Ammann AV 130 X Tandem Roller Operating Manual 3001210 PDF

AV 130 X TANDEM ROLLER CUMMINS QSB4.5-C130 EU Stage IIIA / U.S. EPA Tier 3

OPERATING MANUAL EDITION 01/2021 EN Product identification number 3001210 -

ES / EU Prohlášení o shodě (Původní ES/EU prohlášení o shodě / Original EC/EU Declaration of conformity / Ursprüngliche EG-/EU-Konformitätserklärung )

EC / EU Declaration of conformity / EG-/EU-Konformitätserklärung (Překlad původního ES/EU prohlášení o shodě /Translation original EC/EU Declaration of conformity / Übersetzung der ursprünglichen EG-/EU-Konformitätserklärung ) Originální ES/EU prohlášení o shodě je dodané s dokumenty během expedice stroje. / The original EC/EU Declaration of Conformity is supplied with documents during

expedition of machine. / Das Original der EG-/EU-Konformitätserklärung wird mit den Unterlagen während des Versands der Maschine mitgeliefert.

Výrobce / Manufacturer / Hersteller: Adresa / Address / Adresse: IČ / Identification Number / Ident.-Nr:

Ammann Czech Republic a.s.

Náchodská 145, CZ-549 01 Nové Město nad Metují, Czech Republic 000 08 753

Jméno a adresa osoby pověřené sestavením technické dokumentace podle 2006/42/ES a jméno a adresa osoby, která uchovává technickou dokumentaci podle 2000/14/ES / Name and

Ing. Radek Ostrý Ammann Czech Republic a.s.

Náchodská 145, CZ-549 01 Nové Město nad Metují, Czech Republic

address of the person authorised to compile the technical file according to 2006/42/EC and name and address of the person, who keeps the technical documentation according to 2000/14/EC / Name und Adresse der mit der Zusammenstellung der technischen Dokumentation beauftragten Person gemäß 2006/42/EG und Name und Adresse der mit der Aufbewahrung der technischen Dokumentation beauftragten Person gemäß 2000/14/EG: Popis strojního zařízení / Description of the machinery / Beschreibung

der Maschineneinrichtung: Označení / Designation / Bezeichnung:

Tandemový válec / Tandem roller / Tandemwalze

Typ / Type / Typ:

AV 130 X

Verze / Version / Version: Product Identification Number: Motor / Engine / Motor:

Cummins QSB 4.5-C130, vznětový, jmenovitý výkon (ISO 3046-1): 97,0 kW, jmenovité otáčky: 2300 min-1. / Cummins QSB 4.5-C130, Diesel, nominal power (ISO 3046-1):

97,0 kW, rated speed: 2300 RPM. / Cummins QSB 4.5-C130, Dieselmotor, Nennleistung (ISO 3046-1): 97,0 kW, Nenndrehzahl: 2300 min -1 .

Prohlašujeme, že strojní zařízení splňuje všechna příslušná ustanovení uvedených směrnic / We declare, that the machinery fulfils

Strojní zařízení – směrnice 2006/42/ES / Machinery Directive 2006/42/EC /

all the relevant provisions mentioned Directives / Wir erklären, dass die Maschineneinrichtung sämtliche entsprechenden Bestimmungen aufgeführter Richtlinien erfüllt:

Elektromagnetická kompatibilita – směrnice 2004/108/ES / Electromagnetic

Maschineneinrichtung – Richtlinie 2006/42/EG Compatibility Directive 2004/108/EC / Elektromagnetische Kompatibilität – Richtlinie 2004/108/EG Emise hluku – směrnice 2000/14/ES / Noise Emission Directive 2000/14/EC /

Lärmemissionen – Richtlinie 2000/14/EG Harmonizované technické normy a technické normy použité k posouzení shody / The harmonized technical standards and the

technical standards applied to the conformity assessment / Harmonisierte technische Normen und für die Beurteilung der Konformität verwendete Normen:

ČSN EN ISO 12100, ČSN EN 500-1+A1, ČSN EN 500-4, ČSN EN ISO 4413, ČSN EN 13309

Osoby zúčastněné na posouzení shody / Bodies engaged in the conformity assessment / An der Konformitätsbeurteilung beteiligte Personen:

Notifikovaná osoba č. 1016 / Notified Body No.: 1016 / Notifizierte Stelle Nr.: 1016

Použitý postup posouzení shody / To the conformity assessment applied procedure / Verwendetes Vorgehen der Konformitätsbeurteilung:

Na základě směrnice 2000/14/ES příloha VI / Pursuant to the Noise Emission

Naměřená hladina akustického výkonu / Measured sound power

LWA = 107 dB

level / Gemessener Schallleistungspegel:

Garantovaná hladina akustického výkonu / Guaranteed sound power

level / Garantierter Schallleistungspegel:

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

Státní zkušebna strojů a.s., Třanovského 622/11, 163 04 Praha 6–Řepy, ČR. / The

Government Testing Laboratory of Machines J.S.C., Třanovského 622/11, 163 04 Praha 6–Řepy, Czech Republic / Staatliche Prüfstelle für Maschinen AG, Třanovského 622/11, 163 04 Praha 6–Řepy, Tschechische Republik.

Directive 2000/14/EC, Annex VI / Aufgrund der Richtlinie 2000/14/EG, Anlage VI

LWA = 108 dB

Nové Město nad Metují,

Osoba zmocněná k podpisu za výrobce / Signed by the person entitled to deal in the name of manufacturer / Zeichnungsberechtigter für den Hersteller: Jméno / Name / Name: Funkce / Grade / Stelle: Podpis / Signature / Unterschrift:

Jiří Sychra Logistics Manager CZ / EN / DE

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.com | www.ammann.com

402001

This instruction manual is a “translation of the original instruction manual” within the meaning of the paragraph 1.7.4.1 of the Directive of the European parliament and of the Council 2006/42/EC of 17 Mai 2006.

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.

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

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 - safety and guarantee..................................................................................................................................................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 2.6.1.

Power View control ...............................................................................................................................................................................................60

2.7. Machine control and use.......................................................................................................................70 2.7.1.

Start-up of the engine...........................................................................................................................................................................................71

2.7.2.

Travel and reversing...............................................................................................................................................................................................75

2.7.3.

Emergency stop of the Machine.......................................................................................................................................................................83

2.7.4.

How to stop the Machine and its engine.......................................................................................................................................................83

2.7.5.

Machine parking.....................................................................................................................................................................................................83

2.7.6.

Bonnet raising and lowering..............................................................................................................................................................................85

2.7.7.

Sprinkling...................................................................................................................................................................................................................87

2.7.8

Ammann edgecutter.............................................................................................................................................................................................88

2.7.9.

Infra thermometer..................................................................................................................................................................................................89

2.8. Machine transport.................................................................................................................................90 2.8.1.

How to load the Machine.....................................................................................................................................................................................91

2.9. Special conditions for using the machine...........................................................................................93 2.9.1.

Machine towing......................................................................................................................................................................................................93

2.9.2.

Operating the machine during initial run period.......................................................................................................................................98

2.9.3.

Operating the Machine at low temperatures...............................................................................................................................................98

2.9.4.

Machine operation at high temperatures and humidity..........................................................................................................................98

2.9.5.

Machine operation at high altitudes...............................................................................................................................................................98

2.9.6.

Work of the machine in the dusty environment.........................................................................................................................................98

2.9.7.

Driving with vibrations on compacted and hard materials....................................................................................................................98

AV 130 X

5

Content 3.

MAINTENANCE MANUAL.....................................................................................................................99

3.1. Safety Standards at Lubrication and Maintenance..........................................................................101 3.1.1.

Safety of machine maintenance..................................................................................................................................................................... 101

3.1.2.

Fire precautions during operation media exchanges............................................................................................................................ 101

3.1.3.

Ecological and hygienic principles................................................................................................................................................................ 102

3.2. Specification of fluids..........................................................................................................................103 3.2.1.

Engine oil................................................................................................................................................................................................................ 103

3.2.2.

Fuel............................................................................................................................................................................................................................ 105

3.2.3.

Coolant ................................................................................................................................................................................................................... 106

3.2.4.

Hydraulic oil........................................................................................................................................................................................................... 107

3.2.5.

Gearbox oil............................................................................................................................................................................................................. 107

3.2.6.

Lubricating grease............................................................................................................................................................................................... 107

3.2.7.

Windshield washer liquid................................................................................................................................................................................. 107

3.2.8.

Drum cooling liquid............................................................................................................................................................................................ 108

3.2.9.

Air-conditioning filling....................................................................................................................................................................................... 108

3.3. Fills........................................................................................................................................................109 3.4. Lubrication and Maintenance Chart..................................................................................................110 3.5. Lubrication Chart.................................................................................................................................112 3.6. Individual Operations of Maintenance..............................................................................................113 Every 20 hours of operation (daily)....................................................................................................114 3.6.1.

Engine oil level check......................................................................................................................................................................................... 114

3.6.2.

Engine cooling liquid level check.................................................................................................................................................................. 115

3.6.3.

Hydraulic tank oil level check.......................................................................................................................................................................... 116

3.6.4.

Crankcase breather tube................................................................................................................................................................................... 116

3.6.5.

Checking the condition of the ventilator and belt.................................................................................................................................. 117

3.6.6.

Air filter dust valve check.................................................................................................................................................................................. 118

3.6.7.

Fuel level check..................................................................................................................................................................................................... 119

3.6.8.

Water tank refilling.............................................................................................................................................................................................. 120

3.6.9.

Cleaning the water separator.......................................................................................................................................................................... 121

3.6.10. Warning and control devices checking....................................................................................................................................................... 122 3.6.11. Check of the tightness of the fuel and hydraulic system...................................................................................................................... 123

Every 250 hours of operation (3 months)..........................................................................................124 3.6.12. Air intake cooler, intake piping....................................................................................................................................................................... 124 3.6.13. Checking the cooling circuit of the engine................................................................................................................................................ 125 3.6.14. Checking the engine belt................................................................................................................................................................................. 126 3.6.15. Checking battery................................................................................................................................................................................................. 127 3.6.16. Air filter sensor check......................................................................................................................................................................................... 129 3.6.17. Machine lubrication............................................................................................................................................................................................ 130 3.6.18. Checking oil in gearboxes................................................................................................................................................................................ 132 3.6.19. Watering filter cleaning..................................................................................................................................................................................... 133 3.6.20. Seat switch check................................................................................................................................................................................................. 134

6

AV 130 X

OPERATING MANUAL Every 500 hours of operation (every 6 months) but at least once a year........................................135 3.6.21. Engine oil exchange............................................................................................................................................................................................ 135 3.6.22. Fuel filter exchange............................................................................................................................................................................................. 138 3.6.23. Exchanging cleaner elements of air cleaner.............................................................................................................................................. 139 3.6.24. Cleaning the air cleaner of cabin ventilation............................................................................................................................................. 141 3.6.25. Engine cooling liquid level check.................................................................................................................................................................. 142 3.6.26. Check of wiring..................................................................................................................................................................................................... 142

Every 1000 hours of operation (1 year).............................................................................................143 3.6.27. Check tightening pulley and belt of the engine...................................................................................................................................... 143 3.6.28. Exchanging oil in gearboxes............................................................................................................................................................................ 145 3.6.29. Damping system checking............................................................................................................................................................................... 147 3.6.30. Fuel tank cleaning............................................................................................................................................................................................... 148 3.6.31. Water tank cleaning............................................................................................................................................................................................ 150

Every 2000 hours of operation (2 years)............................................................................................151 3.6.32. Vibrations system oil exchange...................................................................................................................................................................... 151 3.6.33. Replace hydraulic oil and filters ..................................................................................................................................................................... 152 3.6.34. Exchanging the engine cooling liquid......................................................................................................................................................... 156 3.6.35. Inspect, adjust engine valve clearance........................................................................................................................................................ 157

Maintenance - As Needed...................................................................................................................158 3.6.36. Cleaning of coolers.............................................................................................................................................................................................. 158 3.6.37. Water discharge from watering circuit before winter season ............................................................................................................. 159 3.6.38. Cleaning the machine ....................................................................................................................................................................................... 161 3.6.39. Adjustment of scrapers...................................................................................................................................................................................... 162 3.6.40. Checking and tightening bolted joints........................................................................................................................................................ 164

3.7. Defects..................................................................................................................................................167 3.8. Appendixes .........................................................................................................................................168 Wiring scheme....................................................................................................................................................................................................................... 168 Hydraulic Diagram............................................................................................................................................................................................................... 174 Regular maintenance spare parts chart....................................................................................................................................................................... 176 Content of the set of filters after 500 and 1000 operating hours (4-760025)................................................................................................. 177 Content of the set of filters after 2000 operating hours (4-760130).................................................................................................................. 177

AV 130 X

7

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 are designed for operation in arid, temperate and cold climates according to EN 60721-2-1:2014 with a limited temperature range from -15 °C (5 °F) to +45 °C (113 °F) and a maximum absolute humidity of 25 g.m-3.

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

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

Product Identification Number ................................................................................................................

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. Product identification number 4. Rated power 5. Operating weight 6. Maximum weight 7. Shipping weight 8. Version 9. Engine emissions 10.Front axle load 11.Rear axle load 12.Year of manufacture 13.Model year

10

4145

1 2 3 4 5 6 7

AMMANN CZECH REPUBLIC a.s.

549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145 CZECH REPUBLIC

8

DESIGNATION TYPE

VERSION

PRODUCT IDENTIFICATION NUMBER

NOMINAL POWER

ENGINE EMISSIONS

OPERATING MASS

FRONT AXLE LOAD

MAXIMUM MASS

REAR AXLE LOAD

SHIPPING MASS

YEAR OF CONSTRUCTION MODEL YEAR

MADE IN CZECH REPUBLIC

9 10 11 12 13 4145

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 AV 130 X EU Stage IIIA / U.S. EPA Tier 3

Weight Operating weight of CECE with cab, ROPS

kg (lb)

13080 (28840)

Operating weight of CECE with platform, rail

kg (lb)

12650 (27890)

Operating weight of CECE with platform, ROPS

kg (lb)

12960 (28570)

Operating load of CECE with cab, ROPS on front axis

kg (lb)

6610 (14570)

Operating load of CECE with cab, ROPS on rear axis

kg (lb)

6470 (14260)

Weight of half fluid capacities

kg (lb)

590 (1300)

Operating weight of ISO 6016 with cab, ROPS

kg (lb)

13670 (30140)

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

kg (lb)

13870 (30580)

Maximum permitted weight according to ROPS

kg (lb)

14500 (31970)

Static linear load of front drum

kg/cm (lb/in)

31,5 (176,4)

Static linear load of rear drum

kg/cm (lb/in)

30,8 (172,5)

Cab weight

kg (lb)

700 (1540)

Weight of ROPS

kg (lb)

700 (1540)

Weight of sheet roof on ROPS

kg (lb)

70 (150)

Weight of canopy

kg (lb)

40 (90)

Weight of canopy posts (version without ROPS)

kg (lb)

100 (220)

Weight of Ammann edge cutter

kg (lb)

100 (220)

Weight of Ammann diagonal edge cutter

kg (lb)

200 (440)

km/h (MPH)

11,4 (7,1)

Climbing ability without vibration

%

40

Climbing ability with vibration

%

30

Lateral static stability

%

65

Lateral stability during driving with vibration

%

15

Turning radius inner (edge)

mm (in)

4670 (183,9)

Turning radius outer (contour)

mm (in)

6880 (270,9)

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 AV 130 X EU Stage IIIA / U.S. EPA Tier 3 Engine Manufacturer

-

Cummins

Type

-

QSB4.5-C130

kW (HP)

97 (130)

Number of cylinders

-

4

Cylinder capacity

cm3 (cu in)

4500 (275)

Nominal speed

min (RPM)

2300

Maximum torque

Nm (ft lb)/rpm

512 (376)/1600

Average fuel consumption

l/h (gal US/h)

11,6 (3,1)

Engines complies with emission regulations

-

EU Stage IIIA, U.S. EPA Tier 3

Cooling system of engine

-

Liquid

Operating

-

Hydrostatic

Parking

-

Mechanical multiple-disc

Emergency

-

Mechanical multiple-disc

Frequency I

Hz (VPM)

42 (2520)

Frequency II

Hz (VPM)

55 (3300)

Frequency II CE

Hz (VPM)

50 (3000)

Amplitude I

mm (in)

0,8 (0,031)

Amplitude II

mm (in)

0,4 (0,016)

Centrifugal force I

kN

135

Centrifugal force II

kN

96 / 116

Type of drive

-

Hydrostatic

Type of watering

-

Pressure

Number of pumps

-

2

Number of filtrations

-

3

Power according to ISO 3046/1

-1

Brakes

Vibration

Watering

AV 130 X

15

1.3.

Technical data AV 130 X EU Stage IIIA / U.S. EPA Tier 3

Fluid capacities Fuel

l (gal US)

210 (55,5)

Water for drum watering

l (gal US)

1000 (264,2)

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 (2x5,02)

Vibrating drum front

l (gal US)

19 (5)

Vibrating drum rear

l (gal US)

19 (5)

Drum gearbox

l (gal US)

2x2,5 (2x0,66)

Washer tank

l (gal US)

2,75 (0,7)

Drum drive reducer

l (gal US)

2x2,5 (2x0,66)

Pump drive gearbox

l (gal US)

1,8 (0,5)

Drum cooling liquid

l (gal US)

2x60 (2x15,9)

Voltage

V

12

Battery capacity

Ah

135

Measured sound power level A, LpA at the operator's position (cab) *

dB

80

Uncertainty KpA *

dB

2

Guaranteed sound power level A, LWA **

dB

108

Declared highest weighted effective value of vibration acceleration transmitted to the whole body (cab) ***

m/s2 (ft/s2)

<0,5 (<1,6)

Declared total value of vibration acceleration transmitted to hands (cab) ***

m/s2 (ft/s2)

4,7 (15,4)

Wiring

Noise and vibration emissions

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 Filter set 500 h Filter set 1000 h Filter set 2000 h

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.).

•

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

•

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

•

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

•

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

•

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.

•

During Machine operation observe safety regulations, make

•

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

•

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

•

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

•

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

•

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

AV 130 X

23

2.1.

Major Safety Precautions

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 - safety and guarantee Banned are the following •

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

•

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

•

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

•

using the machine when any operating fluid level is low.

•

•

wilful repair of the engine - except common changes of operating fluids and filters, only the Cummins service department can intervene in the engine, in particular in peripheral components of the engine - alternator, starter, thermostat, electrical installation of the engine.

To 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.

•

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

•

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

•

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

•

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

•

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

•

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

•

Lay away material or other objects on the Machine.

•

Remove dirt while the Machine is running.

•

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

•

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

•

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

•

Operate the machine in potentially explosive atmospheres (ATEX) and underground areas.

•

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

•

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

•

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

•

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

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

•

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.

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

•

•

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

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).

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.

Driving with vibration on hard (frozen, concrete, overcompacted) surface or on bedrock. There is a danger of damage to the machine.

•

Leave the engine running in enclosed, unventilated areas.

Exhaust fumes are dangerous to life.

•

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

•

use other than original spare parts

•

interfere in the electrical and electronic units in any manner.

•

•

•

•

To operate the Machine unless driver control stand fixed properly.

•

To operate the Machine when engine bay cover is open.

•

To move and transport persons on the Machine.

•

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

•

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

AV 130 X

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

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

3

20

7 20

15

15 4 3

21

4

10 A 18

21

3

20

20

16 24 9 5

11 1 B

C

12

8

6 2

22

25

4 402617x

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

25

26

24

13

15 !

21

20

19 23

16

0

MM NN

28

!

J1939

22 27 18

1

MAN

2

AUT

IDLE

14

11 17 12

29 6

6

5 7

1

5

7

1

8

2

9

3

10

30

402500

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 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 - Beacon switch (optional) 20 - Alarm lights switch 21 - Additional lights switch (optional) 22 - Switch + indicator lamp for rear lights 23 - lndicator lamps for lights (dipped/distance) 24 - Infrathermometer (optional) 25 - Power view display 26 - Display 27 - Engine diagnostics 28 - Engine diagnostics switch 29 - Steering wheel position adjustment 30 - 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

26

!

0

MM NN !

J1939

6

MAN

2

AUT

IDLE

6

5 7

1

1

5

7

1

8

2

9

3

402501

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

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

The neutral position (N) is indicated by lighting up of the neutral and parking brake indicator lamps on the display (26).

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).

The indicator lamp on the display (26) lights up to indicate the function.

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 the button to turn on/off this function; then the indicator lamp on the display (26) will light up.

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

Emergency brake (8) pushbutton 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.

2582

Press the button to enable the machine emergency brake, then the brake, recharging and neutral indicator lamps will light up on the display (26).

Engine will stop and stall!

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

Sprinkling button (9) 3183

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

Hold the button pressed to enable the sprinkling function of the drums, then the indicator lamp on the display (26) will light up.

3128

It is used for adjusting the soft moving off and braking mode when the machine is stopped and reversed. In this way the creation of “waves” on compacted surface is eliminated. Press the switch to enable the function, then the indicator lamp on the display (26) will light up.

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

AV 130 X

43

2.7.

Machine basic functions control

26 13 15 !

16

0

MM NN !

J1939

18

1

MAN

2

AUT

IDLE

14

11 17 12

10

402502

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

It turns on one of two drum sprinkling pumps; it is indicated by the indicator lamp on the display (26).

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.

IDLE

Indicator lamps (23) light up to signal contour, dipped, and distance lights are ON. The indicator lamp on the display (26) lights up to indicate that the turn signal 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

25

26

24

!

21 22

20

19 23

0

MM NN !

J1939

1

MAN

2

AUT

IDLE

12

402503

46

AV 130 X

OPERATION MANUAL Switch + hazard beacon indicator lamp (19) - (optional) 592348

Switch + indicator lamp rear lights (22) 591668R

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

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

Alarm lights switch (20) Indicator lamps for (dipped / distance) lights (23)

AMN24

It is used for turning on/off the warning lights – the function is indicated by the flashing indicator lamp in the warning light switch on the display (26).

596473

591508

These lamps signal dipped or distance lights switched ON.

Switch + indicator lamp for cabin’s additional lights (21)

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

Infrathermometer (24) - (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 (24).

PowerView Display (25) Multifunctional instrument to display parameters of the engine function.

AV 130 X

47

2.7.

Machine basic functions control

26

!

MM NN !

410900 Display (26)

Fuel consumption gauge AMN25

!

Engine overheating indicator lamp

AMN7A

Not wired.

Not wired.

Level height in the sprinkling tank AMN27A

Seat switch indicator lamp AMN2A

It indicates the current water level in the tank on the LCD display.

Check the water level in the tank during operation of the machine.

The indicator lamp lights up when the operator is not sitting on the seat or when the emergency brake has been engaged.

Turn signal lights indicator lamp (left) AMN008

The lighting indicator lamp indicates that the (left) turn signal lights are ON. Parking brake indicator lamp Neutral indicator lamp

AMN1A

The lighting indicator lamp indicates that the parking brake was enabled.

AMN9A

The lighting indicator lamp indicates that the travel controls are in the neutral position (N).

Before the engine is started, the travel controls (1) must be in the neutral position (N)!

48

AV 130 X

OPERATION MANUAL Turn signal lights indicator lamp (right) AMN008A

Indicator lamp for vibration ON AMN10

The lighting indicator lamp indicates that the (right) turn signal lights are ON.

The lighting indicator lamp indicates that the vibration is on.

Fuel filter indicator lamp

Indicator lamp of hydraulic oil level AMN18

AMN2B

The indicator lamp indicates low hydraulic oil level.

Not wired.

When the indicator lamp is lit during operation of the engine, it indicates a defect. The engine stalls – the machine stops and the parking brake is engaged.

The engine can be started only after the failure is repaired and the oil in the hydraulic tank is refilled to the specified limit.

CRAB mode indicator lamp AMN15

The indicator lamp indicates that the drum is in CRAB mode.

Sprinkling pump indicator lamp Engine lubrication indicator lamp

AMN22

AMN6A

The indicator lamp indicates that the sprinkling pump is ON.

Not wired.

Indicator lamp for hydraulic oil pressure filter clogging

Indicator lamp for hydraulic oil temperature AMN11

AMN3A

The lighting indicator lamp indicates that the filter cartridge is clogged.

The indicator lamp indicates that the maximum allowed temperature of hydraulic oil has been exceeded. If the indicator lamp lights more than 5 seconds, the acoustic signalling will start.

Immediately replace the element!

Stop the machine and check the oil level or search for a defect!

Indicator lamp for soft moving off and soft braking

Air filter clogging indicator lamp

AMN16A AMN5

The lighting indicator lamp indicates that the soft moving off and soft braking mode of the machine is ON. When this indicator lamp is flashing intermittently, it indicates an error code for a defect within the machine travel system.

Shut down the machine and call the service organization to repair a defect on the machine travel system!

AV 130 X

The lighting indicator lamp indicates that the filter element is clogged above the allowed limit. If the indicator lamp lights more than 5 seconds, the acoustic signalling will start.

Stop the machine and replace the cartridge immediately!

49

2.7.

Machine basic functions control Battery charging indicator lamp

AMN4

It indicates that the battery charging function is in order. After the key in the ignition box (12) is switched to the “I” position, the indicator lamp must light up and then go out after the start-up.

If the indicator lamp does not go out, search for a possible defect!

The indicator lamp lighted up during operation of the engine indicates a defect. After 5 seconds, the audible alarm will be enabled and after 2 minutes the engine will stop automatically – the machine will stop and the parking brake will be engaged.

The engine can be started only after the defect is repaired!

Engine glowing indicator lamp AMN1B

It indicates the engine warming up before cold start.

50

AV 130 X

OPERATION MANUAL

!

0

MM NN !

J1939

27

1

MAN

2

AUT

IDLE

28

29 402504

ENGINE DIAGNOSTICS (27) – Use the connector to connect ECM (Electronic Control Module) and diagnostics trouble.

Note

Engine diagnostics switch (28) 2428

Not assigned.

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 (27).

AV 130 X

51

2.7.

Machine basic functions control

Steering wheel positioning (29) 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 (30)) 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 52

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.

MM NN

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°

410008

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

53

2.7.

Machine basic functions control

Cut-out box (34) 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

34

401615Cx 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 54

AV 130 X

OPERATION MANUAL Cabin fuse (35) F15 - 30 A

cabin wiring

Always replace the fuses with the ones of identical value!

35

Diagnostics socket (36)

36

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

Mounting socket (37)

401615Dx

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

Front wiper selector switch (38) 596625

37

41

38 39 40

Three-position selector switch -

Turned OFF

-

Low speed ON

-

High speed ON

Rear wiper selector switch (39) 596307

Three-position selector switch -

Turned OFF

-

Low speed ON

-

High speed ON

401620Cx

Glass washer switch (40) 2260

Two-position selector switch -

Windscreen washing ON

-

OFF

-

Rear window washing ON

Fan switch (41) 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

55

2.7.

Machine basic functions control

Cabin lighting (42) Ceiling lamp incl. selector switch is located overhead the dashboard.

44

Ventilation nozzles (43) 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 (44) (Option)

43

42

2441

401620Dx max

Control tie rod for heating valve (45)

min

47

45

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.

46

Adjust the heating valve before driving!

Hand pump control lever (46)

401622Cx

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

First-aid box stowage place (47)

The Machine shall be equipped with firstaid box!

Extinguisher (48) (OPTION) Place for the installation of a fire extinguisher.

! Attention !

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

401703 56

AV 130 X

OPERATION MANUAL Stowage pockets (49) These are used for Operator’s personal items.

49

401622Dx Anti-dazzle (sun) screen (50) Adjust the anti-dazzle screen through securing it to the fixing on the glass.

400242 Window washer tank (51) Fill with standardly available media.

Fill with antifreeze or drain before winter season starts!

401625 Additional lights (52) Lights located on the Machine cabin (optional).

400258 AV 130 X

57

2.7.

Machine basic functions control

Beacon socket (53) It is used to connect the beacon.

Back mirrors (54) External back mirrors enable to view poorly visible areas.

Maintain these mirrors clean and properly adjusted!

400243 Cabin ventilation air filter (55) It includes replaceable filter element to catch the impurities drawn in from air.

400258A Arm rests on the door (56) Transportation position

400244 Working position

400245 58

AV 130 X

OPERATION MANUAL Battery disconnector (57) 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 (58) It is used to lift or let down the bonnet.

Located on LH side of rear frame.

402218A

AV 130 X

59

2.7.

Machine basic functions control

2.6.1. Power View control 1

Display

2

Red LED lights – ENGINE SHUTOFF – engine substantial defect alarm

3

Yellow LED lights - WARNING – engine failure alarm, or minimal fuel level in tank alarm

4

Menu selection pushbutton – to enter or exit menu

5

Pushbutton – to move cursor UP – illuminates data on display or moves parameter option to the left or up

6

Pushbutton – to move cursor DOWN – illuminates data on display or moves parameter option to the right or down

7

ENTER pushbutton – selects menu or parameter, or conceals/displays active error code

2

3

1

4

7 5

6

396011B

The red LED is lighting – reduce the engine power, park the machine immediately at a safe place and turn off the engine!

Contact your dealer. Do not operate the machine until the failure is removed!

The yellow LED is lighting – warning – engine failure alarm, or minimal fuel level in the tank alarm. Reduce the engine power, park the machine immediately at a safe place and turn off the engine! Remove the failure or contact your dealer. Do not operate the machine until the failure is removed!

If a failure code is displayed, contact your dealer.

60

AV 130 X

OPERATION MANUAL NAVIGATION BASIS After the start-up, a four-parameter screen is displayed (engine speed, coolant temperature, engine oil pressure, fuel consumption rate). By pressing the left or right arrow, you display four additional parameters.

0 RPM ENG RPM

28°C COOL TEMP

0.00 BAR OIL PRES

0.0 L/HR FUEL RATE

410009 (engine oil pressure, engine load, el. system voltage, fuel consumption rate) Press the button MENU to display the main menu.

2.92 BAR OIL PRES

37 % LOAD@RPM

28.6 VDC SYS VOLT

3.1 L/HR FUEL RATE

268073 GO TO 1-UP DISPLAY – one-parameter display Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

431121 Use the cursor (1), to display 8 set parameters one after another (Engine speed, Coolant temperature, Engine oil pressure, Engine load in % at instantaneous engine speed, Electric system voltage, Number of engine hours, Immediate consumption, Fuel level).

0

1100

2200

2000 RPM

Press the button MENU (2) to return to the main menu.

ENG RPM

Note

COOL TEMP

If the engine is at rest, the battery voltage is indicated. If the engine is running, then roller’s el. system voltage is indicated.

2 AV 130 X

1

396117 61

2.7.

Machine basic functions control

LANGUAGES – menu to select a language Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

2 Use the cursor and select a language, then confirm your selection using the button ENTER (1) and return to the main menu by pressing the button MENU (2).

1

431122

*

ENGLISH FRANÇAIS DEUTSCH ITALIANO ESPAÑOL

2

1

431124

STORED CODES – saved defects, which are not enabled.

Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

Note The following message will appear on the display: “Requesting fault codes“. Wait until it disappears.

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

1 If the word MORE appears, use the cursor to move to other saved positions. By pressing the button ENTER, return to the main menu.

2

431125

1 of x

FUEL DELIVERY PRESSURE VERY LOW MORE

HIDE

431126 62

AV 130 X

OPERATION MANUAL ENGINE CONFIGURATION – menu to browse engine parameters

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

431138 Using the cursor you can move among the parameters.

ENGINE SPEED PT 1

850 RPM < NEXT >

431136 SELECT UNITS – selection of units of measure Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

1

2

431128

Use the cursor to set (1) ENGLISH and the indicated variables appear in PSI units (pressure), °F (temperature).

ENGLISH METRIC Kpa METRIC BAR

After you set METRIC KPA, the displayed variables are in kPA, °C units.

After you set METRIC BAR, the displayed variables are in bar, °C units.

Using the button ENTER (2) confirm the variables and using the button MENU (3) return to the main menu.

3 AV 130 X

1

2

431129 63

2.7.

Machine basic functions control

ADJUST BACKLIGHT – adjustment of the display backlight intensity Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

1 Set the backlight intensity using the cursor. By pressing the button MENU, return to the main menu.

2

431130

ADJUST BACKLIGHT

396028 ADJUST CONTRAST – adjustment of the display contrast Move the cursor (1) in the main menu onto the item and use the button ENTER (2) to enter the submenu.

GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONFIGURATION SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

1 Set the display contrast using the cursor. By pressing the button MENU, return to the main menu.

2

431131

ADJUST CONTRAST

396032 64

AV 130 X

OPERATION MANUAL SOFTWARE VERSION – informs about the software version

ADJUST CONTRAST SOFTWARE VERSION OEM

1

2

431132

OEM – service access

ADJUST CONTRAST SOFTWARE VERSION OEM

431133

AV 130 X

65

2.7.

Machine basic functions control

ENGINE FAULT SIGNALLING ALARM SIGNALLING The alarm signal indicated with the lighting yellow LED informs about an engine malfunction – warning.

Engine failure alarm, or min fuel level in tank alarm. Reduce the engine power, park the machine immediately at a safe place and turn off the engine! Remove the failure or contact your dealer. Do not operate the machine until the failure is removed!

396034

A registered failure is indicated on the display through an error code and a description of the failure.

When more errors are registered, please use the cursor to display the registered failures step by step.

1 of x

WARNING

SPN110FMI10 HIGH COOLANT TEMP HIDE

MORE

396036 Press ENTER to confirm and hide the display.

1 of 1

WARNING

SPN110FMI10 HIGH COOLANT TEMP HIDE

MORE

396037 Return to the 1-parameter screen with the warning icon for the active failure in the RH corner.

0

1100

2200

2000 RPM ENG RPM

COOL TEMP

396038 66

AV 130 X

OPERATION MANUAL Return to the 4-parameter screen with the warning icon for the active failure in the RH corner.

If a failure description and a code appear on the display of the instrument board, contact your dealer if it is impossible to remove the failure.

AV 130 X

0 RPM ENG RPM

28°C COOL TEMP

0.00 BAR OIL PRES

0.0 L/HR FUEL RATE

410010A

67

2.7.

Machine basic functions control

ENGINE CUT OFF ALARM The alarm signal indicated by the red lighting LED informs about a serious failure of the engine – Turn off the engine.

Reduce the engine power, park the machine immediately at a safe place and turn off the engine! Contact your dealer. Do not operate the machine until the failure is removed!

396040 A registered serious failure of the engine is indicated by an error code and a description of the failure on the display with the warning message “SHUT DOWN“. Confirm and hide the display using the button ENTER.

1 of x

SHUTDOWN

SPN110FMI10 HIGH COOLANT TEMP MORE

HIDE

396042 1-parameter display with the warning icon “SHUT DOWN“ in the upper right corner.

0

1100

2200

2000 RPM ENG RPM ENG RPM

COOL TEMP

396043 4-parameter display with the warning icon “SHUT DOWN“ in the upper right corner.

Note Press ENTER to display again the hidden error code for failure.

Press ENTER once again to display either 1 parameter or 4 parameters. The warning icon is displayed until the failure is removed.

0 ENG RPM

28°C COOL TEMP

0.00 BAR OIL PRESS

0.0 L/HR FUEL RATE

410011A 68

AV 130 X

OPERATION MANUAL ERROR MESSAGES Error message

Signature

“WAIT TO START PREHEATING” is displayed

The ECU is broadcasting a ‚Wait To Start‘message. Engine manufacturers typically recommend against starting the engine while the ECU is broadcasting this message. Once the ECU stops broadcasting this message,this screen will no longer be displayed on the Power View.

“CANBUS FAILURE” is displayed

The Power View has not received any valid J1939 CAN messages for at least 30 seconds.

“TIMEOUT ECU NOT RESPONDING” is displayed

The Power View sent a request to the ECU for Stored Fault Code (DM2) information, and the ECU did not respond to the request. This message on the PowerView indicates the ECU may not support Stored Fault Code (DM2) functionality over J1939.

“NO STORED CODES” is displayed

The Power View sent a request to the ECU for Stored Fault Code (DM2) information, and the ECU responded. There are zero stored codes.

“NO GAGE DATA” is displayed

The Power View has no record of gages connected to the RS485 bus.

“NO DATA” is displayed in place of a parameter value

The Power View has not received data for the selected parameter for at least 5 seconds.

“NOT SUPPORTED” is displayed in place of a parameter value

The ECU is sending a message that it does not support this parameter.

“DATA ERROR” is displayed in place of a parameter value

The ECU is sending a message that there is a data error with this parameter.

Or (PV101 only) FUEL LEVEL has been selected for display, ANALOG INPUT has been set to FUEL LEVEL, but no Murphy Fuel Sender has been connected to the analog input.

One of the 4-UP quadrants is empty

No parameter has been selected for display in this quadrant.

Display is not readable, either very dim or very dark

The LCD contrast may have been over or under adjusted. Press and hold the MENU key for approximately 5 seconds. This will reset the LCD contrast setting to factory default.

AV 130 X

69

2.7.

Machine control and use

26

!

0

MM NN !

J1939

1

MAN

2

AUT

IDLE

14

18

1

1

8

1

0

N 402505

70

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 (57).

-

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

-

All indicator lamps will light up on the display (26).

-

Then the brake, charging, neutral and engine glowing indicator lamps will remain lit on the display (26).

-

Wait until the engine glowing indicator lamp 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.

-

The recharging indicator lamp must go out on the display (26) after the starting.

-

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.

It is forbidden to quickly increase and decrease engine speed. It can 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

71

2.7.

Machine control and use

+ 0

12

V

1

12

0

4

+ 2

V

3

402005

72

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

73

2.7.

Machine control and use

13 !

0

MM NN !

J1939

1

MAN

2

AUT

IDLE

1

1

2

1

0

N 402506

74

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).

MAX 30%

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.

MAX 40%

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.

402006

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!

MA 25%X

MAX 15%

402007 AV 130 X

75

2.7.

Machine control and use

26

!

0

MM NN !

J1939

1

MAN

2

AUT

IDLE

1

1

2 3

1

0

N 402507

76

AV 130 X

OPERATION MANUAL Travel modes of the Machine: •

RAMP (soft starting to move and stopping to move)

•

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 the button (3) to turn on/off the function; it is indicated by the lighting indicator lamp on the display (26).

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.

AV 130 X

77

2.7.

Machine control and use

26

!

0

MM NN !

J1939

6

1

MAN

2

AUT

IDLE

6

5

5

1

1

2

1

0

N 402508

78

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 the button (5) to deflect the front drum to the right and press the button (6) to deflect it to the left; the function is indicated by the lighting indicator lamp on the display (26).

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

Turning OFF: The indicator lamp on the display (26) goes out to indicate that the 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

79

2.7.

Machine control and use

26 13 15 !

16

0

MM NN !

J1939

1

MAN

2

AUT

IDLE

17

1

7

7

1

2

1

0

N 402509

80

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.

The function is indicated by the lighting on the display (26).

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.

The vibration is indicated by the lighting indicator lamp on the display (26).

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

81

2.7.

Machine control and use

26

!

0

MM NN !

J1939

1

MAN

2

AUT

IDLE

14

12

7

1

7

1

8

2

1

0

N 402510

82

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 the display (26), the seat switch, parking brake and recharging indicator lamps will light up.

How to switch OFF: Turn the press button in the direction of arrows and the acoustic alarm will get turned OFF. The parking brake and neutral indicator lamps on the display (26) remain on.

Shift travel controls (1) to neutral (N) position, the Machine can be started again in this position.

2.7.4. How to stop the Machine and its engine Press the button (7) on the travel control (1) to turn off the vibration; then the indicator lamp on the display (26) will go out.

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 (57).

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

83

2.7.

84

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 (57).

„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

85

2.7.

Machine control and use

26

!

0

MM NN !

J1939

1

MAN

2

AUT

IDLE

9

10

1

0

N 402511

86

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).

The enabled sprinkling pump function is indicated by the indicator lamp on the display (26).

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

87

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. !

0

MM NN !

J1939

11

1

MAN

2

AUT

IDLE

402512 88

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 (24).

24 !

0

MM NN !

J1939

1

MAN

2

AUT

IDLE

402513 AV 130 X

89

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.

90

1

3 9

1

2 402008

AV 130 X

OPERATION MANUAL 2.8.1. How to load the Machine Use drive-up ramps or a crane to load the machine on the transporting vehicle.

2.8.1.1. Loading the machine using a ramp When loading the machine using a ramp, all safety regulations related to loading of the machine valid in the place of loading must be adhered to. The ramp must have appropriate loading capacity, antislip surface and must be stored on a flat surface.

We recommend that you adhere to regulation BGR 233.

Set the scrapers to the working position.

401718 Maximum permissible incline of the ramp is 30 %.

When loading the machine, a second person must be present to signal approach onto the ramp. See the list of hand signals in chapter 2.1.6.

Pay increased attention when loading the machine. Improper handling can cause serious injury or death.

MAX 30%

Non-adherence to the prescribed parameters of the ramp may result in damage to the machine.

AV 130 X

401714

91

2.8.

Machine transport

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

14 500 kg (32 000 lb) 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)

Observe the relevant national safety measures when loading th emachine with a crane.

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!

92

1 2 401647

AV 130 X

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.

When towed the Machine shall be attached with both lugs !

When towing, please use undamaged towing cable or pull rod of sufficient loading capacity 1,5 higher than the weight of hauled Machine. It is forbidden to use a chain for hauling.

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

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

When towing, it is necessary to ensure the continuous movement. Do not exceed a towing speed of more than 2 km/hour (1.2 mph).

The machine should only be towed for the shortest possible distance – to extricate the machine if it gets stuck or is blocking traffic in case of breakdown. Do not tow the machine for a longer distance than 300 m (0.19 mi).

The hauling machine shall fit with its size the Machine broken. It shall have sufficient hauling force (performance), weight and brake effect.

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

402010

A sunken machine can be towed for a short distance if the engine is running and the travel drive and steering are working. The operator on the towed machine must steer the machine in the towing direction.

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

No person may stay on the towed machine!

After the brake is released and the hydraulic circuit is short-circuited, all of the brakes are disabled!

Before releasing the brake, secure the machine with wooden scotch blocks against motion!

Do not touch hot parts of the machine, burn hazard!

AV 130 X

93

2.9.

Special conditions to use the Machine

How to brake off: Lift bonnet and secure via hydraulic cylinder valve.

401621 Turn the bonnet lifting valve anti-clockwise till the stop, do not tighten the valve with force.

402219 Remove hose (3) away from the clip.

Disconnect hose (1) in point (2).

Connect hose (3) into point (2) .

2 1 3 401445

94

AV 130 X

OPERATION MANUAL Travel pump short-circuiting: In the engine compartment, You must use an appropriate tool to press down the buttons of both travel pumps in order to short-circuit the hydraulic loop.

401250

401249 Turn the bonnet lifting valve to the right, up to its stop, do not tighten with force.

Insert the lever into the pump and pressurize the brake circuit by at least 30 full strokes (one stroke = movement of the lever up and down).

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 the drum of the towed machine for the occurrence of braking or skidding.

In such a case interrupt the towing and pump again using the lever in the manual hydrogenerator.

402220

After completion of towing, chock the drums and restore the machine.

AV 130 X

95

2.9.

Special conditions to use the Machine

How to put into initial state Turn the bonnet lifting valve to the left, up to its stop, do not tighten with force.

402219 Put the hose (1) and (3) to its original condition.

2 1 3 401445 Turn the bonnet lifting valve to the right, up to its stop, do not tighten with force.

402220 Unlock the bonnet

401621 96

AV 130 X

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

Confirm safe touch-down of the bonnet.

Remove control lever (46) and put it back in the Machine cabin.

402219 Check the hydraulic oil level in the tank. Refill the oil according to chapter 3.6.3. if required.

MAX

MIN

402317A

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 (3) is not connected at the point (2), the function of “Emergency Hydraulic Machine Brake Releasing”, the hose (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

97

2.9.

Special conditions to use the Machine

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.

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

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).

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.

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:

2.9.7. Driving with vibrations on compacted and hard materials When operating the Machine with vibration on hard materials (e.g. stony loose material), or with high level of compacting the base material, there can be even loss of contact between the drum and the material compacted (so called vibro-hit). This state will show in the increased vibration transfer into the Machine frame and onto the Driver’s control stand. Its partial elimination is possible via increasing the travel speed or changing the Machine vibration parameters (with the use of lower amplitude).

When it is necessary to operate the Machine under conditions where the Operator might be exposed to higher vibrations, then the Machine Operator will be liable to adjust the work procedures so as to prevent any injury to Driver’s health.

Note

-

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).

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.

98

When driving the Machine with vibrations on a different base material than stated in “Specification Manual”, the emission figures for vibration acceleration will be different - “Noise and vibration emissions”.

The driving with vibration on hard (frozen, concrete, overcompacted) surface or on bedrock is forbidden. There is a danger of damage to the machine.

AV 130 X

MAINTENANCE MANUAL

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

AV 130 X

99

100

AV 130 X

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

101

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.

102

•

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) 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.

The oil use according to the API and ACEA classification prescribed by the engine manufacturer:

Recommended Oil Change and Filter Change Intervals American Petroleum Institute Classification (API) CJ-4 (CES 20081)

European Classification (ACEA)

Fuel Sulfur Content

Engine Rating is 260 Hp (194 kW) or less

ACEA E9

< 500 ppm

500 hours or 6 months

JAMA DH-2

500 to 5000 ppm

400 hours* or 6 months

CI-4 (CES 20078)

ACEA E7

up to 5000 ppm

500 hours or 6 months

API CH-4/SJ (CES 20071, 20076 or 20077)

ACEA E5 JAMA DH-1

up to 5000 ppm

500 hours or 6 months

API CF-4/SG (CES 20075)

ACEA E3 ACEA E2

up to 5000 ppm

250 hours or 3 months

API CD API CE API CG-4/SH

ACEA E1

up to 5000 ppm

Obsolete. Do not Use

The oil drain interval must be reduced by 20 percent if American Petroleum Institute (API) CJ-4 (Cummins® Engineering Standard 20081) lubricating oil is used with diesel fuel containing 0.05 to 0.5 mass percent (500 to 5000 ppm) sulfur content.

AV 130 X

103

3.2.

Specification of fluids

The Ammann machines are filled with engine oil of viscosity class SAE 15W-40 during production.

°F

°C

104

40

86

30

68

20

50

10

32

0

14

-10

-4

-20

-22

-30

-40

-40

122

50

Use of synthetic engine oils is permited subjekt to the same performance and viskosity limitations of minarel (petroleum) based engine oils. The same oil change intervals must be applied to the synthetic oils that are applied to mineral (petroleum)based engine oils.

For easier start at temperatures below 0 °C (32 °F), SAE 10W-30 oil is recommended by the engine manufacturer.

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

104

5W - 30

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

10W - 30

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

15W - 40

NOTE

400150A

AV 130 X

MAINTENANCE MANUAL 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”).

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

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

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

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

! CAUTION !

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

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

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

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

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

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

If Bionafta (Biodiesel) is used all the year round, it is necessary to clean the fuel system under the engine operation with a clean diesel fuel for at least 30 minutes before parking the machine for longer than 3 months. Further, it is necessary to drain off the fuel tank, clean it, and either fill it with diesel fuel or minimise the occurrence of moisture and limit the microbiological growth inside the tank. Consult the measures with the fuel supplier.

AV 130 X

105

3.2.

Specification of fluids

3.2.3. Coolant

Water quality 2152

The coolant specification must meet requirements of: •

CES 14603

To fill the cooling circuit, use the coolant in the mixing ratio of 50%/50% with high-quality water (thermal protection up to -37 °C).

The maximum admissible concentration of the coolant is 60% (thermal protection up to -54 °C).

Change the coolant every 2,000 hours of operation, after 2 years at the latest.

Do not use hard water with a higher content of calcium and magnesium, which brings calculus formation, and with a higher content of chlorides and sulphates, which causes corrosion; refer to CUMMINS Engine Operation and Maintenance Manual.

The maximum content of compounds of calcium and magnesium is 170 milligrams – hardness of water.

The maximum content of compounds of chlorine is 40 milligrams.

The maximum content of compounds of sulphur is 100 milligrams.

Safety instructions:

Note

1) Protect your hands with protective gloves.

The machines are filled with a cooling solution with the Bantleon Avia Antifreeze NG coolant, specification CES 14603, ASTM D 4985, ASTM D 6210 at the manufacturer‘s during the production.

2) In case of ingestion immediately seek medical treatment.

It is a coolant based on monoethyleneglycol containing silicates.

It does not contain phosphates, nitrates, amines and borates.

3) In case of contact with skin or clothing immediately wash the affected area with clean water.

4) Do not mix different types of coolants. The mixture can cause a chemical reaction with formation of harmful substances.

There is an Avia NG label placed at the point to fill the coolant into the machine.

Refill the cooling circuit with the same or a completely miscible coolant of the required specification.

If the use of a different, immiscible coolant is necessary, the cooling circuit must be completely drained and cleaned with clean water repeatedly, at least 3 times.

However, it is not allowed to use a coolant of a different specification than stated by the engine manufacturer.

The coolant protects the cooling system from freezing, corrosion, cavitation, overheating, etc.

It is forbidden to operate the machine without coolant even for a short time.

It is forbidden to use a coolant of a different than prescribed specification and base. The engine and the cooling system can get damaged and the warranty lost.

Always check the ratio of antifreeze cooling agent in the coolant with a refractometer before the winter season starts.

106

AV 130 X

MAINTENANCE MANUAL 3.2.4. Hydraulic oil

3.2.5. Gearbox oil 2186

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.

Use high-quality oil corresponding to API GL-5, or EP or MILL-2105 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).

3.2.6. Lubricating grease 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).

Synthetic hydraulic oil 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.

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).

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!

AV 130 X

107

3.2.

Specification of fluids 3.2.9. Air-conditioning filling

3.2.8. Drum cooling liquid

2441

2152

Mixture:

1 kg (2,2 lb) of coolant Halocarbon 134a

46 l (12,2 GalUS) of water

0,2 l (0,05 galUS) of oil PAG 150

19 kg (42 lb) calcium chloride CaCL2

0,005 l (0,0013 galUS) of contrast medium

108

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 3 (0,79)

2186

2 x 19 (5) 2412

Joint bearings - joint and steering cylinder

Plastic grease according to chapter 3.2.6.

Windshield washers

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

2,75 (0,72)

Mixture according to chapter 3.2.8.

2x60 (2x15,9)

Drum cooling liquid

as required 0787

2260

2152

Air-conditioning filling

Mixture according to chapter 3.2.9.

2441

Water tank

Water

1000 (264) 2567

AV 130 X

109

3.4.

Lubrication and Maintenance Chart

Every 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.

Air filter dust valve check

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

3.6.11.

Check of the tightness of the fuel and hydraulic system

After 200 hours of operation 3.6.28.

Exchanging oil in gearboxes *

Every 250 hours of operation (3 months)

110

3.6.12.

Air intake cooler, intake piping

3.6.13.

Checking the cooling circuit of the engine

3.6.14.

Checking the engine belt

3.6.15.

Checking battery

3.6.16.

Air filter sensor check

3.6.17.

Machine lubrication

3.6.18.

Checking oil in gearboxes

3.6.19.

Watering filter cleaning

3.6.20.

Seat switch check

AV 130 X

MAINTENANCE MANUAL Every 500 hours of operation (every 6 months) - but at least once a year 3.6.21.

Engine oil exchange

3.6.22.

Fuel filter exchange

3.6.23.

Exchanging cleaner elements of air cleaner

3.6.24.

Cleaning the air cleaner of cabin ventilation

3.6.25.

Engine cooling liquid level check

3.6.26.

Check of wiring

After 500 hours of operation 3.6.32.

Vibrations system oil exchange **

Every 1000 hours of operation (1 year) 3.6.27.

Check tightening pulley and belt of the engine

3.6.28.

Exchanging oil in gearboxes *

3.6.29.

Damping system checking

3.6.30.

Fuel tank cleaning

3.6.31.

Water tank cleaning

Every 2000 hours of operation (2 years) 3.6.32.

Vibrations system oil exchange **

3.6.33.

Replace hydraulic oil and filters

3.6.34.

Exchanging the engine cooling liquid

3.6.35.

Inspect, adjust engine valve clearance ***

After 5,000 hours of operation 3.6.35.

Inspect, adjust engine valve clearance ***

Maintenance - As Needed 3.6.36.

Cleaning of coolers

3.6.37.

Water discharge from watering circuit before winter season

3.6.38.

Cleaning the machine

3.6.39.

Adjustment of scrapers

3.6.40.

Checking and tightening bolted joints

* First after 200 hours. ** First after 500 hours. *** First after 5000 hours.

AV 130 X

111

3.5.

Lubrication Chart

LUBRICATION AND SERVICE PLAN CONTROL LUBRICATE EXCHANGE 2000 1000 500 250

Filter set 500 h / 4-760025

Filter set 1000 h / 4-760025

Filter set 2000 h / 4-760130

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

112

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 RPM ENG RPM

28°C COOL TEMP

20% FUEL LEVEL

100 ENG HRS

396313A 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 also 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 3.6.40., 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: 3.6.28.

The first oil exchange in drum gearbox and gearbox pumps drive

Following the first 500 hours of new Machine operation or after the major overhaul, please carry out the operations under this Section: 3.6.32.

AV 130 X

Vibrations system oil exchange

113

3.6.

Individual Operations of Maintenance Every 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.

114

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

401307

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.

400159

AV 130 X

115

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 3.6.33.

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 116

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

117

3.6.

Individual Operations of Maintenance

3.6.6. Air filter dust valve check •

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 when dust valve is damaged.

If air filter dust valve is damaged, replace it with new one of identical type!

401316

Dust valve Order number: 1-952454

118

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.

MM NN !

410914 •

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

119

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.

!

MM NN !

410915 •

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 3.6.37.

120

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

121

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

!

MM NN !

410917 •

Furthermore, test the function of the switches of lamps (19-23), the integrated control switch of lamps and horn (18).

22 21 20 19

!

23

0

MM NN !

! WARNING !

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

J1939

1

MAN

2

AUT

IDLE

18 402514 •

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.

MM NN !

410919 •

Drive the machine away:

•

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

-

Travel controller zero position indicator light

-

Brake indicator light

!

MM NN !

410920 122

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!

!

MM NN !

410917

3.6.11. Check of the tightness of the fuel and hydraulic system •

Visually check the condition of the fuel and hydraulic system for leaking operating fluids or damage to individual system components (material degradation – ageing).

•

Remove the identified defects.

AV 130 X

123

3.6.

Individual Operations of Maintenance

Every 250 hours of operation (3 months) 3.6.12. 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 3.6.36.

OK

402340 124

AV 130 X

MAINTENANCE MANUAL 3.6.13. 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 3.6.36.

400181

401329 AV 130 X

125

3.6.

Individual Operations of Maintenance

3.6.14. 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

126

AV 130 X

MAINTENANCE MANUAL 3.6.15. Checking battery •

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

•

Clean the surface of battery.

•

If a maintenance-free battery is installed on the machine, it is not necessary to check the electrolyte level and the electrolyte is not filled up for the whole service life of the battery.

Other tasks prescribed above must be performed. Consult the battery discharge condition – the lowest permissible voltage level (measures on the battery terminals) under which the battery could be damaged and the charging procedure with the manufacturer.

402218 •

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

•

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.

1

1

402349

AV 130 X

127

3.6.

Individual Operations of Maintenance Keep the battery dry and clean.

Recharge insufficiently charged battery.

Recharge battery dismantled from the machine.

Do not disconnect the battery under running engine.

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.

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.

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

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

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

128

AV 130 X

MAINTENANCE MANUAL 3.6.16. 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.

!

MM NN !

410922 •

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!

Indicator Order number: 4-5358520075

402332

AV 130 X

129

3.6.

Individual Operations of Maintenance

3.6.17. 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 130

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

131

3.6.

Individual Operations of Maintenance

3.6.18. 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

132

AV 130 X

MAINTENANCE MANUAL 3.6.19. 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

133

3.6.

Individual Operations of Maintenance

3.6.20. Seat switch check •

Turn the key in the ignition box to the “I” position.

•

On the screen of the display, check that the seat switch indicator lamp changes according to the seat load.

-

Empty seat – indicator lamp on.

-

Occupied seat – indicator lamp off

134

AV 130 X

MAINTENANCE MANUAL Every 500 hours of operation (every 6 months) but at least once a year

The set of filters after 500 operating hours can be ordered under the order number 4-760025. For the list of all spare parts, see the table in the end of this publication.

3.6.21. Engine oil exchange •

Stop the engine.

•

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

•

Dismantle the drain plug and let oil drain.

•

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

402334

Oil filter Order number: 4-9501000048

402309 •

Clean the contact area of the filter sealing.

400173 •

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

282N130T AV 130 X

135

3.6.

•

Individual Operations of Maintenance

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 136

AV 130 X

MAINTENANCE MANUAL 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.

AV 130 X

137

3.6.

Individual Operations of Maintenance

3.6.22. Fuel filter exchange •

Stop the engine.

•

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

2

Fuel filter Order number: 4-9501000102 Cartridge Order number: 4-9501000101

1 402315A

•

Clean the contact area of the filter.

400173 •

Fill the filter with clean fuel.

401N160T •

Wipe the sealing ring with oil.

400174 138

AV 130 X

MAINTENANCE MANUAL •

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!

396250

Collect leaking fuel.

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

3.6.23. 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.

MM NN !

•

•

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

410922

Remove the lid (1).

1

401379 AV 130 X

139

3.6.

•

Individual Operations of Maintenance

Carefully remove the main element (2).

Cartridge Order number: 4-5358520127

2

401380 •

After remove the safety element (3).

Safety element Order number: 4-5358520128

3

401381 •

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

140

AV 130 X

MAINTENANCE MANUAL •

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

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 the dust valve immediately if it is damaged!

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

401316

Dust valve Order number: 1-952454

3.6.24. 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.

Filter Order number: 4-12788

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

401390 AV 130 X

141

3.6.

Individual Operations of Maintenance

3.6.25. 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

3.6.26. 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.

142

AV 130 X

MAINTENANCE MANUAL Every 1000 hours of operation (1 year)

The set of filters after 1000 operating hours can be ordered under the order number 4-760025. For the list of all spare parts, see the table in the end of this publication.

3.6.27. Check tightening pulley and belt of the engine •

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

•

Stop the engine!

•

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

•

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

402320A

Belt Order number: 4-8300750084

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

143

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

144

AV 130 X

MAINTENANCE MANUAL 3.6.28. 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

145

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

146

AV 130 X

MAINTENANCE MANUAL 3.6.29. Damping system checking •

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

Damping system of drums, left and right side 2x14.

Rubber metal Order number: 4-9200000030

402336

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

Rubber metal Order number: 1160052 Rubber metal Order number: 1160051

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

Rubber metal Order number: 4-9200000062

402324 AV 130 X

147

3.6.

Individual Operations of Maintenance

Rubber-metal components of the cooler supports 6x.

Rubber metal Order number: 4-6160070610

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

Replace the damaged parts.

Check the tightening of screws and nuts.

Rubber metal Order number: 1221823

402327A

3.6.30. 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.

!

MM NN !

410914 •

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

402328 148

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

149

3.6.

Individual Operations of Maintenance

3.6.31. 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 3.6.37.

401363 150

AV 130 X

MAINTENANCE MANUAL Every 2000 hours of operation (2 years)

The set of filters after 2000 operating hours can be ordered under the order number 4-760130. For the list of all spare parts, see the table in the end of this publication.

3.6.32. 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

1 401344

Prevent oil leakage to the ground.

AV 130 X

151

3.6.

Individual Operations of Maintenance

3.6.33. 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.

Suction strainer Order number: 4-5451050018 •

Mount back the tank lid – check the gasket.

•

Mount back accumulator holder and accumulator.

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

1

2 3 402327B

4

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

Adhere to fire precautions!

402338 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.

152

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!

MM NN !

410923 Hydraulic system filling •

Fill using the hydraulic unit.

•

You can order the hydraulic unit from the machine manufacturer.

Hydraulic unit 230 V Order number: 1251998 Hydraulic unit 110 V Order number: 1255297

Note:

1251998

The hydraulic unit 230 V is intended for operation in 230-Volt networks (Europe), the hydraulic unit 110 V is intended for operation in 110-Volt networks (North America).

•

Put the filling device fast coupling on the fast coupling for filling on the machine.

! NOTICE !

Continue filling the hydraulic circuit until pure oil starts running out through the drainage hole. After outflow of about 15 litres of oil, close the discharge hole with the plug.

402311A AV 130 X

153

3.6.

•

Individual Operations of Maintenance

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

MAX

MIN

402317A 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.

Filler neck Order number: 4-5358500002

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!

154

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.

Filter cartridge Order number: 4-5358500015

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.

!

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

AV 130 X

!

410924

155

3.6.

Individual Operations of Maintenance

3.6.34. 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 156

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!

•

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.

401307A

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

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

400159

3.6.35. 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

157

3.6.

Individual Operations of Maintenance Maintenance - As Needed

3.6.36. 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!

158

402316

AV 130 X

MAINTENANCE MANUAL 3.6.37. 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

159

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

160

AV 130 X

MAINTENANCE MANUAL 3.6.38. 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!

AV 130 X

161

3.6.

Individual Operations of Maintenance

3.6.39. 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.

Blade Order number: 4-28292

5 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!

162

3

4 402344A

AV 130 X

MAINTENANCE MANUAL HINGED SCRAPERS (OPTION) •

The machine is equipped with four hinged scrapers.

1

The scrapers setting: •

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

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.

Blade Order number: 4-28292 •

6

5

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 wornout scraper blade will ensure perfect cleaning of the drum!

AV 130 X

3

402348

163

3.6.

Individual Operations of Maintenance

3.6.40. 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

Nominal

Min

Max

Nominal

Min

Max

14

12x1,5

6

20

15

25

15

11

18

17

14x1,5

8

38

30

45

28

22

33

19

16x1,5

45

38

52

33

28

38

22

18x1,5

51

43

58

38

32

43

24

20x1,5

58

50

65

43

37

48

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

30

240

210

270

177

155

199

35

290

255

325

214

188

240

330

280

380

243

207

280

41 46 50

36x2 42x2 45x2

50

164

Hose

lb ft

52x2

15

20 22 25 28

38 42

AV 130 X

MAINTENANCE MANUAL 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 AV 130 X

282N222T 165

166

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

167

3.8.

Appendixes

Wiring scheme Legend: A1 Flasher unit for direction indicator lamps A2 Left combined instrument A4 Travel electronics A5 Travel controller A6 Time relay A7 Murphy (option) A8 Modul Telematic (option) B1 Fuel level float B3 Water tank pressure sensor B5 Drum speed sensor C1 Noise suppressing filter E1, 2 Front side lamps E3, 4 Rear lamps 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) 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 Q1 Battery cut off switch R1 Watering interval potentiometer R2 Speed potentiometer

168

R3-5 R6 R8 S1 S2 S2.1 S2.2 S2.3 S2.4 S2.5 S3 S4 S5 S6 S7 S8 S9 S12 S13 S14 S15 S16 S18 S19 S20 S21 S22 S23 S24 S25 S26 S27 S28 S29 S30

S31

Resistory Engine preheating Engine speed control Ignition box Combined switch Switch of side and head-lamps Main / passing beams control switch Headlight flasher switch Loud horn button Direction indicator lamps control switch Rear head-lamps switch Warning lamps switch Front additional-lamps switch (option) Warning beacon switch (option) Brake pressure switch Hydraulic system filter clogging switch Air filter clogging switch Hydraulic oil overheating switch CRAB position switch Reverse horn switch Neutral gear switch Emergency brake button Constant speed or stalling switch Vibration automatics switch Smooth start and stop button Seat switch Vibration button (red) on the left travel lever Vibration button (red) on the right travel lever Watering button Watering pumps control switch Vibration control switch – front / both / rest drum Vibration amplitude control switch Left (yellow) button on the left travel lever – CRAB to the left Right (yellow) button on the left travel lever – CRAB to the right Left (yellow) button on the right travel lever – CRAB to the left or the cutter upwards Right (yellow) button on the right travel lever – CRAB to the right or the cutter downwards

S32 S33 S34 S35 S36 S37 S38 S39 S43 S44 S45 V1-V14 X1 X2 X3-4 X5-62 X63 X64-69 X70-75 Y1 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17

Windscreen wiper control switch Rear screen wiper switch Washers double push-button Fan control switch Air-conditioning switch (option) Engine idle speed switch Engine diagnostic switch Trouble shooting switch Hydraulics temperature switch fan switching Overpressure air conditioning fuse Air conditioner thermostat (optional) Light-emitting diode (LED) Mounting socket Diagnostic socket Connection terminals Interface connector (X60 – unused) Engine diagnostic Connector J1939 Thread-guide couplings Valve of cooling fan engine Brake valve Valve - front runner forward drive Valve – front runner backward drive Valve - back runner forward drive Valve – back runner backward drive Rear drum vibration small amplitude valve Rear drum vibration large amplitude valve Front drum vibration small amplitude valve Front drum vibration large amplitude valve Valve of CRAB to the left Valve of CRAB to the right Pressure relief valve Valve of the cutter upwards (option) Valve of the cutter downwards (option) Compressor clutch (option)

AV 130 X

MAINTENANCE MANUAL F9 X61 engine connector 2

G1

1

30

31

E5

56b 56a

56b E6

X20:1 Y

X14:2

X35:2

X18:2

X35:3

X18:3

K3 X15:2

2

1 X9:3

5

3

X36:1

X18:4

X37:2

X14:3

1

S3

9

E8

3

15(30)A

5 10

K4

2

5

K5 2

1

3

5

3 2

X14:5

E12

X36:3

X18:6

E13

1 5

3

X12:4

5

K7

2

E14

31

3 1

X7:9

X1

X15:6

X52

Rear auxiliary lights

1

X53

X49:2

X12:5

X49:6

X12:6

X21

E18

X37:3

X55:1

1 X7:10

X15:7

5 10

X5:2

87

A6

ta 15 30

87a service socket

1

1

2

7

3

6

A B C

Telematic 12

A8 3

2

A B C

A B C

F G A C B D C E

A B C

X66a

X66b

X63

4

X64

A B C

X66

X67

11

A B C

A B C

A

S6

9

31

X80

X68

10

X55:2

E19

A B C

5

9

X54 X56:2

E17

Brake lights

S5

X56:1

E16

Warning beacon

A1

X7:7 CL

X15:4

6

10

X51

E15

1

X15:5

Front auxiliary lights

5

X7:8

E11

X38:3

S4

2 8

X7:22

F8 1A

A

A3 A4

B X69

X16:11

B X81

Front right direction light

E10

X14:4

Engine diagnostic socket

Rear right direction light

X18:5

X38:2

X72

Rear left direction light

X36:2

K6

X71

X37:4

E9

16 17

15/54

X35:4

Front left direction light

13 14 15

S1

1

S2. 5 O

MC

X20:5

Rear headlights

S2. 4 B X19:4 X9:4

X15:3

X41

E7

S2. 3

X20:2 C X7:6

H3

30

50

F3

X19:3

M

X7:3

15A

S2. 2

Z

C1 Horn

F2

S2. 1 H X19:2 X9:2

X19:1 S

X7:2

56a

X14:1

X3

S2 0 1 2

X20:3

31 Front headlights

X37:1

3

20A

X20:4

E4

F1 1 X9:1

2

X5:18

5

E3 Tail lights

K2

X14:9

X18:1

I

X7:4

X35:1

H1 X7:1

E2

X15:1

Front position lights

G

BAT

H2

K1

G2

F16 125A

E1

50

X7:5

K18

R6

30A

F10

12V 135Ah

Engine glowing

M1

31

Q1

X5:1

3

M

4

X80:1

A2

A7

A1 A6

A5

V13 Cooling fan valve

Y1

X5:19

V14

46 40 42

Connector engine

47

X62

37

29

22 23 9 11 1 34 2

1

X15:12

X7:15

V11

2

X15:17

X7:20

V12

1 5

X5:20

38

K20 3

4

X17:1

1

X17:2

4

R8

7 3

S37 5

1

2

6

2

9

10

X17:3 X17:4

2 5

X17:5

1

K17

3

4

X17:6

S38

X17:7

1 2

3

4

5

6

5 7

8

9 10 11 12

108080A_1en

AV 130 X

169

3.8.

Appendixes

Wiring scheme Legend: A1 Flasher unit for direction indicator lamps A2 Left combined instrument A4 Travel electronics A5 Travel controller A6 Time relay A7 Murphy (option) A8 Modul Telematic (option) B1 Fuel level float B3 Water tank pressure sensor B5 Drum speed sensor C1 Noise suppressing filter E1, 2 Front side lamps E3, 4 Rear lamps 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) 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 Q1 Battery cut off switch R1 Watering interval potentiometer R2 Speed potentiometer

170

R3-5 R6 R8 S1 S2 S2.1 S2.2 S2.3 S2.4 S2.5 S3 S4 S5 S6 S7 S8 S9 S12 S13 S14 S15 S16 S18 S19 S20 S21 S22 S23 S24 S25 S26 S27 S28 S29 S30

S31

Resistory Engine preheating Engine speed control Ignition box Combined switch Switch of side and head-lamps Main / passing beams control switch Headlight flasher switch Loud horn button Direction indicator lamps control switch Rear head-lamps switch Warning lamps switch Front additional-lamps switch (option) Warning beacon switch (option) Brake pressure switch Hydraulic system filter clogging switch Air filter clogging switch Hydraulic oil overheating switch CRAB position switch Reverse horn switch Neutral gear switch Emergency brake button Constant speed or stalling switch Vibration automatics switch Smooth start and stop button Seat switch Vibration button (red) on the left travel lever Vibration button (red) on the right travel lever Watering button Watering pumps control switch Vibration control switch – front / both / rest drum Vibration amplitude control switch Left (yellow) button on the left travel lever – CRAB to the left Right (yellow) button on the left travel lever – CRAB to the right Left (yellow) button on the right travel lever – CRAB to the left or the cutter upwards Right (yellow) button on the right travel lever – CRAB to the right or the cutter downwards

S32 S33 S34 S35 S36 S37 S38 S39 S43 S44 S45 V1-V14 X1 X2 X3-4 X5-62 X63 X64-69 X70-75 Y1 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17

Windscreen wiper control switch Rear screen wiper switch Washers double push-button Fan control switch Air-conditioning switch (option) Engine idle speed switch Engine diagnostic switch Trouble shooting switch Hydraulics temperature switch fan switching Overpressure air conditioning fuse Air conditioner thermostat (optional) Light-emitting diode (LED) Mounting socket Diagnostic socket Connection terminals Interface connector (X60 – unused) Engine diagnostic Connector J1939 Thread-guide couplings Valve of cooling fan engine Brake valve Valve - front runner forward drive Valve – front runner backward drive Valve - back runner forward drive Valve – back runner backward drive Rear drum vibration small amplitude valve Rear drum vibration large amplitude valve Front drum vibration small amplitude valve Front drum vibration large amplitude valve Valve of CRAB to the left Valve of CRAB to the right Pressure relief valve Valve of the cutter upwards (option) Valve of the cutter downwards (option) Compressor clutch (option)

AV 130 X

MAINTENANCE MANUAL 1

32 41

43 44 50 39

3

4

5 6

7

Air filter

8

X5:16

10

P

S7

X14:6

P

S8

X14:7

4

P

S9

X14:8

5

X14:11

15

B1

Fuel gauge

S12

Hydraulics oil overheating

Light Direction lights Direction lights Brake

1

X14:12

S43

X5:21

Fuel gauge

Seat

Charging +12V

A2

Vibration

X7:11

X15:9

X7:12

25

X15:10

X7:13

F4 5A

75 R

3 26

GND

Sprinkling

X15:8

19 Crab

Water level

2 24

7 9

R3

Hydraulic temperature

17

220 R

Neutral

Air filter

14

R4

20

Charging +hours

Hydraulic filter

21

X5:22

Hydraulic temperature switch -fan switch

16 17

H8

X17:12 X5:15

X39

Hydraulic filter

13 14 15

9 10 11 12

X17:11

13

Brake

8

X39

15k

R5

28

X62 Engine connector

2 X17:10

Start-stop

X73

X80:2

X11:1 1(H)

CRAB position switch

Fe S13

X11:2

PNP 4(C) 3(M)

X11:3

B3

X18:7

X7:14

X15:11

Coolant level Water level in the water tank

1

K10

2 2 5

X6:9

1 3

4

X15:13

X11:9

PNP H M

X7:16

X11:4

Fe S15

M

PNP H C

K9 2 5

Fe S14

C

X11:6

X11:7

X11:8

1 3

4

Y4

41

X5:9

Y5

X5:10

Y6

X5:12

Read drum - travel back

Y7

Neutral Start-Stop

Automat. vibration

Brake

1

19 X8:3

X16:3

X10:2

X23:2

X10:3

X22:2

12 X10:4 Vibration 22 Rear drum - travel forward 24 Front drum - travel back 5 Seat 9

X24:1

Start-Stop 4

6

Front drum 7 - travel forward Front drum 8 - travel back

X5:11

Read drum - travel forward

7

X5:13 X5:14

RS2323 TxD

X16:4

X16:5

A4

1

S18 5

S19

5

S20

1

5

S21 S22

X24:2

S23

X26:1

20

X26:2

RS2323 RxD 21 X15:16

Front drum - travel back

X5:8

X16:1 X16:2

X2

Front drum - travel forward

Y3

X8:1

2 3 5 9

40

28,42

X74 18

Brake

X10:1 X7:18

X8:2

3 Constant speed 2 Engine overload

12V

(12V)

15,29

X5:6,7

X23:1

X11:5

1

F5 10A

X22:1

2

3

X25:7 X10:13

K8

1

5

2

X5:4

X15:15

H5 X43:1 X38:1

S16

X43:2

X10:14 X25:8

Reversing horn

Pojezd

26 27

Vibration

14

X6:2

X10:6

34

Speed

2 3

1

R1 X10:7

31

1K

100R

X23:3

R2 100R

X75 X82 1

A5

X25:2

100R

X10:8

X6:3

5

Sprinkling

Sprinkling

1

6

X81:B

17 Drum speed

1(H)

X81:C

32

X25:3

X6:1

(5V)

B5

3(M)

5V

Front drum speed

4(C)

Engine speed

X23:4

16

X7:19

X8:4

X8:5

RS2323 Grd 13

1K

100R X23:5

X10:9

X25:4

X81:A 4 5 6

7 8

9

10

11 12

108080A_2en

AV 130 X

171

3.8.

Appendixes

Wiring scheme Legend: A1 Flasher unit for direction indicator lamps A2 Left combined instrument A4 Travel electronics A5 Travel controller A6 Time relay A7 Murphy (option) A8 Modul Telematic (option) B1 Fuel level float B3 Water tank pressure sensor B5 Drum speed sensor C1 Noise suppressing filter E1, 2 Front side lamps E3, 4 Rear lamps 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) 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 Q1 Battery cut off switch R1 Watering interval potentiometer R2 Speed potentiometer

172

R3-5 R6 R8 S1 S2 S2.1 S2.2 S2.3 S2.4 S2.5 S3 S4 S5 S6 S7 S8 S9 S12 S13 S14 S15 S16 S18 S19 S20 S21 S22 S23 S24 S25 S26 S27 S28 S29 S30

S31

Resistory Engine preheating Engine speed control Ignition box Combined switch Switch of side and head-lamps Main / passing beams control switch Headlight flasher switch Loud horn button Direction indicator lamps control switch Rear head-lamps switch Warning lamps switch Front additional-lamps switch (option) Warning beacon switch (option) Brake pressure switch Hydraulic system filter clogging switch Air filter clogging switch Hydraulic oil overheating switch CRAB position switch Reverse horn switch Neutral gear switch Emergency brake button Constant speed or stalling switch Vibration automatics switch Smooth start and stop button Seat switch Vibration button (red) on the left travel lever Vibration button (red) on the right travel lever Watering button Watering pumps control switch Vibration control switch – front / both / rest drum Vibration amplitude control switch Left (yellow) button on the left travel lever – CRAB to the left Right (yellow) button on the left travel lever – CRAB to the right Left (yellow) button on the right travel lever – CRAB to the left or the cutter upwards Right (yellow) button on the right travel lever – CRAB to the right or the cutter downwards

S32 S33 S34 S35 S36 S37 S38 S39 S43 S44 S45 V1-V14 X1 X2 X3-4 X5-62 X63 X64-69 X70-75 Y1 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17

Windscreen wiper control switch Rear screen wiper switch Washers double push-button Fan control switch Air-conditioning switch (option) Engine idle speed switch Engine diagnostic switch Trouble shooting switch Hydraulics temperature switch fan switching Overpressure air conditioning fuse Air conditioner thermostat (optional) Light-emitting diode (LED) Mounting socket Diagnostic socket Connection terminals Interface connector (X60 – unused) Engine diagnostic Connector J1939 Thread-guide couplings Valve of cooling fan engine Brake valve Valve - front runner forward drive Valve – front runner backward drive Valve - back runner forward drive Valve – back runner backward drive Rear drum vibration small amplitude valve Rear drum vibration large amplitude valve Front drum vibration small amplitude valve Front drum vibration large amplitude valve Valve of CRAB to the left Valve of CRAB to the right Pressure relief valve Valve of the cutter upwards (option) Valve of the cutter downwards (option) Compressor clutch (option)

AV 130 X

MAINTENANCE MANUAL 2 3

1

X10:11

S24

X25:6

1

X8:6

X16:6

X25:5

5

F6

X10:10

K11

1

2

5

3

X8:7

V1 D4

D3

D2

D1

Y11

X14:19

C4

C3

B4

B3

F3

F4

E3

E4

G3

G4

2

CRAB left CRAB right

X12:2

2

X16:8

X15:18

Y12

X13:1

X31:1

X27:1

S28

Y13

X13:2

X31:2

X27:2

S29

X7:21

X12:3

X14:18

X11:10

X24:3

X28:1

X49:3

C1

Y10

2

Radio

A3

C2

F7 30A

A4

A3

3

X12:7

B3

A4

2

5

X49:5

B4

X14:17

1

7.5A

S26

Y9

1

5

F15

S27

X14:16

1

11 12

K13

Y8

Big amplitude of front drum vibration

10

1

X16:7

2

Small amplitude of front drum vibration

9

S25

7

X50

X6:6 X6:7

3

K12

X12:1

1

X47:1 X47:2

5

7 8

X10:12

Big amplitude of rear drum vibration

X6:5

V3

1

X6:4

V4

Small amplitude of rear drum vibration

M3

X46:1 X46:2

6

15A

2

X8:8

M

Sprinkling 2

M2

V2

M

Sprinkling 1

1

4 5

Edge cutter up Edge cutter down

Y15

X13:4

X31:4

Y16

X13:5

X31:5

X29:1

S30

X29:2

S31

X26:3

X30:1 X30:2

E20

Cab light

M

Front wiper

X32:1

F11

X32:4

15A

M4 X32:2

7

5

S32

X32:5

3 1

X32:3

M

Left rear wiper

X33:3

X56:10

X33:1

X56:3

M5 X33:4

X56:5

7

X33:2

X56:4

1

M8

X57:2

M9 X58:2

X56:8

3

Y17

P

S44

S45

5 2

X56:9 5 2

X59:3

Fan 3

1

3

M

X48:1

1

M

X59:1

Fan 2

M10 X59:2 2

3

K14

F12

3

15A

1

S35

K15

5

3

F13

3

5A

1

1

1

M11 X48:2 2

S34

7 1

2

X58:3

3

6

V9

1

X57:1

M

X58:1

Fan 1

X56:6

M7

M

Rear windscreen washer

X56:7

X34:2

M

Front windscreen washer

M6 X34:4

V10

M X57:3

5

2

X34:1

Right rear wiper

S33

8

X34:3

Air conditioning clutch

X49:1

V5

X31:3

V7

X13:3

V8

Y14

Relief valve

V6

X28:2

9

S36

5 10

K16

X48:3 1

2

5

3

F14

X5:5

X4

X12:9 X52

X35:4

X18:8

X37:4

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

108080A_3en

AV 130 X

173

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

Cabine 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 100±3°C

24

Temperature switch 82/74 ±3°C

25

Oil level indicator

26

Ball valve

27

Filling quick coupler

28

Quick-coupler measuring-type

174

AV 130 X

REAR TRAVEL HYDROMOTOR

FRONT TRAVEL HYDROMOTOR

4

55

L2 A

55

M2 Dn16

Dn16 L1 B M1

3

M2 Dn16

Dn16 A M1

L1 B

L2

Dn16

Dn16

Ø1 mm

M8

M8

Ø1 mm

C1

45

L2

20

20

M4

C2

M5

45

45

C1

C1

L1

300

300

A

MA

Dn19

L2

M4

M5

L1

300

300

A

MA

MB

M4

C2

MC

M5

REAR PUMP

X7 M3 E

B

L3

350

350

C2

C

D

MD

1

M4

MB

M5

FRONT PUMP

X7 M3 E

5

REAR VIBRATION HYDROMOTOR

MC

Dn19

45

C2

Dn16

10 l/min

Dn16

Dn16

B

L3

350

350

C1

L1 B

M2

M1

L2 A

35

M2

L1 B

10 l/min

C

D

MD

1

Dn16 Dn16

FRONT VIBRATION HYDROMOTOR

19

Dn16

i=0.707

35

17

rpm

2300

2

28

P

Dn16

i=1.0

Dn16

180

500

10,8

100

Dn19

23,5

LS

Dn13

M1

T

18

82/74 ± 3°C

100°C

40°C

24

Dn8

Dn16

Dn10

Dn10

L

250

13

55°C

R

°C

8

170

80/40-320

80/40-320

Dn10

250

Dn13

A

Dn13 Dn32

Inlet Dn25

Dn13 3 bar

Dn10

Outlet Dn8

16

Dn25

Dn8

Dn8

7

14

9

8

6

25

Dn10

23

12

Dn10

110/56-125

11

63/32-160

L2

Dn10

Dn10

Dn6

100

Ø0.5 mm

M

P1

X

T1

Dn13

Ø1 mm

B2 A2

B1 A1

Ø25 - 320

Crab

Dn6

T Dn16

Ø0.5 mm

P

100

P

B A Ø25 - 320

100 14

190

180

100

B

Edge cutter

T P

A

AV 130 X Dn6

5

PP

10

20 bar

T2

II. rychlost

20

21

26

10

27

A3

Brzda A4

T

13 bar

MAINTENANCE MANUAL

107841Aen

175

3.8.

Appendixes

Regular maintenance spare parts chart Chapter

Spare part

Order No.

Every 20 hours of operation (daily) 3.6.6.

Dust valve

1-952454

Every 250 hours of operation (3 months) 3.6.16.

Indicator

4-5358520075

Every 500 hours of operation (6 months) 3.6.21.

Oil filter

4-9501000048

3.6.22.

Fuel filter

4-9501000102

3.6.22.

Cartridge

4-9501000101

3.6.23.

Cartridge

4-5358520127

3.6.23.

Safety element

4-5358520128

3.6.6.

Dust valve

1-952454

3.6.24.

Filter

4-12788

Every 1000 hours of operation (1 year) 3.6.27.

Belt

4-8300750084

3.6.29.

Rubber metal

4-9200000030

3.6.29.

Rubber metal

1160052

3.6.29.

Rubber metal

1160051

3.6.29.

Rubber metal

4-9200000062

3.6.29.

Rubber metal

4-6160070610

3.6.29.

Rubber metal

1221823

Every 2000 hours of operation (2 years) 3.6.33.

Suction strainer

4-5451050018

3.6.33.

Filler neck

4-5358500002

3.6.33.

Filter cartridge

4-5358500015

Necessary maintenance 3.6.39.

176

Blade

4-28292

AV 130 X

MAINTENANCE MANUAL Content of the set of filters after 500 and 1000 operating hours (4-760025) Chapter

Spare part

Number of parts

Order No.

3.6.21.

Oil filter

1 pc

4-9501000048

3.6.22.

Cartridge

1 pc

4-9501000101

3.6.22.

Fuel filter

1 pc

4-9501000102

3.6.23.

Cartridge

1 pc

4-5358520127

3.6.23.

Safety element

1 pc

4-5358520128

3.6.24.

Filter

1 pc

4-12788

Number of parts

Order No.

Content of the set of filters after 2000 operating hours (4-760130) Chapter

AV 130 X

Spare part

3.6.21.

Oil filter

1 pc

4-9501000048

3.6.22.

Cartridge

1 pc

4-9501000101

3.6.22.

Fuel filter

1 pc

4-9501000102

3.6.23.

Cartridge

1 pc

4-5358520127

3.6.23.

Safety element

1 pc

4-5358520128

3.6.24.

Filter

1 pc

4-12788

3.6.33.

Filter cartridge

1 pc

4-5358500015

3.6.33.

Filler neck

1 pc

4-5358500002

3.6.33.

Suction strainer

1 pc

4-5451050018

177

Notes:

178

AV 130 X

For additional product information and services please visit: www.ammann .com

Materials and specification data are subject to change without notice.

Book ID: 4-P06000-EN | © Ammann Group