STA VH 1150 TANDEM VIBRATORY ROLLER - ENGINE CUMMINS TIER II OPERATING MANUAL - PDF DOWNLOAD

OPERATING MANUAL

VH 1150 TANDEM VIBRATORY ROLLER - ENGINE CUMMINS TIER II. STAVOSTROJ a.s., Nové Město nad Metují

© 10 / 2004

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VH 1150

This operating manual contains: I. Specification manual II. Operating instructions III. Air conditioner IV. Maintenance manual

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

This manual contains basic information on operating and maintaining the machine in general. For more extensive repairs it is necessary to follow the Shop Manual, or let an authorized service shop do the repair. Should the machine be damaged because of an incorrect procedure due to faulty maintenance or repair, the manufacturer may not accept this as a warranty claim.

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.

VH 1150

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VH 1150

! NOTICE !

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

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CONTENT CONTENT 1.

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

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

1.1. Basic specification ......................................................................................................................................................... 12 1.1.1.

1.1.2.

1.1.3.

Machine description .......................................................................................................................................... 12 Area of use ......................................................................................................................................................... 12 Machine design ................................................................................................................................................. 13

1.2. Machine dimension scheme ............................................................................................................................................ 14 1.3. Technical data .............................................................................................................................................................. 16 1.3.1. Weights .............................................................................................................................................................. 16 1.3.2. Driving properties ............................................................................................................................................... 16 1.3.3. Vibration ............................................................................................................................................................. 16 1.3.4. Engine ................................................................................................................................................................ 16 1.3.5. The Brakes ......................................................................................................................................................... 17 1.3.6. Drive ................................................................................................................................................................... 17 1.3.7. Hydrostatic travel drive ...................................................................................................................................... 17 1.3.8. Hydrostatic vibration drive ................................................................................................................................. 17 1.3.9. Pump drive gearbox .......................................................................................................................................... 17 1.3.10. Hydraulic tank .................................................................................................................................................... 17 1.3.11. Tilting of the protective frame and the cab ........................................................................................................ 18 1.3.12. Fills ..................................................................................................................................................................... 18 1.3.13. Sprinkling ........................................................................................................................................................... 18 1.3.14. Electrical installation .......................................................................................................................................... 18 1.3.15. Safety device ...................................................................................................................................................... 18 1.3.16. Hygienic parameters ......................................................................................................................................... 19 1.3.17. Requirements for meeting the traffic regulations .............................................................................................. 19 1.3.18. Auxiliary devices ................................................................................................................................................ 20

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VH 1150

SPECIFIKAČNÍ OPERATINGPŘÍRUČKA MANUAL 2.

OPERATING INSTRUCTIONS ........................................................................................................................................... 27

2.1. Description of the machine ............................................................................................................................................. 28 2.2. Acceptance and de-conservation of a new machine ......................................................................................................... 30 2.3. Main safety measures .................................................................................................................................................... 31 2.3.1. Safety measures during the machine operation .............................................................................................. 31 2.3.1.1. Prior to start of compacting works ..................................................................................................................... 31 2.3.1.2. Work in the dangerous area .............................................................................................................................. 31 2.3.1.3. Ensurance of safety measures by the owner ................................................................................................... 31 2.3.2. Using of protection frame ROPS ....................................................................................................................... 32 2.3.3. Requirements for the driver´s qualification ...................................................................................................... 32 2.3.4. Obligations of driver ........................................................................................................................................... 32 2.3.5. Prohibited activities ........................................................................................................................................... 34 2.3.6. Safety signs and marks applied on the machine ............................................................................................. 35

2.4. Environmental and hygienic principles ............................................................................................................................. 39 2.4.1.

2.4.2.

Hygienic principles ............................................................................................................................................ 39 Environmental principles ................................................................................................................................... 39

2.5. Preservation and storing of machines .............................................................................................................................. 40 2.5.1.

2.5.2.

Short-term preservation and storing for the period of 1 ÷ 2 months ............................................................... 40 Preservation and storing of the machine for a period longer than 2 months .................................................. 40

2.6. Disposal of the machine after finish of its service life ...................................................................................................... 41 2.7. Controls and monitors ..................................................................................................................................................... 42 2.8. Principal functions of the machine .................................................................................................................................. 74 2.8.1. Start-up of the engine ........................................................................................................................................ 74 2.8.2. Troubleshooting on the engine according to flashing codes ........................................................................... 77 2.8.3. Travel and reversing without vibrations ............................................................................................................ 78 2.8.4. Stopping the machine and engine .................................................................................................................... 80 2.8.5. Safety stopping .................................................................................................................................................. 80 2.8.6. Emergency stopping .......................................................................................................................................... 80 2.8.7. Dead parking of the machine ............................................................................................................................ 80 2.8.8. Emergenci control of the travel and driving ...................................................................................................... 82 2.8.9. Steering .............................................................................................................................................................. 84 2.8.9.1. Steering by the front drum ................................................................................................................................. 85 2.8.9.2. Steering by the rear drum .................................................................................................................................. 86 2.8.9.3. Steering by both drums ..................................................................................................................................... 87 2.8.9.4. Steering in the ”CRAB” mode - widened track ................................................................................................. 88 2.8.10. Travel and reversing with vibrations ................................................................................................................. 90 2.8.11. Driving with vibrations on compacted and hard material ................................................................................. 93 2.8.12. Compacting near buildings ............................................................................................................................... 93 2.8.13. Engine overload protection (ANTISTALL) ......................................................................................................... 94 2.8.14. Differential lock ................................................................................................................................................... 94 2.8.15. Sprinkling ........................................................................................................................................................... 96 2.8.16. Edge cutter and compacter - options ................................................................................................................ 98 2.8.17. Strassmayr spreader ......................................................................................................................................... 98 2.8.18. Lifting and lowering the cabin and the safety frame ....................................................................................... 100

2.9. Shifting the machine (transport) .................................................................................................................................... 103 2.9.1.

2.9.2.

2.9.3.

VH 1150

Towing .............................................................................................................................................................. 103 Loading the machine ....................................................................................................................................... 109 Transporting the machine on public roads ..................................................................................................... 110

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OBSAH: CONTENT: 2.10. Special conditions for using the machine ....................................................................................................................... 111 2.10.1. Operating the machine during initial run period ............................................................................................ 111 2.10.2. Operating the machine at higher temperature and humidity ......................................................................... 111 2.10.3. Operating the machine in higher altitude ....................................................................................................... 111 2.10.4. Operating the machine in extremely dusty conditions ................................................................................... 111

3.

AIR CONDITIONER ........................................................................................................................................................ 113 Descriptions ................................................................................................................................................................... 114 Main parts of air conditioning circuit ............................................................................................................................. 114 Operating air conditioner .............................................................................................................................................. 115 Maintenance .................................................................................................................................................................. 116 Troubleshooting ............................................................................................................................................................. 117 Safety .......................................................................................................................................................................... 117

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MAINTENANCE MANUAL ............................................................................................................................................... 119

4.1. Safety Standards at Maintenance .................................................................................................................................. 121 4.1.1. Safety during maintenance ............................................................................................................................. 121 4.1.2. Fire safety during changing contents ............................................................................................................. 121 4.1.3. Environmental and health regulations ........................................................................................................... 122 4.1.3.1. Health regulations ........................................................................................................................................... 122 4.1.3.2. Environmental principles ................................................................................................................................. 122

4.2. Specification of fluids ................................................................................................................................................... 123 4.2.1.

4.2.2.

4.2.3.

4.2.4.

4.2.5.

4.2.6.

4.2.7.

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Engine oil ......................................................................................................................................................... 123 Fuel ................................................................................................................................................................... 124 Coolant ............................................................................................................................................................. 124 Hydraulic oil ..................................................................................................................................................... 125 Gearbox oil ....................................................................................................................................................... 126 Lubricating grease ........................................................................................................................................... 126 Windshield washer liquid ................................................................................................................................ 126

VH 1150

SPECIFIKAČNÍ OPERATINGPŘÍRUČKA MANUAL 4.3. Fills

............................................................................................................................................................ 127

4.4. Lubrication chart ........................................................................................................................................................... 128 4.5. Individual operations of maintenance ............................................................................................................................. 129 After 20 hours of work or daily ...................................................................................................................................... 132 4.5.1. Checking, refilling oil in the engine ................................................................................................................ 132 4.5.2. Checking, refilling of engine coolant .............................................................................................................. 133 4.5.3. Check of cooling fan condition ........................................................................................................................ 134 4.5.4. Checking the engine belt ................................................................................................................................ 134 4.5.5. Cleaning the water separator con the fuel filter ............................................................................................. 135 4.5.6. Checking, cleaning of the fuel pre-cleaner .................................................................................................... 136 4.5.7. Crankcase breather tube ................................................................................................................................. 137 4.5.8. Check of air filter vacuum valve ...................................................................................................................... 137 4.5.9. Check of hydraulic oil filter sensor .................................................................................................................. 138 4.5.10. Check of the amount of fuel ............................................................................................................................. 139 4.5.11. Check of the amount of oil in the hydraulic circuit tank .................................................................................. 140 4.5.12. Refilling the sprinkle tank ................................................................................................................................ 141 4.5.13. Check of warning and checking devices ........................................................................................................ 142

After 250 hours of operation (after 3 months) ............................................................................................................... 143 4.5.14. Changing oil and oil filter ................................................................................................................................ 143 4.5.15. Checking the injection pump .......................................................................................................................... 146 4.5.16. Checking oil level in gearbox .......................................................................................................................... 146 4.5.17. Check of the cooling circuit of the engine ....................................................................................................... 147 4.5.18. Check of inlet piping in the engine ................................................................................................................. 148 4.5.19. Inspection of pressure switch of air cleaner ................................................................................................... 149 4.5.20. Check of batteries ............................................................................................................................................ 150 4.5.21. Lubricating ........................................................................................................................................................ 151 4.5.22. Cleaning of sprinkle filter ................................................................................................................................. 153

After 500 hours of operation (after 6 months) ............................................................................................................... 154 4.5.23. Engine fuel filter exchange .............................................................................................................................. 154 4.5.24. Check of coolant concentration ....................................................................................................................... 156

Every 1000 Hours or Once a Year .................................................................................................................................. 157 4.6.25. Checking and adjusting valve clearance ....................................................................................................... 157 4.6.26. Checking the engine belt ................................................................................................................................ 159 4.5.27. Gearbox oil change ......................................................................................................................................... 161 4.5.28. Check of the exhaust tract ............................................................................................................................... 162 4.5.29. Exchange of oil in the vibrator ......................................................................................................................... 163 4.5.30. Check of the damping system ......................................................................................................................... 164 4.5.31. Cleaning of water tanks ................................................................................................................................... 165

After 2000 hours of operation (every 2 years) ............................................................................................................... 166 4.5.32. Checking torsion vibration damper of the engine .......................................................................................... 166 4.5.33. Exchanging the engine cooling liquid ............................................................................................................ 167 4.5.34. Cleaning of the fuel tank .................................................................................................................................. 169 4.5.35. Exchange of oil and filter in the hydraulic system .......................................................................................... 170

Necessary maintenance ............................................................................................................................................... 173 4.5.36. Deaerating the fuel system .............................................................................................................................. 173 4.5.37. Cleaning of radiator ......................................................................................................................................... 174 4.5.38. Cleaning of air filter in the cabin ventilation ................................................................................................... 174 4.5.39. Cleaning and exchange of air filter element .................................................................................................. 175 4.5.40. Cleaning of scrapers ....................................................................................................................................... 178 4.5.41. Cleaning of the machine ................................................................................................................................. 179 4.5.42. Check of screwed joints tightening ................................................................................................................. 179

4.6. Appendixes

VH 1150

............................................................................................................................................................ 182

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VH 1150

1.

SPECIFICATION MANUAL

SPECIFICATION MANUAL VH 1150

VH 1150

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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 1150 series are the machines with backbone frame, with two steel smooth drums (alternatively non-divided for the VH 1150 or divided for the VH 1150 A). Both drums are hydrostaticaly driven, oscillatory and controllable, when each of these functions is independently selectable. Independent electrical-hydraulic drums 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 drum 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 1150 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

2 1

1 2

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- Production label - Machine frame number

VH 1150

SPECIFIKAČNÍ SPECIFICATIONPŘÍRUČKA 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.

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

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) .................................................................................

Fig. 3 – Cummins engine serial number

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1.2. Machine dimension scheme

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Dimensions

A

B1

B2

D

H1

H2

K1

K2

mm

3060

1890

1965

1300

3096

2424

440

887

in

120,5

74,4

77,4

51,2

121,9

95,4

17,2

34,9

Dimensions

L

O

R1

R2

S

W1

W2

-

mm

4360

70

4598

2745

17

1750

3040

-

in

171,7

2,8

181,0

108,1

0,7

68,9

119,7

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VH 1150

SPECIFIKAČNÍ SPECIFICATIONPŘÍRUČKA MANUAL

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1.3. Technical data 1.3.1.

Weights

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

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

11550 (25463) 5760 (12698) 5790 (12764) 32,9 (184,3) 33,1 (185,4)

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

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

12350 (27227) 6140 (13536) 6210 (13691) 35,1 (196,6) 35,5 (198,8)

The weight data valid for VH 1150 and 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 drum oscillation at the vertical level Turning of both drums at the horizontal level Theoretical machine’s gradeability Side static stability

1.3.3.

km/h (MPH) ±° ±° % °

0 - 11 (0-6,8) 6 25 40 35

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 drum * - valid for sectional drum

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

mm (in) mm (in) cm3 (cu in) kW (HP) min -1 (RPM) Nm (ft lb) g/kWh l (gal US)

Cummins QSB 4.5-30-T-C110 4 102 (4,0) 138 (5,43) 4500 (275) 82 (110) 2200 414 (305) 215 max. 8,5/2,25 Fleetguard FS 19616 Fleetguard LF 3805 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.

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VH 1150

SPECIFIKAČNÍ SPECIFICATIONPŘÍRUČKA MANUAL 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 drum 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.

Sauer S1X-26G2 AMP K 196C Hytos 880-0225 16 (2320) AXL Semily PHM 90/45-250 Hytos 880-0126

cm3 (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

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.

MPa (PSI)

Gear double-pump of tandem order Sauer PNN 11 11 SSCH6 WAX

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

1.3.8.

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

cm3 (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

VH 1150

Hytos AS080-01 Wahler 7036-55

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1.3. Technical Technické data údaje 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 drum Gearbox pump driven 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) l (gal US)

9,5 (2,5) 18,8 (4,96) 210 (55,5) 70 (18,5) 4x2 (4x0,53) 0,8 (0,21) 2,75 (0,72) 660 (174) 640 (169)

1.3.13. Sprinkling Water pump Electrical valve Water filter

SHURFLO 8000-043-235, 12V EVPE 411032 SPRATING SYSTEMS 5358520080

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

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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

VH 1150

SPECIFIKAČNÍ SPECIFICATIONPŘÍRUČKA MANUAL 1.3.16. Hygienic parameters The machine with cab and closed windows : Noise : The acoustic pressure level influenting the driver: (measured due to the EN 11 204 and prEN 500-4:2001 on the elastic material, stopped machine with vibration) Guaranteed sound power level (measured due to the Directive 2000/14/EC, EN ISO 3744 on the elastic material, stopped machine with vibration) Vibrations : Vibrations acceleration nominal equivale value : - transferred to the body (measured due to the EN 1032 when driving under the vibrations on the sand base) - transferred to the hands (measured due to the ISO 5349 when driving under the vibrations on the sand base)

LpA= 79 dB(A)

LWA = 109 dB(A)

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

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

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

LpA=85 dB(A)

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.

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1.3. Technical Technické data údaje 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 screwsM 16x60, CSN 21143.55 (8G) 100 (884)

Edge cutter 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

20

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 CSN 021101.55 80 (708)

VH 1150

SPECIFIKAČNÍ SPECIFICATIONPŘÍRUČKA MANUAL Chip spreader Strasmayer working width capacity weights

mm (in) l (gal US) kg (lb)

typ BS-WA 1900 1900 (74,8) 1000 (264) 420 (925,9)

Infra thermometer Serves for bitumen surface temperature measurement.

VH 1150

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1.3. Technical Technické data údaje Additional lights on the frame machine Serves for lighting drums nad places below front frame of the machine.

Right side of the machine

Left side of the machine

Places below front frame of the machine

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VH 1150

SPECIFIKAČNÍ SPECIFICATIONPŘÍRUČKA MANUAL Additional lights on the cabin

Back-up alarm Serves for cautionary signalling during stern foremost machine.

Warning beacom

VH 1150

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Notes:

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VH 1150

SPECIFIKAČNÍ SPECIFICATIONPŘÍRUČKA MANUAL

Notes:

VH 1150

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26

VH 1150

2.

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS VH 1150 (CUMMINS)

VH 1150

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2.1. Description of the machine

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VH 1150

OPERATING INSTRUCTIONS Tandem roller VH 1150 Legend: 1

Frame

2

Front and rear stirrups

3

Front and rear drum

4

Engine

5

Hydro-generator of travel

6

Hydro-generator of vibration

7

Servo-control hydro-generator

8

Engine and hydraulic oil combined cooler

9

Equalizing tank of coolant

10

Engine air suction filter

11

Gas outlet

12

Fuel tank

13

Hydraulic oil tank

14

Sprinkling water tank, front, rear

15

Cabin

16

Engine hood, left, right

17

Sprinkling of tyre treads

18

Scrapers of tyre treads

19

Accumulator

20

Protective frame ROPS

21

Travel hydraulic motor

22

Vibration hydraulic motor

23

Heating (air conditioning)

VH 1150

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2.2. Acceptance and de-conservation of a new machine Prior to putting a new machine into operation:

• Check the machine according to the shipping documentation

• Check the machine for damage of some parts due to the transport and whether some parts are missing

• Inform the forwarder on any failures/deficiencies • Prior to re-start of operation carry out the overall deconservation of the machine

• Wash the machine with conservation agents with the help of high-pressure stream of hot water containing admixtures of common grease removers. Only exceptionally you can use kerosene or fuel oil providing the environmental principles are observed.

De-conserve and wash the machine only in places having sump pits/intercepting traps for retaining the rinsing water and de-conservation agents.

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VH 1150

2.3. Main safety measures 2.3.1.

Safety measures during the machine operation

Safety measures specified in individual chapters of the Technical Specifications supplied with the machine must be added with safety measures valid in the relevant country of using the machine on the working place considering organization of the work, working process and the personnel.

2.3.1.1. Prior to start of compacting works The contractor of building works (operator/owner of the machine) is obliged to issue instructions for drivers and maintenance prior to start of compacting works. Such instructions shall include requirements necessary to ensure safety of works during the machine operation.

It is necessary to verify and mark as follows: -

engineering services lines underground areas (direction, depth) infiltration or sudden escape of harmful substances load-bearing capacity of the terrain, travel plane slope - Other different obstacles including their removal.

The contractor must acquaint the machine driver carrying out the earth works with the above items.

He must specify technological procedures the part of which shall be the working procedure for particular working activity that besides others shall stipulate as follows: -

precautions during works under extraordinary conditions (work in protection zones, extreme slopes, etc.)

-

precautions for the event of exposure to atmospheric elements

-

requirements for performance of works at observing the principles of work safety

-

technical and organizational measures to provide for safety of employees, working places and surroundings.

OPERATING INSTRUCTIONS 2.3.1.3. Ensurance of safety measures by the owner • The owner must ensure that the machine is operated only in such conditions and only for such purposes to which the machine is technically capable according to conditions specified by the manufacturer and relevant standards.

• He must ensure that the roller is used only in such manner and on such working places without a danger to damage the close structures, sections, etc.

• He must ensure a regular inspection of operation and technical conditions, regular maintenance of the machine in intervals specified in the manuals for greasing and maintenance work. In case the technical condition of the machine does not meet the requirements to such extent it endangers safety of operation, people and property or it causes a damage and impairment to the environment, the machine must be put out of service until the defects are removed.

• He must specify who is allowed to carry out operation, maintenance and repairs of the machine as well as what activities can be carried out during the operation, maintenance and repair of the machine.

• The person (driver) who drives the machine and each person carrying out maintenance and repair of the machine must be acquainted with instructions specified in the operation manual of the machine.

• He must ensure that the fire extinguisher is checked on regular basis.

• He must ensure that ”Operation manual of the machine” and operational book are kept on specified place to be at disposal for the driver all the time.

• He must assign a workman for permanent supervision over the machine work during its operation on public roads and especially he is obliged to issue instructions to ensure safety of works.

• He must ensure that dangerous substances (such as fuel, oils, coolant, break fluid, etc. must be removed from places of leakage according to their nature to prevent from their adverse impact to the environment, safety of operation and health of people.

He is obligatory to familiarize the machine drivers with the technological procedures in a demonstrable manner.

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

2.3.1.2. Work in the dangerous area Observe safety notices - danger of personal injury.

Any damage of engineering technical services must be immediately communicated to their owner, and at the same time the precautions preventing entry of unauthorized persons to the endangered area must be carried out.

Follow ecological regulations.

The workman must not work alone on such working place where there is not any another workman in view or within calling distance that if necessary would be able to provide help or to call for help in case the efficient form of control or connection is not ensured.

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! NOTICE !

Observe all advice.

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2.3. Main safety measures 2.3.2.

Using of protection frame ROPS

The following precautions shall be observed while the protection frame ROPS is used:

• The driver’s seat safety belts must be fastened during the work with a machine.

• The machine frame must not be damaged (broken,

b) assigned by the building works contractor for operation (maintenance), trained and practices in a provable manner and/or having the professional qualification to operate and drive the roller in compliance with special provisions (machine operator licence, etc.).

• The machine driver must be trained and examined from provisions related to safety of works once every two years, at least.

bent, etc.) in the place of connection.

• The ROPS frame itself must not show the marks from corrosion, damage through cracks or splits.

• ROPS frame must not be loose during the machine operation.

• All bolted connections must meet the specifications requirements and must be tightened to the moment specified.

• Bolts and nuts must not be damaged, distorted and they must not show the marks from corrosion.

• None additional modifications can be carried out on the ROPS frame without the approval of the manufacturer because they can result in decrease of its strength (e.g. openings, welding, etc.).

• Weight of the machine with the protective frame must not exceed the permitted weight for which ROPS was approved.

2.3.4.

Obligations of driver

• Prior to start of the machine operation, the driver is obliged to study instructions stated in the documentation supplied together with the machine, especially with safety precautions. The driver is obliged to observe such instructions very strictly. The same above mentioned is valid also for the staff authorized for maintenance, adjustment and repairs of the machine.

In case you do not understand some of parts of manuals, contact the nearest dealer or the manufacturer.

• The driver must not drive a roller, unless he is fully familiarized with all functions of the machine, working and operating elements and unless he precisely knows how to operate the machine.

• The driver is obliged to follow the safety signs located on the machine and keep them legible.

• Prior to start of works, the driver is obliged to acquaint

2.3.3.

Requirements for the driver´s qualification

• Only a driver having been trained according to ISO 7130 and other local and national instructions and standards specified for drivers of such group of machines, is allowed to operate the roller.

• Only such person is allowed to drive a machine without the certificate who learns to drive a roller under direct and permanent supervision of a professional teacher or trainer with a purpose to acquire the practice with an owner ´s approval.

• The Certificate (License) holder is obliged to take a proper care of such Certificate and to submit it to inspection organs when requested to do so.

• The Certificate (License) holder must not put down any enters, changes or corrections in the Certificate.

• In case the holder lost the Certificate, he is obliged to advise the issuer on the loss immediately.

• The roller can be driven by the workman who is physically and mentally capable to drive a roller, who is older than 18 years, and who is as follows: a) entrusted by the machine manufacturer to assemble, test and demonstrate the machine, eventually to train drivers, whereas he must be acquainted with instructions of work safety valid on the working place or

32

himself with the working place surrounding, it means with obstacles, slopes, engineering services, necessary types of the working place protection regarding the surrounding (noise, etc.).

• In case the driver finds out a hazard to health, danger to life of people, property or failure during the technical equipment breakdown, and/or in case he finds out indications of above mentioned during operation, he must, providing he is not able to remove the danger by himself, interrupt the work and secure the machine against unwanted start up. In addition, he must inform the responsible workman on above mentioned and depending the possibilities to notify all people involved who might be endangered.

• Prior to the machine operation start, the driver is obliged to acquaint himself with records and operational deviations found out during the previous working shift.

• The driver is obliged prior to start of works, to inspect the machine and accessories, to check the actuating elements, communication and safety equipment, whether their functions meet the requirements according to the manual. In case he finds out the defect that might endanger the safety of works and he himself is not able to remove such defect, he must not put the machine into operation and he must inform the responsible workman on a defect.

• In case the driver finds out the defect during operation, he must stop the machine immediately and secure it safely against unwanted start up.

VH 1150

OPERATING INSTRUCTIONS • During the operation, the driver is obliged to monitor

• The driver is obliged to use personal protective aids

the machine run and enter the defects found out, if any, into the operational book (log book).

such as working clothes (must not be too loose and damaged), working shoes; and hair shall be protected with the help of suitable headgear. If a driver works in the machine without a cabin, or with the windows open, he is obliged to use the protective ear-plugs 90dB. During maintenance works (greasing/lubrication, replenishment, replacement of working utilities) he must protect his hands with suitable protective gloves.

• The driver must maintain the operational book, which is defined for records on the machine acceptance and take-over carried out between drivers, for defects and repairs done during operation and keeping the serious events during the working shift on files.

• Prior to putting the engine into service, the actuating elements must be in zero position and there cannot be any people within the dangerous reach of the machine.

• The driver must notify the others each time the machine is put into operation with the help of sound or light signal always prior to the machine engine start.

• Prior to the machine operation start, the driver must check the function of brakes and its control.

• The operator is allowed to put the machine into operation after the warning sign not earlier than after all employees leave the endangered area. At not clearly arranged working places, the machine can be put into operation not earlier than after expiration of the period of time needed for people to leave the endangered area.

• The driver is obliged to keep up the specified equipment and accessories of the machine.

• The driver is obliged to keep the driver ´s standing place, the footboard and stepping areas clean.

• He is obliged prior to lifting the cabin and the protective frame off, to check for sufficient space needed for lifting up and for existence of electrical supplies. Prior to dropping the cabin and the protective frame, check whether such activity does not endanger anybody.

• Secure the cabin lifted off with the mechanical brace rod.

• In case the machine gets to the contact with high voltage, the driver is obliged to follow the principles as follows:

• During the machine operation it is necessary to follow

-

the safety instructions and not to carry out any activity that might endanger the work safety. The driver must be fully engaged in driving the machine.

-

• The driver must abide by technological procedures of works or the responsible workman’s instructions.

• During the movement of the machine along the working place, the driving speed must be adapted to the terrain, works carried out and to weather conditions. It is necessary to follow the passing clearance all the time to avoid collision with any obstacle.

-

to aim to abandon the dangerous area with the machine not to leave the driver ´s standing place/operating position to warn the others not to approach and neither touch the machine.

• To keep the machine free of oil contaminants and inflammable materials.

• In case the driver finishes or interrupts the machine operation and he leaves the machine, he must carry out safety measures against an unauthorized use of the machine and undesired start up. He must to take the key out from the switching box, turn in the parking brake switch, disconnect the electrical wiring with the help of the disconnecter, to lock the cabin or the instrument board cover at the machine without a cabin.

• After the run of machine is finished, the machine must be laid up on a suitable standing place (a flat, bearing area) to avoid danger of the machine stability danger to the machine through falling objects (rocks). In addition it is necessary to ensure that the machine does not interfere with traffic roads, and the machine must not be in a place with a danger of natural disasters of any kind (such as floods, landslides, etc.).

• In case the machine is stopped on over-ground roads, it is necessary to carry out measures according to the provisions valid on over-ground roads.

• After the work with the machine is finished, it is necessary to record all failures, damages and repairs carried out into the daily log (operational book). When the drivers change their turns in shifts, the driver finishing his shift must draw attention of the alternating driver to facts found out.

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2.3. Main safety measures 2.3.5.

Prohibited activities

The following is prohibited:

• to operate the machine after consuming alcohol and drugs

• to operate the machine if its service might endanger its

• to operate the machine under poor visibility and at night, if the machine working area and the working place is not sufficiently lit

• to leave the driver ´s place of the machine while the machine is running

• to get on and out during a drive, to jump down from the machine

technical condition, safety ( life and health of people) of premises and things, and/or traffic and its continuity

• to sit on external parts of the machine during a drive

• to put the machine into service and to operate the

• to abandon the unsecured machine - to move away

machine if within its dangerous reach there are other people – with exception of the teacher training the driver

• to put safety, protection and securing systems out of

• to put the machine into operation and to operate the

• to operate the machine leaking the oil, fuel, coolant

machine if some of its safety devices is dismantled or damaged ( emergency brake, working brake, horn, etc.)

• to travel and compact in such inclinations in which the stability of the machine might be failed (upturn). The static stability of the machine is reduced by dynamic actions of a drive!

• to travel and compact in such inclinations in which there might be a danger of tearing the rock away with a machine or loss of adhesion and uncontrolled skid

• to operate the machine in a different manner from that one specified in the manual for drivers

• to travel and compact according to the sub-soil loadbearing capacity within such distance from the edge of slopes or cuts in which might be a danger of material fall or collapse of the shoulder with the machine

• to travel and compact with vibration within such distan-

from the machine without preventing its misuse service and to change their parameters and other charges/cartridges

• to start up the engine in a different way from that one specified in the manual for drivers

• to place subjects (tools, instruments) on the driver ´s operating position except things for his personal use

• to place the materials and other subjects on the machine

• to remove dirt from the machine while it is running • to carry out maintenance, cleaning and repairs if the machine is not secured against unwanted movement and accidental start up and if contact of the workman with moving parts of the machine is not excluded

• to touch moving parts of the machine with the body or tools held in hands

• to smoke and handle the open fire while inspecting

ce from walls, cuts and slopes where there might be a danger of their collapse and burying the machine

and pumping the fuels, replacement and replenishment of the oils, greasing of the machine and while checking the accumulator or its replenishment

• to compact with vibration within such distance from

• to convey rags saturated from inflammable materials

buildings, premises and equipment in which there might be a danger of their damage due vibration transmission

• to operate the machine if the driver ´s operating posi-

and inflammable liquids in unbound/loose vessels on the machine (in the engine space, cabin)

• to leave the engine run in enclosed areas.

tion is not properly fastened

• to operate the machine if some of its side covers of the generating set space is opened

• to replace or transport the people on the machine • to operate the machine within the dangerous reach of which there are other machines or transport vehicles with exception of these ones that co-work together with the machine

• to work with the machine on place which cannot be seen from the operating position of a driver and where might be a danger to people, property, if a safety of work is not ensured in other way, e.g. on base of signaling by properly trained person

• to operate the machine in the protective zone of electrical wiring and transformer stations

• to run across electric cables if they are not properly protected against mechanical damage

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VH 1150

OPERATING INSTRUCTIONS 2.3.6.

VH 1150

Safety signs and marks applied on the machine

35

2.3. Main safety measures Safety signs and marks applied on the machine 1.

Danger of gripping

Do not enter places marked like this! (Marking on the machine frame above the front rear drum from both sides)

2.

Danger of burn

Do no touch hot parts of the machine unless you made sure they are sufficiently cold. Do not open the cooler plug neither do not let cartridges as long as they are hot. There is a danger of stain and burn - (Marking on the exhaust pipe cover)

3.

Danger of injury

Do not touch rotating parts while the machine is running. There is a danger of injury and rolling up - (Marking on the cooler frame)

4.

Adjust while machine is idle

Do not adjust and maintain while the engine is running. There is a danger of injury and attaching to rotating parts of the machine (Marking on the instrument board)

5.

Emergency exit

(Marking on the door windows)

6.

Fasten the belt

Prior to putting the machine into operation, fasten the seat safety belt. (Marking on the instrument board).

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VH 1150

OPERATING INSTRUCTIONS

7.

Read the operation manual

Prior to start of the machine, study carefully safety measures and ways of the machine control according to the manual supplied with the machine. (Marking on the instrument board).

8.

Securing of the cabin

Carry out after the cabin is lifted off! (Marking on the left side of the frame below the cabin)

9.

First-aid kit box

Place for first-aid kit box keeping. Use in case of injury - (The case on the rear wall of the cabin)

10. Manual

Prior to first start-up of the machine, study carefully safety measures and ways of the machine control according to the manual supplied with the machine. (The case on the rear side of the seat)

11. Disconnect the alternator

Prior to welding on the machine disconnect the alternator! (Marking on the instrument board)

12. Machine height

While the machine is running, pay attention on the machine height in places with lower clearance (On the left side of the frame at the front below the cabin)

VH 1150

37

2.3. Main safety measures 13. Suspension scheme

To suspend the machine, use rigging means according to the scheme - (On the left side of the frame at the front below the cabin)

15. Suspension places

To suspend the machine, use only the specified rigging places - (On the left and right side of the machine above rear and front drum)

16. Pushbutton STOP

In case of serious failure of the machine. By pressing the pushbutton with this symbol you stop the engine and all functions of the machine - (On the left control panel next to the seat)

17. Danger zone

Do not touch rotating parts while the machine is edge cutter and compacter running. There is a danger of injurg and rolling up.

(Marking on the right side of the front stirrup.) (Option equipment according to the customer‘s wish.)

18. Noise

Decal 18 placed on the left of rear frame. (Guaranteed sound power level)

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VH 1150

2.4. Environmental and hygienic principles During operation and storing the machines, the owner is obliged to follow the general principles of health and environment protection as well as laws, notices and provisions related to this point at issue and valid within the territory of machine application.

2.4.1.

Hygienic principles

• Petroleum products, cooling systems cartridges, cartridges of accumulators, cleaning and preservative agents, painting materials including paint thinners, are harmful materials to health. Workmen getting into contact with such above mentioned products during operation and maintenance, are obliged to adhere to general principles of health protection and follow the safety and hygienic directions of these products ´ manufacturers.

In particular we draw your attention to the following: -

protection of eyes and skin during work with accumulators

-

protection of the skin during work with petroleum products, coolants, cleaning and preservative agents, painting systems

-

carefully wash your hands after the works are completed and before the meal, treat your hands with a suitable reparation cream

-

follow the operation manual of the machine during works with cooling systems.

OPERATING INSTRUCTIONS

2.4.2.

Environmental principles

• Cartridges of the machine individual systems and some of its parts become after their putting out of service the waste with hazardous properties acting adversely against the environment.

This category of waste products includes especially as follows: -

organic and synthetic greasing materials, oils and fuels

-

coolants

-

cartridges of accumulators and accumulators themselves

-

cartridges of air-conditioning systems

-

cleaning and preservative agents

-

any removed/dismantled filters and filtration cartridges/elements

-

any used and discarded hydraulic and fuel hoses, rubber-metals and other elements of the machine contaminated with the above mentioned products.

It is necessary to treat the above mentioned materials and parts after their discard in accordance with relevant national regulations valid for protection of individual parts of the environment and in compliance with regulations of health protection.

• Always store petroleum products, cooling systems cartridges, cartridges of accumulators, cleaning and preservative agents and painting materials including organic paint thinners and cleaning and preservative agents as well in original properly marked packages.

Never allow storing of the above materials in unmarked bottles and other vessels with respect to danger of their mistaking. In particular, it is very dangerous to confuse these products with drinks and food-staffs.

• If by accident the skin, eyes or mucous membrane is stained or if you breathe in the vapours of such products, apply immediately the principles of the first aid. If you accidentally eat such products, seek for prompt medical attention without delay.

VH 1150

39

2.5. Preservation and storing of machines 2.5.1.

Short-term preservation and storing for the period of 1 ÷ 2 months

Wash and clean the entire machine very carefully. Prior to the machine shut-down before its preservation and storing, heat the engine while running to the operating temperature of 85 °C (185 °F). The machine shall be shutdown on a solid, even area on a safe place without any danger to the machine through natural disasters such as floods, landslip, fire, etc.

Furthermore carry out as follows: ·

touch-up paints (in places of damaged coating)

·

grease any lubrication points, cable hoses, hinges of actuating devices, etc.

·

check whether water fillers of sprinkling are drained

·

make sure whether the coolant has the required frost-resistant properties

·

verify the condition of accumulators charging, and/ or let them recharge

·

treat the chromium plated areas of piston rods with preservative grease

·

we recommend to protect the machine against corrosion with preservative agent spray/coat (applied via spraying), especially in places endangered with corrosion formation.

In case you treated the machine as above described, it is not necessary to prepare the machine in any special manner prior to its next re-commencement.

2.5.2.

Preservation and storing of the machine for a period longer than 2 months

The same principles are valid for a shut-down of the machine as for short-term preservation.

IN addition we recommend as follows:

• dismantle accumulators, check their condition and fully charge them and place in a cold dry room, and charge them up on regular basis every 3 months

• protect rubber elements with the help of special preservative coating

• preserve the machine with the help preservative agent spray application especially in places of possible corrosion formation

• blind the suction and exhaust of the engine with double PE foil and carefully tighten with the help of sealing tape

• protect headlamps, exterior rear mirrors and other elements of external electrical wiring with the help of preservative agent spray application and wrap up to the PE foil.

• preserve the engine according to the manufacturer ´s manual – place a visible mark that the engine is preserved In six months we recommend to inspect the preservation status and to renovate if needed.

Prior to re-commencement of the machine, wash it with preservative agents with the help of high-pressure stream of hot water with admixture of common grease removers, and only exceptionally apply the kerosene or crude oil provided that the environmental principles are observed.

Never start a motor during storage!

De-preserve and wash a machine only in places provided with intercepting traps to retain the rinsing water and de-preservation agents.

In case the machine is stored in field conditions, check whether the place is not exposed to the danger of flooding due to floods, landslip or whether the area is not endangered with some other type of hazard!!!

40

VH 1150

2.6. Disposal of the machine after finish of its service life OPERATING INSTRUCTIONS At disposal of the machine after finish of its service life, the owner is obliged to comply with national regulations and laws on wastes and protection of environment. Therefore we recommend in such cases to contact the following: ·

professional specialized companies engaged in such activities and having the relevant certificate

·

the manufacturers of STA or contracting service organizations authorized by him.

The manufacturer is not responsible for damages to health of owners neither for damages to the environment in events of failing to comply with above mentioned hygienic and ecological principles.

VH 1150

41

2.7. Controls and monitors Table of applied symbols:

42

VH 1150

OPERATING INSTRUCTIONS Legend: 2 - Gear 3 - Operation speed preselector 4 - Smooth start and stop mode switch 5 - CRAB mode switch 7 - Edge cutter control switch - (OPTIONAL equipment - on customer’s request) 9 - Drum control mode switch 10 - Emergency brake stop button 11 - Switch off and on parking brake 12 - Horn switch 13 - Switch of direction indicators 14 - Infra thermometer - (OPTIONAL equipment - on customer’s request) 15 - Electronically operated gas actuator / control 18 - Fuel gauge 19 - Hydraulic oil thermometer 20 - ECM connector of the engine (Electronic Control Module) 21 - Engine-hour counter 22 - Vibration amplitude selector 25 - Vibrating drum selector switch 30 - Engine diagnostics switch (ECM) 31 - Troubleshooting switch 32 - Pilot lamp of STOP engine - red 33 - Pilot lamp - engine warning - yellow 34 - Pilot lamp - water in fuel - blue 35 - Maintenance pilot lamp 36 - Steering failure (front drum) warning light 37 - Steering failure (rear drum) warning light 38 - Gear neutral pilot lamp 39 - Pilot lamp of direction indicators 40 - Air filter fouling pilot lamp 41 - Charging pilot lamp 42 - Pilot lamp of brake 43 - Pilot lamp for smooth start + stop mode 44 - Switch + pilot lamp of headlights 45 - Switch + pilot lamp of tail-lights 46 - Switch + pilot lamp of warning lights 47 - Switch + pilot lamp of additional lights (on drum stirrups and below front frame) - (OPTION) 48 - Hazard beacon switch + pilot lamp - (OPTIONAL equipment - on customer’s request) 49 - On - off vibration mode switch 50 - Switch + pilot lamp for motor overload prevention mode 51 - Differential lock switch + pilot lamp 52 - Sprinkling switch + pilot lamp 53 - Sprinkling pilot lamp - front drum 54 - Sprinkling pilot lamp - rear drum 55 - Sprinkling potentiometer 56 - Air-conditioning switch + pilot lamp - (OPTION equipment according to the customer ´s wish) 57 - Fan switch 58 - Heating regulator 59 - Air circulation flap valve controller 60 - Air-conditioning control 61 - Emergency control of travel and driving 64-67 - Connectors 69 - Seat traverse 70 - Document box 72 - Battery disconnecter 73 - Head wiper switch 74 - Tail wiper switch 75 - Sprayer switch 76 - Cabin additional lights switch - (OPTION equipment according to the customer ´s wish)

VH 1150

43

2.7. Controls and monitors

44

VH 1150

OPERATING INSTRUCTIONS A lay-out diagram of particular controls and pilot components on the dashboard and control panels of the driver’s seat: Legend:

1 - Steering wheel 2 - Gear 3 - Operation speed preselector 4 - Smooth start and stop mode switch 5 - CRAB mode activation switch 6 - Rear drum setting buttons in the CRAB mode 7 - Edge cutter and compacter control switch - (OPTIONAL equipment - on customer’s request) 8 - Vibration on, off switch 9 - Drum control mode switch 10 - Stop button - emergency brake 11 - Switch off and on parking brake 12 - Horn switch 13 - Switch of direction indicators 14 - Infra thermometer - (OPTIONAL equipment - on customer’s request) 15 - Electronically operated gas actuator / control 16 - Multifunctional display 17 - Switch box 18 - Fuel gauge 19 - Hydraulic oil thermometer 20 - ECM connector of the engine (Electronic Control Module) 21 - Engine-hour counter 22 - Vibration amplitude selector 23 - Pilot lamp for vibration on - low amplitude 24 - Pilot lamp for vibration on - high amplitude 25 - Vibrating drum selector switch 30 - Engine diagnostics switch (ECM) 31 - Troubleshooting switch 32 - Pilot lamp of STOP engine - red 33 - Pilot lamp - engine warning - yellow 34 - Pilot lamp - water in fuel - blue 35 - Maintenance pilot lamp 36 - Steering failure (front drum) warning light 37 - Steering failure (rear drum) warning light 38 - Gear neutral pilot lamp 39 - Pilot lamp of direction indicators 40 - Air filter fouling pilot lamp 41 - Charging pilot lamp 42 - Pilot lamp of brake 43 - Pilot lamp for smooth start + stop mode 44 - Switch + pilot lamp of headlights 45 - Switch + pilot lamp of tail-lights 46 - Switch + pilot lamp of warning lights

VH 1150

47 - Switch + pilot lamp of additional lights (on drum stirrups and below front frame) - (OPTIONAL equipment - on customer’s request) 48 - Hazard beacon switch + pilot lamp - (OPTIONAL equipment - on customer’s request) 49 - On - off vibration mode switch 50 - Switch + pilot lamp for motor overload prevention mode 51 - ASC differential lock switch + pilot lamp 52 - Sprinkling switch + pilot lamp 53 - Sprinkling pilot lamp - front drum 54 - Sprinkling pilot lamp - rear drum 55 - Sprinkling potentiometer 56 - Air-conditioning switch - (OPTION equipment according to the customer ´s wish) 57 - Fan switch 58 - Heating regulator 59 - Air circulation flap valve controller 60 - Air-conditioning control 61 - Fuse box 62 - Mounting lamp socket 63 - Emergency control of travel and driving 64 - Connector for drive control electronic unit 65 - Connector for control electronic unit 66 - Connector for ASC control electronic unit 67 - Connector for CAN BUS network 68 - Seat 69 - Seat traverse controller 70 - Document box

45

2.7. Controls and monitors

Steering wheel (1) Serves for machine direction steering. The drum turning angle is signalled on display (16).

When turning a steering wheel there is no extreme position. The steering wheel can be turned to choose the drive direction (drum steering) without limitation. While steering, follow the angle of drum turning through a sight hole in the floor or on display (16).

Operation speed preselector (3) The potentiometer serves for a continuous selection of the speed mode ranging from a low speed ”Turtle” to a higher speed ”Hare”. When setting the preselector (3) of operation speed in an arbitrary position, the vibration function can be activated at all times.

Turn the steering wheel with sensibility!

Gear (2) Serves for setting the drive direction and speed and at the same time does duty as a service brake of the machine.

In the lever handle there are positioned a vibration on - off switch and press buttons for setting the rear drum in the CRAB mode.

If need for an immediate stop of the roller arise, the machine can forthwith be stopped by fast changing the gears (2) through neutral into an opposite position (drive direction) within 1 second - the engine will remain running. A drive is first reactivated slipping the gears (2) into neutral and then in the selected drive direction.

46

VH 1150

OPERATING INSTRUCTIONS

Rear drum setting buttons in the CRAB mode (6) Smooth start and stop mode switch (4) Serves for setting a smooth, continuous machine start and stop in a reverse. Forming of ”waves” on consolidated surface is thus prevented. The function is activated pressing the switch (4).

In the selected smooth start and stop mode there is a longer roller stop in a reverse.

The switch pilot lamp signals the function.

The rear drum is set up in the ”CRABBING” mode by press buttons (6) on the gear operating lever (2). The rear drum turns left by pressing the left button on the gear operating lever (2) and right by pressing the right button. The angles of drum deflexion right or left can arbitrarily be set from 0° to 25°. The angle of drum adjustment is checked on display (16).

If need for an immediate stop of the roller arise, the machine forthwith stops by fast changing the gears (2) through ”0” into an opposite position (drive direction) within 1 second - the motor will remain running - the set mode function will be cut off. The function is reactivated by slipping the gears (2) into ”0” and pressing the button (4).

CRAB mode switch (5) The mode of drums set by a switch (9) is cancelled by switching on the CRAB mode (5) and the rear drum is automatically set in position ”0”. A ”CRABBING” mode control is activated.

The rear drum is automatically set in position pre-selected on switch (9) by switching off the CRAB mode (5). The ”CRABBING” mode control is deactivated.

VH 1150

47

2.7. Controls and monitors

Switch for edge cutter and compacter control (7) (OPTIONAL equipment - on customer’s request) The control switch (7) is fitted with two positions as indicated - operating (downward), transport (upward).

The hydraulically operated arm is set in working position by switching on in the direction of an arrow (downward).

The hydraulically operated arm is set in transport position by switching on in the direction of an arrow (upward). A cutting pulley or a compacting pulley for consolidated surface edges can be mounted on the arm.

48

Vibration on - off button (8) The vibration function is cut off pressing the button (8) positioned on the gear operating lever (2) and cut in repressing the button. The button (8) is designed for vibration cut-in and cut-off in the basic „Manual Vibration Mode“ and in the „Automatic Vibration Mode“.

Control mode switch (9) One of the three control (turning) drum modes can be selected by the switch (9).

Front drum control Both drums control Rear drum control

VH 1150

OPERATING INSTRUCTIONS

Stop button (10) In case of a trouble, when the machine can not be stopped shifting the gears (2), use the stop button (10). The roller will brake by pressing the stop button and the motor stops.

The pilot lamp (42) lights up on the dash board. The brake will release by turning in the direction of arrows on stop button. If the stop button of the emergency brake is pushed, the motor can not be started!

Switch parking brake (11)

Horn switch (12) Switch pushing activates the horn.

Switch of direction indicators (13) The right direction indicators are switched on by pressing the position switch (13) right and the left direction indicators by pressing left. The function is signalled acoustically and by a pilot lamp (39) on the dash board.

Parking brake activate always as far as up stopping machinery.

On the left - Off On the right - On Switch parking brake (11) be instrumental towards instantaneous mechanical brake machinery up his stopping.

Function switch (11) is contingent „0“ position the gear (2). Brake machinery is waft make light pilot light (42).

Near button-down switch parking brake is function the gear (2) forward – at the back eliminated from activities.

Parking brake activate always as far as up stopping machinery!

Brake the machine after: - It has stopped and the driver’s operating position has been left while the motor is on!

- It has stopped in a slope.

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49

2.7. Controls and monitors

Infra thermometer - (OPTIONAL equipment - on customer’s request) (14) It is activated by turning on the key in the switch box (17) and it measures the temperature of the bitumen surface being rolled. The temperature is sensed by a sensor located on the hydraulic tank, point (A). The measured temperature in °C is indicated on the display (14).

A

Electronically operated gas actuator (OPTION equipment according to the customer ´s wish) (15) It serves to adjustment of pilot/free or maximal speed of the internal-combustion engine with the help of the electromagnet. By switching the switch to the left, the free speed of the engine is adjusted (900·min–1 (RPM)) and by switching the switch to the right, the maximal speed of the engine is adjusted (2600·min–1 (RPM)).

14

For the operating mode turn the switch to the right!

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VH 1150

OPERATING INSTRUCTIONS

Multifunctional display (16) After switching on a key (17) of the switch box in position ”1”, notice DLL and then notice STAVOSTROJ VH 1000 DIG SX1 CONTROL are successively displayed.

Basic data will be further displayed according to the preselected functions on the machine(see ch. 2.8.9. - 2.8.10.): Front - front drum control Rear - rear drum control Steer - both drums control Crabbing - a widened trace (a datum is displayed in a crabbing mode activation only) >< Drum zero position - for example (F 0 ><) >> The drum turns right; the turning angle is given in degrees - for example (F 10 >>) << The drum turns left; the turning angle is given in degrees - for example (F 10 <<) Km/h A machine speed in kilometres per hour Rpm Motor speed (min–1 RPM) Hz Vibration frequency of front / rear drum - for example (Hz 0 / 0) cm Drum exceeding in a straight drive direction from 0 to 120 cm (a datum is displayed when the rear drum is turned in a crabbing mode only).

F R S C

The display (16) further monitors the control system. In case of a fault on this system, a running notice in the English language will be displayed. In this case it is necessary to put the machine out of operation and approach your service organisation so as to remedy the fault on the system!!!

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2.7. Controls and monitors

Switch box (17) There are three positions 0-1-2 of the switch box (17). A key can be introduced and pulled out in position ”0” only!

Position ”1” of the switch box is activated first by turning the key right and then position ”2”.

Fuse appliances F1 - F3 are connected in position ”0” Fuse appliances F4 - F12 are connected in position ”1” (see point (61) fuse box).

Spring-loaded position ”2” serves for motor start.

Protect the switch box of the machine without a cab by tilting a cover of the switch box and with a protective shield after pulling out a key.

Fuel gauge (18) Indicates the fuel contents in a tank. In case of a fall to the minimum fuel level (18), the fuel gauge pilot lamp is permanently on. Fuel must be refilled!!!

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OPERATING INSTRUCTIONS

Vibration amplitude selector (22)

Hydraulic oil thermometer (19) Indicates a hydraulic oil temperature. A maximum permissible temperature is 80 °C (185 °F). An optimum working temperature is 50 - 60 °C (122 - 140 °F).

There are three positions of the switch: Left

low amplitude 50 Hz on - engine speed at max. 2600 x min–1

Centre no amplitude pre-selected Connector (14)

Right

high amplitude 42 Hz on - engine speed at max. 2600 x min–1

Use the connector to connect ECM (Electronic Control Module) and diagnostics trouble.

Note ECM processes engine function data and controls the engine. Sensors pick up information on engine function and malfunctions and transfer it to ECM. The control module analyses input and returns commands for the engine to function properly.

Malfunctions and other data is identified and stored in ECM memory. This data will be transferred after connecting a service device (notebook) to connector (20).

Pilot lamp for vibration on - low amplitude (23) Signals low amplitude on

Pilot lamp for vibration on - high amplitude (24) Signals high amplitude on

Vibrating drum selector switch (25)

There are three positions of the switch: Engine-hour counter (21) Indicates the number of hours during which the engine was running. After the pilot lamp (41) for charging goes out, the counter starts to read hours independent of the engine operating speed.

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Left front drum vibration Centre vibration of both drums Right rear drum vibration

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2.7. Controls and monitors

Engine diagnostics switch (30) In case of a malfunction of the engine, clutch the diagnostics switch (30) to identify the defect on the basis of flashing code on signal lamp (32).

Note Signal lamp (32) or (33) will go on in case of an engine malfunction, depending on severity of the defect. After activating switch (30), the will start flashing the code of the first defect see chapter 2.8.2.

If both pilot lamps indicating defects (yellow – 33 and red – 32) go on after pressing the switch when the ignition box is on that means no defects have been identified by engine ECM.

Stop engine - signal lamp (32) Stop the engine as soon as possible if this red lamp goes on.

Note After turning on the DIAG switch (30), the red lamp (32) will start flashing in the code of the first defect.

After the signal lamp goes on, stop operation and engine while keeping safety at work!

Do not start the engine before the defect has been repaired!

Troubleshooting switch (31) The switch is in the middle position.

Turn it continuously any direction (+ forward or - backward) to find defects according to flashing codes of signal lamps (32) or (33).

! NOTE !

Use the switch for trouble shooting only.

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OPERATING INSTRUCTIONS

Engine warning - signal lamp (33) This yellow lamp indicates a defect - the engine must be checked.

Maintenance signal lamp (35) (bílá kontrolka) It is connect. It possibile to connect after agreement with engine producer.

Note The searching fault engine see chap. 2.8.2.

Steering failure (front drum) warning light (36)

! NOTE !

Repair the defect as soon as possible!

Water in fuel - signal lamp (34) (modrá kontrolka) This lamp indicates water or other deposits detected in the fuel filter separator.

Indicates a failure in the front drum steering system.

Steering failure (rear drum) warning light (36) Indicates a failure in the rear drum steering system.

! NOTE !

Blow of water from fuel filter see. chap. 4.5.5.

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2.7. Controls and monitors

Gear neutral pilot lamp (38) The pilot lamp on signals ”0” position of the gear (neutral).

The motor can be started in this position.

Brake pilot lamp (42) The pilot lamp on signals machine braking.

Pilot lamp for smooth start + stop mode (43) Pilot lamp of direction indicators (39) With direction indicators on, the pilot lamp of direction indicators is interrupted on.

Signals switching on in a smooth machine start or stop mode.

!NOTICE! Air filter fouling pilot lamp (40) The pilot lamp on signals an underpressure increase in the motor intake beyond the allowable limit and the necessity to clean or replace the filter sleeves of the engine air intake.

The pilot lamp for smooth start + stop mode (43) further monitors the control system. In case of a fault on this systém, the pilot lamp (43) indicator light up alternatively to indicate a fault. In this case it is possibility finish work and than to put the machine out of operation and approach your service organisation so as to remedy the fault on the system!!!

Charging pilot lamp (41) Signals a correct function of battery charging. The pilot lamp must light up by switching a key in the switch box (17) in position ”1” and go out after engine start. If it is not off, find a fault.

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OPERATING INSTRUCTIONS

Switch + pilot lamp of headlights (44) Serves for switching on headlights - the switch pilot lamp signals the function.

Switch + pilot lamp of tail-lights (45) Serves for switching on tail-lights - the switch pilot lamp signals the function.

Hazard beacon switch + pilot lamp (48) (OPTIONAL equipment - on customer’s request) Serves for switching on a hazard beacon - the switch pilot lamp signals the function.

Switch + pilot lamp for an automatic on - off vibration mode (49) Serves for switching on vibrations.

Automatic on - off vibration mode on

• At a speed increase over 1,8 km x hod-1 (1,12 MPH) the vibration automatically cuts in Switch + pilot lamp of warning lights (46)

• At a speed decrease under 1,8 km x hod-1 (1,12 MPH) the vibration automatically cuts off.

Serves for switching on warning lights - the function is signalled by interrupted lighting up the switch pilot lamp

Switch + pilot lamp of additional lights (on drum stirrups and below front frame) (47) (OPTIONAL equipment - on customer’s request) Serves for switching on additional lights (on drum stirrups) - the switch pilot lamp signals the function.

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! NOTICE !

After switching on (49), the automatic on - off vibration mode is activated by the gear (2) in both directions of machine drive, the machine does not vibrate in zero position of the gear (2).

During a machine drive, the vibration can be cut off or cut in as required by pressing the button (8) on the gear operating lever (2).

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2.7. Controls and monitors

Switch (antistall) + pilot lamp (50) for engine overload prevention mode

Differential lock switch + pilot lamp (51)

Serves for switching in a control unit, the switch pilot lamp signals the function.

Serves for cutting in a differential lock, the switch pilot lamp signals the function.

At a engine overload - a speed reduction under the set limit (vehement ascent, machine sinking) - the control unit automatically decreases the power demand by reducing the set speed (hydraulic motor speed) independent of gear position. Their tractive force is thus increased - the motor is relieved.

! NOTICE !

In case that some of the drum parts slips (revolves) in a difficult terrain (ascent) at decreased adhesion, switch on the differential lock.

Switch off after surmounting a difficult terrain!

Before switching on, adjust a maximum motor speed!

Switch off after surmounting a difficult terrain!

58

Pilot lamp (51) further monitors the control system.

In case of a fault on this systém, the pilot lamp (51) indicator light up alternatively to indicate a fault. In this case it is possibility finish work and than to put the machine out of operation and approach your service organisation so as to remedy the fault on the system!!!

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OPERATING INSTRUCTIONS

Switch + pilot light of sprinkling (52) The switch has three positions and it serves to turning the sprinkling pumps on. The function is signaled by the pilot light in the switch.

II. - It sprinkles all the time – the green pilot light in the switch is lit and the pumps run continuously.

0 - Zero position I. - Regulated sprinkling – the green pilot light in the switch is lit only when the pumps run – which is conditioned by adjustment of the potentiometer (55).

The pilot light of the sprinkling operation – the front drum (53) The red pilot light (53) signals the failure of the front drum spraying. The pilot light blinks when the pump does not give any pressure for 4 cycles. In such case, the interrupted audible warning of the horn located in the control panel is heard at the same time.

! WARNING! In case the pilot light blinks permanently and at the same time the interrupted signaling of the horn is heard, check the status of water in the water tank or check for failure in the circuit of sprinkling.

In the position II. ON, the function of sprinkling is continuously ON also on the idle machine.

In the position I. ON, the intensity of sprinkling is smoothly regulated with the help of the potentiometer of sprinkling (55).

! WARNING! The function of sprinkling is activated in the position I. only during the machine driving except for the right stop position on the potentiometer (55) when sprinkling runs continually even if the machine is idle.

The pilot light of the sprinkling operation back drum (54) The red pilot light (54) signals the failure of the back drum spraying. The pilot light blinks when the pump does not give any pressure for 4 cycles. In such case, the interrupted audible warning of the horn located in the control panel is heard at the same time.

! WARNING! In case the pilot light blinks permanently and at the same time the interrupted signaling of the horn is heard, check the status of water in the water tank or check for failure in the circuit of sprinkling.

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2.7. Controls and monitors

Sprinkling potentiometer (55) The sprinkling intensity of drums on a going machine is continuously controlled by turning the sprinkling potentiometer left from position „0“ to position „IV“. The sprinkling function on a standstill machine is activated by maximum position set-up.

Fan switch (57) Serves for switching on a cab fan, the switch pilot lamp signals the function.

The switch is three-positional (two-speed) - switches on a fan for cab air exchange and blowing the cab windscreen and rear window.

Air-conditioning switch + pilot lamp (56) Serves for cutting in air-conditioning, the switch pilot lamp signals the function.

! NOTICE !

Air-conditioning automatically cuts off and cuts in anew after reaching the set temperature and exceeding the temperature set points.

In order that the air-conditioning functions well, the regulator (58) must cut off heating and the fan must be switched on (57)!

Heating regulator (58) The control valve for warm water content in the heating radiator is operated positioning it in the direction of arrows.

Regulator to the dog in the direction of blue arrow - no heating Regulator to the dog in the direction of red arrow - maximum heating

Air circulation flap valve controller (59) The volume and ratio of sucked air is controlled outside and inside the cab by positioning the regulator.

Air-conditioning regulator (60) The cooling intensity is adjusted by positioning in the direction of arrows (cooling thermostat).

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OPERATING INSTRUCTIONS

Fuse box (61) Includes fuses of the following apparatus: F1

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

F2

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

F3

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

F4

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

F5

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

F6

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

F7

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

F8

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

F9

Instruments, pilot lamps, Infra thermometer ...... 5A

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

Engine fuses Fuses F 10 - F 12 ...... 7,5 A ... Power supply engine electronics Fuses F 13 - F 14 ...... 10 A .... Power supply injection pump Fuse F 15 ................................. Reserve

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2.7. Controls and monitors

Assembling lamp socket (62)

Emergency control of the travel and driving (63)

It serves to connection of the auxiliary assembling lamp 12 V on the control board.

• In case the electronics fails and the information on the error in the electronic system in question will be shown on the display (16).

• In such case activate the function of emergency control of travel and driving which will allow you to drive away with the machine from the work place.

• Description function see 2.8.8. – Emergency control of the travel and driving.

Emergency control of the travel and driving is solely determined for a shortterm displacement of the machine from the work place and it can be always activated only in case of the travel or driving electronics failure!

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OPERATING INSTRUCTIONS

Connectors (64), (65), (66), (67): These connectors are located on the dashboard.

Connector for drive control electronic unit (64) Serves for connecting an external-computing unit (Notebook) to the drive range control unit in order to diagnose flaws and set parameters.

Connector for ASC control electronic unit (66) Serves for connecting an external-computing unit (Notebook) to the lock differential control unit in order to diagnose flaws and set parameters.

Connector for CAN BUS network (67) Serves for connecting an external-computing unit (Notebook) to assure proper communication between control units.

Connector for control electronic unit (65) Serves for connecting an external-computing unit (Notebook) to the steering range control unit in order to diagnose flaws and set parameters.

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63

2.7. Controls and monitors

Driver’s seat (68) Adjustable, sprung, equipped with two-point retractor belt (A).

A

Driver must fasten the seatbelt during drive!

64

VH 1150

OPERATING INSTRUCTIONS SEAT ADJUSTING ELEMENTS:

Adjust the seat before driving the machine!

1 1. Backrest inclination adjustment Raise the lever to tilt the backrest infinitely as necessary.

2. Lumbac support adjustment Turning driver (2) is regulation lumbar support.

2

3. Arm rest adjustment Raise and turn the screw to cast down a raise the rest.

3

4. Vertical seat adjustment Grasp the seat at the bottom and lift it to gradually adjust height of the seat. The seat must click into the position. You have to lift it to the top position first to be able to put it back to its lowest position.

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2.7. Controls and monitors 5. Seat spring stiffness adjustment

9

Turn the catch to adjust stiffness according to driver’s weight indicator (5) between 50 and 130 kg (110 - 266 lb) in 10kg (22 lb) increments.

5

6. Horizontal seat squab adjustment Raise the lever to move the seat single handedly forward or backward.

7 6 7. Horizontal seat adjustment Raise the handle to move the seat with control panel forward or backward.

8. Seat turning The lever controls a seat turning from the centre position to each side within 70°. After releasing the lever, the seat is arrested in the selected position.

8

Do not swivel the seat while driving!

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OPERATING INSTRUCTIONS Seat traverse (69) The lever can control a seat traverse to sides - right and left.

69

Document box (70) A document box is located on the back-wall of the seat.

70

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2.7. Controls and monitors

Chair switch (71)

71

Chair switch (71) is placed in the cushion of the seat.

Function of the seat switch function:

• If the operator of the machine does not seat, the machine is not possible to start the machine and the travel lever (2) is put out of the service.

• The seat switch function is activated when the machine operator stands up from the seat – the machine smoothly stops, the motor stalls and parking brake is activated within the total time limit of 8 seconds.

• If the machine operator stands up from the seat during the drive of the machine and sits down again within the time limit of 4 seconds, the seat switch function is not activated.

• If the time limit of 4 seconds is exceeded, the machine changes over to the mode of soft start + finish, it slows down and smoothly stops from whatever speed within the time limit of 1 second.

• After the machine stops, the travel pump will be reset, consequently the internal-combustion engine will stop in 4 seconds and the parking brake is activated.

• If the machine operator sits down back to the seat prior to finish of above mentioned time limit of 8 seconds, reading of the time to stalling of the motor will be disconnected, the parking brake will be braked and it is possible to re-start the machine.

• The machine will re-start if the operator sits in the seat and shifts the travel lever to the zero position and afterwards with the help of the travel lever (2) he selects the direction of drive.

68

As far as is up stopping machinery activaved function parking brake switch (11) and the gear (2) is in “0” position motor don not stalls, when machine operator rise from seat.

Is prohibited to keep the engine operation by loading the seat with any other objects, from the point of view of safety of the machine operation as well as safety of operators!

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OPERATING INSTRUCTIONS

Battery disconnecter (72) Disconnects a minus battery pole from the frame.

When finishing a drive, always disconnect the battery by means of a disconnecter!

When washing the machine, always switch off the disconnecter!

Head wiper switch (73) The switch is three-positional.

Low speed on Off Higher speed on

Tail wiper switch (74)

73

74

75

76

Off On

Sprayer switch (75) The switch is three-positional.

Windscreen sprinkling on Off Rear window sprinkling on

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2.7. Controls and monitors Switch auxiliary lights cabin (76) (OPTION equipment according to the customer ´s wish) Off On

Cab illumination (77) Two ceiling lamps over the dashboard with switches

77

77

Cab ventilation air filter (78) Includes a replaceable two-part sleeve, on which pollutants of sucked air are trapped.

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OPERATING INSTRUCTIONS Ventilation nozzles (79) Stabile nozzles (1) for the windscreen and rear window prevent hazing.

Adjustable nozzles (2) located on the cab front and back wall allow a change in air volume and its direction by setting and turning the flap valves.

1

2

Two adjustable vent astride above door cab, obstruct in open position rise underpressure near air renewal in precinct cab.

Rear mirrors (80) Window mirrors enable an outlook to badly visible places.

Keep the mirrors clean and properly set!

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71

2.7. Controls and monitors Sunshades (81) Adjustable shades preventing dazzling. Shades are adjusted by fastening to the window grips (A).

A

Extinguisher (82) The method of extinguisher application is described on a package.

Acquaint yourself with the extinguisher operation! Make periodical overhauls of the extinguisher!

Window sprinkler basin (83) Replenish with clear soft water - distilled water best - with cleansing and degreasing agents.

Prior to the winter season, fill with antifreeze or discharge!

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OPERATING INSTRUCTIONS Armrests (84) Remove nut (1) and screw (2).

2

1

Turn amprest from point (A) to the point (B), tighting screw and nut.

A

B

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2.8. Principal functions of the machine 2.8.1.

Start-up of the engine

• Check whether the emergency brake STOP button (10) is not pressed.

Before starting up the engine, check levels of oil in the engine and hydraulic tank, cooling liquid in the cooling circuit and fuel in the fuel tank every day.

Check tyre pressures, tightness of some machine parts, their wear and presence.

• Check whether is on switch parking brake (11).

• Horn to announce starting up of the engine (12).

• At the electronic gas actuator turn the switch (15) to the left position (free revolutions).

• Start for up to 30 seconds. If the engine does not start, wait for a 2 minutes and start again. If the engine does not start up after 2 tries, search for a problem.

• After starting up, check correct engine operation by indicators.

Start the engine only from the driver’s stand!

Blow horn before starting the engine to check that nobody is endangered by starting the engine!

• Let the engine run at idle speed of 900 rpm after starting up. Check speed specified on the display (C).

WARNING! The engine is with arranged a grid heater. Do not use starting fluid. Starting fluid, which contains ether, can cause an explosion.

Start-up procedure:

• Turn on the battery disconnector (72).

Do not start longer than 30 seconds. Wait for 2 minutes before next starting.

Repeat starting procedure 2 times at most; then detect the cause in fuel system. Missing smoke in the exhaust pipe indicates failure in fuel supply to the engine.

After starting up, check correct engine operation by indicators.

Do not run up the engine rapidly; let the engine run at idle speed for 3 to 5 minutes to stabilize pressure in the engine and to have bearings lubricate.

Do not let the engine run at idle speed for longer then 10 minutes to avoid engine damage.

Do not load the engine with full power until the temperature of cooling liquid reaches 60 °C (140 °F).

Starting will be blocked at the following instances: STOP button (10) is pressed

• Put the key to the ignition box (A) in ”0” position and turn it to ”1” position. Indicators of brake (42) and battery charging (41) will light up.

switched off parking breake (11) control (2) is not in neutral.

• Engine diagnostics signal lamps 32, 33, 34 and 35 will light up and go off after 4 seconds.

• ”DLL” will appear on the display; after several seconds, specific data of the machine functions will be displayed (B).

• Check the neutral position of the travel control (2) - the neutral indicator (38) will light (the engine cannot be started if another position is geared - the procedure would be interlocked).

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OPERATING INSTRUCTIONS

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2.8. Principal functions of the machine Starting with the use of starting cables from an other machine

! NOTE !

1/ Connect (+) cable pole to (+) pole of the discharged battery.

When the engine has started, disconnect cables in reverse order.

2/ Connect the other end of the (+) pole cable to (+) pole of the auxiliary source 3/ Connect one end of the (–) pole cable to (–) pole of the auxiliary source.

4/ Connect the other end of the (–) pole cable to the chassis of the engine to be started, or the engine block directly.

Using auxiliary starting with the battery disconnected, do not disconnect before the battery of the machine has been connected.

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.

Naked parts of the clips of the starting cables may not touch each other!

Starting cable connected to (+) pole of the battery must not touch conducting parts of the machine to avoid shortcircuiting.

Do not lean over the batteries. The electrolyte may injure you!

Avoid the presence of source of fire – open flame, cigarettes, etc.

Do not check for the presence of voltage in the cable by sparking against the chassis!

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OPERATING INSTRUCTIONS 2.8.2.

Troubleshooting on the engine according to flashing codes

• In case of engine fault, either stop engine red signal lamp (32) or engine warning yellow lamp (33) will light up.

• Before troubleshooting stop the engine and turn the ignition key to ”I” position.

• Press button (30) to activate error code. The lighting signal lamp will start flashing in the code corresponding to the defect and it repeat in the same sequence.

• Press button (31) to move to the next error. You can search for error codes stored in ECM index using symbols of switch (31): upper symbol forward or bottom symbol backward.

Example of flashing error code Flashing code consists of three digits.

Example: code 123 signal lamp Yellow lamp (33) will flash, red lamp (32) will flash the code after 1-2 sec.

Number 1: red will flash once, then pauses for 1-2 sec.

Number 2: red will flash twice, then pauses for 1-2 sec.

Number 3: red will flash thrice.

When the number has finished flashing in red, a yellow lamp will appear again. The three – digit code will repeat in the same sequence. Press button (31) to move to the next error.

VH 1150

Example: code 234 of red signal lamp Yellow lamp (33) will flash, red lamp (32) will flash the code after 1-2 sec.

Number 2: red will flash twice, then pauses for 1-2 sec.

Number 3: red will flash thrice, then pauses for 1-2 sec.

Number 4: red will flash four times.

When the number has finished flashing in red, a yellow lamp will appear again. The three – digit code will repeat in the same sequence. Press button (31) to move to the next error.

NOTE If only one defect is identified, its error code will be signalled repeatedly even if you press switch (31) in either direction.

After the signal lamp (32) goes on, stop operation and engine while keeping safety at work!

Do not start the engine before the defect has been repaired!

! NOTE !

If signal lamp (33) lights up, repair the defect as soon as possible!

77

2.8. Principal functions of the machine 2.8.3.

Travel and reversing without vibrations

Changing the driving direction • Move the travel control (2) to the opposite direction via ”0” position.

• Set the potentiometer of the speed selector (3) to

• Carry out the movement of the travel control slowly - it

”rabbit” and check whether the emergency brake ”STOP” button (10) is not pressed or on switch parking brake (11).

• At the electronic gas actuator turn the switch (15) to the left position (free revolutions).

• Check the neutral position of the travel control (2) - the neutral indicator (38) will light (the engine cannot be started if another position is geared - the procedure would be interlocked).

• Turn the ignition key (A) to ”2” position to start the engine (hold the key in the position until the engine starts up only).

must take longer than a second!

Smooth driveaway and stopping

• If need be (compacting bitumen surfaces), smooth driveaway and stopping can be activated by button (4).

(43) indicator lights when this function is on.

When (4) button is on, stopping distance is longer when stopping or reversing!

Give the acoustic signal (12) before starting driving the machine and wait for a period sufficiently long for all persons being able to leave the dangerous area around the machine (area under the machine) in time!

Make sure there are no persons within the working range of the machine and the areas in front and behind the machine are free!

Turn on lights in case of poor visibility!

Selecting the driving direction • Move the travel control (2) from ”0” position to select a travel direction - forward (F) or reverse (R) (B).

• After moving the travel control from ”0” position and when the brake release pressure is reached, the brake indicator (42) and the travel control neutral position indicator (38) will go off and the machine will start moving.

Selecting speed

• The machine speed depends on the tilt of the travel control (2) from ”0” position. You can monitor the speed (km/h) on the display (16).

• You can change the selected speed range to transport speed (”rabbit”) or working speed (”turtle”) by the working speed selector (3).

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2.8. Principal functions of the machine 2.8.4.

Stopping the machine and engine

2.8.6.

Emergency stopping

•

When compacting, turn off vibrations by button (8) or selector switch (22).

•

Press the button (10) - the machine and engine will stop.

•

Move the travel control (2) to ”0” position - the neutral indicator (38) will light up.

•

Release the brake by turning the switch (10) in the direction of the arrow.

• At the electronic gas actuator turn the switch (15) to the

•

Before starting the engine, move the travel control (2) to ”0” position.

left position (free revolutions).

•

Turn off appliances being used (heating, ventilation, wipers etc.).

•

Turn the ignition key (A) to ”0” position to stop the engine and take the key out of the ignition box.

•

Having taken the key out, cover the ignition box with the lid to protect it.

Do not stop the engine immediately after full load - leave it run for 3 - 5 minutes at idle speed (900 rpm). The engine and turbocharger will cool down slowly and evenly.

When stopping the machine on a slope, turn on the switch parking brake (11); the machine will brake.

2.8.5.

Use this option in case of defect when the machine cannot be stopped by moving the travel control (2) to ”0” position or to the opposite position via ”0” position.

The engine cannot be started up when the emergency brake button (10) is pressed!

2.8.7.

Dead parking of the machine

•

Park the machine on an even, firm surface with no natural dangers (landslides, floods etc.)

•

After stopping the engine, turn off the battery disconnector (72) before you leave the machine.

•

Clean the machine from dirt (scrapers and drums).

•

Check the whole machine and repair defects arisen during the operation.

•

Lock the cabin (or the dashboard cover at machines without cabin).

Safety stopping

•

Move the travel control (2) quickly to the opposite position via ”0” - the movement must take less than a second; the machine will stop immediately.

•

To start driving the machine again, return the travel control (2) to ”0” position first and then move it to the position of the required driving direction.

Do not use the accelerator (15) to control the machine speed!

The driver’s seat must be moved to the center of the cabin and turned towards the door before the driver leaves his stand.

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2.8. Principal functions of the machine 2.8.8.

Emergenci control of the travel and driving

• In case the electronics fails and the information on the error in the electronic system in question will be shown on the display (16).

• In such case activate the function of emergency control of travel and driving (63) which will allow you to drive away with the machine from the work place.

Carry out the following steps to activave the funkcion:

• Dismantle the cover (1) the sockets X 50, X51 and the

1

fork body X 50 on the control panel.

• The fork body X 50 dismantle from the socket X 50 and mount into the socket X 51.

• For deaktivate function act opposite way.

Control of the machine in the emergency mode:

• In case of activation of the function of emergency control of the travel and driving, the travel actuator (2) remains in its position, the maximal speed is reduced to 5 km/h and the front drum is allowed to be controlled only with the help of push buttons (6) (Driving in the mode CRAB) in driving direction forward with the left push button – to the left and with the right push button – to the right on the travel actuator (2).

• Machine with electronic gas must exist switch (15) setting on the right side (speed motor 2600 min -1 (RPM).

• With regards to activation of the function of emergency mode it is not possible to activate for example the ramp, the sprinkling potentiometer, etc.

• It is impossible to emergency control the back drum – it remains in the same position, as it was when the failure occurred.

• On the display (16) with display running notice PLEASE CHECK SYSTEM.

Emergency control of the travel and driving is solely determined for a shortterm displacement of the machine from the work place and it can be always activated only in case of the travel or driving electronics failure!

After you drive with the machine away from the work place, shut it down and deactivate the function of the emergency control of travel and driving!

Put the machine back to its previous condition!

Call your dealer regarding removal of the failure on the travel or driving electronics!

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2.8. Principal functions of the machine 2.8.9.

Steering

• After turning the ignition key (17) to ”1” position, ”DLL” title will appear on the display followed with title ”STAVOSTROJ VH 1000 DIG SX1 CONTROL”.

Maximum ranges of the data displayed: Displayed values:

Range:

<<

Drum steering angle - left, in degrees

0 - 25

>>

Drum steering angle - right, in degrees

0 - 25

Km/h Driving speed, in kilometers per hour Rpm Engine speed (RPM) Hz

C

0 - 10 900 - 2600

Drum vibrations - small amplitude (frequency in Hz)

0 - 50

- high amplitude (frequency in Hz)

0 - 42

Crabbing - widened track (in cm)

0 - 120

Setting up steering mode parameters

• Turn the ignition key (17) to ”2” position to start up the engine, and set the engine speed to 2600 rpm (this is necessary for reliable steering function).

• At the electronic gas actuator turn the witch (15) after the machine start from the left position (free revolutions) to the right position (normal speed).

Apart from that, main data of the pre-selected functions will be displayed: F

Front - steering by the front drum

R

Rear - steering by the rear drum

S

Steer - steering by both drums

C

Crabbing - widened track (data is displayed only if the ”crabbing” mode is activated)

><

zero position of the drum - (F 0 ><)

>>

drum is turning to the right, steering angle is specified in degrees - e.g. (F 10 >>)

<<

drum is turning to the left, steering angle is specified in degrees - e.g. (F 10 <<)

Km/h driving speed, in kilometers per hour Rpm engine speed (RPM) Hz

front / rear drum vibration frequency - e.g. (Hz 0/0)

cm

drum overhang in the straight driving direction within 0 - 120 cm (this data is displayed only when the rear drum is turning in ”crabbing” mode).

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OPERATING INSTRUCTIONS 2.8.9.1. Steering by the front drum • Turn the selector (9) to the left end position to select this drum steering mode.

The following main data will appear on the display: F

Front - steering by the front drum

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) ><

zero position of the drum - (F 0 ><)

F

Front - steering by the front drum

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) <<

drum is turning to the left, e.g. (F 8 <<)

F

Front - steering by the front drum

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) >>

drum is turning to the right, e.g. (F 8 >>)

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2.8. Principal functions of the machine 2.8.9.2. Steering by the rear drum • Turn the selector (9) to the right end position to select this drum steering mode.

The following main data will appear on the display: R

Rear - steering by the rear drum

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) ><

zero position of the drum - (R 0 ><)

R

Rear - steering by the rear drum

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) <<

drum is turning to the left, e.g. (R 8 <<)

R

Rear - steering by the rear drum

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) >>

86

drum is turning to the right, e.g. (R 8 >>)

VH 1150

OPERATING INSTRUCTIONS 2.8.9.3. Steering by both drums • Turn the selector (9) to the center position to select this drum steering mode.

The following main data will appear on the display: S

Steer - steering by both drums

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) ><

zero position of drums - (S 0 ><)

S

Steer - steering by both drums

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) <<

drums are turning to the left, e.g. (S 8 <<)

S

Steer - steering by both drums

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) >>

drums are turning to the right, e.g. (S 8 >>)

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2.8. Principal functions of the machine 2.8.9.4. Steering in the ”CRAB” mode - widened track

Turn on the CRAB mode button (5).

By turning on the button (5), the drum steering mode set by the selector (9) will automatically be overridden and the rear drum will turn to ”0” position.

Rear drum: Use buttons (6) on the travel control (2) to set the rear drum in the ”CRABBING” mode. Press the left button of the travel control (2) to turn the rear drum to the left and the right button to turn it to the right.

Front drum: When the front drum is in ”CRABBING” mode, driving direction is steered by the steering wheel (1). The rear drum remains in the pre-selected position of the ”CRABBING” mode.

<<

drum is turning to the left (data at the bottom of the display) - e.g. (C 25 <<)

>>

drum is turning to the right (data at the top of the display) - e.g. (C 25 >>)

>>

drum is turning to the right (data at the bottom of the display) - e.g. (C 25 >>)

<<

drum is turning to the left (data at the top of the display) - e.g. (C 25 <<)

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OPERATING INSTRUCTIONS The following main data will appear on the display: C

Crabbing - widened track

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) cm

rear drum overhang in the straight driving direction - e.g. (cm = 120)

>>

front drum is turning to the right, e.g. (C 25 >>)

<<

rear drum is turning to the right, e.g. (C 25 <<)

C

Crabbing - widened track

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front / rear drum vibration frequency - e.g. (Hz 0/ 0)

Rpm engine speed - (Rpm = 2600) cm

rear drum overhang in the straight driving direction - e.g. (cm = 120)

<<

front drum is turning to the left, e.g. (C 25 >>)

>>

rear drum is turning to the left, e.g. (C 25 <<)

When compacting near walls, pay extra attention to the cabin overhanging the outer edge of the rear drum so as not to damage it by a collision. If need be, fold the rear mirror.

There is no limit position when turning the steering wheel. You can turn the steering wheel with no limits to select the driving direction (steering of drums).

While driving, consult the steering angle of drums on the display (16) - turn the steering wheel in a moderate way.

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2.8. Principal functions of the machine 2.8.10. Travel and reversing with vibrations Use the accelerator (15) to set the engine speed to up to 2600 rpm and select the travel speed by the working speed pre-selector (3).

Use the vibration amplitude selector (22) to choose high or small amplitude. Select the vibrating drum with the selector (25).

MANUAL SWITCHING OF VIBRATIONS:

• Use button (8) on the travel control (2) to manually turn on and off vibrations.

• To turn on vibrations, press and release button (8) on the travel control (2).

• To turn off vibrations, press again and release button (8) on the travel control (2).

• Vibration frequency level in Hz appears on the display (16).

AUTOMATIC SWITCHING OF VIBRATIONS:

• Use button (49) to activate automatic turning on and off vibrations.

• Vibrations will be automatically turned on at speeds exceeding 1.8 km/hour (1.12 mph).

• Vibrations will be automatically turned off at speeds under 1.8 km/hour (1.12 mph).

• Vibration frequency level in Hz appears on the display (16).

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2.8. Principal functions of the machine The following main data will appear on the display: F

Front - front drum steering - e.g. (F)

><

zero position of drums - e.g. (F 0 ><)

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front drum vibration frequency (small amplitude) e.g. (Hz 42 / 0)

Rpm engine speed - (Rpm = 2600)

F

Front - front drum steering - e.g. (F)

><

zero position of drums - e.g. (F 0 ><)

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

rear drum vibration frequency (small amplitude) e.g. (Hz 0 / 42)

Rpm engine speed - (Rpm = 2600)

F

Front - front drum steering - e.g. (F)

><

zero position of drums - e.g. (F 0 ><)

Km/h driving speed, in kilometers per hour - e.g. (Km/h = 0.0) Hz

front and rear drum vibration frequency (high amplitude) - e.g. (Hz 50 / 50)

Rpm engine speed - (Rpm = 2600)

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OPERATING INSTRUCTIONS 2.8.11. Driving with vibrations on compacted and hard material When driving with vibrations, contact of drums with compacted material can worsen or be lost (so called vibrouder) due to high level of compactness of the subgrade or due to driving with vibrations on hard material. This situation results in increased transmission of vibrations to the machine frame and the driver’s stand. Partially, it can be reduced by increasing the travel speed. While subgrade material gets more compacted, transmission of vibrations to the driver’s stand can be expected, too.

2.8.12. Compacting near buildings If compacting near buildings or utility lines and cables cannot be avoided, it is necessary to examine influence of the machine vibrations to these buildings or lines and cables so as to protect them from damage.

The manufacturer of the machine cannot be held responsible for damages caused by using the machine near buildings or underground utility lines.

If working with the machine under conditions exposing the operator to increased vibrations cannot be avoided, the keeper of the machine must modify working procedures so that it is not harmful to the driver’s health.

It is not allowed to work on a long-term basis in the ”vibrouder” mode. In the extreme, the machine may be damaged.

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2.8. Principal functions of the machine 2.8.13. Engine overload protection (ANTISTALL)

2.8.14. Differential lock • When working on difficult ground or when driving up

Press the button (50) on the dashboard to activate this function.

a low-bed trailer, some part of a drum may start spinning. Turn on the differential lock to reduce drum spinning.

How to activate ANTISTALL function: • Turn off smooth driveaway and stopping function by using button (4) on the left panel, if the function has been on.

• Turn on the interlock button (51) - the button lamp will light up to indicate activated interlock. Turn off button (51) after the difficult ground has been overcome.

• At the electronic gas actuator turn the witch (15) after the machine start from the left position (free revolutions) to the right position (normal speed).

Turn off button (51) after the difficult ground has been overcome!

• Turn on button (50); the function is active once the indicator lights up.

• Turn off button (50) after the difficult ground has been overcome!

Warning!

When using button (50) to activate ANTISTALL function, smooth driveaway and stopping button (4) on the left panel of the driver’s seat must be turned off.

Use the ANTISTALL function only at maximum engine speed of 2600 rpm set!

Turn off button (50) after the difficult ground has been overcome!

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2.8. Principal functions of the machine 2.8.15. Sprinkling • Check the function of sprinkling prior to commencement of works – check spraying of both the front and back treads.

• By turning the sprinkling switch (52) on in position I. or

Function of emergency sprinkling: • In case of defect on one of sprinkling pumps use the function of emergency sprinkling. This function is activated by opening the valve (1) in the space below the cabin the result of which is connection of the front and back circuit of sprinkling.

II. , the function is activated for both drums – the green pilot light in the switch signals the function of sprinkling and it lights only when both pumps run.

• In the position I. adjust the interval of cycling with the potentiometer (52) – after the machine starts, both pumps of sprinkling will be turned on according to the interval set up.

• In the position II., the machine sprinkles all the time also on the place and the pumps run constantly.

Signaling of the failure of spraying:

• The failure of the spraying of drums is signaled by interrupted lighting of red pilot lights (53) for the front drum and (54) for the back drum and by interrupted audible warning of the horn located in the control panel.

1

• From time to time, a unique and short-term signaling of the failure can occur, that stops in the next cycle. In such case it is not a failure of pumps neither shortage of water in sprinkling tanks.

! NOTE !

If the emergency mode valve is not turned off and if both pumps operate, it is not a functional signaling of failures in the system!

Turning the spraying failure signaling off:

• Signaling of the failure can be canceled after stopping the machine by switching the sprinkling switch (52) over to the position 0 and afterwards the switch (52) switch over back to the position I. or II. and the error will not be signaled anymore.

Check of the sprinkling function:

• Check the function of sprinkling prior to work commen-

Use the function of emergency sprinkling only in case of failure of the front or back sprinkling pump and in case of emptying one of tanks within the shorter time limit, whereas in the second tank there is still water for sprinkling!

After the defect is removed, turn off the valve (1) in the space below the cabin with which the function of emergency sprinkling will be de-activated!

In case the valve (1) is not turned off and both pumps are in operation, signaling of failures in the system is not fully functional!

The idle machine sprinkles in the position of the switch I. only if the potentiometer (55) is in the stop clockwise!

cement – check spraying of both the front and back tread.

• We recommend carrying out the check of the sprinkling function on the idle machine.

• The operator will adjust the position I. on the switch and he must slightly turn the potentiometer 4-5x for the machine to sprinkle in interrupted manner and he will monitor whether the error is announced. The interval of sprinkling for this check must be longer than 2 seconds.

• The other possibility of the check is an automatic check during the machine drive. The switch of sprinkling must be in the position I.

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2.8. Principal functions of the machine 2.8.16. Edge cutter and compacter - options

2.8.17. Strassmayr spreader

(OPTIONAL equipment - on customer’s request)

(OPTIONAL equipment - on customer’s request)

Edge cutter and compacter are options supplied upon request of the customer. They are not included as standard accessories of the machine.

• It is controlled by means of a control box located on the

How to activate the cutter: • Open the valve of disc sprinkling (1) on the edge cutter arm.

When the switch is turned from the 0 position to the 1 position the equipment is supplied with an operating voltage of 12 V. The voltage divider (B) on the control box is used for spreading roller speed setting.

RH side of the instrument panel.

• The control box is provided with a master switch (A).

• The equipment is supplied with a separate Operating and Maintenance Manual. It is necessary to read this Manual before starting to use this equipment.

! NOTE !

1

Read and follow the instructions in the Operating and Maintenance Manual of the spreader!

• Turn the switch of sprinkling (52) on to the position II. Sprinkling of the disk is connected to the circuit of sprinkling of the front tread.

• Press button (7) (see up/down symbols on the button) to set the edge cutter to the required position.

• The required position is being set while the button is pressed. After reaching the limit position in either direction, the cutter will automatically stop.

• The cutting disc (2) can be replaced for the compacting disc (3).

• To replace them, dismantle 5 bolts M 10 holding the compacting disc on the rear strap. Fix the unused cutting disc to the rear right strap of the drum by two bolts M10.

3

2

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2.8. Principal functions of the machine 2.8.18. Lifting and lowering the cabin and the safety frame

• Take the pump control lever embedded in the side cover.

The driver’s cabin can be lifted to provide better access to the engine and other units in the engine compartment.

How to lift the cabin:

• Dismantle 12 bolts M16 on safety frame flanges.

• Dismantle 2 bolts M12 attaching the cabin to the frame.

• Put the lever (1) to the lifting pump; move the pump lever (2) to the safety frame lifting symbol and lift it by pumping.

• Open the left side engine cover and fix it with the support.

2

1

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OPERATING INSTRUCTIONS • Move the pump lever (2) to the symbol of cabin lifting.

• Pump two strokes of the lever (1) to lower the cabin; remove the support (3) from the holder and put it against the frame (4).

2

1

• Lift the cabin it to the upper limit.

3

• Move the pump lever (2) to lowering the cabin.

2 4

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2.8. Principal functions of the machine How to lower the cabin: • Move the pump lever (2) to the position of cabin lifting.

2

• Set the pump lever (2); lower the frame.

2

• Lift the cabin to the limit, fold the support (3) and secure in the holder.

• Lock the cabin with two bolts M12 and the safety frame with 12 bolts M16. Tight to torque of 100 Nm.

3

• Move the pump lever (2) to the position of cabin lowering and pump to lower the cabin.

• After the cabin is lowered, push the piston rod of the lifting linear hydraulic motor to the limit. This state is reached when you feel stronger resistance on the lever (1) during lowering - the piston rod eye must not be in contact with the cabin (the cabin is floating on metal-rubber mountings) so as not to transmit vibrations to the cabin during compacting.

2

Follow the lifting instructions - lift the safety frame first and then the cabin.

Follow the lowering instructions - lower the cabin first and then the safety frame.

Push the piston rod of the lifting linear hydraulic motor to the limit to prevent transmission of vibrations to the cabin during compacting.

Check manually free movements of the lifting linear hydraulic motor in the hinge bearing after the cabin has been lowered to the bottom position.

Do not drive with the cabin and safety frame not fixed.

1

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2.9. Shifting the machine (transport) 2.9.1.

Towing

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

• Towning lug is equipped with a pin locked with a

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

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

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

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

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

(

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2.9. Shifting the machine (transport) • Short-circuit the travel hydraulic circuit.

• Unscrew central parts (1) /haxagonal 27 mm (11/

• Turn the ignition key to I position and check signal lamp of brake (42) switched off.

16´´)/ by tree turns anti – clockwise on two multi – purpose safety velves of the hydro – generator of travel.

! NOTICE !

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

All brakes are disabled!

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

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

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

EMERGENCY RELEASE OF BRAKES OF THE MACHINE - HYDRAULIC – (OPTION) Do the following to prevent drums from skidding:

• Short-circuit the travel hydraulic circuit.

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

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

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

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

Do not start the engine during towing.

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

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

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2.9. Shifting the machine (transport) • Unscrew central parts (1) /haxagonal 27 mm (11/

• Set the lever of the manual hydraulic generator to the

16´´)/ by tree turns anti – clockwise on two multi – purpose safety velves of the hydro – generator of travel.

position displayed on the label of the machine frame.

• Take out the lever hydraulic generator.

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

! Note !

During towing, leakage may cause pressure in brekes decrease. If brakesignal lamp (42) lights up during towing, pump more!

After pulling the machine away carry out the following activities:

(

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

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

• Turn the ignition key to I position and check signal lamp of brake (42) switched off.

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

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2.9. Shifting the machine (transport) • On two multi-purpose check valves of the travel hyd-

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

raulic generator, screw the central parts (1) /hexagon 27 mm (11/16´´)/ into position for three revolutions clockwise.

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

! NOTICE !

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

All brakes are disabled!

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

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

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

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

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

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

Do not start the engine during towing.

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

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OPERATING INSTRUCTIONS 2.9.2.

Loading the machine

Ideally, a drive-up ramp should be used. If it is not available, use a crane. Attach cables to lifting eyes on the frame.

Use the designed lifting eyes only for slings.

Use lifting devices and slings of sufficient load capacity.

Only slingers with slinger’s certificates may attach slings.

Do not step under the hanging load.

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2.9. Shifting the machine (transport) 2.9.3.

Transporting the machine on public roads

• The standard version of the machine is not equipped with facilities to travel on public roads - traveling on public roads is forbidden!

• The roller can be transported on public roads on a vehicle of appropriate load capacity and the platform height so as not to exceed the total height of 4 m (with the roller loaded). The machine must be attached to the transporting vehicle by tying ropes on tying spots.

Tying spots (tying eyes) are located on the front and rear straps of the roller.

• The machine shifts on its own within work sites - other then public roads. Safety precautions specified for the work site must be followed during shifting.

Safety precautions: The vehicle transporting the roller must be braked for loading and unloading and mechanically secured against undesirable movements by scotch blocks.

During driving up and down the transporting vehicle, all persons but the driver must be away from the machine in such a distance that they cannot be injured in case of an accident (fall of the machine).

The person guiding the machine to the transporting vehicle must stand all the time on the same location, away from the machine and the vehicle, and must be within the field of driver’s vision (visual contact) for all the time of driving up and down.

The person guiding the machine must communicate with the driver by prescribed communication signals.

During the actual transport, no persons may stay on the driver’s stand, on the machine or on the transporting vehicle platform.

The machine must be properly anchored on the transporting vehicle and mechanically secured against possible lengthwise or side movements and overturning.

Drums must be blocked by scotch blocks.

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

Check the clearance height before driving under bridges, through tunnels or elevated structures.

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2.10. Special conditions for using the machine

OPERATING INSTRUCTIONS

2.10.1. Operating the machine during initial run period

2.10.3. Operating the machine in higher altitude

When putting the new machine into operation or during the first 30 hours after a complete overhaul, do not run the machine at full power!

In higher altitude, engine power output decreases as a result of lower atmospheric pressure and specific density of incoming air.

Altitude

2.10.2. Operating the machine at higher temperature and humidity Engine power output decreases with increasing temperature and air humidity. With regards to the fact that the two factors are independent of each other, their influence can be described as follows: • every 10°C (18°F) of temperature rise results in power output decrease of up to 4% (at a constant humidity)

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

(ft)

Power output decrease (%)

0

0

0

500

(1640)

3

1000

(3281)

6

1500

(4921)

10

2000

(6562)

15

2500

(8202)

21

3000

(9843)

28

If the engine produces black exhaust fumes in higher altitude, contact a service organisation of the engine manufacturer that will set up the injection pump for the required operating conditions.

! NOTICE !

Engine power output is affected by the environment, in which it is working.

2.10.4. Operating the machine in extremely dusty conditions Shorten intervals of cleaning and changing air filters, intervals of cleaning the engine cooler, hydraulics and changing the dust filter of the cabin.

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111

Note

112

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3.

AIR CONDITIONER

AIR CONDITIONER VH 1150

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113

AIR CONDITIONER Descriptions

Main parts of air conditioning circuit

Heat is taken from the evaporator (5) placed inside the cabin (low-pressure circuit) and transmitted to ambient medium in the condenser (2) placed in front of the engine radiator (high-pressure circuit). The compressor (1) sucks coolant vapours from the evaporator and pushes them to the condenser (2). Coolant vapours change state (phase) from gas to liquid in the condenser and flow to thermoexpansion valve – TEV (4) - through filter-hydrator (3). The TEV (4) sprays the liquid coolant to the evaporator (5) where heat is taken from the cabin while the state changes from liquid to gas and coolant vapours are sucked to the compressor (1) again.

1. Compressor

114

2. Condenser 3. Filter-hydrator 4. Thermo-expansion valve (WEV) 5. Evaporator 6. Control of air conditioner

VH 1150

AIR CONDITIONER Operating air conditioner

Air condition switch off

Operating air conditioner

• Switch off air condition (50) and ventilator (51).

• Move the heat control (52) to the Closed position.

• If the adjusted temperature is to be kept, do not change position of control (54).

• Switch on (50) air condition - pilot lamp light up.

• Switch on (51) ventilator (two speed ventilation switch).

• Move control (54) to adjust required temperature inside the cabin. Position up MAX - Position down MIN.

NOTE Air conditioner can only work while engine is running.

• Move control (53) to adjust a fresh air inside the cabin.

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115

AIR CONDITIONER Maintenance Every month: • Check coolant fill visually while engine is running.

Keep eyesight glass clear. It must not be sweating or fogged, it must be free of bubbles.

Maintenance - according to conditions

• Clean condense gills by pressured air or pressured water. Choose the interval with regards to dust conditions on the worksite. Weekly cleaning is recommended.

• Clean evaporator gills with pressured air.

• Check tension of compressor belt. When pressing the belt in its longest part by force of approx. 3 N (1.5 lbf), slack must not exceed 10 - 15 mm (0.4 - 0.6 in).

• Check drain line of condensate from the evaporator clean it.

116

VH 1150

AIR CONDITIONER Troubleshooting Always contact a service provider to repair any defect!

Fault

Possible cause

The unit does not refrigerate

check evaporator fan - if not working, check fuse F12 (7.5 A) in fuse box check coolant fill in filter-hydrator eyesight for leakage of coolant (bubbles, fogging etc.) check switching of electro-magnetic clutch: turn on AC while engine is running - if the clutch does not switch (no click can be heard on compressor), faulty fuse F12 (7.5 A) fault in thermostat or faulty overpressure fuse

Safety Coolant is classified as safe; however, in case of leak to the atmosphere it will evaporate and contact with skin or mucosae will cause burns. If open flames are present, toxic gases may arise that would cause health risks or death in case of inhalation. In case of leaks in small restricted area, coolant vapours force out oxygen and may cause death by suffocation.

Always use safety goggles and gloves when working close to AC unit or directly on the unit.

Beware of injury caused by aluminium gills when cleaning them.

First aid in case of contact with coolant In case of eye injury caused by contact with coolant, rinse eyes with large amount of water and see medical assistance immediately.

In case of skin injury caused by contact with coolant, rinse the affected spot with large amount of warm water - not hot - immediately. Protect burns with dry sterile gauze. See medical assistance.

In case of inhalation, move the affected person to fresh air and restore respiration. Call medical assistance.

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AIR CONDITIONER

Notes:

118

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4.

MAINTENANCE MANUAL

MAINTENANCE MANUAL VH 1150 (Cummins tier 2)

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119

120

VH 1150

4.1. Safety Standards at Maintenance 4.1.1.

Safety during maintenance

Lubrication, maintenance and adjustment process:

• use qualified personnel.

• according to safety instructions in the Operating manual for the vibration roller.

• according to intervals in the lubrication table according to working hours.

• on machine placed on a flat, firm surface, secured against spontaneous movement (with blocks) and with steering locked.

• with disconnected electric wires and with the starting key taken out.

• with the machine parts cooled off.

• after cleaning the machine, the lubricating and maintenance points, and spots to be repaired.

• with proper undamaged tools.

MAINTENANCE MANUAL 4.1.2.

Fire safety during changing contents

• From fire safety point of view, inflammable liquids used in the machine are classified into following classes: II

class of fire danger - Diesel

IV. class of fire danger - mineral oils, lubrication greases

• The location of oil change operation must not conflict with places subject to explosion or fire hazard.

• It must be marked by tables and signs prohibiting smoking and open flame.

• The manipulation area must be of such design and dimensions so that it can contain the amount of inflammable liquid equal to the content of the largest tank or transport package.

• The site must be equipped with portable fire extinguishers.

• by replacing parts with new original ones. The manu-

• Metal barrels, canisters or tin cans should be used for

facturer cannot be responsible for damages caused by using different units or parts.

• Transport containers must be duly closed while being

• under proper illumination of the machine when working at reduced visibility or at night

handling oils or Diesel fuel. stored.

• The containers must have one opening, they must

cartridges, reassemble them after completing the work

always be stored with the opening upside and secured against leaks.

• retighten bolts with applicable torque and check tight-

• The containers must be marked by permanent signs

• in case the work involves removing covers and safety

ness of the joints.

showing the content and the class of fire danger.

• pay attention not to get burnt after heating up fluids use recommended fills.

Operations performed while the engine is running (adjusting) must be performed with another person present. This person must have immediate access to the emergency stop and must be in permanent communication contact with the adjusting person so that the engine can be stopped immediately, if necessary.

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4.1. Safety Standards at Maintenance 4.1.3.

Environmental and health regulations

4.1.3.2. Environmental principles

During operation and maintenance of the machines the user must follow general principles of health and environment protection, and laws, notices and regulations relating to this subject, applicable in the territory.

Contents of specific machine systems and some of its parts are wastes dangerous to the environment after when discarded (disassembly, changing contents).

4.1.3.1. Health regulations

Especially the following items belong to this category of waste products:

• Oil products, contents of cooling systems and batte-

-

organic and synthetic grease, oils and fuel

ries, and paints including thinners are materials injurious to health. The workers coming into contact with these products when operating and maintaining the machine must follow general principles of health protection and safety and health instructions by manufacturers of these products.

-

coolants

-

battery contents and batteries as such

-

contents of air-conditioning systems

-

cleaning and preservatives

-

fill tires

-

all removed filters and filter cartridges

-

all used and discarded hydraulic and fuel hoses, rubberized metal pieces, and other machine elements contaminated by the above-mentioned products.

We especially draw attention to: -

eyes and skin protection when working with batteries

-

skin protection when working with oil products, painting compounds and coolants

-

proper washing of hands after work and before meals. Treat your hands with proper skin cream

-

follow instructions in the operator’s manual when working with cooling systems.

• Store oil products, coolants and battery acids, painting

After discarding, these materials must be treated in compliance with applicable national regulations for the protection of specific segments of the environment, and in compliance with health protection regulations.

compounds including organic thinners and cleaning and preservation agents always in their original, properly marked containers. Avoid storing these materials in unmarked bottles or other containers because of risk of possible substitutions. Possible substitution of food and beverages is particularly dangerous.

• In case of accidental staining skin, mucous membranes, eyes, or in case of inhaling fumes, immediately apply first aid . In case of accidental ingestion of these products seek out medical help immediately.

• Always use proper type and design of ear-protectors when working with the machine without cabin or with open windows.

122

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4.2. Specification of fluids 4.2.1.

MAINTENANCE MANUAL

Engine oil

Engine oil is specified by its performance and viscosity classifications.

Performance classification according to API (AMERICAN PETROLEUM INSTITUTE) CCMC (COMMITE of COMMON MARKET AUTOMOBILE CONSTRUCTORS).

ACEA (ASSOTIATION DES CONSTRUCTEURS EUROPÉENS DE AUTOMOBILE)

Viscosity classification To determine SAE (Society of Automotive Engineers) viscosity class, the ambient temperature and type of operation in place of usage of the machine are decisive.

Permitted oil according to API: CH-4/SJ; CI-4 CCMC: DHD1 ACEA: E5 All season - SAE 15W-40 (e.g. Valvoline, Premium Blue,).

NOTE Exceeding of the lower temperature limit does not damage the engine, it may only cause starting problems.

It is suitable to use general-purpose multi-grade oil in order that oil need not be exchanged because of ambient temperature changes.

For easier start at temperatures below 0 °C (32 °F), SAE 10W-30 oil is recommended by the engine manufacturer.

! WARNING !

Exceeding the upper temperature limit must not last for long, taking into consideration reduced lubricating properties of oil.

When using oil according to API CF-4/SH, the exchange interval should be cut to one half, i.e. 125 hours or 3 months.

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4.2. Specification of fluids 4.2.2.

Fuel

Diesel is used as fuel:

• CEN EN 590 or DIN/EN 590 (draft) • DIN 51 601 (February, 1986) • BS 2869 (1988): A1 and A2 • ASTM D 975-88: 2-D • VV-F-800C: DF-A, DF-1 and DF-2 • NATO code F-54 and F-75

4.2.3.

Coolant

The engine cooling system is filled by the manufacturer for all the year with anti-freeze liquid consisting of 50 % of ethylene glycol coolant and 50 % of water for temperatures up to –23 °C (-10 °F). Even propylene glycol liquids can be used for filling the cooling system.

Use modified demineralized or distilled water for this mixture. The following table shows application with different content of ethylene glycol or propylene glycol in the cooling liquid: Ethyl glycol antifreeze

Propylglycol antifreeze

40 % = -23 °C (-10 °F)

40 % = -21 °C (-6 °F)

NOTE

50 % = -37 °C (-34 °F)

50 % = -33 °C (-27 °F)

Engine producer recommends to use fuel with sulphur content less than 0.05 weight percent.

60 % = -54 °C (-65 °F)

60 % = -49 °C (-56 °F)

68 % = -71 °C (-90 °F)

68 % = -63 °C (-82 °F)

! NOTE !

Therefore use winter Diesel fuel at outdoor temperatures below 0 °C (32 °F). Special Diesel fuel with additives intended for very low temperatures must be used at outdoor temperatures below -15 °C (5 °F) (”super Diesel”).

! NOTE !

Do not use more than 50% of antifreeze in the coolant, unless absolutely necessary.

Never use a ratio higher than 68%.

Antifreeze is manufactured in different bases.

Their mutual mixing is not recommended. Anticorrosive properties may be lost when mixing different types of coolants.

Nitric amines dangerous to health are formed when mixing the nitride-base antifreeze and the aminebase agent.

Check the ratio of antifreeze in the coolant before wintertime using a refract meter (hydrometer).

Do not use antifreeze aggressive to aluminum - it may cause corrosion of the radiator.

124

VH 1150

MAINTENANCE MANUAL 4.2.4.

Hydraulic oil

! NOTE !

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 mm2/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.

Manufactured by

Sort of oil

Output class on ISO 6743/HV

HV (HVLP)

Viscosity class on ISO 6743/4, DIN 51519

VG 68

Viscosity class on CETOP RP 91H

HV 68

AGIP

AGIP ARNICA 68

AVIA

AVILUB HVI 68

BP

BARTRAN HV 68

CASTROL

HYSPIN AWH 68

CHEVRON

EP 68 HV

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

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 mm2/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 mm2/s - viscosity class HV 32, such as BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.) see Operating Instructions chapt. 2.9.3.

Synthetic hydraulic oil Hydraulic system can be filled with synthetic oil, such as PANOLIN - HLP Synth. 15/22/32/68 that is completely degradable by microorganisms found in water and soil in case of leak.

! NOTE !

Water content (condensation water) in oil must not exceed the limit of 0,1%.

Operating fluid must be checked by taking samples in regular intervals - see the chart.

When filling older machines with synthetic oil, the residual limit of mineral oils must not exceed 8% of the total fill.

When filling biologically degradable oils, mixing with up to 2% of the total tank content is allowed.

When changing over from mineral oil to synthetic or when mixing oils of different brands, always consult the procedure with the oil manufacturer or dealer!

Interval of taking samples

Common operation

Extreme conditions

1. check

500 h

250 h

2. check

1000 h

500 h

1000 h or once a year

500 h or once a year

subsequent checks

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125

4.2. Specification of fluids 4.2.5.

Gearbox oil

4.2.6.

Use high quality oils complying with API GL-5 or EP or MILL-2105 C for lubricating the gearbox pumps driven.

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).

Manufactured by

Lubricating grease

Plastic grease containing lithium in compliance with NLGI2 regulation (Mobilplex EP-1, Retinax A, Alvania, Grease No 3 etc.) must be used to grease the machine.

ISO 6743/9 CCEB 2 DIN 51 502 KP2K-30 (Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, Grease No 3 etc.).

Sort of oil

4.2.7.

Windshield washer liquid

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

! NOTE !

BP - MACH

HYPOGEAR EP

HYPOGEAR EP

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

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

Water (at temperatures down to 0°C) and windshield washer agent are used as fills in the washer can.

! NOTE !

The operating oil temperature must not exceed 85 °C ÷ 90 °C (185 °F ÷ 194 °F).

126

VH 1150

4.3. Fills

MAINTENANCE MANUAL

Fills of...

Type of fill

Engine

Engine oil according to chapter 4.2.1.

9,5 (2,5)

Fuel tank

Diesel according to chapter 4.2.2.

210 (55,5

Hydrostatic system

Hydraulic oil according to chapter 4.2.4.

70 (18,5)

Pump driven gearbox

Gearbox oil according to chapter 4.2.5.

0,8 (0,21)

Joint bearings - joint and steering cylinder

Plastic grease according to chapter 4.2.6.

as required

Engine cooling system - coolant

All year round - anti-freeze liquid according to chapter 4.2.3 for temperatures down to -25°C (-13°F)

18,8 (4,96)

Vibrating drum

Engine oil, see the engine

Battery

Distilled water

as required

Windshield washers

Water and antifreeze - ratio according to outdoor temperature to chapter 4.2.7.

2,75 (0,72)

Front sprinkling tank

Water

660 (174)

Rear sprinkling tank

Water.

640 (169)

VH 1150

Quantity l (gal US)

Brand

4 x 2 (4 x 0,53)

127

4.4. Lubrication chart

128

VH 1150

4.5. Individual operations of maintenance

MAINTENANCE MANUAL

Lubrication and maintenance should be performed in regular intervals based of every day reading of data on workinghours counter (21).

Dismounted or loosened bolts, plugs, threaded joints in the hydraulic system, and the like, should be tightened using tightening torque given in tables in Chapter 4.5.42 if it is not specified otherwise at the particular operation.

This manual includes only basic information of the engine, the other data are given in the Operation and Maintenance Manual which is a part of documentation supplied together with the machine.

! NOTICE !

Observe all the instructions specified in the Operation and Maintenance Manual !

After first fifty hours of operation of a new machine (or after overhaul) do the following: 4.5.22. Clean the sprinkle pump filter

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129

4.5. Individual operations of maintenance

130

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MAINTENANCE MANUAL

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131

4.5. Individual operations of maintenance After 20 hours of work or daily 4.5.1.

Checking, refilling oil in the engine

After 20 hours of work or daily • Refill oil through the filler neck after removing the filling plug (1).

• Do that before starting the engine – the machine must stand on the flat, rigid surface.

• Open the lid in the cabin floor.

1

• Lower mark L (Low) shows the lowest possible oil level, upper mark H (high) the highest one.

• Pull out oil gauge (1) and wipe it.

1 H L

• The amount of oil between the lower (L) and upper (H) marks is 0.95 l (1. U. S. quart).

• Put is back up to the stop, pull out again and read height of the level.

! NOTICE !

If the engine was running, wait approximately 3 minutes when oil flows into the engine tub.

After refilling, wait approximately three minutes before oil flows to the tub and check the level.

Do not use the engine if oil level in the engine is not correct.

Oil level should be between marks coined on the oilgauge.

Use oil of the same brand for refilling as given in Chapter 4.2.1.

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MAINTENANCE MANUAL After 20 hours of work or daily 4.5.2.

After 20 hours of work or daily

Checking, refilling of engine coolant The filling plug should be removed when coolant temperature drops below 50 °C (120 °F). If you tried to take off the plug at higher temperature, there would be a danger of scalding with steam or coolant because of inner overpressure.

• Do that before starting the engine – the machine must stand on the flat, rigid surface.

• Do visual inspection of the level as given in fig.

MAX

MIN

• The level should be between ”MIN” and ”MAX” marks.

• In case of a great loss, find untightness in the cooling system and rectify it.

! NOTICE !

Never use additives used for elimination of untightness of the cooling system in coolant liquid of the engine!

Do not fill cold coolant into hot engine. Motor casts could be damaged by it.

Refill only coolant consisted of anti-freeze agents on the same basis as stipulated in Chapter 4.2.3.

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4.5. Individual operations of maintenance After 20 hours of work or daily 4.5.3.

Check of cooling fan condition

• Check visually before starting the engine or with stopped engine.

• If it is damaged (e. g. some parts of material are missing, scratches, changes in the shape, and the like), replace it.

134

After 20 hours of work or daily 4.5.4.

Checking the engine belt

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

VH 1150

MAINTENANCE MANUAL After 20 hours of work or daily 4.5.5.

Cleaning the water separator con the fuel filter

• Prepare a vessel for draining the settling.

• Turn the separator valve clockwise by 3,5 rotations

After 20 hours of work or daily ! NOTE !

If you drained more than 6 cl (2 ozs) of fuel, refill fuel into the fuel filter according to chapter 4.5.23. or deaerate the system according to chapter 4.5.36. This will prevent problems with starting.

until it shifts down by approx. 25 mm (1”). Let fuel drain until clean fuel starts to drain.

Do not smoke nor use open fire when working.

Do not drain the separator under running engine.

Catch the drained fuel with sediments to a suitable container.

`

• Then push the valve up and screw it in.

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135

4.5. Individual operations of maintenance After 20 hours of work or daily 4.5.6.

Checking, cleaning of the fuel precleaner

After 20 hours of work or daily • Loosen the lower nut (1) and swing the stirrup (2) out.

• Inspect visually before starting the engine.

• Open the right cover of the engine.

4 3 2

1

• Take out a glass (3) with a strainer (4).

• Clean the glass and rinse out the strainer.

• Close the fuel inlet using the valve (A) placed on the fuel tank.

• Mount it back again.

• Open the fuel inlet using the valve (A).

NOTE

A

Frequency of cleaning intervals depends on purity of fuel used.

Observe all fire regulations!

Do not smoke when working with the fuel system and do not use naked flame.

Collect spilt fuel.

136

VH 1150

MAINTENANCE MANUAL After 20 hours of work or daily 4.5.7.

Crankcase breather tube

• Inspect the breather tube for sluge, debris, or ice the tube.

• Inspect the tube more frequently in icy conditions.

After 20 hours of work or daily 4.5.8.

Check of air filter vacuum valve

• Check visually before starting the engine or with stopped engine.

• Clean the outlet slot.

• Remove clotted dust by pressing.

NOTE Dust from the valve is emptied automatically when the machine works.

! NOTICE !

Do not operate the machine if the dust valve is damaged.

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137

4.5. Individual operations of maintenance After 20 hours of work or daily 4.5.9.

Check of hydraulic oil filter sensor

After 20 hours of work or daily • Hydraulic oil filter placed on the left side machine frame.

• Check indicators of both filters.

• Hydraulic oil filter placed under machine cab.

! NOTICE !

The check-up should be carried out with engine started and at oil temperature of 40 – 50 °C (104 – 120 °F).

If an indicator shows a red field, the filter insert must be replaced.

138

VH 1150

MAINTENANCE MANUAL After 20 hours of work or daily 4.5.10. Check of the amount of fuel

After 20 hours of work or daily NOTE

• Fuel in the tank is on the average sufficient for about • Do that before starting the engine – the machine must stand on the flat, rigid surface.

• Check the amount of fuel on the fuel gauge.

20 to 25 hours of operation depending to machine load and the way of travel.

• If signal lamp in the fuel gauge goes on, refill fuel.

! NOTICE !

Use only clean recommended fuel as specified in Chapter 4.2.2.

Keep cleanliness when working.

Do not smoke when working and do not use naked flame.

Do not refill fuel in the closed area.

Do not refill fuel when the engine is running.

• Clean the fuel filler cap (1) and the filler neck.

• Unlock the fuel tank lock and turn the cap as shown in

Do not spill fuel.

fig.

1

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139

4.5. Individual operations of maintenance After 20 hours of work or daily

After 20 hours of work or daily • Unscrew the plug (1) and refill through the sieve.

4.5.11. Check of the amount of oil in the hydraulic circuit tank • Do that before starting the engine – the machine must stand on the flat, rigid surface.

1

• Open the left cover of the engine.

! NOTICE !

Keep the level between upper and lower edges of both oil-gauges.

• Check the oil level in the peep-holes of oil gauges.

Oil level must always be visible in the lower oilgauge!

Refill prescribed oil as given in Chapter 4.2.4.

MAX

In case of a large oil loss find why the hydraulic system is not tight enough (hose screw fitting leakage, hydrogenerator or hydraulic motors leakage) and repair defects.

MIN

140

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MAINTENANCE MANUAL After 20 hours of work or daily 4.5.12. Refilling the sprinkle tank

After 20 hours of work or daily • On left parties frame machinery check quantity water in the front and rear sprinkling tanks.

• Do that before starting the engine – the machine must stand on the flat, rigid surface.

• After opening the cap (1) refill clean water through the sieve (2) fig.

1

2

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141

4.5. Individual operations of maintenance After 20 hours of work or daily 4.5.13. Check of warning and checking devices

After 20 hours of work or daily • Turn on the ignition key (17).

• Signal lamps of parking brake (42), neutral gear (38), charging (41).

• Turn on switches of the warning horn (12), indicator lights (13) and (39), headlights (44), tail lights (45), warning lights (46), extra lights (47) and check how they work.

142

• Switch on the beacon (48) (optional).

• Start the engine, start driving and press emergency brake button (10), the machine will stop and the engine will stall; - brake signal lamp will go on (41).

VH 1150

MAINTENANCE MANUAL After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

4.5.14. Changing oil and oil filter

• Clean the area around the oil filter head. Dismount the filter.

• The roller should stand on the flat, rigid surface.

• Stop the engine and disconnect the wiring.

• Remove the drain plug and let oil flow out.

• Clean the contact area of the filter sealing.

• Remove the engine cover behind the front drum.

• Take a new filter and fill it with clean engine oil.

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143

4.5. Individual operations of maintenance After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

• Wipe the sealing with oil.

• Check the drain plug packing and replace, if damaged.

• Check the thread and clean the seating face for the packing.

• Screw the plug to its place. Tightening torque is 55 Nm (41 ft lb).

• Mount the filter and tighten firmly with hand.

• Take out the cover in the cabin floor.

• Fill the engine with clean engine oil through the filler neck up to maximum.

144

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MAINTENANCE MANUAL After 250 hours of operation (after 3 months) • Fill up to the upper mark of the gauge. Total amount of oil is 9,5 litres (2.5 US gallon).

After 250 hours of operation (after 3 months) ! NOTICE !

Drain only warm oil – preferably after finishing the operation of the machine.

Use only original filters.

Use only recommended oil as given in Chapter 4.2.1.

Do not overscrew the filter – thread and packing could be damaged.

Check tightness.

When oil is drained its temperature must not be higher than 50 °C (120 °F) – danger of burn!

Observe all fire regulations!

• After refilling oil, start the engine and let it run at increased idle speed for two to three minutes.

• When the engine stops, wait about three minutes before oil flows down to the crank case of the engine; check the correct oil level.

Collect drained oil, do not let it soak into the ground.

Observe oil disposal regulations.

Store used filters in a separate container and handle them carefully not to pollute the environment.

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145

4.5. Individual operations of maintenance After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

4.5.15. Checking the injection pump

4.5.16. Checking oil level in gearbox

• Check tightness of the injection pump nuts.

• Position roller horizontally on a firm and flat surface.

• Open and secure the right engine cover.

• Check oil level with the dipstick in the upper plug.

• If needed fill up to top dipstick mark.

Maintain oil level at the top mark!

146

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MAINTENANCE MANUAL After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

4.5.17. Check of the cooling circuit of the engine

NOTE

• The cabin must be lifted off before checking, see Chapter 2.8.18. ”Operating instructions”.

• The roller should stand on the flat, rigid surface.

• Stop the engine and disconnect the wiring.

• At the same time check cleanliness of radiator and oil cooler. If they are dirty, proceed as specified in Chapter ”Needed maintenance” – p. 4.5.37.

• Check tightness of the cooling circuit (hoses and clips).

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147

4.5. Individual operations of maintenance After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

4.5.18. Check of inlet piping in the engine • The roller should stand on the flat, rigid surface.

• Stop the engine and switch off wiring.

• Check the connections.

NOTE The cabin must be lifted off before checking, see Chapter 2.8.18. ”Operating instructions”.

! NOTICE !

Do not operate the machine if the hose is damaged!

148

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MAINTENANCE MANUAL After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

4.5.19. Inspection of pressure switch of air cleaner

• Should the bulb not light up, check cause (faulty bulb, contact, wires, pressure switch).

• Check while the engine is running in max. speed engine.

• Cover momentarily the opening in the air cleaner input manifold - following removal of grid, cover suction intake.

Use heavy paper – light paper may plug up suction opening!

• When covered, the control bulb indicator of air cleaner condition lights up (40).

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149

4.5. Individual operations of maintenance After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

4.5.20. Check of batteries

• Compared the values measured with the table where

• The roller should stand on the flat, rigid surface.

battery charging condition is shown at 25 °C (68 °F) and in the tropics.

• Stop the engine and disconnect the wiring.

Density

• Clean the surface of batteries.

in g/cm

in °Be (Beume)

3

• Check the condition of poles and terminals (1). Clean

Normal Normal Tropics Tropics temperatures temperatures

battery poles and terminals. Apply a thin layer of grease to terminals (make sure that the contact is good). 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°

NOTE

• Check the level using a glass tube.

• If the machine is not used for several weeks in winter, dismount the batteries and store them protected from frost. Before storing and during storing check the batteries and their charging.

• After opening battery cell plugs check the level of electrolyte and find whether it reaches in all the cells up to 5 – 15 mm (0.2 to 0.6 in) above the plates or to the height of check inserts.

• Measure density of electrolyte in each cell.

! NOTICE !

Keep batteries dry and clean.

Close them with plugs after the check-up.

Refill distilled water into cells immediately before starting operation of the machine or before charging the battery.

Use only distilled water – never acid – for refilling.

Charge battery if its charge is not sufficient.

Charge batteries outside the machine.

Do not disconnect battery when the engine is running.

150

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MAINTENANCE MANUAL After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months) 4.5.21. Lubricating

When working with a battery always observe the manufacturer´s instructions.

• Bearings of front and rear stirrups.

When working with a battery, wear rubber gloves and eye-protection devices.

Do not eat, drink or smoke!

After work, wash your hands and face carefully with water and soap!

Protect your skin from electrolyte stains and wear suitable clothes.

If electrolyte gets into your eye, rinse the eye immediately with a stream of water for a few minutes. Then go and see a doctor.

If you swallow electrolyte, drink as much milk, water or magnesian solution as possible.

If electrolyte gets to your skin, take off your clothes and boots, wash the stains as soon as possible with soap water or water and soda solution. Then go and see a doctor.

• Central bearing of the drum. Turn the drum into the position shown in the Figure. Fill with grease (about a half of the manual grease pump content) (part of machine equipment).

Do not examine voltage in a conductor by touching the machine frame.

Disconnect the battery when repairing it or handling conductors and electrical appliances in the wiring to prevent shortcircuit.

When you disconnect the battery, disconnect the cable of (-) pole first. When connecting it, connect (+) pole first.

Do not turn the batteries because electrolyte could flow off from degassing vents.

When electrolyte is spilt, rinse the area with water and neutralize with lime.

Dispose of old batteries which will not be used any more.

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NOTE In the roller with one-piece drums, there is no central bearing – no lubrication is thus necessary.

151

4.5. Individual operations of maintenance After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

Steering pins.

Engine cover suspensions.

Suspensions of front and rear masks.

Cabin door hinges.

NOTE Keep filling with grease as given in Chapter 4.2.6. until new lubricating grease starts to run out.

152

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MAINTENANCE MANUAL After 250 hours of operation (after 3 months)

After 250 hours of operation (after 3 months)

4.5.22. Cleaning of sprinkle filter

• Dismount the container of sprinkle filter (1), take out the sieve (2) and clean it.

• Close the water inlet using the valve.

1

• Remove screws from front and rear masks.

1

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2

153

4.5. Individual operations of maintenance After 500 hours of operation (after 6 months)

After 500 hours of operation (after 6 months)

4.5.23. Engine fuel filter exchange

• Clean the contact area of the filter.

• Stop the engine.

• Disconnect water separator sensor connector (1).

1

• Fill the filter with clean fuel.

• Clean the head of fuel filter and dismantle the filter.

• Wipe the sealing ring with oil.

• Dismantle water separator sensor (2) from the filter and assembly it on new filter.

2

154

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MAINTENANCE MANUAL After 500 hours of operation (after 6 months)

After 500 hours of operation (after 6 months)

• Mount the filter and tighten firmly with hand.

! NOTE !

Use original specified filters.

Do not tighten by force.

Do not smoke nor use open fire when working!

Collect leaking fuel.

Store used filters in a separate container and dispose of them.

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155

4.5. Individual operations of maintenance After 500 hours of operation (after 6 months) 4.5.24. Check of coolant concentration

After 500 hours of operation (after 6 months) or refractometer.

• Inspect as given in concentration of anti-freeze agent in cooling liquid using densimeter

! NOTICE !

The inspection should be done always before winter. If concentration for –23 °C (-10 °F) is not measured, adjust it by refilling anti-freeze agent into the cooling system.

Refill with anti-freeze agent as given in Chapter 4.2.3.

When measuring with densimeter, the liquid temperature must be 20 °C (68 °F).

156

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MAINTENANCE MANUAL Every 1000 Hours or Once a Year 4.6.25. Checking and adjusting valve clearance

Every 1000 Hours or Once a Year • Insert the grooved pin Cummins no. 3824591 with 1/ 2” recess for hex key. Using the key manually turn the engine.

• Dismantle the inlet air piping leading to the turbo charger and valve covers.

•

By slow turning the engine find top dead center of no.1 cylinder. In this position, valve rocker arms of both valves (E, I) are free.

I E • Dismantle the blinding plug on the opening of the flywheel casing, which allows the insertion of the grooved pin.

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4.5. Individual operations of maintenance Every 1000 Hours or Once a Year

Every 1000 Hours or Once a Year

• Measure the clearance of the inlet and exhaust valves

• Check and adjust clearances of remaining valves

of the 1st cylinder using feeler gauge. To adjust clearance, loosen the locking nut and turn the adjusting screw by a screwdriver.

• Check and adjust clearances of remaining valves

according to.

• Remount valve covers. Mount the air input pipes.

according to.

! NOTE !

Check and adjust valves when the engine has cooled down to below 60°C.

The order of cylinders is 1 - 4 from the fan belt pulley valve clearances: -

Inlet valves: 0.254 mm (0.010 in).

-

Exhaust valves: 0.508 mm (0.020 in).

Clearance is adjusted correctly, when resistance can felt while moving the feeler gauge.

• After tightening the locking nut recheck clearances.

• Make a mark on the torsion vibration damper and turn

(I) sign applies to inlet valves, (E) to exhaust valves.

After adjustment tighten the locking nuts and the cover bolts with torque of 24 Nm (18 ftlb).

the crankshaft by 360°.

( 158

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MAINTENANCE MANUAL Every 1000 Hours or Once a Year 4.6.26. Checking the engine belt

Every 1000 Hours or Once a Year • Check the axial clearance of the ventilator belt pulley - it must not exceed 0.15 mm (0.006 in).

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

• Stop the engine!

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

9

• Mount the belt back.

Checking the tensioner:

• Check the tensioner belt pulley and arm for cracks.

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

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159

4.5. Individual operations of maintenance Every 1000 Hours or Once a Year • Check the tensioner for clearance.

Every 1000 Hours or Once a Year • Check the belt tensioner for clearances and for deviation of the pulley from the vertical axis. Maximum deviation is 3 degrees.

160

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MAINTENANCE MANUAL Every 1000 Hours or Once a Year 4.5.27. Gearbox oil change

Every 1000 Hours or Once a Year • Replace drain plug.

• Fill with 0,8 l (0,21 US gal) of oil and check with dipstick

• Position the machine horizontally on a firm and flat

on input lid.

surface.

• Open and secure the right engine cover.

• Remove cover in the frame underneath the engine.

Oil level must reach the upper mark on the dipstick!

• Disconnect the connector (1) boost valve.

• Remove input lid (2) and drain plug (1) – catch oil in a suitable container.

1

3

2

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161

4.5. Individual operations of maintenance Every 1000 Hours or Once a Year 4.5.28. Check of the exhaust tract

Every 1000 Hours or Once a Year • Check the exhaust piping to the damper.

• The machine should stand on the flat, rigid surface.

• Stop the engine and disconnect the wiring.

• Check tightness of exhaust piping joints to the engine.

• Tightening torque of the collector is 21 Nm.

162

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MAINTENANCE MANUAL Every 1000 Hours or Once a Year

Every 1000 Hours or Once a Year

4.5.29. Exchange of oil in the vibrator

on the left-hand side of the rear drum

• The machine should stand on the flat, rigid surface.

• Turn the drums gradually in such a way that the mark (lug) (1) is in its lowest position.

1 2 on the left-hand side of the front drum.

• Stop the engine and disconnect the wiring.

• Put a suitable vessel under the drain plug (2).

• Unscrew the plug and let oil flow out.

• Turn the drum to the upper position using the plug (2).

• Pour 2 litres of recommended engine oil through the filling hole as given in Chapter 4.2. and 4.2.1.

• Install the plug (2).

• Check the amount of oil after the exchange by loosening the check plug on the right-hand side of both the drums.

! NOTICE !

Oil refilling should be done when it is warm, not hot, its temperature should be lower than 50 °C (120 °F).

When hot oil is drained there is a danger of burn!

Collect drained oil and dispose of it according to the local regulations.

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163

4.5. Individual operations of maintenance Every 1000 Hours or Once a Year 4.5.30. Check of the damping system

Every 1000 Hours or Once a Year drum damping systems

Check how bolts and nuts are tightened.

• Check adhesion between metal and rubber and possible splits in the rubber parts. Replace, if damaged. driver´s post

NOTE Check with 75 Nm (55 lb ft) tightening torque.

164

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MAINTENANCE MANUAL Every 1000 Hours or Once a Year 4.5.31. Cleaning of water tanks

Every 1000 Hours or Once a Year • Rinse out the tank with water stream.

• Clean the sieve in the filler neck.

• The machine should stand on the flat, rigid surface.

• Stop the engine and disconnect the wiring.

• Dismount the tank filling cap.

• Open the discharge holes.

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165

4.5. Individual operations of maintenance After 2000 hours of operation (every 2 years)

After 2000 hours of operation (every 2 years)

4.5.32. Checking torsion vibration damper of the engine

• Check visually whether the torsion vibration damper is not moving forward. Check th vibration damper for evidence of fluids loss, dents and wobble.

• Check the position of pressed marks on the face of both parts of torsion vibration damper. If the marks are shifted from each other by more than 1.59 mm (1/16 in), it is necessary to exchange the damper.

! NOTE !

With time, the flexible silicone filling of the damper gets rigid and no longer works properly. Nonworking damper may cause considerable damage to the engine.

• Check whether the rubber component (3) is not higher or lower above the level of metal parts (1) and (2) by more than 3.18 mm (1/8 in). If the limit is exceeded, exchange torsion vibration damper.

1 3

2

166

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MAINTENANCE MANUAL After 2000 hours of operation (every 2 years)

After 2000 hours of operation (every 2 years)

4.5.33. Exchanging the engine cooling liquid

• Open the drain cock in the cooler lower chamber. Let liquid drain into prepared vessels. The quantity drained is approximately 19 l (5 US gal).

! NOTE !

Exchange the coolant after operation of the machine or after warming the coolant (by running the engine) to 80 °C (176 °C).

• Place the roller onto a flat, firm surface.

• Stop the engine.

• Open cooling system by removing pressure plug (1) on the equaliser reservoir.

1

NOTE

• Check cooling system for defective hoses and missing hose clips. Check the condition of the cooler - search for defects, leaks and cooling gills blocked with impurities. Clean and repair it, if necessary.

Do not dismantle the pressure plug before the temperature of cooling liquid falls lower than to 50 °C (122 °C). Beware of gushing of the coolant and scalding when opening the pressure plug.

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167

4.5. Individual operations of maintenance After 2000 hours of operation (every 2 years)

After 2000 hours of operation (every 2 years)

• After closing the drain cock, fill cooling system with

Do not dismantle the pressure plug before the temperature of cooling liquid falls lower than to 50°C (122°C). Beware of gushing of the coolant and scalding when opening the pressure plug.

new cooling liquid with ratio of 50% of water + 50% of anti-freeze agent.

• Fill it up to the upper edge of the level indicator. After filling, wait for approx. 2-3 minutes until air goes off and the circuit is filled. The maximum filling rate is 19 l/min (5 US gal/min). Close the equaliser reservoir with the pressure plug.

! NOTE !

Use cooling liquid according to chapter 4.2.3!

Follow the instructions of the manufacturer of anti-freeze fluid when changing coolant!

Protect your hands with gloves!

Use safety glasses or safety shield!

Collect used liquid and have it safely disposed according to valid regulations!

• Start the engine and wait until the temperature reaches 80 °C (175 °F). Check during your waiting for any leakage of cooling liquid.

• Stop the engine.

• Check the level on the indicator (2). If the level is low, refill cooling liquid to maximum.

168

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MAINTENANCE MANUAL After 2000 hours of operation (every 2 years)

After 2000 hours of operation (every 2 years)

4.5.34. Cleaning of the fuel tank

• Rinse out the tank with clean fuel, remove any impurities.

• The machine should stand on the flat, rigid surface.

• Replace the drain plug and lid – check the packing.

• Stop the engine and disconnect the wiring.

• Clean the tank when there is minimum amount of fuel there – after signal lamp indicating minimum amount goes on.

• Unscrew the drain plug and let the rest of fuel run out into a prepared vessel.

Observe all fire regulations!

Do not smoke when working and do not use naked flame.

Clean the tank in ventilated areas where there is no danger of fire.

Meet hygienic requirements.

Observe ecological regulations.

Prevent fuel soaking into the ground.

• Remove the cleaning lid (1) with the fuel gauge (2).

Make sure that the gauge is not damaged.

2 1

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4.5. Individual operations of maintenance After 2000 hours of operation (every 2 years) 4.5.35. Exchange of oil and filter in the hydraulic system • The machine should stand on the flat, rigid surface.

• Stop the engine and disconnect the wiring.

After 2000 hours of operation (every 2 years) Oil discharging should be done when it is warm, not hot, its temperature should be lower than 50 °C (120 °F).

Observe all fire regulations!

• Open the left cover of the engine.

• Clean properly the fuel filler cap and open it.

Collect drained oil and dispose of it according to the local regulations.

Exchange of filter elements

• Change both the filtration elements.

• Remove the drain plug from below in the cover under the engine, let oil run out into a prepared vessel.

NOTE The content is 65 litres (17 US gallon).

170

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MAINTENANCE MANUAL After 2000 hours of operation (every 2 years)

After 2000 hours of operation (every 2 years)

• Remove the filter vessel (1) together with the filtration

Hydraulic system filling

element (2), clean the vessel properly. Clean the seating face of the filtration block from below. Put a new element into the vessel and screw it back – tighten with torque of 40+10 Nm (30+7 lb ft). Check the O-ring (3).

2

• Put the filling device fast coupling on the fast coupling for filling on the machine.

1

3

! NOTICE ! ! NOTICE !

Change elements when a red field on the filter sensor can be seen.

Use recommended filters only.

Do not overscrew the filter, thread and packing could be damaged.

Continue filling the hydraulic circuit until pure oil starts running out through the drainage hole. After outflow of about 15 litres of oil, close the discharge hole with the plug.

• Fill in maximum content , disconnect the filling device, close the tank with the cap.

MAX Filtration elements used are dangerous waste, dispose of them as it is stipulated in the local regulations.

MIN

• Start the engine, set 2600 . min-1 revolutions, and try functions of the machine.

• Check oil level and tightness.

NOTE

• Filling device can be supplied by the machine manufacturer.

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4.5. Individual operations of maintenance After 2000 hours of operation (every 2 years) Substitute filling of the hydraulic system

• After discharging oil, replace the drain plug and fill the specified sort of oil through the filler neck up to the maximum content.

After 2000 hours of operation (every 2 years) ! NOTICE !

This is only an emergency solution – not recommended by the manufacturer!

For that reason reduce the oil exchange interval by a half – 1000 hours or a year.

Change oil and filtration elements when inner part of the unit was destroyed (hydraulic motors, hydrogenerators) or after substantial repair of the hydraulic system. Clean and rinse out the hydraulic tank before installation of the new unit. Exchange both the filtration elements.

Use devices without fibres for cleaning.

Observe all fire regulations!

Use only oils recommended in Chapter 4.2.4.

When changing oil, keep all hygienic standards!

• Start the engine, set 2600 . min -1 revolutions, and try all functions of the machine until all circuits are filled.

• Check oil level.

NOTE In this case a large portion of old oil containing impurities will remain in the circuit and service life of hydraulic unit is reduced.

172

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MAINTENANCE MANUAL Necessary maintenance 4.5.36. Deaerating the fuel system

Necessary maintenance Collect leaking fuel.

NOTE

• Pressure valve on the fuel pump provides for autodeaerating of the system when replacing most of parts.

• Usually, most of air present in the system will be vented within 25-sec run of the feeding fuel pump.

• Turn the ignition key for a moment to the ”START” position and back to the ”I” position. Feeding pump will start rotating.

• If aeration is heavy, the system must be deaerated.

• Loosen the screw on the overflow pipe.

! NOTE !

Should the system not be deaerated with running engine, check connections and seals of fuel line from the fuel tank to the feeding pump. Check whether fuel is not penetrating in loose connections and defective seals on line from the feeding pump to the injection pump.

Hanging - opened injector causes blowing of burnt exhaust gases back to the pump, which causes air lock of the fuel overflow line.

• If the engine fails and its operation is irregular, loosen the high-pressure line to injectors on the injection pump.

• With the feeding pump running, check when all air is vented; then tighten the screw.

Deaerating the high-pressure piping and injectors:

• If you carried out the previous actions and the engine did not start, deaerate the high-pressure piping.

• Loosen one or more nuts on injectors and crank the engine. Go on until the engine shows regular running.

• Tighten loosened nuts to torque of 30 Nm.

Fuel pressure in the high-pressure piping is rather high - it may cause serious injuries.

Do not deaerate hot engine - fuel may get into contact with hot waste piping and flare up.

• Crank the engine and watch the piping. If exhaust gases blow back through the piping, hanging-opened injector may be the cause. In that case, contact your dealer or Cummins service organisation to have the injector replaced.

! NOTE !

Use two wrenches to loosen the high-pressure piping on the injection pump.

Do not smoke nor use open fire when working on fuel system.

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173

4.5. Individual operations of maintenance Necessary maintenance 4.5.37. Cleaning of radiator • The machine should stand on the flat, rigid surface.

• The cabin must be lifted off before checking, see

Necessary maintenance 4.5.38. Cleaning of air filter in the cabin ventilation • Remove the top grate (1).

Chapter 2.8.18. ”Operating instructions”.

• Clean with pressure air or water (steam) from the side of the fan.

1

• Take out the filter (2) with the filtration element (3).

3 NOTE If the radiator is logged, temperatures of engine coolant and hydraulic system oil go up. Clean very frequently if the machine works in the very dusty environment. In case radiators were contaminated with oil, find the cause!

2

! NOTICE !

If you use a detergent, follow the manufacturer´s instructions!

Do not use cleaners using too high pressure not to damage the radiator fins.

• Carefully hammer out the element and wash in detergent solution. If the element is damaged or cannot be cleaned properly, replace a new one.

Observe all ecological standards and regulations.

Collect rinse water in storage reservoirs.

NOTE Clean regularly once a month. If the environment is very dusty, reduce cleaning intervals.

Do not use forbidden cleaning agents.

174

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MAINTENANCE MANUAL Necessary maintenance 4.5.39. Cleaning and exchange of air filter element

Necessary maintenance • Turn and take off the lid.

• When signal lamp (40) goes on, the element must be cleaned or replaced.

• Carefully take out the main element.

• The machine should stand on the flat, rigid surface.

• Stop the engine and disconnect the wiring.

• Loosen the clips.

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4.5. Individual operations of maintenance Necessary maintenance • Clean the interior of the filter so that duct could not get inside the supply line leading to the engine.

Necessary maintenance ! NOTICE !

Air pressure must not exceed 5 bar (72 PSI).

Clean the element not more than five times, then use a new one.

The element should be changed after a year of operation, at the most.

• After cleaning transilluminate the element to find whether it is not damaged.

• Install a new or cleaned main element. Check its proper seating and packing.

! NOTICE !

Do not blow the interior of the filter with compressed air!

• Clean the element by blowing compressed air from inside towards outside.

176

• Check if the packing is flexible and that it seats properly.

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MAINTENANCE MANUAL Necessary maintenance • Take off the vacuum valve and clean it.

Necessary maintenance ! NOTICE !

Safety element is changed together with the main element or when the signal lamp goes on after cleaning the main one.

Use original elements only!

Never use damaged elements.

Do not take out elements just to check them up.

Do not use the filter with damaged cover or body.

Replace a damaged vacuum valve at once!

Do not hammer an element.

Never clean filtration elements with petrol or liquids.

When washing the machine, take care not to splash water into the air filter.

When the elements absorbed moisture, dismount them and dry. Dry the filter body as well.

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177

4.5. Individual operations of maintenance Necessary maintenance 4.5.40. Cleaning of scrapers

Necessary maintenance • Turn the rubber-metal of the scraper (1) using spanner 36 as it is required.

• The machine should stand on the flat, rigid surface.

Adjustment of rubber-metal prestress.

9

9

• Stop the engine and disconnect the wiring.

• Loosed the screw (1).

1 1

Exchange of blades

• Reduce prestress – see p. ”Adjustment of rubbermetal prestress”.

• Remove screws (1) and take out the blade (2) with bars (3). After blade (2) replacement, mount everything back.

• The central screw on the other side (2) at both the ends of the scraper.

3

2

2

1

• Set rubber-metal prestress to ~ 15o as specified in p. ”Adjustment of rubber-metal prestress”.

178

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MAINTENANCE MANUAL Necessary maintenance

Necessary maintenance

4.5.41. Cleaning of the machine

4.5.42. Check of screwed joints tightening

• After finishing work, clean major impurities.

• Check regularly whether the joints are not loosened.

• Carry out the total cleaning regularly, at least once a

• Use torque spanner for tightening.

week. When working with cohesive soil, cement and lime stabilizations, clean the machine every day.

Table of tightening torques for bolts with metric threads:

! NOTICE !

TIGHTENING MOMENT

Do not use aggressive and easily inflammable cleaning agents (e. g. petrol and/or easily inflammable plastics).

For the screw 5,8 (5S)

For the screw 8,8 (8G)

For the screw 10,9 (10K)

Clean with the engine stopped.

Worm

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

When using a steam cleaner, do not expose electrical parts or insulation material to direct steam stream. Such materials should be always covered.

M4

2

1

3

2

4

3

M5

4

3

6

4

8

6

Take care not to splash water into the air filter.

M6

7

5

10

7

14

10

Before cleaning the machine using pressure cleaners (water, steam, and the like), blind all holes through which the cleaning agent could penetrate (e. g. inlet hole of the engine, interior of the alternator, etc.). Remove these cappings after finishing the cleaning.

M8

16

12

22,5

17

32,5

24

M10

31,5

23

44

32

62

46

M12

53

39

75

55

105

77

M14

79

58

118

87

165

122

M16

113

83

165

122

226

167

M18

172

127

245

181

343

253

M20

226

167

314

232

441

325

M22

284

209

392

289

559

412

M24

392

289

549

405

755

557

M27

520

384

716

528

1020

752

Disconnect the battery isolating switch!!

When cleaning, observe all ecological standards and regulations!

Carry out machine cleaning at sites where there are storage reservoirs for collecting rinse water and detergents.

Do not use forbidden detergents.

Follow the instructions of detergent manufacturers.

Values given in the table mean torque with the dry thread (friction coefficient = 0.14). These values are not valid for lubricated threads.

! NOTICE !

Self-locking nuts may be used three times at the most after their loosening.

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4.5. Individual operations of maintenance Necessary maintenance

Necessary maintenance

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

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

lb-ft

Size spanner

Worm

Hose

Nominal

Min

Max

Nominal

Min

Max

14

M12x1,5

6

20

15

25

15

11

18

17

M14x1,5

8

38

30

45

28

22

33

19

M16x1,5

45

38

52

33

28

38

22

M18x1,5

51

43

58

38

32

43

24

M20x1,5

58

50

65

43

37

48

27

M22x1,5

74

60

88

55

44

65

30

M24x1,5

16

74

60

88

55

44

65

32

M26x1,5

18

105

85

125

77

63

92

36

M30x2

135

115

155

100

85

114

166

140

192

122

103

142

41 46 50

50

180

M36x2

8 10 10 12 12 14 15

20 22 25 28

M42x2

30

240

210

270

177

155

199

M45x2

35

290

255

325

214

188

240

330

280

380

243

207

280

M52x2

38 42

VH 1150

MAINTENANCE MANUAL Necessary maintenance

Necessary maintenance

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

Table of tightening moments for plugs with flat packing

Tightening moments for the plugs

Tightening moments for the necks G-M

Nm

lb - ft

G-M

Nm

lb - ft

G 1/8"

25

18

G 1/8"

15

11

G 1/4"

40

30

G 1/4"

33

24

G 3/8"

95

70

G 3/8"

70

52

G 1/2"

130

96

G 1/2"

90

66

G 3/4"

250

184

G 3/4"

150

111

G 1"

400

295

G 1"

220

162

G 11/4"

600

443

G 11/4"

600

443

G 11/2"

800

590

G 11/2"

800

590

M 10x1

25

18

M 10x1

13

10

M 12x1,5

30

22

M 12x1,5

30

22

M 14x1,5

50

37

M 14x1,5

40

30

M 16x1,5

60

44

M 16x1,5

60

44

M 18x1,5

60

44

M 18x1,5

70

52

M 20x1,5

140

103

M 20x1,5

90

66

M 22x1,5

140

103

M 22x1,5

100

74

M 26x1,5

220

162

M 26x1,5

120

89

M 27x1,5

250

184

M 27x1,5

150

111

M 33x1,5

400

295

M 33x1,5

250

184

M 42x1,5

600

443

M 42x1,5

400

295

M 48x1,5

800

590

M 48x1,5

500

369

VH 1150

181

4.6. Appendixes

Notes:

182

VH 1150

MAINTENANCE MANUAL

Notes:

VH 1150

183

STAVOSTROJ a.s.

549 01 Nové Město nad Metují tel: +420-491 476 111

fax: +420-491 470 405

Issued by:

Literature Department of

STA Stavostroj a.s.

Nové Město nad Metují

© 10 / 2004