Ammann ARR 1575 Workshop Manual Download Page 90

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ARR 1575

555058A

557D104

557D105

5 Frame

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

Connect a pressure gauge (40 bar) to the supply pressure meas-

uring point.
Rotate the engine with the engine starter.

Rotate the engine until the pressure reaches 3–5 bar.

Do not overheat the starter! After no more than 30 sec-

onds, let the starter cool down�

Insert the F21 (40A) fuse in the engine compartment.

Summary of Contents for ARR 1575

Page 1: ...ARR 1575 WORKSHOP MANUAL TRENCH ROLLER YANMAR 3TNV80F SPAMM U S EPA Tier 4f EDITION 04 2019 EN From Serial No 5572567...

Page 2: ......

Page 3: ...ions 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 identi...

Page 4: ...2 ARR 1575...

Page 5: ...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 rep...

Page 6: ...06 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 Replaceme...

Page 7: ...arts 249 14 4 1 Coolant and checking the coolant level 249 14 4 1 1Checking the coolant level 249 14 4 1 2Coolant replenishment 249 14 4 1 3Cooler cleaning 249 15 ENGINE 251 15 1 Engine compartment ov...

Page 8: ...ences 290 18 1 5 2Machine cabling 290 18 1 5 3Operation 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 steer...

Page 9: ...hecking 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 meas...

Page 10: ...8 ARR 1575...

Page 11: ...9 ARR 1575 WORKSHOP MANUAL 1 Introduction...

Page 12: ...lied 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 pr...

Page 13: ...l 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 manua...

Page 14: ...12 ARR 1575...

Page 15: ...13 ARR 1575 WORKSHOP MANUAL 2 Safety measures and instructions...

Page 16: ...m 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 ma...

Page 17: ...ses 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...

Page 18: ...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 outsi...

Page 19: ...ainers 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...

Page 20: ...s 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 compac...

Page 21: ...19 ARR 1575 WORKSHOP MANUAL 3 MACHINE DESCRIPTION...

Page 22: ...ntrol 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 operatio...

Page 23: ...fety require ments 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 Tr...

Page 24: ...nsional drawing of the machine mm in A B C D E F G H I J ARR 1575 T4 final 640 601 302 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 9 850 601 407 36 850 2227 1980...

Page 25: ...h 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 14...

Page 26: ...g system l gal US 1 2 0 3 Hydraulic system l gal US 16 4 2 Electrical installation Voltage V 12 Battery capacity Ah 77 Noise and vibration emissions Measured sound power level A LpA at the operator s...

Page 27: ...25 ARR 1575 WORKSHOP MANUAL 4 Specification of operating fluids...

Page 28: ...g to ACEA E 3 E 4 and E 5 Year round SAE 15W 40 e g Valvoline Premium Blue Note Exceeding the lower temperature limit does not result in dam age to the engine it can only cause some starting difficult...

Page 29: ...esel 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...

Page 30: ...ifferent 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...

Page 31: ...be used in the widest range of ambient tem peratures Synthetic hydraulic oil The hydraulic system can be filled with synthetic oil which if leaks occur will be degraded completely by micro organisms...

Page 32: ...ing to Chapter 4 2 2 28 7 4 Hydrostatic system Hydraulic oil according to Chapter 4 2 4 16 4 23 2158 Engine cooling system Year round anti freeze according to Chapter 4 2 3 1 2 0 3 2152 Articulated be...

Page 33: ...31 ARR 1575 WORKSHOP MANUAL 5 Frame...

Page 34: ...One point lifting lug 2 Name plate 3 Drum scraper 4 Rear bonnet lock 5 Front bonnet lock 6 Front infrared sensor Left side view 7 Articulation joint lock 8 Safety bar optional 9 Control panel cover 1...

Page 35: ...33 ARR 1575 555010A 12 13 14 15 16 WORKSHOP MANUAL 12 Oil cooler 13 Fuel tank 14 Hydraulic oil tank 15 Battery 16 Control unit...

Page 36: ...34 ARR 1575 555011B 17 18 19 5 Frame 17 Engine cooler 18 Coolant level expansion tank 19 Water separator...

Page 37: ...35 ARR 1575 20 26 23 22 557012B 25 21 24 WORKSHOP MANUAL 20 Oil filter 21 Oil dipstick 22 Oil filler cap 23 Fuel filter 24 Coolant filler cap 25 Engine fuses 26 Air filter...

Page 38: ...ate 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...

Page 39: ...ltlessly for many years Gas strut replacement Before you begin replacing the gas struts secure the en gine bonnet against spontaneous fall There is a risk of injury Removal Use a screwdriver to pull o...

Page 40: ...ell as dirt or paint on the pis ton 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 impr...

Page 41: ...D156 557D157 WORKSHOP MANUAL 5 4 6 Front bonnet replacement Removal Remove the sensor Chapter 5 4 6 2 Hang the bonnet Use a screwdriver to lift the clamp Pull the gas cylinder away from the ball joint...

Page 42: ...ame Release the wire rope from the bonnet on the left Lift the engine bonnet using a crane Remove the bottom screws of the butt hinge on the left Remove the bottom screws of the butt hinge on the righ...

Page 43: ...557D165 WORKSHOP MANUAL 5 4 6 1 Replacement of bonnet hinges Remove the bonnet Chapter 5 4 6 Remove the hinge screws Replace the bonnet hinge Apply blue adhesive on the screws Mount the hinges using s...

Page 44: ...42 ARR 1575 557D166 557D167 557D168 557D169 5 Frame 5 4 6 2 Sensor replacement Removal Remove the screws of the sensor cover Remove the sensor cover...

Page 45: ...43 ARR 1575 557D170 557D171 557D172 557D173 WORKSHOP MANUAL Remove the sensor Release the sensor cables from the holders Remove the cable ties...

Page 46: ...44 ARR 1575 557D174 557D175 557D176 557D177 5 Frame Unplug the X5 connector infrared sensor at the front Remove the sensor and wiring Installation Put the sensor into the hole in the bonnet...

Page 47: ...75 557D169 557D178 557D179 557D180 WORKSHOP MANUAL Install the sensor using the special tool Apply blue adhesive on the sensor cover screws Install the sensor cover The tightening torque of the cover...

Page 48: ...57D183 557D184 5 Frame Fasten the sensor harness using the holders Fasten the cables with a cable tie on the holder at the top of the bonnet hinge Fasten the cables with a cable tie on the holder at t...

Page 49: ...en the cables with a cable tie on the 010 hydraulic hose Plug the X5 connector infrared sensor at the front Attach the cable ties 5 4 6 3 Replacement of the rubber metal elements of the front bonnet s...

Page 50: ...48 ARR 1575 557D188 557D189 557D190 557D191 5 Frame Remove the rubber metal element from the holder Apply blue adhesive on the rubber metal element screw Mount the rubber metal element into the holder...

Page 51: ...ance between the bonnet and the machine frame Loosen the rubber metal element holder screws Move the holder to adjust the distance between the bonnet and the machine frame Make sure the distance is ev...

Page 52: ...155 557D196 557D197 557D156 5 Frame 5 4 7 Rear bonnet replacement Removal Remove the sensor Chapter 5 4 7 2 Hang the bonnet Remove the fastening straps of the N2 connector Disconnect the connectors fr...

Page 53: ...D199 557D200 557D201 WORKSHOP MANUAL Disconnect the connectors of the ignition box Disconnect the N2 connector Remove the bonnet cable ties Use a screwdriver to lift the clamp Pull away the gas cylind...

Page 54: ...205 5 Frame Release the wire rope from the bonnet Lift the engine bonnet using a crane Remove the bottom screws of the butt hinges on the left Remove the bottom screws of the butt hinge on the right R...

Page 55: ...53 ARR 1575 557D206 557D207 WORKSHOP MANUAL Lift the bonnet using a crane and put it aside...

Page 56: ...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 Remove the sensor cover Remove the sen...

Page 57: ...55 ARR 1575 557D211 557D169 557D176 557D177 WORKSHOP MANUAL Disconnect the sensor connector Installation Put the sensor into the hole in the bonnet Install the sensor using the special tool...

Page 58: ...1575 557D178 557D212 557D213 557D214 5 Frame Apply blue adhesive on the sensor cover screws Install the sensor cover The tightening torque of the cover is 10 Nm Fasten the sensor harness using the ho...

Page 59: ...the fastening straps 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 Replacement of the rubber metal elements of the front...

Page 60: ...58 ARR 1575 557D535 557D536 5 Frame 5 4 8 Swinging support Removal Mount a lock against cranking Place the hydraulic jack to the centre of the swinging joint Slightly unload the roller...

Page 61: ...59 ARR 1575 557D537 557D538 557D539 557D540 WORKSHOP MANUAL Remove the screws of the swinging support...

Page 62: ...0 ARR 1575 557D543 557D541 557D542 5 Frame Before disassembling the swinging support measure the dis tance between the joint centres Use the measured value during reassembly Remove the swinging suppor...

Page 63: ...557D544 557D545 557D546 557D547 557D548 WORKSHOP MANUAL Replacement of the joint head Removal Remove the retaining screw Place the swinging support under a press Push out the heavy clamping pin with...

Page 64: ...62 ARR 1575 557D549 557D550 557D551 5 Frame Clamp the swinging support in a vice Heat the lock nut and joint head to approximately 200 C 392 F Loosen the lock nut Rotate the joint head using a spanner...

Page 65: ...Apply blue adhesive on the new front joint head and swinging support 2 Mount the rear joint head on the swinging support all the way to the stop Set the front joint head to the required distance Set...

Page 66: ...64 ARR 1575 557D556 557D557 557D558 5 Frame Insert the clamping pin so that the gap is on the push out side Push the clamping pins inside Apply red adhesive on the screw...

Page 67: ...65 ARR 1575 557D559 557D560 557D561 557D562 WORKSHOP MANUAL Installation Mount the joint head fixing screws The tightening torque is 85 Nm Apply blue adhesive on the screws...

Page 68: ...66 ARR 1575 557D563 557D564 557D565 557D566 5 Frame 5 4 9 Replacement of the steering piston Removal Remove hydraulic hoses 017 and 018 from the hydraulic cylin der Remove the steering piston nuts...

Page 69: ...67 ARR 1575 557D567 557D568 557D569 WORKSHOP MANUAL Remove the steering piston Close the screw unions on the steering piston Close the screw unions on hoses 017 and 018...

Page 70: ...ening pins remove corrosion if necessary Mount the sealing washer 1 Lubricate the fastening pins Apply blue adhesive on the threaded pins Install the new steering piston Tighten the nut firmly 100 Nm...

Page 71: ...ging joint Remove the swinging support Chapter 5 4 8 Remove the steering piston Chapter 5 4 9 Cut the hose bundle ties Place a protective plate e g aluminium at the bottom and top between the chassis...

Page 72: ...575 557D577 557D578 1 557D579 557D580 5 Frame Remove the bearing lock screw Cut the thread in the support chassis Mount the screws In the event of corroded bearing seat use 4 screws Remove the bearing...

Page 73: ...nough 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 Use squared wood 1 to separate...

Page 74: ...ulling disc under the articulated bearing using the special tool 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 Pull the bearin...

Page 75: ...73 ARR 1575 557D589 557D590 557D591 557D592 WORKSHOP MANUAL Remove the bearing out of the support Removed binding ring with a bearing Place the binding ring under a press...

Page 76: ...74 ARR 1575 557D593 557D594 557D595 557D596 5 Frame Push out the bearing Clean the binding ring Lubricate the bearing seat Lubricate the new bearing...

Page 77: ...75 ARR 1575 557D597 557D598 557D599 557D600 WORKSHOP MANUAL Push the bearing into the binding ring Clean the support chassis Lubricate the bearing seat...

Page 78: ...76 ARR 1575 557D601 557D602 557D603 557D604 5 Frame Apply sealant on the sealing surface Pull the bearing flange to the support using the screws Lubricate the bearing pins...

Page 79: ...557D606 557D607 557D608 WORKSHOP MANUAL Centre the chassis towards the bearing pins Mount the washer and the screw with the nut into the bearing pin Use the nut to pull the bearings over the bearing p...

Page 80: ...7D609 557D610 1 557D611 5 Frame Mount the lock washer on the screw Apply blue adhesive on the screw Secure the swivel bearing with a screw and a washer The tight ening torque is 210 Nm Remove the moun...

Page 81: ...79 ARR 1575 557D612 557D613 557D614 557D615 WORKSHOP MANUAL Apply sealant on the surface of the binding ring Place the cap Apply blue adhesive on the screws...

Page 82: ...80 ARR 1575 557D616 557D617 5 Frame Secure the cap The tightening torque is 85 Nm Remove the protective plates Arrange the hose bundle and fasten it using cable ties...

Page 83: ...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...

Page 84: ...drain neck Let the diesel flow out 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...

Page 85: ...dle Check the oil level in the inspection hole The ideal hydraulic oil level is when the gauge is half full 5 6 2 Hydraulic oil replenishment Take off the ventilation filter 1 from the filler neck Ref...

Page 86: ...litres under the hy draulic oil drain plug 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 c...

Page 87: ...artridge from the filter housing Dispose of the filter cartridge environmentally Insert the new filter cartridge in the correct place Keep the posi tion of the safety cam Turn the filter cartridge clo...

Page 88: ...575 557D098 557D099 557D097 5 Frame 5 6 7 Hydraulic tank filling Fill the hydraulic oil tank approximately 16 l 5 6 6 Ventilation filter replacement Remove the ventilation filter and replace it with a...

Page 89: ...P MANUAL 5 6 8 Filling the travel pump increasing the supply pressure Remove the 006 S hydraulic hose Fill the travel pump housing with hydraulic oil Fill hydraulic oil 0 3 0 4 l so that it flows out...

Page 90: ...Connect a pressure gauge 40 bar to the supply pressure meas uring point Rotate the engine with the engine starter Rotate the engine until the pressure reaches 3 5 bar Do not overheat the starter After...

Page 91: ...R 1575 557D106 557D107 WORKSHOP MANUAL Start the diesel engine Check the pressure increase Maximum pressure 23 bar If hydraulic components have been replaced or repaired per form a function and leak c...

Page 92: ...90 ARR 1575...

Page 93: ...91 ARR 1575 WORKSHOP MANUAL 6 Cab and platform...

Page 94: ...92 ARR 1575 6 Cab and platform...

Page 95: ...93 ARR 1575 555009B 2 3 4 5 557018 1 WORKSHOP MANUAL 1 Infrared remote control 2 Spiral cable compartment 3 Display unit 4 Ignition box 5 Fuses 6 1 Control and indication elements...

Page 96: ...the following check Turn off the engine Check the V belt of the engine for damage and loosening If the battery charging indicator lamp is still on after this check contact an authorized service centr...

Page 97: ...down 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 RAM04 Coolant temperature indicator lamp...

Page 98: ...is continuously on the whole time the safety bar is connected optional equipment The safety bar indicator lamp also lights up during the activa tion of the near and remote halt RAM05 Preheating indica...

Page 99: ...transistor signals a status error This means for example that a short circuit or broken cable has been detected Check that the cable is not short circuited or broken The Error and Safety Bar indicato...

Page 100: ...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 t...

Page 101: ...is 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...

Page 102: ...Before and during the operation with the infrared re mote control make sure the entire bottom part of the cover remains completely exposed throughout the whole operation The operator must not cover th...

Page 103: ...101 ARR 1575 555116 40 40 555118 40 555120 40 555119 555131 40 WORKSHOP MANUAL Proper use of the infrared remote control...

Page 104: ...e of the infrared remote control 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 in fra...

Page 105: ...103 ARR 1575 40 555125 555129 40 40 555122 WORKSHOP MANUAL...

Page 106: ...e infrared remote control in the direction of the machine only The cable connector 1 must face forward The infrared remote control can lean on the operator s body The side and front diodes of the infr...

Page 107: ...re 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 The infrared re...

Page 108: ...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 abo...

Page 109: ...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 temperatu...

Page 110: ...108 ARR 1575 557D078 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...

Page 111: ...white N1 21 N2 4 Safety bar 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...

Page 112: ...mp 165 1 brown M2 Casing engine Diesel fuel pump 166 1 5 brown Y1 black Casing engine Holding coil 167 1 white Y3 2 Y4 2 Return line 169 1 brown Y5 2 Casing engine Steering to the left 170 1 brown Y6...

Page 113: ...111 ARR 1575 557D001 557D002 557D003 557D004 WORKSHOP MANUAL 6 4 1 Replacement of the remote control battery Removal Remove the protective cover Remove the rubber gaskets Remove the screws...

Page 114: ...112 ARR 1575 557D005 557D006 557D007 557D008 557D009 6 Cab and platform Open the top of the remote control Remove the connector fastening strip Disconnect the connector Remove the battery...

Page 115: ...5 557D010 557D011 557D012 557D008 WORKSHOP MANUAL Installation Insert the battery Connect the connector Fasten the connector with the fastening strip Pull the fastening strip through the hole under th...

Page 116: ...14 ARR 1575 557D013 557D001 557D003 557D004 6 Cab and platform Shorten the fastening strip Install the top of the remote control using the screws Install the rubber gaskets Install the protective cove...

Page 117: ...19 557D220 557D221 WORKSHOP MANUAL 6 4 2 Replacement of the display unit Disconnect the N2 connector Remove the two fasteners of the display unit You can now extract the display unit Install the new u...

Page 118: ...Cab and platform 6 4 3 Replacement of the control unit Removal Remove the battery clamp Disconnect the connectors of the control unit Disconnect the N1 connector Use a screwdriver to lift the clamp P...

Page 119: ...117 ARR 1575 557D226 557D227 WORKSHOP MANUAL Remove the control unit fastening screws and remove the unit...

Page 120: ...ARR 1575 557D228 557D229 557D230 6 Cab and platform 6 4 3 2 Installation Apply blue adhesive on the screws Install the control unit using the screws Connect the N1 connector Connect the battery termi...

Page 121: ...119 ARR 1575 WORKSHOP MANUAL 7 Front drum...

Page 122: ...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 B...

Page 123: ...k 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 ne...

Page 124: ...it 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...

Page 125: ...terface 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...

Page 126: ...enoid valves No Designation Y5 Steering to the left Y6 Steering to the right Y7 High amplitude Y8 Low amplitude Y9 Brake Valve block connections No Designation BR Brake PBR Travel pump G supply pressu...

Page 127: ...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...

Page 128: ...tions 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 Valve block right view Valve block r...

Page 129: ...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 L...

Page 130: ...drum Valve block divider neck 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...

Page 131: ...129 ARR 1575 557D018 557D019 557D020 557D021 WORKSHOP MANUAL 7 4 Mechanical parts 7 4 1 Removal of the drum extension Remove the drum scrapers...

Page 132: ...130 ARR 1575 557D022 557D023 7 Front drum Support the frame using a jack Remove the drum extension screws...

Page 133: ...m removal Support the machine using a jack Hang the drum on a crane and lift it slightly Remove the drum fastening screws Move the drum using a suitable tool under the chassis outwards Keep the drum b...

Page 134: ...132 ARR 1575 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...

Page 135: ...MANUAL Clean the hoses and surroundings Before hanging the hoses place an oil drip container under the travel motor Remove all hoses at the travel motor Close the screw union Install the aid on the t...

Page 136: ...134 ARR 1575 557D267 557D268 557D269 557D270 7 Front drum Remove the screws of the travel hydraulic motor attachment Remove the travel hydraulic motor and put it aside...

Page 137: ...135 ARR 1575 557D272 557D273 557D274 WORKSHOP MANUAL Remove the nuts on the gearbox cover Put an oil drip container under the gearbox Remove the screws on the gearbox cover...

Page 138: ...8 7 Front drum Put the gearbox cover aside Grease comes out of the gearbox The same amount of grease then must be refilled during reas sembly Store the gearbox cover safely for reuse Install the aid o...

Page 139: ...137 ARR 1575 557D279 557D280 557D281 WORKSHOP MANUAL Remove the nuts on the gearbox cover Remove the gearbox and put it aside...

Page 140: ...er 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 uncon...

Page 141: ...139 ARR 1575 557D315 557D316 557D317 557D318 WORKSHOP MANUAL Remove and clean the bearing cap Remove the grease on the hub...

Page 142: ...140 ARR 1575 557D320 557D321 557D319 7 Front drum Loosen the grooved nut lock Use a small chisel or screwdriver...

Page 143: ...141 ARR 1575 557D322 557D323 WORKSHOP MANUAL Mount the special spanner for grooved nuts tool...

Page 144: ...142 ARR 1575 557D324 557D325 557D326 557D327 7 Front drum Loosen the grooved nut lock Remove the grooved nut Remove the grooved nut lock Lift the vibration unit from the shaft...

Page 145: ...143 ARR 1575 557D328 557D329 557D330 557D331 WORKSHOP MANUAL Remove the grease on the hub Remove the spacer rings Pull the bearings from the hub using the pulling tool...

Page 146: ...144 ARR 1575 557D332 557D333 557D334 557D335 7 Front drum Mount the pulling tool here arrow Remove the outer bearing rings and the spacer ring Clean the bearing housing...

Page 147: ...145 ARR 1575 557D282 557D283 WORKSHOP MANUAL Remove the rubber metal elements...

Page 148: ...57D284 557D285 557D286 557D287 7 Front drum 7 4 4 Installation of the drum rubber metal elements Apply blue adhesive on the screws Install new rubber metal elements on the centre beam The tightening t...

Page 149: ...91 WORKSHOP MANUAL Apply blue adhesive on the rubber metal element threads from the vibration motor side Support the hoses with squared wood on the vibration motor side so that they can be released At...

Page 150: ...s 1 to a torque of 50 Nm This concludes the gearbox installation from the vibration mo tor side If bearing replacement or new lubrication is required refer to Chapter Replacement of vibration unit bea...

Page 151: ...OP MANUAL Cut all threads M8 Blow clean the threaded bores Thoroughly remove all glue residues and dirty grease Replace the removed or blow cleaned grease with the same amount of new grease Grease Foo...

Page 152: ...150 ARR 1575 557D299 557D300 557D301 557D302 7 Front drum Spread the sealant with a brush Apply a drop of blue adhesive in all threaded bores Clean blow clean the boreholes in the gearbox cover...

Page 153: ...57D305 557D306 WORKSHOP MANUAL Clean the sealing surface of the gearbox cover Apply blue adhesive on the threads of the rubber elements Mount the gearbox cover Fasten the gearbox cover using the nuts...

Page 154: ...152 ARR 1575 557D307 557D308 1 557D309 1 557D310 7 Front drum Apply blue adhesive on the screws Tighten the screws 1 to a torque of 36 Nm Install the hose guide holder 1 using the same screws...

Page 155: ...SHOP MANUAL 7 4 4 Installation of the vibration unit Install a new wide outer bearing ring 1 into the bearing hous ing Observe the installation position Push the wide outer bearing ring into the housi...

Page 156: ...154 ARR 1575 557D340 557D341 1 557D339 7 Front drum Install a narrow outer bearing ring 1 into the bearing housing Observe the installation position Push the narrow outer bearing ring into the housing...

Page 157: ...ARR 1575 557D342 557D343 557D344 557D345 WORKSHOP MANUAL Heat the rear cone bearing to 110 C Slide the rear cone bearing onto the hub Apply a small amount of grease on the bearing Mount the spacer ri...

Page 158: ...RR 1575 557D346 557D347 557D348 557D349 7 Front drum Lubricate the bearing ring from the outside Insert the vibration unit into the vibration housing Mount the bearing from the outside Mount the lock...

Page 159: ...157 ARR 1575 557D350 557D351 557D352 557D353 WORKSHOP MANUAL Mount the grooved nut Mount the special spanner for grooved nuts tool Tighten firmly 200 Nm Install the bridge for the torque meter...

Page 160: ...meter 20 times clockwise This eliminates any stress The housing must not stand on a support and must be freely rotatable Set the tightening torque to 1 3 Nm If the value does not match perform correct...

Page 161: ...159 ARR 1575 557D358 557D359 557D360 557D361 WORKSHOP MANUAL Grease the bearings Total amount of grease in the bearing housing 100 g of liquid grease BLASER FOODGREASE SPM00...

Page 162: ...365 7 Front drum Put a small amount of blue adhesive in the threaded bores Apply blue adhesive on the screws Mount the bearing cap on the vibrator housing Tighten the screws to a torque of 10 Nm Weigh...

Page 163: ...161 ARR 1575 557D366 557D294 557D295 557D296 WORKSHOP MANUAL Apply 300 g of grease in the vibration housing Clean the sealing surface of the gearbox Cut all threads M8 Blow clean the threaded bores...

Page 164: ...y remove all glue residues and dirty grease Replace the removed or blow cleaned grease with the same amount of new grease Grease Foodgrease SPM00 Apply sealant to the sealing surface Spread the sealan...

Page 165: ...575 557D301 557D302 557D303 557D304 WORKSHOP MANUAL Clean blow clean the boreholes in the gearbox cover Clean the sealing surface of the gearbox cover Apply blue adhesive on the threads of the rubber...

Page 166: ...164 ARR 1575 557D305 557D306 557D307 7 Front drum Mount the gearbox cover Tighten the nuts to a torque of 50 Nm Apply blue adhesive on the screws...

Page 167: ...165 ARR 1575 557D309 1 557D310 557D308 1 WORKSHOP MANUAL Install the hose guide holder 1 using the same screws Tighten the screws 1 to a torque of 36 Nm...

Page 168: ...166 ARR 1575 7 Front drum 7 4 5 Replacement of the travel hydraulic motor Removal Remove the drum travel hydraulic motor Chapter 7 4 2...

Page 169: ...ove the screws on the travel hydraulic motor flange The screws are inaccessible In rare cases 7x where bolts are not accessible the travel hy draulic motor flange must be completely removed You then h...

Page 170: ...rt mark the motor location with a pencil If the travel motor is stuck in the motor support due to corro sion push the traction motor out of the motor support 3x Clean the threads 3x Cut the threads 3x...

Page 171: ...KSHOP MANUAL Lubricate the bearing seat with NeverSeez Put a small amount of blue adhesive in the threaded bores Place the new travel motor in the motor support Pay attention to the motor position pre...

Page 172: ...170 ARR 1575 557D385 557D386 7 Front drum Mount the screws The tightening torque is 85 Nm Apply blue adhesive on the screw unions from the old travel motor...

Page 173: ...ons on the travel motor firmly tighten Material Hydraulic motor K 04 340 0 cm 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...

Page 174: ...9 557D390 557D391 557D271 7 Front drum Installation Clean the seating surface of the motor support and threads Put a small amount of blue adhesive in the threaded bore Mount the aid on the travel hydr...

Page 175: ...57D394 557D395 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 Hang the travel hydraulic motor on a crane...

Page 176: ...4 ARR 1575 557D396 557D397 557D398 557D399 7 Front drum Apply blue adhesive on the screws Mount the travel hydraulic motor using the screws The tighten ing torque is 85 Nm Remove the aid Mount all hos...

Page 177: ...aning agents e g brake cleaner Apply NeverSeez on the flange arrow Before installing the drum let the machine run on blocks Per form a leak check Move the drum under the chassis using an aid Keep the...

Page 178: ...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 Remove the screws of the vibr...

Page 179: ...557D405 557D406 557D407 557D408 WORKSHOP MANUAL Remove the clutch In the case of a defective vibration hydraulic motor remove the screw union and pinion Remove the pinion nut Remove the pinion using a...

Page 180: ...178 ARR 1575 557D409 557D410 557D411 557D412 7 Front drum Remove the screws Remove the angled flanges on both sides Remove the 040 hydraulic hose Remove the threaded neck...

Page 181: ...iew of all parts used for the new vibration motor If the screw unions and other parts are undamaged they may be re used in the new vibration motor Always replace the sealing rings Apply blue adhesive...

Page 182: ...180 ARR 1575 557D417 557D418 557D419 557D420 7 Front drum Mount the pinion Apply blue adhesive on the thread Insert a spring washer Mount the pinion nut...

Page 183: ...1575 557D421 557D422 557D423 557D424 WORKSHOP MANUAL Tighten the pinion nut firmly to a torque of 50 Nm Apply blue adhesive on the straight neck Mount the straight neck and tighten firmly to torque o...

Page 184: ...7D404 557D427 7 Front drum Mount the clutch If the old clutch is undamaged you can reuse it Otherwise in sert a new clutch Apply sealant on the sealing surface Insert the vibration hydraulic motor App...

Page 185: ...183 ARR 1575 557D403 557D428 557D429 WORKSHOP MANUAL Tighten the screws firmly 56 Nm Mount the hydraulic hoses...

Page 186: ...um installation Move the drum under the chassis using an aid Keep the drum balanced using an aid e g squared wood Tighten the screws firmly 85 Nm 7 4 8 Scraper Before driving adjust the scraper so tha...

Page 187: ...185 ARR 1575 WORKSHOP MANUAL 8 Rear drum...

Page 188: ...186 ARR 1575 8 Rear drum 8 2 Hydraulic parts Hydraulic parts Chapter 7 2...

Page 189: ...187 ARR 1575 557D018 557D019 557D020 557D021 WORKSHOP MANUAL 8 3 ACEecon Removal Remove the rear drum scrapers...

Page 190: ...188 ARR 1575 557D022 557D023 557D025 2 1 557D024 8 Rear drum Support the left rear part of the frame with a jack Remove the extension of the left rear drum Remove the left rear drum...

Page 191: ...189 ARR 1575 557D026 557D027 557D028 557D029 WORKSHOP MANUAL Remove the hydraulic motor from the machine frame Remove the hoses from hydraulic motor Mark the outlets and blind them with plugs...

Page 192: ...190 ARR 1575 557D030 557D032 557D033 8 Rear drum Remove the hoses from the vibration hydraulic motor Remove the sensor wiring clips Remove the hose holder...

Page 193: ...191 ARR 1575 557D034 557D035 557D036 WORKSHOP MANUAL Remove the M7 screws using the jig...

Page 194: ...192 ARR 1575 557D037 557W053 557D014 8 Rear drum Remove the holder of the ACEecon sensor Remove the document compartment...

Page 195: ...193 ARR 1575 557D038 557D039 557D040 557D041 WORKSHOP MANUAL Remove the wiring ties Disconnect the X50 connector Disconnect the display panel connectors...

Page 196: ...6 8 Rear drum Installation Mount the hose holder using the screws Secure the screws with the Loxeal 83 54 adhesive Mount the hoses of the vibration hydraulic motor Mount the travel hydraulic motor Sec...

Page 197: ...48 557D049 WORKSHOP MANUAL Attach the hydraulic hoses of the travel hydraulic motor Install the drum Secure the screws with the Loxeal 83 54 ad hesive Install the drum extension Secure the screws with...

Page 198: ...196 ARR 1575 557D050 557D051 557D052 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 8 4 Mechanical parts See Chapter 7 4...

Page 199: ...197 ARR 1575 WORKSHOP MANUAL 9 Front axle not included in the machine equipment...

Page 200: ...198 ARR 1575...

Page 201: ...199 ARR 1575 WORKSHOP MANUAL 10 Rear axle not included in the machine equipment...

Page 202: ...200 ARR 1575...

Page 203: ...201 ARR 1575 WORKSHOP MANUAL 11 Travel...

Page 204: ...202 ARR 1575 11 Travel...

Page 205: ...L 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 Remove the pres...

Page 206: ...204 ARR 1575 557D435 557D436 557D437 557D438 11 Travel Remove the supply pressure travel pump screw union Close the screw union...

Page 207: ...205 ARR 1575 557D439 557D440 557D441 557D031 WORKSHOP MANUAL Remove the supply travel pump hydraulic hose Close the screw union Remove the hydraulic hose of the forward travel B travel pump circuit...

Page 208: ...206 ARR 1575 557D442 557D443 557D032 557D444 11 Travel Close the screw union Remove the T screw union of the reverse travel A travel pump circuit...

Page 209: ...207 ARR 1575 557D445 557D446 557D447 557D448 WORKSHOP MANUAL Close the screw union Remove the suction line vibration pump screw union Close the screw union...

Page 210: ...Travel Remove the angled screw union of the suction line travel pump The hydraulic oil will stop flowing Remove the hydraulic hose of the supply pressure PBR valve block Close the screw union Remove...

Page 211: ...209 ARR 1575 557D453 557D454 557D455 557D456 WORKSHOP MANUAL Remove connectors Y3 and Y4 Remove the screws on the travel pump...

Page 212: ...210 ARR 1575 557D457 557D458 1 557D459 557D460 11 Travel Lift the travel pump from the motor Now close the loose angled screw union of the suction line 1 Pull the pinion off the shaft...

Page 213: ...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...

Page 214: ...ion 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 Strai...

Page 215: ...ARR 1575 557D464 557D465 557D466 WORKSHOP MANUAL Apply blue adhesive on the screw Set the pinion Insert a feeler gauge 1 5 mm between the pinion and the pump housing Tighten the screw to a torque of 8...

Page 216: ...575 557D467 557D468 557D469 557D470 11 Travel Installation Clean the M12 thread on the pump flange Remove the suction hose stopper cap Apply blue adhesive on the screws Move the travel pump on the pum...

Page 217: ...5 ARR 1575 557D471 557D472 557D473 557D474 WORKSHOP MANUAL Tighten the screws to a torque of 85 Nm Mount the suction line screw union Mount the T screw union of the reverse travel A travel pump circui...

Page 218: ...77 557D478 11 Travel Mount the hydraulic hose of the forward travel B travel pump circuit Mount the pressure line vibration pump screw union Mount the supply travel pump hydraulic hose Mount the suppl...

Page 219: ...217 ARR 1575 557D479 557D451 WORKSHOP MANUAL Connect connectors Y3 and Y4 Mount the hydraulic hose of the supply pressure PBR valve block...

Page 220: ...avel 11 2 2 Replacement of the valve block Before removing the valve block drain the hydraulic oil see Hy draulic oil draining 5 6 3 Removal Disconnect connectors Y5 to Y9 Cut all cable ties on the ha...

Page 221: ...219 ARR 1575 557D482 557D483 557D484 557D485 WORKSHOP MANUAL Remove hydraulic hoses A2 B2 PBR T2 Close the screw union Remove the BR hydraulic hose Close the screw union...

Page 222: ...557D489 11 Travel Remove the 018 A3 hydraulic hose Close the screw union Remove the 004 T1 hydraulic hose Close the screw union Remove the 037 T3 hydraulic hose Close the screw union Remove the 030 A1...

Page 223: ...D493 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 Remove the sealing ring 1 Move the magne...

Page 224: ...D495 557D496 557D497 557D498 11 Travel Close the screw union Remove hydraulic hoses A1 B3 T3 Close the screw union Remove hydraulic hoses 010 and 036 screw union of the angled divider Close the screw...

Page 225: ...avel pump has already been re moved 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 View of the motor compar...

Page 226: ...557D503 557D504 557D505 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 Remove the magnetic co...

Page 227: ...MANUAL Removed magnetic valve 1 Nut 2 Sealing ring 3 Magnetic coil 4 Magnetic valve 5 Sealing ring Supply the magnetic valve with 12 V The valve arrow must switch visibly and audibly Check the sealin...

Page 228: ...tude and steering Remove the nut on the magnetic valve Remove the magnetic coil Remove the valve Put the valve in the magnetic coil Supply the magnetic valve with 12 V The piston must switch visibly a...

Page 229: ...513 557D514 557D515 WORKSHOP MANUAL Max pressure brake max pressure vibration You can set the brake drain valve if necessary You can set the vibration drain valve if necessary Magnetic valves can be a...

Page 230: ...228 ARR 1575 557D516 557D517 557D518 557D519 11 Travel Installation Place a new or checked valve block on the bottom plate Apply blue adhesive on the screws Tighten the valve block screws 25 Nm...

Page 231: ...557D522 WORKSHOP MANUAL Mount the 036 hydraulic hose on the screw union of the angled divider Mount the 010 hydraulic hose on the screw union of the angled divider Mount hydraulic hoses A1 B3 T3 Conn...

Page 232: ...230 ARR 1575 557D524 557D525 557D526 557D527 11 Travel Mount the 004 T1 hydraulic hose Mount hydraulic hoses A2 B2 PBR...

Page 233: ...tain 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 Move the magnetic coil 2 back Mount the B1 hydraulic hose 1 Move the...

Page 234: ...232 ARR 1575 557D531 557D532 557D533 557D534 11 Travel Mount the 018 A3 hydraulic hose Mount the 002 P hydraulic hose Mount the 003 T2 hydraulic hose Connect all front connectors Y6 Y9 Y7...

Page 235: ...233 ARR 1575 557D481 WORKSHOP MANUAL Place the cable harness cleanly Fasten the cable harness with a cable tie...

Page 236: ...d 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 If the brake is defective the roller...

Page 237: ...57D231 557D232 557D233 557D234 WORKSHOP MANUAL 11 4 Mechanical parts 11 4 1 Replacement and adjustment of the speed magnet Removal Speed magnet 1 Pull down cables Y2 and Y2 Remove the safety pin from...

Page 238: ...236 ARR 1575 557D235 11 Travel Remove the two screws Remove the speed magnet...

Page 239: ...75 557D236 1 557D237 557D235 557D238 WORKSHOP MANUAL Installation Preassembled speed magnet 1 Apply blue adhesive on the screws Place and firmly fasten the speed magnet Lubricate the safety pin of the...

Page 240: ...238 ARR 1575 557D239 557D240 557D241 11 Travel Mount the safety pin on the plug head Connect cables Y2 and Y2 Do not interchange the and cables...

Page 241: ...P MANUAL Adjustment Loosen the lock nut on the plug head Push the piston rod completely down with your hand The stop arrow must not touch the adjustment screw Use a feeler gauge 1 5 mm to determine th...

Page 242: ...gine 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 When the engine is idling move the adjustment lever to the...

Page 243: ...d 2390 2440 rpm Use a revolution counter to measure the frequency The re quired value is 41 Hz If the speed is not reached check the engine speed If necessary set the speed on the plug head 1 Secure t...

Page 244: ...242 ARR 1575...

Page 245: ...243 ARR 1575 WORKSHOP MANUAL 12 Vibration...

Page 246: ...244 ARR 1575 12 Vibration...

Page 247: ...245 ARR 1575 WORKSHOP MANUAL 13 Steering...

Page 248: ...246 ARR 1575 13 Steering 13 2 Hydraulic parts 13 2 1 Replacement of the steering piston Replacement of the steering piston Chapter 5 4 9...

Page 249: ...247 ARR 1575 WORKSHOP MANUAL 14 Cooling...

Page 250: ...en the cooler is contaminated by petroleum prod ucts use a cleaning agent and proceed according to the manufacturer s instructions Find out the cause of contamination Do not smoke while working Check...

Page 251: ...gine You can see the coolant level on the indicator situated on the expansion vessel The coolant level must be between the upper mark FULL and the lower mark LOW Refill the coolant as required 14 4 1...

Page 252: ...250 ARR 1575...

Page 253: ...251 ARR 1575 WORKSHOP MANUAL 15 Engine...

Page 254: ...er neck 6 Cooling water filler neck 7 Fuel filter 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 Wate...

Page 255: ...y ignition lock K3 Timer 1 s input coil K4 Relay input coil tripping magnet K5 Speed magnet K6 Preheating relay CAUTION K3 is located on the back of the plate Engine compartment fuses Fuse no Value Pr...

Page 256: ...254 ARR 1575 K11 557D076 15 Engine Height sensor Tier 4 Relay Tier 4 Relay functions Tier 4 Functions K11 Height sensor Tier 4...

Page 257: ...nition 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 saf...

Page 258: ...the order in which the clamps are disconnected and connected Ignition on battery voltageThe voltage during the ignition process should not drop below 10 V Otherwise the battery must be recharged Machi...

Page 259: ...p and remove it Loosen the clamp and remove it Loosen the holding angle piece and remove it Lift the battery from the machine area Insert a new battery Connect the battery Start with the clamp Battery...

Page 260: ...ed 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...

Page 261: ...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 Unscrew and empty the filter housing Screw on the f...

Page 262: ...gine oil as required 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 Filler neck on th...

Page 263: ...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 instruct...

Page 264: ...ring appears on the contamination indicator 1 during operation of the machine you must replace the car tridge Air filter cartridge The air filter is located on the left side of the engine Remove the...

Page 265: ...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 fo...

Page 266: ...264 ARR 1575 15 Engine 15 6 Checking the engine speed and frequency Checking the engine speed and frequency Chapter 11 3 2...

Page 267: ...265 ARR 1575 WORKSHOP MANUAL 16 Optional equipment...

Page 268: ...266 ARR 1575 16 Optional equipment 16 1 List of optional equipment Safety bar Drum extension set Scrapers Set of filters 500 h Tarp cover...

Page 269: ...557D621 WORKSHOP MANUAL 16 2 Safety bar 16 2 1 Safety bar replacement Remove the screws 1 on the clip body Remove the safety bar from the chassis Right side remove the screw on the safety bar Remove t...

Page 270: ...268 ARR 1575 557D622 557D623 557D624 557D625 16 Optional equipment Left side remove the screw on the safety bar Remove the stop on the left Remove the magnet Remove the spring...

Page 271: ...D627 557D628 557D629 WORKSHOP MANUAL Check if the removed parts can be reused Apply blue adhesive on the clip body Attach the clip body on the chassis using the screws Move the spring on the right and...

Page 272: ...0 557D631 557D632 557D633 16 Optional equipment Move the safety bar in the clip body to the right Mount the clip body on the left Tighten the screws firmly Place the springs in the dedicated slots on...

Page 273: ...7D636 557D637 1 WORKSHOP MANUAL Place the stop on the right Insert the screw and apply blue adhesive on it Mount the washer and nut Tighten the screw firmly Tighten the screw firmly until the stop 1 l...

Page 274: ...quipment Mount the magnet on the left on the tube Observe the installation position see the figure Insert the screw from below Apply blue adhesive on the screw Tighten the screw firmly Tighten the scr...

Page 275: ...273 ARR 1575 557D642 WORKSHOP MANUAL New safety bar completely installed...

Page 276: ...3 557D644 557D645 557D646 16 Optional equipment 16 2 2 Sensor replacement and adjustment Disconnect the sensor cable connectors Remove the sensor holder under the chassis Remove the old defective sens...

Page 277: ...648 557D649 557D645A WORKSHOP MANUAL Apply blue adhesive on the new sensor Check the installation distance approx 25 mm Observe the installation position see the white mark on the sensor head Mark par...

Page 278: ...l equipment Apply blue adhesive on the screws Put the sensor cable through the hole in the chassis Mount the sensor holder Tighten the screws slightly Set the distance approx 3 mm between the sensor h...

Page 279: ...ighten the screws to a torque of 25 Nm Connect the sensor cable Fasten the connector with a cable tie Function check safety bar at the top The Safety Bar indicator lamp 1 must be on Function check saf...

Page 280: ...278 ARR 1575...

Page 281: ...279 ARR 1575 WORKSHOP MANUAL 17 General procedures...

Page 282: ...ry 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...

Page 283: ...n 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 th...

Page 284: ...282 ARR 1575...

Page 285: ...283 ARR 1575 WORKSHOP MANUAL 18 Troubleshooting...

Page 286: ...k 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...

Page 287: ...e F21 fuse OK 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...

Page 288: ...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 engin...

Page 289: ...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 t...

Page 290: ...m 6 6 66 ft 555151 2 4 5 m 6 6 15 ft 555152 18 Troubleshooting Protected zone and safe zone when using the infrared remote control Protected safe and operating zone during the operation of the infrar...

Page 291: ...near and remote machine halt function Infrared remote control and cable Infrared remote control Near halt approx 2m approx 2m Remote halt approx 4 5m approx 20m If the operator leaves the safe zone th...

Page 292: ...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 F...

Page 293: ...able N3 infrared light emitter Check the engine according to the above procedure If the red LED is always on the N3 manual control with out a cable when any function is performed or if no LED is on wi...

Page 294: ...brate 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 I...

Page 295: ...starting ignition the display unit shows an indi cator lamp for several seconds All indicator lamps are on and every digit of the operating hours counter is dis played as 8 On this occasion check tha...

Page 296: ...is illuminated The control detected an error If the machine is not inclined and the N1 control unit was installed properly there is a problem with the con trol switching outputs control does not work...

Page 297: ...heck the jumping in the S24 place The indicator lamp is flashing rapidly The infrared light emitter is less than 3 m away from the machine The indicator is flashing slowly The infrared light emitter i...

Page 298: ...r lamp is flashing the cable is connected The red indicator lamp is continu ously on The red indicator lamp is on even if the control is activated N3 infrared light emitter No defect Charge the batter...

Page 299: ...or a maximum period of 5 s Use the following pressure gauges For high pressure min 400 bar For supply pressure min 40 bar Travel pump vibration steering pump 1 M1 supply pressure 21 2 bar can only be...

Page 300: ...e Supply pressure valve adjustable using spacers 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 A...

Page 301: ...he entire further procedure 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 lef...

Page 302: ...erformed 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 Remove the hydraulic hose 016...

Page 303: ...1575 2 1 557D024 557D025 1 557D026 1 557D027 WORKSHOP MANUAL Remove the magnetic coil 1 from the magnetic valve 2 Remove the hydraulic hose 030 Pressure close the screw connection Reinstall the magnet...

Page 304: ...n vibration Let it run for no more than 5 seconds 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 pres...

Page 305: ...Remove the 008 hydraulic hose for the supply pressure measur ing point Pressure close the screw connections 1 Remove the hydraulic hose of the B travel circuit forward for the travel pump Pressure clo...

Page 306: ...the supply pres sure measuring point 1 Start the engine Full speed Let it run for no more than 5 seconds If a supply pressure of 21 2 bar is not reached check the supply pressure valve If it is still...

Page 307: ...e while braking Let it run for no more than 5 seconds Connect a pressure gauge at least 400 bar to the MB travel pressure measuring point 1 Start the engine Full speed Drive forward while braking Let...

Page 308: ...close the screw connections 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 t...

Page 309: ...llowing operation is required when The travel pump test is positive The pressure is not reached with the connected travel mo tors Successively check individual travel motors Remove the hydraulic hoses...

Page 310: ...2 Remove the aperture Check the aperture 1 for clogging Blow clean it with compressed air Mount plugs X1 and X2 40 Nm Tighten the aperture properly when mounting it back Place the machine safely on bl...

Page 311: ...557D045 WORKSHOP MANUAL 18 2 7 1 Checking the travel pump magnetic coil travel pump servo block The travel pump magnetic coil cannot be controlled mechani cally Loosen the knurled nut Remove the magne...

Page 312: ...netic valve The valve arrow must visibly switch 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 nu...

Page 313: ...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 Pull out the connector from magnetic coils Y3...

Page 314: ...sen the apertures and screw them out The apertures must not be loose Loose apertures cause problem when driving Loose apertures can be easily removed using a small magnet Improvise as needed A view of...

Page 315: ...8 557D059 557D060 557D061 WORKSHOP MANUAL Remove the magnetic coils Screw out the magnetic valve View of the control piston The control piston is a spring type and shall always spon taneously return t...

Page 316: ...any case It must move smoothly and return easily to the zero posi tion under the force of the spring from both sides If the control piston does not move smoothly after sev eral movements or it does no...

Page 317: ...557D067 557D068 557D069 WORKSHOP MANUAL Mount the magnetic valve Install a cleaned aperture with the holder and tighten firmly Check the plug seal Lubricate the seal slightly with oil Install both plu...

Page 318: ...75 557D070 557D071 18 Troubleshooting Reinstall both magnetic coils Install the round seal ring and tighten firmly with a knurled nut Connect the cable Fasten it using a cable tie Check the function a...

Page 319: ...ont non return valve access 5 Rear non return valve access 1 Quantity divider housing 2 P connection of the B pump 3 Rear interface quantity divider B 4 Rear interface quantity divider A 5 T connectio...

Page 320: ...igh rpm 2250 150 2250 150 Supply pressure bar 21 2 21 2 Travel working pressures forward bar 100 20 100 20 reverse bar 100 20 100 20 Vibration drive pressures low amplitude bar 105 55 65 15 high ampli...

Page 321: ...e ignition 0 position Never try to immediately start the engine Prevent oil shock It can result in serious engine damage Operating fluids pose a risk to the environment Prevent fluids from leaking int...

Page 322: ...sary drain defective tanks 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 the...

Page 323: ...57D138 557D139 557D140 557D141 WORKSHOP MANUAL Remove the air filter hose at the top Remove the air filter hose at the top Remove the fuel filter Remove the fuel filter Remove the electrical sheet and...

Page 324: ...322 ARR 1575 557D142 557D143 557D144 557D145 18 Troubleshooting Screws at the back Screws at the front Remove the electrical sheet at the back front Remove the valve cap Remove the valve cap...

Page 325: ...557D148 WORKSHOP MANUAL Remove the three cables and the contact connection on the glow plugs Remove the cables and the contact connection Remove ALL three glow plugs Tools Long bit and torque spanner...

Page 326: ...ed oil is pushed out by the piston Rotate the engine on the central screw crankshaft clockwise twice using a box end ratchet spanner 1 Danger of cable burn or short circuit Insulate the glow plug cabl...

Page 327: ...install 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 Rotate the engine w...

Page 328: ...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...

Page 329: ...327 ARR 1575 WORKSHOP MANUAL 19 Appendices...

Page 330: ...328 ARR 1575 19 Appendices...

Page 331: ...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 pum...

Page 332: ...ter M1 Starter M2 Fuel pump M3 Hydraulic oil cooler N1 Machine control unit N2 Display unit N3 Infrared remote control P1 Front infrared sensor P2 Rear infrared sensor R1 Ignition coil S1 Switch ignit...

Page 333: ...TIER 4 Pegel A Pegel B Spannungsversorgung Spannungsversorgung X5 6 X5 5 X5 4 X5 3 vorne 6 5 4 3 X4 0 5A 85 30 86 87 87a 87 86 30 85 87a 18 Horn Led On GND X5 2 X5 1 2 1 1 2 3 4 5 Shield U GND CAN H...

Page 334: ...t 7 Left steering hydraulic cylinder 8 Right steering hydraulic cylinder 9 Valve block of vibration steering and brake 10 Vibration hydraulic motor front 11 Vibration hydraulic motor rear 12 Oil coole...

Page 335: ...ccm Rear right travel motor 408 ccm Front right travel motor 408 ccm Valve Block for Vibration Steering and Brake DN12 DN12 DN25 DN8 DN8 DN8 DN8 DN8 DN8 DN20 DN8 DN8 DN8 Rear vibration motor 8ccm Fro...

Page 336: ...557D657 557D584 19 Appendices 19 6 Workshop jigs 19 6 1 Special tools Assembly tool for the travel motor Assembly tool for the vibration unit Removing tool for swinging joint bearings Insertion screw...

Page 337: ...58 557D659 557D660 557D661 WORKSHOP MANUAL Assembly tool for swinging joint bearings 1175656 Pressure screws of the swinging joint bearing Spacer for pressure screws 4x Assembly pin heavy clamping pin...

Page 338: ...557D662 557D663 557D664 557D323 19 Appendices Special bit for the installation of an infrared sensor Spanner for grooved nuts for the vibration gearbox Bridge for the vibration gearbox torque meter T...

Page 339: ...7 ARR 1575 557D665 557D666 WORKSHOP MANUAL 19 6 2 Special tool for measuring the speed and frequency Revolution counter 2 90000030 19 6 3 Special tool for magnetic coil check Solenoid tester 1 1030047...

Page 340: ...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 tighteni...

Page 341: ...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 Tightening torques for plugs with flat sealing Tightening torques of plugs...

Page 342: ...340 ARR 1575 Notes...

Page 343: ...341 ARR 1575 WORKSHOP MANUAL Notes...

Page 344: ...342 ARR 1575 Notes...

Page 345: ...343 ARR 1575 WORKSHOP MANUAL...

Page 346: ...Materials and technical modifications are reserved without prior notice Book ID 4 P08000 EN Ammann Group More information on products and services can be found at www ammann com...

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