STA Roller VV 1100 and VV 1500 VIBRATORY ROLLERS OPERATING MANUAL

OPERATING MANUAL

VV 1100 and VV 1500 VIBRATORY ROLLERS STAVOSTROJ a.s., Nové Město nad Metují

© 7 / 2002

2

VV1100 / VV1500

This set of manuals consists of: I. Specification Manual II. Operation Manual III. Air Conditioning system IV. Maintenance and Lubrication Manual

Read these manuals before attempting to operate the machine.

This manual contains basic information on the operation and maintenance of the machine in general. For more extensive repairs it is necessary to follow the Shop Manual, or have the repair done by an authorized service shop.

Should the machine be damaged or should other defects appear because of non-adherence to specified procedures, improper maintenance or repairs, the manufacturer is not responsible for machine (products) defects caused by non-adherence to specified procedures, incorrect maintenance, or repairs.

Pictures and data shown in these manuals are subject to change without notice, in order to improve quality of the manuals. Re-printing and copying of any kind, whole or in single chapters, is allowed only with our prior written consent.

VV1100 / VV1500

3

CONTENT: CONTENT: 1.

................................................................................................................................................................ 4

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

1.1. Basic Data

.............................................................................................................................................................. 10

1.2. Dimension Chart ............................................................................................................................................................. 12 1.3. Technical Data .............................................................................................................................................................. 20 1.3.1. Weights .............................................................................................................................................................. 20 1.3.2. Travel Parameters .............................................................................................................................................. 24 1.3.3. Vibration ............................................................................................................................................................. 26 1.3.4. Engine ................................................................................................................................................................ 26 1.3.5. Axle ..................................................................................................................................................................... 27 1.3.6. Brakes ................................................................................................................................................................ 27 1.3.7. Steering .............................................................................................................................................................. 27 1.3.8. Vibratory Drum ................................................................................................................................................... 28 1.3.9. Hydrostatic Drive of Travel ................................................................................................................................. 28 1.3.10. Hydrostatic Drive of Vibration ............................................................................................................................ 29 1.3.11. Hydraulic Oil Tank .............................................................................................................................................. 29 1.3.12. Lifting and lowering of the Hood and the Cabin ............................................................................................... 29 1.3.13. Cooling System of Hydraulic Oil ....................................................................................................................... 29 1.3.14. Fluids .................................................................................................................................................................. 30 1.3.15. Electrical Installation .......................................................................................................................................... 30 1.3.16. Safety Devices ................................................................................................................................................... 30 1.3.17. Hygienical Data .................................................................................................................................................. 31 1.3.18. Requirements of Traffic Regulations ................................................................................................................. 31 1.3.19. Accessories ........................................................................................................................................................ 32

2.

OPERATION MANUAL ..................................................................................................................................................... 33

2.1. Description of the Machine ............................................................................................................................................. 34 2.1.1.

2.1.2.

2.1.3.

Drum Part ........................................................................................................................................................... 35 Articulated Joint ................................................................................................................................................. 35 Tractor Part ......................................................................................................................................................... 35

2.2. Safety Regulations ......................................................................................................................................................... 41 2.2.1. Safety Regulations and Instruction for Operation of the Machine ................................................................... 41 2.2.1.1. Beginning of Compaction Works ...................................................................................................................... 41 2.2.1.2. Operation in Danger Space ............................................................................................................................... 41 2.2.1.3. Principles of Safe Operation ............................................................................................................................. 42 2.2.2. Requirements for Driver s Qualification ............................................................................................................ 43 2.2.3. Obligations of the Driver .................................................................................................................................... 43 2.2.4. Prohibited Activities ........................................................................................................................................... 45 2.2.5. Safety Labels and Signs at the Machine .......................................................................................................... 46

2.3. Environmental and Hygienical Principle ........................................................................................................................... 50 2.3.1.

2.3.2.

Hygienical Principles ......................................................................................................................................... 50 Environmental Principles .................................................................................................................................. 50

2.4. Conservation and Storing ................................................................................................................................................ 51 2.4.1.

2.4.2.

2.4.3.

4

Short-Time Conservation and Storing (1-2 months) ........................................................................................ 51 Conservation and Storing Longer Than 2 Months ........................................................................................... 51 Deconservation And Inspection Of New Machine ............................................................................................ 52

VV1100 / VV1500

SPECIFICATION MANUAL 2.5. Liquidation of the Machine After Termination of Its Service Life........................................................................................ 53 2.6. Instruments, Indicators and Controls ............................................................................................................................... 54 2.7. Operating and Using the Machine .................................................................................................................................... 68 2.7.1. Controlling the Basic Functions of the Machine ............................................................................................... 68 2.7.1.1. Starting the Engine ............................................................................................................................................ 68 2.7.1.2. Riding the Machine (see Fig. 2.17) ................................................................................................................... 68 2.7.1.3. Travel with Vibration (see Fig. 2.17) .................................................................................................................. 69 2.7.1.4. Stopping the Machine and the Engine (see Fig. 2.17) .................................................................................... 69 2.7.1.5. Before Leaving the Machine ............................................................................................................................. 70 2.7.1.6. Emergency Stopping (see Fig. 2.17) ............................................................................................................... 70 2.7.1.7. Machine travel in a difficult terrain .................................................................................................................... 70 2.7.1.8. Travel of machine with differential lock ASC ..................................................................................................... 71 2.7.2. Operating the Machine in the Running-in Period ............................................................................................. 72 2.7.3. Lifting the driver s station and the hood ............................................................................................................ 72 2.7.4. Dozing Blade ...................................................................................................................................................... 76 2.7.5. Protective Frame ................................................................................................................................................ 77 2.7.6. Padfoot Segments ............................................................................................................................................. 78 2.7.7. Filling the Tires with Liquid ................................................................................................................................ 80 2.7.8. Air Condition System ......................................................................................................................................... 81

2.8. Transport of the Machine................................................................................................................................................. 82 2.8.1.

2.8.2.

2.8.3.

2.8.4.

2.8.5.

2.8.6.

Traveling at the Jobsite ...................................................................................................................................... 82 Transport on Public Roads ................................................................................................................................ 82 Transport of the machine by rail ........................................................................................................................ 83 Loading the Roller .............................................................................................................................................. 83 Dismantling the Cabin ....................................................................................................................................... 84 Towing the Machine ........................................................................................................................................... 85

2.9. Using the machine under special conditions .................................................................................................................... 87 2.9.1. Travel with vibration on compacted and hard materials .................................................................................. 87 2.9.2. Use at Difficult Climatic Conditions ................................................................................................................... 87 2.9.2.1. Use at Low Ambient Temperatures ................................................................................................................... 87 2.9.2.2. Use at High Temperatures and High Humidity ................................................................................................. 88 2.9.2.3. Use at High Altitude ........................................................................................................................................... 88 2.9.3. Use at Extremely Dusty Environment ................................................................................................................ 89 2.9.4. Compaction near to constructions or underground ingeneers nets and cables ............................................ 89

3.

AIR CONDITIONING SYSTEM........................................................................................................................................ 91 3.1.

3.2.

3.3.

3.4.

3.5.

4.

Basic parts of the air conditioning circuit .......................................................................................................... 92 Air conditioning operation ................................................................................................................................. 93 Maintenance ...................................................................................................................................................... 94 Troubles .............................................................................................................................................................. 95 Safety Rules ....................................................................................................................................................... 95

LUBRICATION AND MAINTENANCE MANUAL ................................................................................................................... 97

4.1. Specification of Fluids .................................................................................................................................................... 98 4.1.1.

4.1.2.

4.1.3.

4.1.4.

4.1.5.

4.1.6.

4.1.7.

Engine Oil .......................................................................................................................................................... 98 Fuel ..................................................................................................................................................................... 99 Hydraulic Oil ..................................................................................................................................................... 100 Gear-Box Oil ..................................................................................................................................................... 101 Lubrication Grease .......................................................................................................................................... 101 Coolant ............................................................................................................................................................. 102 Liquid for the Windscreen Washer .................................................................................................................. 102

4.2. Fluids

............................................................................................................................................................ 103

VV1100 / VV1500

5

CONTENT: 4.3. Lubrication Chart .......................................................................................................................................................... 104 4.4. Safety Standards at Lubrication and Maintenance .......................................................................................................... 105 4.4.1. Safety at Maintenance of the Machine ........................................................................................................... 105 4.4.2. Fire Prevention Regulations ............................................................................................................................ 105 4.4.3. Environmental and Hygienical Principles ...................................................................................................... 106 4.4.3.1. Hygienical Principles ....................................................................................................................................... 106 4.4.3.2. Environmental Principles ................................................................................................................................ 106

4.5. Lubrication and Maintenance Chart................................................................................................................................ 108 4.6. Individual Operations of Lubrication and Maintenance .................................................................................................... 110 Every 20 Hours or Daily ................................................................................................................................................ 110 4.6.1.

4.6.2.

4.6.3.

4.6.4.

4.6.5.

4.6.6.

4.6.7.

4.6.8.

Inspection, Replenishing of Engine Oil ........................................................................................................... 110 Inspection of the Engine Drive Belt ................................................................................................................. 111 Inspection of the Fan ....................................................................................................................................... 111 Inspection, Replenishing of Coolant ............................................................................................................... 112 Inspection of the Dust Filter ............................................................................................................................. 113 Inspection of Fuel Level, Refueling ................................................................................................................. 113 Inspection of Clogging Of The Hydraulic Filter ............................................................................................... 114 Inspection of Warning and Safety Devices ..................................................................................................... 114

Every 100 Hours........................................................................................................................................................... 115 4.6.9. Inspection of Tire Inflation ............................................................................................................................... 115 4.6.10. Inspection, Replenishing of Hydraulic Oil ....................................................................................................... 116

Every 250 Hours or Once in 3 Months ........................................................................................................................... 117 4.6.11. Exchange of Engine Oil ................................................................................................................................... 117 4.6.12. Inspection of Inlet Branch of the Engine ......................................................................................................... 118 4.6.13. Inspection of Cooling System of the Engine ................................................................................................... 118 4.6.14. Inspection of the Batteries ............................................................................................................................... 118 4.6.15. Inspection of the Underpressure Switch of Air Cleaner ................................................................................. 120 4.6.17. Inspection Of Oil Level In The Vibrator ............................................................................................................ 123 4.6.18. Inspection Of Oil Level In The Gear-Box ......................................................................................................... 124

Every 500 Hours or Once in 6 Month ............................................................................................................................. 125 4.6.19. Exchange of the Fuel Filter Elements ............................................................................................................. 125 4.6.20. Inspection of Coolant Concentration .............................................................................................................. 126 4.6.21. Re-Tightening of the Wheel Nuts .................................................................................................................... 126

Every 1000 Hours or Once a Year.................................................................................................................................. 127 4.6.22. Inspection and Adjustment of Valve Clearance ............................................................................................. 127 4.6.23. Inspection of the Drive Belt .............................................................................................................................. 129 4.6.24. Oil change in the gear box .............................................................................................................................. 130 4.6.25. Inspection of the Damping System .................................................................................................................. 131 4.6.26. Cleaning the Fuel Tank ................................................................................................................................... 132

Every 2000 Hours or Every 2 Years ............................................................................................................................... 133 4.6.27. Exchange Of Oil In The Vibrator ...................................................................................................................... 133 4.6.28. Exchange of Hydraulic Oil ............................................................................................................................... 134 4.6.29. Inspection And Cleaning Of The Suction Basket Of The Hood & Cab Lifting System .................................. 139 4.6.30. Exchange of Coolant ....................................................................................................................................... 140 4.6.31. Inspection of the Torsional Vibrations Damper ............................................................................................... 142

6

VV1100 / VV1500

SPECIFICATION MANUAL Maintenance - As Needed ............................................................................................................................................. 143 4.6.32. Cleaning, Exchange of the Air Filter Elements ............................................................................................... 143 4.6.33. Cleaning the Machine ..................................................................................................................................... 144 4.6.34. Cleaning The Engine Radiator And Hydraulic Oil Cooler ............................................................................. 145 4.6.35. Cleaning The Dust Filter Of Cab Ventilation ................................................................................................... 145 4.6.36. Cleaning the Fuel Separator ........................................................................................................................... 146 4.6.37. Deareation Of The Fuel System ...................................................................................................................... 146 4.6.38. Adjustment Of Scrapers ................................................................................................................................... 148 4.6.39. Inspection, Re-Tightening of Bolted Connections .......................................................................................... 149

4.7. Records of Accomplished Operations ............................................................................................................................ 152 4.8. Accessories

............................................................................................................................................................ 156

VV1100 / VV1500

7

8

VV1100 / VV1500

1.

SPECIFICATION MANUAL

SPECIFICATION MANUAL VV 1100 VV 1500

VV1100 / VV1500

9

1.1. Basic Data Introduction

Modifications

Single drum vibratory rollers of line VV 1100, VV 1500 are outstanding by their up-to-date design, adopted technologies, as well as modern styling. These machines offer maximal comfort to the operator, are easy to operate, extremely reliable and require minimal maintenance. The utilized frequency, amplitude and centrifugal force of vibration were optimized by means of compaction tests to reach extra high compaction effect on various materials.

The single drum vibratory roller VV 1100 D with the smooth drum is suitable for compaction of all kinds of soil.

It can be employed at compaction of clayey soils up to the layer thickness (compacted) of 25 cm (9,8 in), loam soils up to the layer thickness of 40 cm (15,7 in), mixed soils up to the layer thickness of 50 cm (19,7 in), sandy soils and rockfills up to the layer thickness of 80 cm (31,4 in), gravels up to the layer thickness of 60 cm (23,6 in). Maximal allowed grain size is up to 2/3 of total layer thickness. The roller is suitable for compaction of stabilized soils as well.

Application Range The vibratory rollers of VV 1100, VV 1500 line are especially suitable for use at mid- and large compaction jobs of highway construction (construction of highways, railways, airports), hydraulic construction (earth dams) and civil engineering (industrial areas, ports etc.).

The rollers are designated for operation under conditions as according to IEC 721-2-1 (038900): WT, WDr, MWDr (i.e. moderate, warm dry, hot dry) with temperature limits from -15°C (5°F) to +45°C (113°F).

The single drum vibratory roller VV 1100 DH with the smooth drum . Modification of machine with higher traction power. The machine is made for permanent operation on slopes over 30% in extreme conditions. Compaction effect is identical with VV 1100 D. The padfoot roller VV 1100 PD (where the vibratory and masticating effect act simultaneously) is suitable mainly for compaction of clayey soils up to the layer thickness (compacted) of 30 cm (11,8 in), loam soils up to the layer thickness of 40 cm (15,7 in), and mixed soils up to the layer thickness of 50 cm (19,7 in).

The padfoot roller VV 1100 PDH. Modification of machine with higher traction power. The machine is made for permanent operation on slopes over 30% in extreme conditions. Compaction effect is identical with VV 1100 PD. The padfoot roller VV 1100 PDB, VV 1100 PDBH with the dozing blade is designated compaction as the VV 1100 PD, VV 1100 PDH roller and enables also spreading of dumped material.

Fig. 1.1 - Decal

The single drum vibratory roller VV 1500 D with the smooth drum is suitable for compaction of all kinds of soil.

It can be employed at compaction of clayey soils up to the layer thickness (compacted) of 30 cm (11,8 in), loam soils up to the layer thickness of 50 cm (19,7 in), mixed soils up to the layer thickness of 70 cm (27,5 in), sandy soils and rockfills up to the layer thickness of 120 cm (47,2 in), gravels up to the layer thickness of 80 cm (31,4 in).

Maximal allowed grain size is up to 2/3 of total layer thickness. The roller is suitable for compaction of stabilized soils as well.

The single drum vibratory roller VV 1500 DH with the smooth drum . Modification of machine with higher traction power. The machine is made for permanent operation on slopes over 30% in extreme conditions. Compaction effect is identical with VV 1500 D.

10

VV1100 / VV1500

SPECIFICATION MANUAL The padfoot roller VV 1500 PD (where the vibratory and masticating effect act simultaneously) is suitable mainly for compaction of clayey soils up to the layer thickness (compacted) of 35 cm (13,7 in), loam soils up to the layer thickness of 50 cm (19,7 in), and mixed soils up to the layer thickness of 70 cm (27,5 in).

The padfoot roller VV 1500 PDH. Modification of machine with higher traction power. The machine is made for permanent operation on slopes over 30% in extreme conditions. Compaction effect is identical with VV 1500 PD. The padfoot roller VV 1500 PDB, VV 1500 PDBH with the dozing blade is designated compaction as the VV 1500 PD, VV 1500 PDH roller and enables also spreading of dumped material.

Please refer to the data in the table below always when approaching the dealer or the manufacturer.

Please fill in the following data: Type of machine (see Figs. 1.1, 1.2) .............................................................................

ICV/PIN (Serial number of the machine) (see Figs. 1.1, 1.2) ..............................................................................

Production year (see Figs. 1.1, 1.2)

The machine meets the requirements for “CE” mark and the requirements due to the law no. 22/1997 Sb. (i.e. CSN EN 500-1,4 and next) for the Czech Republic and Directive 2000/14/EC (EN ISO 3744).

In the course of proposal has been respected requierements of international norms for hygiene, ergonomi and safety. The machine fulfil conditions for „CE“ mark.

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

Type of engine (see Fig. 1.3) ..............................................................................

Serial number of the engine (see Fig. 1.3) .............................................................................

Fig. 1.2 - Location of the decal at the machine

2 1

Fig. 1.3 - Serial number of the CUMMINS engine

2

1. - Decal 2. - Frame number

VV1100 / VV1500

11

1.2. Dimension Chart Fig. 1.4 - Dimension Chart of the Machine VV1100 (with cab and ROPS frame)

Dimensions in mm (in) VV 1100 D VV 1100 DH

VV 1100 PD VV 1100 PDH

VV 1100 PDB VV 1100 PDBH

12

A

B

D

H1

H2

H3

H4

H5

H6

H7

H8

H9

H10

K

2820

2436

1500

3000

2375

3030

-

-

3540

2400

2265

3050

-

420

(111,0) (95,9)

(59,0) (118,1) (93,5) (119,3)

(-)

(-)

(139,4) (94,5)

(89,2) (120,1)

(-)

(16,5)

2820

1440

3030

-

100

3540

2265

3050

-

420

(111,0) (95,9)

(56,7) (118,1) (93,5) (119,3)

(-)

(3,9)

(139,4) (94,5)

(89,2) (120,1)

(-)

(16,5)

2820

1440

277

100

3540

2265

916

420

(56,7) (118,1) (93,5) (119,3) (10,9)

(3,9)

(139,4) (94,5)

(89,2) (120,1) (36,1)

(16,5)

2436

2436

(111,0) (95,9)

3000

3000

2375

2375

3030

2400

2400

3050

VV1100 / VV1500

SPECIFICATION MANUAL Fig. 1.5 - Dimension Chart of the Machine VV 1100 (with cab and ROPS frame)

Dimensions in mm (in) VV 1100 D VV 1100 DH

VV 1100 PD VV 1100 PDH

VV 1100 PDB VV 1100 PDBH

K1

L

L1

L2

O1

O2

R1

R2

R3

S

W1

W2

W3

W4

430

5686

1690

-

118

132

5370

2920

3050

25

2186

2200

1580

-

(16,9) (223,8) (66,5)

(-)

(4,65)

(5,20) (211,4) (115,0) (120,0) (0,98)

(86,1)

(86,6)

(62,2)

(-)

430

1690

-

118

132

2186

2200

1580

-

(16,9) (223,8) (66,5)

(-)

(4,65)

(5,20) (211,4) (115,0) (120,0) (0,79)

(86,1)

(86,6)

(62,2)

(-)

430

6094

118

132

2186

2200

1580

2950

(86,1)

(86,6)

(62,2) (116,1)

5686

5686

1690

(16,9) (223,8) (66,5) (240,0) (4,65)

VV1100 / VV1500

5370

5738

2920

2920

3050

3050

20

20

(5,20) (225,9) (115,0) (120,0) (0,79)

13

1.2. Dimension Chart Fig. 1.6 - Dimension Chart of the Machine VV 1100 (without cab, with ROPS frame)

Dimensions in mm (in) VV 1100 D VV 1100 DH

VV 1100 PD VV 1100 PDH

VV 1100 PDB VV 1100 PDBH

14

A

B

D

H1

H2

H3

H4

H5

H6

H7

H8

H9

H10

K

2820

2436

1500

3000

2375

3030

-

-

3540

2400

2265

3050

-

420

(111,0) (95,9)

(59,0) (118,1) (93,5) (119,3)

(-)

(-)

(139,4) (94,5)

(89,2) (120,1)

(-)

(16,5)

2820

1440

3030

-

100

3540

2265

3050

-

420

(111,0) (95,9)

(56,7) (118,1) (93,5) (119,3)

(-)

(3,9)

(139,4) (94,5)

(89,2) (120,1)

(-)

(16,5)

2820

1440

277

100

3540

2265

916

420

(56,7) (118,1) (93,5) (119,3) (10,9)

(3,9)

(139,4) (94,5)

(89,2) (120,1) (36,1)

(16,5)

2436

2436

(111,0) (95,9)

3000

3000

2375

2375

3030

2400

2400

3050

VV1100 / VV1500

SPECIFICATION MANUAL Fig. 1.7 - Dimension Chart of the Machine VV 1100 (without cab, with ROPS frame)

Dimensions in mm (in) VV 1100 D VV 1100 DH

VV 1100 PD VV 1100 PDH

VV 1100 PDB VV 1100 PDBH

K1

L

L1

L2

O1

O2

R1

R2

R3

S

W1

W2

W3

W4

430

5686

1690

-

118

132

5370

2920

3050

25

2186

2200

1580

-

(16,9) (223,8) (66,5)

(-)

(4,65)

(5,20) (211,4) (115,0) (120,0) (0,98)

(86,1)

(86,6)

(62,2)

(-)

430

1690

-

118

132

2186

2200

1580

-

(16,9) (223,8) (66,5)

(-)

(4,65)

(5,20) (211,4) (115,0) (120,0) (0,79)

(86,1)

(86,6)

(62,2)

(-)

430

6094

118

132

2186

2200

1580

2950

(86,1)

(86,6)

(62,2) (116,1)

5686

5686

1690

(16,9) (223,8) (66,5) (240,0) (4,65)

VV1100 / VV1500

5370

5738

2920

2920

3050

3050

20

20

(5,20) (225,9) (115,0) (120,0) (0,79)

15

1.2. Dimension Chart Fig. 1.8 - Dimension Chart of the Machine VV 1500 (with cab and ROPS frame)

Dimensions in mm (in) VV 1500 D VV 1500 DH

VV 1500 PD VV 1500 PDH

VV 1500 PDB VV 1500 PDBH

16

A

B

D

H1

H2

H3

H4

H5

H6

H7

H8

H9

H10

K

2820

2500

1500

3000

2375

3030

-

-

3540

2400

2265

3050

-

420

(111,0) (98,4)

(59,0) (118,1) (93,5) (119,3)

(-)

(-)

(139,4) (94,5)

(89,2) (120,1)

(-)

(16,5)

2820

1440

3030

-

100

3540

2265

3050

-

420

(111,0) (98,4)

(56,7) (118,1) (93,5) (119,3)

(-)

(3,9)

(139,4) (94,5)

(89,2) (120,1)

(-)

(16,5)

2820

1440

277

100

3540

2265

916

420

(56,7) (118,1) (93,5) (119,3) (10,9)

(3,9)

(139,4) (94,5)

2500

2500

(111,0) (98,4)

3000

3000

2375

2375

3030

2400

2400

3050

(89,2) (120,1) (36,1) (16,5)

VV1100 / VV1500

SPECIFICATION MANUAL Fig. 1.9 - Dimension Chart of the Machine VV 1500(with cab and ROPS frame)

Dimensions in mm (in)

VV 1500 D VV 1500 DH

VV 1500 PD VV 1500 PDH

VV 1500 PDB VV 1500 PDBH

K1

L

L1

L2

O1

O2

R1

R2

R3

S

W1

W2

W3

W4

430

5686

1690

-

142

162

5395

2920

3050

40

2186

2200

1580

-

(16,9) (223,8) (66,5)

(-)

(5,6)

(6,4)

(212,4) (115,0) (120,0) (1,57)

(86,1)

(86,6)

(62,2)

(-)

430

1690

-

142

162

5395

3050

28

2186

2200

1580

-

(16,9) (223,8) (66,5)

(-)

(5,6)

(6,4)

(212,4) (115,0) (120,0)

(1,1)

(86,1)

(86,6)

(62,2)

(-)

430

6094

142

162

5738

3050

28

2186

2200

1580

2950

(16,9) (223,8) (66,5) (240,0)

(5,6)

(6,4)

(225,9) (115,0) (120,0)

(1,1)

(86,1)

(86,6)

(62,2) (116,1)

VV1100 / VV1500

5686

5686

1690

2920

2920

17

1.2. Dimension Chart Fig. 1.10 - Dimension Chart of the Machine VV 1500 (without cab, with ROPS frame)

Dimensions in mm (in) VV 1500 D VV 1500 DH

VV 1500 PD VV 1500 PDH

VV 1500 PDB VV 1500 PDBH

18

A

B

D

H1

H2

H3

H4

H5

H6

H7

H8

H9

H10

K

2820

2500

1500

3000

2375

3030

-

-

3540

2400

2265

3050

-

420

(111,0) (98,4)

(59,0) (118,1) (93,5) (119,3)

(-)

(-)

(139,4) (94,5)

(89,2) (120,1)

(-)

(16,5)

2820

1440

3030

-

100

3540

2265

3050

-

420

(111,0) (98,4)

(56,7) (118,1) (93,5) (119,3)

(-)

(3,9)

(139,4) (94,5)

(89,2) (120,1)

(-)

(16,5)

2820

1440

277

100

3540

2265

916

420

(56,7) (118,1) (93,5) (119,3) (10,9)

(3,9)

(139,4) (94,5)

2500

2500

(111,0) (98,4)

3000

3000

2375

2375

3030

2400

2400

3050

(89,2) (120,1) (36,1) (16,5)

VV1100 / VV1500

SPECIFICATION MANUAL Fig. 1.11 - Dimension Chart of the Machine VV 1500 (without cab, with ROPS frame)

Dimensions in mm (in)

VV 1500 D VV 1500 DH

VV 1500 PD VV 1500 PDH

VV 1500 PDB VV 1500 PDBH

K1

L

L1

L2

O1

O2

R1

R2

R3

S

W1

W2

W3

W4

430

5686

1690

-

142

162

5395

2920

3050

40

2186

2200

1580

-

(16,9) (223,8) (66,5)

(-)

(5,6)

(6,4)

(212,4) (115,0) (120,0) (1,57)

(86,1)

(86,6)

(62,2)

(-)

430

1690

-

142

162

5395

3050

28

2186

2200

1580

-

(16,9) (223,8) (66,5)

(-)

(5,6)

(6,4)

(212,4) (115,0) (120,0)

(1,1)

(86,1)

(86,6)

(62,2)

(-)

430

6094

142

162

5738

3050

28

2186

2200

1580

2950

(16,9) (223,8) (66,5) (240,0)

(5,6)

(6,4)

(225,9) (115,0) (120,0)

(1,1)

(86,1)

(86,6)

(62,2) (116,1)

VV1100 / VV1500

5686

5686

1690

2920

2920

19

1.3. Technical Data 1.3.1.

Weights

kg (lb) 7090(15630) kg (lb) 4175(9204) kg/cm (lb/in) 32,2(180,5)

Operation weight EN500-1 with cab and protective frame ROPS to drum to axle Static linear load

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

11495(25341) 11925(26290) 12835(28296) 7130(15718) 7560(16667) 8800(19400) 4365(9623) 4365(9623) 4035(8896) 32,4(181,5) (-) (-)

Operation weight with cab according to ISO 6016 to drum to axle Static linear load

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

11435(25209) 11865(26157) 12775(28164) 7015(15465) 7445(16413) 8685(19147) 4420(9744) 4420(9744) 4090(9017) 31,9(178,5) (-) (-)

Operation weight with cab and protective frame ROPS according to ISO 6016 to drum to axle Static linear load

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

11665(25716) 12095(26664) 13005(28670) 7055(15553) 7485(16501) 8725(19235) 4610(10163) 4610(10163) 4280(9435) 32,1(179,5) (-) (-)

Operation weight with cab, protective frame ROPS and padfoot segments according to ISO 6016 to drum to axle

kg (lb) kg (lb) kg (lb)

13345(29420) (-) 8735(19257) (-) 4610(10163) (-)

Operation weight with cab and tires filled with liquid (to -25°C/-13°F) according to ISO 6016 to drum to axle Static linear load

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

12635(27855) 13065(28803) 13975(30809) 7015(15465) 7445(16413) 8685(19147) 5620(12390) 5620(12390) 5290(11662) 31,9(178,5) (-) (-)

Operation weight with cab, protective frame ROPS and tires filled with liquid (to -25°C/-13°F) according to ISO 6016 to drum to axle Static linear load

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

12865(28362) 13295(29310) 14205(31316) 7055(15553) 7485(16501) 8725(19235) 5810(12809) 5810(12809) 5480(12081) 32,1(179,5) (-) (-)

*

kg (lb)

VV 1100 D VV 1100 PD VV 1100 PDB 11265(24834) 11695(25782) 12605(27789)

Operation weight with cab EN500-1 Operation weight EN500-1 to drum to axle Static linear load

7520(16578) 4175(9204) (-)

8760(19312) 3845(8477) (-)

*15455(34072) *9975(21991) *5480(12081)

Smooth drum and tires filled with liquid to -25°C /-13 °F/ for maximal weight.

EN500-1 = CECE The weights may differ depending on additional modifications of the machine made on special request of the customer or if additional options and/or accessories are used.

Weights of machine without cabin can be calculated from all the above weights by deducting Operation weight kg (lb) -220 (485) -220 (485) to drum kg (lb) -105 (231) -105 (231) to axle kg (lb) -115 (254) -115 (254) Static linear load kg/cm (lb/in) -0,48 (2,7) (-)

-220 (485) -105 (231) -115 (254) (-)

The weight of the machine with the cover roof is calculated on all models by deducting the weight of the cab and adding the following weights: Operation weight kg (lb) +140 (308) +140 (308) +140 (308) to drum kg (lb) +60 (132) +60 (132) +60 (132) to axle kg (lb) +80 (176) +80 (176) +80 (176) Static linear load kg/cm (lb/in) +0,27 (1,5) (-) (-)

20

VV1100 / VV1500

SPECIFICATION MANUAL

kg (lb) 7125(15708) kg (lb) 5375(11850) kg/cm (lb/in) 32,4(181,4)

Operation weight EN500-1 with cab and protective frame ROPS to drum to axle Static linear load

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

12730(28065) 13160(29013) 14070(31019) 7165(15796) 7595(16744) 8835(19478) 5565(12269) 5565(12269) 5235(11541) 32,6(182,6) (-) (-)

Operation weight with cab according to ISO 6016 to drum to axle Static linear load

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

12670(27933) 13100(28881) 14010(30886) 7050(15543) 7480(16491) 8720(19224) 5620(12390) 5620(12390) 5290(11662) 32,0(179,2) (-) (-)

Operation weight with cab and protective frame ROPS according to ISO 6016 to drum to axle Static linear load

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

12900(28440) 13330(29388) 14240(31393) 7090(15631) 7520(16579) 8760(19312) 5810(12809) 5810(12809) 5480(12081) 32,2(180,3) (-) (-)

Operation weight with cab, protective frame ROPS and padfoot segments according to ISO 6016 to drum to axle

kg (lb) kg (lb) kg (lb)

14580(32143) (-) 8770(19334) (-) 5810(12809) (-)

*

kg (lb)

VV 1100 DH VV 1100 PDH VV 1100 PDBH 12500(27558) 12930(28506) 13840(30512)

Operation weight with cab EN500-1 Operation weight EN500-1 to drum to axle Static linear load

7555(16656) 5375(11850) (-)

8795(19390) 5045(11122) (-)

*15490(34149) *10010(22068) *5480(12081)

Smooth drum

EN500-1 = CECE The weights may differ depending on additional modifications of the machine made on special request of the customer or if additional options and/or accessories are used.

Weights of machine without cabin can be calculated from all the above weights by deducting Operation weight kg (lb) -220 (485) -220 (485) to drum kg (lb) -105 (231) -105 (231) to axle kg (lb) -115 (254) -115 (254) Static linear load kg/cm (lb/in) -0,48 (2,7) (-)

-220 (485) -105 (231) -115 (254) (-)

The weight of the machine with the cover roof is calculated on all models by deducting the weight of the cab and adding the following weights: Operation weight kg (lb) +140 (308) +140 (308) +140 (308) to drum kg (lb) +60 (132) +60 (132) +60 (132) to axle kg (lb) +80 (176) +80 (176) +80 (176) Static linear load kg/cm (lb/in) +0,27 (1,5) (-) (-)

VV1100 / VV1500

21

1.3. Technical Data

kg (lb) 10160(22399) 10070(22200) 11310(24933) kg (lb) 3990(8796) 3990(8796) 3660(8069) kg/cm (lb/in) 46,2(258,6) (-) (-)

Operation weight EN500-1 with cab and protective frame ROPS to drum to axle Static linear load

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

14380(31702) 14290(31503) 15200(33510) 10200(22487) 10110(22288) 11350(25022) 4180(9215) 4180(9215) 3850(8488) 46,4(259,6) (-) (-)

Operation weight with cab according to ISO 6016 to drum to axle Static linear load

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

14320(31569) 14230(31371) 15140(33377) 10090(22244) 10000(22046) 11240(24780) 4230(9325) 4230(9325) 3900(8597) 45,9(256,8) (-) (-)

Operation weight with cab and protective frame ROPS according to ISO 6016 to drum to axle Static linear load

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

14550(32076) 14460(31878) 15370(33884) 10130(22332) 10040(22134) 11280(24868) 4420(9744) 4420(9744) 4090(9016) 46,0(257,8) (-) (-)

Operation weight with cab, protective frame ROPS and padfoot segments according to ISO 6016 to drum to axle

kg (lb) kg (lb) kg (lb)

16230(35780) (-) 11810(26036) (-) 4420(9744) (-)

Operation weight with cab and tires filled with liquid (to -25°C/-13°F) according to ISO 6016 to drum to axle Static linear load

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

15520(34215) 15430(34017) 16340(36023) 10090(22244) 10000(22046) 11240(24780) 5430(11971) 5430(11971) 5100(11243) 45,9(256,8) (-) (-)

Operation weight with cab, protective frame ROPS and tires filled with liquid (to -25°C/-13°F) according to ISO 6016 to drum to axle Static linear load

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

15750(34722) 15660(34524) 16570(36530) 10130(22332) 10040(22134) 11280(24868) 5620(12390) 5620(12390) 5290(11662) 46,0(257,3) (-) (-)

*

kg (lb)

VV 1500 D VV 1500 PD VV 1500 PDB 14150(31195) 14060(30996) 14970(33002)

Operation weight with cab EN500-1 Operation weight EN500-1 to drum to axle Static linear load

*18340(40432) *13050(28770) *5290(11662)

Smooth drum and tires filled with liquid for maximal weight.

EN500-1 = CECE The weights may differ depending on additional modifications of the machine made on special request of the customer or if additional options and/or accessories are used.

Weights of machine without cabin can be calculated from all the above weights by deducting Operation weight kg (lb) -220 (485) -220 (485) to drum kg (lb) -105 (231) -105 (231) to axle kg (lb) -115 (254) -115 (254) Static linear load kg/cm (lb/in) -0,48 (2,7) (-)

-220 (485) -105 (231) -115 (254) (-)

The weight of the machine with the cover roof is calculated on all models by deducting the weight of the cab and adding the following weights: Operation weight kg (lb) +140 (308) +140 (308) +140 (308) to drum kg (lb) +60 (132) +60 (132) +60 (132) to axle kg (lb) +80 (176) +80 (176) +80 (176) Static linear load kg/cm (lb/in) +0,27 (1,5) (-) (-)

22

VV1100 / VV1500

SPECIFICATION MANUAL

kg (lb) 10195(22476) 10105(22278) 11345(25011) kg (lb) 5190(11442) 5190(11442) 4860(10714) kg/cm (lb/in) 46,3(242,5) (-) (-)

Operation weight EN500-1 with cab and protective frame ROPS to drum to axle Static linear load

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

15615(34425) 15525(34227) 16435(36233) 10235(22564) 10145(22366) 11385(25100) 5380(11861) 5380(11861) 5050(11133) 46,5(260,4) (-) (-)

Operation weight with cab according to ISO 6016 to drum to axle Static linear load

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

15555(34293) 15465(34094) 16375(36101) 10125(22322) 10035(22123) 11275(24857) 5430(11971) 5430(11971) 5100(11244) 46,0(257,5) (-) (-)

Operation weight with cab and protective frame ROPS according to ISO 6016 to drum to axle Static linear load

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

15785(34800) 15695(34602) 16605(36607) 10165(22410) 10075(22212) 11315(24945) 5620(12390) 5620(12390) 5290(11662) 46,2(258,7) (-) (-)

Operation weight with cab, protective frame ROPS and padfoot segments according to ISO 6016 to drum to axle

kg (lb) kg (lb) kg (lb)

17465(38504) (-) 11845(26114) (-) 5620(12390) (-)

*

kg (lb)

VV 1500 DH VV 1500 PDH VV 1500 PDBH 15385(33918) 15295(33720) 16205(35725)

Operation weight with cab EN500-1 Operation weight EN500-1 to drum to axle Static linear load

*18375(40509) *13085(28847) *5290(11662)

Smooth drum

EN500-1 = CECE The weights may differ depending on additional modifications of the machine made on special request of the customer or if additional options and/or accessories are used.

Weights of machine without cabin can be calculated from all the above weights by deducting Operation weight kg (lb) -220 (485) -220 (485) to drum kg (lb) -105 (231) -105 (231) to axle kg (lb) -115 (254) -115 (254) Static linear load kg/cm (lb/in) -0,48 (2,7) (-)

-220 (485) -105 (231) -115 (254) (-)

The weight of the machine with the cover roof is calculated on all models by deducting the weight of the cab and adding the following weights: Operation weight kg (lb) +140 (308) +140 (308) +140 (308) to drum kg (lb) +60 (132) +60 (132) +60 (132) to axle kg (lb) +80 (176) +80 (176) +80 (176) Static linear load kg/cm (lb/in) +0,27 (1,5) (-) (-)

VV1100 / VV1500

23

1.3. Technical Data 1.3.2.

Travel Parameters

Travel speed 1st speed range (work)

km/h (MPH)

1.

2.

3.

2nd speed range (transport)

VV 1100 D VV 1100 PD VV 1100 PDB infinitely adjustable in both directions 0 - 2,5 0 - 2,5 0 - 2,5 (0 - 1,55) (0 - 1,55) (0 - 1,55) 0 - 3,5 0 - 3,5 0 - 3,5 ((0 - 2,17) (0 - 2,17) 0 - 2,17) 0 - 5,3 0 - 5,4 0 - 5,4 (0 - 3,29) (0 - 3,35) (0 - 3,35)

km/h (MPH)

0 - 10,6 (0 - 6,58)

0 - 10,7 (0 - 6,64)

0 - 10,7 (0 - 6,64)

Theoretical gradability * 1st speed range (work) 2nd speed range (transport)

% %

68 27

64 26

57 23

Practical gradability by forward run * - without vibration - with vibration

% %

45 45

45 45

45 45

Approach angle - front - rear

(°) (°)

30 28

30 28

21 28

Transversal stability with cabin and ROPS frame - straight frame (static) - full turn (static)

(°) (°)

36 33

36 33

37 33

Max. allowed transversal inclination - without vibration - with vibration

(°) (°)

23 5

23 9

23 9

Travel speed 1st speed range (work)

km/h (MPH)

1.

2.

3.

2nd speed range (transport)

VV 1100 DH VV 1100 PDH VV 1100 PDBH infinitely adjustable in both directions 0 - 2,4 0 - 2,4 0 - 2,4 (0 - 1,49) (0 - 1,49) (0 - 1,49) 0 - 3,1 0 - 3,1 0 - 3,1 (0 - 1,93) (0 - 1,93) 0 - 1,93) 0 - 3,8 0 - 3,8 0 - 3,8 (0 - 2,36) (0 - 2,36) (0 - 2,36)

km/h (MPH)

0 - 8,0 (0 - 4,97)

0 - 8,0 (0 - 4,97)

0 - 8,0 (0 - 4,97)

Theoretical gradability * 1st speed range (work) 2nd speed range (transport)

% %

113 34

105 33

91 30

Practical gradability by forward run * - without vibration - with vibration

% %

60 60

60 60

55 55

Approach angle - front - rear

(°) (°)

30 28

30 28

21 28

Transversal stability with cabin and ROPS frame - straight frame (static) - full turn (static)

(°) (°)

36 33

36 33

37 33

Max. allowed transversal inclination - without vibration - with vibration

(°) (°)

23 5

23 9

23 9

*

24

Weight according to ISO 6016 with cab and ROPS frame

VV1100 / VV1500

SPECIFICATION MANUAL VV 1500 D

VV 1500 PD

VV 1500 PDB

0 - 2,5 (0 - 1,55) 0 - 3,5 (0 - 2,17) 0 - 4,5 (0 - 2,8)

0 - 2,5 (0 - 1,55) 0 - 3,5 (0 - 2,17) 0 - 4,6 (0 - 2,86)

0 - 2,5 (0 - 1,55) 0 - 3,5 0 - 2,17) 0 - 4,6 (0 - 2,86)

km/h (MPH)

0 - 10,0 (0 - 6,2)

0 - 10,1 (0 - 6,27)

0 - 10,1 (0 - 6,27)

Theoretical gradability * 1st speed range (work) 2nd speed range (transport)

% %

69 21

70 21

64 20

Practical gradability by forward run * - without vibration - with vibration

% %

45 45

45 45

45 45

Approach angle - front - rear

(°) (°)

30 28

30 28

21 28

Transversal stability with cabin and ROPS frame - straight frame (static) - full turn (static)

(°) (°)

37 33

37 33

38 33

Max. allowed transversal inclination - without vibration - with vibration

(°) (°)

23 5

23 9

23 9

VV 1500 DH

VV 1500 PDH VV 1500 PDBH

0 - 2,4 (0 - 1,49) 0 - 2,8 (0 - 1,74) 0 - 3,15 (0 - 1,96)

0 - 2,4 (0 - 1,49) 0 - 2,8 (0 - 1,74) 0 - 3,15 (0 - 1,96)

0 - 2,4 (0 - 1,49) 0 - 2,8 0 - 1,74) 0 - 3,15 (0 - 1,96)

km/h (MPH)

0 - 7,0 (0 - 4,35)

0 - 7,0 (0 - 4,35)

0 - 7,0 (0 - 4,35)

Theoretical gradability * 1st speed range (work) 2nd speed range (transport)

% %

96 30

97 30

87 28

Practical gradability by forward run * - without vibration - with vibration

% %

60 60

60 60

55 55

Approach angle - front - rear

(°) (°)

30 28

30 28

21 28

Transversal stability with cabin and ROPS frame - straight frame (static) - full turn (static)

(°) (°)

37 33

37 33

38 33

Max. allowed transversal inclination - without vibration - with vibration

(°) (°)

23 5

23 9

23 9

Travel speed 1st speed range (work)

km/h (MPH)

1.

2.

3.

2nd speed range (transport)

Travel speed 1st speed range (work)

km/h (MPH)

1.

2.

3.

2nd speed range (transport)

*

Weight according to ISO 6016 with cab and ROPS frame

VV1100 / VV1500

25

1.3. Technical Data 1.3.3.

Vibration

Drive

VV 1100 D;DH hydrostatic

VV 1100 PD;PDH hydrostatic

VV 1100 PDB;PDBH hydrostatic

Vibration exciter

two-stage, circular non-directed vibration

Frequency

Hz (VPM)

32/35 (1920/2100)

32/35 (1920/2100)

32/35 (1920/2100)

Rated amplitude

mm (in)

1,85/1,15 (0,073/0,045)

1,85/1,15 (0,073/0,045)

1,85/1,15 (0,073/0,045)

Centrifugal force

kN (lb)

277/206 (62250/46294)

277/206 (62250/46294)

277/206 (62250/46294)

Drive

VV 1500 D;DH hydrostatic

VV 1500 PD;PDH hydrostatic

VV 1500 PDB;PDBH hydrostatic

Vibration exciter

two-stage, circular non-directed vibration

Frequency

Hz (VPM)

29/35 (1740/2100)

29/35 (1740/2100)

29/35 (1740/2100)

Rated amplitude

mm (in)

2,0/1,0 (0,079/0,039)

2,0/1,0 (0,079/0,039)

2,0/1,0 (0,079/0,039)

Centrifugal force

kN (lb)

325/237 (73037/53261)

325/237 (73037/53261)

325/237 (73037/53261)

1.3.4.

Engine

Make Type

Cummins Diesel B5.9-C148

Serial number Number of cylinders Bore

mm (in)

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

6 102 (4,02)

Stroke Total displacement Output according to ISO 3046/1 (DIN 6271) Rated speed

mm (in) cm3 (cu in) kW (HP) min-1 (RPM)

120 (4,72) 5880 (359) 110 (148) 2200

Maximal torque Specific fuel consumption at rated speed Fuel speed at normal operation

Nm (ft lb) 597 (440) /1600 min -1 (RPM) g/kWh 234 l/h (gal US/h) VV 1100 - 11,8 (3,12), VV 1500 - 12,5 (3,3)

Fuel cleaners - Fleetguard Oil cleaner Air cleaner

1x FF 1280 (3925274) a 1x FF 5052 (3903640)* LF 3349 (Fleetguard)* Donaldson FLG 10-0220

Air filter element Air filter safety element Cooling system Coupling

Donaldson P77-2555 Donaldson P13-3138 liquid cooled engine with cooler 34299 CENTA CF-H-030-1 Sa 03

Engine fulfills requirements of 97/68/EC, EPA, CARB. * Exact denomination of these parts is dependent on modification of the engine. For spare parts ordering always refer to the serial number of your engine.

26

VV1100 / VV1500

SPECIFICATION MANUAL 1.3.5.

Axle

The front axle consists of the drum, the rear axle of the axle housing with two drive gearboxes with the wheels.

Number of tires

2

Tire size Average contact pressure on soil Tire inflation

kPa (PSI) kPa (PSI)

23,1x26 thread UK-5 (10 PR) MITAS 304 (44,1) 160 (23,2)

Tire size Average contact pressure on soil Tire inflation

kPa (PSI) kPa(PSI)

23,1x26 thread TR1 (TD-01) (10 PR) MITAS 860 (124,7) 160 (23,2)

1.3.6.

Brakes

Service brake

hydrostatic system of travel

Parking emergency brake

three band brakes installed in the gearboxes of the wheels and the drum, governed by springs with hydraulic release

Releasing pressure

1.3.7.

MPa (PSI)

1,7 (246)

Steering

Hydraulic power steering with two hydraulic cylinders Hydraulic pump of steering

Power steering unit Safety pressure

VV 1100 D;DH

VV 1100 PD;PDH VV 1100 PDB;PDBH

Jihostroj Q 27R

Jihostroj Q 27R

Jihostroj Q 27R/17R

Mannesmann Rexroth Servostat 8477955593 MPa (PSI)

Hydraulic cylinders

15 (2175)

15 (2175)

15 (2175)

2x HV 90/45/400

Steering angle

(±)

36

36

36

Oscillation angle

(±)

10

10

10

VV 1500 D;DH

VV 1500 PD;PDH VV1500 PDB,PDBH

Jihostroj Q 27R

Jihostroj Q 27R

Hydraulic pump of steering

Power steering unit Safety pressure

Jihostroj Q 27R/17R

Mannesmann Rexroth Servostat 8477955593 MPa (PSI)

Hydraulic cylinders

15 (2175)

15 (2175)

15 (2175)

2x HV 90/45/400

Steering angle

(±)

36

36

36

Oscillation angle

(±)

10

10

10

VV1100 / VV1500

27

1.3. Technical Data 1.3.8.

Vibratory Drum VV 1100 D;DH

Drum dia Drum dia over pads Drum width Drum shell thickness Number of pads Height of a pad Area of a pad

mm (in) mm (in) mm (in) mm (in)

1500 (59,0) 2200 (86,6) 25 (0,98) mm (in) cm 2 (sq in) -

VV 1100 PD;PDH VV 1100 PDB;PDBH 1440 (56,7) 1640 (64,6) 2200 (86,6) 20 (0,79) 140 100 (3,93) 120 (18,6)

VV 1500 D;DH Drum dia Drum dia over pads Drum width Drum shell thickness Number of pads Height of a pad Area of a pad

1.3.9.

1500 (59,0) 2200 (86,6) 40 (1,57) mm (in) cm 2 (sq in) -

VV 1500 PD;PDH VV1500 PDB,PDBH 1440 (56,7) 1640 (64,6) 2200 (86,6) 28 (1,1) 140 100 (3,93) 120 (18,6)

1440 (56,7) 1640 (64,6) 2200 (86,6) 28 (1,1) 140 100 (3,93) 120 (18,6)

Hydrostatic Drive of Travel

Hydraulic pump of travel variable output with skew plate, electrohydraulically controlled Delivery per revolution Safety pressure Kontroller Drum drive gear-box Filtration block Filter element Drum drive hydromotor Wheel gears Hydraulic motors of wheel drives The distributor block

Hydraulic pump of travel variable output with skew plate, electrohydraulically controlled Delivery per revolution Safety pressure Kontroller Drum drive gear-box Filtration block Filter element Drum drive hydromotor Wheel gears Hydraulic motors of wheel drives The distributor block

28

mm (in) mm (in) mm (in) mm (in)

1440 (56,7) 1640 (64,6) 2200 (86,6) 20 (0,79) 140 100 (3,93) 120 (18,6)

VV 1100 Sauer 90 R 075 cm3(cu in/rev) 75 (4,57) MPa (PSI) ¨ 42 (6090) Sauer MCH Trasmital 709C3B75,5 H1 Trasmital 710C3B75,5 H2 (DH; PDH; PDBH) Hytos 729-0060 Argo V3.0720-46 Sauer 51 C 060 Trasmital 707C2B33,3 H1 Trasmital 707C3B53,3 H1 (DH; PDH; PDBH) Sauer 51C060 Hytos 880-0303 VV 1500 Sauer 90 R 075 cm3(cu in/rev) 75 (4,57) MPa (PSI) ¨ 42 (6090) Sauer MCH Trasmital 710C3B75,5 H2 (D; PD; PDB) Trasmital 713C3B97,2 H2 (DH; PDH; PDBH) Hytos 729-0060 Argo V3.0720-46 Sauer 51 C 080 Trasmital 707C2B33,3 H1 (D; PD; PDB) Trasmital 707C3B53,3 H1 (DH; PDH; PDBH) Sauer 51C060 Hytos 880-0303

VV1100 / VV1500

SPECIFICATION MANUAL 1.3.10. Hydrostatic Drive of Vibration Hydraulic pump of vibration variable-output, with skew plate, electrohydraulically controlled Delivery per revolution Safety pressure Hydromotor of vibration

Hydraulic pump of vibration variable-output, with skew plate, electrohydraulically controlled Delivery per revolution Safety pressure Hydromotor of vibration

VV 1100 Sauer 90 R 042 cm3(cu in/rev) 42 (2,56) MPa (PSI) 40 (5800) Sauer 90 M 042

VV 1500 Sauer 90 R 055 cm3(cu in/rev) 55 (3,36) MPa (PSI) 40 (5800) Sauer 90 M 055

1.3.11. Hydraulic Oil Tank Suction basket

Argo AS 080-1

1.3.12. Lifting and lowering of the Hood and the Cabin Hydraulic set Filter Block of lifting Hydraulic cylinders of hood lifting Hydraulic cylinder of cab lifting Hand pump Hydraulic locks - for hood lifting and lowering - for cab lifting and lowering

Hytos SMA 03 731-0433 SF 56/48 Hytos 729-0030 2x HM 25/18-320 HM 40/22-300 Technometra RC 16 2x Hytos RJV1-05 Typ 535-0118 Hytos RJV1-05 Typ 535-0118

1.3.13. Cooling System of Hydraulic Oil Oil cooler

VV1100 / VV1500

Emmegi 34299

29

1.3. Technical Data 1.3.14. Fluids Engine oil Cooling system

l (gal US) l (gal US)

16,3 (4,3) 25,0 (6,6)

Fuel Hydraulic system Drum drive gear-box Wheel gears Vibratory drum Tank of windscreen washer

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

410 (108,3) 90 (23,8) 4,2 (1,11) 4,8 (1,27) (VV 1100 DH, PDH, PDBH) 5,1 (1,35) (VV 1500 DH, PDH, PDBH) 2x2,8 (2x0,74) 8,0 (2,1) 2,75 (0,72)

Tires

kg (lb)

2x600 (2x1323) (VV 1100 DH, PDH, PDBH, VV 1500 DH, PDH, PDBH )

V Ah

24 2 x 100

1.3.15. Electrical Installation Rated voltage Capacity of battery

1.3.16. Safety Devices Emergency brake

stoppage of all functions and braking

Hydraulic locks

protective device preventing fall of the hood or cabin at failure of the lifting system

Oil leak protection

automatically stops the machine and optically signals in a case of oil leak

Battery disconnector

disconnects electrical installation

30

VV1100 / VV1500

SPECIFICATION MANUAL 1.3.17. Hygienical Data VV 1100/1500 The machine with cab: Noise: The acoustic pressure level affecting the driver during the travel under the vibrations: (measured according the EN 11204 on the sand base) The acoustic pressure level affecting the driver during the travel without the vibrations: (measured according the EN 11204 on the sand base)

LpA = 75 dB (A)

Guaranteed sound power level (measured due to the Directive 2000/14/EC, EN ISO 3744 on the elastic material, stopped machine with vibration)

LWA = 111 dB(A)

LpA = 78 dB (A)

The vibrations: The mean effective value of the vibrations acceleration: - transfered to the hands (measured according the ISO 5349 on the sand base under the vibration travel) - transfered to the body (measured according the EN 1032 on the sand base under the vibration travel)

a w < 0,5 m/s 2 (vectorial sum)

The machine with the cab with opened windows: Noise: The acoustic pressure level affecting the driver during the travel under the vibrations: (measured according the EN 11204 on the sand base)

LpA = 87 dB(A)

The acoustic pressure level affecting the driver during the travel without the vibrations: (measured according the EN 11204 on the sand base)

LpA = 76 dB(A)

The machine without cab: Noise: The acoustic pressure level affecting the driver during the travel under the vibrations: (measured according the EN 11204 on the sand base)

LpA = 89 dB(A)

The acoustic pressure level affecting the driver during the travel without the vibrations (measured according the EN 11204 on the sand base)

LpA = 87 dB(A)

a w < 2,5 m/s 2 (vectorial sum)

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

VV1100 / VV1500

31

1.3. Technical Data 1.3.19. Accessories A) Rolling Over Protective Structure (ROPS) The protective frame ROPS meets the international specifications EN 500-4:1995; SAE J 1040 APR88; AS 2294:1990; ISO 3471:1994 up to the total weight of the machine 18500 kg (40785 lb).

Weight of the ROPS frame kg (lb) 230 (507) Fastened to the machine flame with 16bolts M 24 x 80 CSN 02 1143.55 (8G) Tightening torque Nm (in lb) 549 (4854) B) Dozing Blade Blade width Blade height Ground clearance at transport position Cutting depth Weight of blade (total) Fastened to the machine frame with

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

Tightening torque Distributor Safety pressure Hydraulic cylinders

Nm (in lb) MPa (PSI)

2950 (116,1) 916 (36,1) 576 (22,6) 277 (10,9) 910 (2006,2) 2 bolts M 20 x 100 (8G) 2 bolts M 20 x 110 (8G) 5 bolts M 20 x 140 (8G) 5 bolts M 20 x 160 (8G) 314 (2776) HP8-1-STA 20 (2900) 2x HM 63/32/500 111131

C) Padfoot Segments Only suitable for VV 1100 D, DH; VV 1500 D, DH Number of segments Drum dia over pads Total number of pads Height of a pad Area of a pad Weight of one segment Total weight of segments Fastened to the drum with Tightening torque

mm (in) mm (in) cm2 (sq in) kg (lb) kg (lb) Nm (in lb)

3 1712 (67,4) 150 100 (3,9) 120 (18,6) 560 (1235) 1680 (3703) 18 bolts M 20 x 150 (8G) 314 (2776)

D) Filling the Tires with Liquid (possibility to use for machinery VV 1100 D; PD; PDB, VV 1500 D; PD; PDB) Added weight with liquid to -25°C (-13°F) Added weight with liquid to 0°C (32°F)

kg (lb) kg (lb)

2 x 600 (2 x 1323) 2 x 500 (2 x 1102)

E) FOPS roof cover The cover complies with international standards ISO 3449:1992; SAE J 231:JAN81; AS 2294:1990 and approval level II. It is mounted on the ROPS protective frame.

Cover weight kg (lb) 140 (309) Attached to ROPS by 4 bolts M16x30(8G) Tightening torque Nm (in lb) 165 (1457) F) ASC lock (possibility to use for machinery VV 1100 D; PD; PDB, VV 1500 D; PD; PDB) Control unit Sauer Susmic S1X-26G2 511982 Proportional valve Sauer 507832 24V Slope sensor Sauer MCX 106A 1005X 742361 G) FOPS cab This is a standard cab with a reinforced roof protecting against falling objects. The cab complies with international standards ISO 3449:1992; SAE J 231:JAN81; AS 2294:1990 and approval level II.

32

VV1100 / VV1500

2.

OPERATION MANUAL

OPERATION MANUAL VV 1100 VV 1500

VV1100 / VV1500

33

2.1. Description of the Machine Fig. 2.1 - Main Components of the Machine

1 - Drum frame 2 - Vibratory drum 3 - Scraper 4 - Articulated joint 5 - Tractor frame 6 - Axle 7 - Fuel tank 8 - Batteries 9 - ROPS frame 10 - Hydraulic oil tank 11 - Cabin 12 - Hood

34

13 - Engine 14 - Hydraulic oil cooler 15 - Liquid radiator 17 - Driver’s workplace 18 - Pump of travel 19 - Pump of vibration 20 - Exhaust silencer 21 - Air cleaner 22 - Dozing blade 23 - Padfoot segments 24 - Hydraulic oil pressure filter 25 - Air condition system

VV1100 / VV1500

OPERATION MANUAL The single drum vibratory roller consists of two parts (drum one and tractor one) mutually interconnected with the articulated joint.

2.1.1.

Drum Part

The drum part consists of the drum frame (1); in the frame there is fitted the vibratory drum (2) suspended on rubber mounts, with drive systems of travel and vibration.

The ratio between the damping system and the vibrating mass of the drum has been optimized to reach maximal compaction effect.

The drum frame (1) is linked with the beam at the front end.

The scrapers (3) are mounted at the front beam and the rear cross plate of the frame.

The vibratory drum (2) is welded from steel sheets. In the drum side covers and inner flange, there are bearings which support the shaft of the vibrator with two vibration exciters. The exciters are interconnected by the shaft. The bearings are lubricated by oil bath.

The vibration exciter consists of two parts and enables to select one of two amplitudes. This is reached by changing the mutual position of the two parts, executed via changing the rotation direction.

The drum is supported by means of the bearings of the right side cover and by the bearings of the travel gear-box.

The vibratory drum enables to utilize two amplitudes and two frequencies. High amplitude and low frequency is utilized for thick layers of compacted material, which high frequency and low amplitude is utilized for thin layers and layers sensitive to compaction.

2.1.2.

Articulated Joint

The articulated joint (4) connects the both parts of the machine. It includes the large-size cross-roll bearing (1) and two vertical pins (2), which enable articulation and oscillation of the frame - see Fig. 2.2.

2.1.3.

Tractor Part

The tractor part consists of the tractor frame, the axle, the drive unit, fuel & hydraulic tanks, hood and cabin.

The tractor frame (5) is a welded assembly with a plate in front to attach the hinge, with an axle for mounting two transmission gears in the midsection, and with fuel tank and battery holders in the rear section. There are openings for mounting the hydraulic tank, the driver’s post and the protective frame ROPS in the upper part.

The axle (6) consists of two driving gears with wheels attached to the axle of the tractor frame.

The scraper (3) serves for removing soil stuck on the drum.

The scrapers are fully adjustable.

Fig. 2.2 - Articulated Joint

2 1

2

1 - Large-size cross-roll bearing 2 - Vertical pins

VV1100 / VV1500

35

2.1. Description of the Machine The drive unit consists of the engine (13) with the coupling and pumps of travel (18) and vibration (19). The drive unit is fitted into the frame by means of the damping system (32). At side of the engine, there is mounted the hydraulic pump of steering. The coolant radiator (15) with the equalization tank (33) and the hydraulic oil cooler (14) are located in front of the engine. The equalization tank replenishes coolant in the cooling circuit.

Air entering the engine is cleaned in tow-stage dry air filter (21) with automatic flush of the pre-cleaner. Exhaust gases pass through the exhaust silencer (20) - see Fig. 2.3.

The fuel tank (7) is integrated into the rear part of the tractor frame. It includes the cleaning cover with the sensor of fuel gauge, the filler and the drain socket. The filler is equipped with the lockable cover and the breathing valve - see Fig. 2.4.

Fig. 2.3 - Scheme of the Drive Unit

Fig. 2.4 - Fuel Tank with the Filler

13 - Engine 14 - Hydraulic oil cooler 15 - Coolant radiator 18 - Pump of travel 19 - Pump of vibration 20 - Exhaust silencer 21 - Air filter

36

32 - Damping system 33 - Equalization tank

VV1100 / VV1500

OPERATION MANUAL The hydraulic oil tank (10) is located at the machine frame behind the cabin. At the cleaning cover (1) there is the filler with the sieve (2), the oil level switch (3) and the flange with the suction basket (4) - see Fig. 2.5. At the rear wall, there is the sight glass, which designates the correct level of hydraulic oil - that must be kept between the MAX and MIN marks and must not drop below the lower edge of the sight glass (1) - see Fig. 2.6. In the lower part of the tank there is the drain valve (2), the unit of cab and hood lifting and lowering (3) and the hydraulic block (4) - see Figs.

2.6., 2.7. The block includes the sensor of hydraulic oil temperature (1), the safety valve of the cooling circuit and the thermostat - see Fig. 2.8. The thermostat keeps optimal temperature of hydraulic oil within 45 to 60°C (113 to 140°F). At low oil temperature, the cooler is bypassed. The hydraulic oil tank included also the siphoning system located in the return branch; this prevents oil leaks at repairs of the machine.

The hydraulic system: Travel drive consists of a regulating piston hydraulic generator inserted in the closed loop with two hydraulic motor for the wheel drive, and one hydraulic motor for the drive of the vibrating drum.

The drive system of vibration drive consists of one variable-output piston-type hydraulic pump and one constant hydromotor.

The hydraulic system is cleaned by the suction basket at the suction flange (4) inside the tank (see Fig. 2.5) and by the pressure filter at the machine frame (see Fig. 2.9).

Change of frequency and eccentric moment is reached by reversing the flow of hydraulic fluid, at simultaneous change of the flow volume.

Steering of the machine is engaged by two hydraulic cylinders fitted at the joint and the tractor frame, controlled by the hydraulic power steering unit. The gear pump is a source of pressured fluid.

The cooling system consists of the hydraulic oil cooler located in front of the coolant radiator.

Fig. 2.6 - Hydraulic oil tank

1

4 3

2 1 - Sight glass 2 - Drain valve

3 - Unit of cab and hood lifting and lowering 4 - Hydraulic block

Fig. 2.7 - Hydraulic oil tank

3

3 - Unit of cab and hood lifting and lowerin

Fig. 2.5 - Hydraulic oil tank

Fig. 2.8 - Hydraulic block

2 3

4

1

1

1 - Cleaning cover 2 - Hydraulic oil tank filler 3 - Sensor of the oil level 4 - Flange with suction basket

VV1100 / VV1500

1 - Sensor of oil thermometer

37

2.1. Description of the Machine Driver’s station (17) The station consists of a dashboard and a driver’s seat. The cabin or safety railing is mounted separately on the platform, which is attached to the frame through shock absorbers preventing vibrations from being transferred onto the driver from the vibrating drum. Operating and control elements are located on the dashboard and the control panel to the right of the seat.

The cab (11) is provided with service lights and rearview mirrors on both sides. Lockable doors of the cab open by means of a gas operated member. Upper windows in the doors are sliding. The cab is ventilated by a ceiling fan and adjustable ducts in the ceiling panel. The front and rear windshields have windshield wipers and washers. Air ducts connected to the heating system keep the inside of the windshields free of dew. Air conditioning may be custom installed.

The construction of the roof of the cab protects the driver from falling objects, such as gravel, tools, etc., and complies with regulations for level I. Compliance with standards ISO 3449:1992 SAE J 231: JAN 81 AS 2294:1990

The hood (12) is hinged at the machine frame and can be lifter by means of two hydraulic cylinders towards the cabin - see Fig. 2.10.

The electrical installation consists of two batteries (see Fig. 2.11), the alternator and other instruments & control elements. The rated voltage of the system is 24V. The minus (-) pole of the battery is frame connected, through the battery disconnector switch, which serves for disconnecting of the complete electrical installation of the machine (See Fig. 2.12).

Fig. 2.10 - Hood

12

The roof may be reinforced by the FOPS cover protecting the driver from large falling objects, such as stones, and complies with regulations for level II. Compliance with standards ISO 3449 : 1992 SAE J 231: JAN 81 AS 2294: 1990 Details are listed on label below the rear window.

Do not work with open doors!

12 - hood

Fig. 2.9 - Pressure filter

38

Fig. 2.11 - Batteries

VV1100 / VV1500

OPERATION MANUAL The rolling over protective structure ROPS (9) is a frame, which protects the driver if the machine rolls over. It meets the international requests for driver’s protection according to EN 500-4:1995; ISO 3471:1994; SAE J 1040: APR 88; AS 2294:1990; up to the total weight of the machine 18500 kg (40785 lb). The data for the frame are stated on the frame decal (see Fig. 2.13).

The FOPS cover (26) is mounted on the ROPS protective frame, and protects the driver from falling objects, such as trees, boulders, etc., and complies with regulations to level II Compliance with standards ISO 3449 : 1992 SAE J 231: JAN 81 AS 2294: 1990 Details are listed on label on the cover (see Fig. 2.14).

The dozing blade (22) is an auxiliary attachment, designated for spreading of dumped soil and its leveling at the area to be compacted. The arms of the blade are hinged at the drum frame. The blade is lifted and lowered by means of two hydraulic cylinders.

Fig. 2.12 - Location of the battery disconnector

1

Padfoot segments (23) are an optional equipment suitable for VV 1100 D, VV 1500 D. These are mounted onto the smooth drum and partially substitute for the padfoot modification. The padfoot segments are used for compaction of soils up to the layer thickness according to following table:

cohesive soils mixed soils

VV 1100 50 cm (19,7 in) 60 cm (23,6 in)

VV 1500 50 cm (19,7 in) 70 cm (27,5 in)

The segments are also suitable for pulverization and compaction of plate-shaped rock (shales).

1 - Disconnector

Fig. 2.13 - Location of the ROPS Decal

VV1100 / VV1500

Fig. 2.14 - Location of the FOPS Decal

39

2.2. Safety Regulations

40

VV1100 / VV1500

OPERATION MANUAL 2.2. Safety Regulations 2.2.1.

Safety Regulations and Instruction for Operation of the Machine

The safety regulations stated in the individual chapters of the documentation delivered with the machine are to be complemented with safety regulations valid for the respective country of use and on the respective jobsite with regards to organization of work, work processes and personnel.

2.2.1.2. Operation in Danger Space Any damage caused to the utility networks must be immediately reported to its operator; at the same time, it is necessary to ensure measures in order to keep all unauthorized people out of the danger area.

A worker must not work alone, where within reach there is no other person which would provide or arrange help in case of emergency, unless there is secured other effective form of control or connection.

2.2.1.1. Beginning of Compaction Works •

•

The contractor (the company which operates the machine) is obliged to issue regulations for operation and maintenance of the machine, which must contain also the requirements for safety of work.

Before the work is started, it is necessary to check: -

location of engineering networks

-

underground spaces (direction, depth)

-

suction and/or escape of dangerous agents

-

bearing power of soil, inclination of the work area

These facts must be communicated to the machine’s operator designated to carry out the work.

•

It is necessary to issue a technological procedures for the actual work activity, which would set up: -

measurements for operation under exceptional conditions (work in protective zones, at extreme slopes, etc.);

-

measurements for protection from the forces of nature;

-

requirements for operational safety;

-

technical and organizational measurements for securing safety of personnel, jobsite and the surrounding area.

The technological procedures must be communicated to the machine’s operator.

VV1100 / VV1500

41

2.2. Safety Regulations 2.2.1.3. Principles of Safe Operation

When the ROPS frame is used:

•

z The driver has to use the safety belt all the time during operation of the machine.

•

•

•

•

• •

•

The contractor must secure that the machine is operated only under such conditions and for such purposes it is designed for, as specified by the manufacturer and respective standards.

The contractor must ensure, that the machine works only at those jobsites and such a way, that transfer of vibrations does not endanger the surroundings and does not cause any damages.

The contractor is obliged ensure regular inspections of the technical shape and operation in interval as according to the Lubrication and Maintenance Manual. If the machine does not any more meet the operational standards, so that it endangers the operation, people and/or property, or damages the environment, the machine must be put off operation until the failures are repaired.

The contractor must specify, who can carry out which operations at the machine (from the point of view of maintenance, adjusting, lubricating and repairing).

The company must check, whether these operations are done by the designated people conscientiously and with keeping the safety standards.

z The safety belt and its fasteners must not show any marks of damage. z The machine frame at the connection point must be not damaged (cracked, bent, etc.). z The ROPS frame itself must not show any marks of rust, damage, hair cracks etc. z The ROPS frame must not be loose during operation of the machine. z All bolted connections must be torqued to specified value. z Bolts and nuts must not be damaged, deformed or rusted. z At the ROPS frame, any additional changes and/or modifications are prohibited without prior approval of the manufacturer, as they may decrease its strength (additional holes, welding, etc.). z Weight of the machine with the ROPS frame must not exceed the limit weight the ROPS frame is approved for.

All persons which takes part at operation, maintenance and repairs of the machine must be acknowledged with these instructions and it should be proved by getting his signature.

The fire extinguisher must be inspected on a regular basis.

The contractor must designate continual supervision when the machine is operated on an open public road; at such case, the contractor must issue instructions of operational safety.

The contractor must arrange elimination of danger agents (fuel, oil, coolant, etc.) in case these agents have escaped, in order to prevent to harm to environment, operational safety and health of people.

The safety standards marked

must

be kept at any case.

42

VV1100 / VV1500

OPERATION MANUAL 2.2.2.

•

•

•

Requirements for Driver’s Qualification

2.2.3.

•

The roller can be operated only by a driver, who is trained to that and is given the Operator’s License according to ISO 7130 and other national regulations and specification valid for this class of machines.

Without the above license, the roller can be operated only by such person, who is learning to operate it with approval of the contractor, under supervision of certified lector or teacher.

The roller can be independently (short-time) operated by mentally and physically adequate person older than 18 years, who is: a) entrusted by the manufacturer of the machine and who is assembling, testing, proving and demonstrating machines, respectively also who is teaching the drivers, while he must be acknowledged with the safety standards and/or regulations valid for the respective jobsite and that must be proved by his signature

•

• •

or b) who is designated by the contractor (the company, which operates the machine) to carry operation and maintenance, who is trained, respectively who is certified in accordance with special regulations (a holder of construction equipment operation license).

•

• •

• • •

• •

VV1100 / VV1500

Obligations of the Driver

Before operation of the machine is begun, the driver is obliged to study instructions given ins the literature delivered with the machine, mainly with the safety standards and regulations, and keep them properly.

The same is valid for personnel entrusted to carry out lubrication, maintenance, adjusting and repairs of the machine.

The driver must not operate the roller until he fully learned all functions of the machine, controls and service points and until he fully understands how the roller works.

He is obliged to pay attention to all warning and safety decals and signs located at the machine. He must keep the signs in readable shape.

Before he starts the work, the driver must learn about the jobsite, i.e. about possible obstacles, about bearing power of soil, about inclination of the compacted area, about location of engineering networks, about possible limiting factors with regards to environment (max. allowed noise and/or vibrations level) etc.

If the driver finds out any danger to health or life, property, or if he finds a failure, or in case he finds marks of that danger, he is obliged to (unless he is able to repair the failure by himself) stop the machine and secure it against accidental starting and report the failure to the responsible supervisor. He is also obliged to warn all people which could be endangered by such failure.

Before he starts the work, the driver must learn about the failures and operational variations which occurred during the previous shift.

Before starting the work, the operator is obliged to check the machine and its accessories, check the controls, warning and emergency devices, as according to the operation manual. If he finds a failure which he is not able to repair by himself and which could endanger work safety, he must not start the work and report the failure to the responsible supervisor.

If the operator finds a failure during operation, he must stop the machine immediately, secure it against accidental moving.

During operation, the operator is obliged to follow the run of the machine and record all failures in the operation book.

The driver is obliged to keep the operation book and put in properly all records of taking-over the machine, of failures and repairs and of significant events during the working shift.

Before starting, he is to check, if all controls are in the zero position and whereas there are no people within reach of the machine.

Always prior to starting engine, he should warn bystanders by means of the horn.

43

2.2. Safety Regulations • •

•

• •

•

•

• •

•

• • •

44

Before moving the machine, he must check, if steering and braking systems work well.

After warning of the bystanders, the operator may start the machine only after all workers have left the endangered area. In case of unclearly seen jobsites, the operator must wait for at least such time interval which is necessary for safe leaving from the endangered area.

The operator must keep the safety regulation and not to carry any activity, which may endanger the safety.

He is also bound to pay full attention to operation.

When driving the machine, the operator must be sitting.

• •

•

Prior to lifting the hood, the operator must check, if there is sufficient space above the machine and whether there are no electrical power cables.

If the machine comes into touch with high - voltage power lines, keep these instructions: -

try to get off the dangerous area

-

do not leave the operator’s workplace

-

give a warning sign to the others to keep them away, out of touch of the machine

Keep the machine clean of oils and other flammables.

The operator is obliged to keep the technological procedure and/or instruction given by the responsible supervisor.

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

Any time the machine is left after work or during the breaks, the machine is to be locked against unauthorized use (by taking off the key, locking the cab, disconnecting the battery and locking the hoods etc.).

After work is finished, the machine is to be placed to a suitable location, where it cannot collide with traffic, where stability of the machine is not endangered (soil flows or sinking down), where is no danger of falling objects (rocks etc.) and where danger of other kinds of disasters is limited (floods, fires etc.).

If the machine needs to be parked on public roads, all activities required by the road traffic regulations must be done. The machine must be properly marked.

When work is finished, all failures and damages of the machine are to be written into the operation book, as well as all repairs; if drivers are changing, the following driver must be noticed of all such matters.

The driver should wear protective clothes, boots. The clothes should not be too loose or damaged, hair should be covered with a suitable hat. For lubrication, use suitable gloves.

The driver must use ear protectors when working on the machine without cab or with open windows at a noise level of about 90 dB. The machine must be fitted with prescribed accessories.

Keep the driver’s workplace, platforms, steps etc. clean of oils and lubricants, dirt, snow and ice.

VV1100 / VV1500

OPERATION MANUAL 2.2.4.

Prohibited Activities

•

It is prohibited to:

• • •

• • • • • • • • • • • •

• •

Operate the machine while intoxicated with alcohol or drugs.

Use of the machine whenever it may endanger its technical shape, safety (health or life) of people, property, traffic etc.

Start or run the machine, if there are other people present in the cabin, at the platform, or anywhere at the machine or within its reach, with exception of training provided by authorized lector.

Start or run the machine, if any of its safety installations are dismantled or damaged (i.e. the emergency brake, the hydraulic locks, the safety beacon etc.).

Travel and compact in such slopes, where the machine could roll over. The given static stability is lowered due to dynamical effects of travel.

Travel and compact in such slopes, where is a dangers of soil flow and machine falling down, or lose of adhesion and uncontrolled skid.

Operate the machine such a way, which is in discrepancy with conditions stated in the operation manual and in the technological prescription.

• • • • • • • • •

•

Travel and compact with vibration within such a range from edges of slopes and digs, where is a danger of soil flow and machine falling down.

•

Travel and compact with vibration within such a range from edges of slopes and heaps, where is a danger of soil flow and burying the machine.

•

Compact with vibration in such range from buildings, structures and equipment, where is a danger of their damage by means of vibration transfer through soil.

•

Work with the machine at low visibility and at night, until the working area and the whole jobsite is sufficiently illuminated.

Leave the seat, until the machine is running.

Leave the machine, i.e. to get so far away, that driver cannot physically prevent to its misuse Put any safety or emergency devices out of operation or to change its operational features.

Use such a machine, where leaks fuel, oil, coolant or other fluids.

Start the engine other than the prescribed way.

Place into the cabin any other staffs than personal staffs of the driver (i.e. toolbox, etc.).

Place material or any other staffs onto the machine.

Clean dirt from the machine, when the machine is running.

Carry out maintenance, cleaning or repairs unless the machine is secured from accidental moving and unless the workers are safe from moving parts. During maintenance or repairs hang notice no. 15, depicted in Chapter 2.2.5, on the left door handle from the outside.

To touch moving parts of the machine with hand or handhold tools.

Smoke and work with naked flame, when inspecting the fuel level or at refueling, when using flammable cleansing agents and at inspections of batteries.

Carry at the machine flammables in open vessels, or oiled rags.

Let the engine run in closed spaced. The exhaust gasses are lethal.

Carry or transport other people on the machine.

Operate the machine if the driver’s workplace is not securely fastened.

Operate the machine with hood open.

Work with the machine, if other machines or equipment are within reach of it, with exception of those who work in collaboration with the machine.

Correlative Regulations: - Specification ISO 6749 Earthmoving Machines - operation, maintenance, conservation and storing.

-

Specification ISO 4510 Earthmoving Machines - maintenance and adjustment tools.

-

Specification ISO 8152 Earthmoving Machines - operation and maintenance, training of engineers.

Work with the machine in such a place, which is not seen from the operator’s workplace and where is danger for other people or property, until sufficient signaling is ensured for example by means of responsible and adequately trained person.

Work with the machine in protective strips of highvoltage power lines and/or transformer stations.

Run across power cables, until they are sufficiently protected against mechanical damage.

VV1100 / VV1500

45

2.2. Safety Regulations 2.2.5.

Safety Labels and Signs at the Machine

Fig. 2.15 - Location of safety labels and signs

46

VV1100 / VV1500

OPERATION MANUAL Safety Labels and Signs at the Machine 1. Danger of squeezing

Danger area where squeezing is possible. Verify that nobody is present in this area. Should any maintenance is to be done within this space, stop the engine. (The labels are located at the rear plate of the drum frame, 100 mm from the frame edge.)

2.

Do not touch hot parts of the machine, unless you have verified that these are cool enough. Do not open the radiator plug neither drain the fluids if these are hot. Danger of burning! (Label located inside the left side door.)

Danger of burning

3. Danger of injury

Do not touch revolving parts when the engine is running. Danger of injury and winding-up. (Label located to the left side of the radiator.)

4. Adjust when in standstill

Do not adjust or maintain when the engine is running. Danger of injury or winding-up on revolving parts. (Label located inside the left side door.)

5.

Use ear protectors on machines without a cab or with open windows, located on the middle steering column.

Use ear protection

VV1100 / VV1500

47

2.2. Safety Regulations 6. STOP push button

In case of serious failure depress the button. All functions of the machine will be stopped. (Label located at the arm rest, besides of the travel controller.

7.

Battery disconnector

In case of failure of the electric system as well as before leaving the machine, switch the battery disconnector into the „0“ position.

(Label located inside the left side door.)

8.

Manual

Label on the box for ”Technical Documentation” (On the back of the seat)

9.

Hooking points

Use only designated points for hooking. (Labels located at both sides of the machine.)

10. Hooking chart

Use only hooking cable of sufficient payload for hooking. Before lifting the machine, secure the articulated joint. (Label located at the left side door.)

11. First aid kit

The first aid kit located in designated space. Use it to treat injuries.

(Label located at the upper left corner of the cab.)

48

VV1100 / VV1500

OPERATION MANUAL 12. Hydraulic oil

Use recommended hydraulic oils only. (Label located at the hydraulic tank cover.)

13. Fuel

Use recommended fuel only. (Label located at the right side next to the fuel tank filler.)

14. Tire inflation

Keep proper tire inflation. (Label located at both sides of the roller.

15. Machine off duty

Do not start the machine! During maintenance, cleaning or repairs, hang this notice on the handle of the left door from the outside.

The notice board is located in the box on the back of the seat.

16. Read instructions

Before operating the machine read all important safety regulations in the Manuals supplied with the machine (Left side of the control deck.)

17. Safety belt

Wear safety belt while driving (Left side of the control deck.)

VV1100 / VV1500

49

2.3. Environmental and Hygienical Principle When operating and storing the machine, the user is obliged to keep the general principles of health and environmental protection as well as relevant and locally valid laws, regulations and rulings.

2.3.2.

•

Environmental Principles

The various fluids and some parts of the machine become dangerous waste after their lifetime is over.

This category of waste includes mainly:

2.3.1.

•

-

organic as well as synthetic lubricants, oils and fuels;

Oil products, coolants, electrolytes and paints including solvents are harmful agents. Workers getting into touch with these agents are obliged to keep general principles of health protection as well as safety and hygienical instructions of the agents’ producers.

-·

coolants;

Pay special attention to:

-· cleansing and conservating agents;

-

eye and skin protection when working with batteries;

-·

all removed filters and filter elements;

-·

-

skin protection when working with oil products, paints and coolants;

all used hydraulic and fuel hoses, rubber elements and other components of the machine, contamined with the above mentioned agents.

-

proper hands washing after the work and before eating; treat your hands with suitable regenerating cream;

-

•

•

•

50

Hygienical Principles

keep the instructions of this manual when working with the cooling system.

-· battery electrolytes as well as the batteries themselves; -· fill tires

The listed agents and parts must be treated in accordance with the valid local environmental and health protection regulations.

Oil derivates, coolants, battery electrolytes and paints including solvents, as well as conservating and cleansing agents should be always kept in original and properly marked containers. Do not allow storing of such agents in unmarked bottles and other containers, in order to avoid interchanging. Interchanging for food and drinks is especially dangerous.

Should accidentally the skin, mucous membranes, eyes be spilled with such agents or should the vapors be inhaled, apply first aid immediately. Should these agents be eaten, seek for medical aid.

Use ear protectors of suitable type and make when working on a machine without a cab or with open windows.

VV1100 / VV1500

2.4. Conservation and Storing 2.4.1.

Short-Time Conservation and Storing (1-2 months)

OPERATION MANUAL 2.4.2.

Conservation and Storing Longer Than 2 Months

Clean the machine. Warm it by adequate operational load to the operation temperature (especially engine temperature should be reached). Then place the machine to firm and level area in a safe location, where is no danger of floods, soil flow, fire, etc.

Proceed as according to short-time conservation. In addition, it is recommended to: • remove batteries, check their charging status and store them in dry cool place (the batteries are to be regularly re-charged);

Then:

• support the drum frame in order to minimize tension of

• repair damaged paint;

• threat the rubber parts with the conservation agent;

• lubricate all lubrication points, control cables, joints of

• inflate tires to prescribed pressure and protect them

controls, etc.

• verify that water is drained off; • verify that the coolant meets specified antifreeze parameters;

• verify the battery charging status, charge the batteries if necessary;

• apply chrome coated surfaces of the piston rods with conservating grease;

• the machine should be then protected against corrosion with conservation agent (applied by spraying), especially at the areas of high danger of corrosion.

A machine treated this way does not need any specific deconservating before it is later put into operation.

the rubber elements;

from sunshine;

• apply chrome coated surfaces of the piston rods with conservating grease;

• conserve the machine with the conservation agent, especially at the areas of high danger of corrosion;

• blind the inlet and exhaust of the engine with doubled PE foil. Secure the foil with an adhesive tape or a rope;

• protect lights, outside mirrors and other components of outer electric system by spraying with agent and wrapping them into the PE foil;

• conserve the engine as according to the engine manufacturer’s instructions. Mark the engine as conservated.

It is recommended to inspect the machine after 6 months and renew conservation if necessary.

Before putting the machine back into operation, wash the conservation agents with high-pressure hot water jet with usual detergent. Exceptionally, use kerosene or diesel to clean the machine - keep safety and environmental principles.

Never start engine of a conservated machine!

Deconservation and washing is to be done at place equipped where waste water separators are available.

In case of field storing, verify that the site is not endangered by floods or by other kind of danger.

VV1100 / VV1500

51

2.4. Conservation and Storing 2.4.3.

Deconservation And Inspection Of New Machine

Inspect the machine according to the transport documents.

Check, whether the machine or its parts have not been damaged during transport and whether some parts are not missing. If any problems like that are found, inform the forwarder.

Deconserve the machine. Wash the machine with a stream of hot water with addition of usual detergent. Exceptionally, use kerosene or diesel to clean the machine keep safety and environmental principles.

52

VV1100 / VV1500

2.5. Liquidation of the Machine After Termination of Its Service Life When liquidating the machine after its service life is over, the user is obliged to keep the locally valid regulations and laws of waste treatment and environmental protection. It is recommended to approach always:

• a company specialized at such activities; • STA or its authorized service organizations.

STA is not responsible for any health harms and/or damages to the environment in case the above listed hygienical and environmental principles are not maintained.

VV1100 / VV1500

53

2.6. Instruments, Indicators and Controls Fig. 2.16 - Table of used symbols

2

3

4

5

6

9

10

11

12

13

20

21

22

23

24

25

26

27

28

29

36

37

38

39

40

41

42

43

44

45

55

56

57

58

73

74

75

80

2 - travel control 3 - transport speed shift 4 - speed adjustment 5 - gas control lever 6 - emergency brake push button 9 - engine thermometer 10 - hydraulic oil thermometer 11 - hour counter 12 - fuel gauge 13 - speedometer 20 - indicator of charging 21 - indicator of brake 22 - indicator of engine lubrication 23 - indicator of hydraulic oil level 24 - indicator of air filter clogging 25 - indicator of hydraulic filter clogging 26 - indicator of vibration 27 - indicator of direction lights 28 - indicator of neutral position of travel control

54

29 - indicator of ASC differential lock 36 - horn push button 37 - switch of front working lights 38 - switch of rear working lights 39 - switch of of auxiliary lights 40 - switch of fan of heating 41 - switch of warning lights 42 - switch of safety beacon 43 - limit switch of traction spin of the drum 44 - changeover switch of direction lights 45 - vibration preselector 55 - switch of windscreen washer 56 - switch of roof fan 57 - switch of front wiper 58 - switch of rear wiper 73 - battery disconnector 74 - switch of cab lifting and lowering 75 - switch of hood lifting and lowering 80 - control cable of heating

VV1100 / VV1500

OPERATION MANUAL Fig. 2.17 - Instruments, Indicators and Controls

1 - steering wheel 2 - travel control 3 - transport speed shift 4 - speed adjustment 5 - gas control lever 6 - emergency brake push button 7 - switch box 9 - engine thermometer 10 - hydraulic oil thermometer 11 - hour counter 12 - fuel gauge 13 - speedometer 14 - socket of hand lamp

VV1100 / VV1500

20 - indicator of charging 21 - indicator of brake 22 - indicator of engine lubrication 23 - indicator of hydraulic oil level 24 - indicator of air filter clogging 25 - indicator of hydraulic filter clogging 26 - indicator of vibration 27 - indicator of direction lights 28 - indicator of neutral position of the travel control 29 - indicator of ASC differential lock 36 - horn push button 37 - switch + indicator of front lights, rear lights 38 - switch +indicator of rear lights

39 - switch +indicator of auxiliary lights 40 - switch of fan of heating 41 - switch of warning lights 42 - switch of safety beacon 43 - limit switch of traction spin of the drum 44 - change-over switch of direction lights 45 - vibration preselector 46 - parking brake push button 47- switch of vibration 50 - fuse box 51- serial port ASC 69 - driver’s seat 90 - dozing blade control

55

2.6. Instruments, Indicators and Controls Steering Wheel (1) The steering wheel serves to steer the machine. Turning the wheel to right causes articulation of the roller to right and opposite.

Travel Control (2) The travel control serves to set up direction and speed of travel. Shifting the lever forward - direction F - causes forward travel of the machine, while shifting the lever backward - direction R - causes backward travel. In center between these positions, there is a zero („neutral“) position (0). Speed of travel is adequate to displacement of the lever from the neutral position.

The lever is kept in the set up position by means of the friction clutch. Based on this control, the electronic system adjusts the hydraulic pump of travel. The travel control includes a cam with a microswitch, which disables starting unless the control is in the neutral (0) position. The neutral position is signaled by the indicator (28). In this position, also vibration is turned out, as the bearings of vibrator are not lubricated if the machine vibrates at standstill. In the lever handle, there is placed a push button „vibration STOP“ (47), which enables to interrupt vibration any time during the work. The travel control serves at the same time as the service brake of the machine.

A special electronic circuit of the travel control system automatically activates the brakes of the machine, whenever the travel control is in the neutral position form more than about 3 s. (This is activated by the indicator of brake (21)).

When is the control shifted forward or backward from the neutral position (0) and after the releasing pressure is reached, the indicator of brake (21) gets off and travel is enabled. If the control is quickly shifted across the neutral position (less than 2 s) - i.e. at normal operational reversing - the brakes would not be activated.

The timing circuit serves at the same time for automatic releasing of brakes in case that the machine is steered at standstill, in order to protect the brakes from overloading.

Transport speed shift (3) engages transport speed of the machine. With the shift engaged the transport speed is on (control light ”hare” is on in the gear shift lever). Travel control lever (2) may change transport speed of the machine continuously from zero to maximum in both directions. A decreased volume of the hydraulic motors is applied for the machine drive and its top speed (pulling force and climbing ability are lowered).

Engage gearshift – transport speed for travel at the site on roads for travel between the working site and the loading/unloading sites.

The shift may be engaged (symbol “hare” lights up) under load. If the pulling force is lacking, switch the transport shift off.

56

During travel at long distances observe cooling off breaks every three hour. Stop machine for one hour. Non-adherence to this regulation may result in damage to the machine and subsequent voiding of warranty by the manufacturer.

It is not permitted the engage the gear during operations!

Switch transport speeds off while the machine is idle or travels at a low speed!

It is not permitted to disengage the gear at higher speeds, since the machine slows down abruptly and cause a shock in the hydraulic system!

Speed Adjustment (4) The pre-selector chooses three speeds in the working speed mode. When the shift (3) is on, the pre-selector (4) becomes inoperative.

Gears “1” to “3” correspond to normal working speeds for compacting, and have been pre-adjusted by the manufacturer. After the pre-selector has been switched to the selected speed gear, travel speed of the machine is controlled by travel controller (2). Individual speed gears may be selected under load. Other working speed ranges may be set up by the manufacturer as agreed upon in advance.

Gas Control Lever (5) The gas control lever serves to set up speed of the combustion engine, within the range from idle to maximal. Moving the lever downwards, the speed is increased. The lever is connected by means of a control cable with the control lever of the injection pump. The gas control lever is fitted with a switch, which enables to turn on vibration only at engine speed over 1800 RPM. At lower speed, vibration is disabled.

Emergency Brake Push Button (6) In a case of failure, when the machine cannot be stopped by means of the travel control (2), the emergency brake is to be used. It is turned on by the push button (6). When activated, it results in activation of the brakes and stopping the engine; it is signaled by the indicator (21). To deactivate the brake, the button is to be half-turned in the arrow direction. If the push-button is depressed, starting of the engine is disabled.

Switch Box (7) The switch box has three positions „0“, „1“, „2“. In the „0“ position, all appliances connected to the fuses F1, F2 and F7 are turned on; in the „1“ position, all the other appliances are connected. The sprung position „2“ serves to start the engine. The engine is stopped by turning the key into the „0“ position, where the key can be also taken out. At machines without the cab, always use the switch box cover to protect the switch box from penetration of water and dirt.

VV1100 / VV1500

OPERATION MANUAL

Engine Thermometer (9) The thermometer indicates temperature of engine coolant. Operational temperature is up to 100°C (212°F). If the temperature exceeds 100°C (212°F), it is necessary to decrease load of the engine and let it cool down.

Hydraulic Oil Thermometer (10) indicates the temperature of hydraulic oil during operations. The highest permitted temperature is 90 °C (194 °F) for oils of viscosity class HV 68 a HV 100. The optimal working temperature is 50 - 60 °C (122 - 140 °F).

Use of oils of different viscosity Oil viscosity Maximum permitted oil temperature HV 46 80°C (176°F) HV32 70°C (158°F)

Hour Counter (11) The hour counter indicates time, when the engine have been working. Whenever the charging indicator (20) gets off, the counter begins to count time. The recorded time is not dependent on the engine speed.

Fuel Gauge (12) The fuel gauge indicates volume of fuel left in the fuel tank.

Speedometer (13) Indicates engine speed in RPM.

Socket of Hand Lamp (14) The socket serves for connecting the auxiliary hand lamp of 24 V voltage.

Fig. 2.18 - Indicator and Controls

VV1100 / VV1500

57

2.6. Instruments, Indicators and Controls Fig. 2.19 - Indicators and Controls

58

VV1100 / VV1500

OPERATION MANUAL

Indicator of Charging (20) The indicator signals proper function of battery charging.

When the key of the switch box (7) is turned into the „1“ position, the indicator must get on; when the engine is started, it must get off (if the indicator does not get off, search for a failure).

Indicator of Brake (21) This indicator signals that the brakes have been activated.

Indicator of Engine Lubrication (22) It indicates, if there is sufficient pressure in the engine lubrication system. After switching the ignition key into the position „1“ at the switch box (7), the indicator must turn on and after starting the engine, it must turn off. If the indicator gets on during operation, it signals insufficient lubrication of the engine.

Indicator of Hydraulic Oil Level (23) If oil escapes out from the hydraulic system of the machine, the oil level in the hydraulic tank drops down. If such drop exceed allowed limit, the environmental protection system becomes activated, indicator of hydraulic oil level gets on and the machine is automatically stopped. Starting is disabled till the failure is repaired and oil is topped up.

Indicator of Hydraulic Filter Clogging (25) If this indicator gets on at operating temperature of hydraulic oil (50-60°C /122 - 140°F), it signals increased pressure difference at the hydraulic filter which is clogged. The filter elements should be replaced.

Switch of Vibration (26) This indicator signals, that the switch of vibration (47) is turned on („ON“). After the travel control (2) is shifted out of the neutral position, the machine begins to vibrate with the selected amplitude and frequency. In case vibration is undesirable, the indicator should not be lit.

Indicator Of Direction Lights (27) This indicator starts blinking when the direction lights are turned on.

Indicator Of Neutral Position Of The Travel Control (28) This indicator signals that the travel control is in the neutral position, where starting is enabled.

Indicator of the differential lock ASC (29) Indicator of Air Filter Clogging (24) This indicator signals increased underpressure in the engine inlet branch. It is necessary to clean or replace the filter elements.

The indicator flashes when the differential lock is faulty ASC.

!NOTE !

See Chapter 2. 7. 1. 8. Travel of machine with differential lock ASC for function description.

VV1100 / VV1500

59

2.6. Instruments, Indicators and Controls Fig. 2.20 - Indicators and Controls

60

VV1100 / VV1500

OPERATION MANUAL

Limit switch of drum slide (43)

Horn Push Button (36) Depress this switch to activate the warning horn.

There are following positions - at all switches, the forward position is listed first.

Switch of parking and front operating lights (37) -

off

-

1. front parking lights and rear end lights, panel illumination

-

2. front lights on

Limit switch of drum slide (43) is included on the panel if the machine is not equipped with the differential lock ASC. - OFF -

! NOTE !

Description of function, see Chapter 2.7.1.7. Machine travel in a difficult terrain.

The spinning limit switch should be used only when the roller is moved onto the loading platform of a vehicle.

Switch of Rear Lights (38) -

limit function of drum slide is ON –signaled by pilot lamp in the switch

turned off rear lights turned on

With the switch (43) on the gearshift (3) must be off. Vibration is blocked as well.

Switch of auxiliary lights (39) -

turned off lights turned on

Switch Of Fan Of Heating (40)

Change-Over Switch Of Direction Lights (44) -

left direction lights turned on turned off right direction lights turned on

When the direction lights are turned on, the indicator of direction lights (27) is also activated.

- turned off - high speed of fan motor - low speed of fan motor

Vibration Preselector (45) - low amplitude and high frequency selected - high amplitude and low frequency selected

The fan circulates the air inside the cab only. Provide for fresh air when the heating system is on!

Parking brake push button (46)

Switch Of Warning Lights (41) -

turned off warning lights turned on (signaled by blinking indicator in the switch)

Switch Of Safety Beacon (42) -

turned off safety beacon turned on (signaled by indicator in the switch)

NOTE: The beacon must be connected to plug (65)

Use when the machine must be stopped immediately on a slope. Travel controller (2) must be in neutral.

NOTE! Following stopping, the machine keeps on moving for a short moment (when traveling up a slope the machine may start backing up slowly) before coming to a complete stop. Therefore, press emergency brake button and the machine stops immediately. The button is deactivated after the machine started traveling.

Switch Of Vibration (47) -

vibration turned on turned off

Activated vibration is signaled by the indicator (26).

VV1100 / VV1500

61

2.6. Instruments, Indicators and Controls Fuse Box (50) Fuse (F1) -20 A

(upper fuse) front and rear lights, front silhouette lights and rear limit lights, auxiliary spotlights, instrument panel illumination, raising and lowering the hood and driver’s station, license plate illumination.

Fuse (F2) -10 A

service light plug, cab illumination, emergency horn, directional lights, beacon.

Fuse (F3) -7,5 A

brake, engine STOP, drive, vibration, brake lights, back-up horn, level of hydraulic oil indicator, vibration on indicator, brake indicator, neutral position of drive control indicator.

Fuse (F6) - 15 A

fan of ventilation, fan of heating, front & rear windscreen wiper, windscreen washer

Fuse (F7) - 20 A

reserve (air conditioning)

Fuse (F8)

reserve

Replace the fuses by that of the same value !!!

Fuse (F4) - 7,5 A indicator of ASC differential lock Fuse (F5) - 5 A

coolant thermometer, hydraulic oil thermometer, fuel gauge, speedometer, hour counter, indicator of engine lubrication, indicator of air filter clogging, indicator of hydraulic filter clogging, indicator of charging

Serial port ASC (51) The serial port enables communication with the ASC computer and for its debugging.

Fig. 2.21 - Fuse box

62

VV1100 / VV1500

OPERATION MANUAL

Switch of front wiper (57)

Switch of windscreen washer (55) -

turned off

-

turned off

-

washers of front and rear windscreen turned on

-

front wiper turned on

Switch of rear wiper (58)

Switch of roof fan (56) -

turned off

-

turned off

-

roof fan turned on

-

rear wiper turned on

The fan suck in outside air. With windows closed ventilate the cab using the fan.

Roof light (61) -

turned off

-

turned off

-

roof light turned on

Fig. 2.22 - Indicators and Controls

Vents of ventilation (62) The vents enable to regulate air flow, as well as its direction.

Sunshade (63) The sunshade it adjustable in vertical direction.

Glove compartment (64) This space is intended for storing of the first aid kit, the book of operation or other documents, etc.

Power plug (65) is used for connecting the beacon or service light (fig.

2.23).

Fig. 2.23

65

55 -switch of windscreen washer 56 -switch of roof fan 57 -switch of front windscreen wiper 58 -switch of rear windscreen wiper 61 -roof light

VV1100 / VV1500

62 -vents of ventilation 63 -sunshade 64 -glove compartment 71 -rear view mirrors

63

2.6. Instruments, Indicators and Controls Driver’s Seat (69)

Adjust the seat before starting driving!

The operator is obliged to use the safety belt during the work!!

The driver’s seat is fully adjustable and equipped with the safety belt. The seat is vertically adjustable in three steps.

At the lower part of the seat, there is a turntable, which enables the seat to swing to left within 50°. Swinging is possible after lifting the lock pin (J) located at left.

To make access from the right side easier, the arm with the travel control can be tilted off. If the arm is lifted, starting of the machine, as well as travel and vibration, are disabled. If the arm is lifted at the engine running, the machine automatically stops, the brakes are activated and the engine is shutdown.

Fig. 2.24 - Driver’s Seat A - main longitudinal shifting of the seat (enabled by lifting of the lock arm) B - auxiliary longitudinal shifting of the seat (enabled by lifting of the lever) C - height adjustment in dependence on driver’s weight (by turning the lever) D - adjustment of the backrest angle (enabled by lifting of the lever) E - adjustment of the backrest shape (by turning the knob) F - adjustment of the arm rests angle (by turning the screw) G - self-winding safety belt H - tilting arm with the travel control I - height adjustment (unload the seat for lifting up) J - lock pin

64

VV1100 / VV1500

OPERATION MANUAL Compartment for the Operation Manuals (70)

Rear View Mirrors (71)

This compartment serves for storing of the operation manuals (see Fig. 2.25).

When working at a limited space, or when transporting the machine, the mirrors can be tilted by 90° to the transport position „B“ (see Fig. 2.26).

Keep the mirrors clean and properly adjusted.

Fig. 2.26 - Rear view mirrors

Fig. 2.25 - Compartment for the Operation Manuals

70

B A

70 - Compartment for the Operation Manuals 71 - Rear view mirrors A - transport position B - service position

VV1100 / VV1500

65

2.6. Instruments, Indicators and Controls

Switch of cabin lifting (74)

Battery disconnector (73) The battery disconnector serves for disconnecting the complete electrical installation. Turn on the system by turning the switch to right.

0

- electrical installation turned off

I

- electrical installation turned on

-

cab lifting

-

zero position

-

cab lowering

The switch activates the electrohydraulical unit of lifting and lowering of the cabin.

Fig. 2.27 - Instruments and Controls

73 - battery disconnector 74 - switch of cabin lifting 75 - switch of hood lifting 76 - fuse F 7(50A) 77 - hand pump of cabin and hood lifting 78 - control lever of the hand pump 80 - control cable of the heating valve 81 - vents of ventilation

66

82 - fire extinguisher 83 - dust filter of cabin ventilation 85 - tank of windscreen washer 86 - bottle holder 89 - depository pocket 90 - control lever of the dozing blade 91 - rear windscreen wiper 92 - front windscreen wiper

VV1100 / VV1500

OPERATION MANUAL Vents of ventilation (81) The vents can be tilted to control air flow and rotated to control the air stream direction.

Switch of hood lifting (75) -

hood lifting

-

zero position

-

hood lowering

Fire Extinguisher (82) Instruction of use of the fire extinguisher are given at the instrument packing, fig. 2.28.

Fuse (76) This fuse (F7 - 50A) protects the electrohydraulical unit of hood & cabin lifting.

Hand Pump (77) The device provides for emergency lifting and lowering of the hood and the cab by handle (1) when the electrical hydraulic system has been damaged or the battery discharged.

Lever of the hand pump (78) This lever is to be used for pumping with the hand pump (77).

Control cable of the heating valve (80) It serves to control the flow of coolant passing through the radiator of heating. Shifting the lever backwards, the valve of heating gets open.

It is not allowed to adjust the temperature using the heating valve lever during travel. Adjust the heating valve before starting driving!

Learn thoroughly use of the fire extinguisher.

Let the fire extinguisher to be inspected on regular basis.

Tank of windscreen washer (85) The tank serves as a source of liquid for the washing system. It includes two pump - separate for front and rear washing nozzles.

Bottle holder (86) The holder can hold a standard bottle with drinks, fig. 2.28.

Depository pocket (89) For the driver’s personal items, Fig. 2.29.

Control Lever of the Dozing Blade (90) The lever has four positions: 0

- basic position

I

- lowering of the blade

II

- lifting of the blade

III - floating position

Fig. 2.28 - Location of Fire Extinguisher

Fig. 2.29 - Depository pocket

82 86

VV1100 / VV1500

67

2.7. Operating and Using the Machine 2.7.1.

Controlling the Basic Functions of the Machine

2.7.1.1. Starting the Engine Daily, prior to starting the engine, check the oil level in the engine, in the hydraulic oil tank, check coolant level and fuel level (if you get out of fuel, deareate the fuel system).

Check, if there are no loose, worn or missing parts at the machine. Check tire inflation.

2.7.1.2. Riding the Machine (see Fig. 2.17) z Make sure that nobody is within the reach of the machine in front and back. z Switch off transport speed shift (3). z Select the proper speed gear on the pre-selector (4). z Adjust proper revolutions of the engine. z Check that vibration is not on – indicator (26) may not be on.. If yes, turn it off by switch (47) z Turn lights on under poor visibility conditions

To start the engine (see Fig. 2.17): z Turn on the battery disconnector (73) - see Fig. 2.27. z Plug the key into the switch box (7) and switch it into the „1“ position (indicators of charging and engine lubrication get on). z Put the travel control lever (2) into the neutral position „0“ - the indicator of neutral position (28) gets on (starting is disabled in other than neutral position of the lever). z Check, whether the emergency brake push button (6) is not depressed and if the arm with the travel control (2) is not lifted. z Verify, that nobody is endangered by starting. z Warn bystanders the others by pushing the button of warning horn (36). z Set the gas lever (5) to increased fuel supply. z Switch the key in the switch box (7) into the position „2“ and start the engine (hold the key only until the engine starts). z Do not start longer than 15 sec. If the engine does not start, wait for about 30 sec. and start again. If the engine does not start even after the third attempt, search for a failure. z When the engine gets started, slowly lower its speed and check its proper function according to the indicators. z Let the engine run unloaded at speed increased to 1300 - 1500 RPM. z Do not fully load the engine until temperature of coolant reaches 45°C (113°F).

When starting the engine with an auxiliary source, connect the „plus“ connectors to „plus“ and „minus“ to „minus“.

Connect the „minus“ connectors always as last and disconnect them as first.

Do not connect (-)cable to discharged battery of the machine you want to start! During starting heavy sparking may occur and gases of the charged battery may explode.

Start the engine from the driver’s workplace only!

If the emergency brake push button (6) is depressed (see Fig. 2.17), or if the seat arm with the travel control is lifted, it is impossible to start the engine, as well as to engage travel or vibration.

68

z Turn other appliances on (heater, wipers) z Select travel direction and speed Forward - travel controller (2) move from (0) forwards - small move equals low speed and vice-versa Back - move travel controller through (0) back. z When moving travel controller, brake light indicator (21) goes off.

Engage gearshift (3)– transport speed for travel at the site on roads for travel between the working site and the loading/unloading sites.

During travel at long distances observe cooling off breaks every three hours .Stop machine for one hour.

Non-adherence to this regulation may result in damage to the machine and subsequent voiding of warranty by the manufacturer.

The gear (icon ”rabbit” lights up) may be shifted only under load.

If the pulling force is insufficient, switch gearshift (3) of transport speed off.

If the travel control stays in position ”0” for more than 3 seconds, the machine brakes automatically.

Do not use gas control (5) to control machine speed.

In case of emergency, particularly on a slope, stop the machine immediately by pressing the parking brake push-button (46) after the travel lever was shifted to neutral.

Prior to travel down a steep slope shift to working speed by switching off shift (3)!

It is not permitted to disengage the gearshift (3) at higher speeds – abrupt slow down occurs and a shock affects the hydraulic system Switch shift (3) off when the machine is still or traveling slowly!

VV1100 / VV1500

OPERATION MANUAL 2.7.1.3. Travel with Vibration (see Fig. 2.17)

2.7.1.4. Stopping the Machine and the Engine (see Fig. 2.17)

z Turn off transport speed shift (3). z Use pre-selector (4) to set suitable working grade. z Using vibration pre-selector (45) adjust suitable amplitude of vibration. z Adjust gas control (5) to maximum revolutions. z Start moving and turn on vibration by vibration switch (47). Indicator (26) turns on. The drum starts vibrating.

Vibration may be turned off anytime by pressing vibration button (47) repeatedly.

NOTE! With transport speed shift (3) on vibration is turned off.

z Turn vibration off by turning the switch (47) into the central position. The indicator of vibration (26) gets off. z Put the travel control (2) into the neutral position. The brakes become automatically engaged. z Lower engine speed. z Stop the engine by switching the key into the „0“ position (do not stop hot engine immediately, but let it idle at approx. 1000 RPM for 1-2 min. z Turn out all used appliances (heating, ventilation, wipers etc.). z Remove the key from the switch box. In case of machine without the cab, cover the switch box with the cap.

Vibration switches on at 1800 RPM. NOTE! If immediate stop is required (for instance on a slope), move travel control (2) to neutral and press parking brake button (46).

Whenever the indicator of the engine lubrication gets on during operation, stop the engine immediately, find out the failure and repair it.

If any fluid begins to accidentally escape, stop the engine immediately.

Catch the leaking fluid and dispose of it in accordance with environmental principles.

VV1100 / VV1500

69

2.7. Operating and Using the Machine 2.7.1.5. Before Leaving the Machine

2.7.1.7. Machine travel in a difficult terrain

z Put the machine to a level area of sufficient bearing power.

While driving on a difficult terrain or on a slope when the wheels or the drum may spin. Switch (43) on. Thereafter switch it off. The indicator in the switch signals the activation and correct function.

z Turn out the battery disconnection switch (73) - see Fig. 2.27. z Clean the machine (the scraper, the tires etc.). z Inspect the machine thoroughly and repair all failures, which appeared during the work. z Check tire inflation. z Lock the wheels and the drum with wedges.

Do not drive across a steep slope – the machine may capsize!

z Be sure, that there is no danger of soil flow down, floods etc. at the respective area. z Lock the instruments cover or the cab door, as well as the small door under the driver’s workplace.

2.7.1.6. Emergency Stopping (see Fig. 2.17) In a case of a failure, if it is impossible to stop the machine by sliding the travel control (2) into the neutral position, the emergency brake must be used. It is activated by the push button of emergency brake (6), which is signaled by the emergency brake indicator (21). To release the brake, turn the push button in the arrow direction.

If the push button of emergency brake (6) is depressed, or when the tilting arm with the travel control is lifted, starting of the engine, travel and vibration are disabled.

70

VV1100 / VV1500

OPERATION MANUAL 2.7.1.8. Travel of machine with differential lock ASC z The differential lock ASC prevents the wheels and the drum from sliding through on a difficult terrain or on a slope.

z The differential lock ASC is activated by turning the key in the switch box, and functions in both modes – working speed, transport speed - to full extent .

z As long as the ASC function is activated the pilot lamp (29) on the control panel is off. Flashing pilot lamp (29) indicates faulty ASC function. The machine is defective !

1. Automatic unlocking of the differential lock ASC:

z When the defect of the ASC system has become visible by the sensors on one of the rear wheels during travel the differential lock will be automatically unblocked within five seconds.

z If you stop the machine, switch off the motor, and start it again. Thereafter, one of the rear wheels will be blocked and the pilot lamp starts flashing (29).

z Thereafter, it is necessary to wait for five seconds during travel until the differential lock is automatically unlocked.

The machine remains defective!

z The majority of defects on the ASC system is not noticeable on the outside; only when the adhesion conditions have been extended, the drum or one of the driving wheels starts turning fast.

z The machine may function under that condition; it travels only in the working speed; the transport speed is automatically off as far as the machine protection is concerned.

z Only with faulty sensors on one of the rear wheels will the defect become visible by one of these wheels being locked during travel for five seconds.

z After five seconds of the limit locking the wheels during travel will the wheel be unlocked

z If you stop the machine, switch the motor off and then

2. Bypassing the function of the differential lock ASC:

z To bypass the function of the lock remove fuse (F4) 7,5 A on the control panel.

The machine remains defective!

! NOTE !

Call your service to correct the defect of the ASC system Do not travel across a slope with a steep gradient !

Ride at right angles to the slope!

start it again, one of the rear wheels will be locked again and the pilot lamp starts flashing (29).

z Thereafter it is necessary to wait five seconds again until the differential lock ASC unblocks automatically.

z During this automatic safety mode the machine cannot be damaged, and the machine can continue working temporarily until the defect has been corrected.

z For that reason we recommend excluding the function of the differential lock ASC until the defect has been corrected.

VV1100 / VV1500

71

2.7. Operating and Using the Machine 2.7.2.

Operating the Machine in the Running-in Period

When a new machine is being put into operation, do not use full load for the initial 30 hours (travel up to a slope with vibration).

2.7.3.

Lifting the driver’s station and the hood

To permit easier access to the hydraulic aggregates, the driver’s station and the hood may be lifted - see Fig. 2.30.

Sequence of lifting and folding

• • •

Unscrew nuts at the rear end of the driver’s station that attach brackets to rubberized metals - see Fig. 2.31.

Switch power on by turning battery disconnect (1) - see Fig. 2.32.

Depress and hold P/B (3) – lifting driver’s station – or P/B (2) – hood lifting – in position ”A” until the end of process. For lifting turn the switch and hold it in position “B” until the end. Lifting and folding may be interrupted anytime by releasing the P/B.

Fig. 2.30

•

Fig. 2.31

Fig. 2.32

After folding, tighten nuts on the driver’s station.

1

3

72

A

A

B

B 2

VV1100 / VV1500

OPERATION MANUAL Manual lifting and folding • The driver’s seat or the hood may be lifted or lowered using the manual hydraulic generator, should the system be faulty or the battery discharged.

After folding, tighten nuts on the driver’s station. Tighten screws on the driver’s station after it has been folded down, since a fatal accident could occur should the machine capsize.

The driver’s station Slide the gate (3) on the distributor (1) and lock in this position - see Fig. 2.33.

• • •

Insert control lever (1) into the manual hydraulic generator and by pumping lift the driver’s station - see Fig. 2.34.

Before lifting remove the lock, slide gate (3) on the other side of the distributor (1), and secure (4). By pumping fold the driver’s station - see Fig. 2.35.

(

Fig. 2.34

1

Fig. 2.33

Fig. 2.35

4

1

1

3

3 4

VV1100 / VV1500

73

2.7. Operating and Using the Machine Hood • Slide the gate (3) on the distributor (2) and lock in this position (4) - see Fig. 2.36.

• •

Lift the hood by pumping - see Fig. 2.37.

Before folding remove safety pin, slide gate (3) on the other side of the distributor and secure by safety pin.

By pumping fold the hood - see Fig. 2.38.

Fig. 2.36

Manual lifting and folding - options Driver’s seat • Remove nuts on the back of the driver’s seat that attach the panel to the rubberized metal pieces.

•

Slide the lever to position A - see Fig. 2.39.

Fig. 2.38

1

4

4

2

3

3

Fig. 2.37

Fig. 2.39

(

A 1

74

VV1100 / VV1500

OPERATION MANUAL • •

Insert operating lever (1) in the manual hydraulic generator, and pump the seat up - see Fig. 2.40.

Fig. 2.41

To lower, slide the lever to position B, and pump the manual hydraulic generator - see Fig. 2.41.

B After folding, tighten nuts on the driver’s station. Tighten screws on the driver’s station after it has been folded down, since a fatal accident could occur should the machine capsize.

Hood • Slide the lever to position A - see Fig. 2.42.

• •

Insert operating lever (1) in the manual hydraulic generator, and pump the driver’s seat up.

Fig. 2.42

To lower, slide the lever to position B, and pump the manual hydraulic generator - see Fig. 2.43.

A

Fig. 2.40

Fig. 2.43

(

B 1

VV1100 / VV1500

75

2.7. Operating and Using the Machine 2.7.4.

z Return the blade control lever (90) back into the „0“ position - see Fig. 2.27.

Dozing Blade

z Unlock the blade removing the lock pins (1) out of the holders at the front frame. The disconnected links (2) should be fastened to the holders at the blade using the lock pins (see Fig. 2.44).

z Shift the travel control (2) - see Fig. 2.17 - forward to ride the machine.

z Start up the engine.

z Lower the blade into the required cutting depth by shifting the control lever (90) - see fig. 2.27, to the position „1“. The actual cutting depth can be rear on the pointers (every beam or space means 50 mm).

z Switch off the speed shift (3) (Fig. 2.17), and on the selector of working speed (4) (Fig. 2.17) select the suitable range of working speed, for instance position „1“

z Control the volume of dozed material by shifting the control lever either forward „1“ (to lower the blade) or backward „2“ (to lift the blade), depending on the tractive force of the machine.

z Set up engine speed to full (or near-full) throttle.

z When dozing material on a firm surface, it is possible to utilize the floating position of the blade - put the control lever to the arrested position „3“. At this position, the spaces above and below the piston are interconnected. At this position, the blade is sliding on the removable skis (96) - see Fig. 2.45. This position is also useful for spreading and leveling of the material at reverse travel of the machine.

z Be sure you have unlocked at blade at both sides.

z Lower the blade to ground by shifting the control lever (90) - see Fig. 2.27 - from position „0“ through position „1“ to position „III“ (floating arrested position). When shifting the lever into the position „III“, increased resistance can be felt. z Find the mutual position of the fixed pointer (93) at the drum frame towards the moving pointer (94) and remember this position. This is the „basic“ position of the blade (see Fig. 2.45).

Fig. 2.45 - Blade and pointer

96 95

Fig. 2.44 - Blade Security Links

1

2 94

93

1 - Lock pin 2 - Security links

76

93 - Fixed pointer 94 - Moving pointer 95 - Cutting edges 96 - Skis

VV1100 / VV1500

OPERATION MANUAL z After finishing the work with the blade, fasten the blade to the frame by means of the links and the lock pins, to avoid undesirable lowering of the blade. z Speed of lifting and lowering of the blade can be adjusted at the limiting valves (98) of the blade control distributor (97) under the driver’s workplace. Follow the symbols at the distributor (see Fig. 2.46).

2.7.5.

Protective Frame

How To Mount The Frame: z Fit on the protective frame and bolt it to the frame with 16 pcs. of bolts M24 x 80 (8G) with washers. Torque the bolts to 549 Nm (4854 in.lb). z Dismantle the frame in the reverse order.

z The cutting edges of the blade are removable. When worn, use the other side of the edges (turn by 180°).

Do not adjust the scrapers, do not carry out any maintenance at the blade unless it is lowered to the ground and the engine stopped, or unless the blade is secured by both safety links.

Do not work with the blade when it is secured. In case that only one link is secured, the blade can be damaged.

When mounting the blade, avoid hands injuries.

Safety Standards: To suspend the frame, use only designated suspension eyes.

Do not suspend the frame on one eye only.

Use a crane and binding means of sufficient payload.

Do not enter under suspended load.

Fig. 2.46 - Location Of The Blade Distributor

97

98

97 - Blade distributor 98 - Limiting valves

VV1100 / VV1500

77

2.7. Operating and Using the Machine 2.7.6.

Padfoot Segments

The padfoot kit contains: - 3 padfoot segments

Using lugs makes the machine more universal. The segments do not replace fully a drum with lugs type PD though. The installation of this relatively heavy accessory decreases compacting efficiency of the roller and its travel up a slope. On clayish ground it may cause the drum to slip when backing up.

-

8 assembly clamps

-

18 bolts M20x150 (8G) - tightening torque 314 Nm (2776 in lb)

-

36 nuts M20 8G

-

36 washers 20

Recommendation The manufacturer recommends filling the wheels with fluid according to instructions when using segments. The use of a roller with ASC lock is to a great advantage.

The versions of machine H are equipped much better than the standard versions for climbing and passing through difficult terrain. However, a worse compacting effect than that of the PD rollers is still there.

The use of segments may not exceed 1/3 of the total life of the machine, since lower life expectancy of hydraulic systems of the roller may be realized.

-

18 scrapers

-

8 washers

-

16 bolts M20x70 (8G), tightening torque 314 Nm (2776 in lb)

-

16 washers 20

Attention!

ASC lock cannot be installed on the machine later; it must be ordered for delivery together with the new machine from the manufacturer.

The padfoot segments are also available for additional mounting to the machine.

Fig. 2.47

78

VV1100 / VV1500

OPERATION MANUAL Process of Mounting: l Dismantle the scraper of the smooth drum with holders. l Clean thoroughly the drum surface. l Suspend the first segment on the hole at the pad (see Fig. 2.47) and place it onto the drum. l Fit the segment in the position by means of four clamps, placed by two at each side of the segment at distance of about 20 cm (7,8 in) from the edge (see Fig. 2.48). l Keep the edges aligned with the edge of the drum. (see Fig. 2.48). l Move the machine slowly forward by about 1,6 m (5,2 ft.) to enable placing of the second segment. Check, when traveling, if the clamps do not catch any part of the drum frame. Place the second segment, so that there is a gap approx. 26 mm (1,02 in) width between the segments (see Fig. 2.49). l Interconnect the segments by the bolts delivered with the kit (fit the washer on the bolt (1) M20x150, slide through the segments, fit on another washer (2) and screw on two nuts (3) M20). l Fit the segment to the drum the same way as in the previous case.

l Move the machine forward again and fit on the third segment. Do not fit it by the clamps. l Interconnect the segments by the remaining bolts. l Dismantle all clamps. l Evenly tighten the nuts to the torque of 314 Nm (2776 in lb). The gaps between the segments should be the same, approx. 26 mm (1,02 in). l Mount the padfoot scrapers to the cross beam of the drum frame. Use also the previously dismantled bolts and washers. Torque to 314 Nm (2776 in lb). l If the segments are to be used altogether with the dozing blade, it is necessary to drill through one of the segments and the drum shell, with two holes of dia 18 mm (0,71 in), according to the pre-drilled holes in the segments. Insert two bolts M16x60 (8G) and lock on two nuts (low) M16 (8G) and two nuts (normal) M16 (8G). Tighten to 165 Nm (1459 in lb). l When mounting is completely done, travel with the machine slowly without vibration for about 10 min. and then check, if the bolts did not get loose. l After one hour of work with vibration check again proper torque of the bolts. Then, inspect the connections from time to time. l Use preferably the high amplitude.

Fig. 2.48

Fig. 2.49

VV1100 / VV1500

26

!

mm

8 8

79

2.7. Operating and Using the Machine 2.7.7.

Filling the Tires with Liquid

How to Fill the Tires:

Filling of tires with fluid increases traction effects of the machine during travel on a flat surface on such ground where it is difficult to pass through, and when backing up a slope.

The STA rollers have been designed so that normally the tires do not need to be filled with fluid.

Adding fluid to tires is recommended mainly on standard versions D (smooth drum) as an inexpensive alternative providing slight improvement when passing through difficult grounds, and stability, when working under more difficult conditions, and as slight compensation for negative effects, when using segments on the D version.

Models VV 910 and VV 2510 are exceptions, where the fluid fill is part of the standard equipment of the machine.

For all other types the manufacturer may be requested to supply tires filled with fluid even for work at low ambient temperatures. Such fill may be accomplished in the field as follows: The inner space of the tire is to be filled with the solution of water, slaked lime and waterless calcium chloride CaCl 2, or magnesium chloride MgCl2. Mixing ratios for one tire at a given temparature are shown in the Table.

l Secure the drum with wedges, lift the rear part of the machine and release brakes of the hydromotors (see 2.8.6.). l Deflate both tires, unscrew the tube valves and plugs M22x1,5. l Screw in the filling valve (see Spare parts catalogue, group. 630) into the hole M22x1,5 and fit on the hose of the filling unit (higher placed vessel, pump etc.). l Fill the tires with 508 lt. (133,9 gal US) of the solution each. l Unscrew the filling valve and mount on the air valve. l Inflate the tire to the prescribed level and put on the protective cap. l Proceed the same way at the other tire. l Dismantle the brake releasing fixtures (see 2.8.6.). l In countries where temperature does not reach the freezing point, the tires can be filled with a solution of water and cupric sulfur CuSO 4 . 5H 2O. l Such solution is to be made of 100 l of water (26,4 gal US) and 0,5 kg (1,1 lb) of the cupric sulfur CuSO 4 .

5H 2 O. l Fill the tires with 500 l (132 gal US) of the solution each.

How to Make the Solution: l The waterless calcium chloride CaCl2 is to be put into water, never opposite! l Spilled solution is to be washed with clean water. l Let the solution cool before filling. Keep the prescribed amount of lime. l The solution must not come into touch with metal parts and with electrical installation.

Protect your eyes with safety goggles. Use safety gloves to protect your hands.

l The solution must not be used as engine coolant!

The waterless calcium chloride CaCl2 is to be put into water, never opposite.

Fig. 2.50 - Table of Mixing Rates - Solution for Filling of Tires

80

Freezing point

Water

Calcium chloride CaCl2

Slaked lime

Added weight

(°C) [°F]

(l) [gal US]

(kg) [lb]

(kg) [lb]

(kg) [lb]

-18 [0]

458 [121]

120 [265]

2 [4,4]

580 [1280]

-25 [-13]

458 [121]

141 [312]

2,2 [4,9]

600 [1323]

-30 [-22]

458 [121]

155,5 [343]

2,5 [5,5]

617 [1360]

VV1100 / VV1500

OPERATION MANUAL How to Drain the Tires:

2.7.8.

z Secure the drum with wedges, lift the rear part of the machine and release brakes of the hydromotors (see 2.8.6.).

z User-installed air condition system:

z Turn the wheels with the air valves up. z Unscrew the air valves from the tubes. Attention! The solution will jet up. Unscrew the plugs M22x1,5. z Screw the filler into the hole M22x1,5 z Turn the wheel with the valve down. z Fit the hose with pressure air to the air valve and inflate the tire till the liquid leaks out.

Air Condition System

At such installation, keep sufficient distance between the oil cooler and the air-condition condenser, so that the air flow to the oil cooler is not decreased. This would cause lower cooling output of the coolers. Minimal distance is 50 mm (2 in). z Manufacturer-installed air condition system: In case of a manufacturer-installed air condition system, this will be supplied with separate operation manual.

z When the tire gets empty, remove the filler, screw in the air valve and the plugs. z Inflate the tires to the prescribed pressure. z Dismantle the brake releasing fixtures (2.8.6.).

Protect your eyes with safety goggles. Use safety gloves to protect your hands.

Keep environmental principles.

VV1100 / VV1500

81

2.8. Transport of the Machine 2.8.1.

Traveling at the Jobsite Safety Standards

When riding out of public roads, the roller can move on its own.

In transport speed engage lever (3) for driving the machine on a road.

Observe safety regulation applicable to the site while moving the machine.

2.8.2.

Transport on Public Roads

The basic modification of the machine is not equipped to meet the public roads requirements and thus it is prohibited to drive it on public roads.

The roller can be transported on a carrier vehicle of adequate payload. Height of the vehicle platform must be low enough to meet the condition of 4m maximal total height. If the total height exceeds 4m, it is possible to dismantle the cabin and the protective frame ROPS. The machine must be properly fastened to the carrier vehicle.

The binding points are following: front and rear suspension eyes, front and rear towing point and fastening eyes at the side plates of the drum frame (see Fig. 2.51). If a machine with the dozing blade is to be transported, the blade must be lowered to the carrier.

Machines equipped and approved for driving on public roads may do so on its own.

During travel at long distances observe cooling off breaks every three hours. Stop machine for one hour.

Non-adherence to this regulation may result in damage to the machine and subsequent voiding of warranty by the manufacturer.

The carrier vehicle must be braked when loading or unloading the roller, and locked by wedges against accidental moving.

When loading the machine onto a platform vehicle, turn the spinning limit function on with the switch (43). We recommend that the drum be supported by rubber bands, or wooden beams underneath.

If the machine is equipped with switch (29) or (43), switch it on during driving onto a platform truck, and check that vibration switch (45) is off. During driving on and off a loading platform all personnel must leave the vicinity to a safe distance not to be endangered by the falling machine.

Before moving the machine check that the vibration is switched off on preselector (45).

The person, who guides the machine when climbing up to the carrier vehicle or down from it must stay at one place during the whole procedure; he must be out of reach of the roller, out of the vehicle and be all the time within the field of view of the driver.

The person, who guides the machine, must signal to the driver using prescribed signs.

Fig. 2.51 - Hooking at a Carrier Vehicle

During the transport, no people are allowed in the cabin of the roller, on its platform or anywhere else on the carrier vehicle’s platform.

The roller must be properly hooked and fixed to the vehicle against longitudinal and transversal sliding, as well as against tipping over. The drum and the wheels must be locked by means of wedges.

When transporting the machine on public roads, the road traffic regulations must be kept.

When driving under bridges, underpasses and subways, etc. check first their clearance.

1 - Front hooking 2 - Rear hooking 3 - Wedges

82

VV1100 / VV1500

OPERATION MANUAL 2.8.3.

Transport of the machine by rail

2.8.4.

Loading the Roller

During transportation, it is imperative that the railway regulations are observed.

The dimensions of the machine must comply with loading regulations of the rail transport.

The height of the machine with the cab and protective frame (3050 mm – 120”) complies with some loading dimensions of European railways for the transport of goods.

The height of the machine with cab and protective frame doesn’t comply with dimensional loading capacities of International rail transport. The cab and the protective frame must removed before transportation on such railways, see Fig. 2.52.

If the machine is transported with a blade installed, this blade must be lowered down.

For loading the roller to means of transport, either loading ramp or a crane is to be used. To enable loading by means of a crane, the roller is equipped with suspension eyes.

Before the machine is lifted, the articulated joint must be locked against accidental turning. The joint is secured by folding the arm from position ”1” to ”2” into the eyelet on the front frame, and is fixed by a pin with a latch (Fig. 2.53, 2.54).

In addition, the joint is to be locked against oscillation by means of two locking wedges, which are to be turned by 180° from posi-tion “3” to “4” and locked by the pin (see Fig. 2.53, 2.54). Wedges are considered special accessory.

Fig. 2.52 - Railway Clearance Profile

Fig. 2.53 - Unsecured joint

After loading is finished, it is necessary to return all the locking devices into their original position.

1

Clearance profile: BDZ, CH, CFL, CFR, ČD, DB, DSB, JZ, MAV, NS, OBB, PKP, TCDD, ZSR International clearance profile

3

1 - Starting position of the safety rod 3 - Starting position of locking wedges

Fig. 2.54 - Secured joint

2

PLATFORM WAGON TYPE PAO

4 List of national railways by country: BDZ Bulgarian Rail CH the Greek Railway Plc. CFL the Luxembourg National Railway Company CFR Romanian Rail CD Czech Rail DB the German Federal Railway DSB the Danish State Railway

VV1100 / VV1500

JZ

the Association of Yugoslav Railways MAV the Hungarian State Railway NS the Dutch State Railway ÖBB the Austrian Federal Railway PKP the Polish State Railway TCDD the Turkish State Railway ZSR the Railway of the Slovak Republic

2 - Position secured by the arm 4 - Position secured by the wedge

83

2.8. Transport of the Machine 2.8.5.

Safety Regulations Learn about your national laws and regulations related to operation of cranes; these must be kept when loading and unloading the machine.

The binding means must too conform to the respective regulations.

Dismantling the Cabin

If necessary for transport (height of the machine at the vehicle exceeds the allowed limit), dismantle the cabin.

Loose the bolts, which fasten the cabin to the platform.

Disconnect the electrical installation (by disconnecting the connector) between the steering column and the front windscreen. Disconnect the electrical installation of the windscreen washer, as well as the washer hose.

To suspend the roller, use only the designated suspension eyes.

Use a crane and binding means of sufficient payload (see Fig. 2.55).

The binding works can be done by trained person with binder’s license only.

Do not enter under the suspended machine.

Fig. 2.55 - Scheme - Suspending the Machine onto a Crane

2

1

1 - Front hooking eyes 2 - Rear hooking eyes

84

VV1100 / VV1500

OPERATION MANUAL 2.8.6.

Towing the Machine

In case of defect the machine may be towed the necessary distance. The machine is provided for this purpose with two tow-hooks. The rear hook on the fuel tank has a pin with a safety against release. The pin may be released by pulling at the safety, Fig. 2.56.

A pin is used also on the front hook on the traverse of the front frame, Fig. 2.57. To prevent the drum from skidding, all brakes should be released.

In case of machine with the dozing blade, the blade must be lowered just slightly above ground. Then, front hooking points can be used for towing.

It is not permitted to use the hooks for towing trailers, such as cisterns, compressors, housing units, etc.

Releasing transmission brakes

Following towing bring the machine in its original state.

When dragging is completed, wedge the wheels and the drum.

l Release hose 4 and quick-coupling 3 in clamp 5, see Fig. 2.58. l Disconnect quick-coupling 2 of hose 1 from pressure filter to hydraulic tank, Fig. 2.59.

Before you release the brakes, wedge the drum and the wheels against any spontaneous movement of the machine thereafter.

Release brakes with the engine off.

Fig. 2.56 - Rear Towing Point

Fig. 2.58

"

Fig. 2.57 - Front Towing Point

#

!

Fig. 2.59

VV1100 / VV1500

85

2.8. Transport of the Machine l Quick-couple hose 4 to the manual hydraulic generator with quick-coupling 2 on hose 1, Fig. 2.60. l Further, s/c hydraulic travel loop. The travel hydraulic generator has two multi-purpose fusing valves, Fig. 2.61. Unscrew middle portions (1) from the valves [hex 27 mm (11/16 )] by three turns cc/w. l Switch key in the switch box to position I. l Insert control lever into the manual hydraulic generator and pump until brake control light goes off. l The machine has brakes released for towing.

Sequence of steps for returning the machine to its original state

• Disconnect hoses (1) and (4).

• Reconnect hose (1) in the loop of the pressure filter and hydraulic tank.

• Reinstall multipurpose valves on the travel hydraulic generator.

• Store the hydraulic generator lever (78) in the holder underneath the driver s seat.

! NOTE !

The brakes can loose pressure during towing.

When towing the roller, check, if the brakes do not get warm because of insufficient releasing. When the brakes of gears, hydromotors are released and the hydraulic circuit short-circuited, no braking system is available! All the service, emergency and parking brakes are out of operation!

Fig. 2.60

!

For towing use undamaged ropes or tow bars of sufficient capacity 1.5 x higher than the weight of the towed vehicle. Do not use a chain for towing!

Nobody may be on the vehicle that is being towed with non-functioning motor.

"

It is necessary to maintain the minimal deviation from the direct towing angle.

Maximum deviation is possible within 30°.

Smooth and constant movement must be maintained in towing. Do not exceed towing speed by more than 2 km/hour (1.2 mph) and do not tow for more than 300 m (0.19 miles)

Fig. 2.61

The towing machine should correspond by its size to the damaged machine. It must have sufficient towing power, weight and braking effect.

When towing down hill an additional machine must be attached to the rear end of the machine. This way it is possible to prevent an inadvertent movement of the damaged machine.

Do not start the engine during towing.

After towing of the roller is finished, renew all function of the machine!

These are general requirements for a safe towing of the machine under normal conditions. Any possibly different situation that could occur during towing must be consulted with the dealer.

86

VV1100 / VV1500

2.9. Using the machine under special conditions 2.9.1.

Travel with vibration on compacted and hard materials

When driving or working with the machine with vibration on over hard surfaces, such as gravel, the drum may loose contact with the compacted material due to the high degree of compactness of the material (so called vibroimpact). Such condition results in an increased transfer of vibrations to the machine frame and to the driver’s seat.

It may be partially remedied by an increase in travel speed or by changing vibration parameters, such as lower amplitude. The increased transfer of vibrations to the driver’s seat may also be expected with the increased degree of compactness of the base material.

2.9.2.

OPERATION MANUAL

Use at Difficult Climatic Conditions

2.9.2.1. Use at Low Ambient Temperatures Possibility of compaction in winter depends on content of water and fine particles in the soil to be compacted. The lower the temperature actually is, the firmer and more difficult to compact is soil.

If compaction at temperatures below 0°C (32°F) is necessary, either dry soils (and rockfills) can be compacted, or rapid compaction of non-frozen soils is needed (soil must be compacted earlier, that it freezes-through).

Prepare the machine for low temperatures: z Check density of the anti-freeze coolant.

If it is necessary to work with the machine under conditions where the operator could be exposed to increased vibrations, the supervisor must change the working process to avoid danger to the driver’s health.

z Use engine oil suitable for the respective temperature range. z Use hydraulic oil of appropriate viscosity. z Exchange oil in the gears for oil suitable for the respective temperature range. z Use winter-grade fuel. z Check charging status of the batteries.

Note: When driving the machine with vibration on over a different base material than that specified in the Specifications Manual - Section on Health Precautions - the emission values of vibration acceleration will be different.

For good starting at low temperature, the batteries must be well charged. Warm the batteries to about 20°C (36°F) - for example by their storing in a warm room - to decrease the limiting temperature for starting by 4-5°C. Minimal temperature of engine coolant is 60°C (140°F).

The machine is to be employed only after the engine warms up to the operational temperature (if necessary, partially cover the radiators).

The machine may be used at full output first after the fluids have been warmed up to operating temperatures. Radiators may be partially covered for this purpose.

With oil HV 100 in the hydraulic system the machine may not be started at ambient temperatures below + 2 °C (36 °F).

If it is required to be starting the machine for a month at ambient temperatures below –8 °C (18 °F), oil in the hydraulic system should be replaced by oil of viscosity class HV 46.

At temperatures below –13 °C (9 °F) oil should be replaced by viscosity class HV 32 such as BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.)

Starting below –23 °C (–9 °C) is not possible without preheating the oil.

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87

2.8. Transport of the Machine 2.9.2.2. Use at High Temperatures and High Humidity When the machine is operated in hot climate and high humidity, the engine power drops. As the both factors are mutually independent, their effect on engine power can be described as follows: - every 10°C (50°F) of increased temperature means a power drop up to 4% (at constant humidity) -

every 10% of increase relative humidity means a power drop up to 2% (at constant temperature)

At high ambient temperatures, when the hydraulic oil temperature long-term exceeds 90°C (194°F), it is recommended to exchange the hydraulic oil for one-degreedenser class (kinematic viscosity 100 mm 2/s, i.e. BP BARTRAN HV 100, ESSO UNIVIS N100 etc.).

With hydraulic system oil HV 46 the maximum permissible temperature is 80 °C (144 °F).

2.9.2.3. Use at High Altitude At higher altitude, it is necessary to count with power derating due to lower atmospheric pressure and thus less specific weight of inlet air.

Altitude m 0 500 1000 1500 2000 2500 3000

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

Power derating (%) 0 3 6 10 15 21 28

If the engine begins to heavily black smoke at higher altitudes (above 1500 m), contact the manufacturer of the engine, who would re-adjust the injection pump specifically for such operational conditions.

With HV 32 this oil temperature is 70 °C (158 °F).

At work at extreme temperatures when the temperature of coolant or hydraulic oil reaches maximum permissible values, it is possible to increase the cooling effect of the radiators by removing covers under the hoods and thus improve the circulation of hot air from space around the engine.

88

Power of the engine is also influenced with the environment, where the engine works - see chapters 2.9.2.1. and 2.9.2.3.

VV1100 / VV1500

OPERATION MANUAL 2.9.3.

Use at Extremely Dusty Environment

At environment with extremely high content of dust, it is necessary to shorten the intervals of replacement of the air filter element, cleaning the coolant radiators, cleaning the hydraulic oil cooler, as well as replacement of the cabin dust filter.

2.9.4.

Compaction near to constructions or underground ingeneers nets and cables

If there isd a need to compact near the constructions or engineers nets and cables, we have to judge the vibrations influence affected by the machine work to the constructions or ingeneers nets and cables, to avoid the threat to the constructions or ingeneers nets and cables.

The manufacturer is not responsible for the damages done by using the machine near to the constructions or underground ingeneers nets and cables !

VV1100 / VV1500

89

90

VV1100 / VV1500

3.

AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM FOR ROLLERS VV 1100 VV 1500

VV1100 / VV1500

91

3. Air Conditioning system DESCRIPTION The heat is extracted out of the evaporator placed inside the cabin ( low-pressure circuit) and transferred to the environment at the condensator installed in front of the engine radiator ( high-pressure circuit). The compressor is drawing in coolant vapour from the evaporator and presses it into the condenser. Inside the condenser the coolant vapour is changing its gaseous state of aggregation to liquid) and flows through the filterdehydrator to the TEV thermoexpansion valve. TEV sprays the liquid coolant into the evaporator where the heat is extracted from the cabin milieu while contemporaneously the liquid state of aggregation is changed to from liquid to gaseous and the coolant vapours are sucked into the compressor.

3.1.

Basic parts of the air conditioning circuit

1. Compressor 2. Condenser 3. Filterdehydrator 4. Thermoexpansive valve (TEV) 5. Evaporator

Fig. 3.1

92

VV1100 / VV1500

Air Conditioning system 3.2.

Air conditioning operation

Switching on the air conditioning system

On the evaporator panel two functions can be controlled temperature (TEM) and ventilation (AIR).

The air conditioning system is working with the machine engine running only.

TEMP temperature control - the temperature inside the cabin Fig. 3.2 can be gradually adjusted by means of the revolving converter (1).

• set in the heat controller to the position closed see

-

Turning the regulator from 0 position to the right the temperature is reduced

• turning the controller (1) adjust the required tempe-

-

Reversing the regulator to the left the temperature is increased.

AIR ventilation control - the exchange and flow of air inside the cabin, Fig. 3.2 from the evaporator is regulated by means of the revolving converter (2) from the cabin to the evaporator.

-

By turning the converter from the 0 position to 1, 2, 3 positions the flow speed is gradually increased.

-

By turning the converter back the flow speed is decreased.

Fig. 3.2

Fig. 3.3.

• change over the reversing switch (2) to one of the 1, 2, 3 positions see Fig. 3.2.

rature inside the cabin Fig. 3.2.

Switching off the air conditioning system

• Switch off the air conditioning system by turning the reversing switch (2) to 0 position.

• Do not handle the controller (1) any more if the adjusted temperature is to remain.

Fig. 3.3

↑

VV1100 / VV1500

93

3. Air Conditioning system 3.3.

Maintenance

Every month: • Carry out visual check of the coolant fill Fig. 3.4 with the engine running. The inspection hole sight glass must be transparent. It must not be either dewed or misty, it must be without visible bubbles.

Maintenance as may be required: • Clean-out the condenser fins with compressed air or power water Fig. 3.7.

• Clean-out the evaporator fins with compressed air.

• Check up the stretch of the compressor belt Fig. 3.5.

• When pressing down the longest part of the belt with a force of ca 3N (1,5 lbf) the belt deflexion must not exceed 10 15 mm ( 0,4 0,6 in).

• Check the condensate removal from the evaporator clean out Fig. 3.6.

Fig. 3.4

Fig. 3.6

Fig. 3.5

Fig. 3.7

94

VV1100 / VV1500

Air Conditioning system 3.4.

Troubles

To remove troubles always contact the service organisation

Troubl e

Fi ndi ng out the cause

The unit does not refrigerate not work

Check of the evaporator ventilator function -it does not work Examine the electrofuse F6 in the fuse box see Driver´s handbook see Fig. 2.21

3.5.

Safety Rules

The coolant is classified as a safe coolant but when leaking into the atmosphere its devaporation develops and touching the epidermis or mucuous membrane burns arise. In the presence of open fire toxical gases develop which can cause serious troubles, eventually death, if inhaled. Leaking inside limited spaces, the coolant vapours are pressing out oxygen and may cause death by asphyxiation.

Check the coolant fill in the inspection hole sight glass of the filterdehydrator leakage of coolant (bubbles, dewing, etc.)

•

Working near the airsonditioning system or directly inside it, it is necessary to use always goggles and protective gloves.

Check of the electromagnetic coupling connection: Switch on the airconditioning with the engine running the coupling does not close (no audible click at the compressor) 1. defective fuse F6, 2. defective thermostat 3. defective overpressure fuse

•

When cleaning the lamelas´ surfaces beware of possible wounds caused by aluminium lamelas.

VV1100 / VV1500

First aid in case of contact with coolant •

Should the eyes come into contact with the liquid coolant rinse eyes immediately with a large quantity of water and call immediately for medical help.

•

Should epidermis come into contact with coolant rinse the attacked place immediately with a rich quantity of warm water not hot water. Protect the burn with a piece of dry sterile cotton. Call medical help.

•

In case of inhaling transfer the afflicted person to fresh air and regenerate breathing if the need be. Call for medical help.

95

96

VV1100 / VV1500

4.

LUBRICATION AND MAINTENANCE MANUAL

LUBRICATION AND MAINTENANCE MANUAL VV 1100 VV 1500

VV1100 / VV1500

97

4.1. Specification of Fluids Viscosity:

4.1.1. Engine Oil Use of high-quality engine oil, as well as keeping of proper exchange intervals, is vital for long lifetime of the engine.

Quality: Oils are sorted according to the output classes and the quality classes. These are specified according to the API (American Petroleum Institute) and the CCMC (Committee of Common Market Automobile Constructors) classifications.

Acceptable oils are following: API CE CCMC D5 In countries, where engine oils according to the CE output class are not available, it is possible to use oils of the CC/CD class. However, the exchange interval must be shortened to one half.

As oils are changing their viscosity depending on temperature, ambient temperature and kind of operation are decisive for selection of the proper viscosity class according to SAE (Society of Automotive Engineers).

Occasional exceeding of the bottom allowed temperature does not cause any damages at the engine, however may cause difficult starting.

Exceeding the upper acceptable temperature should not last for longer period because of limited lubricating ability of the oil.

It is recommended to use universal multi-class oil, to avoid seasonal oil exchanges due to change of ambient temperature. The manufacturer recommends to use the all season SAE 15W-40 oil (i.e. Cummins Premium Blue or Ambra Super Gold 500).

In winter (i.e. at ambient temperatures below -5°C (23°F)) use rather oil SAE 10W-30 for easier starting; in arctic conditions (below -23°C /-10°F) use oil SAE 5W-30.

Fig. 4.1 - Diagram of Viscosity

98

VV1100 / VV1500

Lubrication and Maintenance Manual Winter-Grade Fuel:

4.1.2. Fuel As a fuel for the combustion engine, use the diesel fuel according to these specifications: z CEN EN 590, resp. DIN/EN 590 (suggestion) z DIN 51 601 (Feb. 1986) z BS 2869: A1 and A2 z ASTM D 975-81: 1-D and 2-D z VV-F-800C: DF-A, DF-1 and DF-2 z NATO CODE F-54 and F-75

At low ambient temperatures - below +5 °C (41°F), paraffins are precipitated from common diesel fuels in the fuel system of the machine. The paraffins may cause failures, or even disable operation of the machine. Therefore, use winter-grade fuel at ambient temperatures below +5°C (41°F). Usually, the fuel is replaced at public gas stations for each period of year.

At ambient temperatures below -15°C (5°F), special fuel must be used or special additives must be mixed with the fuel (for example kerosene).

Dependence of allowed temperature on amount of added kerosene is shown at diagram.

Normal diesel fuel contains less then 0,5% (weight) of sulfur; in a case that diesel fuel with higher content of sulfur is used (0,5 - 1%), it is necessary to shorten the oil exchange intervals to one half of usual period.

Mix the fuel always in the tank. Put there first the designated amount of kerosene, then add fuel.

Mixtures of winter-grade fuels are as combustible as gasoline. Keep the fire safety regulations.

It is strictly required to use above specified brands of diesel fuel only.

Usage of different fuel (like Bio-fuels,or Light heating oils of any kind) is strictly PROHIBITED.

Fig. 4.2 - Diagram of Mixing

„Su

per

die

sel

“

Ambient temperature Content of mixed kerosene

VV1100 / VV1500

99

4.1. Specification of Fluids Synthetic Hydraulic Oil

4.1.3.

Hydraulic Oil

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

The machines are filled with hydraulic oil of kinetic viscosity 68 mm 2/s at 40 °C (104 °F) ISO VG 68 by the manufacturer. This particular oil is suited for applications in the widest range of ambient temperatures.

At high ambient temperatures, when the oil temperature reaches continual 90 °C (194°F), we recommend replacing the oil with one of kinetic viscosity 100 mm 2/s - HV 100 (BP BARTRAN HV 100; ESSO UNIVIS N 100, etc.)

Should it be required to start the machine at temperatures below –8 °C (18 °F) lasting more than one month, replace oil in the hydraulic system with one of kinetic viscosity 46 mm2 /s - viscosity class HV 46.

At temperatures below –13°C (9°F), replace oil with one of kinetic viscosity 32 mm 2/s - viscosity class HV 32, such as BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.).

The hydraulic system may be filled with synthetic oil under the following conditions: PANOLIN - HLP Synth 15/22/32/68 is a fully synthetic, highly efficient oil, and according to VDMA 24´568 is classified in HESS . It satisfies standard DIN 51524 Part 2 and 3. The requirements for resistance against aging are exceeded by far. Accidental spills are destroyed by microorganisms found in water or soil. During operation, one has to be careful to avoid its mechanical contamination by wear, dust, etc.. Oil must not exceed contamination class 17/14 (to ISO 4406) Water content due to condensation may not exceed 0.1%.

The fluid must be checked regularly by taking samples, as specified in table below.Taking of such samples must be done in accordance with instructions supplied by the PANOLIN Laboratory, or preferrably, let PANOLIN take the samples directly.

Schedule of samples

Normal use

Extreme conditions

1. inspection

500 h

250 h

2. inspection

1000 h

500 h

subsequent inspections

1000 h or 1x a year

500 h or 1x year

Fig. 4.3 - Comparison Table Of Hydraulic Oils

Brand name

Sort of oil

Output class on ISO 6743/HV

HV (HVLP)

Mixing PANOLIN HLP Synth oil with other biologically neutralized oils, such as unsaturated synthetic esters or vegetable oils, is not allowed!

Viscosity class on ISO 6743/4, DIN 51519

VG 68

Transition from mineral oils onto synthetic ones must be done in compliance with VDMA 24´569

HV 68

When filling older motors with PANOLIN HLP Synth the residual level of mineral oils may not be higher than 8% of the total volume of the fill.

AGIP

AGIP ARNICA 68

When filling biologically fast neutralized oils, mixing with up to 2% of the tank content is allowed

AVIA

AVILUB HVI 68

BP

BARTRAN HV 68

CASTROL

HYSPIN AWH 68

CHEVRON

EP 68 HV

Viscosity class on CETOP RP 91H

ELF

HYDRELF 68

ESSO

UNIVIS N 68

FINA

HYDRAN HV 68

FUCHS

RENOLIN MR 68 HV

MOBIL

MOBIL DTE 16

ÖMV

HLP - M 68

SHELL

TELLUS T 68

TEXACO

RANDO OIL HD CZ 68

TOTAL

EQUIVIS ZS 68

100

Transition to other types of oil, or mixing with other types of oil, should be consulted with the manufacturer or PANOLIN Comp.!

VV1100 / VV1500

Lubrication and Maintenance Manual 4.1.4.

Gear-Box Oil

4.1.5.

For lubrication of the gear-box, use high-quality oils meeting the API GL-5 with the viscosity to SAE 80W/90.

Viscosity SAE 80W/90 for outdoor temperature range -10°C÷ +30°C (14°F ÷ 86°F).

Viscosity SAE 80W/140 for outdoor temperature range +20°C ÷+45°C (68°F ÷ +113°F).

Lubrication Grease

For lubricating of the machine, plastic grease with content of lithium according to NLGI-2 regulation is necessary (Ambra GR9, Mobiplex EP-1, Retinax A, Alvania, Grease No.3 etc.).

! NOTE !

The operating oil temperature must not exceed 85°C ÷ 90°C (185°F ÷ 194°F).

Manufactured by

Sort of oil

Outdoor temperatures

–10 °C ÷ +30 °C (14 °F ÷ 86 °F)

+20 °C ÷ +45 °C (68 °F ÷ +113 °F)

SHELL

SPIRAX HD

SPIRAX HD

AGIP

ROTRA MP

ROTRA MP

ARAL

GETRIEBEOL HYP

GETRIEBEOL HYP

BP - MACH

HYPOGEAR EP

HYPOGEAR EP

CASTROL

HYPOY

HYPOY

CHEVRON

UNIVERSAL GEAR LUBRICANTE

UNIVERSAL GEAR LUBRICANTE

ELF

TRANSELF8

TRANSELF8

ESSO

GEAR OIL GX PONTONIC MP

GEAR OIL GX PONTONIC MP

I.P.

PONTIAX HD

PONTIAX HD

MOBIL

MOBILUBE HD

MOBILUBE HD

TOTAL

TRASMISSION TM

TRASMISSION TM

VV1100 / VV1500

101

4.1. Specification of Fluids 4.1.6.

Coolant

Do not use higher content of ethylene glycol or propylene glycol than 50% until absolute necessary.

As a cooling fluid, use during the whole year coolant containing 40 % to 60 % of anti-freeze ethylenglycole agent and water,as according to the table below. The antifreeze coolant is to be used even in such climate, where temperatures never fall below 0 °C (32 °F). The coolant serves not only as a protection of the cooling system against the frost, but also increases the boiling point. The inhibitors contained in the anti-freeze agent protect the parts of the cooling system of the engine and improve their durability. Instead of ethylenglycole-based agent, a propylenglycole-based one is also suitable. Minimal content of the ethylenglycole or propylenglycole agent in the coolant is 40 %. The suppliers usually deliver coolant with 40 to 50 % of the antifreeze agent.

Never use higher content than 68%.

Use only environmentally harmless anti-freeze agents.

The anti-freeze agents are based on various chemicals; it is not recommended to mix them mutually, as the anti-corrosive features could be lost.

When mixing a nitride-based agent with an amine-based agent, harmful nitroamines will appear.

Pour the antifreeze agent into water to prepare the coolant, never opposite.

Check the coolant by means of a refractometer before winter.

Water intended for use in the cooling system should conform to the following conditions:

Do not use antifreeze with corrosive properties affecting aluminum -the radiator may corrode!

Water parameters

min.

max.

pH - factor at 20 C (69 F)

6,5

8,5

content of chlorides (mg/dm3)

-

100

content of sulfates (mg/dm3)

-

100

total hardness ( dGH)

3

12

Used antifreeze liquid must contain anti-corrosion additives, which protect all parts (including rubber and head sealing) of the cooling system. The liquid must be of lowsilicon type, meeting the specification of ASTM 4985.

Recommended liquids are:

4.1.7.

Liquid for the Windscreen Washer

For the windscreen washing system, water is to be used down to 0°C (32°F). Below the freezing point, it is necessary to use water mixed with an antifreeze liquids for washers.

Miscela Ambra Agriflu SUNOCO - PERMANANT ANTIFREEZE SHELL - Glycoshell AF 511 S TEXACO - HAVOLINE Antifreeze Coolant/AFC CASTROL - ANTIFREEZE MB The application range at various content of antifreeze is shown in the following table: Ethylene glycol 40 %=-23 °C (-10 °F) 50 %=-37 °C (-34 °F) 60 %=-54 °C (-65 °F) 68 %=-71 °C (-90 °F) Propylene glycol 40 %=-21 °C (-6 °F) 50 %=-33 °C (-27 °F) 60 %=-49 °C (-56 °F) 68 %=-63 °C (-82 °F)

102

VV1100 / VV1500

4.2. Fluids

Lubrication and Maintenance Manual

Capacity in lt. (gal US)

Part

Fluid

Engine

engine oil - API: CE/SG acc. to 4.1.1

16,3 (4,3)

Fuel tank

diesel fuel - acc. to 4.1.2

410 (108,3)

Hydrostatic system

hydraulic oil acc. to 4.1.3

90 (23,8)

Drum drive gear-box

Transmission oi - acc. to 4.1.4.

4,2 (1,11)

Axle drive gear-box

Transmission oil - acc. to 4.1.4.

2x2,8 (2x0,7)

Joint bearings Plastic grease with lithium additive according articulated joint and to NGLI-2 - acc. to 4.1.5. the hydraulic cylinders of steering

as needed

Cooling system of the engine

All season coolant for temperatures down to -25 C (-13 F) coolant acc to 4.1.6.

25 (6,6)

Vibratory drum

Engine oil as in the engine

8 (2,1)

Battery

Destilled water

Windscreen washers

Water - above 0 C Water + antifreeze liquid - mixing rate depends on ambient temperature

Tires

VV1100 / VV1500

Symbol

as needed

2.75 (0,72)

Air or liquid - see Operation manual

103

4.3. Lubrication Chart Fig. 4.4 - Lubrication Chart

104

VV1100 / VV1500

4.4. Safety Standards at Lubrication and Maintenance 4.4.1.

Safety at Maintenance of the Machine

Lubrication, maintenance and adjustment is to be done:

4.4.2.

Fire Prevention Regulations

• Regarding fire danger, the flammable liquids are divi-

• by trained personnel only;

ded into four classes:

• in intervals according to this manual, or on basis of

class II

diesel fuel

class IV

mineral oils, grease

technical inspection;

• keeping all safety regulations according to the operation manuals;

• at machine placed on firm and level surface, secured against accidental moving and against accidental starting, with secured articulating joint;

• after the Notice board has been attached to the handle

• The area where oils are exchanged must not interfere with an area of explosion or fire danger.

• The area must be marked with „NO SMOKING“ and „NO NAKED FLAME“ tables and labels.

• The are must be able to catch such volume of flam-

on the left cabin door. Board no. 15, see Chapter. 2.2.5, is stored in the box on the backrest of the seat.

mable liquid, which is equal to the capacity of the biggest transport container.

• with the engine at standstill and with all parts of the

• The area must be equipped with fire extinguishers.

machine cooled down;

• with disconnected electric installation and removed ignition key;

• If necessary to have any activity done at running engine (adjustment), there must be present another person ready to shutdown the machine. This person must be continually in connection with the person which carries out the maintenance or adjustment;

• after cleaning the machine, especially the lubrication

• For handling with oils and diesel fuel use containers as metal drums, barrels, metal cans, etc.

• The storage containers must be properly closed.

• The containers must have only one filling hole, located at the top and must be secured against leaks and drops.

• The containers must be marked with undeletable signs describing the content and the class of flammability.

points and the area of maintenance to be done;

• using suitable, intact tools; • Only genuine replacement part are to be used. The manufacturer bears no responsibility for damages arising from use of non-genuine parts;

• In case of low visibility, the whole machine must be sufficiently illuminated;

• If it is necessary to dismantle the safety covers or other safety devices, they must be mounted back after the work is done;

• All bolts and nuts must be re-tightened to prescribed torque. All connection must be inspected for leaking;

• If necessary, let the fluids to warm up to operation temperature. Danger of burning!

After the adjustment or maintenance is finished, check function of all safety devices.

Before arc welding at the machine disconnect all components based on semi-conductors (incl. alternator, brake timer, computer of the ASC differential lock, protective diodes, speedometer, etc.). The welder is to be frame-connected as close as possible to the point of welding.

Prevent damage to the components!

VV1100 / VV1500

105

4.4. Safety Standards at Lubrication and Maintenance 4.4.3.

Environmental and Hygienical Principles

At operation and maintenance of the machine, the user is obliged to keep the general principles of health and environment protection, as well as locally valid related laws, regulations and instructions.

4.4.3.1. Hygienical Principles •

Oil products, coolants, electrolytes and paints including solvents are harmful agents. Workers getting into touch with these agents are obliged to keep general principles of health protection as well as safety and hygienical instructions of the agents’ producers.

Pay special attention to:

•

•

•

–

eye and skin protection when working with batteries;

–

skin protection when working with oil products, paints and coolants;

–

proper hands washing after the work and before eating; treat your hands with suitable regenerating cream;

–

keep the instructions of this manual when working with the cooling system.

4.4.3.2. Environmental Principles •

The various fluids and some parts of the machine become dangerous waste after their lifetime is over.

This category of waste includes mainly: –

organic as well as synthetic lubricants, oils and fuels;

–

brake fluids;

–

coolants;

–

battery electrolytes as well as the batteries themselves;

–

cooling medium of the air condition systems;

–

fill tires

–

cleansing and conserving agents;

–

all removed filters and filter elements;

–

all used hydraulic and fuel hoses, rubber elements and other components of the machine, contamined with the above mentioned agents.

The listed agents and parts must be treated in accordance with the valid local environmental and health protection regulations.

Oil derivates, coolants, battery electrolytes and paints including solvents, as well as conserving and cleansing agents should be always kept in original and properly marked containers. Do not allow storing of such agents in unmarked bottles and other containers, in order to avoid interchanging. Interchanging for food and drinks is especially dangerous.

Should accidentally the skin, mucous membranes, eyes be spilled with such agents or should the vapors be inhaled, apply first aid immediately. Should these agents be eaten, seek for medical aid.

Use suitable ear protection always when working with the machine without the cab or when working with open door.

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107

4.5. Lubrication and Maintenance Chart Fig. 4.5 - Lubrication and Maintenance Chart

108

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Lubrication and Maintenance Manual

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109

4.6. Individual Operations of Lubrication and Maintenance Lubrication and maintenance is to be done regularly, according to daily readings of the hour counter.

This manual describes only the principal information regarding the engine; further information is stated in the instruction manual of the engine, which is delivered with the machine.

Every 20 Hours or Daily 4.6.1.

Inspection, Replenishing of Engine Oil

z Place the roller on firm and level surface and stop the engine. z Wait about 5 min., until oil flows down into the oil sump.

Keep the instructions listed in the instruction manual of the engine.

z Pull out the oil dipstick (1), wipe with a clean cloth, insert back up to the stop and read the oil level. z The oil level must be within the range between the two gauge marks. The lower mark (L as Low) means the lowest possible oil level, the upper mark (H as High) the highest possible level. The oil volume between the lower and the upper mark is approx. 1,89 lt. (2 US Quart).

After the first 100 working hours of the new machine or its general overhaul, do the following: 4.6.24. Replace oil for the first time in drum and axle gearboxes.

Do not start the engine, until there is sufficient oil level.

z Replenish oil after removing the plug (2) of the filler (loose the locking screw at the plug). Wait about 1 min till the oil flows down and check the level again. z Replenish oil with the same sort only. z Inspect the engine for tightness, repair all failures. z Inspect the engine, whether there are no damaged or missing parts, or if there is no change in appearance.

Use only recommended oils according to chapter 4.1.1.

Fig. 4.6 - Inspection Of Engine Oil Level

1

2

1 - Oil dipstick 2 - Filler

110

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Lubrication and Maintenance Manual Every 20 Hours or Daily 4.6.2.

Inspection of the Engine Drive Belt

Every 20 Hours or Daily 4.6.3.

Inspection of the Fan

z Stop the engine.

z Stop the engine.

z Visually inspect the belt, watch for marks of damage.

Transversal cracks are not a failure. If there are longitudinal cracks, frayed out edges or part of the material torn out, the belt must be replaced - see Fig. 4.7.

z Visually inspect the fan. In a case of its damage (i.e. missing part of material, cracks, deformations etc.) the fan must be replaced.

Do not work with damaged fan.

Fig. 4.7 - Engine Drive Belt

VV1100 / VV1500

Fig. 4.8 - Fan

111

4.6. Individual Operations of Lubrication and Maintenance Every 20 Hours or Daily 4.6.4.

Every 20 Hours or Daily

Inspection, Replenishing of Coolant

z Place the roller on a level and firm surface and stop the engine. z Let the coolant to cool down below 50°C (120°F). z Visually inspect the coolant level (see Fig. 4.9). z Coolant level must not drop below the center of the sight gauge (see Fig. 4.9). z Replenish coolant through the filler, up to the lower edge of the filler (2). Pour the coolant slowly. z At bigger loses of coolant seek for an untightness of the cooling system and repair it z Replenish only antifreeze mixture of the same parameters and same mixing rate, according to chapter 4.1.6.

Remove the filling plug after the coolant temperature drops below 50°C (120°F). If this is remove at higher temperature, there is a danger of burning by steam or by coolant due to internal overpressure.

Do not use additives in order to remove untightness of the cooling system.

Do not pour cool liquid into hot engine.

Danger of damage to the casted parts of the engine.

Fig. 4.9 - Equalization Tank

2

3 1

1 - Equalization tank 2 - Filler with plug 3 - Sight gauge

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Lubrication and Maintenance Manual Every 20 Hours or Daily 4.6.5.

Inspection of the Dust Filter

z Captured dust is disposed in the dust valve (1) - see Fig. 4.10. If the valve works properly, it is timely automatically discharged during operation of the machine. z Check, if the valve is not clogged or damaged. z Depress the dust valve to discharge the dust. z If the dust valve is damaged or missing (see Fig. 4.11), replace it.

Do not operate with damaged dust valve (see Fig. 4.11).

Every 20 Hours or Daily 4.6.6.

Inspection of Fuel Level, Refueling

z Check fuel level at the fuel gauge, replenish if needed. z Stop the engine. z Clean the plug (1) and the filler (2) with a cloth. z Unlock the plug and turn it counter-clockwise to open it. z Fill the tank below the lower edge of the filling opening using a strainer. z Use only clean fuel of recommended sort according to chapter 4.1.2. z Keep cleanness. z Do not fully empty the tank. If the tank is completely emptied, it is necessary to deareate the fuel system. z Total capacity of the fuel tank is 410 lt. (108,3 gal US).

The tank in average remains for 34 hours of operation.

Fig. 4.10 - Dust Filter

Do not smoke when refueling!

No naked flame! Do not refuel in closed spaces!

Do not refuel with engine running.

Do not spill fuel.

1

1 - Dust valve

Fig. 4.11 - Damaged Dust Valve

A

Fig. 4.12 - Fuel Tank

B 2 1

C

A - Broken B - Torn C - Stays open D - Missing

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D

1 - Plug 2 - Filler

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4.6. Individual Operations of Lubrication and Maintenance Every 20 Hours or Daily 4.6.7.

Inspection of Clogging Of The Hydraulic Filter

z Check if the indicator of the hydraulic filter is not lit at operational temperature of hydraulic oil (50 - 60°C / 122 - 140°F). z If the indicator is lit under such conditions, there is increased underpressure at the filter element due to clogged filter element, which needs replacement.

Every 20 Hours or Daily 4.6.8.

Inspection of Warning and Safety Devices

z Check proper function of the warning horn, the warning lights and direction lights. z At stopped engine check proper function of the indicators of charging, engine lubrication, neutral position of travel control and brake. The inspection is to be done by switching the key into the „1“ position; the indicators must get on. z Check function of the safety beacon. z Repair all possible failures.

Fig. 4.13 - Indicators

25 - Indicator of clogging of the hydraulic filter

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Lubrication and Maintenance Manual Every 100 Hours 4.6.9.

Every 100 Hours

Inspection of Tire Inflation

z Inflate the tires (1) with pressured air, through the air valves (2). z The pressure is to be measure at cold tire, by means of a manometer. z The tire inflation should be 160 kPa (23,2 PSI).

Fig. 4.14 - Wheels

2 1

1 - Tire 2 - Air valve

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4.6. Individual Operations of Lubrication and Maintenance Every 100 Hours

Every 100 Hours

4.6.10. Inspection, Replenishing of Hydraulic Oil

z Keep the oil level within the range of the sight glass (1) - see Fig. 4.15.

z Place the roller on a firm and level surface and stop the engine.

z Use only clean, uncontaminated oil of the same sort as the currently used one. Pay attention to absolute cleanness.

z Visually check the oil level. z The proper oil level is within the sight glass (1) - see Fig. 4.15.

Add oil up to the level described in Section4.6.28.

z Oil level must not drop below the lower edge of the sight glass („MIN“) during operation of the machine. In such a case, the engine automatically stops and starting would be possible only after oil replenishing up to the prescribed level. This system serves as protection of the hydraulic system of the machine, as well as protection of environment (at rupture of a hose, only a small limited volume of oil would leak out, not the whole oil tank).

Reinstall removed parts.

Do not loose the part of the hydraulic system unless the circuit is free of pressure.

Damaged components are to be immediately replaced with new ones of the same parameters.

z At bigger loses of oil search for untightness at the hydraulic system (fittings, hoses, pumps, hydromotors etc.) and repair the failure. During the warranty period call service organization.

Fig. 4.15 - Hydraulic Oil Tank

Obr. 4.16 - Hydraulic Oil Tank

3

1

1 - Sight glass

116

1

3 - Filler

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Lubrication and Maintenance Manual Every 250 Hours or Once in 3 Months

Every 250 Hours or Once in 3 Months

4.6.11. Exchange of Engine Oil z Place the roller on a firm and level area.

Pay attention when draining hot oil danger of burning.

z Start the engine and let coolant to warm up to 60°C (140°F).

Use recommended cleaners only.

z Stop the engine.

Use recommended oils only (see chapter 4.1.1.).

z Have prepared a suitable vessel of about 20 lt. capacity.

Do not overtighten the cleaner, as this could damage the thread and the seal.

z Unscrew the drain plug (1) - see Fig. 4.17 - and let oil flow out into the vessel.

Catch the used oil, do not allow the oil to get into soil.

z Clean the surrounding area of the oil cleaner head. z Dismantle the oil cleaner (3) - see Fig. 4.18.

Oil is to be disposed of properly.

z Clean the contact area of the oil cleaner sealing.

The used cleaners are to be stored in an independent container and disposed in accordance with environmental principles.

z Have a new cleaner, fill it with clean oil. z Slightly oil the rubber sealing of the cleaner and screw it on. Tighten the cleaner well - hand tight only. z Check the plug sealing (1); replace if damaged.

Even when the machine did not pass the prescribed number of operation hours, oil must be replaced at least once in 6 months.

z Check the thread of the plug. Clean the contact area of the sealing. z Screw in the plug. Torque it to 80 Nm (60 ft lb). z Pour in clean oil through the filling socket (2) - see Fig. 4.18. Total capacity is 16,3 lt. (4,3 gal US). z Start the engine and let it run at increased idle speed for 2 - 3 min. z Stop the engine, let oil flow down for about 5 min. and check the oil level, as described in the chapter 4.6.1.

Replenish up to the upper mark if necessary. z Inspect the engine for tightness.

Fig. 4.17 - Drain plug of engine oil

Fig. 4.18 - Oil exchange

2 1

3

1 - Drain plug

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2 - Filling socket 3 - Cleaner

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4.6. Individual Operations of Lubrication and Maintenance Every 250 Hours or Once in 3 Months

Every 250 Hours or Once in 3 Months

4.6.12. Inspection of Inlet Branch of the Engine

4.6.14. Inspection of the Batteries z Place the rolled on a firm and level area.

z Inspect the inlet branch of the engine for tightness. z Check, whether there are no damaged rubber parts (holes, cracks etc.) and if there are no missing hose clips. z Check the connection between the hood (2) and the air filter (3). z Replace the seal (1) if damaged.

z Clean the surface of the batteries (for example wash with water and wipe it dry). z Check the level of electrolyte after opening the plugs of battery cells - the level of electrolyte in all cells should be 5 - 15 mm (0.2-0.6 in) above the plates, or to the lower edge of the gauge in the cells. Add distilled water to the cells with electrolyte level lower than 5 mm (0.2 in) above the plates. Check the level using a glass tube. Never replenish sulfuric acid (H 2SO4). z Close the battery. z Check the shape of the pole terminals (+) and (-); apply the terminals with grease. Pay care to good contact.

Do not operate the machine if there is damaged the connection between the hood and the air filter, or if this connection is not tight.

z Keep the batteries clean and dry.

4.6.13. Inspection of Cooling System of the Engine

z There are especially high demands for the batteries during the winter period. At low temperatures, the batteries have only a part of their capacity compared to normal conditions. Because of that, it is highly recommended to verify the shape of the batteries and the re-charge them if needed.

z Inspect the cooling system for tightness. Check, whether there are no damaged rubber parts and if there are no missing hose clips.

z If the machine is going to be out of use for several weeks at heavy frosts, dismantle the batteries and store them inside to protect them from the frost. Otherwise, they may be damaged.

z Check, whether the finning of the coolant radiator and the oil cooler are not clogged. If so, clean the finning, for example by blowing-through with pressured air or with water or steam jet - see 4.6.34.

z When dismantling the batteries, disconnect first the cable of the minus pole (-), then from the plus pole (+).

The batteries must not be disconnected at running engine.

Fig. 4.19 - Air Filter

Fig. 4.20 - Batteries

1

3 2

1 - Seal 2 - Hood 3 - Air filter

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Lubrication and Maintenance Manual Every 250 Hours or Once in 3 Months

Every 250 Hours or Once in 3 Months

Verifying Shape of Battery Electrolyte: z Measure density of electrolyte in the individual cells. z Compare the measured values with the table (Fig. 4.21). z In a case of insufficient capacity, re-charge the battery. z The batteries are to be re-charged out of the machine. z Prior to charging, open the plugs of the cells. z Exhausted battery may get frozen even at several degrees below freezing. If it would be charged when frozen, it may explode. Let it warm up first. z Connect the battery in correct order. z The data below show charging status at 20°C (68°F).

Never replenish destilled water into batteries unless the machine is going to be operated or unless the batteries are to be charged out of the machine. This would result in increased self-discharging effect.

When working with the batteries, keep the following principles and safety regulations: Electrolyte is a strong caustic. When working with the batteries, use protective gloves and protective goggles.

Protect your eyes, skin and cloth from being stained with electrolyte or lead particles.

If the electrolyte accidentally penetrates into eye, wash the eye immediately with water stream for several minutes and then visit physician as soon as possible.

If the electrolyte happens to stain skin or clothes, wash the hit area with soap water as soon as possible and then rinse with a stream of clean water.

If the electrolyte is eaten, visit physician immediately.

Do not turn the batteries upside down, as electrolyte could run out from the breathing holes.

When charging the batteries, hydrogen escapes and creates explosive mixture with air. Therefore, it is prohibited to smoke and/or to use naked flame.

Do not carry out any activities, which may cause sparkling. Avoid such manipulations with cables and electrical instruments, which may cause sparkling.

The battery must be frame-connected with its minus (-) pole; the plus pole (+) must be connected to the „B+“ terminal of alternator. Opposite connection would result is destroying of the whole semiconductor system.

Fig. 4.21 - Table of Electrolyte Density The table shows data valid at 20°C (68°F).

Density 3

in g/cm

in °Be (Beume)

Normal Normal Tropics Tropics temperatures temperatures fully charged

1,28

1,23

32°

27°

semi charged

1,2

1,12

24°

16°

exhausted charge immediately!

1,12

1,08

16°

11°

When carrying out any repair of the charging circuit, disconnect the alternator to prevent accidental short-circuits.

It is inadmissible to check voltage in a cable by sparkling on the frame of the machine.

Do not disconnect the battery when the engine is running.

The alternator must not be run at idle, i.e. with disconnected „B+“ terminal and connected „D+“ terminal.

When starting with aid of an external source, this must not be disconnected earlier, than the battery of the machine is connected. Voltage of the external source must be 24 V. Prior to welding at the machine, disconnect cables from the „B+“ and „D+“ terminals.

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4.6. Individual Operations of Lubrication and Maintenance Every 250 Hours or Once in 3 Months 4.6.15. Inspection of the Underpressure Switch of Air Cleaner

Every 250 Hours or Once in 3 Months 4.6.16. Lubrication of the machine

z The inspection is to be carried out at running engine.

•

z Set up engine speed to approx. 1500 RPM.

•

z Shortly cover the inlet opening of the air cleaner (1) at the engine hood. After that, the indicator of air cleaner clogging must get on.

•

z If not, seek for a failure (faulty bulb, poor contact, broken cable, faulty underpressure switch etc.).

• •

Place the roller on a flat, firm surface.

Stop the engine and disconnect electric system by master switch.

Remove caps of grease nipples.

Successively insert the grease nipple of the lubricator gun and continue greasing until the old grease starts leaking out.

Replace grease nipple caps.

Fig. 4.23 - Steering - upper bearing

Fig. 4.24 - Steering - lower bearing

Fig. 4.22 - Air Inlet Cover

2

1

1 - Inlet opening 2 - Air inlet cover

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Lubrication and Maintenance Manual Every 250 Hours or Once in 3 Months

Every 250 Hours or Once in 3 Months

Fig. 4.25 - Steering - bearing 4x

Fig. 4.28 - Hydraulic cylinders of hood lifting - upper pins 2x

Fig. 4.26 - Steering hydraulic cylinders - front pins 2x

Fig. 4.29 - Hydraulic cylinders of hood lifting - lower pins 2x

Fig. 4.27 - Steering hydraulic cylinders - rear pins 2x

Fig.4.30-Hydraulic cylinder of driver’s station lifting-lower pin

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4.6. Individual Operations of Lubrication and Maintenance Every 250 Hours or Once in 3 Months

Every 250 Hours or Once in 3 Months

Fig. 4.31 - Door hinge pins - pins 6 x

Fig. 4.34 - Front pins of cabin attachment - pins 2 x

Fig. 4.32 - Door hinge pins

Fig. 4.35 - Blade - pins

Fig. 4.33 - Hood hinge pins - pins 2 x

Use only recommended lubricating grease, see chapter 4.1.5.

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Lubrication and Maintenance Manual Every 250 Hours or Once in 3 Months

Every 250 Hours or Once in 3 Months

4.6.17. Inspection Of Oil Level In The Vibrator z Carry out this inspection when oil is still warm. z Set up the drum into horizontal position, upwards with the filling plug (1) (the filling plug is at a skew surface) - See Fig. 4.36. z Clean the surrounding area of the plugs. Unscrew the inspection plug (2) - see Fig. 4.37. z Proper oil level is such a level, that oil begins to slightly run out from the inspection hole. z If necessary, unscrew the filling plug (1) and replenish oil. z Use only the same sort of oil. z Screw in the plugs again.

Keep environmental principles!

Fig. 4.36 - Vibratory Drum

Fig. 4.37 - Vibratory Drum

2 1

1 - Filling plug

VV1100 / VV1500

3

1 - Inspection plug 2 - Drain plug

123

4.6. Individual Operations of Lubrication and Maintenance Every 250 Hours or Once in 3 Months 4.6.18. Inspection Of Oil Level In The GearBox

Every 250 Hours or Once in 3 Months Drum gear-box

Axle gear-box

z Clean the area around the inspection plug (2) to Fig. 4.39.

z Place the roller on a level and firm area, so that the plugs are positioned as according to Fig. 4.38.

z Unscrew the plug (2) and check oil level. Oil level should reach lower edge gap or drop out (Fig. 4.39).

z Clean the area around the plug (1).

z If necessary, top up oil to prescribed level through the filling plug (1).

z Unscrew the plug (1) and check oil level. Oil level should reach lower edge gap or drop out (Fig. 4.38). z If necessary, top up oil to prescribed level through the plug (1) (Fig. 4.38).

z Clean the plugs and screw them back. z Check the gear-box for tightness.

z Clean the plugs and screw them back. z Check the gear-box for tightness.

Do not touch the gear-box and surrounding area, when these are hot. Wait till they cool down.

Fig. 4.39 - Drum Gear-Box

1

2

Fig. 4.38 - Axle Gear-Box

1

1

1 - Inspection + filling plug

124

2

1 - Filling plug 2 - Inspection plug

VV1100 / VV1500

Lubrication and Maintenance Manual Every 500 Hours or Once in 6 Month

Every 500 Hours or Once in 6 Month

4.6.19. Exchange of the Fuel Filter Elements z Stop the engine. z Clean the head of the fuel cleaners. z Dismantle the cleaners. z Catch the escaping fuel. z Clean the contact surface of the cleaners (Fig. 4.40). z Replace the O ring (1) (Fig. 4.40). z Fill new filter elements with clean fuel and oil the O ring (2) (Fig. 4.41). z Mount the cleaners with tighten well (Fig. 4.42).

Fig. 4.41 - Filling the Fuel Cleaners

Used filter elements are to be stored in an separate container and disposed in accordance with environmental principles!

Use only genuine filter elements of the prescribed type.

Do not overtighten the cleaner, it could cause damage of the thread and sealing.

2

No naked flame!

No smoking!

Fig. 4.40 - Fuel Cleaners

Fig. 4.42 - Tightening the Fuel Cleaners

2 1

VV1100 / VV1500

1

125

4.6. Individual Operations of Lubrication and Maintenance Every 500 Hours or Once in 6 Month

Every 500 Hours or Once in 6 Month

4.6.20. Inspection of Coolant Concentration

4.6.21. Re-Tightening of the Wheel Nuts

z Concentration of coolant is to be tested by means of a refractometer (1), at ambient temperature 20°C (68°F).

Or, it is possible to use a densimeter (2) - (see Fig. 4.43).

z Check tightening of the wheel nuts (1) by means of a torque-limiting wrench. z The tightening torque is 540 Nm (400 lb ft).

z This inspection is to be done also before winter. z Minimal share of ethylene glycol or propylene glycol anti-freeze agent is 40%, which is sufficient for temperatures above -23°C (-10°F). z The anti-freeze coolant is to be used for the whole year, in all climates (even there, where are never temperatures below freezing). The coolant serves not only as a protection against frost, but also increases the boiling point. The inhibitors contained in the coolant protect the parts of the cooling system and extend their lifetime.

Fig. 4.43 - Refractometer / Densimeter

1

Fig. 4.44 - Wheel

1

2

1 - wheel nuts

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Lubrication and Maintenance Manual Every 1000 Hours or Once a Year

Every 1000 Hours or Once a Year

4.6.22. Inspection and Adjustment of Valve Clearance

z Find the top dead center (hereinafter „TDC“) of the cylinder No. 1, slowly turning the engine by means of the pin, at simultaneous depressing of the timing pin (see Fig. 4.46).

z Dismantle the valve cover and the air piping, which supplies air to the turbocharger (see Fig. 4.45).

z When the timing pin snaps into a hole in the cam gear, the cylinder No. 1 is in the TDC position of the compression stroke (see Fig. 4.47).

z Dismantle the blinding plugs at the flywheel casing.

The hole serves for inserting the splined pin.

z Pull out the timing pin (see Fig. 4.48).

z Insert the splined shaft Cummins No. 3824591 with 1/2" opening for a allen wrench into the hole. The wrench enables to turn the engine by hand (see Fig. 4.46).

Fig. 4.45 - Valve Cover, Pressure Controller, Air Piping

Fig. 4.47 - Timing Pin

Cam gear

Timing pin

Gar cover

Fig. 4.46 - Splined Pin

VV1100 / VV1500

Fig. 4.48 - Timing Pin

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4.6. Individual Operations of Lubrication and Maintenance Every 1000 Hours or Once a Year

Every 1000 Hours or Once a Year

z Measure clearance of the inlet and exhaust valves between the contact surface of the valve and that of the rocker arm, by means of the feeler gauges (see Fig. 4.49). Proper clearance is as follows: Inlet valves

0,25 mm (0,010 in)

Exhaust valves

0,50 mm (0,020 in)

z Inspection and/or adjustment is to be done only at cool engine (below 60°C, 140°F) (Fig. 4.49). z Adjust the clearance by turning the adjusting screw after loosening the lock nut (see Fig. 4.49). z Re-tighten the lock nut, to 24 Nm (18 ft lb).

Before turning the crankshaft, be sure that the timing pin is pulled out. That would prevent its damage. z Inspect (respectively adjust) clearance of the other valves as well (see Fig. 4.51). z Tighten the lock nuts and re-check the clearances.

Torque the lock nut up to 24 Nm (18 ft lb).

Mount the valve cover and tighten the bolt up to 24 Nm (18 ft lb) (Fig. 4.52). Mount the air piping (see Fig. 4.45).

z At properly adjusted clearance, a resistance must be felt when sliding the feeler gauge. z After tightening the lock nut, check the valve clearance again. z Make a mark at the damper of torque vibrations and turn the crankshaft by 360°.

Fig. 4.49 - Measuring the Valve Clearance

Fig. 4.51 - Valves

Fig. 4.50 - Inlet and Exhaust Valves

Fig. 4.52 - Valve Cover

E - exhaust valves I - inlet valves

128

VV1100 / VV1500

Lubrication and Maintenance Manual Every 1000 Hours or Once a Year 4.6.23. Inspection of the Drive Belt Inspection of Tensioning: z Stop the engine. z Measure deflection of the belt under finger pressure, at the longest side of the belt (see Fig. 4.53). z Maximal deflection is 9,5 - 12,7 mm (3/8 - 1/2 in). To measure the deflection, also the measuring fixture Cummins, part No. ST-1293 can be used. Measured value should be within 267 - 578 N (60 - 130 lb) - see Fig. 4.54.

Every 1000 Hours or Once a Year Inspection: z Tilt off the tensioning pulley by means of a lever (see Fig. 4.55) and remove the belt. z Carry out visual inspection of the belt, watch for marks of damage. Transversal cracks are not a failure. If there are longitudinal cracks, frayed out edges or part of the material torn out, the belt must be replaced (see Fig. 4.56). z Mount the belt to its place. z Check tightening of the bolt at the cover of the tensioner. Torque to 43 Nm (32 lb ft).

Check, tension and replace the belt only when the engine is at standstill.

Fig. 4.53 - Inspection of the Belt Tensioning by Hand

Fig. 4.55 - Dismantling the Belt

Fig. 4.54 - Inspection of the Belt Tensioning by the Fixture

Fig. 4.56 - Inspection of the Belt

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4.6. Individual Operations of Lubrication and Maintenance Every 1000 Hours or Once a Year

Every 1000 Hours or Once a Year

4.6.24. Oil change in the gear box

Axle gear box

Drum gear box z Place the roller level on a firm and straight base.

z Place the roller level on a firm and straight base so that the gear box plugs are positioned as in Fig. 4.58.

z Clean off plugs Fig. 4.57.

z Clean off plugs.

z Place a suitable container underneath the drainage plug (3).

z Place a suitable container underneath the drainage plug (1).

z Unscrew all plugs and let oil drain.

z Unscrew both plugs and clean.

z Clean the plugs.

z Fill oil through upper plug (2) until level reaches hole or starts escaping.

z Replace drainage plug (3) there after.

z Replace both plugs and worn seals.

z Fill with recommended oil through input plug (1). z Check oil level through inspection hole (2). Oil level must be reach the lower edge of the hole or escape moderately. z Replace plugs (1) and (2) and worn seals.

NOTE Change oil for the first time after 100 hours of operations.

Do not touch gear box and adjacent parts while hot.

Fig. 4.57 - Drum Gear-Box

Fig. 4.58 - Axle gear box

1

2

2

3

130

1

VV1100 / VV1500

Lubrication and Maintenance Manual Every 1000 Hours or Once a Year 4.6.25. Inspection of the Damping System

Every 1000 Hours or Once a Year Fig. 4.61 - Rear Rubber Mounts of the Cabin

z Inspect shape of the rubber-to-metal blocks and cohesion of rubber and metal, at the damping system of the vibratory drum, the cab mounting and at the engine suspension. Replace damaged blocks. z Check tightening of all bolts and nuts.

Fig. 4.59 - Rubber Mounts of the Vibratory Drum

Fig. 4.62 - Front Rubber Mounts of the Engine

Fig. 4.60 - Front Rubber Mounts of the Cabin

Fig. 4.63 - Front Rubber Mounts of the Engine

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131

4.6. Individual Operations of Lubrication and Maintenance Every 1000 Hours or Once a Year

Every 1000 Hours or Once a Year

4.6.26. Cleaning the Fuel Tank z Carry out this operation, when there is minimum of fuel in the tank. z Stop the engine and disconnect the electrical installation. z When the tank seems to be empty, there is still about 45 lt. (11,9 gal US) left. z Unscrew the drain plug (1) and let fuel run out, into a vessel. z Flush the tank with clean fuel. z Screw in the plug (1). z In case of heavier dirt in the tank, remove the batteries and the tank cover (2). Check and clean the inner space of the tank. Fit new PTFE seal strip under the tank cover and screw on the cover. Mount back the batteries and the plug (1). z If the fuel system got aerated, carry out its deareation as according to chapter 4.6.37.

Do not smoke during the work!

No naked flame!

Fig. 4.64 - Fuel Tank

2

1

1 - Drain plug 2 - Tank cover

132

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Lubrication and Maintenance Manual Every 2000 Hours or Every 2 Years

Every 2000 Hours or Every 2 Years

4.6.27. Exchange Of Oil In The Vibrator z Oil in the vibrator is to be exchanged when still warm. z Place the roller on a firm and level area, the drain plug (3) should be directed downwards (see Fig. 4.65). z Place a suitable container under the drain plug. z Unscrew all plugs and let oil to run out. z After draining, screw in the drain plug. z Pour in through the filler (1) recommended oil up to the edge of the inspection hole (2) - see Fig. 4.65. z Screw in two remaining plugs.

Pay care when draining oil. Avoid burning!

Keep environmental principles.

Fig. 4.65 - Plugs

1

2

3

1 - Filling plug 2 - Inspection plug 3 - Drain plug

VV1100 / VV1500

133

4.6. Individual Operations of Lubrication and Maintenance Every 2000 Hours or Every 2 Years 4.6.28. Exchange of Hydraulic Oil •

Place the roller on a flat, firm surface.

•

Stop the engine and disconnect electric system.

• • • • • • •

Dismantle the terminal and attach a hose (see Fig. 4.66).

Every 2000 Hours or Every 2 Years •

•

Check the inside of the tank. Carefully clean the bottom and flush it with new oil if there are any impurities at the bottom. For easier cleaning it is possible to dismantle the entire upper cover (3) with the filler (4).

Reassemble the cover with the suction pipe. Lubricate O-ring with clean oil. For dismantled the entire upper cover (3), use a new Teflon sealing strip.

Screw it to the drain valve in the tank bottom (Fig. 4.67).

Let oil drain into a ready container - total amount of oil should be about 60 l (15.8 US gal).

Dismantle suction hose (1), cover (2) with suction strainer (Fig. 4.68).

Dismantle suction strainer from the suction pipe. Wash the suction strainer in gasoline and blow the strainer with pressure air from inside.

Fig. 4.67

Check the condition of the suction strainer; replace the strainer in case of damaged filter part.

Mount the strainer to the suction pipe.

Fig. 4.66

Fig. 4.68

3 2

1

134

4

VV1100 / VV1500

Lubrication and Maintenance Manual Every 2000 Hours or Every 2 Years Exchanging the filter cartridge of pressure filter

•

•

Change the filter cartridge always -

after a major repair of the hydraulic loop

-

after a repair or replacement of the hydraulic generator or hydraulic motor .

-

•

Every 2000 Hours or Every 2 Years

• •

if the indicator of pressure filter (25) lights up after the working temperature has reached 50 to 60°C (122 - 140°F) - Fig. 4.69.

•

Change the filter cartridge of the filtration block (Fig. 4.70).

•

Dismantle the filter container (2) with the filter cartridge (3) using wrench 27 and take out the cartridge (Fig. 4.71).

Carefully clean the filter container.

Clean the contact surface of the filtration block (3) at the lower side.

Check the condition of sealing rings and lubricate them with clean oil.

Insert a new cartridge into the filter container - tighten with torque 40 to10 Nm (30 + 7 lb ft).

Fig. 4.69

Fig. 4.70

Fig. 4.71 - Section of the pressure - type filter

2

3

VV1100 / VV1500

135

4.6. Individual Operations of Lubrication and Maintenance Every 2000 Hours or Every 2 Years Checking the oil temperature sensor

• • •

Every 2000 Hours or Every 2 Years Filling the hydraulic loop:

Dismantle (1) the sensor and clean the contact (Fig. 4.72).

When filling the hydraulic loop with the filling device, old oil and impurities of the hydraulic loop including hydraulic generators and motors will be flushed. Thus the ratio of old oil and impurities in the new oil charge will decrease, thus extending the life of the hydraulic system.

Dip the sensor into warm oil of known temperature and read oil temperature on the thermometer.

Replace the sensor if not operating properly.

•

Fig. 4.72

Filling device (Fig. 4.73), must have the following parameters: min. pressure 6 MPa (870 PSI) filtering 3 to 10 µm

1

• •

Mount the quick-coupler of the filling device to the quick-coupler of fig 4.74.

Fill the hydraulic loop using the filling device until clean oil starts flowing out of the hose - collect it to a clean vessel.

1 - Sensor of hydraulic oil temperature

Fig. 4.73

136

Fig. 4.74

VV1100 / VV1500

Lubrication and Maintenance Manual Every 2000 Hours or Every 2 Years • • • • •

After approximately 15 l (4 US gal) have flowed out, remove the terminal from the drain spout and mount it back to the tank side.

Add oil to the tank to the top and disconnect the filling device (Fig. 4.75).

Check the function of the level gauge sensor (the indicator of oil level should go off after filling the tank)

Every 2000 Hours or Every 2 Years Alternative filling of the hydraulic loop

• • •

Start the engine, let it run at idle speed and test the function of the machine.

Recheck tightness and add oil with the filling device, if necessary.

•

Close the drain valve and refill the tank through the filler with specified type of oil up to the bottom of the strainer in the filling cap (filler).

Check the function of the level gauge sensor (the indicator of oil level should go offafter filling the tank) Start the engine and let it run at idle speed, test all functions of the machine until the loops become saturated.

Add oil to the specified level and check tightness.

Fig. 4.75

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137

4.6. Individual Operations of Lubrication and Maintenance Every 2000 Hours or Every 2 Years

! NOTE !

The cap of the tank filler is sealed. Should the seal be broken, warranty is null and void.

The alternative way of filling the hydraulic loop is an emergency solution only!

Every 2000 Hours or Every 2 Years After disconnecting hydraulic loops blind all holes with plugs.

Collect drained oil; do not leave it soak to ground.

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

In this filling, it is necessary to cut the change interval to a half, i.e. 1000 h or 1 year. Lifetime of hydraulic units decreases as well.

Change oil and clean the hydraulic tank before the working season or after a longer down time of the machine.

Keep the machine clean - avoid polluting the system with materials that may damage important units!

Close and cover containers of new oil - avoid polluting, water penetration etc.

Do not open the hydraulic tank unnecessarily!

In case of failure of hydraulic motor or generator, when inside parts of the unit have been destroyed, it is necessary to clean the inside of the hydraulic tank and remove mechanical impurities prior to the installation of a new unit. A professional service must perform this operation.

Do not use chemical detergents to clean the tank.

Use lint-free rags for cleaning.

Use recommended filters only.

Use only recommended oils according to chapter 4.1.3.

You can order a filling device with a quickcoupler from the manufacturer of the machine or your dealer.

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

Follow fire safety measures!

138

VV1100 / VV1500

Lubrication and Maintenance Manual Every 2000 Hours or Every 2 Years

Every 2000 Hours or Every 2 Years

4.6.29. Inspection And Cleaning Of The Suction Basket Of The Hood & Cab Lifting System z Carry out inspection and cleaning at every exchange of hydraulic oil. z Remove the screws (1). The unit of cab & hood lifting take out from the bottom of the tank (see Fig. 4.76). z Remove the suction basket (4) from the suction pipe (3) of the pump (1). Wash the basket in gasoline and blow it off with pressured air (see Fig. 4.77). z Check if the basket is intact. Replace if damaged. z Mount the basket to its place. z Check the O ring at the flange and mount the unit back. z Check the system for tightness.

Pay care for cleanness.

Fig. 4.76 - Location Of The Unit

Fig. 4.77 - Unit Of Cab & Hood Lifting

3 4 1 5

1

2

1 - Hydraulic pump 2 - Electric motor 3 - Suction pipe 4 - Suction basket 5 - Seal ring

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139

4.6. Individual Operations of Lubrication and Maintenance Every 2000 Hours or Every 2 Years

Every 2000 Hours or Every 2 Years

4.6.30. Exchange of Coolant

z Open the drain cock at the lower chamber of the radiator (see Fig. 4.78).

z To be done after operation, or after warning up the coolant to min. 85 °C (185 °F).

z Let coolant flow out into vessels. Drained volume is about 25,0 lt. (6,6 gal US) (Fig. 4.78).

z Place the roller on a firm and level area.

z Check, if there are no damaged hoses or missing hole clips at the cooling circuit. Inspect the radiator, whether it is not damaged, if does not leak and if the finning is not clogged. Clean and/or repair the radiator if necessary (see Fig. 4.80).

z Stop the engine (see Fig. 4.78). z Wait, till coolant temperature drops below 50°C (120°F).

At higher temperatures, there is a danger of coolant jetting up and burning after the overpressure plug is opened (see Fig. 4.79). z Dismantle the overpressure plug at the equalization tank to open the cooling system (see Fig. 4.84).

z Close the drain cock and fill the system with new coolant (see Fig. 4.81) consisting of 50% of water and 50% of anti-freeze agent. Fill through the filler at the equalization tank, up to the lower edge of the tube (see

Fig. 4.71 - Draining the Cooling System

Fig. 4.73 - Coolant Radiator

Fig. 4.72 - Overpressure Plug

Fig. 4.74 - Mixing the Antifreeze Liquid

50 %

140

50 %

VV1100 / VV1500

Lubrication and Maintenance Manual Every 2000 Hours or Every 2 Years Fig. 4.82). When filling, wait for 2-3 min. till the circuit gets filled. Maximal speed of filling is 19 lt./min (5 gal US/min).

Every 2000 Hours or Every 2 Years z Check coolant level at the sight gauge (fig. 4.84). In case the coolant level is low: -

Wait, till coolant temperature drops below 50°C (120°F). At higher temperatures, there is a danger of coolant jetting up and burning after the overpressure plug is opened.

-

Dismantle the overpressure plug (2) at the equalization tank (Fig. 4.84) to open the cooling system and top up coolant (Fig. 4.84).

-

Fit on the overpressure plug.

z Close the equalization tank by the overpressure plug. z Start the engine and wait, till coolant temperature reaches 80°C (175°F). During this time, inspect whether coolant is not leaking. (Fig. 4.83) z Stop the engine.

Fig. 4.82 - Filling of the equalization tank

Use coolant according to chapter 4.1.6!

Follow instructions by the manufacturer of antifreeze when changing coolant!

Protect your hands with gloves!

Use safety glasses or safety shield!

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

Fig. 4.83 - Inspection of the Cooling System for Tightness

Fig. 4.84 - Equalization tank

2

3 1

1 - Equalization tank 2 - Filler with the plug 3 - Sight gauge

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4.6. Individual Operations of Lubrication and Maintenance Every 2000 Hours or Every 2 Years

Every 2000 Hours or Every 2 Years

4.6.31. Inspection of the Torsional Vibrations Damper z Check the mutual position of the marks stamped at faces of both parts of the torsional damper (A) - see Fig. 4.85. If these marks are mutually shifted by more than 1,59 mm (1/16 in), it is necessary to replace the damper.

Fig. 4.85 - Torsional Vibrations Damper

A

A

A

142

VV1100 / VV1500

Lubrication and Maintenance Manual Maintenance - As Needed 4.6.32. Cleaning, Exchange of the Air Filter Elements Proper maintenance of the air cleaner will keep the engine maximally protected from dust, will prolong lifetime of the filter elements and their effectivity.

Maintenance - As Needed z Mount on the dust valve. z Mount on the new or cleaner filter element. Verify, that the elements sits properly and seals well. In a case a new element is used, replace also the safety element.

Cleaning the Main Filter Element:

The caught dust is stored in the dust valve (3) - see Fig. 4.86. If the valve works well, it is automatically discharged during operation.

z Only dry cleaning with pressured air is allowed. Air pressure must not exceed 5 bar (72 PSI). Blow the element under a slight angle, from inside to outside.

Lifetime of the filter element depends on the environment, where the machine is being operated. Whenever the underpressure indicator of gets on, replace or clean the filter element.

z The filter element can be cleaned only 5 times, then it must be replaced. Either, the filter element must be replaced after one year of operation.

Replace or clean the element only in the case that resistance gets to maximal allowed level. Do not judge the element by its appearance; the element always looks dirty. The filtering ability of the element improves with increased clogging.

z Every cleaning is to be marked at the filter element cover. z If the filter element is clogged with carbon black, cleaning is not possible. The element must be replaced. z After cleaning, inspect the filter element for possible holes (see it against light). If the element is damaged, it must be replaced. Therefore, we recommend to have always at least one spare filter element. Damaged filter element is not effective and penetrating dirt and dust would result in lower lifetime of the engine.

z Lift the hood up to the end position. z Unscrew the wing nut (1) and remove the cover with the main filter element (2) - see Fig. 4.86.

Do not use any liquids to clean the filter element.

z The safety element is to be removed only when the main filter element is replaced with a new one. z Remove the dust valve (3) and clean it (see Fig. 4.86). z Clean the inner space of the cleaner with a cloth, not with pressured air.

Fig. 4.86 - Air Filter

Safety Filter Element: z Replace the safety filter element (6) - see Fig. 4.86 always, when: -

the main filter element is replaced; the main filter element was five times cleaned; after two years of operation; if the underpressure indicators gets on at cleaned main filter element; if the main filter element is damaged.

z To dismantle the safety element, unscrew the sealing nut (4) and remove the element from the center pin (see Fig. 4.86). z Replace the element as well as the sealing nut. z Mount all parts in the reverse order. z When washing the machine, blind the holes of the air cleaner to protect it from water. Remove the blinds after washing!

1 - Wing nut 2 - Main air filter element 3 - Dust valve 4 - Seal nut 5 - Nut 6 - Safety air filter element

VV1100 / VV1500

z If the dust absorbs humidity, the dust valve and the element can get clogged quickly. In this case, remove the elements, clean thoroughly the cleaner body, let it dry and mount the parts back.

143

4.6. Individual Operations of Lubrication and Maintenance Maintenance - As Needed

Maintenance - As Needed 4.6.33. Cleaning the Machine

Use genuine filter elements only! z After daily work, clean the machine from major dirt.

Principles of Proper Replacement of the Filter Element: z pull out the used element as carefully as possible; z always clean the inner space of the cleaner housing in such manner that dust cannot get into the inner part of the inlet branch; z clean the sealing surfaces in the cleaner housing; z watch the marks of dust at the old element, which may judge of its untightness in the filter housing; z depress the sealing at the new element and check, whether it is flexible; z check, if the element sits properly; z inspect connections and guiding, if they are tight and whether the inlet opening is not clogged.

z Complete cleaning is to be done at least once a week.

When compacting the cohesive soils, or soils stabilized with cement or lime, complete cleaning must be done daily. z Do not use aggressive or flammable cleaning agents (i.e. gasoline and similar). z Carry out the work at stopped engine. z When the steam jet cleaner is used, do not expose the electrical installation or insulation materials to direct jet. Always cover these parts first. Disconnect the battery insulator switch. z Before cleaning the machine by means of pressure cleaners (water, steam etc.), blind all holes, where the agent could enter (inlet hole of the engine, inner space of the alternator etc.). When the work is finished, remove the blinds.

Prohibited Activities: z never use damaged element; z do not take out the element to check it; z do not judge the used element by its

appearance; z do not let the cleaner open for longer than

necessary; z do not use cleaner with damaged cover or

the cleaner housing; z do not knock the filter element to clean it; z do not use other than prescribed element; z do not wash the filter element in gasoline or

other liquids.

144

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Lubrication and Maintenance Manual Maintenance - As Needed

Maintenance - As Needed

4.6.34. Cleaning The Engine Radiator And Hydraulic Oil Cooler

4.6.35. Cleaning The Dust Filter Of Cab Ventilation

z Due to various operational conditions, the cleaning intervals are to be adjusted individually.

z This operation is to be carried out at least once a month. Shorten this interval when working in extremely dusty environment.

z Clean the radiator and cooler with pressured air or water or steam jet. Clean from the side of the fan.

z Dismantle the cover grill (1).

z Do not damage the fins of the radiators.

z Take out the filter and the filter element (2).

z Do not use cleaner with too high pressure.

z Carefully knock-off and wash the filter element in a detergent solution. If the filter element is damaged or too dirty, replace it.

z In case of operation in extremely dusty environment, this operation is to be done daily. Clogged radiators result in lower cooling output, increased coolant and hydraulic oil temperature. z When the radiators gets contamined with oil derivates, sprinkle the radiator with usual solvent and let it about 10 minutes. Then, rinse with water.

Fig. 4.87 - Dust Filter Of Cab Ventilation

Do not damage the fins of the radiators.

1 2

1 - Cover grill 2 - Filter element

VV1100 / VV1500

145

4.6. Individual Operations of Lubrication and Maintenance Maintenance - As Needed

Maintenance - As Needed

4.6.36. Cleaning the Fuel Separator

4.6.37. Deareation Of The Fuel System

z In a case, that fuel continually contains impurities, clean the fuel separator at the fuel cleaner.

z After you have done exchange of the fuel filter elements according to the previous chapter, it is not necessary to deareate the fuel system.

z Have ready a vessel to drain the sediment. z Turn the valve of the separator (1) by 4 turns clockwise, so that the valve slides by approx. 25 mm (1") downwards. Let fuel run out so long, until it is clean. z Force the valve upwards and screw it. z If you have drained more then about 6 cl (2 ozs) of fuel, replenish fuel into the fuel cleaner (see chapter 4.6.19.) or also deareate the system (see 4.6.37.). That will eliminate possible problems with starting.

Deareation of the fuel system is to be done when: -

the fuel cleaner have not been filled with fuel;

-

after replacement of the fuel feed pump;

-

after replacement or repair of the high-pressure fuel lines or an injector (at the first start);

-

after the machine has been out of operation for a long time;

-

when the fuel tank has been completely exhausted.

Fig. 4.89 - Fuel Cleaner

Fig. 4.88 - Fuel Separator

1

C 1 - Valve of the separator

146

1

1 - Deareation screw of fuel cleaners

VV1100 / VV1500

Lubrication and Maintenance Manual Maintenance - As Needed

Maintenance - As Needed

Deareation of the low-pressure hoses and cleaners:

Deareation of the high-pressure fuel lines and the injectors:

-

Loose the deareation screw at the fuel cleaners (1) - see Fig. 4.89.

-

Prime fuel by means of the hand priming pump (2) - see Fig. 4.90 - until the runs out free of air bubbles.

-

Tighten the deareation screw. Torque it to 9 Nm (7 ft lb).

z If the previous operation have been done and the engine did not start, deareate the high-pressure lines (see Figs. 4.91 and 4.92). z Loose one or more nuts at the injectors and run the starter, until air is pushed out from the lines. z Continue this operation so long, till the engine runs regularly. z Tighten the connection previously loosen, up to 30 Nm.

If the starter is used for deareation, do not run the starter for more than 30 s. Wait 2 minutes between starting. At this operation, the engine may get started, so that keep all safety regulations.

Fig. 4.90 - Feed Pump

Fuel pressure in the high-pressure lines is high and it may cause skin penetration and serious injury.

Do not carry out this operation at hot engine; fuel could get to the exhaust and cause fire.

2

Catch escaping fuel.

No naked flame!

2 - Hand feed pump

Fig. 4.91 - Deareation of the High-Pressure Lines

VV1100 / VV1500

No smoking!

Fig. 4.92 - Deareation of High-Pressure Fuel Lines

147

4.6. Individual Operations of Lubrication and Maintenance Maintenance - As Needed

Maintenance - As Needed

4.6.38. Adjustment Of Scrapers

Scarpers for drums with lugs

Scrapers for smooth drums

Loosen bolts (1) and move individual scrapers (2) to 35 mm (1,4 in) from he drum, Fig. 4.94.

Loosen bolts, see Fig. 4.93 and move holders (1) to the drum surface to 20 mm (0,8 in) between the scraper and the drum.

NOTE NOTE! If the scraper cannot be move any further in the oval holes of the holders (1) with the scraper worn, remove the scraper (2) and move it by one hole to the drum.

Fig. 4.93

Rear scrapers on these drums are longer. When replacing worn scrapers, install rear scrapers instead of front ones, and replace rear scrapers with new ones.

If too small a gap is adjusted between the scraper and the drum, the machine may turn toward the contact of the scraper with the drum.

Fig. 4.94

1

1 2 2

148

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Lubrication and Maintenance Manual Maintenance - As Needed

Maintenance - As Needed

4.6.39. Inspection, Re-Tightening of Bolted Connections z Regularly check, whether the bolted connection are not loose. z Use torque limiting wrenches to tighten the bolts and nuts.

Fig. 4.95 - Table of Tightening Torques For Bolts With Metric Threads

Bolt size

Torque* [Nm] 5,8

8,8

10,9

M4

2

3

4

M5

4

6

8

M6

7

10

14

M8

16

22,5

32,5

M10

31,5

44

62

M12

53

75

105

M14

78,5

118

165

M16

113

165

226

M18

172

245

343

M20

226

314

441

M22

284

392

559

M24

392

549

755

* Strength classification of bolts with dry threads. The bolt class is marked at its head: 5.8= without marking, or 5.S

8.8= 8G

10.9= 10K

Data shown in the table are torques at dry thread (friction coefficient = 0,14); these data are not valid for lubricated thread.

The self-locking nuts can be used 3 times only.

VV1100 / VV1500

149

4.6. Individual Operations of Lubrication and Maintenance Maintenance - As Needed Fig. 4.96 - Table of insert nuts tightening moments with tightening “O” circle – the hoses

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

Size spanner

lb-ft

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

8

45

38

52

33

28

38

51

43

58

38

32

43

10 22

M18x1.5

10 12

24

M20x1.5

12

58

50

65

43

37

48

27

M22x1.5

14

74

60

88

55

44

65

15 30

M24x1.5

16

74

60

88

55

44

65

32

M26x1.5

18

105

85

125

77

63

92

36

M30x2

20

135

115

155

100

85

114

166

140

192

122

103

142

22 41

M36x2

46

25 28

50

M42x2

30

240

210

270

177

155

199

50

M45x2

35

290

255

325

214

188

240

M52x2

38

330

280

380

243

207

280

42

150

VV1100 / VV1500

Lubrication and Maintenance Manual Maintenance - As Needed

Maintenance - As Needed

Fig. 4.97 - Table of tightening moments for necks with tightening edge, or with flat packing

Fig. 4.98 - Table of tightening moments for plugs with flat packing

Tightening moments for the necks

Tightening moments for the plugs

G-M

Nm

lb -ft

G-M

Nm

lb -ft

G 1/8"

25

18

G 1/8"

15

11

G 1/4"

40

30

G 1/4"

33

24

G 3/8"

95

70

G 3/8"

70

52

G 1/2"

130

96

G 1/2"

90

66

G 3/4"

250

184

G 3/4"

150

111

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 10 x 1

25

18

M 10 x 1

13

10

M 12 x 1,5

30

22

M 12 x 1,5

30

22

M 14 x 1,5

50

37

M 14 x 1,5

40

30

M 16 x 1,5

60

44

M 16 x 1,5

60

44

M 18 x 1,5

60

44

M 18 x 1,5

70

52

M 20 x 1,5

140

103

M 20 x 1,5

90

66

M 22 x 1,5

140

103

M 22 x 1,5

100

74

M 26 x 1,5

220

162

M 26 x 1,5

120

89

M 27 x 1,5

250

184

M 27 x 1,5

150

111

M 33 x 1,5

400

295

M 33 x 1,5

250

184

M 42 x 1,5

600

443

M 42 x 1,5

400

295

M 48 x 1,5

800

590

M 48 x 1,5

500

369

VV1100 / VV1500

151

4.7. Records of Accomplished Operations

Date

152

Hours

Accomplished Operation

VV1100 / VV1500

Lubrication and Maintenance Manual

Date

Hours

VV1100 / VV1500

Accomplished Operation

153

4.7. Records of Accomplished Operations

Date

154

Hours

Accomplished Operation

VV1100 / VV1500

Lubrication and Maintenance Manual

Date

Hours

VV1100 / VV1500

Accomplished Operation

155

4.8. Accessories

NO.

DESCRIPTION

DRAWING NO.

1.

Wrenc h

32234 4

1

2.

Double- ended wre nch 9x10

CSN 23061 0

1

3.

Double- ended wre nch 11x12

CSN 23061 0

1

4.

Double- ended wre nch 13x16

CSN 23061 0

1

5.

Double- ended wre nch 14x17

CSN 23061 0

1

6.

Double- ended wre nch 18x21

CSN 23061 0

1

7.

Double- ended wre nch 19x22

CSN 23061 0

1

8.

Double- ended wre nch 24x27

CSN 23061 0

1

9.

Double- ended wre nch 30x32

CSN 23061 0

1

10.

Double- ended wre nch 36x41

CSN 23061 0

1

11.

Combi ned plie rs 160 mm

CSN 23038 0

1

12.

Locksmi th hammer 450GR

CSN 23011 0

1

13.

Scr ewd river 71 1/1

1

14.

Scr ewd river 71 1/3

1

15.

Grea se head 500

CSN 23149 2.3

1

16.

Grea se gun 3648- 500 cm 3

CSN 23146 2

1

156

PCS.

VV1100 / VV1500

Lubrication and Maintenance Manual

VV1100 / VV1500

157

STAVOSTROJ a.s.

549 01 Nové Město nad Metují tel: +42 0-441/476 111

fax: +420-441/ 470 405

Issued by:

Literature Department of

STA Stavostroj a.s.

Nové Město nad Metují

© 7 / 2002