Ammann ARR 1575 Workshop Manual
Ammann ARR 1575 is a powerful trench roller designed for efficient and precise compaction of trenches. It is equipped with a Tier 4f compliant YANMAR 3TNV80F-SPAMM engine, providing reliable performance and low emissions. This machine features a robust frame, a comfortable cab, and a user-friendly control panel. The ARR 1575 is suitable for various trenching applications, including utility installation, road construction, and landscaping. It offers features like adjustable vibration frequency and amplitude, variable speed control, and a convenient hydraulic system for smooth operation. The ARR 1575 is built for durability and ease of maintenance, making it a valuable asset for any construction project.
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ARR 1575 TRENCH ROLLER YANMAR 3TNV80F-SPAMM U.S. EPA Tier 4f WORKSHOP MANUAL EDITION 04/2019 EN From Serial No. 5572567 WORKSHOP MANUAL Preface Information, specifications, and recommended instructions for the assembly and disassembly of individual machine components or parts contained in this publication represent basic and final information at the time of the printing of this publication. Print errors, technical modifications and modifications of illustrations are reserved. All dimensions and weights are approximate, and therefore not binding. Ammann Czech Republic a.s. reserves the right to perform modifications at any time with no 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. 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.com ARR 1575 1 2 ARR 1575 Contents WORKSHOP MANUAL CONTENTS�������������������������������������������������������������������������������������������������������������������������������������������������������3 1 INTRODUCTION��������������������������������������������������������������������������������������������������������������������������������������9 2 SAFETY MEASURES AND INSTRUCTIONS�����������������������������������������������������������������������������������������13 3 4 5 2.1 Safety rules���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������14 2.2 Environmental and hygiene principles����������������������������������������������������������������������������������������������������������������������������������������������������������17 2.3 Fire prevention��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������18 2.4 Claim conditions and disclaimer of liability�������������������������������������������������������������������������������������������������������������������������������������������������18 MACHINE DESCRIPTION����������������������������������������������������������������������������������������������������������������������19 3.1 Machine description���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������20 3.2 Dimensional drawing of the machine������������������������������������������������������������������������������������������������������������������������������������������������������������22 3.3 Technical data���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������23 SPECIFICATION OF OPERATING FLUIDS��������������������������������������������������������������������������������������������25 4.1 Engine oil������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������26 4.2 Fuel������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������27 4.3 Coolant����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������28 4.4 Hydraulic oil�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������29 4.5 Lubricating grease�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������29 4.6 Fillings������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������30 FRAME���������������������������������������������������������������������������������������������������������������������������������������������������31 5.1 Description of basic elements���������������������������������������������������������������������������������������������������������������������������������������������������������������������������32 5.4 Mechanical parts����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������36 5.4.1 Swinging support, replacement of the joint head�����������������������������������������������������������������������������������������������������������������������������������36 5.4.2 Replacement of swinging joint bearing������������������������������������������������������������������������������������������������������������������������������������������������������36 5.4.3 Steering piston, bearing lubrication�������������������������������������������������������������������������������������������������������������������������������������������������������������36 5.4.5 Gas strut������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������37 5.4.6 Front bonnet replacement�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������39 5.4.6.1 Replacement of bonnet hinges����������������������������������������������������������������������������������������������������������������������������������������������������������������������41 5.4.6.2 Sensor replacement��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������42 5.4.6.3 Replacement of the rubber-metal elements of the front bonnet stop��������������������������������������������������������������������������������������������47 5.4.6.4 Adjustment of the rubber-metal elements of the front bonnet stop�����������������������������������������������������������������������������������������������49 5.4.7 Rear bonnet replacement���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������50 5.4.7.1 Replacement of bonnet hinges����������������������������������������������������������������������������������������������������������������������������������������������������������������������54 5.4.7.2 Sensor replacement��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������54 5.4.7.3 Replacement of the rubber-metal elements of the rear bonnet stop����������������������������������������������������������������������������������������������57 5.4.7.4 Adjustment of the rubber-metal elements of the rear bonnet stop�������������������������������������������������������������������������������������������������57 5.4.8 Swinging support������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������58 5.4.9 Replacement of the steering piston��������������������������������������������������������������������������������������������������������������������������������������������������������������66 5.4.10 Swinging joint�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������69 5.5 ARR 1575 Fuel tank��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������81 5.5.1 Fuel level check�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������81 5.5.2 Fuel replenishment���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������81 5.5.3 Fuel draining����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������82 5.5.4 Fuel tank cleaning������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������82 3 Contents 5.6 Hydraulic tank���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������83 5.6.1 Checking the hydraulic oil level����������������������������������������������������������������������������������������������������������������������������������������������������������������������83 5.6.2 Hydraulic oil replenishment�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������83 5.6.3 Hydraulic oil draining�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������84 5.6.4 Hydraulic oil filter replacement����������������������������������������������������������������������������������������������������������������������������������������������������������������������85 5.6.6 Ventilation filter replacement��������������������������������������������������������������������������������������������������������������������������������������������������������������������������86 5.6.7 Hydraulic tank filling�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������86 5.6.8Filling the travel pump, increasing the supply pressure������������������������������������������������������������������������������������������������������������������������87 6 CAB AND PLATFORM���������������������������������������������������������������������������������������������������������������������������91 6.1 Control and indication elements���������������������������������������������������������������������������������������������������������������������������������������������������������������������93 6.1.1 Display unit������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������94 6.1.1.1 Indicator lamps�����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������94 6.1.2 Error indication via LEDs on the display unit���������������������������������������������������������������������������������������������������������������������������������������������97 6.1.3 Infrared light emitter������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������98 6.1.3.1 Layout����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������98 6.1.3.2 Indication of faults by LEDs on the infrared light emitter���������������������������������������������������������������������������������������������������������������������98 6.1.3.3 Cable connection�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������99 6.1.3.4 Handling��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 100 6.3.3 Relays and fuses in the engine compartment���������������������������������������������������������������������������������������������������������������������������������������� 106 6.3.4 Dashboard����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 107 6.3.4.1 Other components������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 108 6.3.4.2 N1 connector / cable harness����������������������������������������������������������������������������������������������������������������������������������������������������������������������� 108 6.4.1 Replacement of the remote control battery������������������������������������������������������������������������������������������������������������������������������������������� 111 6.4.2 Replacement of the display unit����������������������������������������������������������������������������������������������������������������������������������������������������������������� 115 6.4.3 Replacement of the control unit����������������������������������������������������������������������������������������������������������������������������������������������������������������� 116 6.4.3.2 Installation����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 118 7 FRONT DRUM��������������������������������������������������������������������������������������������������������������������������������������119 7.2 7.4 8 4 Hydraulic parts����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 120 7.2.1 Travel drive/vibration hose���������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 120 7.2.2 Valve block connections��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 124 7.2.3 Valve block hose������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 127 Mechanical parts������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 129 7.4.1 Removal of the drum extension������������������������������������������������������������������������������������������������������������������������������������������������������������������ 129 7.4.2 Drum removal���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 131 7.4.3 Replacement of vibration unit rubber elements����������������������������������������������������������������������������������������������������������������������������������� 132 7.4.3 Disassembly of the vibration unit��������������������������������������������������������������������������������������������������������������������������������������������������������������� 138 7.4.4 Installation of the drum rubber-metal elements����������������������������������������������������������������������������������������������������������������������������������� 146 7.4.4 Installation of the vibration unit������������������������������������������������������������������������������������������������������������������������������������������������������������������ 153 7.4.5 Replacement of the travel hydraulic motor�������������������������������������������������������������������������������������������������������������������������������������������� 166 7.4.6 Replacement of the vibration hydraulic motor�������������������������������������������������������������������������������������������������������������������������������������� 176 7.4.7 Drum installation���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 184 7.4.8 Scraper ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 184 REAR DRUM����������������������������������������������������������������������������������������������������������������������������������������185 8.2 Hydraulic parts����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 186 8.3 ACEecon����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 187 8.4 Mechanical parts������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 196 ARR 1575 WORKSHOP MANUAL 9 FRONT AXLE (NOT INCLUDED IN THE MACHINE EQUIPMENT)����������������������������������������������������������������������������197 10 REAR AXLE (NOT INCLUDED IN THE MACHINE EQUIPMENT)����������������������������������������������������������������������������199 11 TRAVEL������������������������������������������������������������������������������������������������������������������������������������������������201 11.2 Hydraulic parts����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 203 11.2.1 Replacement of the travel pump���������������������������������������������������������������������������������������������������������������������������������������������������������������� 203 11.2.2 Replacement of the valve block������������������������������������������������������������������������������������������������������������������������������������������������������������������ 218 11.2.3 Brake test������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 234 11.2.4 Replacement of the travel hydraulic motor�������������������������������������������������������������������������������������������������������������������������������������������� 234 11.4 Mechanical parts������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 235 11.4.1 Replacement and adjustment of the speed magnet��������������������������������������������������������������������������������������������������������������������������� 235 11.3.2 Checking the engine speed and frequency�������������������������������������������������������������������������������������������������������������������������������������������� 241 12 VIBRATION������������������������������������������������������������������������������������������������������������������������������������������243 13 STEERING��������������������������������������������������������������������������������������������������������������������������������������������245 13.2 Hydraulic parts����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 246 13.2.1 Replacement of the steering piston����������������������������������������������������������������������������������������������������������������������������������������������������������� 246 14 COOLING���������������������������������������������������������������������������������������������������������������������������������������������247 14.2 Hydraulic parts����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 248 14.2.1 Cleaning of the hydraulic oil cooler����������������������������������������������������������������������������������������������������������������������������������������������������������� 248 14.4 Mechanical parts������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 249 14.4.1 Coolant and checking the coolant level��������������������������������������������������������������������������������������������������������������������������������������������������� 249 14.4.1.1 Checking the coolant level���������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 249 14.4.1.2 Coolant replenishment����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 249 14.4.1.3 Cooler cleaning�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 249 15 ENGINE������������������������������������������������������������������������������������������������������������������������������������������������251 15.1 Engine compartment, overview�������������������������������������������������������������������������������������������������������������������������������������������������������������������� 252 15.1.1 Engine, left side������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 252 15.1.2 Engine, right side���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 252 15.3 Electrical installation������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 253 15.3.1 Engine compartment�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 253 15.3.2 Chassis at the rear��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 255 15.3.3 Battery������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 256 15.3.3.1 Battery replacement���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 257 15.3.4 Batteries���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 258 15.3.5 Alternator replacement���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 258 15.3.6 Starter replacement����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 258 15.4 Mechanical parts������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 259 15.4.1 Fuel filter element��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 259 15.4.2 Water separator filter element��������������������������������������������������������������������������������������������������������������������������������������������������������������������� 259 15.4.3 Checking the engine oil level����������������������������������������������������������������������������������������������������������������������������������������������������������������������� 260 15.4.4 Engine oil replenishment������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 260 15.4.5 Engine oil draining������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 260 15.4.6 Engine oil filter replacement������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 261 15.4.7 Inlet air filter�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 262 15.5 Replacement and adjustment of the speed magnet����������������������������������������������������������������������������������������������������������������������������� 263 15.6 Checking the engine speed and frequency���������������������������������������������������������������������������������������������������������������������������������������������� 264 ARR 1575 5 Contents 16 OPTIONAL EQUIPMENT���������������������������������������������������������������������������������������������������������������������265 16.1 16.2 List of optional equipment������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 266 Safety bar��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 267 16.2.1 Safety bar replacement����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 267 16.2.2 Sensor replacement and adjustment�������������������������������������������������������������������������������������������������������������������������������������������������������� 274 17 GENERAL PROCEDURES��������������������������������������������������������������������������������������������������������������������279 17.2 Electrical installation������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 280 17.2.2 Preparation for welding work����������������������������������������������������������������������������������������������������������������������������������������������������������������������� 280 17.2.3 Starting the battery by means of another battery (jumping)���������������������������������������������������������������������������������������������������������� 281 17.2.4 Charging the battery with a charger��������������������������������������������������������������������������������������������������������������������������������������������������������� 281 17.2.5 Long-term storage�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 281 17.2.6 Battery replacement���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 281 18 TROUBLESHOOTING��������������������������������������������������������������������������������������������������������������������������283 18.1 Error diagnostics������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 284 18.1.1 The engine does not start�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 285 18.1.2 Start of the conductor and infrared radiation test�������������������������������������������������������������������������������������������������������������������������������� 287 18.1.3 Near and remote machine halt ������������������������������������������������������������������������������������������������������������������������������������������������������������������� 289 18.1.4 Control does not work�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 290 18.1.5.1 External influences������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 290 18.1.5.2 Machine cabling������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 290 18.1.5.3 Operation������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 291 18.1.6 Display unit����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 293 18.1.7 Manual control����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 296 18.2 Pressure check����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 297 18.2.1 Pressure check and adjustment������������������������������������������������������������������������������������������������������������������������������������������������������������������� 297 18.2.2 Checking the steering pressure������������������������������������������������������������������������������������������������������������������������������������������������������������������� 299 18.2.4 Checking the maximum vibration pressure�������������������������������������������������������������������������������������������������������������������������������������������� 300 18.2.5 Checking the travel pump����������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 303 18.2.5.1 Checking the maximum supply pressure������������������������������������������������������������������������������������������������������������������������������������������������ 303 18.2.5.2 Checking the travel pressures (reverse/forward)���������������������������������������������������������������������������������������������������������������������������������� 305 18.2.5.3 Checking the maximum pressure of the travel pump (reverse/forward)������������������������������������������������������������������������������������� 306 18.2.6 Checking the travel hydraulic motors������������������������������������������������������������������������������������������������������������������������������������������������������� 307 18.2.7 Adjustment of the travel pump zero position���������������������������������������������������������������������������������������������������������������������������������������� 308 18.2.7.1 Checking the travel pump magnetic coil / travel pump servo block��������������������������������������������������������������������������������������������� 309 18.2.8 Travel pump servo block check������������������������������������������������������������������������������������������������������������������������������������������������������������������� 311 18.2.9 Checking the quantity divider��������������������������������������������������������������������������������������������������������������������������������������������������������������������� 317 18.2.10 Speeds and pressures�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 318 18.3 Roller overturning���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 319 18.3.1 Checking damage��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 320 18.3.2 Preventing oil shock����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 320 18.3.3 Starting the engine������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 326 6 ARR 1575 WORKSHOP MANUAL 19 APPENDICES���������������������������������������������������������������������������������������������������������������������������������������327 19.1 Hydraulic system������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 329 19.1.1 Adjustment of the travel pump zero position���������������������������������������������������������������������������������������������������������������������������������������� 329 19.1.1.1 Checking the travel pump magnetic coil / travel pump servo block �������������������������������������������������������������������������������������������� 329 19.2 Wiring diagram���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 330 19.4 Hydraulic system diagram������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 332 19.6 Workshop jigs������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 334 19.6.1 Special tools�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 334 19.6.2 Special tool for measuring the speed and frequency�������������������������������������������������������������������������������������������������������������������������� 337 19.6.3 Special tool for magnetic coil check���������������������������������������������������������������������������������������������������������������������������������������������������������� 337 19.7 Checking the tightness of screw connections����������������������������������������������������������������������������������������������������������������������������������������� 338 ARR 1575 7 8 ARR 1575 WORKSHOP MANUAL 1 Introduction ARR 1575 9 1 Introduction The workshop manual is divided into separate chapters and contains technical and maintenance data, instructions for adjustment and instructions for the use of special tools, jigs and aids. The main purpose of this manual is to provide basic information for disassembly, assembly and service repairs of the main subassemblies of the machine. Labelling of machine subassemblies in this manual corresponds to the spare parts catalogue. In order to ensure smooth operation of the AMMANN compaction equipment, use only original spare parts supplied by AMMANN for repairs. Before disassembly, it is recommended to always mark the removed parts for their reassembly and blank off all holes of individual parts of the hydraulic system in order to prevent contamination of the hydraulic circuits. When mounting individual parts on the machine, tighten individual screws or nuts according to the table of tightening torques (see the appendix), unless specified otherwise in the text. During work, always follow the safety instructions and measures given in Chapter 2. The manufacturer constantly improves its products on the basis of operational experience and the latest findings. Due to development, the manufacturer reserves the right to change the images, descriptions, procedures and designs presented in this manual. 10 ARR 1575 WORKSHOP MANUAL SAFETY NOTICES AND SIGNS: The notice warns of a serious risk of personal injury or other personal hazards. The notice warns of possible damage to the machine or its parts. The notice warns of the necessity of environmental protection. ! CAUTION! As used in this operating manual, the terms right, left, front and rear indicate sides of the machine moving forward. FRONT LEFT RIGHT REAR 555001 ARR 1575 11 12 ARR 1575 WORKSHOP MANUAL 2 Safety measures and instructions ARR 1575 13 2 Safety measures and instructions 2.1 Safety rules These safety rules must be followed by all persons involved in machine repairs! •• Repairs of this machine may be carried out only by qualified, professionally trained and experienced workers or by the service personnel of our dealers. •• Always use our workshop manual when performing repairs. Individual chapters contain special instructions regarding assembly work. •• Before putting the machine into operation, familiarize yourself with the machine controls according to the Operating Manual and make sure you have well understood all the equipment of your machine. •• Do not use the machine if you do not fully understand all operating and control elements and if you do not know exactly how the machine works. •• Familiarize yourself with the area where you work. •• Do not carry out any alterations or modifications to the machine, as this may affect the safety of the machine. •• Original parts and accessories have been designed specifically for this machine. •• Installation and use of spare parts that are not supplied or authorized by the machine manufacturer may have a negative impact on the operational characteristics and safe operation of the machine. •• It is forbidden to remove components of individual parts during the warranty period. If you fail to comply with this prohibition, the warranty of the damaged component will not be recognized. Safety measures for machine repairs and inspection •• Wear work clothes and footwear. •• Use gloves when handling oil, fuel and coolant. •• When handling the battery, protect your eyes with goggles or a shield. •• Place the machine on a level and firm surface before performing repairs. Secure the machine against rolling. •• Secure the machine and drum frame against relative rotation with a lock pin and rod. •• Before starting work, remove the key from the ignition, disconnect the batteries and allow hot parts to cool. •• Attach a “machine out of order” sign to the steering wheel and leave it there for the duration of the work. •• Properly wash the entire machine. In the case of steam cleaning, avoid aiming the steam flow directly at electrical components and insulating material or cover them beforehand. •• When removing, installing and repairing individual groups, maintain absolute cleanliness of all parts. Protect removed parts against dirt. •• Clean the surface of removed parts and create a corresponding dust-free work environment with the necessary storage area. •• Handle cleaning agents with caution. Do not use petrol or other flammable substances for cleaning! •• Dry the cleaned parts and immediately coat them with anti-corrosion oil – never install corroded parts! •• Tools, lifting equipment, securing elements, supports and other auxiliary equipment must be in a good, working condition. •• Lifting equipment and slings (ropes, chains) must have adequate load capacity and be intact. •• Ensure sufficient air supply when starting the machine indoors. •• Before putting the machine into operation, make sure there are no persons on the machine or in its dangerous proximity. Use the audible warning signal when putting the machine into operation, always before starting the engine and after each break, before the machine starts moving. Persons located on the machine and in its dangerous proximity must leave the machine and the area after the audible warning signal. •• Do not adjust the machine in operation. •• When performing necessary work on a running engine (adjustment), avoid contact with hot and rotating parts of the machine. Work performed when the engine is running (adjustment) must be carried out in the presence of another person who has immediate access to emergency shut-down and who is continuously in contact with the person performing the adjustment, so that the engine can be immediately switched off if necessary. •• Only use prescribed kinds of engine, transmission and hydraulic oil and coolant. 14 ARR 1575 WORKSHOP MANUAL Safety measures for work on hydraulic circuits •• Before disassembly, make sure the hydraulic circuits are depressurized. Hydraulic oil leaking under pressure may damage your skin and cause serious injury. •• Before disassembly, mark the parts, hoses and pipes. •• Do not put hydraulic pumps and motors into operation without oil. •• Work with hot oil may result in scalding. •• Do not heat the oil to temperatures above 160 °C – the oil or its vapours may ignite. •• When removing hydraulic components, always blank off the hose ends and outlets of the components. •• Use lint-free cloth when wiping and cleaning hydraulic parts. •• When assembling parts, use hydraulic oil as a slip agent – not lubricating grease. •• Before installation, carefully clean the fittings and flush and blow compressed air through hoses and pipes. •• Only use new seals. •• Fill new aggregates with hydraulic oil before installation. •• After a hydraulic aggregate replacement, flush the hydraulic circuit and clean the hydraulic tank. •• Replace the oil filter cartridge. •• Fill the hydraulic circuit with clean oil of prescribed viscosity, only when the engine is off! •• Wipe any overflowed oil. •• Check the connections for any leaks before the system pressurizes. •• Check all connections after finishing all work. •• Do not adjust safety valves. •• After finishing work, reinstall all protective elements. Check after putting into operation •• Oil level in the hydraulic tank. •• Check the charge pressure of replaced hydraulic pumps and the pressure of safety valves. •• Perform the measurement at 40 °C (104 °F). Safety measures for work on the fuel system Petrol and diesel mixtures (winter fuel) are as flammable as petrol. -- Do not refuel in enclosed spaces. -- Wipe any overflowed fuel. -- Do not smoke and do not use an open flame while working on the fuel system! There is a risk of fire! ARR 1575 15 2 Safety measures and instructions Safety measures for work on the electrical system •• Disconnect the battery when repairing the charging circuit to prevent accidental short circuits. •• Before removal, disconnect the cable from the negative pole (–) and then from the positive pole (+). •• Do not disconnect the batteries when the engine is running. •• Connect the negative battery pole to the ground and the positive pole to the “B+” alternator output. The opposite connection would destroy the whole semiconductor equipment. •• When starting using an auxiliary external power supply, do not disconnect this power supply until the machine battery is connected. Pay attention to the starting voltage of the auxiliary external power supply (for 24 V). •• Do not put the alternator into idle operation, i.e. with a disconnected wire from the “B+” terminal and connected “D+” terminal. •• Do not check the presence of voltage in the wire by sparking against the machine frame. •• Do not perform any activities generating sparks. •• Use protective rubber gloves and eye protection when handling batteries. •• Protect your skin and clothes against being splashed by the electrolyte or lead particles. •• In case of eye contact with the electrolyte, immediately flush the affected eye thoroughly with running water for several minutes. Then, seek medical treatment as soon as possible. •• If the electrolyte comes in contact with skin or clothing, remove the clothes, immediately wash the affected areas with soapy water or a solution of baking soda and water and seek medical treatment. •• In case of ingestion of electrolyte, drink the maximum possible amount of milk, magnesium oxide dissolved in water or at least water and immediately seek medical treatment. •• Never fill the cells with distilled water, unless it is followed by work with the machine or recharging outside the machine. It would otherwise cause excessive battery self-discharge. •• Never fill up the acid (H2SO4)! •• Do not turn over the batteries to avoid electrolyte flowing out of the degassing vents. •• In case of acid (electrolyte) spillage, wash the affected area with water and neutralize with lime. •• The battery charging process releases hydrogen, which forms an explosive, easily combustible mixture with air. Do not smoke or use open flame or lights in the vicinity. Welding work on the machine •• Before performing welding work on the machine using an electric arc, disconnect all elements containing semiconductors from the electrical system, including the machine electronics: -- ground the power supply as well as the repaired machine, -- protect the power supply against moisture, -- place the ground terminal in close proximity to the weld joint, -- When performing welding work on suspended parts or machine, it is necessary to prevent current from reaching the lifting equipment by insulating the point of current transition or using non-conductive slings (hemp rope). Sealing •• Use new seals for all installation. •• Seal kits are obtained as spare parts. Tightening torques •• In order to apply the correct tightening torque, use a torque spanner. •• Fastening screws and nuts of used quality shall be tightened according to the respective tables. •• The screw quality is indicated on the screw head. •• Different tightening torques are specified in the respective chapters. •• Threaded joints of hydraulic circuits shall be tightened according to the tables. •• The presented tightening torques apply to non-lubricated threads. •• Only use new self-locking nuts. 16 ARR 1575 WORKSHOP MANUAL 2.2 Environmental and hygiene principles When repairing the machines, observe general principles of health and environmental protection as well as laws and regulations related to this issue and being in force within the territory where the machine is used. Hygiene principles •• Petroleum products, fillings of cooling systems, battery fluids and paints, including thinners, are harmful substances that can cause severe injuries when in contact with body organs. •• It is therefore necessary to strictly follow safety and hygiene instructions of products and use personal protective equipment when handling these substances. •• Workers coming into contact with the above products when repairing the machine are obliged to follow general principles of their own health protection and comply with safety and hygiene manuals of the manufacturers of the products. In particular we draw your attention to the following: •• -- protect your eyes and skin while working with the batteries -- protect your skin while handling petroleum products, coating compounds and coolants -- Wash your hands properly after finishing the work and before eating, treat your hands with a suitable reparation cream. -- when handling the cooling system, follow the instructions given in the manuals supplied with the machine -- Always store petroleum products, cooling system fluids, battery fluids and coating compounds including thinners and also cleaners and preservative agents in their original and properly labelled containers. These materials are not allowed to be stored in unlabelled bottles or in any other containers considering the possible risk of confusion. Possible confusion with foodstuffs or beverages is very dangerous. If by accident the skin, eyes or mucous membrane is stained or if you breathe in the vapours of such products, apply first aid measures immediately. In case of accidental ingestion of these products, immediately seek medical help. Environmental measures •• Discarded operating fluids of individual systems of the machine and also some of its parts become hazardous wastes with dangerous properties for the environment. This category of waste products includes in particular: -- organic and synthetic lubricating materials, oils and fuels; -- coolants; -- battery fluids and batteries; -- cleaning and preservative agents; -- all removed filters and filter cartridges; -- all used and discarded hydraulic or fuel hoses, rubber-metal elements and other parts of the machine contaminated by the above mentioned products. •• It is necessary to treat the above mentioned materials and parts after their discard in accordance with relevant national regulations valid for protection of individual parts of the environment and in compliance with regulations of health protection. •• When disassembling hydraulic, fuel and cooling systems and their units. Escape of fluids into the ground has to be prevented by using suitable vessels placed underneath and by plugging of the holes. •• In case of leakage, the affected area must be immediately dried with the use of sawdust, Vapex, etc. •• The affected soil must be removed to prevent further leakage. The contaminated soil and absorbent should then be handed over for further safe disposal. ARR 1575 17 2 Safety measures and instructions 2.3 Fire prevention •• The oil change point must be where it cannot interfere in explosion or fire hazard areas. •• It must be identified by “No smoking” and “No open flame” plates and signs. •• The handling area must be dimensioned so that it can capture a volume of the flammable liquid equal to the capacity of the biggest transport container. •• It must be equipped with portable fire extinguishers. •• For handling the oil and diesel fuel, use metal barrels, jerry cans, sheet-metal cans and similar vessels. •• The transport containers must be properly closed during storage. •• Vessels must be with only one outlet, stored always with the outlet up and secured against the outflow and drains. •• Vessels must be marked with non-removable writings showing the contents and flammability classes. Special tools, jigs – see relevant chapters of the manual 2.4 Claim conditions and disclaimer of liability 1. Warranty rules •• Regular inspections and correct operation of the equipment •• Products have been registered at the service portal •• The equipment is operated by a trained operator •• Following parts are excluded from warranty: part subject to wear and tear, including, without limitation, rubber washers/wheels, belts, scrapers, wipers, filters, grease, fluids, conveyor parts, chains, foundation boards, compacting rods, auger elements, bearings, fuel and consumables. •• Batteries are provided with a warranty for 12 months / 1,000 hours. After this period, batteries are included in parts subject to wear and tear and are excluded from the warranty. •• Hydraulic hoses can be purchased from local dealers and charged as an expense to Ammann. 2. Procedure for raising a claim •• In case of raising a warranty claim, the owner/user shall immediately submit the manufacturer a completed warranty claim and images of the fault. The owner/user shall also send a proof of regular maintenance before sending the warranty claim or together with it at the latest. •• Ammann recommends that you send a proof of regular maintenance regularly. •• The document can be sent in various ways (e.g. via the service portal, service application). The document shall contain a machine serial number and a serial number of the original maintenance kit of Ammann. This information can be provided either typed, or scanned according to the selected manner of handover. 3. Breach •• 18 If a dealer breaches obligations stated in points 1) and 2), any warranty claims will be rejected. ARR 1575 WORKSHOP MANUAL 3 MACHINE DESCRIPTION ARR 1575 19 3 Machine description 3.1 Machine description The ARR 1575 trench roller is a roller specially designed for compacting trenches. The drums enable compacting even in very narrow trenches right up to the trench wall. Please fill in the following data: (see nameplate and Yanmar engine nameplate) Machine type Specification of the expected use of the machine This modern trench roller can be used on wet, clay soils in the construction of sewers, utility lines, roads, building refills, etc. On hazardous jobsites, the operator can control the machine from a safe distance without being exposed to danger. Only use the ARR 1575 roller for driving on and compacting of non-cohesive (loose) materials. The machines are designed for operation under the conditions of the following EN 60721-2-1:2014 types: WT, WDr, MWDr (warm temperate, warm dry, mild warm dry a with limited temperature range from -15 °C (5 °F) to +45 °C (113 °F). ................................................................................................................ Serial number of the machine ................................................................................................................ Year of manufacture ................................................................................................................ Engine type ................................................................................................................ Serial number of the engine ................................................................................................................ The data mentioned in the table refer always when you contact the dealer or manufacturer. 20 ARR 1575 WORKSHOP MANUAL The machine that complies with the health and safety requirements is provided with a nameplate with CE marking. 1 - Name – always stated only in the English version 2 - Type 3 - Serial number 4 - Operating weight 5 - Maximum weight 6 - Rated power 7 - Version 8 - Transport weight 9 - Front axle load 10 - Rear axle load 11 - Year of manufacture 1 2 3 4 5 6 7 8 9 10 11 3487 Nameplate position 555005 Engine nameplate position 556207 ARR 1575 21 3 Machine description 3.2 Dimensional drawing of the machine I J A C H B G F D E 555003 mm (in) A B C D E F G H I J 601 302 36 640 2227 1980 1000 525 1282 1317 (23.7) (11.9) (1.4) (25.2) (87.7) (78.0) (39.4) (20.7) (50.5) (51.9) 601 407 36 850 2227 1980 1000 525 1282 1317 (23.7) (16.0) (1.4) (33.5) (87.7) (78.0) (39.4) (20.7) (50.5) (51.9) 640 ARR 1575 T4 final 850 22 ARR 1575 WORKSHOP MANUAL 3.3 Technical data ARR 1575 U.S. EPA Tier 4f 640 850 (mm) 640 850 Operating weight EN 500-1+A1 (CECE) kg (lb) 1340 (2950) 1440 (3170) Operating load EN 500-1+A1 (CECE) on the front axis kg (lb) 730 (1610) 780 (1720) Operating load EN 500-1+A1 (CECE) on the rear axis kg (lb) 610 (1340) 660 (1460) Weight of the half volume of operating fluids kg (lb) 10 (20) 10 (20) Operating weight ISO 6016 kg (lb) 1350 (2980) 1450 (3200) Maximum weight with accessories kg (lb) 1450 (3200) 1450 (3200) km/h (mph) 2.8 (1.7) 2.8 (1.7) 1.4 (0.9) 1.4 (0.9) Dimensions Drum width Weight Riding qualities Maximum transport speed Working speed Climbing ability without vibration % 30 30 Climbing ability with vibration % 25 25 Lateral static stability % 80 80 Lateral stability when driving without vibration % 25 25 Lateral stability when driving with vibration % 15 15 Turning radius, inner (edge) mm (in) 1540 (60.6) 1440 (56.7) Turning radius, outer (contour) mm (in) 2190 (86.2) 2290 (90.2) Drive type - Hydrostatic Number of driving axles - 2 Oscillation angle ° ±7 Steering angle ° ±30 Steering type - Joint Steering control - Hydraulic Linear hydraulic motors - 2 Manufacturer - YANMAR Type - 3TNV80F-SPAMM Steering Engine kW (HP) 14.6 (20) Number of cylinders Power according to ISO 3046-1 - 3 Cylinder capacity cm³ (cu in) 1266 (77) Nominal speed min (RPM) 2400 Maximum torque Nm (ft lb)/rpm 68.4/1800 Fuel consumption in common operation -1 l/h (gal US/h) 3.2 (0.8) The engine complies with emission regulations - U.S. EPA Tier 4 Final Engine cooling system - Liquid Operating - Hydrostatic Parking - Mechanical multi-disc Brakes ARR 1575 23 3 Machine description ARR 1575 U.S. EPA Tier 4f 640 850 Vibration Frequency I Hz (vpm) 40 (2400) Amplitude I mm (in) 0.6 (0.024) Amplitude II mm (in) 1.1 (0.043) Fuel l (gal US) 28 (7.4) Engine (oil filling) l (gal US) 3.4 (0.9) Cooling system l (gal US) 1.2 (0.3) Hydraulic system l (gal US) 16 (4.2) Voltage V 12 Battery capacity Ah 77 Measured sound power level A, LpA at the operator's position * dB 70 Uncertainty KpA * dB 1 Guaranteed sound power level A, LWA ** dB 101 Operating fluids Electrical installation Noise and vibration emissions Optional equipment Safety bar Drum extension set Scrapers Set of filters, 500 h Tarp cover * measured according to EN 500-4 ** measured according to DIRECTIVE 2000/14/EC 24 ARR 1575 WORKSHOP MANUAL 4 Specification of operating fluids ARR 1575 25 4 Specification of operating fluids 4.1 Engine oil °F °C 122 50 104 40 86 30 68 20 50 10 32 0 14 -10 -4 -20 2412 The engine oil is specified according to the performance and viscosity classification. Performance classification according to API (AMERICAN PETROLEUM INSTITUTE) ACEA (ASSOCIATION DES CONSTRUCTEURS EUROPÉENS D'AUTOMOBILE) To determine the SAE (Society of Automotive Engineers) viscosity class, the ambient temperature and type of operation where the machine is used are decisive. 20W50 Viscosity classification Year-round SAE 15W-40 (e.g. Valvoline, Premium Blue). Note Exceeding the lower temperature limit does not result in damage to the engine; it can only cause some starting difficulties. It is recommended that universal multi-range oils are used to avoid the necessity of oil changes due to changes of ambient temperature. It is possible to use synthetic engine oils if the performance and viscosity classification of the oils corresponds to the recommended mineral oils. The oil change periods must be observed in the same intervals like when mineral oils are used. For easier starting at the temperatures below 0 °C (32 °F), the engine manufacturer recommends the SAE 10W-30 oil. 10W30 Use of permissible oils according to ACEA: E-3, E-4 and E-5 15W40 Use of permissible oils according to API: CF 555072 Considering the reduced lubricating capabilities of the oil, the upper temperature limit must not be exceeded for a long period. 26 ARR 1575 WORKSHOP MANUAL Use of biofuel (diesel fuel) 3686 4.2 Fuel D < 15 ppm S < 15 mg/kg S 3686 Diesel oil is used as fuel for the engine: •• CEN EN 590 (2009) •• ASTM D 975-94: 1-D, 2-D •• ISO 8217 DMX Note The use of the fuel mixture under the trade name of biodiesel is in principle approved by the engine manufacturer for the engine of this machine if it conforms to the specifications according to EN 14214 or ASTM D6751. A fuel mixture with 5% portion of biodiesel at most is acceptable. Before using biodiesel in the machine, make sure that it is supplied by a reputable supplier who supplies fuels corresponding to the above mentioned standards. Always ask the supplier of biodiesel for information concerning the condition under which it can be used. The engine manufacturer recommends fuels with a sulphur content not exceeding 0.0015 percent by weight. Water and sediment in fuel should not exceed 200 mg/kg. Ash in fuel should not exceed 0.01 percent by weight. The engine guarantee will be rejected when biodiesel is used which does not correspond to the above mentioned standards and when the fuel system or engine is damaged due to the use of the improper biodiesel! At ambient temperatures below 0 °C (32 °F), use winter diesel fuel. Mixing diesel with special additives is forbidden. When biodiesel is used, the power can be reduced by up to 12% depending on the used mixture of biodiesel. Therefore, never adjust the engine or the injection pump to increase the power. Never mix the fuel mixture by yourself on the work site. Biodiesel has a higher cloud point at low ambient temperatures and therefore wax crystals form in the fuel, which results in clogging of the fuel filter. When biodiesel is used, it is necessary to shorten replacement intervals of the fuel filter. When you start using biodiesel, corrosion and impurities made on internal walls of the fuel tank will get separated. Impurities are carried away by the fuel to the filter where they are caught and the filter must be replaced. Biodiesel has a higher ability to absorb atmospheric moisture and therefore the atmospheric moisture condenses on internal walls of the tank, which results in higher content of water in the fuel, which must be more frequently drained from the separator of the fuel filter. This problem occurs more often in cold weather. When biodiesel is used all the year round, it is necessary to clean the fuel system with a clean diesel fuel for at least 30 minutes during operation of the engine before the machine is shut down for longer than 3 months. Further, it is necessary to drain off and clean the fuel tank, and either fill with diesel fuel or minimise the occurrence of moisture and limit the microbiological growth inside the tank. Consult these measures with the fuel supplier. ARR 1575 27 4 Specification of operating fluids 4.3 Coolant Water quality 2152 The coolant specification must meet requirements of: ASTM D6210 ASTM D4985 JIS K-2234 SAE J814C, J1941, J1034 or J2036 To fill the cooling circuit, use the coolant in the mixing ratio of 50%/50% with high-quality water (thermal protection up to -37 °C). Change the coolant every 2,000 hours, after 2 years at the latest. Do not use hard water with a higher content of calcium and magnesium, which results in calculus formation, and with a higher content of chlorides and sulphates, which causes corrosion. The maximum content of compounds of calcium and magnesium is 170 milligrams – hardness of water. The maximum content of compounds of chlorine is 40 milligrams. The maximum content of compounds of sulphur is 100 milligrams. Safety instructions: 1. Protect your hands with protective gloves. 2. In case of ingestion, immediately seek medical treatment. 3. In case of contact with skin or clothing, immediately wash the affected area with clean water. Note: The machines are filled with a cooling solution with the Bantleon Avia Antifreeze NG coolant, specification SAE J 1034 at the manufacturer's during the production. 4. Do not mix different types of coolants. The mixture can cause a chemical reaction with formation of harmful substances. It is a coolant containing silicates based on monoethylene glycol. It does not contain phosphates, nitrates, amines and borates. There is an Avia NG label placed where the coolant is to be filled into the machine. Refill the cooling circuit with the same or a completely miscible coolant of the required specification. If the use of a different, immiscible coolant is necessary, the cooling circuit must be completely drained and cleaned with clean water repeatedly, at least 3 times. However, it is not allowed to use a coolant of a different specification than stated by the engine manufacturer. The coolant protects the cooling system from freezing, corrosion, cavitation, overheating etc. It is forbidden to operate the machine without coolant even for a short time. It is forbidden to use a coolant of a different than prescribed specification and base. The engine and the cooling system can get damaged, which will void the warranty. Always check the ratio of antifreeze cooling agent in the coolant with a refractometer before the winter season starts. 28 ARR 1575 WORKSHOP MANUAL 4.4 Hydraulic oil 4.5 Lubricating grease 2158 For the hydraulic system of the machine, it is necessary to use only high-quality hydraulic oil grades according to ISO VG 46 HVLP (corresponding to DIN 51524 part 3 HVLP). Fill the machines normally with the ISO VG 46 hydraulic oil with a kinematic viscosity of 46 mm2/s at 40 °C (104 °F). This oil is the most suitable to be used in the widest range of ambient temperatures. 0787 For lubrication of the machine, use lubricants according to: ISO 2137 DIN 51 502 Synthetic hydraulic oil The hydraulic system can be filled with synthetic oil, which if leaks occur will be degraded completely by micro-organisms present in water and soil. Hydraulic oil on the basis of HE ester, HEES category according to ISO 15380, can only be used. Please consult always with oil manufacturer or dealer any switching from mineral oil to synthetic one or mixing the oils of various brands! ARR 1575 29 4 Specification of operating fluids 4.6 Fillings Part Fluid type Engine Engine oil according to Chapter 4.2.1 Fluid quantity l (gal US) Brand 3.4 (0.9) 2412 Fuel tank Diesel according to Chapter 4.2.2 28 (7.4) Hydrostatic system Hydraulic oil according to Chapter 4.2.4 16 (4.23) 2158 Year-round anti-freeze according to Chapter 4.2.3 1.2 (0.3) Articulated bearings – steering joint and steering cylinders Plastic grease according to Chapter 4.2.5 as required Vibrator bearings Plastic grease according to Chapter 4.2.5 Engine cooling system 2152 0787 year-round filling 0787 30 ARR 1575 WORKSHOP MANUAL 5 Frame ARR 1575 31 5 Frame 5.1 Description of basic elements 1 6 4 5 2 3 555007B 11 10 9 7 8 555008B Right side view Left side view 1 - One-point lifting lug 7 - Articulation joint lock 2 - Name plate 8 - Safety bar (optional) 3 - Drum scraper 9 - Control panel cover 4 - Rear bonnet lock 10 - Rear infrared sensor 5 - Front bonnet lock 11 - Light indication 6 - Front infrared sensor 32 ARR 1575 WORKSHOP MANUAL 12 14 15 13 16 555010A 12 - Oil cooler 13 - Fuel tank 14 - Hydraulic oil tank 15 - Battery 16 - Control unit ARR 1575 33 5 Frame 17 18 19 555011B 17 - Engine cooler 18 - Coolant level expansion tank 19 - Water separator 34 ARR 1575 WORKSHOP MANUAL 24 25 23 22 21 26 20 557012B 20 - Oil filter 21 - Oil dipstick 22 - Oil filler cap 23 - Fuel filter 24 - Coolant filler cap 25 - Engine fuses 26 - Air filter ARR 1575 35 5 Frame 5.4 Mechanical parts 5.4.1 Swinging support, replacement of the joint head Check the swinging support once a year for potential occurrence of inadequate clearance. Hang the roller on a crane (central suspension). The clearance can be checked when lifting and lowering the roller (visual check). 557D116 5.4.2 Replacement of swinging joint bearing Check the swinging joint once a year for potential occurrence of inadequate clearance. If axial clearance exceeds 4 mm, the joint must be replaced (Chapter 5.4.10). Hang the roller on a crane (central suspension). The clearance can be checked when lifting and lowering the roller. 557D117 5.4.3 Steering piston, bearing lubrication To lubricate the piston, completely turn the roller. Move the roller from right to left briefly. This will unload the bearing. 1 1 Clean the grease nipple head (1) before lubrication. Put a grease gun on the nipple. Inject a sufficient quantity of grease so that it flows out of the bearing. Re-attach the protective cover. 557D118 Material damage in case of excessive wear! Lubricate the bearing after every roller cleaning/ spraying. 36 ARR 1575 WORKSHOP MANUAL 5.4.5 Gas strut Gas struts are maintenance-free! No maintenance, such as oil application or grease lubrication, is required. They are always equipped for relevant requirements and operate faultlessly for many years. Gas strut replacement Before you begin replacing the gas struts, secure the engine bonnet against spontaneous fall. 557D129 There is a risk of injury! Removal Use a screwdriver to pull out the clamps and release the struts. 557D130 Pull out the gas strut away from the ball stud. 557D131 Installation Push new gas struts on the ball stud. The clamp then needs to be safely seated. When reinstalling the gas strut, fasten the extracted part at the bottom. 557D132 ARR 1575 37 5 Frame Do not install gas struts if they are damaged due to mechanical handling. Welds on the gas struts as well as dirt or paint on the piston rod may lead to equipment failure. Avoid changes and manipulations, shocks, tensile loads, heating, repainting and removal of prints. Do not install any defective or improperly processed products. If you do not need the gas struts any more, dispose of them in an environmentally-friendly manner. 38 ARR 1575 WORKSHOP MANUAL 5.4.6 Front bonnet replacement Removal Remove the sensor (Chapter 5.4.6.2). Hang the bonnet. 557D155 557D156 Use a screwdriver to lift the clamp. Pull the gas cylinder away from the ball joints to the right and left. 557D157 ARR 1575 39 5 Frame Release the wire rope from the bonnet on the left. Lift the engine bonnet using a crane. 557D158 Remove the bottom screws of the butt hinge on the left. 557D159 Remove the bottom screws of the butt hinge on the right. 557D160 Lift the bonnet using a crane and put it aside. 557D161 40 ARR 1575 WORKSHOP MANUAL 5.4.6.1 Replacement of bonnet hinges Remove the bonnet (Chapter 5.4.6). Remove the hinge screws. 557D162 Replace the bonnet hinge. 557D163 Apply blue adhesive on the screws. 557D164 Mount the hinges using screws. The tightening torque is 50 Nm. 557D165 ARR 1575 41 5 Frame 5.4.6.2 Sensor replacement Removal Remove the screws of the sensor cover. 557D166 557D167 Remove the sensor cover. 557D168 557D169 42 ARR 1575 WORKSHOP MANUAL Remove the sensor. 557D170 Release the sensor cables from the holders. 557D171 Remove the cable ties. 557D172 557D173 ARR 1575 43 5 Frame Unplug the X5 connector (infrared sensor at the front). 557D174 Remove the sensor and wiring. 557D175 Installation Put the sensor into the hole in the bonnet. 557D176 557D177 44 ARR 1575 WORKSHOP MANUAL Install the sensor using the special tool. 557D169 Apply blue adhesive on the sensor cover screws. 557D178 Install the sensor cover. The tightening torque of the cover is 10 Nm. 557D179 557D180 ARR 1575 45 5 Frame Fasten the sensor harness using the holders. 557D181 557D182 Fasten the cables with a cable tie on the holder at the top of the bonnet hinge. 557D183 Fasten the cables with a cable tie on the holder at the bottom of the bonnet hinge. 557D184 46 ARR 1575 WORKSHOP MANUAL Fasten the cables with a cable tie on the 010 hydraulic hose. 557D185 Plug the X5 connector (infrared sensor at the front). Attach the cable ties. 557D186 5.4.6.3 Replacement of the rubber-metal elements of the front bonnet stop Remove the fastening nut of the rubber-metal element. 557D187 ARR 1575 47 5 Frame Remove the rubber-metal element from the holder. 557D188 Apply blue adhesive on the rubber-metal element screw. 557D189 Mount the rubber-metal element into the holder. 557D190 557D191 48 ARR 1575 WORKSHOP MANUAL 5.4.6.4 Adjustment of the rubber-metal elements of the front bonnet stop After installing the bonnet or replacing a bonnet stop rubbermetal element, adjust the distance between the bonnet and the machine frame. Loosen the rubber-metal element holder screws. 557D192 Move the holder to adjust the distance between the bonnet and the machine frame. Make sure the distance is even. 557D193 Loosen the bottom screws of the bonnet hinges. 557D194 Move the bonnet to adjust the distance between the bonnet and the machine frame. The bonnet and the chassis should be aligned. Tighten the screws. The tightening torque is 50 Nm. 557D195 ARR 1575 49 5 Frame 5.4.7 Rear bonnet replacement Removal Remove the sensor (Chapter 5.4.7.2). Hang the bonnet. 557D156 557D155 Remove the fastening straps of the N2 connector. 557D196 Disconnect the connectors from the fuse box. 557D197 50 ARR 1575 WORKSHOP MANUAL Disconnect the connectors of the ignition box. 557D198 Disconnect the N2 connector. 557D199 Remove the bonnet cable ties. 557D200 Use a screwdriver to lift the clamp. Pull away the gas cylinder from the ball joint. 557D201 ARR 1575 51 5 Frame Release the wire rope from the bonnet. Lift the engine bonnet using a crane. 557D202 Remove the bottom screws of the butt hinges on the left. 557D203 Remove the bottom screws of the butt hinge on the right. 557D204 Remove the cable ties on the bonnet hinge. 557D205 52 ARR 1575 WORKSHOP MANUAL Lift the bonnet using a crane and put it aside. 557D206 557D207 ARR 1575 53 5 Frame 5.4.7.1 Replacement of bonnet hinges Replacement of bonnet hinges (Chapter 5.4.6.1). 5.4.7.2 Sensor replacement Removal Remove the screws of the sensor cover. 557D208 Remove the sensor cover. 557D209 Remove the sensor using the special tool. 557D169 Remove the sensor. 557D210 54 ARR 1575 WORKSHOP MANUAL Disconnect the sensor connector. 557D211 Installation Put the sensor into the hole in the bonnet. 557D176 557D177 Install the sensor using the special tool. 557D169 ARR 1575 55 5 Frame Apply blue adhesive on the sensor cover screws. 557D178 Install the sensor cover. The tightening torque of the cover is 10 Nm. 557D212 557D213 Fasten the sensor harness using the holders. 557D214 56 ARR 1575 WORKSHOP MANUAL Connect the connector of the ignition box. Connect the N2 connector. Fasten the connector with a cable tie. 557D215 Fasten the cables using the fastening straps. 557D216 Place the sensor cables and fasten with a cable tie. 5.4.7.3 Replacement of the rubber-metal elements of the rear bonnet stop 557D217 Replacement of the rubber-metal elements of the front bonnet stop (Chapter 5.4.6.3). 5.4.7.4 Adjustment of the rubber-metal elements of the rear bonnet stop Adjustment of the rubber-metal elements of the front bonnet stop (Chapter 5.4.6.4). ARR 1575 57 5 Frame 5.4.8 Swinging support Removal Mount a lock against cranking. 557D535 Place the hydraulic jack to the centre of the swinging joint. Slightly unload the roller. 557D536 58 ARR 1575 WORKSHOP MANUAL Remove the screws of the swinging support. 557D537 557D538 557D539 557D540 ARR 1575 59 5 Frame Remove the swinging support. 557D541 557D542 Before disassembling the swinging support, measure the distance between the joint centres. Use the measured value during reassembly. 557D543 60 ARR 1575 WORKSHOP MANUAL Replacement of the joint head Removal Remove the retaining screw. 557D544 557D545 Place the swinging support under a press. Push out the heavy clamping pin with the mandrel. 557D546 557D547 ARR 1575 557D548 61 5 Frame Clamp the swinging support in a vice. Heat the lock nut and joint head to approximately 200 °C (392 °F). 557D549 Loosen the lock nut. Rotate the joint head using a spanner. 557D550 557D551 62 ARR 1575 WORKSHOP MANUAL Installation Apply red adhesive on the new rear joint head and swinging support (1). Apply blue adhesive on the new front joint head and swinging support (2). 1 1 Mount the rear joint head on the swinging support all the way to the stop. Set the front joint head to the required distance. 2 2 557D552 Set the swinging support to the measured length. Secure the nut. X 557D553 Lubricate the boreholes in the joint head at the back and front. 557D554 Lubricate the clamping pins. 557D555 ARR 1575 63 5 Frame Insert the clamping pin so that the gap is on the push-out side. Push the clamping pins inside. 557D556 Apply red adhesive on the screw. 557D557 557D558 64 ARR 1575 WORKSHOP MANUAL Installation Mount the joint head fixing screws. The tightening torque is 85 Nm. Apply blue adhesive on the screws. 557D559 557D560 557D561 557D562 ARR 1575 65 5 Frame 5.4.9 Replacement of the steering piston Removal Remove hydraulic hoses 017 and 018 from the hydraulic cylinder. 557D563 557D564 Remove the steering piston nuts. 557D565 557D566 66 ARR 1575 WORKSHOP MANUAL Remove the steering piston. 557D567 Close the screw unions on the steering piston. 557D568 Close the screw unions on hoses 017 and 018. 557D569 ARR 1575 67 5 Frame Installation Clean the fastening pins (remove corrosion if necessary). Mount the sealing washer (1). 1 Lubricate the fastening pins. Apply blue adhesive on the threaded pins. 557D570 Install the new steering piston. 557D567 Tighten the nut firmly (100 Nm). Lubricate the grease nipple (2) at the front and back. 2 1 557D571 Mount hydraulic hoses 017 and 018. 557D572 68 ARR 1575 WORKSHOP MANUAL 5.4.10 Swinging joint Remove the swinging support (Chapter 5.4.8). Remove the steering piston (Chapter 5.4.9). Cut the hose bundle ties. 557D573 Place a protective plate (e.g. aluminium) at the bottom and top between the chassis and the hose bundle. 1 1 557D574 Remove the screws of the swinging joint. 557D575 Remove the cap. 557D576 ARR 1575 69 5 Frame Remove the bearing lock screw. 557D577 Remove the bearing lock (1). 1 557D578 Cut the thread in the support chassis. 557D579 Mount the screws. In the event of corroded bearing seat, use 4 screws. 557D580 70 ARR 1575 WORKSHOP MANUAL Screw in the screws until the swivel bearing from the bearing pin. 557D581 Because there is not enough space for longer screws than M12x100, spacers (approx. 20 mm) must be placed under the screws. Remove the screws as soon as the bearing is pushed out of the bearing pin. 557D582 Use squared wood (1) to separate the chassis at the front and back. Use another squared wood (2) to support the chassis at the back. 2 1 557D583 Special tool for the removal of the articulated bearing. 557D584 ARR 1575 71 5 Frame Move the pulling disc under the articulated bearing using the special tool. 557D585 557D586 Use the special tool to mount the upper part (1) on the support chassis. Use the special tool to mount the M20 hex screw (2). 2 1 557D587 Pull the bearing out of the support. Tighten the screw until the bearing is loose. 557D588 72 ARR 1575 WORKSHOP MANUAL Remove the bearing out of the support. 557D589 557D590 Removed binding ring with a bearing. 557D591 Place the binding ring under a press. 557D592 ARR 1575 73 5 Frame Push out the bearing. 557D593 Clean the binding ring. 557D594 Lubricate the bearing seat. 557D595 Lubricate the new bearing. 557D596 74 ARR 1575 WORKSHOP MANUAL Push the bearing into the binding ring. 557D597 Clean the support chassis. 557D598 557D599 Lubricate the bearing seat. 557D600 ARR 1575 75 5 Frame Apply sealant on the sealing surface. 557D601 557D602 Pull the bearing flange to the support using the screws. 557D603 Lubricate the bearing pins. 557D604 76 ARR 1575 WORKSHOP MANUAL Centre the chassis towards the bearing pins. 557D605 557D606 Mount the washer and the screw with the nut into the bearing pin. 557D607 Use the nut to pull the bearings over the bearing pin. Remove the screw. 557D608 ARR 1575 77 5 Frame Mount the lock washer on the screw. Apply blue adhesive on the screw. 557D609 Secure the swivel bearing with a screw and a washer. The tightening torque is 210 Nm. 1 Remove the mounting screws (1). 557D610 557D611 78 ARR 1575 WORKSHOP MANUAL Apply sealant on the surface of the binding ring. 557D612 557D613 Place the cap. 557D614 Apply blue adhesive on the screws. 557D615 ARR 1575 79 5 Frame Secure the cap. The tightening torque is 85 Nm. 557D616 Remove the protective plates. Arrange the hose bundle and fasten it using cable ties. 557D617 80 ARR 1575 WORKSHOP MANUAL 5.5 Fuel tank 5.5.1 Fuel level check Open the engine bonnet. Check the level in the plastic tank. Do not smoke while working! 5.5.2 Fuel replenishment Fill the fuel tank with diesel fuel up to the lower edge of the filler neck. Every day before starting to work The tank capacity is 28 litres of diesel. Do not smoke while working! Check the fuel tank and the fuel circuit for leaks. 557D081 Catch the drained fuel. ARR 1575 81 5 Frame 5.5.3 Fuel draining 1 Operating fluids pose a risk to the environment! Prevent fluids from leaking into sewage systems, soil or the environment. Loosen the screw plug (1) under the roller. Place a vessel under the drain neck. Let the diesel flow out. 557D082 Put on the screw plug (1). Diesel drain, chassis at the back, left 5.5.4 Fuel tank cleaning Over time, condensed water accumulates in the fuel tank. It must be drained once a year. Loosen the screw plug (1) under the roller. Place a vessel under the drain neck. Let approximately 1/2 litre of the fluid flow out. Water which has accumulated on the bottom of the tank flows out as the first. Put on the screw plug (1). 82 ARR 1575 WORKSHOP MANUAL 5.6 Hydraulic tank 5.6.1 Checking the hydraulic oil level 1 Check the hydraulic oil level always when the engine is cold but running. Put the machine on a flat terrain. Let the engine run at idle. Check the oil level in the inspection hole. The ideal hydraulic oil level is when the gauge is half-full. 555075A 5.6.2 Hydraulic oil replenishment Take off the ventilation filter (1) from the filler neck. Refill the required quantity of hydraulic oil. Screw in the ventilation filter (1) back in place. Always lubricate the O-ring before screwing it in place. Check the oil when it is cooled down. Fill up the same oil type, see Chapter 4.4. ARR 1575 83 5 Frame 5.6.3 Hydraulic oil draining Drain hydraulic oil only at operating temperature. Residues in the tank are drained with the oil. 1 Put a vessel (with a volume of at least 30 litres) under the hydraulic oil drain plug. 555085 Take out the ventilation filter (1). Remove the plug (2) from the hydraulic tank. Let the oil flow out into the vessel. Put on the screw plug (2). Tighten the screw connection with your hand. Tighten the screw connections in the hydraulic tank with hand. 2 When draining the hydraulic oil, replace the hydraulic oil filter and the ventilation filter as well. See Chapter 5.6.4. 557017A 84 ARR 1575 WORKSHOP MANUAL 5.6.4 Hydraulic oil filter replacement Take off the filter cap. Unlock the filter cartridge. Pull out the filter cartridge from the filter housing. Dispose of the filter cartridge environmentally. 555037 Insert the new filter cartridge in the correct place. Keep the position of the safety cam. Turn the filter cartridge clockwise up to the stop. 555038 Oil the sealing ring on the filter cap slightly. Put the filter cap in place. Tighten the cap with the torque spanner (tightening torque 20 Nm). 555039 ARR 1575 85 5 Frame 5.6.6 Ventilation filter replacement Remove the ventilation filter and replace it with a new one. 557D097 5.6.7 Hydraulic tank filling Fill the hydraulic oil tank (approximately 16 l). 557D098 557D099 86 ARR 1575 WORKSHOP MANUAL 5.6.8Filling the travel pump, increasing the supply pressure Remove the 006 (S) hydraulic hose. 557D100 Fill the travel pump housing with hydraulic oil. 557D101 Fill hydraulic oil (0.3–0.4 l) so that it flows out of the screw union (S). 557D102 Mount the 006 (S) hydraulic hose. 557D103 ARR 1575 87 5 Frame Remove the F21 (40A) fuse in the engine compartment. 555058A Connect a pressure gauge (40 bar) to the supply pressure measuring point. Rotate the engine with the engine starter. 557D104 Rotate the engine until the pressure reaches 3–5 bar. Do not overheat the starter! After no more than 30 seconds, let the starter cool down. 557D105 Insert the F21 (40A) fuse in the engine compartment. 555058A 88 ARR 1575 WORKSHOP MANUAL Start the diesel engine. Check the pressure increase. Maximum pressure = 23 bar. 557D106 If hydraulic components have been replaced or repaired, perform a function and leak check. 557D107 ARR 1575 89 90 ARR 1575 WORKSHOP MANUAL 6 Cab and platform ARR 1575 91 6 92 Cab and platform ARR 1575 WORKSHOP MANUAL 6.1 Control and indication elements 1 557018 2 3 4 5 555009B 1. Infrared remote control 2. Spiral cable compartment 3. Display unit 4. Ignition box 5. Fuses ARR 1575 93 6 Cab and platform 6.1.1 Display unit 6.1.1.1 Indicator lamps 1 2 4 3 Operating hours counter (1) - + Charging indicator lamp (2) + ! hours RAM02 The indication lamp goes on after the key in the ignition box is switched into the position "I" and goes out after the engine starts. If the indicator lamp turns on during operation or does not turn off after starting, immediately perform the following check. •• Turn off the engine. •• Check the V-belt of the engine for damage and loosening. 5 6 7 555012 If the battery charging indicator lamp is still on after this check, contact an authorized service centre of Ammann. ! Error indicator lamp (3) RAM01 The error indicator lamp turns on when the control unit detects an error. The inclination sensor is activated. The machine is positioned at an angle exceeding 45°. Place the machine upright. The wiring is faulty. Check for a short circuit or cable break. If the error indicator lamp is still on after this check, contact an authorized service centre of Ammann. 94 ARR 1575 WORKSHOP MANUAL Engine oil pressure indicator lamp (4) RAM03 1 2 The indication lamp goes on after the key in the ignition box is switched into the position "I" and goes out after the engine starts. 4 3 - + ! hours If the engine oil pressure indicator lamp turn on during operation or does not turn off after starting, immediately stop the machine and the engine. 5 6 7 555012 •• Check the engine for oil leaks and correct oil level. •• If the oil level in the engine is correct, contact an authorized service centre of Ammann. Note: The machine is equipped with an automatic shutdown system. If the oil pressure drops below the limit value, the oil pressure indicator lamp turns on. It lights up for 4 seconds and then the machine turns off. Coolant temperature indicator lamp (5) RAM04 There is a risk of engine overheating. Immediately stop the operation! If the coolant temperature indicator lamp turns on during machine operation, immediately turn off the engine and refill the coolant. •• Check the cooling system for leaks and the level of coolant in the cooler / expansion vessel. •• No error found: Contact an authorized service centre of Ammann. Note: The machine is equipped with an automatic shutdown system. If the coolant temperature exceeds the limit value, the temperature indicator lamp turns on. It lights up for 4 seconds and then the machine turns off. ARR 1575 95 6 Cab and platform Safety bar indicator lamp (6) RAM06 1 2 The safety bar indicator lamp is continuously on the whole time the safety bar is connected (optional equipment). The safety bar indicator lamp also lights up during the activation of the near and remote halt. Preheating indicator lamp (7) RAM05 4 3 - + ! hours 5 6 7 The preheating time is approximately 6 seconds. The preheating indicator lamp turns off after the engine starts. 555012 96 ARR 1575 WORKSHOP MANUAL 6.1.2 Error indication via LEDs on the display unit Error indication (inclination switch) Indication Reason Error lights up The inclination switch activated. The roller is inclined by more than approx. 45° or Set the machine upright. overturned. Corrective action If the roller overturns, the ignition deactivates for safety reasons. The machine control is equipped with an inclination sensor. This sensor activates when the inclination angle exceeds 45°. The engine then automatically turns off. After the sensor activates, the machine cannot be started. If the machine is overturned, engine oil cannot reach the combustion chamber. Starting the engine after the machine is set upright again may cause engine damage. Set the machine upright. Do not start the engine. Contact a service workshop. Error and Safety Bar indication Indication Reason Corrective action Error lights up The switching transistor signals a status error. This means, Check that the cable is not for example, that a short circuit or broken cable has been short-circuited or broken. detected. The Error and Safety Bar indicator lamps The control unit of the machine waits until the “Oil Pres- Check the Oil Pressure and are on simultaneously sure” and “Alternator” inputs are in the basic position. Alternator outputs. Pay attention to the indicator lamp priority: First the inclination switch, then “waiting” and finally the status error transistor. Safety Bar indication Indication Reason The Safety Bar indicator lamp is on The safety bar switch activated. Put the safety bar to the initial position. The Safety Bar indicator lamp is flashing Near halt detected. The Safety Bar indicator lamp is illumi- Near field detected. nated brightly Corrective action Move at least 2.5 m away from the roller. If the roller is controlled using a cable, the user must be located in the so-called near field (at a distance of 2.5 to 4 m). CAUTION! Pay attention to the indicator lamp priority: First the safety bar switch, then near halt and finally near field. ARR 1575 97 6 Cab and platform 6.1.3 Infrared light emitter 6.1.3.1 Layout 4 2 1 Working speed (tortoise) / transport speed (hare) 2 Forward / reverse 3 High / low amplitude vibration 4 Steering angle left / right 5 Start / Stop 6 LED indicators 7 Warning horn switch 3 1 7 6 5 557019 6.1.3.2 Indication of faults by LEDs on the infrared light emitter There are two LEDs on the cover: green and red. 555014 Standard indicator lamp (green) Indicator lamp Reason The green LED is flashing slowly The machine is controlled by the infrared remote control and cable The green LED is flashing rapidly The machine is controlled by the infrared remote control Battery charge status indicator (red). The red LED indicator flashes faster or slower depending on the battery charge status. The more the battery is discharged, the slower the red LED indicator flashes. When the battery is discharged, the red LED indicator lights continuously. Controlling via the infrared remote control Indicator lamp Reason Solution The red LED is flashing. The battery is running low. Connect the charging cable for at least an hour. The red LED is on. The battery is discharged, the control does not work. Connect the charging cable for at least an hour. Controlling via the infrared remote control and cable Indicator lamp Reason The red LED is flashing rapidly. The battery is charging. The red LED is on. The battery is fully charged. 98 Solution ARR 1575 WORKSHOP MANUAL When the battery is discharged, the machine can still be controlled using a cable. The battery warning and error are then indicated also during control (if the controller is activated). When and as long as the infrared light emitter is connected via a cable to the machine’s control unit and the ignition is in the “I” position, the red LED must be flashing or illuminated. Automatic pairing function •• If you wish to control the machine via the infrared remote control, you must first perform a mutual assignment of addresses. This is only necessary when registering a new infrared remote control to the machine. •• Connect the cable to the emitter. •• Turn the ignition key to the “I” position. •• After about 3 seconds, you can disconnect the cable. •• The cable is not required for operation with the infrared remote control. Indicator lamp Reason The green and red LEDs are both flashing rapidly. The infrared remote control is paired with the control unit of the machine. Note: This process normally takes a maximum of 3 seconds. If the flashing is longer or even persistent, a pairing problem occurred: •• cable break in one of the signal connections, •• short circuit in one of the signal connections, 6.1.3.3 Cable connection 1 Spiral cable connector / protective cover fastener 2 Solar cells / transmission elements 2 1 ARR 1575 555199A 99 6 Cab and platform 6.1.3.4 Handling The infrared remote control is located under the dashboard cover. It contains the following transmission elements: -- solar cells, -- infrared diodes for data transmission and measurement of safe distance. Clean the transmission elements before starting. Keep the solar cells clean during operation. 557021 Risk of injury due to obstructed bottom part of the cover! Before and during the operation with the infrared remote control, make sure the entire bottom part of the cover remains completely exposed throughout the whole operation. The operator must not cover the bottom part of the cover, not even partially. Proper carrying and use of the infrared remote control Ensure correct positioning. •• Proper function requires direct visual contact between the manual infrared remote control and the infrared sensor on the machine. The infrared sensor must always be in the area of effect of the infrared remote control. The operating angle of the infrared remote control is 40°. 100 ARR 1575 WORKSHOP MANUAL Proper use of the infrared remote control 40° 555116 40° 555118 40° 555120 40° 40° 555131 ARR 1575 555119 101 6 Cab and platform Improper use of the infrared remote control 40° During the operation of the machine, it is forbidden to use the infrared remote control without direct visual contact between the infrared remote control and the infrared sensor on the machine. The operating angle of the infrared remote control is 40°. 555117 ° 40 555121 40° 555124 40° 555123 102 ARR 1575 WORKSHOP MANUAL 40° 555122 40° 555125 40° 555129 ARR 1575 103 6 Cab and platform During operation, aim the infrared remote control in the direction of the machine only. The cable connector (1) must face forward. 1 •• The infrared remote control can lean on the operator's body. 555192 555193 The side and front diodes of the infrared remote control must not be covered (e.g. by fingers, hand, foreign objects or dirt). 555197 555194 104 ARR 1575 WORKSHOP MANUAL Do not aim the transmitter at reflective objects (large surfaces, light objects, other machinery, etc.). Do not use the infrared remote control in the protected 2 m zone or if there is insufficient visual contact between the machine and the operator or the infrared remote control, unless stated otherwise. For optimum comfort, adjust the strap to the correct length. 555195 555196 The infrared remote control is provided with a protective cover. This cover reduces risk of inadvertent covering of the side and front diodes with hands or fingers of the operator. Do not remove the cover from the infrared remote control. 557022 ARR 1575 105 6 Cab and platform 6.3.3 Relays and fuses in the engine compartment Dashboard fuses The fuses are located under the cover in the dashboard. F11 - 10 A������������������������Control unit, power supply F12 - 25 A������������������������Control unit, outputs F13 - 10 A������������������������Display unit, safety bar F14 - 25 A������������������������Hydraulic oil cooler Fuses in the engine compartment The fuses are located above the engine. F21 - 40 A������������������������Pull solenoid F22 - 10 A������������������������Fuel pump, alternator F23 - 40 A������������������������Working speed F24 - 40 A������������������������Ignition coil F25 - 40 A������������������������Altitude sensor 106 ARR 1575 WORKSHOP MANUAL 6.3.4 Dashboard N2 S1 F N3 557018B Functions N2 Display unit N3 Infrared light emitter S1 Ignition box N2 display unit Functions H1 Charging indicator lamp H2 Preheating indicator lamp H3 Oil pressure indicator lamp H4 Water temperature indicator lamp H5 Safety bar indicator lamp H6 Error indicator lamp P3 Operating hours counter P3 H3 H1 H6 - + ! hours H4 H5 H2 555012C ARR 1575 107 6 Cab and platform 6.3.4.1 Other components 6.3.4.2 N1 connector / cable harness Make sure there is no water or dirt on the N1 connector. 557D078 108 ARR 1575 WORKSHOP MANUAL List of harness wires / N1 connector No. Crosssection Colour from Pin to Pin Note 101 2.5 white N1 1 F11 1 Control 12 V F12 102 2.5 white N1 2 103 2.5 brown N1 3 Casing - back 2 Casing - control Control 12 V 104 2.5 brown N1 4 Casing - back Casing - control 105 0.75 white N1 5 K1 86 Ignition relay 106 0.75 white N1 6 S1 19 9 Preheating relay 107 0.75 white N1 7 S1 50 7 Ignition relay 108 1 white N1 8 S25 1 Holding coil 109 0.75 white N1 9 K5 86 Accelerator relay 110 1 white N1 10 Y3 1 Forward 111 1 white N1 11 Y4 1 Reverse 112 1 white N1 12 Y3 2 Return line 113 1 white N1 13 Y5 1 Steering to the left 114 1 white N1 14 Y6 1 Steering to the right 115 1 white N1 15 Y7 1 high amplitude 116 1 white N1 16 Y8 1 low amplitude 117 1 white N1 17 Y9 1 Brake valve 118 0.75 white N1 19 K2 85 120 0.75 white N1 21 N2 4 Safety bar Engine signal 121 0.75 white N1 22 N2 2 Error 122 0.5 white N1 23 X1 1 Control bus D+ 123 0.5 white N1 24 X1 2 Control bus D- 124 1 white N1 25 X1 3 +V12 125 1 brown N1 26 X1 4 Casing 126 0.5 white N1 27 N2 5 Engine oil pressure 127 0.75 white N1 28 S24 1 Safety bar 128 0.5 white N1 29 N2 6 Water temperature 129 1 white N2 1 F13 3 +12 V 130 0.5 white N2 3 S1 19 8 Preheating lamp 131 0.5 white N2 5 S21 132 0.5 white N2 6 S22 Oil pressure indicator lamp 1 Water temperature 133 0.5 white N2 7 K2 85 134 2.5 white K1 30 S1 15 5 Ignition 135 2.5 white K1 87 F14 D Ignition Engine signal X3 2 Ignition 136 2.5 white K1 87 137 0.75 brown K1 85 138 4 white K2 30 139 0.75 white K2 86 S1 50 7 Starter 140 2.5 white K2 87 M1 50 Starter 141 1.5 white K2 87 F21 A Input coil 142 0.75 white K2 85 G1 D+ 1 Ignition lock 143 0.75 white K3 red F21 1 Timer 144 0.75 brown K3 black 145 0.75 white K3 red/black K4 86 Timer 146 0.75 white K3 yellow K4 85 Timer ARR 1575 indicator Casing - back M1 Ignition relay 30 Casing - engine Battery 12 V Timer 109 6 Cab and platform No. 110 Crosssection Colour from Pin to F21 Pin 147 1.5 white K4 30 148 1.5 white K4 87 Y1 white 1 149 0.75 brown K5 85 Casing - engine 150 1.5 white K5 30 Note Input relay Input coil Accelerator relay F23 3 Accelerator magnet 151 1.5 white K5 87 Y2 + Accelerator magnet 152 0.75 white K6 86 S1 19 9 Preheating relay 153 0.75 brown K6 85 Casing - engine 154 4 white K6 30 F24 155 4 white K6 87 R1 156 0.75 white K7 86 S25 157 0.75 brown K7 85 158 2.5 white K7 30 159 2.5 white K7 Preheating relay 4 Preheating Preheating 2 Cooler relay F14 4 Oil cooler 87 M3 1 Oil cooler Casing - back Cooler relay 160 0.75 white S24 2 S24 3 Safety bar 161 0.75 white S24 4 F13 3 Safety bar 162 4 white G1 30 M1 30 Charging current 163 0.75 white G1 15 F22 2 Exciter voltage 164 0.75 white M2 F22 2 Diesel fuel pump 165 1 brown M2 Casing - engine Diesel fuel pump 166 1.5 brown Y1 black Casing - engine Holding coil 2 167 1 white Y3 2 Y4 169 1 brown Y5 2 Casing - engine 2 Steering to the left Return line 170 1 brown Y6 2 Casing - engine Steering to the right 171 1 brown Y7 2 Casing - engine high amplitude 172 1 brown Y8 2 Casing - engine low amplitude 173 1 brown Y9 2 Casing - engine Brake valve 174 1.5 brown Y2 Casing - engine Accelerator magnet 175 1 brown N2 8 Casing - back Display unit 176 2.5 brown M3 2 Casing - back Oil cooler 177 1.5 white F13 C F14 D Display unit 178 2.5 white F12 B S1 15 6 Control 12 V 179 1 white F12 B F11 A Control 12 V 180 4 white M1 30 S1 30 1 +12 V 181 4 white M1 30 F24 D Preheating 182 1.5 white M1 30 F23 C Accelerator magnet 183 4 brown Casing - engine 184 4 brown Casing - engine Casing - front Connection 185 1 white S25 1 Y1 red Holding coil 186 1 white X3 2 F22 Casing - back Connection B Ignition 187 1 white F21 A X3 1 Starter 188 1.5 white M1 30 X3 3 Battery + 189 2.5 brown X3 4 Casing - engine 2. Holding coil Y11 ARR 1575 WORKSHOP MANUAL 6.4.1 Replacement of the remote control battery Removal Remove the protective cover. 557D001 557D002 Remove the rubber gaskets. 557D003 Remove the screws. 557D004 ARR 1575 111 6 Cab and platform Open the top of the remote control. 557D005 Remove the connector fastening strip. 557D006 Disconnect the connector. 557D007 Remove the battery. 557D008 112 557D009 ARR 1575 WORKSHOP MANUAL Installation Insert the battery. 557D008 Pull the fastening strip through the hole under the connector. 557D010 Connect the connector. 557D011 Fasten the connector with the fastening strip. 557D012 ARR 1575 113 6 Cab and platform Shorten the fastening strip. 557D013 Install the top of the remote control using the screws. 557D004 Install the rubber gaskets. 557D003 Install the protective cover. 557D001 114 ARR 1575 WORKSHOP MANUAL 6.4.2 Replacement of the display unit Disconnect the N2 connector. 557D218 Remove the two fasteners of the display unit. 557D219 You can now extract the display unit. 557D220 Install the new unit in the reversed order. 557D221 ARR 1575 115 6 Cab and platform 6.4.3 Replacement of the control unit Removal Remove the battery clamp (–). 557D222 Disconnect the connectors of the control unit. 557D223 Disconnect the N1 connector. 557D224 Use a screwdriver to lift the clamp Pull away the gas cylinder from the ball joint. 557D225 116 ARR 1575 WORKSHOP MANUAL Remove the control unit fastening screws and remove the unit. 557D226 557D227 ARR 1575 117 6 Cab and platform 6.4.3.2 Installation Apply blue adhesive on the screws. 557D228 Install the control unit using the screws. 557D229 Connect the N1 connector. Connect the battery terminal (–). 557D230 118 ARR 1575 WORKSHOP MANUAL 7 Front drum ARR 1575 119 7 Front drum 7.2 Hydraulic parts 7.2.1 Travel drive/vibration hose Drum, front left 557D004 Drum hose, front left 120 No. from to 31 Travel circuit B forward Hydraulic block, left 33 Travel motor brake Valve block BR 35 Travel circuit A reverse Travel pump A – T neck 37 Leaked oil – travel motor, front left – L neck Valve block T3 38 Brake, front left Travel motor brake, front right 39 Leaked oil – travel motor, front left – L neck Leaked oil – travel motor, front right – L neck ARR 1575 WORKSHOP MANUAL Drum, front right 557D005 Drum hose, front right No. from to 30 Vibration motor front Valve block A1 32 Travel circuit B forward Hydraulic block right 34 Travel circuit A reverse Travel pump A – T neck 36 Vibration motor, front, connection rear Vibration interface – angled divider neck 38 Travel motor brake, front right Travel motor brake, left – L neck 39 Leaked oil – travel motor, front right – L neck Leaked oil – travel motor, front left – L neck 40 Leaked oil – travel motor, front right – L neck Leaked oil vibration motor front ARR 1575 121 7 Front drum Drum, rear left 557D006 Drum hose, rear left 122 No. from to 50 Vibration motor rear, connection rear Interface, rear, angled neck 52 Travel circuit B forward Interface, rear 54 Travel circuit A reverse Interface, rear 56 Vibration motor rear, connection front Interface, rear, angled neck 58 Travel motor brake, rear left Travel motor brake, rear right – L neck 59 Leaked oil – travel motor, rear left – L neck Leaked oil – travel motor, rear right – L neck 60 Leaked oil – travel motor, rear left Leaked oil – vibration motor, rear ARR 1575 WORKSHOP MANUAL Drum, rear right 557D007 Drum hose, rear right No. from to 51 Travel circuit A reverse Interface, rear 53 Travel motor brake rear right Interface, rear 55 Travel circuit B forward Interface, rear 57 Leaked oil – return flow Hydraulic oil tank – return flow 58 Travel motor brake, rear right – L neck Travel motor brake, rear left 59 Leaked oil – travel motor, rear right – L neck Leaked oil – travel motor, rear left – L neck ARR 1575 123 7 Front drum 7.2.2 Valve block connections Valve block – top view Y8 Y5 BR B2 P A2 BPR Y6 Y9 Y7 557D008 Valve block – solenoid valves No. Designation Y5 Steering to the left Y6 Steering to the right Y7 High amplitude Y8 Low amplitude Y9 Brake Valve block – connections 124 No. Designation BR Brake PBR Travel pump G supply pressure P Vibration control pump pressure A2 Steering to the right / right steering piston B2 Steering to the left / right steering piston ARR 1575 WORKSHOP MANUAL Valve block – front view 4 T2 B1 A3 3 557D009 Valve block – connections at the front No. Designation T2 Tank line to travel pump T1 A3 Steering to the left / left steering piston B1 Vibration motor rear left / high amplitude, angled divider screw connection Valve block – pressure drain valve No. Designation 3 Vibration pressure drain valve (min. 210 bar / max. 230 bar)* 4 Steering pressure drain valve (min. 60 bar / max. 75 bar)* * Values measured at an engine speed of at least 2380 rpm / max. 2430 rpm ARR 1575 125 7 Front drum Valve block – rear view Valve block – hydraulic hose connections, rear No. Designation A1 Vibration motor front right – low amplitude T3 Leaked oil / travel motor, front left and right B3 Steering to the left / left steering piston A1 B3 T3 557D010 Valve block – right view Valve block – return line No. Designation T1 Return flow through the oil cooler, return flow filter in the hydraulic oil tank T1 557D011 126 ARR 1575 WORKSHOP MANUAL 7.2.3 Valve block hose Valve block – top view 557D012 Valve block – solenoid valves No. from to 2 Valve block P Vibration – steering pump pressure – L neck 3 Valve block T2 – angled neck Travel pump T1 4 Valve block T1 – angled neck Hydraulic oil cooler – angled neck 7 Valve block PBR – L neck Quantity divider T 8 Valve block PBR – L neck Travel pump G – L neck 13 Valve block BR – T neck Interface, rear 16 Valve block B1 Interface, rear – angled neck 17 Valve block B3 Left steering piston – cylinder 18 Valve block A3 Left steering piston – piston rod 19 Valve block A2 Right steering piston – cylinder 20 Valve block B2 Right steering piston – piston rod 30 Valve block A1 Vibration motor at the front, connection at the front 33 Valve block BR – T neck Travel motor brake, front left – L neck 37 Valve block T3 Leaked oil – travel motor, front left – L neck ARR 1575 127 7 Front drum Valve block – divider neck 557D013 Valve block – solenoid valves No. from to 10 Divider neck near the valve block holder Interface, rear – angled neck 36 Divider neck near the valve block holder Vibration motor, front, connection rear Interface, rear 557D014 128 ARR 1575 WORKSHOP MANUAL 7.4 Mechanical parts 7.4.1 Removal of the drum extension Remove the drum scrapers. 557D018 557D019 557D020 557D021 ARR 1575 129 7 Front drum Support the frame using a jack. 557D022 Remove the drum extension screws. 557D023 130 ARR 1575 WORKSHOP MANUAL 7.4.2 Drum removal Support the machine using a jack. Hang the drum on a crane and lift it slightly. 557D250 Remove the drum fastening screws. 557D251 Move the drum using a suitable tool under the chassis outwards. Keep the drum balanced using an aid (e.g. squared wood) 557D252 Store the drum safely for reuse. 557D253 ARR 1575 131 7 Front drum 7.4.3 Replacement of vibration unit rubber elements If any rubber element has cracks deeper than 10 mm, it must be replaced. Removal Remove the drum (Chapter 7.4.2). 132 ARR 1575 WORKSHOP MANUAL Clean the hoses and surroundings. Before hanging the hoses, place an oil drip container under the travel motor. 557D263 557D264 Remove all hoses at the travel motor. Close the screw union. 557D265 Install the aid on the travel hydraulic motor flange. Hang the aid on a crane. 557D266 ARR 1575 133 7 Front drum Remove the screws of the travel hydraulic motor attachment. 557D267 557D268 Remove the travel hydraulic motor and put it aside. 557D269 557D270 134 ARR 1575 WORKSHOP MANUAL Remove the nuts on the gearbox cover. 557D272 557D273 Put an oil drip container under the gearbox. Remove the screws on the gearbox cover. 557D274 ARR 1575 135 7 Front drum Put the gearbox cover aside. 557D275 Grease comes out of the gearbox. The same amount of grease then must be refilled during reassembly. 557D276 Store the gearbox cover safely for reuse. 557D277 Install the aid on the gearbox cover. Hang the aid on a crane. 557D278 136 ARR 1575 WORKSHOP MANUAL Remove the nuts on the gearbox cover. 557D279 Remove the gearbox and put it aside. 557D280 557D281 ARR 1575 137 7 Front drum 7.4.3 Disassembly of the vibration unit View of the vibration housing after opening. The grease in the housing is consumed after a certain number of operating hours and must be refilled. The following steps were performed on a new vibration unit. The grease is therefore unconsumed and light in all pictures. 557D294 Clean the vibration housing, remove the consumed grease. 557D313 Remove the screws on the bearing cap. 557D314 138 ARR 1575 WORKSHOP MANUAL Remove and clean the bearing cap. 557D315 557D316 Remove the grease on the hub. 557D317 557D318 ARR 1575 139 7 Front drum Loosen the grooved nut lock. Use a small chisel or screwdriver. 557D319 557D320 557D321 140 ARR 1575 WORKSHOP MANUAL Mount the special “spanner for grooved nuts” tool. 557D322 557D323 ARR 1575 141 7 Front drum Loosen the grooved nut lock. 557D324 Remove the grooved nut. 557D325 Remove the grooved nut lock. 557D326 Lift the vibration unit from the shaft. 557D327 142 ARR 1575 WORKSHOP MANUAL Remove the grease on the hub. 557D328 Remove the spacer rings. 557D329 557D330 Pull the bearings from the hub using the pulling tool. 557D331 ARR 1575 143 7 Front drum Mount the pulling tool here (arrow). 557D332 Remove the outer bearing rings and the spacer ring. 557D333 557D334 Clean the bearing housing. 557D335 144 ARR 1575 WORKSHOP MANUAL Remove the rubber-metal elements. 557D282 557D283 ARR 1575 145 7 Front drum 7.4.4 Installation of the drum rubber-metal elements Apply blue adhesive on the screws. 557D284 Install new rubber-metal elements on the centre beam. The tightening torque is 50 Nm. 557D285 557D286 557D287 146 ARR 1575 WORKSHOP MANUAL Apply blue adhesive on the rubber-metal element threads from the vibration motor side. 557D288 Support the hoses with squared wood on the vibration motor side so that they can be released. 557D289 Attach the gearbox to a crane using the aid. 557D290 557D291 ARR 1575 147 7 Front drum Align the gearbox. Place the gearbox on the rubber-metal elements. 557D292 Tighten the nuts (1) to a torque of 50 Nm. 1 557D278A This concludes the gearbox installation from the vibration motor side. If bearing replacement or new lubrication is required, refer to Chapter “Replacement of vibration unit bearings” (Chapter 7.4.3). Without bearing replacement or new lubrication, you cannot proceed further here. 557D293 Clean the sealing surface of the gearbox. 557D294 148 ARR 1575 WORKSHOP MANUAL Cut all threads (M8). 557D295 Blow-clean the threaded bores. 557D296 Thoroughly remove all glue residues and dirty grease. Replace the removed or blow-cleaned grease with the same amount of new grease. Grease: Foodgrease SPM00 557D297 Apply sealant to the sealing surface. 557D298 ARR 1575 149 7 Front drum Spread the sealant with a brush. 557D299 Apply a drop of blue adhesive in all threaded bores. 557D300 Clean / blow-clean the boreholes in the gearbox cover. 557D301 557D302 150 ARR 1575 WORKSHOP MANUAL Clean the sealing surface of the gearbox cover. 557D303 Apply blue adhesive on the threads of the rubber elements. 557D304 Mount the gearbox cover. 557D305 Fasten the gearbox cover using the nuts. The tightening torque is 50 Nm. 557D306 ARR 1575 151 7 Front drum Apply blue adhesive on the screws. 557D307 Tighten the screws (1) to a torque of 36 Nm. 1 557D308 557D309 Install the hose guide holder (1) using the same screws. 1 557D310 152 ARR 1575 WORKSHOP MANUAL 7.4.4 Installation of the vibration unit 1 Install a new wide outer bearing ring (1) into the bearing housing. Observe the installation position. 557D336 Push the wide outer bearing ring into the housing. 557D337 Insert the spacer ring (1) into the bearing housing. 1 557D338 557D339 ARR 1575 153 7 Front drum Install a narrow outer bearing ring (1) into the bearing housing. Observe the installation position. 1 557D341 Push the narrow outer bearing ring into the housing. 557D340 557D339 154 ARR 1575 WORKSHOP MANUAL Heat the rear cone bearing to 110 °C. 557D342 Slide the rear cone bearing onto the hub. 557D343 Apply a small amount of grease on the bearing. 557D344 Mount the spacer rings. 557D345 ARR 1575 155 7 Front drum Lubricate the bearing ring from the outside. 557D346 Insert the vibration unit into the vibration housing. 557D347 Mount the bearing from the outside. 557D348 Mount the lock ring. 557D349 156 ARR 1575 WORKSHOP MANUAL Mount the grooved nut. 557D350 Mount the special “spanner for grooved nuts” tool. 557D351 Tighten firmly (200 Nm). 557D352 Install the bridge for the torque meter. 557D353 ARR 1575 157 7 Front drum Mount the torque meter. 557D354 Turn the vibrator with the torque meter 20 times clockwise. This eliminates any stress. The housing must not stand on a support and must be freely rotatable. 557D355 Set the tightening torque to 1–3 Nm. If the value does not match, perform correction using spacers until it does. 1/10 = 4 Nm 557D356 Bend the securing plate with a suitable tool into the suitable nut groove. 557D357 158 ARR 1575 WORKSHOP MANUAL 557D358 Grease the bearings. 557D359 557D360 Total amount of grease in the bearing housing: 100 g of liquid grease BLASER FOODGREASE SPM00 557D361 ARR 1575 159 7 Front drum Put a small amount of blue adhesive in the threaded bores. 557D362 Apply blue adhesive on the screws. 557D363 Mount the bearing cap on the vibrator housing. 557D364 Tighten the screws to a torque of 10 Nm. Weight of the vibration unit must move freely. 557D365 160 ARR 1575 WORKSHOP MANUAL Apply 300 g of grease in the vibration housing. 557D366 Clean the sealing surface of the gearbox. 557D294 Cut all threads (M8). 557D295 Blow-clean the threaded bores. 557D296 ARR 1575 161 7 Front drum Thoroughly remove all glue residues and dirty grease. Replace the removed or blow-cleaned grease with the same amount of new grease. Grease: Foodgrease SPM00 557D297 Apply sealant to the sealing surface. 557D298 Spread the sealant with a brush. 557D299 Apply a drop of blue adhesive in all threaded bores. 557D300 162 ARR 1575 WORKSHOP MANUAL Clean / blow-clean the boreholes in the gearbox cover. 557D301 557D302 Clean the sealing surface of the gearbox cover. 557D303 Apply blue adhesive on the threads of the rubber elements. 557D304 ARR 1575 163 7 Front drum Mount the gearbox cover. 557D305 Tighten the nuts to a torque of 50 Nm. 557D306 Apply blue adhesive on the screws. 557D307 164 ARR 1575 WORKSHOP MANUAL Tighten the screws (1) to a torque of 36 Nm. 1 557D308 557D309 Install the hose guide holder (1) using the same screws. 1 557D310 ARR 1575 165 7 Front drum 7.4.5 Replacement of the travel hydraulic motor Removal Remove the drum, travel hydraulic motor (Chapter 7.4.2). 166 ARR 1575 WORKSHOP MANUAL On the removed travel motor, remove all screw unions. 557D373 557D374 Remove the screws on the travel hydraulic motor flange. The screws are inaccessible: In rare cases (7x) where bolts are not accessible, the travel hydraulic motor flange must be completely removed. You then have to remove (5x) hexagon bolts. Lift the flange from the travel motor. 557D375 Screw two eye screws in the travel motor flange. 557D376 ARR 1575 167 7 Front drum Attach slings to a crane and the eye screws. Before lifting the travel motor from the motor support, mark the motor location with a pencil. 557D377 If the travel motor is stuck in the motor support due to corrosion, push the traction motor out of the motor support. •• (3x) Clean the threads. •• (3x) Cut the threads. •• (3x) Mount M12x60 hex screws. •• Push the travel motor out of the motor support. 557D378 Lift the travel motor from the motor support. 557D379 Clean the seating surface and threads. 557D380 168 ARR 1575 WORKSHOP MANUAL Lubricate the bearing seat with NeverSeez. 557D381 Put a small amount of blue adhesive in the threaded bores. 557D382 Place the new travel motor in the motor support. Pay attention to the motor position (previously marked). 557D379 Apply blue adhesive on the screws. 557D383 ARR 1575 169 7 Front drum Mount the screws. The tightening torque is 85 Nm. 557D385 Apply blue adhesive on the screw unions from the old travel motor. 557D386 170 ARR 1575 WORKSHOP MANUAL Mount the screw unions on the travel motor, firmly tighten. Material 3 4 1 Hydraulic motor K 04/340.0 cm³/rev. (1) •• (2x) Straight neck with thread GES10L M22x1.5 (2) (125 Nm) •• (1x) Straight neck with thread GES10L M16x1.5 (3) (55 Nm) •• (1x) Straight neck with thread GES10L M14x1.5 (4) (45 Nm) 2 2 557D387 Cover the screw unions with caps. 557D388 ARR 1575 171 7 Front drum Installation Clean the seating surface of the motor support and threads. 557D389 557D390 Put a small amount of blue adhesive in the threaded bore. 557D391 Mount the aid on the travel hydraulic motor flange. 557D271 172 ARR 1575 WORKSHOP MANUAL Screw one threaded pin to the right and left of the vibration housing flange as a mounting aid for the travel hydraulic motor. 557D392 Hang the travel hydraulic motor on a crane and install it in the machine. 557D393 557D394 557D395 ARR 1575 173 7 Front drum Apply blue adhesive on the screws. 557D396 Mount the travel hydraulic motor using the screws. The tightening torque is 85 Nm. 557D397 Remove the aid. 557D398 Mount all hoses. 557D399 174 ARR 1575 WORKSHOP MANUAL Clean the hose fittings and the surroundings using cleaning agents (e.g. brake cleaner). Apply NeverSeez on the flange (arrow). Before installing the drum, let the machine run on blocks. Perform a leak check. 557D400 Move the drum under the chassis using an aid. Keep the drum balanced using an aid (e.g. squared wood). 557D252 Mount the drum using the screws. The tightening torque is 85 Nm. 557D262 ARR 1575 175 7 Front drum 7.4.6 Replacement of the vibration hydraulic motor Removal Remove the drum, travel hydraulic motor (Chapter 7.4.2). Remove all hoses at the travel motor. Close the screw union. 557D401 557D402 Remove the screws of the vibration hydraulic motor. 557D403 Remove the vibration hydraulic motor. 557D404 176 ARR 1575 WORKSHOP MANUAL Remove the clutch. 557D405 In the case of a defective vibration hydraulic motor, remove the screw union and pinion. 557D406 Remove the pinion nut. 557D407 Remove the pinion using a pulling tool. 557D408 ARR 1575 177 7 Front drum 557D409 Remove the screws. Remove the angled flanges on both sides. 557D410 Remove the 040 hydraulic hose. 557D411 Remove the threaded neck. 557D412 178 ARR 1575 WORKSHOP MANUAL Installation Overview of all parts used for the new vibration motor. If the screw unions and other parts are undamaged, they may be reused in the new vibration motor. 557D413 Always replace the sealing rings. 557D414 Apply blue adhesive on the screws. 557D415 Mount the angled flanges using the screws with a torque of 10 Nm. 557D413 ARR 1575 179 7 Front drum Mount the pinion. 557D417 Apply blue adhesive on the thread. 557D418 Insert a spring washer. 557D419 Mount the pinion nut. 557D420 180 ARR 1575 WORKSHOP MANUAL Tighten the pinion nut firmly to a torque of 50 Nm. 557D421 Apply blue adhesive on the straight neck. 557D422 Mount the straight neck and tighten firmly to torque of 40 Nm. 557D423 557D424 ARR 1575 181 7 Front drum Mount the clutch. If the old clutch is undamaged, you can reuse it. Otherwise, insert a new clutch. 557D425 Apply sealant on the sealing surface. 557D426 Insert the vibration hydraulic motor. 557D404 Apply blue adhesive on the screws. 557D427 182 ARR 1575 WORKSHOP MANUAL Tighten the screws firmly (56 Nm). 557D403 Mount the hydraulic hoses. 557D428 557D429 ARR 1575 183 7 Front drum 7.4.7 Drum installation Move the drum under the chassis using an aid. Keep the drum balanced using an aid (e.g. squared wood). 557D252 Tighten the screws firmly (85 Nm). 557D251 7.4.8 Scraper Before driving, adjust the scraper so that there is a gap of about 5 mm between the scraper and the drum. 5 mm 557W054 184 ARR 1575 WORKSHOP MANUAL 8 Rear drum ARR 1575 185 8 Rear drum 8.2 Hydraulic parts Hydraulic parts (Chapter 7.2). 186 ARR 1575 WORKSHOP MANUAL 8.3 ACEecon Removal Remove the rear drum scrapers. 557D018 557D019 557D020 557D021 ARR 1575 187 8 Rear drum Support the left rear part of the frame with a jack. 557D022 Remove the extension of the left rear drum. 557D023 Remove the left rear drum. 2 1 557D024 557D025 188 ARR 1575 WORKSHOP MANUAL Remove the hydraulic motor from the machine frame. 557D026 557D027 557D028 Remove the hoses from hydraulic motor. Mark the outlets and blind them with plugs. 557D029 ARR 1575 189 8 Rear drum Remove the hoses from the vibration hydraulic motor. 557D030 Remove the sensor wiring clips. 557D032 Remove the hose holder. 557D033 190 ARR 1575 WORKSHOP MANUAL Remove the M7 screws using the jig. 557D034 557D035 557D036 ARR 1575 191 8 Rear drum Remove the holder of the ACEecon sensor. 557D037 557W053 Remove the document compartment. 557D014 192 ARR 1575 WORKSHOP MANUAL Remove the wiring ties. 557D038 557D039 Disconnect the X50 connector. 557D040 Disconnect the display panel connectors. 557D041 ARR 1575 193 8 Rear drum Installation Mount the hose holder using the screws. Secure the screws with the Loxeal 83-54 adhesive. 557D042 Mount the hoses of the vibration hydraulic motor. 557D043 Mount the travel hydraulic motor. Secure the screw joints with the Loxeal 83∙-54 adhesive. 557D044 557D045 194 557D046 ARR 1575 WORKSHOP MANUAL Attach the hydraulic hoses of the travel hydraulic motor. 557D047 Install the drum. Secure the screws with the Loxeal 83-54 adhesive. 557D048 Install the drum extension. Secure the screws with the Loxeal 83-54 adhesive. 557D049 ARR 1575 195 8 Rear drum Install the scrapers. Set the scrapers so that there is a gap of about 5 mm between the scraper and the drum. 557D050 557D051 557D052 8.4 Mechanical parts See Chapter 7.4. 196 ARR 1575 WORKSHOP MANUAL 9 Front axle (not included in the machine equipment) ARR 1575 197 198 ARR 1575 WORKSHOP MANUAL 10 Rear axle (not included in the machine equipment) ARR 1575 199 200 ARR 1575 WORKSHOP MANUAL 11 Travel ARR 1575 201 11 202 Travel ARR 1575 WORKSHOP MANUAL 11.2 Hydraulic parts 11.2.1 Replacement of the travel pump Drain the hydraulic oil (Chapter 5.6.3). Removal Place an oil drip container under the chassis at the front or the travel pump. 557D431 Remove the pressure line, vibration pump screw union. 557D432 557D433 Close the screw union. 557D434 ARR 1575 203 11 Travel 557D435 Remove the supply pressure, travel pump screw union. 557D436 Close the screw union. 557D437 557D438 204 ARR 1575 WORKSHOP MANUAL Remove the supply, travel pump hydraulic hose. 557D439 Close the screw union. 557D440 557D441 Remove the hydraulic hose of the forward travel (B), travel pump circuit. 557D031 ARR 1575 205 11 Travel Close the screw union. 557D442 557D443 Remove the T screw union of the reverse travel (A), travel pump circuit. 557D032 557D444 206 ARR 1575 WORKSHOP MANUAL Close the screw union. 557D445 Remove the suction line, vibration pump screw union. 557D446 Close the screw union. 557D447 557D448 ARR 1575 207 11 Travel Remove the angled screw union of the suction line, travel pump. The hydraulic oil will stop flowing. 557D449 557D450 Remove the hydraulic hose of the supply pressure, PBR valve block. Close the screw union. 557D451 Remove the cable ties on both sides on the servo block. 557D452 208 ARR 1575 WORKSHOP MANUAL 557D453 Remove connectors Y3 and Y4. 557D454 557D455 Remove the screws on the travel pump. 557D456 ARR 1575 209 11 Travel Lift the travel pump from the motor. 557D457 Now close the loose angled screw union of the suction line (1). 1 557D458 557D459 Pull the pinion off the shaft. 557D460 210 ARR 1575 WORKSHOP MANUAL Preparation of a new vibration travel pump If the old screw unions are undamaged, you can reuse them. Otherwise, use new screw unions. 1 5 8 9 4 13 2 12 2 3 6 10 11 10 7 557D461 Travel pump screw unions SW Nm 1 Hydraulic pump 2* Straight neck with thread GES12L/M27x2-WD 32 180 3* Straight neck with screw union GES 8LM-WD 17 25 4* Straight neck with screw union 12L/M 14x1.5-WD 19 45 5* Straight neck with screw union GES15LM-WD 27 70 6* Straight neck with screw union GES22LM-WD 32 125 7 Screwed connection MINIMESS-1620 DKO 8L 17 8* Screwed connection MINIMESS-1620 M12x1.5 17 9 Screwed connection MINIMESS-1620 DKOL 12L 22 10 Adjustable angled neck EWSD 8L 17 11 Adjustable angled neck EWSD 22L 36 12 Adjustable T-neck ETSD12L 22 13 Adjustable L-neck ELSD12L 22 * Apply blue adhesive on all straight threaded necks and Minimess M12x1.5. ARR 1575 211 11 Travel Torque 10 Nm 2 3 5 4.1 5.1 4 1 557D462 Vibration control pump 1 Gear pump 11 ccm/rev. 9 teeth 82.55 mm 2 Screwed connection MINIMESS-1620 DKOL 15L 3 Adjustable L-neck ELSD15L o.M+D K 4 Straight neck with flange GFS 15L-35 4.1 Sealing ring 5 Straight neck with flange GFS 22L-40 5.1 Sealing ring Appy NeverSeez on the shaft. 557D463 212 ARR 1575 WORKSHOP MANUAL Apply blue adhesive on the screw. 557D464 Set the pinion Insert a feeler gauge (1.5 mm) between the pinion and the pump housing. 557D465 Tighten the screw to a torque of 85 Nm. 557D466 ARR 1575 213 11 Travel Installation Clean the M12 thread on the pump flange. 557D467 Remove the suction hose stopper cap. 557D468 Apply blue adhesive on the screws. 557D469 Move the travel pump on the pump flange. 557D470 214 ARR 1575 WORKSHOP MANUAL Tighten the screws to a torque of 85 Nm. 557D471 557D472 Mount the suction line screw union. 557D473 Mount the T screw union of the reverse travel (A), travel pump circuit. 557D474 ARR 1575 215 11 Travel Mount the hydraulic hose of the forward travel (B), travel pump circuit. 557D475 Mount the pressure line, vibration pump screw union. 557D476 Mount the supply, travel pump hydraulic hose. 557D477 Mount the supply pressure, travel pump screw union. 557D478 216 ARR 1575 WORKSHOP MANUAL Connect connectors Y3 and Y4. 557D479 Mount the hydraulic hose of the supply pressure, PBR valve block. 557D451 ARR 1575 217 11 Travel 11.2.2 Replacement of the valve block Before removing the valve block, drain the hydraulic oil, see “Hydraulic oil draining” (5.6.3). Removal Disconnect connectors Y5 to Y9. Y6 Y9 Y7 557D480 Cut all cable ties on the harness / valve block. Loosen the cable harness. 557D481 218 ARR 1575 WORKSHOP MANUAL Remove hydraulic hoses A2, B2, PBR, T2. 557D482 Close the screw union. 557D483 Remove the BR hydraulic hose. 557D484 Close the screw union. 557D485 ARR 1575 219 11 Travel Remove the 018 (A3) hydraulic hose. Close the screw union. 557D486 Remove the 004 (T1) hydraulic hose. Close the screw union. 557D487 Remove the 037 (T3) hydraulic hose. Close the screw union. 557D488 Remove the 030 (A1) hydraulic hose. Close the screw union. 557D489 220 ARR 1575 WORKSHOP MANUAL To maintain access to the screw union of the B1 hose (1), first move the magnetic coil (2) back. Remove the knurled nut on the Y7 magnetic valve. 1 2 557D490 Remove the sealing ring (1). 1 557D491 Move the magnetic coil back. 557D492 Remove the 016 (B1) hydraulic hose. 557D493 ARR 1575 221 11 Travel Close the screw union. 557D494 Remove hydraulic hoses A1, B3, T3. Close the screw union. 557D495 Remove hydraulic hoses 010 and 036 (screw union of the angled divider). Close the screw union. 557D496 Remove the screws. 557D497 222 557D498 ARR 1575 WORKSHOP MANUAL Lift the valve block from the chassis. CAUTION: In this example, the travel pump has already been removed. It is not necessary to remove the travel pump to remove the valve block. You can remove the side plates on the right and left on the chassis. 557D499 View of the motor compartment, removed valve block. 557D500 Before installing a new or tested valve block, clean the bottom plate of hydraulic oil and dirt. 557D501 ARR 1575 223 11 Travel Check Magnetic valve – brake We recommend checking all magnetic coils and valves on the removed valve block. Remove the nut on the magnetic valve. 557D502 Remove the magnetic coil. 557D503 557D504 Remove the valve. 557D505 224 ARR 1575 WORKSHOP MANUAL Removed magnetic valve: 1 Nut 2 Sealing ring 3 Magnetic coil 4 Magnetic valve 5 Sealing ring 3 4 5 1/2 557D506 Supply the magnetic valve with 12 V. The valve (arrow) must switch visibly and audibly Check the sealing rings (1) for damage. 1 1 557D507 Brake magnetic coil resistance (4.9 Ohm). 557D508 ARR 1575 225 11 Travel Magnetic valve – high, low amplitude and steering Remove the nut on the magnetic valve. Remove the magnetic coil. 557D509 Remove the valve. Put the valve in the magnetic coil. 557D510 Supply the magnetic valve with 12 V. The piston must switch visibly and audibly 557D511 Resistance of the high / low amplitude and steering magnetic valve (4.4 Ohm). 557D512 226 ARR 1575 WORKSHOP MANUAL Max. pressure – brake, max. pressure – vibration You can set the brake drain valve if necessary. 557D513 You can set the vibration drain valve if necessary. 557D514 Magnetic valves can be activated manually. 557D515 ARR 1575 227 11 Travel Installation Place a new or checked valve block on the bottom plate. 557D516 Apply blue adhesive on the screws. 557D517 Tighten the valve block screws (25 Nm). 557D518 557D519 228 ARR 1575 WORKSHOP MANUAL Mount the 036 hydraulic hose on the screw union of the angled divider. 557D520 Mount the 010 hydraulic hose on the screw union of the angled divider. 557D521 Mount hydraulic hoses A1, B3, T3. 557D522 Connect the connectors in the back (Y5, Y8). 557D523 ARR 1575 229 11 Travel Mount the 004 (T1) hydraulic hose. 557D524 557D525 Mount hydraulic hoses A2, B2, PBR. 557D526 557D527 230 ARR 1575 WORKSHOP MANUAL Mount the hydraulic hose of the T-screw union (BR). 557D528 To maintain access to the screw union of the B1 hose (1), first move the magnetic coil (2) back. Remove the knurled nut. Remove the sealing ring. 1 Move the magnetic coil (2) back. Mount the B1 hydraulic hose (1). 2 557D529 Move the magnetic hose back to the initial position. Mount the sealing ring (1). 1 557D491 Mount the knurled nut. Firmly tighten the magnetic coil. 557D530 ARR 1575 231 11 Travel Mount the 018 (A3) hydraulic hose. 557D531 Mount the 002 (P) hydraulic hose. 557D532 Mount the 003 (T2) hydraulic hose. 557D533 Connect all front connectors (Y6, Y9, Y7). 557D534 232 ARR 1575 WORKSHOP MANUAL Place the cable harness cleanly. Fasten the cable harness with a cable tie. 557D481 ARR 1575 233 11 Travel 11.2.3 Brake test The brake function must be regularly checked. 557D119 Set the machine to the working position. Disconnect the Y9 connector from the magnet located under the front bonnet. Drive forward and reverse using the infrared controller. Check for drum spinning. If the brake is defective, the corresponding drum will spin. 1 If the brake is defective, the roller is not safe to operate. Contact an authorized dealer and have the drum repaired by a specialist. 557D120 557D121 11.2.4 Replacement of the travel hydraulic motor Replacement of the travel hydraulic motor (Chapter 7.4.2). 234 ARR 1575 WORKSHOP MANUAL 11.4 Mechanical parts 11.4.1 Replacement and adjustment of the speed magnet Removal Speed magnet (1). 557D231 Pull down cables Y2+ and Y2-. 557D232 Remove the safety pin from the plug head. 557D233 557D234 ARR 1575 235 11 Travel Remove the two screws. Remove the speed magnet. 557D235 236 ARR 1575 WORKSHOP MANUAL Installation Preassembled speed magnet (1). 1 557D236 Apply blue adhesive on the screws. 557D237 Place and firmly fasten the speed magnet. 557D235 Lubricate the safety pin of the plug head. 557D238 ARR 1575 237 11 Travel Mount the safety pin on the plug head. 557D239 Connect cables Y2+ and Y2-. 557D240 Do not interchange the - and + cables. 557D241 238 ARR 1575 WORKSHOP MANUAL Adjustment Loosen the lock nut on the plug head. 557D242 Push the piston rod completely down with your hand. The stop (arrow) must not touch the adjustment screw. 557D243 Use a feeler gauge (1.5 mm) to determine the distance between the adjustment screw and the stop. 557D244 557D245 ARR 1575 239 11 Travel Push the speed magnet completely to the stop! There must be a 1.5 mm gap between the stop and the adjustment screw. 557D246 Start the engine. Push the speed magnet completely to the stop! Measure the engine speed using the engine speed counter. If the specified speed (at least 2390–2440 rpm) is not reached, it must be adjusted on the plug head (1). 1 557D242A When the engine is idling, move the adjustment lever to the adjustment screw. 557D247 After the adjustment, firmly tighten the lock nut on the plug head. Movement test: Move the speed magnet up and down with your hand. 1 When pushing the rod mechanism, it must move back to its original position by itself and without tension. 557D242A 240 ARR 1575 WORKSHOP MANUAL 11.3.2 Checking the engine speed and frequency Adjust the speed at the machine operating temperature. Place the machine on two large or four small old tyres or adequately soft ground. 557D248 Start the engine. Select vibration. The machine sets the maximum speed = 2390–2440 rpm. Use a revolution counter to measure the frequency. The required value is 41 Hz. 557D249 If the speed is not reached, check the engine speed. If necessary, set the speed on the plug head (1). 2 Secure the nuts. Make sure the lock (2) is engaged on the plug head. 1 557D242B Engine speed rpm after 5 min. after 60 min. Engine speed 100% 2415 ± 25 2405 ± 25 Vibration speed, front low 2250 ± 150 2250 ± 150 Vibration speed, rear low 2250 ± 150 2250 ± 150 Vibration speed, front high 2250 ± 150 2250 ± 150 Vibration speed, rear high 2250 ± 150 2250 ± 150 ARR 1575 241 242 ARR 1575 WORKSHOP MANUAL 12 Vibration ARR 1575 243 12 244 Vibration ARR 1575 WORKSHOP MANUAL 13 Steering ARR 1575 245 13 Steering 13.2 Hydraulic parts 13.2.1 Replacement of the steering piston Replacement of the steering piston (Chapter 5.4.9). 246 ARR 1575 WORKSHOP MANUAL 14 Cooling ARR 1575 247 14 Cooling 14.2 Hydraulic parts 14.2.1 Cleaning of the hydraulic oil cooler Check that the cooler fins are not dirty or clogged. Clean the fins with water or blow-clean them with compressed air. Never clean the cooler with high pressure (e.g. with strong water jets). When the cooler is contaminated by petroleum products, use a cleaning agent and proceed according to the manufacturer’s instructions! Find out the cause of contamination! 555023 Do not smoke while working! Check the hydraulic circuit for leakage. Follow environmental standards and regulations when cleaning the machine! Clean the machine in a workplace equipped with a catching system of cleaning agents to avoid contamination of the soil and water resources! Do not use forbidden cleaning agents! 248 ARR 1575 WORKSHOP MANUAL 14.4 Mechanical parts 14.4.1 Coolant and checking the coolant level A mixture of water and an anti-freeze liquid to -25 °C has been filled in the factory. The liquid shall be replaced with a suitable cooler mixture at temperatures below -25 °C. 14.4.1.1 Checking the coolant level FULL Check the coolant level daily. Check it at a horizontal position of the roller and with cold engine. You can see the coolant level on the indicator situated on the expansion vessel. LOW 557D108 The coolant level must be between the upper mark (FULL) and the lower mark (LOW). Refill the coolant as required. 14.4.1.2 Coolant replenishment Risk of scalding from hot coolant! Do not open the cooler tank until the coolant and the engine cool down. Unscrew the coolant tank cap. Fill up the cooler with a coolant with an anti-freeze liquid. 557D109 14.4.1.3 Cooler cleaning Check that the cooler fins are not dirty or clogged. Clean the fins with water or blow-clean them with compressed air. Never clean the cooler with high pressure (e.g. with strong water jets). 555043 ARR 1575 249 250 ARR 1575 WORKSHOP MANUAL 15 Engine ARR 1575 251 15 Engine 15.1 Engine compartment, overview 15.1.1 Engine, left side 6 7 3 5 1 2 4 557D079 1 Inlet air filter 5 Engine oil, filler neck 2 Engine oil filter 6 Cooling water, filler neck 3 Oil dipstick 7 Fuel filter 4 Cooling water drain 15.1.2 Engine, right side 1 Engine oil, filler neck 2 Alternator 3 Fuel pump 4 Cooling water level indicator 5 Quantity divider 6 Hydraulic block 7 Water separator 1 2 3 Risk of burns and injury when handling the parts in the engine compartment! Always switch off the diesel engine before any inspection operations. The parking brake is active when the engine is switched off. 252 4 6 5 7 557D080 ARR 1575 WORKSHOP MANUAL 15.3 Electrical installation 15.3.1 Engine compartment K4 F21-24 K2 F25 K3 K6 K5 557D075 Engine compartment relays / fuses Functions of the engine compartment relays Functions K2 Ignition relay, ignition lock K3 Timer 1 s, input coil K4 Relay, input coil, tripping magnet K5 Speed magnet K6 Preheating relay Engine compartment fuses Fuse no. Value Protected electric circuit F21 40 A Input coil, tripping magnet A-1 F22 10 A Diesel fuel pump, alternator 15+ B-2 F23 40 A Speed magnet C-3 F24 40 A Preheating plug D-4 40 A 2. Single coil (Tier 4) (optional equipment) F25 Socket CAUTION! K3 is located on the back of the plate. ARR 1575 253 15 Engine Height sensor Tier 4 Relay Tier 4 Relay functions Tier 4 Functions K11 Height sensor Tier 4 K11 557D076 254 ARR 1575 WORKSHOP MANUAL 15.3.2 Chassis at the rear N1 G2 K1 K7 X4 X6 S24 557D077 Relay, chassis at the rear Relay functions, chassis at the rear Functions G2 Battery K1 Relay, ignition K7 Relay, hydraulic oil cooler N1 Machine control unit S24 Switch, sensor, safety bar (optional equipment) X4 Infrared sensor at the front P1 X6 Infrared sensor at the rear P2 Machines without a safety bar do not have the S24 proximity switch. The bridge retracts instead of the switch. Infrared sensor connectors X4 and X6 are interchangeable. This has no effect on the machine. ARR 1575 255 15 Engine 15.3.3 Battery Danger of cable burn or short circuit. Follow the order in which the clamps are disconnected and connected. •• Ignition on = battery voltage The voltage during the ignition process should not drop below 10 V. Otherwise, the battery must be recharged. •• Machine running = alternator charging voltage. The voltage should be between 13 and 14.5 V. 256 ARR 1575 WORKSHOP MANUAL 15.3.3.1 Battery replacement Loosen the (–) clamp and remove it. 557D124 Loosen the (+) clamp and remove it. 557D125 Loosen the holding angle piece and remove it. 557D126 Lift the battery from the machine area. Insert a new battery. Connect the battery. Start with the (+) clamp. Battery poles and clamps must be clean. If they show a coat of sulphate (whitish or greenish), they must be cleaned. 557D127 ARR 1575 257 15 Engine 15.3.4 Batteries The batteries are filled with an acid at a density of 1.28 g/ml by the manufacturer and charged sufficiently for immediate use. When the starting power is insufficient, recharging is required. Charging •• The battery must be recharged if the open-circuit voltage is below 12.5 V due to a longer storage time. The open-circuit voltage shall be checked after 2–4 quarters from the production date. If the open-circuit voltage is below 12.5 V, the battery must be recharged before a longer storage time to a level from 12.7 to 12.8 V. The open-circuit voltage shall be measured with a digital multimeter. The measurement should be made at about 20 °C. •• Ensure good ventilation of working areas. •• Use suitable DC chargers only. •• Connect the plus pole of the battery with the plus output of the charger; connect the minus pole in a similar way. •• Turn on the charger after the battery is connected and turn it off after it is recharged. •• Recommended charging current: 1/10 battery capacity in Amperes (Ah). •• If the acid temperature exceeds 55 °C, interrupt the charging. •• The battery is fully charged when the charging voltage does not increase further in the course of two hours. •• When the charging is completed, always measure the open-circuit voltage (do it no sooner than 1 hour after the charging). Removal •• While disassembling, first disconnect the cable of the negative (–) pole and then of the positive (+) pole. Never disconnect the battery when the engine is running. Installation •• Remove the protective cover of the plus pole only in the machine while connecting the pole terminals and put it on the pole of the removed battery to prevent short-circuits. •• Clean the poles and clamps and apply a thin layer of grease on the poles. •• First, attach the plus poles and make sure the clamps are firmly attached. •• Leave at least one degassing vent free. 15.3.5 Alternator replacement The alternator is a part of the engine. In the event of a fault, contact the engine manufacturer Yanmar. 15.3.6 Starter replacement The starter is a part of the engine. In the event of a fault, contact the engine manufacturer Yanmar. 258 ARR 1575 WORKSHOP MANUAL 15.4 Mechanical parts 15.4.1 Fuel filter element Replace the fuel filter element (1) according to the service plan. Close the cock (3). Switch to OFF. 2 3 Remove the filter cap (2) Remove the old filter element (1). Insert the new filter element (1). Screw on the filter cap (2). 1 Open the cock (3). 557D083 Switch to ON. Turn the ignition on. The fuel pump will automatically bleed the system. 15.4.2 Water separator filter element Empty the filter housing If there is water in the filter housing, immediately empty it. Close the cock (3). Switch to OFF. 3 2 1 Unscrew and empty the filter housing. Screw on the filter housing. Open the cock (3). 555029 Switch to ON. Turn the ignition on. The fuel pump will automatically bleed the system. Filter element, cleaning Clean the water separator filter element (1) according to the service plan. Close the cock (3). Switch to OFF. Remove the filter cap (2) Clean the filter element (1). Screw on the filter cap (2). Open the cock (3). Switch to ON. Turn the ignition on. The fuel pump will automatically bleed the system. ARR 1575 259 15 Engine 15.4.3 Checking the engine oil level Oil dipstick Check the engine oil level daily using the oil dipstick. The oil dipstick (1) is located on the left side of the engine. Check it at a horizontal position of the roller and with cold engine. The engine oil level can be seen on the oil dipstick. The oil level must be between the upper mark (x) and the lower mark (y). Refill the engine oil as required. 555079 15.4.4 Engine oil replenishment Replenish the engine oil through one of the two filler necks. Filler neck on the left side of the engine. Filler neck on the engine. b Filler neck on the left and filler neck on the top. a To assure permanent operational safety of the engine, no additives may be added to the engine oil. 555031A 15.4.5 Engine oil draining The engine oil drain (1) is located under the chassis, front left. Operating fluids pose a risk to the environment! Prevent fluids from leaking into sewage systems, soil or the environment. 1 Place a vessel under the drain. Remove the drain plug. The oil flows out immediately. 557D084 260 ARR 1575 WORKSHOP MANUAL 15.4.6 Engine oil filter replacement Release the filter (1) manually or using the filter key. The oil starts to automatically flow out. First place a rag under it. Replace the oil filter. Install in accordance with instructions (see filter packaging or filter housing). Screw the filter back in place. 1 557D087 557D086 2 557D085 ARR 1575 261 15 Engine 15.4.7 Inlet air filter Dirt indicator •• If the red ring appears on the contamination indicator (1) during operation of the machine, you must replace the cartridge. 1 557D112 Air filter cartridge •• The air filter is located on the left side of the engine. •• Remove the wing nuts (1) with the cap. 1 557D112 •• Remove the wing nuts (2) from the air filter cartridge. 2 557D113 •• Remove the air filter cartridge (3). 3 557D114 262 ARR 1575 WORKSHOP MANUAL Check the air filter cartridge for: •• Damage: replace the cartridge. •• Dirt: clean the cartridge. If the machine is used on heavily dusty grounds, the air filter must be checked daily for dirt. When cleaning / replacing the cartridge, make sure that no dirt enters the suction hose. Suction port Check the suction port for: •• Dirt: clean the suction port. 557D115 15.5 Replacement and adjustment of the speed magnet Replacement and adjustment of the speed magnet (Chapter 11.4.1). ARR 1575 263 15 Engine 15.6 Checking the engine speed and frequency Checking the engine speed and frequency (Chapter 11.3.2). 264 ARR 1575 WORKSHOP MANUAL 16 Optional equipment ARR 1575 265 16 Optional equipment 16.1 List of optional equipment Safety bar Drum extension set Scrapers Set of filters, 500 h Tarp cover 266 ARR 1575 WORKSHOP MANUAL 16.2 Safety bar 16.2.1 Safety bar replacement 1 Remove the screws (1) on the clip body. Remove the safety bar from the chassis. 557D618 Right side, remove the screw on the safety bar. 557D619 Remove the stop on the right. 557D620 Remove the spring. 557D621 ARR 1575 267 16 Optional equipment Left side, remove the screw on the safety bar. 557D622 Remove the stop on the left. 557D623 Remove the magnet. 557D624 Remove the spring. 557D625 268 ARR 1575 WORKSHOP MANUAL Check if the removed parts can be reused. 557D626 Apply blue adhesive on the clip body. 557D627 Attach the clip body on the chassis using the screws. 557D628 Move the spring on the right and left to the safety bar. 557D629 ARR 1575 269 16 Optional equipment Move the safety bar in the clip body to the right. 557D630 Mount the clip body on the left. 557D631 Tighten the screws firmly. 557D632 Place the springs in the dedicated slots, on the right and left. 557D633 270 ARR 1575 WORKSHOP MANUAL Place the stop on the right. 557D634 Insert the screw and apply blue adhesive on it. 557D635 Mount the washer and nut. 557D636 Tighten the screw firmly. Tighten the screw firmly until the stop (1) lies in the tube without a gap. 1 557D637 ARR 1575 271 16 Optional equipment Mount the magnet on the left on the tube. Observe the installation position (see the figure). Insert the screw from below. 557D638 557D639 Apply blue adhesive on the screw. 557D640 Tighten the screw firmly. Tighten the screw firmly until the stop (1) lies in the tube without a gap. 557D641 272 ARR 1575 WORKSHOP MANUAL New safety bar, completely installed. 557D642 ARR 1575 273 16 Optional equipment 16.2.2 Sensor replacement and adjustment Disconnect the sensor cable connectors. 557D643 Remove the sensor holder under the chassis. 557D644 557D645 Remove the old (defective) sensor from the holder. 557D646 274 ARR 1575 WORKSHOP MANUAL Apply blue adhesive on the new sensor. 557D647 Check the installation distance (approx. 25 mm). 557D649 Observe the installation position (see the white mark on the sensor head). 557D648 Mark parallel to the holder bend. 557D645A ARR 1575 275 16 Optional equipment Apply blue adhesive on the screws. 557D650 Put the sensor cable through the hole in the chassis. Mount the sensor holder. 557D651 Tighten the screws slightly. 557D644 S et the distance (approx. 3 mm) between the sensor head and the magnet. Move the sensor holder appropriately. 557D652 276 ARR 1575 WORKSHOP MANUAL Tighten the screws to a torque of 25 Nm. 557D644 Connect the sensor cable. Fasten the connector with a cable tie. 557D643 Function check, safety bar at the top: The “Safety Bar” indicator lamp (1) must be on. 1 557D653 Function check, safety bar at the bottom: The “Safety Bar” indicator lamp (1) must be off. 1 557D654 ARR 1575 277 278 ARR 1575 WORKSHOP MANUAL 17 General procedures ARR 1575 279 17 General procedures 17.2 Electrical installation 17.2.2 Preparation for welding work Welding work on a roller with an installed battery may damage the machine control device! Completely remove the battery before welding work on the roller. Place grounding cables of the welding equipment as near to the point of welding as possible. The grounding point must be free of paint. Danger of injury! Incorrectly welded castings may result in material cracks. Welding of castings is prohibited! 280 ARR 1575 WORKSHOP MANUAL 17.2.3 Starting the battery by means of another battery (jumping) Attach the red cable to the (+) clamps of both batteries. Connect one end of the green or black cable to the (–) clamps of both batteries. Press the starter. Let the engine run. Wait until the engine evenly rotates at idle speed and disconnect the cables form the clamps. Start with the (+) clamp. 557D128 Battery poles and clamps must be clean. If they show a coat of sulphate (whitish or greenish), they must be loosened and cleaned. 17.2.4 Charging the battery with a charger Disconnect the battery from the clamps. Connect the charger. Observe the operating manual of the charger manufacturer. When reconnecting the battery, start with the (+) clamp. Battery poles and clamps must be clean. If they show a coat of sulphate (whitish or greenish), they must be loosened and cleaned. 17.2.5 Long-term storage In case of prolonged downtime of more than two weeks, remove the battery cable from the negative battery pole. 17.2.6 Battery replacement Battery replacement (Chap. 15.3.2.1). ARR 1575 281 282 ARR 1575 WORKSHOP MANUAL 18 Troubleshooting ARR 1575 283 18 Troubleshooting 18.1 Error diagnostics This chapter states possible causes of faults and their troubleshooting according to fault symptoms. Although it is not expressly mentioned, respect that cabling may always be a possible cause of an electric failure. According to our experience, faults are mostly caused by the cable harness or connection of connectors. It is a good idea to first check the machine for worn cables and loose or defective connectors. Because it is a remotely controlled machine, faults can have countless causes. We recommend reading this chapter briefly to get an insight. In any case, also pay attention to the LEDs on the manual control and signals on the display unit. The machine does not switch off automatically if the hydraulic oil temperature is too high! If you suspect that the machine has become too hot, check the following: F14 fuse S25 oil temperature switch K7 relay M3 cooler The S25 oil temperature switch must turn on the fan when the oil temperature exceeds 50 °C. 284 ARR 1575 WORKSHOP MANUAL 18.1.1 The engine does not start The following description applies to starting using the ignition lock: If the machine cannot be started using only the manual control, refer to the next chapter. Defect description, the engine does not start Defect description Probable cause Check The engine does not start G2 battery Is the battery voltage OK? Battery terminals? Battery cable on the terminals? The starter does not rotate S1 ignition Can the engine be started by ignition? -> Control does not work. F11 fuse Is F11 OK? N1 control unit Is the connector connected? K1 relay The relay must close when the ignition turns on. F22 fuse Is F22 OK? G1 alternator Is the connector connected? With the ignition turned on, the connection must be D+=0V. Is the connector correctly connected? Relay checked? K2 ignition relay With the ignition in the Start position, the connection must be 50 + 12 V. M1 engine starter The engine does not start M2 diesel fuel pump Is there enough diesel in the tank? Is the diesel fuel pump working? The starter rotates F21 fuse Is the F21 fuse OK? But the engine does not start S21 engine oil pressure switch If the motor is stopped, the switch must be closed. Is F12 OK? F12 fuse When the starter rotates, there must be +12 V on Y1 (red). N1 control unit Is the connector connected? K3 timer Is the connector connected? Relay checked? K4 relay For the 50 starting position, the input coil (white) must be +12 V for 1 s. Y1 input/holding coil Was the safety bar checked? The engine starts but runs only for ap- S22 water temperature switch prox. 4 s At normal operating temperature, the switch must be open. Grounding? Is the connector firmly connected? Corrosion-free? S21 engine oil pressure switch When starting, the switch must be closed. When the engine is running, it must be open. Is the connector firmly connected? Corrosion-free? Preheating does not work Yanmar engine (Yanmar TNVDI, service manual) R1 preheating plug In cold weather, please also check the preheating system. In the preheating ignition position, the H2 indicator lamp must be on and there must be +12 V on the glow plug. F24 fuse Is F24 OK? K6 relay Is the connector connected? Relay checked? Diesel Diesel in the tank? Passable diesel inlet? Air in the injection system? Passable filter? Air in the system? “Smoke signals” on the exhaust pipe? Compression, injection system, valve clearance? Is the fuel pump working? Is F22 OK? ARR 1575 285 18 Troubleshooting Defect description Probable cause Check The hydraulic oil cooler is not rotating Hydraulic oil temperature sensor Bypass the switch, start the engine F14 fuse Is F14 OK? K7 relay Is the K7 relay switching? Defective engine Connect the engine to the power supply directly. 286 ARR 1575 WORKSHOP MANUAL 18.1.2 Start of the conductor and infrared radiation test Normal test Open the cab cover. Open the cover without covering the sensor. Turn the ignition on. Keep a distance of three metres from the roller. Always keep an eye on the safety bar indicator lamp. If the safety bar indicator lamp is flashing, increase the distance from the roller. Hold down the switch button on the infrared sensor. The preheating indicator lamp must be on. If the preheating indicator lamp is off, reduce the distance from the roller. When the preheating indicator lamp turns on, the roller starts after 6 seconds. Quick start Open the cab cover. Open the cover without covering the sensor. Turn the ignition on. Keep a distance of three metres from the roller. Always keep an eye on the safety bar indicator lamp. If the safety bar indicator lamp is flashing, increase the distance from the roller. Hold down the switch button on the infrared sensor. The preheating indicator lamp must be on. If the preheating indicator lamp is off, reduce the distance from the roller. When the preheating indicator lamp turns on, immediately let go of the switch. Start the engine. ARR 1575 287 18 Troubleshooting Protected zone and safe zone when using the infrared remote control 2m (6,6 ft.) 2 - 20 m (6,6 - 66 ft) 555151 Protected, safe and operating zone during the operation of the infrared remote control and cable 2 - 4,5 m (6,6 - 15 ft) 555152 288 ARR 1575 WORKSHOP MANUAL 18.1.3 Near and remote machine halt The near and remote machine halt function is an electronic safety feature designed to prevent the loss of visual contact between the operator and the machine and excessive proximity of the operator to the machine. A machine equipped with infrared remote control contains infrared sensors determining the safe distance of the operator from the working machine. This creates a protected zone and a safe zone. The protected zone is within 2 m from the infrared sensors. The safe zone is an area marked in grey located at a distance of 2 ÷ 20 m when using the infrared remote control; see Fig. 555151. When using the infrared remote control, the operator is allowed to move only within the safety zone. The safe zone is an area marked in grey located at a distance of 2 ÷ 4.5 m when using the infrared remote control and cable; see Fig. 555152. When using the infrared remote control and cable, the operator is allowed to move only within the safety zone. Conditions for the near and remote machine halt function Infrared remote control and cable Infrared remote control Near halt approx. 2 m approx. 2 m Remote halt approx. 4.5 m approx. 20 m If the operator leaves the safe zone, the machine halts. The engine keeps running, but all other functions are disabled. In order to reactivate the machine, the operator must be located in the safe zone according to specific conditions, with the cable connected (2–4.5 m) and when controlling via the infrared remote control (2–20 m). The infrared sensors do not react to people approaching the machine, only to the infrared remote control. During the operation of the machine, do not enter the protected zone of two metres. The border of the protected 2 m zone might be deformed by the deflection of rays of the infrared remote control or insufficient direct visual contact. Do not use the infrared remote control in the protected 2 m zone or when there is insufficient visual contact between the machine and the operator or the infrared remote control, unless stated otherwise. Operate the machine exclusively from the area in grey, i.e. from the safe zone. Outside the safe zone, the control switches of control elements do not correspond to directions of machine movements. ARR 1575 289 18 Troubleshooting 18.1.4 Control does not work To localize and remove the fault, proceed step by step as described below. 18.1.5.1 External influences •• Reflective surfaces (mirrors, reflective stripes...) in the vicinity may interfere with the remote control distance detection. •• Under certain circumstances, special light sources (fluorescent lamps, light beacons...) may interfere with infrared communication. •• The control may be adversely affected by strong electromagnetic radiation (e.g. near high-current equipment). If the faults occur only in certain locations or situations, check the area for the above interference and try to avoid it. 18.1.5.2 Machine cabling •• Are fuses F11 and F12 OK? •• Are the connectors on the N1 control unit dirty or wet? •• Is the N1 control unit properly fastened? •• Are both infrared sensors P1 and P2 clean and undamaged? •• Is the cabling from N1 to P1 and P2 undamaged? Do not forget that there is the X5 interconnecting connector near the sensor at the front of the engine compartment. •• Are the N3 manual control cable and the corresponding connectors undamaged and clean? Do not forget the X1 connector on the inside of the bonnet. 290 ARR 1575 WORKSHOP MANUAL 18.1.5.3 Operation •• Has the manual control already been connected to the machine? -> Connect the cable to the manual control. •• Is the distance between the manual control and the machine OK? (2.5–4 m when using a cable or 2.5–20 m when using remote control) •• Is the N3 manual control battery discharged? -> Temporarily work with cable control. Keep in mind that open anti-vandal protection may shield the infrared signal. This also applies to cable operation. Troubleshooting, the control does not work Defect description Probable cause The control does not work at all, the Fuses F11, F12 engine cannot be started even with N1 control unit the ignition. Check Are F11 and F12 OK? Check the engine according to the above procedure. Pay special attention to the signal of the D+ alternator and the S21 engine oil pressure switch. If the K1 relay does not switch, the problem is probably in the N1 control unit. Is the battery voltage OK? Battery terminals? Battery cable on the terminals? The machine can only be started via N3 infrared light emitter ignition, otherwise nothing works Infrared sensors P1, P2 Check the engine according to the above procedure. If no LEDs are flashing on the N3 manual control during cable operation, it probably must be replaced. Check the cabling. The machine only works when used N3 infrared light emitter with a cable. Check the engine according to the above procedure. The diesel engine suddenly turns off N1 control unit during operation. Watch also the display unit. The inclination sensor may not be activated correctly. If the red LED is always on the N3 manual control without a cable when any function is performed or if no LED is on without a cable, the battery may be defective. S22 water temperature switch At normal operating temperature, the switch must be open. S21 engine oil pressure switch When the engine is running, the switch must be open. G1 alternator When the engine is running, the connection must be D+=12 V. The machine is not moving (noth- N3 manual control ing is happening) N1 control unit Is the green LED flashing when you press the switch? Is the H6 warning indicator lamp illuminated on the display unit? Y3 travel pump Are the connectors connected? Are the magnetic coil and valves OK? Is the supply pressure OK? Is the servo block OK? Y9 brake valve Is the connector connected? The machine is not moving (moves Y9 brake valve against the brake) Is the connector connected? The machine moves only forward Activate the magnetic valve. Does the brake release? Is the supply pressure OK? N1 control unit Does Y9 activate? S24 contactless switch If the machine is equipped with a safety bar, check that the magnet is positioned correctly on the bar. If the safety bar is not activated, the switch must be closed. Otherwise, check the jumping in the S24 place. Travel pump Y3, Y4 ARR 1575 Are the connectors connected? 291 18 Troubleshooting Defect description Probable cause Check The machine moves too slowly N3 manual control Is the green LED is flashing when you set the transport speed? F23 fuse Is F23 OK? K5 relay The relay must close when the function is performed. Does K5 activate? The machine does not vibrate Control does not work. N1 control unit The magnet must pull when the function is performed. Y2 magnet Engine speed? Quantity divider OK? Travel motor OK? Travel pump OK? N3 manual control The green LED is flashing when vibration is activated. Magnets Y7, Y8 Are the connectors connected? Are the magnetic coils activated manually? Are the magnetic coil and valves OK? Is the vibration pressure OK? Is the clutch on the vibration motor OK? Is the vibration unit OK? N1 control unit Do Y7 and Y8 activate? N3 manual control Is the green LED flashing when you switch on control? Magnets Y5, Y6 Are the connectors connected? Are the magnetic coil and valves OK? Are the magnetic coils activated manually? N1 control unit Do Y5 and Y6 activate? Steering pressure OK? Mechanical damages? Steering piston OK? 292 ARR 1575 WORKSHOP MANUAL 18.1.6 Display unit When starting ignition, the display unit shows an indicator lamp for several seconds. All indicator lamps are on and every digit of the operating hours counter is displayed as 8. - + ! hours On this occasion, check that the display unit functions properly. Otherwise, it must be replaced. 555012B ARR 1575 293 18 Troubleshooting Defect description, the machine is not moving Defect description Probable cause Check The display unit is not working. F13 fuse Is F13 OK? After turning on ignition, neither N2 display unit the indicator lamps nor the display are illuminated. K1 relay After turning on ignition, there must be +12 V on pin 1 and ground on pin 8. The P3 operating hours counter is G1 alternator not working and the H1 charging N2 display unit indicator lamp does not go off during when the engine is running. Is the connector connected? The relay must close when the ignition turns on. After turning on ignition, there must be 0 V (ground) on pin 7. When the engine is running, however, there must be +12 V. If the battery is charging anyway (voltage approx. 14 V), the problem is likely in N2. When ignition is on, the H1 charging G1 alternator indicator lamp is not illuminated. Cable, connectors, N2 display unit Connect the 133 cable to the ground. The indicator lamp must be on. The H6 warning indicator lamp is N1 control unit on. •• The inclination sensor measured a value exceeding 45° (the diesel engine turns off ). •• If the H5 safety bar indicator lamp flashes at the same time: The engine may start after the S21 oil pressure switch is closed (H3 is illuminated) and when D+ at G1 is 0 V (H1 is illuminated). •• The control detected an error. F22 fuse G1 alternator S21 engine oil pressure switch If the machine is not inclined and the N1 control unit was installed properly, there is a problem with the control switching outputs -> control does not work. The H3 oil pressure indicator lamp is S21 engine oil pressure switch on when the engine is running. Is the connector connected? Grounding? Engine oil level OK? Engine oil pressure OK? When the engine is stopped, the connection must have a ground contact. When the engine is running, the switch must be open. The diesel engine suddenly turns off after 4 s. The H3 oil pressure indicator lamp is S21 engine oil pressure switch off when ignition is on. Cable, connectors, N2 display unit Disconnect the connector from the switch and connect it to ground. The indicator lamp must be on. Is the connector firmly connected? Corrosion-free? The H4 water temperature warning S22 cooling water temperature Is the connector connected? Grounding? indicator lamp is on. The engine is switch At normal operating temperature, the switch must be running. open. The diesel engine suddenly turns off after 4 s. When ignition is on, the H4 water S22 cooling water temperature Defective? Is the connector firmly connected? Corrotemperature indicator lamp is not switch sion-free? Disconnect the connector from the cooling illuminated. Indicator lamp test. water temperature switch and connect it to ground. The indicator lamp must be on. Cable, connectors, N2 display unit At normal operating temperature, the switch must be open. The diesel engine suddenly turns off after 4 s. 294 ARR 1575 WORKSHOP MANUAL Defect description Probable cause The H5 safety bar warning indicator S24 contactless switch lamp is on even if the safety bar is not activated or installed. Check The indicator lamp is continuously on: If the machine is equipped with a safety bar, check that the magnet is positioned correctly on the bar. If the safety bar is not activated, the switch must be closed. Otherwise, check the jumping in the S24 place. The indicator lamp is flashing rapidly: N1 control unit The infrared light emitter is less than 3 m away from the machine. The indicator is flashing slowly: The infrared light emitter is 3 to 4 m away from the machine. No defect! The prerequisite for operation with a cable is remote control. The H2 preheating indicator lamp is S1 ignition never on. N1 control unit The indicator lamp is continuously K6 relay on ARR 1575 The indicator lamp must be on even if the S1 ignition is in the “preheating” position. The indicator lamp must be on when you hold the Start switch on the manual control. F24 OK? Ignition OK? Relay OK? 295 18 Troubleshooting 18.1.7 Manual control Infrared light emitter 557020A When ignition is turned on, indicator lamp test is displayed briefly. Both LEDs are flashing. On this occasion, check that the LEDs function properly. Otherwise, the unit must be replaced. Defect description, manual control Defect description Probable cause Check The indicator lamps are never on. N3 infrared light emitter The battery might be discharged or defective. Connect the control to the cable. If the battery is defective, replace the control. The red indicator lamp is flashing N3 infrared light emitter No defect! Charge the battery. (the cable is not connected). No defect! The battery is charging. The red indicator lamp is flashing (the cable is connected). No defect! The battery is fully charged. The red indicator lamp is continuously on. The battery is charged, no data is transmitted to the machine. The red indicator lamp is on even if the control is activated. The green indicator lamp is always N3 infrared light emitter flashing when the control is activated. No defect! Data is transmitted to the machine. Both indicator lamps flash synchro- N3 infrared light emitter nously. No defect! The infrared light emitter connects to the machine control unit. This happens always when: •• another manual control connects to the machine via a cable for the first time. •• ignition turns on. If indicator lamps are flashing, the engine cannot be started. 296 ARR 1575 WORKSHOP MANUAL 18.2 Pressure check 18.2.1 Pressure check and adjustment All mentioned values are applicable at a hydraulic oil temperature of approximately 60 °C and the maximum speed of the diesel engine. Drain the pressure-relief valves for a maximum period of 5 s. Use the following pressure gauges: •• For high pressure = min. 400 bar •• For supply pressure = min. 40 bar 2 1 4 3 557D015 Travel pump, vibration/steering pump 1 M1 supply pressure 21 ± 2 bar can only be set by means of washers. 2 MB forward travel pressure 330 ± 15 bar should be measured when drums are locked. 3 MA reverse travel pressure 330 ± 15 bar should be measured when drums are locked. 4 M2 vibration activation indicator lamp 220 ± 10 bar. M2 steering pressure 67 ± 8 bar. ARR 1575 297 18 Troubleshooting Adjust the reverse travel pressure. 2 Adjust the forward travel pressure. 1 557D016 Supply pressure valve (adjustable using spacers). 1 557D017 Oil may overheat and seals may get damaged. For the test procedures below, strictly observe the following: Let the engine run only briefly, for up to 5 s. After performing the test procedures, reconnect all hydraulic hoses. Start a test run. Check the tightness of all connections. 298 ARR 1575 WORKSHOP MANUAL 18.2.2 Checking the steering pressure Turn the machine to the limit position. Hold the lever pressed throughout the entire further procedure. 557D018 Measurement point (1) Vibration/steering pressure. If a steering pressure of 67 ± 7 bar is not reached: •• remove the right steering piston line and pressure-close it. •• remove the left steering piston line and pressure-close it. •• remove the valve block, see “Replacement of the valve block” (Chapter 11.2.2). •• check the steering pressure relief valve. 1 557D019 ARR 1575 299 18 Troubleshooting 18.2.4 Checking the maximum vibration pressure This procedure must be performed when the vibration setting pressure is lower than 200 bar. Open the rear bonnet. Ensure access to the angled screw connection. Cut the cable ties on the hose bundle. 557D020 Remove the hydraulic hose (016) from the angled screw connection. 557D021 Pressure-close the screw connections (1). 1 1 557D022 Remove the knurled nut and sealing ring at the Y8 magnetic valve (1). 1 557D023 300 ARR 1575 WORKSHOP MANUAL Remove the magnetic coil (1) from the magnetic valve (2). 2 1 557D024 Remove the hydraulic hose (030). 1 557D025 Pressure-close the screw connection. 1 557D026 Reinstall the magnetic coil. 557D027 ARR 1575 301 18 Troubleshooting Connect a pressure gauge (at least 250 bar) to the vibration pressure measuring point (1). Start the engine. Full speed Turn on vibration. Let it run for no more than 5 seconds. 1 557D028 If a vibration pressure of 220 ± 10 bar is not reached: •• remove the valve block, see “Replacement of the valve block” (Chapter 11.2.2). •• check the vibration pressure relief valve. After the tests, perform the following: •• Mount the hydraulic hoses •• Refill oil •• Clean the machine •• Start the machine •• Check the tightness and function 302 ARR 1575 WORKSHOP MANUAL 18.2.5 Checking the travel pump 18.2.5.1 Checking the maximum supply pressure Remove the 008 hydraulic hose for the supply pressure measuring point. 557D029 Pressure-close the screw connections (1). 1 1 557D030 Remove the hydraulic hose of the B travel circuit (forward) for the travel pump. Pressure-close the screw connections. 557D031 Remove the screw connection of the A travel T-circuit (reverse) for the travel pump. Pressure-close the screw connections. 557D032 ARR 1575 303 18 Troubleshooting Connect a pressure gauge (at least 40 bar) to the supply pressure measuring point (1). Start the engine. •• Full speed •• Let it run for no more than 5 seconds. 1 557D033 If a supply pressure of 21 ± 2 bar is not reached: •• check the supply pressure valve. If it is still not reached, replace the travel pump. See “Replacement of the travel pump” (Chapter 11.2.1). 304 ARR 1575 WORKSHOP MANUAL 18.2.5.2 Checking the travel pressures (reverse/ forward) Pull out the Y9 connector (1) on the valve block. 1 557D034 Connect a pressure gauge (at least 400 bar) to the travel pressure measuring point (1). Start the engine. Full speed Reverse while braking. 1 Let it run for no more than 5 seconds. 557D035A Connect a pressure gauge (at least 400 bar) to the MB travel pressure measuring point (1). Start the engine. Full speed 1 Drive forward while braking. Let it run for no more than 5 seconds. 557D036 If a travel pressure of 330 ± 15 bar is not reached: •• check the travel hydraulic motors (Chapter 18.2.6). •• check the maximum pressure of the travel pump. If it is still not reached, replace the travel pump. See “Replacement of the travel pump” (Chapter 11.2.1). ARR 1575 305 18 Troubleshooting 18.2.5.3 Checking the maximum pressure of the travel pump (reverse/forward) Remove the hydraulic hose of the B travel circuit (forward) for the travel pump. Pressure-close the screw connections. 557D031 Remove the screw connection of the A travel T-circuit (reverse) for the travel pump. Pressure-close the screw connections. 557D032 Connect a pressure gauge (at least 400 bar) to the MA travel pressure measuring point. Start the engine. Full speed Reverse at full speed while locked. Let it run for no more than 5 seconds. 557D035 Connect a pressure gauge (at least 400 bar) to the MB travel pressure measuring point (1). Start the engine. Full speed 1 Drive forward at full speed while locked. Let it run for no more than 5 seconds. If the travel pump maximum pressure of 330 ± 15 bar is not reached: •• replace the travel pump, see “Replacement of the travel pump” (Chapter 11.2.1). 306 557D036 ARR 1575 WORKSHOP MANUAL 18.2.6 Checking the travel hydraulic motors The following operation is required, when: •• The travel pump test is positive. •• The pressure is not reached with the connected travel motors. Successively check individual travel motors. Remove the hydraulic hoses of the travel circuit A and B on the travel motor. Pressure-close the screw connections. 557D037 ARR 1575 307 18 Troubleshooting 18.2.7 Adjustment of the travel pump zero position X2 X1 Remove both plugs X1 and X2. 557D038 Remove the aperture. 557D039 Check the aperture (1) for clogging. Blow-clean it with compressed air. Mount plugs X1 and X2 (40 Nm). 1 Tighten the aperture properly when mounting it back! 557D040 Place the machine safely on blocks! Let the machine run. Loosen the lock screw (1). 1 2 Adjust the zero position (2). Carefully turn the spanner until the drum stops. Tighten the lock screw firmly. 557D041 308 ARR 1575 WORKSHOP MANUAL 18.2.7.1 Checking the travel pump magnetic coil / travel pump servo block The travel pump magnetic coil cannot be controlled mechanically. 557D042 Loosen the knurled nut. 557D043 Remove the magnetic coil. 557D044 Screw out the magnetic valve. 557D045 ARR 1575 309 18 Troubleshooting 557D046 Measure the resistance of the Y3/Y4 magnetic coil. The resistance value is approximately 6 Ohm. 557D047 Connect 12 V to the magnetic valve. The valve (arrow) must visibly switch. 557D048 Change the position of the magnetic coil connector The position of the connector can be changed by turning the magnet body as needed. Release the lock nut (1) of the magnet. 2 1 Turn the lock nut (1) by one turn to the left. Turn the body of the magnet (2) to the required position. Tighten the lock nut again. Tightening torque of the lock nut: 5+1 Nm. 557D049 310 ARR 1575 WORKSHOP MANUAL 18.2.8 Travel pump servo block check The procedure shall be performed when: •• The electric part of the machine has been checked and the machine is still not running. •• The machine only moves in one direction. •• The machine only moves slowly with the lever switched to the limit position. •• The machine moves unequally. A view of the travel pump. 557D050 Pull out the connector from magnetic coils Y3 (on the left) and Y4 (on the right). 557D051 Remove plugs X1 and X2. 557D052 A view of the travel pump without a plug. If the oil does not flow under the unscrewed plug back to the pump housing, apertures are clogged or the piston is out of the centre and jammed. 557D053 ARR 1575 311 18 Troubleshooting Loosen the apertures and screw them out. The apertures must not be loose! Loose apertures cause problem when driving. 557D054 Loose apertures can be easily removed using a small magnet. Improvise as needed. 557D055 A view of the dismounted aperture holder (1) with apertures. 1 1 557D056 Loosen the knurled nut. 557D057 312 ARR 1575 WORKSHOP MANUAL Remove the magnetic coils. 557D058 Screw out the magnetic valve. 557D059 557D060 View of the control piston. The control piston is a spring type and shall always spontaneously return to the zero position. 557D061 ARR 1575 313 18 Troubleshooting Checking the control piston movement e.g. by means of a screwdriver. Press the piston to the stop from the left to the right three to four times. The movement must not be stiff in any case! It must move smoothly and return easily to the zero position under the force of the spring, from both sides. 557D062 If the control piston does not move smoothly after several movements, or it does not spontaneously return to the zero position, it is mechanically damaged. The servo block must be repaired in a professional workshop. 557D063 A view of the pump before assembly. 557D064 Check the magnetic valve seals for damage. Lubricate them slightly with oil. 557D065 314 ARR 1575 WORKSHOP MANUAL Mount the magnetic valve. 557D066 Install a cleaned aperture with the holder and tighten firmly. 557D067 Check the plug seal. Lubricate the seal slightly with oil. 557D068 Install both plugs and tighten firmly. 557D069 ARR 1575 315 18 Troubleshooting Reinstall both magnetic coils. 557D070 Install the round seal ring and tighten firmly with a knurled nut. 557D071 Connect the cable. Fasten it using a cable tie. Check the function and sealing. 316 ARR 1575 WORKSHOP MANUAL 18.2.9 Checking the quantity divider 3 1 2 5 4 557D072 Quantity divider 1. Aperture access 1 2 7 2. Front piston access 3. Rear piston access 4. Front non-return valve access 5. Rear non-return valve access 1. Quantity divider – housing 6 2. P connection of the B pump 3. Rear interface quantity divider B 4. Rear interface quantity divider A 5. T connection of the G pump 4 5 3 7 557D073 6. Aperture 7. Two spring pistons In case of a fault (jerky movement) check the aperture for contamination. If required, short circuit the quantity divider = remove the whole piston assembly. 557D074 ARR 1575 317 18 Troubleshooting 18.2.10 Speeds and pressures after 5 min. after 60 min. rpm 2415 ±25 2405 ±25 front low rpm 2250 ± 150 2250 ± 150 rear low rpm 2250 ± 150 2250 ± 150 Diesel engine speed Vibration speed front high rpm 2250 ± 150 2250 ± 150 rear high rpm 2250 ± 150 2250 ± 150 bar 21 ±2 21 ±2 Supply pressure Travel working pressures Vibration drive pressures * Maximum travel pressure Maximum pressure forward bar 100 ±20 100 ±20 reverse bar 100 ±20 100 ±20 low amplitude bar 105 ±55 65 ±15 high amplitude bar 110 ±50 80 ±20 Forward locking bar - 330 ±15 Reverse locking bar - 330 ±15 Steering bar - 67 ±7 Vibration bar - 220 ±10 * During the first start, only low amplitude vibration can be used for the first 2 minutes. 318 ARR 1575 WORKSHOP MANUAL 18.3 Roller overturning 557D133 Place the machine on belts as quickly as possible. Turn off the ignition (0 position). Never try to immediately start the engine! Prevent oil shock! It can result in serious engine damage! 557D134 Operating fluids pose a risk to the environment! Prevent fluids from leaking into sewage systems, soil or the environment. Immediately collect any leaked liquids, oil, diesel fuel, anti-freeze agent, battery sulphur! ARR 1575 319 18 Troubleshooting 18.3.1 Checking damage Open both bonnets. Disconnect the grounding cable (–). Disconnect the battery. Check the machine for visible defects, especially for leaked liquids. If necessary, drain defective tanks. 557D135 18.3.2 Preventing oil shock Before removing parts, thoroughly clean the area of valve caps, cylinder heads and electrical sheet. If no visible damages can be detected or if they were already removed, perform the following: Removal of parts Remove the F21 fuse in the engine compartment. Engine compartment fuses F21 557D136 Remove the air filter element (Chapter 15.4.7). If it is oily, replace it. Clean the air filter housing. 557D137 320 ARR 1575 WORKSHOP MANUAL Remove the air filter hose at the top. Remove the air filter hose at the top. 557D138 Remove the fuel filter. Remove the fuel filter. 557D139 557D140 Remove the electrical sheet and tilt it back. 557D141 ARR 1575 321 18 Troubleshooting Screws at the back. 557D142 Screws at the front. Remove the electrical sheet at the back / front. 557D143 Remove the valve cap. Remove the valve cap. 557D144 557D145 322 ARR 1575 WORKSHOP MANUAL emove the three cables and the contact connection on the R glow plugs. Remove the cables and the contact connection. 557D146 Remove ALL three glow plugs. Tools: Long bit and torque spanner. Remove the tool / glow plugs. 557D147 557D148 ARR 1575 323 18 Troubleshooting Rotate the engine with a spanner Make sure that any accumulated oil is pushed out by the piston. Rotate the engine on the central screw crankshaft clockwise twice using a box-end ratchet spanner (1). 557D149 1 557D150 Danger of cable burn or short circuit. Insulate the glow plug cables e.g. with a piece of hose. Insulate the connecting cables. 557D151 Reattach the electrical sheet with two screws (1). Reconnect the battery (–). 1 557D152 324 ARR 1575 WORKSHOP MANUAL Risk of burns from splashing oil! Eye damage, burns. Wear safety goggles. Rotate the engine with the starter Rotate the engine with the starter (1–2 min.). After several turns, the accumulated oil in the combustion area should be pushed through the glow plug holes. Repeat the process after approx. 5 min. Make sure there is no oil in the combustion area! 557D153 Reinstall the glow plugs, tightening torque 18 Nm. Reconnect the glow plugs to the contact connection and cables (tightening torque 1.5 Nm). Mount the valve cap. Mount the electrical sheet. 557D154 Rotate the engine with the ignition key Rotate the ignition key clockwise to the III position. The engine must rotate. If it does not, never attempt to start the engine! There may still be oil in the combustion area. Repeat the procedure as described above. Otherwise, immediately contact your authorized dealer! If the engine rotates: Check the levels of all fluids. Refill the liquid if needed. Reinstall the F21 fuse. ARR 1575 325 18 Troubleshooting 18.3.3 Starting the engine 1. Attempt to start Rotate the ignition key clockwise to the III position. The starting attempt was successful, the engine is running: See below under “The engine is running”. The starting attempt was unsuccessful, the engine is not running: There may be air in the diesel system. See “Checking the pump” below. Checking the pump Rotate the ignition key clockwise to the I position. Check if the electric fuel pump is working. Let the pump run for approximately 1 minute. The system will automatically vent any air. 2. Attempt to start Rotate the ignition key clockwise to the III position. Let the engine run idle! Do not activate any function. The engine is running The engine will emit smoke until the oil accumulated in the exhaust system burns out (this can take up to 1 h). Risk of fire! The exhaust pipe might shoot flames / glowing material. Immediately visually check any leaking liquids. If everything is OK: Bring the engine to full speed. Check the function. Engine smoking must noticeably decrease and disappear completely. Otherwise, the engine may have a mechanical defect. Stop the engine. Check the levels of fluids. Refill if necessary. Check fluid losses. Start the engine. 326 ARR 1575 WORKSHOP MANUAL 19 Appendices ARR 1575 327 19 328 Appendices ARR 1575 WORKSHOP MANUAL 19.1 Hydraulic system 19.1.1 Adjustment of the travel pump zero position Adjustment of the travel pump zero position (Chapter 18.2.7). 19.1.1.1 Checking the travel pump magnetic coil / travel pump servo block Checking the travel pump magnetic coil / travel pump servo block (Chapter 18.2.7.1). ARR 1575 329 19 Appendices 19.2 Wiring diagram Legend: A1 A2 A3 F11 F12 F13 F14 F21 F22 F23 F24 F25 G1 G2 K1 K2 K3 K4 K5 K6 K7 K11 M1 M2 M3 N1 N2 N3 P1 P2 R1 S1 S21 S22 S24 S25 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y11 ACEecon display ACEecon display ACEecon sensor Fuse, control unit, power supply Fuse, control unit, outputs Fuse, display unit, safety bar Fuse, hydraulic oil cooler Fuse, pull solenoid Fuse, fuel pump, alternator Fuse, working speed Fuse, ignition coil Fuse, second solenoid Alternator Battery Relay, ignition Relay, start lock Time relay Relay, pull solenoid Relay, working speed Relay, ignition coil Relay, hydraulic oil cooler Relay, solenoid exciter Starter Fuel pump Hydraulic oil cooler Machine control unit Display unit Infrared remote control Front infrared sensor Rear infrared sensor Ignition coil Switch, ignition switch Sensor, engine oil pressure Sensor, coolant temperature Sensor, safety bar Sensor, hydraulic oil temperature Magnet, pull / holding solenoid Magnet, working speed Magnet, pump with a drive, forward Magnet, pump with a drive, reverse Valve, steering, left Valve, steering, right Valve, vibration with high amplitude Valve, vibration with low amplitude Valve, parking brake Magnet, second solenoid The texts are given only in the original language version or as a translation of the original into the English language version. 330 ARR 1575 WORKSHOP MANUAL +12V S1 58 142 133 141 Dieselpumpe M 68Ω 163 M2 30 Zündung R2 H1 7 F22 10A 136 164 137 3 203 grosse Amplitude Y8 116 kleine Amplitude 173 Y9 117 Bremsventil GND - Pegel A X8 17 (K1) Error 87a 30 2 0.2A Wassertemperatur bl F23 40A 150 N2 132 6 H4 131 5 H3 F24 40A 212 1 X6 A2 + 5 CAN L 4 CAN H 3 GND - A1 2 U+ 1 Shield 213 5 CAN L 4 CAN H 3 GND 2 U+ 1 Shield A3 ASC 8 - 181 F13 10A 177 1 129 175 ACEecon 154 + Motoröldruckschalter 182 130 Wassertemperaturschalter S21 Handsteuerung 18 Motoröldruck + S22 106 Vorglühen S24 ACEecon 3 86 127 87 30A N2 H2 152 K6 85 Abschaltbügel hinten 128 155 30 Arbeitsdrehzahl 6 (G1) 87 153 R1 87a 109 0.2A GND - 3 151 85 Spannungsversorgung Led On + 9 (F1) K5 86 Spannungsversorgung + 160 br 2 121 2 Pegel B 1 3 H6 vorne P2 28 (W1) Abschaltbügel gedrückt IR Sensor with Beacon X4 3 ye 27 (Y1) 120 4 Spannungsversorgung shield 29 (Z1) H5 N2 Horn gn Spannungsversorgung + ws 21 (L1) 210 Pegel B 22 (L2) B1 br gr 4 172 P1 Pegel A hinten 115 Spannungsversorgung - 125 IR Sensor with Beacon Y7 123 Spannungsversorgung +124 Led On + 2 Lenkung rechts 122 1 114 Steuerbus D+ Steuerbus D- 6 Y6 5 170 13 (C1) Lenkung links 14 (C2) 113 15 (D1) Y5 16 (D2) 169 F12 25A 161 Rückführung F11 10A N3 gr 4 sw 1 112 Y2 102 4 X1 3 X1 2 X1 1 X1 Rückwärts 25A/1A Spannungsversorgung Ausgänge 1 X5 2 X5 3 X5 4 X5 5 X5 6 X5 111 5 Y4 4 Vorwärts 4 Masse 110 10 (B1) 104 Y3 11 (B2) Masse 12 (U1) 103 174 101 1 87 Hydraulikölkühler 149 Spannungsversorgung Logik 126 30 Motorhaltespule 2 87a 108 26 25 24 23 (IRGnd) (IRVcc) (SB-) (SB+) 159 S25 156 Öltempschalter 6 M 86 8 (E2) K7 157 85 3 rt sw 185 0.5A 105 N1 179 147 145 Zündung 19 (V1) 30 F14 25A 158 178 143 7 5 (E1) (H1) 148 87 hold 211 134 F21 40A Anlasser 86 202 Motorsignal rt sw 85 pull ws Timer 1s gb K4 146 Y1 171 86 X3 1 X3 Solenoid Driver rt 208 0.5A 206 201 K3 M3 F25 40A 207 (TIER 4) sw ws pull 144 167 30 87a 2 X3 K11 rt/ws 204 4 X3 Y11 hold 176 K1 87 85 205 166 19 2 X6 165 86 139 180 + D+ 15 30 85 135 P G 87 162 107 +14.5V 30 31 140 50 15 P3 + G1 88888.8 K2 50 Anlasser N2 Vorglühen 30 M 118 31 138 M1 Batterie G2 10958087 ARR 1575 331 19 Appendices 19.4 Hydraulic system diagram Legend: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Travel pump Steering and vibration pump Travel hydraulic motor, rear left Travel hydraulic motor, rear right Travel hydraulic motor, front left Travel hydraulic motor, front right Left steering hydraulic cylinder Right steering hydraulic cylinder Valve block of vibration, steering and brake Vibration hydraulic motor, front Vibration hydraulic motor, rear Oil cooler Hydraulic oil filter Hydraulic oil tank Ventilation filter Diesel fuel tank Nozzle block Flow divider The texts are given only in the original language version or as a translation of the original into the English language version. 332 ARR 1575 WORKSHOP MANUAL DN8 DN8 6 5 L R R Front left travel motor 408 ccm DN6 11 Rear vibration motor 8ccm Front right travel motor 408 ccm R DN8 F F R F F R DN8 DN8 DN10 DN8 DN10 17 Nozzle block DN 8 DN 10 DN8 DN8 DN10 DN8 DN12 DN8 DN12 8 DN8 L Front vibration motor 8ccm DN8 3 R R F R Rear left travel motor 408 ccm DN8 R F F R F 4 DN8 DN8 DN8 BR A T3 PBR 18 Y8 P P DN10 DN8 210 Y5 Y6 B T2 B2 A3 A2 Diesel engine 2400 RPM Fuel tank 16 A Mb 60 B3 DN12 Flow divider 9 Valve Block for Vibration, Steering and Brake B DN12 Y7 T DN8 Y9 Backwards A1 Forwards B1 Rear right travel motor 408 ccm DN8 DN8 DN10 DN6 Ma Fe 5.6 S T1 20 320 320 14 DN12 1 Travel pump 0 to18 ccm DN8 DN20 DN12 DN12 DN25 DN8 DN8 G Hydraulic oil tank Ps DN8 Y4 DN8 X2 X1 Y3 19.2 l/min 15 Vent filter T2 R T1 11 2 7 Left hydraulic cylinder for steering DN20 26.4 l/min Vibration and Steering Pump 8 Right hydraulic cylinder for steering out 12 0.4 bar Oil cooler in DN25 2.5 bar 50/40°C S25 ARR 1575 13 Hydraulic oil filter 10442344A 333 19 Appendices 19.6 Workshop jigs 19.6.1 Special tools Assembly tool for the travel motor 557D655 Assembly tool for the vibration unit 557D656 Removing tool for swinging joint bearings 557D584 Insertion screw of the swinging joint bearing 557D657 334 ARR 1575 WORKSHOP MANUAL Assembly tool for swinging joint bearings 1175656 557D658 Pressure screws of the swinging joint bearing 557D659 Spacer for pressure screws (4x) 557D660 Assembly pin, heavy clamping pin, swinging support 557D661 ARR 1575 335 19 Appendices Special bit for the installation of an infrared sensor. 557D662 Spanner for grooved nuts for the vibration gearbox 557D323 Bridge for the vibration gearbox torque meter 557D663 Torque meter 557D664 336 ARR 1575 WORKSHOP MANUAL 19.6.2 Special tool for measuring the speed and frequency Revolution counter 2-90000030 557D665 19.6.3 Special tool for magnetic coil check Solenoid tester 1-10300477 557D666 ARR 1575 337 19 Appendices 19.7 Checking the tightness of screw connections •• Check regularly the screw connections for loosening. •• Use torque spanners for tightening. Tightening torque For screws 8.8 (8G) Thread Nm Tightening torque For screws 10.9 (10K) For screws 8.8 (8G) For screws 10.9 (10K) lb ft Nm lb ft Thread Nm lb ft Nm lb ft M6 10 7.4 14 10.3 M18×1.5 220 162.2 312 230.1 M8 24 25.0 34 25.0 M20 390 287.6 550 405.6 M8×1 19 14.0 27 19.9 M20×1.5 312 230.1 440 324.5 M10 48 35.4 67 49.4 M22 530 390.9 745 549.4 M10×1.25 38 28.0 54 39.8 M22×1.5 425 313.4 590 435.1 M12 83 61.2 117 86.2 M24 675 497.8 950 700.6 M12×1.25 66 48.7 94 69.3 M24×2 540 398.2 760 560.5 M14 132 97.3 185 136.4 M27 995 733.8 1400 1032.5 M14×1.5 106 78.2 148 109.1 M27×2 795 586.3 1120 826.0 M16 200 147.5 285 210.2 M30 1350 995.7 1900 1401.3 M16×1.5 160 118.0 228 168.1 M30×2 1080 796.5 1520 1121.0 M18 275 202.8 390 287.6 Values given in the table are tightening torques for dry threads (friction coefficient = 0.14). The values are not applicable to lubricated threads. Tightening torques of compression nuts with an O ring – hoses Tightening torques of compression nuts with an O ring – hoses Nm Spanner size Thread Nominal Min Max Nominal Min Max 14 12×1.5 6 20 15 25 15 11 18 17 14×1.5 8 38 30 45 28 22 33 19 16×1.5 45 38 52 33 28 38 22 18×1.5 51 43 58 38 32 43 24 20×1.5 58 50 65 43 37 48 27 22×1.5 74 60 88 55 44 65 30 24×1.5 16 74 60 88 55 44 65 32 26×1.5 18 105 85 125 77 63 92 135 115 155 100 85 114 166 140 192 122 103 142 30 240 210 270 177 155 199 35 290 255 325 214 188 240 330 280 380 243 207 280 36 41 46 50 30×2 36×2 42×2 45×2 50 338 Pipe lb ft 52×2 8 10 10 12 12 14 15 20 22 25 28 38 42 ARR 1575 WORKSHOP MANUAL Tightening torques for necks with sealing edge or flat sealing Tightening torques for plugs with flat sealing Tightening torques of necks G-M Nm lb ft G 1/8 25 18 G 1/4 40 30 G 3/8 95 70 G 1/2 130 96 G 3/4 250 184 G1 400 295 G 11/4 600 443 G 11/2 800 10 x 1 Tightening torques of plugs G-M Nm lb ft G 1/8 15 11 G 1/4 33 24 G 3/8 70 52 G 1/2 90 66 G 3/4 150 111 G1 220 162 590 G 11/4 600 443 G 11/2 800 590 25 18 12 x 1.5 30 22 10 x 1 13 10 14 x 1.5 50 37 12 x 1.5 30 22 16 x 1.5 60 44 14 x 1.5 40 30 18 x 1.5 60 44 20 x 1.5 140 103 22 x 1.5 140 103 26 x 1.5 220 162 27 x 1.5 250 184 33 x 1.5 400 295 42 x 1.5 600 443 48 x 1.5 800 590 ARR 1575 16 x 1.5 60 44 18 x 1.5 70 52 20 x 1.5 90 66 22 x 1.5 100 74 26 x 1.5 120 89 27 x 1.5 150 111 33 x 1.5 250 184 42 x 1.5 400 295 48 x 1.5 500 369 339 Notes 340 ARR 1575 WORKSHOP MANUAL Notes ARR 1575 341 Notes 342 ARR 1575 WORKSHOP MANUAL ARR 1575 343 More information on products and services can be found at: www.ammann.com Materials and technical modifications are reserved without prior notice. Book ID: 4-P08000-EN | © Ammann Group ">
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Key features
Tier 4f engine
Robust frame
Comfortable cab
User-friendly controls
Adjustable vibration
Variable speed
Hydraulic system
Frequently asked questions
Ammann ARR 1575 is a trench roller designed for compacting trenches in various construction projects, including utility installation, road construction, and landscaping.
The ARR 1575 is powered by a YANMAR 3TNV80F-SPAMM engine that complies with U.S. EPA Tier 4f emissions standards.
Yes, the ARR 1575 allows you to adjust the vibration frequency and amplitude for optimal compaction in different trench conditions.
Refer to Chapter 5.6 in the Workshop Manual for instructions on checking and replenishing the hydraulic oil level.