STA MAINTENANCE AND SERVICE MANUAL VH 1000 CUMMINS engine ROLLER - PDF DOWNLOAD

ROLLER MAINTENANCE AND SERVICE MANUAL

VH 1000 CUMMINS engine Stavostroj, a.s. Nové Město nad Metují © 3 / 2002

Read the instruction mentioned in the manuals before manipulating with this device

This manual contains: I. Specification manual II. Driver’s manual III. Lubrication and Maintenance manual

Read the instruction mentioned in the manuals before manipulating with this device

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

SPECIFICATION MANUAL VH 1000

CONTENT:

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CONTENT: CONTENT:

Specification manual ................................................................................................................................................................ 5

1.1. Basic specification ........................................................................................................................................................... 6 1.1.1.

1.1.2.

1.1.3.

Machine description ............................................................................................................................................ 6 Area of use ........................................................................................................................................................... 6 Machine design ................................................................................................................................................... 7

1.2. Machine dimension scheme.............................................................................................................................................. 8 1.3. Technical data .............................................................................................................................................................. 10 1.3.1. Weights .............................................................................................................................................................. 10 1.3.2. Driving properties ............................................................................................................................................... 10 1.3.3. Vibration ............................................................................................................................................................. 10 1.3.4. Engine ................................................................................................................................................................ 11 1.3.5. The Brakes ......................................................................................................................................................... 11 1.3.6. Drive ................................................................................................................................................................... 11 1.3.7. Hydrostatic travel drive ...................................................................................................................................... 11 1.3.8. Hydrostatic vibration drive ................................................................................................................................. 12 1.3.9. Pump drive gearbox .......................................................................................................................................... 12 1.3.10. Hydraulic tank .................................................................................................................................................... 12 1.3.11. Tilting of the protective frame and the cab ........................................................................................................ 12 1.3.12. Fills ..................................................................................................................................................................... 12 1.3.13. Sprinkling ........................................................................................................................................................... 12 1.3.14. Electrical installation .......................................................................................................................................... 13 1.3.15. Safety device ...................................................................................................................................................... 13 1.3.16. Hygienic parameters ......................................................................................................................................... 13 1.3.17. Requirements for meeting the traffic regulations .............................................................................................. 14 1.3.18. Auxiliary devices ................................................................................................................................................ 14

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1.1. Basic specification 1.1.1.

Machine description

1.1.2.

Area of use

Tandem vibration rollers of the VH 1000 series are the machines with backbone frame, with two steel smooth carriages (alternatively non-divided for the VH 1000 or divided for the VH 1000A). Both carriages are hydrostaticaly driven, oscillatory and controllable, when each of these functions is independently selectable. Independent electrical-hydraulic carriages driving enables to set the extended track (crabing). The frame and cab conception enables the compaction close to the curbs or walls, when the swivel driver’s working place enables good control of the machine driving at both directions. The weight distribution to the front and rear carriage and also the equal centrifugal power of the front and rear vibrator prevent making the track in the compacted surface when using the crab drive. Ergonomically designed cab can be, including the protective frame ROPS, tilt by the hydraulic means for simplification the access to the drive aggregate.

The vibration rollers of the VH 1000 series are designed for compaction works of the middle and extended scope in the area of road engineering (building of highways and roads, airport areas) and ground engineering (industry areas and so on).

The rollers can be used for compaction of asphalt compositions to the layer thickness (after compaction) of 150 mm (5,9 in), hydraulic cemented compositions to the layer thickness of 250 mm (9,8 in), composed earth to the layer thickness of 400 mm (15,7 in), sand and gravel materials to the layer thickness of 500 mm (19,7 in).

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

The machines of these series are engineered for operations under the conditions due to the CSN IEC 721-2-1 (038900) : WT, WDr, MWDr (i.e. temper climate zone, hot dry zone or warm dry zone with limited temperature scope from –15 °C (5 °F) to +45 °C (113 °F) of ambient temperature.)

Fig. 1 – Machine’s production label

Fig. 2 – Placing of the production label

1

2

1 - Production label 2 - Machine frame number

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Specification manual 1.1.3.

Machine design

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.

To the machine can be mounted the individual auxiliary device, so called cutter, for cutting or re-compaction of the road constructional borders of asphalt compositions.

Please complete following data: Machine type (fig. 1, 2) .............................................................................

PIN (fig. 1, 2) ..............................................................................

Year of the production (fig. 1, 2) ..............................................................................

Engine type (fig. 3) ..............................................................................

Engine serial number (fig. 3) .............................................................................

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

Fig. 3 – Cummins engine serial number

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1.2. Machine dimension scheme Fig. 4 - Machine dimension scheme (with the cab and protective frame)

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D im en sion s

A

B1

B2

D

H1

H2

K1

K2

mm

3 06 0

1 84 0

2 16 5

1 30 0

3 09 6

2 42 4

4 40

8 87

in

1 20 ,5

7 2,4

8 5,2

5 1,2

1 21 ,9

9 5,4

1 7,2

3 4,9

D im en sion s

O

L1

R1

R2

S

W1

W2

mm

70

4 36 0

4 57 3

2 77 0

17

1 70 0

2 99 0

in

2 ,8

1 71 ,7

1 80

1 09 ,1

0 ,7

6 6,9

1 17 ,7

Specification manual Fig. 5 - Machine dimension scheme (with the cab and protective frame)

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1.3. Technical data 1.3.1.

Weights

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

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

10220 (22531) 5010 (11045) 5210 (11486) 29,5 (165,2) 30,6 (171,3)

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

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

10440 (23016) 5200 (11464) 5240 (11532) 30,6 (171,3) 30,8 (172,5)

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

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

11020 (24295) 5410 (11927) 5610 (11479) 31,8 (178) 33 (184,8)

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

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

11200 (24692) 5500 (12125) 5700 (12566) 32 (179,2) 33 (184,8)

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

1.3.2.

Driving properties

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

1.3.3.

0 - 11 (0-6,8) 6 25 42 32

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

hydrostatic two-level, circle undirected vibration 42/50 (2520/3000) 0,66/0,3 (0,026/0,012)* 0,8/0,37 (0,31/0,14) 106/69,6 (23830/15646)

Vibration

Drive Vibration driver Frequency Nominal amplitude Centrifugal power at one carriage

* - valid for sectional drum

10

km/h (MPH) ±° ±° % °

Specification manual 1.3.4.

Engine

Manufacturer Engine type Number of cylinders Perforation Stroke Stroke volume Engine output due to ISO 3046/1 Nominal revolutions Maximum torsional moment Specific fuel consumption under nominal output Fuel consumption under normal operation/hour Fuel filter

mm (in) mm (in) cm 3 (cu in) kW (HP) min-1 (RPM) Nm (ft lb) g/kWh l(gal US)

Oil filter Air filter Air filter insert Air filter securing insert Engine cooling set

Cummins B 3.9 - C 110 4 102 (4,0) 120 (4,72) 3900 (238) 82 (110) 2200 273 (201) 215 max. 8,5/2,25 Fleetguard FF 1280 Fleetguard FF 5052 Fleetguard LF 3345 Donaldson FPG 08-2503 Donaldson P77 2580 Donaldson P77-5302 liquid-cooled engine with the Nissens radiator 011297N2

Engine fulfills requirements of 97/68/EC, EPA, CARB.

1.3.5.

The Brakes

Working brake Parking and emergency brake

Brake-releasing pressure

1.3.6.

MPa (PSI)

Drive

Electro-hydraulic servo controls individual for front and rear carriage Hydro-generator of the servo control Servo control: Anti-slip control system Block of steerage Securing pressure Straight hydro engine Block of filtration

1.3.7.

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

MPa (PSI)

Gear double-pump of tandem order Sauer PNN 11 11 SSCH6 WAX Sauer S1X-26G2 AMP K 196C Hytos 880-0225 16 (2320) AXL Semily PHM 90/45-250 Hytos 880-0126

Hydrostatic travel drive

Hydro generator, piston, regulating with electric-hydraulic controlling of tandem order with hydro generator of the vibration The capacity per revolution Securing pressure Control Anti-slip control system Travel hydro engines ASC differential lock: Anti-slip control system Proportional valves

cm 3 (cu in/rev) MPa (PSI)

Sauer 90L 075 75 (4,57) 42 (6090) Sauer MCH Sauer S1X-26G2 AMP K 196C Sauer 60C 1048 H 100 Sauer S1X-26G2 AMP K 196C Sauer 507479

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1.3. Technical data 1.3.8.

Hydrostatic vibration drive

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

1.3.9.

cm 3 (cu in/rev) MPa (PSI)

Sauer 90L 042 42 (2,56) 35 (5075) Sauer 511260 Sauer 40 MMF 035

Pump drive gearbox

Pump drive gearbox

Sauer 41PVG 082 NEKENN-ADEM

1.3.10. Hydraulic tank Suction grid Thermoregulator

Hytos AS080-01 Wahler 7036-55

1.3.11. Tilting of the protective frame and the cab Hand pump

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

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

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

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

9,5 (2,5) 18,8 (4,96) 210 (55,5) 70 (18,5) 4x2 (4x0,53) 2,75 (0,72) 660 (174) 640 (169)

1.3.13. Sprinkling Water pump Electrical valve Water filter

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FLOJET 2100-130 12V EVPE 411032 MANN 954 0000041

Specification manual 1.3.14. Electrical installation Electric set voltage Accumulator – capacity Grounded

V Ah

12 135 - pole

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

Cab brace Automatic control of the servo-driving electrical parts

Battery disconnector

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

1.3.16. Hygienic parameters The machine with cab and closed windows : Noise : The acoustic pressure level influenting the driver when driving under vibrations : (measured due to the EN 11 202 on the sand base) The acoustic pressure level influenting the driver when driving without vibrations : (measured due to the EN 11 202 on the sand base) Guaranteed sound power level (measured due to the Directive 2000/14/EC, EN ISO 3744 on the elastic material, stopped machine with vibration) Vibrations : Vibrations acceleration nominal effective value : - transferred to the hands (measured due to the ISO 5349 when driving under the vibrations on the sand base) - transferred to the body (measured due to the EN 1032 when driving under the vibrations on the sand base)

LpA= 82 dB(A)

LpA= 73 dB(A) LWA = 109 dB(A)

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

The machine with cab and opened windows : Noise : The acoustic pressure level influenting the driver when driving under vibrations : (measured due to the EN 11 202 on the sand base) The acoustic pressure level influenting the driver when driving without vibrations : (measured due to the EN 11 202 on the sand base)

LpA=86 dB(A)

LpA=84 dB(A)

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1.3. Technical data 1.3.17. Requirements for meeting the traffic regulations The roller is not designed for travel on its own on public roads, so both its design and equipment don’t meet the promulgation for operations on traffic roads.

1.3.18. Auxiliary devices Protective frame The construction of protective frame ROPS meets the international standards EN 500-4.1995, SAE J 1040. APR 88, AS 2294.19, ISO 3471.1994 for maximum machine’s weight 12500 kg (27558 lb) Protective frame weight to the machine’s frame is fasten

kg (lb)

Tightening moment

Nm (in lb)

180 (397) 12 screws M 16x60, ČSN 21143.55 (8 G) 100 (884)

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

14

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

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