Multiquip Rammax 1575 Trench Roller Service Manual

SERVICE

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Updated 5/7/15

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SCHEMATICS ○ TEST PROCEDURES ○ TROUBLESHOOTING

Manual No. RX1575SM

Rammax 1575

(Yanmar 3TNV76 Diesel Engine)

2 Rammax 1575

Preface

This manual was created for field and in the shop service.

Along with maintenance and repair instructions, this Service Manual also contains a description of the machine.

This Service Manual does not, however, replace the roller operating manual.

Because the content of the deliverable depends on the order, the features of your roller may differ in some descriptions and pictures.

3

4

The Rammax 1575 trench roller is a roller specially designed for trench compacting.

Rammax 1575

Table of contents

2.3.2

2.3.3

2.3.4

2.3.5

2.4

2.4.1

2

2.1

2.1.1

2.2

2.2.1

2.2.2

2.3

2.3.1

1

1.1

1.1.1

1.1.2

1.1.3

1.1.4

1.1.5

1.1.6

1.1.7

1.2

1.2.1

1.2.2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

About this Service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Target audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Scope of this Service manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Completeness of the Service Manual . . . . . . . . . . . . . . . . . . . . . . 12

Technical changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Copyrights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Structure of the Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Orientation on the roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Identification of the roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Machine type Rammax 1575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Product data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Dimensions Rammax 1575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Roller designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Machine rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Location of machine rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Location of machine chassis number . . . . . . . . . . . . . . . . . . . . . . 21

Location of Yanmar engine rating plate . . . . . . . . . . . . . . . . . . . . . 22

Location of engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5

6

6.3.1

6.3.2

6.3.3

6.3.4

6.3.5

6.3.6

6.4

6.4.1

6

6.1

6.1.1

6.2

6.2.1

6.2.2

6.2.3

6.3

6.5

6.6

6.7

6.8

6.8.1

5

5.1

5.1.1

5.1.2

5.1.3

5.2

5.2.1

5.2.2

5.2.3

5.2.4

3

3.1

3.2

3.2.1

3.3

3.4

3.4.1

3.4.2

3.5

4

4.1

7

7.1

7.1.1

7.1.2

7.1.3

7.2

7.2.1

7.2.2

7.3

7.3.1

7.4

7.4.1

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

General working safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Roller operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Shear points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Noise levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Safety markings on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Warning stickers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Notice stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Radiation compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Structure and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Component overview Rammax 1575 . . . . . . . . . . . . . . . . . . . . . . . . .32

Operating and display elements. . . . . . . . . . . . . . . . . . . . . . . . . . .35

Display unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Control lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Control lamp functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

LED error display on the display unit . . . . . . . . . . . . . . . . . . . . . . .38

Infrared transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

LED error display on the IR transmitter . . . . . . . . . . . . . . . . . . . . .40

Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Overview of the hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Hydraulic hose service life and storage . . . . . . . . . . . . . . . . . . . . .46

Overview of hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Hoses for travel/vibro drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Valve block connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Valve block hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Checking and adjusting pressures . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Checking the steering pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Checking the maximum vibration pressure . . . . . . . . . . . . . . . . . .58

Checking the maximum charge pressure. . . . . . . . . . . . . . . . . . . .61

Checking the drive pressures (reverse / forwards) . . . . . . . . . . . .62

Checking the drive motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Checking the maximum drive pump pressure (reverse / forwards) 64

Setting the drive pump to the neutral position . . . . . . . . . . . . . . . . . .65

Checking the drive pump’s solenoid . . . . . . . . . . . . . . . . . . . . . . .66

Checking the drive pump servo-block . . . . . . . . . . . . . . . . . . . . . . . .67

Checking the flow divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Speeds and pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Hydraulics diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Hydraulics Diagram Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Engine electrical system / Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Chassis rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Connector N1 / wiring harness. . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Tier 4 / Wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Explanations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Wiring diagram key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Rammax 1575

9.9

9.9.1

9.9.2

9.9.3

9.9.4

9.9.5

9.9.6

9.10

9.7.4

9.7.5

9.7.6

9.8

9.8.1

9.8.2

9.8.3

9.8.4

9.5

9.6

9.6.1

9.6.2

9.7

9.7.1

9.7.2

9.7.3

9

9.1

9.1.1

9.2

9.3

9.3.1

9.3.2

9.4

9.10.1

9.10.2

9.11

9.11.1

9.11.2

9.11.3

9.12

9.12.1

9.12.2

9.12.3

9.12.4

9.13

9.14

9.14.1

8

8.1

8.2

8.2.1

8.2.2

8.3

8.3.1

8.3.2

8.3.3

8.4

8.5

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Engine doesn’t start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Start test for cable and infrared modes . . . . . . . . . . . . . . . . . . . . . 98

Position of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

The controller is not working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

External factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Machine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Handheld controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Battery safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

General information about maintenance . . . . . . . . . . . . . . . . . . . . . 110

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Maintenance plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Yanmar engine service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Maintenance check sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Opening the hood, front and rear. . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Engine compartment overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Left side of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Right side of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Fuel (diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Checking fuel level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Draining fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Cleaning the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Water separator filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Topping up the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Draining engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Replacing the engine oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Topping up hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Draining the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Cleaning the hydraulic oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . 125

Replacing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Replacing the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Hydraulic oil replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Filling the hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Filling the drive pump, building charge pressure . . . . . . . . . . . . . 128

Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Checking coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Topping up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Cleaning the radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Scrapers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Air-intake filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Replacing the pendulum support joint head. . . . . . . . . . . . . . . . . 134

Replacing the pendulum joint bearing . . . . . . . . . . . . . . . . . . . . . 134

Lubricating steering cylinder, bearing . . . . . . . . . . . . . . . . . . . . . . . 135

Brake test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Cable/connector Y9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7

8

9.14.2

9.15

9.16

9.17

9.17.1

9.18

9.19

10.6.5

10.7

10.7.1

10.8

10.8.1

10.8.2

10.9

10.9.1

10.5.3

10.5.4

10.5.5

10.6

10.6.1

10.6.2

10.6.3

10.6.4

10.3.1

10.4

10.4.1

10.4.2

10.4.3

10.5

10.5.1

10.5.2

10

10.1

10.2

10.2.1

10.2.2

10.2.3

10.2.4

10.3

10.9.2

10.9.3

10.10

10.11

10.12

10.13

10.13.1

10.13.2

10.14

10.14.1

10.14.2

10.14.3

10.14.4

10.15

10.15.1

10.15.2

10.15.3

10.16

Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Cementing hydraulic threaded joints . . . . . . . . . . . . . . . . . . . . . .141

Conversion table for bar à psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Cleaning the roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

Preparation for welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Starting with another battery (jumpering) . . . . . . . . . . . . . . . . . . .147

Charging the battery using a battery charger. . . . . . . . . . . . . . . .148

Long-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Gas strut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Replacing gas struts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Overturning/Tipping of the Rammax 1575 . . . . . . . . . . . . . . . . . . . .150

Inspect for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Prevent an oil shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

Front engine hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158

Replacing the hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

Replacing the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

Replacing the rubber hood buffers. . . . . . . . . . . . . . . . . . . . . . . .165

Adjusting the rubber hood buffers . . . . . . . . . . . . . . . . . . . . . . . .167

Rear engine hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

Replacing the hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171

Replacing the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171

Replacing the rubber hood buffers. . . . . . . . . . . . . . . . . . . . . . . .174

Adjusting the rubber hood buffers . . . . . . . . . . . . . . . . . . . . . . . .175

Replacing the display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175

Replacing the controller (machine controller). . . . . . . . . . . . . . . . . .176

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

Replacing and adjusting the magnetic rotational speed sensor. . . .179

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

Testing the engine speed and frequency . . . . . . . . . . . . . . . . . . . . .183

Roller drum removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

Installing the roller drum extender . . . . . . . . . . . . . . . . . . . . . . . . . .185

Rubber elements of vibro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188

Installation of the rubber elements . . . . . . . . . . . . . . . . . . . . . . . .193

Replacing bearing, vibro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200

Gaining access to the vibro unit . . . . . . . . . . . . . . . . . . . . . . . . . .200

Dismantling the vibro unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203

Assembling the vibro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208

Assembling the vibro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209

Replacing the drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226

Replacing vibromotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229

Rammax 1575

12

12.1

12.1.1

12.1.2

12.1.3

12.1.4

12.1.5

12.1.6

13

13.1

13.2

10.22

10.22.1

10.22.2

10.23

10.24

10.24.1

10.24.2

10.25

10.25.1

10.25.2

10.25.3

10.26

10.26.1

10.26.2

10.26.3

10.26.4

10.26.5

10.26.6

10.16.1

10.16.2

10.17

10.18

10.18.1

10.18.2

10.18.3

10.19

10.19.1

10.19.2

10.19.3

10.20

10.21

10.21.1

10.21.2

10.21.3

11

11.1

11.1.1

11.1.2

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Roller drum installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Replacing the drive pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Preparing the new drive vibro pump . . . . . . . . . . . . . . . . . . . . . . 244

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Replacing the valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Readying the machine for operation . . . . . . . . . . . . . . . . . . . . . . . . 263

Pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Replacing the joint head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Replacing the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Removing the old steering cylinder . . . . . . . . . . . . . . . . . . . . . . . 269

Install a new steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Pendulum joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Shutdown bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Replacing the shutdown bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Sensor replacement and adjustment . . . . . . . . . . . . . . . . . . . . . . 288

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Special tool for measuring speed and frequency. . . . . . . . . . . . . 294

Special tool for checking solenoids . . . . . . . . . . . . . . . . . . . . . . . 295

Plugs and stoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Vibromotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Vibromotor valve block maximum pressure . . . . . . . . . . . . . . . . . 295

Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Drive pump drive pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Drive pump charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Steering valve block maximum pressure . . . . . . . . . . . . . . . . . . . 296

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Long-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Shipping weights and dimensions . . . . . . . . . . . . . . . . . . . . . . . . 300

Transportation overseas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Joint protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Lifting at the 1-point lifting eye . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Securing the roller on the transporter . . . . . . . . . . . . . . . . . . . . . 302

Center of gravity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Removal and depressurization of the gas strut . . . . . . . . . . . . . . . . 306

9

SERVICE & SUPPORT CENTER

Operation and Parts manuals as well as other service related material can be viewed and downloaded on the MULTIQUIP Service & Support Center website - use the link below

http://service.multiquip.com

You can also access the Service & Support Center website using the QR code below on your mobil device

10 Rammax 1575

1

General

11

1.1

1.1.1

1.1.2

1.1.3

About this Service manual

This manual is part of the customer documentation for the Rammax 1575 trench roller.

It is customer documentation of the Ammann Schweiz AG and its representatives in other countries.

Target audience

This Service manual is intended for service technicians in the field and at repair shops who have been authorized to service and repair MQ vibratory rollers by the relevant operating company.

Purpose

The purpose of this Service manual is to ensure that the roller will be used optimally and safely during the following processes.

●

●

Maintenance

Repair

Scope of this Service manual

This Service manual covers the following rollers:

Rammax 1575

Some of the figures and descriptions in this Service manual may not exactly match your roller.

1.1.4

1.1.5

Completeness of the Service Manual

Never remove sections from this manual. Missing pages - specifically the Safety section - must be replaced immediately if lost.

Technical changes

In the interest of technical developments, Multiquip reserves the right to make changes to this document at any time without separate notice.

12 Rammax 1575

1.1.6

Copyrights

The publisher of this EC compliant customer document is Ammann Schweiz AG.

We reserve all rights for this document and the roller described therein.

Reproduc-tion, disclosure to third parties or utilization of its content is forbidden without our express permission. © 2011 Ammann Schweiz AG

1.1.7

Spare parts

When performing scheduled and unscheduled repairs, you may need to replace components of the roller.

Only use spare parts which meet the requirements specified by the Amman Schweiz AG.

These requirement are fulfilled if only original Ammann spare parts are used.

For the ordering spare parts, download parts manual at http://service.multiquip.com

1.2

1.2.1

Structure of the Service Manual

The following explanations are designed to familiarize you with the roller and to provide support for handling and maintenance.

It is essential that you read chapter 3 Safety information, page 23 carefully before commissioning and carrying out maintenance work.

Observing the "safety instructions" in particular increases the reliability of the roller in operation and its service life. This reduces repair costs and down time.

Orientation on the roller

When describing the components of the roller, we inform you of their position on the roller.

We adhere to the orientation below when doing so.

Structure of the

Service Manual

General 13

Top

Left

1.2.2

Bottom

Right

Fig. 1-1 Rammax 1575 orientation

We view the roller from the position of the driver standing behind the roller looking in the direction of travel.

Warnings

Please observe the meaning of the following warnings:

!

DANGER

●

DANGER represents an immediate hazard leading to severe bodily injury or death.

!

WARNING

●

WARNING represents a possibly hazardous situation which could lead to severe

bodily injury or to death.

!

CAUTION

●

●

CAUTION represents a possibly hazardous situation which could lead to slight

bodily injury.

Caution also represents a hazard of environmental pollution causing local or global environmental damage.

14 Rammax 1575

NOTE The battery poles and terminals must be clean. If they are coated with a (whitish or greenish) sulfur crust they must be cleaned.

NOTE Risk of cable fire or short circuit

●

●

●

NOTE represents first of all: damage which could be caused to the roller or parts of it.

NOTE represents secondly: Application tips and other particularly useful information.

NOTE is not a signal word for a hazardous or damaging situation.

Structure of the

Service Manual

General 15

16 Rammax 1575

2

Product description

17

2.1

2.1.1

Identification of the roller

Machine type Rammax 1575

This Service Manual is valid for the following machines of the Rammax 1575 series.

Tab. 2-1 Roller drum width Rammax 1575

Model

Rammax 1575 with 24" drums with drum rings

Roller drum width

24 in (640mm)

33in (850mm)

Rammax 157533 33in (850mm)

Weight

3,087 lbs (1400kg)

3,197 lbs (1450kg)

3,197 lbs (1450kg)

18 Rammax 1575

2.2

2.2.1

Product data

Dimensions Rammax 1575

23.66 in (601 mm)

11.89 in (302 mm)/

16.02 in (407 mm)

1.42 in

(36 mm)

25.20 in (640 mm)/

33.46 in (850 mm)

Fig. 2-1 Dimensions Rammax 1575

2.2.2

Specifications

Tab. 2-2 Rammax 1575 performance data

Roller drum width (mm)

Service weight according to CECE (kg)

Static linear load (kg / cm)

Outside / inside turning radius (mm)

Large/ small amplitude (mm)

Gradient in % with/without vibration

Drive

Performance according to ISO 3046

Operating speed

Travel speed, working gear

Transport gear travel speed

Steering angle / pivoting

Vibration frequency

Product data

Product description

20.67 in

(525 mm)

39.37 in (1000 mm)

77.95 in (1980 mm)

87.68 in (2227 mm)

Rammax 1575

24 (640)

3,087 (1400)

10.1 (11.6)

33(850)

3,197 (1450)

7.7 (8.9)

86.25/61 (2191/1541) 90/57 (2286/1436)

.024 (0.6)/0.43 (1.1)

40/50

YANMAR 3TNV76

/

EPA 4

15.0kW

/

20.4HP

2400 1/min

82 (25) m/min

148 (45) m/min

+/-30°

/

+/-7°

2,460 (41) Hz

19

Tab. 2-3 Rammax 1575 filling capacities

Container

Hydraulic oil tank

Diesel tank

Contents

4.2 (16l)

7.4 (28)

2.3

2.3.1

Roller designation

Identification plate

An identification plate is affixed to the roller for identification. The identification plate is attached to the rear part of the chassis below the steering column.

1

2

3 4

8

9

10

5

6

7

11 12

Fig. 2-2 Data on the identification plate

13

7

8

5

6

3

4

1

2

Roller designation

Homologation number

Name and address of the manufacturer

Vehicle Identification Number (VIN)

Roller model

Year of manufacture

Serial number

Fuel engine output at

9 Speed of fuel motor (rpm)

10 CECE total weight

11 Axle load, front

12 Axle load, rear

13 Number stamped in chassis

20 Rammax 1575

NOTE When ordering spare parts you must indicate the serial number (S/N) of the roller.

2.3.2

Location of machine rating plate

1

The rating plate is located on the front right of the rear chassis.

2.3.3

Fig. 2-3 201309200003

Location of machine chassis number

1

The front chassis number is located under the steering/Vibro pump.

Fig. 2-4 201309200004

1

The rear chassis number is located hidden on the rear-most part of the center beam.

Fig. 2-5 201309200005

Roller designation

Product description 21

2.3.4

Location of Yanmar engine rating plate

1

The Yanmar engine’s rating plate is located on the valve cover.

2.3.5

Fig. 2-6 201309200002

Location of engine number

1

The engine number is located on the starter side (on the machine’s righthand side) of the engine block.

Fig. 2-7 201212140000

2.4

2.4.1

Disclaimer

Multiquip accepts no liability for the continued reliable functioning of the roller if it is not used appropriately.

Unauthorized conversions and changes to the roller are prohibited for safety reasons and void any and every Multiquip guarantee as well as, possibly, the CE directive.

Replaced spare or wear parts must meet the technical requirements specified by

Multiquip. These requirements are fulfilled if only original Multiquip spare parts are used.

The instructions given in the various sections must be adhered to. The safety instructions must be observed at all times. Failure to adhere to working instructions, their correct order, safety instructions or safety labeling requirements causes liability claims to become void.

Warranty

Opening or attempting to repair defective parts will void their warranty.

22 Rammax 1575

3

Safety information

23

3.1

3.2

General working safety

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

The roller may only be used for driving on and compacting loose top layers (gravel, earth). Other uses are prohibited.

Rollers may only be operated with all safety devices operating. Manipulation or disregard of safety devices and regulations invalidates the CE conformity.

Before starting every shift, check the effectiveness of the operation and safety devices and that the protection devices are in place.

Check the steering and brakes when you start work. If defects are apparent, roller operation is not permitted.

If you identify any defects on the safety system or defects that impair safe operation of the equipment, inform your supervisor immediately. The roller may no longer be operated.

If you identify any defects which endanger safe operation, cease operation immediately.

Only perform work on and clean the roller if it is stationary and secured from rolling away.

Switch off the engine when filling the fuel tank. Do not fill up fuel in enclosed spaces. No open flames.

Do not vibrate on slopes or inclines where there is a hazard of slipping or overturning.

Do not drive on slopes that are steeper than the maximum climbing capacity of the equipment. Always drive the roller carefully perpendicular to the slope dip.

Do not vibrate inside buildings and on unstable ground.

The driving and working field of view must not be obstructed in any way.

Switch off the engine before leaving the roller. Secure the roller against unauthorized start-up and rolling away.

Take suitable visible measures to secure parked rollers that pose an obstruction.

Never work under the influence of drugs, alcohol or medicines that impair consciousness.

Only operate the roller in good general light conditions and good workspace illumination.

The workplace of the operator is located at a safe distance of at least 2m.

Roller operation

!

DANGER

Rollover hazard when driving the roller!

• Only start the roller using the handheld transmitter.

• Personnel may not stand in front of or behind the roller while it is in operation.

• Persons necessary for operations at the sides of the equipment must remain at a safe distance of at least 2 m.

3.2.1

Shear points

●

●

●

When closing the hood ensure that no objects are situated between the hood and the chassis.

Take care that nothing is jammed in the joint plates when rotating the roller drums.

Do not put hands between the roller drum and support during operation.

24 Rammax 1575

!

DANGER

Danger to life through tipping or slipping of the roller! The edges of filled areas may give way!

• Only travel directly up or down slopes.

• Do not drive across slopes.

• Keep your distance to embankments and edges!

• Do not drive at an angle into or out of the trench.

• Park the roller on slopes only in such a way that it cannot overturn.

• Use the roller on slopes only in such a way that it cannot overturn.

• The roller drums have very poor adhesion on snow and ice.

Driving or working on a slope in snow or ice is prohibited.

• Damp and loose surfaces reduce the traction of the machine on upward and downward grades considerably. Adapt the speed of the machine to the terrain when driving on grades.

• The nature of the ground and weather conditions can negatively affect the climbing ability of the machine.

Never drive on slopes that are steeper than the maximum climbing ability of the machine.

Fig. 3-1 Tipping hazard

Construction site conditions can have a negative effect on stability and the tipping angle.

!

DANGER

Crushing hazard in the area of the articulated joint

• During operation, there is always a crushing hazard in the area of the articulated joint. Therefore, it is not permitted for persons to be in this area during operation. In general, a safety distance of at least 2 meters to the machine must be maintained during operation.

!

DANGER

Crushing of toes through careless handling of the roller!

• Wear safety shoes when working with the roller in order to help avoid crushed toes.

Roller operation

Safety information 25

!

DANGER

Danger of accident through improper operation of the roller!

• Read the operating instructions before operating the roller.

• Adhere to the safety regulations at all costs.

• In case of lack of clarity, contact your authorized dealer.

3.3

NOTE

Noise levels

!

WARNING

Hearing damage due to continuous noise level!

Depending on the use of equipment it is possible that the permissible noise level of 85 dB (A) will be exceeded.

• Wear ear protectors in accordance with national accident prevention regulations when working at higher noise levels.

The following noise level measurements were carried out by an accredited testing and monitoring body in accordance with machine directive 2000/14/EEC of the European parliament and council.

Inspecting and monitoring organization: TÜV Österreich (Austrian technical inspectorate)

Testing body no. 0408

Tab. 3-1 Sound power level

Model

Measured sound power level

Value

100dB (A)

The obligation to wear ear protection is standardized nationally. In Switzerland and

Germany, this is as of a measured level of 85 dB (A) (sound pressure).

3.4

Safety markings on the machine

●

●

●

●

Observe and adhere to the rules.

Keep the safety stickers and signs complete and legible.

Replace any damaged or illegible stickers and signs immediately.

You can order new stickers from Multiquip.

From the moment the signs are no longer recognizable and understandable at first glance, the machine must be shut down until new signs are installed.

26 Rammax 1575

3.4.1

Warning stickers

Tab. 3-2 Warning stickers on board

Warning stickers Meaning

Location on roller:

Air intake opening

/

Inside of cowling

Danger:

Damage to electrical controls!

Explanation:

Never spray a water jet into electrical or electronic components.

Never spray into the engine combustion air intake.

Location on roller: Outer cowling cover.

Danger: Danger of injury due to incompetent operation:

Explanation: Read the operating instructions before operating the roller. Adhere to the safety regulations at all costs. Contact your authorized dealer if anything is unclear.

Location on roller: Between the front and rear parts of the roller.

Danger: Crushing hazard!

Explanation: Only stand in this area when necessary and only with extreme caution!

Location on roller: In the middle of the front and back.

Danger: Rollover hazard

Explanation: Only stand in this area when necessary and only with extreme caution!

Safety markings on the machine

Safety information 27

Warning stickers Meaning

Location on roller: Radiator, both sides.

Danger: Warnings for cooling water radiator

Explanation: Do not put hands in the radiator fan when the machine is running.

28

Location on roller: Inner cowling cover.

Danger: If the roller has overturned, do not start the machine.

Explanation: Avoid oil shock.

Location on roller: Outer cowling cover.

Requirement: Wear ear protectors!

Explanation: Wear ear protectors in accordance with national accident prevention regulations when working at higher noise levels.

Rammax 1575

3.4.2

Notice stickers

Tab. 3-3 Notice stickers on board

Notice stickers Meaning

Location on roller: Chassis rear

Designation: Guaranteed sound power level.

Explanation: Indicates the overall noise level produced by the roller.

Location on roller: On the hydraulic oil tank

Designation: Hydraulic oil

Explanation: Please only use hydraulic oil indicated

Location on roller: Chassis rear.

Designation: Hydraulic oil drain.

Explanation: Drain hole for the hydraulic oil

Location on roller: Chassis, front right.

Designation: Motor oil drain.

Explanation: Drain hole for the motor oil

Location on roller: Chassis rear.

Designation: Fuel.

Explanation: Filler neck for diesel fuel.

Location on roller: On the middle of the front and rear chassis.

Designation: Tie-down point.

Explanation: Points on the roller at which lashing means for securing the roller on the transport vehicle can be attached.

Safety markings on the machine

Safety information 29

Notice stickers Meaning

Location on roller: Roll bar, rear.

Designation: Suspension hooks.

Explanation: Points on the roller at which hoisting tackle for lifting the roller can be attached.

Location on roller: Rear chassis, front upper left.

Designation: Lifting and tie-down points.

Explanation: Illustrates how the machine is to be loaded and transported.

Location on roller: Rear chassis, front upper left.

Designation: Spare parts information

Explanation: Information about the filters of the machine.

Location on roller: Inner cowling cover.

Designation: Close the cover.

Explanation: Attention: When driving using remote control and when parking the machine, the cover must be closed.

Location on roller: Inner cowling cover.

Designation: Ignition

Explanation: Attention: Current is present when the ignition is on.

3.5

Radiation compliance

This machine complies with the emission requirements for radio interference due to radiation, European Norm EN 13309, for construction machinery.

30 Rammax 1575

4

Structure and function

31

4.1

Component overview Rammax 1575

32

Fig. 4-1 View from the right

3

4

1

2

5

6

1-point lifting eye

Identification plate

Roller drum scraper

Rear hood latch (cowling)

Front hood latch (engine hood)

Front infrared sensor

Fig. 4-2 View from left

3

4

1

2

Articulated joint protection

Shutdown bar (optional)

Cockpit cover

Rear infrared sensor

1

4

3

2

Rammax 1575

6

1

2

3

4

1

2

5

6

Fig. 4-3 Cockpit overview

Infrared transmitter

Storage area for spiral cable

Display unit

Ignition switch

Fuses

Connector for spiral cable to infrared sensor (back area)

1

3

4

5

3

4

5

2

Fig. 4-4 Overview of interior of rear chassis

3

4

1

2

5

Oil cooler

Fuel tank

Hydraulic tank

Battery

Controller (machine controller)

Component overview Rammax 1575

Structure and function 33

1

Fig. 4-5 Front bottom view

1 Engine oil drain plug

34 Rammax 1575

5

Operating and display elements

35

5.1

5.1.1

Display unit

Control lamps

5.1.2

5

6

7

3

4

1

2

Display/operating hours counter

Control lamp for battery charge level (charge control)

Error control lamp

Control lamp for engine oil pressure

Control lamp for cooling water temperature

Control lamp for shutdown bar

Control lamp for pre-heating

Control lamp functions

Error

The Error control lamp lights as soon as the controller recognizes an error.

1

Check whether the desired function is working. (This also applies when the tilt sensor is triggered.)

If the Error control lamp is still lit after carrying out these checks, call a specialist to help solve the problem.

36 Rammax 1575

Battery

If the

battery charge level control lamp lights up during operation or does not go off after starting, carry out the following check immediately.

1

Stop the engine.

2

Check the engine for defective or loose V-belt.

If the battery charging lamp is still lit after carrying out these checks, call a specialist.

NOTE

If the

engine oil pressure control lamp lights up during operation or does not go off after starting, stop the roller and turn off the engine immediately!

1

Check the engine for oil loss and correct oil level.

1.1

The oil level in the engine is correct: Call a specialist to remedy the problem.

The machine is equipped with an automatic shutdown system. If the oil pressure falls below the limit value, the oil pressure warning lamp lights up. After the warning lamp has been lit for 4 seconds, the machine is shut down.

!

WARNING

Danger of scalding! The cooling circuit is pressurized.

NOTE Danger of engine overheating. Stop immediately!

If the coolant temperature control lamp lights up during operation of the machine, switch off the engine immediately and top up coolant!

1

Allow the engine to cool down.

2

Remove the radiator cap.

3

In order to avoid scalding, first unscrew the radiator cap one turn and allow the pressure to drop.

4

As soon as the pressure has dropped, remove the cap and top up the liquid.

5

Check the cooling system for leaks and the radiator/expansion vessel for correct coolant level.

5.1

You are unable to find an error: Call a specialist to remedy the problem.

Display unit

Operating and display elements 37

NOTE The machine is equipped with an automatic shutdown system. If the cooling water temperature exceeds the limit value, the temperature warning lamp lights up. After the warning lamp has been lit for 4 seconds, the machine is shut down.

Pre-heating

The pre-heating time amounts to about 6 sec. When the motor is started, the

Pre-heating

control lamp goes off.

5.1.3

NOTE

The shutdown bar indicator lamp remains lit as long as the shutdown bar is actuated.

1

Check whether the shutdown bar has been released.

2

Release the shutdown bar.

LED error display on the display unit

Tab. 5-1 Error display (tilt switch)

Display

Error lights up

Cause

The tilt switch has been triggered. The roller is at an angle of more than about 45° or has tipped over.

Remedy

Set the machine upright.

For safety reasons, as soon as the roller tips over, the ignition is also shut off.

The machine controller is equipped with an inclination sensor. It triggers as of an angle of 45°. In this case, the engine shuts itself off automatically. The machine cannot be started as long as the inclination sensor remains triggered.

If the machine has tipped over, it is possible for engine oil to enter the combustion area. If the machine is started after it has been righted, engine damage is possible.

• Set the machine upright. Do not start the engine under any circumstances.

• Inform the service Service.

38

Tab. 5-2 Error and shutdown bar display

Display

Error lights up

Error and shutdown bar light up in unison

Cause

A switching transistor signals a status error. This means that, for example, a short circuit or a cable break has been detected.

The machine controller is waiting for both the inputs “Oil pressure” and

“Alternator” to be at the rest position.

Remedy

Check the cable for a short circuit or cable break.

Check the oil pressure and

Alternator outputs.

Rammax 1575

NOTE Bear in mind the priority of the displays: First is the tilt switch, then “Wait” and last, the status error transistor.

NOTE

Shutdown bar display

Tab. 5-3 Shutdown bar display

Display Cause

Shutdown bar lights up Switch on shutdown bar has triggered.

Shutdown bar is blinking

Close proximity shutdown has been detected.

Shutdown bar is flashing

Close proximity has been detected.

Remedy

Move the shutdown bar to its original position.

Move more than 2.5 m away from the roller.

If the roller is controlled by means of the cable, the user must be present in the close proximity area

(between 2.5 and 4m)

Bear in mind the priority of the displays: First the bar switch, then the close proximity shutdown and last, the close proximity area.

Display unit

Operating and display elements 39

5.2

5.2.1

Infrared transmitter

Design

5.2.2

Fig. 5-1 Infrared transmitter

5

6

7

3

4

1

2

Work gear/transport gear

Forward travel/backward travel

Large/small amplitude vibration

Steering angle left/right

Start/Stop

LED (error and charging display from IR transmitter)

Cable

LED error display on the IR transmitter

There are two LEDs on the cover: a green one and a red one.

Fig. 5-2 LED error display, green/red

40 Rammax 1575

NOTE

Standard

Tab. 5-4 Standard display

Display

The green LED is blinking slowly.

The green LED is flashing.

Cause

The roller is being controlled via the cable.

The roller is being controlled via infrared.

Battery charge monitoring

The red LED blinks either faster or slower depending on the battery charge level. The lower the charge state, the longer the on-phase of the LED.

Tab. 5-5 Battery charge monitoring display while performing a function

Display

The red LED flashes briefly

The red LED always lights when a control is operated.

The red LED flashes.

The red LED is lit.

Cause

The battery is slowly becoming drained

When the battery is drained, it is no longer sent.

The battery is being charged.

The battery is fully charged.

Remedy

Connect the charging cable for at least 1h.

Connect the charging cable for at least 1h.

It is still possible to control via the cable once the battery is empty.

Battery warnings and errors are only displayed during active control (i.e., when a control element is actuated).

As soon as and as long as the infrared transmitter is attached to the machine controller via the cable and the ignition is turned to I, the red LED must flash or be lighted.

NOTE

Tab. 5-6 Automatic pairing display

Display

The green and red LEDs are blinking in unison quickly.

Cause

The infrared transmitter is coupled with the machine controller.

This procedure normally only takes a maximum of about 3 seconds. If this blinking lasts longer or should even become permanent, there is a problem with pairing:

• A cable break in one of the signal lines

• A short circuit in one of the signal lines

As long as this blinking pattern remains, no control signals will be sent to the machine controller. Engine does not start.

Infrared transmitter

Operating and display elements 41

Automatic pairing occurs at the moment the cable is unplugged, or, if the cable is plugged in, when the ignition is switched on.

Special cases

●

●

When the infrared transmitter is switched on, both LEDs are switched on briefly. This feature helps to determine that the LEDs are still functioning.

As soon as the cable is unplugged from the handheld transmitter or from the roller, the red LED lights up for about 1 second.

5.2.3

Cable connection

2

5.2.4

1

Fig. 5-3 Spiral cable connector

1

2

Spiral cable connector/protective cover fastener

Solar cells/Transmission elements

Handling

Sticker

The infrared transmitter is located in the black lower part of the housing. It contains the following transmission elements:

●

●

The solar cells

The infrared diodes for data transmission and measuring the safety distance.

42

●

●

Before startup, clean the transmission elements.

Before startup, be sure that the solar cells in the lower part of the housing are not covered over.

Rammax 1575

●

Keep the solar cells clean during operation.

!

CAUTION

Accident hazard due to covered over lower part of the housing!

• Before and during operation with the infrared transmitter, make sure that the entire lower part of the housing remains completely uncovered for the entire time of operation.

• In particular, the operator’s hand must not cover the lower part of the housing even partially.

Wear the infrared transmitter correctly

1

Pay attention to correct positioning.

1.1

The cable connector must face forwards or be oriented according to the sticker on the transmitter. The infrared transmitter may rest on the stomach of the operator.

1.2

Adjust the strap for the correct length to ensure optimal wearing comfort.

2

Pay attention to correct operation.

2.1

Only hold the housing by the upper part; see the warning information.

NOTE

Fig. 5-4 Wear the infrared transmitter correctly

Be certain that the desired confirmation can be carried out safely.

Infrared transmitter

Operating and display elements 43

44 Rammax 1575

6

Hydraulic System

45

6.1

Overview of the hydraulic system

3 2

11

4

10

9

1

6

6.1.1

NOTE

7

4

5

8

4

5

4

7

8

5

6

3

4

1

2

Hydraulic oil tank

Drive pump

Vibro-steering pump

Drive motor

Vibromotor

Valve block

Hydraulic manifold

Steering cylinder

9 Hydraulic oil filter

10 Oil cooler

11 Flow divider

Hydraulic hose service life and storage

The hydraulic hoses should not be used for more than six years (this includes any storage periods). In addition, the hoses should not be stored for more than two years

(as per DIN 20066).

46 Rammax 1575

6.2

6.2.1

Overview of hydraulic hoses

Hoses for travel/vibro drive

Front left roller drum

Fig. 6-1 201310020003

Tab. 6-1 Hoses for front left roller drum

No.

of

37

38

39

31

33

35

Drive circuit B, forwards

Drive motor brake

Drive circuit A, reverse

Front left drive motor leakage oil, L-fitting

Front left brake

Front left drive motor leakage oil, L-fitting

position

Hydraulic manifold, left

Valve block BR

Drive pump A, T-fitting

Valve block T3

Front right drive motor brake

Front right drive motor leakage oil, L-fitting

Overview of hydraulic hoses

Hydraulic System 47

Front right roller drum

48

Fig. 6-2 201310020004

Tab. 6-2 Hoses for front right roller drum

No.

of

38

39

40

30

32

34

36

position

Vibro motor, front

Drive circuit B, forwards

Drive circuit A, reverse

Front vibromotor, connection at rear

Valve block A1

Hydraulic manifold, right

Drive pump A, T-fitting

Junction, vibration elbow bulkhead fitting

Front right drive motor brake Left drive motor brake, L-fitting

Front right drive motor leakage oil, L-fitting Front left drive motor leakage oil, L-fitting

Front right drive motor leakage oil, L-fitting Leakage oil, front vibromotor

Rammax 1575

Rear left roller drum

Fig. 6-3 201310020002

Tab. 6-3 Hoses for rear left roller drum

No.

of

58

59

60

50

52

54

56

Rear vibromotor, connection at rear

Drive circuit B, forwards

Drive circuit A, reverse

Rear vibromotor, connection at front

Rear left drive motor brake

Rear left drive motor leakage oil L-fitting

Rear left drive motor leakage oil

position

Junction rear elbow fitting

Junction at rear

Junction at rear

Junction rear elbow fitting

Rear right drive motor brake L-fitting

Rear right drive motor leakage oil L-fitting

Rear vibromotor leakage oil

Overview of hydraulic hoses

Hydraulic System 49

Rear right roller drum

50

Fig. 6-4 201310020001

Tab. 6-4 Hoses for rear right roller drum

No.

of

51

53

55

57

58

59

Drive circuit A, reverse

Rear right drive motor brake

Drive circuit B, forwards

Leakage-oil return

Rear right drive motor brake L-fitting

Rear right drive motor leakage oil L-fitting

position

Junction at rear

Junction at rear

Junction at rear

Hydraulic oil tank return

Rear left drive motor brake

Rear left drive motor leakage oil L-fitting

Rammax 1575

6.2.2

Valve block connections

General information: The valve block is factory set.

Y5

BR

B2

A2

Y6

BPR

Fig. 6-5 201309210103 / valve block top view

Tab. 6-5 Valve block solenoid valves

No.

Y5

Y6

Y7

Y8

Y9

Designation

Steering left

Steering right

Big amplitude

Small amplitude

Brake

Tab. 6-6 Valve block connections

No. Designation

BR Brake

PBR Charge pressure from drive pump G

P

A2

B2

Pressure from vibro/steering pump

Steering right / right steering cylinder

Steering left / right steering cylinder

Y9

Overview of hydraulic hoses

Hydraulic System

Y8

P

Y7

51

52

4

B1

T2

A3

3

Fig. 6-6 201309210104 / valve block front view

Tab. 6-7 Valve block front connections

No. Designation

T2

A3

B1

Tank supply line to drive pump T1

Steering left / left steering cylinder

Rear left vibromotor / large amplitude elbow bulkhead screw connection

Tab. 6-8 Valve block pressure relief valve

No. Designation

3

4

Vibration pressure relief valve (min. 210 bar / max. 230 bar)*

Steering pressure relief valve (min. 60 bar / max. 75 bar)*

* Values measured with engine speed of min. 2380 rpm / max. 2430 rpm

Rammax 1575

A1

T3

B3

Fig. 6-7 201309210105 / valve block rear view

Tab. 6-9 Valve block connections for hydraulic hoses, rear

No. Designation

A1

T3

B3

Front right vibromotor, small amplitude

Front left and right drive motor leakage oil

Steering left / left steering cylinder

T1

Fig. 6-8 201309210106 / valve block right side view

Tab. 6-10 Valve block return

No.

T1

Designation

Return via oil cooler, return flow filter to hydraulic oil tank

Overview of hydraulic hoses

Hydraulic System 53

6.2.3

Valve block hoses

54

Fig. 6-9 201309220068 / valve block top view

Tab. 6-11 Valve block solenoid valves

No.

30

33

37

17

18

19

20

7

8

13

16

2

3

4

of

Valve block P

Valve block T2, elbow fitting

Valve block T1, elbow fitting

PBR valve block L-fitting

PBR valve block L-fitting

Valve block BR, T-fitting

Valve block B1

Valve block B3

Valve block A3

Valve block A2

Valve block B2

Valve block A1

Valve block BR, T-fitting

Valve block T3

position

Vibro/steering pump pressure L-fitting

Drive pump T1

Hydraulic oil cooler in, elbow fitting

Flow divider T

Drive pump G, L-fitting

Junction at rear

Junction rear elbow fitting

Left steering cylinder piston

Left steering cylinder rod

Right steering cylinder piston

Right steering cylinder rod

Front vibromotor, connection at front

Front left drive motor brake, L-fitting

Front left drive motor leakage oil, L-fitting

Rammax 1575

Fig. 6-10 201310180001 / valve block bulkhead fitting

Tab. 6-12 Valve block solenoid valves

No.

10

36

of

Bulkhead fitting at valve block bracket

Bulkhead fitting at valve block bracket

position

Junction rear elbow fitting

Front vibromotor, connection at rear

Fig. 6-11 201311040001 / junction at rear

Overview of hydraulic hoses

Hydraulic System 55

6.3

Checking and adjusting pressures

All values apply at a hydraulic oil temperature of approx. 60 °C and max. diesel engine speed.

Bleed pressure relief for a maximum of 5 sec.

Use the following pressure gauge:

●

●

For high pressure = min. 400 bar

For charge pressure = min. 40 bar

2

1

56

3

Fig. 6-12 201309210060 / drive pump, vibro/steering pump

1

M1 charge pressure

21 ± 2 bar; can only be adjusted using washers.

2

MB forward drive pressure

330 ± 15 bar; measure with the roller drums blocked.

3

MA backward drive pressure of

330 ± 15 bar; measure with the roller drums blocked.

4

M2 vibration switch-on pressure

220 ± 10 bar

M2 steering pressure

67 ± 8 bar.

4

Rammax 1575

1

Set drive pressure forward

2

Setting drive pressure forward.

2

1

Fig. 6-13 201309210060

1

Charge pressure valve

(adjustable with spacer disks)

1

Fig. 6-14 201309210057

!

CAUTION

Oil can overheat and seals can be damaged.

During the test procedures listed below, be certain that:

• The engine only runs at full speed for max. 5 s.

1

After the test procedures, reconnect all hydraulic hoses.

2

Start test run.

3

Check to be sure connections do not leak.

Checking and adjusting pressures

Hydraulic System 57

6.3.1

Checking the steering pressure

1

Use the control unit to steer the machine fully to the right or left end stop.

1.1

Keep the lever actuated throughout the entire following procedure.

Fig. 6-15 10460297 / 1575 steering end position

1

Measuring point (1) vibro/steering pressure.

1

6.3.2

Fig. 6-16 201310020006

If a steering pressure of 67 ± 7 bar is not achieved, then:

●

●

●

●

The right steering cylinder line must be removed and sealed pressure-tight.

The left steering cylinder line must be removed and sealed pressure-tight.

The valve block must be removed. Siehe “Replacing the valve block” see page 250.

The steering pressure relief valve must checked.

Checking the maximum vibration pressure

This procedure must be carried out if the vibration switch-on pressure falls below 200 bar.

1

Open the rear hood.

2

Gain access to the elbow screw connection.

2.1

Cut through all the cable ties on the hose bundle.

Fig. 6-17 21311190001

58 Rammax 1575

1

Disconnect the hydraulic hose (016) from the elbow screw connection (AF size 27/AF size 22).

Fig. 6-18 21311190002

1

1

Seal the screw connections pressure-tight.

(1)

1

Fig. 6-19 21311190003

1

Remove the knurled nut and O-ring on solenoid valve Y8 (1) .

Fig. 6-20 21311190004

1

2

1

1

Remove the magnetic coil (1) from the solenoid valve (2).

Fig. 6-21 21311190006

Checking and adjusting pressures

Hydraulic System 59

1

Remove the hydraulic hose (030).

1

Fig. 6-22 21311190008

1

Fig. 6-23 21311190014

1

Seal the screw connection (AF size 22) pressure-tight.

1

Re-mount the magnetic coil.

60

Fig. 6-24 21311190009

1

1

Connect a pressure gauge (min. 250 bar) to the vibration pressure measuring point (1).

2

Start the engine.

2.1

Full speed

3

Switch on vibration

3.1

Let it run for a maximum of 5 sec.

Fig. 6-25 201310020007

If the vibration pressure of 220 ± 10 bar is not achieved, then:

●

●

The valve block must be removed. Siehe “Replacing the valve block” see page 250.

The vibration pressure relief valve must checked.

Rammax 1575

6.3.3

After the test, the following tasks must be carried out:

●

●

●

●

●

Connect the hydraulic hoses

Top up oil

Clean the machine

Start the machine

Check for leakage and proper function

Checking the maximum charge pressure

1

Remove hydraulic hose 008 at the charge pressure measuring point.

Fig. 6-26 201311210010

1

Fig. 6-27 201311210011

1

Seal the screw connections (1) pressure-tight.

1

Remove the hydraulic hose for drive circuit B (forwards) from the drive pump.

2

Seal the screw connections pressuretight.

Fig. 6-28 201309210080

Checking and adjusting pressures

Hydraulic System 61

1

Remove the drive circuit A (reverse) Tscrew connection from the drive pump.

2

Seal the screw connections pressuretight.

Fig. 6-29 201309210084

1

1

Connect the pressure gauge (min.

40 bar) to the charge pressure measuring point (1).

2

Start the engine.

2.1

Full speed

2.2

Let it run for a maximum of 5 sec.

6.3.4

Fig. 6-30 201310020010

If a charge pressure of 21 ± 2 bar is not achieved, then:

●

The charge pressure valve must be checked. See page 57.

If the pressure still cannot be achieved, the drive pump must be replaced. Siehe

“Replacing the drive pump” see page 237.

Checking the drive pressures (reverse / forwards)

1

Disconnect connector Y9 (1) from the valve block.

1

Fig. 6-31 201310020005

62 Rammax 1575

6.3.5

1

1

Connect a pressure gauge (min. 400 bar) to the drive pressure measuring point MA

(1).

2

Start the engine.

2.1

Full speed

3

Drive in

reverse against the brake.

3.1

Let it run for a maximum of 5 sec.

Fig. 6-32 201310020009

1

1

Connect a pressure gauge (min. 400 bar) to the drive pressure measuring point MB (1).

2

Start the engine.

2.1

Full speed

3

Drive forwards against the brake.

3.1

Let it run for a maximum of 5 sec.

Fig. 6-33 201211270001

If one of the drive pressures of 330 ± 15 bar is not achieved, then:

●

●

The drive motors must be checked. page 63.

The drive pump maximum pressure must be checked. page 64.

If the pressure still cannot be achieved, the drive pump must be replaced. Siehe “Replacing the drive pump” see page 237.

Checking the drive motors

The following operation is necessary if:

●

●

The drive pump test is positive.

The pressure is not achieved with the drive motor which is connected.

Check the drive motors individually one after the other.

1

Remove the hydraulic hoses for drive circuits A and B from the drive motor.

2

Seal the screw connections pressuretight.

3

Perform test procedure as described under 6.3.4.

Fig. 6-34 201310010053

Checking and adjusting pressures

Hydraulic System 63

6.3.6

Checking the maximum drive pump pressure (reverse / forwards)

1

Remove the hydraulic hose for drive circuit B (forwards) from the drive pump.

2

Seal the screw connections pressuretight.

Fig. 6-35 201309210080

1

Remove the drive circuit A (reverse) Tscrew connection from the drive pump.

2

Seal the screw connections pressuretight.

64

Fig. 6-36 201309210084

1

Connect a pressure gauge (min. 400 bar) to the drive pressure measuring point MA.

2

Start the engine.

2.1

Full speed

3

Drive at full in reverse against a block.

3.1

Let it run for a maximum of 5 sec.

Fig. 6-37 201310020009

1

1

Connect a pressure gauge (min. 400 bar) to the drive pressure measuring point MB (1).

2

Start the engine.

2.1

Full speed

3

Drive at full forwards against a block.

3.1

Let it run for a maximum of 5 sec.

Fig. 6-38 201211270001

If the maximum drive pump pressure of 330 ± 15 bar is not achieved, then:

●

The drive pump must be replaced. Siehe “Replacing the drive pump” see page 237.

Rammax 1575

6.4

Setting the drive pump to the neutral position

1

Remove the X1 and X2 plugs (size 6).

X1 X2

Fig. 6-39 201211260060

1

Use an Allen key (size 3) to remove the cap.

Fig. 6-40 201211260061

X 1

Fig. 6-41 201211260062

1

2

1

Check the cap (1) for any dirt accretions or other blockages.

1.1

Use compressed air to clean them out.

2

Install plugs X1 and X2 (40 Nm).

NOTE

The cap must be tightened securely when reassembled!

1

Safely jack up the machine.

2

Let the machine run.

3

Unscrew the lock screw (size 4) (1).

4

Set the neutral position (2).

4.1

Carefully turn the key (size 3) until the roller drum stops.

5

Tighten the lock screw.

Fig. 6-42 201211270063

Setting the drive pump to the neutral position

Hydraulic System 65

6.4.1

Checking the drive pump’s solenoid

1

The drive pump’s solenoid cannot be actuated mechanically.

2

Fig. 6-43 201301170001

1

2

1

Unscrew the knurled nut.

Fig. 6-44 201301170002

1

2

1

Pull out the solenoid.

66

Fig. 6-45 201301170003

1

2

1

Unscrew the solenoid valve (size 17).

Fig. 6-46 201301170004

Fig. 6-47 201301170005

Rammax 1575

1

2

1

Measure the solenoid’s Y3 / Y4 resistance.

1.1

Approx. resistance of 6 ohms.

Fig. 6-48 201301170006

1

2

1

Apply a voltage of 12 V to the solenoid valve.

2

The valve (arrow) must be visibly actuated.

Fig. 6-49 201301170007

6.5

Fig. 6-50 201301170007

1

2

2

1

If necessary, you can change the connector’s position by turning the solenoid body.

1

Loosen the solenoid’s securing nut (1).

1.1

Turn the securing nut (1) one full counterclockwise rotation.

2

Turn the solenoid body (2) to the position you want.

3

Tighten the securing nut. Securing nut tightening torque: 5+1 Nm.

Checking the drive pump servo-block

This operation must be carried out if:

●

●

●

●

The machine has been checked over electrically but still does not drive.

The machine only move in one direction.

The machine only moves slowly even when the operating lever is at full speed.

The machine moves erratically.

Checking the drive pump servo-block

Hydraulic System 67

View of drive pump.

Fig. 6-51 201308290001

1

Pull the connectors off of the magnetic coils Y3 (left) and Y4 (right).

68

Fig. 6-52 201308290002

1

Remove closure plugs X1 and X2

(AF size 6).

Fig. 6-53 201308290003

View of the drive pump without the closure plugs.

NOTE

If the oil at the site of the unscrewed plug does not flow back into the pump housing, then the apertures are clogged or the piston is not at the center and is jammed.

Fig. 6-54 201308290004

Rammax 1575

Fig. 6-55 201308290005

1

Loosen and unscrew the apertures

(size 3).

NOTE

The apertures must not be loose! Loose apertures lead to problems with driving.

1

The loosened apertures can best be lifted out with a small magnet.

Improvise if needed.

Fig. 6-56 201308290006

1

1

View of the dismantled aperture holder (1) with the apertures.

Fig. 6-57 201308290007

1

Unscrew the knurled nut.

Fig. 6-58 201308290008

Checking the drive pump servo-block

Hydraulic System 69

70

1

Pull off the magnetic coils.

Fig. 6-59 201308290009

Fig. 6-60 201308290010

1

Unscrew the solenoid valve (size 17).

Fig. 6-61 201308290011

View of the control spools.

NOTE

The control spool is spring-loaded and must always slide back to the 0 position by itself.

Fig. 6-62 201308290012

Rammax 1575

Fig. 6-63 201308290013

1

Checking the movement of the control spool, for example using a screwdriver.

2

Push the control spool from the left and right all the way to the stop three or four times.

NOTE

●

●

It must not jam under any circumstances!

It must slide smoothly without catching and return smoothly to the 0 position by means of the spring force. This must be the case on both sides.

Fig. 6-64 201308290014

NOTE If the control spool does not move without catching after several tries or it does not return to the 0 position by itself, then it is mechanically damaged.

The servo-block must be repaired in a qualified repair shop.

View of the pump before assembly.

Fig. 6-65 201308290015

Checking the drive pump servo-block

Hydraulic System 71

Fig. 6-66 201308290016

1

Check the seals of the solenoid valve for damage.

2

Oil lightly.

1

Install the solenoid valve (AF size 17).

72

Fig. 6-67 201308290017

1

Put the cleaned aperture with the aperture holder in place and tighten.

Fig. 6-68 201308290018

1

Check the seal of the closure plug.

2

Lubricate the seal lightly with oil.

Fig. 6-69 201308290020

Rammax 1575

1

Put both plugs in place and tighten.

Fig. 6-70 201308290019

1

Re-mount the two magnetic coils.

Fig. 6-71 201308290021

1

Put the O-ring in place and tighten the knurled nut.

Fig. 6-72 201308290022

1

Connect the cable.

2

Secure them with cable ties.

3

Perform a functional check and look for leakage.

Checking the drive pump servo-block

Hydraulic System 73

6.6

Checking the flow divider

74

3

5

1

2

4

Fig. 6-73 201311050001 / flow divider

3

4

1

2

5

1

Access to aperture

Access to front piston

Access to rear piston

Access to front check valve

Access to rear check valve

2

6

7

1

Flow divider housing

2

Connector P of pump B

3

Flow divider B to junction at rear

4

Flow divider A to junction at rear

5

Connector T of pump G

6

Aperture

7

Two spring-loaded pistons

4

5

Fig. 6-74 200907220001

3

Fig. 6-75 201211130107

Rammax 1575

NOTE In case of faults, jerky driving, check aperture for soiling. If necessary, short-circuit the flow divider = remove the entire piston package.

6.7

Speeds and pressures

Tab. 6-13 Speeds and pressures

Diesel engine speed

Vibration speed

Charge pressure

Working pressures for driving

Vibro drive pressures *

Maximum drive pressure

Maximum pressure

Front, small

Rear, small

Front, large

Rear, large

Forwards

Reverse

Small amplitude big amplitude

Blocked, forwards

Blocked, in reverse

Steering

Vibration rpm rpm rpm rpm rpm

PSI (bar)

PSI (bar)

PSI (bar)

PSI (bar)

PSI (bar)

PSI (bar)

PSI (bar)

PSI (bar)

PSI (bar)

After 5 min.

After 60 min.

2415

±25

2250 ±150

2250 ±150

2405

±25

2250 ±150

2250 ±150

2250 ±150

2250 ±150

2250 ±150

2250 ±150

306 (21)

±2

1450 (100)

±20

306 (21)

±2

1450 (100)

±20

1450 (100)

±20

1450 (100)

±20

1522 (105)

±55

942 (65)

±15

1595 (110)

±50

-

-

-

-

1160 (80)

4786 (330)

±20

±15

4786 (330)

±15

972 (67)

±7

3191 (220)

±10

* When first started, it is only possible to use the small amplitude vibration function for the first

2minutes.

Speeds and pressures

Hydraulic System 75

6.8

Hydraulics diagram

76

Fig. 6-76 Hydraulics diagram no. 10442344

Rammax 1575

6.8.1

Hydraulics Diagram Legend

Tab. 6-14 Hydraulics Diagram Legend

Element

13

14

15

16

9

10

11

12

17

18

7

8

5

6

3

4

1

2

Description

Drive pump

Vibro-steering pump

Drive motor, rear left

Drive motor, rear right

Front left drive motor

Front right drive motor

Left steering cylinder

Right steering cylinder

Valve block

Vibro motor, front

Vibro motor, rear

Oil cooler

Hydraulic oil filter

Hydraulic oil tank

Ventilation filter

Diesel tank

Hydraulic manifold

Flow divider

Hydraulics diagram

Hydraulic System 77

78 Rammax 1575

7

Electrical system

79

7.1

NOTE

2

Engine electrical system / Fuses

!

DANGER

There is danger to life if the roller does not stop in hazardous situations!

• Fuses and safety switches must never be shorted.

!

CAUTION

Risk of injury through short circuit and cable fire when handling electrical parts!

• Always disconnect the power supply when working on the electrical system.

Before replacing the fuse, you must identify and remove the cause of the fault.

Always replace a defective fuse

(1) with a functioning fuse (2) of the same amperage

(according to the label or color of the fuse).

7.1.1

1

Engine compartment

K4 F21-F24 K2 K3

F25

80

K6

K5

Fig. 7-1 Relay / Engine compartment fuses

Rammax 1575

NOTE

K2

K3

K4

K5

K6

Tab. 7-1 Engine compartment relay functions

Function

Starter relay start inhibit

Timer 1s pull-in solenoid

Relay for pull-in solenoid of stop solenoid

Magnetic rotational speed sensor

Relay for pre-heating

K3 is located on the back of the metal sheet.

Tab. 7-2 Engine compartment fuses

Fuse No.

F21

F22

F23

F24

F25

Power

40 A

10 A

40 A

40 A

40 A

Fuse-protected circuit

Pull-in solenoid of stop solenoid

Diesel pump, alternator 15+

Magnetic rotational speed sensor

Pre-heating glow plug

2. Single coil (tier 4) (option)

Height sensor, tier 4

Socket

A-1

B-2

C-3

D-4

K11

Fig. 7-2 Relay, tier 4

Tab. 7-3 Tier 4 relay functions

K11

Function

Height sensor, tier 4

Engine electrical system / Fuses

Electrical system 81

7.1.2

Chassis rear

N1

X4

X6

G2

K1 K7

S24

NOTE

Fig. 7-3 Rear chassis relay

G2

K1

K7

N1

S24

X4

X6

Tab. 7-4 Rear chassis relay functions

Function

Battery

Relay, ignition

Relay, hydraulic oil cooler

Machine controller

Switch, shutdown bar sensor (option)

Front infrared sensor P1

Rear infrared sensor P2

Machines without a shutdown bar will not have an S24 proximity switch. A jumper is inserted instead of the switch.

NOTE Infrared sensor connectors X4 and X6 can be interchanged. This will not affect the machine in any way.

82 Rammax 1575

7.1.3

Cockpit

N2

S1

N3

Fig. 7-4 Relay / cockpit fuses

Tab. 7-5 Cockpit relay functions

N2

N3

S1

Function

Display unit

Infrared transmitter

Ignition switch

Fuses

1

Fig. 7-5 Cockpit fuses

Tab. 7-6 Cockpit fuses

Fuse No.

F11

F12

F13

F14

2

Power

10 A

25 A

10 A

25 A

3

4

Fuse-protected circuit

Machine controller supply

Machine controller outputs

Display unit, shutdown bar

Hydraulic oil cooler

Engine electrical system / Fuses

Electrical system

F11-F14

Socket

A-1

B-2

C-3

D-4

83

84

Display unit N2

P3

H1 H6

H3

H5

H6

P3

H1

H2

H3

H4

Fig. 7-6 Display unit N2

Tab. 7-7 N2 display unit functions

Function

Battery charge indicator

Pre-heating control lamp

Oil pressure warning indicator

Water temperature warning indicator

Shutdown bar warning lamp

Error warning lamp

Operating hours counter

H4 H5

H2

Rammax 1575

7.2

7.2.1

Other components

Connector N1 / wiring harness

empty

NOTE

Fig. 7-7 Connector N1

Make sure that the connector N1 is free of water and dirt.

No.

101

102

103

104

105

106

107

108

109

110

111

112

113

114

Tab. 7-8 List of wiring harness wires / connector N1

Cross-section Color

2.5

2.5

2.5

2.5

0.75

0.75

0.75

1

0.75

1

1

1

1

1 white white brown brown white white white white white white white white white white

Of

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

Pin To

3

4

5

1

2

8

9

6

7

10

11

12

13

14

Pin

Y3

Y4

Y3

Y5

Y6

F11

F12

1

2

Ground at rear

Ground at rear

K1 86

S1 19

S1 50

S25

K5

9

7

1

86

2

1

1

1

1

Comment

12V controller

12V controller

Controller ground

Controller ground

Ignition relay

Pre-heater relay

Starter relay

Holding solenoid

Gas relay

Forwards

Reverse

Return

Steering left

Steering right

Other components

Electrical system 85

Cross-section Color

0.75

0.5

1

0.5

0.5

0.5

1

1

0.5

1

1

1

0.75

0.75

0.75

0.5

1.5

1.5

0.75

1.5

0.75

0.75

0.75

0.75

1.5

0.75

2.5

0.75

4

0.75

0.5

0.5

2.5

2.5

2.5

1.5

0.75

white white brown white white white white white white white white white white white white white white brown white white white white brown white white white white white white white white brown white white white white white

No.

127

128

129

130

131

123

124

125

126

115

116

117

118

120

121

122

147

148

149

150

143

144

145

146

151

152

136

137

138

139

132

133

134

135

140

141

142

86

Of Pin To Pin

M1

S1 50

M1

F21

G1 D+

F21 1

Engine ground

K4

K4

86

85

F21

Y1 white

1

Engine ground

F23 3

Y2

S1 19

+

9

30

7

50

A

1

N2

N2

X1

Y7

Y8

Y9

K2 85

X1

X1

X1

N2

S24

N2

F13

S1 19

S21

S22

K2 85

S1 15

F14

1

X3 2

Ground at rear

5

D

3

8

1

6

4

5

2

3

4

2

1

1

1

1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N2

N2

N2

N1

N1

N1

N1

N2

N2

K1

K1

K1

K1

K2

K2 86

K2

K2

K2 85

87

87

K4

K4

K5

K5

K3 red

K3 black

K3 red/black

K3 yellow

K5

K6

30

87

85

30

87

86

30

87

87

85

30

5

6

7

1

3

24

25

26

27

28

29

15

16

17

19

21

22

23

Comment

big amplitude small amplitude

Brake valve

Engine signal

Shutdown bar

Error

Control bus D+

Control bus D-

+12V

Earth

Engine oil pressure

Shutdown bar

Water temperature

+12V

Preheating lamp

Oil pressure lamp

Water temperature

Engine signal

Ignition

Ignition

Ignition

Ignition relay

Battery 12V

Starter

Starter

Pull-in solenoid

Starting interlock

Timer

Timer

Timer

Timer

Pull-in relay

Pull-in solenoid

Gas relay

Gas magnet

Gas magnet

Pre-heater relay

Rammax 1575

Cross-section Color

0.75

1

1.5

1

1

0.75

0.75

4

0.75

0.75

4

4

0.75

0.75

2.5

2.5

1

1.5

1

1

2.5

4

1.5

4

4

1.5

1

2.5

1.5

2.5

1

4

1

1

1

1 white white white white white brown brown white brown brown white white white brown white white white white brown brown white white white white brown brown brown brown brown brown brown brown white white white white

No.

164

165

166

167

169

160

161

162

163

153

154

155

156

157

158

159

185

186

187

188

189

181

182

183

184

174

175

176

177

170

171

172

173

178

179

180

Of Pin To

K6

K6

K6

K7

K7

K7

K7

S24

S24

G1 30

G1 15

M2

M2

Y1 black

Y3

Y5

2

Y2

N2

M3

F13

Y6

Y7

Y8

Y9

F12

F12

M1

S25

X3

F21

M1

X3

M1

M1

Engine ground

Engine ground

30

30

1

2

A

30

4

8

2

C

B

B

30

2

2

2

2

2

2

2

4

85

30

87

85

30

87

86

Pin

Engine ground

F24 4

R1

S25 2

Ground at rear

F14 4

M3 1

S24

F13

M1

F22

F22 2

Engine ground

Engine ground

Y4 2

Engine ground

3

3

30

2

Engine ground

Engine ground

Engine ground

Engine ground

Engine ground

Ground at rear

Ground at rear

F14 D

S1 15

F11

S1 30

6

A

1

F24

F23

D

C

Ground at rear

Ground at front

Y1 red

F22

X3

X3

B

1

3

Engine ground

Comment

Pre-heater relay

Pre-heating

Pre-heating

Radiator relay

Radiator relay

Oil cooler

Oil cooler

Shutdown bar

Shutdown bar

Charging current

Exciting voltage

Diesel pump

Diesel pump

Holding solenoid

Return

Steering left

Steering right big amplitude small amplitude

Brake valve

Gas magnet

Display unit

Oil cooler

Display unit

12V controller

12V controller

+12V

Pre-heating

Gas magnet

Connection

Connection

Holding solenoid

Ignition

Starter

Battery +

2. Holding solenoid Y11

Other components

Electrical system 87

88

Fig. 7-8 Front chassis wiring harness

Rammax 1575

Fig. 7-9 Rear chassis wiring harness

Other components

Electrical system 89

7.2.2

Tier 4 / Wiring harness

Fig. 7-10 Tier 4 wiring harness

Tab. 7-9 List of wiring harness wires / tier 4

No.

205

206

207

208

201

202

203

204

Cross-section

1

2.5

2.5

1

1

2.5

1

2.5

Color

white white white brown brown white white white

Of

X3

X3

X3

Y11

K11

F25

K11

K11

Pin To

3

2

1

2

2

X3

K11

Y11

Y11

K11

F25

K11

X3

3

1

4

4

Pin

1

Comment

Starter

Ignition

Battery

Earth

Earth

Ignition

Pull-in solenoid

Holding solenoid

90 Rammax 1575

7.3

7.3.1

Wiring diagram

Explanations

6

4

2

1

7

5

3

S19

5

6

7

3

4

1

2

Connection

Connector name

Contact number

Cable number

All white cables are serially numbered, the brown cables are not numbered and are always a connection to earth.

Component separation

(In some cases also optional cable connections)

Contact number on device connector

Element name

(cf. wiring diagram key page 93)

Wiring diagram

Electrical system 91

7.4

Wiring diagram

92

Fig. 7-11 Wiring diagram no. 10378070

Rammax 1575

7.4.1

Wiring diagram key

Element

S1

S21

S22

S24

N3

P1

P2

R1

S25

Y1

M2

M3

N1

N2

K6

K7

K11

M1

K2

K3

K4

K5

F25

G1

G2

K1

F21

F22

F23

F24

F11

F12

F13

F14

Description

Fuse, controller, supply

Fuse, controller, outputs

Fuse, display unit, shutdown bar

Fuse, hydraulic oil cooler

Fuse, pull-in solenoid

Fuse, diesel pump, alternator

Fuse, operating speed

Fuse, preheating glow plug

Fuse, “2nd solenoid”

Alternator

Battery

Relay, ignition

Relay, starting interlock

Timer relay

Relay, pull-in solenoid

Relay, operating speed

Relay, preheating glow plug

Relay, hydraulic oil cooler

Relay, “solenoid driver” (tier 4)

Starter motor

Diesel pump

Hydraulic oil cooler

Machine controller

Display unit

Infrared transmitter

Front infrared sensor

Rear infrared sensor

Preheating glow plug

Switch, ignition switch

Sensor, engine oil pressure

Sensor, coolant temperature

Sensor, shutdown bar

Sensor, hydraulic oil temperature

Magnet, pull-in

/

holding solenoid

Wiring diagram

Electrical system 93

Element

Y6

Y7

Y8

Y9

Y11

Y2

Y3

Y4

Y5

Description

Magnet, operating speed

Magnet, drive pump, forwards

Magnet, drive pump, backwards

Valve, steering, left

Valve, steering, right

Valve, large amplitude vibration

Valve, small amplitude vibration

Valve, locking brake

Magnet, “2nd holding solenoid” (tier 4)

94 Rammax 1575

8

Troubleshooting

95

8.1

NOTE

NOTE

Introduction

This section describes possible causes and action sorted according to error symptoms.

Note that the machine wiring, although not mentioned explicitly, is always a possible cause of electrical problems.

In our experience, in most cases errors are caused by the wiring harness or connectors.

Therefore, it is a good idea to check the machine for frayed cables and defective or loose connectors first.

Since the machine is remote-controlled, faults can be due to a variety of causes. The best thing to do is to read through this chapter quickly at first in order to get a general overview.

Also make sure to pay attention to the LEDs on the handheld controller and the lamps on the display unit.

The machine will not shut down automatically when the hydraulic oil temperature is too high!

If you think the machine may be getting too hot, check:

• Fuse F14

• Oil temperature switch S25

• Relay K7

• Radiator M3

Oil temperature switch S25 should turn on the fan if the oil temperature is 50°C or higher.

96 Rammax 1575

8.2

Engine doesn’t start

The following description applies when starting the machine with the ignition switch. If the machine cannot be turned on with the handheld controller only, please refer to the next section.

Tab. 8-1 Fault description, engine won’t start

Fault description

Engine doesn’t start

Starter does not turn

Engine doesn’t start

Starter turns

But engine doesn’t start

Diesel pump

M2

Fuse

F21

Engine oil pressure switch

S21

The engine starts, but only runs for about 4 s

Possible cause

Battery

G2

Ignition switch

S1

Fuse

F11

Controller

N1

Relay

K1

Fuse

F22

Alternator

G1

Starter relay

K2

Starter motor

M1

Fuses F12, F12

Controller

N1

Timer

K3

Relay

K4

Pull-in/holding solenoid

Y1

Water temperature switch

S22

Engine oil pressure switch

S21

Checks

Is the battery voltage OK? Battery terminal clamps?

Battery cables in terminal clamps?

Can the engine be started with the ignition switch? ->

Controller not working.

Is

F11 OK?

Is the connector connected?

The relay must be switched as soon as the ignition is switched on.

Is F22 OK?

Is the connector connected?

Connection D+ must have a voltage of 0 V when the ignition is on.

Is the connector connected correctly? Relay checked?

With the ignition in the Start position, connector 50 must have +12 V.

Is there enough diesel in the tank?

Does the diesel pump work?

Is fuse F21 OK?

The switch must be closed when the engine is stopped.

Is

F12 OK?

As soon as the starter turns, holding solenoid

Y1 (red) must have a voltage of +12 V.

Is the connector connected?

Is the connector connected? Relay checked?

In ignition Start position 50, pull-in solenoid (white) must have +12 V for 1s.

Has the shutdown bar been checked?

The switch must be open when the operating temperature is normal. Short-circuit to ground?

Solid connector connection? No corrosion?

The switch must be closed when starting and open when the engine is running.

Solid connector connection? No corrosion?

Engine doesn’t start

Troubleshooting 97

Fault description

Pre-heating doesn’t work

Yanmar engine

(Yanmar TNVDI, service manual)

Hydr. oil cooler does not turn

Possible cause

Glow plug

R1

Checks

In cold weather, please check the pre-heating system too.

In ignition Pre-heating position, control lamp H2 must light up and heater plug must have +12 V.

Is F24 OK?

Is the connector connected? Relay checked?

Fuse

F24

Relay

K6

Diesel

Hydr. oil temperature sensor

Fuse F14

Relay K7

Motor defective

Diesel in tank?

Diesel flow line free?

Air in injection system?

Filter free?

Air in system?

“Smoke signals” from exhaust tailpipe?

Compression, injection system, valve play?

Is the fuel pump working? F22 OK?

Bridge the switch, start the engine.

Is F14 OK?

Does relay K7 switch?

Apply current directly to motor.

8.2.1

Start test for cable and infrared modes

98

1

Open the cockpit cover.

1.1

Open the cover without covering the sensor.

2

Turn the ignition on.

3

Position yourself three meters from the roller.

4

Keep an eye on the shutdown bar indicator lamp.

4.1

If the shutdown bar indicator lamp blinks, increase your distance from roller.

5

Hold down the Start switch on the infrared transmitter.

5.1

The pre-heating indicator lamp must be lit.

5.1a If the pre-heating indicator lamp is not lit, decrease your distance from the roller.

5.1b Once the pre-heating indicator lamp lights, the roller will start in 6 s.

1

Open the cockpit cover.

1.1

Open the cover without covering the sensor.

Rammax 1575

8.2.2

2

Turn the ignition on.

3

Position yourself three meters from the roller.

4

Keep an eye on the shutdown bar indicator lamp.

4.1

If the shutdown bar indicator lamp blinks, increase your distance from roller.

5

Hold down the Start switch on the infrared transmitter.

5.1

The pre-heating indicator lamp must be lit.

5.1a If the pre-heating indicator lamp is not lit, decrease your distance from the roller.

5.1b Once the pre-heating indicator lamp lights, release the switch immediately.

The engine starts.+

Position of the operator

Distance to roller:

< 2m Operation is not possible.

> 4.5 m Cable is too short, operation is not possible (do not overstretch the cable).

Fig. 8-1 Position of the operator/Distance to roller

Engine doesn’t start

Troubleshooting 99

Overview of functions

Operation with the cable Operation with the infrared sensor

automatic pairing

Steering functions

Vibration functions max. range = 3.5 - 4.5 m max. range = 20 m

Close proximity shutdown 2-2.5 m

8.3

8.3.1

8.3.2

8.3.3

The controller is not working

Follow the instructions below step by step in order to pinpoint faults and fix them.

External factors

●

●

●

Reflective surfaces (mirrors, reflective strips, etc.) in the machine’s close vicinity can interfere with the remote controller’s distance calculating function.

Special sources of light (fluorescent tubes, flash lamps, etc.) may interfere with infrared communications under certain circumstances.

Strong electromagnetic radiation (e.g., in the proximity of power plants) may affect the controller.

If faults occur only at specific locations or in specific situations, check the machine’s surroundings to see if any of the above factors are present and try to avoid them.

Machine wiring

●

●

●

●

●

●

Are fuses F11 and F12 OK?

Are the connectors on controller N1 free of soiling and water?

Is controller N1 properly mounted?

Are both the P1 and P2 infrared sensors clean and free of damage?

Is the wiring from N1 to P1 and P2 free of damage? Keep in mind that there is an X5 adapter (going towards the front sensor) in the engine compartment.

Is the cable to handheld controller N3, together with the corresponding connectors, free of damage and of soiling? Do not forget connector X1 on the hood’s inside.

Operation

●

●

●

Is the handheld controller already paired with the machine? -> Briefly connect the handheld controller to the cable for this purpose.

Is the distance between the handheld controller and the machine OK? (2.5m - 4m in cable mode or 2.5m - 20m in remote control mode)

Is the battery for handheld controller N3 empty? -> Use the cable mode temporarily fir control.

100 Rammax 1575

NOTE Please note that the vandalism protection cover may shield the infrared signal when open. This applies to cable operation as well.

Tab. 8-2 Troubleshooting, controller is not working

Fault description

The controller is not working at all and the engine cannot be started with the ignition switch either

Possible cause

Fuses

F11, F12

Controller

N1

The machine can only be started with the ignition switch and is not working otherwise

The machine only works in cable operation mode

The diesel engine turns off all of a sudden during operation.

Machine does not drive

(nothing happens)

Infrared transmitter

Infrared sensors

Drive pump

Brake valve

Y3

Y9

P1, P2

Infrared transmitter

Controller

N1

N3

N3

Water temperature switch

S22

Engine oil pressure switch

S21

Alternator

G1

Handheld controller

N3

Controller

N1

Checks

Are

F11 and F12 OK?

Check the machine as instructed in the previous description.

Pay special attention to alternator signal D+ and to engine oil pressure switch S21.

If relay

K1 is not being switched, the problem probably has to do with controller N1.

Is the battery voltage OK? Battery terminal clamps?

Battery cables in terminal clamps?

Check the machine as instructed in the previous description.

If none of the LEDs on handheld controller N3 flash even during cable operation, the unit may have to be replaced.

Check the wiring.

Check the machine as instructed in the previous description.

If the red LED on handheld controller N3 always flashes when a function is carried out during wireless operation, or if none of the LEDs light up during wireless operation, the battery is probably faulty.

Also check the display unit. The tilt sensor may have been incorrectly triggered.

The switch must be open when the operating temperature is normal.

The switch must be open when the engine is running.

Connection D+ must have a voltage of 12 V when the engine is running.

Does the green LED flash when the switch is actuated?

Does error warning lamp

H6 on the display unit light up?

Are the connectors connected? Are the magnetic coils and valves OK? Charge pressure OK? Servoblock OK?

Is the connector connected?

The controller is not working

Troubleshooting 101

Fault description

Machine does not drive

(it attempts to move against the brakes)

The machine moves forward only

Machine drives too slowly

Machine does not vibrate

Possible cause

Brake valve

Y9

Controller

Fuse

F23

Relay

K5

N1

Proximity switch

S24

Drive pump Y3, Y4

Handheld controller

N3

Controller

N1

Magnet

Y2

Handheld controller

Magnets

Y7, Y8

N3

The steering system is not working

Controller

N1

Handheld controller

N3

Magnets

Y5, Y6

Controller

N1

Checks

Is the connector connected?

Actuate the solenoid valve manually; is the brake released? Charge pressure OK?

Is

Y9 being actuated?

If the machine features a shutdown bar, check to make sure that the magnet on the shutdown bar is positioned correctly. The switch must be closed when the shutdown bar is not being actuated.

Otherwise, check the jumper that is plugged in instead of S24.

Are the connectors connected?

Does the green LED flash when the machine is put in transport gear?

Is F23 OK?

The relay must be switched as soon as a function is carried out.

Is

K5 being actuated?

The magnet must pull as soon as a function is carried out.

Engine speed? Flow divider OK?

Drive motors OK? Drive pump OK?

Does the green LED flash when vibration is switched on?

Are the connectors connected? Has the magnetic coil been actuated manually? Are the magnetic coils and valves OK? Vibration pressure OK? Coupling on vibromotor OK? Vibro unit OK?

Are Y7 and Y8 being actuated?

Does the green LED flash when the steering is actuated?

Are the connectors connected? Are the magnetic coils and valves OK? Has the magnetic coil been actuated manually?

Are Y5 and Y6 being actuated?

Steering pressure OK? Mechanical faults? Steering cylinder OK?

102 Rammax 1575

8.4

Display unit

NOTE

Fig. 8-2 Display unit

When the ignition is turned on, a lamp test will run on the display unit for a couple of seconds. During this test, all the lamps will light up and every digit in the operating hours counter will be shown as an 8.

Use this test to check whether the display unit is working correctly. If it is not, it will have to be replaced.

Tab. 8-3 Fault description, machine won’t move

Fault description

Display unit is dead.

No lamps and displays when ignition is switched on.

Possible cause

Fuse

F13

Display unit

N2

Relay

K1

Operating hours counter

P3 is not working and battery charging lamp

H1 does not turn off when the engine is running

Control lamp H1 does not light when the ignition is switched on.

Alternator

Alternator

G1

Display unit

N2

G1

Cable, connector, display unit

N2

Checks

Is F13 OK?

When the ignition is on, pin 1 must have a voltage of

+12 V and pin 8 must have the chassis ground voltage level.

The relay must be switched as soon as the ignition is switched on.

Is the connector connected?

When the ignition is on, pin 7 must have a voltage of

0 V = chassis ground. When the engine is running, on the other hand, it must have +12 V.

If the battery charges anyway (voltage approx. 14 V), the problem is probably with

N2.

Hold cable 133 against ground. The lamp must be lit.

Error warning indicator

H6 lights up.

Controller

N1

Fuse

F22

Alternator

G1

Engine oil pressure switch

S21

●

●

●

The tilt sensor measured a tilt angle greater than

45° (the diesel engine is turned off when this happens).

If shutdown bar

H5 is flashing at the same time: It will not be possible to start the engine until oil pressure switch

S21 is closed (H3 is lit up) and D+ for G1 has a voltage of 0 V (H1 is lit up).

The controller detected a fault.

If the machine is not inclined and controller

N1 is properly mounted, there is a fault in the controller’s switching outputs -> The controller does not work

Display unit

Troubleshooting 103

Fault description

Oil pressure warning lamp

H3

lights up while the engine is running.

Possible cause

Engine oil pressure switch

S21

Oil pressure warning lamp

H3

does not light when the ignition is switched on.

Engine oil pressure switch

S21

Cable, connector, display unit

N2

Checks

Is the connector connected? Short-circuit to ground?

Engine oil level OK? Engine oil pressure OK?

When the engine is stopped, the connection must have contact to chassis earth. The switch must be open when the engine is running.

The diesel engine turns off after 4 s.

Pull the connector off of the switch and ground it. The lamp must be lit.

Solid connector connection? No corrosion?

Water temperature warning indicator lights up. Engine running.

H4

Water temperature warning lamp

H4 does not light when the ignition is switched on.

Lamp test.

Coolant temperature switch

S22

Cable, connector, display unit

N2

Shutdown bar warning lamp H5 lights up even though the shutdown bar is not being actuated / a shutdown bar is not installed

Pre-heating control lamp up.

H2 never lights

Control lamp is lit continuously

Cooling water temperature switch

Relay

S22

Proximity switch

Controller

N1

Ignition switch

Controller

K6

N1

S1

S24

Is the connector connected? Short-circuit to ground?

The switch must be open when the operating temperature is normal.

The diesel engine turns off after 4 s.

Defective? Solid connector connection? No corrosion?

Pull the connector off of the coolant temperature switch and ground it. The lamp must be lit.

The switch must be open when the operating temperature is normal.

The diesel engine turns off after 4 s.

The lamp lights up with a solid light:

If the machine features a shutdown bar, check to make sure that the magnet on the shutdown bar is positioned correctly. The switch must be closed when the shutdown bar is not being actuated.

Otherwise, check the jumper that is plugged in instead of

S24.

The lamp flashes:

The infrared transmitter is located less than 3 m from the machine.

The lamp flashes like a camera flash:

The infrared transmitter is located between 3 m and 4 m from the machine.

Not a fault! Prerequisite for cable operation of the remote control.

The lamp must light up when ignition switch S1 is in the pre-heating position.

The lamp must light up when the switch is held at the

Start position on the handheld controller.

F24 OK? Ignition switch OK?

Relay OK?

104 Rammax 1575

8.5

Handheld controller

NOTE

Fig. 8-3 Infrared transmitter

When the ignition is turned on, a lamp test will run on the display unit briefly. Both

LEDs blink while this is done.

Use this test to check whether the LEDs are working correctly. If they are not, the device will have to be replaced.

Fault description

The lamps never light up.

Tab. 8-4 Fault description, handheld controller

Possible cause

Infrared transmitter N3

Checks

The battery may be empty or faulty. Connect the cable to the controller. If the battery is faulty, the controller will have to be replaced.

The red lamp flashes

(cable not connected).

The red lamp flashes

(cable connected).

The red lamp lights up with a solid light.

The red lamp lights up when a control is operated.

Infrared transmitter N3 Not a fault! The battery needs to be charged.

Not a fault! The battery is being charged.

Not a fault! The battery is fully charged.

The battery is empty; no data is being sent to the machine.

Handheld controller

Troubleshooting 105

Fault description

The green lamp always flashes when a control is operated.

Possible cause

Infrared transmitter

N3

Checks

Not a fault! Data is being sent to the machine.

Both lamps flash synchronously.

Infrared transmitter

N3

Not a fault! The infrared transmitter is coupled with the machine controller.

This always occurs when:

●

A different handheld controller is connected to the machine for the first time using a cable.

●

The ignition is switched on.

When the lamps are blinking, it is not possible to start the engine.

106 Rammax 1575

9

Maintenance

107

9.1

General safety information

Maintenance and repairs must be performed exclusively by trained and qualified

personnel!

●

●

●

●

●

Only perform maintenance and repair work on the roller if it is static and secured from rolling away.

Secure the roller with the joint protection.

Before carrying out any work on hydraulic hoses, make sure to relieve the pressure in the system.

Disconnect the battery before commencing work on the roller's electrical systems.

○

Cover the battery with isolating material or remove it completely. This does not apply

○ to work requiring an electric current.

In the event of injuries caused by acid, rinse immediately with clean water and consult a doctor.

Replace all protection devices properly after performing maintenance and repair work.

!

DANGER

Danger to life through an unsafe work area!

• Always use an accident-proof support when working on a raised roller.

• Never work below a roller which is only supported by a crane or other electrical / hydraulic lifting device.

• Only stand under a raised roller if it has been mechanically secured.

• Only use stable loading ramps suitable for the weight of the roller for loading.

• On transport vehicles, correctly secure the roller against rolling, slipping and overturning.

!

DANGER

Gas poisoning through letting engine run in enclosed spaces!

• Do not leave the engine running in closed areas.

• If use of the roller in a confined space cannot be avoided, the exhaust fumes must be extracted directly from the exhaust pipe.

!

DANGER

Danger of scalding from hot water / steam!

• Never remove the expansion cap or radiator cap while the engine is running or hot!

• First loosen the cap to the first stop to release the pressure. Only then remove the cap.

108 Rammax 1575

NOTE

NOTE

!

DANGER

Danger of severe injury through loose clothing being caught and drawn in!

• Only open the engine hood when the engine is switched off.

• If trouble shooting makes working on moving parts (engine or roller) unavoidable,

never wear: necklaces, bracelets, rings, scarves, ties or other loose items of clothing.

If any of these get caught in moving parts there is a danger of serious injury!

!

WARNING

Danger of burns from hot roller parts!

• Only work on a cool engine.

• Keep enough distance to the exhaust.

!

CAUTION

Environmental hazard through operating materials!

• Do not allow any liquids to enter drains, the soil or the environment.

Damage to electrical controls through contact with water!

• Never spray a water jet into electrical or electronic components.

• Never spray into the engine combustion air intake.

Damage to hydraulic controls through use of wrong oil!

Hydraulic tubes decompose.

• It is forbidden to change used rollers for use with biodegradable hydraulic oils!

• If hydraulic hoses on a roller running on synthetic ester HE need replacing, only those declared by the supplier as being compatible with synthetic esters may be used.

General safety information

Maintenance 109

9.1.1

NOTE

Battery safety instructions

!

DANGER

Risk of serious injury through leaking battery acid!

The sulfuric acid in the battery is poisonous and so strong it can burn holes in clothes and dissolve skin. If it gets into eyes it can lead to blindness.

• Protect the battery from fire, flames and sparks.

• Protect the battery from mechanical damage.

!

DANGER

Risk of explosion when charging battery!

• Never check the battery charge level with a metal object. Use a voltmeter or the battery's charge indicator.

• When disconnecting the battery always disconnect the negative terminal first (-).

• Connect the positive terminal (+) first when reconnecting.

Doing welding work on the roller when the battery in installed can damage the electrical controls!

Always remove the battery completely before performing welding work on the roller.

NOTE Always replace the battery with a service-free battery. If you are using a battery that requires maintenance, always observe the safety instructions in the battery manual.

9.2

General information about maintenance

●

●

●

●

●

When carrying out maintenance work always observe the applicable safety regulations in the 3 Safety information, page 23 section.

Maintenance work and inspections must be performed according to the following maintenance tables in order to guarantee reliable roller operation.

Remove all dirt before taking off any covers, plugs, measuring rods, etc. to inspect or top up engine oil, hydraulic oil, diesel or other liquids.

Any parts that do not pass the following inspections must be replaced immediately.

The protective devices must be correctly refitted after every service.

110 Rammax 1575

9.3

Maintenance

9.3.1

Maintenance plan

Chapter / D = information from dealer

• •

•

• •

•

• • •

•

•

•

• •

• •

Maintenance

Maintenance 111

nee- ded

• •

• • •

• • • •

•

•

•

•

•

•

•

•

•

•

NOTE

112

Please also observe the Yanmar engine operating manual and the detailed instructions given there.

Rammax 1575

9.3.2

Yanmar engine service

If you have any questions or doubts regarding how to service and/or repair the Yanmar engine, please consult the Yanmar service manual and the application manual to obtain the required information.

These manuals can be obtained through the directly from Yanmar.

Maintenance

Maintenance 113

9.4

Maintenance check sheet

Roller, serial no.________________

Date

Operating hours

Comments /

Activity

Signature

114 Rammax 1575

9.5

Opening the hood, front and rear

!

DANGER

Danger of severe injury through loose clothing being caught and drawn in!

• Only open the engine hood when the engine is switched off.

• If trouble shooting makes working on moving parts (engine or roller) unavoidable,

never wear: Necklaces, bracelets, rings, scarves, ties or other loose items of clothing.

If any of these get caught in moving parts there is a danger of serious injury!

!

WARNING

Danger of burns from hot roller parts!

• Only work on a cool engine.

• Keep enough distance to the exhaust.

There is one locking device each on the front and back as well as the left and right of the roller.

1

Open both catches, on the right and the left.

2

Open the hood.

2.1 Lift the hood with slight pressure toward the center of the roller.

2.2* If the hood is defective, replace it immediately.

NOTE

Fig. 9-1 Locking device

Two gas struts reduce the force required to open the hood and give it its final position. If you need more force to open the hood, replace the gas absorbers.

Siehe “Gas strut” see page 148.

Opening the hood, front and rear

Maintenance 115

9.6

9.6.1

Engine compartment overview

Left side of the engine

7 6

116

Fig. 9-2 Left side of the engine

5

6

7

3

4

1

2

Air-intake filter

Engine oil filter

Oil dipstick

Coolant drain

Engine oil filler neck

Coolant filler neck

Fuel filter

1 2

3 4 5

Rammax 1575

9.6.2

Right side of the engine

1

4

5

6

7

2

3

Fig. 9-3 Right side of the engine

5

6

7

3

4

1

2

Engine oil filler neck

Alternator

Fuel pump

Coolant level display

Flow divider

Hydraulic manifold

Water separator

!

WARNING

Risk of burning and injury when handling parts in the engine compartment!

• Switch the diesel engine off when performing any inspection work.

The locking brake is active when the diesel engine is switched off.

Engine compartment overview

Maintenance 117

9.7

9.7.1

9.7.2

Fuel (diesel)

Checking fuel level

1

Open the hood.

2

Check the level in the plastic tank.

Refueling

1

Fill the fuel tank with diesel fuel up to the lower edge of the filler neck.

1a Every day before beginning work

The tank holds 28 liters of diesel fuel.

Fig. 9-4 Diesel fuel filler neck

NOTE

Tab. 9-1 Excerpt from the Yanmar engine manual about diesel specifications

Diesel specifications

No. 2-D, No.1-D, ASTM D975-94

EN 590:96

ISO 8217 DMX

BS 2869-A1 or A2

JIS K2204 grade no. 2

KSM-2610

GB252

Application

USA

Europe

International

Great Britain

Japan

Korea

China

Poor quality diesel can:

• Reduce the performance of the engine

• Damage the engine

118 Rammax 1575

NOTE For more detailed information, please see the Yanmar engine manual.

9.7.3

Draining fuel

!

CAUTION

Environmental hazard through operating materials!

• Do not allow any liquids to enter drains, the soil or the environment.

1

Unscrew the cover screw (1) under the roller (AF size 27 wrench).

2

Place a container under the drain tap.

3

Drain off the diesel.

4

Install the screw plug (1).

4.1 Tighten the screw connection hand tight.

1

Fig. 9-5 Diesel drain, rear left on chassis

9.7.4

Cleaning the fuel tank

Over time, condensation water gathers in the fuel tank. It must be drained once a year.

1

Unscrew the cover screw (1) under the roller (AF size 27 wrench).

2

Place a container under the drain tap.

3

Allow about 1/2 liter of fluid to drain.

First, the water which has collected on the bottom of the tank will run out.

4

Install the screw plug (1).

4.1

Tighten the screw connection hand tight.

Fuel (diesel)

Maintenance 119

9.7.5

Fuel filter element

2

3

9.7.6

1

Fig. 9-6 Fuel filter

Replace fuel filter element (1) according to the maintenance plan.

1

Close stop cock (3).

1.1 Move to OFF.

2

Unscrew the filter housing (2).

3

Remove the old filter element (1).

4

Insert new filter element (1).

5

Screw the filter housing (2) on.

6

Open stop cock (3).

6.1 Move to ON.

7

Switch on the ignition.

7.1

The fuel pump bleeds the system automatically.

Water separator filter element

Drain filter housing

3

2

Fig. 9-7 Water separator

1

120 Rammax 1575

If there is water in the filter housing, the housing must be drained at once.

1

Close stop cock

(3).

1.1 Move to OFF.

2

Unscrew filter housing and empty.

3

Screw the filter housing on.

4

Open stop cock

(3).

4.1

Move to ON.

5

Switch on the ignition.

5.1

The fuel pump bleeds the system automatically.

Clean filter element

Clean water separator element

(1) according to the maintenance plan.

1

Close stop cock

(3).

1.1

Move to OFF.

2

Unscrew the filter housing

(2).

3

Clean filter element

(1).

4

Screw the filter housing

(2) on.

5

Open stop cock

(3).

5.1

Move to ON.

6

Switch on the ignition.

6.1

The fuel pump bleeds the system automatically.

9.8

9.8.1

Engine oil

Checking the engine oil level

y x

1

Check engine oil level daily using the dipstick. The dipstick (1) is located on the left of the engine.

1.1

Check oil level while the roller is standing on a level surface and the engine is cold.

1.2

You can see the engine oil level on the dipstick.

The oil level must be between the top (x) and bottom (y) marks.

Engine oil

Maintenance 121

2

Top up engine oil as required.

1

9.8.2

Fig. 9-8 Location of dipstick

Topping up the engine oil

1

Top up the engine oil at one of the two oil filler necks.

1a Filler neck on the left-hand side of the engine.

1b Filler neck on the engine.

b

NOTE

a

Fig. 9-9 Filler neck to the left and filler neck on top.

In order to guarantee operating safety of the engine for the long term, you must not put any additives in the engine oil.

9.8.3

Draining engine oil

The engine oil drain (1) is located under the chassis at the front left.

122 Rammax 1575

1

9.8.4

Fig. 9-10 Roller turned fully

/

Engine oil drain

!

CAUTION

Environmental hazard through operating materials!

• Do not allow any liquids to enter drains, the soil or the environment.

1

Place a container under the drain.

2

Open the union by turning it anti-clockwise (27 mm wrench).

The oil starts to flow out immediately.

Replacing the engine oil filter

2

1

Fig. 9-11 Engine oil filter

1

Loosen the filter (1) by hand or using a filter wrench.

1.1

The oil starts to flow out immediately. It’s best to place a rag under it beforehand.

2

Replace oil filter (2).

2.1

Install in accordance with regulations (see filter packaging or filter housing).

3

Screw the complete filter back in place.

Engine oil

Maintenance 123

9.9

9.9.1

Hydraulic oil

Checking the hydraulic oil level

9.9.2

Always check the hydraulic oil level when the system is cold.

1

Place the roller on level ground.

2

Check the oil level in the inspection window.

The hydraulic oil level is ideal when the display itself is half full.

Topping up hydraulic oil

1

Remove the breather filter (1) from the filler neck.

2

Pour in hydraulic oil.

3

Screw the breather filter (1) back in place.

3.1 Important: Always grease the O-ring before screwing it in place.

1

NOTE

Fig. 9-12 Hydraulic oil filler neck

Observe the table of lubricants in chapter 9.15.

9.9.3

NOTE

Draining the hydraulic oil

Only drain the hydraulic oil at operating temperature.

• The oil flows better.

• Residues in the tank will be flushed out with the oil.

1

Place a container (with at least a 30 liter capacity) under the hydraulic oil drain.

2

Remove the breather filter.

124 Rammax 1575

3

Unscrew the cover screw

(1) under the roller (AF size 27 wrench).

4

Allow the oil to drain into the container.

5

Install the screw plug

(1).

5.1 Tighten the screw connection hand tight.

NOTE

Fig. 9-13 Hydraulic oil drain

When you drain the hydraulic oil, please also replace the hydraulic oil filter and breather filter. See Replacing the hydraulic oil filter 9.9.5, page 126

NOTE Tighten the screw connections in the hydraulic tank hand tight.

9.9.4

NOTE

Cleaning the hydraulic oil cooler

1

Check the cooling ribs of the hydraulic oil cooler for dirt and clogging.

2

Clean the ribs with water or blow them out with compressed air.

Never clean the cooler with high pressure (e.g. powerful water jet).

1

Hydraulic oil

Maintenance

Fig. 9-14 Hydraulic oil cooler grill

125

9.9.5

Replacing the hydraulic oil filter

1

Remove the filter lid.

2

Unlock the filter element.

3

Lift the filter element out of the filter housing.

3.1

Dispose of the filter element in an ecologically appropriate manner.

1 2

Fig. 9-15 Replacing the hydraulic oil filter, steps 1 to 3

4

Place the new filter element in the proper position.

4.1

Observe the position of the locking cam.

5

Turn the filter element fully clockwise to the stop.

3

126

4

4.1

Fig. 9-16 Replacing the hydraulic oil filter, steps 4 to 6

6

Lightly oil the sealing ring on the filter lid.

7

Put the filter lid in place.

7.1

Tighten the lid with a torque wrench (max. torque, 20 Nm).

5

Rammax 1575

9.9.6

7 8

Fig. 9-17 Replacing the hydraulic oil filter, steps 7 to 8

Replacing the ventilation filter

1

Ventilation filter according to the maintenance plan.

Fig. 9-18 Ventilation filter

9.10

Hydraulic oil replacement

9.10.1

Filling the hydraulic tank

1

Fill the hydraulic oil tank (approx. 16 l).

Fig. 9-19 201310010071

Hydraulic oil replacement

Maintenance

Fig. 9-20 201310010072

127

9.10.2

Filling the drive pump, building charge pressure

1

Remove hydraulic hose 006 (S).

Fig. 9-21 201310010074

1

Fill the drive pump housing with hydraulic oil.

Fig. 9-22 201310010075

Fig. 9-23 201310010078

1

Pour in hydraulic oil (0.3 - 0.4 l) until the oil runs out of the screw connection

(S).

1

Install hydraulic hose 006 (S).

128

Fig. 9-24 201310010079

Rammax 1575

Fig. 9-28 201310010080

Hydraulic oil replacement

Maintenance

1

Remove fuse F21 (40 A) located in the engine compartment.

Fig. 9-25 201310010080

Fig. 9-26 201310010082

Fig. 9-27 201310010084

1

Connect the pressure gauge (40 bar) to the charge pressure measuring point.

2

Turn the engine over using the starter.

1

Turn the engine over until 3-5 bar of pressure has been built up.

NOTE:

Do not overheat the starter! After 30 seconds at the latest, allow the starter to cool down.

1

Install fuse F21 (40 A) located in the engine compartment.

129

Fig. 9-29 201310010086

1

Start the diesel engine.

2

Check the buildup of pressure.

Maximum pressure = 23 bar.

1

If hydraulic components have been replaced or repaired, perform a check for proper function and for leaks.

Fig. 9-30 201310010087

9.11

Coolant

A coolant antifreeze mixture for up to -25° is provided upon delivery from the factory. For temperatures colder than -25°, the fluid must be replaced by a suitable coolant antifreeze mixture.

9.11.1

Checking coolant level

1

Check coolant level every day.

1.1

Check oil level while the roller is standing on a level surface and the engine is cold.

1.2

You can read off the level of coolant on the expansion tank display.

The water level must be between the top (FULL) and bottom (LOW) marks.

2

Top up coolant as required.

130 Rammax 1575

FULL

LOW

Fig. 9-31 Expansion tank

9.11.2

Topping up coolant

!

CAUTION

Danger of scalding from hot water / steam!

• Only open the radiator once the engine and the coolant have cooled down.

1

Unscrew the lid of the radiator.

2

Add coolant with antifreeze until the radiator is full.

Fig. 9-32 Coolant filler neck

9.11.3

Cleaning the radiator

1

Check the cooling ribs of the water tank for dirt and clogging.

2

Clean the ribs with water or blow them out with compressed air.

NOTE Never clean the cooler with high pressure (e.g. powerful water jet).

Coolant

Maintenance 131

Fig. 9-33 Radiator grill

9.12

Functional check

9.12.1

Scrapers

1

Before driving, adjust the roller drum scraper so that there is a clearance of about 5mm between the roller drum and the scraper.

Fig. 9-34 Roller drum scraper

9.12.2

Air-intake filter

1

If a red ring appears on the soiling display (1) during operation of the roller, you must:

2a clean the air filter cartridge,

2b or replace it.

132 Rammax 1575

1

Fig. 9-35 Soiling indicator

The air filter is located on the left side of the engine.

1

Remove the wing nut (1) with the cover.

2

Remove the wing nut (2) from the air filter cartridge.

3

Remove the air filter cartridge (3).

4

Check the air filter cartridge for:

5a Damage: replace the cartridge.

6a Soiling: clean the cartridge.

1

2

3

NOTE

Fig. 9-36 Air filter cartridge

If the machine is used on very dusty surfaces, the air filter must be checked for clogging daily.

• When cleaning/replacing the cartridge, take care that no dirt enters the intake hose.

Functional check

Maintenance

1

Check the intake opening for:

1a Soiling: clean the intake opening.

133

Fig. 9-37 Intake opening

9.12.3

Replacing the pendulum support joint head

Check the pendulum support once a year for excessive play.

1

Attach the roller to a crane (central lifting point).

The play can be checked by alternately applying and releasing upward pressure to the roller

(visual inspection).

Fig. 9-38 Pendulum support

9.12.4

Replacing the pendulum joint bearing

Check the pendulum joint once a year for excessive play.

If the axial play is greater than 4 mm, the joint bearing must be replaced. See page 272.

1

Attach the roller to a crane (central lifting point).

Lift and lower the roller to check the play.

134 Rammax 1575

Fig. 9-39 Pendulum joint

9.13

Lubricating steering cylinder, bearing

1

Rotate the roller's steering fully to the stop in order to grease the cylinder.

2

Steer the roller briefly to the right and the left. This causes the bearing to be unloaded.

3

Clean the grease nipple

(1) before greasing.

4

Connect the grease gun to the grease nipple.

5

Press grease into the bearing until it visibly begins to ooze out.

6

Put the protective cover back on.

1

1

NOTE

Fig. 9-40 Location of grease nipples on steering cylinder

Damager to property due to increased wear!

• Regrease the bearing after every cleaning/steam cleaning of the roller.

9.14

Brake test

The function of the brakes must be checked periodically.

Lubricating steering cylinder, bearing

Maintenance 135

9.14.1

Cable/connector Y9

The cable/connector Y9, which must be disconnected for the brake test, is located at the front under the hood.

Fig. 9-41 Cable/connector Y9 under the hood

9.14.2

Brake test

1

NOTE

Fig. 9-42 201309220064 cable/201309220064 connector Y9 under the hood

1

Put the machine into the work gear.

2

Disconnect connector Y9 (1) from the connector housing at the magnet.

3

Perform the forwards and backwards driving functions using the infrared sensor.

4

Check all four roller drums for rotation (slipping).

If a brake is defective, the corresponding roller drum will rotate.

If a brake is defective, the roller is no longer safe for operation. Contact your authorized dealer and have the roller repaired professionally.

136 Rammax 1575

9.15

Lubricant table

Tab. 9-2 Lubricant table

Brand Hydraulic oil

Standard

Application

AGIP

BLASER

Synthetic hydraulic oil based on HE esters

ISO VG 46 HVLP DIN

51524 T3

Drive and vibration hydraulics

Amica 46

Blasol 148

ISO 15380 HEES

Drive and vibration hydraulics

Grease

ISO 2137

DIN 51502

Foodgrease SPM00

(Rammax vibro bearing)

BP

CASTROL

ESSO

MOBIL

Motorex

PANOLIN

SHELL

TOTAL

Bartran HV 46

Hyspin AWH 46

Univis HP 46

Mobil DTE15

Corex HV 46

HLP Universal 46

Tellus T 46

Equivis ZS 46

HLP Synth 46

MOLY 218

(steering cylinder)

NOTE Using the wrong oil can cause damage to the hydraulic controls! Hydraulic tubes decompose.

• It is forbidden to change used rollers for use with biodegradable hydraulic oils!

• If hydraulic hoses on a roller running on synthetic ester HE need replacing, only those declared by the supplier as being compatible with synthetic esters may be used.

Lubricant table

Maintenance 137

9.16

NOTE

Consumables

Tab. 9-3 Consumables

Designation

Engine oil

Grease

Grease

Blue adhesive

Red adhesive

Paint spray

Paint spray

Sealant

Brand

Motorex Focus CF SAE 10W/40

Motorex Moly 218

Blaser Foodgrease SPM00

Ergo 4052

Ergo 4100

RAL 1016 Sulfur yellow

RAL 6033 Mint turquoise

Ergo 4207

Quantity

1l

400g

0.38 kg

50 ml

50 ml

400 ml

400 ml

250 g

The screws can loosen due to the vibration of the roller!

• Unless otherwise specified, secure all screws with the blue adhesive.

Art.no.

1242375

1111368

1094392

1-907977

1-907978

1-922700

1-922701

1-923054

9.17

Tightening torques

The values below apply:

●

●

Unless otherwise specified in the operating manual or in the Service manual

To female steel threads

Hex screws/bolts and hexagon-socket-head cap screws

Tab. 9-4 Tightening torque: Hex screws/bolts (including tapping hex screws) and hexagon-socket-head cap screws

AF

SIZE hex

13

13

15

17

7

8

10

AF

SIZE

Hex socket

3

4

5

6

6

8

Screw diameter

M4

M5

M6

M8

M8

M10x1.25

M10

Steel quality

8.8

8.8

8.8

8.8

10.9

10.9

8.8

Tightening torque in

Nm

3

6

10

25

36

90

48

138 Rammax 1575

AF

SIZE hex

19

19

24

AF

SIZE

Hex socket

10

10

-

Screw diameter

M12

M12

M16

Steel quality

8.8

10.9

8.8

Tightening torque in

Nm

84

123

206

Extremely low-profile cylinder screws and filister-head screws

Tab. 9-5 Tightening torque: Extremely low-profile cylinder screws and filister-head screws

Allen key size

3

4

Screw diameter

M6

M8

Steel quality

10.9

10.9

Tightening torque in Nm

6

13

Tab. 9-6 Tightening torque: Flanged oval-head screws

Allen key size

3

Screw diameter

M5

Steel quality

10.9

Countersunk head screws

Tab. 9-7 Tightening torque: Countersunk head screws

Allen key size

5

Screw diameter

M8

Steel quality

10.9

Tightening torques

Maintenance

Threaded / Metric threads

Tab. 9-8 Tightening torques for threaded adapters / metric threads

Thread size

M10x1.0

M12x1.5

M14x1.5

M16x1.5

M18x1.5

M22x1.5

M26x1.5

Cutting ring

18 Nm

25 Nm

45 Nm

55 Nm

70 Nm

125 Nm

180 Nm

Soft seat ring

18 Nm

25 Nm

45 Nm

55 Nm

70 Nm

125 Nm

180 Nm

Tightening torque in Nm

5

Tightening torque in Nm

16

Nominal joint size

12

15

18

22

6

8

10

L

L

L

L

L

L

L

139

NOTE

Thread size

M33x2.0

M12x1.5

M14x1.5

M16x1.5

M18x1.5

M20x1.5

M22x1.5

M27x1.5

Cutting ring

310 Nm

35 Nm

55 Nm

70 Nm

110 Nm

150 Nm

170 Nm

270 Nm

Soft seat ring

310 Nm

40 Nm

40 Nm

70 Nm

90 Nm

125 Nm

135 Nm

180 Nm

Nominal joint size

28 L

14

16

20

10

12

6

8

S

S

S

S

S

S

S

Threaded adapters / Inch threads

Tab. 9-9 Tightening torques for threaded adapters / inch threads

Thread size

1/2“

1/2“

3/8“

1"

1/8“

1/4“

1/4“

3/8“

Cutting ring

18 Nm

25 Nm

45 Nm

55 Nm

70 Nm

125 Nm

180 Nm

310 Nm

Soft seat ring

18 Nm

25 Nm

45 Nm

55 Nm

70 Nm

125 Nm

180 Nm

310 Nm

Nominal joint size

15

18

22

28

10

12

6

8

L

L

L

L

L

L

L

L

1/4“

1/4“

3/8“

3/8“

1/2“

1/2“

3/4“

35 Nm

55 Nm

70 Nm

110 Nm

150 Nm

170 Nm

270 Nm

40 Nm

40 Nm

70 Nm

90 Nm

125 Nm

135 Nm

180 Nm

12

14

16

20

6

8

10

S

S

S

S

S

S

S

To tighten hydraulic hoses and fittings:

• Screw the union nut by hand all the way to the stop, then tighten ¼ of a turn with the wrench (90°)

140 Rammax 1575

9.17.1

Cementing hydraulic threaded joints

Blue adhesive must be used when installing all hydraulic threaded joints in the engine assembly and in the roller drum assemblies.

NOTE

Fig. 9-43 Hydraulic threaded joint cemented correctly / incorrectly

The person that applies the adhesive on the threaded joint is responsible for ensuring that the threaded joint is tightened.

NOTE Do not retighten cemented threaded joints!

Tightening torques

Maintenance 141

9.18

Conversion table for bar à psi

Tab. 9-10 Conversion table for bar

à psi

bar

150

200

250

300

40

45

50

100

350

400

450

20

25

30

35

10

15

8

9

6

7

4

5

1

2

3

psi

2175

2901

3626

4351

580

653

725

1450

5076

5801

6526

290

363

435

508

116

131

145

218

58

73

87

102

15

29

44

KPa

4000

4500

5000

10000

15000

19999

24999

29999

34999

39999

44999

2000

2500

3000

3500

800

900

1000

1500

100

200

300

400

500

600

700

●

●

●

1 psi = 0.06895 bar

1 bar = 14.50326 psi

1 psi = 6.8948 KPa

142

Atm

39.48

44.41

49.35

98.69

148.04

197.39

246.74

296.08

345.43

394.78

444.13

7.90

8.88

9.87

14.80

19.74

24.67

29.61

34.54

0.99

1.97

2.96

3.95

4.93

5.92

6.91

Rammax 1575

9.19

NOTE

Cleaning the roller

After completion of work, clean the roller:

●

● of major soiling; and the lower scrapers of deposits.

Regularly clean completely; at least once a week. When working on cohesive soils, or with cement and lime stabilizers, complete cleaning must be performed daily.

!

DANGER

Danger to life through runaway roller. Persons standing in the vicinity can be rolled over!

• Before cleaning the roller, be absolutely certain to secure it against unintentional rolling away.

While cleaning, observe the following:

• Do not use aggressive or flammable cleansing agents (e.g. gasoline or inflammable substances).

• Only work with the engine turned off.

• Do not directly subject electrical components or isolating materials to a steam jet when using a steam cleaner. Always cover these materials.

• When washing the roller, ensure that no water is sprayed into the air-intake filter.

• Before cleaning the roller with pressure cleaners using water, steam, etc., cover all openings into which the cleaning agent may penetrate. Remove these dummy flanges after cleaning the roller.

Cleaning the roller

Maintenance 143

144 Rammax 1575

10

Repair

145

10.1

NOTE

Preparation for welding work

Doing welding work on the roller when the battery is installed can damage the machine controller!

Always remove the battery completely before performing welding work on the roller.

Attach the welder’s ground cable as close to the welding point as possible. The grounding point must be free of paint.

!

WARNING

Accident hazard!

Poorly welded cast parts can result in material failure.

DO NOT weld cast parts!

10.2

NOTE

Battery

Risk of cable fire or short circuit.

• Keep to the proper sequence when removing or installing the terminal connections.

●

●

Ignition on = battery voltage. The battery voltage should not fall below 10 volts while starting, otherwise the battery must be charged.

Machine running = alternator charging voltage. The voltage should lie in a range of from

13 to 14.5 volts.

10.2.1

Replacing the battery

1

Loosen the (-) terminal and disconnect it (size13).

2

Loosen the (+) terminal and disconnect it (size13).

3

Loosen and remove the mounting bracket.

146

Fig. 10-1 Loosening the terminals

Rammax 1575

4

Lift the battery out of the engine compartment.

5

Set the new battery in place.

6

Connect the battery.

6.1

Begin with the

(+) terminal.

NOTE

Fig. 10-2 Replacing the battery

The battery poles and terminals must be clean. If they are coated with a (whitish or greenish) sulfur crust they must be cleaned.

10.2.2

Starting with another battery (jumpering)

1

Connect the red cable to the (+) terminals of both batteries.

2

Connect one end of the green or black cable to the (-) terminals of both batteries.

3

Actuate the starter. Allow the engine to run.

4

Wait until the engine is idling smoothly and then disconnect the cables.

4.1

Begin with the (-) terminal.

NOTE

Fig. 10-3 Starting with an external battery

The battery poles and terminals must be clean. If they are coated with a (whitish or greenish) sulfur crust they must be removed and cleaned.

Battery

Repair 147

10.2.3

Charging the battery using a battery charger

1

Disconnect the battery.

2

Connect the battery charger.

2.1

Observe the battery charger manufacturer’s manual.

3

Start with the

(+) terminal when reconnecting the battery.

NOTE The battery poles and terminals must be clean. If they are coated with a (whitish or greenish) sulfur crust they must be removed and cleaned.

10.2.4

Long-term storage

Remove the negative battery cable from the battery if a standstill period of more than two weeks is expected.

10.3

Gas strut

Gas struts are maintenance-free! They require no maintenance such as lubrication. They are designed for the respective requirements and work trouble-free for many years.

10.3.1

Replacing gas struts

!

WARNING

Risk of accident through hood falling down!

• Secure the hood before you replace the gas struts.

○

Support the hood with a rod.

removal

1

Use a screwdriver to lift the clips.

2

Pull the gas strut away from the ball joint.

148 Rammax 1575

NOTE

Fig. 10-4 Using a screwdriver, lift the clips and loosen the springs

installing

1

The new gas struts can easily be installed by pressing them onto the ball joint.

1.1

The clamp must be seated securely afterward.

When reinstalling the gas strut, secure the extended part at the bottom:

NOTE

NOTE

1

2 3 4

Fig. 10-5 Gas strut

Gas struts should not be installed if they have been damaged through mechanical manipulation.

• Welding on gas struts as well as dirt or paint on the piston rods can lead to failure of the units.

• Avoid modifications, manipulation, impacts, tensile loading, heating, painting over or removal of imprints.

• Do not install defective or improperly handled products.

If gas struts are no longer needed, they must be disposed of in an environmentally appropriate manner. For this purpose, they will be drilled out to allow the compressed nitrogen to escape and to drain the oil they contain. See also

Removal and depressurization of the gas strut

, page 306

Gas strut

Repair 149

10.4

Overturning/Tipping of the Rammax 1575

NOTE

Fig. 10-6 Rammax 1575 overturned

1

Place the machine back onto the roller drums as quickly as possible.

2

Turn the ignition off (position 0).

Do not under any circumstances attempt to restart the engine right away!

• Avoid oil shock!

• Severe engine damage can result!

!

CAUTION

Environmental hazard through operating materials!

• Do not allow any liquids to enter drains, the soil or the environment.

• Immediately bind any fluids which have leaked out, such as oil, diesel, antifreeze, battery acid!

150

Fig. 10-7 Rammax 1575

Rammax 1575

10.4.1

Inspect for damage

1

Open both hoods.

2

Disconnect the ground cable (-).

Fig. 10-8 Disconnect the battery

3

Inspect the machine for visible damage.

3.1

Especially for fluids which have leaked out.

4

Empty any containers (tanks) which may be defective.

10.4.2

Prevent an oil shock

NOTE Before you begin the dismantling and disassembly of parts, you must thoroughly clean the area around the valve cover, cylinder head and electrical steel.

If no visible damage is found or it has already been repaired, perform the following procedure:

1

Remove fuse F21 in the engine compartment.

F21

Fig. 10-9 Engine compartment fuses

2 Remove the air filter element. See page 84.

2.1

If it is oily, replace it.

Overturning/Tipping of the Rammax 1575

Repair 151

152

3

Clean the air filter housing.

4

Disassemble the air filter hose at the top.

Fig. 10-10 Remove the air filter hose at the top

5

Disassemble the fuel filter (AF size 13).

Fig. 10-11 Disassembling fuel filter

6

Disassemble the electrical steel and fold it toward the back.

6.1

Screws at back (2 Allen screws, AF size 4).

6.2

Screws at front (4 hex screws, AF size 13).

Fig. 10-12 Disassembling electrical steel at back/front

Rammax 1575

7

Disassemble the valve cover (9 hex screws, AF size 10).

Fig. 10-13 Disassembling the valve cover

8

Remove the three cables and contact connectors on the glow plugs (AF size 8).

1

2 3 4

Fig. 10-14 Remove cables and contact connectors

9

Remove ALL three glow plugs (AF size 12).

9.1

Tools: Long socket (AF size 12) and torque wrench.

Fig. 10-15 Tools/Spark plug removal

Overturning/Tipping of the Rammax 1575

Repair 153

Turn the engine over (rotate crankshaft) with a wrench

Ensure that the oil which may have collected is displaced by the piston.

1

Turn the engine over twice clockwise by means of the central bolt (AF size 17) on the crankshaft using a box-end ratchet wrench

(1).

1

NOTE

Fig. 10-16 Box-end ratchet wrench/Rotate crankshaft

Risk of cable fire or short circuit.

Insulate the connection cables for the glow plugs, e.g. using a piece of hose.

Fig. 10-17 Insulate the connection cable

2

Refasten the electrical steel using two screws (1).

1

154

1

1

Fig. 10-18 Fasten electrical steel

3

Reconnect the battery ground cable (-).

Rammax 1575

!

WARNING

Danger of burns due to ejected oil!

Eye injury, burns

• Wear safety goggles

Turn the engine over using the starter

1

Turn the engine over using the starter for 1-2 minutes.

After a few revolutions, the oil which has gathered in the combustion chambers should have been pressed out through the openings for the glow plugs.

Repeat the procedure after about 5 minutes. It is essential to be sure that no more oil is present in the combustion chambers!

2

Reinstall the glow plugs (AF size 12, torque, 18Nm).

Fig. 10-19 Glow plugs

3

Reconnect the contact connectors and cables to the glow plugs (AF size8, torque,

1.5 Nm).

Fig. 10-20 Connection cable

4

Install the valve cover.

5

Install the electrical steel.

Overturning/Tipping of the Rammax 1575

Repair 155

Turn the engine over with the ignition key

1

Turn the ignition key clockwise to position III.

1.1

The engine must turn over.

If this is not the case, do not under any circumstances attempt to start the engine!

It is possible that there could still be oil in the combustion chambers. Repeat the procedure described above, or otherwise contact your authorized dealer right away!

If the engine turns over:

1

Check all fluid levels.

1.1

If needed, top up the fluids.

2

Put fuse F 21 back in place.

10.4.3

Start the engine

1. Attempt to start

1

Turn the ignition key clockwise to position III.

1.1a Attempt to start is successful, engine is running: See “Engine is running” further down.

1.1b Attempt to start is unsuccessful, engine is not running: There could be air in the diesel system. See “Check the pump” in the following.

1

Turn the ignition key clockwise to position I.

1.1

Check whether the electrical fuel pump is working.

Allow the pump to operate for about 1 minute. The system will be bled automatically.

2. Attempt to start

1

Turn the ignition key clockwise to position III.

2

Allow the engine to turn over in neutral!

2.1

Do not activate any functions.

The engine will smoke until the oil that has gathered in the exhaust system has been burned away (can take up to 1h).

156 Rammax 1575

!

WARNING

Danger of fire!

It is possible for flames/glowing embers to be shot out of the exhaust pipe.

1

Immediately perform a visual inspection for any leaking fluids.

If everything is in order:

1

Bring the engine up to maximum speed.

1.1

Check the functions.

The smoke from the engine must be decreasing noticeably and then stop completely.

Otherwise, there may be a mechanical defect in the engine.

1

Switch off the engine.

2

Check all fluid levels.

2.1

Top up as needed.

3

Inspect for fluid losses.

4

Start the engine.

Overturning/Tipping of the Rammax 1575

Repair 157

10.5

Front engine hood

10.5.1

Removal

The sensor must be removed before the hood can be taken off. Siehe “Replacing the sensor” auf page 161.

1

Attach the hood to an anchor sling.

158

Fig. 10-21 201309210017

Fig. 10-22 201309210018

1

Use a screwdriver to lift the clips.

2

Pull the gas struts off of the ball joint on the left and right.

Fig. 10-23 201309210019

Rammax 1575

Fig. 10-24 201309210021

1

Disconnect the wire cable on the left from the hood.

2

Use a crane to lift the hood up.

1

Remove the lower screws from the hinge on the left (AF size 17).

Fig. 10-25 201309210022

1

Remove the lower screws from the hinge on the right (AF size 17).

Fig. 10-26 201309210023

1

You can now use the crane to completely remove the hood from the chassis.

Front engine hood

Repair

Fig. 10-27 201309210024

159

10.5.2

Replacing the hinges

1

Remove the hood as shown above.

2

Remove the

two M10x20 hex screws.

Fig. 10-28 201309210028

1

Replace the hinge.

Fig. 10-29 201309210029

1

Apply blue adhesive to the M10x20

(AF size 17) hex screws.

Fig. 10-30 201309210031

1

Retighten the screws with a torque of

50 Nm.

160

Fig. 10-31 201309210033

Rammax 1575

10.5.3

Replacing the sensor

Fig. 10-32 201309210003

1

Remove the

four M6x30 (AF size 5)

Allen screws.

Fig. 10-33 201309210002

1

Remove the protective cover of the sensor.

Fig. 10-34 201309210004

1

Unscrew the sensor using the special tool (AF size 36).

Fig. 10-35 201309260007

1

Remove the sensor from the inside.

Front engine hood

Repair

Fig. 10-36 201309210006

161

1

Remove the sensor cable from the cable mountings.

Fig. 10-37 201309210007

1

Remove cable ties.

Fig. 10-38 201309210008

1

Remove cable ties.

162

Fig. 10-39 201309210009

1

Disconnect connector X5 (front IR sensor).

Fig. 10-40 201309210010

Rammax 1575

1

Disassembled sensor. Now it can be replaced.

Fig. 10-41 201309210011

Fig. 10-42 201309260005

Fig. 10-44 201309260007

1

Insert the new sensor.

Fig. 10-43 201309260006

1

Screw the sensor in place from the outside using the special tool

(AF size 36).

1

Apply blue adhesive to the screws of the protective cover of the sensor.

Front engine hood

Repair

Fig. 10-45 201309260009

163

1

Position the protective cover for the sensor on the hood.

164

Fig. 10-46 201309260010

Fig. 10-47 201309260011

Fig. 10-48 201309260013

1

Secure the cables in the cable mountings under the hood.

Fig. 10-49 201309260012

1

Secure the cable to the bracket on the upper part of the hinge with a cable tie.

Fig. 10-50 201309260014

1

Securely tighten the M6x30 (AF size 5)

Allen screws to a torque of 10 Nm.

Rammax 1575

1

Secure the cable to the bracket on the lower part of the hinge with a cable tie.

Fig. 10-51 201309260016

1

Secure the cable to hydraulic hose 010 with a cable tie.

Fig. 10-52 201309260017

1

Screw connector X5 (front IR sensor) back together.

2

Secure cable with cable tie.

Fig. 10-53 201309260018

10.5.4

Replacing the rubber hood buffers

1

Remove the M8 hex nut from the rubber buffer (AF size 13).

Front engine hood

Repair

Fig. 10-54 201311050004

165

166

1

Remove the rubber buffer from the mounting.

Fig. 10-55 201311050005

1

Apply blue adhesive to the threads of the new rubber buffer.

Fig. 10-56 201311050006

1

Install the new rubber buffer into the mounting.

Fig. 10-57 201311050007

1

Screw the rubber buffer firmly in place with the M8 hex nut and washer.

Fig. 10-58 201311050009

Rammax 1575

10.5.5

Adjusting the rubber hood buffers

If the hood makes contact with the chassis, the distance between the two can be adjusted.

1

Slightly loosen the two M8 screws on the rubber buffer mounting.

Fig. 10-59 201309260003

Fig. 10-60 201309260001

1

The distance between the hood and the chassis can now be adjusted by shifting the mounting.

1.1

Be sure the spacing is uniform.

1

Slightly loosen the four M10 lower hinge screws.

Fig. 10-61 201309260004

1

The hood can now be aligned with the chassis by shifting it accordingly.

1.1

The hood and chassis should be flush.

2

When finished, tighten all screws

(50 Nm).

Front engine hood

Repair

Fig. 10-62 201309260002

167

10.6

Rear engine hood

10.6.1

Removal

The sensor must be removed before the hood can be taken off. Siehe “Replacing the sensor” see page 161.

1

Attach the hood to an anchor sling.

Fig. 10-63 201309210038

Fig. 10-64 201309210037

1

Cut through and remove the two cable ties at connector N2.

Fig. 10-65 201309210040

1

Pull the two connectors off of the fuse box.

168

Fig. 10-66 201309210041

Rammax 1575

1

Pull the connector off of the ignition switch.

Fig. 10-67 201309210042

1

Disconnect connector N2.

Fig. 10-68 201309210043

1

Remove cable ties on hood.

Fig. 10-69 201309210044

1

Use a screwdriver to lift the clips.

2

Pull the gas strut away from the ball joint.

Rear engine hood

Repair

Fig. 10-70 201309210045

169

170

Fig. 10-71 201309210046

1

Disconnect the wire cable from the hood.

2

Use a crane to lift the hood up.

1

Remove the lower screws from the hinges on the left (AF size 17).

Fig. 10-72 201309210047

1

Remove the lower screws from the hinges on the right (AF size 17).

Fig. 10-73 201309210049

1

Remove the cable tie on the hinge.

Fig. 10-74 201309210050

Rammax 1575

1

You can now use the crane to completely remove the hood from the chassis.

Fig. 10-75 201309210051

Fig. 10-76 201309210052

10.6.2

Replacing the hinge

For “Replacing the hinge” of the rear engine hood, see the section “Replacing the hinges” of the front engine hood, page 160

10.6.3

Replacing the sensor

1

Remove the four M6x30 (AF size 5)

Allen screws.

Fig. 10-77 201309210012

1

Remove the protective cover of the sensor.

Rear engine hood

Repair

Fig. 10-78 201309210013

171

1

Unscrew the sensor using the special tool (AF size 36).

Fig. 10-79 201309260007

1

Remove the sensor from the inside.

Fig. 10-80 201309210015

1

Unscrew the rear sensor connector.

Fig. 10-81 201309210016

172

Fig. 10-82 201309260005

1

Insert the new sensor.

Fig. 10-83 201309260006

Rammax 1575

Fig. 10-84 201309260007

1

Screw the sensor in place from the outside using the special tool

(AF size 36).

1

Apply blue adhesive to the screws of the protective cover of the sensor.

Fig. 10-85 201309260009

1

Position the protective cover for the sensor on the hood.

Fig. 10-86 201309260040

1

Securely tighten the M6x30 (AF size 5)

Allen screws to a torque of 10 Nm.

Rear engine hood

Repair

Fig. 10-87 201309260041

173

1

Secure the cables in the cable mountings under the hood.

Fig. 10-88 201309260030

Fig. 10-89 201309260031

1

Plug in the ignition switch connector.

2

Plug in connector N2.

3

Secure the connector with a cable tie.

1

Secure the cable along the wiring harness with cable ties.

Fig. 10-90 201309260032

1

Route the sensor cable and secure it with cable ties.

Fig. 10-91 201309260039

10.6.4

Replacing the rubber hood buffers

For “Replacing the rubber hood buffers” of the rear engine hood, see the section

“Replacing the rubber hood buffers” of the front engine hood, page 165.

174 Rammax 1575

10.6.5

Adjusting the rubber hood buffers

For “Adjusting the rubber hood buffers” of the rear engine hood, see the section

“Adjusting the rubber hood buffers” of the front engine hood, page 167.

10.7

Replacing the display unit

10.7.1

Removal

1

Disconnect connector N2.

Fig. 10-92 201309260033

1

Remove the two fasteners of the display unit (AF size 5.5).

Fig. 10-93 201309260035

1

The display unit can now be removed from the inside toward the outside.

Fig. 10-94 201309260036

Replacing the display unit

Repair 175

1

Install the new unit in the opposite order.

Fig. 10-95 201309260038

10.8

Replacing the controller (machine controller)

10.8.1

Removal

1

Disconnect the (-) pole of the battery.

Fig. 10-96 201309260019

1

Unscrew both sensor connectors.

Fig. 10-97 201309260020

176 Rammax 1575

Fig. 10-101 201309260026

Replacing the controller (machine controller)

Repair

1

Disconnect connector N1.

Fig. 10-98 201309260022

Fig. 10-99 201309260024

1

Use a screwdriver to lift the clips.

2

Pull the gas strut away from the ball joint.

1

Remove the four fastening screws

(AF size 13).

Fig. 10-100 201309260025

1

Remove the controller.

177

10.8.2

Installation

1

Apply blue adhesive to the M8x20 hex screws.

Fig. 10-102 201309260027

1

Screw the new controller firmly in place using M8x30 (AF size 13) hex screws.

Fig. 10-103 201309260028

1

Connect connector N1.

2

Reconnect the (-) pole of the battery.

Fig. 10-104 201309260029

178 Rammax 1575

10.9

Replacing and adjusting the magnetic rotational speed sensor

10.9.1

Removal

Magnetic rotational speed sensor

(1)

1

Fig. 10-105 201309220001

1

Pull off the two leads Y2+ and Y2-.

Fig. 10-106 201309220002

Fig. 10-107 201309220003

1

Remove safety bolt from the clevis head.

Fig. 10-108 201309220004

Replacing and adjusting the magnetic rotational speed sensor

Repair 179

1

Remove the two Allen screws

(AF size 5).

2

Remove the magnetic rotational speed sensor.

Fig. 10-109 201309220007

10.9.2

Installation

1

Fig. 10-110 201311060001

Premounted magnetic rotational speed sensor

(1)

1

Apply blue adhesive to the two Allen screws.

Fig. 10-111 201309220006

1

Position the magnetic rotational speed sensor and screw firmly in place.

180

Fig. 10-112 201309220007

Rammax 1575

1

Grease the safety bolt of the clevis head.

Fig. 10-113 201309220008

1

Put the safety bolt onto the clevis head.

Fig. 10-114 201309220009

Fig. 10-115 201309220025

10.9.3

Adjusting

1

Connect the two leads Y2+ and Y2-.

1.1

Do not reverse - and + cables.

Fig. 10-116 201309220005

1

Loosen counter nut on clevis head

(AF size 10).

Fig. 10-117 201309220011

Replacing and adjusting the magnetic rotational speed sensor

Repair 181

Fig. 10-118 201309220013

1

Push the piston rod all the way down by hand.

1.1

The stop (arrow) must not be allowed to touch the adjustment screw.

1

Use a feeler gauge (1.5mm) to set the spacing between the adjustment screw and the stop.

182

Fig. 10-119 201309220021

Fig. 10-121 201309220016

Fig. 10-120 201309220015

1

Push the magnetic rotational speed sensor

all the way through to the stop!

There must be a gap of 1.5 mm between the stop and the adjustment screw.

1

1

Start the engine.

2

Push the magnetic rotational speed sensor all the way through to the stop!

3

Measure the engine speed using the tachometer.

If the specified speed (min. 2390 -

2440rpm) is not reached, the clevis head

(AF size 10) (1) must be adjusted.

Fig. 10-122 201309220011

Rammax 1575

Fig. 10-123 201309220018

1

1

After the adjustment is completed, tighten the counter nut on the clevis head (AF size 10).

2

Motion test: Move the magnetic rotational speed sensor up and down by hand.

IMPORTANT: When the linkage is

pressed down, it must return to its starting position strain-free on its own.

Fig. 10-124 201309220011

10.10

Testing the engine speed and frequency

NOTE Adjust the speed when the roller is at operating temperature

1

Put the machine on two large or four small old tires or on a suitably soft base.

Fig. 10-125 201311150005

The governor lever must rest against the adjustment screw when the diesel engine is at the idle position.

Testing the engine speed and frequency

Repair 183

Fig. 10-126 201311190100

Fig. 10-127 201309220011

Tab. 10-1 Diesel engine speeds

Engine rpms, 100%

Vibration speed, front, small

Vibration speed, rear, small

Vibration speed, front, large

Vibration speed, rear, large

10.11

Roller drum removal

1

Start the engine.

2

Select vibration.

3

The machine goes to full speed:

100% = 2390 - 2440 rpm

4 Use a tachometer to measure the frequency.

100% = Desired value: 41 Hz.

2

1

1

If the rotational speed is not reached, check the engine speed.

2

If necessary, adjust the speed at the clevis head (AF size 10) (1).

3

Counter the nuts.

4

Be certain that the safety bolt (2) on the clevis head is engaged.

After 5 min.

2415 ±25

2250 ±150

2250 ±150

2250 ±150

2250 ±150

RPM

After 60 min.

2405 ±25

2250 ±150

2250 ±150

2250 ±150

2250 ±150

1

Safely jack up the machine.

2

Attach an anchor sling to the roller drum.

3

Use a crane to slightly lift the roller drum.

Fig. 10-128 201309270028

184 Rammax 1575

1

Remove the roller drum screws

(AF size 19).

Fig. 10-129 201309300003

Fig. 10-130 201309300001

1

Pull the roller drum out from under the chassis using a suitable aid.

1.1

Keep the roller drum balanced using a suitable aid (e.g. piece of square timber).

1

Set the roller drum down securely until needed again.

Fig. 10-131 201309270031

10.12

Installing the roller drum extender

1

Place the roller on a firm, stable surface.

2

Use a crane or hydraulic jack to slightly lift the roller.

3

For roller drum removal, see page 184.

Fig. 10-132 201310010088

Installing the roller drum extender

Repair 185

1

Screw in the

two installation pins.

Fig. 10-133 201312180002

1

Position the new roller drum.

186

Fig. 10-134 201312180003

1

Push the roller drum over the two installation pins (1).

1

Fig. 10-135 201312180004

1

1

Screw in four hex screws M12 x 25

(AF size 19) (87 Nm).

NOTE

Pay attention to the position of the screws, see photo at left.

Fig. 10-136 201312180005

Rammax 1575

1

Screw in the

two installation pins.

Fig. 10-137 201312180006

1

Fig. 10-138 201312180007

1

Push the roller drum extender over the two installation pins (1).

1

Screw in six M12 x 90 hex screws

(AF size 19) (87 Nm).

Fig. 10-139 201312180008

10.13

Rubber elements of vibro unit

If a rubber element has cracks that are deeper than 10 mm, it must be replaced.

Rubber elements of vibro unit

Repair 187

10.13.1

Removal

Fig. 10-140 201309270028

1

Safely jack up the machine.

2

Attach an anchor sling to the roller drum.

3

Use a crane to slightly lift the roller drum.

1

Remove the roller drum screws

(AF size 19).

Fig. 10-141 201309270029

Fig. 10-142 201309270030

1

Pull the roller drum out from under the chassis using a suitable aid.

1.1

Keep the roller drum balanced using a suitable aid (e.g. piece of square timber).

1

Set the roller drum down securely until needed again.

188

Fig. 10-143 201309270031

Rammax 1575

Fig. 10-144 201309270032

1

Clean hoses and the immediate surroundings.

2

Place an oil catch basin beneath the drive motor before disconnecting the hoses.

1

Remove all hoses from the drive motor.

2

Plug the fittings.

Fig. 10-145 201309270034

Fig. 10-147 201309270036

Fig. 10-146 201309220015

1

Mount auxiliary tool on drive motor flange using three M12 screws

(AF size 19).

2

Attach an anchor sling to the auxiliary tool and a crane.

3

Use the crane to slightly lift the auxiliary tool.

4

Remove six M12 hex screws

(AF size 19) from the drive motor support.

Fig. 10-148 201309270037

Rubber elements of vibro unit

Repair

Fig. 10-149 201309260068

189

1

Pull the drive motor complete with the auxiliary tool away from the gear box.

Fig. 10-150 201309270038

Fig. 10-151 201309270039

1

Set the drive motor down securely until needed again.

Fig. 10-152 201309270040

1

Remove

seven M10 hex screws

(AF size 17) from the gear box cover.

Fig. 10-153 201309270041

Fig. 10-154 201309270041

1

Remove

twelve M8 hex screws

(AF size 13) from the gear box cover.

2

Relocate the oil catch basin beneath the gear box before removing the gear box cover.

190

Fig. 10-155 201309270043

Rammax 1575

1

Carefully remove the gear box cover by hand.

Fig. 10-156 201309270044

Fig. 10-157 201309270045

Grease will escape from the unbalanced drive gear box.

During reassembly later, the same amount of grease must be added once again.

1

Set the gear box cover down securely until needed again.

Fig. 10-158 201309270046

Fig. 10-159 201310010017

Rubber elements of vibro unit

Repair

1

Support the hoses with square timber to keep them free.

2

Screw the auxiliary tool securely onto the vibromotor side of the gear box cover (AF size 19).

3

Attach an anchor sling to the auxiliary tool and a crane.

4

Use the crane to slightly lift the auxiliary tool.

191

192

Fig. 10-160 201310010018

Fig. 10-161 201310010015

1

Pull the gear box complete with the auxiliary tool away from the center beam.

1

Set the entire gear box down securely until needed again.

Fig. 10-162 201309270050

1

Remove

seven M10 hex screws

(AF size 17) from the gear box cover.

1

Remove fourteen M10 hex screws

(AF size 17) from the center beam / rubber elements.

Fig. 10-163 201309270056

Rammax 1575

1

Remove the rubber elements.

Fig. 10-164 201309270058

10.13.2 Installation of the rubber elements

1

Apply blue adhesive to the fourteen

M10 hex screws.

Fig. 10-165 201310010001

1

Place the new rubber elements onto the center beam.

Fig. 10-166 201310010002

Rubber elements of vibro unit

Repair 193

194

Fig. 10-167 201309270057

1

Securely tighten the

fourteen M10 hex screws (AF size 17) on the center beam / rubber elements to a torque of

50 Nm.

Fig. 10-168 201310010004

1

Apply blue adhesive to the rubber elements’ threads on the vibromotor side.

Fig. 10-169 201310010007

1

Support the hoses on the vibromotor side as well with square timber to keep them free.

Fig. 10-170 201309270053

Rammax 1575

1

Attach the gear box to the crane by means of the auxiliary tool.

Fig. 10-172 201310010009

Fig. 10-171 201310010011

1

Align the gear box.

2

Place the gear box onto the rubber elements.

Fig. 10-173 201310010016

1

Tighten the

seven hex nuts (1)

(AF size 17) to a torque of 50 Nm.

1

Fig. 10-174 201310010017

Fig. 10-175 201310010018

This completes the installation of the gear box on the vibromotor side. If a bearing replacement or regreasing is necessary, please see chapter “Replacing bearing, vibro unit” see page 200.

Without a bearing replacement or regreasing, you may proceed here.

Rubber elements of vibro unit

Repair 195

1

Clean the sealing surface of the gear box housing.

Fig. 10-176 201310010008

1

Retap all threads (M8).

Fig. 10-177 201310010012

1

Blow out the thread bores.

196

Fig. 10-178 201310010014

1

Thoroughly remove all soiling in the form of adhesive residues and contaminated grease.

2

Replace grease that has been removed or has run out with the same amount of new grease.

Grease: Castrol Longtime PD2 - or compatible

(extreme pressure grease for long term lubrication)

Fig. 10-179 201310010020

Rammax 1575

1

Apply sealant to the sealing surface.

Fig. 10-180 201310010021

1

Spread the sealant with a brush.

Fig. 10-181 201310010023

1

Place one drop of blue thread adhesive in each threaded bore.

Fig. 10-182 201310010024

Fig. 10-183 201310010026

Rubber elements of vibro unit

Repair

1

Clean / blow out the holes in the gear box cover.

Fig. 10-184 201310010028

197

1

Clean the sealing surface of the gear box cover.

Fig. 10-185 201310010027

1

Apply blue adhesive to the threads of the rubber elements.

Fig. 10-186 201310010025

1

Put the gear box cover in place.

198

Fig. 10-187 201310010029

Fig. 10-188 201310010031

1

1

Tighten the seven M10 hex nuts (1)

(AF size 17) to a torque of 50 Nm.

Rammax 1575

1

Apply blue adhesive to the

twelve

M8x35/22 hex screws.

Fig. 10-189 201310010034

1

Tighten the hex screws (1) (AF size 13) to a torque of 36 Nm.

Fig. 10-190 201310010035

1

Fig. 10-191 201310010038

1

Install the hose guide bracket (1) using the same screws.

Fig. 10-192 201310010036

1

Rubber elements of vibro unit

Repair 199

10.14

Replacing bearing, vibro unit

10.14.1 Gaining access to the vibro unit

1

Safely jack up the machine.

2

Attach an anchor sling to the roller drum.

3

Use a crane to slightly lift the roller drum.

Fig. 10-193 201309270028

1

Remove the roller drum screws

(AF size 19).

Fig. 10-194 201309270029

Fig. 10-195 201309270030

1

Pull the roller drum out from under the chassis using a suitable aid.

1.1

Keep the roller drum balanced using a suitable aid (e.g. piece of square timber).

1

Set the roller drum down securely until needed again.

200

Fig. 10-196 201309270031

Rammax 1575

Fig. 10-197 201309270032

1

Place an oil catch basin beneath the drive motor before disconnecting the hoses.

1

Remove all hoses from the drive motor.

2

Plug the fittings.

Fig. 10-198 201309270034

Fig. 10-200 201309270036

Fig. 10-199 201309220015

1

Mount auxiliary tool on drive motor flange using three M12 screws

(AF size 19).

2

Attach an anchor sling to the auxiliary tool and a crane.

3

Use the crane to slightly lift the auxiliary tool.

1

Remove six M12 hex screws

(AF size 19) from the drive motor support.

Fig. 10-201 201309270037

Replacing bearing, vibro unit

Repair

Fig. 10-202 201309260068

201

1

Pull the drive motor complete with the auxiliary tool away from the gear box.

Fig. 10-203 201309270038

Fig. 10-204 201309270039

1

Set the drive motor down securely until needed again.

Fig. 10-205 201309270040

1

Remove

seven M10 hex screws

(AF size 17) from the gear box cover.

202

Fig. 10-206 201309270041

Fig. 10-207 201309270041

1

Remove twelve M8 hex screws

(AF size 13) from the gear box cover.

2

Relocate the oil catch basin beneath the gear box before removing the gear box cover.

Fig. 10-208 201309270043

Rammax 1575

1

Carefully remove the gear box cover by hand.

Fig. 10-209 201309270044

Fig. 10-210 201309270045

Grease will escape from the unbalanced drive gear box.

During reassembly later, the same amount of grease must be added once again.

1

Set the gear box cover down securely until needed again.

Fig. 10-211 201309270046

10.14.2 Dismantling the vibro unit

View of the vibro housing after opening.

NOTE:

The grease in the housing is spent after a certain number of operating hours and must be replaced.

The following steps were performed on a new vibro unit. This is why the grease in all the photos is unspent and light in color.

Fig. 10-212 201310010008

Replacing bearing, vibro unit

Repair 203

204

1

Clean the vibro housing and remove spent grease.

Fig. 10-213 201311130001

1

Remove the M6 Allen screws

(AF size 5) from the bearing cover.

Fig. 10-214 201311130002

1

Remove the bearing cover and clean it.

Fig. 10-215 201311130003

Fig. 10-216 201311130004

1

Remove grease from the boss.

Fig. 10-217 201311130005

Fig. 10-218 201311130004

Rammax 1575

1

Loosening the grooved nut lock ring.

1.1

Use a small chisel or screwdriver.

Fig. 10-219 201311130007

Fig. 10-220 201311130008 Fig. 10-221 201311130009

1

Put the special “grooved nut wrench” in place.

Fig. 10-222 201311130010

Fig. 10-223 201311130011

1

Loosen the grooved nut.

Fig. 10-224 201311130013

Replacing bearing, vibro unit

Repair 205

1

Remove the grooved nut.

Fig. 10-225 201311130014

1

Remove the grooved nut lock ring.

206

Fig. 10-226 201311130015

1

Lift the unbalance unit off of the shaft.

Fig. 10-227 201311130016

1

Remove grease from the boss.

Fig. 10-228 201311130017

Rammax 1575

1

Removing the spacer rings.

Fig. 10-229 201311130018

Fig. 10-230 201311130019

1

Pull the bearing off of the boss with a bearing puller.

1.1

Apply the bearing puller here

(arrows).

Fig. 10-231 201311130020

Fig. 10-232 201311130021

1

Remove the bearing outer rings and the spacer ring.

Fig. 10-233 201311140002

Fig. 10-234 201311140010

Replacing bearing, vibro unit

Repair 207

1

Clean the bearing housing.

Fig. 10-235 201311140001

10.14.3 Assembling the vibro unit

1

1

Place the new, wide bearing outer ring

(1) into the bearing housing.

1.1

Observe the mounting orientation.

Fig. 10-236 201311140003

1

Press the wide bearing outer ring into the housing.

Fig. 10-237 201311140004

1

208

Fig. 10-238 201311140005

1

Place the spacer ring (1) into the bearing housing.

Fig. 10-239 201311140006

Rammax 1575

1

Fig. 10-240 201311140007

1

Place the narrow bearing outer ring

(1) into the bearing housing.

1.1

Observe the mounting orientation.

1

Press the narrow bearing outer ring into the housing.

Fig. 10-241 201311140008

10.14.4 Assembling the vibro unit

Fig. 10-242 201311140006

1

Heat the rear taper roller bearing to

110°C.

Fig. 10-243 201311130022

Replacing bearing, vibro unit

Repair 209

1

Push the rear taper roller bearing onto the boss.

210

Fig. 10-244 201208250003

1

Lightly grease the bearing.

Fig. 10-245 201311130022

1

Install the spacer rings.

Fig. 10-246 201311130023

Rammax 1575

1

Grease the outside of the bearing rings.

Fig. 10-247 201311130024

1

Place the unbalance unit into the vibro housing.

Fig. 10-248 201311130025

1

Install the outer bearing.

Fig. 10-249 201311130026

1

Install the lock ring.

Fig. 10-250 201311130027

Replacing bearing, vibro unit

Repair 211

1

Install the grooved nut.

Fig. 10-251 201311130028

1

Put the special “grooved nut wrench” in place.

Fig. 10-252 201311130029

1

Tighten to a torque of 200 Nm.

212

Fig. 10-253 201311130031

1

Screw on the bracket for the torque measurement instrument.

Fig. 10-254 201311130033

Rammax 1575

1

Attach the torque measurement instrument.

Fig. 10-255 201311130032

Fig. 10-256 201311130035

Fig. 10-257 201311130036

1

Rotate the unbalance with the torque measurement instrument clockwise 20 times.

This will eliminate any tension points.

NOTE:

Under no circumstances may the housing hit against the support; it must rotate freely.

1

Set the torque to a value of 1-3 Nm.

If the value is not correct, a correction must be made using the spacers until the target value is achieved.

1/10 = 4Nm

1

Bend the tooth of the lock ring into the matching groove of the nut using a suitable tool.

Fig. 10-258 201311130037

Replacing bearing, vibro unit

Repair

Fig. 10-259 201311130038

213

214

1

Regrease the bearing.

Fig. 10-260 201311130039

Fig. 10-262 201311130041

Fig. 10-261 201311130040

Total amount of grease in the bearing housing: 100 g of

Castrol Longtime PD2 - or compatible

(extreme pressure grease for long term lubrication)

1

Put a little blue adhesive into the threaded holes.

Fig. 10-263 201311130042

1

Apply blue adhesive to the M6x20

Allen screws.

Fig. 10-264 201311130043

Rammax 1575

Fig. 10-265 201311130044

Fig. 10-266 201311130048

1

Securely tighten the M6x20 (AF size 5)

Allen screws to a torque of 10 Nm.

NOTE

The unbalance weight must be able to move with complete freedom.

1

Fill the vibro housing with 300 g of grease.

Fig. 10-267 201311130049

1

Place the bearing cover onto the unbalance housing.

1

Clean the sealing surface of the gear box housing.

Fig. 10-268 201310010008

Replacing bearing, vibro unit

Repair 215

1

Retap all threads (M8).

Fig. 10-269 201310010012

1

Blow out the thread bores.

216

Fig. 10-270 201310010014

Fig. 10-271 201310010020

1

Thoroughly remove all soiling in the form of adhesive residues and contaminated grease.

2

Replace grease that has been removed or has run out with the same amount of new grease.

Grease: Castrol Longtime PD2 - or compatible

(extreme pressure grease for long term lubrication)

1

Apply sealant to the sealing surface.

Fig. 10-272 201310010021

Rammax 1575

1

Spread the sealant with a brush.

Fig. 10-273 201310010023

1

Place one drop of blue thread adhesive in each threaded bore.

Fig. 10-274 201310010024

Fig. 10-275 201310010026

1

Clean / blow out the holes in the gear box cover.

Fig. 10-276 201310010028

1

Clean the sealing surface of the gear box cover.

Fig. 10-277 201310010027

Replacing bearing, vibro unit

Repair 217

1

Apply blue adhesive to the threads of the rubber elements.

Fig. 10-278 201310010025

1

Put the gear box cover in place.

218

Fig. 10-279 201310010029

Fig. 10-280 201310010031

1

1

Tighten the seven M10 hex nuts (1)

(AF size 17) to a torque of 50 Nm.

1

Apply blue adhesive to the twelve

M8x35/22 hex screws.

Fig. 10-281 201310010034

Rammax 1575

1

Tighten the hex screws

(1) (AF size 13) to a torque of 36 Nm.

Fig. 10-282 201310010035

1

Fig. 10-283 201310010038

1

Install the hose guide bracket (1) using the same screws.

1

Fig. 10-284 201310010036

10.15

Replacing the drive motor

10.15.1 Removal

1

Safely jack up the machine.

2

Remove the hex screws (AF size 19) on the roller drum scraper.

Fig. 10-285 201309260053

Replacing the drive motor

Repair 219

220

1

Remove the scraper

Fig. 10-286 201309260054

Fig. 10-288 201309260058

Fig. 10-287 201309260056

1

Attach an anchor sling to the roller drum.

2

Use a crane to slightly lift the roller drum.

1

Remove the roller drum screws

(AF size 19).

Fig. 10-289 201309260059

1

Pull the roller drum out from under the chassis using a suitable aid.

1.1

Keep the roller drum balanced using a suitable aid (e.g. piece of square timber).

Fig. 10-290 201309260060

Rammax 1575

Fig. 10-291 201309270032

1

Place an oil catch basin beneath the drive motor before disconnecting the hoses.

1

Remove all hoses from the drive motor.

2

Plug the fittings.

Fig. 10-292 201309270034

Fig. 10-294 201309270036

Fig. 10-293 201309220015

1

Mount auxiliary tool on drive motor flange using three M12 screws

(AF size 19).

2

Attach an anchor sling to the auxiliary tool and a crane.

3

Use the crane to slightly lift the auxiliary tool.

1

Remove six M12 hex screws

(AF size 19) from the drive motor support.

Fig. 10-295 201309270037

Replacing the drive motor

Repair

Fig. 10-296 201309260068

221

1

Pull the drive motor complete with the auxiliary tool away from the gear box.

Fig. 10-297 201309270038

Fig. 10-298 201309270039

1

Set the drive motor down securely until needed again.

Fig. 10-299 201309270040

10.15.2 replace

Fig. 10-300 201309260073

222

Fig. 10-302 201309260078

1

Completely remove all of the screw connections from the demounted drive motor.

Fig. 10-301 201309260076

1

Remove the seven M12x25 Allen screws (AF size 10) from the drive motor flange.

Screws inaccessible:

In infrequent cases, the seven M12x25

Allen screws are not accessible, which means that the drive motor flange must be completely removed. In this case, the five hex screws (AF size 24) must be removed.

Lift the flange from the drive motor.

Rammax 1575

1

Screw two eye bolts into the drive motor flange.

Fig. 10-303 201309260079

Fig. 10-304 201309260080

Fig. 10-305 201312180001

1

Attach the tackle to the crane and the eye bolts.

2

The orientation of the drive motor must be marked with a marker before the drive motor is lifted out of the motor support.

If the drive motor is rusted in place in the motor support, the drive motor must be pressed out of the motor support:

1

Clean three threads.

2

Retap three threads.

3

Install three M12x60 hex screws.

4

Press the drive motor out of the motor support.

1

Lift the drive motor out of the motor support.

Fig. 10-306 201309260083

Replacing the drive motor

Repair 223

1

Clean the bearing surface and the threads.

Fig. 10-307 201309260085

1 Apply Anti-Seize to the seat of the bearing on the drive motor support.

224

Fig. 10-308 201309260086

1

Put a little blue adhesive into the threaded bores.

Fig. 10-309 201309260087

1

Place the new drive motor into the motor support.

1.1

Bear in mind the orientation of the motor (marked previously).

Fig. 10-310 201309260083

Rammax 1575

1

Apply blue adhesive to the

six M12

Allen screws.

Fig. 10-311 201309260089

1

Install the Allen screws.

Fig. 10-312 201309260091

1

Tighten the Allen screws (SW10) to a torque of 85 Nm.

Fig. 10-313 201309260092

1

Apply blue adhesive to the screw connections from the old drive motor.

Fig. 10-314 201309260093

Replacing the drive motor

Repair 225

3

Fig. 10-315 201309260094

2

4

1

1

Mount the screw connections on the drive motor and tighten to the proper torque.

●

Material

○

Hydraulic motor

MK 04/340.0 cm3/rev.

(1)

○

○

○

(2x) straight screw-in fittings

GES10L M22x1.5

(2) (125 Nm)

(1x) straight screw-in fitting GES10L

M16x1.5 (3) (55 Nm)

(1x) straight screw-in fitting GES10L

M14x1.5

(4) (45 Nm)

1

Cover the screw connections with protective caps.

Fig. 10-316 201309260096

10.15.3 Installation

Fig. 10-317 201310010039

1

Clean the contact surface of the motor support and the threads.

Fig. 10-318 201310010040

1

Put a little blue adhesive into the threaded hole.

226

Fig. 10-319 201310010042

Rammax 1575

Fig. 10-320 201309270040

1

Mount the auxiliary tool on drive motor flange using three M12 hex screws

(AF size 19).

1

Screw in one threaded bolt to the right and left of the vibro gearbox flange as an aid for assembly of the drive motor.

Fig. 10-321 201310010061

1

Lift the premounted drive motor using the auxiliary tool and crane...

Fig. 10-322 201310010043

Fig. 10-323 201310010045

Replacing the drive motor

Repair

1

... and install it.

Fig. 10-324 201310010063

227

1

Apply blue adhesive to the

six M12 hex screws.

Fig. 10-325 201310010064

1

Install the hex screws.

228

Fig. 10-326 201310010047

Fig. 10-327 201310010065

1

Tighten hex screws (AF size 19) to a torque of 85 Nm.

2

Remove the auxiliary tool.

1

Mount all of the hoses.

Fig. 10-328 201310010056

Rammax 1575

Fig. 10-329 201310010057

Fig. 10-330 201309270030

1

Clean the hose fittings and surroundings with cleaner (such as brake cleaner).

2 Apply Anti-Seize to the shoulder

(arrow).

3

Allow the machine to run while still jacked up before the roller drums are once again installed. Perform an inspection for leakage.

1

Push the roller drum under the chassis using a suitable aid.

1.1

Keep the roller drum balanced using a suitable aid (e.g. piece of square timber).

1

Tighten the ten M12 hex screws

(AF size 19) to a torque of 85 Nm.

Fig. 10-331 201309270029

10.16

Replacing vibromotor

10.16.1 Removal

The vibromotors are installed at the front right and rear left. To gain access to the vibromotors, the drive motors must first be removed. Siehe “Replacing the drive motor” see page 219.

Replacing vibromotor

Repair 229

Fig. 10-332 201309270001

1

Remove all hoses from the drive motor.

2

Plug the fittings.

Fig. 10-333 201309270002

1

Install two hex screws on the vibromotor.

Fig. 10-334 201309270003

1

Pull out the vibromotor.

Fig. 10-335 201309270004

1

Remove the coupling.

230

Fig. 10-336 201309270005

Rammax 1575

Fig. 10-337 201309270008

1

The screw connections and the sprocket must be removed from the defective vibromotor.

1

Remove the sprocket nut (AF size 19).

Fig. 10-338 201309270007

2

Remove the sprocket with puller device.

Fig. 10-339 201309270009

Fig. 10-340 201309270010

1

Remove the Allen screws (AF size 5).

2

Remove the elbow flanges on both sides.

Fig. 10-341 201309270012

Replacing vibromotor

Repair 231

1

Remove hydraulic hose 040.

Fig. 10-342 201309270013

1

Remove the screw-in fittings

(AF size 17).

Fig. 10-343 201309270014

10.16.2 Installation

232

Fig. 10-344 201309270006

Overview of all parts that are used for the new vibromotor. If the screw connections and other parts are not damaged, they can be reused for the new vibromotor.

Rammax 1575

Fig. 10-348 201309270018

Replacing vibromotor

Repair

1

O-rings must always be replaced.

Fig. 10-345 201309270015

1

Apply blue adhesive to the Allen screws.

Fig. 10-346 201309270016

Fig. 10-347 201309270017

1

Install the elbow flanges using the M6 screws (AF 5) and tighten to a torque of 10 Nm.

1

Put the sprocket in place.

233

1

Apply blue adhesive to the threads.

Fig. 10-349 201309270019

1

Install the spring washer.

Fig. 10-350 201309270020

1

Install the sprocket nut.

234

Fig. 10-351 201309270021

1

Tighten the sprocket nut (AF size 19) to a torque of 50 Nm.

Fig. 10-352 201309270022

Rammax 1575

1

Apply blue adhesive to the straight screw-in fitting GES10L/M12x1.5WD.

Fig. 10-353 201309270023

Fig. 10-354 201309270024

Fig. 10-356 201309270005

2

Install the straight screw-in fittings and tighten them to a torque of 40 Nm.

Fig. 10-355 201309270025

1

Install the coupling.

1.1

If the old coupling is not defective, it can be reused.

Otherwise install a new coupling.

1

Apply sealant to the sealing surface.

Fig. 10-357 201208250034

Replacing vibromotor

Repair 235

1

Insert the Vibromotor.

236

Fig. 10-358 201309270004

1

Apply blue adhesive to the two

M10x95 hex screws.

Fig. 10-359 201208250037

1

Tighten the M10x95 hex screws

(AF size 17) to a torque of 56 Nm.

Fig. 10-360 201309270003

1

Mount the hydraulic hoses.

Fig. 10-361 201310010059

Fig. 10-362 201310010060

Rammax 1575

1

Completely assembled vibromotor.

Fig. 10-363 201310010061

10.17

Roller drum installation

1

Push the roller drum under the chassis using a suitable aid.

1.1

Keep the roller drum balanced using a suitable aid (e.g. piece of square timber).

Fig. 10-364 201309300001

1

Tighten the twelve M12 hex screws

(AF size 19) to a torque of 85 Nm.

Fig. 10-365 201309300003

10.18

Replacing the drive pump

The hydraulic oil must be drained before the drive pump can be demounted.

Siehe “Draining the hydraulic oil” see page 124.

Roller drum installation

Repair 237

10.18.1

Removal

Fig. 10-366 201309210065

1

Place an oil catch basin beneath the chassis toward the front at the drive pump.

1

Remove the pressure line screw connection for the vibro pump.

Fig. 10-367 201309210066 Fig. 10-368 201309210067

1

Plug the fittings.

Fig. 10-369 201309210069 Fig. 10-370 201309210070

1

Remove the charge pressure screw connection for the drive pump.

238

Fig. 10-371 201309210071

Rammax 1575

1

Plug the fittings.

Fig. 10-372 201309210072 Fig. 10-373 201309210074

1

Remove the supply hydraulic hose for the drive pump.

Fig. 10-374 201309210077

1

Plug the fittings.

Fig. 10-375 201309210078 Fig. 10-376 201309210079

1

Remove the hydraulic hose for the forwards drive circuit (B) drive pump.

Fig. 10-377 201309210080

Replacing the drive pump

Repair 239

1

Plug the fittings.

Fig. 10-378 201309210082 Fig. 10-379 201309210083

1

Remove the T-screw connection for the reverse drive circuit (A) drive pump.

Fig. 10-380 201309210084

Fig. 10-381 201309210085

1

Plug the fittings.

Fig. 10-382 201309210086

1

Remove the intake line screw connection for the vibro pump.

240

Fig. 10-383 201309210087

Rammax 1575

1

Plug the fittings.

Fig. 10-384 201309210088

Fig. 10-385 201309210089

1

Remove the intake line elbow screw connection for the drive pump.

1.1

Hydraulic oil will run out.

Fig. 10-386 201309210090

Fig. 10-388 201309220063

Fig. 10-387 201309210093

1

Remove the charge pressure hydraulic hose for the PBR valve block.

2

Plug the fittings.

1

Remove the cable ties on both sides of the servo-block.

Fig. 10-389 201309210094

Replacing the drive pump

Repair

Fig. 10-390 201309210095

241

1

Remove connectors Y3 and Y4.

Fig. 10-391 201309210096

Fig. 10-392 201309210098

1

Remove the M12 hex screws

(AF size 19) on the drive pump.

Fig. 10-393 201309210099

1

Lift the drive pump away from the motor.

242

Fig. 10-394 201309210100

1

Fig. 10-395 201309210101

1

Plug the elbow screw connection for the intake line (1) which is now exposed.

Fig. 10-396 201309210102

Rammax 1575

Fig. 10-397 201309220034

1

Remove the M10 Allen screw

(AF size 8).

2

Pull the gear wheel off the shaft.

Replacing the drive pump

Repair 243

10.18.2 Preparing the new drive vibro pump

If the old screw connections are not defective, they can be reused. Otherwise new screw connections must be used.

1

8

5

244

4

13

9

12

2

2

3

10

6

11

10

7

Fig. 10-398 Drive pump screw connections

AF

SIZE

7

8*

5*

6*

3*

4*

1

2*

9

10

11

12

13

Hydraulic pump

Straight screw-in fitting GES12L/M27x2-WD

Straight screw-in fitting GES 8LM-WD

Straight screw-in fitting 12L/M 14x1.5-WD

Straight screw-in fitting GES15LM-WD

Straight screw-in fitting GES22LM-WD

Screw coupling MINIMESS-1620 DKO 8L

Screw coupling MINIMESS-1620 M12x1.5

Screw coupling MINIMESS-1620 DKOL 12L

Elbow fitting, adjustable, EWSD 8L

Elbow fitting, adjustable, ESWD 22L

T-fitting, adjustable ETSD12L

L-fitting, ELSD12L

*Apply blue adhesive to all straight screw-in fittings and Minimess M12x1.5.

Siehe “Cementing hydraulic threaded joints” see page 141.

27

32

17

17

32

17

19

22

17

36

22

22

Nm

180

25

45

70

125

Rammax 1575

Allen screws, M6 (AF size 5)

Torque 10 Nm

3

5 5.1

4.1

4

1

Fig. 10-399 Vibro-steering pump

3

4

1

2

Gear pump, 11 ccm/rev. 9 teeth 82.55mm

Screw coupling MINIMESS-1620 DKO 15L

L-fitting, ELSD15L w/o M+D K

Straight flange fitting GFS 15L-35

4.1

O-ring

5 Straight flange fitting GFS 22L-40

5.1

O-ring

1 Apply Anti-Seize to the shaft.

2

Fig. 10-400 201309220035

1

Apply blue adhesive to the M10 Allen screw.

Fig. 10-401 201309220036

Replacing the drive pump

Repair 245

Fig. 10-402 201309220037

1

Adjust the gearwheel

1.1

Place a feeler gauge (1.5 mm) between the gearwheel and the pump housing.

1

Firmly secure the gearwheel with the

M10 Allen screw (AF size 8) tightening it to a torque of 85 Nm.

Fig. 10-403 201309220038

10.18.3 Installation

1

Clean the M12 thread on the pump flange.

Fig. 10-404 201309220039

1

Remove the cap from the intake hose.

246

Fig. 10-405 201309220040

Rammax 1575

1

Apply blue adhesive to the

two

M12x35 hex screws.

Fig. 10-406 201309220042

1

Push the drive pump onto the pump flange.

Fig. 10-407 201309220043

Fig. 10-408 201309220044

1

Tighten the two M12x35 hex screws

(AF size 19) to a torque of 85 Nm.

Fig. 10-409 201309220045

1

Install the screw connection for the intake line.

Fig. 10-410 201309220051

Replacing the drive pump

Repair 247

1

Install the T-screw connection for the reverse drive circuit (A) drive pump.

Fig. 10-411 201309220053

1

Install the hydraulic hose for the forwards drive circuit (B) drive pump.

248

Fig. 10-412 201309220054

1

Install the pressure line screw connection for the vibro pump.

Fig. 10-413 201309220055

1

Install the supply hydraulic hose for the drive pump.

Fig. 10-414 201309220059

Rammax 1575

1

Install the charge pressure screw connection for the drive pump.

Fig. 10-415 201309220061

1

Connect connectors Y3 and Y4.

Fig. 10-416 201309220062

1

Install the charge pressure hydraulic hose for the PBR valve block.

Fig. 10-417 201309220063

Replacing the drive pump

Repair 249

10.19

Replacing the valve block

The hydraulic oil must be drained before the valve block can be demounted.

Siehe “Draining the hydraulic oil” see page 124.

10.19.1

Removal

Y6

Fig. 10-418 201309220066

1

Disconnect connectors Y5 through Y9.

Y9

Y7

250

Fig. 10-419 201309220067

1

Cut through all the cable ties on the wiring harness / valve block.

2

Pull back the wiring harness.

Rammax 1575

1

Remove hydraulic hoses (A2, B2,

PBR, T2).

Fig. 10-420 201309220072

1

Plug the fittings.

Fig. 10-421 201309220073

1

Remove the hydraulic hose (BR).

Fig. 10-422 201309220074

1

Plug the fitting.

Fig. 10-423 201309220075

Replacing the valve block

Repair 251

1

Remove hydraulic hose 018 (A3).

2

Plug the fitting.

252

Fig. 10-424 201309220076

1

Remove hydraulic hose 004 (T1).

2

Plug the fitting.

Fig. 10-425 201309220077

1

Remove hydraulic hose 037 (T3).

2

Plug the fitting.

Fig. 10-426 201309220078

1

Remove hydraulic hose 030 (A1).

2

Plug the fitting.

Fig. 10-427 201309220079

Rammax 1575

1

Fig. 10-428 201309220080

1

Fig. 10-429 201309220081

To gain access to hose screw connection

B1

(1), the magnetic coil (2) must first be pushed back.

1

Remove the knurled nut on solenoid valve Y7.

2

1

Remove round sealing ring (1).

1

Push back the magnetic coil.

Fig. 10-430 201309220082

1

Remove hydraulic hose 016 (B1).

Fig. 10-431 201309220083

Replacing the valve block

Repair 253

1

Plug the fitting.

254

Fig. 10-432 201309220085

1

Remove hydraulic hoses (A1, B3, T3).

2

Plug the fittings.

Fig. 10-433 201309220086

Fig. 10-434 201309220087

1

Remove hydraulic hoses 010 and 036

(elbow bulkhead screw connection).

2

Plug the fittings.

1

Remove the four M8 hex screws

(AF size 13).

Fig. 10-435 201309220089

Fig. 10-436 201309220090

Rammax 1575

Fig. 10-437 201309220093

1

Lift the valve block out of the chassis.

NOTE:

In our example, the drive pump was already demounted. To demount the valve block, it is not necessary to remove the drive pump.

The side panels to the right and left on the chassis can be removed.

View of the engine compartment with valve block demounted.

Fig. 10-438 201309220094

1

Before the new or tested valve block can be installed, the floor panel must be cleaned to remove hydraulic oil and dirt.

Fig. 10-439 201309220095

Replacing the valve block

Repair 255

10.19.2 Check

Brake solenoid valve

Fig. 10-440 201309210113

It is recommended that all magnetic coils and valves be checked on the demounted valve block.

1

Remove the nut on the solenoid valve.

1

Remove the solenoid.

Fig. 10-441 201309210116

Fig. 10-442 201309210114

1

Remove valve (AF size 22).

256

Fig. 10-443 201309210115

3

4

1/2

5

Disassembled solenoid valve:

●

●

●

●

●

Nut

(1)

Gasket

(2)

Solenoid

(3)

Solenoid valve

(4)

Gasket

(5)

Fig. 10-444 201309210111

Rammax 1575

Fig. 10-445 201309210112

1

Apply a voltage of 12 V to the solenoid valve.

2

The valve (arrow) must be visibly and audibly actuated.

3

Check the ring seals

(1)for damage.

1

1

Resistance of the solenoid

(4.9Ohm).

Fig. 10-446 201311150002

Solenoid valve for large / small amplitude vibration and steering.

1

Remove the nut on the solenoid valve.

2

Remove the solenoid.

Fig. 10-447 201309210118

1

Remove valve (AF size 26).

2

Place valve in magnetic coil.

Fig. 10-448 201309210119

Replacing the valve block

Repair 257

Fig. 10-449 201309210120

1

Apply a voltage of 12 V to the solenoid valve.

2

The valve must be visibly and audibly actuated.

1

Resistance of the magnetic coil for large / small amplitude vibration and steering

(4.4Ohm).

Fig. 10-450 201311150001

brake max. vibration pressure

1

The brake pressure relief valve

(AF size 22 / AF size 6) can be adjusted if necessary.

Fig. 10-451 201309210121

1

The vibration pressure relief valve

(AF size 22 / AF size 6) can be adjusted if necessary.

258

Fig. 10-452 201309210122

Rammax 1575

1

The solenoid valves can be actuated manually.

Fig. 10-453 201309210117

10.19.3 Installation

1

Place the new or tested valve block on the floor panel.

Fig. 10-454 201309220096

1

Apply blue adhesive to the M8 hex screws.

Fig. 10-455 201309220097

Fig. 10-456 201309220100

Replacing the valve block

Repair

1

Tighten the M8 hex screws

(AF size 13) to a torque of 25 Nm.

Fig. 10-457 201309220098

259

1

Install hydraulic hose 036 on the elbow bulkhead screw connection.

Fig. 10-458 201309220101

1

Install hydraulic hose 010 on the elbow bulkhead screw connection.

Fig. 10-459 201309220115

1

Install hydraulic hoses (A1, B3, T3).

Fig. 10-460 201309220104

1

Connect the plugs in back (Y5, Y8).

260

Fig. 10-461 201309220105

Rammax 1575

1

Install hydraulic hose 004 (T1).

Fig. 10-462 201309220106

Fig. 10-463 201309220107

1

Install hydraulic hoses (A2, B2, PBR).

Fig. 10-464 201309220108

Fig. 10-465 201309220110

1

Install hydraulic hose onto T-screw connection (BR).

Fig. 10-466 201309220113

1

2

To gain access to hose screw connection

B1 (1), the magnetic coil (2) must first be pushed back.

1

Remove the knurled nut.

2

Remove the O-ring.

3

Push back the magnetic coil (2).

4

Install hydraulic hose B1 (1).

Fig. 10-467 201309220111

Replacing the valve block

Repair 261

1

Fig. 10-468 201309220081

1

Push the magnetic coil back to the original position.

2

Install the O-ring

(1).

1

Install the knurled nut.

2

Tighten the magnetic coil.

Fig. 10-469 201309220116

1

Install hydraulic hose 018 (A3).

Fig. 10-470 201309220120

1

Install hydraulic hose 002 (P).

262

Fig. 10-471 201309220121

Rammax 1575

1

Install hydraulic hose 003 (T2).

Fig. 10-472 201309220122

1

Connect all the connectors at the front

(Y6, Y9, Y7).

Fig. 10-473 201309220125

Fig. 10-474 201309220067

1

Route the wiring harness with care.

2

Secure the wiring harness with cable ties.

10.20

Readying the machine for operation

After replacing components (drive pump, valve block, drive motor) for which all of the oil had to be drained, the machine must be refilled and the charge pressure must be built up once again. Siehe “Hydraulic oil replacement” see page 127.

Readying the machine for operation

Repair 263

10.21

Pendulum support

10.21.1

Removal

1

Install joint protection.

Fig. 10-475 Joint protection

Fig. 10-476 201309240011

1

Place the hydraulic jack at the center of the pendulum joint.

2

Slightly relieve the pressure on the roller.

1

Remove the two M12 hex screws

(AF size 19) for front support.

264

Fig. 10-477 201309240014

Fig. 10-478 201309240012

1

Remove the two M12 hex screws

(AF size 19) for rear support.

Fig. 10-479 201309240015

Fig. 10-480 201309240016

Rammax 1575

Fig. 10-481 201309240019

2

Remove the pendulum support.

Fig. 10-482 201309240020

Fig. 10-483 201309240032

1

The on-center dimension from one joint to the other must be recorded before disassembling the pendulum support. This dimension is required for the reassembly.

10.21.2 Replacing the joint head

1

Remove M10 securing bolt (AF size 6,

AF size 17).

2

Procedure is the same for rear and front

Fig. 10-484 201309240023

Fig. 10-485 201309240021

Pendulum support

Repair 265

Fig. 10-486 201309240027

1

Place the pendulum support under the press.

2

Use the drift pin to press out the heavyduty dowel pin.

3

Procedure is the same for rear and front.

Fig. 10-487 201309240028

Fig. 10-488 201309240029

Fig. 10-489 201309240030

266

Fig. 10-490 201309240031

1

Clamp the pendulum support in a vise.

2

Heat up the locknut and joint head to approx. 200°C (392°F).

1

Loosen the locknut.

2

Use a wrench to unscrew the joint head (AF size 46) from the rod.

3

Procedure is the same for rear and front

Fig. 10-491 201309240034

Rammax 1575

Installing a new joint head

red blue

Fig. 10-492 201309240034-2

1

Apply

red adhesive to the rear inner thread of the new joint head and the outer thread of the pendulum support.

2

Apply

blue adhesive to the front inner thread of the new joint head and to the outer thread of the pendulum support.

3

Screw the

rear joint head onto the pendulum support all the way to the stop.

4

Set the

front joint head to the dimension.

1

Adjust the pendulum support until it has the length you measured previously.

2

Counter the nuts.

Fig. 10-493 201309240037

X

1

Grease the bores of the rear and front joint heads.

Fig. 10-494 201309240039

1

Grease the dowel pins.

Pendulum support

Repair

Fig. 10-495 201309240040

267

Fig. 10-496 201309240038

1

Insert the dowel pin in such a way that the gap is on the pressure side.

2

Press in the dowel pins.

1

Secure the M10x60 countersunk Allen screw with red adhesive.

Fig. 10-497 201309240042

1

Install the M10x60 Allen bolt (AF size 6

/ AF size 17) with an M10 nut and washer.

Fig. 10-498 201309240043

10.21.3 Installation

1

Apply blue adhesive to the two

M12x160 hex screws at the

rear.

2

Apply blue adhesive to the

two

M12x65/30 hex screws at the

front.

268

Fig. 10-499 201309250001

Rammax 1575

1

Install

two M12x160 hex screws

(AF size 17) and washers

at the rear and torque to 85 Nm.

Fig. 10-500 201309250002

Fig. 10-501 201309250003

1

Install two M12x65/30 hex screws

(AF size 17) and washers at the front and torque to 85 Nm.

Fig. 10-502 201309250004

10.22

Replacing the steering cylinder

The removal of the left steering cylinder will be described in the following. The removal of the right steering cylinder is exactly the same.

10.22.1 Removing the old steering cylinder

1

Remove hydraulic hoses 017 and 018 from the hydraulic cylinder.

Fig. 10-503 201309240001

Replacing the steering cylinder

Repair

Fig. 10-504 201309250004

269

Fig. 10-505 201309240005

1

Remove the M16 (AF size 24) securing nut from the

front steering cylinder.

1

Remove the M16 (AF size 24) securing nut from the rear steering cylinder.

Fig. 10-506 201309240006

1

Remove the steering cylinder.

270

Fig. 10-507 201309240007

1

Plug the screw connections on the steering cylinder.

Fig. 10-508 201309240008

Rammax 1575

1

Plug the screw connections on hoses

017 and 018.

Fig. 10-509 201309240010

10.22.2 Install a new steering cylinder

1

1

Clean the securing bolt (remove rust as needed).

2

Install the spacer (1).

3

Grease the securing bolt.

4

Apply blue adhesive to threaded bolt.

Fig. 10-510 201309250006

1

Install a new steering cylinder.

Fig. 10-511 201309240007

Fig. 10-512 201309250009

Replacing the steering cylinder

Repair

1

2

1

Tighten the M16 nut (AF size 24)

(1) to a torque of 100 Nm.

2

Grease the front and rear grease nipples

(2).

271

1

Install hydraulic hoses 017 and 018.

Fig. 10-513 201309250014

10.23

Pendulum joint

Before the pendulum joint can be demounted, the following components must be removed:

●

●

The pendulum support (“Pendulum support” see page 264)

The steering cylinder (“Replacing the steering cylinder” see page 269)

1

Cut through the cable tie on the hose bundle.

272

Fig. 10-514 201309250016

1

Fig. 10-515 201309240057

1

Place a protective sheet (e.g. aluminum) beneath and above the hose bundle between it and the chassis.

Rammax 1575

1

Remove the M12 hex screws

(AF size 19) from the pendulum joint.

Fig. 10-516 201309240046

1

Remove the cover.

Fig. 10-517 201309240049

Fig. 10-518 201309240050

1

Remove the M16 hex screw

(AF size 24) from the bearing lock.

2

Remove the bearing lock (1).

1

Fig. 10-519 201309240051

1

Retap the thread in the chassis support.

Pendulum joint

Repair

Fig. 10-520 201309240052

273

Fig. 10-521 201309240053

1

Screw in

two M12x100 hex screws

(AF size 19).

NOTE:

If the bearing seat is rusted, use 4 screws.

1

Screw the screws in until the pendulum bearing is separated from the bearing bolt.

274

Fig. 10-522 201309240054

Fig. 10-523 2201309240055

2

1

Space limitations mean that no screws longer than M12x100 can be used.

Therefore, spacer blocks (approx.

20 mm) must be placed under the screws.

2

When the bearing has been pressed free of the bearing bolt, remove the screws.

1

Use a piece of square timber (1) to force the chassis apart at the front and rear.

2

Support the chassis at the rear using another piece of square timber (2).

1

Fig. 10-524 201309240058

Rammax 1575

Special tool for removing the joint bearing.

Fig. 10-525 201311210022

1

Place the thrust washer of the special tool under the joint bearing.

Fig. 10-526 201309240061

2

1

Fig. 10-528 201309240063

Fig. 10-527 201309240062

1

Position the upper part (1) of the special tool on the chassis support.

2

Put the M20 hex screw (2) of the special tool in place.

1

Press the bearing out of the support.

1.1

Turn the screw until the bearing is free.

Pendulum joint

Repair

Fig. 10-529 201309240064

275

1

Lift the bearing out of the support.

Fig. 10-530 201309240065

Fig. 10-531 201309240068

Dismantled clamp ring with bearing.

Fig. 10-532 201309240066

1

Place the clamp ring under the press.

Fig. 10-533 201309240069

1

Press the bearing out.

276

Fig. 10-534 201309240070

Rammax 1575

1

Clean the clamp ring.

Fig. 10-535 201309240071

2

Grease the bearing seat.

Fig. 10-536 201309240072

1

Position the new bearing.

Fig. 10-537 201309240074

1

Press the bearing into the clamp ring.

Pendulum joint

Repair

Fig. 10-538 201309240075

277

2

Clean the chassis support.

Fig. 10-539 201309240076

Fig. 10-540 201309240077

1

Grease the bearing seat.

Fig. 10-541 201309240078

2

Apply sealant to the sealing surface.

Fig. 10-542 201309240079

Fig. 10-543 201309240081

1

Draw the bearing flange into the support with M12x60 hex screws and spring washers.

278

Fig. 10-544 201309240083

Rammax 1575

1

Grease the bearing bolt.

Fig. 10-545 201309240086

1

Center the chassis relative to the bearing bolt.

Fig. 10-546 201309240087

Fig. 10-548 201309240089

Fig. 10-547 201309240088

1

Position the washer.

2

Screw the M16x100 hex screw with the nut into the bearing bolt.

1

Using the M16 (AF size 24) hex nut, pull the bearing over the bearing bolt.

2

Remove the hex screw.

Pendulum joint

Repair

Fig. 10-549 201309240090

279

1

Install retaining washer onto the screw.

2

Apply blue adhesive to the M16x30 hex screw.

Fig. 10-550 201309240091

1

1

Secure the pendulum bearing with the

M16 hex screw (AF size 24) and washer (210 Nm).

2

Remove the four mounting screws (1).

Fig. 10-551 201309240092

Fig. 10-552 201309240093

3

Apply sealant to the surface of the clamp ring.

Fig. 10-553 201309240095

Fig. 10-554 201309240096

1

Put cover in place.

280

Fig. 10-555 201309240097

Rammax 1575

Pendulum joint

Repair

1

Apply blue adhesive to the

four

M12x40 hex screws.

Fig. 10-556 201309240098

1

Install the M12x40 hex screw

(AF size 19) and torque to 85 Nm.

Fig. 10-557 201309240099

1

Remove the protective metal sheets.

2

Arrange the hose bundle and secure with cable tie.

Fig. 10-558 201309250015

281

10.24

Shutdown bar

10.24.1 Replacing the shutdown bar

1

1

Remove the Allen screws (AF size 5)

(1) on the clamp body.

2

Remove the shutdown bar from the chassis.

Fig. 10-559 201311170052

1

Remove the hex screw (AF size 8 /

AF size 17) from the right side of the shutdown bar.

Fig. 10-560 201311200001

1

Remove the stop on the right.

Fig. 10-561 201311200002

1

Remove the spring.

282

Fig. 10-562 201311200003

Rammax 1575

Fig. 10-563 201311200004

1

Remove the hex screw (AF size 8 /

AF size 17) from the left side of the shutdown bar.

1

Remove the stop on the left.

Fig. 10-564 201311200006

1

Remove the magnet.

Fig. 10-565 201311200007

1

Remove the spring.

Shutdown bar

Repair

Fig. 10-566 201311200008

283

1

Inspect the removed parts for suitability for reuse.

Fig. 10-567 201311170001

1

Apply blue adhesive to the Allen screws on the clamp body.

284

Fig. 10-568 201311170032

1

Secure the clamp body to the chassis using the M6 hex screws (AF size 5).

Fig. 10-569 201311170033

1

Push the right and left springs onto the shutdown bar.

Fig. 10-570 201311170034

Rammax 1575

1

Push the shutdown bar into the right clamp body.

Fig. 10-571 201311170035

1

Install left clamp body.

Fig. 10-572 201311170036

1

Tighten the Allen screws (AF size 5).

Fig. 10-573 201311170037

1

Insert the springs into the recesses provided for them on the left and right.

Shutdown bar

Repair

Fig. 10-574 201311170040

285

1

Insert the stop on the right.

Fig. 10-575 201311170041

Fig. 10-576 201311170045

1

Install the M10 Allen screw (AF size 8).

2

Apply blue adhesive to the Allen screw.

1

Put the washer in place.

2

Put the M10 hex nut in place.

286

Fig. 10-577 201311170048

1

1

Tighten the M10 Allen screw

(AF size 8).

1.1

Tighten the screw until the stop

(1) rests in the tube without play.

Fig. 10-578 201311170051

Rammax 1575

Shutdown bar

Repair

1

Place the magnet on the tube on the left side.

1.1

Observe the mounting orientation (see photo).

2

Insert the hex screw from below.

Fig. 10-579 201311170053

Fig. 10-580 20131117055

1

Apply blue adhesive to the Allen screw.

Fig. 10-581 201311170057

1

Tighten the M10 Allen screw

(AF size 8).

1.1

Tighten the screw until the stop

(1) rests in the tube without play.

Fig. 10-582 201311170058

287

The new shutdown bar is fully installed.

Fig. 10-583 201311170104

10.24.2 Sensor replacement and adjustment

1

Disconnect the sensor cable connector.

Fig. 10-584 201311170112

2

Remove the sensor mounting bracket

(AF size 13) under the chassis.

Fig. 10-585 201311170086

Fig. 10-586 201311170080

1

Remove the old (defective) sensor from the bracket.

288

Fig. 10-587 201311170079

Rammax 1575

1

Apply blue adhesive to the new sensor.

Fig. 10-588 201311170090

1

Check the mounted dimension

(approx. 25 mm).

Fig. 10-589 201311170094

2

Observe the mounting orientation (see the white mark on the sensor head).

2.1

Marking parallel to bracket bend.

Fig. 10-590 201311170093

Fig. 10-591 201311170080

1

Apply blue adhesive to the M8x65/22 hex screws.

Shutdown bar

Repair

Fig. 10-592 201311170082

289

Fig. 10-593 201311170083

1

Feed the sensor cable through the opening in the chassis.

2

Install the sensor mounting bracket.

1

Lightly tighten the M8x 65/22 hex screws (AF size 13).

290

Fig. 10-594 201311170086

Fig. 10-595 201311170097

1

Set the gap (approx. 3 mm) between the sensor head and the magnet.

1.1

Adjust the sensor mounting bracket accordingly for this.

1

Tighten the M8x 65/22 hex screws

(AF size 13) to a torque of 25 Nm.

Fig. 10-596 201311170086

Rammax 1575

1

Connect the sensor cable.

2

Secure connector with cable ties.

Fig. 10-597 201311170112

Perform functional check of shutdown bar, up: “Shutdown bar” indicator lamp (1) must light.

Fig. 10-598 201311210002

1

Perform functional check of shutdown bar, down: “Shutdown bar” indicator lamp (1) must not light.

Fig. 10-599 201311210001

1

10.25

Tools

Inquire with your local MQ Field Service Manager for Special Tool needs

10.25.1 Special tools

Assembly tool for drive motor

Tools

Repair

Fig. 10-600 201311210020

291

Assembly tool for vibro unit

Fig. 10-601 201311210021

Puller for pendulum joint bearing

Fig. 10-602 201311210022

Bolt for pressing in the pendulum joint bearing

Fig. 10-603 201311210024

Assembly tool for pendulum joint bearing

292

Fig. 10-604 201301150031

Rammax 1575

Pressure screws for pendulum joint bearing

Fig. 10-605 201311210025

Spacer block for pressure screws (4x)

Fig. 10-606 201311210027

Assembly drift pin for pendulum support heavy-duty dowel pin

Fig. 10-607 201311210026

Special socket for assembly of the infrared sensor.

Tools

Repair

Fig. 10-608 201311210023

293

Grooved nut wrench for vibro gearbox

Fig. 10-609 201311130011

Bracket for torque measurement instrument for vibro gearbox

Fig. 10-610 201312110001

Torque measurement instrument

Fig. 10-611 201312110002

10.25.2 Special tool for measuring speed and frequency

294

Fig. 10-612 201212130022

Rammax 1575

10.25.3 Special tool for checking solenoids

Fig. 10-613 200608300003

10.26

Plugs and stoppers

10.26.1 Vibromotor

Tab. 10-2 Plugs and stoppers for 1 vibromotor

Material

Pipe plug

End plug

Cap nut

Size

15L

15L

15L

Quantity

2

2

2

10.26.2 Vibromotor valve block maximum pressure

Tab. 10-3 Vibromotor valve block maximum pressure plugs

Material

Pipe plug

End plug

Cap nut

Pipe plug

End plug

Cap nut

Size

12L

12L

12L

15L

15L

15L

Quantity

2

2

2

1

1

1

Material number

1-901441

1-901276

1-901003

Material number

1-901441

1-901276

1-901003

1-901440

1-901275

1-901325

Plugs and stoppers

Repair 295

10.26.3 Drive motor

Tab. 10-4 Plugs and stoppers for 1 drive motor

Material

Pipe plug

End plug

Cap nut

Size

10 L

10 L

10 L

Quantity

2

2

2

10.26.4 Drive pump drive pressure test

Tab. 10-5 Plugs and stoppers for drive pump drive pressure test

Material

Pipe plug

End plug

Cap nut

Size

12L

12L

12L

Quantity

2

2

2

10.26.5 Drive pump charge pressure

Tab. 10-6 Plugs and stoppers for drive pump charge pressure

Material

Pipe plug

End plug

Cap nut

Size

12L

12L

12L

Quantity

1

1

1

10.26.6 Steering valve block maximum pressure

Tab. 10-7 Plugs and stoppers for B2, A2

Material

Pipe plug

End plug

Cap nut

Size

10 L

10 L

10 L

Quantity

2

2

2

Material number

1-901439

1-901274

1-901397

Material number

1-901440

1-901275

1-901325

Material number

1-901440

1-901275

1-901325

Material number

1-901439

1-901274

1-901397

296 Rammax 1575

11

Storage

297

11.1

Storage

11.1.1

Short-term storage

●

●

●

Move the Start/Stop lever on the infrared transmitter to the neutral position.

Secure the roller from unauthorized start-up and unintentional rolling away.

Remove the ignition key.

11.1.2

Long-term storage

Tab. 11-1 Long-term storage

Component

Diesel engine

Fuel (diesel)

Battery

Air filter unit, exhaust pipe

Steering cylinder

precautions

Observe the information in the "Long-term storage" section in the diesel engine manual.

Drain.

Uninstall the battery and clean the outside.

Charge the battery once a month during standstill time.

Cover the air filter unit or its intake opening and the exhaust pipe with adhesive tape. This prevents moisture from getting into the engine.

Lubricate the bearings of the steering knuckle and the front bearing of the steering cylinder with grease.

Lubricate the piston rod of the steering cylinder with grease guard.

Infrared transmitter Always move the “Start/Stop” switch to the Stop position.

Chapter

9.7.3

10.1

9.12

298 Rammax 1575

12

Transport

299

12.1

Transport

12.1.1

Shipping weights and dimensions

Tab. 12-1 Shipping weight and dimensions

Roller drum width - inch (mm)

Shipping weight - lbs (kg)

Dimensions: L x W x H - without shutdown bar inch

Dimensions: L x W x H - without shutdown bar (cm)

Dimensions: L x W x H - with shutdown bar inch

Dimensions: L x W x H - with shutdown bar (cm)

Rammax 1575

24 (640)

3086 (1400)

79x25x52

200x64x132

81x25x52

205x64x132

33 (850)

3196 (1450)

79x33x52

200x85x132

81x33x52

205x85x132

!

DANGER

Risk of crushing through presence in the pivoting area (danger zone)!

• The articulated joint lock (joint protection) must be fitted before lifting the roller for transport.

• Be certain that no persons are present in the area of the joint protection.

12.1.2

Transportation overseas

The machine is ready for transportation overseas when the “Environmentally Damaging” (1) and “Hazardous Goods, Class 3“ (2) labels have been applied to the machine.

2

1

Fig. 12-1 Labels for overseas transportation

300 Rammax 1575

12.1.3

Joint protection

NOTE

Blocking the joint protection

1

Release the lower part of the joint protection

(1).

1.1

First, remove the compression spring

(2) and then the lock bolt (3).

2

Carefully turn the roller steering until you can insert the joint protection into the loop on the opposite side.

3

Now steer to the left all the way to the stop.

In order to operate the steering, you must start the roller and maintain a distance of at least 2 meters.

!

DANGER

Risk of crushing through presence in the pivoting area (danger zone)!

• As soon as the roller is aligned, shut if off again.

4

Secure the joint protection with the lock bolt

(3).

5

Secure the lock bolt with the compression spring

(2).

2

1

3

Fig. 12-2 Joint protection open / joint protection locked in place

Transport

Transport 301

12.1.4

Lifting at the 1-point lifting eye

!

DANGER

Crushing hazard!

• Always lift the roller vertically.

• Do not stand under suspended loads!

• Use only anti-slip, stable ramps when loading!

• Secure the roller on transport vehicles to prevent it from rolling away, slipping to the side or tipping over!

NOTE

!

DANGER

Accident hazard due to falling load

• Before lifting, check to be sure all screws on the 1-point lifting eye are damage free and securely tightened.

The lifting devices (steel cables, etc.) must be dimensioned in accordance with relevant regulations.

1

Bring the joint protection into place.

2

Lift the roller vertically with suitable hoisting tackle.

2.1

Use suitable lifting equipment.

The 1-point lifting eye is designed for a WLL of 1.6 tons (Working Load Limit).

Fig. 12-3 1-point lifting eye

12.1.5

Securing the roller on the transporter

1

Bring the joint protection into place.

302 Rammax 1575

2

Attach the lashing straps to the lashing rings on the roller and on the truck

2.1

Lashing method: Direct lashing / diagonal lashing as shown in photo

2.2

Use a lashing strap with a permissible tensile force of LC = 2,500daN

The lashing rings on the roller are designed for a permissible tensile force of 2,500daN.

Permissible angle ranges for diagonal lashing:

●

●

15° ≤ α ≤ 65°

30° ≤ β ≤ 75°

Fig. 12-4 Lashing the roller / side view

Fig. 12-5 Lashing the roller / top view

!

CAUTION

Risk of accident through blocked steering!

• Open the joint protection before starting the roller.

12.1.6

Center of gravity

The center of gravity relevant to transport is located 460mm from the floor and approx. in the center of the roller, depending on the fill level of the diesel or water tanks.

Transport

Transport 303

Fig. 12-6 Roller's center of gravity

304 Rammax 1575

13

Disposal

305

13.1

Introduction

!

CAUTION

Environmental hazard through operating materials!

• Do not allow any liquids to enter drains, the soil or the environment.

The roller must be disposed of properly; ask your authorized dealer.

13.2

Removal and depressurization of the gas strut

!

WARNING

Eye injury!

Because of the high internal pressure, chips and oil can spatter from the site of sawing or drilling.

• Wear eye and face protection.

• Cover the site of the saw cut.

!

CAUTION

Environmental hazard through operating materials!

Gas struts are filled with oil.

• Do not allow any liquids to enter drains, the soil or the environment.

In case of disposal, pressurized gas struts must be depressurized according to the following regulations:

1

Fasten the pressurized tube between two prismatic jaws without deforming it and in such a way that the dimension X is at least 25 mm (see below).

2

To depressurize:

2a Slowly cut the pressurized tube open at the points indicated using a handsaw or,

2b Drill a hole in the tube using a drill with about a 3mm diameter.

306 Rammax 1575

1. Saw cut / drilled hole

X

2. Saw cut / drilled hole

Piston rod

Pressurized tube about 20

Bottom

Fig. 13-1 Removal and depressurization of the gas strut

NOTE

1. saw cut / hole position: Cut or drill into the pressurized tube about 20 mm from the bottom.

2. saw cut / hole position: Cut or drill into the pressurized tube in the bead.

If disposal according to these regulations is not possible, ask your authorized dealer.

Removal and depressurization of the gas strut

Disposal 307

Corporate Headquarters • Multiquip Inc. 18910 Wilmington Ave. Carson, Ca. 90746