Ammann Pneumatic Tyred Roller AP 240 Cummins - Tier II Operating manual

Operating manual

E

AP 240 Cummins - Tier II

© 12 / 2005

We preserve the right for changes at pictures and data for improving the manual’s quality. Overprint and copying of any kind and also individual paragraphs is conditioned by our written approval only.

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AP 240

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,

Verdichtung AG,

CH-4900 Langenthal

0041 (0)62 916 63 56

FAX: 0041 (0)62 916 64 03

This manual consists of: I. Specification manual

III. Air – Conditioning system

II. Operating instructions

IV.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.

AP 240

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4

AP 240

! NOTICE !

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

REAR

RIGHT

LEFT

FRONT

AP 240

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CONTENT CONTENT 1.

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

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

1.1. Basic specification ......................................................................................................................................................... 12 1.2. Dimensional machine drawing ........................................................................................................................................ 14 1.3. Technical data .............................................................................................................................................................. 16 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.3.8 1.3.9 1.3.10 1.3.11 1.3.12 1.3.13 1.3.14

6

Weights .............................................................................................................................................................. 16 Technical information ........................................................................................................................................ 17 Driving qualities ................................................................................................................................................. 17 Engine ................................................................................................................................................................ 18 Gearbox .............................................................................................................................................................. 18 Axles ................................................................................................................................................................... 18 Brakes ................................................................................................................................................................ 19 Driving ................................................................................................................................................................ 19 Fills ..................................................................................................................................................................... 19 Electric installation ............................................................................................................................................. 20 Safety regulations .............................................................................................................................................. 20 Hygienic data of the machine ............................................................................................................................ 21 Traffic regulations ............................................................................................................................................... 22 Extended devices .............................................................................................................................................. 22

AP 240

OPERATING MANUAL 2.

Operating Instructions .................................................................................................................................................... 25

2.1. The main safety precaution ............................................................................................................................................. 27 2.1.1. Safety precaution by the machine operating .................................................................................................... 27 2.1.1.1. Before starting the compactional works ............................................................................................................ 27 2.1.1.2. Secure the safety disposals by watcher ........................................................................................................... 28 2.1.1.3. By using the safety frame ROPS ....................................................................................................................... 28 2.1.2. The requirements for the driver´s qualification ................................................................................................ 29 2.1.3. Driver´s Obligations ........................................................................................................................................... 29 2.1.4. Prohibited Activities ........................................................................................................................................... 31 2.1.5. Safety signs and symbols marked on the machine .......................................................................................... 32

2.2. Environmental & Hygienical Principles ............................................................................................................................ 35 2.2.1.

2.2.2.

Hygienic fundamentals ...................................................................................................................................... 35 Ecologic fundamentals ...................................................................................................................................... 35

2.3. Conservation and Storage of the machines ...................................................................................................................... 36 2.3.1.

2.3.2.

2.3.3.

Short-term storage of 1 to 2 months .................................................................................................................. 36 Conservation and storage for more than 2 months .......................................................................................... 36 De-conservation and inspection of brand new machines ............................................................................... 37

2.4. Machine dispose after its lifecycle .................................................................................................................................. 38 2.5. Machine description ....................................................................................................................................................... 39 2.6. Controls and Control Devices .......................................................................................................................................... 40 2.7. Operating Instructions .................................................................................................................................................... 55 2.7.1.

2.7.2.

2.7.3.

2.7.4.

2.7.5.

2.7.6.

2.7.7.

2.7.8.

Starting the Engine ............................................................................................................................................ 55 Travel & Reversing ............................................................................................................................................. 57 Stopping the Machine & Engine ....................................................................................................................... 59 Changing ENABLED workplace position .......................................................................................................... 60 Parking, Dead Parking of the Machine ............................................................................................................. 61 Emergency Stopping ......................................................................................................................................... 61 Driving the Machine Under Heavy Conditions ................................................................................................. 62 Operating the Machine During Break-In Period ............................................................................................... 62

2.8. Transporting the Machine ................................................................................................................................................ 63 2.8.1.

2.8.2.

2.8.3.

2.8.4.

2.8.5.

2.8.6.

Transportation by Its Own Axle .......................................................................................................................... 63 Transporting the Machine by a Public Road ..................................................................................................... 63 Transporting the Machine by Rail ..................................................................................................................... 64 Loading of the Machine ..................................................................................................................................... 64 Dismantling ROPS Frame & Cabin ................................................................................................................... 65 Towing ................................................................................................................................................................ 67

2.9. Using the Machine Under Special Conditions ................................................................................................................... 69 2.10. Tyre Inflating Pressure .................................................................................................................................................... 70

3.

Air conditioner .............................................................................................................................................................. 73 Air-conditioning system description ................................................................................................................................ 74 Air-conditioning circuit ..................................................................................................................................................... 74 Air-conditioning system controls ..................................................................................................................................... 75 Maintenance .................................................................................................................................................................... 76 Failures ............................................................................................................................................................................ 77

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CONTENT: 4.

MAINTENANCE MANUAL ................................................................................................................................................. 79

4.1. Safety standards and other maintenance regulations ....................................................................................................... 81 4.1.1.

4.1.2.

4.1.3.

Maintenance safety ........................................................................................................................................... 81 Fire regulations when changing the working fills ............................................................................................. 81 Ecological and hygienic standards ................................................................................................................... 82

4.2. Filling Specifications ....................................................................................................................................................... 83 4.2.1.

4.2.2.

4.2.3.

4.2.4.

4.2.5.

4.2.6.

4.2.7.

4.2.8.

4.2.9.

Motor Oil ............................................................................................................................................................. 83 Fuel ..................................................................................................................................................................... 84 Coolant ............................................................................................................................................................... 84 Hydraulic Oil ....................................................................................................................................................... 85 Oil in CLARK Gearbox ....................................................................................................................................... 86 Gearbox Oil ........................................................................................................................................................ 86 Brake Fluid ......................................................................................................................................................... 87 Grease ................................................................................................................................................................ 87 Windscreen Washer Fluid ................................................................................................................................. 87

4.3. Fillings

.............................................................................................................................................................. 88

4.4. Lubrication & Maintenance Table ..................................................................................................................................... 89 4.5. Lubrication Chart ............................................................................................................................................................ 92 4.6. Lubrication & Maintenance Operations ............................................................................................................................ 93 Following 20 hours of operation or daily .......................................................................................................................... 94 4.6.1. Check oil in the engine ...................................................................................................................................... 94 4.6.2. Check coarse fuel filter ...................................................................................................................................... 95 4.6.3. Check the motor belt .......................................................................................................................................... 96 4.6.4. Check the fan condition ..................................................................................................................................... 96 4.6.5. Check the coolant .............................................................................................................................................. 97 4.6.6. Check vacuum valve’s air filter ......................................................................................................................... 97 4.6.7. Check the amount of fuel ................................................................................................................................... 98 4.6.8. Refill the water tank ........................................................................................................................................... 98 4.6.9. Check the oil in the hydraulic system tank ....................................................................................................... 99 4.6.10. Check the brake fluid ......................................................................................................................................... 99 4.6.11. Check the alarm & control equipment ............................................................................................................ 100 4.6.12. Check the amount of oil in CLARK gearbox ................................................................................................... 102 4.6.13. Check the suction line (induction manifold) ................................................................................................... 102 4.6.14. Check the air tank blowdown valve ................................................................................................................ 103

Every 250 hours of operation (3 months) ....................................................................................................................... 104 4.6.15. Replace oil in the engine ................................................................................................................................. 104 4.6.16. Inspect the injection pump .............................................................................................................................. 106 4.6.17. Inspect the compressor ................................................................................................................................... 106 4.6.18. Inspect engine’s cooling circuit ....................................................................................................................... 107 4.6.19. Check air filter’s vacuum switch function ........................................................................................................ 108 4.6.20. Inspect the battery (accumulator) condition .................................................................................................... 109 4.6.21. Lubricate the joint (cardan) shaft & brakes ..................................................................................................... 111 4.6.22. Clean the sprinkling filter ................................................................................................................................. 112 4.6.23. Lubrication ........................................................................................................................................................ 112

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AP 240

OPERATING MANUAL Every 500 hours of operation (6 months) ....................................................................................................................... 114 4.6.24. Check the rear axle oil ..................................................................................................................................... 114 4.6.25. Replace CLARK gearbox filter oil .................................................................................................................... 115 4.6.26. Replace the fuel filter ....................................................................................................................................... 116 4.6.27. Check coolant concentration .......................................................................................................................... 118

Every 1000 hours of operation (1 year) ......................................................................................................................... 119 4.6.28. Inspect and adjust brake shoes ...................................................................................................................... 119 4.6.29. Check and adjust valve clearance .................................................................................................................. 121 4.6.30. Check belt & tensioner .................................................................................................................................... 123 4.6.31. Change CLARK gearbox oil ............................................................................................................................ 125 4.6.32. Replace the Air Drier ........................................................................................................................................ 126 4.6.33. Check the bolted connections ......................................................................................................................... 126 4.6.34. Change the oil in the differential ..................................................................................................................... 128

Every 2000 hours of operation (every 2 years) .............................................................................................................. 130 4.6.35. Change the oil in the rear axle ........................................................................................................................ 130 4.6.36. Change the oil & filter in the steering hydraulics ............................................................................................ 131 4.6.37. Replace oil in the front axle’s hydraulic cylinder ............................................................................................ 133 4.6.38. Change the brake fluid .................................................................................................................................... 134 4.6.39. Exchange the coolant ...................................................................................................................................... 136 4.6.40. Inspect the discharge line of the air compressor ............................................................................................ 138

Maintenance as required ............................................................................................................................................... 139 4.6.41. Clean the Fuel Tank ......................................................................................................................................... 139 4.6.42. Vent the Fuel System ....................................................................................................................................... 140 4.6.43. Replace air filter element ................................................................................................................................. 141 4.6.44. Clean the Cooler ............................................................................................................................................. 143 4.6.45. Clean the water tank & sprinkling filter ........................................................................................................... 144 4.6.46. Clean the brush scrapers ................................................................................................................................ 145 4.6.47. Clean the cabin ventilation air filter ................................................................................................................ 145 4.6.48. Clean the Machine .......................................................................................................................................... 146 4.6.49. Check the bolt connections are tightened ..................................................................................................... 146

4.7. Appendixes – scheme ................................................................................................................................................... 148 Electric installation scheme ........................................................................................................................................... 148 Hydraulic scheme .......................................................................................................................................................... 151 Air circuit ......................................................................................................................................................................... 152

AP 240

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AP 240

SPECIFICATION MANUAL AP 240 (Cummins Tier II)

AP 240

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1.1.

Basic specification

Introduction

Area of use

Wheeled rollers AP 240 are based on world most spread conception of setting the wheeled rollers in the category of weight of 3t for one wheel.

Machine technical parameters (weight, axle base, tire dimension, turning diameter, levelling the front wheels profile grade) allowed together with the good engine and gearbox the quality working output, high reliability and working safety.

Mainly the possibility to change the tires pressure enables to compact many different materials with wide scope of consistence and adjust the machine for optimal using conditions.

The wheeled roller is designed for compaction works of middle and large scope in a highway engineering (construction of highways and roads, railroads, airport areas) and in the land engineering (industry areas and so on).

The roller is convenient for compaction of asphalt composites to the thickness of layer (after compaction) of 120 mm, for hydraulic cemented composites to the layer thickness of 150 mm, earth and clayey soils to layer thickness of 150 mm, mixed soils to layer thickness of 200 mm and sand and aggregate materials to layer thickness of 250 mm.

The roller is not convenient for compaction of rockfill.

The machine is designed for operations under the conditions due to CSN IEC 721-2-1 (038900) : WT, WDr, MWDr (it is temper, warm dry, hot dry with reduced temperature scope -15 °C (5 °F) to +45 °C (113 °F).

Fig. 1 - Decal

Fig. 2 - Location of the decal at the machine

2

1

1. - Decal 2. - Frame number

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AP 240

SPECIFICATION MANUAL Machine design The machine meets the requirements for marking with the “CE” mark and the requirements for the law no. 22/1997 Sb. (it is for CSN EN 500-1,4 and other) for Czech Republic and Directive 2000/14/EC (EN ISO 3744).

The machine can be equipped with opened driver’s post, with roof or cab, two driver’s posts. Driven rear axle can be equipped with the differential lock.

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

Please fill in the following data: Type of machine (see Figs. 1, 2) ..................................................................................

Serial number of the machine (see Figs. 1, 2) ..................................................................................

Production year (see Figs. 1, 2) ..................................................................................

Type of engine (see Fig. 3) ..................................................................................

Serial number of the engine (see Fig. 3) ..................................................................................

Fig. 3 - Serial number of the CUMMINS engine

AP 240

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1.2.

Dimensional machine drawing

Dimensional machine drawing

Dimensions

A

G

H

H1

H3

L

W

W1

W2

mm

3500

300

3110

3010

2540

4775

1986

2265

33

(in)

(137,8) (11,8) (122,4) (118,5)

(100)

(188)

(78,2)

(89,2)

(1,3)

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AP 240

SPECIFICATION MANUAL Dimensional machine drawing

Dimensions

A

G

H

H1

H3

L

W

W1

W2

mm

3500

300

3110

3010

2540

4775

1986

2265

33

(in)

(137,8) (11,8) (122,4) (118,5)

(100)

(188)

(78,2)

(89,2)

(1,3)

AP 240

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1.3.

Technical data

1.3.1

Weights

AP 240 (design without weight under frame, without ballast in frame, without option) EN 500-1

ISO 6016

design with the cab

kg (lb)

9 510 (20966)

9 750 (21495)

design with the platform and the rail

kg (lb)

9 270 (20437)

9 510 (20966)

max. operation weight

kg (lb)

23 760 (52381)

24 000 (52910)

The weight under frame Weight 1 t

kg (lb)

1 000 (2205)

Weight 2,4 t

kg (lb)

2 400 (5291)

Weight 6 t

kg (lb)

6 000 (13228)

Water

kg (lb)

1 800 (3968)

Sand

kg (lb)

4 000 (8818)

Steel

kg (lb)

max. 8 750 (19290)

ROPS

kg (lb)

400 (882)

ROPS with FOPS

kg (lb)

650 (1433)

Ballast in frame 1,8 m3

Option

ROPS with canopy

kg (lb)

450 (992)

Carrier with canopy

kg (lb)

150 (331)

Edge cutter

kg (lb)

150 (331)

Tires cover

kg (lb)

200 (441)

AP 240 - design with the cab

EN 500-1

ISO 6016

ROPS, weight 2,4t

kg (lb)

12310 (27138)

12550 (27668)

ROPS, weight 6 t

kg (lb)

15910 (35075)

16150 (35604)

ROPS, weight 6 t, tires cover

kg (lb)

16110 (35516)

16350 (36045)

weight 2,4t

kg (lb)

11910 (26257)

12150 (26786)

weight 6 t

kg (lb)

15510 (34193)

15750 (34722)

EN 500-1

ISO 6016

AP 240 - design with the platform and the rail ROPS, weight 2,4t

kg (lb)

12070 (26609)

12310 (27138)

ROPS, weight 6 t

kg (lb)

15670 (34546)

15910 (35075)

ROPS, FOPS, weight 6 t

kg (lb)

15920 (35097)

16160 (35626)

ROPS, weight 6 t, tires cover

kg (lb)

15870 (34986)

16110 (35516)

Carrier with canopy, weight 2,4t

kg (lb)

11820 (26058)

12060 (26587)

Carrier with canopy, weight 6 t

kg (lb)

15420 (33995)

15660 (34524)

Carrier with canopy, weight 6 t, tires cover

kg (lb)

15620 (34436)

15860 (34965)

Weight according to EN 500-1 = CSN EN 500-1 is weight of the machine with half filling of fuel, lubrication, water tank of sprinkling and operator’s weight 75 kg (165 lb).

Weight according to ISO 6016 is weight of the machine with maximum filling of fuel, lubrication, water tank of sprinkling and operator’s weight 75 kg (165 lb).

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AP 240

SPECIFICATION MANUAL 1.3.2

Technical information

Length

mm (in)

4775 (188)

Width

mm (in)

2265 (89,2)

Height with cab/without cab with ROPS

mm (in)

3110 (122,4)

Inner diameter

mm (in)

300 (11,8)

km/h (MPH)

0 - 5 (0 - 3,1)

1.3.3

Driving qualities

The travel speed to front and back under each gear level : I. II.

km/h (MPH)

0 - 11 (0 - 6,8)

III.

km/h (MPH)

0 - 19 (0 -11,8)

%

25

- with the wheel directly

%

36

- with the wheel to the lean

%

32 left

right

mm (in)

5350 (210,6)

5800 (228,3)

Gradeability under full load Side machine stability with the cab and protective frame (total weight 24 000 kg – standing machine):

Turning radius rut internal - outer

mm (in)

8150 (320,9)

8250 (324,8)

contour internal

mm (in)

5350 (210,6)

5580 (219,7)

- outer

mm (in)

8350 (328,7)

8630 (339,8)

AP 240

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1.3.

Technical data

1.3.4

Engine

Manufacturer

Cummins Diesel

Engine type

B4.5 C 99

Kind of the engine

Diesel engine, liquid cooled

Cylinder number

4

Perforation

mm (in)

102 (4.02)

Stroke

mm (in)

138 (5.42)

3

Stroke capacity

cm (cu in)

4500 (275)

Engine output according to the ISO 3046/1, DIN 6271

kW (HP)

74 (99)

Nominal revolutions

min -1 (RPM)

2200 (2200)

Max. tightening moment

Nm (ft lb)

414 (305) / 1500 min-1 (RPM)

Fuel filter

Fleetguard FS 1960800*

Oil filter

Fleetguard LF 0380500*

Air filter

DONALDSON FPG 08-2503

Marking of the air filter inserts main insert

P77 - 2580

securing insert

P77 - 5302

Engine fulfills requirements of

Dir 97/68/EU Stage 2 EPA/CARB 40 CFR Part 89 Tier 2

*/ The exact notation these sparts is accordant with to engine. When ordering spare parts, please, always state serial number of engine.

1.3.5

Gearbox

Gearbox type

CLARK 1204FT20302-102

Gearbox kind:

3-level reversing gearbox with hydrodynamic moment changer, with shifting the gear levels under electrical loading.

Kind of the gearbox oil filter

CLARK 247 050

Cooling the gearbox and the engine by combined radiator

ORLANDI 15287

1.3.6

Axles

The front axle consists of two pairs of wheels, each pair has variation suspension on the hydraulic cylinder piston rod, round its axe it is turning to the turning radius. The pair of the hydraulic cylinders is connected with the isostatic function.

The rear axle consists of 2 drive boxes with end gearing solid mounted to the back part of the cylinder frame.

Wheel base

mm (in)

Number of tires Tires dimension Tires pressure Type

18

3500 (138) 8 11,00 x 20" without the pattern

MPa

0,2 - 0,6 TT

AP 240

SPECIFICATION MANUAL 1.3.7

Brakes

The working brake is controlled by the foot pedal, the hydraulic with the air-liquid booster, acting to the 4 wheels of the rear axle.

The parking and the auxiliary (emergency) brakes are mechanical, disc – gear, placed on the entrance spindle of the final drive. It is controlled by the switch (hand brake valve – on the machine > in Czech Republic).

Compressor

HOLSET SS191 100 cm3 (8,5cfm)

Air-liquid booster

WABCO

Pedal brake valve

KNORR

Air dryer

KNORR

Dryer spare cartridge

KNORR KNORR

1.3.8

Driving

Hydraulic servo-driving with one direct hydraulic motor Hydro generator

2-Q10R.54600-00

Driving unit

LAGC 200 LSD 102-L202 REXROTH

Priority valve Securing pressure

LSPSD 205-A201 REXROTH MPa

14

Direct hydraulic motor

HV 80/40/200-111 131

Driving tank

N-05-25-5 JIHOSTROJ

Tank oil filter insert

H23 MANN-JIPAP

1.3.9

Fills

Engine oil in the crankcase

l (gal US)

9,75 (2.61)

Oil in the gearbox

l (gal US)

21,5 (5,68)

Oil in the differential

l (gal US)

6 (1.58)

Oil in the end transmissions

l (gal US)

2x5,2 (2x1,4)

Oil in the hydraulic distribution of the driving

l (gal US)

6,5 (1,72)

Oil in the ejector of the front axle

l (gal US)

6 (1,6)

Brake liquid in the brakes

l (gal US)

0,75 (0,2)

Engine diesel in the tank

l (gal US)

250 (66)

Water in the tire sprinkling tank

l (gal US)

285 (75)

Cooling liquid

l (gal US)

20,5 (5.4)

AP 240

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1.3.

Technical data

1.3.10 Electric installation Power

V

12

Accumulator capacity

Ah

135

Grounded

- pole

1.3.11 Safety regulations Orange beacon of the warning light signalling on the cab.

Accumulator disconnector disconnects the minus pole from the machine ground.

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AP 240

SPECIFICATION MANUAL 1.3.12 Hygienic data of the machine Machine with cab and with closed windows : Noise : Level of acoustic pressure influenced the driver :

LpA = 83 dB (A)

(measured due to EN ISO 11 204 on layer of asphalt mixture, still machine) Guaranteed sound power level

LWA = 105 dB (A)

(measured due to Directive 2000/14/EC and EN ISO 3744 on layer of asphalt mixture, still machine) /applicable to a noise insulated set/.

Vibrations : Measured effective value of vibration acceleration : - transferred to hands

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

(measured due to ISO 5349 during the drive on layer of asphalt mixture) - transferred to body

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

(measured due to EN 1032 during the drive on layer of asphalt mixture) Machine with cab with opened windows : Noise : Level of acoustic pressure influenced the driver :

LpA = 82 dB (A)

(measured due to EN ISO 11 204 on layer of asphalt mixture, still machine) Machine without cab : Noise : Level of acoustic pressure influenced the driver :

LpA = 86 dB (A)

(measured due to EN ISO 11 204 on layer of asphalt mixture, still machine) Vibrations : Measured effective value of vibration acceleration : - transferred to hands

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

(measured due to ISO 5349 during the drive on layer of asphalt mixture) - transferred to body

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

(measured due to EN 1032 during the drive on layer of asphalt mixture)

AP 240

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1.3.

Technical data

1.3.13 Traffic regulations The basic machine model is not intended to be moved under own power on public roads, since its appointment is not in compliance with the regulation for public roads.

1.3.14 Extended devices The protective frame ROPS meets the international standards EN 500-4:1995; ISO 3471:1994; SAE J 1040:APR88; AS 2294:1990 for the maximum machine weight 24000 kg.

Frame weight

kg (lb)

420 (926)

Nm

700

kg (lb)

140 (309)

Mounted to the machine by 8 screws Tightening moment

M27x1,5-370

Edge cutter Weight Maximum thickness of cutter level

mm (in)

100 (3,94)

Diameter of cutter disk

mm (in)

400 (15,75)

It is fasten with screws

2 screws M 16 x 50 CSN 021143.55, 2 screws M 16 x 140 CSN 021143.55

Tightening moment

22

Nm (in lb)

200 (1770)

AP 240

SPECIFICATION MANUAL

Notes:

AP 240

23

24

AP 240

2.

Operating Instructions

OPERATING INSTRUCTIONS AP 240 (Cummins Tier II)

AP 240

25

2.1.

26

The main safety precaution

AP 240

2.1.

The main safety precaution

2.1.1.

Safety precaution by the machine operating

The safety precautions mentioned in individual chapters of the technical documentation delivered with this machine must be supplied with safety precautions valid in the contractor country on the workplace according to work ogranization, working process and personnel.

Operating Instructions 2.1.1.1. Before starting the compactional works The contractor of building works (operator of the machine) has to give before the starting of compactional works the instructions for the driver and maintenance staff, that include the requirements for securing the work safety during operating the machine.

• He has to check and mark: -

engineering nets

-

under-surface spaces (direction, depth)

-

percolatin or the outflow of harmful substances

-

the weighting of the terrain, the lean of driving area

-

next obstacles including their removal

With this results he has to meet the machine driver, who will do the work.

• He has to establish the technological procedure, which part is a working procedure for given working activity, that establishes: -

the working arrangments for extraordinery conditions (work in a safety areas, under extreme leans etc.)

-

the arrangements for the situation of threate by natural elements

-

the requirements for providing the work with meeting the fundamentals of work safety

-

technical and organizational arrangements for ensuring the staff, working place and surround safety.

With this technological procedure he has to apprise the machine driver.

AP 240

27

2.1.

The main safety precaution

2.1.1.2. Secure the safety disposals by watcher • The watcher has to secure the observating of the machine only in that conditions, and for that purposes, for which is technically designed under the conditions approved by the manufacturer and by appropriate standarts.

• All damages of the engineering nets must be immediately reported to their watcher, simultaneously the securing acts must come into performance for avoiding the enter of unauthorized personnel to endangered area.

• He has to secure using of the roller only by that way and on such working places, where is no danger of making some damages on near buildings etc.

• Operator shall ensure a worker is not left alone while working at his/her location. There must always be another worker in sight and within a hearing distance at the location for a case of accident to provide or call for first aid unless any other effective form of control or communication is available.

2.1.1.3. By using the safety frame ROPS • The machine frame in the place of connection has not to be damaged (broken, bent etc.).

• The frame itself has not to be marked as rusty, damaged, thin leak or splits.

• The ROPS frame has not to be released during the actions.

• All screw connections must meet the specification and have to be tightened to prescribed power.

• The screws and nuts have not to be damaged, deformed and have not to show the rusty marks.

• There aren´t allowed any next additional edits on the ROPS frame without manufacturer approval, because they could cause the decrease of its strength(for ex. holes, weldings etc.).

• The weight of the machine including the safety frame must not overreach the weight allowed for the ROPS.

• He has to secure the regular checking of the machine operation, technical status, regular machine maintenance in the intervals corresponding with those in the maintenance and lubrication manual. In the case of unsatisfactory technical machine status in such scale, that it threat the safety of the work, personnel, property or damages and devaluates the enviroment must be the machine set out of operations until correcting of the faults.

• He has to establish who and what actions can do during the operations, maintenance and repairing of the machine.

• Who is driving the machine (driver) and whoever is providing the maintenance and repairing, must be met with the instruction in the driver´s manual.

• He must secure the regular check of extinguisher fire.

• He must secure the placing of the “User´s manual” and the working sheet on the determined place to be ready for the driver.

• He must secure the continuous supervision by assigned worker during the operations of the machine by traffic on public roads and mainly he is obliged to give the orders for securing the work safety.

• He has to secure the removing of harmful substancies (fuel, oil, cooling and brake liquid etc.) from the places of evasions due to their qualities such way to avoid their harmful effects to enviroment, work safety and helth of the personnel.

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AP 240

Operating Instructions 2.1.2.

The requirements for the driver´s qualification

• The roller may be provided by driver trained according the ISO 7130 and next international and national rules and standarts assigned for the drivers of such machine group.

• Without the needed approval may drive the machine only who is learning to drive the machine with approval of the owner under stright and continual supervising of the expert teacher or trainer, for the purpose of getting the preliminary skills.

• The owner of the approval (licence) is obliged to take care about the licence and has to give the licence for controll to the authorities - police.

• The approval (licence) owner has not to make any records, changes or edits to the licence.

• The lost of the driving licence is obliged to report to the publisher of the licence.

• The roller can be individualy for a short time operated by a mentally and physically adequate person older than 18 years, who is: a) entrusted by the manufacturer of the machine and who is assembling, testing, proving and demonstrating the machines, respectively aslo who is teaching the drivers, while he must be acknowledged with the safety regulations valid on the respective working place or b) who is designated by the contractor for maintenance and carry operations, who is trained, who have proved the professional skills another way (has a driving licence etc.)

2.1.3.

Driver´s Obligations

• Before operation of the machine begun, driver is obliged to study instructions given in the manual delivered with the machine, mainly with the safety regulations, and obey them properly. The same is valid for a personnel entrusted to carry out lubrication, maintenance, adjusting and repairs of the machine. If you don´t understand some parts of the manual, contact the nearest dealer or the manufacturer.

• Don´t operate the roller until fully learn all functions of the machine, controls and service points and until exactly know how to operate the machine.

• The driver is obliged to pay attention to all warnings and safety decals and signs located on the machine.

He must keep the signs in readable shape.

• Before he strats working, he must learn about the working place, i.e. with obstacles, with lean of the terrain, about locations of the enginnering networks, about possible limiting factors with regards to enviroment (the noise level etc.).

• If the driver finds out the threat of health, people lifes, of the private property, some damages, the malfunction of the technical installations, possibly finding these remarks during the operating of the machine, the driver is obliged to (when he is not able to repair it himself) don´t run the machine and secure the mahine against unauthorized running, report it to the supervisor and give a warning to all personnel threated by that threat.

• Before he starts, he must study all machine records and running deviations, founded out during last work.

• Before he starts, he is to check the machine, the devices, control elements, radio and safety systems, if they are fully functionall and readable according the manual. After finding out some faults, that could endangered the work safety and he cann´t repair it himself, he is not allowed to run the machine and is obliged to report the fault to the appropriate supervisor.

• Driver must fasten the seat belt when operating his machine. Safety belt and its mountings must not be damaged !

• If any faults appears during the operation, he must stop the machine instantly and safely ensure the machine against unauthorized running.

• During the operating the machine is driver obliged to watch the machine work and founded faults write to the operation book.

• The driver is obliged to write the operation book, which is necessary for taking records of acceptance and taking the machine among the drivers, of damages and repairs during the running of the machine, for the records of significant accidents during the work.

• Before the start must be all controls in zero position and if there aren´t any personnel within the reach of the machine.

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29

2.1.

The main safety precaution

• Give the light or sound signal before all running the

• If the machine comes into contact with high voltage,

machine, always before the starting of the machine.

keep these instructions: - try to get off the dangerous area with the machine - don´t leave the driver´s post - give a warning to the others to keep them away, out of the touch to the machine

• Before starting the machine supply the air reserve in the air tank for a minimum pressure of 7,5 bar (0,75 MPa) (109 PSI).

• Before moving the machine he is obliged to check is the steering and braking systems work well.

• Before getting the warning signal is the driver allowed

Observe all safety notices under all circumstances - danger of death.

to run the machine only after all workers are out of the threated space. On a blind working places is possible to run the machine only after a period of time necessary for the personnel to get out of the threated space.

• During running the machine must driver obey the

Observe safety notices - danger of personal injury.

safety regulations, doesn´t make any actions threating the work safety and pay full attention to the driving the machine.

• Respect the technological work progress, or the regu-

Follow ecological regulations.

lations of appropriate supervisor.

• When running around the jobsite, travel speed must be adequate to the terrain, provided work and the weather conditions. The driver is obliged to observe the path to prevent collisions with any obstacles.

• Any time the machine is left after or during the work,

! NOTE !

Observe all advice.

when the worker leaves the machine, he is obliged to lock the machine against unauthorized use and against selfrunning. Take off the key, locking the brake, disconnect the electrical installation by the isolator, lock the cab, ...

• Upon parking the vibration roller on the road all the measures required as per the road regulations in force shall be carried out.

• After work is finished, the machine is to be placed on a suitable place, where it cann´t collide with the traffic, where the stability of the machine is not endangered (soil flows or sinking down), where is no danger of falling objects (rocks etc.) and where danger of other kinds of natural disasters is limited (floods, fire etc.).

• If the machine must be left on a public road, all activities required by the road traffic regulations must be done.

• When work is finished, all failures and damages of the machine are to be written into the operation book.

When the drivers are changing, the next driver must be noticed of all such matters.

• The driver must wear the protective clothes - working suit, working shoes. The suit must not be too loose, damaged, the hair have to be protected by suitable head-cover. When doing the maintenance (lubrications, refuelling, changing the working devices) the hands have to be protected by suitable gloves. The driver must wear headsets effective against noise on a machine without cabin or while driving to 3rd speed.

• Maintain the machine installations by appropriate machine accessories and sets.

• Keep the driver´s post, footboards and climbing-iron perfectly cleen.

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AP 240

Operating Instructions 2.1.4.

Prohibited Activities

• to change the driver´s post from left to right and vice versa

Is prohibited

• to use the machine after consuming some spirits or narcotics

• to use of the machine, when its activity may endanger its technical shape, safety (health or life), of the people, property or for example traffic.

• to use the machine if there are some personnel within the reach of the machine - with exception of training provided by authorized lector.

• to use the machine, if any of its safety installation are dismantled or damaged (emergency brake, safety beacon etc.).

• to travel and compact within such a leans, where is danger of distability of the machine (turnover). The mean static stability of the machine is degraded by the dynamical effects of travel.

• to travel and compact within such a leans, where is a danger of soil flow down and burying the machine, or the adhesion lost and nondrivable slip.

• to drive the machine in other way then as specified in the manual.

• to travel and compact within such a range from edges of slopes and heaps according the weighting of the earth, where is danger of soil flow down and burying the machine.

• to travel and compact within such a range from edges of slopes, walls and heaps, where is danger of soil flow down and burying the machine.

• to carry and transport personnel on the machine.

• to work with the machine, if another machines or other transport means are within the threat reach of it, with exception of these working with collaboration with the machine.

• to leave the driver´s post when the machine is running • to get in or get out the machine when it is running • to sit on the external parts of the machine when it is running

• to leave the unsecured machine - to leave the machine without the appropriate secure against its misuse

• to put off operation any safety, protective or emergency equipment or to change their operational features.

• to use that machine, where is a leak of fuel, oil, coolant or next fillings.

• to start the engine in another way then described in the manual.

• to place on the driver´s post another kind of things then personal needs (i.e. tools, kits).

• to put the material and next parts on the machine.

• to clean the machine while it is running • to make the maintenance, cleaning and repairs, until themachine is secured against the move and accidental running, and until is eliminated the contact of the worker with moving parts of the machine.

• to touch the moving parts of the machine with the body or with equipment and tool handed

• to smoke and workwith naked flame when inspecting the fuel or refueling, when changing, filling the iol, lubricating the machine, and during the accumulator check a refilling.

• to carry the rags full of flammables or flammables in open vessels on the machine (in a engine space, in the cab).

• to run the engine in a closed spaces.

• to work with the machine in such a place, where the driver cann´t see from the driver´s post and where could exist the danger for other personnel and property, until sufficient work safety is reached for ex. by means of signalizations by adequately trained person.

• to work with the machine in the protective area of highvoltage viring and transformer stations.

• to run across the power cables, if they are not sufficiently protected against mechanical damage.

• to work with the machine at a low visibility and at night, until the working area and the jobsite is sufficiently illuminated.

AP 240

CAUTION !

ADDITIONAL LOAD comprises 2pcs and will be attached, if required by a client, from the bottom to the machine frame at the manufacturer. It is therefore considered the integrated part of the machine. Any handling of the weight is hazardous and is forbidden.

In case of a need, please contact your dealer !

31

2.1.

The main safety precaution

2.1.5.

Safety signs and symbols marked on the machine

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AP 240

Operating Instructions 1.

Risk of burn

Do not touch the hot parts of the machine until you have checked they are cold enough. Hazard of burn. (Symbol locted at the suction filter bracket)

2.

Risk of injury

Do not touch the rotating parts when the engine is running. Risk of injury and being caught. (On the cooler)

3. Adjust machine while switched OFF

Do not make adjustment and maintenance while the motor is running. Risk of injury and hand capture in the rotating parts of the machine. (On the dashboard)

4.

Read instruction manual

Read thoroughly safety measures and the way of controlling the machine, its units, contained in the manuals supplied with the machine. (On the dashboard)

5.

Manual

On the box of seat backrest.

6.

Disconnet a.c.generator

Disconnect a.c.generator before welding on the machine!

(Symbols on the dashboard)

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33

2.1.

The main safety precaution

7.

Fasten the seat belt

Fasten the seat belt before starting to go with the machine.

(Symbol located on the control panel)

8.

Hanging figure

Use the rigging of adequate loading capacity to lift the machine.

(Symbol located on the left side of the frame behind the cab

9.

Hanging points

Hang the machine in these points (Symbol located near the mounting lugs on both sides of the frame)

10. First-aid kit

Symbol of the first-aid kit box. (Symbol located underneath the left seat)

11. Noise emission

Outside noise of the machine (Symbol located on the frame’s left side).

12. Ear protection

Wear ear muffs when there is no cab installed with the machine.

(On the control panel’s left side)

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AP 240

2.2.

Environmental & Hygienical Principles The user must observe general rules of health and environment protection, and all applicable laws, notices and regulations in the country of use, when operating or parking the machine.

2.2.1.

Hygienic fundamentals

Oils, radiator, brake systems and accumulators fillings and paints including thinners are health threating materials. Workers in contact with these products during the driving or maintenance of the machine are obliged to obey common rules of the health protection and and follow the safety and hygienical manuals from the manufacturers of this products.

2.2.2.

skin protection when working with oils, radiatior or brake liquids, with paints

-

proper washing the hands after finishing the work and before the meal, treat the hands with appropriate reparational cream.

-

when working with cooling systems obey the maintenance manual

Oils, radiator, brake systems and accumulators fillings and paints including organic thinners and also cleaning and conservational means always keep in original properly signed vessels. Don´t allow the storing of these materials in non-signed vessels and other bottles due to danger of exchange. Extremly dangerous is a possibility of exchange with meal or drinkables.

Ecologic fundamentals

The fillings of individual machine systems and also some parts are after blackout the garbage risc for the enviroment.

To this category of waste products includes: - organical and synthetic lubricants, iols and fuels -

brake fluid

-

cooling liquid

-

accumulator filling and accumulators themself

-

the conditioner systems fillings

-

cleaning and conservational materials

-

all dismounted filters and filter inserts

-

all used and blackouted hydraulic and fuel pipes, rubber steels and other machine parts, contamined by materials above

We emphasize on: - eyes and skin protection when working with accumulators -

Operating Instructions

Producer and contractual service organizations accredited by him, or dealers take back the following materials or parts free of charge: -

oils

-

batteries

-

tyres

With materials and parts listed we must work after blackout according to the appropriate national regulations for individual enviroment parts protection andaccording to the health protection regulations.

In the case of acidental stain of the skin, mucous membranes, eyes or of inhalation of the vapour, aply immediately the first aid. In such case find the emergency first aid by the doctors.

AP 240

35

2.3.

Conservation and Storage of the machines

2.3.1.

Short-term storage of 1 to 2 months

Wash and clean the machine thoroughly. Warm up the engine to operating temperature 85 °C before starting conservation for storage. Place the machine on a firm and flat surface in a secure location where there is no danger of damaging the machine by forces of nature like floods, landslides, fire, etc.

2.3.2.

Conservation and storage for more than 2 months

Same rules for short-term storage apply here as well, moreover, -

remove batteries, check condition and store in a dry, cool room – recharge battery regularly,

then - repair any defective lacquer

-

support the drum frame so that the shock absorbing system is not loaded,

-

grease all lubrication places, cables, lever elbows, etc.

-

protect rubber components with a layer of special conservation preparation

-

check that water tanks are drained

-

-

check whether the refrigerant is frost resistant

inflate tires to prescribed pressure and protect them against direct sunshine

-

check the charge of batteries and recharge if necessary

-

cover chrome plated surface of pistons with conservation grease

-

cover chrome plated surface of pistons with conservation grease

-

for conservation spray the machine with a special preparation particularly in places subject to possible corrosion

-

we recommend to protect the machine against corrosion by spraying it with conservation means, mainly in spots endangered by corrosion.

-

cover exhaust and intake of the engine with double PE foil and sticky tape over it

-

protect headlights, outside rearview mirrors and other electrical components outside by spraying over them special preparation and covering with PE foil,

-

conserve the engine as instructed by manufacturer and leave a sign that the engine has been conserved.

A machine that has been treated in this manner doesn’t require any special processing before next use.

! NOTE !

We recommend that you inspect the conservation condition. After 6 months inspect and renew if necessary.

Do not start the engine while stored!

If the machine is stored outside, check whether the site is not in danger of being flooded in case of bad weather or endangered in any other way.

Before starting operations again, wash off conservation with high-pressured 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.

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AP 240

Operating Instructions 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 with high-pressured 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.

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37

2 . 4 . Machine dispose after its lifecycle By the machine dispose after its lifecycle is the user obliged to obey the national regulations and laws about wastes and enviroment protection. We recommend to use in such cases always -

specialized companies, with a professional prime activities on this field and with appropriate licence

-

to manufacturer or by them delegated acredited contractor service organizations.

! NOTE !

Manufacturer is not responsible both for the damages on the owners health and the damages caused on the enviromet in the cases of infringement of upper specified hygienic and ecologic fundamentals.

38

AP 240

2.5.

Machine description

Operating Instructions

Rubber-tyred compactor AP 240 (machine description)

1 - Frame

15 - Fuel tank

2 - Engine

16 - Cowling

3 - Gearbox

17 - Driver’s post

4 - Liquid + oil cooler

18 - Sprinkling tank

5 - Equalizing tank

19 - Tires sprinkling

6 - Propeller shaft

20 - Wheels

7 - Differential final drive

21 - Scrapers

8 - End transmissions

22 - Protective frame ROPS

9 - Front axle

23 - Extensive weights

10 - Telescopic cylinders

24 - Loading and covers

11 - Working brakes (at the rear axle)

25 - Exhaust extinguisher

12 - Parking and emergency brake

26 - Suction filter

13 - Servo driving

27 - Seat

14 - Hydraulic tank

AP 240

39

2.6.

Controls and Control Devices

Table with the symbols applied

40

AP 240

Operating Instructions 1 - Oil pressure in gearbox 2 - Oil temperature in grearbox 3 - Engine temperature 4 - Brake circuit (air) pressure gauge 5 - Tyre gauge 6 - Fuel gauge 7 - Battery charging – signal lamp 8 - Parking brake – signal lamp 9 - Neutral – signal lamp 10 - Direction lights (switch + signal lamp) 11 - Engine lubrication – signal lamp 12 - Brake failure – signal lamp 13 - Air filter clogged – signal lamp 14 - Sprinkling of tyres – signal lamp 15 - Front lights - switch + signal lamp 16 - Rear lights - switch + signal lamp 17 - Warning lights – switch + control lamp 17 - Warning beacon - switch + control lamp 19 - Differential interlock – switch + signal lamp 20 - Sprinkling switch - interval 21 - Emergency brake pushbutton 22 - Horn 23 - Windshield washer switch 24 - Front wiper switch 25 - Rear wiper switch 26 - Fan switch 27 - Heating control 28 - Recirculation flap controller 29 - Air conditioner control 30 - Air conditioner switch 31 - Bonnet release control 32 - Tyre inflating controller 33 - Tyre blowing off controller 34 - Battery disconnector 35 - Switchbox

AP 240

41

2.6.

Controls and Control Devices

Controls and Control Devices

42

A - Signal lamps

11 - Fuel gauge

B - Switches

12 - Revolution counter

1 - Steering wheel

13 - Active workplace - signal lamps

2 - Travel Controller

14 - Emergency brake pushbutton

5 - Gearbox lubrication pressure gauge

15 - Sprinkling – switch + cycle control

6 - Gearbox thermometer

16 - Fuses

7 - Engine thermometer

17 - Switchbox

8 - Brake circuit pressure gauge

18 - Tire inflating

9 - Tyre pressure gauge

19 - Tire air relief

10 - Hourmeter

20 - Disconnetor

AP 240

Operating Instructions Travel Control (2)

Accelerator (3)

Use the travel control to adjust the direction of running (reversation) and gear control via a twist grip (A). „F“ position - forward „R“ position - reverse

Used to control the engine speed.

4

3

Brake Pedal (4) Used to control rear wheel brakes.

Travel control includes a fuse While in ”N” position – no shifting of the control from neutral is possible.

When In ”D” position – travel control functions can be used.

AP 240

43

2.6.

44

Controls and Control Devices

AP 240

Operating Instructions INSTRUMENTS Tyre Pressure Gauge (9) Gearbox Oil Pressure (5) Oil filling pressure must stay within 12,5-15,5 bar.

Minimal air pressure following the release of pressure from tyre has been adjusted to 1,5-2 bar.

WARNING! Stop the machine immediately when pressure drops below 12,5 bar.

Hourmeter (10) Indicates hours of running engine. After battery charging lamp goes off the hourmeter starts counting (adding) regardless of engine operating speed.

Gearbox Oil Thermometer (6) Temperature can move within 80 - 120 °C. Maximal temperature is 120 °C.

Engine Temperature (7) Engine operation temperature can move within 80 - 100 °C.

Fuel Gauge (11) When fuel drops below 16 l the lamp signals minimal fuel level.

Revolution Counter (12) Optional item of the machine.

Brake Circuit Pressure Gauge (8) White indicator shows air pressure inside ir-brake reservoir – adjusted to max. 7,5 bar.

Red indicator shows air pressure when braking – air pressure from air brake valve to the booster.

AP 240

45

2.6.

46

Controls and Control Devices

AP 240

Operating Instructions CONTROLS Active Workplace Signal Lamps (13) Both of the Signal Lamps are OFF – starting the engine is possible now Turning the ignition key of the switchbox to ”1” position the neutral position lamp goes ON, and lamps (13) do not light. Both of the travel controllers are in ”N” position.

Lamp is ON – driver’s cockpit ENABLED Start the engine and engage travel controller to “F” or “R” position, and the lamp (13) on the left or right side of the driver goes ON while the neutral position lamp goes OFF simultaneously.

WARNING! With the parking brake NOT braked the machine will start moving following gear engagement.

Both of the lamps are flashing – impossible to start the engine Turning the ignition key (17) to ”1” position both of the lamps (13) start flashing and the neutral position lamp does NOT light since one or both of the travel controllers are NOT in “N” position.

F7 (5A) - differential interlock signal lamp, engine lubrication signal lamp, brake failure signal lamp, parking brake, air filter-clogged signal lamp, engine temperature, gearbox temperature, fuel gauge, gearbox lubrication pressure gauge F8 (15A) - wipers, washer F9 (10A) - sprinkling F10 (25A) - fan F11 (10A) - elektromagnetic clutch of air conditioner compressor F12 (7,5A) - relay, stop engine, emergency brake, differential interlock switch

Switch Box (17) There are three positions, i.e. 0-1-2. In ”0” position the consumers of 1-5 fuses i.e. machine illumination & portable lamp connector are connected. In ”1” position the remaining consumers are connected. “2” spring loaded position is used to start the engine. stop the machine by turning the key to “0” position; the key can then be removed.

NOTE Concerning cabinless machines protect the ignition box by folding the box cover and using protective cover after having removed the key.

Emergency Brake Pushbutton (14) Used to stop the engine instantaneously in case of emergency (machine stops with its engine OFF) .

Sprinkling Switch (15) Turn the switch leftward and the pump starts running continuously – tyres are sprinkled constantly.

Turn the switch to some of the four positions rightward and the sprinkling cycle interval is ON. Position I 10 s Sprinkling 10 s Dwell Position II 10 s Sprinkling 15 s Dwell Position III 10 s Sprinkling 22 s Dwell Position IV 10 s Sprinkling 33 s Dwell Sprinkling lamp is ON only when the pump is running.

Tyre Inflating Control (18) Used to replenish air into the tyres.

Tyre Deflating Control (19) Used to deflate tyres.

Pressure gauge (9) indicates air pressure in tyres.

WARNING! Do NOT swiitch both of the valves simultaneously into “I” position!

Battery cut OFF switch (20) Fuse Box (16)

Cuts OFF the minus pole of the battery from the frame.

Contains fuses of the following devices: F1 (5A) - dashboard illumination, left front parking light, left rear light F2 (5A) - right front parking light, right end light F3 (15A) - front lights+ signal light F4 (15A) - rear lights + signal light F5 (20A) - Warning beacon, cabin illumination, brake lights, direction indicators, portable lamp connector F6 (5A) - travel control, steering-enabled signal lamp, forward-backward travel electromagnets

AP 240

WARNING! Following work completion make sure to use the battery cut OFF switch do disconnect the battery!

47

2.6.

Controls and Control Devices

Direction Indicators – Signal Lamp With direction indicators ON this signal lamp flashes up (flickers) at the workplace enabled.

Engine Lubrication – Signal Lamp When this lamp goes ON while the machine is running it indicates insufficient oil pressure within the lubrication system. Switch the ignition key to “1” position and the signal lamp must light – following the engine start the lamp goes OFF.

WARNING!

SIGNAL LAMPS

If this signal lamp is ON during idle engine speed you must shut off the engine and check oil amount, cable leading to the oil pressure switch, or the switch itself.

Battery Charging - Signal Lamp Switch the ignition key to ”1” position and the signal lamp goes ON, start the engine and the lamp goes OFF.

Parking Brake – Signal Lamp Brake off and the lamp goes OFF. When air has escaped from the system (air-brake reservoir) following a longterm shutdown of the machine, then you must wait before moving the machine until pressure gauge (8) indicates air pressure of 5,2 bar.

Neutral Position – Signal Lamp The lighted lamp signals both of the controls are in their “N” (neutral) positions.

Brake Failure – Signal Lamp This lamp lights up when pressure in the air reservoir drops below 5,2 bar – there is intermittent acoustic signal as well.

Air Filter Clogged – Signal Lamp When this signal lamp lights up you must clean or replace the main cartridge.

Tyre Sprinkling – Signal Lamp When this signal lamp lights up the pump is running.

NOTE: Start the engine with both of the controls in their neutral positions.

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AP 240

Operating Instructions SWITCHES Front lights switch + signal lamp Use this switch to turn ON the front headlights and rear parking lights.

Rear lights switch + signal lamp

Warning light switch + signal lamp

Beacon switch + signal lamp - optional

Differential lock switch + signal lamp Machine’s option

Parking brake switch + signal lamp Standard appointments of the machine

Horn Pushbutton

Indicators - Toggle Switch Toggle the switch to the right or left and the direction indicator of the selected side will flash up together with its signal lamp. You can use toggle switch at the enabled workplace only.

AP 240

49

2.6.

Controls and Control Devices

SWITCHES INSIDE THE CABIN

„B“ VENTILATION-HEATING

„A“ CANOPY SWITCHES Fan Switch Windshield washer switch Three-position & two-speed switch The fan provides for air circulation & air exchange inside the cabin – used to blow front & rear windows.

Front wiper switch Recirculation Flap Control Rear wiper switch

Position this one to control the amount and ratio of air induced from outside and inside the cabin.

„C“ Dome lamp switch Heating Control Designed to control air temperature.

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AP 240

Operating Instructions Vacuum Pressure Compensating Device Air Conditioner Control – by special order

Open the flap to avoid vacuum pressure within the cabin space with the fan turned ON.

Designed to control cooling intensity.

Air Conditioner Switch – by special order Note: ”Air Conditioner Manual” supplied attached.

Heating Vents Tilt to adjust the amount of fresh air flowing into the cabin; swivel to adjust its direction

Cabin Ventilation Air Filter It comprises a replaceable cartridge where induced air contaminats are trapped.

Its change period depends on dust nuisance where the machine operates.

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51

2.6.

Controls and Control Devices

Driver’s Seat Adjustable, sprung, fitted with two-point retractor belt.

Adjust horizontal seat – raise the handle to move the seat longitudinally forward or backward.

Driver must fasten the seat belt when driving!

Seat Adjusting Elements: Adjust backrest inclination – raise the lever to tilt the backrest infinitely as necessary.

Adjust seat squab - grasp the seat squab to raise gradually the seat height to another position where it locks (clicking sound). Once raised to its highest position the seat goes down back to its lowest position.

Adjust seat spring stiffness - turn the catch (1) to adjust stiffnes per driver’s weight indicator (2) ranging from 50 to 130 kg (110 - 266 lb) by 10 kg (22 lb).

1

2

! NOTE !

Adjust your seat before driving!

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AP 240

Operating Instructions Box for Documentation Situated at the backrest’s rear section. Fold out the back wall of the seat to open the box.

First Aid Kit There is a locker underneath the left seat to store first aid kit, logbook, reports, etc.

Note: Pneumatic Accumulator Drainage Valve

Use the box underneath the right seat to store your logbook, reports, etc.

Use this valve to operate the drier or to drain condensate from pneumatic accumulator. Pull the chain on the floor near the left seat to operate.

Portable Lamp Connector Use to connect auxiliary portable lamp 12 V on the control console’ s right side.

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53

2.6.

Controls and Control Devices

Bonnet Release Control

Windshield Washer Tank

Pull the control lever to release the bonnet lock.

Replenish with clean soft water – preferably the distilled one – complete with cleaning and degreasing agent.

When lifted secure with bonnet stay.

Fill the tank with antifreeze before winter season or drain!

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AP 240

2.7.

Operating Instructions

2.7.1.

Starting the Engine

Operating Instructions • Turn ON battery disconnector (20).

• Turn the key (17) to ”I” position. Confirm the charging

WARNING! Before starting up the engine, check levels of oil int the engine and hydraulic tank, fuel in the fuel tank, amount of oil in the gearbox, brake fluid level. In addition, confirm no machine’s parts are loose, worn or missing.

, motor lubrication, neutral, parking brake – machine braked – signal lamps light up. Active steering (13) signal lamps must not flash – otherwise impossible to start.

Blow horn before starting the engine and confirm nobody is endangered by starting the engine!

Start the engine from the driver’s stand only!

Startup Procedure:

• Make additional fuel pumping via hand feed pump on the engine after long machine shutdown.

• Confirm both of the travel controls are in neutral position.

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55

2.7.

Operating Instructions

• Turn the ignition key (17) to „2“ position – start the engine.

Start with the idle engine speed, do NOT actuate the accelerator pedal when starting.

WARNING! NEVER start the engine by towing the machine!

Starting voltage of the external starting source must be 12 V. Follow the procedure for connecting the starting cables: 1. Connect one terminal of the (+) cable pole to the (+) pole of the flat battery.

2. Connect the other terminal of the (+) cable pole to the (+) pole of the battery in the supporting machine.

3. Connect one terminal of the (–) cable pole to the (–) pole of the battery in the supporting machine.

4. Connect the other terminal of the (–) cable pole to the part of the part of the started machine that is securely connected to the engine (or the engine block itself)

Repeat starting procedure 3 times at most.

NOTE: Unless the motor starts even with 3 trials made – then detect the cause in fuel system. When starting, please watch exhaust gas colouring – any absence of blue or white fume indicates the fuel supply is insufficient.

WARNING! • Do NOT start longer than 30 seconds. Wait for 2 minutes before next starting.

• The charging and lubrication signal lamps must go OFF after starting up the engine.

Lubrication signal lamp must go OFF within 15 sec.

• Do NOT run up the engine or reduce the engine speed rapidly – these may damage the engine.

• After starting up let the engine run with no load at increased idle speed 1500 min–1 for 3÷5 min. depending on outside temperature until the brake system makes up to the pressure of 5,3 bar.

• Do NOT let the engine run at idle speed for more than 10 minutes – any longer idle run will cause clogged fuel injection nozzles, sticking of piston rings, valve seizure!

• Unless the temperature of cooling liquid reaches min. 60 °C the engine is not lubricated enough - do NOT apply full engine power!

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AP 240

Operating Instructions 2.7.2.

Travel & Reversing Give the acoustic signal before starting driving the machine and wait for a period long enough for all persons to be able to leave the danger area (area under the machine) in time!

• Use travel control (2) to select driving direction, ”F” for forwarr or ”R” for reverse, driving ENABLED – signal lamp (13) lights up, and Neutral Position – signal lamp goes OFF.

Confirm the area in front and back of the machine is free and that no persons are present within this area!

Machine Driveaway

• Confirm the travel control fuse is in ”D” position.

• With the idle engine speed turn the gear selector (A) to select the gear , e.g. 1st gear.

• Press the button to brake off the machine – signal lamp goes OFF.

• Increase engine speed via accelerator pedal – machine starts moving in the selected direction.

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57

2.7.

Operating Instructions

Selecting Driving Direction When changing direction of running you should slow the speed down to about 3 km/h (1,9 MPH), then it is possible to reverse for the second driving direction. Reverse to the 1st or 2nd gear according to the machine load and terrain slope – NEVER reverse to the 3rd speed.

Gear Control Use Power shift (A) to engage gears 1÷ 3 while driving – upon machine operation or moving on its own.

NOTE: When engaging one travel control (2) from ”N” to ”F” or ”R” the ENABLED workplace - signal lamp will light up.

All the commands, i.e. driving direction change, gear control, switching ON the direction lights at the driver’s DISABLED point (on the second side) are non-operable!

ENABLED workplace – signal lamp will go OFF with the engine shut off.

WARNING! With the driving direction selected via the control the machine with its brake released starts moving slowly.

Do NOT alter your place from left to right and vice versa while driving!

Do NOT use 3rd gear to start moving! Do NOT reverse to 3rd speed!

Keep the engine at higher speed to ensure better steering manoeuvrability of the machine.

Do NOT drive at low speed at higher gear! When decelerating you should gear down in time!

When changing down from high gear to low one you should decelerate the machine adequately.

Prior to driving down a steep slope, engage 1 st gear!

If oil temperature inside the gearbox rises to 120 °C, stop working, stop driving and while staying on the spot with the increased engine speed of 1500.min–1 (RPM), cool down the gearbox oil to optimal 80-100 °C. When oil heats up to 120 °C rather frequently, alter the driving manner – i.e. shift more frequently, clean the oil cooler!

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AP 240

Operating Instructions 2.7.3.

Stopping the Machine & Engine

• Secure the machine with parking brake – signal lamp goes ON

• Lower the engine speed to idling one.

• Engage neutral position

• Stop the machine

• Switch the key to ”0” position to stop the engine, take out this key from the ignition box (17).

NOTE: Close the ignition box cover to protect it once the key has been taken out.

WARNING! Do NOT stop the engine immediately, instead let it run for 3÷5 minutes at idle speed of 800min-1.

ALWAYS use the parking brake control to brake the machine before stopping its engine – when in braked condition the signal lamp goes ON. Then turn OFF the igniton box.

Protect your dashboard with cover when the machine has no cabin.

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2.7.

Operating Instructions

2.7.4.

Changing ENABLED workplace position

• Brake OFF – signal lamp of this brake goes OFF.

• Shift the travel control to neutral position – signal lamp lights up.

• Use travel control to select direction of running – • Stop and apply the parking brake – signal lamp goes ON.

ENABLED workplace signal lamp (13) goes ON, neutral position signal lamp goes OFF – workplace ENABLED.

• Change the seat.

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AP 240

Operating Instructions 2.7.5.

Parking, Dead Parking of the Machine

• Stop the machine on even and firm surface. Check the place of parking for no natural hazard (landslides, floods, etc.).

• Turn OFF the battery disconnector and remove the lever, slip the cap over.

• Clean the machine from dirt (scrapers and tyres).

• Carry out overall machine checkup and repair any defects arisen during its operation.

• Check the tyre pressure and inflate to maximal pressure of 7,5 bar.

• Brake the machine using its parking brake, secure the

2.7.6.

Emergency Stopping

! NOTE !

Use this way of stopping in case of defect, when the machine cannot be stopped via the driving brake using the pedal, or impossible to apply the parking brake control, or unable to shut down the engine with the ignition key.

• Press one of the buttons – machine stops (brakes) and the engine is shut OFF.

• Turn the buttons a slight amount in arrow direction to release the brake.

wheels and drum with scotch blocks (if the machine is equipped therewith).

• Lock the cabin (or the dashboard cover when the machine has no cabin).

WARNING! Before restarting the engine confirm both of the travel controls are in their neutral positions and the emergency brake button is released (signal lamps 13 must not flash up with the ignition box switched ON, and the neutral position signal lamp must go ON & the brake lamp must go OFF).

NEVER apply emergency brake during normal operation to stop the machine or shut down its engine.

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2.7.

Operating Instructions

2.7.7.

Driving the Machine Under Heavy Conditions

Turn ON the differential lock switch when driving in difficult terrain, with lowered adhesion causing a drive slip. Signal lamp indicates the differential lock switched ON.

2.7.8.

Operating the Machine During BreakIn Period

Do NOT load the machine at its full capacity when putting a new machine into operation or following a major overhaul during its first 30 hours.

WARNING! Use the differential lock only when rescueing a sunk machine! Switch OFF the differential lock right after the heavy conditions were overcome – risk of differential or tyres being damaged.

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AP 240

2.8.

Transporting the Machine

2.8.1.

Transportation by Its Own Axle

The roller may move by its own axle between the locations outside public roads.

! NOTE !

Follow safety measures specified for the location when making a shift.

2.8.2.

Transporting the Machine by a Public Road

! NOTE !

Basic construction of the the machine has not been equipped for transportation by a public road using its own axle and its transport is FORBIDDEN. You are allowed to transport the machine by a public road using a carrier that corresponds to actual curb mass of the roller.

BE CAREFUL ABOUT THE MASS OF THE WEIGHT!

Refer to fig. for the method of securing a transported machine.

Operating Instructions Brake and mechanically secure against undesired move using scotch blocks 3 when loading & unloading the machine for its transportation.

If the machine is fitted with differential lock – then turn ON the differential lock before driving up the carrier’s ramp!

A person that guides the machine must communicate with the operator using specified intercommunication signals. He/she must stay constantly at one spot outside the reach of the machine and out of the way of the carrier. He/she must be within the field of view of operator (in visual contact) throughout the machine drive-up & drive-down.

During drive-up & drive-down the carrier all the personnel must move away as far as possible except for the machine operator, so as not get hit when any accident (fall of the machine) occurs.

No persons are permitted to stay inside cabin (on the ramp), on the machine or carrier’s loading area during transportation of the machine.

Anchor and mechanically secure the machine on the carrier against its longitudinal as well as side movements and against its upturn (1).

Drum the wheels with scotch blocks (2).

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63

2.8.

Transporting the Machine

2.8.3.

Transporting the Machine by Rail

You can use railway platform wagon to transport the machine. The height of the wagon together with the roller may not exceed a clearance designed for inland as well as international transportation. In case of exceeding the clearance size (international gauge loading) you will have to dismantle the cabin and the protective frame as well as the exhaust. Observe provisions of the regulations concerning carriage by rail when transporting.

2.8.4.

Loading of the Machine

It is best to use drive-up ramp. If not available, use a crane. The roller is equipped with lifting eyes for loading by crane.

NOTE: Should the total transportation height (height of the carrier from the ground to the cargo area + overall machine height) be higher than admissible, you must dismantle the protective frame, the cabin.

WARNING !

When using the ropes less than 8m (26.3ft) long, insert a cross bar (A) 1.95m (6.4ft) long between the ropes overhead the cabin.

BDZ CH CFL CFR CD DB DSB JZ MAV NS ÖBB PKP TCDD ZSR

64

Bulgarian RR Greek RR RR Company of Luxembourg Romanian RR Czech RR German RR Danish RR Yugoslavian RR Hungarian RR Dutch RR Austrian RR Polish RR Turkish RR Slovakian RR

AP 240

Operating Instructions 2.8.5.

Dismantling ROPS Frame & Cabin

• Remove the frame from the machine using hoisting equipment.

Dismantling ROPS:

• Dismantle the covers (1) behind the seats.

• Insert the cover (4) on the gaps of ROPS (supplied with the machine).

1 4

• Dismantle the bolts away from ROPS frame and mount

• Reinstall the panels (1) behind the seats again.

the lifting eyes, hang the frame onto the crane.

Proceed in reverse order when mounting back.

NOTE. Frame mass of 450 kg.

Hang the frame by ALL the lifting eyes.

Use lifting equipment and rigging of sufficient loading capacities.

• Screw the nuts (2) off. Pull the bolts (3) out from the

NEVER step under the hanging load!

machine frame via a hole behind the seats.

2 3

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2.8.

Transporting the Machine

Dismantling the Cabin

• rear right

• Remove the bolts alongside cabin’s periphery at the front right.

• Disconnet wiring between the cabin and the machine.

• front left

• rear left

! NOTE !

Use only the specified lifting eyes for rigging.

Use lifting equipment & rigging of adequate loading capacities.

NEVER step under the hanging load!

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AP 240

Operating Instructions 2.8.6.

Towing

• Dismantle.

• The machine is fitted with the front towing lug with the pin secured with a locking catch.

• Screw bolt (1), (2) in to the suspension cylinder (3).

• Dismantle floor cover in between the seats.

1

2 3

NOTE:

ge.

Brake the machine OFF via bolt (1), (2) in case of insufficient air pressure 5,3 bar and there is no way how to make up the pressure since the engine does not work. The bolt is part of machine outfit.

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67

• Dismantle the joint shaft within the gearbox inlet flan-

2.8.

Transporting the Machine

! NOTE !

In case the rear axle drive is not disconnected, then you must relieve it when towing the machine!

Check air pressure when towing the machine. It must NOT drop below 5,3bar.

Use unimpaired towing cables or towing eyebars of sufficient loading capacity - dimensioned to weight 1.5 times higher than the weight of towed machine.

NEVER use chains for towing purposes. NO person is allowed to remain on towed machine with its engine not working.

Keep deflection from the straight towing angle as little as possible. Maximal deflection permissible is up to 30°.

Maintain smooth continuous movement while towing. Do NOT exceed towing speed of 10 km/ hod (6 mph).

Do NOT tow the machine for distances over 300 m (0.19 mil).

The hauling machine should be equal by size to the damaged one. It must have sufficient pulling power, weight and brake effect.

When towing downhill using a cable you must attach another pulling machine to the rear section of the damaged machine. This will prevent uncontrolled movement of the failed machine.

NOTE These are general requirements for safe towing of a damaged machine under standard conditions. Consult with your dealer any specific conditions that may occur when towing.

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AP 240

2.9.

Using the Machine Under Special Conditions

Operating the machine in higher altitude In higher altitude, engine power output decreases depending on elevation.

Altitude in m 0 500 1000 1500 2000 2500 3000

(ft) 0 (1640) (3281) (4921) (6562) (8202) (9843)

Power Output Decrease 0 3% 6% 10 % 15 % 21 % 28 %

Operating Instructions

Operating the Machine at Higher Temperature and Humidity Engine power output decreases with increasing temperature & air humidity. · every 10 °C of temperature rise results in power output decline of up to 4% (at a constant humidity), ·

every 10 % of relative humidity rise results in power output decline of up to 2 % (at a constant temperature).

Engine power output will be affected by the environmental conditions where the machine operates.

If the engine produces black exhaust fumes in the altitude above 1500 m, contact a service organisation of the engine manufacturer (refer to Engine Operating & Maintenance Manual) that will set up your injection pump for these operating conditions.

Operating the Machine in Dusty Conditions Shorten intervals of cleaning & replacing suction filter elements, shorten the intervals of cleaning the engine cooler, replacement of cabin’s dust filter. Refer to the Machine Maintenance Table.

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2.10. Tyre Inflating Pressure Contact pressure, effective width & surface in relation to the single wheel load and tyre inflating pressure.

(For 11.oo x 20" plain-tread tire)

MEAN GROUND CONTACT PRESSURE (kPa) Load on the wheel (kN) 11,00 - 20 Compactor

Infloation (kPa)

12,75

14,71

19,61

24,52

29,42

300

312

332,7

369,6

405,6

427,5

600

381,4

403,7

452,4

484,1

525,4

700

410,8

427

462

494,9

544,3

800

436,2

447,9

492

529,9

575,2

900

473,8

487,2

521,4

562,1

594,1

1000

509,8

513,3

530,7

586,5

623,6

W I D T H O F C O N TA C T A R E A (mm) Load on the wheel (kN) 11,00 - 20 Compactor

Infloation (kPa)

12,75

14,71

19,61

24,52

29,42

300

278

280

281

282

283

600

278,2

279

280

282,3

283

700

277

279

281

282

283

800

274,5

279

282,5

282

283

900

270

276

280,5

282

283,5

1000

265,5

275

280

281

283

CONTACT AREA (cm2) Load on the wheell (kN) 11,00 - 20 Compactor

Infloation (kPa)

70

12,75

14,71

19,61

24,52

29,42

300

408,7

442,1

530,6

604,5

688,2

600

334,3

364,4

433,5

506,5

560

700

310,5

344,5

424,5

495,5

540,5

800

292,3

328,4

398,6

462,7

511,5

900

269,1

301,9

376,1

436,2

495,2

1000

250,1

288,6

369,5

416,1

471,8

AP 240

Operating Instructions

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71

Notes:

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AP 240

3.

AIR CONDITIONER

AIR CONDITIONER AP 240 (Cummins Tier II)

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73

Air conditioner Air-conditioning system description

Air-conditioning circuit

The compressor (1) sucks up refrigerant vapours from the evaporator (5) and forces them into the condenser (2). In the condenser the refrigerant vapours change their condition into liquid state and flow via the filter-drier (3) to the thermostatic expansion valve (4) - TEE. The TEE injects the liquid refrigerant into the evaporator (5). There heat from the cabin is extracted, the gaseous state changes into liquid state, and the refrigerant vapours are sucked by the compressor.

1 - Compressor

74

2 - Condenser 3 - Filter-drier 4 - Thermostatic expansion valve (TEV) 5 - Evaporator 6 - Recirculation flap 7 - Air-blast nozzles

AP 240

Air conditioner Air-conditioning system controls 1 - Fan switch 2 - Recirculation flap controller (6) - controls the proportion of air sucked from the outside and from the inside of the cabin (white arrows) ”0” -air intake to the cabin is closed.

Air-conditioning system switching on

• Switch on the fan switch (1).

• Switch on theair-conditioning system switch (5).

• Set the controller (4) to a position between „MIN - MAX“ to select the required temperature.

• The heating controller (3) must be in the „0” position.

”MAX” - air intake to the cabin is fully open.

3 - Heating controller 4 - Air-conditioning system controller 5 - Air-conditioning system switch

NOTE When switching the air-conditioning system for the first time, set the controller (4) to a position corresponding to the required temperature in the cabin according to temperature measured by a thermometer.

! NOTE !

The air-conditioning system is only operating when the engine of the machine is running.

When the air-conditioning system is switched on, heating must be switched off by the controller.

To maintain the preselected temperature do not move the controller (4) after the air-conditioning system has been switched off.

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Air conditioner Maintenance

On-condition maintenance:

Every month:

• Clean the condenser vanes with compressed air or

• Check the filter-drier with the engine running. The

pressure water.

sight glass must be clear, without any visible bubbles.

It must not be steamed up or fogged.

• Clean the evaporator vanes with compressed air after • Check the belt of the compressor. Apply a force of

removal of the floor cover between the seats.

approximately 3 N (1.5 lb) on the longest part of the belt. The belt deflection must not exceed 10-15 mm (0.4-0.6 in).

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AP 240

Air conditioner Failures ! NOTE !

Always contact your dealer for trouble shooting!

If the unit does not cool check: 1. that the evaporator fan is running, and check the fuse No. 10 2. the refrigerant through the filter-drier sight glass there must be no bubbles, fogging, and the like.

3. that the electromagnetic clutch engages, with the engine running, after the air-conditioning system switchon. Listen if the clutch engages (a click on the compressor must be heard). If the clutch does not engage, either the fuse No. 11, or the thermoregulator, or the overpressure protection may be defective.

The refrigerant causes burns when it comes into contact with the skin or mucous membranes.

In the presence of open flame toxic gases are formed which can cause serious health problems or even death when inhaled.

In the event of leakage in small confined spaces the refrigerant vapours force out oxygen and can cause death by suffocation.

Always wear protective goggles and gloves when working near to the airconditioning system or on the airconditioning system.

First aid instructions Eye contact with liquid refrigerant - Flush immediately with large quantities of water. Seek immediate medical attention.

Skin contact with refrigerant - Wash the affected skin immediately with large quantities of warm water. Protect the burn with dry sterile gauze. Seek medical attention.

Inhalation - Move the person to fresh air. Apply artificial respiration if necessary. Call for medical assistance.

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Air conditioner

Notes:

78

AP 240

4.

MAINTENANCE MANUAL

MAINTENANCE MANUAL AP 240 (Cummins tier 2)

AP 240

79

80

AP 240

4.1.

Safety standards and other maintenance regulations

4.1.1.

Maintenance safety

4.1.2.

Fire regulations when changing the working fills

Lubrication, maintenance and the adjusting make only:

• With trained personnel • In the terms showed in the lubrication program chart or when checking the technical status.

• In the accordance with the safety, fire, ecological and hygienic standards as written in the Manual for the use of AP 240 Roller

• After cleaning the machine, lubrication places and maintenance places, repairs

• On the machine stopped on the horizontal stabile flat, secured against spontaneous moves by the parking brake, (scotches)

• When disconnected the electroinstalation using the disconnector and taken the starting key out

• During the operations, put the warning sign on the machine steering wheel :”Machine out of order”.

• on the cooled parts of the machine • Using the convenient tools in a good shape • The maintenance and the repairs of the hydrostatic and air delivery system make only according to the valid regulations. Before the maintenance or repair must be the delivery system out of pressure.

• By changing the parts and replacement of new original

From the danger of fire point of view are the used flammable fills on the machine differed to the danger classes: II

danger class - diesel fuel

IV danger class – mineral oils, greases

• The oil changing place must be placed such way to don’t overlap to the spaces with possible danger of explosion, fire.

• It must be signed by tables and signs of smoke prohibition and using of the live fire.

• The manipulating area must be so designed to catch the amount of flammable liquid equal to the biggest vessel, transport cover.

• It must be equipped with extinguisher fire.

• When manipulating with the oils, diesel fuel, use vessel such as metal vats, barrels, cans, metallic ewers.

• When storing, the transport vessels must be properly closed.

• The vessel must have only one leak, place the vessels always with the leak up and secure against the outflows and drops.

• The vessels must be marked by ineffaceable writing showing the content and flammable class.

parts. The manufacturer is not responsible for the damages caused using non-original parts !

• By downgraded visibility and in the night using the sufficient lightning of the whole machine

• By necessary dismounting the shelters and securing elements, when finished the work, mount it back

• By retighten the screw connections – using the tightening moment and check of the connections tight

• After warming the working fills – watch out for the burn ups – use the recommended fills.

! NOTE !

After made adjusting or maintenance check the function of all safety devices.

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4.1.

Safety standards and other maintenance regulations

4.1.3.

Ecological and hygienic standards

Ecological standards

When operating and maintening the machine the owner is obliged to keep the common regulations of health and environment protection and the laws, regulations and promuglations, correlative to this problems and valid in the region of the machine use.

Hygienic standards The petroleum products, cooling systems fills, accumulators, brake liquids and fills and paints including the thinners are harmful materials. Workers that come into contact with these materials during the service and maintenance of the machine, are obliged to keep the common standards of health protection and they must keep the safety and hygienic manuals of the manufacturers of these materials.

We want you to focus your attention mainly on these areas: -

eyes and skin protection when manipulating with the accumulators

-

skin protection when manipulating with the petroleum products, paints, cooling liquids and brake liquids

-

proper washing the hands after finishing the work and before the meal, treat the hands using the appropriate regenerating cream

-

when manipulating with cooling systems, keep the machine manipulating manual instructions.

The fills of individual machine systems and also some parts are after blackout (dismounting, changing the fills) the garbage with risk attributes for the environment.

To this category of waste products includes: -

organic and synthetic lubricants, oils and fuels

-

brake fluids

-

cooling liquids

-

accumulator filling and accumulators themselves

-

the conditioner systems fillings

-

cleaning and preservative materials

-

all dismounted filters and filter inserts

-

all used and blackouted hydraulic and fuel pipes, rubber steels and other machine parts, contaminated by materials above

With materials and parts listed we must work after blackout according to the appropriate national regulations for individual environment parts protection and according to the health protection regulations.

• The petroleum products, cooling systems fills, accumulators fills, brake liquids and paints including the organic thinners and also cleaning and preservative means always store on a original, properly signed covers. Don’t allow storing of these materials in the non-marked vessels and other cans due to danger of exchange. Extremely danger may be the exchange with meal or drinks.

• In the case of accidental stain of the skin, mucous membranes, eyes or of inhalation of the vapour, apply immediately the first aid. In such case find the emergency first aid.

•

82

When working with the machine unequipped with the cab, or with opened windows and cab door, always use the ears protections of convenient kind and design.

AP 240

4.2.

Filling Specifications

4.2.1.

Motor Oil

Maintenance manual

Motor oil has been specified as per the performance & viscosity classifications.

Performance Classification as per API (AMERICAN PETROLEUM INSTITUTE) CCMC (COMMITTEE OF COMMON MARKET AUTOMOBILE CONSTRUCTORS) ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE AUTOMOBILE)

Viscosity classification Ambient temperature & operations type at a place where the machine is used are decisive to determine SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) viscosity class.

Admissible Oils Applied under API:

CH-4/SJ; CI-4 CCMC DHD1 ACEA: E-5

SAE 15W-40 (e.g. Valvoline, Premium Blue) year round.

Exceeding low temperature limit shall not cause engine damage, only the problems when starting.

It is convenient to use multigrade oil to avoid oil exchanges due to altered ambient temperature.

! NOTE !

Exceeding high temperature limit may NOT last for a long period of time due lowered lubricating capabilities of oil.

When using oil under API CF-4/SH you must cut oil change interval to half, i.e. 125 hours or 6 weeks.

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83

4.2.

Filling Specifications

4.2.2.

Fuel

Use Diesel fuel for the motor: CEN EN 590 or DIN/EN 590 (suggested) DIN 51 601 BS 2869 (1988): A1 & A2 ASTM D 975-88: 1-D & 2-D VV-F-800C: DF-A, DF-1 & DF-2 NATO code F-54 & F-75

4.2.3.

Coolant

The coolant in the ration of 50% of water and 50% of antifreeze (for ambient temperature up to -36 °C[-25 °F]) shall be used even within climatic zone where temperatures do not drop below 0 °C (32 °F). Coolant is not used solely to protect the cooling system against freezing but also to increase the boiling point. The inhibitors contained within the antifreeze serve to protect the engine cooling system parts. Filling the cooling system with propylene antifreeze agents is possible.

Use treated demineralized or distilled water to make the coolant.

! NOTE !

Use winter Diesel oil with ambient temperatures below 0 °C (32 °F). Use special Diesel oil with additives for these purposes (”super Diesel oil) with ambient temperatures below -15 °C (5 °F).

It is FORBIDDEN to use fuels (like for instance bio Diesel oil, blended bio Diesel oil, LFO, etc.) other than those Diesel oils specified above.

Use the following antifreeze like for instance : SUNOCO - PERMANANT ANTIFREEZE SHELL - Glycoshell AF 511 S TEXACO - HAVOLINE Antifreeze Coolant/AFC CASTROL - ANTIFREEZE MB

! NOTE !

Do NOT use antifreeze over 50% ratio in the coolant unless urgently required.

NEVER use the ratio over 68%! DANGER of silicogel problem (becoming jelly) Use environmentally friently antifreeze agents.

We do NOT recommend antifreeze agents mutually blended. Mixing different types of coolants may cause anticorrosion characteristics to be lost.

Confirm antifreeze portion within the coolant before winter season via the refractometer (densimeter).

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AP 240

Maintenance manual 4.2.4.

Synthetic Hydraulic Oil

Hydraulic Oil

Use only the quality hydraulic oil with power class as per ISO 6743/ HV (corresponds to DIN 51524 part 3 HVLP; CETOP RP 91 H) designed for the machine hydraulic system.

Refill the hydraulic system with synthetic oil – e.g. PANOLIN - HLP Synth. 15/22/32/68 oil, which in case of any leakage will become restlessly degradable via the microorganisms found in water and soil.

Machines are normally filled with hydraulic oil of cinematic viscosity 68 mm 2/s at 40 °C (104 °F) ISO VG 68 at their manufacturer. This oil is the most appropriete one to be applied within the ambient temperatures’ most extensive range.

! WARNING !

Manufactured by

Sort of oil

Output class on ISO 6743/HV

HV (HVLP)

When replenishing older machines with synthetic oil then the residual limit of mineral oils may NOT be over 8% of the entire filling.

Viscosity class on ISO 6743/4, DIN 51519

VG 68

Viscosity class on CETOP RP 91H

HV 68

AGIP

AGIP ARNICA 68

AVIA

AVILUB HVI 68

BP

BARTRAN HV 68

CASTROL

HYSPIN AWH 68

CHEVRON

EP 68 HV

Water contents (condensation water) in oil may NOT exceed the maximal level of 0,1 %.

Make sampling within regular intervals to check up the operating fluid, refer to the Table.

When replenishing biologically degradable oils you are allowed to mix at up to 2 % of the tank’s total capacity.

ALWAYS consult with oil producer or dealer any switching from mineral oil to synthetic one, or mixing oils of various brands !

Interval of taking samples

Common operation

Extreme conditions

ELF

HYDRELF 68

1. check

500 h

250 h

ESSO

UNIVIS N 68

2. check

1000 h

500 h

FINA

HYDRAN HV 68

FUCHS

RENOLIN MR 68 HV

1000 h or once a year

500 h or once a year

MOBIL

MOBIL DTE 16

ÖMV

HLP - M 68

SHELL

TELLUS T 68

TEXACO

RANDO OIL HD CZ 68

TOTAL

EQUIVIS ZS 68

subsequent checks

! WARNING !

When under high ambinent temperatures with oil temp constantly reaching 90 °C (194 °F) we recommend to replace with HV 100 (BP BARTRAN HV 100; ESSO UNIVIS N 100, etc.) oil of 100mm2/s cinematic viscosity.

AP 240

85

4.2.

Filling Specifications

4.2.5.

Oil in CLARK Gearbox

Cylinder manufacturer uses OTHP 3 oil for the initial filling. Fill the gearbox alternatively with the following oils: Mogul

ATF II

Caterpillar

TO-4

John Deere

J20 C,D

Military

MIL-PRF-2104G

Allison

C-4

General Motors

Dexron II Equivalent

4.2.6.

Gearbox Oil

Use SAE 80W-90H API GL 5 or MIL-L-2105 B/C/LS oil to lubricate the hypoid gearbox Use SAE 80W-90H API GL 5 or MIL-L-2105 B/C/LS oil to lubricate down (descending) gears.

WARNING: Do NOT use motor oils, gearbox oils or DEXRON III !

During normal ambient temperature you can use 10W20 multigrade oil of lower viscosity value as if 10W low-grade oil was used. When applying C-4 oil instead of J20 we recommend the viscosity range not to exceed 10W i.e 10W/20. Use J20C, D when temperature fluctuates extensively.

Synthetic oil is approved for gearbox application when in line with the the aforementioned specifications.

86

AP 240

Maintenance manual 4.2.7.

Brake Fluid

The fluid complies with ISO 4925, SAE J 1703 f, DOT 3 international specifications and is not designed for arctic conditions . It is miscible with brake fluids of all brands that correspond to these specifications. The brake fluid has been designed for brake systems that operate at ambient temperatures ranging from –50 °C (–58 °F) to 60 °C (140 °F) and at operating temp between –50 °C (–58 °F) and 205 °C (400 °F).

NOTE: The brake system has been filled with Syntol HD 205 brake fluid at the manufacturer. A brake fluid that is in line with DOT 4 international classification (Syntol HD 260) can also be used for the brake system.

4.2.8.

4.2.9.

Windscreen Washer Fluid

Use clear water of down to 0 °C (32 °F) temperature to refill the windscreen washer liquid tank. We recommend to use water with antifreeze detergent designed for motor vehicle windscreen washers in ration as according to the machine operating conditions.

! NOTE !

Add antifreeze or let the water out when there is a risk of temperature dropping below 0 °C (32 °F) !

Grease

Use a plastic lubricant that contains lithium under the following standards : ISO 6743/9 CCEB2 DIN 51502 KP2K-30 (Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, Grease No 3 etc.).

AP 240

87

4.3.

Fillings

Filling Quantity (gal US)

Machine Part

Type of Filling

Engine

Engine oil per chap. 4.2.1.

9,75 (2,61)

Engine

Coolant per 4.2.3.

20,5 (5,4)

Fuel Tank

Diesel oil per 4.2.2.

250 (66)

Steering

Hydraulic oil per chap. 4.2.4.

6,5 (1,7)

Front wheel hydraulic cylinders

Hydraulic oil per chap. 4.2.4.

6 (1,6)

CLARK Gearbox

Oil per chap. 4.2.5.

Gearbox

Gearbox oil per chap. 4.2.6.

6 (1,6)

End Gear Boxes

Gearbox oil per chap. 4.2.6.

2x5,2 (2x1,4)

Brake System

Brake fluid per chap. 4.2.7.

0,75 (0,2)

Lubrication per Lubrication Plan

Plastic grease per chap. 4.2.8.

as needed

Windscreen Washer

Filling per chap. 4.2.9.

2,5 (0,66)

Water tank for pneu sprinkling

Water

285 (75)

Battery

Distilled water

as needed

88

Brand

21,5 (5,77)

AP 240

4.4.

AP 240

Lubrication & Maintenance Table

Maintenance manual

89

4.4.

90

Lubrication & Maintenance Table

AP 240

Maintenance manual

AP 240

91

4.5.

92

Lubrication Chart

AP 240

4.6.

Lubrication & Maintenance Operations

Maintenance manual

Following the initial 100 hours of the new machine operation (following its major overhaul) you should carry out pursuant to: 4.6.25. CLARK gearbox oil filter replacement Following the initial 250 hours of the new machine operation (following its major overhaul) you should carry out pursuant to: 4.6.34. Oil change in differential 4.6.35. Oil change in rear axle Following the initial 1000 hours of the new machine operation (following its major overhaul) you should carry out pursuant to: 4.6.36. Hydraulic oil filter replacement

Perform lubrication and maintenance within regularly repeated intervals according to the daily data readouts on the counter of actually operated hours.

This Manual states only the basic information about the engine, others are in the Engine Operating & Maintenance Manual, supplied together with the machine as part of its documentation.

! NOTE !

Follow the instructions given in the Engine Operating & Maintenance Manual!

Before maintenance start you put the cylinder on a fixed, flat surface! Inspect with the cylinder braked and engine stopped (unless otherwise required)!

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93

4.6.

Lubrication & Maintenance Operations

Following 20 hours of operation or daily 4.6.1.

Check oil in the engine

NOTE: Wait for ca 3 minutes for oil to flow down into the engine sump if the engine was running before.

Following 20 hours of operation or daily • Maintain the level in between the division marks stamped on the dipstick. Low mark indicates lowest possible oil level, High mark indicates its highest level.

• Make up the level through the filler. Wait ca 1 minute for oil to flow down and check again.

• Take out the oil dipstick, wipe it , insert back to the stop and pull out to read the level.

! NOTE !

Do NOT use the engine unless there is proper oil level in the motor.

Replenish oil of IDENTICAL type.

Use ONLY the recommended oils under chap.

4.2.1.

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Maintenance manual Following 20 hours of operation or daily 4.6.2.

Check coarse fuel filter

Following 20 hours of operation or daily • Install a small vessel underneath the separator to drain the sediments & water.

Clean immedialtely when clogged or when water has settled in the tank :

• Turn the drain valve by 4 revolutions clockwise and move the plug out by 25 mm (1”).

• Loosen the bottom nut (1) and tilt the clip (2) to the side.

Remove the glass (3) complete with strainer. Clean the glass & and flush the strainer.

3

2

1

C • Let the fuel flow out until it runs out clear.

• Press the valve back upward and bolt it.

• Make final fuel pumping via a manual delivery pump.

• When draining over 60 cm3 (2ozs) of fuel you should replenish the fuel into the filter as per 4.6.26., or deaerate according to 4.6.42.

! NOTE !

Fire Hazard - observe fire regulations.

Do NOT use open fire, and do NOT smoke while performing work on the fuel system.

Collect any fuel leakage.

• Cleaning intervals depend on the purity of fuel applied.

NOTE: Check the water separator should the glass of coarse filter be full of water when cleaning.

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95

4.6.

Lubrication & Maintenance Operations

Following 20 hours of operation or daily 4.6.3.

Check the motor belt

• Monitor for any damage. Any cracks perpendicular to the belt are not damaging. Should any longitudinal cracks occur on the belt, and if belt edges are shattered, or parts of the material are torn away, then you must replace the belt.

96

Following 20 hours of operation or daily 4.6.4.

Check the fan condition

• If damaged (e.g. missing parts of the material, crackts, shape changes, etc.) replace the fan.

AP 240

Maintenance manual Following 20 hours of operation or daily 4.6.5.

Check the coolant

• Make visual check of its level . Maintain the level between ”MIN” & ”MAX”.

Following 20 hours of operation or daily 4.6.6.

Check vacuum valve’s air filter

NOTE: The dust collected is emptied automatically during machine operation.

• Clean the exit slit, press to remove the dust collected.

Wait until the motor coolant drops below 50 °C and then dismantle the fill-in plug. Hazard of scalding with steam or coolant due to the internal overpressure with plug dismantled and high temperature. ! NOTE !

Do NOT operate the machine when the dust valve shows any defect. ! NOTE !

Replenish the coolant the composition thereof is given under chap. 4.2.3.

Do NOT use any additives to remove cooling system leakages to the engine coolant !

Do NOT replenish cold coolant into the hot motor!

Danger of causing damage to the engine castings.

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97

4.6.

Lubrication & Maintenance Operations

Following 20 hours of operation or daily 4.6.7.

Check the amount of fuel

• Check the amount of fuel on the fuel level indicator

Following 20 hours of operation or daily 4.6.8.

Refill the water tank

• Open the filler cap and refill with clear water.

(fuel gauge); and make up its level in case of its shortcoming. Clean the fuel tank filter cap along with its filler. Fill the tank up to the bottom edge of the filler pipe.

NOTE: Fuel tank will normally last ca 20÷30 operating hours provozu depending on the machine load and driving manner. When the fuel gauge lamp ligts up there is still ca 16 l (3,5 gal US) more in the tank , i.e.. 1÷2 operating hours.

Do NOT smoke nor use open flame when at work.

! NOTE !

Do NOT use up the tank completely. When you use the tank up completely the entire fuel system has to be deaerated.

Do NOT refill the fuel with the engine running.

Use solely a pure recommended fuel compliant to chap. 4.2.2.

Do NOT replenish the fuel inside closed areas.

98

AP 240

Maintenance manual Following 20 hours of operation or daily 4.6.9.

Check the oil in the hydraulic system tank

Following 20 hours of operation or daily 4.6.10. Check the brake fluid • Maintain the level between ”MIN” and ”MAX”. Clean

• Open the hydraulic steering oil tank.

• Unscrew the dipstick, wipe it and screw in again.

Unscrew again and read out the oil level.

the cap and filler before refilling.

• In case of any loss of fluid, check the following: piping connection tightness master brake cylinder brake cylinders inside rear axle wheels.

Ensure the defects are repaired instantly!

Brake fluid is toxic!

Protect your skin against contact with brake fluid – wear rubber gloves to protect your hands !

Eye contact – immediately flush eyes with water. Get prompt medical attention!

Store your brake fluid in the genuine, properly closed packages!

! NOTE !

Keep the level at the cutout’s upper edge.

Replenish oil as required – chap. 4.2.4.

! NOTE !

Brake fluid causes damage to the varnished parts of the machine.

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99

4.6.

Lubrication & Maintenance Operations

Following 20 hours of operation or daily

Following 20 hours of operation or daily

4.6.11. Check the alarm & control equipment

• Switch the key to ”I” position – the following indicator

• First confirm the travel controllers are in their neutral

lamps must light up: lubrication, charging, neutral , parking brake. Confirm the operation of the alarm horn, beacon and lights. Have the lubrication lamp and charging lamp gone out the light following the engine START?

position.

100

AP 240

Maintenance manual Following 20 hours of operation or daily

Following 20 hours of operation or daily

• Engage the travel and turn OFF the parking brake

• Confirm brake failure indicator lamp (with the engine

switch. The indicator lamp of the ENABLED point lights up and the brake and neutral indicator lamps goes OFF.

turned OFF). ”Floor” the brake pedal a couple of times repeatedly to lower the air pressure to 5,2 bar as per the pressure meter - brake failure indicator lamp must light up.

• Check up the emergency brake operation following the a driveaway.

NOTE: Attain 5,3 bar air pressure for drivaway (brake release).

! NOTE !

Check up in course of the the working activitiy as well.

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101

4.6.

Lubrication & Maintenance Operations

Following 20 hours of operation or daily 4.6.12. Check the amount of oil in CLARK gearbox ! NOTE !

Following 20 hours of operation or daily 4.6.13. Check the suction line (induction manifold) • Inspect the hose, clamps & packing flange (1).

Check it with the engine running idle at 82÷93 °C oil temperature – best after machine operation ended – the machine has to stand flat.

1 • Open and lift off the cover between the pedals on the machine floor.

! NOTE !

Do NOT operate the machine when induction manifold & air filter packing flange are damaged !

• Unscrew and pull out the dipstick, wipe it and slide in again. Take it out again and check the level height – it must reach the upper graduation line.

! NOTE !

Refill with oil as per chap. 4.2.5.

102

AP 240

Maintenance manual Following 20 hours of operation or daily

Following 20 hours of operation or daily

4.6.14. Check the air tank blowdown valve • Perform this task with the air tank at full air pressure of 7,5 bar as per the brake circuit pressure gauge.

• Turn the engine OFF, engage the parking brake.

• Pull the chain of the blowdown valve a bit and release the air.

NOTE:

• When suspicious of water contents (strange sound effect) during air relief, you must dismantle the floor cover.

• If water is there, replace immediately air drier insert on the floor beneath the valve. Refer to chap. 4.6.32.

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103

4.6.

Lubrication & Maintenance Operations

Every 250 hours of operation (3 months) 4.6.15. Replace oil in the engine

Every 250 hours of operation (3 months) • Take a new filter, fill it with pure motor oil.

• Get an adequate vessel of ca 9.75 l capacity.

• Dismantle the drain plug and let the oil run out.

• Apply a thin layer of oil on the filter’s rubber gasket.

• Clean the surface round oil filter head. Dismantle the filter.

• Screw the filter in and tighten properly with hand.

• Clean the contact area for filter gasket.

104

AP 240

Maintenance manual Every 250 hours of operation (3 months) • Check again the drain plug’s thread & gasket.

• Check again the thread and clean the contact area designed for motor sump gasket.

• Fit the plug, tighten to 80 Nm (59 flb) torque.

• Fill the motor via the filler neck.

Every 250 hours of operation (3 months) ! NOTE !

Drain oil when it is hot after stopping the operation, or when running you must heat up the engine until the coolant gets to 60 °C. Replace the oil every 3 months at the latest even when 250 hours have not been worked off. Replace the oil at an interval whichever occurs first.

Use the recommended filters, refer to specifications manual, or Spare Parts Catalogue.

Use only the recommended oils under chap. 4.2.1.

Do NOT overtighten the filter, it may damage the threads & gaskets.

Caution, burn hazard when discharging hot oil. Leave the oil to cool down below 50 °C. Observe fire precautions!

• Fill up to the top graduation line of the dipstick (H).

Total oil filling is 9,75 l (2,61 gal US).

Discharge oil to a retention (catch) vessel.

Used oil & filter are ecological waste – hand it over for disposal.

NOTE:

• Start the engine for 2 - 3 minutes following the replacement. Inspect the tightness of the drain plug and filter.

• Stop the engine and wait for 5 minutes until oil flows down to the engine sump. Keep checking oil level with dipstick afterwards.

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105

4.6.

Lubrication & Maintenance Operations

Every 250 hours of operation (3 months)

Every 250 hours of operation (3 months)

4.6.16. Inspect the injection pump

4.6.17. Inspect the compressor

• Check the fixing of fuel pump & its flange.

• Check the fixing of compressor & its flange, air valve.

Check up for any oil or coolant leakages.

106

AP 240

Maintenance manual Every 250 hours of operation (3 months) 4.6.18. Inspect engine’s cooling circuit

Every 250 hours of operation (3 months) • Inspect the engine cooling gills and oil cooling gills.

• Inspect cooling circuit’s tightness. Check that hoses are NOT damaged (cracks, buckling, distortion) & NO hose clamps are missing.

• Purge with compressed air in the direction away from the cooling fan when the cooler is clogged.

• Confirm the grill is clean.

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107

4.6.

Lubrication & Maintenance Operations

Every 250 hours of operation (3 months) 4.6.19. Check air filter’s vacuum switch function

Every 250 hours of operation (3 months) • Unless it lights up you must find out the cause – broken bulb, contact, supply cable, vacuum switch (1) etc.

• Check with the engine running.

• Raise engine speed to its high level of about 1500 rpm.

• Cover air filter suction hole.

1

Beware of machine’s rotating parts!

• Indicator lamp for air filter clogged shall light up when covered.

108

AP 240

Maintenance manual Every 250 hours of operation (3 months) 4.6.20. Inspect the battery (accumulator) condition

Every 250 hours of operation (3 months) NOTE: Use glass tube to check the level.

• Measure the electrolyte density in all individual cells

• Open the lid.

via a refractometer.

• Clean battery surface. Check up the condition of poles & terminals (2). Clean the terminals & poles, apply grease (make sure the contact is OK). Open battery cell plugs (1) and check electrolyte level, in all cells this level must reach 5 ÷ 15 mm (0.2÷0.6 in) above the electrodes, or to the low edge of dipstick inside the battery cells.

1

• Or via a density meter.

2 2

• Compare measured values with those in the Table.

Density 3

in g/cm

AP 240

in °Be (Beume)

20 °C 68 °F

Tropics

20 °C 68 °F

Tropics

fully charged

1,28

1,23

32°

27°

semi charged

1,2

1,12

24°

16°

exhausted - charge immediately!

1,12

1,08

16°

11°

109

4.6.

Lubrication & Maintenance Operations

Every 250 hours of operation (3 months)

Every 250 hours of operation (3 months)

• The requirements for accumulators during winter season are especially high. Accumulators during low temperatures possess only a part of their capacity required to start the machine when compared to their capacity under normal conditions. For this reason we recommend to check the condition of battery electrolyte and to recharge if necessary.

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

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

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

WARNING Unless you use the machine under severe frost conditions, you should dismantle the accumulators and store them so to be protected against any frost.

In course of storage you must check 1x per month the battery charging condition and recharge.

! NOTE !

Keep the batteries dry and clean.

Close batteries after checking.

Refill battery with distilled water only - never with acid.

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

Recharge insufficiently charged battery.

Recharge batteries dismantled from the machine.

Open the plugs before recharging.

Do not disconnect the battery under running engine.

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

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

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

Do not eat, drink and smoke during operation!

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

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

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

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

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

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

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

Dispose of old damaged batteries.

110

AP 240

Maintenance manual Every 250 hours of operation (3 months) 4.6.21. Lubricate the joint (cardan) shaft & brakes • Dismantle the floor covers to access the lubricating

Every 250 hours of operation (3 months) ! NOTE !

Pay attention to prevent brake disc from being greased !

points and the sprinkling filter. Refer to the following chap. 4.6.22.

• Grease the shaft joints until fresh lube grease starts flowing from the bearings.

• Lubricate the pin (1). Check the lever (2) position in order to consider the brake-pad wear. If the lever (2) in braked state is overhead the horizontal position, then displace pin (3) to another brake bar hole (4).

1 4

3 2

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111

4.6.

Lubrication & Maintenance Operations

Every 250 hours of operation (3 months)

Every 250 hours of operation (3 months)

4.6.22. Clean the sprinkling filter

4.6.23. Lubrication

• Dismantle the tank for sprinkling filter, remove the

Fill with grease as per chap. 4.2.8.

strainer & clean it.

Front axle lubrication

• Front wheel bearings

• Bearings of the front wheel swing front lubricator, rear lubricator.

• Steering pivots

112

AP 240

Maintenance manual Every 250 hours of operation (3 months) Lubricating the hinges of

Every 250 hours of operation (3 months) • hydraulic tank lid

• bonnet

• doors

AP 240

• battery cover

113

4.6.

Lubrication & Maintenance Operations

Every 500 hours of operation (6 months)

Every 500 hours of operation (6 months)

4.6.24. Check the rear axle oil • Clean & unscrew the gearbox check plug. Confirm the oil level to the hole.

• Clean & dismantle the plug at the rear side of down gear case and monitor the level reaching the hole or slightly pouring out.

Tightening torque: Check plug 80÷90Nm (59÷66.4 ft lb) Vent (filling) plug 70÷80 Nm (52÷59 ft lb)

• Replenish oil compliant to chap. 4.2.6.

114

AP 240

Maintenance manual Every 500 hours of operation (6 months) 4.6.25. Replace CLARK gearbox filter oil

Every 500 hours of operation (6 months) • Apply oil on seal ring of the new filter.

• Open the lid underneath the control panel.

• Screw on the new filter and hand tighten securely.

• Unscrew oil filter. Capture any oil residues pouredout.

Replace for the first time following 100 hours of operation of the new machine or following a major overhaul!

Let the gearbox to cool down below 50 °C before you make the replacement.

! NOTE !

Use ONLY the recommended CLARK filters.

Do NOT overtighten the filter, potential of damage to its thread & gasket.

A used filter becomes environmentally hazardous waste. Hand it over for its disposal.

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115

4.6.

Lubrication & Maintenance Operations

Every 500 hours of operation (6 months) 4.6.26. Replace the fuel filter

Every 500 hours of operation (6 months) • Replenish filters with clear fuel.

• Clean fuel filter head.

• Slacken the water separator and let fuel to drain away from the filter for about 5 seconds into a vessel set up.

Dismantle the filter afterwards.

• Apply oil onto the seal ring.

• Clean contact surface designed for the filter.

116

AP 240

Maintenance manual Every 500 hours of operation (6 months) • Mount the filter and hand tighten properly.

Every 500 hours of operation (6 months) NOTE: The small amount of air that got into the system during filter replacement undergoes automatic bleeding under condition you have strictly followed the replacement procedure specified. Otherwise you must vent the system in line with chap. 4.6.42.

! NOTE !

Use genuine filters as specified.

Do NOT overtighten the filters. You may damage their thread and gasket.

Observe fire precautions!

Do NOT smoke and use NO open flame when at work.

Carry out the replacement procedure in well-ventilated place with NO fire hazard.

Retain the effluent fuel!

Store the used filters in a separate container and hand them over for their disposal.

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117

4.6.

Lubrication & Maintenance Operations

Every 500 hours of operation (6 months)

Every 500 hours of operation (6 months)

4.6.27. Check coolant concentration • Inspect your coolant concentration with a refractometer.

! NOTE !

Check always before a winter season. Unless the measured concentration for ambient temperatures -32 °C (-25 °F) fits, you must adjust it or replace the coolant according to chap. 4.2.3.

118

AP 240

Maintenance manual Every 1000 hours of operation (1 year) 4.6.28. Inspect and adjust brake shoes NOTE: Brake OFF the machine prior to any wheel dismantling!

Every 1000 hours of operation (1 year) • Disassemble brake drums step by step, and inspect the state of brake linings. When dismantling is difficult you can use M12-60 forcing-off screws of min. 8G strength into the holes (1) of brake drum (2). Inspect drum’s inner diameter – scratches & cracks.

• Lift the machine a bit onto the frame’ s rear eyes so the rear wheels do NOT touch the ground. Undelay the rear section of the machine frame. Wedge the front wheels from both of their sides.

1 1

2

1 1

• Dismantle tyre inflating & deflating hoses (1) at the little rotors (2). Dismantle gradually the nuts (3) and wheels – beware of damage to wheel bolts’ threads.

3 2

1

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119

4.6.

Lubrication & Maintenance Operations

Every 1000 hours of operation (1 year)

Every 1000 hours of operation (1 year)

Inspect:

Adjust the brake shoes whenever there is:

• Any contamination, uneven wear, thickness of the

• Insufficient brake efficiency (substantial dwell between

lining (1). Apply a thin layer of lube grease on the adjusting screw (2) – avoid lube grease to reach active surface of the brake lining or brake drum.

depresseing the brake pedal and start of the braking – long brake pedal step);

• Installation of new brake shoes; • Following new brake drum mounting, or after the brake drum’s inner diameter has been machined;

• Following brake repair.

• Fit the drums back following their inspection. Swivel

1

2

1

the brake drum so its adjusting hole is downward to the adjusting wheel. Turn the adjusting wheel (1) round until the brake shoes lean against the brake drum (brake drum is impossible to be moved around). Turn the adjusting wheel back to only such an extent that the brake shoes get released (brake drum now able to be moved around).

• Brake drum – brake fluid leakage.

1

• Fit the wheels back. When reinstalling the wheels swivel the brake drums behind the bolts using an appropriate lever so to enable the wheels to slip over the brake drums. Tighten the wheel nuts to 330÷350 Nm (245÷260 ft lb) torque.

! NOTE !

When you find out the thickness of lining is 4 mm (0,16”) and less, then you must cut short the inspection intervals to half – i.e. every 500 operating hours.

Replace the lining always when its thickness gets to minimal figure of 2 mm (0,08”).

Replace all the brake shoes at one time to maintain uniform braking!

Always replace a failed adjusting device with a new one.

Use only the genuine brake shoes!

120

AP 240

Maintenance manual Every 1000 hours of operation (1 year) 4.6.29. Check and adjust valve clearance

Every 1000 hours of operation (1 year) • Insert Cummins jig No.3824591 into this hole to rotate the motor.

! NOTE !

Check and adjust only when the engine has cooled down below 60 °C. • Dismantle air filter, air supply pipe leading to the turboblower, and the valve bonnets.

• Rotate the motor to the right in view of the belt pulley, towards the top of compression stroke of cylinder No. 1 (at cylinder No.4 intake rocker arm starts to open the intake valve). In this position the valves (E, I) are closed, with their rocker arms loose.

• Dismantle the blinder at the flywheel casing hole used

1

to insert a grooved pivot.

I E

• Measure the clearances of suction valve & exhaust valve of the 1 st cylinder with coupled setting gages.

Adjust the clearance (gap). Loosen the counternut and turn the adjusting screw with a screwdriver.

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4.6.

Lubrication & Maintenance Operations

Every 1000 hours of operation (1 year)

Every 1000 hours of operation (1 year) • Check and adjust the clearance of other remaining

NOTE: The clearance is right when you feel resistance while pulling the setting gage between the valve and the rocker arm. Tighten the counternut when adjusted. The torque is 24 Nm (18 ft-lb). With the counternut fully tightened check the clearance again.

marked valves.

Valve gap: Suction valveí (I)

0,254 (0.01 in)

Exhaust valve (E)

0,508 (0.02 in)

• Check and adjust the clearance of other valves marked.

• The sequence of cylinders 1÷4 goes from the fan pulley.

• Make a mark on the belt pulley, and rotate the cranshaft by 360°.

122

AP 240

Maintenance manual Every 1000 hours of operation (1 year) 4.6.30. Check belt & tensioner

Every 1000 hours of operation (1 year) • Check the axial clearance of the ventilator belt pulley - it must not exceed 0.15 mm (0.006 in).

• With the engine running, visually check the ventilator belt pulley - whether it is not vibrating and whether the belt runs with its all surface on the tensioning pulley.

• Stop the engine!

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

• Mount the belt back.

Checking the tensioner:

• Check the tensioner belt pulley and arm for cracks.

• Check visually the belt, search for its damage. Cracks perpendicular to the belt are not defects. In case any lengthwise cracks appear on the belt or its edges are frayed or its parts torn out, it is necessary to exchange the belt.

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123

4.6.

Lubrication & Maintenance Operations

Every 1000 hours of operation (1 year) • Check the tensioner for clearance.

Every 1000 hours of operation (1 year) • Check the belt tensioner for clearances and for deviation of the pulley from the vertical axis. Maximum deviation is 3 degrees.

124

AP 240

Maintenance manual Every 1000 hours of operation (1 year) 4.6.31. Change CLARK gearbox oil

Every 1000 hours of operation (1 year) • Pour 21,5 l (5,6 gal US) through the hole after lifting a dipstick to FULL mark.

• Drain oil following operation stop and cooling down to 60 °C, or with when the engine is running (while driving) you must wait for the oil temp to reach 60 °C.

• Dismantle the plug, drain the oil into 21,5 l (5,6 gal US) vessel fixed, and replace the filter per chap. 4.6.25.

• Start the engine and while idling you check the oil level. It should be at ADD mark.

• Heat oil up to 82÷93 °C and check, make up to FULL if required.

• Open the cover under control board.

WARNING! Burn hazard when draining hot oil. Let oil to cool down below 50 °C. Observe fire precautions!

! NOTE !

Apply recommended filters, refer to Specifications Manual, or Spare Parts Catalogue.

Use ONLY the recommended oils under chap. 4.2.5.

Do NOT overtighten the filter, potential of damage to the thread & gasket.

Drain oil into a catch vessel.

Used oil & filter are ecological waste – hand them over for their disposal.

AP 240

125

4.6.

Lubrication & Maintenance Operations

Every 1000 hours of operation (1 year)

Every 1000 hours of operation (1 year)

4.6.32. Replace the Air Drier

4.6.33. Check the bolted connections

• Dismantle the floor cover.

Inspect and tighten the main bolted connections to their torque.

• Motor fixing at the front – left side, right side: 1 - M12 bolts - 75 Nm (55 ft lb) torque.

2 - M12 bolts - 75 Nm (55 ft lb) torque.

3 - M10 bolts - 44 Nm (33 ft lb) torque.

4 - M16 - 165 Nm (122 ft lb) torque.

5 - M12 bolts - 75 Nm (55 ft lb) torque.

5 4 2

• Dismantle air drier cartridge. Clean the upper section of the body – NO contaminant may ever reach the clean air section (non-return valve). Apply oil on the gasket of the new drying cartridge. Tighten the cartridge manually with 15 Nm (11 lb - ft) torque.

3

1

• Motor fixing at the rear – left side, right side: 1 - M12 bolts - 75 Nm (55 ft lb) torque.

2 - M14 bolts - 118 Nm (87 ft lb) torque.

3 - M14 bolts - 118 Nm (87 ft lb) torque.

4 - UNC 3/4” x 10 bolt - 300 Nm (220 ft lb) torque.

3 ! NOTE !

Use genuine KNORR cartridge ONLY! Pressureless air system required.

Used drying cartridge is an ecological waste – hand it over for its disposal.

126

2

1

4

AP 240

Maintenance manual Every 1000 hours of operation (1 year)

Every 1000 hours of operation (1 year)

• Fixing of the rear axle to the frame with M20x1,5 bolts

• Fixing of the front axle with M20 bolts - 190 Nm (140

- 320 Nm (240 ft lb) torque.

• Fixing the control lever with M20 bolts - 190 Nm (140 ft lb) torque.

AP 240

ft lb) torque.

Tighten the bolt connections for the first time after 100 operating hours of the new machine or following its major overhaul !

127

4.6.

Lubrication & Maintenance Operations

Every 1000 hours of operation (1 year) 4.6.34. Change the oil in the differential

Every 1000 hours of operation (1 year) • Dismantle the drain plug, screw in the discharge spout (supplied with machine accessories) and drain 6 l (1.58 gal US) of oil into the vessel fixed. Reinstall the plug – check the gasket.

NOTE: Drain oil following the operation and cooling down to 50 °C, or when upon driving the machine, wait until oil gets heated. Change oil for the first time following 250 operating hours of the new machine, or after its major overhaul!

Differential:

• Dismantle the lid within frame’ s rear section.

• Pour 6 l (1.58 gal US) of oil as per chap. 4.2.6.

• Dismantle the check plug, verify the level up to the hole (there should be a slight pouring out) – adjust the level hight.

• Dismantle the filler plug (1).

1

2

• Screw on the check & drain plugs again – check the gasket.

Tightening torque: Check plug 80÷90 Nm (59÷66.4 ft lb) Vent (filling) plug 70÷80 Nm (52÷59 ft lb)

128

AP 240

Maintenance manual Every 1000 hours of operation (1 year)

Every 1000 hours of operation (1 year)

WARNING!

Drain oil into a catch vessel.

Burn hazard when draining hot oil. Let oil cool down below 50 °C.

Used oil is an ecological waste – hand it over for its disposal.

Observe fire precautions!

! NOTE !

Use ONLY those oil recommended persuant to chap.

4.2.6.

AP 240

129

4.6.

Lubrication & Maintenance Operations

Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

4.6.35. Change the oil in the rear axle

WARNING! Burn hazard when draining hot oil. Let oil cool down below 50 °C.

NOTE: Drain oil following the operation and cooling down to 50 °C, or when upon driving the machine, wait until oil gets heated. Change oil for the first time following 250 operating hours of the new machine, or after its major overhaul!

Observe fire precautions!

Rear axle:

• Underlay the drain plugs with 6 l (1,6 gal US) vessel, clean & disassemble the drain plugs (1), inspection plugs (2). When drained fit plugs (1) again.

! NOTE !

Use ONLY those oil recommended persuant to chap.

4.2.6.

Drain oil into a catch vessel.

Used oil is an ecological waste – hand it over for its disposal.

2 1

• Dismantle the lids and pour 5,2 l (1,4 gal US) into each case as per chap. 4.2.6.

• Check oil level via inspection hole (2) – it may flow out sliightly, close with plugs. Reinstall the lids, replace the gasket. Confirm the tightness following a brief time of operation.

130

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Maintenance manual Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

4.6.36. Change the oil & filter in the steering hydraulics

• Remove the tank lid.

NOTE: Drain oil after stopping the operation and cooling down to 50 °C temp, or when driving the machine you should wait until oil is heated. Replace the filter for the first time following 1000 operating hours of the new machine or after the major overhaul !

• Dismantle a drain plug from below in the cutout – capture 3,5 l (0.92 US gal) of oil in a vessel installed.

• Dismantle nut (1), remove lid (2). Remove filter (3) & replace with the new one.

2

1

3 • Open the cover.

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131

4.6.

Lubrication & Maintenance Operations

Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

• Close the drain hole using the plug. Check the gasket.

WARNING!

• Pour 3,5 l of new oil as per par. 4.2.4 – close the lid.

Burn hazard when draining hot oil. Let oil cool down below 50 °C.

Start the motor and turn the steering wheel a couple of times to the right – left.

• Check the level with dipstick - adjust the level.

Observe fire precautions!

! NOTE !

Use the recommended filters – refer to Specifications Manual, or Spare Parts Catalogue.

Use ONLY the recommended oils as per chap.

4.2.4.

Do NOT overtighten the filter, potencial of damaging its thread & gasket.

Drain oil into a catch vessel.

• Close the tank with its filler cap. Lock the cover.

132

Used oil & filter are ecological waste – hand them over for disposal.

AP 240

Maintenance manual Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

4.6.37. Replace oil in the front axle’s hydraulic cylinder

Observe fire precautionsí!

• Scotch the rear wheel from both sides.

• Lift a bit the cylinder’s front section by the front mounting lugs so the front wheels become unweighted. Lay fixed supports under the Machine’s frame behind the front wheels.

! NOTE !

Use ONLY the recommended oil as per chap. 4.2.4.

The used oil represents ecological waste – hand these over for their disposal.

• Loosen the plugs of the front axle’s hydraulic cylinders.

• Draw out the oil.

• Fill each of the hydraulic cylinders with 3 l (0.79 US gal) of oil. Refer to chap. 4.2.4.

• Close with plugs. Use new gaskets.

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133

4.6.

Lubrication & Maintenance Operations

Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

4.6.38. Change the brake fluid

• Put the hoses into a vessel, and loosen the bleeding

NOTE:

screw of the brake cylinder. It is possible for you to handle a pair of wheels simultaneously.

There must be air pressure level within the brake system for its bleeding. Pressurize the system with the engine running unless there is air level – observe safety precautions when starting the engine. Two persons carry out together the bleeding process.

Draw the brake fluid out from the circuit:

• Dismantle the rear wheels per chap. 4.6.28.

• Slip the box end wrench No. 9 on the hose.

• Another person floors the brake pedal repeatedly to displace the liquid step by step from all the brake cylinders into the vessel. Tighten the bleeding screw.

• Slip the hose complete with the wrench on the bleeding screw.

134

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Maintenance manual Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

Replenish the circuit with brake fluid & carry out the bleeding

Brake fluid is TOXIC material! Keep it inside genuine packages well closed!

• Fill the expansion tank with fluid, and when bleeding maintain the level at ”MIN”.

Protect your skin against contact with the brake fluid. Wear rubber gloves to protect your hands!

Upon eye contact immediately flush eyes with large amounts of water. Get prompt medical attention!

! NOTE !

Brake fluid will cause damage to the varnished parts of the machine.

Use ONLY the recommended brake fluid per chap.

4.2.3.

• Loosen the air relief screw at the booster by 2 revolutions, and once the booster has been replenished with fluid you tighten the screw back again.

Catch the brake fluid in a tank and hand it over for its disposal !

• Replenish the tanks with new brake fluid (the hose end to be deep under the surface). Loosen the air relief screws. Start depressing the brake pedal until fluid with air bubbles stops coming out. Then with the brake pedal depressed, you close the air relief screw of all the brake cylinders, wipe them, and fit on the protective caps.

• Confirm the circuit tightness, level height in the tank, and adjust if required.

• Reinstall the wheels per chap. 4.6.28.

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135

4.6.

Lubrication & Maintenance Operations

Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

4.6.39. Exchange the coolant

• Underlay the plug with the vessel. Clean and dismantle the plug. Drained amount equals to ca 19,5 l (5.1 gal US). At those machines with heating system installed the amout drained would equal to 20,5 l (5.4 gal US).

NOTE: Drain the coolant with the operation completed, or when upon driving the machine, you must wait until the coolant heats up to 80 °C.

• Remove the lid on top of the expansion tank.

• Confirm there are NO damaged hoses and NO missing hose clamps within the engine’s cooling system. Inspect the cooler for any damage, leaks and cooling gills fouled. Clean and repair if required.

Do NOT remove the lid before coolant temp drops below 50 °C. Hot water burn hazard.

136

AP 240

Maintenance manual Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

• Replenish the cooling system with the new cooland at the ration of 50 % of water + 50 % of anti-freeze. Max. filling rate is 19 l/min [5 gal US per minute]. Close the expansion tank with the lid.

Before replenishment let the temperature drop below 50 °C. WARNING; Hazard of fluid splashing out and causing burn when you open the overpressure plug (1).

• START the engine and wait until its temp gets to 80 °C. Then STOP the engine. Check at the same time for any coolant leakage. Confirm the level at the expansion tank.

Follow strictly manufacturer’s instructions when exchanging the coolant !

Wear rubber gloves to protect your hands!

Wear safety glasses & face shield to protect your eyes !

! NOTE !

Use the coolant in line with chap. 4.2.3!

Drain the fluid into the catch vessel !

Hand over the used fluid for its safe disposal in conformity with the regulations !

AP 240

137

4.6.

Lubrication & Maintenance Operations

Every 2000 hours of operation (every 2 years)

Every 2000 hours of operation (every 2 years)

4.6.40. Inspect the discharge line of the air compressor

• When the total amount of carbon deposit on the wall exceeds the value of X+X=2 mm (1/16 in), then you have to clean or replace the discharge pipe leading from the compressor, and contact your dealer or Cummins service department to carry out compressor’s overall revision & repair.

Confirm the air discharge line is pressureless. Let the air out from the system.

• Dismantle the air dischage line leading from the compressor.

138

AP 240

Maintenance manual Maintenance as required

Maintenance as required

4.6.41. Clean the Fuel Tank Observe fire precautions!

• Clen with minimum amount of fuel contained – when lamp lights up there is ca 16 l (3,5 US gal) left in the tank.

• Unscrew the drain plug, let fuel flow out into a vessel

Clean in well-ventilated place away from fire hazard DO NOT smoke or use open flame.

made ready.

Avoid fuel escape into the ground.

• Flush with pure fuel, screw on the plug again – check up the gasket.

NOTE: When the fuel system has a pocket (vacuum) you have to bleed it as per chap. 4.6.42.

AP 240

139

4.6.

Lubrication & Maintenance Operations Maintenance as required

4.6.42. Vent the Fuel System

Maintenance as required Bleed the high pressure piping & injectors:

• Unless engine starts despite you proceeded as menBleed the fuel system prior to the first Start : -

with the fuel filters NOT replenished with fuel – upon filter replacement

tioned above, then bleed the high pressure line.

• Switch the ignition box key to ”1” position to energize engine’s ”STOP” solenoid valve .

• Loosen one or two nuts on the injectors, and by cran-

-

upon fuel pump replacement

-

when replacing high pressure piping, injectors

-

upon longterm machine shutdown

• Bleed until the engine makes regular running.

-

with the fuel pumped out.

• Tighten the connections with 38 Nm torque.

king the engine you bleed the air from high pressure piping.

Bleed the low pressure piping & the filters:

• Loosen the air relief screw at the fuel filter.

When you use engine starter to bleed the system, do NOT start for more than 30 s. Wait 2 minutes in between the starts. Caution, engine may start when bleeding. Follow safety measures to prevent any hazard.

There is HIGH fuel pressure inside the high-pressure line. Hazard of skin defect or serious injury.

DO NOT bleed with hot engine. Fuel may flow over the exhaust manifold and cause fire.

DO NOT smoke!

• Pump the fuel via a feed pump until it flows clear, with no air bubbles.

Contain any leaking fuel!

• Tighten the air relief screw with 9 Nm (7 ftlb) torque.

140

AP 240

Maintenance manual Maintenance as required 4.6.43. Replace air filter element

Maintenance as required • Pull out the main element.

NOTE: The air cleaner contains the main and safety elements.

! NOTE !

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

• Check the connections’ s tightness and the suction hose.

• Replace the safety insertion piece after pulling the old one out from the lead-in hole.

• Loosen the clips and remove the cover.

AP 240

141

4.6.

Lubrication & Maintenance Operations Maintenance as required

• Install a new main element. Confirm it contacts the surface and seals properly.

• Take off the dust valve, clean it and reinstall.

Maintenance as required ! NOTE !

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

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

Replace the sealing nut with a new one when replacing the element.

Use original elements only.

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

In case of absorbing water, exchange main element.

Dry the cleaner body.

Replace defective vacuum valve immediately!

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

142

AP 240

Maintenance manual Maintenance as required

Maintenance as required

4.6.44. Clean the Cooler NOTE: No regular cleaning interval can be set due to the machine operating in various working environments. Clean daily when operating the machine within a very dusty environment. Fouled cooler will cause engine coolant and hydraulic system oil temperatures rising.

• Purge with compressed air or pressure water (steam)

! NOTE !

Caution. Do NOT damage cooling gills. DO NOT use cleaners with too high pressure.

Use cleaning agent & and follow manufacturer’s instructions for coolers clogged with crude oil products (oil). Find out the cause of contamination.

from the side of the fan.

NEVER use readily flammable cleaning agents (petrol, Diesel-oil, paraffin, diluents, etc.).

Observe environmental standards & regulations when cleaning up !

DO NOT use banned cleaning agents!

Carry out the cleaning within a workplace fitted with a retention (catch) system to avoid soil or ground water contaminations !

AP 240

143

4.6.

Lubrication & Maintenance Operations Maintenance as required

Maintenance as required

4.6.45. Clean the water tank & sprinkling filter

• Disassemble the filter tank complete with strainer, flush & clean them.

• Dismantle the tank filler cap.

• Dismantle the cover behind the front wheels, and open

• Dismantle the lid and flush the tank with heavy stream of water.

the water discharge stop. Turn ON the sprinkling pump to remove the remaining water out from the sprinkling circuit – let the pump run until water flows out from the nozzles.

! NOTE !

• Disassemble the floor cover between the seats.

144

Drain the tank & sprinkling system always before am bient temperature drops below 0 °C (32 °F)!

AP 240

Maintenance manual Maintenance as required

Maintenance as required

4.6.46. Clean the brush scrapers

4.6.47. Clean the cabin ventilation air filter

• Lift the brushes upward, and lock in this position with

• Dismantle the cover grating.

latch (1).

1

2

2

• Check visually the condition of the brushes (2) – clean and repair.

• Replace the filter element, shake up carefully & wash in detergent solution.

• Release the latch, let the brushes descend to the wheels – springs will press the brushes.

NOTE: Clean regularly 1x per month. Cut short the cleaning intervals in case you work within extremely dusty environment. Wash the element for 2 times only.

AP 240

145

4.6.

Lubrication & Maintenance Operations Maintenance as required

4.6.48. Clean the Machine Clean the machine from any major dirtiness following the work completion! Carry out overall cleaning operation on regular basis at least once per week. Clean daily all the machine when working on compact soils, soil cement and soil lime. Give attention to scrapers’ operability!

Maintenance as required 4.6.49. Check the bolt connections are tightened • Inspect regularly the bolt connections are NOT loosened.

• Tighten with torque wrench.

TIGHTENING MOMENT

! NOTE !

NEVER apply readily flammable cleaning agents.

For the screws 5.8 (5 S)

For the screws 8.8 (8 G)

For the screws 10.9 (10 K)

DO NOT expose electric parts or insulation materials to direct stream of water, or steam. ALWAYS cover these materials (alternator, etc.).

Wor m

Nm

l b- f t

Nm

l b- f t

Nm

l b- f t

M4

2

1

3

2

4

3

Disconnect the battery cut off switch!

M5

4

3

6

4

8

6

M6

7

5

10

7

14

10

M8

16

12

22, 5

17

32, 5

24

M10

31, 5

23

44

32

62

46

M12

53

39

75

55

105

77

M14

79

58

118

87

165

122

M16

113

83

165

122

226

167

M18

172

127

245

181

343

253

M20

226

167

314

232

441

325

M22

284

209

392

289

559

412

M24

392

289

549

405

755

557

M27

520

384

716

528

1020

752

Blind all the holes (e.g. engine suction port, alternator’s internal space, etc.) with potential of cleaning agent penetrating inside thereof, before cleaning the machine with water/steam pressure cleaners and other pressure cleaners). Remove these blinds as soon as the machine has been cleaned.

NEVER use forbidden cleaning agents!

Clean the machine at an area equipped with cleaner retaining system to prevent any soil and ground water contaminations.

The values given in the Table are torques at dry thread (at coefficient of friction = 0,14). These values DO NOT apply to greased thread.

Loosen and reuse the self-locking nut MAX 3 times.

146

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Maintenance manual

AP 240

147

4.7.

Appendixes – scheme

Electric installation scheme Legend: A 1 Interrupter of direction lights

Q 1 Battery disconnection

A 2 Electronics switches steering

S 1 Switch box

B 1 Sensor of engine temperature

S 2 Switch of front headlights

B 2 Sensor of gear - box temperature

S 3 Switch of rear headlights

B 3 Float of fuel lavel

S 4 Switch of beacon (Optional)

B 4 Sensor of gear - box lubrication

S 5 Pressure switch of brake lights

E 1 Instruments illumination

S 6, 7 Push - button of Horn

E 2, 3 Front outline lights

S 8 Switch of warning lights

E 4, 5 Tail lights

S 9 Left switch directions lights

E 6, 7 Front headlights

S 10 Right switch directions lights

E 8, 9 Rear headlights

S 11 Left controller

E 10 Safety beacon (optional) E 11, 12 Cabin illumination

S 12 Right controller S 13, 14 Push - button of emergency brake

E 13, 14 Brake lights

S 15 Switch of differential lock (optional)

E 15-17 Left directions lights

S 16 Indicator of differential lock (optional)

E 18-20 Right directions lights

S 17 Switch of engine lubrication

E 21 Backup light F 1-12 Fuses

S 18 Switch of brake filature S 19 Undpressure switch of air filter clogging

G 1 Battery

S 20 Pressure switch of brake

G 2 Alternator

S 21 Switch of front wiper

H 1 Horn

S 22 Switch of rear wiper

H 2 Indicator of dir. lights

S 23 Push - button of washer

H 3 Back - up alarm (Optional)

S 24 Switch cycle sprikling

H 4 Indicator of neutral position of the travel control

S 25 Owerpressure switch sprikling (pump sprikling)

H 5 Indicator right steering

S 26 Switch of van

H 6 Indicator left steering

S 27 Switch of air conditioning (optional)

H 7 Indicator of charging

S 28 Thermostat of air conditioning (optional)

H 8 Indicator of engine lubrication

S 29 Safety cup of air conditioning (zvláštní výbava)

H 9 Indicator of brake filature

S 30 Position switch heating

H 10 Alarm of brake filature

S 31 Switch of parking brake

H 11 Indicator of air filter clogging

S 32 Thermostat of cold start (options)

H 12 Indicator of brake

S 50 Push buton of the edge cuter - up (options)

H 13 Indicator sprikling

S 51 Push buton of the edge cuter - down (options)

K 1 Contactor

V 1, 2 Diodes

K 2-6 Auxiliary relay

148

X 1 Hand lamp socket

M 1 Starter

X 2-29 Conectors

M 2 Front wiper

Y 1, 2 Electromagnet gear changing

M 3 Rear wiper

Y 3 Electromagnet travel forvard

M 4 Front windscreen washer

Y 4 Elektromagnet travel revers

M 5 Rear windscreen washer

Y 5 Electromagnetic valve of engine STOP

M 6 Pump sprikling

Y 6 Electromagnetic valve of brake

M 7 Fan

Y 7 Electromagnetic valve of differential lock (optional)

P 1 Hour counter P 2 Thermometer of engine

Y 8 Electromagnetic clutch of compressor of air conditionig (optional)

P 3 Thermometer of gear - box

Y 10 Valve solenoid of the cuter edge - up (options)

P 4 Fuel level meter

Y 11 Valve solenoid of the cuter edge - down (options)

P 5 Pressure gauges of Gear - box lubrication

Y 12 Cold start solenoid of the engine

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Maintenance manual

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149

4.7.

150

Appendixes – scheme

AP 240

Maintenance manual Hydraulic scheme

AP 240

151

4.7.

Appendixes – scheme

Air circuit 1 AIR DRAYER 2 CONTROL VALVE 3 RELIEF VALVE 4 DOUBLE CHECK VALVE 5 DRAIN VALVE 6 BRAKE PEDAL 7 MASTER BRAKE CYLINDER 8 AIR RESERVOIR 9 ELECTRICAL VALVE 10 CHECK VALVE 11 SWITCH PRESSURE 12 BRAKE SERVO 13 SPRING BRAKE ACTUATOR 14 ELECTRICAL VALVE 15 COMPRESSED AIR SHIFT CYLINDER OF LOCK DIFERENTIAL 16 TYRE PRESSURE GAUGE 17 BRAKE PRESSURE GAUGE 18 ROTOR 19 SAFETY VALVE 20 RESERVOIR 21 DIFFERENTIAL LOCK

152

AP 240

Maintenance manual

AP 240

153

4.7.

Appendixes – scheme

Notes:

154

AP 240

Maintenance manual

Notes:

AP 240

155

Notes:

EC DECLARATION OF CONFORMITY EG – KONFORMITÄTSERKLÄRUNG / DECLARATION DE CONFORMITE CE DICHIARAZIONE CE DI CONFORMITA / DECLARACION CE DE CONFORMIDAD DECLARAÇÃO CE DE CONFORMIDADE/ ES PROHLÁŠENÍ O SHODĚ in accordance with EC Directives 98/37/EC and 2000/14/EC

I

Category / Art / Catégorie / Categoria / Tipo / Categoria / Název

II

Make (Type) / Hersteller (Typ) / Marque (Type) / Marca (Tipo) / Marca (Codice) / Marca (Tipo) / Značka (Typ)

Non-vibrating roller AP 240 (VP 2400) S/N:

III

Measured sound power level / gemessener Schalleistungspegel / niveau de puissance acoustiyue mesure / livello di potenza sonora rilevato / nivel de potencia acústica medido / Nivel de potência sonora midido / naměřená hladina akustického výkonu

LWA = 104 dB (A)

IV

Guaranteed sound power level /garantierter Schalleistungspegel / niveau de puisance acoustique garanti / livello di potenza sonora garantito / nivel de potencia acustica garantizado / Nivel sonoro garantido/ garantovaná hladina akustického výkonu

V

Notified body involved / beteiligte Zertifizierungsstelle / de l´organisme notifié / dell`organismo notificato che l´ha effettuata / dirección del organismo notificado que haya intervenido / organismo notificado envolvido/ zúčastněná notifikovaná osoba

VI

Conformity assessment procedure followed / KonformitätsBewertungsverfahren / la procédure appliquée pour l`éevaluation de la conformté et / procedura di valutazione della conformità / procedimiento de evaluación de la conformidad / procedimento de avaliação de conformidade/ použitý postup posuzování shody

LWA = 105 dB (A) RWTÜV Systems GmbH Langemarckstraße 20 45141 Essen Deutschland Notified body 0044 internal control of production according to Annex VI Directive 2000/14/EC

has been produced in accordance with following standards / ist in Übereinstimmung mit folgenden Richtlinien hergestellt worden / est produit conforme aux dispositions des directives europeenes ci-apres / ha sido fabricado en conformidad con las siguienter normas / é stato fabbricato in conformità alle sequenti norme / é fabricado conforme as seguintes normas/ byl vyroben v souladu následujícími směrnicemi a normami 98/37/EC 89/336/EEC 2000/14/EC EN 500-1 EN 500-4

Machinery Directive of the European Parliament and of the Council of 22 June 1998 EMC Directive of the Council of 3 May 1989 Noise emission Directive of the European Parliament and of the Council of 8 May 2000 Mobile road construction machinery - Safety Part 1: Common requirements Mobile road construction machinery - Safety Part 4: Specific requirements for compaction machines

File certificate carefully / Bescheinigung bitte sorgfältig aufbewahren / Conserver certificat soigneusement / Conservar certificado cuidadosamente / Pregasi conservare accuratamente certificato / Conservar o certificado com cuidado / Prohlášení o shodě pečlivě uschovejte.

Nové Město nad Metují 26.4.2005

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

Quality Control Manager

Ammann Compaction Stavostroj, a.s.

Náchodská 145 549 01 Nové Město nad Metují Czech Republic telefon: +420 491 476 111, fax: +420 491 470 215 E-mail:. stavo@sta.cz, internet: http\\ www.sta.cz