AV 80 X4 Operating manual Articulated tandem roller

156 Pages·2008·14.23 MB·English

Operating manual
Articulated tandem roller
AV 80 X4
AV 80 X4
Articulated tandem roller
Cummins Tier 2
Operating manual
Edition09/2008 EN
AV 80 X4
Articulated tandem roller
Cummins Tier 2
Operating manual
Edition09/2008 EN

Congratulations on your purchase of an AMMANN road roller. This modern compaction device is characterised
by simple operation and maintenance and is the product of many years of AMMANN experience in the field of
road roller engineering. In order to avoid faults due to improper operation and maintenance we request that
you read this operating manual with great care and keep it for later reference.
With kind regards,
Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují
%
+ 420 491 476 111 | Fax + 420 491 470 215 | [email protected] | www.ammann-group.cz
400100
This manual consists of:
I. Specification manual II. Operating instructions III. Maintenance manual
The following explanations serve to familiarise the machinist (operator) with the roller and to support him
during handling and maintenance. It is therefore absolutely necessary to provide the operator with these
instructions and to ensure that he reads them carefully before using the road roller. This aids training compre-
hension during the first use of the road roller.
Subsequent faults due to improper operating are avoided.
Adherence to maintenance instructions increases the reliability and lifetime of the machinery. It reduces re-
pair costs and down time.
AMMANN accepts no liability for continued safe functioning of the road roller if it is incorrectly operated and
/ or operating modes are employed which represent improper use.
Spare parts must meet AMMANN technical specifications. These requirements are fulfilled if only original AM-
MANN spare parts are used.
These instructions must always be kept available on the equipment.
AV 80 X4 1
Preface
Information, specifications, and recommended operation and maintenance instructions contained in this
publication are basic and final information at the time of the printing of this publication. Printer’s errors, tech-
nical modifications, and modifications of figures are reserved. All dimensions and weights are approximate
and, therefore, not binding.
Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to inform the
machine user. If you identify any differences between the machine operated by you and the information con-
tained in this publication, contact your local dealer.
Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic
a.s.
2 AV 80 X4
SYMBOLS OF THE SAFETY NOTICES IN THE OPERATION MANUAL:
The notice warns of a serious risk of personal injury or other personal hazards.
The notice warns of possible damages to the machine or its parts.
The notice warns of the necessity of environmental protection.
! WARNING !
As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indicate the sides of
the machine moving forward.
FRONT
LEFT RIGHT
REAR
400101en
AV 80 X4 3
Content
Content .............................................................................................................................................................4
1. SPECIFICATION MANUAL ......................................................................................................................9
1.1. Basic specification ................................................................................................................................10
1.1.1. Area of use ................................................................................................................................................................................................................10
1.1.2. Machine design ......................................................................................................................................................................................................10
1.2. Machine dimension scheme ................................................................................................................12
1.3. Technical data .......................................................................................................................................14
1.3.1. Weights ......................................................................................................................................................................................................................14
1.3.2. Drive of travel - driving properties ..................................................................................................................................................................14
1.3.3. The vibrations ..........................................................................................................................................................................................................14
1.3.4. Engine ........................................................................................................................................................................................................................14
1.3.5. Brakes .........................................................................................................................................................................................................................15
1.3.6. Drive ...........................................................................................................................................................................................................................15
1.3.7. Fills ...............................................................................................................................................................................................................................15
1.3.8. Sprinkling ..................................................................................................................................................................................................................15
1.3.9. Electrical installation .............................................................................................................................................................................................15
1.3.10. Hygienic parameters .............................................................................................................................................................................................16
4 AV 80 X4
OPERATING MANUAL
2. OPERATION MANUAL ..........................................................................................................................19
2.1. Major Safety Precautions .....................................................................................................................21
2.1.1. Safety Measures during Machine Operation ..............................................................................................................................................21
2.1.1.1. Compaction Work Commencement ..............................................................................................................................................................21
2.1.1.2. Work Safety Secured by User .............................................................................................................................................................................21
2.1.1.3 Ensurance of safety measures by the owner ...............................................................................................................................................22
2.1.1.4. ROPS Cab .................................................................................................................................................................................................................22
2.1.2. Reguirements on Driver’s Qualification .........................................................................................................................................................23
2.1.3. Driver’s Liabilities ...................................................................................................................................................................................................23
2.1.4. Banned Operations ...............................................................................................................................................................................................25
2.1.5. Safety inscriptions and signs used on the Machine .................................................................................................................................26
2.1.6. Hand Signals ............................................................................................................................................................................................................30
2.2. Ecological & Hygienic Principles .........................................................................................................33
2.2.1. Hygienic Principles ...............................................................................................................................................................................................33
2.2.2. Ecological Principles ............................................................................................................................................................................................33
2.3. Preservation & Storage .......................................................................................................................34
2.3.1. Short-Term Preservation & Storate for the Period of 1 ÷ 2 Months .....................................................................................................34
2.3.2. Machine Preservation & Storage for the Period Over 2 Months Long ................................................................................................34
2.3.3. De-conservation and inspection of brand new machines .....................................................................................................................35
2.4. Machine Disposal Following Its Life Termination ..............................................................................36
2.5. Machine Description ............................................................................................................................37
2.6. Controls & Dashboard Instruments ....................................................................................................38
2.7. Machine basic functions control .........................................................................................................58
2.7.1. Engine starting .......................................................................................................................................................................................................59
2.7.2. Machine travel and reversing with no vibration .........................................................................................................................................63
2.7.3. Machine travel and reversation incl. vibrations ..........................................................................................................................................69
2.7.4. Driving with vibrations on compacted and hard materials....................................................................................................................69
2.7.5. Compacting near constructed facilities .........................................................................................................................................................69
2.7.6. How to stop the Machine and its engine ......................................................................................................................................................71
2.7.7. Safe stopping of the Machine ...........................................................................................................................................................................71
2.7.8. Emergency stop of the Machine ......................................................................................................................................................................73
2.7.9. Machine shutdown ...............................................................................................................................................................................................73
2.7.10. Sprinkling ..................................................................................................................................................................................................................73
2.7.11. How to lift and let down the engine bonnet ...............................................................................................................................................74
2.8. Machine transport ................................................................................................................................75
2.8.1. Machine towing......................................................................................................................................................................................................75
2.8.2. How to load the Machine ....................................................................................................................................................................................77
2.8.3. Transporting by the road ....................................................................................................................................................................................78
2.9. Special conditions to use the Machine ...............................................................................................79
2.9.1. How to operate the Machine during its running-in ..................................................................................................................................79
2.9.2. Operating the Machine at low temperatures ..............................................................................................................................................79
2.9.3. Machine operation at high temperatures and humidity .........................................................................................................................79
2.9.4. Machine operation at high altitudes ..............................................................................................................................................................79
2.9.5. Machine operation within very dusty environment .................................................................................................................................79
AV 80 X4 5
Content
3. MAINTENANCE MANUAL ....................................................................................................................83
3.1. Safety and other measures for machine maintenance ......................................................................85
3.1.1. Safety of machine maintenance .......................................................................................................................................................................85
3.1.2. Fire precautions during operation media exchanges...............................................................................................................................85
3.1.3. Ecological and hygienic principles ..................................................................................................................................................................86
3.2. Media specification ..............................................................................................................................87
3.2.1. Engine oil ................................................................................................................................................................................................................87
3.2.2. Fuel .............................................................................................................................................................................................................................88
3.2.3. Hydraulic oil ............................................................................................................................................................................................................88
3.2.4. Lube grease .............................................................................................................................................................................................................89
3.2.5. Coolant ......................................................................................................................................................................................................................89
3.2.6. Glass washer fluid .................................................................................................................................................................................................90
3.3. Media ....................................................................................................................................................91
3.4. Lubrication and Maintenance Chart ...................................................................................................92
3.5. Lubrication Chart ..................................................................................................................................94
3.6. Lubrication and Maintenance Operations ..........................................................................................95
Following the 20 hours of operation or daily .....................................................................................96
3.6.1. Inspect, refill the oil amount in the engine ..................................................................................................................................................96
3.6.2. Inspect, replenish the engine coolant amount ...........................................................................................................................................97
3.6.3. Inspect the engine belt .......................................................................................................................................................................................98
3.6.4. Crankcase breather ...............................................................................................................................................................................................98
3.6.5. Inspect air filter vacuum valve ..........................................................................................................................................................................99
3.6.6. Inspect fan condition ...........................................................................................................................................................................................99
3.6.7. Check fuel amount .............................................................................................................................................................................................100
3.6.8. Inspect oil amount in the hydraulic circuit tank .....................................................................................................................................101
3.6.9. Fill up sprinkling water tank ...........................................................................................................................................................................101
3.6.10. Inspect alarm and control devices ................................................................................................................................................................102
Following 250 hours of operation (after 3 months) .........................................................................104
3.6.11. How to exchange motor oil and oil filter ....................................................................................................................................................104
3.6.12. Inspect engine induction manifold ..............................................................................................................................................................106
3.6.13. Inspect engine cooling circuit ........................................................................................................................................................................107
3.6.14. Inspect the battery .............................................................................................................................................................................................108
3.6.15. Inspect the function of air filter vacuum switch ......................................................................................................................................110
3.6.16. Sprinkling filter & sprinkler strainer..............................................................................................................................................................111
3.6.17. Machine lubrication ...........................................................................................................................................................................................112
3.6.18. How to replace fuel filter .................................................................................................................................................................................114
3.6.19. Inspect coolant concentration ......................................................................................................................................................................114
Following 1000 hours of operation (after 1 year) ............................................................................115
3.6.20. Inspect engine belt ............................................................................................................................................................................................115
3.6.21. Inspect the exhaust system .............................................................................................................................................................................115
3.6.22. Inspect the silencing system ..........................................................................................................................................................................116
3.6.23. Clean the water tank ..........................................................................................................................................................................................117
6 AV 80 X4