STA Roller VH 850 & VH950 Tandem Vibratory Rollers Repair Manual - PDF DOWNLOAD

WORKSHOP MANUAL

VH 850 and VH 950 TANDEM VIBRATORY ROLLERS STAVOSTROJ a.s., Nové Město nad Metují

© 2 / 2004

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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VH 850/VH 950

CONTENT

Content .............................................................................................................................................................................. 3

1. INTRODUCTION .............................................................................................................. 5 2. REPAIR SAFETY INSTRUCTIONS .................................................................................. 9 2.1.

2.2.

2.3.

REPAIR SAFETY INSTRUCTIONS .................................................................................................................... 12 ENVIRONMENTAL MEASURES AND HEALTH PRECAUTIONS ..................................................................... 16 FIRE PRECAUTIONS ......................................................................................................................................... 17

3. DESCRIPTION OF THE MACHINE ............................................................................... 19 3.1.

3.2.

3.3.

3.4.

Basic data .......................................................................................................................................................... 22 ............................................................................................................................................................................ 23 Machine dimension scheme ............................................................................................................................. 24 Technical data .................................................................................................................................................... 26

4. DRUM ............................................................................................................................ 31 4.1.

4.2.

4.3.

4.4.

4.5.

4.6.

4.7.

4.8.

Dismantling the vibration hydromotor (replacement on the machine) ............................................................ 34 Dismantling of hydromotors of the travel and dust cover (Change in the machine) ...................................... 38 Dismantling the drum out of the machine ......................................................................................................... 45 Drum dismantling ............................................................................................................................................... 47 The dismantling of vibrator bearings and flange oil seal ................................................................................. 52 The dismantling of the inner ring of the bearing out of the vibrator shaft ........................................................ 54 Drum assembling ............................................................................................................................................... 55 The dismantling of rubber-metals (replacement on the machine) .................................................................. 60

5. THE DISMANTLING OF THE TIRE AXLE ..................................................................... 63 5.1. The dismantling of the travel hydromotor ......................................................................................................... 66

6. WATER TANKS .............................................................................................................. 69 6.1. Removing the tank from the machine frame ..................................................................................................... 72

7. YOKE ............................................................................................................................. 73 7.1. Removing the yoke from the machine frame, replacement of the bearing and replacement the drum turning sensor ................................................................................................................................................................. 78 7.2. Removal of the first yoke shaft and replacement of bearings .......................................................................... 88

8. THE CABIN .................................................................................................................... 93 8.1. Removing both front and rear rubber-metals of the cabin (replacement on the machine) ............................ 96 8.2. Removing the cabin out of the machine frame ............................................................................................... 101

9. THE HYDRAULIC SYSTEM ......................................................................................... 109 9.1.

9.2.

9.3.

9.4.

9.5.

9.6.

Dismantling hydromotors for steering and lifting (packing replacement) ...................................................... 114 The assembly of hydromotors for steering and lifting (packing replacement) .............................................. 116 Dismantling pumps of travel and vibration (replacement on the machine) ................................................... 118 Dismantling the clutch of the pump for travel and vibration (replacement on the machine) ........................ 120 Dismantling the steering pump (replacement on the machine) ..................................................................... 121 Hydraulic diagrams ......................................................................................................................................... 123

10. THE COOLING OF ENGINE AND HYDRAULIC CIRCUIT ....................................... 131 10.1. Removal of the wather and of the oil cooler (replacement on the machine) ................................................ 134

11. ENGINE .................................................................................................................... 137 11.1. Removal of the engine from the machine ....................................................................................................... 140

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12. ELECTRICAL WIRING ................................................................................................ 143 12.1. Layout of electric components in the machine ................................................................................................. 146 12.2. Fuse box .............................................................................................................................................................. 148 12.3. Accumulator ........................................................................................................................................................ 149 12.4. Exchange bulbs headlights ............................................................................................................................... 150 12.5. Exchange bulbs of dashboard ........................................................................................................................... 152 12.6. Wiring diagram .................................................................................................................................................... 154

13. APPENDICES.............................................................................................................. 157 13.1. Measuring points ................................................................................................................................................ 160 13.2. Pulse sensors adjustment .................................................................................................................................. 162 13.3. Vibration adjustment ........................................................................................................................................... 166 13.4. Towing ................................................................................................................................................................. 167 13.5. Troubleshooting .................................................................................................................................................. 176 13.6. Table of tightening moments .............................................................................................................................. 204 13.7. List fixtures ........................................................................................................................................................... 207

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VH 850/VH 950

1. INTRODUCTION

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1. INTRODUCTION

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VH 850/VH 950

1. INTRODUCTION This service manual consists of independent chapters dealing with both technical and assembling data, adjustment instructions and the guideline how to use special tools, jigs, fixtures and aids.

The main purpose of this manual is to provide basic information for assembly, dismantling and service repairs of main assemblies of the machine.

The unit assemblies are marked in this manual in the same way as in the spare parts catalogue.

Before the dismounting, we recommend you to mark the parts disassembled keeping in mind the way how they will be put back and to blind all holes of the hydraulic system to prevent contamination of hydraulic circuits.

During assembling the parts to the machine, tighten each bolt or nut according to the tightening torque table (Chapter 13.6.) if it is not stipulated otherwise in the text.

Always follow safety regulations and measures shown in Chapter 2.

The manufacturer is continuously improving his products on the basis of operational experience and latest developments.

He, therefore, retains the right to make changes, on the basis of research and development, as compared with Figures, descriptions, procedures and designs given in this manual.

Terms such as in the right-hand, left-hand, front or back are used in this manual for the customer´s information - that means when the machine goes forward.

Data and Figures in this manual must not be reproduced and spread in any way as they are protected by copyright.

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VH 850/VH 950

2. REPAIR SAFETY INSTRUCTIONS

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VH 850/VH 950

Content:

2.1. REPAIR SAFETY INSTRUCTIONS 2.2. ENVIRONMENTAL MEASURES AND HEALTH PRECAUTIONS 2.3. FIRE PRECAUTIONS

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2.1.

2.1. REPAIR SAFETY INSTRUCTIONS THE FOLLOWING SAFETY INSTRUCTIONS MUST BE OBSERVED BY ALL REPAIRING THE MACHINE! • Repairs may be carried out by skilled, trained and experienced personnel or dealer only and/or by STA service.

• When performing repairs, always use our shop manual. Special instructions for the assembly work are given in individual chapters of the manual.

• Before putting the machine into operation acquaint yourselves with the machine control as given in the “Operator’s Manual“ and make sure that you understand well all outfit of the machine.

• • • • •

Do not use the machine if you do not fully understand all controls and until you know how the machine works.

Know the area where you will work.

Do not make any redesign or modifications on the machine because you could decrease safety of the equipment.

Original parts and accessories have been designed especially for this machine.

Installation and usage of spare parts not supplied by the manufacturer of the machine or not authorized by him can have negative effects on operational characteristics and safety operation of the machine.

SAFETY PRECAUTIONS WHEN REPAIRING AND INSPECTING THE EQUIPMENT • • • •

Wear work clothe and boots.

• • • •

Secure the frame of the equipment and the drum against mutual rotation using a safety pin and a draw bar.

Use gloves when handling oils, fuel or coolant.

Protect your eyes with goggles or a shield when handling the battery.

Place the equipment on a flat and firm surface before starting repair. Secure the equipment against spontaneous movement.

Before starting work remove the ignition key, disconnect the batteries and let hot parts cool down.

Attach a warning note “Equipment out of work“ to the steering wheel and leave it there for the duration of service work.

Wash the equipment thoroughly. If you use steam, do not expose electrical components and insulation directly to stem jet, or else cover them beforehand.

• Keep all parts absolutely clean when dismantling, mounting, and servicing each assembly. Protect removed parts from getting soiled.

• Clean the surface of dismantled parts and provide for adequately dust-free working conditions and a needed lay-off area.

• • • • • •

Be careful when handling cleaning agents. Do not use petrol or other easy inflammable materials for cleaning.

Dry the cleaned parts and immediately cover with anticorrosive protective oil- never install corroded parts!

Tools, hoists, safety equipment of the supports, and other additional items must be serviceable and in good condition.

Use hoists and fasteners (ropes, chains) that have sufficient carrying capacity and are in good condition.

Make sure that there is enough fresh air supply when starting up the equipment in an enclosed area.

Before placing the equipment into operation make sure there nobody on the equipment or close by. The start of the equipment must always be announced with an audible alarm , also after any pause in operation before the equipment is restarted. Persons present on the equipment and dangerously close by must leave the equipment after such alarm has been sounded.

• Do not adjust moving equipment.

• When working (adjusting) on the running engine, avoid touching hot and rotating parts.. During work on the running engine, another person must be present that can easily access the emergency switch and must be in contact at all times with the person performing the adjustment, to be able to switch off the engine immediately when necessary.

• Use only prescribed makes of motor, gear and hydraulic oils and coolants.

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VH 850/VH 950

2.1.

SAFETY INSTRUCTIONS FOR WORK ON HYDRAULIC CIRCUITS • Make sure that no hydraulic circuit is under pressure before dismantling it. Hydraulic oil leaks under pressure may injure your skin and cause a serious injury.

• • • • • • • • • • • • • • • • •

Mark all parts, hoses and pipes before removing them.

Do not operate hydraulic generators and hydraulic motors without oil.

There is danger of being scalded when handling hot oil.

Do not warm oil to temperatures above 160 °C (320 °F) - oil or its fumes may ignite.

For cleaning and wiping hydraulic parts use such textiles that do not leave lint.

When reassembling parts use hydraulic oil - not grease - as lubricants.

Clean screws and bolts carefully before installation, wash hoses and pipes and blow them off using compressed air.

Always use new packing in seals.

Fill new aggregates with hydraulic oil before installation.

Rinse hydraulic circuit after replacing the hydraulic device, clean the hydraulic tank as well.

Replace the oil filter cartridge.

Fill the hydraulic circuit with pure oil of the prescribed viscosity, but only when the engine has been stopped!

Wipe off overflow oil.

Check connections for tightness, whether they leak oil, before applying pressure to the system.

Do not adjust safety valves.

After all work has been finished, recheck all connections and replace all safety elements After finishing the work install again all protective elements.

AFTER PUTTING THE MACHINE INTO OPERATION, CHECK • Oil level in the hydraulic tank.

• Check up filling pressure in hydraulic generators in case they are replaced as well as pressure in safety valves. Carry out the measurement at temperature of 40 °C (104 °F).

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2.1.

SAFETY INSTRUCTION FOR WORK ON THE FUEL SYSTEM Mixtures of petrol and diesel (winter fuel) are as inflammable as petrol.

• Do not refuel in closed areas.

• Wipe off overflowed fuel.

• Do not smoke when working on the fuel system and do not use naked light! There is a danger of fire!

SAFETY INSTRUCTION FOR WORK ON ELECTRICAL WIRING • • • •

Disconnect the battery when carrying out any repair in the charging circuit to avoid incidental short-circuits.

When dismantling, first disconnect the cable from the negative pole (-), then from the positive one (+).

Do not disconnect batteries when the engine is running!

Connect the “minus“ pole of the battery to the chassis and the “plus“ pole to lead “B+“ from the alternator. In case of the reverse connection the whole semiconductor device could get destroyed.

• When starting with auxiliary external supply, do not disconnect such supply sooner than the battery of the machine is connected.

• Do not put the alternator into no-load run, i. e. with the wire disconnected from the “+“ terminal and connected “D+“ terminal.

• • • • •

Do not check the presence of voltage in the wire by sparking it on the chassis of the equipment.

Do not do anything that produces sparks.

When handling batteries, use protective rubber gloves and goggles.

Protect your skin and clothes from stains by electrolyte or lead particles.

When electrolyte gets into your eye, rinse it with a stream of water for a few minutes. Then see a doctor as soon as possible.

• When electrolyte stains your skin or clothes, take off your clothes, wash the stained area with soap water or with a solution of baking soda and water and see a doctor.

• After taking electrolyte incidentally, drink as much milk or water as possible or a solution of magnesia and immediately see a doctor.

• Never pour distilled water into the cells unless the operation of the machine or charging outside the equipment follows.

In such case the battery would self discharge increasingly.

• • • •

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Never add sulfuric acid (H2SO 4)!

Do not overturn the batteries because electrolyte could run out of the degassing holes of the battery.

If acid (electrolyte) is spilled, rinse the place with water and neutralize it with lime.

When the batteries are being charged, hydrogen is released and it makes mixed with air, an explosive, easily combustible mixture. Do not use open flame and do not smoke.

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2.1.

WELDING ON THE MACHINE Before starting arc welding, disconnect all parts with semiconductors from electrical wiring, i. e.:

• • • • • • •

engine alternator hours counter all electronic element on the machine it is necessary to earth both the supply and the machine that is being repaired secure the supply against moisture place ground terminal close to the welded joint. when parts are welded or when the machine is in the suspended position, it is necessary to insulate the point of current transfer to avoid current entering the hoist, or to use a non-conducting rope.

SEALS • Always use new packing.

• You will receive packing kits as spares.

TIGHTENING TORQUE • • • • • • •

Use a torque key for the right tightening torque.

Fastening bolts and nuts of the given quality are tightened according to the table (Chapter 13.6).

Quality of the bolt is shown visibly on the bolt head.

Tightening torque is given in tables.

Thread joints of hydraulic circuits are tightened according to tables.

The given tightening torque is valid for not oiled bolt thread.

Use new self-locking nuts only.

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2.2.

2.2. ENVIRONMENTAL MEASURES AND HEALTH PRECAUTIONS When repairing the machine, keep general principles of health protection and environment protection as well, and observe laws, regulations, and guidelines related to these problems as applicable to the territory where the equipment is used.

PRINCIPLES OF HYGIENE • Oil products, coolants, battery acids, and paints including thinners can be harmful to your health and they can injure your organs seriously.

• It is necessary to observe consistently safety and health instructions enclosed with the products and to use personal protective aids when handling them.

• Personnel in contact with these products during servicing are obliged to observe general principles of their health protection and keep in mind safety and health guidelines as given by manufacturers of such products, especially the following: - protection of eyes and skin when working with batteries, - protection of the skin when handling oil products, paint, and cooling liquids, - workers should wash their hands properly after finishing their work and apply proper healing hand lotions, - when working with the cooling system it is necessary to observe instruction manuals supplied with the machine.

• Oil products, coolants, batteries, and paint including organic thinners as well as cleaners and preservatives should be always stored in their original packages properly labeled. Do not store such materials in unlabelled bottles and other vessels because there is a danger of confusion. Confusion of food or drinks is especially dangerous.

• If the skin or eyes are by chance stained or fumes are breathed, apply immediately first aid. In case of incidental consumption of such products see your doctor immediately.

ECOLOGICAL PRECAUTIONS • Contents of machine systems and some parts of the machine can produce, when no longer in use, represent great risks to the environment.

The following products especially belong to this category: - both organic and synthetic lubricating materials, oils and fuel, - coolants, - battery acids and batteries themselves, - cleaning agents and preservatives, - all removed filters and filter elements, - all used and discarded hydraulic and fuel hoses, rubber - metals and the other elements stained with the above products.

• The above parts and materials must be handled, after they had been discarded, in accordance with valid national regulations on environmental protection and according to directions concerning health protection.

• When hydraulic liquids, fuel, cooling systems and their aggregates are being removed it is necessary to prevent their infiltration into the ground by using retaining vessels and by plugging the holes.

• After leaks the place must be immediately dried with sawdust, Vapex, and such.

• The contaminated earth must be removed to prevent further leakage. Then the soil and absorbing material must be disposed of safely.

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VH 850/VH 950

2.3.

2.3. FIRE PRECAUTIONS • From the standpoint of fire danger, the inflammable liquids used are divided into the following risk classes II. risk class - oil IV. risk class - mineral oils - lubricants - antifreeze The place where oil is being changed must not situated in an area where there is danger of explosion or fire.

• • Notices showing that smoking and open flame are not allowed must be installed there.

• The handling area must have sufficient dimensions to capture the amount of inflammable liquid equal to the volume of the largest vessel or the transport package.

• • • •

Portable fire-extinguishers must be available.

Oil and oil products should be handled in special vessels, e. g. metal barrels, cans, tin cans.

Transport vessels must be properly closed when stored.

The vessels should have one hole and should be always stored with the hole up and they must be secured against leakage.

• The vessels must be labeled with indelible inscriptions showing their contents and burning power class.

THE MACHINE IS SUPPLIED WITH THE FOLLOWING ITEMS: Operations manual Spare parts katalogue Spare parts of engine Operations manual of engine

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3. DESCRIPTION OF THE MACHINE

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VH 850/VH 950

Content:

3.1. Basic data 3.2. Machine design 3.3. Machine dimension scheme 3.4. Technical data

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3.1.

3.1. BASIC DATA The name plate of the machine containing basic data about the machine is attached on the left side of the machine.

Serial and type numbers are important for verification of the machine identity and/or in case of claims.

Plate with the serial number of engine.

Serial numbers and data of the aggregate purchased are shown directly on each aggregate.

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

Please complete following data: Machine type ..............................................................

Machine serial number .............................................

Year of the production ...............................................

Engine type ................................................................

Engine serial number ................................................

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VH 850/VH 950

3.2. MACHINE DESIGN

Legend 1 Frame 2 Front and rear stirrups 3 Front and rear drum 4 Engine 5 Tandem hydro-generator of travel and vibration 6 Servo-control hydro-generator 7 Engine and hydraulic oil combined cooler 8 Equalizing tank of coolant 9 Engine air suction filter 10 Gas outlet 11 Fuel tank

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3.2.

12 13 14 15 16 17 18 19 20 21 22

Hydraulic oil tank Sprinkling water tank, front, rear Cabin Engine hood, left, right Sprinkling of tyre treads Scrapers of tyre treads Accumulator Protective frame ROPS Travel hydraulic motor Vibration hydraulic motor Heating (air conditioning)

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3.3. MACHINE DIMENSION SCHEME

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Dimensions

A

B1

B2

D

H1

H2

K1

K2

mm

3060

1820

1867

1220

2950

2400

340

897

in

120,5

71,7

73,5

48

116

94,5

13,4

35,3

Dimensions

L

O

R1

R2

S

W1

W2

-

mm

4270

70

4502

2780

17

1680

2973

-

in

168

2,8

177,2

109,4

0,7

66,1

117

-

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3.3.

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3.4.

3.4. TECHNICAL DATA Weights VH 850

VH 950

Working weight with the cab – CECE Load of the front drum Load of the rear drum Static linear load of the front drum Static linear load of the rear drum

kg (lb) kg (lb) kg (lb) kg/cm (lb/in) kg/cm (lb/in)

8484 (18704,0) 4175 (9204,3) 4309 (9499,7) 24,9 (139,4) 25,9 (145,0)

9340 (20591) 4597 (10135) 4743 (10457) 27,4 (153,4) 28,2 (157,9)

Working weight with the cab and protective frame CECE front drum rear drum Static linear load of the front drum Static linear load of the rear drum

kg (lb) kg (lb) kg (lb) kg/cm (lb/in) kg/cm (lb/in)

8629 (19023,7) 4248 (9365,2) 4381 (9658,4) 25,3 (141,7) 26,1 (146,2)

9485 (20911) 4670 (10296) 4815 (10615) 27,8 (155,7) 28,7 (160,7)

Working weight (maximum) with cab due to ISO 6016 front drum rear drum Static linear load of the front drum Static linear load of the rear drum

kg (lb) kg (lb) kg (lb) kg/cm (lb/in) kg/cm (lb/in)

8879 (19574,8) 4365 (9623,2) 4514 (9951,7) 26 (145,6) 26,9 (150,6)

9735 (21462) 4787 (10554) 4948 (10908) 28,5 (159,6) 29,5 (165,2)

Working weight (maximum) with cab and protective frame due to ISO 6016 front drum rear drum Static linear load of the front drum Static linear load of the rear drum

kg (lb) kg (lb) kg (lb) kg/cm (lb/in) kg/cm (lb/in)

9024 (19894,5) 4438 (9784,1) 4586 (10110,4) 26,4 (147,8) 27,3 (152,9)

9880 (21782) 4860 (10714) 5020 (11067) 28,9 (161,8) 29,9 (167,4)

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

Driving properties The travel speed smoothly regulable in booth directions Front drum oscillation at the vertical level Turning of both drum at the horizontal level Theoretical machine’s gradeability Side static stability

km/h (MPH) ±° ±° % °

0 - 10 (6,2) 6 25 35 32

Hz (VPM) mm (in) kN (lb)

hydrostatic two-level, circle undirected vibration 42/50 (2520/3000) 0,66/0,26 (0,026/0,01) 88/49 (19782/11015)

The vibrations Drive Vibration driver Frequency Nominal amplitude Centrifugal power at one drum

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3.4.

Engine Manufacturer Engine type Number of cylinders Perforation Stroke Stroke volume Engine output due to ISO 3046/1 Nominal revolutions Maximum torsional moment Fuel filter Oil filter Air filter Air filter insert Air filter securing insert Engine cooling set Engine fulfills requirements of

Cummins B 3,3 - C 85 4 mm (in) 95 (3,7) mm (in) 115 (4,5) cm3 (cu in) 3260 (198,9) kW (HP) 63 (84) min -1 (RPM) 2600 Nm (ft lb) 291 (214,6) Cummins C6003117460 Fleetguard LF 3855 Donaldson G 08-2580 Donaldson P82-8889 Donaldson P82-9333 liquid-cooled engine with the Nissens radiator DIR. 97/68/EU, STAGE 1 EPA/CARB NON ROAD, 40 CFR, PART 89 TIER 1

The Brakes Working brake Parking and emergency brake

Brake-releasing pressure

MPa (PSI)

travel hydrostatic set four lamellas brakes built to the travel hydro motors controlled by springs with hydraulic brake-release 2,4 (348)

Drive Electro-hydraulic servo controls individual for front and rear drum Hydro-generator of the servo control Servo control: Control unit Block of steerage Securing pressure Straight hydro motor pressure filter filter insert

MPa (PSI)

Gear double-pump of tandem order Sauer PNN 11 11 SSC46 WAX Sauer S1X-36G2 AMP K 196C Hytos 729-0129 16 (2320) AXL Semily PHM 80/40-230 Hytos HD 069-176 Hytos V3.0520-06

Hydrostatic travel drive Hydro generator, piston, regulating with electric-hydraulic controlling of tandem order with hydro generator of the vibration The capacity per revolution cm3 (cu in/rev) Securing pressure MPa (PSI) Control Control unit Travel hydro motors ASC differential lock: Control unit Proportional valves

VH 850/VH 950

Sauer B90L055 55 (3,35) 42 (6090) Sauer MCH Sauer S1X-26G2 AMP K 196C Sauer 60C 0606 H 120C1 Sauer S1X-26G2 AMP K 196C Sauer 507479

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3.4.

Hydrostatic vibration drive Hydro generator, piston, regulating with electrical-hydraulic control The capacity per revolution Securing pressure Block of vibration Hydro motors of the vibration

cm3 (cu in/rev) MPa (PSI)

Sauer 42R32 32 (1,95) 35 (5075) Sauer 511260 Sauer MMF 025

Hydraulic tank Suction grid Thermoregulator

Hytos AS080-01 Wahler 7036-55

Tilting of the protective frame and the cab Hand pump

Hydraulic Benešov HA10-4P-VSH700 ZH1-63/32x250-K-ATYP ZH1-40/22x100-R Hytos RJV1-05-M/CJ

Straight hydro motor of lifting the cab Straight hydro motor of lifting the protective frame Hydraulic lock

Fills Engine (oil fill) Cooling system Fuel Hydraulic system Vibration drum Sprinkling tank Front sprinkling tank Rear sprinkling tank

l (gal US) l (gal US) l (gal US) l (gal US) l (gal US) l (gal US) l (gal US) l (gal US)

8 (2,1) 18 (4,76) 160 (42,3) 65 (17,2) 4x2 (4x0,53) 2,75 (0,72) 362 (95,6) 348 (91,9)

Sprinkling Water pump Water filter

SHURFLO 8000-043-235, 12V JABSCO TYP 01740002S

Electrical installation Electric set voltage Accumulator – capacity Grounded

28

V Ah

12 140 - pole

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3.4.

Safety device Emergency brake Automatic turning off the smooth start and end run Hydraulic lock

Cab brace Automatic control of the servo-driving electrical parts

Battery disconnector

Turning on optically signalized Turning off optically signalized Protective securing devices preventing the cab fall when fault hydraulic when lifting or lowering the cab Mechanical cab safety lock for lifted position The check is done continuously by the computer drive unit SIX – optically signalized Disconnecting the el. installation

Hygienic parameters VH 850, VH 950 The machine with cab and closed windows : Noise : The acoustic pressure level influenting the driver: (measured due to the ČSN EN ISO 11 204 and prEN 500-4:2001 on the elastic material, stopped machine with vibration) Guaranteed sound power level (measured due to the Directive 2000/14/EC and ČSN EN ISO 3744 on the elastic material, stopped machine with vibration) Vibrations : Vibrations acceleration nominal effective value : - transferred to the hands (measured due to the ISO 5349 when driving under the vibrations on the sand base) - transferred to the body (measured due to the EN 1032 when driving under the vibrations on the sand base)

LpA= 80 dB (A)

LWA= 108 dB (A)

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

The machine with cab and opened windows : Noise : The acoustic pressure level influenting the driver: (measured due to the ČSN EN ISO 11 204 and prEN 500-4:2001 on the elastic material, stopped machine with vibration)

LpA= 85 dB (A)

Requirements for meeting the traffic regulations The roller is not designed for travel on its own on public roads, so both its design and equipment don’t meet the promulgation for operations on traffic roads.

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3.4.

Auxiliary devices Protective frame The construction of protective frame ROPS meets the international standards EN 500-4.1995, SAE J 1040. APR 88, AS 2294.19, ISO 3471.1994 for maximum machine’s weight 10500 kg (23149 lb) Protective frame weight to the machine’s frame is fasten

kg (lb)

Tightening moment

Nm (in lb)

145 (320) 12 screws M 16x60, CSN 21143.55 (8 G) 100 (885)

Edge cutter and compactor Device weight Max. thickness of the cut layer Max. thickness of the compacted layer Cutting disc diameter Compacting disc diameter to the machine’s frame connected by screws tightening moment

30

kg (lb) mm (in) mm (in) mm (in) mm (in) Nm (in lb)

100 (220,5) 100 (3,94) 95 (3,74) 400 (15,75) 390 (15,36) 7 screws M 12x60 CSN 021101.55 80 (708)

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4. DRUM

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Content:

4.1. Dismantling the vibration hydromotor (replacement on the machine) 4.2. Dismantling of hydromotors of the travel and dust cover (replacement in the machine) 4.3. Dismantling the drum out of the machine 4.4. Drum dismantling 4.5. The dismantling of vibrator bearings and flange oil seal 4.6. The dismantling of the inner ring of the bearing out of the vibrator shaft 4.7. Drum assembling 4.8. The dismantling of rubber-metals (replacement on the machine)

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4.1.

4.1. DISMANTLING THE VIBRATION HYDROMOTOR (REPLACEMENT ON THE MACHINE) The method of the disassembly is the same for the left-hand side of the front and rear drums.

The machine should be set to the position suitable for discharging oil filling from the drum. The drum should be gradually set in such a way that the sign (lug) (1) was in the lowest position and the drain plug (2) on the left-hand side of the drum should be dismounted.

2 1

Install the Socket (4) with hose (5) belonging to the accessories to the machine (group 520) and discharge oil filling from the flange.

4

After the oil is discharged, install the plug (2) again.

The amount of oil filling in one flange is 2 litres.

5

Note: When you dismantle the drum out of the machine, oil filling on the right-hand side of the drum should be discharged as well.

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4.1.

A vessel should be put under the vibration hydromotor.

Remove hoses on the vibration hydromotor as well as the revolution sensor.

Note: When you install the sensor back, do it in keeping with Chapter 13.2. Sensors adjustment.

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4.1.

Remove two bolts in the vibration hydromotor gripping and take out the engine together with the clutch.

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4.1.

Take the flange off the vibration hydromotor and check O-rings.

When you install a new or original vibration hydromotor proceed in the reverse order.

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4.2.

4.2. DISMANTLING OF HYDROMOTORS OF THE TRAVEL AND DUST COVER (CHANGE IN THE MACHINE) The following procedure is the same for both front and rear drums.

Left-hand side: Before the dismantling of hydromotors of the travel and dust cover, first proceed as it is given in Chapter 4.1 and then carry out the operations specified in this chapter.

Right-hand side: Perform the operations specified in this chapter.

Note: When you dismantle the drum out of the machine (see Chapter 4.3), carry out the operations specified in this chapter on both left- and right-hand sides of the drum.

Dismantle the support and clip of hoses on the bracket.

Remove the revolution sensor and hoses on the travel hydromotor.

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4.2. left side of drum

right side of drum

Note: When you install the sensors back, do it in keeping with Chapter 13.2. Sensors adjustment.

Dismantle the lighting on the bracket.

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39

4.2.

Lift the machine on both left- and right hand sides using lifting-jacks in such a way that the drum slightly touches the ground.

Remove the bolts of the bracket gripping and take the bracket off the machine using a crane.

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4.2.

Note: Before both the brackets are taken out of the yoke the drum should be secured bilaterally against spontaneous rotation using the fixture item no. ND 090535.

Remove four bolts of the profile gripping.

Remove the profile using the puller from the travel hydromotor, put the puller head between the profile and body of the drum.

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4.2.

On the right-hand side of the drum take the weight out of the travel hydromotor using two bolts.

Check the O-ring in the weight.

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4.2.

Remove bolts along the perimeter of the lid as well as two screw plugs from the withdrawal holes.

Put the jig used for taking the hydromotor with the lid off the drum body into the hole in the travel hydromotor jig No. ND 118038.

Suspend the jig to the crane and balance the dismantled body by holding it at its end.

Put bolts into the withdrawal holes and dismantle the travel hydromotor with the lid from the drum body by gradual tightening it.

Remove the lid out of the hydromotor body.

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4.2.

After removing the lid, take off and check the dust cover.

Check the O-ring in the flange.

When you install a new hydromotor of the travel and dust cover proceed in the reverse order.

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4.3.

4.3. DISMANTLING THE DRUM OUT OF THE MACHINE The dismantling method is the same for both front and rear drums.

Before the dismantling of the drum proceed first as it is given in Chapter 4.1 and, secondly, according to Chapter 4.2 and then carry out the operations described in this chapter.

Remove two bolts of the ramp gripping and swing the ramp back.

Remove bolts of the scrapper gripping on both sides and take the scrapper off the machine.

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4.3.

Attach the ramp again back to the yoke of the machine using the bolts.

Lift the machine on both sides using lifting-jacks and roll out the drum.

Put the jack stand under the frame of the machine item No. ND 080399 and drop it using the lifting-jack on the jack stand.

The drum should be secured bilaterally against spontaneous rotation using the fixture item No. ND 090535.

If you install the drum to the machine proceed in the reverse order.

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4.4.

4.4. DRUM DISMANTLING The dismantling method is the same for both the front and rear drums.

The drum is assembled of two welded cylindrical parts, which are connected with the bearing. The expressions left-hand side of the drum and right-hand side of the drum are used in the following instructions for your better orientation to distinguish between the two welded cylindrical parts in the sense when the machine goes forward.

Before the dismantling of the drum proceed first as it is given in Chapter 4.1, secondly, according to Chapter 4.2 and, thirdly, as it is specified in Chapter 4.3, and then carry out the operations described in this chapter.

Part 1: The dismantling of flanges and vibrator from the body of the drum Dismantle the hoses for oil filling discharging on both sides of the drum.

Remove retaining rings on both sides of the drum.

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4.4.

Fasten the clamp item No. ND 080399 to the right-hand side of the drum and stand the drum up using the crane.

Remove the flange bolts.

Remove four screws of the withdrawal holes.

Insert the screws into the holes and by gradual tightening push away the flange out of the drum body.

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4.4.

Put suspension eyes into the withdrawal holes, tie them to the crane and take the flange out of the drum body.

Note: If it is necessary, dismantle the opposite flange in the same way after turning the drum.

Put the suspension eye to the vibrator shaft, tie it to the crane and take the vibrator out of the drum body.

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4.4.

Part 2: The dismantling of the drum bearing Remove bolts and washers all along the perimeter in the internal part of the drum.

Attach two clamps to the drum and take off the right-hand side of the drum using the crane.

Check the O-ring of the drum bearing all along its circumference.

Remove bolts and washers all along the perimeter in the left-hand internal part of the drum.

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4.4.

Install suspension eyes to the drum bearing and take it off using the crane.

Check the packing all along the perimeter in the left-hand part of the drum.

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4.5.

4.5. THE DISMANTLING OF VIBRATOR BEARINGS AND FLANGE OIL SEAL The dismantling method is the same for both the left- and right-hand sides of both the front and rear drum vibrators.

Before the dismantling of the vibrator bearings and flange oil seal, proceed first as it is given in Chapter 4.1, secondly, according to Chapter 4.2, thirdly, as it is specified in Chapter 4.3, fourthly, as shown in Chapter 4.4 Part 1 and then carry out the operations described in this chapter.

Remove the retaining ring out of the flange.

Turn the flange and remove three screws from the withdrawal holes.

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4.5.

Insert the screws (M10x120 G8) into the holes and by gradual tightening take the bearing out of the flange.

Dismantle the oil seal out of the flange.

If you install the vibrator bearings and flange oil seal, proceed in the reverse order.

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4.6.

4.6. THE DISMANTLING OF THE INNER RING OF THE BEARING OUT OF THE VIBRATOR SHAFT The dismantling method is the same for both the left- and right-hand sides of the vibrator in both the front and rear drums.

Before the dismantling of the inner ring of the bearing out of the vibrator shaft, proceed first as it is given in Chapter 4.1, secondly, according to Chapter 4.2, thirdly, as it is specified in Chapter 4.3, fourthly, as shown in Chapter 4.4 Part 1 and then carry out the operations described in this chapter.

Remove the inner ring of the bearing (1) together with the guide ring of the flange oil seal (2) out of the vibrator shaft using the puller.

Note: If you want to dismantle and replace the vibrator ”exents”, please contact your dealer or his service company.

The following rules should be observed when you mount the inner ring of the bearing (1) and ring of the flange oil seal (2) to the vibrator shaft: Check the inner O-ring in the guide ring (2). Warm the bearing (1) before putting it on the shaft. Temperature of the heating must not exceed 100 °C (212°F).

1

54

2

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4.7.

4.7. DRUM ASSEMBLING The assembling method is the same for both the front and rear drums.

The drum of the machine is assembled of two welded cylindrical parts, which are connected with the bearing. The expressions left-hand side of the drum and right-hand side of the drum are used in the following instructions for your better orientation to distinguish between the two welded cylindrical parts in the sense when the machine goes forward.

The left-hand side of the drum: Put the packing (or check it) into the drum and grease it.

Suspend the bearing to the crane using suspension eyes and place it above the drum.

Set the bearing using bolts and drop it down to the contact area using the crane.

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4.7.

Install bolts with washers all along the perimeter of the bearing.

Tighten the bolts with 75 Nm torque using the torque wrench.

Install the O-ring to the bearing.

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4.7.

Grease the whole perimeter of the O-ring.

Mark one of four opposite lubricating holes and the same time, mark this lubricating hole on the edge of the drum.

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4.7.

Right-hand side of the drum: Mark one of lubricating holes which is connected in the internal part of the drum using the hose for lubricating the drum bearing.

Put Lukoprén packing all along the perimeter of the contact area of the drum bearing.

Turn the drum using the crane.

Attach two clamps to the drum and suspend it to the crane.

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4.7.

The crane will take the right-hand side of the drum above the left-hand pre-assembled part of it in such a way that the marking of the lubricating holes in both the drums is aligned in one axis and then the right-hand drum is dropped down to the contact area of the bearing.

Put bolts with washers to the inner part of the drum and tighten them with 75 Nm using the torque wrench.

Further instructions for drum assembling can be found in the following chapters:

Chapter 4.6.

Chapter 4.5.

Chapter 4.4.

Chapter 4.3.

Chapter 4.2.

Chapter 4.1.

Always proceed in the reverse order in these chapters.

The order of the chapters is always given by the extent and method of the dismantling performed.

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4.8.

4.8. THE DISMANTLING OF RUBBER-METALS (REPLACEMENT ON THE MACHINE) The replacement method is the same for both the left- and right-hand sides of both front and rear drums.

Lift the machine frame using the lifting jack to relieve prestressing of rubber-metals.

Loosen bolts in the bracket gripping in such a way that clearance occurs between the bracket as well as between the yoke and bracket and rubber-metals.

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4.8.

Gradually replace rubber-metals by new ones, use the extension with the hollow hexagonal size 19 jig no. ND 080579 for dismantling bolts which fasten rubber-metals to the profile.

Note: All four rubber-metals must always be replaced.

If you install new rubber-metals proceed in the reverse order. Tighten rubber-metal bolts to 75 Nm torque.

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5. THE DISMANTLING OF THE TIRE AXLE

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Content:

5.1. The dismantling of the travel hydromotor

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5.1.

5.1. THE DISMANTLING OF THE TRAVEL HYDROMOTOR Remove the rear cover.

Remove bolts on the ramp gripping and swing the ramp back.

Remove bolts in the side cover gripping and attach the ramp back using the bolt.

Remove bolts in the side cover and take the cover off.

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5.1.

Lift the machine by lifting-jacks and put the jack stand item No. ND 080399 under the machine frame and then drop it using the lifting-jack down on the jack stand.

Remove wheel clamping bolts.

Take the wheel off the machine using a hand forklift.

Remove four hoses on the travel hydromotor.

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5.1.

Remove gripping bolts of the travel hydromotor.

Tie the rope to the travel hydromotor and take it off the machine using a forklift truck.

Proceed in the reverse order if you install the travel hydromotor to the machine.

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6. WATER TANKS

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Content:

6.1. Removing the tank from the machine frame

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6.1.

6.1. REMOVING THE TANK FROM THE MACHINE FRAME The method is the same for dismantling both the front and rear tanks.

Remove the sprinkling and water indicator hoses.

Turn the valve and discharge water from the tank.

Remove two fastening belts of the water tank using four bolts, remove the water indicator hose on the filler gap and take the tank out of the machine frame.

Proceed in the reverse order if you install the tank to the machine.

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7. YOKE

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74

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Content:

7.1. Removal the yoke from the machine frame, replacement of the bearing and replacement the drum turning sensor 7.2. Removal of the first yoke shaft and replacement of bearings

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7.1.

7.1. REMOVAL THE YOKE FROM THE MACHINE FRAME, REPLACEMENT OF THE BEARING AND REPLACEMENT THE DRUM TURNING SENSOR The following method is the same for both the front and rear drums.

Before removing the yoke out of the machine proceed first as it is given in Chapter 6.1. and then carry out operations specified in this chapter.

Remove hoses and the revolution sensor at the vibration hydromotor. (left side)

Remove hoses and the revolution sensor at the travel hydromotor.

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7.1.

Remove hoses and the revolution sensor at the travel hydromotor. (right side)

Note: When you install the sensors back, do it in keeping with Chapter 13.2. Sensor adjustment.

Remove the lighting on the bracket.

Remove the support and hose clip on the bracket.

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7.1.

Remove the hose clip at the yoke.

Fasten the hoses, sensors and lights to the machine frame.

Remove the cover.

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7.1.

Remove the washer with spring.

Note: Mark the position of the drum turning sensor to be used in the reverse assembly.

Remove the lid.

Remove the holder with the sensor and disconnect the socket and plug X 38.

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7.1.

Note: Mark the position of the holder to be used in the reverse assembly.

Use four bolts on the holder when removing the sensor.

Mark each conductor at the socket and take all of them out of it.

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7.1.

Remove the conductors from the body.

Remove the wiring clip on the yoke and take the conductors off the yoke body.

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7.1.

Remove bolts used for clamping the ramp and swing the ramp away.

Remove sprinkling hoses and take them out of the yoke body.

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7.1.

Remove the socket and plug X 16 on the ramp and take them out of the yoke body.

Take the driving hydromotor out of the yoke body.

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7.1.

Install it to the drum stop item no. ND 090535.

Remove bolts used for clamping the yoke to the machine frame.

Lift the machine on both left- and right-hand sides using lifting-jack in such a way that a gap of at least 100 mm occurs between the frame and the yoke.

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7.1.

Fasten the yoke body together with the drum to the crane and take it out of the machine.

Put the jack stand item No. 080399 under the machine frame and then drop it using the lifting-jack down on the jack stand.

Remove the bearing after loosening bolts along its perimeter.

Note: Proceed in the reverse order if you assemble the yoke to the machine and observe the following instructions.

Always keep the assembly position towards the marking you made during the dismantling when you put the sensor of drum and holder turning back to the machine!

If any differences in operation and driving adjustment appear after the assembly and testing the machine, contact your dealer for adjusting and setting the system.

If you replace the drum turning sensor by a new one, adjustment and setting of the system must be always carried out. Contact your dealer for this service.

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7.2.

7.2. REMOVAL OF THE FIRST YOKE SHAFT AND REPLACEMENT OF BEARINGS Before removing the shaft out of the front yoke body proceed first as it is given in Chapter 6.1, secondly, according to Chapter 7.1 and then carry out operations specified in this chapter.

Remove the bearing cap and spacer rings situated above the ramp.

Remove bolts and the cap.

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7.2.

Remove the bearing cap on the other side.

Knock out the shaft by 100 mm in the direction to the ramp.

Take off the spacer ring and outer ring of the bearing placed over the ramp.

Tie the shaft with the rope to the crane and knock it out.

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7.2.

Remove gradually the inner ring of the bearing and the other bearing with the thrust ring over the ramp using the puller.

Take the shaft out of the yoke using the crane.

Remove the bearing retaining ring on the shaft.

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7.2.

Remove the bearings using the puller.

Proceed in the reverse order if you assemble the shaft to the yoke.

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8. THE CABIN

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Content:

8.1. Removing both front and rear rubber-metals of the cabin (replacement on the machine) 8.2. Removing the cabin out of the machine frame

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8.1.

8.1. REMOVING BOTH FRONT AND REAR RUBBER-METALS OF THE CABIN (REPLACEMENT ON THE MACHINE) Before removing both front and rear rubber-metals of the cabin proceed first as it is given in Chapter 6.1 and then carry out operations specified in this chapter.

Note: All four rubber-metals of the cabin mount should be always replaced at the same time.

Remove bolts used for clamping the Rops safety frame on both the sides.

Push the lever (1) to the pump of lifting, the pump lever (2) set to the sign of swinging the safety frame and swing it away by pumping.

1

2

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8.1.

Loosen bolts used for clamping the rubber-metals and two bolts of the safety piece on the rear side of the cabin.

Remove two bolts used for clamping the partition of the cabin placed on the rear side of the cabin.

Install eyes for suspending the cabin on the front side of the cabin.

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8.1.

Suspend the cabin using the lifting eyes to the crane using the jig item no. ND 081957 on the front and rear sides.

Remove the stop with the plate on the front side of the frame using three bolts.

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8.1.

Loosen the pin of the cabin gripping.

Remove the nut in the front rubber-metals clamping.

Remove three bolts of clamping of the front rubber-metals plate.

Lift the cabin by at least 200 mm using a crane.

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8.1.

Remove the rubber-metals on the front part of the cabin.

Remove the rubber-metal partition on the rear side of the cabin.

Remove rubber-metals from the cabin holder on the rear side of the cabin.

Proceed in the reverse order if you mount front and rear rubber-metals of the cabin.

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8.2.

8.2. REMOVING THE CABIN OUT OF THE MACHINE FRAME Before removing the cabin out of the machine frame proceed first as it is given in Chapter 6.1 and then carry out operations specified in this chapter.

Part 1: Discharging water filling from the cooling circuit Drain the filling to a ready vessel.

Note: If you mount the cabin back to the machine again, pour cooling liquid through the cap on the equalizer reservoir and check its level at the upper level indicator.

Part 2: Disconnecting the throttle control cable Remove the throttle control cable in the hand controller placed on the right-hand side of the instrument panel.

Note: It can be done only in machines with manual throttle control.

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8.2.

Part 3: Disconnecting wiring elements in the cabin and taking the cabin out of the machine Remove three bolts of the instrument panel gripping and swing the panel away.

Disconnect sockets and plugs X2, X3, X9, X10, X11, X12, X13, X14, X29, X32, X33, X45 as well as the main supply connector.

Put out two connectors in X 32 plug.

Mark the cable with two connectors which you removed to facilitate the reverse mounting.

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8.2.

Remove bolts used for clamping the Rops safety frame on both the sides.

Push the lever (1) to the pump of lifting, the pump lever (2) set to the sign of swinging the safety frame and swing it away by pumping.

1

2

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8.2.

Remove two bolts used for clamping the partition of the cabin placed on the rear side of the cabin.

Install eyes for suspending the cabin on the front side of the cabin.

Suspend the cabin using the lifting eyes to the crane using the jig item no. ND 081957.

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8.2.

Remove the stop with the plate using three bolts.

Remove the nut in the front rubber-metals clamping.

Remove three bolts of clamping of the front rubber-metals plate.

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8.2.

Lift the cabin by at least 500 mm (19,6 in) using a crane.

Remove four bolts and take the cover with electrical cables out of the cabin.

Remove the clip on the cabin and take the hoses out.

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8.2.

Remove two clips in the lower part of the cabin and take the hoses out.

Remove the hoses out of the heater body.

Remove the pull rod used for controlling the heater valve.

Take the cabin out of the machine and lay it by.

Proceed in the reverse order if you mount the cabin to the machine.

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9. THE HYDRAULIC SYSTEM

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Content:

9.1. Dismantling hydromotors for steering and lifting (packing replacement) 9.2. The assembly of hydromotors for steering and lifting (packing replacement) 9.3. Dismantling pumps of travel and vibration (replacement on the machine) 9.4. Dismantling the clutch of the pump for travel and vibration (replacement on the machine) 9.5. Dismantling the steering pump (replacement on the machine) 9.6. Hydraulic diagrams

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9.1.

9.1. DISMANTLING HYDROMOTORS FOR STEERING AND LIFTING (PACKING REPLACEMENT) VH 850 and VH 950 machines are equipped with the following three types of hydromotors: Hydromotors controlling the front and rear drums

Hydromotor for lifting the cabin

Hydromotor for lifting the Rops safety frame

The following procedure is the same for the dismantling of the above engines.

Release the cover of the steering hydromotor.

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9.1.

Remove the cover using a hook spanner and take it out.

Take out the piston of the steering hydromotor.

Remove the piston nut and pack the piston together with the cover again.

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9.2.

9.2. THE ASSEMBLY OF HYDROMOTORS FOR STEERING AND LIFTING (PACKING REPLACEMENT) The following procedure is the same for mounting the below hydromotors and the difference is only in the diameter of ND 101783 mounting device.

Hydromotors controlling the front and rear drums, ............................ ND 101783 - ∅ 63 Hydromotor for lifting the cabin ............................................................. ND 101783 - ∅ 80 Hydromotor for lifting the Rops safety frame. ...................................... ND 101783 - ∅ 40

ND 101783 device.

Install the device into the steering hydromotor body ND 101 783 and put on the piston.

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9.2.

Remove the device out of the steering hydromotor.

Mount and secure the follower.

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9.3.

9.3. DISMANTLING PUMPS OF TRAVEL AND VIBRATION (REPLACEMENT ON THE MACHINE) Before dismantling pump for travel and vibration first, lift the machine cabin using the lifting pump on the hydraulic tank, secondly, remove the protective cover of the exhaust piping and, thirdly, remove the exhaust piping.

Remove the lower sheet from the machine frame.

Remove hoses and wiring on the pump for travel and vibration. Put a vessel for discharged oil under the pump

Note: All dismantled elements should be marked to facilitate the reverse mounting.

Suspend the pump on the crane using a rope.

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9.3.

Remove four bolts used for clamping the pump to the engine.

Take the pump out of the machine using the crane.

Proceed in the reverse order while mounting the pump for travel and vibration again.

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9.4.

9.4. DISMANTLING THE CLUTCH OF THE PUMP FOR TRAVEL AND VIBRATION (REPLACEMENT ON THE MACHINE) Before removing the clutch of the pump for travel and vibration proceed first as it is given in Chapter 9.3 and then carry out operations specified in this chapter.

Remove the inner part of the clutch in the pump.

Note: Tighten the bolt with 86 Nm torque while mounting the clutch to the pump.

Remove bolts along the perimeter of the engine flange.

Remove bolts along the perimeter of the external part of the clutch and take the clutch out.

Note: Tighten the bolt with 48 Nm torque while mounting the clutch to the pump.

Proceed in the reverse order if you assemble the clutch again.

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9.5.

9.5. DISMANTLING THE STEERING PUMP (REPLACEMENT ON THE MACHINE)

Remove covers on the machine frame behind the front drum.

Remove the hoses on the pump. Put a vessel for discharged oil under the pump.

Remove caps on the pump and two bolts of the pump gripping.

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9.5.

Take the pump out of the engine flange.

Proceed in the reverse order if you assemble the pump again.

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9.6.

9.6. HYDRAULIC DIAGRAMS

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Hydraulic system

-

Hydraulic system of the pneumatic version

-

Hydraulic system - ASC

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9.6.

Hydraulic system Key: 1 - Tandem pump

SAUER

2 - Vibration block

SAUER

3 - Travel hydromotor

SAUER

4 - Vibration hydromotor

SAUER

5 - Steering hydromotor 6 - Non-applicable 7 - Steering pump

SAUER

8 - Non-applicable 9 - Flushing block

HYTOS

10 - Steering block

HYTOS

11 - Brake block

HYTOS

12 - Combined cooler

NISSENS

13 - Filter

HYTOS

14 - Hydraulic tank

STAVOSTROJ

15 - Suction strainer

HYTOS

16 - Filler

ARGO

17 - Oil level gauge 18 - Non-return valve

HYTOS

19 - Non-return valve

HYTOS

20 - Thermoregulator 21 - Temperature sensor

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9.6.

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125

9.6.

Hydraulic system of the pneumatic version Key: 1 - Tandem pump

SAUER

2 - Travel hydromotor

SAUER

3 - Travel hydromotor

POCLAIN

4 – Vibration hydromotor

SAUER

5 - Steering hydromotor 6 - Non-applicable 7 - Steering pump

SAUER

8 - Non-applicable 9 - Flushing block

HYTOS

10 - Steering block

HYTOS

11 - Brake block

HYTOS

12 - Combined cooler

NISSENS

13 - Filter

HYTOS

14 - Hydraulic tank

STAVOSTROJ

15 - Suction strainer

HYTOS

16 - Filler

ARGO

17 - Oil level gauge 18 - Non-return valve

HYTOS

19 - Non-applicable 20 - Thermoregulator 21 - Temperature sensor

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9.6.

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127

9.6.

Hydraulic system - ASC Key: 1 - Tandem pump

SAUER

2 - Vibration block

SAUER

3 - Travel hydromotor

SAUER

4 - Vibration hydromotor

SAUER

5 - Steering hydromotor 6 - Non-applicable 7 - Steering pump

SAUER

8 - ASC valve

SAUER

9 - Flushing block

HYTOS

10 - Steering block

HYTOS

11 - Brake block

HYTOS

12 - Combined cooler

NISSENS

13 - Filter

HYTOS

14 - Hydraulic tank

STAVOSTROJ

15 - Suction strainer

HYTOS

16 - Filler

ARGO

17 - Oil level gauge 18 - Non-return valve

HYTOS

19 - Non-return valve

HYTOS

20 - Thermoregulator 21 - Temperature sensor

128

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10. THE COOLING OF ENGINE AND HYDRAULIC CIRCUIT

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Content:

10.1. Removal of the wather and of the oil cooler (replacement on the machine)

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10.1.

10.1. REMOVAL OF THE WATHER AND OF THE OIL COOLER (REPLACEMENT ON THE MACHINE) Before removing the water radiator and oil cooler proceed first as it is given in Chapter 6.1, secondly, swing the Rops safety frame away as specified in Chapter 8.2 and then carry out operations specified in this chapter.

Remove the lower sheet out of the machine frame.

Remove the left cover on the machine frame behind the front drum.

Take the battery out of the frame machine.

Drain the filling from the cooling circuit to a ready vessel.

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10.1.

Remove the holder with the valve of emergency sprinkling.

Remove two bolts of rubber-metals gripping of the coolers.

Remove the rubber-metal bolt and take the rubber-metal out.

Remove hoses in the water radiator and oil cooler.

Note: Drained oil and water filling collect in ready vessels.

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10.1.

Remove bolts in the collector gripping and take the collector off the frames of the coolers.

Suspend the coolers using the suspension eyes item no.

ND 081958 to the crane.

Take the coolers out of the machine using the crane and lay them by.

Take the collector out of the machine.

Note: When you install the collector back check the uniform distribution of clearance between the collector and the fan.

Proceed in the reverse order when you install the water radiator and oil cooler back to the machine.

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Content:

11.1. Removal of the engine from the machine

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11.1.

11.1. REMOVAL OF THE ENGINE FROM THE MACHINE Before removing the engine out of the machine frame proceed first as it is given in Chapter 6.1 then swing away the Rops safety frame, thirdly, proceed as it is shown in Chapter 8.2,, fourthly, as it is specified in Chapter 10.1 and then carry out operations specified in this chapter.

Remove all wiring elements from the engine, e. g., at the alternator, starter, sensors, motor frame, and the like.

Then remove, e. g. hoses of the hydraulic circuits, suction heater hoses and the throttle control cable.

Note: All dismantled elements should be marked to facilitate the reverse mounting.

Remove two bolts clamping the brackets at the right-hand side of the engine.

Remove two bolts on the lower side of the rubber-metal on the left-hand side of the engine.

Note: While loosening two nuts on the lower side of the rubber-metal, the bolt head on the upper part of the rubber-metal must be held with a wrench.

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11.1.

Remove two bolts of rubber-metal gripping on the lefthand side of the engine.

Suspend the engine to the crane and take it out of the machine frame.

Proceed in the reverse order when you install the engine back. Tighten the bolt with 75 Nm of the clamping brackets.

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142

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12. ELECTRICAL WIRING

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Content:

12.1. Layout of electric components in the machine 12.2. Fuse box 12.3. Accumulator 12.4. Exchange bulbs headlights 12.5. Exchange bulbs of deshboard 12.6. Wiring diagram

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12.1.

12.1. LAYOUT OF ELECTRIC COMPONENTS IN THE MACHINE

Legend: Drum speed sensor

18

2

Vibrator speed sensor

19

Hydraulic oil temperature sensor

3

Solenoid of small vibration amplitude

20

Heater socket

4

Solenoid of great vibration amplitude

21

Socket for rear supplementary headlights

5

Front sprinkling pressure switch

22

Sprinkling pump

6

Rear sprinkling pressure switch

23

Drum steer sensor

7

Fuel gauge float

24

Air filter sensor (cleanness)

8

Susmic ASC (control unit)

25

Engine starter

9

Battery

26

Servo-valve of the travel pump

10

Solenoid – drum – in the right

27

Front drum vibration solenoid

11

Solenoid – drum – in the left

28

Engine revolution sensor

12

Socket for front supplementary headlights

29

Rear drum vibration solenoid

13

Alternator

30

Brake solenoid

14

Engine lubrication

31

Machine grounding

15

Engine temperature sensor

32

Brake pressure switch

16

Starter contactor

33

Battery disconnector

17

Water in the fuel filter sensor

1

146

STOP solenoid of the engine

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12.2.

12.2. FUSE BOX Includes fuses of the following apparatus: F1

Headlights, tail-lights, clearance headlights ... 15A

F2

Back-up lights, cab illumination ........................ 15A

F3

Direction indicators, working lights, beacon, mounting lamp socket, horn ............... 20A

F4

Drive electronics, electronically operated gas, engine stop, brake, reverse horn ...................... 10A

F5

Sprinkling ............................................................. 25A

F6

Vibrations, cutter and compacter ...................... 7.5A

F7

Control electronics .............................................. 10A

F8

Differential lock electronics ................................ 10A

F9

Instruments, pilot lamps ....................................... 5A

F10 Wipers and sprinkler ........................................... 15A F11 Heating ................................................................. 25A F12 Air-conditioning .................................................. 7.5A

Note: Replace fuses with same type fuses only!

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12.3. ACCUMULATOR The accumulator type Warta is located to the left side of the frame.

Handling Fill cells with sulfuric acid of specific density 1.28 g/cu. cm, 5-10 mm above the plates. Equalize the electrolyte and the battery to 15 – 20 °C when filling.

Let the electrolyte soak in the plates for 20 minutes, in batteries older than 6 months for 3 hours. Top possible level drop to 5 – 10 mm above plates. Charge the battery according to table.

The highest charging temperature is 40 °C. If necessary, cool by air flow or water bath, or lower charging current, or charge intermittently.

Currents lower than those indicated in the table are beneficial, however, charging will be prolonged. Leave input openings uncovered. Check the level and density of the electrolyte when finished charging. If necessary, top the level and adjust density to 1.28 g/ cu.cm. Tighten the plugs after 2 hours of degassing, flush the outside of the battery with water and clean dry.

Charging current table - example Type

Capacity

Charging

War ta

140 Ah

12 A

The values are correct for electrolyte temperature of 27 degrees C. At temperature lowers by 15 degrees C the electrolyte density is higher by 0.01 g/cu.cm. When topping up the electrolyte, density readings are correct after 10 to 30 minutes of charging, depending on the current and the intensity of bubbling. The level may be raised before charging up, to 5 to 10 mm above cell dividers.

Maintenance during operation Correctly working charging circuit maintains the battery close to full charge. The level of regulated voltage is between 27.6 and 28.4 V. When the voltage level is adjusted to these values, the electrolyte level is checked every 3 months. In summertime, check once a week. Battery overcharging is indicated by the electrolyte volume decrease. Insufficient charge affects the density of the electrolyte. Idle battery discharge is 1% of the capacity per day.

Battery is charged by current 0,1 overall capacity until fully charged.

The batteries must be kept clean, properly fastened, the holder must not deform the battery block.

Vaporization of the electrolyte forms a layer of sulfites on the surface of metal pieces, which must be cleaned.

Cleaned surfaces are to be protected by a light layer of Vaseline or oil.

Idle batteries must be charged up after two months.

Safety rules

Indication of completed charging Battery is considered fully charged when all cells bubble intensively and the electrolyte indicates density of 1.28 g/cu.cm. The terminals read 15 to 16 V. Full charge is checked after further two hours; values shouldn‘t vary from initial readings. Battery is discharged when density drops to 1.12 g/cu.cm.

Instantaneous charge rate is indicated in the following table:

Charge level in %

Electrolyte density in g/cu.cm

100

1,28

70

1,23

50

1,20

20

1,15

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While handling full batteries one must be very careful. Use gloves and goggles.

Stained skin must be washed and neutralized by soap and soda. During charging the electrolyte develops oxygen and hydrogen, an explosive mixture. It is not allowed to handle open flame near charging batteries. An explosion may occur if caused by a spark resulting from disconnecting or loosening the clamp while the charging current is present.

When removing the battery, disconnect minus cable first.

It is not allowed to disconnect the battery while the engine is running.

149

12.4.

12.4. EXCHANGE BULBS HEADLIGHTS Remove bolts on the ramp gripping and swing the ramp back.

Disconnet the connector.

Remove cap.

Press fixing spring.

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12.4.

Remove bulb.

Proceed in the reverse order when you install the bulbs back.

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12.5.

12.5. EXCHANGE BULBS OF DASHBOARD Remove three bolts of the instrument panel gripping and swing the panel away.

Disconnect connectors.

Push out panel of switch from dashboard and remove socket with bulb.

Push out panel of warning lamp from dashboard and remove socket with bulb.

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Remove bulb.

Proceed in the reverse order when you install the bulbs back.

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12.6. WIRING DIAGRAM Key: (the diagram represents the machine with maximum number of control elements and accessories) A1 - Indicator lights flasher (optional) A2 - Travel electronics A3 - Travel controller A4 - Travel controller A5 - Steering electronics A6 - Display A7 - Differential lock electronics (optional) A8 - Steering wheel A9 - Brake timer A10 - Electronics for travel security A11 - Heating control electronics B1 - Engine revolution sensor B2 - Front vibrator revolution sensor B3 - Rear vibrator revolution sensor B4 - Sensor of the front drum turning B5 - Sensor of the rear drum turning B6 - Revolution sensor of the left front drum B7 - Revolution sensor of the right front drum B8 - Revolution sensor of the left rear drum (optional) B9 - Revolution sensor of the right rear drum (optional) B10 - Engine temperature sensor B11 - Hydraulic system temperature sensor B12 - Fuel gauge float E1 - Instrument lighting E2,3 - Front sidelights E4,5 - Tail lights E6,7 - Front headlights E8,9 - Rear headlights E10,11 - Cabin lighting E12,13 - Left direction indicator lights E14,15 - Right direction indicator lights E16,17 - Side front headlights (optional)) E18 - Drum lighting (optional) E19,20 - Side rear headlights (optional) E21 - Beacon E22-25 - Auxiliary headlights on the cabin (optional) F1-12 - Safety fuses G1 - Battery G2 - Alternator H1 - Pilot lamp of direction indicators H2 - Horn H3 - Backing horn (optional) H4 - Neutral gear pilot lamp H5 - Brake pilot lamp H6 - Smooth drive-away and stopping pilot lamp H8 - Pilot lamp for small vibration amplitude H9 - Pilot lamp for great vibration amplitude H10 - Recharging pilot lamp H11 - Engine lubrication pilot lamp H12 - Water in fuel filter pilot lamp H13 - Air filter clogging pilot lamp H14 - Front sprinkler pilot lamp H15 - Rear sprinkler pilot lamp

154

H16 - Pilot lamp indicating a defect in the front steering H17 - Pilot lamp indicating a defect in the rear steering H18 - Acoustic indicator of sprinkling K1-6 - Auxiliary relay K7-8 - Contactor M1 - Engine starter M2 - Sprinkling engine of the front drum M3 - Sprinkling engine of the rear drum M4 - Front windshield wiper M5 - Rear wiper M6 - Front windscreen sprayer M7 - Rear windscreen sprayer M8 - Heater fan P1 - Engine thermometer P2 - Hydraulic oil thermometer P3 - Hour meter P4 - Fuel gauge Q1 - Master switch R2-6 - Resistors R9-11 - Resistors R15 - Sprinkling interval potentiometer R16 - Gear potentiometer R17 - Resistor (installed into the travel lever) S1 - Switch box S2 - Front lights switch S3 - Rare lights switch S4 - Warning lights switch S5 - Direction indicators switch S6 - Side lights switch (optional) S7 - Beacon switch (optional) S8 - Horn button S9 - Emergency brake button S10 - Backing horn switch (in the travel controller) S11 - Neutral gear switch (in the travel controller)) S12 - Brake pressure switch S13 - Engine overload protection switch S14 - Smooth drive-away and stopping pushbutton S15 - Sprinkling switch S16 - Vibration switch (in the travel controller)) S17 - Vibration automatic system switch S18 - Vibration amplitude switch S19 - Front/rear drum vibration switch S20 - Edge cutter double-pushbutton S22 - Steering method switch S23 - CRAB switch S24 - ASC switch (optional) S25 - Engine lubrication pressure switch S26 - Water sensor in fuel filter S27 - Air filter clogging vacuum switch S28 - Front wiper switch S29 - Rear wiper switch S30 - Sprayer pushbutton S31 - Fan switch

S32 - Air-condition switch (optional) S33 - Air-condition thermostat (optional) S34 - Air-condition overpressure safety piece (optional) S35 - Heater control position switch (optional) S36 - CRAB push button on the lefthand side (in the travel controller) S37 - CRAB push button on the right-hand side (in the travel controller S39 - Parking brake button S40 - Front sprinkling pressure switch S41 - Rear sprinkling pressure switch S42 - Switch for auxiliary headlights on the cabin (optional) S43 - Full throttle switch (optional) S44 - Seat switch V1-3 - Diodes X1-39 - Interconnection connectors X40 - Lamp socket (optional) X41 - CAN BUS plug X42-44 - Diagnostic sockets X45-50 - Interconnection connectors X51 - Connector – emergency/defect in electronics X52-54 - Interconnection connectors Y1 - Solenoid for engine stop Y2 - Solenoid brake valve Y4 - Servo-valve of the travel pump Y7 - Vibration solenoid valve small amplitude Y8 - Vibration solenoid valve great amplitude Y9 - Solenoid valve of the front drum vibration Y10 - Solenoid valve of the rear drum vibration Y11 - Solenoid valve of the edge cutter up (optional)) Y12 - Solenoid valve of the edge cutter down (optional)) Y13 - Solenoid valve for the front drum in the left Y14 - Solenoid valve for the front drum in the right Y15 - Solenoid valve for the rear drum in the left Y16 - Solenoid valve for the rear drum in the right Y17 - Solenoid valve ASC - left front drum (optional) Y18 - Solenoid valve ASC - right front drum (optional) Y19 - Solenoid valve ASC - left rear drum (optional) Y20 - Solenoid valve ASC - right front drum (optional) Y21 - Solenoid compressor clutch (optional) Y22 - Full throttle solenoid valve (optional)

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12.6.

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13. APPENDICES

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Content:

13.1. Measuring points 13.2. Pulse sensors adjustment 13.3. Vibration adjustment 13.4. Towing 13.5. Troubleshooting 13.6. Table of tightening moments 13.7. List fixtures

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13.1.

13.1. MEASURING POINTS Measuring points are furnished with quick-coupling devices.

Measuring points

Measured pressure (maximum number of revolutions must be set while measuring pressure values.)

Maximum pressure of safety valves in MPa (PSI)

Supplementary pressure in MPa (PSI)

1

Pressure in the travel circuit forwards * /Supplementary pressure - forward **

44 (6380)

2,5 (362,5)

2

Pressure in the travel circuit forwards * /Supplementary pressure - forward **

44 (6380)

2,5 (362,5)

3

Pressure in the vibration circuit *** / Supplementary pressure when vibration is off / Supplementary vibration pressure when vibration is on

35 (5075)

2,3 (333,5) / 1,3 (188,5)

4

Pressure in the front steering circuit ****

19 (2755)

5

Pressure in the rear steering circuit ****

19 (2755)

*

- The machine must get going forward or backward when the value is being measured.

**

- The machine is resting (the travel must not be activated).

***

- It is measured when vibration starts.

**** - It is measured on a resting machine with blocked steering. While turning, the drum must be blocked against revolving (e.g. lean it, e. g., against the kerbstone) and thus the steering circuit can be pressurized. The value measured includes the supplementary pressure.

Specification of measuring points: Vibration and travel circuits: Measuring points for low and great vibration frequency and those for forward and backward travel are placed on flow blocks on the right-hand side of the frame under the machine cabin.

Great vibration frequency 42 Hz Low vibration frequency 50 Hz Travel forwards Travel backwards

(point 1) (point 2) (point 3) (point 4)

2 1

4 3

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13.1.

Steering circuits: The measuring point of the front steering circuit is on the left-hand side under the front part of the machine frame.

The measuring point of the rear steering circuit is on the left-hand side under the rear part of the machine frame.

Supplementary pressures: The measuring point of supplementary pressures is on the block, on the right-hand side of the frame under the machine cabin.

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13.2.

13.2. PULSE SENSORS ADJUSTMENT Every time a hydromotor of vibration or travel is changed, the pulse sensor must be removed and then installed again and adjusted. The same procedure is required when a faulty pulse sensor is replaced by a new one.

The machine is furnished with pulse sensors type KPPF 156.

Location of pulse sensors in the machine.

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13.2.

Location of the pulse sensor in the vibration hydromotor.

Location of the pulse sensor in the travel hydromotor.

Adjustment of sensors is carried out using a flat side spanner 12.7 mm (0.50 in) (point 1) and hexagonal wrench for nuts 11/16 in (point 2).

2

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1

163

13.2.

The following procedure should be performed when adjusting the sensors: Install the pulse sensor (1) fully into the hydromotor of vibration or travel in such a way that it touches the magnetic ring (2).

Turn the pulse sensor by 1/2 to 1 revolution backward in such a way that clearance appears between the sensor and magnetic ring. Such clearance must not be greater that 1.52 mm (0.060 in) see Fig.

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13.2.

When adjusting the clearance, set the pulse sensor using the flat side spanner to such a position that the axis of gripping the spanner is deflected from the vibration or travel hydromotor axis by not more that 22° to the left or right, see Fig.

Hold the sensor in this position using the flat side spanner and tighten the nut of the pulse sensor with a hexagonal wrench. Torque for the nut is 13 Nm (10 lbs).

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13.3.

13.3. VIBRATION ADJUSTMENT Vibration adjustment is carried out using bolts on the vibration pump placed on the right-hand side of the frame under the machine cabin.

Frequency value is measured using a frequency meter whose sensor is fixed to the body of the drum.

Vibration frequency adjustment: If you adjust low or great vibration frequency, maximum number of engine revolutions must be set.

The correct value of great frequency is 42 Hz. If necessary, the value can be adjusted by loosening the nut and turning the bolt on the upper part of the vibration pump to the left or right.

The correct value of great frequency is 50 Hz. If necessary, the value can be adjusted by loosening the nut and turning the bolt on the lower part of the vibration pump to the left or right.

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13.4.

13.4. TOWING For pulling the machine away carry out Emergency release of the machine brakes . Emergency release of brakes of the machine can be carried out by mechanical release of brakes (STANDART standard equipment), or hydraulically with the help of manual pump on the hydraulic tank (OPTION equipment according to the customer ´s wish).

It is forbidden to use the machine for towing towed vehicles (e.g. tangs, compressors, house trailers etc.)

• The machine is equipped on the rear frame with towning lug for this purpose.

• Towning lug is equipped with a pin locked with a

locking catch againts jumping out. It is possible to remove the pin after raising the locking pin.

EMERGENCY RELEASE OF BRAKES OF THE MACHINE - MECHANICAL (STANDART) Do the following to prevent drums from skidding:

• Dismantle 3 screw plug on each hydraulic motor and under them tighten the imbus screws.

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13.4.

( • Short-circuit the travel hydraulic circuit.

• Unscrew central parts (1) /haxagonal 27 mm (11/ 16´´)/ by tree turns anti clockwise on two multi purpose safety velves of the hydro generator of travel.

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13.4.

• Turn the ignition key to I position and check signal lamp of brake (31) switched off.

! NOTICE !

When towing, check brakes for heating due to insufficient brake release. Working, emergency and parking brakes cannot be used after hydraulic motors were braked off and the travel hydraulic circuit was short-circuited.

All brakes are disabled!

After towing is finished, put the roller to its original condition!

Use unimpaired towing cables or towing bars of sufficied capacity – dimensioned to weight 1,5 times higher than weight of the towed machine. It is not permitted to use chains for towing machine.

No persons can be present on the machine with non – working engine.

It is necessary to keep the deviation from the straight towing angle as little as possible. Maximum deviation is 30 degrees.

The movement during towing must be smooth. Do not exceed towing speed of 2 kmph (1,2mph). Do not tow the machine for distances longer than 300 m (0,19miles).

The towing machine should be equal by size to the damaget machine. It must by sufficiently powerful (towing power), heavy and have sufficient brake effect.

Do not start the engine during towing.

Note: These are general requirements for safe towing of the damaged machine under standard conditions. Any specific conditions that may occur during towing must be consulted with a machine distributor.

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13.4.

EMERGENCY RELEASE OF BRAKES OF THE MACHINE - HYDRAULIC – (OPTION) Do the following to prevent drums from skidding: • Short-circuit the travel hydraulic circuit.

• Dismantle the hose with the snap coupling (1) in the

point (A) and protective rubber end cap (2) in the point (B).

2

B

A

1

• Mount the hose with the snap coupling (1) in the point (B) and the protective rubber end cap (2) in the point (A).

B A

1 2

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13.4.

• Unscrew central parts (1) /haxagonal 27 mm (11/ 16´´)/ by tree turns anti clockwise on two multi purpose safety velves of the hydro generator of travel.

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13.4.

• Set the lever of the manual hydraulic generator to the

position displayed on the label of the machine frame.

• Take out the lever hydraulic generator.

• Insert the lever into the manual hydro generator and pump until the machine is unbraked for towing now.

( 172

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13.4.

• Turn the ignition key to I position and check signal lamp of brake (31) switched off.

! Note !

During towing, leakage may cause pressure in brekes decrease. If brakesignal lamp (31) lights up during towing, pump more!

After pulling the machine away carry out the following activities:

B

• Cancel the function of the travel hydraulic circuit short circuit.

1

A

• Dismantle the hose with the snap coupling (1) in the point (B) and the protective rubber end cap (2) in the point (A).

2

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13.4.

• Mount the hose with the snap coupling (1) in the point

(A) and the protective rubber end cap (2) in the point (B).

B

A

2

1

• On two multi-purpose check valves of the travel hydraulic generator, screw the central parts (1) /hexagon 27 mm (11/16´´)/ into position for three revolutions clockwise.

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13.4.

During the usual operation of the machine when the hose with the snap coupling (1) is not connected in the point (B), the function of ”Emergency release of brakes of the machine hydraulic”, the hose with the snap coupling (1) must be always connected in the point (A)!!!

If it happens that the machine is in operation and the hose with the snap coupling (1) is not connected in the point (A) and neither in the point (B), the machine brakes will be spontaneously released!!! In such case it is impossible to use operating, emergency and parking brakes on the machine and therefore put the machine always to the original condition after it is pulled away!!!

! NOTICE !

When towing, check brakes for heating due to insufficient brake release. Working, emergency and parking brakes cannot be used after hydraulic motors were braked off and the travel hydraulic circuit was short-circuited.

All brakes are disabled!

After towing is finished, put the roller to its original condition!

Use unimpaired towing cables or towing bars of sufficied capacity – dimensioned to weight 1,5 times higher than weight of the towed machine. It is not permitted to use chains for towing machine.

No persons can be present on the machine with non – working engine.

It is necessary to keep the deviation from the straight towing angle as little as possible. Maximum deviation is 30 degrees.

The movement during towing must be smooth. Do not exceed towing speed of 2 kmph (1,2mph). Do not tow the machine for distances longer than 300 m (0,19miles).

The towing machine should be equal by size to the damaget machine. It must by sufficiently powerful (towing power), heavy and have sufficient brake effect.

Do not start the engine during towing.

Note: These are general requirements for safe towing of the damaged machine under standard conditions. Any specific conditions that may occur during towing must be consulted with a machine distributor.

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13.5.

13.5. TROUBLESHOOTING

TABLET NUMBER

176

SPECIFICATION TROUBLE

1.

Oil is leaking under the vibration lid

2.

Oil is leaking through the bleeding plung from the hydromotor of vibration or travel

3.

Oil leaks from the vibrator

4.

The machine does not vibrate

5.

The machine does not vibrate, the hydraulic system is OK

6.

Vibration does not reach required frequency

7.

Only one amplitude works

8.

The machine cannot by star ted, the star ter is rotating

9.

The engine is only idle running

10.

The machine does not travel

11.

Traction force of the machine is low or it does not travel in one direction

12.

Incorrect functions of drive away and stopping

13.

The display evaluates speed of the machine inorrectly

14.

The steering does not work, the defect is not shown on the display

15.

The steering does not work message is shown on the display Sensor supply voltage

16.

The steering does not work after cooling down the machine steering is OK

17.

The drums turn incorrectly ( Z is shown on the display)

18.

The drum oscillates after star ting the machine and during driving

19.

One drum reacts with delay. The angle of its turning is not shown on the display.

20.

Crabbing does not work

21.

Crabbing function works slowly

22.

ASC does not work

23.

The jerky drive of machine after switching of ASC

24.

ASC switches on spontaneously the pilot lamp is on

25.

Sprinkling system indicates a defect

26.

Sprinkling does not work or works irregularly

27.

The pump is off, water is running out of the sprinkler

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180

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182

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184

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190

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192

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198

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200

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13.5.

202

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13.6.

13.6. TABLE OF TIGHTENING MOMENTS Check regularly if there aren’t relaxed screw connections.

For tightening use the moment spanners.

Table of Tightening Torques For Bolts With Metric Threads

TIGHTENING MOMENT For the screw 5,8 (5S)

For the screw 8,8 (8G)

For the screw 10,9 (10K))

Závit

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

M4

2

1

3

2

4

3

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

The values mentioned in the table are tightening moments for dry worm (for friction coefficient = 0,14). For lubricated worm are these values not valid.

The self-securing nuts can be used maximally 3 times after approval.

204

VH 850/VH 950

13.6.

Table of insert nuts tightening moments with tightening “O” circle - the hoses

Tightening moments for the sliding nuts with the tightening circle "O" - hoses Nm

lb-ft

Size spanner

Worm

Hose

Nominal

Min

Max

Nominal

Min

Max

14

M12x1,5

6

20

15

25

15

11

18

17

M14x1,5

8

38

30

45

28

22

33

19

M16x1,5

45

38

52

33

28

38

22

M18x1,5

51

43

58

38

32

43

24

M20x1,5

58

50

65

43

37

48

27

M22x1,5

74

60

88

55

44

65

30

M24x1,5

16

74

60

88

55

44

65

32

M26x1,5

18

105

85

125

77

63

92

36

M30x2

135

115

155

100

85

114

166

140

192

122

103

142

41 46 50

50

VH 850/VH 950

M36x2

8 10 10 12 12 14 15

20 22 25 28

M42x2

30

240

210

270

177

155

199

M45x2

35

290

255

325

214

188

240

330

280

380

243

207

280

M52x2

38 42

205

13.6.

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

Table of tightening moments for plugs with flat packing

Tightening moments for the necks

206

Tightening moments for the plugs

G-M

Nm

lb - ft

G-M

Nm

lb - ft

G 1/8"

25

18

G 1/8"

15

11

G 1/4"

40

30

G 1/4"

33

24

G 3/8"

95

70

G 3/8"

70

52

G 1/2"

130

96

G 1/2"

90

66

G 3/4"

250

184

G 3/4"

150

111

G 1"

400

295

G 1"

220

162

G 11/4"

600

443

G 11/4"

600

443

G 11/2"

800

590

G 11/2"

800

590

M 10x1

25

18

M 10x1

13

10

M 12x1,5

30

22

M 12x1,5

30

22

M 14x1,5

50

37

M 14x1,5

40

30

M 16x1,5

60

44

M 16x1,5

60

44

M 18x1,5

60

44

M 18x1,5

70

52

M 20x1,5

140

103

M 20x1,5

90

66

M 22x1,5

140

103

M 22x1,5

100

74

M 26x1,5

220

162

M 26x1,5

120

89

M 27x1,5

250

184

M 27x1,5

150

111

M 33x1,5

400

295

M 33x1,5

250

184

M 42x1,5

600

443

M 42x1,5

400

295

M 48x1,5

800

590

M 48x1,5

500

369

VH 850/VH 950

13.7.

13.7. LIST FIXTURES

LIST OF FIXTURES FOR VH 850-950 CYLINDERS GROUP

NUMBER FIXTURE

NAME OF THE FIXTURE

DRUM

ND 0 9 0 5 3 5

Stops against revolving the drum

ND 1 1 8 0 3 8

Assembling fixture (travel hydromotor)

ND 0 8 0 3 9 9

Jack stand

ND 0 8 0 5 7 9

Assembling fixture (rubber-metals)

ND 0 9 0 5 1 2

H a n d l i n g c l a mp

CABIN

ND 0 8 1 9 5 7

Sus pens i on f i x t ur e

HYDRAULIC SYSTEM

ND 1 0 1 7 8 3

Assembling fixture (for repacking of the steering hydromotor)

COOLING

ND 0 8 1 9 5 8

Handling (suspension eyes)

VH 850/VH 950

207

Notes:

208

VH 850/VH 950

Notes:

VH 850/VH 950

209

STAVOSTROJ a.s.

549 01 Nové Město nad Metují tel: +42 0-491 476 111

fax: +420-491 470 405

Issued by:

Literature Department of

STA Stavostroj a.s.

Nové Město nad Metují

© 2 / 2004