Page 1
Workshop Manual
Pneu tyred roller
AP 240
Page 2
Page 3
AP 240
Pneu tyred roller
Cummins Tier 2
Workshop manual
01/2011
From Serial No.
ENEdition
3742050
Page 4
Page 5
Preface
Information, specication or recommended instructions to assemble or disassemble individual parts of sections of the Machine as included in this publication represent basic and nal information at the time this publication has been printed. Any printing errors, technical alterations or illustration changes are reserved. All the
dimensions and weights are approximate and therefore unbinding.
Ammann Czech Republic a.s. reserves the right to make changes any time with no obligation to inform Machine user. In the event any dierences are found between the Machine used by you and the data given in this
publication, please contact your dealer.
Any reprinting or dissemination of any type shall be preconditioned by a written consent from Ammann Czech
Republic a.s.
Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují
+ 420 491 476 111 | Fax + 420 491 470 215 | info@ammann-group.com | www.ammann-group.com
%
1AP 240
Page 6
Contents
Preface ....................................................................................................................................................................................................................1
Contents ...........................................................................................................................................................2
1. Introduction ..............................................................................................................................................7
2. Safety precautions and instructions .....................................................................................................11
3. Review of applications ...........................................................................................................................19
4. Roller description ...................................................................................................................................21
5. Engine ......................................................................................................................................................25
5.1. Specications ......................................................................................................................................................................................26
5.1.1. Engine ..................................................................................................................................................................................... 26
5.1.2. Motor oils and grease used ............................................................................................................................................. 26
5.1.3. Coolant ...................................................................................................................................................................................27
5.2. Disassembly of the engine .............................................................................................................................................................28
5.3. Installation of the engine ................................................................................................................................................................ 33
5.4. Radiator disassembly and assembly ........................................................................................................................................... 34
5.5. Locating engine defects .................................................................................................................................................................. 35
5.6. Location of CLARK gearbox defects ............................................................................................................................................ 37
5.7. Fixtures ..................................................................................................................................................................................................38
6. Rear axle ..................................................................................................................................................39
6.1. Technical data - description ...........................................................................................................................................................40
6.1.1. Description ............................................................................................................................................................................ 40
6.1.2. Technical specications .................................................................................................................................................... 43
6.1.3. Torque ..................................................................................................................................................................................... 43
6.1.4. Lubricants and glues .........................................................................................................................................................44
6.2. Possible defects and remedies ......................................................................................................................................................44
6.3. Disassembly of axle ........................................................................................................................................................................... 45
6.3.1. Preparations ..........................................................................................................................................................................45
6.3.2. Axle disassembly from the machine ............................................................................................................................ 45
6.3.3. Disassembly of axle ............................................................................................................................................................ 47
6.3.4. Disassembly of drive housing ........................................................................................................................................48
6.3.5. Cleaning and inspecting parts ....................................................................................................................................... 51
6.4. Axle assembly ...................................................................................................................................................................................... 52
6.4.1. Drive housing assembly ...................................................................................................................................................52
6.4.2. Dierential assembly ......................................................................................................................................................... 58
6.4.3. Assembling axle to the machine ................................................................................................................................... 60
6.5. Fixtures ..................................................................................................................................................................................................61
2 AP 240
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3AP 240
WORKSHOP MANUAL
7. Front axle ................................................................................................................................................63
7.1. Technical data...................................................................................................................................................................................... 64
7.1.1. Specications .......................................................................................................................................................................64
7.1.2. Lubricants and glues ..........................................................................................................................................................64
7.2.
Axle disassembly - valid up to the serial number 1189 ........................................................................................................ 65
7.2.1. Disassembly of axle from the equipment .................................................................................................................. 66
7.2.2. Disassembly of guiding pipe of the front axle .........................................................................................................67
7.2.3. Disassembly of fork ............................................................................................................................................................ 68
7.2.4. Cleaning and inspection of parts .................................................................................................................................. 70
7.3. Installation of front axle - valid up to the S/N 1189 ............................................................................................................... 71
7.3.1. Installation of guiding pipe and fork ........................................................................................................................... 71
7.3.2. Assembly of wheel hubs and shaft ............................................................................................................................... 73
7.3.3. Assembly of fork and shaft assembly with wheel hubs ........................................................................................ 75
7.4. Fixtures - valid up to the S/N 1189 ...............................................................................................................................................77
7.5. Assembly of axle to the machine ................................................................................................................................................. 81
7.6. Front Axle Disassembly - valid for rollers from serial number 1190 ................................................................................82
7.6.1. How to remove front axle from the Machine ............................................................................................................ 83
7.6.2. Dismantling wheel hubs, bearings, gufero rings ..................................................................................................... 86
7.6.3. Replace front axle’s sealants ............................................................................................................................................ 88
7.6.4. Assembling wheel hubs and bearings .....................................................................................................................100
7.7. Fixtures - valid for version from serial number 1190 ...........................................................................................................108
8. Flexible shaft .........................................................................................................................................113
8.1. Specications ....................................................................................................................................................................................115
8.1.1. Torque ...................................................................................................................................................................................115
8.1.2. Grease ...................................................................................................................................................................................115
8.2. Disassembly and re-assembly .....................................................................................................................................................115
8.2.1. Preparatory work ...............................................................................................................................................................115
9. Steering .................................................................................................................................................117
9.1. Specications - description ..........................................................................................................................................................119
9.1.1. Technical data ....................................................................................................................................................................119
9.1.2. Lubricants and glues ........................................................................................................................................................119
9.2. Possible defects and remedies ....................................................................................................................................................120
9.3. Disassembly and assembly of the steering assembly .........................................................................................................121
9.3.1. Preparatory work ...............................................................................................................................................................121
9.3.2. Disassembly of steering hydraulic generator U10 ...............................................................................................121
9.3.3. Disassembly of power steering ....................................................................................................................................122
9.3.3.1. Disassembly of steering column .................................................................................................................................122
9.3.4. Disassembly of linear hydraulic motor ......................................................................................................................123
9.3.5. Removal of power steering tank .................................................................................................................................128
9.3.6. Removal and installation of the lever assembly ...................................................................................................128
9.4. The front - axle alingment - valid up to the serial number 1189 ....................................................................................130
9.5. The front - axle alingment - valid for rollers from S/N 1190 ..............................................................................................131
9.5.1. Filling the hydraulic cylinders .......................................................................................................................................133
9.6. Fixtures ................................................................................................................................................................................................134
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4 AP 240
Contents
10. Service brake.........................................................................................................................................135
10.1. Specications ....................................................................................................................................................................................136
10.1.1. Description ..........................................................................................................................................................................136
10.1.2. Specications .....................................................................................................................................................................137
10.1.3. Brake uid ............................................................................................................................................................................139
10.2. Defects .................................................................................................................................................................................................139
10.3. Disassembly and installation ......................................................................................................................................................141
10.3.1. Preparations ........................................................................................................................................................................141
10.3.2. Disassembly of pedal brake .........................................................................................................................................141
10.3.3. Disassembly of booster...................................................................................................................................................142
10.3.4. Disassembly of brake system ........................................................................................................................................143
10.4. Brake shoes adjustment ................................................................................................................................................................144
10.5. Service brake venting .....................................................................................................................................................................145
10.6. Machining brake drums .................................................................................................................................................................146
11. Parking brake ........................................................................................................................................147
11.1. Specications - description ..........................................................................................................................................................149
11.1.1. Description ..........................................................................................................................................................................149
11.1.2. Specications .....................................................................................................................................................................149
11.2. Maintenance ......................................................................................................................................................................................149
11.2.1. Disassembly and installation of the disk brake ......................................................................................................150
11.2.2. Removal and installation of the spring-loaded cylinder ....................................................................................151
12. Inating the tires ..................................................................................................................................153
12.1. Specications ....................................................................................................................................................................................155
12.1.1. Description ..........................................................................................................................................................................155
12.1.2. Specications .....................................................................................................................................................................155
12.2. Removal and installation ...............................................................................................................................................................156
12.2.1. Control valve .......................................................................................................................................................................156
12.2.2. Rotor .....................................................................................................................................................................................156
13. Wheels ...................................................................................................................................................157
13.1. Specications ....................................................................................................................................................................................159
13.1.1. Description ..........................................................................................................................................................................159
13.1.2. Specications .....................................................................................................................................................................159
13.2. Removal of wheels ...........................................................................................................................................................................160
13.2.1. Preparation for work ........................................................................................................................................................160
13.2.2. Front axle wheels ..............................................................................................................................................................160
13.2.3. Rear axle wheels ................................................................................................................................................................161
13.3. Removal and installation of tires ................................................................................................................................................161
13.4. Installation of wheel to the machine ........................................................................................................................................161
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WORKSHOP MANUAL
14. Electrical wiring ....................................................................................................................................163
14.1. Description .........................................................................................................................................................................................165
14.1.1. Battery breaker ..................................................................................................................................................................165
14.2. Battery ..................................................................................................................................................................................................166
14.2.1. Specications .....................................................................................................................................................................166
14.2.2. Operation .............................................................................................................................................................................166
14.2.3. Indications of full charge ................................................................................................................................................166
14.2.4. Service during operations .............................................................................................................................................167
14.2.5. Safety regulations .............................................................................................................................................................167
14.3. Alternator ............................................................................................................................................................................................168
14.3.1. Checking the alternator on the roller ........................................................................................................................168
14.3.2. Determining defects of alternator-regulator ..........................................................................................................169
14.3.3. Voltage regulator ..............................................................................................................................................................169
14.4. Starter ...................................................................................................................................................................................................170
14.4.1. Operation and maintenance .........................................................................................................................................170
14.4.2. Check of idling – on the machine ...............................................................................................................................170
14.4.3. Starter defects ....................................................................................................................................................................171
15. Annexes .................................................................................................................................................173
Bolted connection checking, tightening ..............................................................................................................................................174
Wiring Diagram (to S/N 1908)
Wiring Diagram (for S/N 1909÷1970)
Wiring Diagram (for S/N 1971÷3742036)
Electric installation scheme (from S/N 3742037)
Layout of wiring elements in the Machine
Hydraulics Diagram
Air Distribution System
Hand Signals
.......................................................................................................................................................................................195
....................................................................................................................................................................................................198
...................................................................................................................................................................176
.....................................................................................................................................................180
..............................................................................................................................................184
...............................................................................................................................188
...........................................................................................................................................192
................................................................................................................................................................................196
Page 10
6 AP 240
Page 11
1. Introduction
WORKSHOP MANUAL
7AP 240
Page 12
8 AP 240
1. Introduction
The roller, series AP 240, is designed for compacting operations of medium to large magnitudes in the construction of highways, railroads, airports, dams, industrial tracts, harbors, etc. Specications of the machine,
weight, tire sizes, turning radius, leveling of front wheels, and the rst-rate engine, provide for an ecient
roller with very good output, high reliability, and safety in operations. The fact that the ination of tires can be
adjusted continuously allows for compacting of all kinds of materials in a wide range of consistency, and for
the optimal adaptation of the roller.
The roller is well suited for compacting asphalt mixtures, hydraulically compacted mixtures, clay soils, and soil
mixtures of sand and gravel. However, it is nor suited for rocklls.
The roller operates under conditions specied in standards ČSN IEC 721-2-1 (038900): WT, WDr, MWDr - that is
mild, warm and dry, hot and dry environment at temperatures of –15 °C (5 °F) to 45 °C (113 °F).
The roller is manufactured to most modern rules and standards of work safety.
There exists danger of damage or injury, should the roller be applied incorrectly, by untrained personnel, or
for other than specied purposes.
The main purpose of this manual is to provide basic information for the disassembly, assembly, and service
of the main construction elements of the roller. The manual consists of separate chapters in reference to the
catalogue of spare parts, and contains data on assembly, adjustment, and instructions for the application of
special tools and xtures.
The manufacturer improves the product continually under application of the most recently gained experience
and know-how, and for that reason, reserves the right to install modications that have not been included in
the pictures, descriptions, and/or construction details of this manual.
This Manual is copyrighted and it is not permitted to copy and distribute it or its parts.
The text in this Manual refers to right, left, forward, or backward from the direction of forward travel.
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9AP 240
WORKSHOP MANUAL
FRONT
REAR
RIGHT
LEFT
37402A
This symbol indicates serious personal hazard or injury.
This symbol indicates the potential of damage to the Machine or its parts.
This symbol indicates necessity of environmental protection.
This Manual uses the terms like RH, LH, in the front, in the rear. These indicate the sides
of the Machine viewed during forward drive.
SAFETY SYMBOLS APPLIED:
! CAUTION !
Page 14
10 AP 240
Page 15
2. Safety precautions and instructions
WORKSHOP MANUAL
11AP 240
Page 16
12 AP 240
2. Safety precautions and instructions
These safetyregulations must be obeyed by all that maintain the roller!
The roller may be maintained only by a trained, certied, and experienced professional, or by the Ammann Service. •
Maintenance should always follow our Service Shop Manual. Each chapter contains special instructions for proper maintenance
•
procedures.
Before using the roller, become acquainted with the Driver’s Manual, and make sure that you understand the equipment of the
•
roller completely.
Never use the machine, unless you understand all control elements and the operation of the roller.
•
Become acquainted with the site, where you work.
•
Do not re-build or modify the roller, since the stability of the machine may be disturbed.
•
Original parts and accessories have been designed especially for the roller
•
Installation and use of spare parts not supplied with the roller or not authorized by the manufacturer may have a detrimental eect
•
on the operation and safety of the machine.
Safety precautions for repair and inspection of the machine
Wear work clothes and shoes. •
When handling oil, fuel, and/or coolant always wear gloves.
•
Wear glasses or goggles, when handling batteries.
•
Situate the roller on a at, rm ground before you start repair. Wedge the machine.
•
Secure the frame and the drum against turning against each other by a safety pin and a push rod.
•
Remove the key from ignition, disconnect batteries, and let hot parts cool o.
•
Attach a warning label ”The Machine is being repaired” on the steering wheel and leave it there until nished.
•
Wash the roller thoroughly. If using hot steam, avoid direct stream aecting electrical components and insulation, or cover it be-
•
forehand.
During assembly and service repair of particular assemblies, keep them clean. Protect removed parts from dirt.
•
Clean removed parts and provide dust-free shop area with a necessary area for depositing parts.
•
Be careful with cleaners. Do not use gasoline or other ammables!
•
Dry cleaned parts and apply anti-corrosion oil – never use corroded parts!
•
All tools, hoists, supports and other xtures must be in a useable shape and condition.
•
Hoists, cables, and chains should be of sucient carrying capacity, and undamaged.
•
Provide sucient air supply, when starting the engine in closed areas.
•
Before starting the roller, make sure that nobody is in the vicinity. The start of the engine must be announced by a warning sound
•
beforehand and after every pause before the roller starts moving. Persons on the machine or its vicinity must leave after the sound.
Sound, light, and hand signals should be used as specied in ČSN 27 7012 standard, Appendix no.1.
Do not adjust while moving.
•
During work on a running engine, avoid contact with hot and rotating parts of the roller. Adjustments in such cases must be done
•
while another person is nearby, who has access to emergency switches and is in continuous contact with the service person, so
that the engine could be turned o immediately when needed.
Use only specied types of motor, transmission, and hydraulic oils, and coolant.
•
Page 17
13AP 240
WORKSHOP MANUAL
Safety rules for work on hydraulic loops
Check, whether hydraulic loops are not under pressure, before disassembly. Hydraulic oil seeping under pressure may injure your •
skin and cause serious injury.
Mark all parts, hoses, and pipes before removal.
•
Do not run hydraulic generator and hydraulic motor with oil.
•
Hot oil may burn the skin.
•
Do not heat oil to temperatures above 160 °C - oil or its vapors may catch re.
•
For wiping and cleaning of hydraulic parts use lint-free rags.
•
For assembly and installation of parts use hydraulic oil as lubricant – not grease.
•
Clean thoroughly all threads, hoses, and pipes, wash them and blow with pressurized air.
•
Use only new seals.
•
Fill devices with hydraulic oil before installation.
•
Following the replacement of a hydraulic device, ush the hydraulic loop and the tank.
•
Replace the oil lter cartridge.
•
Fill the hydraulic loop with clean oil of prescribed viscosity, only when the engine is o.
•
Wipe o spilled oil.
•
Check the tightness of joints for seeping oil before the system is pressurized.
•
Finally, check all joints and connections.
•
Do not adjust safety valves.
•
Install all safety elements before nishing work.
•
While running check
Oil level in the hydraulic tank. •
Fill pressure of hydraulic generators and safety valves pressure.
•
Test at 40 °C (104 °F).
•
Page 18
14 AP 240
2. Safety precautions and instructions
Safety precautions when working of the fuel system
Gasoline and diesel fuel mixtures are as ammable as pure gasoline
Do not ll in closed areas
•
Wipe o spilled fuel
•
During work do not use open ame and do not smoke! Danger of re!
•
Safety precautions when working on electrical wiring
Disconnect batteries when repairing the charging circuit to avoid accidental shorts. •
When disconnecting, remove rst the negative pole and then the positive.
•
Do not disconnect while the engine is running.
•
Connect the negative pole to chassis, and the positive pole to the alternator output B+. Otherwise, the entire semiconductor circuit
•
would be damaged.
When starting from an auxiliary external source, do not disconnect the source before the battery is in. Watch for the voltage of the
•
source – 24V.
Do not run the alternator without load. Conductor on terminal B+ should be on and terminal D+ as well.
•
Do not check for voltage by touching conductor against the chassis.
•
Do not produce sparks.
•
Use rubber gloves and eye protection, when working with the battery.
•
Protect your skin and clothing against the electrolytic and lead particles.
•
Should electrolyte enter your eye, wash the eye thoroughly for a few minutes with water. Thereafter, see your doctor as soon as
•
possible.
After coming in contact with the electrolyte on your skin or clothing, disrobe, wash o the aected spot by soapy water or soda
•
solution, and see your doctor.
If you swallowed electrolyte, drink a large quantity of milk or dissolved magnesia in water, and see your doctor.
•
Never add distilled water in the cells, unless followed by a charging process, in the machine or outside. Involuntary discharge
•
would follow otherwise.
Never ll with sulfuric acid (H
•
Battery shouldn’t be turned upside. The electrolyte would start seeping through aerating holes.
•
Use water and lime to neutralize spilled electrolyte.
•
When batteries are being charged, the emanating hydrogen mixes and air create a highly explosive mixture. Do not approach with
•
open ame, and do not smoke.
2SO4
)!
Page 19
15AP 240
WORKSHOP MANUAL
Welding on the machine
Before electrical arc welding on the machine, all components containing semiconductors must be disconnected from the
alternator
-
operating hours counter
-
travel and shifting electronic assemblies
-
Ground the source and the machine
-
protect the source against moisture
-
place the ground terminal as close as possible to the weld.
-
During welding, protect plastic tubes WABCO Tecalan in the air loop, and Schlemmer plastic hoses in
the electrical circuit.
The maximum permissible temperature for the WABCO tubes without pressure is 130 °C (266 °F) for 60
minutes.
When welding a part on a machine attached to a hoist, the tying spot must be isolated or a non-conductive tie should be used, like a cable of organic material, to prevent the current from owing through
the hoist.
Seals
Always use new seals. •
Sets of seals are available as spare parts.
•
Torque
Use torque wrench for tightening bolts to the correct torque. •
Bolts and nuts are tightened to the correct torque listed in the table.
•
The correct type of bolt is visible on the head.
•
Other torque values are specied in applicable chapters.
•
Threaded connections in hydraulic loops are tightened according to tables.
•
Specied torque values are valid for not lubricated screws.
•
Use only new self-locking nuts.
•
Page 20
16 AP 240
2. Safety precautions and instructions
Ecological and health provisions
In repairing the machine, observe rules of environment and health protection, laws, notices, and regulations valid in the territory of
use.
Health provisions
Oil products, coolants, battery content, and lacquers with thinners are injurious to health, and may cause severe injuries when in •
contact with the body.
It is therefore necessary to observe safety and health protection instructions and use personal protection when handling these
•
products.
Workers handling these products must obey general rules of protection and follow instructions issued by the manufacturers of
•
such products.
We draw your attention primarily to
•
eye and skin protection when handling batteries
-
skin protection when handling oil products, lacquers, and coolants
-
washing your hands after work and before meals, application of special skin creams
-
instructions supplied with the cooling systems.
-
Keep oil products, coolants, battery lls, lacquers with thinners, cleaning and preservation chemicals in original containers prop-
•
erly described on the outside. Do not allow their storage in unmarked bottles and other containers to avoid danger of substitution,
mainly for food or drink.
Should the skin, mucous membranes, or eyes come in contact, or should vapors be inhaled, apply rst aid immediately. In case of
•
accidental consumption, see your doctor immediately.
Ecological provisions
Contents of some systems and some of the parts become waste bearing risks to the environment, when discarded. •
This category includes mainly
•
organic and synthetic lubricants, oils, and fuel
-
coolants
-
batteries and their contents
-
cleaning and preservation chemicals
-
all removed lters and cartridges
-
all removed hydraulic and fuel hoses, rubberized metal parts, and other parts soiled by above-mentioned chemicals.
-
Such parts and chemicals must be handled in accordance with national standards for the protection of the environment and
•
health.
When replacing hydraulic, fuel, and cooling systems, seepage of liquids in the ground must be prevented by suitably placing catch
•
basins underneath, and openings must be plugged.
Apply sawdust, Vapex, etc. to places of seepage in the ground.
•
Remove soiled ground to prevent continuous seepage, and transfer contaminated soil to further liquidation.
•
Page 21
17AP 240
WORKSHOP MANUAL
Fire prevention
The place for oil changes must be situated away from areas with danger of explosion or re. •
Such place must be provided with information boards forbidding smoking and open ame.
•
The working area must be of a size large enough to contain the contents of the largest fuel container.
•
It must be equipped with a portable re extinguisher.
•
For handling oils and diesel fuel use metal barrels, cans, and/or metal pails.
•
Such vessels must be properly closed in storage.
•
Cans with one opening must be stored with the opening up, and protected against dripping.
•
The cans must be indelibly described as to contents and re danger class.
•
Special tools and xtures as listed in specic chapters of the manual.
Page 22
18 AP 240
Page 23
3. Review of applications
WORKSHOP MANUAL
19AP 240
Page 24
20 AP 240
374N001
374N002
3. Review of applications
The serial and type numbers are important for the identication of the machine in case of warranty claim. The label with the
main machine data is attached on the left side of the frame.
The label with Cummins engine and other data is attached to
the injection drive and steering pump case.
Serial numbers and data of subcontracted aggregates are to be
found stamped in them.
Page 25
4. Roller description
WORKSHOP MANUAL
21AP 240
Page 26
22 AP 240
4. Roller description
The AP 240 roller is constructed on a welded box frame. The frame contains the engine with a three-speed reversible gearbox with
torque converter. The gearbox is connected by a exible shaft to the rear axle with the dierential and brakes. Steered telescopic axle
without brakes is mounted in the front section of the frame. The front and rear axles are suspended so that the wheels of one axle
overlap the space between the wheels of the other axle longitudinally. Steering is hydraulic by means of steering rods and levers
controlled by a linear hydraulic motor, which is supplied with pressurized oil from a geared hydraulic generator over power assisted
steering assembly controlled by the steering wheel. Operating brakes are hydraulic, drum-type, with pressurized hydraulic power assistance on the rear wheels. The driver’s compartment has two seats xed to the frame, and is equipped with dual steering, travel and
other controls. The driver’s compartment is protected by a cabin, or a guard railing sheltered by a roof.
Accessories:
Guard railing ROPS
protects the driver in case of roller upset. See data on label.
Dierential lock
improves the movement of the roller in dicult terrain (on inclines) with low adhesion, when driving up a loading platform, in assisting
in emergency situations, etc.
Additional load - 4,5 t (9922 lb)
Weight assisting plates (5 pieces) installed underneath the frame between the wheels.
Wheel covers
Insulating wheels by means of covers installed on the frame when compacting asphalt surface.
Page 27
23AP 240
WORKSHOP MANUAL
Specications
Engine
Manufacturer CUMMINS Engine Company, Inc.
Type BT4.5 C 99
Number of cylinders 4
Power to ISO 3046/1, DIN 6271 kW (HP) 74 (99)
Nominal revolutions min-1 (RPM) 2200
Water-cooled
Engine complies with emission regulations Dir 97/68/EU Stage 2
EPA/CARB 40 CFR Part 89 Tier 2
Operating weights to iso 6016
Roller, cabin, ROPS, wheel covers kg (lb) 10590 (23347)
Max. total weight kg (lb) 24000 (52910)
Weight according to ISO 6016 is weight of the machine with maximum lling of fuel, lubrication, water tank of sprinkling and operator’s weight 75 kg (165 lb).
Other weight data for specic types of machine listed in Specications Manual, Chapter 1.3.1.
Overall dimensions
Total length mm (in) 4775 (188)
Total width mm (in) 2265 (89,2)
Axle base mm (in) 3500 (137,8)
Height incl. cabin mm (in) 3040 (119,7)
Clearance mm (in) 300 (11,8)
Page 28
24 AP 240
4. Roller description
Driving properties:
Speed in both directions in specic gears
I. gear km/h 0 - 5
MPH 0 - 3,1
II. gear km/h 0 - 11
MPH 0 - 6,8
III. gear km/h 0 - 19
MPH 0 - 11,8
Climbing with full load % 25
Turning radius left right
Inside track mm (in) 5350 (210,6) 5800 (228,3)
- outside mm (in) 8150 (320,9) 8250 (324,8)
Contour inside mm (in) 5350 (210,6) 5580 (219,7)
- outside mm (in) 8350 (328,7) 8630 (339,8)
Fluid content:
Motor oil in crankcase l (gal US) 15,5 (4,1)
Oil in gearbox l (gal US) 21,5 (5,68)
Oil in dierential l (gal US) 13,5 (3,57)
Oil in end gearbox l (gal US) 2x5,2 (2x1,4)
Oil in hydraulic steering l (gal US) 6,5 (1,72)
Oil in telescopic front axle l (gal US) 6 (1,6)
Fluid in brakes l (gal US) 0,75 (0,2)
Diesel fuel in tank l (gal US) 250 (66)
Water in tires sprinkling tank l (gal US) 285 (75)
Electrical wiring
Voltage V 24
Batteries Ah 2 x 100
Page 29
WORKSHOP MANUAL
5. Engine
25AP 240
Page 30
26 AP 240
5. Engine
5.1. Specications
5.1.1. Engine
Manufacturer Cummins Engine Company, Inc.
Engine model BT4.5 C 99
Type of engine diesel, water-cooled
Number of cylinders 4
Bore mm (in) 102 (4,02)
Lift mm (in) 138 (5.42)
Lift volume cm3 (cu in) 4500 (275)
Engine power to ISO 3046/1, DIN 6271 kW (HP) 74 (99)
Nominal revolutions 1.min–1 (RPM) 2200 (2200)
Max. tightening moment Nm (ft lb) 414 (305) / 1500 min-1 (RPM)
Engine complies with emission regulations Dir 97/68/EU Stage 2
EPA/CARB 40 CFR Part 89 Tier 2
State always the serial number of the applicable engine when ordering spare parts.
5.1.2. Motor oils and grease used
Motor oil
Oil in the engine Make
Quantity [l] 16,4 Benzina Mobil ESSO SHELL CASTROL
Quantity [gal US] 4,4 M7ADS III
Grease
Synthetic grease containing lithium to NLGI-2* (National Lubricating Grease Institute, part 2) must be used.
Grease – make
BENZINA MOBIL ESSO SHELL CASTROL
P-ML-A2 Mobilgrease MP
Mobilgrease Special
Mobilplex EP-1
Multi-Purpouse
Grease H
API C7- SGE, ACEA E1-E2, CCMC D2-D3
SAE 15 W/40
Retinax A
Alvania
Grease No.3
Castrolease LM
Spherol
Grease RBB2
Page 31
27AP 240
WORKSHOP MANUAL
5.1.3. Coolant
For cooling the engine use coolant containing 50% of ethylene-glycol antifreeze and 50% water, see table, down to –37 °C (–35 °F) year
round. Use coolant containing antifreeze even in regions where temperature doesn’t drop below 0 °C (32 °F). The coolant doesn’t only
protect the cooling system against freezing, but also increases the boiling point. The inhibitors in the antifreeze protect parts of the
cooling system of the engine, and extend their life. In addition, propylene antifreeze may be used in the cooling system. The content
of the ethylene glycol or propylene glycol antifreeze must be at least 40% of the coolant.
Mix the coolant by adding antifreeze to water. Use water that complies with the rules of the following table:
Water parameters min. max.
pH - factor at 20 °C (69 °F) 6,5 8,5
3
content of chlorides (mg/dm
content of sulfates (mg/dm
total hardness (°dGH) 3 12
Antifreeze must contain anti-corrosive ASTM 4985.
The content of antifreeze in the coolant at dierent temperature levels is indicated in the following table:
Ethylene-glycol antifreeze
40 % = -23 °C (-10 °F)
50 % = -37 °C (-35 °F)
60 % = -54 °C (-65 °F)
68 % = -71 °C (-90 °F)
Propylene-glycol antifreeze
40 % = -21 °C (-6 °F)
50 % = -33 °C (-27 °F)
60 % = -49 °C (-56 °F)
68 % = -63 °C (-82 °F)
) - 100
3
) - 100
Do not use more than 50% of antifreeze in the coolant, unless absolutely necessary.
Never use more than 68 %!
Use antifreeze that is environment friendly.
Antifreeze uids are formulated on dierent bases.
We do not recommend mixing them, since deterioration of their anti-corrosive properties may result.
When mixing nitride-based antifreeze with amino based uids, the resulting nitric amine is injurious
to health.
Check the content of antifreeze in the coolant prior to the arrival of winter, using densimeter.
Page 32
28 AP 240
374N049
1
374N050
374N048
4
5. Engine
5.2. Disassembly of the engine
Perform all work prior to and during disassembly and assembly in accordance with the introductory chapter on Safety, and
comply with ecological and health protection rules and regulations.
Preparatory work
•
Place the machine horizontally on a rm surface.
Wedge front wheels on both sides.
•
Turn the battery breaker o – brakes are automatically ap-
•
plied.
Place a sign on the steering wheel
• “MACHINE BEING RE-
PAIRED”.
Remove the protective frame ROPS
Remove cover plates 1 behind the seat in front of the fuel
•
tank.
•
Install lifting loops on ROPS frame, hook up by hoist of at
least 450-kg carrying capacity.
•
Unfold lid 4.
Page 33
87AP 240
424616
A
A
3
424617
424618
424637
WORKSHOP MANUAL
Dismantle hubs 5 with no need to remove axle from the Machine.
Remove step by step the guards 30, 31, tyre inating pipe, dismantle rotors, support the axle 3, and remove calipers A.
Note
Under hub the ring 23 has been secured with pin 19.
Unlock and remove step by step the washers 17 and nuts 16.
Pull the hub with opening lever (claw).
Drive out (eject) gufero rings 11, 12 from the hub, from its both
sides.
Drive out bearings’ inner rings 9, 10.
Page 34
88 AP 240
2
B
(200)
B-B
B
3
4
5
6
7
9
10
11
8
8
9
1
424500_22
7. Front axle
7.6.3. Replace front axle’s sealants
Page 35
122 AP 240
374099
374100
1
374101
1
1
374102
2
9. Steering
9.3.3. Disassembly of power steering
Remove lid from the panel. •
Disconnect hoses from power steering, before that, note the
•
connection of hoses.
Remove power steering from the steering column.
•
Re-assemble in reverse order.
•
9.3.3.1. Disassembly of steering column
Remove cover in the center of the column. •
Remove nut (1), insert xture no.1 under the wheel, and
•
with the spanner remove the wheel.
•
Remove collar of travel control (1).
•
After screws (2) were removed, separate power steering, and
remove steering column from the bottom.
Assemble in reverse order. Grease grooved shaft of the col-
•
umn, to 9.1.3.
Page 36
123AP 240
374103
4
59
60
374104
374105
59
60
4
3
WORKSHOP MANUAL
9.3.4. Disassembly of linear hydraulic motor
Removal from machine
•
Place the roller on rm, at surface, and a catch basin under
the hydraulic cylinder.
Remove high-pressure hoses.
•
•
Remove safety rings 59 and nipples 60 on the pins. Knock
out pins, slide the hydraulic motor from the steering lever
and bracket.
Page 37
203AP 240 203AP 240
WORKSHOP MANUAL
Notes
Page 38
204 AP 240
15. Annexes
Notes
204 AP 240
Page 39
Page 40
Ammann Schweiz AG
Eisenbahnstrasse 5
CH-4901 Langenthal
www.ammann-group.com Printed in Czech Republic
Ammann Verdichtung GmbH
Josef-Dietzgen-Strasse 36
D-53773 Hennef
Rammax Maschinenbau GmbH
Gutenbergstrasse 33
D-72555 Metzingen
Ammann Czech Republic a.s.
Náchodská 145
CZ-54901 Nové Město nad Metují
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