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Ammann AP 240, Operating Manual

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154

AP 240

3.8.  Annexes

Wiring Diagram

Legend:

 

A1  Light interruptor

 

A2  Steering changeover electronics

 

A3  Multifunctional display device Murphy PV - 101

 

B1   Accelerator pedal position switch

 

B2  Gearbox temperature sensors

 

B3  Gearbox lubrication pressure gauge sensor

 

B4  Fuel gauge float

 

C1  Interference filter

 

E1  Instrument lighting

  E2, 3  Front contour lamp
  E4, 5  Tail lamps
  E6, 7  Front lights
  E8, 9  Rear lights
 

E10  Flashing beacon (optional)

 E11,12  Cabin lighting
 E13,14  Brake lights
 E15-17  LH traffic indicator lights
 E18-20  RH traffic indicator lights
 

E21  Backing headlight (optional)

  F1-21  Drop out fuses
 

G1  Battery

 

G2  Alternator

 

H1  Horn

 

H2  Backing horn (optional)

 

H3  Pilot lamp for traffic indicator lights

 

H4  Pilot lamp for neutral

 

H5  Pilot lamp for RH steering

 

H6  Pilot lamp for LH steering

 

H7  Pilot lamp for hydraulic oil level

 

H8  Pilot lamp for engine glowing

 

H9  Pilot lamp for battery recharging

  H10  Pilot lamp for brake failures
  H11  Acoustic indicator for brake failure
  H12  Pilot lamp for brake
  H13  Pilot lamp for air filter fouled
  H14  Pilot lamp for engine air filter fouled 
  H16  Pilot lamp for hydraulics overheating
  H17  Pilot lamp for sprinkling
  K1-3  Auxiliary relay
  K5-8  Auxiliary relay
 K11-13  Contactors
 

M1  Starter

 

M2  Front windscreen wiper

 

M3  Rear windscreen wiper

 

M4  Fron windscreen sprayer

 

M5  Rear windscreen sprayer

 

M6  Sprinkling pump motor

  M7-9  Cooling air blowers
 

P1   Gearbox thermometer

 

P2  Gearbox lubrication pressure gauge

 

Q1  Master switch

  R1,2  Engine glowing
 

R3  Resistor

 

S1  Ignition box

 

S2  Front light switch

 

S3  Rear light switch

 

S4  Flashing beacon switch (optional)

 

S5  Brake light pressure switch

  S6, 7  Horn pushbuttons
 

S8  Warning light switch

 

S9  Traffic indicator light changeover switch 

 

S11  LH gear selector

 

S12  RH gear selector

 

S13  Hydraulic tank float switch

 

S14  Emergency brake pushbutton

 

S15  Parking brake switch

 

S16  Differential lock switch (optional)

 

S17  Indication for differential lock contacted (optional)

 

S18  Double pushbutton to adjust engine idling speed

 

S19  Pressure switch for brake failure

 

S20  Pressure switch for brakes

 

S21  Hydraulic oil filter pressure switch 

 

S22  Engine air filter pressure switch

 

S24  Hydraulic oil overheating switch

 

S25  Rear windscreen wiper changeover switch

 

S26  Rear windscreen wiper switch

 

S27  Double pushbutton for windscreen sprayers

 

S29  Cycling device for sprinkling

 

S30  Cooling air blower changeover switch 

 

S31  Air conditioner switch (optional)

 

S32  Air conditioner thermostat (optional)

 

S33  Air conditioner overpressure safety piece (optional)

 

S34  Double pushbutton for edge cutter (optional)

  V1, 2  Interlocking diodes
  X1-33  Interconnecting connectors (X1, 11, 24, 32 and 33 are 

vacant)

  X34  Field socket
 X35,36  Engine connectors
  X37  Engine diagnostics connectors
 X38-43  Connectors J1939
  Y1, 2  Electromagnets for valves, gear change
 

Y3  Electromagnet for valves, forward travel 

 

Y4  Electromagnet for valves, back travel

 

Y5  Electromagnet for brake valves

 

Y6  Electromagnets for differential lock valve (optional)

 

Y7  Electromagnetic clutch for air conditioner compressor 

(optional)

 

Y8  Electromagnet for valve, edge cutter, upward (optional)

 

Y9  Electromagnet for valve, edge cutter, downward (optional)

Summary of Contents for AP 240

Page 1: ...Book ID 4 P06430CU AP 240 Cummins EN Operating manual...

Page 2: ......

Page 3: ...AP 240 Cummins Tier 3 01 2012 4302395 Operating manual Edition EN From Serial No Translation of Original Operating Manual Pneu tyred roller...

Page 4: ......

Page 5: ...M sto a datum vyd n Place and date of issue Ort und Datum der Ausgabe...

Page 6: ......

Page 7: ...ve to familiarise the machinist operator with the roller and to support him during handling and main tenance It is therefore absolutely necessary to provide the operator with these instructions and to...

Page 8: ...ns of figures are reserved All dimensions and weights are approximate and therefore not binding Ammann Czech Republic a s reserves the right to perform modifications without obligation to inform the m...

Page 9: ...des of the machine moving forward SYMBOLS OF THE SAFETY NOTICES The notice warns of a serious risk of personal injury or other personal hazards The notice warns of possible damages to the machine or i...

Page 10: ...4 AP 240 Content Content 4 1 SPECIFICATION MANUAL 9 1 1 Basic Data 10 1 2 Dimensional machine drawing 12 1 3 Technical data 15...

Page 11: ...on and storage for the period over 2 months long 36 2 3 3 Dewaxing and inspection of a supplied machine 37 2 4 Machine disposal following its life cycle end 38 2 5 Machine Description 39 2 6 Controlle...

Page 12: ...ing liquid level check 99 3 6 3 Crankcase breather tube 99 3 6 4 Check of the fan and engine belt condition 100 3 6 5 Check air filter vacuum valve 101 3 6 6 Hydraulic tank oil level check 101 3 6 7 C...

Page 13: ...130 3 6 31 How to exchange oil in hydraulic cylinders for front axle 134 3 6 32 How to exchange brake fluid 135 3 6 33 Exchanging the engine cooling liquid 137 3 6 34 Check the compressor 139 Mainten...

Page 14: ...8 AP 240...

Page 15: ...9 AP 240 SPECIFICATION MANUAL 1 SPECIFICATION MANUAL AP 240 Cummins Tier 3...

Page 16: ...mm mixed soils up to a layer thickness of 200 mm and sand and gravel materials up to a layer thickness of 250 mm The roller is not suitable for the compaction of rockfill The machine is intended for o...

Page 17: ...kg kg kW kg kg 3 8 9 4 1 2 6 10 3487 5 7 SPECIFICATION MANUAL Name plate location 1 Name plate 2 Machine frame number Engine name plate location The machine that complies with the requirements as to h...

Page 18: ...12 AP 240 A L H1 G 374002 G 1 2 Dimensional machine drawing A G G H H1 L L1 W W1 W2 mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310 in 149 6 13 4 10 2 122 4 96 5 197 6 227 6 78 2 82 7 90 9...

Page 19: ...13 AP 240 374001 W W1 H SPECIFICATION MANUAL A G G H H1 L L1 W W1 W2 mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310 in 149 6 13 4 10 2 122 4 96 5 197 6 227 6 78 2 82 7 90 9...

Page 20: ...14 AP 240 L2 W2 L1 374016 1 2 Dimensional machine drawing A G G H H1 L L1 W W1 W2 mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310 in 149 6 13 4 10 2 122 4 96 5 197 6 227 6 78 2 82 7 90 9...

Page 21: ...620 Weight of ROPS kg lb 300 660 Weight of ROPS FOPS CNH design kg lb 530 1170 Weight of sheet roof on ROPS kg lb 50 110 Weight of canopy kg lb 50 110 Weight of canopy posts version without ROPS kg lb...

Page 22: ...um tyre pressure MPa PSI 0 2 29 Pattern of tyres COM HL Number of tyres 8 Number of front wheels 4 Number of rear wheels 4 Size of tyres 11 00x20 Type of tyres Tube Type Brakes Operating Hydrostatic P...

Page 23: ...a cab version only Radio CD MP3 cab version only Waterproofed Frame Towing hinge front Thermal aprons Edge cutter Ammann Traction System Diff lock 4 4 tyres MITAS radial instead of standard ones 4 4 t...

Page 24: ...18 AP 240 Notes...

Page 25: ...19 AP 240 SPECIFICATION MANUAL Notes...

Page 26: ...20 AP 240...

Page 27: ...21 AP 240 OPERATION MANUAL 2 OPERATION MANUAL AP 240 Cummins Tier 3...

Page 28: ...22 AP 240...

Page 29: ...such condition He she shall set forth the technological procedure part of which is the work process for given labour activity and such technological procedure will inter alia include Precautions duri...

Page 30: ...ied in the operation manual of the machine He must ensure that Operation manual of the machine and operational book are kept on specified place to be at dispos al for the driver all the time He must a...

Page 31: ...ies chan ges or corrections in the licence Holder shall report immediately his her licence loss to the one who issued such licence Person mentally competent and physically fit person over 18 years old...

Page 32: ...erytime the Machine is put into operation and this always before starting Machine engine Before driving make up air reservoir to 8 bar 116 PSI pres sure in order to brake off the Machine Before starti...

Page 33: ...stem and substations and of gas To drive over electric cables unless these are properly pro tected against any mechanical damage To operate the Machine under reduced visibility and at night unless Mac...

Page 34: ...28 AP 240 374040 14 4 5 6 8 10 10 7 18 12 11 13 15 15 16 12 2 3 1 9 17 18 2 1 Main Safety Measures 2 1 5 Safety inscriptions and symbols used on the Machine...

Page 35: ...id is deleterious Please read the Operation Manual when filling up or changing on radiator 4 Adjust at Standstill Do NOT carry make any adjustment or maintenance with the engine running Imminent risk...

Page 36: ...nual On the seat backrest stowage box 8 Disconnect Alternator Disconnect alternator before welding on the Machine labelled on dashboard 9 Danger of explosion Imminent danger of explosion while handlin...

Page 37: ...f Injury Observe safe distance when operating the trimmer sym bol located on frame s RH side 17 Machine braking Engage the gear before downhill driving symbol located on the instrument panel 18 Distan...

Page 38: ...palm in the Operator di rection second arm akimbo Attention Both arms horizontally sideways raised palms facing forward Attention Danger Oscillating motion of both arms with antebrachium from the pos...

Page 39: ...illating motions of antebrachium towards the body and back Slow driving backward away from me Both arms stretched upward abreast bent with palms away from the body short oscillating motions of antebra...

Page 40: ...on Both arms lifted forward bent Mark distance X between palms then follows the motion signal Engine start Circular motion of antebrachium of right hand with tight fist Engine cut off Oscillating moti...

Page 41: ...e cleaning and preservation agents as well in their origi nal properly marked packages Admit no storage of these materials in unidentified bottles or other vessels with regard to the risk of being int...

Page 42: ...hort time preservation In addition we recommend the following Remove the batteries check their condition and store in cold dry room recharge the batteries on regular basis Bottom the drum frame up so...

Page 43: ...arts are missing Inform shipper about any deficiencies Before restoration of the Machine serv ice please dewax and wash the preser vation agents away with high pressure stream of hot water added with...

Page 44: ...onmental policy acts We therefore recommend to always contact Specialized companies with relevant authorization to deal with these operations Machine Manufacturer or Manufacturer appointed accredi ted...

Page 45: ...d Emergency Brake 9 Driving Brakes rear wheels only 10 Front Axle incl Telescopic Cylinders 11 Pump for Compressor Drive 12 Power Assisted Steering 13 Battery cylinder s LH side 14 Hydraulic Tank cyli...

Page 46: ...40 AP 240 13 9 8 20 20 17 3 374004 B 11 19 20 7 6 5 A 16 20 10 4 1 12 18 15 11 22 21 20 2 15 IDLE 14 A B 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 2 6 Controllers Control Instruments...

Page 47: ...entilation Nozzles 21 Accelerator Pedal controls engine rpms travel speed 22 Brake Pedal controls rear wheel brakes A Indicator Lamps 23 Battery Recharging 24 Parking brake 25 Engine heating 26 Hydrau...

Page 48: ...42 AP 240 I II III IV 0 9 13 10 15 14 1 4 3 2 5 6 7 2 374005 F R N 1 2 3 1 2 3 F R N P 0 START START START 3236 3236 3397 0 I 0 I II N D 11 11 8 12 2 6 Controllers Control Instruments...

Page 49: ...circuit pressure gauge 8 White indicator shows air pressure inside air res ervoir adjusted to max 8 bar Red one indicates air pressure when braking air pressure from air brake valve to brake booster T...

Page 50: ...ke lights cab lighting horn 4 15A Direction indicator lights 5 5A Front fender lights rear lamps instrument illumination 6 15A Headlamps 7 7 5A Gearbox solenoids backing horn 8 7 5A Differential lock...

Page 51: ...amp socket 17 It serves to connection of the auxiliary assembling lamp 12 V on the dashboard Lock the bonnet 18 by pressing the supports in marked up direction 9 30A ECM electric motor supply 10 A Res...

Page 52: ...es necessity to heat engine Hydraulic oil filter fouled 26 indicates filter element to replace Idle 27 indicates position of both controllers in N idle neutral CAUTION When starting please check both...

Page 53: ...turned on un til the sufficient pressure in the brake circuit is achieved If the pilot lamp turns on during driving stop the machine Before driving the machine again it is necessary to repair the fai...

Page 54: ...ferential interlock 39 optional Headlamps 34 incl fender lights Parking brake 38 While stopping the machine at any time the driver must apply the parking brake Rear lights 35 Warning lights 36 Idle RP...

Page 55: ...Washer Switch 41 Rear Wiper Switch 43 Front Wiper Switch 42 Cab Lighting 44 Fan Switch 45 Temperature Control 46 Air Conditioner optional 47 Cabin Induction Air Control 48 Filter 49 Do not handle the...

Page 56: ...ers Control Instruments Filter for internal air circulation Note Air Conditioner Operation Manual supplied with air con ditioner Venting 50 increases efficiency of cabin fans CAUTION We recommend to s...

Page 57: ...seat in your hand and slowly lift it to adjust its height to higher position where it will be arrested When lifted to MAX position the seat will drop to its lowest position Document compartment 52 A...

Page 58: ...r tank 55 Refill with clean soft water best is distilled water incl cleaning and degreasing agent Before winter season please fill the tank with de icing or drain Turn OFF the master switch after 30 s...

Page 59: ...re alarm or minimal fuel level in tank alarm Reduce engine power stop the machine immediately at safe place and shut off the engine Repair the defect or call Cummins service centre Do NOT op erate the...

Page 60: ...ETUP 4 UP DISPLAY SELECT UNITS 396045 396322 20 FUEL LEVEL 100 ENG HRS 28 C COOL TEMP 0 RPM ENG RPM 2 6 Controllers Control Instruments Use ENTER 1 to open highlighted item Press buttons in Menu 2 Mai...

Page 61: ...ove to GO TO 1 UP DISPLAY menu where parameters are displayed one by one Use cursor 1 to display step by step nine parameters set Number of engine operating hours engine rpm el system voltage engine l...

Page 62: ...L FRAN AIS DEUTSCH ENGLISH ESPA OL FRAN AIS DEUTSCH 396048 ENGLISH ESPA OL FRAN AIS DEUTSCH 396022 2 6 Controllers Control Instruments First press ENTER to select language Another time use cursor to s...

Page 63: ...7 1 of x MORE SPN110FMI10 HIGH COOLANT TEMP HIDE 396019 396020 MORE SPN110FMI10 HIGH COOLANT TEMP HIDE 1 of x OPERATION MANUAL STORED CODES stored defects not enabled Move cursor in main menu to the i...

Page 64: ...isplayed Number of engine operating hours engine rpm wir ing voltage battery voltage engine load during actual engine speed in cooling liquid temperature oil pressure etc The following parameters have...

Page 65: ...025 1 2 3 OPERATION MANUAL Press ENTER to open units menu Use cursor to set 1 ENGLISH and the indicated variables will be displayed in PSI units pressure F temperature When METRIC KPA or METRIC BAR ar...

Page 66: ...CONTRAST UTILITIES 396030 ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES 396031 2 1 2 6 Controllers Control Instruments Use CURSOR to adjust backlight intensity Press MENU to return to main menu In main m...

Page 67: ...with yellow LED ON informs about en gine malfunction Warning Engine failure registered from engine ECU Electronic Actuator Unit will be displayed via error code for a failure and description on the di...

Page 68: ...display 1 of parameter display with warning icon for active failure in RH corner or display 4 of parameter display with warning icon for active failure in the centre Note Press ENTER to display again...

Page 69: ...Shut off engine Engine failure registered from engine ECU Electronic Actuator Unit will be displayed via error code for a failure and description on the display warning to SHUT DOWN Press ENTER to ac...

Page 70: ...n the hidden error code for failure Press ENTER again to display again either with 1 parameter or 4 parameters Until defect is eliminated the displaying of warning icon will remain active CAUTION When...

Page 71: ...lt Code DM2 information and the ECU responded There are zero stored codes NO GAGE DATA is displayed The Power View has no record of gages connected to the RS485 bus NO DATA is displayed in place of a...

Page 72: ...66 AP 240 3351 30 sec 0 3351 30 sec 0 374014 F R N 1 2 3 1 2 3 F R N 3397 0 I I II III IV 0 0 I II P 0 START START START 3236 3236 374020 1 7 2 2 10 2 7 Machine Control and Usage...

Page 73: ...re first starting the engine check daily the amount of oil in the engine and hydraulic tank fuel level in fuel tank oil level in gearbox brake fluid level cooling liquid level Make sure no parts on th...

Page 74: ...edure designed for connecting the battery jump cables 1 Connect cable to pole of discharged battery 2 Connect second cable end to pole of charged battery 3 Connect cable to pole of charged battery 4 C...

Page 75: ...ction of running indicator lamp for enabled work place 11 goes ON switch OFF parking brake brake indi cator lamp goes off Increase rpm use pedal 21 to start moving the Roller Brake and stop the roller...

Page 76: ...hift Use differential interlock only when re covering the Machine Switch OFF the in terlock once heavy conditions are over come danger of damage to differential or tires When oil temperature in gearbo...

Page 77: ...to idle or with the use of brake pedal or with parking brake unable to apply Press down TOTAL STOP pushbutton Machine will stop brake and the engine will be shut off Before starting the engine again...

Page 78: ...Roller will auto matically be braked With the engine running the parking brake switch must be ON with the Roller at standstill Do NOT shut off the engine immediately instead let it run for 3 5 minute...

Page 79: ...potential of natural hazard landslide potential flooding etc Switch off battery disconnector Clean the Machine of any rough dirt scrapers tires Make overall inspection of the Machine and repair any d...

Page 80: ...ring and scrapers When compacting fresh laid asphalt coat please turn ON the sprinkling and set adequate sprinkling interval Use ap propriate separation emulsion Lift the scrapers during normal compac...

Page 81: ...109B OPERATION MANUAL 2 7 7 Edge Cutter Press the switch to lower the edge cutter to its end position and vice versa Confirm nobody is in hazard before low ering lifting When operating the edge cutter...

Page 82: ...uld be transported on a vehicle When loading and unloading the ve hicle transporting the machine must be braked and mechanically protected against accidental movement using scotch blocks 3 If the Mach...

Page 83: ...N When using ropes shorter than 8 m 26 3 ft insert cross bar A 1 95 m 6 4 ft long between the ropes overhead the cab Beware of Roller s actual mass incl weight and additional load in ballast spaces of...

Page 84: ...e Roller for towing Dismantle floor covers between the seats Dismantle the bolting To tow the Roller use towing hitch mounted in the Machine front Towing hitch is optional When the roller has no coupl...

Page 85: ...cement of straight angle of haul ing Maximal misalignment possible is at an angle of up to 30 One must maintain the continuous mo tion when towing Do NOT exceed the towing speed of 2 km hr 1 2 mph Tow...

Page 86: ...e the soil freezes up can be quickly compacted at temperatures below 0 C 32 F Preparation for works at low temperatures Check the concentration of the engine cooling liquid Exchange the engine oil wit...

Page 87: ...ication of Caterpillar TO 4 2 9 5 Machine work in high altitudes With altitude growing the atmospheric pressure and speci fic gravity of intake air decrease and in connection therewi th the engine per...

Page 88: ...82 AP 240 Notes...

Page 89: ...83 AP 240 OPERATION MANUAL Notes...

Page 90: ...84 AP 240...

Page 91: ...85 AP 240 MAINTENANCE MANUAL 3 MAINTENANCE MANUAL AP 240 Cummins Tier 3...

Page 92: ...86 AP 240...

Page 93: ...with torque specified and through checking the connection tightness with the operation media heated beware of burns use recommended media only Upon completion of the adjustment or maintenance please...

Page 94: ...ills accumulators fills brake liquids and paints including the organic thinners and also cleaning and preservative means always store on a original properly signed covers Don t allow storing of these...

Page 95: ...CI 4 CCMC DHD1 ACEA E 5 Year round SAE 15W 40 refer to the Table Note Exceeding low temperature limit will not lead to any engine damage It may only cause problems when starting the engine Itisapprop...

Page 96: ...asing the power in any case Never mix the fuel mixture at the place of use Bionafta has a higher cloud point at a low ambi ent temperature which leads to the creation of wax crystals in the fuel resul...

Page 97: ...eeze mixture and 50 of water Do NOT use earthy water with high content of calcium and mag nesium which causes formation of scale incrustation and with high content of chlorides and sulphates which cau...

Page 98: ...tions Brake fluid is designed for brake systems that operate at ambient tempera tures from 50 C 58 F to 60 C 140 F and at operating tem perature from 50 C 58 F to 205 C 400 F Note As for the brake sys...

Page 99: ...tion 3 2 4 22 5 81 Hydraulic cylinders for front wheels Hydraulic oil as per 3 2 4 6 1 6 CLARK transmission Oil as per Section 3 2 5 21 5 5 7 Final drive Transmission oil as per Section 3 2 6 6 1 6 Ca...

Page 100: ...water separator 3 6 10 Check oil level in gearbox 3 6 11 Check alarm and control instruments After 100 hours of operation weekly 3 6 12 Checking the tyre pressure After 250 hours of operation 3 months...

Page 101: ...ange oil in hydraulic cylinders for front axle 3 6 32 How to exchange brake fluid 3 6 33 Exchanging the engine cooling liquid 3 6 34 Check the compressor Maintenance if required 3 6 35 Fuel Pre Cleane...

Page 102: ...15W 40 API CI 4 CH 4 SAE 80W 90H API GL 5 ISO VG 68 ISO 6743 HV ISO 6743 9 CCEB 2 2000 1000 500 250 20 374105en Engine oil Fluid for automatic transmission see chapter 3 2 5 Gear oil Hydraulic oil Gr...

Page 103: ...d Maintenance Manual which is part of documentation supplied with the Machine Following the first 50 hours of operation of the new Machine after Major Overhaul please perform the following Make single...

Page 104: ...and pull out again to read oil level Maintain level between division lines stamped on oil dip stick LOW division mark shows lowest possible oil level HIGH division mark shows the highest one Replenis...

Page 105: ...sbelow 50 C If filler plug is removed at higher temperature then there is hazard of va pour scald or cooling liquid scald due to inner overpressure effect CAUTION Top up cooling liquid the composition...

Page 106: ...example you find missing part of the material cracks shape changes etc please replace the cooling air blower Inspect visually the belt If longitudinal cracks or smooth bright flats occur on the belt...

Page 107: ...chine be fitted with air pre cleaner clean the vessel 1 when filled with dirt up to the mark first unscrew nut 2 and remove cover 3 Do NOT operate the Machine when dust valve is damaged 3 6 6 Hydrauli...

Page 108: ...uel has dropped Pipes and hoses of the system Connection tightness brake master cylinder brake cylinders in rear axle wheels Keep brake fluid in its original well closed containers When it is to be us...

Page 109: ...t OFF engine switch ON parking brake Pull drain valve s chain to confirm valve operation is OK 3 6 10 Check oil level in gearbox Unscrew and pull out dipstick wipe off and push in again Pull it out on...

Page 110: ...ition I confirm travel controllers are in idle position neutral parking brake switched ON pilot lamps for recharging idle position parking brake must light up Check Power View display and horn Start t...

Page 111: ...edly several times to lower air pressure in line with pressure gauge to 5 2 bar pilot lamp for brake failure must light up and alarm signal be heard When in operation check continuously the instrument...

Page 112: ...protective cap Outer condition of tyres whether not damaged due to local deforma tion part of rubber separated cracks fissures Contact area and effective load depending on the wheel load and tyre infl...

Page 113: ...hile running warm up the engine until cooling liquid reaches 60 C Observe fire precautions Beware of hot oil burn hazard when draining oil Let oil cool down below 50 C Remove drain plug and let oil fl...

Page 114: ...ver for disposal Do not tighten excessively the filter its thread and gasket may get damaged Note Refer to Engine Operation and Maintenance Manual for the spe cial spanner required When exchanged star...

Page 115: ...TENANCE MANUAL 3 6 14 Check the engine induction manifold and air filter sensor Check pipe hoses and fixing of clips Check air filter cuff Cover suction hole Start the engine turn off IDLE switch incr...

Page 116: ...240 374066A 1 3 6 Lubrication and Maintenance Operations Unless it lights up check vacuum switch 1 pilot lamp on dashboard wiring Do NOT operate the Machine if induction manifold air filter cuff are d...

Page 117: ...to confirm electrolyte level in all cells reaches 5 15 mm 0 2 0 6 in above electrodes or up to the bottom edge of dipstick in accumulator cells Note Use glass tube to check the level Measure the elec...

Page 118: ...least a couple of minutes Get prompt medical attention Upon ingestion of electrolyte drink max amount of milk water or solution of calcined magnesia in wa ter Get prompt medical attention Upon skin co...

Page 119: ...as per Section 3 2 8 Remove floor coverings to make lubrication points acces sible Lubricate pin 1 If lever 2 is overhead the horizontal posi tion when braked then reposition pin 3 into another hole o...

Page 120: ...Lubrication and Maintenance Operations Internal bearings of front wheels Steering pins Bonnet hinges In order to grease the inner and outer bearings of front axle wheels thoroughly the lubricating gr...

Page 121: ...115 AP 240 374078 374108 374109 MAINTENANCE MANUAL Door hinges Cover suspensions Edge cutter pins...

Page 122: ...49 374079 3 6 Lubrication and Maintenance Operations After 500 hours of operation 6 months 3 6 17 Fuel filter replacement Clean and remove filter Clean seating face for filter Apply oil on sealing rin...

Page 123: ...during filter re placement will automatically deaerate if the replacement pro cedure described has been adhered to Unless filters are filled with fuel deaerate the system according to Section called F...

Page 124: ...ine cooling liquid check Inspect cooling liquid concentration with the refractometer using cold engine Check always before winter season Unless concentration for ambient tem peratures of 36 C 33 F is...

Page 125: ...b ft torque Let gearbox cool down below 50 C be fore replacing 3 6 19 How to replace CLARK gearbox oil filter Open the cover in the floor Replace first after 100 hours of operation of new Machine of a...

Page 126: ...ection named Oil Exchange after 1000 hours Clean and remove plug on rear side of down gear hous ing and check if level reaches up to the inspection hole or flows out slightly Fill up with oil as per S...

Page 127: ...remov al Lift a bit the Machine onto the rear lugs of the frame so the rear wheels do not touch the ground Chock the rear part of Machine frame Secure front wheels with Scotch blocks on both sides Re...

Page 128: ...ment during Insufficient brake efficiency long step of brake pedal Replacement of worn clips for new ones Following the installation of new brake drum or after brake drum s inner diam eter is machined...

Page 129: ...mulator Remove floor covering Let filling pressure of 120 bar on nameplate be checked and made up by authorized service department Call your dealer if required When operating the Roller at the tem per...

Page 130: ...force refer to the Fig If slack X is higher than belt thickness tighten the belt Tighten the belt after you have slackened bolt for alternator holder 1 tensioning arm 2 by tilting out the alternator a...

Page 131: ...fter having pulled out check dipstick up to FULL mark Start the engine and while idling check oil level to confirm it reaches up to ADD mark With oil warmed up to 82 93 C please check and fill up to F...

Page 132: ...ion called How to clean sprinkling filter Remove the tank Remove filler plug 1 and inspection plug 2 Drain oil when operation has ended af ter oil has cooled down to 50 C or while driving wait until o...

Page 133: ...ding to Section 3 2 6 Drain oil into collection vessels Spent oil is ecological waste hand over for disposal Use hole 1 to pour 6 l 1 58 gal US of oil Check oil level in hole 2 oil must pour out sligh...

Page 134: ...y No dirt may enter the clean air area non return valve Apply oil over the gasket of new drying cartridge Tighten manually the cartridge with 15 Nm 11 lb ft torque Spent drying cartridge is ecological...

Page 135: ...tall plugs 1 and pour 5 2 l 1 4 gal US amount through the holes into each housing as per Section 3 2 6 close with plugs Oil may flow out slightly from holes 2 Observe fire precautions Use recommended...

Page 136: ...e cover and drain 22 l 5 81 US gal of oil via the valve When drained close the valve Disconnect sensor for filter 1 clogged remove filter cover 2 Exchange oil before season or following a long term sh...

Page 137: ...oil level sensor 3 remove pipe hoses 4 and 5 and cover 6 clean tank interior Remove suction strainer wash and blow out strainer with pressure air from inside Check condition of suction strainer in ca...

Page 138: ...filling device over the filler adapter with the following parameters min pressure of 6 MPa 870 PSI 3 to 10 m filtration Note Order the filling equipment with the Machine manufacturer or dealer Fill oi...

Page 139: ...2 4 Exchange oil and filter always when de struction of internal parts of the units hydromotors hydrogenerators occurs or following a major repair of hydraulic system Clean suction strainer and hy dra...

Page 140: ...and jack behind front wheels Remove cover Remove fast coupling on the pipe that connects hydraulic cylinders for front axles put on the hose and descend the Machine slowly to drain oil into a vessel s...

Page 141: ...less there is air level the system must be filled while the engine is running follow safety measures during engine start Two persons must work together to carry out deaeration Slip hose pipe incl key...

Page 142: ...bbles Then with the brake pedal pressed close deaeration screws for brake cylinders wipe them and install protective caps Check cir cuit tightness level in the tank and adjust Reinstall wheels Tighten...

Page 143: ...the lid before cooling liquid drops below 50 C 122 F Hot water scald hazard Remove plug Let liquid flow out into the vessel of 11 5 l 3 gal US capacity Check no hose pipes are damaged within engine s...

Page 144: ...clean Start the engine and wait until temperature reaches 80 C 176 F Then stop the engine At the same time check that no cooling liquid is leaking Check level in equalizer tank make up to MAX Before f...

Page 145: ...hen the overall extent of carbon deposited on the wall ex ceeds the value of X X 2 mm 1 16 in you must clean or replace delivery pipe leading from compressor and please contact your dealer to carry ou...

Page 146: ...arm signal from yellow pilot lamp Code No 97 VODA V PALIVU will be displayed WATER IN FUEL Drain water from separator Collect drained fuel incl sediment into a proper vessel CAUTION If you drained mor...

Page 147: ...fuel pump replacement Upon long term shutdown of the Machine With fuel pumped out from the tank Deaerate second filter via air relief screw Deaerate the filters Slacken air relief screw 1 at fuel pre...

Page 148: ...do NOT clean it Clean inner space of the filter and the contact faces so to avoid any dust penetrating into the supply piping that leads to the engine Put back safety element and new main element When...

Page 149: ...ny dust penetrat ing into engine induction manifold Use original elements only When washing the Machine be careful not to splash water into air filter Replace instantly vacuum valve damaged Do NOT ope...

Page 150: ...oil Clean with pressure air or pressure water steam from the side of cooling air blower Do NOT use cleaners with too high pres sure so to avoid any damage to radiators plates With radiator contaminat...

Page 151: ...lter clean its strainer Drain tank 1 Drain sprinkling pipes at the front and back by slackening the nozzles 2 3 6 40 Clean brush scrapers Check condition of front brushes 1 rear brushes 2 clean them a...

Page 152: ...it out carefully and blow it out Note Clean it beat out blow out 1x per month In case you work in dusty environment shorten the cleaning intervals Replace ele ment after 2 cleaning processes Remove co...

Page 153: ...ort etc With the Machine cleaned remove these blinds Disconnect master switch NEVER expose electric parts or insula tion material alternator electric con nections etc to direct stream of pres sure wat...

Page 154: ...32 97 3 185 136 4 M27 995 733 8 1400 1032 5 M14x1 5 106 78 2 148 109 1 M27x2 795 586 3 1120 826 0 M16 200 147 5 285 210 2 M30 1350 995 7 1900 1401 3 M16x1 5 160 118 0 228 168 1 M30x2 1080 796 5 1520 1...

Page 155: ...1 5 60 44 18 x 1 5 60 44 20 x 1 5 140 103 22 x 1 5 140 103 26 x1 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 Chart for torques of plugs with flat gasket Plug Torques...

Page 156: ...150 AP 240...

Page 157: ...ns given in the operation and maintenance manual for the machine and engine If you cannot identify the cause contact a service department of an authorised dealer or the manufacturer Troubleshooting in...

Page 158: ...S1 Ignition box S2 Front light switch S3 Rear light switch S4 Flashing beacon switch optional S5 Brake light pressure switch S6 7 Horn pushbuttons S8 Warning light switch S9 Traffic indicator light c...

Page 159: ...P F X10 2 X10 8 X10 4 X10 10 X10 3 X10 7 X10 1 X10 9 X5 6 X5 7 X5 8 X5 9 X18 2 X18 1 X5 10 X25 2 X25 1 X6 4 X6 3 X6 2 X4 1 X6 1 2 5 4 1 3 2 1 7 5A 7 2 5 6 5 10 1 9 R1 R2 K12 F19 F20 G1 F10 X35 Q1 G2 F...

Page 160: ...ne glowing R3 Resistor S1 Ignition box S2 Front light switch S3 Rear light switch S4 Flashing beacon switch optional S5 Brake light pressure switch S6 7 Horn pushbuttons S8 Warning light switch S9 Tra...

Page 161: ...10 X13 1 25A X4 11 X5 11 X7 4 X7 5 X13 2 X6 11 10A 7 1 3 X113 4 X113 1 X113 2 X113 3 C MPa S18 A B B C D E G H8 F11 P1 P2 H9 H10 H12 H13 H14 H16 H11 R3 X36 B1 B2 B3 S19 S20 S21 S22 S24 X41 X42 X43 X3...

Page 162: ...alve 8 Diaphragm type accumulator 9 Safety valve 10 Non return valve 11 Logic valve 12 Edge cutter block 13 Combined cooler 14 Hydraulic tank 15 Suction strainer 16 Filter element 17 Sensor for filter...

Page 163: ...2900 PSI 200 200 M T P P T A B 63 32 250 A1 B1 P LD 3045 PSI 1885 PSI 1595 PSI Dn10 Dn10 Dn8 Dn8 Dn19 Dn16 Dn12 Dn8 Dn12 Dn10 Dn10 Dn12 Dn12 Dn12 Dn12 Dn10 Dn10 Dn32 85 C 17 4 PSI i 1 0 72 5 PSI Dn19...

Page 164: ...r for filter clogged 15 Pressure switch 16 Coupling T measuring type 17 Coupling T measuring type 18 Coupling T measuring type Option Central Tyre Inflation System 20 Control valve 21 Non return valve...

Page 165: ...160 200 kPa Dn18 3 2 5 1 4 Dn9 200 kPa Dn9 Dn9 520 kPa 500 50 kPa 62mbar Dn9 63 36 160 RPM 2400 Hydromotor 18 ccm Dn19 Dn12 Dn12 Dn12 20 20 21 8 29 26 10 4 16 3 25 7 14 18 6 6 9 13 28 11 27 24 23 22...

Page 166: ...160 AP 240 3 8 Annexes Notes...

Page 167: ...161 AP 240 MAINTENANCE MANUAL Notes...

Page 168: ...162 AP 240 3 8 Annexes Notes...

Page 169: ......

Page 170: ...Ammann Unternehmungen Eisenbahnstrasse 25 CH 4901 Langenthal Phone 41 62 916 61 61 www ammann group com...

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