STA Maintenance & Lubrication Manual VH 700 - PDF DOWNLOAD

MAINTENANCE AND LUBRICATION MANUAL After 2000 motorhours (every 2 years) Fig. 91

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3.5. Individual operations of lubrication and maintenance After 2000 motorhours (every 2 years) 3.5.34. Exchange of cooling liquid

After 2000 motorhours (every 2 years) Fig. 92

• Let the oil out after finishing the work or after decrea-

1

sing the temperature to 60 °C (140 °F), or with the engine turned on (when driving the machine) wait until the coolant temperature reaches the 60 °C (140 °F).

• Place the roller to the horizontal position on a flat, solid

MAX

base.

• Turn the engine off and disconnect the electric machine’s installations.

MIN

• Open the cooling system by dismounting the overpressure plug (1) on the equalizing basin Fig. 92.

• Open the outlet valve (1) Fig. 93.

• Let the liquid flow into prepared vessel 20 l (5,3 US gal) – the amount is approx. 18 l (4,8 US gal).

• Check if there are not any damaged hoses and missing hose braces in the engine cooling system.

• Check the radiator status, if it isn’t damaged, if it doesn’t soak and if the radiator lamellas are not soated by impurities.

Fig. 93

• Clean see Chapter 3.5.39. and repair it if necessary.

• After emptying, refill the cooling system by new coolant Fig. 94 (60% of water, 40% of antifreeze agent).

• During refilling, wait for approx. 2-3 min. to let the circuit fully fill.

• Close the equalizing basin by overpressure plug.

1

• Start the engine and wait until the temperature reaches the 80 °C (175 °F). When waiting, check if there is no outflowing coolant.

• Stop the engine.

• Check the level in equalizing basin Fig. 93.

• If the level is below “MIN”, wait until the coolant temperature drops below 50 °C (120 °F). There is danger of spirt of the liquid and possibility of burn ups.

• Open the cooling system by dismounting the overpressure plug on the equalizing basin and replenish the coolant to “MAX”.

• Mount the overpressure plug back.

When changing operate due to the ecological instructions and the hygienic principles !

Use the coolant according to chap. 3.1.5.!

Protect your hand with rubber gloves !

Used liquid dispose due to valid regulations !

56

Fig. 94

40 %

60 %

MAINTENANCE AND LUBRICATION MANUAL After 2000 motorhours (every 2 years)

After 2000 motorhours (every 2 years)

3.5.35. Cleaning of fuel tank Observe fire protection regulations!

• Place the machine level on a firm and flat surface in a

Refrain from smoking and douse open flame during work!

well-ventilated area, protected against fire.

• Stop the engine and disconnect the machine’s elect-

Observe environmental and health rules!

rical installation.

• Do the cleaning when there is a minimum of the fuel in

Clean in ventilated areas preventing chances of fire!

tank.

• Unscrew the outlet plug (1) Fig. 95 and let flow the rest

Prevent fuel from seeping into the ground!

of fuel out to prepared vessel.

• Dismount the cleaning cover (1) with the fuel gauge (2) Fig. 96. Keep attention to don’t damage the fuel gauge.

• Wash the tank by pure fuel, remove the impurities.

• Replace drain valve and cover – check for tightness.

• Purge air from fuel system, see Chapter 3.5.40.

Fig. 96

Fig. 95

2

1

1

57

3.5. Individual operations of lubrication and maintenance After 2000 motorhours (every 2 years) 3.5.36. Oil and filter exchange in the hydraulic system

After 2000 motorhours (every 2 years) Fig. 98 - valid VH 700

• Let the oil out when it is warm – not hot – after cooling below 50 °C (122 °F).

• Place the roller horizontally on solid, flat base.

• Stop the engine and disconnect the electrical machine’s installation.

• Open the left engine cover.

• Properly clean and open the tank seal.

• Below under the engine, dismount the outlet plug, catch the oil into prepared vessel – the fill capacity is 65 l (17 US gal).

• Dismount the cover behind the front carriage.

Replacement of filter cartridge

Fig. 98a - valid VH 700, VH 1000

• Replace always –

–

after a major repair of the hydraulic system – repair or replacement of the hydraulic generator and/or hydraulic motor. when the control light of the pressure filter (1) of the hydraulic oil at working temperature between 50 to 60 °C (122-140 °F) goes on Fig. 97.

• Replace filter cartridge in the filtration block Fig. 98, 98a, 98b.

Fig. 98b - valid VH 700, VH 1000

Fig. 97

1

58

MAINTENANCE AND LUBRICATION MANUAL After 2000 motorhours (every 2 years) • Dismount the filter vessel (1) with the filtration insert (2) using the key 27 and take out the insert Fig. 99.

• Properly clean the filter vessel.

• Clean the filtration block contact area from bottom position.

• Insert into the filter vessel the new insert and screw it back – tighten by the moment 40 +10 Nm (30+7 lb ft).

After 2000 motorhours (every 2 years) Hydraulic system filling

• When filling with the new oil using filling device, it cause the flush of old oil and the impurities out of the hydraulic circuit including the hydro-generators and hydro-engines. It will decrease the portion of old oil and impurities and prolong the aggregates lifetime.

This is the same way how the manufacturer fills the machines.

• Filling device Fig. 100 must meet these parameters : Minimum pressure – 6 MPa (870 PSI) Filtration ability 3-10 µm

• Insert the fast-clutch of filling device to the filling fastclutch on the machine Fig. 101.

Fig. 99

• Fill the hydraulic circuit until the clear oil flows out of outlet hole – let flow out approx. 10 l (26,5 US gal) – such way is the pure oil 2 times filtered.

• Close the outlet hole by the plug, check the tightness.

1

• Replenish with amount of 65 l (17,2 US gal) of new oil due to 3.1.3.

• Check the oil level Fig. 102 – disconnect the filling 2

device, close the tank with seal.

• Start the engine, set the revolutions to 1200/min, try the machine’s functions.

• Check the tightness – if necessary, refill the oil.

• To used fast-clutch of filling circuit FASTER 2FFN38 GAS M equals the filling device’s fast-clutch 2FFN38 GAS F.

• The filling device or fast-clutch can be ordered by the machine manufacturer.

Fig. 100

Fig. 101

59

3.5. Individual operations of lubrication and maintenance After 2000 motorhours (every 2 years)

After 2000 motorhours (every 2 years)

Alternate filling of hydraulic system

• This kind of filling do as a emergency solution – the manufacturer doesn’t recommend such kind !

• Doing this filling method, there will rest big portion of old oil in the circuit with the impurities and it causes the decrease of hydraulic aggregate lifetime.

• For that reason, shorten the oil exchange intervals to half – 1000 hours or 1 year.

• Mount the outlet plug and fill through the filling neck specified kind of oil of amount due to Fig. 102 to maximum.

• Start the engine, set the revolutions to 1200/min and try all machine’s functions until filling the circuits.

• Replenish the oil to level max. due to Fig. 102.

On hydro-engines, hydro-generators fault, that cause the destruction of inner aggregates parts, is necessary to clean the hydraulic tank inside and remove the mechanical impurities before mounting the new aggregate.

This professional work must do the worker trained on the hydraulics branch only.

When working, keep the cleanness – avoid the contamination of the system by agents that can cause damage of important aggregates !

For cleaning use the cleaning means without staples.

The vessels with new hydraulic oil close (cover) – they can be contaminated, penetrated by water and so on.

Don’t open the hydraulic tank unnecessarily !

When changing the oil operate due to the ecological instructions and the hygienic principles !

Keep the fire regulations !

When out-flowing the hot oil, watch out for possibility of burn ups.

Use recommended filters only.

Use recommended foils only due to chap. 3.1.3.

Catch the outflowing oil, don’t let it suck in to the ground.

Don’t over-tighten the filter, it can cause the worm and packing damage.

Fig. 99

Used filters store in the individual container and manipulate with them such way to prevent the pollution of the environment.

MAX

MIN

60

MAINTENANCE AND LUBRICATION MANUAL Maintenance when necessary Fig. 103

61

3.5. Individual operations of lubrication and maintenance Maintenance when necessary

Maintenance when necessary

3.5.37. Cleaning and replacing air cleaner filter element.

• The usefulness of the element depends on the environment in which it is used. When the control light (29) Fig. 104 goes on, the element must be cleaned or replaced – at least once a year.

The main element

• Place the machine level – on a flat, firm surface.

• Shut off the engine and disconnect electrical cables.

• Remove dust valve (1) and clean it, Fig. 105.

• Loosen clamps (2) and remove lid (3), Fig. 105.

Fig. 105 - VH 700

2

2

Fig. 104

3

1

D Fig. 105 - VH 1000

2

Detail

3

29

62

1

MAINTENANCE AND LUBRICATION MANUAL Maintenance when necessary

Maintenance when necessary

• Remove main element (4), Fig. 106.

Cleaning of main element:

• Clean the inside of the filter housing using a rag - not

• Dry-clean only with compressed air. The pressure

compressed air!

• Remove safety element (5) only when replacing the main element, Fig. 107! Used in VH 700.

shouldn’t be higher than 5 bar (72 PSI). Blow air at an obtuse angle outward.

• The element may be cleaned only 5 times at the most.

Then it must be replaced, however, at least once a year.

• Install dust valve.

• Install new or clean element. Check whether properly seated and tight.

• Every cleaning should be noted on the lid.

• If the element is soiled with soot, it cannot be cleaned properly and must be replaced.

• Following cleaning, check the element against light to see if not damaged! Replace a damaged element immediately.

• We recommend to have at least one spare element on hand. Damaged element is not effective and may reduce the function of the engine.

Fig. 106

!

4

Fig. 107

5

!

63

3.5. Individual operations of lubrication and maintenance Maintenance when necessary

Maintenance when necessary

Main element replacement:

The safety element replacement

• Remove carefully the worn element.

• Loosen nut (6).

• Clean the inside of the filter housing not allowing dust

• Remove safety element (5).

to enter the engine intake manifold.

• Clean the seating area for the element in the filter

• Insert a new element, and tighten nut Fig. 109.

housing.

• Check dust traces in the old element, indicating its tightness in the filter housing.

Restrictions!

• Press seal on the new element to see if it is flexible Fig. 108.

Use original elements only!

• Check whether the seal is effectively seated.

Never install worn elements.

• Check connections and hoses, whether tight..

Do not remove elements for checking purposes.

Safety element (as used in VH 700):

Do not judge worn element by its looks.

• Replace safety element (5) Fig. 109.

Do not leave the filter open longer than absolutely necessary.

-

always when replacing main element

-

after the main element has been cleaned five times

-

after two years of operations

-

if the control light goes on following cleaning of the main element

-

should the main element be damaged

• Remove by taking out the element from the central opening

• Should moisture be sucked in, the dust valve and elements may foul up quickly. In such a case the elements must be removed, dried, the filter housing cleaned, and replaced.

Fig. 108

Do not use filter with damaged lid or filter element.

Do not clean the elements by knocking on them.

Only approved, specified element.

Do not clean filter elements with gasoline or other fluids.

When washing the machine, be careful that water doesn’t enter inside the air cleaner.

Should humidity be sucked in, remove and dry out both elements. Dry out the filter body.

Fig. 109 - VH 700

6 5

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MAINTENANCE AND LUBRICATION MANUAL Maintenance when necessary 3.5.38. Cleaning water separator of the fine fuel filter

Maintenance when necessary 3.5.39. Radiator cleaning • Place the machine horizontally on solid, flat base.

• perform before start or with engine stopped.

• Place a receptacle under the separator for drained

• Stop the engine and disconnect the electrical machine’s installation.

• Fold down the cab according to chapter 2.8.12. “Dri-

deposits and water.

• Turn drain valve (1) by 4 revolutions c/w and release the plug down by 25 mm (1”), Fig. 110.

• Drain fuel until pure.

ver’s manual”.

• Do the cleaning using the pressure air or water (steam) from the fan side.

• Press valve up and turn closed.

• Don’t use the cleaner with too high pressure.

• Should more than 60 cu.cm (2 oz.) of fuel be drained,

• Should the machine be working in a dusty environ-

refill fuel in the filter, see Chapter 3.5.24, or purge air, see Chapter 3.5.40.

ment, clean more often – with a dirty radiator temperature of the coolant and the hydraulic system oil increases.

• If the radiator is soiled with oil products, spray the fins with cleaning substance.

Follow directions of the cleaning substance manufacturer!

Find the reason for the fins being soiled with oil, grease etc.!

Do not damage fins when cleaning.

Collect rinse water in receptacles – observe environmental regulations.

Fig. 110

" 1 #

65

3.5. Individual operations of lubrication and maintenance Maintenance when necessary

Maintenance when necessary

3.5.40. Purging fuel system Purging fuel system to be performed before the first start when -

the fuel filters are not full – when replacing filters

-

replacing fuel pump

-

replacing high-pressure lines, injectors

-

the machine has been idle for a long period

-

the fuel ran out.

When using the starter, do not run it for more than 15 seconds. Wait for 1 minute between tries.

During purging the engine may start up. Observe safety rules!

Purging low-pressure lines and filters

• Loosen purge bolt on fuel filters (1), Fig. 111.

• Pump fuel manually (2), Fig. 112, until pure fuel without air bubbles appears.

• Tighten purge bolt with torque 9 Nm (7 ftlb).

Obr. 112 - VH 700

Purging injection pump

• Loosen purging screw of the injection pump (3), Fig. 113.

• Turn key in the switch box to position “1” to energize solenoid “Stop”.

• Pump fuel manually until pure fuel without air bubbles

2

appears.

• Tighten purging screw.

• Purging may be accomplished also by means of the starter (key in the switch box in position “2”) through drainpipes without opening the purge screw.

Fig. 111

Fig. 112 - VH 1000

1

2

66

MAINTENANCE AND LUBRICATION MANUAL Maintenance when necessary

Maintenance when necessary

Purging high-pressure lines and injectors

• If the engine doesn’t start after the preceding procedu-

Fuel pressure in the high-pressure lines is considerable and may cause skin and other serious injuries.

re, purge high-pressure lines, Fig. 114 and 115.

• Loosen one or more nuts on the injectors. By turning

Do not purge hot engine. Fuel may escape on hot exhaust pipes and ignite.

the engine air is removed from the high-pressure lines.

• Keep on purging until the engine runs smoothly.

• Tighten loose connectors with torque 30 Nm (22 ftlb.).

Collect escaping fuel!

Extinguish open flame while working!

No smoking!

Fig. 113

3

Fig. 114

Fig. 115

67

3.5. Individual operations of lubrication and maintenance Maintenance when necessary

Maintenance when necessary

3.5.41. Cleaning of the cab ventilation air filter

3.5.42. Adjusting of the scrapers

• Do the cleaning regularly once per month. In case you

• Stop the engine and disconnect the electrical machi-

working in very dusty environment shorten the intervals of cleaning.

• Place the machine horizontally on solid, flat base. ne’s installation.

• Dismount the covering grid (1).

Adjustment of rubberized metal parts pre-stress.

• Replace the filter (2) with the filtration insert (3)Fig. 116.

• Loosen bolt (1), Fig. 117, and the centering bolt (2)

• Carefully knock out the insert and wash in detergent

from the other side, Fig. 118, on both sides of the scraper.

solution. If the filter insert will be ruptured or it can’t be properly cleaned of the impurities, replace it with a new one.

Fig. 116

• Turn the rubberized metal parts of the scraper (3) using key 36 as needed, Fig. 119.

Fig. 118

3

2

1

2

Fig. 119

Fig. 117

1

$

$

2

68

3

MAINTENANCE AND LUBRICATION MANUAL Maintenance when necessary Replacing the blade

Maintenance when necessary 3.5.43. Machine cleaning

• Decrease the rubber-steel self-bias see paragraph • After ending the works clean the machine from main

above.

• Dismount the screws (1) and take down the blade (2) with ribbons (3) Fig. 120.

• After replacing the blade (2) mount back and adjust the rubber-steel self-bias to approx. 15° according to the scale Fig. 117.

impurities.

• The complete cleaning do regularly minimal once per week. When working on cohesive grounds, cement and lime stabilizations must be the complete cleaning done daily.

• Don’t use the aggressive and easily inflammable cleaning agents (e.g. petrol and/or easily flammable agents).

• Do the work under engine set down.

• When using the steam cleaner don’t expose the electrical parts or insulation material to direct steam stream. Always cover such materials.

Disconnect the accumulator’s disconnector !

• When washing the machine observe that water doesn’t enter air filter through the grill behind the cabin, Fig. 121.

• Before cleaning the machine by pressure water cleaners, by steam and so on, daze all holes where is the possibility of contamination by the cleaning agent (e.g. engine suction hole, inner alternator space and so on). After cleaning the machine remove the dazes.

The machine washing do on places equipped with catchments for catching the waste water.

Fig. 120

Fig. 121

1 3 2

69

3.5. Individual operations of lubrication and maintenance Maintenance when necessary

Maintenance when necessary

3.5.44. Checking the screw connections tightness • Check regularly if there aren’t relaxed screw connections.

• For tightening use the moment spanners.

Fig. 122 - Table of screw tightening moments with metric worm.

TIGHTENING MOMENT For the screws For the screws For the screws 5.8 (5 S) 8.8 (8 G) 10.9 (10 K) Worm

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

M4

2

1

3

2

4

3

M5

4

3

6

4

8

6

M6

7

5

10

7

14

10

M8

16

12

22,5

17

32,5

24

M10

31,5

23

44

32

62

46

M12

53

39

75

55

105

77

M14

79

58

118

87

165

122

M16

113

83

165

122

226

167

M18

172

127

245

181

343

253

M20

226

167

314

232

441

325

M22

284

209

392

289

559

412

M24

392

289

549

405

755

557

M27

520

384

716

528

1020

752

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

70

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

MAINTENANCE AND LUBRICATION MANUAL Maintenance when necessary Fig. 123 - 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

8

45

38

52

33

28

38

51

43

58

38

32

43

10 22

M18x1.5

10 12

24

M20x1.5

12

58

50

65

43

37

48

27

M22x1.5

14

74

60

88

55

44

65

15 30

M24x1.5

16

74

60

88

55

44

65

32

M26x1.5

18

105

85

125

77

63

92

36

M30x2

20

135

115

155

100

85

114

166

140

192

122

103

142

22 41

M36x2

46

25 28

50

M42x2

30

240

210

270

177

155

199

50

M45x2

35

290

255

325

214

188

240

M52x2

38

330

280

380

243

207

280

42

71

3.5. Individual operations of lubrication and maintenance Maintenance when necessary

Maintenance when necessary

Fig. 124 - Table of tightening moments for necks with tightening edge, or with flat packing

Fig. 125 - Table of tightening moments for plugs with flat packing

Tightening moments for the necks

72

Tightening moments for the plugs

G-M

Nm

lb -ft

G -M

Nm

lb -ft

G 1/8"

25

18

G 1/8"

15

11

G 1/4"

40

30

G 1/4"

33

24

G 3/8"

95

70

G 3/8"

70

52

G 1/2"

130

96

G 1/2"

90

66

G 3/4"

250

184

G 3/4"

150

111

G 1"

400

295

G 1"

220

162

G 11/4"

600

443

G 11/4"

600

443

G 11/2"

800

590

G 11/2"

800

590

M 10 x 1

25

18

M 10 x 1

13

10

M 12 x 1,5

30

22

M 12 x 1,5

30

22

M 14 x 1,5

50

37

M 14 x 1,5

40

30

M 16 x 1,5

60

44

M 16 x 1,5

60

44

M 18 x 1,5

60

44

M 18 x 1,5

70

52

M 20 x 1,5

140

103

M 20 x 1,5

90

66

M 22 x 1,5

140

103

M 22 x 1,5

100

74

M 26 x 1,5

220

162

M 26 x 1,5

120

89

M 27 x 1,5

250

184

M 27 x 1,5

150

111

M 33 x 1,5

400

295

M 33 x 1,5

250

184

M 42 x 1,5

600

443

M 42 x 1,5

400

295

M 48 x 1,5

800

590

M 48 x 1,5

500

369

MAINTENANCE AND LUBRICATION MANUAL Maintenance when necessary 3.5.45. Adjusting the vibrator’s frequency

Maintenance when necessary Adjusting the frequency High amplitude :

Measuring of the frequency can be done by two ways : 1. Using the portable device FAM 012 Geodynamic AB – Sweden ECM Vibrometer VM – Czech rep.

Fasten the device’s sensor (1) perpendicularly to the ground see Fig. 126 (on the device is marked the perpendicular direction to the vibration scan) and in accordance with the manual read the frequency on the device’s display.

The frequency measure ECM Vibrometer can be ordered by the manufacturer.

Unscrew the securing nut (3), by turning the upper screw (1) adjust to required frequency 42 Hz (VPM) and re-tighten the securing nut Fig. 127. By unscrewing the screw you will increase the frequency and vice versa.

Low amplitude : Relax the securing nut (3). Turn with the bottom screw (2) until reach the frequency value of 50 Hz (VPM), tighten the securing screw (3) Fig. 127. By unscrewing the screw you will increase the frequency and vice versa.

2. By reading the vibration frequency in Hz on the dashboard’s multifunctional display – this way is less exact.

Do the adjusting when the engine is off !

Fig. 126

Fig. 127

1

1 3

3 2

73

3.6. Records of done acts

Date

74

Hours

Accomplished Operation

MAINTENANCE AND LUBRICATION MANUAL

Date

Hours

Accomplished Operation

75

3.6. Records of done acts

Date

76

Hours

Accomplished Operation

MAINTENANCE AND LUBRICATION MANUAL

Date

Hours

Accomplished Operation

77

3.7. Seeking the faults Due to the technical machine’s conception is practically impossible to exactly find the fault without appropriate diagnostic equipment and determine the process of removal the fault. At no cost don’t try to determine the fault yourself and remove it by self-help !

In the case of machine’s failure contact the manufacturer’s servicing department !

For understandable communication with the servicing department in case of fault identification proceed according to chap. 3.7.2.

3.7.1.

Searching the engine faults Fault

The engine can’t start, the starter is working

Cause

Definition (removing) the fault

Empty fuel tank

Replenish the fuel and possible vent the fuel system

Non-tightness, aeration of the fuel

Check and remove the non-tightness of the

system

connections. Replenish the fuel using the hand pump, vent the fuel system.

Clogged rough fuel cleaner, filters and

1. Clean the cleaner, distribution

the distribution aggraded

2. Replace the filters

Rough fuel cleaner, filters and the

1. Clean the cleaner, distribution

distribution aggraded by paraffin

2. Replace the filters

sediments in the winter season

3. Replace the fuel

Used too dense oil during the winter

Use the suitable oil for the given temper.

season The engine can’t

The electrical installation is not

start, the starter

connected – the indicators don’t shine.

doesn’t working or turning slowly

The travel controller is not in the Neutral

Connect the el. installation.

Shift the controller to the neutral pos.

position – the neutral indicator is off The grips (oxidation, released), starter

1. Re-tighten the grips, clean, conserve

connectors, ground cable, accumulator

2. Inspect the starter connectors

fault

3. Inspect the grounding cable 4. Inspect the battery status (electrolyte level,density)

Starter

Check the connection and the working moment of the pinion (the el.mag. reel)

The engine is

Starting relay

Check the connection and confirm the function

Electro-stop of the engine

Check the connection and confirm the function

Shortage of coolant.

Quickly stop the engine, replenish coolant, find the

getting overheated.

untightness and repair it.

Clogged coolant radiator.

Clean the radiator.

Failure of the belt tensioning, or broken

Repair the failure, replace the belt.

belt.

Improperly working thermostat.

Verify function of the thermostat;replace if necessary.

Considerable amount of dirt and

Clean the cooling circuit.

sediments in the cooling circuit.

78

MAINTENANCE AND LUBRICATION MANUAL

Fault

Cause

Definition (removing) the fault

The engine is getting

Faulty injection nozzles.

Let expert to check them.

overheated.

Improperly adjusted fuel volume supplied

Let to be adjusted in a specialized

by the injection pump.

workshop.

Ambient temperature too high.

Work for a limited time and allow the engine to cool down.

Improperly adjusted beginning of

Let expert to check it.

injection.

The engine is not sufficiently lubricated -

Engine oil level too low.

Replenish oil.

Engine oil is leaking.

Immediately stop the engine, inspect

the indicator

connections of the lubrication system and

of lubrication is on.

repair the untightness.

Used oil is of improper viscosity.

Exchange oil for a recommended sort.

Overheated engine.

Allow the engine to cool down.

Seek for the reason.

The engine runs

Aerated fuel system.

irregularly, with low output.

Deareate the fuel system, repair the untightness.

Faulty injection nozzles.

Let expert to check it.

Improper valve clearance.

Let expert to check it.

Broken injection pipe.

Let expert to check it.

Improperly adjusted injection pump.

Let expert to check it.

The engine excessively

Increased underpressure in the inlet branch

Check function of the underpressure switch.

smokes.

of the engine.

Replace the filter elements if needed.

Oil level too high.

Lower oil level to the upper mark at the dipstick.

Poor compression due to burned or broken

Let the piston rings to be tested in a

piston rings, or due to wrong valve

specialized workshop; adjust the valve

clearance.

clearance.

Excessive oil

Untight oil system.

Repair the untightness.

consumption.

Untight piston rings, or generally worn

Let expert to check it.

engine.

The engine has not

Excessively clogged fuel cleaners.

Replace the filter elements.

sufficient output.

Wrong valve clearance.

Adjust valve clearance.

Clogged holes of the injection nozzles;

Let expert to check it.

the injectors are not adjusted to correct injection pressure.

Improperly adjusted injection pump.

Let expert to check it.

Improperly adjusted advanced injection angle. The cylinders have not sufficient compression pressure. Failure of the turbocharger.

Further possible failures are described in the instruction manual of the engine, which is supplied with the machine.

79

3.7. Seeking the faults 3.7.2.

Defects of electrical wiring

Travel system

• Orange light of soft stop-travel indicator (31) flashes, Fig. 128.

System of indicators and wiring

• “ERROR” message on the display (14) of the dashboard, Fig. 128.

• Red diode STATUS (A) flashes on control unit (2), Fig. 129.

• Red light STATUS (A) flashes, Fig. 129, on the control unit below the dashboard (dashboard must be folded).

Fig. 128

Fig. 129

14

2

A

31

A 1

80

MAINTENANCE AND LUBRICATION MANUAL ASC differential system

• Red diode STATUS (A) flashes on control unit (3), Fig. 130.

Signaling of STATUS in diodes of all control units is coded. The signal code indicates the cause of defect.

Fig. 130

3

A

81

3.7. Seeking the faults 3.7.3.

Faults in hydraulic system

The fault spectrum in the hydraulic system is determined by measuring of the hydraulic circuit pressure where the fault occurred.

Values of measured pressures in the hydraulic circuit

C o nd u it T er m in al

*

-

** -

82

M ea s ured p ress ure

M a xim u m p ress ure M P a (P S I)

1

Pre ssure in the travel circuit – tow ard

4 2 (6 09 0)

2

Pre ssure in the travel circuit – ba ckw ard

4 2 (6 09 0)

3

Pre ssure in the vib ration circuit (low a m plitud e)

3 5 (5 07 5)

4

Pre ssure in the vib ration circuit (high a m plitud e)

3 5 (5 07 5)

5

S up ply pres sure in the vib ration circuit *

2 ,4 (34 8)

6

Pre ssure in the driving circuit * *

1 9 (2 75 5)

7

S up ply pres sure in the circuits

3 ,0 (43 5)

Measured during vibration This pressure builds up only when turning of the drum is blocked and revalution of the engine is at maximum.

MAINTENANCE AND LUBRICATION MANUAL Location of conduit terminals of measured pressures in hydraulic loops Terminal 1 to 5 – purging valve on the engine frame, Fig. 131.

Fig. 132

Terminal 6 in steering loop – on the frame behind the front Fig. 132 and rear drum Fig. 133.

Terminal 7 of the pressure replenisher in the loops – on the pressure filter of the hydraulic oil, Fig. 134.

6

Fig. 133

Fig. 131 - VH 700

6 1 5 2 3 4

Fig. 131 - VH 1000

Fig. 134

7

1

2 3

5 4

83

Appendixes – scheme Electrical installation – scheme VH 700 A1 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 E1 E2,3 E4,5 E6,7 E8,7 E10,11 E12,13 E14,15 E16,17 E18 E19,20 E21 F1-12 G1 G2 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 K1-9 K7 M1 M2 M3 M4 M5 M6 M7 M8 P1 P2 P3 P4 Q1 R1-11 R15 R16 R17 S1 S2 S3

84

Interrupter of the direction lights Travel electronics Travel controller Drive electronics Display Electronics of differential lock (special equipment) Sensor of engine revolutions Sensor of front vibrator revolutions Sensor of rear vibrator revolutions Sensor of front carriage turn Sensor of rear carriage turn Sensor of left front carriage Sensor of right front carriage Sensor of left rear carriage (special equipment) Sensor of right rear carriage (special equipment) Detector of engine temperature Detector of hydraulics temperature Floater of fuel gauge Instruments illumination Front sidelights Tail lights Head lights Rear lights Cab illumination Left direction lights Right direction lights Side head lights – front (special equipment) Carriage illumination (special equipment) Side head lights – rear (special equipment) Warning beacon (special equipment) Fusing fuses Accumulator Alternator Indicator of direction lights Horn Reverse horn (special equipment) Neutral indicator Brake indicator Indicator for soft start and end run Sprinkling indicator Indicator – low vibration amplitude Indicator – high vibration amplitude Indicator of accumulator replenish Indicator of engine lubrication Indicator of air filter aggradation Indicator of oil filter aggradation Supply relay Starter contactor Engine starter Engine of front carriage sprinkling Engine of rear carriage sprinkling Front wiper Rear wiper Windscreen washer Rear screen washer Ventilating fan Engine thermometer Hydraulic oil thermometer Motorhour counter Fuel gauge Accumulator disconnector Resistors Sprinkling intervals potentiometer Speed potentiometer Potentiometer of steering direction (steering wheel) Switch box Headlights switch Rear lights switch

S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 S21 S22 S23 S24 S25 S26 S27 S28 S29 S30 S31 S32 S33 S34

Warning lights switch Direction lights controller Side lights switch (special equipment) Warning beacon switch (special equipment) Horn button Emergency brake switch Reverse horn switch (travel controller) Neutral switch (in travel controller) Pressure switch of the brake Switch – protection of engine overload Button – soft start and end run Sprinkling switch Vibration switch (on travel controller) Circuit breaker of vibration automatics Controller of vibration amplitude Vibration controller front/rear carriage Double button of the cutter (special equipment) Double button crab Controller of way of steering Crab switch Differential lock switch (special equipment) Pressure switch of engine lubrication Pressure switch of hydraulic oil filter aggradation Underpressure switch of air filter aggradation Frond wiper switch Rear wiper switch Screen washer switch Fan controller Air conditioning switch (special equipment) Air conditioning thermostat (special equipment) Overpressure air conditioning fuse (special equipment) S35 Position switch on the radiator controller (special equipment) S39 Parking brake push button V1-3 Blocking diode X1-39 Bind connectors X40 Service plug X41 Plug can bus X42-44 Diagnostic plugs X45,46 Conduit terminals Y1 Electromagnet of engine stop Y2 Electromagnetic brake valve Y3 Electromagnetic steering wheel blocking Y4 Servo-valve of the travel pump Y7 Electromagnetic valve of vibration – low amplitude Y8 Electromagnetic valve of vibration – high amplitude Y9 Electromagnetic valve of front carriage vibration Y10 Electromagnetic valve of rear carriage vibration Y11 Electromagnetic valve – cutter up (special equipment) Y12 Electromagnetic valve – cutter down (special equipment) Y13 Electromagnetic valve - front carriage left Y14 Electromagnetic valve - front carriage right Y15 Electromagnetic valve - rear carriage left Y16 Electromagnetic valve – rear carriage right Y17 Electromagnetic valve of differential lock – left front carriage (special equipment) Y18 Electromagnetic valve of differential lock – right front carriage (special equipment) Y19 Electromagnetic valve of differential lock – left rear carriage (special equipment) Y20 Electromagnetic valve of differential lock – right rear carriage (special equipment) Y21 Electromagnetic clutch of air conditioning compressor (special equipment)

MAINTENANCE AND LUBRICATION MANUAL Fig. 135 - Electrical installation – scheme - VH 700

FRONT SIDELIGHTS

TAIL LIGHTS

HEAD LIGHTS

REAR LIGHTS CAB ILLUMINATION LEFT FRONT DIRECTION INDICATOR LEFT REAR DIRECTION INDICATOR

RIGHT REAR DIRECTION INDICATOR RIGHT FRONT DIRECTION INDICATOR SIDE HEAD LIGHTS – FRONT CARRIAGE ILLUMINATION

SIDE HEAD LIGHTS – REAR

WARNING BEACON HORN REVERSE HORN

ENGINE STOP

NEUTRAL INDICATOR BRAKE INDICATOR

BRAKE PRESSURE SWITCH OF BRAKE

85

Appendixes – scheme Fig. 135 - Electrical installation – scheme - VH 700

SENSOR OF ENGINE REVOLUTIONS

REVOLUTIONS SENSOR - LEFT FRONT CARRIAGE - RIGHT FRONT CARRIAGE

FRONT SPRINKLING

REAR SPRINKLING

LOW VIBRATION AMPLITUDE HIGH VIBRATION AMPLITUDE FRONT CARRIAGE VIBRATION REAR CARRIAGE VIBRATION CUTTER UP CUTTER DOWN

86

TRAVEL ELECTRONICS

SERVO-VALVE

MAINTENANCE AND LUBRICATION MANUAL Fig. 135 - Electrical installation – scheme - VH 700

FRONT CARRIAGE LEFT FRONT CARRIAGE RIGHT REAR CARRIAGE LEFT REAR CARRIAGE RIGHT

REAR VIBRATOR REVOLUTIONS

DRIVE ELECTRONICS

FRONT VIBRATOR REVOLUTIONS

FRONT CARRIAGE TURN

REAR CARRIAGE TURN

RIGHT FRONT CARRIAGE LEFT REAR CARRIAGE RIGHT REAR CARRIAGE

REVOLUTIONS SENSOR - LEFT REAR CARRIAGE

ELECTRONICS OF DIFFERENTIAL LOCK

DIFFERENTIAL LOCK VALVE

LEFT FRONT CARRIAGE

- RIGHT REAR CARRIAGE

87

Appendixes – scheme Fig. 135 - Electrical installation – scheme - VH 700

ENGINE THERMOMETER HYDRAULICS THERMOMETER MOTORHOUR COUNTER FUEL GAUGE RECHARGING INDICATOR ENGINE LUBRICATION HYDRAULIC OIL FILTER AIR FILTER

FRONT WIPER

REAR WIPER

WINDSCREEN WASHER REAR SCREEN WASHER

VENTILATING FAN AIR CONDITIONING THERMOSTAT

OVERPRESSURE AIR CONDITIONING FUSE

AIR CONDITIONING COMPRESSOR CLUTCH

88

MAINTENANCE AND LUBRICATION MANUAL

89

Appendixes – scheme Electrical installation – scheme - VH 1000 A1 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 E1 E2,3 E4,5 E6,7 E8,7 E10,11 E12,13 E14,15 E16,17 E18 E19,20 E21 F1-12 G1 G2 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 K1-9 K7 M1 M2 M3 M4 M5 M6 M7 M8 P1 P2 P3 P4 Q1 R1-11 R15 R16 R17 S1 S2

90

Interrupter of the direction lights Travel electronics Travel controller Drive electronics Display Electronics of differential lock (special equipment) Sensor of engine revolutions Sensor of front vibrator revolutions Sensor of rear vibrator revolutions Sensor of front carriage turn Sensor of rear carriage turn Sensor of left front carriage Sensor of right front carriage Sensor of left rear carriage (special equipment) Sensor of right rear carriage (special equipment) Detector of engine temperature Detector of hydraulics temperature Floater of fuel gauge Instruments illumination Front sidelights Tail lights Head lights Rear lights Cab illumination Left direction lights Right direction lights Side head lights – front (special equipment) Carriage illumination (special equipment) Side head lights – rear (special equipment) Warning beacon (special equipment) Fusing fuses Accumulator Alternator Indicator of direction lights Horn Reverse horn (special equipment) Neutral indicator Brake indicator Indicator for soft start and end run Sprinkling indicator Indicator – low vibration amplitude Indicator – high vibration amplitude Indicator of accumulator replenish Indicator of engine lubrication Indicator of air filter aggradation Indicator of oil filter aggradation Supply relay Starter contactor Engine starter Engine of front carriage sprinkling Engine of rear carriage sprinkling Front wiper Rear wiper Windscreen washer Rear screen washer Ventilating fan Engine thermometer Hydraulic oil thermometer Motorhour counter Fuel gauge Accumulator disconnector Resistors Sprinkling intervals potentiometer Speed potentiometer Potentiometer of steering direction (steering wheel) Switch box Headlights switch

S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 S21 S22 S23 S24 S25 S26 S27 S28 S29 S30 S31 S32 S33 S34

Rear lights switch Warning lights switch Direction lights controller Side lights switch (special equipment) Warning beacon switch (special equipment) Horn button Emergency brake switch Reverse horn switch (travel controller) Neutral switch (in travel controller) Pressure switch of the brake Switch – protection of engine overload Button – soft start and end run Sprinkling switch Vibration switch (on travel controller) Circuit breaker of vibration automatics Controller of vibration amplitude Vibration controller front/rear carriage Double button of the cutter (special equipment) Double button crab Controller of way of steering Crab switch Differential lock switch (special equipment) Pressure switch of engine lubrication Pressure switch of hydraulic oil filter aggradation Underpressure switch of air filter aggradation Frond wiper switch Rear wiper switch Screen washer switch Fan controller Air conditioning switch (special equipment) Air conditioning thermostat (special equipment) Overpressure air conditioning fuse (special equipment) S35 Position switch on the radiator controller (special equipment) S39 Parking brake push button V1-3 Blocking diode X1-39 Bind connectors X40 Service plug X41 Plug can bus X42-44 Diagnostic plugs X45,46 Conduit terminals Y1 Electromagnet of engine stop Y2 Electromagnetic brake valve Y3 Electromagnetic steering wheel blocking Y4 Servo-valve of the travel pump Y7 Electromagnetic valve of vibration – low amplitude Y8 Electromagnetic valve of vibration – high amplitude Y9 Electromagnetic valve of front carriage vibration Y10 Electromagnetic valve of rear carriage vibration Y11 Electromagnetic valve – cutter up (special equipment) Y12 Electromagnetic valve – cutter down (special equipment) Y13 Electromagnetic valve - front carriage left Y14 Electromagnetic valve - front carriage right Y15 Electromagnetic valve - rear carriage left Y16 Electromagnetic valve – rear carriage right Y17 Electromagnetic valve of differential lock – left front carriage (special equipment) Y18 Electromagnetic valve of differential lock – right front carriage (special equipment) Y19 Electromagnetic valve of differential lock – left rear carriage (special equipment) Y20 Electromagnetic valve of differential lock – right rear carriage (special equipment) Y21 Electromagnetic clutch of air conditioning compressor (special equipment)

MAINTENANCE AND LUBRICATION MANUAL Fig. 136 - Electrical installation – scheme - VH 1000

FRONT SIDELIGHTS

TAIL LIGHTS

HEAD LIGHTS

REAR LIGHTS CAB ILLUMINATION LEFT FRONT DIRECTION INDICATOR LEFT REAR DIRECTION INDICATOR

RIGHT REAR DIRECTION INDICATOR RIGHT FRONT DIRECTION INDICATOR

SIDE HEAD LIGHTS – FRONT CARRIAGE ILLUMINATION

SIDE HEAD LIGHTS – REAR

WARNING BEACON HORN REVERSE HORN

ENGINE STOP

NEUTRAL INDICATOR BRAKE INDICATOR

BRAKE PRESSURE SWITCH OF BRAKE

91

Appendixes – scheme Fig. 136 - Electrical installation – scheme - VH 1000

SENSOR OF ENGINE REVOLUTIONS

REVOLUTIONS SENSOR - LEFT FRONT CARRIAGE - RIGHT FRONT CARRIAGE

FRONT SPRINKLING

REAR SPRINKLING

LOW VIBRATION AMPLITUDE HIGH VIBRATION AMPLITUDE FRONT CARRIAGE VIBRATION REAR CARRIAGE VIBRATION CUTTER UP CUTTER DOWN

92

TRAVEL ELECTRONICS

SERVO-VALVE

MAINTENANCE AND LUBRICATION MANUAL Fig. 136 - Electrical installation – scheme - VH 1000

FRONT CARRIAGE LEFT FRONT CARRIAGE RIGHT REAR CARRIAGE LEFT REAR CARRIAGE RIGHT

REAR VIBRATOR REVOLUTIONS

DRIVE ELECTRONICS

FRONT VIBRATOR REVOLUTIONS

FRONT CARRIAGE TURN

REAR CARRIAGE TURN

RIGHT FRONT CARRIAGE LEFT REAR CARRIAGE RIGHT REAR CARRIAGE

REVOLUTIONS SENSOR - LEFT REAR CARRIAGE

ELECTRONICS OF DIFFERENTIAL LOCK

DIFFERENTIAL LOCK VALVE

LEFT FRONT CARRIAGE

- RIGHT REAR CARRIAGE

93

Appendixes – scheme Fig. 136 - Electrical installation – scheme - VH 1000

ENGINE THERMOMETER HYDRAULICS THERMOMETER MOTORHOUR COUNTER FUEL GAUGE RECHARGING INDICATOR ENGINE LUBRICATION HYDRAULIC OIL FILTER AIR FILTER

FRONT WIPER

REAR WIPER

WINDSCREEN WASHER REAR SCREEN WASHER

VENTILATING FAN AIR CONDITIONING THERMOSTAT

OVERPRESSURE AIR CONDITIONING FUSE

AIR CONDITIONING COMPRESSOR CLUTCH

94

MAINTENANCE AND LUBRICATION MANUAL

95

Appendixes – scheme Hydraulic scheme - VH 700 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

96

Tandem pump Vibration block Travel hydro engine Vibration hydro engine Steering hydro engine Steering pump ASC valve Block flushing Block of steering Block filter-brake Combined radiator Filter Hydraulic tank Suction basket Filling neck Oil gauge One-way valve One-way valve Thermoregulator Temperature sensor Measuring fast-clutch Pressure switch

B90L055 Sauer Id.-Nr.511260 Sauer 60C0606H Sauer MMF025 Sauer ZH1-80/40x230 PNN 11+11 Sauer 12V DC Sauer Sauer Hytos Hytos Nissens 2x HD 069-176 Stavostroj AS080-01 Hytos Argo VJ2 Hytos VJ2 Hytos IHR Praha SKK20-9/16UNF-PE STAUFF PAL

MAINTENANCE AND LUBRICATION MANUAL Fig. 137 - Hydraulic scheme - VH 700

97

Appendixes – scheme Hydraulic scheme - VH 1000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

98

Travel pump Vibration pump Travel hydro engine Vibration hydro engine Steering hydro engine Vibration block Steering pump ASC valve Block flushing Block of steering Block filter Combined radiator Filter Hydraulic tank Suction basket Filling neck Oil gauge One-way valve One-way valve Thermoregulator Temperature sensor

90L075KA Sauer 90L042 DC Sauer 60C1048H Sauer MMF035D Sauer 90/45x250 Id.-Nr.511260 Sauer PNN 11+11 Sauer 12V DC Sauer Sauer Hytos Hytos Nissens Hytos Stavostroj AS080-01 Hytos Argo VJ2 Hytos VJ2 Hytos IHR Praha

MAINTENANCE AND LUBRICATION MANUAL Fig. 138 - Hydraulic scheme - VH 1000

99

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