

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

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.

400183

3.6.22. Check of wiring Check for any damage to cables, connectors, protective hoses, and their fastening, especially if in the vicinity of hot surfaces and moving parts of the machine including the engine. Replace damaged parts. Use only original spare parts.

128

AV 130 X

MAINTENANCE MANUAL After 1,000 hours of operation (after 1 year) 3.6.23. How to check tightening pulley and belt of the engine •

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

402320A •

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.

282N171T •

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.

AV 130 X

129

3.6.

Individual Operations of Maintenance

•

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.

27824T3

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.

400161

130

AV 130 X

MAINTENANCE MANUAL 3.6.24. Exchanging oil in gearboxes 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.

1 2

3 402342A

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.

402334A AV 130 X

131

3.6.

Individual Operations of Maintenance

•

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.

402322 •

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

•

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

Perform the first oil exchange after 200 engine hours.

Keep the oil level on the upper mark!

401347

132

AV 130 X

MAINTENANCE MANUAL 3.6.25. Damping system checking •

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

Damping system of drums, left and right side 2x 12.

402336

402335 Rubber-metal components of the driver’s working place 4x.

401362A Rubber-metal components of the engine 3x.

402324 AV 130 X

133

3.6.

Individual Operations of Maintenance

Rubber-metal components of the cooler supports 6x.

402337 Rubber-metal components of the battery carrier 4x.

Replace the damaged parts.

Check the tightening of screws and nuts.

402327A

3.6.26. 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.

478320 h

400111A •

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

402328 134

AV 130 X

MAINTENANCE MANUAL •

Dismount the cleaning cap.

402329 •

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.

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.

401366

Comply with the sanitary principles.

Follow the environmental protection regulations!

Prevent oil leakage to the ground.

AV 130 X

135

3.6.

Individual Operations of Maintenance

3.6.27. Water tank cleaning •

Stop the engine and disconnect the machine electrical equipment.

•

Dismount the caps of the filler necks of the tank.

401322A •

Open the drain holes of the tank.

•

Wash out the tank by water jet.

401698A

401339A •

Clean the screens in the filler necks.

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

Follow the instructions as specified in Chapter 3.6.34.

401363 136

AV 130 X

MAINTENANCE MANUAL After 2,000 hours of operation (after 2 years) 3.6.28. 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.

•

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

Change the oil when it is warm.

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

1

2 401345

2

Prevent oil leakage to the ground.

1 401344

AV 130 X

137

3.6.

Individual Operations of Maintenance

3.6.29. 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.

402339A •

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

•

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

•

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.

2

•

Mount back accumulator holder and accumulator.

3

1

402327B Carry out oil replacement before season starts, or following a long-term machine shutdown. Clean together a suction basket.

Drain oil when cooled down below 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.

138

4

402338

AV 130 X

MAINTENANCE MANUAL How to check oil temperature sensor •

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

402330 •

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!

478320 h

400111E 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 quickcoupler 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.

402311A •

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

MAX

MIN

402317A AV 130 X

139

3.6.

•

Individual Operations of Maintenance

Order your filling equipment at your machine manufacturer or dealer.

401370 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.

402312

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!

140

AV 130 X

MAINTENANCE MANUAL How to replace pressure filter element •

Dismantle filter container.

402331 •

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.

401375

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.

478320 h Used filter elements become ecologically hazardous waste – hand them over for disposal.

AV 130 X

400111G

141

3.6.

Individual Operations of Maintenance

3.6.30. Exchanging the engine cooling liquid •

Stop the engine.

•

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

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.

401376

400159 •

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).

402339B 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.

400181 142

AV 130 X

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!

400219 •

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.

MAX MIN

Use cooling liquid according to chapter 3.2.3!

401307A •

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!

400159 Collect used liquid and have it safely disposed according to valid regulations!

AV 130 X

143

3.6.

Individual Operations of Maintenance

3.6.31. Exchanging cleaner elements of air cleaner Note •

The air cleaner contains the main and safety elements.

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

•

•

478320 h

Lift the bonnet to the limit position. (See Operating instructions, chapter 2.7.6.)

400111H

Remove the lid (1).

1

401379 •

Carefully remove the main element (2).

2

401380 •

After remove the safety element (3).

3

401381 144

AV 130 X

MAINTENANCE MANUAL •

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.

401382 •

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

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

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.

401316

3.6.32. Inspect, adjust engine valve clearance •

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

AV 130 X

145

3.6.

Individual Operations of Maintenance Maintenance - As Needed

3.6.33. Cleaning of coolers •

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.

402341A

401329 •

Clean it using pressure air or pressure water (steam). Cleaning direction is from the ventilator side.

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!

146

402316

AV 130 X

MAINTENANCE MANUAL 3.6.34. 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 twin-compartment tank for watering. Keep the drain caps at a safe place.

•

The volume of the full tank amounts to 1000 l.

401698A

401339A •

Dismount and clean the container (1) with the watering filter (2). Store the container with the filter at a safe place.

1

2

400262 •

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

401698 AV 130 X

147

3.6.

•

Individual Operations of Maintenance

Dismount the hoses of displacement of water from the pumps.

401698B •

Dismount at least one sprinkler of each pipe on the front and rear side of the machine.

401385 •

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.

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.

401397A

148

AV 130 X

MAINTENANCE MANUAL 3.6.35. Cleaning the air cleaner of cabin ventilation •

Dismantle the cover grill.

401389 •

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.

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

401390

AV 130 X

149

3.6.

Individual Operations of Maintenance

3.6.36. 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.

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!

150

AV 130 X

MAINTENANCE MANUAL 3.6.37. Adjustment of scrapers ADJUSTABLE SCRAPERS (STANDARD) •

The machine is equipped with four adjustable scrapers.

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 oval-shaped 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.

2

3 402344

402345 Blade replacement: •

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

•

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

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

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

5 3

4 402344A

AV 130 X

151

3.6.

Individual Operations of Maintenance

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.

402346 •

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 to the drum body.

2

3 402347 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.

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

152

6

5

3

402348

AV 130 X

MAINTENANCE MANUAL 3.6.38. 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)

TIGHTENING MOMENT

For the screws 10,9 (10K)

For the screws 8,8 (8G)

For the screws 10,9 (10K)

Worm

Nm

lb ft

Nm

lb ft

Worm

Nm

lb ft

Nm

lb ft

M6

10

7,4

14

10,3

M18x1,5

220

162,2

312

230,1

M8

24

25,0

34

25,0

M20

390

287,6

550

405,6

M8x1

19

14,0

27

19,9

M20x1,5

312

230,1

440

324,5

M10

48

35,4

67

49,4

M22

530

390,9

745

549,4

M10x1,25

38

28,0

54

39,8

M22x1,5

425

313,4

590

435,1

M12

83

61,2

117

86,2

M24

675

497,8

950

700,6

M12x1,25

66

48,7

94

69,3

M24x2

540

398,2

760

560,5

M14

132

97,3

185

136,4

M27

995

733,8

1400

1032,5

M14x1,5

106

78,2

148

109,1

M27x2

795

586,3

1120

826,0

M16

200

147,5

285

210,2

M30

1350

995,7

1900

1401,3

M16x1,5

160

118,0

228

168,1

M30x2

1080

796,5

1520

1121,0

M18

275

202,8

390

287,6

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

Table of insert nuts tightening moments with tightening “O” circle - the hoses Tightening moments for the sliding nuts with the tightening circle „O“ - hoses Nm Size spanner

Worm

Hose

Nominal

Min

lb ft Max

Nominal

Min

Max

14

12x1,5

6

20

15

25

15

11

18

17

14x1,5

8

38

30

45

28

22

33

19

16x1,5

45

38

52

33

28

38

22

18x1,5

51

43

58

38

32

43

24

20x1,5

58

50

65

43

37

48

74

60

88

55

44

65

8 10 10 12 12 14

27

22x1,5

30

24x1,5

16

74

60

88

55

44

65

32

26x1,5

18

105

85

125

77

63

92

36

30x2

135

115

155

100

85

114

166

140

192

122

103

142

41 46 50 50

AV 130 X

36x2

15

20 22 25 28

42x2

30

240

210

270

177

155

199

45x2

35

290

255

325

214

188

240

330

280

380

243

207

280

52x2

38 42

153

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

Tightening moments for the necks

Tightening moments for the plugs

G -M

Nm

lb ft

G -M

Nm

lb ft

G 1/8

25

18

G 1/8

15

11

G 1/4

40

30

G 1/4

33

24

G 3/8

95

70

G 3/8

70

52

G 1/2

130

96

G 1/2

90

66

G 3/4

250

184

G 3/4

150

111

G1

400

295

G1

220

162

G 11/4

600

443

G 11/4

600

443

G 11/2

800

590

G 11/2

800

590

10 x 1

25

18

10 x 1

13

10

12 x 1,5

30

22

12 x 1,5

30

22

14 x 1,5

50

37

14 x 1,5

40

30

16 x 1,5

60

44

16 x 1,5

60

44

18 x 1,5

60

44

18 x 1,5

70

52

20 x 1,5

140

103

20 x 1,5

90

66

22 x 1,5

140

103

22 x 1,5

100

74

26 x1,5

220

162

26 x1,5

120

89

27 x 1,5

250

184

27 x 1,5

150

111

33 x 1,5

400

295

33 x 1,5

250

184

42 x 1,5

600

443

42 x 1,5

400

295

48 x 1,5

800

590

48 x 1,5

500

369

M-G

M-G

M-G

282N221T 154

282N222T AV 130 X

3.7.

Defects 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.

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

155

3.8.

Appendixes

Wiring scheme Legend: A1 Flasher unit for direction indicator lamps A2 Left combined instrument A3 Right combined instrument A4 Travel electronics A5 Travel controller A6 Time relay B1 Fuel level float B2 Cooling liquid level sensor B3 Water tank pressure sensor

Q1 Battery cut off switch R1 Watering interval potentiometer R2 Speed potentiometer R3-5 Resistory R6 Engine preheating R8 Engine speed control S1 Ignition box S2 Combined switch S2.1 Switch of side and head-lamps

B5 Drum speed sensor

S2.2 Main / passing beams control switch

C1 Noise suppressing filter

S2.3 Headlight flasher switch

E1, 2 Front side lamps

S2.4 Loud horn button

E3, 4 Rear lamps

S2.5 Direction indicator lamps control switch

E5, 6 Front head-lamps E7, 8 Rear head-lamps E9, 10 Left direction indicator lamps 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 G1 Battery G2 Alternator 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 K1 Contactor K2-17,20 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 M7 Windscreen washer M8 Rear screen washer M9-11 Fans

156

S3 Rear head-lamps switch S4 Warning lamps switch S5 Front additional-lamps switch (option) S6 Warning beacon switch (option) S7 Brake pressure switch S8 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 Constant speed or stalling switch S19 Vibration automatics switch S20 Smooth start and stop button S21 Seat switch S22 Vibration button (red) on the left travel lever S23 Vibration button (red) on the right travel lever S24 Watering button S25 Watering pumps control switch S26 Vibration control switch – front / both / rest drum

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) S37 Engine idle speed switch S38 Engine diagnostic switch S39 Trouble shooting switch S43 Hydraulics temperature switch fan switching S44 Overpressure air conditioning fuse V1-V14 Light-emitting diode (LED) X1 Mounting socket X2 Diagnostic socket X3-4 Connection terminals X5-62 Interface connector (X60 –unused) X63 Engine diagnostic X64-69 Connector J1939 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 Y7 Valve – back runner backward drive Y8 Rear drum vibration small amplitude valve Y9 Rear drum vibration large amplitude valve Y10 Front drum vibration small amplitude valve Y11 Front drum vibration large amplitude valve Y12 Valve of CRAB to the left

S27 Vibration amplitude control switch

Y13 Valve of CRAB to the right

S28 Left (yellow) button on the left travel lever – CRAB to the left

Y15 Valve of the cutter upwards (option)

S29 Right (yellow) button on the left travel lever – CRAB to the right

Y16 Valve of the cutter downwards (option)

S30 Left (yellow) button on the right travel lever – CRAB to the left or the cutter upwards

Y17 Compressor clutch (option)

Y14 Pressure relief valve

AV 130 X

MAINTENANCE MANUAL X61

G1

Engine connector 1

2

56b 56a

X35:3

X18:3

56b 56a

2 X15:2 5 X7:2

S2.3 S2.4

M MC

F3

3 2

K4

2 3

1 5 3 2

X37:4 X36:2

X18:5

E10

X38:2

X14:4

Right rear direction light Right front direction light

E11

X38:3

X14:5

E12

X36:3

X18:6

E13

Front additional lights

K7

5 2

3 1 X7:9

X49:2

A1

CL X7:7

31

X1

X15:6 1 9

X12:5

S5

5 10

X15:5

X56:1 X54 X56:2 X55:1 X49:6 X12:6

X21

E17

X7:10

1 9

X15:7

S6

5 10

X55:2

Brake lights

87

X64

E19

1 5

2 3

22

29

38

23

37

9

47

11

X17:1

1

X17:2

4

2 10

34

42

X17:6

2

1

24 25

1 7

X17:9

43

28

44 50

32

H6 H7 H8

X17:12 X5:15

X14:6

8 18 19 11

X14:7

Instrument illumination Direktion light Charging +motohours Direktion light Neutral Brake

13

Seat

X70

39

41

X11:3

X15:9 X7:12

20

X15:10 X7:13

1

Warning

Warning lights Instrument illumination

13

R3

X18:7

2 5

X6:9

14

Ground

Air condition Engine overheating Watering Konstant speed Away - stopping pushbutton Water tank level

K8

H4

10 12 19 6

F5 3 1

X11:5 C

H X11:4

S15 H X11:7

2 X25:8

C

S16

X7:16

1 X11:8 3

X10:14

X7:17

2 5

M

4

1 3

R P ON M

L

10A X25:7 1

X11:9 M

K9

S14

Fe PNP

X15:13

X15:14

K10 4

Warning

Fe PNP

5 2

A3

Cooling liquid level

X10:13

X5:4 X38:1

Engine stop

75 R 1 X40

16

R4

20

Supply +12V

Crab

X15:11 9

X14:13

2

F4 5A

10

Ground

X11:6

AV 130 X

X15:8 X7:11

12

Vibration

7 8

2

X43:1

X39

X43:2 H5

Supply +12V

Hydraulic oil overheating Engine stop

X40

1

X11:2

B3

X39

1

A2

Fuel gauge

3

75 R

X7:14

Reverse horn

X5:21

Air filter

14

X73

Water tank level

Hydraulic filter

6 9 5

X11:1 Fe PNP

Cooling liquid level

3

X17:11

S12

S 3

5

X17:10

2

B2

1 3

S39

X17:8

X14:12

3(M) 2

6 9

S38

X17:7

X14:11

4(C)

5

4

15

S13

S37

K17 2 5

X14:8

1(H)

V12

1

X17:5

X5:3

Crab position switch

X7:20

2

X17:4

S7 S8 S9 B1

S43

V11

X15:17

3

X17:3

X5:22

Hydraulics temperature switch – fan switch

X7:15

7

R8

1

40

Engine connector X62

46

15k

R5

Hydraulic oil overheating

X15:12

4

X5:16

P

1A

V13

K20

X5:20

P

X7:22

X65

X69

X5:19

V14

P

F8

X16:10

B

Y1

Brake Hydraulic filter Air filter Fuel gauge

30

A

A

B

Valve of cooling

A B C

B

A B C

A B C

X63

X68

A B C

A

15

87a

C D E F G

X66

X67

A B C

A6

31

X5:2

ta

X37:3

E18

5 1

X7:8

X53

E16

Warning beacon

6 X15:4 1 5 10

3

X52

E15

Rear additional lights

X12:4

X51

E14

S4

2 8

X72

E9

Left rear direction light

K6

X71

Left front direction light

15/54

5 1

K5

O

X35:4

S1 50

15(30)A

X19:4 X9:4 B

S2.5

30

X20:3

5 10

X7:3

15A

X7:4

X20:2 C

X20:5

1 9

S2.2

F2

X19:2 X9:2 H

X20:4

E8

X14:3

S3

Z X19:3

X18:4

X37:2

E7

Rear headlights

1 X9:3 3

X7:6 X15:3

X36:1 X41

S2.1

X19:1 S

C1

H3

20A

S2

X7:5

31

F1 3 1 X9:1 X20:1 Y

K3

X5:18

X14:2 X18:2

X5:1

31

E6

X37:1 X35:2

V13 X14:1

E5

E4

K2

5 2

0 12

Teil lights

G

X18:1

X7:1

X15:1

X35:1

E2

H1

E3

K1

I

X3

E1

50

G2 BAT

H2

M1

M

F10

30A

F16

31 30

12V 135Ah

125A

Front side lights

Horn

3

4

Engine preheating

Front headlights

K18

R6

F9

Q1

K J I

H G F

E D C

B

A

107620_1en

157

3.8.

Appendixes

Wiring scheme Legend: A1 Flasher unit for direction indicator lamps

Q1 Battery cut off switch

A2 Left combined instrument

R2 Speed potentiometer

A3 Right combined instrument A4 Travel electronics A5 Travel controller A6 Time relay B1 Fuel level float B2 Cooling liquid level sensor B3 Water tank pressure sensor

R1 Watering interval potentiometer R3-5 Resistory R6 Engine preheating R8 Engine speed control S1 Ignition box S2 Combined switch S2.1 Switch of side and head-lamps

B5 Drum speed sensor

S2.2 Main / passing beams control switch

C1 Noise suppressing filter

S2.3 Headlight flasher switch

E1, 2 Front side lamps

S2.4 Loud horn button

E3, 4 Rear lamps

S2.5 Direction indicator lamps control switch

E5, 6 Front head-lamps E7, 8 Rear head-lamps E9, 10 Left direction indicator lamps 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 G1 Battery G2 Alternator 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 K1 Contactor K2-17,20 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 M7 Windscreen washer M8 Rear screen washer M9-11 Fans

158

S3 Rear head-lamps switch S4 Warning lamps switch S5 Front additional-lamps switch (option) S6 Warning beacon switch (option) S7 Brake pressure switch S8 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 Constant speed or stalling switch S19 Vibration automatics switch S20 Smooth start and stop button S21 Seat switch S22 Vibration button (red) on the left travel lever S23 Vibration button (red) on the right travel lever S24 Watering button S25 Watering pumps control switch S26 Vibration control switch – front / both / rest drum

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) S37 Engine idle speed switch S38 Engine diagnostic switch S39 Trouble shooting switch S43 Hydraulics temperature switch fan switching S44 Overpressure air conditioning fuse V1-V14 Light-emitting diode (LED) X1 Mounting socket X2 Diagnostic socket X3-4 Connection terminals X5-62 Interface connector (X60 –unused) X63 Engine diagnostic X64-69 Connector J1939 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 Y7 Valve – back runner backward drive Y8 Rear drum vibration small amplitude valve Y9 Rear drum vibration large amplitude valve Y10 Front drum vibration small amplitude valve Y11 Front drum vibration large amplitude valve Y12 Valve of CRAB to the left

S27 Vibration amplitude control switch

Y13 Valve of CRAB to the right

S28 Left (yellow) button on the left travel lever – CRAB to the left

Y15 Valve of the cutter upwards (option)

S29 Right (yellow) button on the left travel lever – CRAB to the right

Y16 Valve of the cutter downwards (option)

S30 Left (yellow) button on the right travel lever – CRAB to the left or the cutter upwards

Y17 Compressor clutch (option)

Y14 Pressure relief valve

AV 130 X

MAINTENANCE MANUAL R P O N M

L

K J I

12V

Konstant speed 3

1

1

Seat 5

X10:3 X22:2

6 Front drum - travel for

Front drum - travel backward

Y5

X5:10

drum 7 Front - travel back

X5:11

8

Rear drum - travel forward

Y6

X5:12

22 Rear drum - travel for Vibration

Rear drum - travel backward

Y7

X5:13

24 Rear drum - travel back

X5:14

9

Away - stopping pushbutton

12 X10:4

S20

5

S21

X24:1

S22

X24:2

X26:1

S23

X26:2

9 5 3 2

A4

5

20 21

RS2323 RxD

X8:4

X8:5

X15:16

X16:4

X16:5

RS2323 TxD

13

RS2323 Grd Travel

X10:5

X25:1

17 Drum speed

34

X10:6 X25:2

6

Watering

26 Vibration

1(H)

27 Watering

X6:5

X47:1

X6:6

X47:2

X6:7

1

2

5

3

1

2

5

3

Y11

5

S26

A4

A3

C2

C1

X14:18

D4

D3

D2

D1

X14:19

C4

C3

B4

B3

F3

F4

E3

E4

Y12

X13:1

X31:1

X27:1

S28

Crab to the right

Y13

X13:2

X31:2

X27:2

S29

Cutter upwards

Y15

X13:4

X31:4

Cutter downwards

Y16

X13:5

X31:5

X29:1

If the edge cutter is instaled to left hand side of the roller changeover the plug X27 to socket X28.The buttons S28,S29 on the left controllever are used to lifting cutter.

S30 X26:3 S31

X29:2

V7

V8

X30:1

X24:3

If the edge cutter is instaled to right hand side

X30:2 of the roller changeover the plug X29 in socket X30.

The buttons S30,S31 on the left controllever are used to lifting cutter.

E20

Cab light

F11

X32:1

S32

X32:4

M

Windscreen wiper

M4

X32:2

5

3

X32:3

M

Left rear screen wiper

M5

1

X56:10

X33:1

X56:3

X33:4

X56:5

7

X33:2

X56:4

1

X57:1

M8

X57:2

M

1

M7

M X58:1

Fan 1

M

Rear screen washer

M X57:3

Windscreen washer

M9

X56:6

S34 7

X58:2

X56:8

5 2

3

15A

S35 5

3

V10

1

5A

S36

5 10

3

K16

X48:3 1

S44

F13

3

1

1

9

2

P

1

M11 X48:2

M

1

Y17

F12

3

V9

M10

2

K15

K14

2

M

1

X48:1

X58:3 X59:3 3

Fan 3

X56:9 5

X59:2

3

1

2

Fan 2

X59:1

6

X56:7

M6

X34:2

5

2

X34:1 X34:4

S33

8

X34:3

Right rear screen wiper

15A

7

X32:5

X33:3

Air condition clutch

Radio

X31:3

X11:10

X49:1

X13:3

V5

Y14

V6

Pressure relief valve

X7:21

X12:1

Crab to the left

X28:2

F7 7.5A

X16:8

X15:18

X28:1

3

X49:3

X14:17

2

X12:3

A3

X49:5

A4

X12:7

B3

5

X50

B4

1

X12:2

2

X16:7

30A

2

1

X8:7

F15

1

Y9

S25 1

K13

X14:16

Y10

X16:6

X10:12

2

F6

X8:8

Front drum vibration large amplitude

2

1

X25:4

X25:5 X10:10

5

7

K12

V4

Front drum vibration small amplitude

1

X8:6

V3

Rear drum vibration large amplitude

Y8

1

100R

15A

S27

Rear drum vibration small amplitude

X23:4

X75

X46:2

X25:3

14 5V (5V) 1

X6:4

V2

M3

M

Watering 2

X46:1

V1

M

M2

1K X23:5

S24

X25:6

K11

Watering 1

100R

X10:9

X10:11

100R

R2

X10:8

X6:3

R1

100R 1K X10:7 X23:3

Speed 31

X6:2

A5 1 X7:19

32

5 X6:1

X2

X5:9

3(M)

A

X22:1

X10:2 X23:2

X5:8

B5

B

X23:1

4

Y3

5

S19

1

Y4

16 Engine speed

7 S18

X16:3

Front drum - travel forward

4(C)

E D C

X15:15

X16:1 X16:2

(12V)

X8:1

2 X8:2 18 Neutral Engine overload Away-stopping 40 pushbutton Automat 19 X8:3 vibration 41 Brake

Brake

Front drum speed

H G F

X10:1 X7:18

28,42

15,29

X5:6,7

5

2 3

F14 10A

X5:5 X4

X12:9 X52

X35:4

X18:8

X37:4

X24:2 X26:2 X5:6,7 X6:5,7

AV 130 X

107620_2en

159

3.8.

Appendixes

Hydraulic Diagram 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

11

Power steering

12

Combined cooler

13

Hydraulic tank

14

Steering block

15 16

Thermo regulator

17

Non-return valve

18

Intake strainer

19

Filler neck

20

Safety unit

21

Hand pump

22 23

Temperature switch

24

Temperature switch

25

Oil level indicator

26

Ball valve

27

Filling quick coupler

28

Quick-coupler measuring-type

160

AV 130 X

REAR HYDROMOTOR OF TRAVEL

FRONT HYDROMOTOR OF TRAVEL

L2 A

55

L1 B

L1 B

55

L2 A

M2 Dn16

M1

Dn16

3

M2 Dn16

M1

Dn16

4

Ø1 mm

M8

M8

Ø1 mm

C1

M5

L2

E

20

E

M4

C2

M5

45

45

C1

C1

L1

300

300

A

MA

MC

C

D

MD

1

L3

350

350

Dn19

45

M5

M4 L2

X7 M3

REAR PUMP

C2

M4

20

M4

C2

M5

L1

300

300

MB

B

A

MA

MB

FRONT PUMP

X7 M3

MC

Dn19

45

C2

5

REAR HYDROMOTOR OF VIBRATION

B

L3

350

350

C1

Dn16

10 l/min

Dn16

Dn16

C

D

MD

1

L1 B

M2

M1

L2 A

35

M2

L1 B

19

17

2300 ot/min

2

28

Dn16

P

175

Dn16

i=1.0

Dn16 Dn16

500

11

100

Dn19

22

LD

Dn13

FRONT HYDROMOTOR 10 l/min OF VIBRATION

T

3 bar

35

L

Dn13

18

40°C

82/74± 3°C 100°C

24

Dn8

Dn16

Dn10

Dn10

240

240

13

°C

55°C

170

8

80/40-320

80/40-320

Dn10

INLET Dn25

R Dn13

Dn16

Dn10

16

7

6

25

Dn10

23

12

14

9

8

Dn10

110/56-125

11

63/32-160

M1

OUTLET

Dn10 Ø1 mm

Dn13

M

P1

X

T1

B2 A2

B1 A1

Ø0.5 mm

100

T

Dn10

Dn6

Ø0.5 mm

P

P 100

Dn16

100 14

190

180

B A 100

T P

EDGE CUTTER

PP

10

T2

A3

20

21

26

10

27

20 bar

A4

II. TRAVEL SPEED

B A Ø25 - 320

L2 A

Ø25 - 320

Dn8

Dn8

Dn13 Dn32

Dn16

Dn16

Dn8 Dn25

CRABING

Dn6

BRAKE

AV 130 X Dn6

5

T

13 bar

MAINTENANCE MANUAL

211338en

161

i=0.707

Notes:

162

AV 130 X

Ammann Schweiz AG Eisenbahnstrasse 25 CH-4901 Langenthal www.ammann-group.com

Ammann Verdichtung GmbH Josef-Dietzgen-Strasse 36 D-53773 Hennef

Rammax Maschinenbau GmbH Gutenbergstrasse 33 D-72555 Metzingen

Ammann Czech Republic a.s.

Náchodská 145 CZ-54901 Nové Město nad Metují Printed in Czech Republic