STA OPERATING MANUAL VP 2400 RUBBER TYREO ROLLER ENGINE CUMMINS - PDF DOWNLOAD

OPERATING MANUAL

VP 2400 RUBBER-TYRED ROLLER - ENGINE CUMMINS STAVOSTROJ a.s., Nové Mìsto nad Metují

© 5 / 2003

This set of manuals consists of: I. Specification Manual II. Driver´s manual III. Maintenance and Lubrication Manual

Read these manuals before attempting to operate the machine.

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

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

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

SPECIFICATION MANUAL VP 2400

CONTENT:

4

CONTENT: CONTENT:

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

1.1. Basic information ............................................................................................................................................................. 6 1.2. Dimensional machine drawing .......................................................................................................................................... 8 1.3. Technical information...................................................................................................................................................... 10 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.3.8 1.3.9 1.3.10 1.3.11 1.3.12 1.3.13 1.3.14

Weights .............................................................................................................................................................. 10 Technical information ........................................................................................................................................ 11 Driving qualities ................................................................................................................................................. 12 Engine ................................................................................................................................................................ 12 Gearbox .............................................................................................................................................................. 13 Axles ................................................................................................................................................................... 13 Brakes ................................................................................................................................................................ 13 Driving ................................................................................................................................................................ 14 Fills ..................................................................................................................................................................... 14 Electric installation ............................................................................................................................................. 14 Safety regulations .............................................................................................................................................. 14 Hygienic data of the machine ............................................................................................................................ 15 Traffic regulations ............................................................................................................................................... 15 Extended devices .............................................................................................................................................. 15

5

1.1. Basic information Introduction

Machine design

Wheeled rollers VP 2400 are based on world most spread conception of setting the wheeled rollers in the category of weight of 3t for one wheel.

Machine technical parameters (weight, axle base, tire dimension, turning diameter, levelling the front wheels profile grade) allowed together with the good engine and gearbox the quality working output, high reliability and working safety.

Mainly the possibility to change the tires pressure enables to compact many different materials with wide scope of consistence and adjust the machine for optimal using conditions.

The machine meets the requirements for marking with the “CE” mark and the requirements for the law no. 22/1997 Sb. (it is for CSN EN 500-1,4 and other) for Czech Republic and Directive 2000/14/EC (EN ISO 3744).

The machine can be equipped with opened driver’s post, with roof or cab, two driver’s posts. Driven rear axle can be equipped with the differential lock.

Area of use The wheeled roller is designed for compaction works of middle and large scope in a highway engineering (construction of highways and roads, railroads, airport areas) and in the land engineering (industry areas and so on).

The roller is convenient for compaction of asphalt composites to the thickness of layer (after compaction) of 120 mm, for hydraulic cemented composites to the layer thickness of 150 mm, earth and clayey soils to layer thickness of 150 mm, mixed soils to layer thickness of 200 mm and sand and aggregate materials to layer thickness of 250 mm.

The roller is not convenient for compaction of rockfill.

The machine is designed for operations under the conditions due to CSN IEC 721-2-1 (038900) : WT, WDr, MWDr (it is temper, warm dry, hot dry with reduced temperature scope -15 °C (5 °F) to +45 °C (113 °F).

Fig. 1 - Decal

Fig. 2 - Location of the decal at the machine

2

1

1. - Decal 2. - Frame number

6

Specification manual

Please fill in the following data: Type of machine (see Figs. 1, 2) .............................................................................

Serial number of the machine (see Figs. 1, 2) ..............................................................................

Production year (see Figs. 1, 2) ..............................................................................

Type of engine (see Fig. 3) ..............................................................................

Serial number of the engine (see Fig. 3) .............................................................................

Fig. 3 - Serial number of the CUMMINS engine

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1.2. Dimensional machine drawing Fig. 4 - Dimensional machine drawing

Dimensions

A

G

H

H1

H3

L

W

W1

W2

mm

3500

300

3040

3010

2540

4775

1986

2265

33

(in)

(137,8)

(11,8)

(119,7)

(118,5)

(100)

(188)

(78,2)

(89,2)

(1,3)

8

Specification manual Fig. 5 - Dimensional machine drawing

Dimensions

A

G

H

H1

H3

L

W

W1

W2

mm

3500

300

3040

3010

2540

4775

1986

2265

33

(in)

(137,8)

(11,8)

(119,7)

(118,5)

(100)

(188)

(78,2)

(89,2)

(1,3)

9

1.3. Technical information 1.3.1

Weights

VP 2400 (design without weight under frame, without ballast in frame, without option) CECE

ISO 6016

design with the cab

kg

9 510

9 750

design with the platform and the rail

kg

9 270

9 510

max. operation weight

kg

23 760

24 000

Weight 1 t

kg

1 000

Weight 2,4 t

kg

2 400

Weight 6 t

kg

6 000

Water

kg

1 800

Sand

kg

4 000

Steel

kg

max. 8 750

ROPS

kg

400

ROPS with FOPS

kg

650

ROPS with canopy

kg

450

Carrier with canopy

kg

150

Edge cutter

kg

150

Tires cover

kg

200

The weight under frame

Ballast in frame 1,8 m 3

Option

VP 2400 - design with the cab

CECE

ISO 6016

ballast in frame max.*

ROPS, weight 2,4t

kg

12 310

12 550

ROPS, weight 6 t

kg

15 910

16 150

7 850

ROPS, weight 6 t, tires cover

kg

16 110

16 350

7 650

weight 2,4t

kg

11 910

12 150

weight 6 t

kg

15 510

15 750

8 250

CECE

ISO 6016

ballast in frame max.*

12 070

12 310

VP 2400 - design with the platform and the rail ROPS, weight 2,4t

kg

ROPS, weight 6 t

kg

15 670

15 910

8 090

ROPS, FOPS, weight 6 t

kg

15 920

16 160

7 840

ROPS, weight 6 t, tires cover

kg

15 870

16 110

7 890

Carrier with canopy, weight 2,4t

kg

11 820

12 060

Carrier with canopy, weight 6 t

kg

15 420

15 660

8 340

Carrier with canopy, weight 6 t, tires cover

kg

15 620

15 860

8 140

*/ Weight for max. operation weight 24 000 kg.

10

Specification manual VP 2400 (design without weight under frame, without ballast in frame, without option) CECE

ISO 6016

design with the cab design with the platform and the rail

lb lb

20 966 20 437

21 495 20 966

max. operation weight

lb

52 381

52 910

lb lb lb

2 205 5 291 13 228

The weight under frame Weight 1 t Weight 2,4 t Weight 6 t Ballast in frame 1,8 m 3 Water

lb

3 968

Sand Steel

lb lb

8 818 max. 19 290

ROPS ROPS with FOPS ROPS with canopy

lb lb lb

882 1 433 992

Carrier with canopy Edge cutter

lb lb

331 331

Tires cover

lb

441

Option

VP 2400 - design with the cab

CECE

ISO 6016

ballast in frame max.*

ROPS, weight 2,4t ROPS, weight 6 t ROPS, weight 6 t, tires cover weight 2,4t

lb lb lb lb

27 138 35 075 35 516 26 257

27 668 35 604 36 045 26 786

17 306 16 865

weight 6 t

lb

34 193

34 722

18 188

VP 2400 - design with the platform and the rail ROPS, weight 2,4t ROPS, weight 6 t

ISO 6016 27 138 35 075

ballast in frame max.*

lb lb

CECE 26 609 34 546

ROPS, FOPS, weight 6 t ROPS, weight 6 t, tires cover Carrier with canopy, weight 2,4t Carrier with canopy, weight 6 t

lb lb lb lb

35 097 34 986 26 058 33 995

35 626 35 516 26 587 34 524

17 284 17 394 18 386

Carrier with canopy, weight 6 t, tires cover

lb

34 436

34 965

17 945

17 835

*/ Weight for max. operation weight 52 910 lb.

1.3.2

Technical information

Length

mm (in)

4775 (188)

Width

mm (in)

2265 (89,2)

Height with cab/without cab with ROPS

mm (in)

3040 (119,7)

Inner diameter

mm (in)

300 (11,8)

11

1.3. Technical information 1.3.3

Driving qualities

The travel speed to front and back under each gear level : I.

km/h (MPH)

0 - 5 (0 - 3,1)

II.

km/h (MPH)

0 - 11 (0 - 6,8)

III.

km/h (MPH)

0 - 19 (0 -11,8)

Gradeability under full load

%

25

Side machine stability with the cab and protective frame (total weight 24 000 kg standing machine): - with the wheel directly - with the wheel to the lean

% %

36 32

Turning radius

1.3.4

left

right

rut internal

mm (in)

5350 (210,6) 5800 (228,3)

- outer

mm (in)

8150 (320,9) 8250 (324,8)

contour internal

mm (in)

5350 (210,6) 5580 (219,7)

- outer

mm (in)

8350 (328,7) 8630 (339,8)

Engine

Manufacturer

Cummins Engine Company, Inc.

Engine type

4BT3.9 C 99

Kind of the engine

Diesel engine, liquid cooled

Cylinder number

4

Perforation

mm (in)

102 (4,02)

Stroke

mm (in)

120 (4,72)

Stroke capacity

cm (cu in)

3922 (239,3)

3

Engine output according to the ISO 3046/1, DIN 6271 kW (HP) Nominal revolutions

74 (99) min (RPM) -1

2400 (2400) 2200 (2200) **/

Fuel consumption under normal operation

l/h (gal US/h) 7,3 (1,93) - 12,8(3,38) (Due to machine loading and the way of operation)

Kind of fuel filters

FLEETGUARD FF1280 and FF5052

Kind of oil filters

FLEETGUARD LF3345

Kind of Air filter Dry cleaner with the rotary pre-cleaner

DONALDSON FPG 08-2503

Marking of the air filter inserts main insert securing insert

P77 - 2580 P77 - 5302

Injection pump */

Bosch ES4 A95D 320/3 RS2880

Alternator kind */

Bosch K1 14V 23/65A

Starter kind */

Delco-Remy 12V

Fuel tank capacity

l (gal US)

250 (66)

Engine fulfills requirements of 97/68/EC, EPA, CARB. */ The kind and marking can vary (delivery with the Cummins engine), when ordering the spare parts always indicate the own engine number. **/ With useful of noise reduction for the fulfil limit of external noise 105 dB to standard 2000/14/EC and ISO 3744.

Specification manual 1.3.5

Gearbox

Gearbox type

CLARK 12.2 HR 18302

Gearbox kind:

3-level reversing gearbox with hydrodynamic moment changer, with shifting the gear levels under electrical loading.

Kind of the gearbox oil filter

CLARK 247 050

Cooling the gearbox and the engine by combined radiator

NISSENS 280 898N1

1.3.6

Axles

The front axle consists of two pairs of wheels, each pair has variation suspension on the hydraulic cylinder piston rod, round its axe it is turning to the turning radius. The pair of the hydraulic cylinders is connected with the isostatic function.

The rear axle consists of 2 drive boxes with end gearing solid mounted to the back part of the cylinder frame.

Wheel base

3500 mm

Number of tires

8

Tires dimension

11,00 x 20" without the pattern

Tires pressure

0,2 - 0,6 MPa

1.3.7

Brakes

The working brake is controlled by the foot pedal, the hydraulic with the air-liquid booster, acting to the 4 wheels of the rear axle.

The parking and the auxiliary (emergency) brakes are mechanical, disc – gear, placed on the entrance spindle of the final drive. It is controlled by the switch (hand brake valve – on the machine > in Czech Republic).

Compressor

HOLSET SS191 100 cm 3 (8,5cfm)

Air-liquid booster

(03.9690-68) PAL-INALFA

Pedal brake valve

(03.9316-95) KNORR

Air dryer

432 415 003 0 WABCO

Dryer spare cartridge

432 410 020 2 WABCO or 432 410 222 7 WABCO

13

1.3. Technical information 1.3.8

Driving

Hydraulic servo-driving with one direct hydraulic motor Hydro generator

2-Q10R.54600-00

Driving unit

LAGC 200 LSD 102-L202 REXROTH

Priority valve

LSPSD 205-A201 REXROTH

Securing pressure

MPa

14

Direct hydraulic motor

HV 80/40/200-111 131

Driving tank

N-05-25-5 JIHOSTROJ

Tank oil filter insert

H23 MANN-JIPAP

1.3.9

Fills

Engine oil in the crankcase

l (gal US)

15,5 (4,1)

Oil in the gearbox

l (gal US)

21,5 (5,68)

Oil in the differential

l (gal US)

13,5 (3,57)

Oil in the end transmissions

l (gal US)

2x5,2 (2x1,4)

Oil in the hydraulic distribution of the driving

l (gal US)

6,5 (1,72)

Oil in the ejector of the front axle

l (gal US)

6 (1,6)

Brake liquid in the brakes

l (gal US)

0,75 (0,2)

Engine diesel in the tank

l (gal US)

250 (66)

Water in the tire sprinkling tank

l (gal US)

285 (75)

Cooling liquid

l (gal US)

17,6 (4,7)

Power

V

12

Accumulator capacity

Ah

135

1.3.10 Electric installation

Grounded

- pole

1.3.11 Safety regulations Orange beacon of the warning light signalling on the cab.

Accumulator disconnector disconnects the minus pole from the machine ground.

14

Specification manual 1.3.12 Hygienic data of the machine Machine with cab and with closed windows : Noise : Level of acoustic pressure influenced the driver : (measured due to EN 11 204 during the drive on layer of asphalt mixture)

LpA = 85 dB (A)

Level of acoustic output (outer noise) (measured due to ISO 6393 on concrete layer, still machine)

LWA = 107 dB (A)

Guaranteed sound power level (measured due to 2000/14/EC and ISO 3744 on layer of asphalt mixture, still machine) /applicable to a noise insulated set/.

LWA = 105 dB (A)

Vibrations : Measured effective value of vibration acceleration : - transferred to hands (measured due to ISO 5349 during the drive on layer of asphalt mixture) - transferred to body (measured due to EN 1032 during the drive on layer of asphalt mixture)

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

Machine with cab with opened windows : Noise : Level of acoustic pressure influenced the driver : (measured due to EN 11 204 during the drive on layer of asphalt mixture) Machine without cab : Noise : Level of acoustic pressure influenced the driver : (measured due to EN 11 204 during the drive on layer of asphalt mixture) Vibrations : Measured effective value of vibration acceleration : - transferred to hands (measured due to ISO 5349 during the drive on layer of asphalt mixture) - transferred to body (measured due to EN 1032 during the drive on layer of asphalt mixture)

LpA = 86 dB (A)

LpA = 89 dB (A)

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

1.3.13 Traffic regulations The machine can be driven on the public roads, its equipment meets the regulation no.102/1995 Sb. For the Czech Rep.

1.3.14 Extended devices The protective frame ROPS meets the international standards EN 500-4:1995; ISO 3471:1994; SAE J 1040:APR88; AS 2294:1990 for the maximum machine weight 24000 kg.

Frame weight Mounted to the machine by 8 screws Tightening moment

kg (lb) Nm

420 (926) M27x1,5-370 700

15