Ammann AV 70 X Tandem Roller Operating Manual SN 00031 PDF

Operating manual Articulated tandem roller AV 70 X

AV 70 X Articulated tandem roller Cummins Tier 3

Operating manual Edition 07/2009 EN From Serial No. 00031

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

With kind regards,

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

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

400270

This manual consists of: I. Specification manual

II. Operating instructions

III. Maintenance manual

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

Subsequent faults due to improper operating are avoided.

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

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

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

These instructions must always be kept available on the equipment.

AV 70 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 70 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.

! WARNING !

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

FRONT

RIGHT

LEFT

REAR 400101en

AV 70 X

3

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

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

1.1. Basic specification.................................................................................................................................10 1.1.1.

Area of use.................................................................................................................................................................................................................10

1.1.2.

Machine design.......................................................................................................................................................................................................10

1.2. Machine dimension scheme.................................................................................................................12 1.3. Technical data........................................................................................................................................14 1.3.1.

Weights.......................................................................................................................................................................................................................14

1.3.2.

Drive of travel - driving properties...................................................................................................................................................................14

1.3.3.

The vibrations...........................................................................................................................................................................................................14

1.3.4.

Engine.........................................................................................................................................................................................................................14

1.3.5.

Brakes..........................................................................................................................................................................................................................15

1.3.6.

Drive............................................................................................................................................................................................................................15

1.3.7.

Fills................................................................................................................................................................................................................................15

1.3.8.

Sprinkling...................................................................................................................................................................................................................15

1.3.9.

Electrical installation..............................................................................................................................................................................................15

1.3.10. Hygienic parameters..............................................................................................................................................................................................16

4

AV 70 X

OPERATING MANUAL 2.

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

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

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

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

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

2.1.3.

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

2.1.4.

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

2.1.5.

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

2.1.6.

Hand Signals.............................................................................................................................................................................................................30

2.2. Ecological & Hygienic Principles..........................................................................................................33 2.2.1.

Hygienic Principles . ..............................................................................................................................................................................................33

2.2.2.

Ecological Principles .............................................................................................................................................................................................33

2.3. Preservation & Storage ........................................................................................................................34 2.3.1.

Short-Term Preservation & Storate for the Period of 1 ÷ 2 Months......................................................................................................34

2.3.2.

Machine Preservation & Storage for the Period Over 2 Months Long.................................................................................................34

2.3.3.

De-conservation and inspection of brand new machines......................................................................................................................35

2.4. Machine Disposal Following Its Life Termination...............................................................................36 2.5. Machine Description.............................................................................................................................37 2.6. Controls & Dashboard Instruments .....................................................................................................38 2.7. Machine basic functions control..........................................................................................................58 2.7.1.

Engine starting........................................................................................................................................................................................................59

2.7.2.

Machine travel and reversing with no vibration..........................................................................................................................................63

2.7.3.

Machine travel and reversation incl. vibrations...........................................................................................................................................69

2.7.4.

Driving with vibrations on compacted and hard materials....................................................................................................................69

2.7.5.

Compacting near constructed facilities..........................................................................................................................................................69

2.7.6.

How to stop the Machine and its engine.......................................................................................................................................................71

2.7.7.

Safe stopping of the Machine............................................................................................................................................................................71

2.7.8.

Emergency stop of the Machine.......................................................................................................................................................................73

2.7.9.

Machine shutdown................................................................................................................................................................................................73

2.7.10. Sprinkling...................................................................................................................................................................................................................73 2.7.11. How to lift and let down the engine bonnet................................................................................................................................................74

2.8. Machine transport.................................................................................................................................76 2.8.1.

Machine towing......................................................................................................................................................................................................76

2.8.2.

How to load the Machine.....................................................................................................................................................................................79

2.8.3.

Transporting by the road.....................................................................................................................................................................................80

2.9. Special conditions to use the Machine................................................................................................81 2.9.1.

How to operate the Machine during its running-in...................................................................................................................................81

2.9.2.

Operating the Machine at low temperatures...............................................................................................................................................81

2.9.3.

Machine operation at high temperatures and humidity..........................................................................................................................81

2.9.4.

Machine operation at high altitudes...............................................................................................................................................................81

2.9.5.

Machine operation within very dusty environment..................................................................................................................................81

AV 70 X

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Content 3.

MAINTENANCE MANUAL.....................................................................................................................83

3.1. Safety and other measures for machine maintenance.......................................................................85 3.1.1.

Safety of machine maintenance........................................................................................................................................................................85

3.1.2.

Fire precautions during operation media exchanges...............................................................................................................................85

3.1.3.

Ecological and hygienic principles...................................................................................................................................................................86

3.2. Media specification...............................................................................................................................87 3.2.1.

Engine oil...................................................................................................................................................................................................................87

3.2.2.

Fuel...............................................................................................................................................................................................................................88

3.2.3.

Hydraulic oil . ...........................................................................................................................................................................................................88

3.2.4.

Lube grease . ............................................................................................................................................................................................................89

3.2.5.

Cooling liquid...........................................................................................................................................................................................................89

3.2.6.

Glass washer fluid ..................................................................................................................................................................................................90

3.2.7.

Gear oil........................................................................................................................................................................................................................90

3.3. Media .....................................................................................................................................................91 3.4. Lubrication and Maintenance Chart....................................................................................................92 3.5. Lubrication Chart...................................................................................................................................94 3.6. Lubrication and Maintenance Operations...........................................................................................95 Following the 20 hours of operation or daily......................................................................................96 3.6.1.

Inspect, refill the oil amount in the engine...................................................................................................................................................96

3.6.2.

Inspect, replenish the engine coolant amount............................................................................................................................................97

3.6.3.

Inspect the engine belt .......................................................................................................................................................................................98

3.6.4.

Crankcase breather................................................................................................................................................................................................98

3.6.5.

Inspect air filter vacuum valve...........................................................................................................................................................................99

3.6.6.

Inspect fan condition............................................................................................................................................................................................99

3.6.7.

Check fuel amount.............................................................................................................................................................................................. 100

3.6.8.

Inspect oil amount in the hydraulic circuit tank . .................................................................................................................................... 101

3.6.9.

Fill up sprinkling water tank ........................................................................................................................................................................... 101

3.6.10. Inspect alarm and control devices................................................................................................................................................................. 102

Following 250 hours of operation (after 3 months)..........................................................................104 3.6.11. How to exchange motor oil and oil filter..................................................................................................................................................... 104 3.6.12. Inspect engine induction manifold............................................................................................................................................................... 106 3.6.13. Inspect engine cooling circuit......................................................................................................................................................................... 106 3.6.14. Inspect the battery.............................................................................................................................................................................................. 108 3.6.15. Inspect the function of air filter vacuum switch....................................................................................................................................... 110 3.6.16. Sprinkling filter & sprinkler strainer.............................................................................................................................................................. 111 3.6.17. Machine lubrication............................................................................................................................................................................................ 113

After 500 hours of operation (after 6 months)..................................................................................115 3.6.18. How to replace fuel filter . ................................................................................................................................................................................ 115 3.6.19. Inspect coolant concentration . ..................................................................................................................................................................... 116

6

AV 70 X

OPERATING MANUAL Following 1000 hours of operation (after 1 year).............................................................................117 3.6.20. Inspect engine belt............................................................................................................................................................................................. 117 3.6.21. Inspect the exhaust system.............................................................................................................................................................................. 117 3.6.22. Inspect the silencing system........................................................................................................................................................................... 118 3.6.23. Clean the water tank........................................................................................................................................................................................... 120 3.6.24. Oil change in the gearboxes............................................................................................................................................................................ 121

Following 2000 hours of operation (every 2 years)..........................................................................122 3.6.25. Inspect, adjust engine valve clearance........................................................................................................................................................ 122 3.6.26. Engine coolant exchange................................................................................................................................................................................. 122 3.6.27. How to exchange oil in the vibrators............................................................................................................................................................ 126 3.6.28. How to exchange hydraulic oil and filters.................................................................................................................................................. 126

Maintenance as required....................................................................................................................130 3.6.29. Fuel system breathing........................................................................................................................................................................................ 130 3.6.30. How to replace air filter elements.................................................................................................................................................................. 131 3.5.31. How to clean water separator of fuel filter................................................................................................................................................. 133 3.6.32. Clean the engine radiators and hydraulic oil coolers............................................................................................................................. 134 3.6.33. How to clean cab ventilation filter................................................................................................................................................................. 134 3.6.34. Drain water from sprinkling circuit before winter season..................................................................................................................... 135 3.6.35. Adjust the scrapers.............................................................................................................................................................................................. 137 3.6.36. Machine cleaning ............................................................................................................................................................................................... 138 3.6.37. Check the tightening of bolted connections............................................................................................................................................. 138

3.7. Defects..................................................................................................................................................141 3.8. Attachments.........................................................................................................................................142 Wiring Diagram..................................................................................................................................................................................................................... 142 Hydraulic Diagram .............................................................................................................................................................................................................. 146

AV 70 X

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8

AV 70 X

SPECIFICATION MANUAL

1. SPECIFICATION MANUAL AV 70 X (Cummins Tier 3)

AV 70 X

9

1.1.

Basic specification

1.1.1. Area of use

Please fill in the following data:

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

Type of machine

1.1.2. Machine design

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

The tandem vibration roller AV 70 X with an articulated frame enables the steering and offset of drums (crabbing). The roller conception allows compaction close to curbs or walls. The cabin is in version with integrated frame ROPS, compliant with international standards ISO 3471:1994/Amd.1:1997; EN 13510:2000; SAE J/ISO 3471:2003; AS 2294-2003; for maximum machine weight 9000 kg (19845 lb).

(see Pin label, Label of the CUMMINS engine)

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

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

The rollers can be used for compaction of asphalt compositions to the layer thickness (after compaction) of 140 mm (5,5 in), hydraulic cemented compositions to the layer thickness of 200 mm (7,9 in), composed earth to the layer thickness of 270 mm (10,6 in), sand and gravel materials to the layer thickness of 370 mm (14,6 in).

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

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

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

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 meets requirements of international standards for hygiene, ergonomics and safety of operation and is provided with the production plate CE. Machine’s production label – CE

AMMANN CZECH REPUBLIC a.s.

NOVÉ MĚSTO NAD METUJÍ, CZECH REPUBLIC

3171

TYP / TYPE

IČV / S/N PROVOZ. HMOTNOST / OPERAT. WEIGHT BETRIEBSMASSE / POIDS DE SERVICE

ZAT. PŘEDNÍ OSY / FRONT AXLE LOAD BELASTUNG DER VORDERACHSE CHARGE DE ESSIEN ARANT

kg MAX. HMOTNOST / MAXIMUM WEIGHT MAX. MASSE / POIDS MAX

ZAT. ZADNÍ OSY / REAR AXLE LOAD BELASTUNG DER HINTERACHSE CHARGE DE ESSIEN ARRIÉRE

VÝKON MOTORU / ENGINE OUTPUT MOTORLEISTUNG / PUISSANCE DU MOT.

ROK VÝROBY / PRODUCTION YEAR BAUJAHR / ANNÉ DE FABRICATION

kg

3171

MADE IN CZECH REPUBLIC

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

AMMANN CZECH REPUBLIC a.s.

NOVÉ MĚSTO NAD METUJÍ, CZECH REPUBLIC

3172

TYP / TYPE

IČV / S/N PROVOZ. HMOTNOST / OPERAT. WEIGHT BETRIEBSMASSE / POIDS DE SERVICE

ZAT. PŘEDNÍ OSY / FRONT AXLE LOAD BELASTUNG DER VORDERACHSE CHARGE DE ESSIEN ARANT

kg MAX. HMOTNOST / MAXIMUM WEIGHT MAX. MASSE / POIDS MAX

ZAT. ZADNÍ OSY / REAR AXLE LOAD BELASTUNG DER HINTERACHSE CHARGE DE ESSIEN ARRIÉRE

VÝKON MOTORU / ENGINE OUTPUT MOTORLEISTUNG / PUISSANCE DU MOT.

ROK VÝROBY / PRODUCTION YEAR BAUJAHR / ANNÉ DE FABRICATION

kg

MADE IN CZECH REPUBLIC

10

3172 AV 70 X

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

3 1

2

400102 Cummins engine serial number

400103

AV 70 X

11

1.2.

Machine dimension scheme

S

S

H4

D

A

L

400271

12

A

D

H1

H2

H3

H4

L

O

mm

3260

1150

3005

2300

965

240

4410

45

in

128,4

45,3

118,3

90,6

38

9,4

173,6

1,8

R1

R2

R3

S

W1

W2

W3

mm

6410

4600

6050

15

1450

1550

180

in

252,4

181,1

238,2

0,6

57,1

61

7,1

AV 70 X

H3

H2

H1

SPECIFICATION MANUAL

W1

O

W3

W2

R3

R1

R2 400268

AV 70 X

13

1.3.

Technical data

1.3.1. Weights Working weight with the cab ROPS according to EN 500 - 1

kg (lb)

7360 (16226)

front drum

kg (lb)

3750 (8267)

rear drum

kg (lb)

3610 (7959)

The service weight of the machine according to EN 500-1 is the machine weight with the full content of working liquids, half content of propellants, half content of sprinkling tanks and with an operator (75kg/165lb).

The machine weight according to ISO 6016 is the weight with full content of propellants, lubricants, sprinkling tanks and an operator (75kg/165 lb). It is calculated by adding 350 kg (772 lb).

The weight data can differ from above mentioned data according to the further customers’ requirements for the machine’s equipment and accessories.

1.3.2. Drive of travel - driving properties Drive type

hydrostatic

Drive

front and rear

Travelling speed in both directions

km/h (MPH)

11,4 (7,1)

Theoretical machine’s gradeability

%

40

Side static stability - straight frame

°

28

1.3.3. The vibrations Drive type

hydrostatic

Small frequency CE

Hz (VPM)

43 (2580)

Big frequency CE

Hz (VPM)

52 (3120)

Small frequency - without CE

Hz (VPM)

48 (2880)

Big frequency - without CE

Hz (VPM)

62 (3720)

Small amplitude

mm (in)

0,35 (0,012)

Big amplitude

mm (in)

0,6 (0,023

1.3.4. Engine Manufacturer

Cummins

Engine type

BTAA 3,3 - C80

Number of cylinders

4

Stroke volume

cm3 (cu in)

3260 (198,9)

Engine output due to ISO 3046/1

kW (HP)

60 (80)

Nominal revolutions - CE

min (RPM)

2100

Nominal revolutions - without CE

min (RPM)

2200

Maximum torsional moment

Nm (ft lb)

304 (224)

Fuel consumption during common operation/hour*

l (gal US)

max. 10 (2,6)

-1 -1

Engine fulfills requirements of

DIR. 97/68/EU, STAGE III A

EPA/CARB NON ROAD 40 CFR, PART 89 TIER 3

* - according to ACZ methodology 14

AV 70 X

SPECIFICATION MANUAL 1.3.5. Brakes Working brake

hydrostatic

Parking and emergency brake

mechanical lamella

1.3.6. Drive Steering type

articulated joint

Steering control

hydraulic

Linear hydraulic motors

2 + 1 (Crab)

Swing of frames in vertical plane

±°

8

Turning of both frames in horizontal plane

±°

34

Engine (oil fill)

l (gal US)

7 (1,85)

Cooling system

l (gal US)

15 (3,96)

Fuel

l (gal US)

110 (29,05)

Hydraulic tank

l (gal US)

40 (10,56)

Drum vibrator

l (gal US)

2x10 (2x2,64)

Watering tank

l (gal US)

600 (158,5)

Sprinkling tank

l (gal US)

2,75 (0,72)

Drum drive gearbox

l (gal US)

2x1,4 (0,37)

1.3.7. Fills

1.3.8. Sprinkling Sprinkling

pressure

Number of pumps

2

Number of filtration stages

3

1.3.9. Electrical installation Electric set voltage

V

12

Accumulator – capacity

Ah

100

AV 70 X

15

1.3.

Technical data

1.3.10. Hygienic parameters Cabin machine: Sound pressure level applied to the driver:

LpA = 80 dB (A)

measured according to CSN EN 11 201 Guaranteed sound-power level of machine version according CE:

LWA = 106 dB (A)

measured according to CSN EN ISO 3744 Weighted eguivale value of vibration acceleration transferred to the body:

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

measured according to CN 1032 - sand Weighted eguivale value of vibration acceleration transferred to the hands:

aw = 3,7 m.s-2 (vector sum)

measured according to ISO 5349 - sand

16

AV 70 X

SPECIFICATION MANUAL Notes

AV 70 X

17

18

AV 70 X

OPERATION MANUAL

2. OPERATION MANUAL AV 70 X (Cummins Tier 3)

AV 70 X

19

20

AV 70 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 70 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 70 X

OPERATION MANUAL 2.1.2. Reguirements on Driver’s Qualification

2.1.3. Driver’s Liabilities

••

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

••

••

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

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

••

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

••

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

••

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

••

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

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

••

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

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

••

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

••

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

••

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

••

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

••

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

••

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

••

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

••

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

••

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

••

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

••

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

••

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

••

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

••

AV 70 X

23

2.1.

Major Safety Precautions

••

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

••

Respect Code of Practice or instructions of a person responsible.

••

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

••

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

••

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

••

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

••

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

••

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.

To keep the machine free of oil contaminants and inflam mable materials.

AV 70 X

OPERATION MANUAL 2.1.4. Banned Operations

••

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

Banned are the following

••

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

••

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

••

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

••

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

••

Lay away material or other objects on the Machine.

••

Remove dirt while the Machine is running.

••

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

••

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

••

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

••

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

••

Let the engine run inside confined spaces.

•• ••

To 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.

••

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

••

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

••

To control the Machine in some other way than stated in Driving Manual.

••

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

••

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

••

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

••

To operate the Machine unless driver control stand fixed properly.

••

To operate the Machine when engine bay cover is open.

••

To move and transport persons on the Machine.

••

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

••

To operate the Machine at places impossible to see from driver’s stand, and where hazard to people or property could occur unless work safety has been secured through some other way like for instance via signalling by duly instructed person.

••

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

••

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

••

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

••

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

••

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

••

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

AV 70 X

25

2.1.

Major Safety Precautions

2.1.5. Safety inscriptions and signs used on the Machine 1.

Read Operation Manual!

Get perfectly well familiar with the Machine operation and its maintenance per the Operation Manual! (Symbols located on the LH side of the control console )

2702bz

2.

Handbook

The Operation Manual stowage box. (symbol located at the rear on the stowage box at the seat) 2428

3.

Fasten your seat belt!

Fasten your seat belt before driving! (symbol located on the left on the control panel) 2687

2687bz

4.

Clamping hazard

Maintain safe distance from the Machine, danger of being clamped by the Machine in between the front and rear frame. (symbols located on the left and right near steering joint)

2941bz

5.

Danger area

Maintain safe distance! (symbol located on the left and right, on the front frame)

2942bz

3352

Maintain safe distance from the cutter and final compactor if running. (symbol located on the RH front yoke – optional)

3352bz

26

AV 70 X

OPERATION MANUAL

6.

Adjust while at rest

Adjust and maintain with the engine stopped. (symbol located on the left, on the rear frame )

2584bz

7.

Risk of injury

Maintain safe distance. (symbol located on the fan cover)

3322bz

8.

Risk of burn

Do not touch Machine’s hot parts unless you make certain these have cooled down sufficiently. (symbol located on the LH side of the rear frame overhead exhaust pipe )

2586bz

3292

9.

Bonnet lifting – adjust at rest

Lift the bonnet with the engine switched OFF. (symbol located on the left, on the rear frame)

3292bz

10.

Bonnet lifting

Pump to lift the bonnet. (Symbol located on the left, on the rear frame near door)

3201BZ

11.

Bonnet locking

3326

Lock the bonnet. (symbol located on the left, on the rear frame)

3326bz

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27

2.1.

12.

Major Safety Precautions

Danger of explosion

Read the Operation Manual before any maintenance of the battery, or before starting via the jump cables. (Symbol located in the battery door) 3017bz

13.

Disconnect wiring

Before welding, please disconnect wiring, alternator, Machine’s electronics, and engine control unit. (symbol located on the LH side of the control panel)

2668bz

14.

Electric apparatuses

Cover electric apparatuses when washing the Machine. (symbol located on the LH side of control panel )

2225bz

15.

Cooling liquid

Cooling liquid is deleterious. Scald hazard during its exchange. Read Operation Manual! (symbol located on the cooling liquid tank) 3323bz

16.

Emergency exit

Symbol located on the window of RH door.

2411bz

17.

Machine’s max height

3,05 m

Caution when passing locations with height limit. (symbol located on the left beneath the cabin, on the Machine frame)

3207

28

AV 70 X

OPERATION MANUAL 18.

Noise emitted

Machine’s external noise. (symbol located on the LH side of the front frame)

LWA

106dB

3191bz

19.

Sling points

Sling the Machine in these points only. (symbols located along both sides of both frames overhead the drum) 2153bz

20.

Sling points

Sling the Machine in these points only. (symbols located along both sides of the frame) 3048bz

21.

Supporting point

Locate hand jack or fixed support of the Machine here. (symbol located on the front and rear frame along both sides) 3208bz

22.

8400 kg

Lifting diagram

Use rigging of sufficient loading capacity to lift the Machine. Secure the Machine’s joint before lifting. (symbol located on the left, on the front frame)

(18 520 lb)

Lmin = 5m 2x min 2100 kg (2x min 4630 lb)

Lmin = 5 m 2x min 2100 kg (2x min 4630 lb)

3325

3325bz

23.

Hearing protectors

If there is no cab on the machine or you are working with the windows open, use hearing protectors (the symbol located on the left side of the control panel).

2408bz

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29

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

30

AV 70 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

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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

32

AV 70 X

2.2.

Ecological & Hygienic Principles

2.2.1. Hygienic Principles

OPERATION MANUAL 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 70 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.

33

2.3.

Preservation & Storage

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

2.3.2. Machine 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,

••

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

••

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,

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

••

••

Apply preservative grease over the chormed surfaces of piston rods,

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

••

••

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.

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

••

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

34

AV 70 X

OPERATION MANUAL 2.3.3. De-conservation and inspection of brand new machines ••

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 70 X

35

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.

36

AV 70 X

2.5.

Machine Description

OPERATION MANUAL

14 12

20

17

15

13

18

16 11

20

5 6

21 7

4

21 1

3 9

2

8

10 19

21

21 400625

1 - Front frame

12 - Fuel tank

2 - Rear frame

13 - Sprinkling tank

3 - Front drum

14 - Cabin with integrated ROPS arm

4 - Rear drum

15 - Driver’s control stand

5 - Engine

16 - Battery

6 - Drum travel hydroelectric generator

17 - Combined engine and hydraulic oil cooler

7 - Drum vibration hydroelectric generator

18 - Air filter

8 - Travel hydraulic motor

19 - Exhaust pipe

9 - Vibration hydraulic motor

20 - Sprinkling jets

10 - Steering joint

21 - Drum scrapers

11 - Hydraulics tank

AV 70 X

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2.6.

Controls & Dashboard Instruments

26

25

23 22 21 20 19 11

30

24

16

1 2

18 0

12 28

17

29

6

5

1

7

13

15

27

31 6

14

5

7

1

2

8

3

9

4

10 32

400272

38

AV 70 X

OPERATION MANUAL Dashboard and control panels 1 – Travel controls 2 – Speed potentiometer 3 – Pushbutton for mode of soft starting to move and stopping to move 4 – CRAB mode resetting switch 5 – Pushbuttons for CRAB mode – front drum, to the right* 6 – CRAB pushbuttons – front drum, to the 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 – Front / both / rear vibration selector switch 15 – Vibration amplitude selector switch 16 – Vibration mode selection switch (MAN/AUT) 17 – Combined switch 18 – Switch for constant speed and protection against engine overload 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 – LH cluster 26 – RH cluster 27 – Cut-out box 28 – Cabin fuse 29 – Diagnostics socket 30 – Mounting socket 31 – Steering wheel position adjustment 32 – 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).

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39

2.6.

Machine basic functions control

25

26

1 2

0

6 1

8 9

6

5 7

5

7

1

2 3 4

1

0

N

400273

40

AV 70 X

OPERATION MANUAL 3317

Steer angle of the front 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) – front drum to the right Pushbutton (6) – front drum to the left

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

Indicator lamp on cluster (26) goes ON to signal this function.

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

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

Neutral position (N) is signalled through lighting up of neutral and parking brake indicator lamps on the cluster (25).

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

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

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

Vibration ON / OFF pushbuttons (7) Press these buttons to turn ON/OFF this function. Indicator lamp on cluster (25) will go ON.

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

Emergency brake (8) pushbutton 2582

Speed potentiometer (2) 2685

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

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

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

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

Press this button to enable Machine’s emergency brake, and indicator lamps on cluster (25) for brakes, recharging, neutral, and engine oil pressure will light up.

Engine will stop and stall!

Sprinkling button (9) 3183

Hold down this pushbutton to enable drum additional sprinkling function. Indicator lamp on cluster (26) will light up.

3128

It is used to adjust soft starting to move and stopping to move when stopping and reversing the Machine. In this way the creation of “waves” on compacted surface will be eliminated. Press the switch to enable the function, and indicator lamp on cluster (26) will go ON. Attention, in this mode the Machine stopping distance is longer!

Switch for CRAB mode resetting (4) 3319

Press this switch to adjust front drum in CRAB mode.

CRAB mode resetting is signalled by indicator lamp on cluster (26) going OFF.

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41

2.6.

Machine basic functions control

25

26

23

16

11

1 2

0

12

14

15

13

17

10

400274

42

AV 70 X

OPERATION MANUAL Drum vibration selector switch (14)

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 (15)

Pumps sprinkling selector switch (11)

2682

The selector switch has three positions:

3181

One of two drum sprinkling pumps will turn ON, and indicator lamp on cluster (26) will light up.

Adjust sprinkling potentiometer before switching ON the pump!

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

Ignition box (12 ) MAN / AUT vibration mode selector switch (16)

The ignition-starter switch has four positions “0-I-II-III”. It is only possible to put in and remove the key at the position “0”.

Turning the key to the right at first activates the position “I”, then the suspended position “II” (engine heating), and afterwards the position “III”. ”III” position is used to start the engine.

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.

AUT – automatic mode to switch OFF/ON vibrations

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

Cluster (17) It is used to turn ON/OFF contour lights, dipped lights, distance lights, traffic-indicator lights and horn.

Indicator lamps (23) light up to signal contour, dipped, and distance lights are ON.

Accelerator control (13)

Indicator lamp on cluster (25) lights up to signal traffic-indicator lights are ON.

2406

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

AV 70 X

43

2.6.

Machine basic functions control

25

26

23 22 21 20 19

24

1 2

18 0

13

12

1

1

2

400275

44

AV 70 X

OPERATION MANUAL

0

Switch for constant speed and protection against engine overload (18)

3185

Switch + indicator lamp rear lights (22) 591668R

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

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

Indicator lamps for (dipped / distance) lights (23)

When control unit is switched ON the indicator lamp on cluster (26) signals this function.

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

591508

These lamps signal dipped or distance lights switched ON.

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

With the control unit switched ON the indicator lamp on cluster (26) will signal this function. The control unit will automatically lower the power take-off (PTO) through reducing the set speed (rpm of travel hydraulic motor) independently on travel control position. Thus the tractive force (of travel hydraulic motor) will increase - engine will get relieved.

Infrathermometer (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).

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

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

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

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

Alarm lights switch (20) AMN24

It is used to turn ON/OFF alarm lights - indicator lamp in the alarm lights switch and on clusters (25) and (26) will flicker to signal this function.

596473

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

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

AV 70 X

45

2.6.

Machine basic functions control

25

478320 h

400501 LH cluster (25) Indicator lamp for hydraulic oil pressure filter fouled

Fuel consumption gauge AMN25

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

Check fuel operation.

level

during

AMN3

Indicator lamp ON signals filter element is fouled.

Machine

Immediately replace the filter element!

Counter of motohours actually worked AMN26

Battery recharging indicator lamp AMN4

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

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

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

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

Unless indicator lamp goes OFF, find a defect!

Parking brake indicator lamp AMN1

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

Seat switch indicator lamp AMN2

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

46

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

Engine can be started once its defect has been repaired!

AV 70 X

OPERATION MANUAL Indicator lamp that the vibration is ON

Indicator lamp for air filter fouled AMN5

AMN10

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

Stop the Machine and replace the filter element instantly!

Indicator lamp ON will signal the vibration is ON.

Indicator lamp for hydraulic oil temperature AMN11

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

Engine lubrication lamp

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

AMN6

When switching the key in the ignition box (12) over to “I” position and indicator lamp shall go ON, and when engine is started it must go OFF. Indicator lamp lighted ON during engine run will signal a defect. Following 5 seconds the acoustic alarm will start, and after 2 minutes the engine will stall automatically – the Machine will stop and parking brake will be enabled.

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

Indicator lamp for engine overheated

Check hydraulic oil level AMN12

Indicator lamp signals low hydraulic oil level.

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

Engine can only be started when failure is repaired and oil in hydraulic tank refilled to a limit specified!

AMN7

This indicator lamp signals the cooling liquid’s max temperature allowed has been exceeded.

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

Stop the Machine and check cooling liquid amount, or find out any defect!

Indicator lamp for traffic-indicator lights AMN8

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

Neutral indicator lamp AMN9

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

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

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47

2.6.

Machine basic functions control

26

400502

48

AV 70 X

OPERATION MANUAL RH Cluster (26) ASC indicator lamp Level height in sprinkling tank.

AMN17

Not connected.

AMN27

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

Fuel filter indicator lamp

Check water level in the tank during Machine run.

AMN18

Indicator lamp lighted ON signals water presence in fuel filter.

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

Cooling liquid indicator lamp AMN13

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

Engine glowing indicator lamp AMN19

The lighted control lamp signals the engine heating.

Engine can only be started when failure is repaired and cooling liquid refilled to a limit specified!

Spreader indicator lamp AMN20

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

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

AMN14

Indicator lamp signals air conditioner is ON (optional).

AMN21

This indicator lamp signals the ANTISTALL is ON. CRAB mode indicator lamp AMN15

Sprinkling pump indicator lamp

Indicator lamp signals the front run is set to CRAB mode.

AMN22

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

Indicator lamp ON signals the mode of soft starting to move and stopping to move is ON. Intermittent flashing of this indicator lamp signals an error code for a defect within Machine travel system.

Shut down the Machine and call service organization in respect of failure repair on the Machine travel system!!!

Constant speed indicator lamp AMN23

This indicator lamp signals the constant speed mode is ON.

Alarm lights indicator lamp AMN24

This indicator lamp signals alarm lights are ON.

AV 70 X

49

2.6.

Machine basic functions control

Cut-out box (27) It contains F1 - F8 fuses.

F1 - 20 A

front, rear headlamps

F2 - 15 A

roof lights, light switches

F3 - 15 (30)A

traffic-indicator lights, horn, beacon, extra lights, mounting socket

F4 - 5 A

clusters

F5 - 10 A

travel electronics, backing horn

F6 - 15 A

sprinkling

F7 - 7,5 A

vibrations, CRAB (trimmer)

27 400116

F8 reserve Other fuses located on the Machine At battery disconnector F9

radio (as per car radio manufacturer)

400600 Under the cabin lighting cover F11 - 15 A

wipers + window washers

F12 - 15 A

fans

F13 - 5 A

fan control + air conditioner control

F14 - 10 A

air conditioner

400118

400119 50

AV 70 X

OPERATION MANUAL F16, F17 - 125A

Heating of the engine

F16

F17

400601 Cabin fuse (28) F15 - 30 A

cabin wiring

30

Always replace the fuses with the ones of identical value!

Diagnostics socket (29)

28

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

29 400116A

Mounting socket (30) It is used to connect auxiliary inspection lamp (12V).

Steering wheel positioning (31) 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 AV 70 X

51

2.6.

Machine basic functions control

Operator seat (32) 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.

2

3

1

6

4 5

400122

Adjust your seat before driving !

Driver must be fastened with the seat belt while driving!

400253 How to swivel operator’s place: Operator’s place can be swivelled within the range of 40° when accelerator pedal is pressed. Once the pedal is released the operator’s place is locked (arrested) in one of 4 positions.

Seat switch: Seat switch is located in its cushion.

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

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

MAX 40°

400124

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!

52

AV 70 X

OPERATION MANUAL Documentation stowage box 2428

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

400123 Front wiper selector switch (33) 596625

34

Three-position selector switch --

Turned OFF

--

Low speed ON

--

High speed ON

35

33

Glass washer switch (34) 2260

Two-position selector switch --

OFF

--

Windscreen washing ON

400120

Fan switch (35) 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 Switch of air-conditioning (optional equipment)

2441

Cabin lighting (36) Ceiling lamp incl. selector switch is located overhead the dashboard.

Ventilation nozzles (37) Adjustable nozzles are located on cabin ceiling, please adjust and swivel the dampers to alter the amount and direction of flowing air.

37

37

36

400120A AV 70 X

53

2.6.

Machine basic functions control

max

Control tie rod for heating valve (38)

min

It is used to switch ON the cabin heating.

38

40

2638

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

39 41

Adjust the heating valve before driving!

Hand pump control lever (39) It is used to control the hand pump when lifting or letting down the bonnet.

400603

First-aid box stowage place (40)

The Machine shall be equipped with first-aid box!

Fire extinguisher (41) - (Optional) Place of keeping the fire extinguisher.

We recommend to equip the Machine with fire extinguisher!

Make yourself familiar with the application of fire extinguisher !

Carry out regular inspections of the fire extinguisher!

Stowage pockets (42) These are used for Operator’s personal items.

400121A 54

AV 70 X

OPERATION MANUAL Anti-dazzle (sun) screen (43) Adjust the anti-dazzle screen through securing it to the fixing on the glass.

400242 Window washer tank (44) Fill with standardly available media.

Fill with antifreeze or drain before winter season starts!

400127 Additional lights (45) Lights located on the Machine cabin (optional).

400258 Beacon socket (46) It is used to connect the beacon.

Back mirrors (47) External back mirrors enable to view poorly visible areas.

Maintain these mirrors clean and properly adjusted!

400243 AV 70 X

55

2.6.

Machine basic functions control

Cabin ventilation air filter (48) It includes replaceable filter element to catch the impurities drawn in from air.

1

400234 Arm rests on the door (49) Transportation position

400244 Working position

400245 Battery disconnector (50) It is used to disconnect the battery from the Machine frame.

Position „0“ – Machine wiring disconnected.

„0“

„I“

Position „I“ – Machine wiring connected.

401678 56

AV 70 X

OPERATION MANUAL Hand pump (51) It is used to lift or let down the bonnet.

Located on LH side of rear frame.

400602

AV 70 X

57

2.7.

Machine basic functions control

25

26

1 2

0

13

12 17

1

1

8

1

0

N

400276

58

AV 70 X

OPERATION MANUAL 2.7.1. Engine starting 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 (50).

••

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

••

All indicator lamps on clusters (25 and 26) will light up.

••

Then on cluster (25) the indicator lamps for brakes, recharging, neutral, will remain ON, along with engine lubrication indicator lamp (flickers).

••

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 (17) to signal engine starting.

••

Adjust accelerator control (13) for increased rpm (1/4 stroke).

••

Switch over the key to the suspended position “II” and keep it at the position for approximately 15 seconds (engine heating) (this action can be skipped with a hot engine or at a high ambient temperature).

••

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

••

On cluster (25), following the starting, the engine lubrication indicator lamp and recharging indicator lamp shall go OFF.

••

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

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)

--

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 (1/2 stroke of accelerator actuator) for 3÷5 min.

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

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

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

AV 70 X

59

2.7.

Machine basic functions control

1 3

2

-

0

12

V

+ -

+ 12

0

4

V

400604

60

AV 70 X

OPERATION MANUAL How to start via cables from external power source: 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!

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61

2.7.

Machine basic functions control

26

1 2

0

13

1

1

2 3

1

0

N

400277

62

AV 70 X

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

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

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

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

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

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

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

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

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

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

Travel modes of the Machine: ••

RAMP (soft starting to move and stopping to move)

••

CONSTANT SPEED (continuous Machine drive)

••

ANTISTALL (engine protection against overload)

••

CRAB (extended track of the Machine)

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

Attention, in this mode the Machine stopway is longer!

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

Press pushbutton (3) to switch ON/OFF this function, indicator lamp on cluster (26) will light up to signal this function.

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

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

Note You may switch ON the function during Machine travel.

AV 70 X

63

2.7.

Machine basic functions control

26

1 2

0

18

13

1

1

2 3

1

0

N

400278

64

AV 70 X

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

AMN23

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

Use switch (18) to turn ON/OFF the function, indicator lamp on cluster (26) will light up to signal this function.

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

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

Note The function can be turned ON during Machine travel.

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

AMN21

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

Switch OFF the function of soft starting to move and stopway via switch (3) if this function is turned ON! Before turning ON the switch (18), please use accelerator control (13) to adjust engine’s max rpm!

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

Use switch (18) to turn ON/OFF this function, the indicator lamp on cluster (26) will light up to signal this function.

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

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

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

AV 70 X

65

2.7.

Machine basic functions control

26

1 2

0

6

5

6

5

1

1

2 4

1

0

N

400279

66

AV 70 X

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

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

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

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

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

Turning ON: Press button (5) to deflect the front drum to the right and press button (6) to deflect to the left, the indicator lamp on cluster (26) will light up to signal this function.

Max deflection of the front drum to both sides is 180 mm.

Turning OFF: Press switch (4) to cancel CRAB mode of front drum.

Indicator lamp on cluster (26) will go OFF to signal CRAB mode has been reset.

Note In the event that the control lamp on the combined instrument (26) is flashing, hold the switch and turn the steering wheel (to the left/ right) until the control lamp goes out.

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 70 X

67

2.7.

Machine basic functions control

25

16

1 2

0

14

1

7

15

13

0

N

1

7

2

1

400280

68

AV 70 X

OPERATION MANUAL 2.7.3. 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 (14) to choose vibration (front / both / rear), and use vibration amplitude selector switch (15) to choose high or low amplitude.

Vibration manual switching ON/OFF mode (MAN): Use switch (16) to turn ON/OFF this function.

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

Indicator lamp on cluster (25) lighted up will signal this function.

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

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

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

Automatic vibration switching ON/OFF mode (AUT): Use switch (16) to turn ON/OFF this function.

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

Indicator lamp lighted up on cluster (25) will signal vibration function.

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

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

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

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

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

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

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

2.7.5. Compacting near constructed facilities When required to compact in the vicinity of building facilities, utility lines, buried line systems and cables, then their operating company shall assess the impact of vibrations generated by the Machine so to avoid their damage.

Manufacturer bears no responsibility for damage caused by operating company!

AV 70 X

69

2.7.

Machine basic functions control

25

1 2

0

13

12

1

7

7

1

1

0

N

400281

70

AV 70 X

OPERATION MANUAL 2.7.6. How to stop the Machine and its engine Press button (7) on travel control (1) to switch OFF vibration, indicator lamp on cluster (25) will go OFF. Stop the Machine through shifting travel controls (1) to neutral (N) position.

Use accelerator control (13) to adjust idle engine speed.

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!

2.7.7. Safe stopping 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.

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 70 X

71

2.7.

Machine basic functions control

25

26 11 1 2

0

1

1

8 9

10

1

0

N

400282

72

AV 70 X

OPERATION MANUAL 2.7.8. Emergency stop of the Machine Apply this in the event of failure where the engine is unable to be shut off via the key in the ignition box, or through shifting the travel controls (1) to position (0)!

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

On cluster (25) the indicator lamps for seat switch, parking brake, recharging will light up, and lubrication indicator lamp will start to flicker.

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

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

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

2.7.9. Machine shutdown 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 (50).

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.

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

2.7.10. Sprinkling It is used to sprinkle the Machine drums.

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

Indicator lamp on cluster (26) will signal the function of switching ON the sprinkling pump.

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

Use potentiometer for sprinkling interval (10) to adjust sprinkling intensity within the MIN / MAX range.

Use sprinkling pushbutton (9) for additional sprinkling of the drums before the Machine runs on the bitumen surface being compacted.

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 70 X

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2.7.

Machine basic functions control

2.7.11. How to lift and let down the engine bonnet

„0“

„I“

Stop the Machine, shut off the engine, and disconnect battery disconnector (50).

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

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

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

Turn the bonnet raising lever to the horizontal position; see the figure.

Pump to lift the bonnet.

400605

Once lifted, secure the bonnet with strut.

400140 Let down the bonnet

Set the foot step to the original position!

400606 74

AV 70 X

OPERATION MANUAL Pump to lift the bonnet and secure with strut.

Turn the bonnet raising lever to the vertical position, see the figure, and the bonnet will start to drop.

Confirm safe touch-down of the bonnet.

Remove control lever (39) and put it inside Machine cabin.

400602A

AV 70 X

75

2.8.

Machine transport

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

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

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

Unless the engine works, or a defect exists within the hydraulic system, or travel pump is broken, then you must brake off the Machine and short-circuit the hydraulic circuit.

No person may stay on the Machine towed!

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

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

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

400283

How to brake off the Machine:

400140 Raise the bonnet and secure it with a support.

3

2

Remove hose (3) away from the clip.

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

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

1

400607 Unscrew two multi-purpose relieve valves by three threads in CCW direction (hexagon 22 mm).

400147 76

AV 70 X

OPERATION MANUAL Multi-purpose relieve valves are located on travel hydroelectric generator. The travel hydroelectric generator is located on the LH side, in engine compartment.

Connect battery disconnector (50).

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

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

400608 Lever of the bonnet raising in the horizontal position.

Insert control lever into the hand pump and start pumping until brake indicator lamp on cluster (25) goes OFF. Now the Machine is braked off, and it will be possible to tow it away.

400605

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

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

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

478320 h

400111K

How to brake the Machine: Turn the bonnet raising lever to the vertical position, the machine will brake to a stop.

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

Unscrew two multi-purpose relieve valves by three threads in CW direction (hexagon 22 mm).

Turn the bonnet raising lever to the horizontal position.

Start pumping to lift the bonnet, secure the strut.

Turn the bonnet raising lever to the vertical position, the bonnet will start to drop.

Confirm safe touch-down of the bonnet.

Remove control lever (39) and put it back in the Machine cabin.

AV 70 X

400602A 77

2.8.

Machine transport Do NOT start the engine while the Machine is being towed!

To tow, use unbroken hauling ropes, or drawbar of sufficient loading capacity 1,5 times higher than the weight of towed Machine. It is forbidden to use chains to tow the Machine.

Do NOT tow the Machine for a distance over 300 m (0,19 mi) long!

Max admissible deflection is 30° away from forward direction of towing!

Max speed limit while towing the Machine is 2 km/hour (1,2 mph)!

Hauling machine must have sufficient tractive force (power), weight and brake effect!

While hauling downhill, please use a rope to attach another hauling machine to the rear part of the towed Machine so to prevent its uncontrolled motion!

While towing the Machine do NOT start its engine!

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

78

AV 70 X

OPERATION MANUAL 2.8.2. How to load the Machine Use loading ramps or a crane to load the Machine on its transporting vehicle.

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

8400 kg (18 520 lb) Lmin = 5 m 2x min 2100 kg (2x min 4630 lb)

Lmin = 5 m 2x min 2100 kg (2x min 4630 lb)

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

400142 How to secure the joint: Dismantle the arm (1).

1

400143 Secure the arm with pivots (2) and safety pins locks (3).

Observe safety regulations when loading and unloading!

Use the crane of sufficient loading capacity!

Use corresponding and unbroken rigging of sufficient loading capacity!

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

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

Keep off the area beneath the hanging load!

AV 70 X

3

2

2 3

400144

79

2.8.

Machine transport

2.8.3. Transporting by the road The Machine may pass by its own axis between its workplaces.

During movement, please observe safety measures set for the workplace.

When on highway, the Machine must be transported on a transport carrier of adequate loading capacity!

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

The transport carrier must be braked and mechanically locked against any undesired move by scotch blocks (2) when loading and unloading!

A person guiding the Machine must communicate with driver through using communication signals required, refer to Section 2.1.6., and must stay all the time at one point beyond reach of the Machine. At the same time he/she must be within driver’s field of view (in visual contact) over the entire period of moving the Machine onto a transport carrier and down from the carrier.

When moving onto a transport carrier and moving down from the carrier all the persons aside from Machine operator must move away as far as not to cause hazard if the Machine falls down!

While transported the Machine must be fixed to the transport carrier with tie offs (1) in rigging points!

Rigging points are the front and rear rigging holes in drum frames.

When transporting the Machine no persons may be present on the Machine, driver’s control stand or transport carrier!

80

1

2 9

1

2 400285

AV 70 X

2.9.

Special conditions to use the Machine

2.9.1. How to operate the Machine during its running-in 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!

2.9.2. Operating the temperatures

Machine

at

low

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

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

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

Check concentration of engine cooling liquid.

••

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

••

Use hydraulic oil of corresponding cinematic viscosity.

••

Use winter diesel oil.

••

Confirm battery has been recharged.

2.9.4. 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.

Engine power depends on the environment where the Machine is operating.

2.9.5. Machine operation within very dusty environment While in very dusty environment, please cut short the intervals of cleaning and replacing the air filter elements; and the replacement intervals of cabin dust filter, and cut short the intervals of cleaning the coolers.

Recommended interval of cleaning is 1x per week.

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.

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

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

--

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

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

AV 70 X

81

82

AV 70 X

MAINTENANCE MANUAL

3. MAINTENANCE MANUAL AV 70 X (Cummins Tier 3)

AV 70 X

83

84

AV 70 X

3.1.

Safety and other measures for machine 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 70 X

85

3.1.

Safety and other measures for machine maintenance

3.1.3. Ecological and hygienic principles

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.

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.

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

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

--

Cleaners & preserving agents

--

All dismantled filters and filter elements

--

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

--

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

--

Adherence to the instructions given in this Manual.

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

Eye protection and skin protection during work with the batteries.

•

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.

86

•

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 70 X

3.2.

Media specification

MAINTENANCE MANUAL

3.2.1. Engine oil 2412

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

Performance classification under API (AMETICAN PETROLEUM INSTITUTE) CCMC (COMMITE OF COMMON MARKET AUTOMOBILE CONSTRUCTORS) ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE AUTOMOBILE) Viscosity classification To determine SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) viscosity class the ambient temperature and type of operations at the place where the Machine will be used are decisive.

The use of admissible oil under API: CH-4/SJ; CI-4 CCMC DHD1 ACEA: E-5 API CI-4 oil is recommended as especially appropriate.

All the year round: SAE 15W-40, refer to Fig. Note Exceeding low temperature limit leads to no engine damage; it may only cause some starting difficulties.

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

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

400150

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

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

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

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

AV 70 X

87

3.2.

Media specification

3.2.2. Fuel

3.2.3. Hydraulic oil 2158

Diesel oil is used as the engine fuel: •

EN 590

•

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

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

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

At ambient temperatures below 0 °C (32 °F) you must use winter diesel oil.

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

NEVER use other fuels (e.g. bio diesel oil, mixed bio diesel oil, LFO, etc.) than the Diesel fuels specified above.

NEVER mix diesel oil with gasoline, with alcohol. These mixtures may cause explosion!

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

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.

At high ambient temperatures when oil temperature reaches constantly 90 °C (194 °F) we recommend to exchange oil with cinematic viscosity of 100 mm2/s - HV 100 (BP BARTRAN HV 100; ESSO UNIVIS N 100, etc.).

If it is necessary to start the Machine for the period of one month or longer at ambient temperatures below –8 °C (18 °F), please exchange oil in the hydraulic system for the oil with cinematic viscosity of 46 mm2/s – viscosity class HV 46.

At the temperatures below –13 °C (9 °F), please exchange oil for the one with cinematic viscosity of 32 mm2/s – viscosity class HV 32 (e.g. BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.).

Hydraulic oil synthetic type Hydraulic system is possible to be filled with synthetic oil, which is during any leakage this oil will be restless degraded via microorganisms found in water or in soil.

Please, always consult with the producer or dealer any switching to another type of oil or blending with other types of oils.

88

AV 70 X

MAINTENANCE MANUAL 3.2.4. Lube grease

3.2.5. Cooling liquid 0787

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

Note For instance Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, Grease No 3, etc.

2152

Fill the engine cooling system with cooling liquid comprising 50 % of ethylene glycol antifreezing mixture and 50 % of water.

Do NOT use earthy (hard) water with higher content of calcium, and magnesium which brings calculus formation, and with higher content of chlorides and sulphates which causes corrosion. Refer to CUMMINS Engine Operation and Maintenance Manual. CUMMINS. Max content of compounds of calcium and magnesium is 170 milligrams - hardness of water Max content of compounds of chlorine is 40 milligrams Max content of compounds of sulphur is 100 milligram

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

NEVER use the portion over 68 %!

We do NOT recommend to mutually blend antifreeze agents. Mixing various types of cooling liquid may cause loss of anticorrosion properties.

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

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

AV 70 X

89

3.2.

Media specification

3.2.6. Glass washer fluid

3.2.7. Gear oil 2260

Use water (up to 0 °C temperature) and agent for motor vehicle glass washers when filling the glass washer tank.

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

90

2186

For greasing the drum reducers, use high-quality oils corresponding to API GL-5 or EP or MIL-L-2105 D. Viscosity SAE 80W-90H for an ambient temperature of -10 °C÷ +30 °C (14 °F ÷ 86 °F).

The operation temperature of oil must not exceed 85 °C – 90 °C (185°F – 194°F).

AV 70 X

3.3.

Media

MAINTENANCE MANUAL

Part

Engine

Medium Type

Engine oil under Section 3.2.1.

Medium Amount l (gal US)

Brand

7 (1,85) 2412

Fuel tank

Fuel under Section 3.2.2.

110 (29,05)

Hydraulic tank

Hydraulic oil under Section 3.2.3.

40 (10,56) 2158

Drum bearings, calliper bearings, king pins, sus- Lube grease under Section 3.2.4. pensions

As required

Cooling system

15 (3,96)

Coolant under Section 3.2.5.

0787

2152

Vibration drum

Engine oil under Section 3.2.1.

2x10 (2x2,64) 2412

Drum drive gearbox

Gear oil under section 3.2.7.

2x1,4 (0,37) 2186

Baterry

Distilled water

As required 2587

Glass washer tank

Liquid under Section 3.2.6.

2,75 (0,72) 2260

Sprinkling tank

Water

600 (158,5) 2567

AV 70 X

91

92

250

3 monts

20

daily

6 monts

1 year

2 years

as needed

500 1000 2000 Maintenan.

(hours)

TO BE CARIED OUT REGULARLY, EVERY

3.6.1.

3.6.2.

3.6.3.

3.6.4.

3.6.5.

3.6.6.

3.6.7.

3.6.8.

3.6.9.

3.6.10.

3.6.11.

3.6.12.

3.6.13.

3.6.14.

3.6.15.

3.6.16.

3.6.17.

3.6.18.

3.6.19.

3.6.20.

3.6.21.

3.6.22.

Engine – coolant amount Engine - belt Engine – crankcase breather Air filter vacuum valve Cooling circuit – fan condition Fuel tank – fuel amount Hydraulics tank – oil amount Sprinkling tank – water amount Alarm and control devices Engine – oil and filter Engine – induction manifold Engine – cooling circuit Battery Air filter vacuum switch Sprinkling filter and sprinkler strainers Machine lubrication Engine – fuel filter Engine – coolant concentration Engine - belt Engine - exhaust Silencing system

CHAPTER

Engine – oil amount

ACTIVITY

EXCHANGE

LUBRICATION

CLEANING

INSPECTION, CHECKING, REPLENISHMET, ADJUSTMENT

3.4.

Lubrication and Maintenance Chart

400298en

AV 70 X

AV 70 X

**

2 years

as

needed

3.6.25.

3.6.26.

3.6.27.

3.6.28.

3.6.29.

3.6.30.

3.6.31.

3.6.32.

3.6.33.

3.6.34.

3.6.35.

3.6.36.

3.6.37.

Engine - coolant Drums – oil in drum vibrators Hydraulics tank – oil and filter Fuel system venting Engine – air intake filter Engine – fuel filter water trap Engine radiator and hydraulic oil cooler Cabin – air intake filter Sprinkling tank – water drain before winter season Drums – scraper adjustment Machine cleaning Bolted connections

3.6.24.

Drums – oil in the gearboxes Engine – valve clearance adjustment

3.6.23.

CHAP.

Sprinkling tank

ACTIVITY

! PLEASE, CONTACT CUMMINS SERVICE!

*

1 year

** First following the first 250 motohours.

6 monts

Oil change in the gearboxes

3 monts

daily

500 1000 2000 Maintenan.

* First following the first 200 motohours.

250

20

MAINTENANCE MANUAL

400299en

93

3.5.

Lubrication Chart

LUBRICATION PLAN LEGEND: INSPECTION LUBRICATE EXCHANGE

2000 h every 2 years 1000 h yearly 250 h quarterly 20 h daily

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

Gear oil:

SAE 80W - 90H

API GL-5 400286en

94

AV 70 X

3.6.

Lubrication and Maintenance Operations

Carry out lubrication and maintenance in regularly repeated intervals as per the everyday data reading on the counter of hours actually worked.

478320 h

400154

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

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

Removed or loose bolts, plugs, threaded joints of the hydraulics, etc. shall be tightened with the torque according to the charts in Section 3.6.37 unless a different value is given with the relevant operation.

Carry out the inspection of 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 with the wiring disconnected (unless otherwise required).

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

Oil change in the gearboxes

Following the first 250 hours of new Machine operation or after the major overhaul, please carry out the operations under this Section: 3.6.25.

AV 70 X

Valve adjustment

95

3.6.

Lubrication and Maintenance Operations

Following the 20 hours of operation or daily 3.6.1. Inspect, refill the oil amount in the engine •

Pull out oil dipstick (1), wipe it.

•

Put it back down to the stop and pull out again to read the oil level.

Note If the engine was running, wait ca 3 minutes until oil descends into engine sump.

1 400609

•

Replenish oil through filler-neck with the filler plug removed (2).

2

400609A Note •

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

•

The amount of oil between Low and High marks is 1,5 l (1,6 U.S. Quart).

•

Following the refill, please wait ca 3 minutes until oil descends into the sump, then check the level.

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

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

Refill the oil of identical type as stated in Section 3.2.1.

96

400157

AV 70 X

MAINTENANCE MANUAL 3.6.2. Inspect, replenish the engine coolant amount •

Do it before starting the engine, visual inspection of the level.

•

Top up through filler neck (1).

•

Keep level between ”MIN” and ”MAX” lines.

•

At higher losses find out any cooling system leakage and repair the cause.

Wait to remove the filler plug only after engine coolant temperature drops below 50 °C (120 °F). If filler plug is removed at higher temperature then the hazard of vapour scald or coolant scald will occur due to inner overpressure effect.

1

400158

Do NOT use any additives to repair cooling system leaking into the engine coolant!

Do NOT refill cold coolant in hot engine!

Danger of engine castings damaged.

Top up only with the coolant consisting of antifreeze agents of identical base under the Section 3.2.5.

400159

AV 70 X

97

3.6.

Lubrication and Maintenance Operations

3.6.3. Inspect the engine belt •

Make visual belt inspection, monitor any of its damage.

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

400609B

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

400161

3.6.4. Crankcase breather •

Check crankcase breather pipe so it is not clogged due to any deposits, fragments, chips, or in winter frozen with ice.

400609C

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

400162 98

AV 70 X

MAINTENANCE MANUAL 3.6.5. Inspect air filter vacuum valve •

Clean the exit slit, press to remove any dust trapped.

Note Any dust trapped in the dust valve will automatically be emptied with the Machine running.

Do NOT operate the Machine when dust valve is damaged.

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

400610

3.6.6. Inspect fan condition •

Inspect visually the fan. If damaged (e.g. missing parts of material, cracks, shape changes, etc.), replace the fan.

400611

AV 70 X

99

3.6.

Lubrication and Maintenance Operations

3.6.7. Check fuel amount •

Check the amount of fuel on LH cluster signalled by LEDs, and in case of lack of fuel, please replenish.

•

Minimal amount of fuel is signalled by red LED flickering.

478320 h

400111A •

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

•

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

•

Refill the tank up to the bottom edge of filler neck via the strainer (3).

1 2

Note Fuel tank capacity is 110 l (29 gal US). Fuel tank will last ca 14 hours of the Machine operation.

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

Do NOT refill fuel while engine is running.

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

Use solely a clean recommended fuel per Section 3.2.2.

NEVER replenish fuel in confined space.

400165

3

Fuel must NOT be spilled.

400166

100

AV 70 X

MAINTENANCE MANUAL 3.6.8. Inspect oil amount in the hydraulic circuit tank •

Lift the bonnet.

•

Check oil level in oil gauge.

•

Fill up oil via the filling device using quick-coupling (1), proceed as per Section 3.6.28.

MAX

1

MIN

2

Tank filler neck cap (2) has been sealed.

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

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

Oil level shall always be visible in oil gauge!

Refill required oil according to the Section 3.2.3.

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

400612

3.6.9. Fill up sprinkling water tank •

Check water amount on the RH cluster. It is signalled by LEDs, and in case of lack of water, please refill.

•

Minimal amount of water is signalled by red LED flashing.

•

Perform the following before engine is started.

400112A Open the cap (1) and refill with clean water via the strainer (2).

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

Proceed according to Section 3.6.34.

2

1

400148 AV 70 X

101

3.6.

Lubrication and Maintenance Operations

3.6.10. Inspect alarm and control devices •

Turn ON the ignition key into position I.

•

On the LH and RH clusters the automatic control of the lighting function will occur, and this through the pilot lamps going on.

1

0

•

I

II

III

400634

Then all the pilot lamps will go off on the RH cluster, and the lamps on the LH cluster will remain on: --

Indicator lamp for the zero position of travel controller.

--

Brake alarm indicator lamp.

--

Battery charge control lamp.

--

Engine lubrication indicator - flickers.

478320 h

400111B •

In addition, please test if the switches (19 - 22) and the combined switch (17) work.

22 21 20 19

Note When lights are switched ON the luminous intensity of indicator lamps (25) and (26) on clusters will lower.

17 •

Start the engine

•

The indicator lamps on LH cluster must go off: --

Battery charge control lamp.

--

Engine lubrication indicator.

400128

Note If the engine is not started within 10 sec. after ignition key has bee turned ON into position I, then acoustic signal will be enabled (to warn operator of the battery possibly discharged).

478320 h

400111C 102

AV 70 X

MAINTENANCE MANUAL Start moving the Machine: •

Indicator lamps on LH cluster shall go OFF. --

Indicator lamp for the idle (neutral) of travel controller.

--

Brake alarm indicator.

478320 h

400111D Emergency brake push button function: Check whether emergency brake works (8).

•

The engine stalling.

•

Then the following indicator lamps on LH cluster remain ON: STOP

•

•

--

Seat switch indicator lamp.

--

Parking brake warning lamp.

--

Battery charging indicator.

--

Engine lubrication indicator - flickers.

N

0

8

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

400169

Use sound signal to indicate the engine start!

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

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

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

During operation, check continuously the instruments and indicator lamps.

Promptly repair any failures!

478320 h

400111 AV 70 X

103

3.6.

Lubrication and Maintenance Operations Following 250 hours of operation (after 3 months)

3.6.11. How to exchange motor oil and oil filter •

Prepare an appropriate vessel of ca 9 l (2,4 galUS) capacity.

•

Remove drain plug (1) and let the oil flow out.

•

Check the drain plug gasket, replace if damaged.

•

Check the thread and clean seating face for gasket.

•

Reinstall the plug. Torque is 50 Nm (37 ft lb).

When draining the oil temperature shall not be over 60°C (140°F) – risk of burn.

•

1 400613

Clean the surface round oil filter head. Remove the filter.

400614 •

Clean seating face for filter gasket.

400173 104

AV 70 X

MAINTENANCE MANUAL •

Fill the new filter with clean engine oil.

282N130T •

Apply oil slightly across rubber gasket for the filter and screw back, tighten properly with hand.

400174

Do not overtighten the filter, the thread and gasket may get impaired!

388N134 •

Use filler neck (2) to fill the engine with clean motor oil.

2

400609A AV 70 X

105

3.6.

Lubrication and Maintenance Operations

Note •

Fill up to the dipstick’s top division mark. Total sump capacity is 7 l (1,85 gal US).

•

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

•

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

Drain oil when hot – best upon operation completion.

Use original filters only.

Use recommended oil under Section 3.2.1, only.

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

Check the tightness.

400178

Collect the oil drained, do not let oil soak into soil.

Dispose of oil compliant to regulations.

Store used filters in a separate container and handle them so these do not pollute the environment.

3.6.12. Inspect engine induction manifold •

Check the pipes and clamps.

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

400611A

3.6.13. Inspect engine cooling circuit •

Check the cooling circuit tightness. Confirm no pipes are damaged and no clamps are missing.

400615 106

AV 70 X

MAINTENANCE MANUAL

400616

400617 •

Check that oil cooling gills and radiator fins are not fouled.

If fins are fouled then clean them, for instance purging the coolers with pressure air (steam or hot water) according to Section 3.6.32.

400181

400618 AV 70 X

107

3.6.

Lubrication and Maintenance Operations

3.6.14. Inspect the battery •

Stop the engine and use disconnector to disconnect the wiring.

400619 •

Clean the battery surface.

•

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

1 1

400620 •

Open the battery cell plugs (2) to check electrolyte level to confirm the electrolyte level reaches 5 ÷ 15 mm (0.2÷0.6 in) above the plates (electrodes) in all the cells, or to the bottom edge of the gauge inside the battery cells. Refill with distilled water those cells having electrolyte less than 5 mm (0.2 in) above the plates.

2

400620A •

Measure the electrolyte density in individual cells with the refractometer or density meter.

400183 108

AV 70 X

MAINTENANCE MANUAL •

Compare measured values with the chart.

Density in g/cm3 20 °C 68 °F fully charged semi charged

Tropics

in °Be (Beume) 20 °C 68 °F

Tropics

1,28

1,23

32°

27°

1,2

1,12

24°

16°

1,12

1,08

16°

11°

exhausted charge immediately!

Note •

Check the level with glass tube.

•

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

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

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

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

Get prompt medical attention.

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

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

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

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

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

AV 70 X

Keep the battery dry and clean.

Close the battery when checking is completed.

Refill the battery with distilled water only – never with acid.

Replenish distilled water just before operating the Machine or before battery recharging.

Recharge the undercharged battery.

Recharge the battery off the Machine.

Open battery plugs before recharging.

Never disconnect the battery with the engine running.

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

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

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

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

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

Flush spilled electrolyte with water, and neutralize with lime.

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

109

3.6.

Lubrication and Maintenance Operations

3.6.15. Inspect the function of air filter vacuum switch •

Adjust the engine rpm to round 1500 rmp.

•

Cover briefly the air filter intake hole.

Inspect always when cleaning the induction air pre-filter!

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

400618A •

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

478320 h

400185 •

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

400186

110

AV 70 X

MAINTENANCE MANUAL 3.6.16. Sprinkling filter & sprinkler strainer •

Close water supply through the valve (1, 2).

1

2

400288 •

Remove sprinkler filter vessel, replace the strainer and clean it.

400635

400262A

AV 70 X

111

3.6.

•

Lubrication and Maintenance Operations

Remove and clean sprinkler strainers (3).

400289

3

400190

112

AV 70 X

MAINTENANCE MANUAL 3.6.17. Machine lubrication •

Take off the caps on the greasing nipples.

•

Step by step, put on the greasing nipple of high-pressure press and lubricate till the old grease starts pouring out.

•

Reinstall the greasing nipple caps.

Use only the recommended lube greases, refer to Section 3.2.4.

Steering joint Upper bearings 2 x Lower bearings 2 x

400191 Main bearing 4x

400192 Linear hydraulic motors for steering Pins 6x

400193 AV 70 X

113

3.6.

Lubrication and Maintenance Operations

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

400194 Cabin door hinge pins pins 8 x

400195

114

AV 70 X

MAINTENANCE MANUAL After 500 hours of operation (after 6 months) 3.6.18. How to replace fuel filter •

Clean the fuel filter.

•

Remove the filter.

400616A •

Clean the sealing face of filter holder.

400173 •

Fill new filter with clean fuel and lubricate sealing “O” ring (2) with oil.

2

400198 •

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

388N134 AV 70 X

115

3.6.

Lubrication and Maintenance Operations

•

Use a hand pump to add fuel into the filter.

•

Inspect the filter tightness when engine is started!

Observe fire precautions during replace­ ment!

Replace in ventilated rooms with no fire hazard.

Do not smoke or use open flame when at work.

Use the recommended original filters, only.

Make no over-tightening of filters, the thread and gasket may get damaged.

400616B

Avoid fuel leaking into soil.

Store used filters in environmentally friendly manner.

3.6.19. Inspect coolant concentration •

Check the concentration via refractometer.

Inspect always before winter season.

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

Add antifreeze according to Section 3.2.5.

400183

116

AV 70 X

MAINTENANCE MANUAL Following 1000 hours of operation (after 1 year) 3.6.20. Inspect engine belt

Check the belt with the engine OFF!

Check the belt tension: •

Use parking brake to secure the Machine.

•

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

•

Max slack is 10 mm (0,39 in).

400199

Check the belt wear: •

Inspect visually the belt.

•

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

400161 Belt tension:

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

400623

3.6.21. Inspect the exhaust system •

Check the leak tightness of exhaust manifold in the direction towards the engine.

•

Check the exhaust manifold leading to the exhaust muffler.

•

Torque of the exhaust-header (collector) pipe - 21 Nm.

400626 AV 70 X

117

3.6.

Lubrication and Maintenance Operations

3.6.22. Inspect the silencing system •

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

Replace the damaged ones.

Check the bolts and nuts of the following are tightened:

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

400290

400621 Rubber-metal of driver’s compartment 4x.

400291 118

AV 70 X

MAINTENANCE MANUAL Rubber-metal for the engine 3x.

400622 Rubber-metal for battery holder 4x.

400620B

AV 70 X

119

3.6.

Lubrication and Maintenance Operations

3.6.23. Clean the water tank •

Remove the tank filler neck cap.

400148A •

Open tank drain hole.

•

Flush the tank with stream of water.

400206 •

Clean the strainer inside the filler neck.

Drain water from water tank before winter season!

Proceed in line with the Section 3.6.34.

400148B

120

AV 70 X

MAINTENANCE MANUAL 3.6.24. Oil change in the gearboxes Oil draining: •

Clean the places around the plugs.

•

Place the machine so that the plug (1) is at the lowest position.

•

Dismount the plug (1), (2) and let the oil flow out to a container with a capacity of 15 l (3.96 US gal).

Note Renew the oil when it is hot.

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

400627

1

Oil filling: •

Place the machine so that the (1) is at the highest position.

•

Fill in the recommended oil using the filler plug (1).

2 Check of the oil level: •

Check the oil level using the inspection hole 2.

•

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

•

Remount the plugs; if the plug seals are damaged, remove them.

400628

Change the oil after the first 200 engine hours.

Do not touch the gearbox and adjacent parts if hot.

Catch the drained oil.

Dispose of according regulations.

AV 70 X

to

legal

121

3.6.

Lubrication and Maintenance Operations Following 2000 hours of operation (every 2 years)

3.6.25. 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.

3.6.26. Engine coolant exchange How to drain cooling circuit:

Before you drain the coolant from the cooling circuit let the engine run for 5 minutes for the liquid temperature to reach 82°C (180°F).

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

400159 Stop the engine.

•

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

1

400158A 122

AV 70 X

MAINTENANCE MANUAL •

Remove the cooling circuit drain plug. Let the liquid pour down into the vessels set up. The drained amount is ca 15 l (3,96 gal U.S.).

400613A •

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

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

First part: •

Install the drain plug, fill the cooling system with the mixture of the following ratio: 0,5 kg (1 lb) of sodium carbonate and 23 l of water, or agents normally available on this base.

•

When filled, wait for ca 2-3 min until air escapes and the circuit gets filled. Max filling rate is 10 l/min (2,6 gal US/min).

•

Do not close the tank with overpressure plug.

•

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

400613A Inspect cooling circuit tightness and liquid level on water gauge.

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

400217 AV 70 X

123

3.6.

Lubrication and Maintenance Operations

Second part: •

Fill the cooling circuit with clean water. When filled, wait ca 2-3 min until air escapes and the circuit gets filled. Max filling rate is 10 l/min (2,6 gal US/min).

•

Do not close the tank with overpressure plug.

•

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

400218

Inspect cooling circuit tightness and liquid level on water gauge.

•

Stop the engine and drain the cooling circuit.

Note Repeat this process until clean water flows out.

400158B Fill the cooling circuit: •

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

Wear gloves to protect your hands!

Wear safety glasses or face shield to protect your eyes!

Fill with the coolant according to the Section 3.2.5!

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

400219 •

Refill the coolant to max level. When filled wait ca 2-3 min until air escapes and the circuit gets filled. Max filling rate is 10 l/min (2,6 gal US/min). Close the expansion tank with overpressure plug.

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

400218 124

AV 70 X

MAINTENANCE MANUAL •

Stop the engine.

•

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

400158B

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

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

400159

AV 70 X

125

3.6.

Lubrication and Maintenance Operations

3.6.27. How to exchange oil in the vibrators How to drain oil: •

Locate the Machine so the plug (1) is in its lowest position.

•

Remove plug (1) and let oil pour down into the vessel of 15l (4 US gal) capacity.

•

Reinstall the plug.

Note

1

Exchange oil at the time when oil is hot.

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

400293 Oil filling: •

Locate the Machine so the plug (1) is in its highest position.

•

Remove the plug (1).

•

Check the amount of oil through loosening plug (2), oil must flow out.

•

Reinstall the plug (2).

•

Use port (1) to refill 2 more litres of oil (0,5 galUS).

•

Reinstall the plug (1).

1

2

Avoid oil escape into ground.

400294

3.6.28. How to exchange hydraulic oil and filters Carry out oil exchange before the season starts, or following a rather long shutdown of the Machine. At the same time clean the inlet strainer, as well.

•

Dismount the drain plug.

•

Let oil pour down into the vessel set up – total amount of oil flowing out is 40 l (10,56 gal US).

400624 •

Dismount the suction hose.

400629 126

AV 70 X

MAINTENANCE MANUAL •

Remove the cap (1) along with inlet strainer (2).

•

Remove the inlet strainer away from the inlet pipe. Wash the inlet strainer and purge the strainer with compressed air from inside.

•

Check the inlet strainer condition, in case filter element is impaired you must replace it.

•

Inspect the tank’s inner space. Should there be any impurities on its bottom, clean thoroughly and flush the tank with new oil.

•

Remount the tank lid (1) and use a new seal.

1

2

Drain oil when cooled down below 50 °C (122 °F).

Observe the fire precautions!

400630

When disconnecting the hydraulic circuits blind all the ports with plugs.

Collect drained oil and do not let it soak into ground.

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

Check oil temperature sensor: •

Remove the sensor on the hydraulic tank cube and clean the contact.

400629A •

Dip the sensor in water of 100°C (212°F) temperature, check its function correctness on the LH cluster – hydraulic oil level indicator lamp will light up, refer to the Fig.

478320 h

400111E AV 70 X

127

3.6.

Lubrication and Maintenance Operations

Fill the hydraulic circuit: •

Fill with the filling device of the following parameters:

MAX

1

Min pressure 6 MPa (870 PSI) Filtering property 3 to 10 µm •

Slip the filling device quick-coupling (1) ����������������������� over ������������������� the quick-coupler.

•

Fill the hydraulic circuit until clean oil starts to flow out from the drain plug.

•

After approximately 15 l (4 gal US) flow out, mount the drain plug.

•

Top up the tank with oil its max level and disconnect the filling device.

MIN

2

400612 Spare filling via tank filler neck (2):

Carry out hydraulic circuit filling via the filler neck in emergency cases only!

This filling method will need to reduce the next exchange interval by one half, i.e. 1000 hours or 1 year.

•

Tank filler neck plug has been sealed. When this seal is broken during guarantee period then the guarantee will terminate.

•

Fill the tank through its filler neck with the required type of oil up to the bottom of a strainer inside the filler neck.

Note •

When filling through the tank filler neck a large portion of old oil will remain in the circuit along with the impurities, and the life of hydraulic units will lower.

•

You may order the filling device with the Machine manufacturer or a dealer.

When the circuit is filled, please check the hydraulic oil level indicator lamp is not ON. Start the engine and test the Machine functions at the increased RPM so to fill the circuits.

Check the filter tightness, temperature sensors, inlet pipes and lids.

Observe cleanliness at work. Prevent any contamination of the system with the materials that might cause damage to the major units!

Follow the fire precautions!

Do not open uselessly the hydraulic tank!

Exchange oil and filter element always when destruction of the inner parts of the units (hydraulic motors, hydroelectric generators) occurs, or following a major repair of the hydraulic system. Clean and flush the hydraulic tank before new unit is installed. Replace filter element.

Never use chemical cleaning agents to clean the tank.

To clean, please use cleaners with no fibre let-off.

Refill oil according to the Section 3.2.3.

128

AV 70 X

MAINTENANCE MANUAL How to replace pressure filter element

Replace always during: •

oil exchange

•

pressure filter indicator lamp goes on when oil operating temperature reaches 50 - 60 °C (122 - 140 °F).

478320 h

400111G •

Remove the filter vessel.

•

Remove the filter element.

•

Clean thoroughly the filter vessel.

•

Clean from the bottom the seating face of filtration block.

•

Check the condition of sealing rings and paint the rings with clean oil.

•

Insert new element into the filter vessel and screw on again – tighten with 40 +10 Nm (30 +7 ft lb) torque.

400226

Use the original filter elements according to the Spare Parts Catalogue, only.

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

400227

AV 70 X

129

3.6.

Lubrication and Maintenance Operations Maintenance as required

3.6.29. Fuel system breathing Deaerate the fuel system before the first start upon: •

filter replacement

•

long term shutdown of the Machine

•

fuel drawn off

Low-pressure piping blow-off and filter deaeration: Use the pump on fuel filter head to blow off the low-pressure piping.

400616B

Follow safety regulations!

No smoking or use of open flame while at work on fuel system!

Avoid fuel escape into soil!

130

AV 70 X

MAINTENANCE MANUAL 3.6.30. How to replace air filter elements The proper maintenance of air filter and of the entire inlet piping, the rubber parts in particular, will ensure maximal protection of the engine against dust effects, and prolong the life of the element and its efficiency.

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

Principles of correct filter element replacement: •

Slowly pull out the clogged element as carefully as possible.

•

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

•

Clean the seating faces for gasket in the cleaner body.

•

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

•

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

•

Make sure the gasket is seated properly.

NEVER use damaged elements!

Do NOT use other elements than those required!

Do NOT remove the elements just for checking purposes!

Do NOT left the filter opened longer than necessarily required!

NEVER operate the Machine with filter body damaged!

How to replace air filter element: •

The air filter comprises the main element and safety element.

•

Replace the main element always when signalled by indicator lamp for air filter fouled.

•

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

•

Confirm the fixing and integrity of the air filter and intake piping.

•

Saturation of the air filter element will be signalled by the indicator lamp for air filter fouled.

•

When the indicator lamp goes on you must replace the main filter element.

•

478320 h

400111H

Remove filter cap (1) and replace the main filter element (2) from the filter shell.

1

400610A AV 70 X

131

3.6.

Lubrication and Maintenance Operations

2 400631 •

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

•

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

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

3

400632 •

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

NEVER use compressed air to clean the inner space.

400633 •

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

Replace instantly a damaged vacuum valve!

400610 132

AV 70 X

MAINTENANCE MANUAL 3.5.31. How to clean water separator of fuel filter •

Water trap indicator lamp is ON.

400112B •

Loosen the drain valve (1).

•

Let the deposits flow out and screw it.

Follow the fire precautions.

No smoking allowed at work on fuel system.

400197B

Collect escaped fuel in the vessel set up.

1

400233

AV 70 X

133

3.6.

Lubrication and Maintenance Operations

3.6.32. Clean the engine radiators and hydraulic oil coolers •

Due to various working conditions no regular cleaning interval can be set.

•

In case of work in very dusty environment, perform daily cleaning. Cooler fouling will show in a reduced cooling performance and increased temperatures of engine coolant and of hydraulic oil.

•

Remove the cover.

•

Clean with compressed air or pressure water (steam). Clean in the direction from the fan side.

400618

Do NOT clean the radiator with too high pressure so to avoid its damage.

When radiator is contaminated with crude oil products, use a cleaner and proceed according to the manufacturer’s manual!

Find out a cause of contamination!

Clean the Machine at a workplace equipped with cleaner collection system to prevent soil contamination and water resource contamination!

NEVER use forbidden cleaners!

400611

3.6.33. How to clean cab ventilation filter •

Remove the cover grill (1).

•

Remove the filter element.

•

Beat out the element carefully and wash in a detergent solution. If filter element will become damaged or unable to be made rid of the impurities, please replace it with new one.

Clean regularly 1 x per month. Should it be you work in a very dusty environment then the cleaning intervals should be cut short.

1

400234 134

AV 70 X

MAINTENANCE MANUAL 3.6.34. Drain water from sprinkling circuit before winter season •

Before winter season it will be necessary to drain water from the sprinkling circuit with regard to any potential damage to individual parts because of frost.

How to drain water from the sprinkling circuit: •

Remove sprinkling water tank drain plug. Store the drain plug at a safe place.

•

Tank’s full capacity is 600 l (158,5 gal/US).

400206 •

Remove and clean the vessel (1) incl. sprinkling filter (2).

Store the vessel complete with filter at a safe place.

1

2

400262 •

Keep the valve for water supply from the tank opened.

400295 •

Dismount the drain plugs.

400635A AV 70 X

135

3.6.

Lubrication and Maintenance Operations

•

Detach at least one sprinkler from each pipe on the front and rear sides of the Machine. Store the sprinklers at a safe place.

•

Switch ON the sprinkling pumps for 20 sec. so these become drained.

•

This procedure will guarantee you max drainage of the sprinkling circuit.

•

when all the abovementioned operations are completed, please proceed in reverse steps, clean thoroughly the individual parts, first.

By draining the water from the sprinkling circuit in time you will avoid any potential damage that the manufacturer shall bear no responsibility for!

136

400289

AV 70 X

MAINTENANCE MANUAL 3.6.35. Adjust the scrapers •

The Machine is fitted with four hinged (tilting) scrapers.

1

Position the scrapers: •

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

400235 •

In position (2) the scraper is set in working position.

•

When in working position, the scraper blade (3) is pressed against the drum body (4) by means of gas struts (4).

2

4 3 400236 Replace the blade: •

When the blade becomes excessively worn, please lift off the scraper, remove the bolts (5) and take off the blade (3) along with the strip (6).

•

Proceed in reverse steps to reinstall a new blade.

•

At the same time always check the proper function of the gas struts (4).

Only when the gas struts work properly and the worn scraper blades are replaced in time, this will provide you with perfect drum cleaning!

AV 70 X

5

3

6

400237

137

3.6.

Lubrication and Maintenance Operations

3.6.36. Machine cleaning •

When the work is completed clean the Machine to get rid of major impurities.

•

Carry out overall cleaning on regular basis, at least once per week. Total cleaning must be done daily if working on cohesive soils, cement or lime stabilizations.

Disconnect the disconnector.

Carry out the work with the engine stopped.

NEVER use aggressive or easily ignitable cleaners (e.g. petrol or easily or flash fuels).

Before pressure cleaning with water or steam, please blind all the ports into which a cleaner might penetrate (e.g. engine inlet port). With the Machine cleaned remove these blinds.

Do NOT expose electric parts or insulation material to direct water or steam streams. Always cover these materials (alternator’s inner space, etc.).

Clean the Machine at a workplace equipped with cleaner collection system so to avoid soil or water recourse contaminations!

NEVER use banned cleaners!

3.6.37. Check the tightening of bolted connections •

Confirm regularly that no loosening of bolted connections has occurred.

•

Use the torque spanners to do the tightening.

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

For the screws 10,9 (10K)

Worm

Nm

lb-ft

Nm

lb-ft

M6

10

7,4

14

10,3

M8

24

25,0

34

25,0

M8x1

19

14,0

27

19,9

M10

48

35,4

67

49,4

M10x1,25

38

28,0

54

39,8

M12

83

61,2

117

86,2

M12x1,25

66

48,7

94

69,3

M14

132

97,3

185

136,4

M14x1,5

106

78,2

148

109,1

M16

200

147,5

285

210,2

M16x1,5

160

118,0

228

168,1

M18

275

202,8

390

287,6

M18x1,5

220

162,2

312

230,1

M20

390

287,6

550

405,6

M20x1,5

312

230,1

440

324,5

M22

530

390,9

745

549,4

M22x1,5

425

313,4

590

435,1

M24

675

497,8

950

700,6

M24x2

540

398,2

760

560,5

M27

995

733,8

1400

1032,5

M27x2

795

586,3

1120

826,0

M30

1350

995,7

1900

1401,3

M30x2

1080

796,5

1520

1121,0

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

138

AV 70 X

MAINTENANCE MANUAL Chart showing the torques for cap nuts with sealing “O” ring – hoses Tightening moments for the sliding nuts with the tightening circle „O“ - hoses Nm Size spanner

Worm

Hose

Nominal

Min

lb ft Max

Nominal

Min

Max

14

12x1,5

6

20

15

25

15

11

18

17

14x1,5

8

38

30

45

28

22

33

19

16x1,5

45

38

52

33

28

38

22

18x1,5

51

43

58

38

32

43

24

20x1,5

58

50

65

43

37

48

74

60

88

55

44

65

8 10 10 12 12 14

27

22x1,5

30

24x1,5

16

74

60

88

55

44

65

32

26x1,5

18

105

85

125

77

63

92

36

30x2

135

115

155

100

85

114

166

140

192

122

103

142

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

AV 70 X

52x2

15

20 22 25 28

38 42

139

3.6.

Lubrication and Maintenance Operations

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

Chart showing the torques for plugs with flat gasket

Tightening moments for the necks

Tightening moments for the plugs

G -M

Nm

lb ft

G -M

Nm

lb ft

G 1/8

25

18

G 1/8

15

11

G 1/4

40

30

G 1/4

33

24

G 3/8

95

70

G 3/8

70

52

G 1/2

130

96

G 1/2

90

66

G 3/4

250

184

G 3/4

150

111

G1

400

295

G1

220

162

G 11/4

600

443

G 11/4

600

443

G 11/2

800

590

G 11/2

800

590

10 x 1

25

18

10 x 1

13

10

12 x 1,5

30

22

12 x 1,5

30

22

14 x 1,5

50

37

14 x 1,5

40

30

16 x 1,5

60

44

16 x 1,5

60

44

18 x 1,5

60

44

18 x 1,5

70

52

20 x 1,5

140

103

20 x 1,5

90

66

22 x 1,5

140

103

22 x 1,5

100

74

26 x1,5

220

162

26 x1,5

120

89

27 x 1,5

250

184

27 x 1,5

150

111

33 x 1,5

400

295

33 x 1,5

250

184

42 x 1,5

600

443

42 x 1,5

400

295

48 x 1,5

800

590

48 x 1,5

500

369

400239 140

400240 AV 70 X

3.7.

Defects In most cases the defects are due to operating the Machine improperly. Therefore during any failure read thoroughly once more the instructions given in the Machine and Engine Operation and Maintenance Manual. Unless you will be able to specify the cause of a defect, please contact authorized dealer’s or manufacturer’s Help Desk (service assistance).

The troubleshooting of hydraulics and wiring requires expertise in the field of hydraulics and wiring, so we strongly recommend to hand over the troubleshooting process to the Help Desk of an authorized dealer or manufacturer.

AV 70 X

141

3.8.

Attachments

Wiring Diagram Legend: A1 Clicker (course light interrupter)

R2 Speed potentiometer

A2 LH cluster

R3 Resistor

A3 RH cluster

S1 Ignition box

A5 Travel controller

S2 Combined switch

A6 Time relay B1 Fuel level float B3 Pressure sensor in water tank B4 Engine RPM sensor B5 Drum speed sensor C1 Interference filter E1,2 Front contour lights E3,4 Rear lights E5,6 Front headlamps E7,8 Rear headlamps E9,10 Left traffic-indicator lights E11,12 Right traffic-indicator lights E13,14 Auxiliary headlamps front (optional) E15,16 Auxiliary headlamps rear (optional) E17 Hazard beacon (optional) E18,19 Brake (stop) lights E20 Cabin lighting E21 Car make lighting (optional) F1-17 Cut-out fuses G1 Battery G2 Alternator H1 Dipped light indicator lamp H2 Distance light indicator lamp

S2.1 Switch for contour lights and headlights S2.2 Distance / dipped lights switch S2.3 Light horn switch S2.4 Loud horn pushbutton S2.5 Traffic-indicator lights switch S3 Rear headlamp switch S4 Warning lights switch S5 Auxiliary lights switch (optional) S6 Hazard beacon switch (optional) S7 Brake pressure switch S8 Switch for hydraulics filter fouled

S32 Front wiper switch S34 Spaeyer pushbutton S35 Fan switch S36 Air conditioner switch (optional) S38 Float in hydraulic oil tank S39 CRAB resetting pushbutton S40,41

CRAB position switches

S42 Hydraulics temperature switch S44 Air conditioner overpressure fuse (optional) S45 Switch of scraper watering X1 Mounting socket X2 Diagnostics socket X3-4 Connection terminals X5-64 Interface connectors

S9 Switch for air filter fouled

Y1 Engine stop solenoid

S10 Engine lubrication pressure switch

Y3 Brake valve Y4 Back drive valve

S11 Engine overheating switch

Y5 Rearward drive valve

S12 Hydraulic oil overheating switch

Y8 Vibration low amplitude valve

S13 Float – water in fuel filter

Y9 Vibration high amplitude valve

S14 Backing horn switch

Y10 Front drum vibration valve

S15 Neutral switch

Y11 Rear drum vibration valve

S16 Emergency brake pushbutton

Y12 CRAB left valve

S18 Constant speed or engine overload switch

Y13 CRAB right valve

S19 Vibration automatics switch

Y15 Edge cutter upward valve (optional)

Y14 Relief valve

H3 Loud horn

S20 Smooth start or smooth stop pushbutton

H4 Acoustic warning indicator

S21 Seat switch

Y16 Edge cutter downward valve (optional)

H5 Backing horn (optional)

S22 Vibration pushbutton (red) on LH travel lever

Y17 Air conditioner compressor clutch magnet (optional)

S23 Vibration pushbutton (red) on RH travel lever

Y18 Solenoid valve of the edge cutter watering (optional)

K1 Contactor K2-19 Auxiliary relay K20 Glowing contactors K22 Auxiliary relay M1 Engine starter M2 Sprinkling motor M3 Sprinkling motor M4 Front wiper M7 Windscreen washer M9,10,11 Fans Q1 Battery disconnector R1 Sprinkling interval potentiometer

142

R4, 5 Engine preheating

A4 Travel electronics

S31 RH (yellow) pushbutton on RH travel lever – CRAB right or edge cutter downward

S24 Sprinkling pushbutton S25 Sprinkling pumps switch S26 Vibration amplitude switch S27 Front / both / rear vibration selector switch S28 LH (yellow) pushbutton on LH travel lever – CRAB left S29 RH (yellow) pushbutton on LH travel lever – CRAB right S30 LH (yellow) pushbutton on RH travel lever – CRAB left or edge cutter upward

AV 70 X

MAINTENANCE MANUAL F9 F16 12V 100Ah

125A

F17

G

X7:1 86 30

X8:2

C1

H3

X27:1 X31

E7

X5:36

15(30)A

K4

17 87 86

K5 85 30

5 10

30

86 87

30 85

K6

87 86

X8:3

E8

S3

30 85

S2.5 O

X8:4

1 9

X8:5

Rear headlamps

X28:2

X7:4

S1

19

F3

S2.3 S2.4 B

C M MC

X5:5

15A

S2.2

X7:3

15/54 50a

F2

X7:2

X5:25

31

K3 85 87

S2.1 H

K1

X5:32

X5:27

Y S Z

X5:2

X5:26

X26:3

X8:1

X62:5

X26:2

E6

56b 56a

X5:4

X5:60

E5

56b 56a

X3

X28:1

20A

S2

X61

E21

F1 30 86

0 12

87 85

E4

31

H1 K2

X5:35

H2

X5:3

50

L IG X62:4

80A

X26:1

E3

Car make lighting

Loud horn

F10

E2

Rear lights

Front headlamps

B

E1

Front contour lights

30

G2

125A

K21

R5

Engine glowing

M1

31

Q1

M

R4

Engine glowing

G1

K20

X26:4 X28:4

Left front traffic-indicator light Left rear traffic-indicator light

E9

X27:2

X5:7

E10

X29:2

X5:8

2 8

Right rear traffic-indicator light Right front traffic-indicator light

E11

X29:3

X5:9

3

E12

X27:3

X5:10

E13

Auxiliary headlamps front

X6:4

X51

87 85

E14

S4 CL

6 1 5 10

K7

31

30 86

X1

X52

E15

Auxiliary headlamps rear

X56:2

E17

Hazard beacon

X30

Brake (stop) lights

X28:3

31

X5:11

87

X5:12

8 18 19 11

S42

P

X5:13

13 16

X5:16

17

X5:17

2 7 6 9 5

S12

Hydraulic oil overheating

X5:18

Air filter Engine lubrication

Water tank level

11 13 5 14

X62:7

H5

X32:2

X5:24

X32:1 X29:1

Air condition

Water in fuel

Engine overload

Crab

Konstant speed

Sprinkling

X12:2 black Blue

X62:1

85 87

S38

87a

X65:2

X5:44

white X65:1

X5:43

A4/17

Front drum speed

1(Brown)

Blue

B5

4(Black)

X5:43

17 Drum

speed

Seat

X5:38

41

X5:39

6

Y5

X5:40

7 Travel backward

20

X5:41 X60

8

21

Vibration

A4

RS2323 RxD

B4

X33:1

RS2323 Grd

X5:29

15

X5:30

29

X5:42

16 26

(12V)

Travel

X11:5

S20

1

5

S21

X15:1

S22

X17:1

S23

X17:2

2 3 5 9

32

X11:6 X16:1

34

X11:7 X16:2

31

100R 1K X11:8 X14:3

5

Engine speed Sprinkling Vibration Sprinkling

X15:2

X2

Speed

X16:3

6

A5

1

R1 100R

R2 100R

X14:4

X5:46

X14:2

5

13

X11:9 X33:2

1

(12V)

5V 14 (5V) 1

27

12

Travel forward RS2323 TxD

5

S19

5 X11:4 X13:2

Y4

Brake

S18

1

Y3

X5:6

Drum speed sensor

7

2 19

3(Blue)

Brake Travel forward Travel backward

3

Automat. vibration 4 X11:3 Smooth start - smooth stop

X5:44

K10/3

X11:2

V14

X13:1 X14:1

B5

30 86

Konstant speed Engine overload

12V

brown

K17

87 85

Neutral 40 Smooth start - smooth stop

X5:45

X5:45

30

30

18

X65:3

X12:4

87a 86

87a X5:37

brown

86 X12:6

28,42

Hydraulic oil level

Y1

X62:8

X12:1

S15

2 X16:8

Engine stop Front drum speed - in the roller with one-piece drums

black

S14

brown

S16

Fe PNP

Blue

K9 K10

F5 10A

30 86

X12:5

85 X5:28 87

H4

Smooth start-smooth stop

K8

X12:3

V11

20 1 10 12 19 6

X11:1 X16:7 1

87 85

Warning lights

Fe PNP

Backing horn

75 R

X10

X5:21 X62:2

R3

1

Warning

A3

S13 X63:1 X63:2

5A

10

Ground

Engine stop Supply +12V Instrument illumination Warning Water tank level Ground

X10

Float – water in fuel filter

2

F4

20

Supply +12V

Vibration

7 9 8 2

X5:20

1

3 12

Engine overheating Fuel gauge Hydraulic oil level Hydraulic oil overheating Engine stop

X5:19

B3

30

X9

15

X5:15

A2

X5:14 X62:6 X62:3

15

14

Seat

Hydraulic filter

A6

87a

Instrument illumination Traffic-indicator Charging+ lights motohours Traffic-indicator lights Neutral Brake

X9

S7 S8 P S9 P S10 S11 B1 P

5 10

X55:2 X49:6

E19

Brake Hydraulic filter Air filter Engine lubrication Engine overheating Fuel gauge

S6

1 9

X6:6

X55:1

ta

E18

X54

5 10

X6:5

X56:1

E16

S5

1 9

X49:2

X53

A1

X11:10

1K

100R X14:5 X16:4

A

C

B

D E F

G H I

J

107636_1en

AV 70 X

143

3.8.

Attachments

Wiring Diagram Legend: A1 Clicker (course light interrupter)

R2 Speed potentiometer

A2 LH cluster

R3 Resistor

A3 RH cluster

S1 Ignition box

A5 Travel controller

S2 Combined switch

A6 Time relay B1 Fuel level float B3 Pressure sensor in water tank B4 Engine RPM sensor B5 Drum speed sensor C1 Interference filter E1,2 Front contour lights E3,4 Rear lights E5,6 Front headlamps E7,8 Rear headlamps E9,10 Left traffic-indicator lights E11,12 Right traffic-indicator lights E13,14 Auxiliary headlamps front (optional) E15,16 Auxiliary headlamps rear (optional) E17 Hazard beacon (optional) E18,19 Brake (stop) lights E20 Cabin lighting E21 Car make lighting (optional) F1-17 Cut-out fuses G1 Battery G2 Alternator H1 Dipped light indicator lamp H2 Distance light indicator lamp

S2.1 Switch for contour lights and headlights S2.2 Distance / dipped lights switch S2.3 Light horn switch S2.4 Loud horn pushbutton S2.5 Traffic-indicator lights switch S3 Rear headlamp switch S4 Warning lights switch S5 Auxiliary lights switch (optional) S6 Hazard beacon switch (optional) S7 Brake pressure switch S8 Switch for hydraulics filter fouled

S32 Front wiper switch S34 Spaeyer pushbutton S35 Fan switch S36 Air conditioner switch (optional) S38 Float in hydraulic oil tank S39 CRAB resetting pushbutton S40,41

CRAB position switches

S42 Hydraulics temperature switch S44 Air conditioner overpressure fuse (optional) S45 Switch of scraper watering X1 Mounting socket X2 Diagnostics socket X3-4 Connection terminals X5-64 Interface connectors

S9 Switch for air filter fouled

Y1 Engine stop solenoid

S10 Engine lubrication pressure switch

Y3 Brake valve Y4 Back drive valve

S11 Engine overheating switch

Y5 Rearward drive valve

S12 Hydraulic oil overheating switch

Y8 Vibration low amplitude valve

S13 Float – water in fuel filter

Y9 Vibration high amplitude valve

S14 Backing horn switch

Y10 Front drum vibration valve

S15 Neutral switch

Y11 Rear drum vibration valve

S16 Emergency brake pushbutton

Y12 CRAB left valve

S18 Constant speed or engine overload switch

Y13 CRAB right valve

S19 Vibration automatics switch

Y15 Edge cutter upward valve (optional)

Y14 Relief valve

H3 Loud horn

S20 Smooth start or smooth stop pushbutton

H4 Acoustic warning indicator

S21 Seat switch

Y16 Edge cutter downward valve (optional)

H5 Backing horn (optional)

S22 Vibration pushbutton (red) on LH travel lever

Y17 Air conditioner compressor clutch magnet (optional)

S23 Vibration pushbutton (red) on RH travel lever

Y18 Solenoid valve of the edge cutter watering (optional)

K1 Contactor K2-19 Auxiliary relay K20 Glowing contactors K22 Auxiliary relay M1 Engine starter M2 Sprinkling motor M3 Sprinkling motor M4 Front wiper M7 Windscreen washer M9,10,11 Fans Q1 Battery disconnector R1 Sprinkling interval potentiometer

144

R4, 5 Engine preheating

A4 Travel electronics

S31 RH (yellow) pushbutton on RH travel lever – CRAB right or edge cutter downward

S24 Sprinkling pushbutton S25 Sprinkling pumps switch S26 Vibration amplitude switch S27 Front / both / rear vibration selector switch S28 LH (yellow) pushbutton on LH travel lever – CRAB left S29 RH (yellow) pushbutton on LH travel lever – CRAB right S30 LH (yellow) pushbutton on RH travel lever – CRAB left or edge cutter upward

AV 70 X

X11:12

K11 X34:1

X5:31

V2

M2

V1

M

Sprinkling 1

86 87 86 87

X34:2

M

Sprinkling 2

M3

X35:1

1

7

K22 85 87

A

C

15A

S25 5

1

85 30

X35:2

F6

X11:11

5 X16:5

85 30

K12 X5:33

S24

X16:6

B

F E D

J

I H G

MAINTENANCE MANUAL

86 30

1 9

Edge cutter sprinkling

Y18

X5:1

Vibration - low amplitude Vibration - high amplitude

Y8

X5:47

B4

B3

Y9

X5:48

A4

A3

D4

D3

C4

C3

S45

5 10

K13

Front drum vibration Rear drum vibration

X11:13

S27

X5:49

B4

B3

Y11

X5:50

A4

A3

X5:22

S40

3(blue) 2(white)

PNP

1(brown)

3(blue)

Fe

S41

PNP

1(brown)

X5:51 X5:54 X5:53

X14:10

X14:7 X12:7 X14:9 X12:9

X12:16 X22:4

X17:3

Radio

X12:15

X5:59

S31 If the edge cutter is instaled to right hand side of the roller change over the plug X20 in socket X21.

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

X21:1 X21:2

X22:5

X49:3

X5:58

Y16

S30

X6:3

Y15

X20:1 X20:2

X50

X22:3

X49:1

X12:14

V7 V8

Edge cutter downward

X5:57

V5 V6

Edge cutter upward

Y14

X49:5

If the edge cutter is instaled to left hand side of the roller change over the plug X18 to socket X19.

The buttons S28, S29 on the left control lever are used to lifting cutter.

X19:1 X19:2

Relief valve

X15:3

X6:7

S29

X6:1

S28

X18:2

X6:2

X18:1

X12:13 X22:2

30A

X12:12 X22:1

X5:56

F15

X5:55

Y13

X12:11

Y12

87 85

Crabing left Crabing right

87 85

X5:23

K18

2

30 86

1

6

K19

X12:10

5

30 86

X5:52

4(black)

S39

X12:8 X14:8

V12 V13

CRAB position switch - right

F7 7.5A

Y10

Fe

CRAB position switch - left

85 30

86 87

S26

F8 Reserve

E20

Cabin lighting F11

X32:1 X32:4 M

Front wiper

M4 X32:2

5

X32:5 X32:3

Windscreen washer

M

X64:3

X52

M7 X64:1

15A

S32 3

X6:9

1

X6:8

S34

1

5

X56:6 X58:1

M9 X58:2

2 2 X58:3 X59:3 3 M M 3 1 1

Fan 1

85

X48:3

5

30 86

15A

S35

F13

3

5A

1

V9

M11 X48:2

S44

F12

30 86

V10

M10 X59:2

X48:1

2 M 3 1

X59:1

P

87 85

K14

K15

Fan 2

Y17

X56:4

X56:5 87

Fan 3 Air conditioner

7

1 9

S36

5 10

K16 86 87

85 30

F14 10A

X4 X15:2 X17:2 X6:9

107636_2en

AV 70 X

145

3.8.

Attachments

Hydraulic Diagram Legend: 1. Travel pump 2. Vibration pump 3. Steering and cooling pump 5. Vibration and purging block 6. Travel hydraulic motor 7. Vibration hydraulic motor 8. Cooling hydraulic motor 9. Steering hydraulic motor 10. Crab hydraulic motor 11. Lifting hydraulic motor 12. Edge entter hydraulic motor (optional) 14. Power-assisted steering 15. Flow divider 16. Filter 17. Steering block 18. Flushing (purging) block 19. Cooler combined-type 20. Hydraulic tank 21. Hand pump 22. Thermoregulator 23. Inlet strainer 24. Filler neck 25. Level indicator 26. Oil gauge 27. Check valve 28. Check valve 29. Temperature switch

85±3°C

30. Ball valve 31. Ball valve 32. Quick-coupler filling-type 33. Quick-coupler for brake off 34. Quick-coupler for brake off 35. Quick-coupler measuring-type

146

AV 70 X

FRONT

REAR

1

1

A

25

B

A

25

B

2

2

A

C

B

D

3

2

3

2

1

1

5

Dn16

200

MA

MB

M3

P2

T

Dn10

Dn10

A

B

MA

330

330

MB E M3

P1

13 l/min

C1

L2

45

22

400

400

C1

S1

S2

C2

L2 M5 M4 L1 Dn16 Dn10 Dn13 Dn13

M5 M4

C2

2

B

P

78

T

MB

T

1 MPa E

26

M3

13 l/min Dn10

A

MA

L3

MB L4 L1

Dn10

Dn10

MA

Dn10 Dn10 A

B

2200 ot/min

Dn16

3

35

28 30 1

3 bar

18

P

P1

Dn13 i=1.0

29

22 27

15

23

100

11

17

S

420

420

Dn13

B

C

A

24

°C

1,2 mm 3 bar

25

40°C

8 19

Dn16 D

9.5

180

20

°C

55°C

Dn14

Dn16

Dn16

30 A

D

26

P LD

T

Dn13

Dn13

L

240

Dn8

Dn13

Dn13

33 34 11

Dn13

Dn13

175

400

Dn10

20

100

Ø0.5 mm

21

31

Ø0.5 mm

R

80/40-200

80/40-200

Dn13

240

Dn13 Dn13

12 17 9

10

Dn10

Dn10 Ø1 mm

90/45-125

14

M

P1

X

T1

B2 A2

B1 A1

100

CRAB

16

P

2.7 bar

5

3.5 bar

190

100

B A

100

T P

32

PP

EDGE CUTTER B A

Dn8

FRONT RIGHT HYDROMOTOR Dn19

Dn10

30

Dn10

Dn8

REAR LEFT HYDROMOTOR Dn19

Dn16 Dn16 Dn8

B

Dn6

B

Dn6

7

Dn16

Dn16

0.5 bar

0.5 bar

Dn16

Dn16

Dn13

Dn32

Ø25 - 230 Dn6 Dn6 Dn6

Ø25 - 230

A

50/25-130

T P

AV 70 X Dn16

6

T2

20 bar

A5

T3

13 bar

A4

MAINTENANCE MANUAL

211391en

147

Dn10

1 MPa

3 bar

0.5 bar

Notes

148

AV 70 X

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

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

Rammax Maschinenbau GmbH Gutenbergstrasse 33 D-72555 Metzingen

Ammann Czech Republic a.s.

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