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Operating manual
AV 70 X
Cummins
Book ID: 4-P06406CU -EN
AV 70 X
Articulated tandem roller
Cummins Tier 3
Operating manual
Edition 09/2010 EN
From Serial No.
4062001
Translation of Original Operating Manual
AV 70 X
Articulated tandem roller
Cummins Tier 3
Operating manual
Edition 06/2011 EN
From Serial No.
4062005
Translation of Original Operating Manual
Místo a datum vydání / Place and date of issue / Ort und Datum der
Ausgabe:
Congratulations on your purchase of an AMMANN road roller. This modern compaction device is characterised by simple operation and maintenance and is the product of many years of AMMANN experience in the field of road roller engineering. In order to avoid faults due to improper operation and maintenance we request that you read this operating manual with great care and keep it for later reference.
With kind regards,
Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují
%
+ 420 491 476 111 | Fax + 420 491 470 215 | [email protected] | www.ammann-group.com
406001
This manual consists of:
I. Specification manual II. Operating instructions III. Maintenance manual
The following explanations serve to familiarise the machinist (operator) with the roller and to support him during handling and maintenance. It is therefore absolutely necessary to provide the operator with these instructions and to ensure that he reads them carefully before using the road roller. This aids training comprehension during the first use of the road roller.
Subsequent faults due to improper operating are avoided.
Adherence to maintenance instructions increases the reliability and lifetime of the machinery. It reduces repair costs and down time.
AMMANN accepts no liability for continued safe functioning of the road roller if it is incorrectly operated and / or operating modes are employed which represent improper use.
Spare parts must meet AMMANN technical specifications. These requirements are fulfilled if only original AMMANN spare parts are used.
These instructions must always be kept available on the equipment.
AV 70 X 1
Preface
Information, specifications, and recommended operation and maintenance instructions contained in this publication are basic and final information at the time of the printing of this publication. Printer’s errors, technical modifications, and modifications of figures are reserved. All dimensions and weights are approximate and, therefore, not binding.
Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to inform the machine user. If you identify any differences between the machine operated by you and the information contained in this publication, contact your local dealer.
Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic a.s.
2 AV 70 X
SYMBOLS OF THE SAFETY NOTICES:
The notice warns of a serious risk of personal injury or other personal hazards.
The notice warns of possible damages to the machine or its parts.
The notice warns of the necessity of environmental protection.
! WARNING !
As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indicate the sides of the machine moving forward.
FRONT
LEFT RIGHT
REAR
AV 70 X
400101en
3
Content
4 AV 70 X
OPERATING MANUAL
AV 70 X 5
6
Content
AV 70 X
OPERATING MANUAL
AV 70 X 7
8 AV 70 X
SPECIFICATION MANUAL
1. SPECIFICATION MANUAL
AV 70 X
(Cummins Tier 3)
AV 70 X 9
1.1. Basic specification
Machine description
Tandem roller with an articulated frame with two smooth steel driven vibrating drums. Steering using the articulated frame enables the setting of extended track (crabbing).
Machine application
The AV 70 X vibratory rollers are intended for medium and largesized compaction works in transport construction (roads and motorways and airfields) and building construction (industrial zones, etc.).
The rollers are suitable for compacting the asphalt mixtures up to a layer thickness (after compaction) of 140 mm (5.5 in), hydraulically consolidated mixtures up to a layer thickness of
200 mm (7.9 in), mixed soils up to a layer thickness of 270 mm
(10.6 in), and sand and gravel materials up to a layer thickness of 370 mm (14.6 in).
The rollers are not suitable for the compaction of rockfill and loam and clay materials.
The rollers are intended for the operation under conditions according to ČSN IEC 721-2-1 (038900): WT, WDr, MWDr (i.e. a moderate climate zone, warm dry or hot dry zone with a limited ambient temperature range from -7 °C (19.4 °F) to +45 °C (113 °F).
The standard type of the machine is not intended for road traffic. For more information, please contact your dealer.
Please fill in the following data:
(see Pin label, Label of the CUMMINS engine)
Type of machine
................................................................................................................
ICV/PIN (Serial number of the machine)
................................................................................................................
Production year
................................................................................................................
Type of engine
................................................................................................................
Serial number of the engine
................................................................................................................
The data mentioned in the table refer always when you contact the dealer or manufacturer.
The machine that complies with the requirements as to health protection and safety is identified with a name plate with CE marking.
1 - Name - always mentioned only in the English version
2 - Type
3 - Version
4 - Serial number
5 - Operating weight
6 - Maximum weight
7 - Rated power
8 - Front axle load
9 - Rear axle load
10 - Year of manufacture
1
2
4
5
6
7
3487
AMMANN CZECH REPUBLIC a.s.
549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145
CZECH REPUBLIC
DESIGNATION
TYPE VERSION
SERIAL NUMBER
OPERATING MASS
MAXIMUM MASS
NOMINAL POWER kg kg
FRONT AX LE LOAD
REAR AXLE LOAD kW
YEAR OF CONSTRUCTION
MADE IN CZECH REPUBLIC kg kg
3
8
9
10
3487
10 AV 70 X
Placing of the production label
1 - Production label
2 - Machine’s production number
3 - Label of the ROPS cabin
Cummins engine serial number
1
SPECIFICATION MANUAL
2
3
400102
400103
AV 70 X 11
1.2. Machine dimension scheme
D
S
A
L
S
406002
12 mm in mm in
A
3260
128,4
L
4410
173,6
D
1150
45,3
O
45
1,8
H1
3005
118,3
S
15
0,6
H2
2300
90,6
W1
1450
57,1
H3
965
38
W2
1550
61
H4
240
9,4
W3
180
7,1
AV 70 X
W1
W2
O
SPECIFICATION MANUAL
AV 70 X
406003
13
1.3. Technical data
1.3.1. Weights
Working weight with the cab ROPS according to EN 500 - 1 front drum rear drum kg (lb) kg (lb) kg (lb)
7360 (16226)
3750 (8267)
3610 (7959)
The service weight of the machine according to EN 500-1 is the machine weight with the full content of working liquids, half content of propellants, half content of sprinkling tanks and with an operator (75kg/165lb).
The machine weight according to ISO 6016 is the weight with full content of propellants, lubricants, sprinkling tanks and an operator
(75kg/165 lb). It is calculated by adding 350 kg (772 lb).
The weight data can differ from above mentioned data according to the further customers’ requirements for the machine’s equipment and accessories.
The maximum permissible weight of theAV 70 X machine including equipment and accessories is 9100 kg (20062 lb).
1.3.2. Driving properties
Drive type
Drive
Turning radius outer (contour)
Turning radius outer (edge)
Travelling speed in both directions - Speed 2000
Travelling speed in both directions - Speed 2200
Theoretical machine’s gradeability
Side static stability - straight frame
1.3.3. Drive
Steering type
Steering control
Linear hydraulic motors
Swing of frames in vertical plane
Turning of both frames in horizontal plane mm (in) mm (in) km/h (MPH) km/h (MPH)
%
% hydrostatic front and rear
6410 (252,4)
4600 (181,1)
10,6 (6,6)
11,4 (7,1)
40
62,5 articulated joint hydraulic
2 + 1 (Crab)
±°
±°
8
34
1.3.4. Engine
Manufacturer
Engine type
Number of cylinders
Stroke volume
Engine output due to ISO 3046/1
Nominal revolutions - CE
Nominal revolutions
Maximum torsional moment
Fuel consumption during common operation/hour*
Engine fulfills requirements of
* - according to ACZ methodology
14 cm3 (cu in) kW (HP) min -1 (RPM) min -1 (RPM)
Nm (ft lb) l (gal US)
Cummins
BTAA 3,3 - C80
4
3260 (198,9)
60 (80)
2000
2200
304 (224) max. 10 (2,6)
Directive 97/68/EU, STAGE III A
EPA/CARB NON ROAD 40 CFR, PART 89
TIER 3
AV 70 X
1.3.5. Brakes
Working brake
Parking and emergency brake
1.3.6. The vibrations
Drive type
Small frequency CE
Big frequency CE
Small frequency
Big frequency
Small amplitude
Big amplitude
1.3.7. Sprinkling
Sprinkling
Number of pumps
Number of filtration stages
1.3.8. Fluid capacities
Engine (oil fill)
Cooling system
Fuel
Hydraulic tank
Drum vibrator
Watering tank
Sprinkling tank
Drum drive gearbox
1.3.9. Electrical installation
Electric set voltage
Accumulator – capacity
AV 70 X
SPECIFICATION MANUAL hydrostatic mechanical lamella
Hz (VPM)
Hz (VPM)
Hz (VPM)
Hz (VPM) mm (in) mm (in) hydrostatic
43 (2580)
52 (3120)
48 (2880)
62 (3720)
0,35 (0,012)
0,6 (0,023 pressure
2
3 l (gal US) l (gal US) l (gal US) l (gal US) l (gal US) l (gal US) l (gal US) l (gal US)
7 (1,85)
15 (3,96)
110 (29,05)
40 (10,56)
2x10 (2x2,64)
600 (158,5)
2,75 (0,72)
2x1,4 (0,37)
V
Ah
12
100
15
1.3. Technical data
1.3.10. Noise and vibration emissions
Machine with cab:
Declared value of acoustic pressure A at the operator’s working place:
(According to EN 500-4+A1 and EN ISO 11201)
Guaranteed sound power level A (for the machines with “CE” marking):
(According to 2000/14/EC and EN ISO 3744)
Highest weighted effective value of acceleration of vibrations transmitted to the whole body:
(According to EN 1032+A1 - gravel)
Total value of vibrations transmitted to hands (vector sum):
(According to EN 1032+A1 - gravel)
1.3.11. Optional equipment
Tier II engine - non CE - limited quantity
Air-conditioning
Installations for radio (antenna, 2 loudspeakers) (only a cab version)
Radio with CD
Reversing alarm
Beacon
Additional working headlights
Adjustable scrapers
Cutter/final compaction device
Fire extinguisher
Ammann set of tools
Biologically degradable oil
Different colour design (Ammann scheme), max. 2 different colours
Special colour design
Filters for the first 500 Mh
Additional documentation
L pAd
= 80 dB
L
WA
= 106 dB
a wmax
< 0.5 m.s
-2 a hv
= 2,7 + 0,6 m.s
-2
16 AV 70 X
Notes
SPECIFICATION MANUAL
AV 70 X 17
18 AV 70 X
OPERATION MANUAL
2. OPERATION MANUAL
AV 70 X
(Cummins Tier 3)
AV 70 X 19
20 AV 70 X
2.1. Major Safety Precautions
2.1.1. Safety Measures during Machine
Operation
Safety measures given in the individual chapters of Enginering
Documentation supplied with the Machine shall be added with
Safety Precautions in force within a respective country that uses the Machine at workplace with regard to work organization, work process and personnel involved.
2.1.1.1. Compaction Work Commencement
•
•
•
-
-
-
-
Constructional Supplier (Machine User) is liable to issue instructions for driver and maintenance before compaction work is started, that will include requirements on work safety provision during Machine operation.
He must verify and mark:
utility lines underground areas (direction, depth) seepage or escape of hazardous materials soil bearing capacity, slope of travelling plane other obstractions incl. their removal.
He must make Machine driver, who will carry out earth work, familiar with these conditions.
He must specify Code of Practice (C.O.P.) part of which is work procedure for a given work operation and this work procedure will specify inter alia:
measures when working under extraordinary conditions (work within protective zones, within extreme slopes, etc.)
-
precautions for any natural disaster hazards requirements on work performance while observing job safety principles
technical and organizational measures to secure safety of personnel, workplace and environment.
He must make Machine driver evidently familiar with the
Code of Practice.
OPERATION MANUAL
2.1.1.2. Work Safety Secured by User
•
•
User shall promptly communicate any damage to the utility lines to their operator, and at same time he make measures to prevent unauthorized persons from entering endangered area.
He must ensure an employee does not work alone at a workplace. Another worker must always be in sight and within an ear-shot, who in case of accident will provide or call for help unless another effective form of monitoring or communication exists.
AV 70 X 21
2.1. Major Safety Precautions
2.1.1.3 Ensurance of safety measures by the owner
•
•
•
•
•
•
•
•
•
User shall provide for the Machine to be operated merely under those conditions and only for those purposes it is technically capable for under conditions set by manufacturer and respective standards.
He must make sure the use of the Roller (Compacter) is used merely in such a way and at such workplaces where there is no hazard of making damage within nearby facilities, etc.
He shall provide for regular inspection of operation, technical condition, regular machine maintenance in cycles per the Lubrication and Maintenance Manual. In cases of failing technical condition of the Machine to such an extent it poses hazard to safety of operation, persons, property or causes damage or impairs the environment, then the Machine must be put out of operation until a defect is repaired.
He must specify who and what tasks may carry out under operation, maintenance or repair of the Machine.
Any who drives the Machine (driver) and anybody who performs Machine maintenance or repairs must get familiar with the guidelines given in the Machine Operation Manual.
He shall provide for fire extinguisher to undergo regular inspections.
He must ensure the “Machine Operation Manual” and Operation Logbook are stowed at certain place inside seat box so always available to the driver.
He shall furnish constant supervision by an appointed person during Machine operation under traffic on public roads, and he will in particular be liable to release instructions on securing the work safety.
He must secure the removal of hazardous materials (fuel, oil, cooling liquid, brake fluid, etc.) from where these are spilled depending on their nature so as to avoid their adverse impact against environment, operation safety and persons’ health.
2.1.1.4. ROPS Cab
• The ROPS cab must not be deformed and must not show signs of corrosion, cracks or breaks. It must be fixedly connected to the machine frame. No additional adjustments of the cab may be performed without approval of the manufacturer as such adjustments can cause a reduction in its strength. The screwed connections must comply with the specification and must be tightened to the specified torque, must be neither damaged nor deformed, and must not show signs of corrosion.
22 AV 70 X
2.1.2. Reguirements on Driver’s Qualification
•
•
•
•
•
•
•
Only a driver trained under ISO 7130 and other local and national regulations designed for drivers of this group of machines may operate the Roller (Compacter).
With no licence only the one who learns driving the Machine for the purpose of getting preliminary practice with the approval of User may drive the Machine, and such person has to be under direct and continuous surveillance of professional teacher or trainer.
Licence holder is liable to take due care of the licence, and when requested, put it forward to the control authorities.
Licence holder can make no registrations, changes or corrections in the licence card.
He/she is liable to promptly report his/her licence loss to the authority that issued this licence.
Driving the Roller alone may be performed by an employee mentally and physically fit, over 18 years old, who is: a) assigned by machine manufacturer for the assembly, testing and presentation of the Machine, for training the drivers, whereas he/she must be made familiar with safety work regulations in force at the workplace or b) assigned by Constructional Supplier to operate (carry out maintenance) and is evidently trained and acquainted with, or owns professional competence to operate and drive under special regulations (machinist licence, etc.).
Machine driver must undergo training and examination concerning work safety regulations at least 1x every 2 years.
OPERATION MANUAL
2.1.3. Driver’s Liabilities
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Before starting to operate the Machine the driver will be liable to get familiar with the guidelines given in the documentation delivered with the Machine, with safety precautions in particular, and observe these thoroughly. This applies as well to the personnel in charge of maintenance, adjustments and repairs of the Machine.
Do not drive the Roller unless made familiar with all the Machine functions, working and operating elements, and unless knowing exactly how to control the Machine.
Follow safety signs located on the Machine, and keep them in legible condition. Replace or add those impaired or missing ones.
Before work commencement the driver must get familiar with the workplace environment, i.e. with the slopes, utility line system, with necessary types of workplace protections with regard to the environment (noise, etc.).
When finding out any health hazard, life hazard to persons, hazard to property, failures, during hardware accidents, or when finding symptoms of such hazards during operation, the driver must, unless able to remove such hazard by himself/herself, stop his/her work and secure the Machine against undesired starting, communicate this to a person accountable, and depending on chances, notify all the persons exposed to such hazard.
Before Machine operation startup the driver will be liable to get familiar with the records and operation deviations found out in course of the previous work shift.
When you find out any hazard to health or life of persons, property hazard, failure, or upon technology equipment accident, or when finding any symptoms of such hazards in course of operation, then the driver, unless able to eliminate such hazard by himself/herself, must stop the work and secure the machine against any undesirable start; please attach “MACHINE REPAIR” [OPRAVA STROJE] warning sign onto steering wheel as depicted in Section called “Safety signs used on the machine“, report this to the person in charge, and if possible, notify all persons exposed to such danger.
During work with the Machine the driver must be fastened with the seat belt. The seat belt and its mounting shall not be damaged!
When driver finds any defect during operation he/she must immediately stop the Machine, secure it safely against undesired ignition.
During operation the driver shall follow the Machine run and record any defects found in the Operation Logbook.
Driver shall keep his/her Operation Logbook designed to maintain records about Machine handover between the drivers, about the defects or repairs in course of operation, to write down major events during work shift.
Prior turning on the engine the controls have to be in their zero position, no persons may stay within dangerous reach of the Machine.
Indicate each Machine startup via an acoustic or light signal and this always before igniting the Machine engine.
Confirm brake function and steering function before starting to run the Machine.
AV 70 X 23
2.1. Major Safety Precautions
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Following the alarm an operator may start the Machine only when all the workers have left the danger area. At close
(blind) workplaces it will be possible to start the operation only after a time necessary to leave danger area has elapsed.
During Machine operation observe safety regulations, make no action that might endanger work safety, give full attention to Machine steering.
Respect Code of Practice or instructions of a person responsible.
When rolling (traversing) the Machine within a workplace adapt your speed to a terrain condition, to a work performed and weather conditions. Watch permanently the clearance so to avoid collision with any obstruction.
Upon completion or stop of the Machine operation during which driver leaves the Machine, he/she must make measures against unauthorized use of the Machine or against spontaneous starting the engine. Remove key from the ignition box, disconnect the wiring via disconnector, lock the cabin, engine bonnet.
When shutting down the Machine on roads the measures under regulations effective on roads shall be taken.
When operation is completed, park the Machine at a proper parking place (flat, bearing area) so as not to endanger Machine stability, not to make the Machine interfere with traffic roads, not to expose the Machine to falling objects (rock), and where the Machine is safe against any natural disaster of other kind (floods, landslides, etc.).
In the event that the machine has no cab or when the windows are open, the operator must wear ear protectors.
When working with the Machine is ended all the defects, damage to the Machine and any repairs made shall be written down in the Operation Logbook. Upon immediate changing of drivers the driver will be liable to call attention of changing driver to any facts identified.
Driver shall use personal protective equipment (PPE) – work clothing, safety shoes, the clothing shall not be too loose, impaired, hair protected with proper head piece. During maintenance (lubrication, refilling, replacement of working media) your hands must be protected with proper gloves.
Use proper muffs when using Machine with no cabin or with open windows.
Driver shall maintain the Machine equipped with fittings and outfit required.
Maintain the Machine free of oil dirt or flammable materials.
Keep the drive’s stand, foot rests and runner areas clean.
-
-
When the Machine comes into contact with high voltage observe the following principles: try to leave with the Machine a hazardous zone do not leave driver’s stand
give warning to others to keep off and not touch the
Machine.
To keep the machine free of oil contaminants and inflammable materials.
24 AV 70 X
2.1.4. Banned Operations
OPERATION MANUAL
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Put into operation and use the machine when some of its safeguarding device (emergency brake, driving brake, horn, etc.) Has been dismantled or damaged.
To roll and compact at such slopes where machine stability would be disrupted (turning over). Machine’s static stability stated will lower by drive’s dynamic effects.
To roll and compact at such angles of slopes where hazard of soil breaking off (dropping) under the machine exists, or loss of adhesion followed by uncontrolled slip might occur.
To control the machine in some other way than stated in driving manual.
To roll and compact per bearing capacity of subsoil at such a distance from the edge of slope or trenches, where hazard of landslide or shoulder breaking off (dropping) together with the machine would occur.
To roll and compact with vibration at such a distance from the walls, cuts, slopes, where their slip (slide) would happen and the machine covered in.
To compact with vibration at such a distance from buildings or facilities and equipment within which the risk of them being damaged due to vibration transfer impact, would occur.
To operate the machine unless driver control stand fixed properly.
To operate the machine when engine bay cover is open.
To move and transport persons on the machine.
To operate the machine when within hazardous reach thereof are other machines or transportation means aside from those that operate in mutual concert with the machine.
To operate the machine at places impossible to see from driver’s stand, and where hazard to people or property could occur unless work safety has been secured through some other way like for instance via signalling by duly instructed person.
To work with the machine at a protected zone of electric lines or substations.
To cross electric cables if these are not properly protectedli against mechanical damage.
To operate the machine under lowered visibility or at night, unless machine’s working area and workplace are illuminated sufficiently.
To leave driver’s cockpit of the machine when the machine is running.
Boarding or or getting off while on the run, jumping off the machine.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Sit or stand on the outside parts of the machine when driving, or stand on the steps.
Leave unsecured machine – move away from the machine without having prevented its misuse.
Disable safeguarding, protective or locking systems or alter their parameters.
Use the machine with oil, fuel, cooling liquid or other fillings leaking.
Start the engine through some other way than given in the driving manual.
Locate some other items (tools, accessories) aside from personal needs at driver’s stand.
Lay away material or other objects on the machine.
Remove dirt while the machine is running.
Perform maintenance, cleaning or repairs with the machine not secured against spontaneous move or accidental start, and when contact of a person with moving parts of the machine is not excluded.
Contact of moving parts of the machine with human body or objects and tools held in hands.
Smoke or handle open fire when checking or pumping fuels, refilling oils, lubricating the machine, or inspecting the accumulator or making up the accumulator.
Carry rags soaked with flammable materials, or carry flammable liquids in free vessels on the machine (in engine bay).
Let the engine run inside confined spaces.
Drive with open doors.
Perform any adjustments on the machine without the prior consent of the manufacturer.
Drive without the seat belt fastened.
Shift electrical conductors.
Use other than original spare parts.
Interfere in the electrical and electronic units in any manner.
AV 70 X 25
2.1. Major Safety Precautions
2.1.5. Safety inscriptions and signs used on the Machine
20
19
5
22
17
A
B
18
4
6
10
9
11
D
19
20
C
21
4
8
21
26
13 1
23
20
19
A
14
3
16
E
4
5
24
19
20
21
B
4
2
C
5
D
21
15
7
E
12
406004
AV 70 X
1. Read Operation Manual!
2. Handbook
3. Fasten your seat belt!
4. Clamping hazard
5. Danger area
6. Adjust while at rest
AV 70 X
2939
OPERATION MANUAL
Get perfectly well familiar with the Machine operation and its maintenance per the Operation Manual! (Symbols located on the LH side of the control console )
2702bz
The Operation Manual stowage box. (symbol located at the rear on the stowage box at the seat)
2428bz
2939
2941bz
2687bz
Fasten your seat belt before driving! (symbol located on the left on the control panel)
Maintain safe distance from the Machine, danger of being clamped by the Machine in between the front and rear frame. (symbols located on the left and right near steering joint)
Keep a safe distance! (Symbol located on the rear rail, on the left and on the right on the front frame)
2939
2942bz
Adjust and maintain with the engine stopped. (symbol located on the left, on the rear frame )
2939
2584bz
27
2.1. Major Safety Precautions
7. Risk of injury
8. Risk of burn
2586
3322bz
Maintain safe distance. (symbol located on the fan cover)
Do not touch Machine’s hot parts unless you make certain these have cooled down sufficiently. (symbol located on the LH side of the rear frame overhead exhaust pipe )
2586bz
9. Bonnet lifting – adjust at rest Lift the bonnet with the engine switched OFF. (Symbol located on the disconnector door)
10. Bonnet lifting
11. Bonnet locking
12. Danger of explosion
2939
3292bz
Pump to lift the bonnet. (Symbol located on the left, on the rear frame near door)
3445
3445
Lock the bonnet. (symbol located on the left, on the rear frame)
2939
3326bz
3017bz
Read the Operation Manual before any maintenance of the battery, or before starting via the jump cables. (Symbol located on the inner side of the battery door)
28 AV 70 X
13. Disconnect wiring
14. Electric apparatuses
15. Cooling liquid
16. Cooling liquid
17. Machine’s max height
18. Noise emitted
AV 70 X
OPERATION MANUAL
Before welding, please disconnect wiring, alternator, Machine’s electronics, and engine control unit. (symbol located on the LH side of the control panel)
2668bz
Cover electric apparatuses when washing the Machine.
(symbol located on the LH side of control panel )
2225bz
2939
3227bz
3323bz
Cooling liquid is deleterious. Scald hazard during its exchange. Read Operation Manual! (symbol located on the cooling liquid tank)
Danger of scalding. Do not open the expansion tank lid until the liquid cools down below 50 °C (122 °F). (Symbol located on the inner side of the bonnet door)
10ft/3,05m
3207
Caution when passing locations with height limit. (symbol located on the left beneath the cabin, on the Machine frame)
106
L
WA dB
3191bz
3191
Machine’s external noise. (symbol located on the LH side of the front frame)
29
2.1. Major Safety Precautions
19. Sling points
2153bz
20. Sling points
3048bz
21. Supporting point
22. Lifting diagram
23. Hearing protectors
24 . Danger zone.
Sling the Machine in these points only. (Symbols located on both sides of frames)
Sling the Machine in these points only. (symbols located along both sides of the frame)
3208bz
Lmin = 5m
2x min 2100 kg
(2x min 4650 lb)
8400 kg
(18 600 lb)
Lmin = 5 m
2x min 2100 kg
(2x min 4650lb)
3325
3325bz
Use rigging of sufficient loading capacity to lift the Machine. Secure the Machine’s joint before lifting. (symbol located on the left, on the front frame)
If there is no cab on the machine or you are working with the windows open, use hearing protectors (the symbol located on the left side of the control panel).
2408bz
Locate hand jack or fixed support of the Machine here.
(symbol located on the front and rear frame along both sides)
Keep a safe distance from the cutter and final compaction device, if in operation. (Symbol located on the front right yoke – optional equipment)
2939
3352bz
25. Machine repair
2775
Do NOT start the engine! Hang the sign onto steering wheel. The sign is supplied together with machine accessories and should be kept in documentation locker.
2775bz
30 AV 70 X
2.1.6. Hand Signals
Signals given by Machine assistant operator unless driver visually contains the rolling space or working space or working equipment, tool.
Signals for general commands
Stop
One arm erected with open palm in the direction of the driver, second arm akimbo.
Attention
Both arms sideways raised horizontally – palms forward.
STOP
OPERATION MANUAL
Sig. 1
Attention, Danger
Swinging motion of both of the arms with antebrachium from the position of arms sideways raised horizontally to the position of arms sideways raised – arms bending across and back.
SIGNALS FOR DRIVE
Departure with the Machine
One arm erected – bent with open palm, long motion of antebrachium in the direction of required motion, second arm akimbo.
!
!
Sig. 2
Sig. 3
Sig. 4
31 AV 70 X
2.1. Major Safety Precautions
Low-speed cruising forward – towards me
Both arms erected abreast bending across, with palms towards the body – short swinging movements of antebrachium towards the body and backward.
Low-speed cruising backward – away from me
Both arms erected abreast bending across, with palms away from the body - short swinging movements of antebrachium away from the body and back.
Driving to the right
Left arm sideways raised, right arm akimbo.
Driving to the left
Right arm sideways raised, left arm akimbo.
32
Sig. 5
Sig. 6
Sig. 7
Sig. 8
AV 70 X
Short motion
Both arms lifted forward bending across. Mark the „X“ distance between palms, then the motion signal follows.
OPERATION MANUAL
X
Sig. 9
Engine start
Circular motion of right hand’s antebrachium, with the fist closed.
Sig. 10
Engine cut off
Oscillating motion of right hand sideways raised in front of the body to the sides.
Sig. 11
AV 70 X 33
34 AV 70 X
2.2. Ecological & Hygienic Principles
2.2.1. Hygienic Principles 2.2.2. Ecological Principles
When operating and storaging the machines a User will be liable to observe general principles of health and environmental protection, laws and regulations that relate to the given issue and are in force within a territory where the
Machine is used.
-
-
-
Accumulator fillings and the accumulators themselves,
Cleaning & preservation agents,
All filters and filter elements dismantled,
All used and discarded hydraulic hoses or fuel hoses, metal rubbers and other Machine’s elements, foulded with the abovementioned products.
•
•
•
-
Skin protection when handling oil products, painting materials or cooling liquids
Washing your hands properly upon work completion or before meals, apply a proper reparation cream on your hands
When handling cooling systems, please follow the instructions given in the Manuals supplied with the Machine.
Always maintain oil products, cooling system and accumulator fillings and painting materials incl. organic thinners and also the cleaning and preserving agents in their original properly designated packages. Do not allow storage of these materials in undesignaged bottles or other vessels due to the hazard of them being interchanged. Especially hazardous is the possibility of interchanging them with eatables or drinks.
Upon skin, mucosa, eye contacts or inhalation of vapour, immediately apply the principles of first aid. Upon accidental use of these products get prompt medical attention.
When operating the Machine with no cabin provided, or with cabin windows opened, always use ear defenders
(muffs) of proper type and version.
Accumulators
Handle the given materials and parts following their disposal in line with the respective national regulations on protection of individual components of environment, and in conformity with health regulations.
AV 70 X 35
2.3. Preservation and storing of machines
2.3.1. Short-term preservation and storage for a period of 1 – 2 months
2.3.2. Machine Preservation & Storage for the
Period Over 2 Months Long
•
•
•
•
•
•
Repair those spots with damaged paint,
Lubricate all lubricating points, control cables, joints of the controls, etc.,
Confirm water fillings are drained,
Check that cooling liquid has antifreezing characteristics requiered,
Check the state of accumulator charges, recharge them if necessary,
Apply preservative grease over the chormed surfaces of piston rods,
•
•
•
•
•
Protect the headlamps, external back mirrors and other elements of external wiring through spraying a special agent and wrapping into PE foil,
Preserve the engine per Manufacturer’s Instruction Manual
– mark visibly the engine has been preserved.
After 6 months we recommend to inspect the condition of preservation and renew if required.
NEVER start the engine in course of storage!
In case of Machine storage under field conditions, please check the parking place whether not exposed to the hazard of flooding, and that danger of any other type is not present!
Prior to restoration of Machine operation, please wash the preservation agents away with the use of high pressure stream of hot water incl. addition of normal degreasers while observing the
Instructions for Use along with ecological principles.
Carry out the dewaxing (deconservation) and washing of the Machine at places equipped with intercepting sumps to trap the rinsing water as well as dewaxing agents.
36 AV 70 X
2.3.3. Dewaxing and inspection of the supplied machine
•
•
Check the machine against delivery documentation.
Check whether any parts were damaged during transport or are missing. Inform the shipper of any discrepancies.
Before starting operations again, wash off conservation ith highpressured hot water with ordinary degreasing means added as directed, while observing environmental rules.
Remove conservation and wash the machine in places with catch basins available to collect rinse water and chemicals.
OPERATION MANUAL
AV 70 X 37
2.4. Machine Disposal Following Its Life Termination
During Machine disposal following its service life the User will be liable to follow national waste and environmental regulations and acts. We recommend to always contact in these cases:
• the specialized companies with respective authorization to deal professionally with these operations,
• the Machine manufacturer or manufacturer-appointed accredited contracting service organizations put in charge by manufacturer.
In no event shall Manufacturer be liable for damage to User health or environmental damage that arises from non-observance of the abovementioned note.
38 AV 70 X
2.5. Machine Description OPERATION MANUAL
21
3
14
12
20
13
9
15
5
21
1
10
2
17
18
11
6
7
19 21
8
16
20
21
4
400625
1 - Front frame
2 - Rear frame
3 - Front drum
4 - Rear drum
5 - Engine
6 - Drum travel hydroelectric generator
7 - Drum vibration hydroelectric generator
8 - Travel hydraulic motor
9 - Vibration hydraulic motor
10 - Steering joint
11 - Hydraulics tank
12 - Fuel tank
13 - Sprinkling tank
14 - Cabin with integrated ROPS
15 - Driver’s control stand
16 - Battery
17 - Combined engine and hydraulic oil cooler
18 - Air filter
19 - Exhaust pipe
20 - Sprinkling jets
21 - Drum scrapers
AV 70 X 39
2.6. Controls & Dashboard Instruments
8
9
10
25
17
1
6 5
7
31
24
26
30
12
28
27
23
22 21 20
19
11
16
1
MAN
2
AUT
0
14 15
0 kg
18
13
29
6
5
7
1
2
3
4
32
40
400272
AV 70 X
OPERATION MANUAL
Dashboard and control panels
1 – Travel controls
2 – Speed potentiometer
3 – Pushbutton for mode of soft starting to move and stopping to move
4 – CRAB mode resetting switch
5 – Pushbuttons for CRAB mode – front drum, to the right*
6 – CRAB pushbuttons – front drum, to the left*
7 – Vibration pushbuttons
8 – Emergency brake pushbutton
9 – Sprinkling pushbutton
10 – Sprinkling interval potentiometer
11 – Sprinkling pumps selector switch
12 – Ignition box
13 – Accelerator control
14 – Front / both / rear vibration selector switch
15 – Vibration amplitude selector switch
16 – Vibration mode selection switch (MAN/AUT)
17 – Combined switch
18 – Switch for constant speed and protection against engine overload
19 – Beacon switch (optional)
20 – Alarm lights switch
21 – Additional lights switch (optional)
22 - Switch + indicator lamp for rear lights
23 – lndicator lamps for lights (dipped/distance)
24 – Infrathermometer (optional)
25 – LH cluster
26 – RH cluster
27 – Cut-out box
28 – Cabin fuse
29 – Diagnostics socket
30 – Mounting socket
31 – Steering wheel position adjustment
32 – Operator seat
* If the Machine is equipped with cutter and final compactor then pushbuttons (5) and (6) on the travel control (1) are used to control it, and this on the same side where it has been mounted (optional).
AV 70 X 41
2.6. Machine basic functions control
25
1
6 5
7
8
9
26
0
0 kg
1
MAN
2
AUT
7
6
5
1
2
3
4
1
0 N
42
400272A
AV 70 X
3317
Travel controls (1)
3317
These controls are used to adjust travel direction and speed.
Travel speed depends on the degree of swing of travel controls from zero position (0), in dependence on speed potentiometer
(2) adjustment.
Travel controls have two positions, i.e. “N” and “0”:
“N” - neutral
- in this position the Machine parking brake is enabled.
“0” - zero position
- the Machine is not braked in this position.
Neutral position (N) is signalled through lighting up of neutral and parking brake indicator lamps on the cluster (25).
Located on the travel control are vibration ON/OFF pushbuttons
(7) and pushbuttons (5), (6) to control in CRAB mode.
If the Machine is equipped with cutter and final compactor then pushbuttons (5) and (6) on travel control are used to control it, i.e. those on the same side where it is mounted (optional).
Engine start is possible only in neutral position (N).
OPERATION MANUAL
Steer angle of the front drum in CRAB mode – yellow pushbuttons (5) and (6)
2721
Press pushbuttons on travel controls (1) to steer in CRAB mode
Pushbutton (5) – front drum to the right
Pushbutton (6) – front drum to the left
Indicator lamp on cluster (26) goes ON to signal this function.
Note
If the Machine is equipped with cutter and final compactor then it will be controlled via pushbuttons (5) and (6) on travel control (1), and this on the same side where it has been mounted
(optional).
Vibration ON / OFF pushbuttons (7)
Press these buttons to turn ON/OFF this function. Indicator lamp on cluster (25) will go ON.
Speed potentiometer (2)
2685
Potentiometer is used to smoothly select speed mode within the range from min speed of “turtle” to max speed of “rabbit”.
When adjusting potentiometer speed in any position you may always enable vibration function.
Machine will not move with speed potentiometer set to MIN position.
Emergency brake (8) pushbutton
2582
Press this button to enable Machine’s emergency brake, and indicator lamps on cluster (25) for brakes, recharging, neutral, and engine oil pressure will light up.
Engine will stop and stall!
Sprinkling button (9)
3183
Hold down this pushbutton to enable drum additional sprinkling function. Indicator lamp on cluster (26) will light up.
Switch for the mode of soft starting to move (driveaway) and stopping to move (stopway) (3)
3128
It is used to adjust soft starting to move and stopping to move when stopping and reversing the Machine. In this way the creation of “waves” on compacted surface will be eliminated. Press the switch to enable the function, and indicator lamp on cluster
(26) will go ON.
Attention, in this mode the Machine stopping distance is longer!
Switch for CRAB mode resetting (4)
3319
Press this switch to adjust front drum in CRAB mode.
CRAB mode resetting is signalled by indicator lamp on cluster
(26) going OFF.
AV 70 X 43
2.6. Machine basic functions control
25 26
12
23 11 16
0
14 15
0 kg
1
MAN
2
AUT
13
17
10
44
400272B
AV 70 X
OPERATION MANUAL
Sprinkling interval potentiometer (10)
3186
Swing the sprinkling potentiometer from „MIN“ to „MAX“ position to control smoothly drum sprinkling intensity.
Sprinkling function will not be enabled with the sprinkling potentiometer set to MIN position.
Drum vibration selector switch (14)
3179
The selector switch has three positions:
Left – front drum vibration
Centre – both drums’ vibration
Right – rear drum vibration
Pumps sprinkling selector switch (11)
3181
One of two drum sprinkling pumps will turn ON, and indicator lamp on cluster (26) will light up.
Adjust sprinkling potentiometer before switching ON the pump!
Ignition box (12 )
The ignition-starter switch has four positions “0-I-II-III”. It is only possible to put in and remove the key at the position “0”.
Turning the key to the right at first activates the position “I”, then the suspended position “II” (engine heating), and afterwards the position “III”.
”III” position is used to start the engine.
Protect ignition box with cover once the key is pulled out.
Accelerator control (13)
Vibration amplitude selector switch (15)
2682
The selector switch has three positions:
Left – low amplitude switched ON
Centre - OFF
Right – high amplitude switched ON
MAN / AUT vibration mode selector switch (16)
3180
It is used to switch ON vibrations in MAN or AUT mode.
MAN – manual mode, vibrations can be switched ON even with stationary Machine.
AUT – automatic mode to switch OFF/ON vibrations
Cluster (17)
It is used to turn ON/OFF contour lights, dipped lights, distance lights, traffic-indicator lights and horn.
Indicator lamps (23) light up to signal contour, dipped, and distance lights are ON.
Indicator lamp on cluster (25) lights up to signal traffic-indicator lights are ON.
2406
It is used to adjust combustion engine rpm ranging from idle to max speed. Move the accelerator control towards operator seat to increase the rpm and vice versa. Accelerator control is connected with the engine injection pump control lever via a cable.
AV 70 X 45
2.6. Machine basic functions control
1
25
24
26 kg
23
22 21 20
19
1
MAN
2
AUT
0
0 kg
18
13
2
1
46
400272C
AV 70 X
OPERATION MANUAL
0
Switch for constant speed and protection against engine overload (18)
3185
Constant speed function:
It is used to maintain constant speed of the Machine when driving on flat surface, uphill, or downhill.
When control unit is switched ON the indicator lamp on cluster
(26) signals this function.
The driving speed corresponds to the degree of swing of travel control (1) from neutral position (0), depending on speed potentiometer (2) adjustment.
Switch + indicator lamp rear lights (22)
591668R
It is used to turn ON/OFF rear lights, indicator lamp in the switch signals this function.
Indicator lamps for (dipped / distance) lights
(23)
591508
These lamps signal dipped or distance lights switched ON.
ANTISTALL function
It is used to protect the engine on steep grade or the Machine not to sink in ground.
With the control unit switched ON the indicator lamp on cluster
(26) will signal this function. The control unit will automatically lower the power take-off (PTO) through reducing the set speed
(rpm of travel hydraulic motor) independently on travel control position. Thus the tractive force (of travel hydraulic motor) will increase - engine will get relieved.
Infrathermometer (24) - (optional)
3044
It will be enabled through the key turned ON in the ignition box (12) and it will measure through temperature sensor for a bitumen surface rolled. The value measured is indicated in C° degrees on display (24).
Adjust engine max rpm by means of accelerator control (13) before turning ON the switch!
When a hard terrain has been overcome, turn OFF the switch!
Switch + hazard beacon indicator lamp (19)
- (optional)
592348
It is used to switch ON/OFF hazard beacon, indicator lamp in the switch signals this function.
Alarm lights switch (20)
AMN24
It is used to turn ON/OFF alarm lights - indicator lamp in the alarm lights switch and on clusters (25) and (26) will flicker to signal this function.
Switch + indicator lamp for cabin’s additional lights (21) - (optional)
596473
It is used to switch ON/OFF additional lights, indicator lamp in the switch signals this function.
AV 70 X 47
2.6. Machine basic functions control
25
400501
LH cluster (25)
Fuel consumption gauge
AMN25
It signals current fuel level in the tank, when emptied to min the red LED will flicker.
Check fuel level during Machine operation.
Indicator lamp for hydraulic oil pressure filter fouled
AMN3
Indicator lamp ON signals filter element is fouled.
Immediately replace the filter element!
Counter of motohours actually worked
AMN26
It will display the number of motohours the engine was running.
With the engine started the counter will begin counting the motohours.
Note
Counting the number of motohours does not depend on engine rpm.
Parking brake indicator lamp
AMN1
The indicator lamp ON will signal the parking brake has been enabled.
Battery recharging indicator lamp
AMN4
It signals proper function of battery recharging. When switching the key on the ignition box (12) over to “I” position the indicator lamp shall go ON and following the start it must go OFF.
Unless indicator lamp goes OFF, find a defect!
Indicator lamp lighted ON during engine run will signal a defect. Following 5 seconds the acoustic alarm will start, and after
2 minutes the engine will stall automatically – the Machine will stop and parking brake will be enabled.
Seat switch indicator lamp
AMN2
Indicator lamp will light ON when operator is not sitting on the seat or when emergency brake has been enabled.
48
Engine can be started once its defect has been repaired!
AV 70 X
OPERATION MANUAL
Indicator lamp for air filter fouled
AMN5
Indicator lamp ON signals filter element is fouled above a limit admissible.
Indicator lamp that the vibration is ON
AMN10
Indicator lamp ON will signal the vibration is ON.
Stop the Machine and replace the filter element instantly!
Engine lubrication lamp
AMN6
When switching the key in the ignition box (12) over to “I” position and indicator lamp shall go ON, and when engine is started it must go OFF.
Indicator lamp lighted ON during engine run will signal a defect. Following 5 seconds the acoustic alarm will start, and after
2 minutes the engine will stall automatically – the Machine will stop and parking brake will be enabled.
Stop the Machine and check oil amount or find a defect!
Indicator lamp for hydraulic oil temperature
AMN11
Indicator lamp signals max hydraulic oil temperature admissible has been exceeded. The control lamp lighting up during the engine running signals a defect. After 5 seconds, audible alarm will be activated and the engine will be stopped automatically – the machine will stop and the parking brake will be activated.
Stop the Machine and check oil level or find a defect!
Check hydraulic oil level
AMN12
Indicator lamp signals low hydraulic oil level.
When the control lamp lights up, the engine is immediately stopped and audible alarm is on - the machine stops and the parking brake is activated.
Indicator lamp for engine overheated
AMN7
This indicator lamp signals the cooling liquid’s max temperature allowed has been exceeded.
Indicator lamp lighted ON during engine run will signal a defect. Following 5 seconds the acoustic alarm will start, and after
2 minutes the engine will stall automatically – the Machine will stop and parking brake will be enabled.
Engine can only be started when failure is repaired and oil in hydraulic tank refilled to a limit specified!
Stop the Machine and check cooling liquid amount, or find out any defect!
Indicator lamp for traffic-indicator lights
AMN8
Indicator lamp ON will signal traffic-indicator lights are ON, or alarm lights have been turned ON.
Neutral indicator lamp
AMN9
Indicator lamp ON will signal the position of travel controls is in neutral (N).
Before starting the engine the travel controls (1) shall be in neutral position (N)!
AV 70 X 49
2.6. Machine basic functions control
26
400501A
50 AV 70 X
RH Cluster (26)
Level height in sprinkling tank.
AMN27
It signals the actual level of water in the tank, and when emptied to min the red LED will start to flash.
Check water level in the tank during
Machine run.
OPERATION MANUAL
ASC indicator lamp
AMN17
Not connected.
Fuel filter indicator lamp
AMN18
Indicator lamp lighted ON signals water presence in fuel filter.
If this indicator is ON, please clean the fuel filter!
Cooling liquid indicator lamp
AMN13
Indicator lamp lighted ON during engine run will signal a defect. Following 5 seconds the acoustic alarm will start, and after
2 minutes the engine will stall automatically – the Machine will stop and parking brake will be enabled.
Engine glowing indicator lamp
AMN19
The lighted control lamp signals the engine heating.
Engine can only be started when failure is repaired and cooling liquid refilled to a limit specified!
Spreader indicator lamp
AMN20
This indicator lamp signals the spreader is ON (optional).
Air conditioner indicator lamp
AMN14
Indicator lamp signals air conditioner is ON (optional).
Indicator lamp to protect against engine overload (ANTISTALL)
AMN21
This indicator lamp signals the ANTISTALL is ON.
CRAB mode indicator lamp
AMN15
Indicator lamp signals the front run is set to CRAB mode.
Sprinkling pump indicator lamp
AMN22
Indicator lamp signals sprinkling pump is ON.
Indicator lamp for soft starting to move and stopping to move
AMN16
Indicator lamp ON signals the mode of soft starting to move and stopping to move is ON.
Intermittent flashing of this indicator lamp signals an error code for a defect within Machine travel system.
Constant speed indicator lamp
AMN23
This indicator lamp signals the constant speed mode is ON.
Shut down the Machine and call service organization in respect of failure repair on the Machine travel system!!!
Alarm lights indicator lamp
AMN24
This indicator lamp signals alarm lights are ON.
AV 70 X 51
2.6. Machine basic functions control
Cut-out box (27)
It contains F1 - F8 fuses.
F1 - 20 A
F2 - 15 A front, rear headlamps roof lights, light switches
F3 - 15 (30)A traffic-indicator lights, horn, beacon, extra lights, mounting socket
F4 - 5 A clusters
F5 - 10 A
F6 - 15 A
F7 - 7,5 A travel electronics, backing horn sprinkling vibrations, CRAB (trimmer)
F8 reserve
Other fuses located on the Machine
At battery disconnector
F9
F10 - 80A radio (as per car radio manufacturer)
Dashboard fuse
27
F9
F10
400116
416013
Under the cabin lighting cover
F11 - 15 A
F12 - 15 A wipers + window washers fans
F13 - 5 A
F14 - 10 A fan control + air conditioner control air conditioner
400118
52
400119
AV 70 X
F16, F17 - 125A Heating of the engine
Cabin fuse (28)
F15 - 30 A cabin wiring
Always replace the fuses with the ones of identical value!
Diagnostics socket (29)
It is used to check and set the control units’ parameters via external computer units (notebook).
Mounting socket (30)
It is used to connect auxiliary inspection lamp (12V).
Steering wheel positioning (31)
It is used to facilitate boarding and leaving the Machine by its operator.
Release lever (A) to position the steering wheel in the direction away from the column axis towards a dashboard.
The lever (A), when shifted out, can be arrested in any position.
OPERATION MANUAL
F16
F17
400601
30
28
29
400116A
A
400125
A
AV 70 X
400126
53
2.6. Machine basic functions control
Operator seat (32)
Seat adjustment:
1 Backrest position
2 Arm support position and lifting
3 Seat turning
4 Seat shifting
5 Seat springing stiffness according to weight indicator.
6 Seat height – grasp the seat and lift slowly to adjust seat height in its next higher position and lock it there. Once lifted to its highest position, the seat will drop back to its lowest position.
4
5
3
Adjust your seat before driving !
Driver must be fastened with the seat belt while driving!
2
1
6
400122
400253
How to swivel operator’s place:
Operator’s place can be swivelled within the range of 40° when accelerator pedal is pressed. Once the pedal is released the operator’s place is locked (arrested) in one of 4 positions.
Seat switch:
Seat switch is located in its cushion.
Description of seat switch function:
It is used to interlock the engine starting or to stop the Machine if no operator sits on the seat.
Interlocking of engine starting:
When operator is not sitting on the seat the Machine cannot be started.
Machine stopping:
If operator stands up from the seat while driving then the Machine will stop following 8 seconds.
Machine starting to move:
Its operator must sit down on the seat and shift the travel controls (1) to neutral (N) and then select direction of running.
Do NOT load seat switch with other objects!
54
MAX 40°
416014
AV 70 X
Documentation stowage box
2428
The locker for documentation is located on the seat’s rear side.
OPERATION MANUAL
400123
Front wiper selector switch (33)
596625
Three-position selector switch
Turned OFF
-
-
Low speed ON
High speed ON
Glass washer switch (34)
2260
Two-position selector switch
OFF
Windscreen washing ON
Fan switch (35)
594701
It is used to switch ON cabin fan, its function is signalled via indicator lamp in the switch.
-
-
OFF
High delivery ON
Low delivery ON
Switch of air-conditioning (36) (optional equipment)
2441
Cabin lighting (37)
Ceiling lamp incl. selector switch is located overhead the dashboard.
Ventilation nozzles (38)
Adjustable nozzles are located on cabin ceiling, please adjust and swivel the dampers to alter the amount and direction of flowing air.
38
33
34
35 36
38
37
416001
AV 70 X
416001A
55
2.6. Machine basic functions control max min
Control tie rod for heating valve (39)
It is used to switch ON the cabin heating.
2638
Make continuous control from MIN position (valve closed) to
MAX position (valve fully open) for the amount of liquid flowing to the heating body.
Adjust the heating valve before driving!
39
Hand pump control lever (40)
It is used to control the hand pump when lifting or letting down the bonnet.
Location in case of the machine with a ROPS cab
Location in case of the machine with a ROPS platform and rail
40
40
416002
416002B
First-aid box stowage place (41)
The Machine shall be equipped with first-aid box!
41
416036
56
416002C
AV 70 X
Fire extinguisher (42) - (optional)
Place for the installation of a fire extinguisher.
! Attention !
The manufacturer recommends that the machine be equipped with a fire extinguisher.
Stowage pockets (43)
These are used for Operator’s personal items.
OPERATION MANUAL
42
416003
416002A
Anti-dazzle (sun) screen (44)
Adjust the anti-dazzle screen through securing it to the fixing on the glass.
400242
Window washer tank (45)
Fill with standardly available media.
Fill with antifreeze or drain before winter season starts!
AV 70 X
400127
57
2.6. Machine basic functions control
Additional lights (46)
Lights located on the Machine cabin (optional).
Beacon socket (47)
It is used to connect the beacon.
Back mirrors (48)
External back mirrors enable to view poorly visible areas.
Maintain these mirrors clean and properly adjusted!
Cabin ventilation air filter (49)
It includes replaceable filter element to catch the impurities drawn in from air.
58
416031A
416004
AV 70 X
416031
400243
Arm rests on the door (50)
Transportation position
OPERATION MANUAL
400244
Working position
Battery disconnector (51)
It is used to disconnect the battery from the Machine frame.
Position „0“ – Machine wiring disconnected.
Position „I“ – Machine wiring connected.
„0“ „I“
400245
401678
Hand pump (52)
It is used to lift or let down the bonnet.
Located on LH side of rear frame.
AV 70 X
400602
59
1
8
2.7. How to Control and Use the Machine
17
25 26
12
0
0 kg
1
MAN
2
AUT
13
1
1
0 N
60
400272D
AV 70 X
OPERATION MANUAL
2.7.1. Start-up of the engine
Check daily before engine starting the amount of oil in the engine and hydraulic tank, cooling liquid in the cooling circuit, fuel in fuel tank, water level in water tank. Confirm no loosened, worn or missing parts exist on the Machine.
Start the engine only from the driver’s control stand! Use alarm horn to signal the engine starting and check nobody is endangered by starting the engine!
•
•
•
•
•
•
•
•
•
•
Insert key in the ignition box (12) in “0” position and switch over to “I” position.
All indicator lamps on clusters (25 and 26) will light up.
Then on cluster (25) the indicator lamps for brakes, recharging, neutral, will remain ON, along with engine lubrication indicator lamp (flickers).
If you leave the key in ”I“ position for over 15 seconds then the acoustic alarm will switch ON – to warn operator about the battery discharged (acoustic alarm will turn OFF once engine is started). Unless it is started within 2 minutes, please get your key back to
“0” position before starting the engine again.
Use alarm horn on combined switch (17) to signal engine starting.
Adjust accelerator control (13) for increased rpm (1/4 stroke).
Switch over the key to the suspended position “II” and keep it at the position for approximately 15 seconds (engine heating) (this action can be skipped with a hot engine or at a high ambient temperature).
Turn the key to “III” position to start the engine.
On cluster (25), following the starting, the engine lubrication indicator lamp and recharging indicator lamp shall go OFF.
Once the Machine has started to move the neutral lamp and brake lamp will go OFF.
Note
If starting is unsuccessful, please turn your key back to ”0“ position. Unless engine starts even after 3 attempts – please check the oil system.
Starting is interlocked:
unless travel controls (1) are in neutral position (N)
emergency brake (8) function is enabled.
Do NOT start the engine for over 30 seconds. Wait 2 minutes before any next starting.
When starting at low temperatures the recharge indicator lamp will remain ON accompanied by a sound alarm – increase engine rpm adequately – the indicator lamp will go OFF.
Following the engine start let the engine idle at increased rpm (1/2 stroke of accelerator actuator) for
3÷5 min.
Steep rpm increase or decrease is inadmissible – it may damage the engine.
Do NOT let the engine idle for over 10 minutes – any idling longer then that may cause fouling of injectors, piston rings, or valves to get seized!
Unless oil temperature reaches min. 60 °C, then the engine will not be lubricated sufficiently – do not load the engine fully!
AV 70 X 61
2.7. Machine basic functions control
-
4
1
+
0
1
2
V
2 3
+
0
12V
-
406005
62 AV 70 X
How to start via cables from external power source:
OPERATION MANUAL
Starting voltage from external power source shall be the voltage of 12V.
Follow unconditionally the operation sequence below.
1/ Connect one end of (+) cable pole to (+) pole of the battery discharged.
2/ Connect second end of (+) cable pole to (+) pole.
3/ Connect one end of (–) cable pole to (–) pole of external battery.
4/ Connect the second end of (–) cable pole to such part of started Machine which is fix-wired with the engine (or with the engine block itself).
When started, disconnect the battery jump cables in reverse order.
Do not connect (–) pole cable to (–) pole of discharged battery of the Machine being started! There is risk of strong sparking in course of starting followed by explosion of battery-generated gas.
Make sure the non-insulated parts of the battery jump cable clamps do NOT contact each other!
Make sure the jump cable connected to (+) pole of the battery does NOT come into contact with electrically conductive parts of the Machine – danger of short circuit!
Do NOT lean over the battery – risk of electrolyte burn!
Rule out any presence of flammable sources (open flame, burning cigarettes, etc.)
Do NOT confirm voltage presence in a wire through sparking via Machine frame!
AV 70 X 63
2.7. Machine basic functions control
26
1
0
0 kg
1
MAN
2
AUT
13
2
3
1
1
0 N
64
400272E
AV 70 X
2.7.2. Travel and reversing
OPERATION MANUAL
Before starting to move, please check the area in front and behind the Machine is clear and with no persons or obstructions present!
Use loud horn to signal engine starting and wait long enough for those persons present to leave the in time the area round the Machine or the area beneath the Machine!
Operator must sit on the seat before the Machine starts moving! If the operator gets up from the seat during the Machine travel then the Machine will stop and brake.
Machine travel and reversation:
Select travel direction:
Start the engine. Adjust max engine rpm via accelerator control (13)
Get the Machine moving by shifting travel controls (1) from (N) zero position to (0) neutral position and then by selecting a direction of running.
Shift the controls (1) to opposite direction to change the direction of Machine travel.
Travel speed selection:
Travel speed corresponds to the deflection magnitude of travel controls (1) from zero position (0).
Travel speed can continuously be altered using speed potentiometer (2) within the range of MIN (turtle) to MAX (rabbit).
If the speed potentiometer (2) is in MIN position then the Machine is unable to start moving.
Note
The instantaneous stopping of the Machine by means of travel controls (1) applies to all travel modes of the Machine.
Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.
Travel modes of the Machine:
•
•
•
•
RAMP (soft starting to move and stopping to move)
CONSTANT SPEED (continuous Machine drive)
ANTISTALL (engine protection against overload)
CRAB (extended track of the Machine)
Travel in RAMP mode
The function of soft starting to move or stopping to move prevents from forming the waves when compacting the bitumen surface during Machine travel.
Attention, in this mode the Machine stopway is longer!
Use speed potentiometer (2) to adjust the speed, and use travel control (1) to adjust travel direction.
Press pushbutton (3) to switch ON/OFF this function, indicator lamp on cluster (26) will light up to signal this function.
Move travel controls (1) to opposite position via (0), and then return it back to (0) position within 1 second interval to stop the Machine
– the engine will remain running.
Following the travel controls (1) moved to neutral (N) the function will be OFF!
Shift travel controls (1) to neutral (N) position, press pushbutton (3) – the function will become enabled again.
Note
You may switch ON the function during Machine travel.
AV 70 X 65
2.7. Machine basic functions control
1
26 kg
0
0 kg
1
MAN
2
AUT
18
13
2
3
1
1
0 N
66
400272F
AV 70 X
OPERATION MANUAL
Travel in CONSTANT SPEED mode
This function is used to maintain continuous travel while the Machine is ascending or descending.
AMN23
Use speed potentiometer (2) to adjust travel speed and use travel controls (1) to adjust its direction.
Use switch (18) to turn ON/OFF the function, indicator lamp on cluster (26) will light up to signal this function.
Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.
By deflecting the travel controllers (1) from the position (0), the machine drives off.
Note
The function can be turned ON during Machine travel.
Travel in ANTISTALL mode
It is used to protect against engine overload on steep grade or with the Machine sunk.
AMN21
Control unit will automatically reduce the power take-off through lowering the set rpm (rpm of travel hydraulic motor) independently of travel control position. Thus the pulling power (of the travel hydraulic motor) will increase – the engine will get relieved.
Switch OFF the function of soft starting to move and stopway via switch (3) if this function is turned
ON!
Before turning ON the switch (18), please use accelerator control (13) to adjust engine’s max rpm!
Use speed potentiometer (2) to adjust travel speed, and use travel controls (1) to adjust its direction.
Use switch (18) to turn ON/OFF this function, the indicator lamp on cluster (26) will light up to signal this function.
Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.
By deflecting the travel controllers (1) from the position (0), the machine drives off.
When having overcome a difficult terrain, please turn OFF the switch!
AV 70 X 67
2.7. Machine basic functions control
1
6 5
26
0
0 kg
1
MAN
2
AUT
6
5
1
2
4
1
0 N
68
400272G
AV 70 X
OPERATION MANUAL
Travel in CRAB mode
This function is used to adjust extended track during Machine travel.
Use potentiometer (2) to adjust travel speed, and use travel controls (1) to adjust its direction.
Press pushbuttons (5) and (6) on travel controls (1) to control the Machine in CRAB mode, and at the same you may turn the Machine.
Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Machine – the engine will continue to run.
By deflecting the travel controllers (1) from the position (0), the machine drives off.
Turning ON:
Press button (5) to deflect the front drum to the right and press button (6) to deflect to the left, the indicator lamp on cluster (26) will light up to signal this function.
Max deflection of the front drum to both sides is 180 mm.
Turning OFF:
Press switch (4) to cancel CRAB mode of front drum.
Indicator lamp on cluster (26) will go OFF to signal CRAB mode has been reset.
Note
In the event that the control lamp on the combined instrument (26) is flashing, hold the switch and turn the steering wheel (to the left/ right) until the control lamp goes out.
If the Machine is equipped with cutter and final compactor, then pushbuttons (5) and (6) on travel control (1) on the same side where it has been mounted, are used to control it. Then pushbuttons (5) and (6) on the second travel control (1)) are used to control the Machine in CRAB mode.
Take special care when Machine travels in CRAB mode near constructed facilities so to avoid their damage due to any collision (hitting)!
If necessary, fold the external mirrors!
AV 70 X 69
2.7. Machine basic functions control
25
1 7
0
14 15
0 kg
1
MAN
2
AUT
16
13
7
2
1
1
0 N
70
400272H
AV 70 X
Machine travel and reversation incl. vibrations
Adjust max engine rpm via accelerator control (13), and adjust travel speed via speed potentiometer (2).
Use selector switch of the vibrating drum (14) to choose vibration (front / both / rear), and use vibration amplitude selector switch (15) to choose high or low amplitude.
Vibration manual switching ON/OFF mode (MAN):
Use switch (16) to turn ON/OFF this function.
Press button (7) on travel control (1) to switch ON the vibration.
Indicator lamp on cluster (25) lighted up will signal this function.
Press button (7) on travel control (1) again to switch OFF vibration.
Note
MAN mode enables to switch ON vibration on stationary Machine, the travel controls (1) shall be in (0) position.
You can switch OFF the vibration by shifting travel controls (1) to neutral (N) position.
Automatic vibration switching ON/OFF mode (AUT):
Use switch (16) to turn ON/OFF this function.
Press button (7) on travel control (1) to switch ON vibration.
Indicator lamp lighted up on cluster (25) will signal vibration function.
Vibration will automatically switch ON at travel speed over 0,5 km x hour –1 (0,3 MPH).
Vibration will automatically switch OFF at travel speed below 0,5 km x hour –1 (0,3 MPH).
Automatic vibration function remains enabled even after travel controls (1) have been moved via position (0).
Note
Vibration can be switched OFF through shifting travel controls
(1) to neutral (N) position.
For the maximum permissible slope gradient when driving uphill and across the slope gradient, see figures.
The values given are lower depending on adhesive conditions and the machine instantaneous weight!
OPERATION MANUAL
416038
AV 70 X
416039
71
2.7. Machine basic functions control
25
1
8
7
12
0
0 kg
1
MAN
2
AUT
13
7
1
1
0 N
72
400272I
AV 70 X
2.7.3. Emergency stop of the Machine
OPERATION MANUAL
Apply this in the event of failure where the engine is unable to be shut off via the key in the ignition box, or through shifting the travel controls (1) to position (0)!
How to switch ON:
Press emergency brake button (8) and the Machine will brake, engine will turn OFF and the acoustic alarm will start.
On cluster (25) the indicator lamps for seat switch, parking brake, recharging will light up, and lubrication indicator lamp will start to flicker.
How to switch OFF:
Turn the press button in the direction of arrows and the acoustic alarm will get turned OFF.
On cluster (25) the parking brake indicator lamp and neutral indicator lamp will remain ON.
Shift travel controls (1) to neutral (N) position, the Machine can be started again in this position.
Do NOT use emergency brake to stop or switch OFF the engine during normal operation of the
Machine!
2.7.4. How to stop the Machine and its engine
Press button (7) on travel control (1) to switch OFF vibration, indicator lamp on cluster (25) will go OFF.
Stop the Machine through shifting travel controls (1) to neutral (N) position.
Use accelerator control (13) to adjust idle engine speed.
Switch over the key in the ignition box (12) to “0“ position, and tilt back the ignition box lid to close it.
Do not stop hot engine instantly but keep it running idle for 3 minutes. The engine and turbocharger will get cooled down slowly and evenly!
Travel controls (1) shall be always in neutral (N) position!
Switch OFF the battery disconnector during Machine shutdown!
2.7.5. Machine parking
Shut down the Machine on flat and solid surface at a point with no potential of natural hazard (landslides, possible flooding, etc.)
Following the engine stop, before leaving the Machine, please disconnect its battery disconnector (51).
Clean the Machine to remove dirt (scrapers and drums).
Make overall inspection of the Machine and repair any defects that have occurred during operation.
Lock the Machine covers and its cabin.
Do NOT stop hot engine instantly, but instead let it idle for 3 minutes. The engine and turbocharger will cool down slowly and evenly!
AV 70 X 73
2.7. Machine basic functions control
2.7.6. Bonnet raising and lowering
Stop the Machine, shut off the engine, and disconnect battery disconnector (51).
Lift the bonnet with the engine shut off and battery disconnector disconnected!
Check that no persons are under hazard when letting the bonnet down!
„0“
Lift the bonnet
Remove control lever and insert in the hand pump.
Turn the bonnet raising lever to the horizontal position; see the figure.
Pump to lift the bonnet.
„I“
401678
400605
Once lifted, secure the bonnet with strut.
400140
Let down the bonnet
Set the foot step to the original position!
74
400606
AV 70 X
Pump to lift the bonnet and secure with strut.
Turn the bonnet raising lever to the vertical position, see the figure, and the bonnet will start to drop.
Confirm safe touch-down of the bonnet.
Remove control lever (39) and put it inside Machine cabin.
OPERATION MANUAL
416005
400602A
AV 70 X 75
76
9
10
2.7. Machine basic functions control
26
0
11
0 kg
1
MAN
2
AUT
400272J
AV 70 X
OPERATION MANUAL
2.7.7. Sprinkling
It is used to sprinkle the Machine drums.
Switch ON one of two sprinkling pumps via sprinkling pumps selector switch (11).
Indicator lamp on cluster (26) will signal the function of switching ON the sprinkling pump.
Green LEDs signal water level in the tank, red LED flashes when emptied to min.
Using the potentiometer of the watering cycle interval (10), set the watering intensity within the range of MIN/MAX.
The watering intensity depends on the driving speed; the standing machine performs watering only if the potentiometer (10) is set to MAX.
Using the watering button (9), it is possible to switch on the additional watering of drums, e.g. before driving on a compacted bitumen surface.
Check water level in the tank during Machine operation.
We recommend to alter the pumps following 100 motohours in order to ensure their uniform wear.
AV 70 X 77
2.8. Machine transport
• The machine can move on its own between working sites.
When moving, observe the safety measures applicable to the working site.
1
93
2
• The machine should be transported on a vehicle on public roads.
When transporting the machine on a vehicle, observe the provisions applicable to the given territory.
When loading and unloading, the vehicle transporting the machine must be braked and mechanically protected against accidental movement using scotch blocks 3.
The machine on the vehicle must be properly tied and mechanically secured against longitudinal and lateral displacement as well as against tipping 1.
The drums must be secured using scotch blocks 2.
1
406008
78 AV 70 X
2.8.1. How to load the Machine
Use loading ramps or a crane to load the Machine on its transporting vehicle.
For loading with crane the Machine is fitted with lifting lugs.
Before lifting, the Machine joint must be secured against slight turning.
Lmin = 5 m
2x min 2100 kg
(2x min 4630 lb)
OPERATION MANUAL
8400 kg
(18 520 lb)
Lmin = 5 m
2x min 2100 kg
(2x min 4630 lb)
406007
How to secure the joint:
Dismantle the arm (1).
1
400143
Secure the arm with pivots (2) and safety pins locks (3).
Observe safety regulations when loading and unloading!
Use the crane of sufficient loading capacity!
Use corresponding and unbroken rigging of sufficient loading capacity!
The Machine must be tied to the lifting lugs on the Machine!
Only a trained person (slinger) may carry out the tying of the Machine!
Keep off the area beneath the hanging load!
3
2
2
3
400144
AV 70 X 79
2.9. Special conditions of the machine use
2.9.1. Machine towing
To provide for towing the Machine is equipped with two lugs on front frame, and with two lugs on rear frame.
A Machine sunk can be hauled for a short distance if the engine is running and the travel drive and steering do work.
Operator on towed Machine shall steer the Machine in the direction of hauling.
Unless the engine works, or a defect exists within the hydraulic system, or travel pump is broken, then you must brake off the Machine and short-circuit the hydraulic circuit. No person may stay on the Machine towed!
When braked off and hydraulic circuit for the travel is short-circuited, this means that all the brakes are disabled!
Before braking off secure the Machine with wooden scotch blocks against starting to move!
Do NOT touch hot parts of the Machine, burn hazard!
Turn off the battery disconnector (51)
Raise the bonnet and secure it with a support.
Travel pump short-circuiting:
Unscrew two multi-purpose relieve valves by three threads in
CCW direction (hexagon 22 mm).
80
416010
400140
416027
AV 70 X
Multi-purpose relieve valves are located on travel hydroelectric generator. The travel hydroelectric generator is located on the
LH side, in engine compartment.
OPERATION MANUAL
400608
Releasing of the brakes of the machine:
Before releasing the brakes, secure the machine using wooden blocks against accidental moving!
Turn the bonnet raising lever to the vertical position, see the figure.
Remove hose (3) away from the clip.
Disconnect hose (1) in quick-coupler (2).
Connect hose (3) into quick-coupler (2).
3 2
1
400602A
Connect battery disconnector (51).
„0“ „I“
400607
AV 70 X
401678
81
2.9. Zvláštní podmínky použití stroje
Switch over the key in ignition box to “ I“ position.
Note
If the key remains in “I“ position for more than 15 seconds the acoustic alarm will switch ON – to warn operator the battery has been discharged.
Turn the bonnet raising lever to the horizontal position.
0 I II
416006
400605
Insert control lever into the hand pump and start pumping until brake indicator lamp on cluster (25) goes OFF.
Now the Machine is braked off, and it will be possible to tow it away.
Due to leakage the pressure in the brakes may lower in course of towing.
Check regularly the Machine brakes do not become hot in course of towing the
Machine.
If brake indicator lamp will go ON in course of towing, stop towing the
Machine and start pumping until the indicator lamp goes OFF!
When towing is completed, secure the
Machine with scotch blocks against its driving away, and carry out the application of its brakes!
478320 h
400111K
82 AV 70 X
How to brake the Machine:
Turn the bonnet raising lever to the vertical position, the machine will brake to a stop.
Put the hose (1) and (3) to its original condition.
Unscrew two multi-purpose relieve valves by three threads in
CW direction (hexagon 22 mm).
Turn the bonnet raising lever to the horizontal position.
Start pumping to lift the bonnet, secure the strut.
Turn the bonnet raising lever to the vertical position, the bonnet will start to drop.
Confirm safe touch-down of the bonnet.
Remove control lever (40) and put it back in the Machine cabin.
Make sure that nobody is endangered by the bonnet lowering!
Do not leave your limbs in the area of the bonnet lowering!
OPERATION MANUAL
400602A
When operating the machine under normal conditions when the hose with the quick coupling (3) is not connected at the point (2), the function of “Emergency
Hydraulic Machine Brake Releasing”, the hose with quick coupling (1) must always be connected at the point (2)!!!
No persons may be on the towed roller with a non-functional engine.
After towing the roller away, restore the roller into original condition!
For towing purposes, use only intact tow-ropes or towing-bars with a sufficient capacity 1.5 times higher than the towed machine weight. It is banned to use chains for towing the machine!
It is necessary to keep the minimum departure from the direct towing angle. The maximum departure is possible at an angle of 30°.
When towing, it is necessary to ensure the continuous movement. Do not exceed a towing speed of more than 2 km/hour (1.2 mph). Do not tow the machine for a longer distance than 300 m (0.19 mi).
The size of the towing machine should correspond to the size of the towed machine. It must have a sufficient traction force (power), weight, and brake effect.
Do not start the engine when towing.
When towing downhill using a rope, another towing machine must be connected to the rear part of the damaged machine. Thus it is possible to prevent an uncontrolled movement of the damaged machine.
Note
These are general requirements for safe towing of a damaged machine under normal conditions. Please consult with your dealer any and all different situations that may occur while towing the Machine.
AV 70 X 83
2.9. Zvláštní podmínky použití stroje
2.9.2. How to operate the Machine during its running-in
Do NOT load the Machine at its full capacity when putting the new Machine into operation or following its major overhaul during the first 30 hours!
2.9.5. Machine operation at high altitudes
With the altitudes increasing the engine power drops due to lower atmospheric pressure and lower specific weight of intake air.
2.9.3. Operating the Machine at low temperatures
Compacting during winter season depends on the content of fine particles and water in the soil being compacted. With the temperature dropping below freezing point the soil becomes more solid and harder to compact.
Engine power depends on the environment where the Machine is operating.
The machine may be used up to a maximum altitude of 3,658 m (12,000 ft).
2.9.6. Machine operation within very dusty environment
At the temperatures below 0 °C (32 °F) it is possible to compact only dry soils (and stony loose materials), or carry out rapid compaction of non-frozen materials (before soil gets frozen).
•
•
•
•
Exchange motor oil for the one recommended for given external temperature range.
Use hydraulic oil of corresponding cinematic viscosity.
Use winter diesel oil.
Confirm battery has been recharged.
While in very dusty environment, please cut short the intervals of cleaning and replacing the air filter elements; and the replacement intervals of cabin dust filter, and cut short the intervals of cleaning the coolers.
Recommended interval of cleaning is 1x per week.
A precondition for proper starting at low temperatures is that the battery is OK. The Machine can be used at its full capacity only after the media have been heated to their operating temperatures.
2.9.4. Machine operation at high temperatures and humidity
2.9.7. Driving with vibrations on compacted and hard materials
During Machine travel with vibration the drums may loose contact with the materials being compacted (so called vibro-stroke) due to high level of compaction of the background material or travel with vibration on hard materials. This condition will come to light in the form of increased vibration transfer into Machine frame and onto operator’s control stand. The vibro-stroke can partly be eliminated through the increased travel speed.
The engine power lowers with the air temperature and moisture increasing. Due to the fact that both these factors reducing the engine power, are independent on each other, it is possible to describe their impact as follows:
It is banned to work in vibro-stroke mode in the long term!
In extreme cases there is Machine damage hazard or operator’s health hazard!
-
each 10 °C (18 °F) of temperature rise means power drop by up to 4 % (at constant humidity) each 10 % of RH increase means power drop by up to 2
% (at constant temperature).
At ambient temperatures when hydraulic oil temperature is constantly round 90 °C (194 °F), we recommend to exchange oil for the one with cinematic viscosity of 100 mm 2 /s.
84 AV 70 X
Notes
OPERATION MANUAL
AV 70 X 85
86 AV 70 X
AV 70 X
MAINTENANCE MANUAL
3. MAINTENANCE MANUAL
AV 70 X
(Cummins Tier 3)
87
88 AV 70 X
3.1. Safety and other measures for machine maintenance
3.1.1. Safety of machine maintenance
•
•
•
•
Carry out lubrication, maintenance and adjustments:
• By professionally trained personnel
•
•
In line with safety instructions given in the Operation Manual
According to schedule given in the Lubrication Chart following the hours actually worked
•
•
On the machine located on flat solid surface, secured against self-motion (scotch blocks), and this always with the engine
OFF, key removed from ignition box, and the wiring cut off
Only after Machine Repair sign is attached onto steering wheel (the sign is supplied together with machine accessories)
•
•
•
•
On machine parts cooled out
After having cleaned the machine, lubrication points and maintenance locations
Using proper, undamaged tools
Through replacement with new original parts as per the
Spare Parts Catalogue
With sufficient lighting of the entire machine in the event of lowered visibility and at night so the guards and safety elements are reinstalled again upon work completion through retightening bolted connections – with torque specified, and through checking the connection tightness with the operation media heated – beware of burns – use recommended media, only.
3.1.2. Fire precautions during operation media exchanges
•
•
•
•
• In terms of fire hazard the flammable liquids used on the
Machine have been divided into three hazard classes:
IInd Hazard class – Diesel oil
IVth Hazard class – mineral oils, lube greases
•
•
Oil exchange point shall be located so it does not interfere with the explosion or fire hazard area.
It shall be identified with notice boards and signs of no smoking and no use of open flame.
• Handling area shall be sized so the capture the amount to flammable liquid equal to the capacity of biggest vessel, transport container.
It must be equipped with portable fire extinguishers.
To handle the oil, Diesel oil, please use such vessels like metal barrels, canisters or sheet-metal cans.
Transport containers shall be properly closed when stored.
•
Vessels shall have one opening, be stored with the opening on top, and secured against any flowing out or dripping of their content.
Vessels shall be designated with indelible inscription indicating the content and flammability class.
Upon completion of the adjustment or maintenance, please examine the function of all safeguard equipment!
AV 70 X 89
3.1. Safety and other measures for machine maintenance
3.1.3. Ecological and hygienic principles
When operating or maintaining the Machines the user shall be liable to follow the general principles of health and environment protection according to the laws, ordinances and regulations in individual territories of the Machine use.
Ecological principles
The media of Machine’s individual systems, and some of its parts after having been discarded (dismantled, media exchanged) become waste with hazardous properties against the environment.
Hygienic principles
•
•
Crude oil products, cooling system media, battery media and coating compositions incl. thinners are materials harmful to health. Workers coming into contact with these products during machine operation or maintenance shall be liable to follow the general principles of their own health protection and conform to the safety and hygienic manuals of these products’ manufacturers.
We call your attention to the following in particular:
-
-
-
-
Eye protection and skin protection during work with the batteries.
Skin protection during work with crude oil products, coating compositions or cooling liquids.
Proper hand washing upon work completion and before any meal; use adequate reparation cream to treat your hands.
Adherence to the instructions given in this Manual.
•
-
-
-
-
-
-
-
This category of waste products includes the following in particular
Organic and synthetic lubricating materials, oils and fuels
Brake fluids
Cooling liquids
Battery media and the batteries themselves
Cooling system media
Cleaners & preserving agents
All dismantled filters and filter elements
All used and discarded hydraulic or fuel hoses, rubbermetal and Machine’s other elements, made dirty due to the abovementioned products.
•
•
•
Always store the crude oil products, cooling system media and battery media, and coating compositions incl. organic thinners, and also the cleaners and preserving agents, in the genuine, original and properly labelled packages. Do not admit any storage of these materials in unlabelled bottles or in any other vessels with regard to the hazard of mistaken identification (faulty change).
When skin, mucosa, eyes are accidentally stained, or vapours inhaled, immediately apply the first aid principles. In the event of accidental use of these products get prompt medical attention.
When working with the Machine in cases where the Machine has platform fitted, cabin windows are left opened, always use ear protectors of adequate type and version.
The given materials and parts, when scrapped, shall be handled compliant to the respective national regulations on environmental protection, and in line with the health protection regulations, as well.
90 AV 70 X
3.2. Media specification
3.2.1. Engine oil
2412
Engine oil has been specified as per its performance classification and viscosity classification.
Performance classification under
API (AMETICAN PETROLEUM INSTITUTE)
CCMC (COMMITE OF COMMON MARKET AUTOMOBILE CON-
STRUCTORS)
ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE
AUTOMOBILE)
Viscosity classification
To determine SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) viscosity class the ambient temperature and type of operations at the place where the Machine will be used are decisive.
The use of admissible oil under API: CH-4/SJ; CI-4
CCMC DHD-1
ACEA: E-5
API CI-4 oil is recommended as especially appropriate.
All the year round: SAE 15W-40, refer to Fig.
Note
Exceeding low temperature limit leads to no engine damage; it may only cause some starting difficulties.
It is convenient to use universal multi-range oils so to avoid any necessity to exchange oil due to ambient temperature.
It is possible to use synthetic engine oils when oils’ performance and viscosity classifications correspond to the recommended mineral oils.
Exchange periods shall be observed at the same intervals like when mineral oils are used.
To perform starting at the temperatures below 0 °C (32 °F) easier the engine manufacturer recommends SAE 10W-30 oil.
Exceeding upper temperature limit, with regard to oil’s reduced capabilities, must not last for some long period.
When using oil under API CG-4/SH the exchange interval must be reduced to half, i.e. 125 hours.
MAINTENANCE MANUAL
400150
AV 70 X 91
3.2. Media specification
3.2.2. Fuel
•
•
Diesel oil is used as the engine fuel:
EN 590
ASTM D6078-78: 1-D and 2-D
The ASTM 2D is recommended to use as optimal one.
Fuel viscosity shall be over 1,3 cST at 40 °C (104 °F) to provide for fair characteristics of the liquidity and lubricating of the fuel system components.
3.2.3. Cooling liquid
2152
Fill the engine cooling system with cooling liquid comprising 50
% of ethylene glycol antifreezing mixture and 50 % of water.
Do NOT use earthy (hard) water with higher content of calcium, and magnesium which brings calculus formation, and with higher content of chlorides and sulphates which causes corrosion. Refer to CUMMINS Engine Operation and Maintenance
Manual. CUMMINS.
Max content of compounds of calcium and magnesium is 170 milligrams - hardness of water
Max content of compounds of chlorine is 40 milligrams
Max content of compounds of sulphur is 100 milligram
At ambient temperatures below 0 °C
(32 °F) you must use winter diesel oil.
At ambient temperatures below -15 °C
(5 °F) it will be necessary to use special diesel oil with additives for these purposes (”engine super diesel oil”).
NEVER use other fuels (e.g. bio diesel oil, mixed bio diesel oil, LFO, etc.) than the
Diesel fuels specified above.
NEVER mix diesel oil with gasoline, with alcohol. These mixtures may cause explosion!
Do NOT use the portion of antifreeze cooling agent in cooling liquid higher than 50 % (point of congelation is -36 °C
[-34 °F], boiling point is 110 °C [228 °F]) unless badly required.
NEVER use the portion over 68 %!
We do NOT recommend to mutually blend antifreeze agents. Mixing various types of cooling liquid may cause loss of anticorrosion properties.
Check the portion of antifreeze cooling agent in cooling liquid with refractometer always before winter season starts.
When mixing antifreeze cooling agent based on nitrides with the agent based on amines the health hazardous nitroamines will form.
92 AV 70 X
3.2.4. Hydraulic oil
2158
Only the quality hydraulic oils of power class under ISO 6743/
HV (corresponds to DIN 51524 Part 3 HVLP; CETOP RP 91 H) must be used for the Machine’s hydraulic system.
Standardly refill the machines with hydraulic oil of kinematic viscosity 68 mm 2 /s at the temperature of 40 °C (104 °F) ISO VG 68.
This oil is the most suitable one to use in the broadest range of ambient temperatures.
At high ambient temperatures when oil temperature reaches constantly 90 °C
(194 °F) we recommend to exchange oil with cinematic viscosity of 100 mm 2 /s
- HV 100 (BP BARTRAN HV 100; ESSO
UNIVIS N 100, etc.).
If it is necessary to start the Machine for the period of one month or longer at ambient temperatures below –8 °C (18 °F), please exchange oil in the hydraulic system for the oil with cinematic viscosity of
46 mm2/s – viscosity class HV 46.
At the temperatures below –13 °C (9 °F), please exchange oil for the one with cinematic viscosity of 32 mm
ESSO UNIVIS N 32, etc.).
2 /s – viscosity class HV 32 (e.g. BP BARTRAN HV 32,
MAINTENANCE MANUAL
3.2.5. Lube grease
0787
Use plastic lubricant with lithium content to lubricate the Machine under the following standards:
ISO 6743/9 CCEB 2
DIN 51 502 KP2K-30
Note
For instance Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania,
Grease No 3, etc.
Hydraulic oil synthetic type
Hydraulic system is possible to be filled with synthetic oil, which is during any leakage this oil will be restless degraded via microorganisms found in water or in soil.
Please, always consult with the producer or dealer any switching to another type of oil or blending with other types of oils.
AV 70 X 93
3.2. Media specification
3.2.6. Glass washer fluid
2260
Use water (up to 0 °C temperature) and agent for motor vehicle glass washers when filling the glass washer tank.
3.2.7. Gear oil
2186
For greasing the drum reducers, use high-quality oils corresponding to API GL-5 or EP or MIL-L-2105 D.
Viscosity SAE 80W-90H for an ambient temperature of -10 °C÷
+30 °C (14 °F ÷ 86 °F).
Replace water with antifreeze agent at the temperatures below 0 °C (32 °F).
The operation temperature of oil must not exceed 85 °C – 90 °C (185°F – 194°F).
94 AV 70 X
3.3. Media
Part
Engine
Medium Type
Engine oil under Section 3.2.1.
Fuel tank Fuel under Section 3.2.2.
Hydraulic tank Hydraulic oil under Section 3.2.4.
Drum bearings, calliper bearings, king pins, suspensions
Lube grease under Section 3.2.5.
Cooling system Coolant under Section 3.2.3.
Vibration drum Engine oil under Section 3.2.1.
Drum drive gearbox Gear oil under section 3.2.7.
Baterry
Glass washer tank
Sprinkling tank
Distilled water
Liquid under Section 3.2.6.
Water
MAINTENANCE MANUAL
Medium Amount l (gal US)
7 (1,85)
Brand
2412
110 (29,05)
40 (10,56)
2158
As required
0787
15 (3,96)
2152
2x10 (2x2,64)
2x1,4 (0,37)
2412
2186
As required
2587
2,75 (0,72)
2260
600 (158,5)
2567
AV 70 X 95
3.4. Lubrication and Maintenance Chart
After 20 hours of operation (daily)
3.6.1.
3.6.2.
Engine oil level check
Engine cooling liquid level check
3.6.3.
3.6.4.
3.6.5.
3.6.6.
3.6.7.
3.6.8.
Inspect the engine belt
Crankcase breather
Inspect air filter vacuum valve
Inspect fan condition
Fuel level check
Hydraulic tank oil level check
3.6.9.
3.6.10.
Water tank refilling
Inspect alarm and control devices
Following 250 hours of operation (after 3 months)
3.6.11.
Engine oil exchange
3.6.12.
3.6.13.
3.6.14.
3.6.15.
3.6.16.
Inspect engine induction manifold
Inspect engine cooling circuit
Inspect the battery
Air filter sensor check
Watering filter cleaning
3.6.17.
Machine lubrication
After 500 hours of operation (after 6 months)
3.6.18.
Engine fuel filter exchange
3.6.19.
Engine cooling liquid level check
Following 1000 hours of operation (after 1 year)
3.6.20.
Inspect engine belt
3.6.21.
3.6.22.
3.6.23.
3.6.24.
Inspect the exhaust system
Inspect the silencing system
Clean the water tank
Oil change in the gearboxes *
96 AV 70 X
After 2,000 hours of operation (after 2 years)
3.6.25.
Checking and adjusting valve clearance **
3.6.26.
3.6.27.
Engine coolant exchange
How to exchange oil in the vibrators
3.6.28.
How to exchange hydraulic oil and filters
Maintenance as required
3.6.29.
3.6.30.
3.5.31.
3.6.32.
3.6.33.
3.6.34.
3.6.35.
3.6.36.
3.6.37.
Fuel system breathing
How to replace air filter elements
How to clean water separator of fuel filter
Cleaning of coolers
How to clean cab ventilation filter
Drain water from sprinkling circuit before winter season
Adjust the scrapers
Machine cleaning
Check the tightening of bolted connections
* First after 200 hours
** First after 250 hours
MAINTENANCE MANUAL
AV 70 X 97
3.5. Lubrication Chart
LUBRICATION PLAN
INSPECTION
LUBRICATE
EXCHANGE
2000
1000
250
20
98
Engine oil:
Hydraulic oil:
Grease:
Gear oil:
SAE 15W - 40
ISO VG 68
ISO 6743/9
SAE 80W - 90H
API CH-4/SJ; CI-4/SK
ISO 6743/HV
CCEB 2
API GL-5
406009en
AV 70 X
3.6. Lubrication and Maintenance Operations
Carry out lubrication and maintenance in regularly repeated intervals as per the everyday data reading on the counter of hours actually worked.
416023
This Manual includes only the basic engine information, others are given in the Engine Operaion and Maintenance Manual which is part of documentation supplied with the Machine.
Follow the instructions given in the Engine Operation and Maintenance Manual!
Removed or loose bolts, plugs, threaded joints of the hydraulics, etc. shall be tightened with the torque according to the charts in Section 3.6.37 unless a different value is given with the relevant operation.
Carry out the inspection of the Machine located on flat, solid surface secured against self-motion (scotch blocks), and this always with the engine OFF, key removed from ignition box, and with the wiring disconnected (unless otherwise required).
Following the first 200 hours of new Machine operation or after the major overhaul, please carry out the operations under this
Section:
3.6.24. Oil change in the gearboxes
Following the first 250 hours of new Machine operation or after the major overhaul, please carry out the operations under this
Section:
3.6.25. Valve adjustment
AV 70 X 99
3.6. Lubrication and Maintenance Operations
After 20 hours of operation (daily)
3.6.1. Engine oil level check
•
•
Pull out oil dipstick (1), wipe it.
Put it back down to the stop and pull out again to read the oil level.
Note
If the engine was running, wait ca 3 minutes until oil descends into engine sump.
• Replenish oil through filler-neck with the filler plug removed
(2).
2
1
400609
400609A
Note
• Low division mark L shows lowest possible oil level, high division mark H (High) shows the highest level.
•
•
The amount of oil between Low and High marks is 1,5 l
(1,6 U.S. Quart).
Following the refill, please wait ca 3 minutes until oil descends into the sump, then check the level.
Do NOT run the engine unless there is correct oil level in the engine.
Maintain the level between the division lines stamped on the dipstick.
Refill the oil of identical type as stated in
Section 3.2.1.
400157
100 AV 70 X
3.6.2. Engine cooling liquid level check
•
•
•
• Do it before starting the engine, visual inspection of the level.
Top up through filler neck (1).
Keep level between ”MIN” and ”MAX” lines.
At higher losses find out any cooling system leakage and repair the cause.
Wait to remove the filler plug only after engine coolant temperature drops below
50 °C (120 °F). If filler plug is removed at higher temperature then the hazard of vapour scald or coolant scald will occur due to inner overpressure effect.
Do NOT use any additives to repair cooling system leaking into the engine coolant!
Do NOT refill cold coolant in hot engine!
Danger of engine castings damaged.
Top up only with the coolant consisting of antifreeze agents of identical base under the Section 3.2.3.
1
MAINTENANCE MANUAL
400158
400159
AV 70 X 101
3.6. Lubrication and Maintenance Operations
3.6.3. Inspect the engine belt
• Make visual belt inspection, monitor any of its damage.
Cracks perpendicular to the belt width are not considered a damage.
When longitudinal cracks occur on the belt, or belt edges are shattered, or extracted parts of material, then the belt must be replaced.
3.6.4. Crankcase breather
• Check crankcase breather pipe so it is not clogged due to any deposits, fragments, chips, or in winter frozen with ice.
400609B
400161
400609C
When running the Machine during low temperature period or under low temperature conditions, make the inspections in shorter intervals.
102
400162
AV 70 X
3.6.5. Inspect air filter vacuum valve
• Clean the exit slit, press to remove any dust trapped.
Note
Any dust trapped in the dust valve will automatically be emptied with the Machine running.
Do NOT operate the Machine when dust valve is damaged.
If air filter vacuum valve is damaged, replace it with new one of identical type!
MAINTENANCE MANUAL
400610
3.6.6. Inspect fan condition
• Inspect visually the fan. If damaged (e.g. missing parts of material, cracks, shape changes, etc.), replace the fan.
AV 70 X
400611
103
3.6. Lubrication and Maintenance Operations
3.6.7. Fuel level check
•
•
Check the amount of fuel on LH cluster signalled by LEDs, and in case of lack of fuel, please replenish.
Minimal amount of fuel is signalled by red LED flickering.
478320 h
1
2
400111A
•
•
•
Clean tank filler cap (1) and filler neck (2).
Unlock tank filler cap lock, turn the filler cap and remove it.
Refill the tank up to the bottom edge of filler neck via the strainer (3).
Note
Fuel tank capacity is 110 l (29 gal US). Fuel tank will last ca 14 hours of the Machine operation.
NO smoking and no use of open flame when at work.
Do NOT refill fuel while engine is running.
Do NOT use up fully the tank. When used up fully the entire fuel system must then be deaerated, which is rather hard and demanding.
Use solely a clean recommended fuel per
Section 3.2.2.
NEVER replenish fuel in confined space.
Fuel must NOT be spilled.
3
400165
400166
104 AV 70 X
3.6.8. Hydraulic tank oil level check
•
•
•
Lift the bonnet.
Check oil level in oil gauge.
Fill up oil via the filling device using quick-coupling (1), proceed as per Section 3.6.28.
Tank filler neck cap (2) has been sealed.
If this seal is damaged during guarantee period, then the Machine guarantee will terminate.
Conduct this filling method as emergency one – not recommended by manufacturer!
Oil level shall always be visible in oil gauge!
Refill required oil according to the
Section 3.2.4.
Upon higher loss of oil, find out the cause of hydraulic system leaking (leaks through hose screw joints, screwed fitting of hydroelectric generators or of hydraulic motors, etc.), and repair the defects.
3.6.9. Water tank refilling
•
•
•
Check water amount on the RH cluster. It is signalled by
LEDs, and in case of lack of water, please refill.
Minimal amount of water is signalled by red LED flashing.
Perform the following before engine is started.
MAX
MAINTENANCE MANUAL
1
MIN
2
400612
400112A
Open the cap (1) and refill with clean water via the strainer (2).
Before winter period, drain water from the water tank and sprinkling system!
Proceed according to Section 3.6.34.
2
AV 70 X
1
400148
105
3.6. Lubrication and Maintenance Operations
3.6.10. Inspect alarm and control devices
•
•
Turn ON the ignition key into position I.
On the LH and RH clusters the automatic control of the lighting function will occur, and this through the pilot lamps going on.
1
0 I II III 416024
•
-
-
-
Then all the pilot lamps will go off on the RH cluster, and the lamps on the LH cluster will remain on:
Indicator lamp for the zero position of travel controller.
Brake alarm indicator lamp.
Battery charge control lamp.
Engine lubrication indicator - flickers.
• In addition, please test if the switches (19 - 22) and the combined switch (17) work.
Note
When lights are switched ON the luminous intensity of indicator lamps (25) and (26) on clusters will lower.
478320 h
400111B
22 21 20 19
17
416024A
•
•
-
-
Start the engine
The indicator lamps on LH cluster must go off:
Battery charge control lamp.
Engine lubrication indicator.
Note
If the engine is not started within 10 sec. after ignition key has bee turned ON into position I, then acoustic signal will be enabled (to warn operator of the battery possibly discharged).
478320 h
106
400111C
AV 70 X
MAINTENANCE MANUAL
Start moving the Machine:
• Indicator lamps on LH cluster shall go OFF:
Indicator lamp for the idle (neutral) of travel controller.
Brake alarm indicator.
•
•
Emergency brake push button function:
• Check whether emergency brake works (8).
The engine stalling.
Then the following indicator lamps on LH cluster remain
ON:
•
-
-
Seat switch indicator lamp.
Parking brake warning lamp.
Battery charging indicator.
Engine lubrication indicator - flickers.
When travel controller is shifted to neutral position (N) the seat switch indicator lamp goes OFF, and idle indicator lamp lights up. Now you can start the engine again.
Use sound signal to indicate the engine start!
Before engine is started, check there is no hazard of any person if engine is started!
Use sound signal before Machine starts moving and wait long enough to any persons present can leave the area round the Machine (space beneath the
Machine) in time!
Make sure the area in front and behind the Machine is free, with no persons present within thereof!
During operation, check continuously the instruments and indicator lamps.
Promptly repair any failures!
8
478320 h
400111D
N 0
400169
AV 70 X
478320 h
400111
107
3.6. Lubrication and Maintenance Operations
Following 250 hours of operation (3 months)
3.6.11. Engine oil exchange
•
•
•
•
•
Prepare an appropriate vessel of ca 9 l (2,4 galUS) capacity.
Remove drain plug (1) and let the oil flow out.
Check the drain plug gasket, replace if damaged.
Check the thread and clean seating face for gasket.
Reinstall the plug. Torque is 50 Nm (37 ft lb).
When draining the oil temperature shall not be over 60°C (140°F) – risk of burn.
1
400613
• Clean the surface round oil filter head. Remove the filter.
• Clean seating face for filter gasket.
108
400614
400173
AV 70 X
MAINTENANCE MANUAL
• Fill the new filter with clean engine oil.
282N130T
• Apply a thin layer of oil on the filter rubber sealing.
400174
• Mount the filter and tighten it by hand.
Do not overtighten the filter, the thread and gasket may get impaired!
• Use filler neck (2) to fill the engine with clean motor oil.
AV 70 X
2
388N134
400609A
109
3.6. Lubrication and Maintenance Operations
Note
• Fill up to the dipstick’s top division mark. Total sump capacity is 7 l (1,85 gal US).
•
•
When oil is exchanged, start the engine and let it run at higher idle rmp for 2 - 3 min.
Stop the engine and wait for ca 3 min until oil descends into the crankcase, then check the proper oil level.
Drain oil when hot – best upon operation completion.
Use original filters only.
Use recommended oil under Section
3.2.1, only.
To not overtighten the filter, its thread and gasket may get damaged.
Check the tightness.
Collect the oil drained, do not let oil soak into soil.
Dispose of oil compliant to regulations.
Store used filters in a separate container and handle them so these do not pollute the environment.
3.6.12. Inspect engine induction manifold
• Check the pipes and clamps.
Do not operate the Machine if pipes and clamps are damaged!
3.6.13. Inspect engine cooling circuit
• Check the cooling circuit tightness. Confirm no pipes are damaged and no clamps are missing.
110
400178
400611A
400615
AV 70 X
• Check that oil cooling gills and radiator fins are not fouled.
If fins are fouled then clean them, for instance purging the coolers with pressure air (steam or hot water) according to
Section 3.6.32.
AV 70 X
MAINTENANCE MANUAL
400616
400617
400181
400618
111
3.6. Lubrication and Maintenance Operations
3.6.14. Inspect the battery
• Stop the engine and use disconnector to disconnect the wiring.
400619
•
•
•
Clean the battery surface.
Inspect the condition of poles and terminals. Clean the poles and terminals. Apply thin layer of grease on terminals.
In case of a maintenance-free battery (the battery has no freely accessible plugs), only the no-load voltage on terminals is checked. The batteries cannot be replenished. If the no-load voltage is 12.6 V and more, the battery is fully charged. If the no-load voltage is below 12.2 V, the battery should be charged immediately. After it has been charged, leave the battery at rest for 2 – 3 hours and then measure the no-load voltage again. It is recommended to be mounted 24 hours after charging.
• Open the battery cell plugs (2) to check electrolyte level to confirm the electrolyte level reaches 5 ÷ 15 mm (0.2÷0.6 in) above the plates (electrodes) in all the cells, or to the bottom edge of the gauge inside the battery cells. Refill with distilled water those cells having electrolyte less than 5 mm
(0.2 in) above the plates.
2
1
1
400620
416033
• Measure the electrolyte density in individual cells with the refractometer or density meter.
112
400183
AV 70 X
• Compare measured values with the chart.
Density in g/cm 3
20 °C
68 °F
1,28
Tropics
1,23 in °Be (Beume)
20 °C
68 °F
Tropics
32° 27° fully charged semi charged exhausted charge immediately!
1,2
1,12
1,12
1,08
24°
16°
16°
11°
Note
• Check the level with glass tube.
• Unless the Machine is going to be used during winter season for a couple of months, remove the battery and store it so it is protected against any frost. Carry out inspections of the battery and its recharging before its storage and for the period it is stored.
Use rubber gloves and safety glasses when working with the battery.
Protect your skin with proper clothing against being stained by electrolyte.
Upon eye contact with electrolyte immediately flush eyes with large amounts of water for at least a couple of minutes.
Get prompt medical attention.
Upon ingestion of electrolyte drink max amount of milk, water or solution of calcined magnesia in water.
Upon skin contact with electrolyte remove contaminated clothing, including shoes, wash affected spots as soon as possible with soap water or solution of soda and water. Get prompt medical attention.
Do not eat, drink, smoke, while at work!
Having finished the work, please wash your hands and your face thoroughly with water and soap!
Do not try whether wires are energized through contacting Machine frame.
MAINTENANCE MANUAL
Keep the battery dry and clean.
Close the battery when checking is completed.
Refill the battery with distilled water only – never with acid.
Replenish distilled water just before operating the Machine or before battery recharging.
Recharge the undercharged battery.
Recharge the battery off the Machine.
Open battery plugs before recharging.
Never disconnect the battery with the engine running.
Follow the battery manufacturer’s manual when working with the battery!
Disconnect the battery during its repair, or when handling the wires and electric devices within the wiring circuit to avoid any short circuit.
To disconnect the battery you must first disconnect (–) pole of the cable. To connect, first connect (+) pole.
Never make direct conductive connection between the battery’s both poles, short circuit will occur with the risk of battery explosion.
Do not turn the battery upside down, electrolyte may pour down from the degassing plugs.
Flush spilled electrolyte with water, and neutralize with lime.
Hand over the aged battery that does not work, for its disposal.
AV 70 X 113
3.6. Lubrication and Maintenance Operations
3.6.15. Air filter sensor check
•
•
Adjust the engine rpm to round 1500 rmp.
Cover briefly the air filter intake hole.
Inspect always when cleaning the induction air pre-filter!
• Once covered, the indicator lamp for air filter clogged shall light up.
• Unless indicator lamp goes ON, check the vacuum switch, contacts and feeder cables.
400618A
478320 h
400185
400186
114 AV 70 X
3.6.16. Watering filter cleaning
• Close water supply through the valve (1, 2).
• Remove sprinkler filter vessel, replace the strainer and clean it.
1
MAINTENANCE MANUAL
2
400288
400635
400262A
AV 70 X 115
3.6. Lubrication and Maintenance Operations
• Remove and clean sprinkler strainers (3).
3
400289
400190
116 AV 70 X
MAINTENANCE MANUAL
3.6.17. Machine lubrication
• Take off the caps on the greasing nipples.
• Step by step, put on the greasing nipple of high-pressure press and lubricate till the old grease starts pouring out.
• Reinstall the greasing nipple caps.
Use only the recommended lube greases, refer to Section 3.2.5.
Steering joint
Upper bearings 2 x
Lower bearings 2 x
400191
Main bearing 4x
400192
Linear hydraulic motors for steering
Pins 6x
AV 70 X
400193
117
3.6. Lubrication and Maintenance Operations
Linear hydraulic motors to lift off the bonnet
Upper pins 2 x
Lower pins 2 x
Cabin door hinge pins pins 8 x
400194
400195
118 AV 70 X
After 500 hours of operation (after 6 months)
3.6.18. Engine fuel filter exchange
•
•
Clean the fuel filter.
Remove the filter.
• Clean the sealing face of filter holder.
MAINTENANCE MANUAL
400616A
• Fill new filter with clean fuel and lubricate sealing “O” ring
(2) with oil.
2
400173
400198
• Screw the filter with hand until the gasket gets seated, and then tighten by another half-turn.
AV 70 X
388N134
119
3.6. Lubrication and Maintenance Operations
•
•
Use a hand pump to add fuel into the filter.
Inspect the filter tightness when engine is started!
Observe fire precautions during replacement!
Replace in ventilated rooms with no fire hazard.
Do not smoke or use open flame when at work.
Use the recommended original filters, only.
Make no over-tightening of filters, the thread and gasket may get damaged.
Avoid fuel leaking into soil.
Store used filters in environmentally friendly manner.
3.6.19. Engine cooling liquid level check
• Check the concentration via refractometer.
Inspect always before winter season.
Unless concentration for -36 °C (-33 °F) has been measured, you must adjust it through adding antifreeze into the cooling system.
Add antifreeze according to Section
3.2.3.
400616B
400183
120 AV 70 X
After 1,000 hours of operation (after 1 year)
3.6.20. Inspect engine belt
When the engine is running, check visually the belt pulley of alternator 1 and crank shaft 2 to make sure that it does not oscillate.
1
MAINTENANCE MANUAL
2
416025
Stop the engine!
Check the belt tension by applying a pressure of 110 N (25 lb). If the deflection X exceeds the belt thickness, tighten the belt.
X
416026
Tighten the belt after slackening screws and by moving the alternator.
Make sure that the engine is switched off when tightening the belt!
Note
Measure the belt tension by means of a jig that can be ordered from CUMMINS, according to the manual Engine Maintenance
(Section V15) that is a part of the machine documentation.
3.6.21. Inspect the exhaust system
•
•
•
Check the leak tightness of exhaust manifold in the direction towards the engine.
Check the exhaust manifold leading to the exhaust muffler.
Torque of the exhaust-header (collector) pipe - 21 Nm.
400623
AV 70 X
400626
121
3.6. Lubrication and Maintenance Operations
3.6.22. Inspect the silencing system
• Check the condition of rubber-metal, coherence (bond strength) between metal and rubber.
Replace the damaged ones.
Check the bolts and nuts of the following are tightened:
Rubber-metal of drums – LH side and RH side 2x 10.
Rubber-metal of driver’s compartment 4x.
122
400290
400621
400291
AV 70 X
Rubber-metal for the engine 3x.
Rubber-metal for battery holder 4x.
Cooler metal rubber parts, 4 pieces.
AV 70 X
MAINTENANCE MANUAL
400622
400620B
416018
123
3.6. Lubrication and Maintenance Operations
3.6.23. Clean the water tank
• Remove the tank filler neck cap.
•
•
Open tank drain hole.
Flush the tank with stream of water.
400148A
400206
• Clean the strainer inside the filler neck.
Drain water from water tank before winter season!
Proceed in line with the Section 3.6.34.
400148B
124 AV 70 X
3.6.24. Oil change in the gearboxes
Oil draining:
• Clean the places around the plugs.
•
•
Place the machine so that the plug (1) is at the lowest position.
Dismount the plug (1), (2) and let the oil flow out to a container with a capacity of 15 l (3.96 US gal).
Note
Renew the oil when it is hot.
Let the drained oil cool down below 50 °C
(120 °F).
Oil filling:
• Place the machine so that the (1) is at the highest position.
• Fill in the recommended oil using the filler plug (1).
Check of the oil level:
• Check the oil level using the inspection hole 2.
• The oil level must reach the bottom edge of the hole or the oil must flow out slightly.
• Remount the plugs; if the plug seals are damaged, remove them.
Change the oil after the first 200 engine hours.
Do not touch the gearbox and adjacent parts if hot.
Catch the drained oil.
Dispose of according to legal regulations.
MAINTENANCE MANUAL
1
1
400627
2
400628
AV 70 X 125
3.6. Lubrication and Maintenance Operations
After 2,000 hours of operation (after 2 years)
3.6.25. Checking and adjusting valve clearance
• Call CUMMINS service department to adjust the engine valves. Next valve adjustment will follow periodically after
2000 hours or after two years - for contact points, please refer to Engine Operation and Maintenance Manual.
3.6.26. Engine coolant exchange
How to drain cooling circuit:
Before you drain the coolant from the cooling circuit let the engine run for 5 minutes for the liquid temperature to reach 82°C (180°F).
Do not open overpressure plug before coolant temperature drops below 50 °C
(122 °F). If you open overpressure plug the liquid may splash out causing scald.
Stop the engine.
• Open the cooling system by removing the overpressure plug (1) on the expansion tank.
1
126
400159
400158A
AV 70 X
• Remove the cooling circuit drain plug. Let the liquid pour down into the vessels set up. The drained amount is ca 15 l
(3,96 gal U.S.).
MAINTENANCE MANUAL
400613A
• Check whether pipes within the engine cooling system are not damaged, clips missing. Check the radiator condition whether not damaged, not leaking, and cooling gills not fouled with impurities. Clean and repair the radiator, if required.
400181
Clean the cooling circuit:
The process of cleaning the cooling circuit is divided into two parts.
•
•
First part:
• Install the drain plug, fill the cooling system with the mixture of the following ratio: 0,5 kg (1 lb) of sodium carbonate and 23 l of water, or agents normally available on this base.
• When filled, wait for ca 2-3 min until air escapes and the circuit gets filled. Max filling rate is 10 l/min (2,6 gal US/min).
Do not close the tank with overpressure plug.
Start the engine and let it run for 5 minutes for liquid temperature to reach 82°C (180°F).
Inspect cooling circuit tightness and liquid level on water gauge.
Stop the engine, drain the cooling circuit and reinstall the drain plug.
AV 70 X
400613A
400217
127
3.6. Lubrication and Maintenance Operations
•
•
Second part:
• Fill the cooling circuit with clean water. When filled, wait ca
2-3 min until air escapes and the circuit gets filled. Max filling rate is 10 l/min (2,6 gal US/min).
Do not close the tank with overpressure plug.
Start the engine and let it run for 5 minutes for liquid temperature to reach 82°C (180°F).
Inspect cooling circuit tightness and liquid level on water gauge.
• Stop the engine and drain the cooling circuit.
Note
Repeat this process until clean water flows out.
Fill the cooling circuit:
• Install the drain plug, fill the cooling system with new coolant at the ratio of min 50 % water + 50 % antifreeze.
Wear gloves to protect your hands!
Wear safety glasses or face shield to protect your eyes!
Fill with the coolant according to the
Section 3.2.3!
To make the change proceed as per the manual from antifreeze producer!
• Refill the coolant to max level. When filled wait ca 2-3 min until air escapes and the circuit gets filled. Max filling rate is 10 l/min (2,6 gal US/min). Close the expansion tank with overpressure plug.
Start the engine and wait until the temperature reaches 82 °C (180 °F). Check during your waiting for any leakage of cooling liquid and check the level on the indicator.
128
400218
400158B
400219
400218
AV 70 X
•
•
Stop the engine.
Confirm the coolant level on water gauge is between MIN and MAX.
MAINTENANCE MANUAL
400158B
Do not open the overpressure plug before coolant temperature drops below
50 °C (122 °F). If you open overpressure plug the liquid may splash out causing scald!
Hand over the used liquid for its safe disposal under the regulations!
400159
AV 70 X 129
3.6. Lubrication and Maintenance Operations
3.6.27. How to exchange oil in the vibrators
How to drain oil:
• Locate the Machine so the plug (1) is in its lowest position.
•
•
Remove plug (1) and let oil pour down into the vessel of 15l
(4 US gal) capacity.
Reinstall the plug.
Note
Exchange oil at the time when oil is hot.
Let the drained oil to cool down below 50 °C (120 °F).
•
•
•
•
Oil filling:
• Locate the Machine so the plug (1) is in its highest position.
Remove the plug (1).
Check the amount of oil through loosening plug (2), oil must flow out.
Reinstall the plug (2).
Use port (1) to refill 2 more litres of oil (0,5 galUS).
• Reinstall the plug (1).
Avoid oil escape into ground.
3.6.28. How to exchange hydraulic oil and filters
Carry out oil exchange before the season starts, or following a rather long shutdown of the Machine. At the same time clean the inlet strainer, as well.
•
•
Dismount the drain plug.
Let oil pour down into the vessel set up – total amount of oil flowing out is 40 l (10,56 gal US).
1
• Dismount the suction hose.
1
400293
2
400294
400624
130
400629
AV 70 X
•
•
•
•
•
Remove the cap (1) along with inlet strainer (2).
Remove the inlet strainer away from the inlet pipe. Wash the inlet strainer and purge the strainer with compressed air from inside.
Check the inlet strainer condition, in case filter element is impaired you must replace it.
Inspect the tank’s inner space. Should there be any impurities on its bottom, clean thoroughly and flush the tank with new oil.
Remount the tank lid (1) and use a new seal.
Drain oil when cooled down below 50 °C
(122 °F).
Observe the fire precautions!
When disconnecting the hydraulic circuits blind all the ports with plugs.
Collect drained oil and do not let it soak into ground.
Used oil is ecologically hazardous waste
– hand it over for professional disposal.
Check oil temperature sensor:
• Remove the sensor on the hydraulic tank cube and clean the contact.
MAINTENANCE MANUAL
1
2
400630
400629A
• Dip the sensor in water of 100°C (212°F) temperature, check its function correctness on the LH cluster – hydraulic oil level indicator lamp will light up, refer to the Fig.
AV 70 X
478320 h
400111E
131
3.6. Lubrication and Maintenance Operations
Fill the hydraulic circuit:
• Fill with the filling device of the following parameters:
Min pressure 6 MPa (870 PSI)
Filtering property 3 to 10 µm
• pler.
• Fill the hydraulic circuit until clean oil starts to flow out from the drain plug.
•
•
After approximately 15 l (4 gal US) flow out, mount the drain plug.
Top up the tank with oil its max level and disconnect the filling device.
MAX
MIN
2
1
400612
Spare filling via tank filler neck (2):
Carry out hydraulic circuit filling via the filler neck in emergency cases only!
This filling method will need to reduce the next exchange interval by one half, i.e. 1000 hours or 1 year.
•
•
Tank filler neck plug has been sealed. When this seal is broken during guarantee period then the guarantee will terminate.
Fill the tank through its filler neck with the required type of oil up to the bottom of a strainer inside the filler neck.
Note
• When filling through the tank filler neck a large portion of old oil will remain in the circuit along with the impurities, and the life of hydraulic units will lower.
• You may order the filling device with the Machine manufacturer or a dealer.
When the circuit is filled, please check the hydraulic oil level indicator lamp is not ON.
Start the engine and test the Machine functions at the increased RPM so to fill the circuits.
Check the filter tightness, temperature sensors, inlet pipes and lids.
Observe cleanliness at work. Prevent any contamination of the system with the materials that might cause damage to the major units!
Follow the fire precautions!
Do not open uselessly the hydraulic tank!
Exchange oil and filter element always when destruction of the inner parts of the units (hydraulic motors, hydroelectric generators) occurs, or following a major repair of the hydraulic system. Clean and flush the hydraulic tank before new unit is installed. Replace filter element.
Never use chemical cleaning agents to clean the tank.
To clean, please use cleaners with no fibre let-off.
Refill oil according to the Section 3.2.4.
132 AV 70 X
MAINTENANCE MANUAL
How to replace pressure filter element
Replace always during:
• oil exchange
• pressure filter indicator lamp goes on when oil operating temperature reaches 50 - 60 °C (122 - 140 °F).
•
•
•
•
•
•
Remove the filter vessel.
Remove the filter element.
Clean thoroughly the filter vessel.
Clean from the bottom the seating face of filtration block.
Check the condition of sealing rings and paint the rings with clean oil.
Insert new element into the filter vessel and screw on again
– tighten with 40 +10 Nm (30 +7 ft lb) torque.
Use the original filter elements according to the Spare Parts Catalogue, only.
Used filter elements are ecologically hazardous waste – hand them over for professional disposal.
478320 h
400111G
400226
400227
AV 70 X 133
3.6. Lubrication and Maintenance Operations
Maintenance as required
3.6.29. Fuel system breathing
Deaerate the fuel system before the first start upon:
• filter replacement
• long term shutdown of the Machine
• fuel drawn off
Low-pressure piping blow-off and filter deaeration:
Use the pump on fuel filter head to blow off the low-pressure piping.
Follow safety regulations!
No smoking or use of open flame while at work on fuel system!
Avoid fuel escape into soil!
400616B
134 AV 70 X
MAINTENANCE MANUAL
3.6.30. How to replace air filter elements
The proper maintenance of air filter and of the entire inlet piping, the rubber parts in particular, will ensure maximal protection of the engine against dust effects, and prolong the life of the element and its efficiency.
The inherent sign of fouled filter is the exhaust pipe that smokes, higher fuel consumption, output loss and engine temperature increased.
•
•
•
•
•
Principles of correct filter element replacement:
• Slowly pull out the clogged element as carefully as possible.
Always clean the inner bodies of the cleaner in a way to avoid dust penetrating inside the engine feed piping.
Clean the seating faces for gasket in the cleaner body.
Examine the dust traces in the element removed, any traces would be an indication of its leakage in the filter body.
Press the gasket on the new element, whether it is flexible.
Make sure the gasket is seated properly.
NEVER use damaged elements!
Do NOT use other elements than those required!
Do NOT remove the elements just for checking purposes!
Do NOT left the filter opened longer than necessarily required!
NEVER operate the Machine with filter body damaged!
How to replace air filter element:
• The air filter comprises the main element and safety element.
• Replace the main element always when signalled by indicator lamp for air filter fouled.
•
•
•
•
Replace the safety element always following the three replacements of the main element.
Confirm the fixing and integrity of the air filter and intake piping.
Saturation of the air filter element will be signalled by the indicator lamp for air filter fouled.
When the indicator lamp goes on you must replace the main filter element.
• Remove filter cap (1) and replace the main filter element (2) from the filter shell.
AV 70 X
478320 h
400111H
1
400610A
135
3.6. Lubrication and Maintenance Operations
2
•
•
Replace the safety element (3) from the filter shell and check it.
Replace the safety element always following three replacements of the main element.
When safety element is damaged, please replace it with the new one of identical type as per identification!
• Clean filter’s inner space in such a way to avoid dust penetration into the inner feed piping to the engine.
NEVER use compressed air to clean the inner space.
3
400631
400632
400633
• Take off the air filter vacuum valve, clean it and reinstall.
Replace instantly a damaged vacuum valve!
136
400610
AV 70 X
3.5.31. How to clean water separator of fuel filter
• Water trap indicator lamp is ON.
MAINTENANCE MANUAL
400112B
•
•
Loosen the drain valve (1).
Let the deposits flow out and screw it.
Do not drain separator when the engine is running.
Follow the fire precautions.
No smoking allowed at work on fuel system.
Collect escaped fuel in the vessel set up.
416021
1
400233
AV 70 X 137
3.6. Lubrication and Maintenance Operations
3.6.32. Cleaning of coolers
•
•
Due to various working conditions no regular cleaning interval can be set.
In case of work in very dusty environment, perform daily cleaning. Cooler fouling will show in a reduced cooling performance and increased temperatures of engine coolant and of hydraulic oil.
• Remove the cover.
• Clean with compressed air or pressure water (steam). Clean in the direction from the fan side.
Do NOT clean the radiator with too high pressure so to avoid its damage.
When radiator is contaminated with crude oil products, use a cleaner and proceed according to the manufacturer’s manual!
Find out a cause of contamination!
Clean the Machine at a workplace equipped with cleaner collection system to prevent soil contamination and water resource contamination!
NEVER use forbidden cleaners!
3.6.33. How to clean cab ventilation filter
•
•
•
Remove the cover grill (1).
Remove the filter element.
Beat out the element carefully and wash in a detergent solution. If filter element will become damaged or unable to be made rid of the impurities, please replace it with new one.
Clean regularly 1 x per month. Should it be you work in a very dusty environment then the cleaning intervals should be cut short.
138
1
400618
400611
416004A
AV 70 X
3.6.34. Drain water from sprinkling circuit before winter season
• Before winter season it will be necessary to drain water from the sprinkling circuit with regard to any potential damage to individual parts because of frost.
How to drain water from the sprinkling circuit:
• Remove sprinkling water tank drain plug. Store the drain plug at a safe place.
• Tank’s full capacity is 600 l (158,5 gal/US).
• Remove and clean the vessel (1) incl. sprinkling filter (2).
Store the vessel complete with filter at a safe place.
MAINTENANCE MANUAL
1
2
400206
400262
• Keep the valve for water supply from the tank opened.
400295
• Dismount the drain plugs.
AV 70 X
400635A
139
3.6. Lubrication and Maintenance Operations
•
•
•
•
Detach at least one sprinkler from each pipe on the front and rear sides of the Machine. Store the sprinklers at a safe place.
Switch ON the sprinkling pumps for 20 sec. so these become drained.
This procedure will guarantee you max drainage of the sprinkling circuit.
when all the abovementioned operations are completed, please proceed in reverse steps, clean thoroughly the individual parts, first.
By draining the water from the sprinkling circuit in time you will avoid any potential damage that the manufacturer shall bear no responsibility for!
400289
140 AV 70 X
3.6.34. Adjust the scrapers
ADJUSTABLE SCRAPERS (Standard)
• The machine is equipped with four adjustable scrapers.
Setting of scrapers:
• Slacken two screws on both sides of the scraper at point (1) and (2) and by moving the scraper in the oval-shaped hole set up the correct function of the blade (3).
• If the scraper is set in the oval-shaped hole at the maximum and the blade is worn-out, remove the blade and replace with a new one.
1
3
MAINTENANCE MANUAL
1 3
2
416040
416041
Blade replacement:
• Dismount the screws (4) and remove the blade (3) with strips (5).
• Follow the above-mentioned steps in reverse order when mounting a new blade.
Correct setting of scrapers ensures perfect cleaning of the drum during the machine operation!
Set up the correct function of the scraper upon the replacement of the blade!
4
5 3
416040A
AV 70 X 141
3.6. Lubrication and Maintenance Operations
HINGED SCRAPERS (optional)
• The Machine is fitted with four hinged (tilting) scrapers.
Position the scrapers:
• In position (1) the scraper is set in transport position.
1
•
•
In position (2) the scraper is set in working position.
When in working position, the scraper blade (3) is pressed against the drum body (4) by means of gas struts (4).
•
•
Replace the blade:
• When the blade becomes excessively worn, please lift off the scraper, remove the bolts (5) and take off the blade (3) along with the strip (6).
Proceed in reverse steps to reinstall a new blade.
At the same time always check the proper function of the gas struts (4).
Only when the gas struts work properly and the worn scraper blades are replaced in time, this will provide you with perfect drum cleaning!
416034
2
5
6
4
3
416035
3
416034A
142 AV 70 X
3.6.36. Machine cleaning
•
•
When the work is completed clean the Machine to get rid of major impurities.
Carry out overall cleaning on regular basis, at least once per week. Total cleaning must be done daily if working on cohesive soils, cement or lime stabilizations.
Disconnect the disconnector.
Carry out the work with the engine stopped.
NEVER use aggressive or easily ignitable cleaners (e.g. petrol or easily or flash fuels).
Before pressure cleaning with water or steam, please blind all the ports into which a cleaner might penetrate (e.g. engine inlet port). With the Machine cleaned remove these blinds.
Do NOT expose electric parts or insulation material to direct water or steam streams. Always cover these materials
(alternator’s inner space, etc.).
Clean the Machine at a workplace equipped with cleaner collection system so to avoid soil or water recourse contaminations!
NEVER use banned cleaners!
MAINTENANCE MANUAL
3.6.37. Check the tightening of bolted connections
•
•
Confirm regularly that no loosening of bolted connections has occurred.
Use the torque spanners to do the tightening.
Worm
M6
M8
M8x1
M10
M10x1,25
M12
M12x1,25
M14
M14x1,5
M16
M16x1,5
M18
83
66
132
106
200
160
275
19
48
38
TIGHTENING MOMENT
For the screws
8,8 (8G)
Nm lb-ft
For the screws
10,9 (10K)
Nm lb-ft
10
24
7,4
25,0
14
34
10,3
25,0
14,0
35,4
28,0
27
67
54
19,9
49,4
39,8
61,2
48,7
97,3
78,2
147,5
118,0
202,8
117
94
185
148
285
228
390
86,2
69,3
136,4
109,1
210,2
168,1
287,6
M18x1,5
M20
M20x1,5
M22
M22x1,5
M24
M24x2
M27
425
675
540
995
220
390
312
530
162,2
287,6
230,1
390,9
313,4
497,8
398,2
733,8
312
550
440
745
590
950
760
1400
230,1
405,6
324,5
549,4
435,1
700,6
560,5
1032,5
M27x2
M30
M30x2
795
1350
1080
586,3
995,7
796,5
1120
1900
1520
826,0
1401,3
1121,0
The figures given in the chart are torques at dry thread (with coefficient of friction = 0,14). These figures do not apply to a lubricated thread.
AV 70 X 143
3.6. Lubrication and Maintenance Operations
Chart showing the torques for cap nuts with sealing “O” ring – hoses
Tightening moments for the sliding nuts with the tightening circle „O“ - hoses
Nm lb ft
Size spanner
14
17
Worm
12x1,5
14x1,5
Hose Nominal
20
38
Min
15
30
Max
25
45
Nominal
15
28
Min
11
22
Max
18
33
19
22
24
27
30
32
36
41
46
50
50
16x1,5
18x1,5
20x1,5
22x1,5
24x1,5
26x1,5
30x2
36x2
42x2
45x2
52x2
18
20
22
25
12
14
15
16
28
30
35
38
42
8
10
6
8
10
12
45
51
58
74
74
105
135
166
240
290
330
38
43
50
60
60
85
115
140
210
255
280
52
58
65
88
88
125
155
192
270
325
380
33
38
43
55
55
77
100
122
177
214
243
28
32
37
44
44
63
85
103
155
188
207
38
43
48
65
65
92
114
142
199
240
280
144 AV 70 X
10 x 1
12 x 1,5
14 x 1,5
16 x 1,5
18 x 1,5
20 x 1,5
22 x 1,5
26 x1,5
27 x 1,5
33 x 1,5
42 x 1,5
48 x 1,5
G -M
G 1/8
G 1/4
G 3/8
G 1/2
G 3/4
G 1
G 11/4
G 11/2
Chart showing the torques for necks with sealing edge, or with flat gasket
Tightening moments for the necks
Nm lb ft
25
40
18
30
95
130
70
96
250
400
600
800
184
295
443
590
220
250
400
600
60
60
140
140
25
30
50
800
162
184
295
443
44
44
103
103
18
22
37
590
10 x 1
12 x 1,5
14 x 1,5
16 x 1,5
18 x 1,5
20 x 1,5
22 x 1,5
26 x1,5
27 x 1,5
33 x 1,5
42 x 1,5
48 x 1,5
G -M
G 1/8
G 1/4
G 3/8
G 1/2
G 3/4
G 1
G 11/4
G 11/2
MAINTENANCE MANUAL
Chart showing the torques for plugs with flat gasket
120
150
250
400
60
70
90
100
13
30
40
500
Tightening moments for the plugs
Nm lb ft
15
33
11
24
70
90
52
66
150
220
600
800
111
162
443
590
89
111
184
295
44
52
66
74
10
22
30
369
AV 70 X
M-G M-G
400239
M-G
400240
145
146 AV 70 X
3.7. Defects
In most cases the defects are due to operating the Machine improperly. Therefore during any failure read thoroughly once more the instructions given in the Machine and Engine Operation and Maintenance
Manual. Unless you will be able to specify the cause of a defect, please contact authorized dealer’s or manufacturer’s Help Desk (service assistance).
The troubleshooting of hydraulics and wiring requires expertise in the field of hydraulics and wiring, so we strongly recommend to hand over the troubleshooting process to the Help Desk of an authorized dealer or manufacturer.
AV 70 X 147
3.8. Attachments
Wiring Diagram
Legend:
A1 Clicker (course light interrupter)
A2 LH cluster
A3 RH cluster
A4 Travel electronics
A5 Travel controller
A6 Time relay
B1 Fuel level float
B3 Pressure sensor in water tank
B4 Engine RPM sensor
B5 Drum speed sensor
C1 Interference filter
E1,2 Front contour lights
E3,4 Rear lights
E5,6 Front headlamps
E7,8 Rear headlamps
E9,10 Left traffic-indicator lights
E11,12 Right traffic-indicator lights
E13,14 Auxiliary headlamps front
(optional)
E15,16 Auxiliary headlamps rear
(optional)
E17 Hazard beacon (optional)
E18,19 Brake (stop) lights
E20 Cabin lighting
E21 Car make lighting (optional)
F1-17 Cut-out fuses
G1 Battery
G2 Alternator
H1 Dipped light indicator lamp
H2 Distance light indicator lamp
H3 Loud horn
H4 Acoustic warning indicator
H5 Backing horn (optional)
K1 Contactor
K2-19 Auxiliary relay
K20 Glowing contactors
K22 Auxiliary relay
M1 Engine starter
M2 Sprinkling motor
M3 Sprinkling motor
M4 Front wiper
M7 Windscreen washer
M9,10,11 Fans
Q1 Battery disconnector
R1 Sprinkling interval potentiometer
R2 Speed potentiometer
R3 Resistor
R4, 5 Engine preheating
S1 Ignition box
S2 Combined switch
S2.1 Switch for contour lights and headlights
S2.2 Distance / dipped lights switch
S2.3 Light horn switch
S2.4 Loud horn pushbutton
S2.5 Traffic-indicator lights switch
S3 Rear headlamp switch
S4 Warning lights switch
S5 Auxiliary lights switch (optional)
S6 Hazard beacon switch (optional)
S7 Brake pressure switch
S8 Switch for hydraulics filter fouled
S9 Switch for air filter fouled
S10 Engine lubrication pressure switch
S11 Engine overheating switch
S12 Hydraulic oil overheating switch
S13 Float – water in fuel filter
S14 Backing horn switch
S15 Neutral switch
S16 Emergency brake pushbutton
S18 Constant speed or engine overload switch
S19 Vibration automatics switch
S20 Smooth start or smooth stop pushbutton
S21 Seat switch
S22 Vibration pushbutton (red) on
LH travel lever
S23 Vibration pushbutton (red) on
RH travel lever
S24 Sprinkling pushbutton
S25 Sprinkling pumps switch
S26 Vibration amplitude switch
S27 Front / both / rear vibration selector switch
S28 LH (yellow) pushbutton on LH travel lever – CRAB left
S29 RH (yellow) pushbutton on LH travel lever – CRAB right
S30 LH (yellow) pushbutton on RH travel lever – CRAB left or edge cutter upward
S31 RH (yellow) pushbutton on RH travel lever – CRAB right or edge cutter downward
S32 Front wiper switch
S34 Spaeyer pushbutton
S35 Fan switch
S36 Air conditioner switch (optional)
S38 Float in hydraulic oil tank
S39 CRAB resetting pushbutton
S40,41 CRAB position switches
S42 Hydraulics temperature switch
S44 Air conditioner overpressure fuse (optional)
S45 Switch of scraper watering
(optional)
X1 Mounting socket
X2 Diagnostics socket
X3-4 Connection terminals
X5-64 Interface connectors
Y1 Engine stop solenoid
Y3 Brake valve
Y4 Back drive valve
Y5 Rearward drive valve
Y8 Vibration low amplitude valve
Y9 Vibration high amplitude valve
Y10 Front drum vibration valve
Y11 Rear drum vibration valve
Y12 CRAB left valve
Y13 CRAB right valve
Y14 Relief valve
Y15 Edge cutter upward valve
(optional)
Y16 Edge cutter downward valve
(optional)
Y17 Air conditioner compressor clutch magnet (optional)
Y18 Solenoid valve of the edge cutter watering (optional)
148 AV 70 X
MAINTENANCE MANUAL
Front drum speed
- in the roller with one-piece drums brown
Blue
X65:3
X65:2
X65:1
X5:45
X5:44
X5:43
K10/3
A4/17
Engine glowing
Engine glowing
Front contour lights
Rear lights
Car make lighting
Front headlamps
Loud horn
Rear headlamps
Left front traffic-indicator light
Left rear traffic-indicator light
Right rear traffic-indicator light
Right front traffic-indicator light
Auxiliary headlamps front
Auxiliary headlamps rear
Hazard beacon
Brake (stop) lights
Brake
Hydraulic filter
Air filter
Engine lubrication
Engine overheating
Fuel gauge
Hydraulic oil overheating
Water tank level
Float – water in fuel filter
Backing horn
Engine stop
Hydraulic oil level
Front right drum speed
Brake
Travel forward
Travel backward
Drum speed sensor
R4
K20
F16
125A
F17
125A
G1
12V
100Ah
Q1
F9
B
G2
L
IG
30
31
M1
50
K1
R5
K21
31
31
H3
E1
E2
E3
E4
X26:1
E21
56b
E5
56a
56b
E6
56a
E7
E8
X28:1
X26:2
X26:3
C1
X27:1
X31
X28:2
X26:4
X28:4
E9
E10
X27:2
X29:2
X5:3
X5:4
X5:26
X5:27
X5:5
X5:36
X5:7
X5:8
E11
E12
X29:3
X27:3
X5:9
X5:10
H2
85
87
9
1
E13
E14
X51 X6:4
E15
E16
E17 X30
X28:3
X52
X53 X49:2
X56:1 X6:5
X56:2
X54
X55:1
X55:2 X49:6
X6:6
X5:11 E18
E19
H1
87
85
K2
K3
30
86
86
30
S3
5
10
P
P
P
P
S7
S8
S9
S10
S11
B1
S12
S42
X62:6
X62:3
X5:12
X5:13
X5:14
X5:15
X5:16
X5:17
X5:18
X5:19
8
18
19
11
13
15
16
17
6
9
5
7
2
X8:1
X7:1
X7:3
X8:2 C
M
MC
Y
S
Z
2
8
3
S4
6
1
5
10
87
85
K7
30
86
S2
S2.1
H X7:2
S2.2
S2.3
S2.4
B
S2.5
O
X7:4
CL
1
9
1
9
A1
Instrument illumination
Traffic-indicator
Traffic-indicator lights
Brake
Charging+ motohours
Neutral
Hydraulic filter
Seat
Air filter
Engine overheating
Fuel gauge
Hydraulic oil level
Supply +12V
Ground
Engine stop
Vibration
Warning
31
S5
5
10
S6
5
10
14
3
12
20
10
1
X32:2
B3
1
X63:2
2
S13 X63:1
X62:2
X62:8
1(Brown)
B4
X62:7
H5
Y3
Y4
Y5
X32:1
X29:1
B5
4(Black)
3(Blue)
X33:1
X33:2
X5:20
X5:21
X5:24
S38
V11
Y1 X62:1 X5:28
X5:37
85
87
87a
K10
86
30
X5:45
X5:44
X5:43
X5:38
X5:39
X5:40
X5:41
X60
X5:6
X5:29
X5:30
X5:42
X5:46
F1
20A
F2
15A
F3
15(30)A
31
87
87a
X1
A6
R3
75 R
30
85
85
30
15
30
K4
87
86
K5
86
87
F4
5A
11
13
5
14
7
9
8
2
87
85
K8
30
86
Warning lights
Engine stop
Instrument
Water tank level
Supply +12V
Warning
Ground
Glowing
Water in fuel
Crab
Air condition
Engine overload
Sprinkling Konstant speed
Smooth start-smooth stop
X12:2 black
X12:3 Blue
S14 brown
X12:1
12
19
6
20
1
10
17
S15 brown
X12:4
85
87
K9
87a
X12:5
86
30
Blue black
X12:6
87a
K17
30
87
86
85
V14
18
Neutral
40
Konstant speed
3
2
17
Seat
19
4 X11:3 X14:2
5 X11:4 X13:2
H4
X11:2
7
S18
1 5
1
S19
5
1
S20
5
S21
41
Brake
6
Travel forward
7
8
Vibration
Travel backward
RS2323 TxD
RS2323 RxD
RS2323 Grd
15
(12V)
Travel
29
(12V)
16
Engine speed Sprinkling
26
Vibration
27
Sprinkling Speed
31
20
21
13
12
X11:5
32 X11:6
X15:1
X17:1
X16:1
S22
X15:2
S23
X2
5
9
2
3
X17:2
5
A5
6
1
34
X11:7 X16:2
R1
100R
X11:8 X14:3
1K
R2
100R
X11:9
100R 1K
X11:10 X16:4
F5
10A
15/54
50a
19
17
30
85
S1
30
K6
87
86
AV 70 X
107641_1en
149
3.8. Attachments
Wiring Diagram
Legend:
A1 Clicker (course light interrupter)
A2 LH cluster
A3 RH cluster
A4 Travel electronics
A5 Travel controller
A6 Time relay
B1 Fuel level float
B3 Pressure sensor in water tank
B4 Engine RPM sensor
B5 Drum speed sensor
C1 Interference filter
E1,2 Front contour lights
E3,4 Rear lights
E5,6 Front headlamps
E7,8 Rear headlamps
E9,10 Left traffic-indicator lights
E11,12 Right traffic-indicator lights
E13,14 Auxiliary headlamps front
(optional)
E15,16 Auxiliary headlamps rear
(optional)
E17 Hazard beacon (optional)
E18,19 Brake (stop) lights
E20 Cabin lighting
E21 Car make lighting (optional)
F1-17 Cut-out fuses
G1 Battery
G2 Alternator
H1 Dipped light indicator lamp
H2 Distance light indicator lamp
H3 Loud horn
H4 Acoustic warning indicator
H5 Backing horn (optional)
K1 Contactor
K2-19 Auxiliary relay
K20 Glowing contactors
K22 Auxiliary relay
M1 Engine starter
M2 Sprinkling motor
M3 Sprinkling motor
M4 Front wiper
M7 Windscreen washer
M9,10,11 Fans
Q1 Battery disconnector
R1 Sprinkling interval potentiometer
R2 Speed potentiometer
R3 Resistor
R4, 5 Engine preheating
S1 Ignition box
S2 Combined switch
S2.1 Switch for contour lights and headlights
S2.2 Distance / dipped lights switch
S2.3 Light horn switch
S2.4 Loud horn pushbutton
S2.5 Traffic-indicator lights switch
S3 Rear headlamp switch
S4 Warning lights switch
S5 Auxiliary lights switch (optional)
S6 Hazard beacon switch (optional)
S7 Brake pressure switch
S8 Switch for hydraulics filter fouled
S9 Switch for air filter fouled
S10 Engine lubrication pressure switch
S11 Engine overheating switch
S12 Hydraulic oil overheating switch
S13 Float – water in fuel filter
S14 Backing horn switch
S15 Neutral switch
S16 Emergency brake pushbutton
S18 Constant speed or engine overload switch
S19 Vibration automatics switch
S20 Smooth start or smooth stop pushbutton
S21 Seat switch
S22 Vibration pushbutton (red) on
LH travel lever
S23 Vibration pushbutton (red) on
RH travel lever
S24 Sprinkling pushbutton
S25 Sprinkling pumps switch
S26 Vibration amplitude switch
S27 Front / both / rear vibration selector switch
S28 LH (yellow) pushbutton on LH travel lever – CRAB left
S29 RH (yellow) pushbutton on LH travel lever – CRAB right
S30 LH (yellow) pushbutton on RH travel lever – CRAB left or edge cutter upward
S31 RH (yellow) pushbutton on RH travel lever – CRAB right or edge cutter downward
S32 Front wiper switch
S34 Spaeyer pushbutton
S35 Fan switch
S36 Air conditioner switch (optional)
S38 Float in hydraulic oil tank
S39 CRAB resetting pushbutton
S40,41 CRAB position switches
S42 Hydraulics temperature switch
S44 Air conditioner overpressure fuse (optional)
S45 Switch of scraper watering
(optional)
X1 Mounting socket
X2 Diagnostics socket
X3-4 Connection terminals
X5-64 Interface connectors
Y1 Engine stop solenoid
Y3 Brake valve
Y4 Back drive valve
Y5 Rearward drive valve
Y8 Vibration low amplitude valve
Y9 Vibration high amplitude valve
Y10 Front drum vibration valve
Y11 Rear drum vibration valve
Y12 CRAB left valve
Y13 CRAB right valve
Y14 Relief valve
Y15 Edge cutter upward valve
(optional)
Y16 Edge cutter downward valve
(optional)
Y17 Air conditioner compressor clutch magnet (optional)
Y18 Solenoid valve of the edge cutter watering (optional)
150 AV 70 X
AV 70 X
MAINTENANCE MANUAL
Sprinkling 1
Sprinkling 2
Edge cutter sprinkling
Vibration - low amplitude
Vibration - high amplitude
Front drum vibration
Rear drum vibration
Crabing left
Crabing right
Relief valve
Edge cutter upward
Edge cutter downward
M M2
M M3
X34:1
X34:2
X35:1
X35:2
Y18
X5:31
X5:33
X5:1
Y8
Y9
Y10
Y11
CRAB position switch - left
CRAB position switch - right
3(blue)
2(white)
3(blue)
4(black)
S40
1(brown)
S41
1(brown)
Y12
Y13
Y14
Y15
Y16
X5:47
X5:48
X5:57
X5:58
X5:59
X12:14 X22:3
V6 V5
X12:15 X22:4
X12:16 X22:5
V8 V7
86
87
K11
85
30
86
K12
85
87 30
X11:12 X16:6
85
87
K22
86
30
1
7
1
S24
S25
5
9
1
S45
5
10
5
X16:5 X11:11
F6
15A
B4
A4
D4
C4
S26
B3
A3
D3
C3
B4
A4
S27
B3
A3
86
K13
85
87 30
X11:13
F7
7.5A
X5:49
X5:50
X5:22
X5:51
X5:54
X5:53
X5:52
X5:23
X5:55
X5:56
X12:12 X22:1
X12:13 X22:2
X12:8 X14:8
X14:10
X12:10
5
S39
1
6 2
X14:7 X12:7
X14:9 X12:9
X18:1
X18:2
S28
S29
X15:3
X19:1
X19:2
X20:1
X20:2
If the edge cutter is instaled to left hand side of the roller change over the plug X18 to socket X19.
The buttons S28, S29 on the left control lever are used to lifting cutter.
S30
X17:3
S31
X21:1
X21:2
If the edge cutter is instaled to right hand side of the roller change over the plug X20 in socket X21.
The buttons S30, S31 on the left control lever are used to lifting cutter.
F8
Reserve
E20
Cabin lighting
Front wiper
Windscreen washer
Fan 1
Fan 2
Fan 3
Air conditioner
Y17
P
S44
X64:3
M M4
M M7
X32:1
X32:4
X32:2
X32:5
X32:3
X64:1
X58:1
1
3
M M9
2
X58:2
X59:1
X48:1
1
1
M M10
2
3
M M11
2
X59:2
X48:2
X48:3
5
1
7 S32
1
S34
5
3
X52 X6:9
X6:8
X56:6
X56:4
87
K14
30
85 86
X56:5
87
K15
30
85 86
5
S35
3
1
86
87
K16
85
30
9
1
S36
5
10
X4 X15:2
X17:2
X6:9
F11
15A
F14
10A
F12
15A
F13
5A
107641_2en
151
3.8. Attachments
Hydraulic Diagram
Legend:
1. Travel pump
2. Vibration pump
3. Steering and cooling pump
5. Vibration and purging block
6. Travel hydraulic motor
7. Vibration hydraulic motor
8. Cooling hydraulic motor
9. Steering hydraulic motor
10. Crab hydraulic motor
11. Lifting hydraulic motor
12. Edge entter hydraulic motor (optional)
14. Power-assisted steering
15. Flow divider
16. Filter
17. Steering block
18. Flushing (purging) block
19. Cooler combined-type
20. Hydraulic tank
21. Hand pump
22. Thermoregulator
23. Inlet strainer
24. Filler neck
25. Level indicator
26. Oil gauge
27. Check valve
28. Check valve
29. Temperature switch 85±3°C
30. Ball valve
31. Ball valve
32. Quick-coupler filling-type
33. Quick-coupler for brake off
34. Quick-coupler for brake off
35. Quick-coupler measuring-type
152 AV 70 X
AV 70 X
MAINTENANCE MANUAL
T
B
P
A
B
T
A
P
Dn8
Dn8
Dn16
Dn16
OMOTOR
OMOTOR
Dn16
HYDR
FRONT
Dn16
RIGHT
HYDR
LEFT
REAR
Dn10
Dn10
1,2 mm
Dn10
Dn13
50/25-130
Dn13
Dn13
Dn10
1 MPa
13 l/min
Dn10
Dn16
Dn10
Dn8
Dn19
Dn19
Ø25 - 230
Ø25 - 230
Dn6
Dn10
Dn6
Dn6 Dn6 Dn6
3 bar
Dn13
Dn13 i=1.0
Dn32
13 l/min
1 MPa
0.5 bar
3 bar
0.5 bar
0.5 bar
Dn16
FRONT
Dn16
Dn16
REAR
Dn16
211391en
153
Notes
154 AV 70 X
Ammann Unternehmungen
Eisenbahnstrasse 25
CH-4901 Langenthal
Phone +41 62 916 61 61 www.ammann-group.com
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