Operating Manual Articulated Tandem Roller

Operating manual
Articulated tandem roller

AV 80 X4
AV 80 X4
Articulated tandem roller
Cummins Tier 2
Operating manual
Edition 09/2008 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 | info@ammann-group.cz | 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
OPERATING MANUAL
Following 2000 hours of operation (every 2 years)..........................................................................118
3.6.24. Inspect, adjust engine valve clearance........................................................................................................................................................ 118
3.6.25. Engine coolant exchange................................................................................................................................................................................. 121
3.6.26. How to exchange oil in the vibrators and bearings of the drums...................................................................................................... 124
3.6.27. How to exchange hydraulic oil and filters.................................................................................................................................................. 125
Maintenance as required....................................................................................................................129
3.6.28. Fuel system breathing........................................................................................................................................................................................ 129
3.6.29. How to replace air filter elements.................................................................................................................................................................. 130
3.5.30. How to clean water separator of fuel filter................................................................................................................................................. 132
3.6.31. Clean the engine radiators and hydraulic oil coolers............................................................................................................................. 133
3.6.32. How to clean cab ventilation filter................................................................................................................................................................. 133
3.6.33. Drain water from sprinkling circuit before winter season..................................................................................................................... 134
3.6.34. Adjust the scrapers.............................................................................................................................................................................................. 136
3.6.35. Machine cleaning ............................................................................................................................................................................................... 137
3.6.36. Check the tightening of bolted connections............................................................................................................................................. 137
3.7. Defects..................................................................................................................................................140
3.8. Attachments.........................................................................................................................................142
AV 80 X4 Wiring Diagram................................................................................................................................................................................................... 142
AV 80 X4 Hydraulic Diagram . .......................................................................................................................................................................................... 146
AV 80 X4 7
8 AV 80 X4
1. SPECIFICATION MANUAL
AV 80 X4
(Cummins tier 2)
AV 80 X4 9
1.1. Basic specification
1.1.1. Area of use
Please fill in the following data:
The machines of these series are engineered for operations un-
der the conditions due to the CSN IEC 721-2-1 (038900) : WT, (see Pin label, Label of the CUMMINS engine)
WDr, MWDr (i.e. temper climate zone, hot dry zone or warm dry
zone with limited temperature scope from –7 °C (19,4 °F) to +45
°C (113 °F) of ambient temperature.) Type of machine
1.1.2. Machine design ................................................................................................................

ICV/PIN (Serial number of the machine)
The tandem vibration roller AV 80 X4 with an articulated frame
enables the steering and offset of drums (crabbing). The roller
conception allows compaction close to curbs or walls. The cabin ................................................................................................................
is in version with integrated frame ROPS, compliant with inter- Production year
national standards ISO 3471:1994/Amd.1:1997; EN 13510:2000;
SAE J/ISO 3471:2003; AS 2294-2003; for maximum machine
weight 9000 kg (19845 lb). ................................................................................................................
The rollers can be used for compaction of asphalt composi- Type of engine
tions to the layer thickness (after compaction) of 140 mm
(5,5 in), hydraulic cemented compositions to the layer thickness
of 200 mm (7,9 in), composed earth to the layer thickness of ................................................................................................................
270 mm (10,6 in), sand and gravel materials to the layer thick- Serial number of the engine
ness of 370 mm (14,6 in).
The rollers are not convenient for compaction of rockfill, alumi-
nous and clayey materials. ................................................................................................................
The data mentioned in the table refer always when you contact
the dealer or manufacturer.
The machine meets requirements of international standards for

hygiene, ergonomics and safety of operation and is provided
with the production plate CE.
AMMANN CZECH REPUBLIC a.s.
NOVÉ MĚSTO NAD METUJÍ, CZECH REPUBLIC
3171
TYP / TYPE
IČV / S/N
PROVOZ. HMOTNOST / OPERAT. WEIGHT ZAT. PŘEDNÍ OSY / FRONT AXLE LOAD
BETRIEBSMASSE / POIDS DE SERVICE BELASTUNG DER VORDERACHSE
CHARGE DE ESSIEN ARANT
kg
ZAT. ZADNÍ OSY / REAR AXLE LOAD
MAX. HMOTNOST / MAXIMUM WEIGHT BELASTUNG DER HINTERACHSE
MAX. MASSE / POIDS MAX CHARGE DE ESSIEN ARRIÉRE
kg
VÝKON MOTORU / ENGINE OUTPUT ROK VÝROBY / PRODUCTION YEAR
MOTORLEISTUNG / PUISSANCE DU MOT. BAUJAHR / ANNÉ DE FABRICATION
MADE IN CZECH REPUBLIC

3171
Machine’s production label – CE

The machine does not comply with the conditions for being
marked with the “CE” symbol and it is equipped with a name
plat without “CE“. AMMANN CZECH REPUBLIC a.s.
NOVÉ MĚSTO NAD METUJÍ, CZECH REPUBLIC
3172
TYP / TYPE
IČV / S/N
PROVOZ. HMOTNOST / OPERAT. WEIGHT ZAT. PŘEDNÍ OSY / FRONT AXLE LOAD
BETRIEBSMASSE / POIDS DE SERVICE BELASTUNG DER VORDERACHSE
CHARGE DE ESSIEN ARANT
kg
ZAT. ZADNÍ OSY / REAR AXLE LOAD
MAX. HMOTNOST / MAXIMUM WEIGHT BELASTUNG DER HINTERACHSE
MAX. MASSE / POIDS MAX CHARGE DE ESSIEN ARRIÉRE
kg
VÝKON MOTORU / ENGINE OUTPUT ROK VÝROBY / PRODUCTION YEAR
MOTORLEISTUNG / PUISSANCE DU MOT. BAUJAHR / ANNÉ DE FABRICATION
MADE IN CZECH REPUBLIC

3172
10 AV 80 X4
SPECIFICATION MANUAL
Placing of the production label
1 - Production label
2 - Machine’s production number
3 - Label of the ROPS cabin
2
1
400102
Cummins engine serial number
400103
AV 80 X4 11
1.2. Machine dimension scheme
H4
S
S
A
L
400104
A D H1 H2 H3 H4 L O
mm 3260 1150 3012 2300 755 240 4410 45
in 128,4 45,3 118,6 90,6 29,7 9,4 173,6 1,8
R1 R2 R3 S W1 W2 W3
mm 6410 4600 6050 20 1600 1730 180
in 252,4 181,1 238,2 0,8 63,0 68,1 7,1
12 AV 80 X4
H1
H2
H3
W1 O
W2
W3
R3
R1
R2
400105
AV 80 X4 13
1.3. Technical data
1.3.1. Weights
Working weight with the cab ROPS

according to EN 500 - 1 kg (lb) 7910 (17438)
front drum kg (lb) 4025 (8873)
rear drum kg (lb) 3885 (8864)
The service weight of the machine according to EN 500-1 is the machine weight with the full content of working liquids, half content
of propellants, half content of sprinkling tanks and with an operator (75kg/165lb).
The machine weight according to ISO 6016 is the weight with full content of propellants, lubricants, sprinkling tanks and an operator
(75kg/165 lb). It is calculated by adding 590kg (1300 lb).
The weight data can differ from above mentioned data according to the further customers’ requirements for the machine’s equipment
and accessories.
1.3.2. Drive of travel - driving properties
Drive type hydrostatic

Drive front and final
Traverse speed in both directions - speed 2000 RPM - CE km/h (MPH) 10 (6,2)
Traverse speed in both directions - speed 2200 RPM - without CE km/h (MPH) 11,4 (7,1)
Theoretical machine’s gradeability % 45
Side static stability - straight frame ° 32
1.3.3. The vibrations
Drive type hydrostatic

Small frequency CE Hz (VPM) 43 (2580)
Big frequency CE Hz (VPM) 52 (3120)
Small frequency - without CE Hz (VPM) 48 (2880)
Big frequency - without CE Hz (VPM) 62 (3720)
Small amplitude mm (in) 0,35 (0,012)
Big amplitude mm (in) 0,6 (0,023
1.3.4. Engine
Manufacturer Cummins
Engine type B3,3 - C80
Number of cylinders 4
Stroke volume cm3 (cu in) 3260 (198,9)
Engine output due to ISO 3046/1 kW (HP) 60 (80)
Nominal revolutions - CE min (RPM)
-1
2000
Nominal revolutions - without CE min (RPM)
-1
2200
Maximum torsional moment Nm (ft lb) 291 (215)
Fuel consumption during common operation/hour* l (gal US) max. 10 (2,6)
Engine fulfills requirements of DIR. 97/68/EU, STAGE 2
EPA/CARB 40 CFR, PART 89 TIER 2
* - according to ACZ methodology
14 AV 80 X4
1.3.5. Brakes
Working brake hydrostatic

Parking and emergency brake mechanical lamella
1.3.6. Drive
Steering type articulated joint

Steering control hydraulic
Linear hydraulic motors 2 + 1 (Crab)
Swing of frames in vertical plane ±° 8
Turning of both frames in horizontal plane ±° 34
1.3.7. Fills
Engine (oil fill) l (gal US) 8 (2,11)

Cooling system l (gal US) 18 (4,75)
Fuel l (gal US) 110 (29,05)
Hydraulic tank l (gal US) 54 (14,26)
Drum vibrator l (gal US) 2x10 (2x2,64)
Watering tank l (gal US) 600 (158,5)
Sprinkling tank l (gal US) 2,75 (0,72)
1.3.8. Sprinkling
Sprinkling pressure
Number of pumps 2
Number of filtration stages 3
1.3.9. Electrical installation
Electric set voltage V 12

Accumulator – capacity Ah 100
AV 80 X4 15
1.3. Technical data
1.3.10. Hygienic parameters
Cabin machine:
Sound pressure level applied to the driver: LpA = 80 dB (A)
measured according to CSN EN 11 201
Guaranteed sound-power level of machine version according CE: LWA = 106 dB (A)
measured according to CSN EN ISO 3744
Weighted eguivale value of vibration acceleration transferred to the body: aw < 0,5 m.s-2 (vector sum)
measured according to CN 1032 - sand
Weighted eguivale value of vibration acceleration transferred to the hands: aw = 2,5 m.s-2 (vector sum)
measured according to ISO 5349 - sand
16 AV 80 X4
Notes
AV 80 X4 17
Notes
18 AV 80 X4
2. OPERATION MANUAL
AV 80 X4
(Cummins tier 2)
AV 80 X4 19
20 AV 80 X4

2.1. Major Safety Precautions OPERATION MANUAL
2.1.1. Safety Measures during Machine 2.1.1.2. Work Safety Secured by User
Operation
•• User shall promptly communicate any damage to the utility
Safety measures given in the individual chapters of Enginering lines to their operator, and at same time he make measures
Documentation supplied with the Machine shall be added with to prevent unauthorized persons from entering endangered
Safety Precautions in force within a respective country that uses area.
the Machine at workplace with regard to work organization, •• He must ensure an employee does not work alone at a wor-
work process and personnel involved. kplace. Another worker must always be in sight and within
an ear-shot, who in case of accident will provide or call for
help unless another effective form of monitoring or commu-
2.1.1.1. Compaction Work Commencement nication exists.
•• Constructional Supplier (Machine User) is liable to issue in-

structions for driver and maintenance before compaction
work is started, that will include requirements on work safe-
ty provision during Machine operation.
•• He must verify and mark:

-- utility lines
-- underground areas (direction, depth)
-- seepage or escape of hazardous materials
-- soil bearing capacity, slope of travelling plane
-- other obstractions incl. their removal.
He must make Machine driver, who will carry out earth work,
familiar with these conditions.
•• He must specify Code of Practice (C.O.P.) part of which is

work procedure for a given work operation and this work
procedure will specify inter alia:
-- measures when working under extraordinary conditi-
ons (work within protective zones, within extreme slo-
pes, etc.)
-- precautions for any natural disaster hazards
-- requirements on work performance while observing job
safety principles
-- technical and organizational measures to secure safety
of personnel, workplace and environment.
He must make Machine driver evidently familiar with the
Code of Practice.
AV 80 X4 21
2.1. Major Safety Precautions
2.1.1.3 Ensurance of safety measures by the 2.1.1.4. ROPS Cab
owner
•• The ROPS cab must not be deformed and must not show
•• User shall provide for the Machine to be operated merely signs of corrosion, cracks or breaks. It must be fixedly con-
under those conditions and only for those purposes it is nected to the machine frame. No additional adjustments
technically capable for under conditions set by manufactu- of the cab may be performed without approval of the ma-
rer and respective standards. nufacturer as such adjustments can cause a reduction in its
strength. The screwed connections must comply with the
•• He must make sure the use of the Roller (Compacter) is used specification and must be tightened to the specified torque,
merely in such a way and at such workplaces where there is must be neither damaged nor deformed, and must not
no hazard of making damage within nearby facilities, etc. show signs of corrosion.
•• He shall provide for regular inspection of operation, tech-
nical condition, regular machine maintenance in cycles per
the Lubrication and Maintenance Manual. In cases of failing
technical condition of the Machine to such an extent it po-
ses hazard to safety of operation, persons, property or cau-
ses damage or impairs the environment, then the Machine
must be put out of operation until a defect is repaired.
•• He must specify who and what tasks may carry out under
operation, maintenance or repair of the Machine.
•• Any who drives the Machine (driver) and anybody who per-
forms Machine maintenance or repairs must get familiar with
the guidelines given in the Machine Operation Manual.
•• He shall provide for fire extinguisher to undergo regular in-
spections.
•• He must ensure the “Machine Operation Manual” and Ope-
ration Logbook are stowed at certain place inside seat box
so always available to the driver.
•• He shall furnish constant supervision by an appointed per-
son during Machine operation under traffic on public roads,
and he will in particular be liable to release instructions on
securing the work safety.
•• He must secure the removal of hazardous materials (fuel, oil,
cooling liquid, brake fluid, etc.) from where these are spilled
depending on their nature so as to avoid their adverse im-
pact against environment, operation safety and persons’
health.
22 AV 80 X4
OPERATION MANUAL
2.1.2. Reguirements on Driver’s Qualification 2.1.3. Driver’s Liabilities
•• Only a driver trained under ISO 7130 and other local and na- •• Before starting to operate the Machine the driver will be
tional regulations designed for drivers of this group of ma- liable to get familiar with the guidelines given in the docu-
chines may operate the Roller (Compacter). mentation delivered with the Machine, with safety precauti-
•• With no licence only the one who learns driving the Machi- ons in particular, and observe these thoroughly. This applies
ne for the purpose of getting preliminary practice with the as well to the personnel in charge of maintenance, adjust-
approval of User may drive the Machine, and such person ments and repairs of the Machine.
has to be under direct and continuous surveillance of pro- •• Do not drive the Roller unless made familiar with all the Ma-
fessional teacher or trainer. chine functions, working and operating elements, and un-
•• Licence holder is liable to take due care of the licence, and less knowing exactly how to control the Machine.
when requested, put it forward to the control authorities. •• Follow safety signs located on the Machine, and keep them
•• Licence holder can make no registrations, changes or corre- in legible condition. Replace or add those impaired or mis-
ctions in the licence card. sing ones.
•• He/she is liable to promptly report his/her licence loss to the •• Before work commencement the driver must get familiar
authority that issued this licence. with the workplace environment, i.e. with the slopes, utility
line system, with necessary types of workplace protections
•• Driving the Roller alone may be performed by an employee with regard to the environment (noise, etc.).
mentally and physically fit, over 18 years old, who is:
•• When finding out any health hazard, life hazard to persons,
a) assigned by machine manufacturer for the assembly, hazard to property, failures, during hardware accidents, or
testing and presentation of the Machine, for training when finding symptoms of such hazards during operati-
the drivers, whereas he/she must be made familiar with on, the driver must, unless able to remove such hazard by
safety work regulations in force at the workplace himself/herself, stop his/her work and secure the Machine
or against undesired starting, communicate this to a person
accountable, and depending on chances, notify all the per-
b) assigned by Constructional Supplier to operate (carry out
sons exposed to such hazard.
maintenance) and is evidently trained and acquainted
with, or owns professional competence to operate and •• Before Machine operation startup the driver will be liable to
drive under special regulations (machinist licence, etc.). get familiar with the records and operation deviations found
out in course of the previous work shift.
•• Machine driver must undergo training and examination con-
cerning work safety regulations at least 1x every 2 years. •• Before work is started he/she must inspect the Machine, its
accessories, check up control elements, communication and
safety devices, whether these are operable in line with the
Manual. When finding out a malfunction that might be ha-
zardous to job safety, and he/she is not able to repair it, then
he/she must not start running the machine and instead re-
port such failure to the person accountable.
•• During work with the Machine the driver must be fastened
with the seat belt. The seat belt and its mounting shall not
be damaged!
•• When driver finds any defect during operation he/she must
immediately stop the Machine, secure it safely against un-
desired ignition.
•• During operation the driver shall follow the Machine run
and record any defects found in the Operation Logbook.
•• Driver shall keep his/her Operation Logbook designed to
maintain records about Machine handover between the dri-
vers, about the defects or repairs in course of operation, to
write down major events during work shift.
•• Prior turning on the engine the controls have to be in their
zero position, no persons may stay within dangerous reach
of the Machine.
•• Indicate each Machine startup via an acoustic or light signal
and this always before igniting the Machine engine.
•• Confirm brake function and steering function before star-
ting to run the Machine.
•• Following the alarm an operator may start the Machine only
when all the workers have left the danger area. At close
(blind) workplaces it will be possible to start the operation
only after a time necessary to leave danger area has elap-
sed.
AV 80 X4 23
•• During Machine operation observe safety regulations, make
no action that might endanger work safety, give full attenti-
on to Machine steering.
•• Respect Code of Practice or instructions of a person respon-
sible.
•• When rolling (traversing) the Machine within a workplace
adapt your speed to a terrain condition, to a work perfor-
med and weather conditions. Watch permanently the clea-
rance so to avoid collision with any obstruction.
•• Upon completion or stop of the Machine operation during
which driver leaves the Machine, he/she must make mea-
sures against unauthorized use of the Machine or against
spontaneous starting the engine. Remove key from the ig-
nition box, disconnect the wiring via disconnector, lock the
cabin, engine bonnet.
•• When shutting down the Machine on roads the measures
under regulations effective on roads shall be taken.
•• When operation is completed, park the Machine at a proper
parking place (flat, bearing area) so as not to endanger Ma-
chine stability, not to make the Machine interfere with traffic
roads, not to expose the Machine to falling objects (rock),
and where the Machine is safe against any natural disaster
of other kind (floods, landslides, etc.).
•• When working with the Machine is ended all the defects, da-
mage to the Machine and any repairs made shall be written
down in the Operation Logbook. Upon immediate changing
of drivers the driver will be liable to call attention of chan-
ging driver to any facts identified.
•• Driver shall use personal protective equipment (PPE) – work
clothing, safety shoes, the clothing shall not be too loose,
impaired, hair protected with proper head piece. During
maintenance (lubrication, refilling, replacement of working
media) your hands must be protected with proper gloves.
Use proper muffs when using Machine with no cabin or with
open windows.
•• Driver shall maintain the Machine equipped with fittings
and outfit required.
•• Maintain the Machine free of oil dirt or flammable materials.
Keep the drive’s stand, foot rests and runner areas clean.
•• When the Machine comes into contact with high voltage
observe the following principles:
-- try to leave with the Machine a hazardous zone
-- do not leave driver’s stand
-- give warning to others to keep off and not touch the
Machine.
24 AV 80 X4
OPERATION MANUAL
2.1.4. Banned Operations without having prevented its misuse.
•• Disable safeguarding, protective or locking systems or alter
Banned are the following their parameters.
•• To use the Machine following ingestion of alcoholic bewe- •• Use the Machine with oil, fuel, cooling liquid or other fillings
rages or dopes. leaking.
•• To use the Machine if its operation might put its technical •• Start the engine through some other way than given in the
condition, safety (life, health) of persons, facilities or objects, Driving Manual.
or road traffic and its continuity, at risk.
•• Locate some other items (tools, accessories) aside from per-
•• Put into operation and use the Machine when other persons sonal needs at driver’s stand.
are within its hazardous reach – exception is training a driver
•• Lay away material or other objects on the Machine.
by lector.
•• Remove dirt while the Machine is running.
•• Put into operation and use the Machine when some of its
safeguarding device (emergency brake, driving brake, horn, •• Perform maintenance, cleaning or repairs with the Machine
etc.) has been dismantled or damaged. not secured against spontaneous move or accidental start,
and when contact of a person with moving parts of the Ma-
•• To roll and compact at such slopes where Machine stability
chine is not excluded.
would be disrupted (turning over). Machine’s static stability
stated will lower by drive’s dynamic effects. •• Contact of moving parts of the Machine with human body
or objects and tools held in hands.
•• To roll and compact at such angles of slopes where hazard
of soil breaking off (dropping) under the Machine exists, or •• Smoke or handle open fire when checking or pumping fuels,
loss of adhesion followed by uncontrolled slip might occur. refilling oils, lubricating the Machine, or inspecting the accu-
mulator or making up the accumulator.
•• To control the Machine in some other way than stated in Dri-
ving Manual. •• Carry rags soaked with flammable materials, or carry flam-
mable liquids in free vessels on the Machine (in engine
•• To roll and compact per bearing capacity of subsoil at such
bay).
a distance from the edge of slope or trenches, where hazard
of landslide or shoulder breaking off (dropping) together •• Let the engine run inside confined spaces.
with the Machine would occur
•• To roll and compact with vibration at such a distance from
the walls, cuts, slopes, where their slip (slide) would happen
and the Machine covered in.
•• To compact with vibration at such a distance from buildings
or facilities and equipment within which the risk of them be-
ing damaged due to vibration transfer impact, would occur.
•• To operate the Machine unless driver control stand fixed
properly.
•• To operate the Machine when engine bay cover is open.
•• To move and transport persons on the Machine.
•• To operate the Machine when within hazardous reach the-
reof are other machines or transportation means aside from
those that operate in mutual concert with the Machine.
•• To operate the Machine at places impossible to see from dri-
ver’s stand, and where hazard to people or property could
occur unless work safety has been secured through some
other way like for instance via signalling by duly instructed
person.
•• To work with the Machine at a protected zone of electric li-
nes or substations.
•• To cross electric cables if these are not properly protectedli
against mechanical damage.
•• To operate the Machine under lowered visibility or at night,
unless Machine’s working area and workplace are illumina-
ted sufficiently.
•• To leave driver’s cockpit of the Machine when the Machine
is running.
•• Boarding or or getting off while on the run, jumping off the
Machine.
•• Sit or stand on the outside parts of the Machine when dri-
ving, or stand on the steps.
•• Leave unsecured Machine – move away from the Machine
AV 80 X4 25
2.1.5. Safety inscriptions and signs used on the Machine
1. Read Operation Manual! Get perfectly well familiar with the Machine operation
and its maintenance per the Operation Manual! (Symbols
located on the LH side of the control console )
2702bz
2. Handbook The Operation Manual stowage box (symbol located at

the rear on the stowage box at the seat )
2428
3. Fasten your seat belt! Fasten your seat belt before driving! (symbol located on
the left on the control panel )
2687
2687bz
4. Clamping hazard Maintain safe distance from the Machine, danger of being
clamped by the Machine in between the front and rear
frame. (symbols located on the left and right near steer-
ing joint .
2941bz
5. Danger area Maintain safe distance! (symbol located on the left and
right, on the front frame)
Maintain safe distance from the cutter and final compac-
tor if running. (symbol located on the RH front yoke – op-
tional
2942bz
6. Adjust while at rest Adjust and maintain with the engine stopped. (symbol
located on the left, on the rear frame )
2584bz
26 AV 80 X4
OPERATION MANUAL
7. Risk of injury Maintain safe distance. (symbol located on the fan cover)
3322bz
8. Risk of burn Do not touch Machine’s hot parts unless you make cer-
tain these have cooled down sufficiently. (symbol located
on the LH side of the rear frame overhead exhaust pipe )
2586bz
3292
9. Bonnet lifting – adjust at rest Lift the bonnet with the engine switched OFF. (symbol
located on the left, on the rear frame )
3292bz
10. Bonnet lifting Pump to lift the bonnet. (Symbol located on the left, on
the rear frame near door )
3201BZ
11. Bonnet locking Lock the bonnet (symbol located on the left, on the rear
frame)
3326bz
12. Danger of explosion Read the Operation Manual before any maintenance of
the battery, or before starting via the jump cables. (sym-
bol located on the left, on the rear frame )
3017bz
AV 80 X4 27
13. Disconnect wiring Before welding, please disconnect wiring, alternator, Ma-
chine’s electronics, and engine control unit. (symbol lo-
cated on the LH side of the control panel
2668bz
2225
14. Electric apparatuses Cover electric apparatuses when washing the Machine.
(symbol located on the LH side of control panel )
2225bz
15. Cooling liquid Cooling liquid is deleterious. Scald hazard during its ex-
change. Read Operation Manual! (symbol located on the
cooling liquid tank )
3323bz
16. Emergency exit Symbol located on the window of RH door .
2411bz
17. First aid kit Designation of box designed for first aid kit (symbol lo-
cated inside cabin, behind seat )
2427bz
18. Machine’s max height Caution when passing locations with height limit (symbol
3,05 m located on the left beneath the cabin, on the Machine )
frame
3207
28 AV 80 X4
OPERATION MANUAL
19. Noise emitted LWA Machine’s external noise (symbol located on the LH side
106dB
of the front frame )
3191bz
20. Sling points Sling the Machine in these points only. (symbols located
along both sides of both frames overhead the drum )
2153bz
21. Sling points Sling the Machine in these points only. (symbols located
along both sides of the frame )
3048bz
22. Supporting point Locate hand jack or fixed support of the Machine here
(symbol located on the front and rear frame along both
sides )
3208bz
8400 kg
23. Lifting diagram (18 520 lb)
Use rigging of sufficient loading capacity to lift the Ma-
Lmin = 5m
2x min 2100 kg chine. Secure the Machine’s joint before lifting. (symbol
located on the left, on the front frame )
(2x min 4630 lb) Lmin = 5 m
2x min 2100 kg
(2x min 4630 lb)
3325
3325bz
AV 80 X4 29
2.1.6. Hand Signals
Signals given by Machine assistant operator unless driver visu-

ally contains the rolling space or working space or working
equipment, tool.
Signals for general commands
Stop
One arm erected with open palm in the direction of the driver, STOP
second arm akimbo.
Sig. 1
Attention
Both arms sideways raised horizontally – palms forward.
! Sig. 2
Attention, Danger
Swinging motion of both of the arms with antebrachium from
the position of arms sideways raised horizontally to the position
of arms sideways raised – arms bending across and back.
! Sig. 3
SIGNALS FOR DRIVE
Departure with the Machine

One arm erected – bent with open palm, long motion of an-
tebrachium in the direction of required motion, second arm
akimbo.
Sig. 4
30 AV 80 X4
OPERATION MANUAL
Low-speed cruising forward – towards me
Both arms erected abreast bending across, with palms towards
the body – short swinging movements of antebrachium towards
the body and backward.
Sig. 5
Low-speed cruising backward – away from me

Both arms erected abreast bending across, with palms away
from the body - short swinging movements of antebrachium
away from the body and back.
Sig. 6
Driving to the right

Left arm sideways raised, right arm akimbo.
Sig. 7
Driving to the left

Right arm sideways raised, left arm akimbo.
Sig. 8
AV 80 X4 31
Short motion
Both arms lifted forward bending across. Mark the „X“ distance
between palms, then the motion signal follows.
X
Sig. 9
Engine start
Circular motion of right hand’s antebrachium, with the fist
closed.
Sig. 10
Engine cut off

Oscillating motion of right hand sideways raised in front of the
body to the sides.
Sig. 11
32 AV 80 X4

2.2. Ecological & Hygienic Principles OPERATION MANUAL
2.2.1. Hygienic Principles 2.2.2. Ecological Principles
•• The fillings of Machine’s individual systems and some of its

When operating and storaging the ma- parts become waste with hazardous properties against the
chines a User will be liable to observe environment when discarded.
general principles of health and envi- This category of waste products includes in particular:
ronmental protection, laws and regula-
-- Organic as well as synthetic lubricating materials, oil or
tions that relate to the given issue and fuels,
are in force within a territory where the
Machine is used. -- Cooling liquids,
-- Accumulator fillings and the accumulators themselves,
-- Cleaning & preservation agents,
•• Oil proudcts, cooling system fillings, accumulator fillings, or
-- All filters and filter elements dismantled,
painting materials incl. thinners are materials that pose he-
alth hazard. Workers coming into contact with these produ- -- All used and discarded hydraulic hoses or fuel hoses,
cts during Machine operation or maintenance will be liable metal rubbers and other Machine’s elements, foulded
to follow general principles of one’s own health protection, with the abovementioned products.
and abide by safety and hygienic guidelines of these produ- • Manufacturer and manufacturer-accredited contracting
cts’ manufacturers. service organizations or dealers take back the following used
We call your attention to the following in particular: materials or parts free of charge:
-- Eye and skin protection when handling accumulators Oils
-- Skin protection when handling oil products, painting Accumulators
materials or cooling liquids
-- Washing your hands properly upon work completion or
before meals, apply a proper reparation cream on your Handle the given materials and parts
hands following their disposal in line with the
-- When handling cooling systems, please follow the in- respective national regulations on pro-
structions given in the Manuals supplied with the Ma- tection of individual components of
chine. environment, and in conformity with
•• Always maintain oil products, cooling system and accumu- health regulations.
lator fillings and painting materials incl. organic thinners
and also the cleaning and preserving agents in their original
properly designated packages. Do not allow storage of the-
se materials in undesignaged bottles or other vessels due
to the hazard of them being interchanged. Especially haza-
rdous is the possibility of interchanging them with eatables
or drinks.
•• Upon skin, mucosa, eye contacts or inhalation of vapour, im-
mediately apply the principles of first aid. Upon accidental
use of these products get prompt medical attention.
•• When operating the Machine with no cabin provided, or
with cabin windows opened, always use ear defenders
(muffs) of proper type and version.
AV 80 X4 33
2.3. Preservation & Storage
2.3.1. Short-Term Preservation & Storate for the 2.3.2. Machine Preservation & Storage for the
Period of 1 ÷ 2 Months Period Over 2 Months Long
•• Wash and clean the entire Machine carefully. Before parking To park the Machine the same principles will apply like at short-
the Machine for its preservation and storage, please warm term preservation.
up the engine to its operating temperature while running. In addition it is recommended to:
Park the Machine on solid, flat surface at a safe place with
no risk of natural disaster (floods, landslides, fire, etc.) to the •• Dismantle the accumulators, check their condition, and sto-
Machine. re in a cool, dry room (recharge the accumulators regularly),
In addition: •• Support the runner frame so the damping system shows
minimal sag,
•• Repair those spots with damaged paint,
•• Protect rubber elements through painting with spec. preser-
•• Lubricate all lubricating points, control cables, joints of the vation agent,
controls, etc.,
•• Inflate the tyres to a pressure required, and protect them
•• Confirm water fillings are drained, from direct sunlight,
•• Check that cooling liquid has antifreezing characteristics •• Apply preservation grease over the chromed surfaces of the
requiered, piston rods,
•• Check the state of accumulator charges, recharge them if •• Preserve the Machine via spraying with special agent, and
necessary, this at places of possible corrosion origin,
•• Apply preservative grease over the chormed surfaces of pis- •• Blind the engine suction and discharge ports with double
ton rods, PE foil, and tighten this foil thoroughly with adhesive tape,
•• We recommend to protect the Machine against corrosion •• Protect the headlamps, external back mirrors and other ele-
through spraying the preservation agent (applied spraying), ments of external wiring through spraying a special agent
and this in particular in places with potential of corrosion and wrapping into PE foil,
origin.
•• Preserve the engine per Manufacturer’s Instruction Manual
The Machine treated like that will need no special preparation – mark visibly the engine has been preserved.
prior to its subsequent putting into operation.
After 6 months we recommend to inspect

the condition of preservation and renew
if required.
NEVER start the engine in course of
storage!
In case of Machine storage under field
conditions, please check the parking
place whether not exposed to the hazard
of flooding, and that danger of any other
type is not present!
Prior to restoration of Machine op-

eration, please wash the preservation
agents away with the use of high pres-
sure stream of hot water incl. addition of
normal degreasers while observing the
Instructions for Use along with ecologi-
cal principles.
Carry out the dewaxing (deconservation)
and washing of the Machine at places
equipped with intercepting sumps to
trap the rinsing water as well as dewax-
ing agents.
34 AV 80 X4
OPERATION MANUAL
2.3.3. De-conservation and inspection of brand
new machines
•• Check the machine against delivery documentation.

•• Check whether any parts were damaged during transport or
are missing. Inform the shipper of any discrepancies.
Before starting operations again, wash

off conservation ith highpressured hot
water with ordinary degreasing means
added as directed, while observing envi-
ronmental rules.
Remove conservation and wash the ma-
chine in places with catch basins availa-
ble to collect rinse water and chemicals.
AV 80 X4 35
2.4. Machine Disposal Following Its Life Termination
During Machine disposal following its service life the User will
be liable to follow national waste and environmental regulations
and acts. We recommend to always contact in these cases:
•• the specialized companies with respective authorization to
deal professionally with these operations,
•• the Machine manufacturer or manufacturer-appointed
accredited contracting service organizations put in charge
by manufacturer.
In no event shall Manufacturer be liable

for damage to User health or environ-
mental damage that arises from non-ob-
servance of the abovementioned note.
36 AV 80 X4

2.5. Machine Description OPERATION MANUAL
14
17
15
18 20
12 11
16
21
13
5
20 6
7
4
21
2 8
1
3
10 21
19
9
21
400106
1 - Front frame 12 - Fuel tank

2 - Rear frame 13 - Sprinkling tank
3 - Front drum 14 - Cabin with integrated ROPS arm
4 - Rear drum 15 - Driver’s control stand
5 - Engine 16 - Battery
6 - Drum travel hydroelectric generator 17 - Combined engine and hydraulic oil cooler
7 - Drum vibration hydroelectric generator 18 - Air filter
8 - Travel hydraulic motor 19 - Exhaust pipe
9 - Vibration hydraulic motor 20 - Sprinkling jets
10 - Steering joint 21 - Drum scrapers
11 - Hydraulics tank
AV 80 X4 37
2.6. Controls & Dashboard Instruments
25 26
30 23 22 21 20 19 11
24
1 16
2
18
0
14 15
12
17 28 29
27
31
6 5 6 5 13
1 7 7
1
2
8
3
9
4
10
32
400107
38 AV 80 X4
OPERATION MANUAL
Dashboard and control panels
1 - Travel controls
2 – Speed potentiometer
3 – Pushbutton for mode of soft starting to move and stopping to move
4 – CRAB mode resetting switch
5 – Pushbuttons for CRAB mode – front drum, to the right*
6 – CRAB pushbuttons – front drum, to the left*
7 – Vibration pushbuttons
8 – Emergency brake pushbutton
9 – Sprinkling pushbutton
10 – Sprinkling interval potentiometer
11 – Sprinkling pumps selector switch
12 – Ignition box
13 – Accelerator control
14 – Front / both / rear vibration selector switch
15 – Vibration amplitude selector switch
16 – Vibration mode selection switch (MAN/AUT)
17 – Combined switch
18 – Switch for constant speed and protection against engine overload
19 – Beacon switch (optional)
20 – Alarm lights switch
21 – Additional lights switch (optional)
22 - Switch + indicator lamp for rear lights
23 – lndicator lamps for lights (dipped/distance)
24 – Infrathermometer (optional)
25 – LH cluster
26 – RH cluster
27 – Cut-out box
28 – Cabin fuse
29 – Diagnostics socket
30 – Mounting socket
31 – Steering wheel position adjustment
32 – Operator seat
* If the Machine is equipped with cutter and final compactor then pushbuttons (5) and (6) on the travel control (1) are used to
control it, and this on the same side where it has been mounted (optional).
AV 80 X4 39
2.7. Machine basic functions control
25 26
6 5 6 5
1 7 7
1
2
8
3
9
4
0 N
400108
40 AV 80 X4
OPERATION MANUAL
3317
Steer angle of the front drum in CRAB mode – yel-

Travel controls (1)
low pushbuttons (5) and (6)
3317 2721
These controls are used to adjust travel direction and speed. Press pushbuttons on travel controls (1) to steer in CRAB mode
Travel speed depends on the degree of swing of travel controls
from zero position (0), in dependence on speed potentiometer
(2) adjustment. Pushbutton (5) – front drum to the right
Pushbutton (6) – front drum to the left
Travel controls have two positions, i.e. “N” and “0”: Indicator lamp on cluster (26) goes ON to signal this function.
“N” - neutral
- in this position the Machine parking brake is enabled. Note
“0” - zero position If the Machine is equipped with cutter and final compactor then
it will be controlled via pushbuttons (5) and (6) on travel con-
- the Machine is not braked in this position.
trol (1), and this on the same side where it has been mounted
(optional).
Neutral position (N) is signalled through lighting up of neutral
and parking brake indicator lamps on the cluster (25).
Vibration ON / OFF pushbuttons (7)
Located on the travel control are vibration ON/OFF pushbuttons
(7) and pushbuttons (5), (6) to control in CRAB mode.
Press these buttons to turn ON/OFF this function. Indicator lamp
If the Machine is equipped with cutter and final compactor then
on cluster (25) will go ON.
pushbuttons (5) and (6) on travel control are used to control it,
i.e. those on the same side where it is mounted (optional).
Engine start is possible only in neutral position (N).
Emergency brake (8) pushbutton
2582
Press this button to enable Machine’s emergency brake, and in-

Speed potentiometer (2) dicator lamps on cluster (25) for brakes, recharging, neutral, and
engine oil pressure will light up.
2685
Engine will stop and stall!
Potentiometer is used to smoothly select speed mode within
the range from min speed of “turtle” to max speed of “rabbit”.
When adjusting potentiometer speed in any position you may
always enable vibration function.
Sprinkling button (9)
Machine will not move with speed potentiometer set to MIN
position. 3183
Hold down this pushbutton to enable drum additional sprin-

kling function. Indicator lamp on cluster (26) will light up.
Switch for the mode of soft starting to move (dri-
veaway) and stopping to move (stopway) (3)
3128
It is used to adjust soft starting to move and stopping to move

when stopping and reversing the Machine. In this way the crea-
tion of “waves” on compacted surface will be eliminated. Press
the switch to enable the function, and indicator lamp on cluster
(26) will go ON.
Attention, in this mode the Machine stopping distance is
longer!
Switch for CRAB mode resetting (4)

3319
Press this switch to adjust front drum in CRAB mode.

CRAB mode resetting is signalled by indicator lamp on cluster
(26) going OFF.
AV 80 X4 41
25 26
23 11 16
14 15
12
17
13
10
400109
42 AV 80 X4
OPERATION MANUAL
Sprinkling interval potentiometer (10) Drum vibration selector switch (14)

3186 3179
Swing the sprinkling potentiometer from „MIN“ to „MAX“ posi- The selector switch has three positions:
tion to control smoothly drum sprinkling intensity. Left – front drum vibration
Sprinkling function will not be enabled with the sprinkling Centre – both drums’ vibration
potentiometer set to MIN position.
Right – rear drum vibration
Vibration amplitude selector switch (15)

Pumps sprinkling selector switch (11)
2682
The selector switch has three positions:

3181
Left – low amplitude switched ON
One of two drum sprinkling pumps will turn ON, and indicator
lamp on cluster (26) will light up. Centre - OFF
Right – high amplitude switched ON
Adjust sprinkling potentiometer before switching ON the
pump!
Ignition box (12 )

Ignition box has three positions of „0-I-II“. The key can be insert- MAN / AUT vibration mode selector switch (16)
ed and removed in ”0” position only.
Turn a bit the key to RH side to enable first the ”I” position and 3180
then ”II” position.
It is used to switch ON vibrations in MAN or AUT mode.
”II” position is used to start the engine.
MAN – manual mode, vibrations can be switched ON even with
stationary Machine.
AUT – automatic mode to switch OFF/ON vibrations
Protect ignition box with cover once the
key is pulled out.
Cluster (17)
It is used to turn ON/OFF contour lights, dipped lights, distance
lights, traffic-indicator lights and horn.
Indicator lamps (23) light up to signal contour, dipped, and dis-
tance lights are ON.
Accelerator control (13) Indicator lamp on cluster (25) lights up to signal traffic-indicator
lights are ON.
2406
It is used to adjust combustion engine rpm ranging from idle

to max speed. Move the accelerator control towards operator
seat to increase the rpm and vice versa. Accelerator control is
connected with the engine injection pump control lever via a
cable.
AV 80 X4 43
25 26
23 22 21 20 19
24
18
0
12
13
1 1
400110
44 AV 80 X4
OPERATION MANUAL
Switch + indicator lamp rear lights (22)

Switch for constant speed and protection against
0 591668R
engine overload (18)
It is used to turn ON/OFF rear lights, indicator lamp in the switch
3185 signals this function.
Constant speed function:
It is used to maintain constant speed of the Machine when driv-
ing on flat surface, uphill, or downhill.
When control unit is switched ON the indicator lamp on cluster Indicator lamps for (dipped / distance) lights
(26) signals this function. (23)
The driving speed corresponds to the degree of swing of travel
591508
control (1) from neutral position (0), depending on speed poten-
tiometer (2) adjustment. These lamps signal dipped or distance lights switched ON.
ANTISTALL function
It is used to protect the engine on steep grade or the Machine Infrathermometer (24) - (optional)
not to sink in ground. 3044
With the control unit switched ON the indicator lamp on cluster It will be enabled through the key turned ON in the ignition
(26) will signal this function. The control unit will automatically box (12) and it will measure through temperature sensor for a
lower the power take-off (PTO) through reducing the set speed bitumen surface rolled. The value measured is indicated in C°
(rpm of travel hydraulic motor) independently on travel control degrees on display (24).
position. Thus the tractive force (of travel hydraulic motor) will
increase - engine will get relieved.
Adjust engine max rpm by means of ac-

celerator control (13) before turning ON
the switch!
When a hard terrain has been overcome,
turn OFF the switch!
Switch + hazard beacon indicator lamp (19)

- (optional)
592348
It is used to switch ON/OFF hazard beacon, indicator lamp in the

switch signals this function.
Alarm lights switch (20)

AMN24
It is used to turn ON/OFF alarm lights - indicator lamp in the

alarm lights switch and on clusters (25) and (26) will flicker to
signal this function.
Switch + indicator lamp for cabin’s additional

lights (21 )
596473
It is used to switch ON/OFF additional lights, indicator lamp in

the switch signals this function.
AV 80 X4 45
25
478320 h
400501
LH cluster (25)
Fuel consumption gauge Indicator lamp for hydraulic oil pressure filter
AMN25
fouled
AMN3
It signals current fuel level in the tank, when emptied to min the
red LED will flicker. Indicator lamp ON signals filter element is fouled.
Check fuel level during Machine

operation. Immediately replace the filter element!
Counter of motohours actually worked

Battery recharging indicator lamp
AMN26
AMN4
It will display the number of motohours the engine was running. It signals proper function of battery recharging. When switching
With the engine started the counter will begin counting the mo- the key on the ignition box (12) over to “I” position the indicator
tohours. lamp shall go ON and following the start it must go OFF.
Note
Counting the number of motohours does not depend on en-
gine rpm. Unless indicator lamp goes OFF, find a
defect!
Parking brake indicator lamp

AMN1 Indicator lamp lighted ON during engine run will signal a de-
fect. Following 5 seconds the acoustic alarm will start, and after
The indicator lamp ON will signal the parking brake has been
2 minutes the engine will stall automatically – the Machine will
enabled.
stop and parking brake will be enabled.
Seat switch indicator lamp

Engine can be started once its defect has
AMN2
been repaired!
Indicator lamp will light ON when operator is not sitting on the
seat or when emergency brake has been enabled.
46 AV 80 X4
OPERATION MANUAL
Indicator lamp for air filter fouled Indicator lamp that the vibration is ON
AMN5 AMN10
Indicator lamp ON signals filter element is fouled above a limit Indicator lamp ON will signal the vibration is ON.
admissible.
Indicator lamp for hydraulic oil temperature

Stop the Machine and replace the filter
element instantly! AMN11
Indicator lamp signals max hydraulic oil temperature admissible

has been exceeded.
Engine lubrication lamp

Stop the Machine and check oil level or
AMN6 find a defect!
When switching the key in the ignition box (12) over to “I” posi-
tion and indicator lamp shall go ON, and when engine is started
it must go OFF.
Indicator lamp lighted ON during engine run will signal a de-
fect. Following 5 seconds the acoustic alarm will start, and after Check hydraulic oil level
2 minutes the engine will stall automatically – the Machine will AMN12
Indicator lamp signals low hydraulic oil level.
Stop the Machine and check oil amount
or find a defect! stop and parking brake will be enabled.
Engine can only be started when failure

is repaired and oil in hydraulic tank re-
Indicator lamp for engine overheated filled to a limit specified!
AMN7
This indicator lamp signals the cooling liquid’s max temperature

allowed has been exceeded.
Stop the Machine and check cooling liq-

uid amount, or find out any defect!
Indicator lamp for traffic-indicator lights

AMN8
Indicator lamp ON will signal traffic-indicator lights are ON, or

alarm lights have been turned ON.
Neutral indicator lamp

AMN9
Indicator lamp ON will signal the position of travel controls is in

neutral (N).
Before starting the engine the travel controls (1) shall be in neu-
tral position (N)!
AV 80 X4 47
26
400502
48 AV 80 X4
OPERATION MANUAL
RH Cluster (26)
ASC indicator lamp
Level height in sprinkling tank. AMN17
AMN27 Not connected.

It signals the actual level of water in the tank, and when emptied
to min the red LED will start to flash.
Fuel filter indicator lamp

Check water level in the tank during AMN18
Machine run.
Indicator lamp lighted ON signals water presence in fuel filter.
If this indicator is ON, please clean the

fuel filter!
Cooling liquid indicator lamp
AMN13

fect. Following 5 seconds the acoustic alarm will start, and after Engine glowing indicator lamp
stop and parking brake will be enabled. AMN19
Not connected.
Engine can only be started when failure

is repaired and cooling liquid refilled to a
limit specified! Spreader indicator lamp
AMN20
This indicator lamp signals the spreader is ON (optional).
Air conditioner indicator lamp

AMN14 Indicator lamp to protect against engine over-
Indicator lamp signals air conditioner is ON (optional). load (ANTISTALL)
AMN21
This indicator lamp signals the ANTISTALL is ON.
CRAB mode indicator lamp

AMN15
Sprinkling pump indicator lamp
Indicator lamp signals the front run is set to CRAB mode.
AMN22
Indicator lamp signals sprinkling pump is ON.

Indicator lamp for soft starting to move and stop-
ping to move
AMN16
Indicator lamp ON signals the mode of soft starting to move and Constant speed indicator lamp
stopping to move is ON. AMN23
Intermittent flashing of this indicator lamp signals an error code This indicator lamp signals the constant speed mode is ON.
for a defect within Machine travel system.
Shut down the Machine and call service Alarm lights indicator lamp
organization in respect of failure repair
on the Machine travel system!!! AMN24
This indicator lamp signals alarm lights are ON.
AV 80 X4 49
Cut-out box (27)
It contains F1 - F8 fuses.
F1 - 20 A front, rear headlamps

F2 - 15 A roof lights, light switches
F3 - 15 (30)A traffic-indicator lights, horn, beacon, extra lights,
mounting socket
F4 - 5 A clusters
F5 - 10 A travel electronics, backing horn
27
F6 - 15 A sprinkling
F7 - 7,5 A vibrations, CRAB (trimmer) 400116
F8 reserve
Other fuses located on the Machine
At battery disconnector
F9 radio (as per car radio manufacturer)
400117
Under the cabin lighting cover

F11 - 15 A wipers + window washers
F12 - 15 A fans
F13 - 5 A fan control + air conditioner control
F14 - 10 A air conditioner
400118
400119
50 AV 80 X4
OPERATION MANUAL
Cabin fuse (28)
F15 - 30 A cabin wiring
Always replace the fuses with the ones of

identical value!
30
Diagnostics socket (29)

It is used to check and set the control units’ parameters via exter- 28
nal computer units (notebook). 29
Mounting socket (30)

It is used to connect auxiliary inspection lamp (12V). 400116A
Steering wheel positioning (31)

It is used to facilitate boarding and leaving the Machine by its
operator.
Release lever (A) to position the steering wheel in the direction
away from the column axis towards a dashboard.
400125
The lever (A), when shifted out, can be arrested in any position.
400126
AV 80 X4 51
Operator seat (32)
Seat adjustment:
1 Backrest position 3 2
2 Arm support position and lifting
3 Seat turning 6
4 Seat shifting 1
5 Seat springing stiffness according to weight indicator.
6 Seat height – grasp the seat and lift slowly to adjust seat
height in its next higher position and lock it there. Once
lifted to its highest position, the seat will drop back to its
4
lowest position. 5
400122
Adjust your seat before driving !

Driver must be fastened with the seat
belt while driving!
400253
How to swivel operator’s place:

Operator’s place can be swivelled within the range of 40° when
accelerator pedal is pressed. Once the pedal is released the op-
erator’s place is locked (arrested) in one of 4 positions.
Seat switch:
Seat switch is located in its cushion.
Description of seat switch function:
It is used to interlock the engine starting or to stop the Machine
if no operator sits on the seat.
Interlocking of engine starting:
When operator is not sitting on the seat the Machine cannot be MAX 40°
400124
started.
Machine stopping:
If operator stands up from the seat while driving then the Ma-
chine will stop following 8 seconds.
Machine starting to move:
Its operator must sit down on the seat and shift the travel con-
trols (1) to neutral (N) and then select direction of running.
Do NOT load seat switch with other

objects!
52 AV 80 X4
OPERATION MANUAL
Documentation stowage box
2428
The locker for documentation is located on the seat’s rear side.
400123
Front wiper selector switch (33)

Three-position selector switch 35
-- Turned OFF 34
-- Low speed ON
33
-- High speed ON
Glass washer switch (34)

Two-position selector switch
-- Windscreen washing ON
-- OFF
-- Rear window washing ON
400120
Fan switch (35)

It is used to switch ON cabin fan, its function is signalled via indi-
cator lamp in the switch.
-- OFF
-- High delivery ON
-- Low delivery ON
Cabin lighting (36)

Ceiling lamp incl. selector switch is located overhead the dash-
board.
Ventilation nozzles (37)

37
Adjustable nozzles are located on cabin ceiling, please adjust
and swivel the dampers to alter the amount and direction of
flowing air.
37 36
400120A
AV 80 X4 53
Control tie rod for heating valve (38)
It is used to switch ON the cabin heating. 38
40
Make continuous control from MIN position (valve closed) to
MAX position (valve fully open) for the amount of liquid flowing
to the heating body. 39
Adjust the heating valve before driving!
Hand pump control lever (39)

It is used to control the hand pump when lifting or letting down
the bonnet. 400121
First-aid box stowage place (40)
The Machine shall be equipped with

first-aid box!
Fire extinguisher (41) - (Optional)

The way of using fire extinguisher is described on the apparatus
package.
We recommend to equip the Machine

with fire extinguisher!
Make yourself familiar with the applica-
tion of fire extinguisher !
Carry out regular inspections of the fire
extinguisher!
400241
Stowage pockets (42)

These are used for Operator’s personal items.
400121A
54 AV 80 X4
OPERATION MANUAL
Anti-dazzle (sun) screen (43)
Adjust the anti-dazzle screen through securing it to the fixing
on the glass.
400242
Window washer tank (44)

Fill with standardly available media.
Fill with antifreeze or drain before winter

season starts!
400127
Additional lights (45)

Lights located on the Machine cabin (optional).
400258
Beacon socket (46)

It is used to connect the beacon.
Back mirrors (47)

External back mirrors enable to view poorly visible areas.
Maintain these mirrors clean and prop-

erly adjusted!
400243
AV 80 X4 55
Cabin ventilation air filter (48)
It includes replaceable filter element to catch the impurities
drawn in from air.
400234
Arm rests on the door (49)

Transportation position
400244
Working position
400245
Battery disconnector (50)

It is used to disconnect the battery from the Machine frame. „0“ „I“
Position „0“ – Machine wiring disconnected.
Position „I“ – Machine wiring connected.
400246
56 AV 80 X4
OPERATION MANUAL
Hand pump (51)
It is used to lift or let down the bonnet.
Located on LH side of rear frame.
400257
AV 80 X4 57
25 26
12
17
13
1 1
0 N
400113
58 AV 80 X4
OPERATION MANUAL
2.7.1. Engine starting
Check daily before engine starting the amount of oil in the engine and hydraulic tank, cooling liquid in the cooling circuit, fuel in fuel
tank, water level in water tank. Confirm no loosened, worn or missing parts exist on the Machine.
Start the engine only from the driver’s control stand! Use alarm horn to signal the engine starting and
check nobody is endangered by starting the engine!
How to start:
•• Switch ON the battery disconnector (50).
•• Insert key in the ignition box (12) in “0” position and switch over to “I” position.
•• All indicator lamps on clusters (25 and 26) will light up.
•• Then on cluster (25) the indicator lamps for brakes, recharging, neutral, will remain ON, along with engine lubrication indicator
lamp (flickers).
•• If you leave the key in ”I“ position for over 15 seconds then the acoustic alarm will switch ON – to warn operator about the battery
discharged (acoustic alarm will turn OFF once engine is started). Unless it is started within 2 minutes, please get your key back to
“0” position before starting the engine again.
•• Use alarm horn on combined switch (17) to signal engine starting.
•• Adjust accelerator control (13) for increased rpm (1/4 stroke).
•• Turn the key to “II” position to start the engine.
•• On cluster (25), following the starting, the engine lubrication indicator lamp and recharging indicator lamp shall go OFF.
•• Once the Machine has started to move the neutral lamp and brake lamp will go OFF.
Note
If starting is unsuccessful, please turn your key back to ”0“ position. Unless engine starts even after 3 attempts – please check the oil
system.
Starting is interlocked:
-- unless travel controls (1) are in neutral position (N)
-- emergency brake (8) function is enabled.
Do NOT start the engine for over 30 seconds. Wait 2 minutes before any next starting.
When starting at low temperatures the recharge indicator lamp will remain ON accompanied by a sound
alarm – increase engine rpm adequately – the indicator lamp will go OFF.
Following the engine start let the engine idle at increased rpm (1/2 stroke of accelerator actuator) for
3÷5 min.
Steep rpm increase or decrease is inadmissible – it may damage the engine.
Do NOT let the engine idle for over 10 minutes – any idling longer then that may cause fouling of injec-
tors, piston rings, or valves to get seized!
Unless oil temperature reaches min. 60 °C, then the engine will not be lubricated sufficiently – do not
load the engine fully!
AV 80 X4 59
4 -
2 + 12
V
- 1
0
12
0 V +
400131
60 AV 80 X4
OPERATION MANUAL
How to start via cables from external power source:
Starting voltage from external power source shall be the voltage of 12V.
Follow unconditionally the operation sequence below.
1/ Connect one end of (+) cable pole to (+) pole of the battery discharged.
2/ Connect second end of (+) cable pole to (+) pole.
3/ Connect one end of (–) cable pole to (–) pole of external battery.
4/ Connect the second end of (–) cable pole to such part of started Machine which is fix-wired with the engine (or with the engine
block itself ).
When started, disconnect the battery jump cables in reverse order.

Do not connect (–) pole cable to (–) pole of discharged battery of the Machine being started! There is
risk of strong sparking in course of starting followed by explosion of battery-generated gas.
Make sure the non-insulated parts of the battery jump cable clamps do NOT contact each other!
Make sure the jump cable connected to (+) pole of the battery does NOT come into contact with electri-
cally conductive parts of the Machine – danger of short circuit!
Do NOT lean over the battery – risk of electrolyte burn!
Rule out any presence of flammable sources (open flame, burning cigarettes, etc.)
Do NOT confirm voltage presence in a wire through sparking via Machine frame!
AV 80 X4 61
26
13
1 1
0 N
400114
62 AV 80 X4
OPERATION MANUAL
2.7.2. Machine travel and reversing with no vibration
Before starting to move, please check the area in front and behind the Machine is clear and with no
persons or obstructions present!
Use loud horn to signal engine starting and wait long enough for those persons present to leave the in
time the area round the Machine or the area beneath the Machine!
Operator must sit on the seat before the Machine starts moving! If the operator gets up from the seat
during the Machine travel then the Machine will stop and brake.
Machine travel and reversation:

Select travel direction:
Start the engine. Adjust max engine rpm via accelerator control (13)
Get the Machine moving by shifting travel controls (1) from (N) zero position to (0) neutral position and then by selecting a direction
of running.
Shift the controls (1) to opposite direction to change the direction of Machine travel.
Travel speed selection:

Travel speed corresponds to the deflection magnitude of travel controls (1) from zero position (0).
Travel speed can continuously be altered using speed potentiometer (2) within the range of MIN (turtle) to MAX (rabbit).
If the speed potentiometer (2) is in MIN position then the Machine is unable to start moving.
Note
The instantaneous stopping of the Machine by means of travel controls (1) applies to all travel modes of the Machine.
Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Ma-
chine – the engine will continue to run.
Travel modes of the Machine:

•• RAMP (soft starting to move and stopping to move)
•• CONSTANT SPEED (continuous Machine drive)
•• ANTISTALL (engine protection against overload)
•• CRAB (extended track of the Machine)
Travel in RAMP mode

The function of soft starting to move or stopping to move prevents from forming the waves when compacting the bitumen surface
during Machine travel.
Attention, in this mode the Machine stopway is longer!
Use speed potentiometer (2) to adjust the speed, and use travel control (1) to adjust travel direction.
Press pushbutton (3) to switch ON/OFF this function, indicator lamp on cluster (26) will light up to signal this function.
Move travel controls (1) to opposite position via (0), and then return it back to (0) position within 1 second interval to stop the Machine
– the engine will remain running.
Following the travel controls (1) moved to neutral (N) the function will be OFF!
Shift travel controls (1) to neutral (N) position, press pushbutton (3) – the function will become enabled again.
Note
You may switch ON the function during Machine travel.
AV 80 X4 63
26
18
0
13
1 1
0 N
400130
64 AV 80 X4
OPERATION MANUAL
Travel in CONSTANT SPEED mode
This function is used to maintain continuous travel while the Machine is ascending or descending.
AMN23
Use speed potentiometer (2) to adjust travel speed and use travel controls (1) to adjust its direction.
Use switch (18) to turn ON/OFF the function, indicator lamp on cluster (26) will light up to signal this function.
Swivel the travel controls (1) from position (0) and the Machine will start moving.
Note
The function can be turned ON during Machine travel.
Travel in ANTISTALL mode

It is used to protect against engine overload on steep grade or with the Machine sunk.
AMN21
Control unit will automatically reduce the power take-off through lowering the set rpm (rpm of travel hydraulic motor) independently
of travel control position. Thus the pulling power (of the travel hydraulic motor) will increase – the engine will get relieved.
Switch OFF the function of soft starting to move and stopway via switch (3) if this function is turned
ON!
Before turning ON the switch (18), please use accelerator control (13) to adjust engine’s max rpm!
Use speed potentiometer (2) to adjust travel speed, and use travel controls (1) to adjust its direction.
Use switch (18) to turn ON/OFF this function, the indicator lamp on cluster (26) will light up to signal this function.
Swivel travel controls (1) from (0) and the Machine will start moving.
When having overcome a difficult terrain, please turn OFF the switch!
AV 80 X4 65
26
6 5 6 5
1 1
0 N
400132
66 AV 80 X4
OPERATION MANUAL
Travel in CRAB mode
This function is used to adjust extended track during Machine travel.
Use potentiometer (2) to adjust travel speed, and use travel controls (1) to adjust its direction.
Press pushbuttons (5) and (6) on travel controls (1) to control the Machine in CRAB mode, and at the same you may turn the Machine.
Swivel travel controls (1) from (0) and the Machine will start moving.
Turning ON:
Press button (5) to deflect the front drum to the right and press button (6) to deflect to the left, the indicator lamp on cluster (26) will
light up to signal this function.
Max deflection of the front drum to both sides is 180 mm.
Turning OFF:
Press switch (4) to cancel CRAB mode of front drum.
Indicator lamp on cluster (26) will go OFF to signal CRAB mode has been reset.
Note
If the Machine is equipped with cutter and final compactor, then pushbuttons (5) and (6) on travel control (1) on the same side where
it has been mounted, are used to control it.
Then pushbuttons (5) and (6) on the second travel control (1)) are used to control the Machine in CRAB mode.
Take special care when Machine travels in CRAB mode near constructed facilities so to avoid their dam-
age due to any collision (hitting)!
If necessary, fold the external mirrors!
AV 80 X4 67
25 16
14 15
13
1 7 7 1
0 N
400133
68 AV 80 X4
OPERATION MANUAL
2.7.3. Machine travel and reversation incl. vibrations
Adjust max engine rpm via accelerator control (13), and adjust travel speed via speed potentiometer (2).
Use selector switch of the vibrating drum (14) to choose vibration (front / both / rear), and use vibration amplitude selector switch (15)
to choose high or low amplitude.
Vibration manual switching ON/OFF mode (MAN):

Use switch (16) to turn ON/OFF this function.
Press button (7) on travel control (1) to switch ON the vibration.
Indicator lamp on cluster (25) lighted up will signal this function.
Press button (7) on travel control (1) again to switch OFF vibration.
Note
MAN mode enables to switch ON vibration on stationary Machine, the travel controls (1) shall be in (0) position.
You can switch OFF the vibration by shifting travel controls (1) to neutral (N) position.
Automatic vibration switching ON/OFF mode (AUT):

Use switch (16) to turn ON/OFF this function.
Press button (7) on travel control (1) to switch ON vibration.
Indicator lamp lighted up on cluster (25) will signal vibration function.
Vibration will automatically switch ON at travel speed over 0,5 km x hour–1 (0,3 MPH).
Vibration will automatically switch OFF at travel speed below 0,5 km x hour–1 (0,3 MPH).
Automatic vibration function remains enabled even after travel controls (1) have been moved via position (0).
Note
Vibration can be switched OFF through shifting travel controls (1) to neutral (N) position.
2.7.4. Driving with vibrations on compacted and hard materials
During Machine travel with vibration the drums may loose contact with the materials being compacted (so called vibro-stroke) due to
high level of compaction of the background material or travel with vibration on hard materials. This condition will come to light in the
form of increased vibration transfer into Machine frame and onto operator’s control stand. The vibro-stroke can partly be eliminated
through the increased travel speed.
It is banned to work in vibro-stroke mode in the long term!

In extreme cases there is Machine damage hazard or operator’s health hazard!
2.7.5. Compacting near constructed facilities
When required to compact in the vicinity of building facilities, utility lines, buried line systems and cables, then their operating com-
pany shall assess the impact of vibrations generated by the Machine so to avoid their damage.
Manufacturer bears no responsibility for damage caused by operating company!
AV 80 X4 69
25
12
13
1 7 7 1
0 N
400134
70 AV 80 X4
OPERATION MANUAL
2.7.6. How to stop the Machine and its engine
Press button (7) on travel control (1) to switch OFF vibration, indicator lamp on cluster (25) will go OFF.
Stop the Machine through shifting travel controls (1) to neutral (N) position.
Use accelerator control (13) to adjust idle engine speed.
Switch over the key in the ignition box (12) to “0“ position, and tilt back the ignition box lid to close it.
Do not stop hot engine instantly but keep it running idle for 3 minutes. The engine and turbocharger
will get cooled down slowly and evenly!
Travel controls (1) shall be always in neutral (N) position!
Switch OFF the battery disconnector during Machine shutdown!
2.7.7. Safe stopping of the Machine
Deflect travel controls (1) from position (0) and the Machine will start moving.
The Machine will stop only with the travel controls (1) set to the position.
Upon the Machine shutdown the travel controls (1) shall be in the parking brake position (neutral
”N“)!
AV 80 X4 71
25 26
11
1 1
10 1
0 N
400135
72 AV 80 X4
OPERATION MANUAL
2.7.8. Emergency stop of the Machine
Apply this in the event of failure where the engine is unable to be shut off via the key in the ignition box,
or through shifting the travel controls (1) to position (0)!
How to switch ON:

Press emergency brake button (8) and the Machine will brake, engine will turn OFF and the acoustic alarm will start.
On cluster (25) the indicator lamps for seat switch, parking brake, recharging will light up, and lubrication indicator lamp will start to
flicker.
How to switch OFF:

Turn the press button in the direction of arrows and the acoustic alarm will get turned OFF.
On cluster (25) the parking brake indicator lamp and neutral indicator lamp will remain ON.
Shift travel controls (1) to neutral (N) position, the Machine can be started again in this position.
Do NOT use emergency brake to stop or switch OFF the engine during normal operation of the
Machine!
2.7.9. Machine shutdown
Shut down the Machine on flat and solid surface at a point with no potential of natural hazard (landslides, possible flooding, etc.)
Following the engine stop, before leaving the Machine, please disconnect its battery disconnector (50 ).
Clean the Machine to remove dirt (scrapers and drums).
Make overall inspection of the Machine and repair any defects that have occurred during operation.
Lock the Machine covers and its cabin.
Do NOT stop hot engine instantly, but instead let it idle for 3 minutes. The engine and turbocharger will
cool down slowly and evenly!
2.7.10. Sprinkling
It is used to sprinkle the Machine drums.

Switch ON one of two sprinkling pumps via sprinkling pumps selector switch (11).
Indicator lamp on cluster (26) will signal the function of switching ON the sprinkling pump.
Green LEDs signal water level in the tank, red LED flashes when emptied to min.
Use potentiometer for sprinkling interval (10) to adjust sprinkling intensity within the MIN / MAX range.
Use sprinkling pushbutton (9) for additional sprinkling of the drums before the Machine runs on the bitumen surface being com-
pacted.
Check water level in the tank during Machine operation.

We recommend to alter the pumps following 100 motohours in order to ensure their uniform wear.
AV 80 X4 73
2.7.11. How to lift and let down the engine
bonnet „0“ „I“
Stop the Machine, shut off the engine, and disconnect battery
disconnector (50).
Lift the bonnet with the engine shut off

and battery disconnector disconnected!
Check that no persons are under hazard
when letting the bonnet down!
400246
Lift the bonnet

Remove control lever (39) and insert in the hand pump (51).
Turn the bonnet lifting valve clockwise till the stop, do not tight-
en the valve with force.
Pump to lift the bonnet.
400139
Once lifted, secure the bonnet with strut.
400140
Let down the bonnet

Pump to lift the bonnet and secure with strut.
Turn anticlockwise the valve designed to lift the bonnet, the
bonnet will start to descend.
Confirm safe touch-down of the bonnet.
Remove control lever (39) and put it inside Machine cabin.
400139
74 AV 80 X4
2.8. Machine transport
2.8.1. Machine towing
To provide for towing the Machine is equipped with two lugs on

front frame, and with two lugs on rear frame.
A Machine sunk can be hauled for a short

distance if the engine is running and
the travel drive and steering do work.
Operator on towed Machine shall steer
the Machine in the direction of hauling.
Unless the engine works, or a defect ex-
ists within the hydraulic system, or travel
pump is broken, then you must brake off 400145
the Machine and short-circuit the hy-
draulic circuit.
No person may stay on the Machine 3
towed!
When braked off and hydraulic circuit for
the travel is short-circuited, this means
that all the brakes are disabled! 2
Before braking off secure the Machine
with wooden scotch blocks against start- 1
ing to move!
Do NOT touch hot parts of the Machine,
burn hazard!
400146
How to brake off the Machine:

Lift the bonnet and secure it.
Remove hose (3) away from the clip.
Disconnect hose (1) in quick-coupler (2).
Connect hose (3) into quick-coupler (2) .
Unscrew two multi-purpose relieve valves by three threads in
CCW direction [hexagon 22 mm (0,866 inc)].
400147
Multi-purpose relieve valves are located on travel hydroelectric

generator. The travel hydroelectric generator is located on the
LH side, in engine compartment .
Connect battery disconnector (50).
Switch over the key in ignition box to “ I“ position.
Note
If the key remains in “I“ position for more than 15 seconds the
acoustic alarm will switch ON – to warn operator the battery has
been discharged.
400148
AV 80 X4 75
Turn the bonnet lifting valve to the right, up to its stop, do not
tighten with force.
Insert control lever into the hand pump and start pumping until
brake indicator lamp on cluster (25) goes OFF.
Now the Machine is braked off, and it will be possible to tow it
away.
Due to leakage the pressure in the brakes

may lower in course of towing.
Check regularly the Machine brakes do
not become hot in course of towing the
Machine.
If brake indicator lamp will go ON in
course of towing, stop towing the 400139
Machine and start pumping until the in-
dicator lamp goes OFF!
When towing is completed, secure the
Machine with scotch blocks against its
driving away, and carry out the applica-
tion of its brakes!
How to brake the Machine:

Turn the bonnet lifting valve to the left, up to its stop, do not
tighten with force.
478320 h
Put the hose (1) and (3) to its original condition.
Unscrew two multi-purpose relieve valves by three threads in
CW direction [hexagon 22 mm (0,866 inc)].
400111K
Start pumping to lift the bonnet, secure the strut.
Turn the bonnet lifting valve to the left, bonnet will start to de-
scend.
Confirm safe touch-down of the bonnet.
Remove control lever (39) and put it back in the Machine cabin.
Do NOT start the engine while the

Machine is being towed!
To tow, use unbroken hauling ropes,
or drawbar of sufficient loading capac-
ity 1,5 times higher than the weight of
towed Machine. It is forbidden to use
chains to tow the Machine.
Do NOT tow the Machine for a distance
over 300 m (0.19 mi) long!
Max admissible deflection is 30° away
from forward direction of towing!
Max speed limit while towing the
Machine is 2 km/hour (1.2 mph)!
Hauling machine must have sufficient
tractive force (power), weight and brake
effect!
While hauling downhill, please use a
rope to attach another hauling machine
Note
to the rear part of the towed Machine so
to prevent its uncontrolled motion! These are general requirements for safe towing of a damaged
machine under normal conditions. Please consult with your
While towing the Machine do NOT start dealer any and all different situations that may occur while tow-
its engine! ing the Machine.
76 AV 80 X4
OPERATION MANUAL
2.8.2. How to load the Machine 8400 kg
(18 520 lb)
Use loading ramps or a crane to load the Machine on its trans-
porting vehicle. Lmin = 5 m Lmin = 5 m
2x min 2100 kg 2x min 2100 kg
For loading with crane the Machine is fitted with lifting lugs. (2x min 4630 lb) (2x min 4630 lb)
Before lifting, the Machine joint must be

secured against slight turning.
400142
How to secure the joint:

Dismantle the arm (1).
1
Secure the arm with pivots (2) and safety pins locks (3).
400143
Observe safety regulations when load-

ing and unloading!
Use the crane of sufficient loading 3
capacity! 2
Use corresponding and unbroken rig-
ging of sufficient loading capacity!
The Machine must be tied to the lifting
lugs on the Machine!
Only a trained person (slinger) may carry
out the tying of the Machine! 2
Keep off the area beneath the hanging
load! 3
400144
AV 80 X4 77
2.8.3. Transporting by the road
The Machine may pass by its own axis between its workplaces.
During movement, please observe safety measures set for the
workplace.
1 1
When on highway, the Machine must be
transported on a transport carrier of ad-
equate loading capacity!
When moving onto the transport car-
rier we recommend to switch ON the
ANTISTALL function.
2
2
9
The transport carrier must be braked 400141
and mechanically locked against any un-
desired move by scotch blocks (2) when
loading and unloading!
A person guiding the Machine must
communicate with driver through using
communication signals required, refer
to Section 2.1.6., and must stay all the
time at one point beyond reach of the
Machine. At the same time he/she must
be within driver’s field of view (in visual
contact) over the entire period of mov-
ing the Machine onto a transport carrier
and down from the carrier.
When moving onto a transport carrier
and moving down from the carrier all the
persons aside from Machine operator
must move away as far as not to cause
hazard if the Machine falls down!
While transported the Machine must be
fixed to the transport carrier with tie offs
(1) in rigging points!
Rigging points are the front and rear rig-
ging holes in drum frames.
When transporting the Machine no per-
sons may be present on the Machine,
driver’s control stand or transport
carrier!
78 AV 80 X4
2.9. Special conditions to use the Machine
2.9.1. How to operate the Machine during its 2.9.3. Machine operation at high temperatures
running-in and humidity
Do NOT load the Machine at its full capacity when putting the
new Machine into operation or following its major overhaul dur- The engine power lowers with the air temperature and moisture
ing the first 30 hours! increasing. Due to the fact that both these factors reducing the
engine power, are independent on each other, it is possible to
describe their impact as follows:
2.9.2. Operating the Machine at low
temperatures -- each 10 °C (18 °F) of temperature rise means power drop
by up to 4 % (at constant humidity)
Compacting during winter season depends on the content of
fine particles and water in the soil being compacted. With the -- each 10 % of RH increase means power drop by up to 2
temperature dropping below freezing point the soil becomes % (at constant temperature).
more solid and harder to compact.
At ambient temperatures when hydraulic oil temperature is
At the temperatures below 0 °C (32 °F) it is possible to compact constantly round 90 °C (194 °F), we recommend to exchange oil
only dry soils (and stony loose materials), or carry out rapid com- for the one with cinematic viscosity of 100 mm2/s.
paction of non-frozen materials (before soil gets frozen).
2.9.4. Machine operation at high altitudes
Set up the Machine for operation at low temperatures: With the altitudes increasing the engine power drops due to
•• Check concentration of engine cooling liquid. lower atmospheric pressure and lower specific weight of intake
•• Exchange motor oil for the one recommended for given ex- air.
ternal temperature range.
•• Use hydraulic oil of corresponding cinematic viscosity. Engine power depends on the environ-
•• Use winter diesel oil. ment where the Machine is operating.
•• Confirm battery has been recharged.
A precondition for proper starting at low temperatures is that 2.9.5. Machine operation within very dusty
the battery is OK. The Machine can be used at its full capacity environment
only after the media have been heated to their operating tem-
peratures.
While in very dusty environment, please
cut short the intervals of cleaning and
replacing the air filter elements; and the
replacement intervals of cabin dust fil-
ter, and cut short the intervals of clean-
ing the coolers.
Recommended interval of cleaning is 1x
per week.
AV 80 X4 79
Notes
80 AV 80 X4
Notes
AV 80 X4 81
Notes
82 AV 80 X4
3. MAINTENANCE MANUAL
AV 80 X4
(Cummins tier 2)
AV 80 X4 83
84 AV 80 X4
3.1. Safety and other measures for machine maintenance
3.1.1. Safety of machine maintenance 3.1.2. Fire precautions during operation media
exchanges
Carry out lubrication, maintenance and adjustments:
• By professionally trained personnel • In terms of fire hazard the flammable liquids used on the
Machine have been divided into three hazard classes:
• In line with safety instructions given in the Operation Man-
ual IInd Hazard class – Diesel oil
• According to schedule given in the Lubrication Chart follow- IVth Hazard class – mineral oils, lube greases
ing the hours actually worked • Oil exchange point shall be located so it does not interfere
• On the machine located on flat solid surface, secured against with the explosion or fire hazard area.
self-motion (scotch blocks), and this always with the engine • It shall be identified with notice boards and signs of no
OFF, key removed from ignition box, and the wiring cut off smoking and no use of open flame.
• On machine parts cooled out • Handling area shall be sized so the capture the amount to
• After having cleaned the machine, lubrication points and flammable liquid equal to the capacity of biggest vessel,
maintenance locations transport container.
• Using proper, undamaged tools • It must be equipped with portable fire extinguishers.
• Through replacement with new original parts as per the • To handle the oil, Diesel oil, please use such vessels like met-
Spare Parts Catalogue al barrels, canisters or sheet-metal cans.
• With sufficient lighting of the entire machine in the event of • Transport containers shall be properly closed when stored.
lowered visibility and at night • Vessels shall have one opening, be stored with the opening
• so the guards and safety elements are reinstalled again on top, and secured against any flowing out or dripping of
upon work completion their content.
• through retightening bolted connections – with torque • Vessels shall be designated with indelible inscription indi-
specified, and through checking the connection tightness cating the content and flammability class.
• with the operation media heated – beware of burns – use

recommended media, only
Upon completion of the adjustment or

maintenance, please examine the func-
tion of all safeguard equipment!
AV 80 X4 85
3.1. Safety and other measures for machine maintenance
3.1.3. Ecological and hygienic principles Ecological principles
When operating or maintaining the Machines the user shall be

liable to follow the general principles of health and environment
protection according to the laws, ordinances and regulations in The media of Machine’s individual sys-
individual territories of the Machine use. tems, and some of its parts after having
been discarded (dismantled, media ex-
changed) become waste with hazardous
Hygienic principles properties against the environment.
-- Crude oil products, cooling system media, battery me-

dia and coating compositions incl. thinners are materi- • This category of waste products includes the following in
als harmful to health. Workers coming into contact with particular
these products during machine operation or mainte- -- Organic and synthetic lubricating materials, oils and fu-
nance shall be liable to follow the general principles of els
their own health protection and conform to the safety
-- Brake fluids
and hygienic manuals of these products’ manufacturers.
-- Cooling liquids
• We call your attention to the following in particular:
-- Battery media and the batteries themselves
-- Eye protection and skin protection during work with the
batteries -- Cooling system media
-- Skin protection during work with crude oil products, -- Cleaners & preserving agents
coating compositions or cooling liquids -- All dismantled filters and filter elements
-- Proper hand washing upon work completion and before -- All used and discarded hydraulic or fuel hoses, rubber-
any meal; use adequate reparation cream to treat your metal and Machine’s other elements, made dirty due to
hands the abovementioned products.
-- Adherence to the instructions given in this Manual
• Always store the crude oil products, cooling system media The given materials and parts, when
and battery media, and coating compositions incl. organic scrapped, shall be handled compliant to
thinners, and also the cleaners and preserving agents, in the the respective national regulations on
genuine, original and properly labelled packages. Do not environmental protection, and in line
admit any storage of these materials in unlabelled bottles with the health protection regulations,
or in any other vessels with regard to the hazard of mistaken as well.
identification (faulty change).
• When skin, mucosa, eyes are accidentally stained, or va-
pours inhaled, immediately apply the first aid principles. In
the event of accidental use of these products get prompt
medical attention.
• When working with the Machine in cases where the Machine
has platform fitted, cabin windows are left opened, always
use ear protectors of adequate type and version.
86 AV 80 X4
3.2. Media specification MAINTENANCE MANUAL
3.2.1. Engine oil Viscosity Diagram
2412
Engine oil has been specified according to the performance

classification and viscosity classification.
Performance classification per

API (AMERICAN PETROLEUM INSTITUTE)
CCMC (COMMITTEE of COMMON MARKET AUTOMOBILE CON-
STRUCTORS).
ACEA (ASSOTIATION DES CONSTRUCTEURS EUROPÉENS DE AU-
TOMOBILE)
Viscosity classification
Ambient temperature and type of operation at the location
where the Machine is used are decisive to determine the SAE
(Society of Automotive Engineers) viscosity class.
Use of admissible oils:

API CH4/SG
CCMC D5
Year round SAE 15W-40 (e.g. Cummins Premium Blue).
Note
Exceeding low temperature limit will not lead to any engine
damage. It may only cause problems when starting the engine.
It is appropriate to use universal multigrade oils so there shall be
no need to exchange oil due to ambient air change.
To make starting easier at the temperatures below 0 °C (32 °F)
the engine oil producer recommends SAE 10W-30 oil as per the
diagram.
400150
Exceeding upper temperature limit must
not be of long duration due to lowered
lubricating capability of oil.
AV 80 X4 87
3.2. Media specification
3.2.2. Fuel 3.2.3. Hydraulic oil

2158
The following Diesel oils are used as engine fuel: Only the quality hydraulic oils of power class under ISO 6743/
CEN EN 590 HV (corresponds to DIN 51524 Part 3 HVLP; CETOP RP 91 H) must
be used for the Machine’s hydraulic system.
ASTM D 975-88: 1-D a 2-D
Standardly refill the machines with hydraulic oil of kinematic vis-
cosity 68 mm2/s at the temperature of 40 °C (104 °F) ISO VG 68.
This oil is the most suitable one to use in the broadest range of
Use winter Diesel fuel at low ambient
ambient temperatures.
temperatures below 0 °C (32 °F).
Note
At high ambient temperatures when oil
Sufficient frost resistance can be achieved also through provid-
ing the fuel with additive to improve its fluidity (fuel additives). temperature reaches constantly 90 °C
(194 °F) we recommend to exchange oil
with cinematic viscosity of 100 mm2/s
- HV 100 (BP BARTRAN HV 100; ESSO
Winter fuel mixtures are of the same UNIVIS N 100, etc.).
ignitability like petrol – follow the fire
If it is necessary to start the Machine for
regulations!
the period of one month or longer at am-
bient temperatures below –8 °C (18 °F),
please exchange oil in the hydraulic sys-
tem for the oil with cinematic viscosity of
Do NOT use other fuels (e.g. bio diesel
46 mm2/s – viscosity class HV 46.
fuel, mixed bio diesel fuel, LFO, etc.) than
those diesel fuels specified above. At the temperatures below –13 °C (9 °F),
please exchange oil for the one with cin-
ematic viscosity of 32 mm2/s – viscos-
ity class HV 32 (e.g. BP BARTRAN HV 32,
ESSO UNIVIS N 32, etc.).
Hydraulic oil synthetic type

Hydraulic system is possible to be filled with synthetic oil, which
is during any leakage this oil will be restless degraded via micro-
organisms found in water or in soil.
Please, always consult with the producer

or dealer any switching to another type
of oil or blending with other types of
oils.
88 AV 80 X4
MAINTENANCE MANUAL
3.2.4. Lube grease 3.2.5. Coolant

0787 2152
Use plastic lubricant with lithium content to lubricate the Ma- Cooling liquid in the ratio of 50% water and 50% antifreeze
chine under the following standards: agent (for ambient temperature of up to -37 °C [-34 °F]) will be
ISO 6743/9 CCEB 2 used within the climatic zone with no temperature drops be-
low 0 °C (32 °F). Cooling liquid is not used only as protection of
DIN 51 502 KP2K-30 the cooling system against frost but also to increase the boiling
point. The inhibitors contained in antifreeze agent protect the
Note
parts of engine cooling system. The propylene antifreeze agent
For instance Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, can be used as cooling system medium as well.
Grease No 3, etc.
Use treated demineralised or distilled water to prepare the cool-
ing liquid.
The following antifreeze agents can be among others:

SUNOCO - PERMANENT ANTIFREEZE
SHELL - Glycoshell AF 511 S
TEXACO - HAVOLINE Antifreeze Coolant/AFC
CASTROL - ANTIFREEZE MB
Unless necessarily required, never use

higher than 50% ratio of antifreeze cool-
ant in the cooling liquid.
Never use the ratio over 68%!
We do not recommend antifreeze agents
to be mutually mixed. Mixing together
various types of coolants may case loss
of antifreeze characteristics.
Check the portion of antifreeze coolant
in cooling liquid always before winter
period, using refractometer (density
meter).
Health hazardous nitroamines occur
when mixing nitride-based antifreeze
coolant with amine-based agent.
AV 80 X4 89
3.2. Media specification
3.2.6. Glass washer fluid

2260
Use water (up to 0 °C temperature) and agent for motor vehicle

glass washers when filling the glass washer tank.
Replace water with antifreeze agent at

the temperatures below 0 °C (32 °F).
90 AV 80 X4
3.3. Media MAINTENANCE MANUAL
Medium Amount
Part Medium Type Brand
l (gal US)
Engine Engine oil under Section 3.2.1. 8 (2,11)

2412
Fuel tank Fuel under Section 3.2.2. 110 (29,05)
Hydraulic tank Hydraulic oil under Section 3.2.3. 54 (14,27)

2158
Drum bearings, calliper

bearings, king pins, sus- Lube grease under Section 3.2.4. As required
pensions 0787
Cooling system Coolant under Section 3.2.5. 18 (4,75)

2152
Vibration drum Engine oil under Section 3.2.1. 2x10 (2x2,64)

2412
Baterry Distilled water As required

2587
Glass washer tank Liquid under Section 3.2.6. 2,75 (0,72)

2260
Sprinkling tank Water 600 (158,5)

2567
AV 80 X4 91
92
INSPECTION, CHECKING, REPLENISHMET, ADJUSTMENT
TO BE CARIED
OUT REGULARLY, EVERY CLEANING
(hours)
LUBRICATION
20 250
CHAPTER
500 1000 2000 Maintenan. EXCHANGE

as
needed
daily 3 monts 6 monts 1 year 2 years
ACTIVITY
Engine – oil amount 3.6.1.
Engine – coolant amount 3.6.2.
Engine - belt 3.6.3.
Engine – crankcase breather 3.6.4.
Air filter vacuum valve 3.6.5.
Cooling circuit – fan condition 3.6.6.
Fuel tank – fuel amount 3.6.7.
Hydraulics tank – oil amount 3.6.8.
3.4. Lubrication and Maintenance Chart
Sprinkling tank – water amount 3.6.9.

Alarm and control devices 3.6.10.
Engine – oil and filter 3.6.11.
Engine – induction manifold 3.6.12.
Engine – cooling circuit 3.6.13.
Battery 3.6.14.
Air filter vacuum switch 3.6.15.
Sprinkling filter and sprinkler strainers 3.6.16.
Machine lubrication 3.6.17.
Engine – fuel filter 3.6.18.
Engine – coolant concentration 3.6.19.
Engine - belt 3.6.20.
Engine - exhaust 3.6.21.
Silencing system 3.6.22.
400151en
AV 80 X4
20 250 500 1000 2000 Maintenan.
as ACTIVITY CHAP.
needed
AV 80 X4
daily 3 monts 6 monts 1 year 2 years
Sprinkling tank 3.6.23.

* Engine – valve clearance adjustment 3.6.24.
Engine - coolant 3.6.25.
Drums – oil in drum vibrators and drum bearings 3.6.26.
Hydraulics tank – oil and filter 3.6.27.
Fuel system venting 3.6.28.
Engine – air intake filter 3.6.29.
Engine – fuel filter water trap 3.6.30.
Engine radiator and hydraulic oil cooler 3.6.31.
Cabin – air intake filter 3.6.32.
Sprinkling tank – water drain before winter season 3.6.33.
Drums – scraper adjustment 3.6.34.
Machine cleaning 3.6.35.
Bolted connections 3.6.36.
* First following the first 250 motohours. ! PLEASE, CONTACT CUMMINS SERVICE!
400152en
MAINTENANCE MANUAL
93
3.5. Lubrication Chart
LUBRICATION PLAN
2000 h
every 2 years
1000 h
yearly
250 h
quarterly
20 h
daily
Legend symbol:
Inspection, Replenishment
Lubricate
Exchange
Type of fill:
Engine oil: API: CH4/SJ; CCMC: DHD1; ACEA: E5; SAE 15W/40
Hydraulic oil: ISO: VG 68; ISO 6743/HV
Grease: ISO: 6743/9 CCEB 2, DIN 51 502 KP2K - 30
400153en
94 AV 80 X4
3.6. Lubrication and Maintenance Operations MAINTENANCE MANUAL
Carry out lubrication and maintenance in regularly repeated intervals as per the everyday data reading on the counter of hours actu-
ally worked.
478320 h
400154
This Manual includes only the basic engine information, others are given in the Engine Operaion and Maintenance Manual which is
part of documentation supplied with the Machine.
Follow the instructions given in the Engine Operation and Maintenance Manual!
Removed or loose bolts, plugs, threaded joints of the hydraulics, etc. shall be tightened with the torque according to the charts in Sec-
tion 3.5.36 unless a different value is given with the relevant operation.
Carry out the inspection of the Machine located on flat, solid surface secured against self-motion (scotch
blocks), and this always with the engine OFF, key removed from ignition box, and with the wiring dis-
connected (unless otherwise required).
Following the first 250 hours of new Machine operation or after the major overhaul, please carry out the operations under this
Section:
3.6.24. Valve adjustment
AV 80 X4 95
3.6. Lubrication and Maintenance Operations
Following the 20 hours of operation or daily
3.6.1. Inspect, refill the oil amount in the

engine
• Pull out oil dipstick (1), wipe it.

• Put it back down to the stop and pull out again to read the
oil level.
Note
1
If the engine was running, wait ca 3 minutes until oil descends
into engine sump.
400155
• Replenish oil through filler-neck with the filler plug removed

(2).
2
400156
Note
• Low division mark L shows lowest possible oil level, high di-
vision mark H (High) shows the highest level.
• The amount of oil between Low and High marks is 1,5 l (1.6
U.S. Quart).
• Following the refill, please wait ca 3 minutes until oil de-
scends into the sump, then check the level.
400157
Do NOT run the engine unless there is

correct oil level in the engine.
Maintain the level between the division
lines stamped on the dipstick.
Refill the oil of identical type as stated in
Section 3.2.1.
96 AV 80 X4
MAINTENANCE MANUAL
3.6.2. Inspect, replenish the engine coolant
amount 1
• Do it before starting the engine, visual inspection of the
level.
• Top up through filler neck (1).
• Keep level between ”MIN” and ”MAX” lines.
• At higher losses find out any cooling system leakage and
repair the cause.
Wait to remove the filler plug only after 400158

engine coolant temperature drops below
50 °C (120 °F). If filler plug is removed at
higher temperature then the hazard of
vapour scald or coolant scald will occur
due to inner overpressure effect.
Do NOT use any additives to repair

cooling system leaking into the engine
coolant!
Do NOT refill cold coolant in hot engine!
Danger of engine castings damaged.
Top up only with the coolant consisting
of antifreeze agents of identical base un- 400159
der the Section 3.2.5.
AV 80 X4 97
3.6.3. Inspect the engine belt
• Make visual belt inspection, monitor any of its damage.

Cracks perpendicular to the belt width are not considered
a damage.
400160
When longitudinal cracks occur on the

belt, or belt edges are shattered, or ex-
tracted parts of material, then the belt
must be replaced.
400161
3.6.4. Crankcase breather
• Check crankcase breather pipe so it is not clogged due to

any deposits, fragments, chips, or in winter frozen with ice.
400156A
When running the Machine during low

temperature period or under low tem-
perature conditions, make the inspec-
tions in shorter intervals.
400162
98 AV 80 X4
MAINTENANCE MANUAL
3.6.5. Inspect air filter vacuum valve
• Clean the exit slit, press to remove any dust trapped.

Note
Any dust trapped in the dust valve will automatically be emp-
tied with the Machine running.
400163
Do NOT operate the Machine when dust

valve is damaged.
If air filter vacuum valve is damaged, re-
place it with new one of identical type!
3.6.6. Inspect fan condition
• Inspect visually the fan. If damaged (e.g. missing parts of

material, cracks, shape changes, etc.), replace the fan.
400148A
AV 80 X4 99
3.6.7. Check fuel amount
• Check the amount of fuel on LH cluster signalled by LEDs,

and in case of lack of fuel, please replenish.
• Minimal amount of fuel is signalled by red LED flickering.
478320 h
400111A
• Clean tank filler cap (1) and filler neck (2).

1
• Unlock tank filler cap lock, turn the filler cap and remove it.
• Refill the tank up to the bottom edge of filler neck via the
strainer (3). 2
Note
Fuel tank capacity is 110 l (29 gal US). Fuel tank will last ca 14
hours of the Machine operation.
400165
NO smoking and no use of open flame

when at work.
Do NOT refill fuel while engine is
running. 3
Do NOT use up fully the tank. When used

up fully the entire fuel system must then
be deaerated, which is rather hard and
demanding.
Use solely a clean recommended fuel per
Section 3.2.2.
400166
NEVER replenish fuel in confined space.
Fuel must NOT be spilled.
100 AV 80 X4
MAINTENANCE MANUAL
3.6.8. Inspect oil amount in the hydraulic
circuit tank 2
• Lift the bonnet.
• Check oil level in oil gauge.
• Fill up oil via the filling device using quick-coupling (1), pro-
ceed as per Section 3.6.27..
Tank filler neck cap (2) has been sealed.

If this seal is damaged during guarantee
1
period, then the Machine guarantee will
terminate. 400167
Conduct this filling method as emer-
gency one – not recommended by
manufacturer!
Oil level shall always be visible in oil
gauge!
Refill required oil according to the
Section 3.2.3..
Upon higher loss of oil, find out the
cause of hydraulic system leaking (leaks
through hose screw joints, screwed fit-
ting of hydroelectric generators or of
hydraulic motors, etc.), and repair the
defects.
3.6.9. Fill up sprinkling water tank
• Check water amount on the RH cluster. It is signalled by

LEDs, and in case of lack of water, please refill.
• Minimal amount of water is signalled by red LED flashing.
• Perform the following before engine is started.
400112A
Open the cap (1) and refill with clean water via the strainer (2).
2
Before winter period, drain water from
the water tank and sprinkling system!
Proceed according to Section 3.6.33.
400148
AV 80 X4 101
3.6.10. Inspect alarm and control devices
• Turn ON the ignition key into position I.

• On the LH and RH clusters the automatic control of the light-
ing function will occur, and this through the pilot lamps go-
ing on.
0 I II
400164
• Then all the pilot lamps will go off on the RH cluster, and the
lamps on the LH cluster will remain on:
-- Indicator lamp for the zero position of travel controller
-- Brake alarm indicator lamp
-- Battery charge control lamp
-- Engine lubrication indicator - flickers
478320 h
400111B
• In addition, please test if the switches (19 - 22) and the com-
bined switch (17) work. 22 21 20 19
Note
When lights are switched ON the luminous intensity of indicator
lamps (25) and (26) on clusters will lower.
17
400128
• Start the engine

• The indicator lamps on LH cluster must go off:
-- Battery charge control lamp
-- Engine lubrication indicator
Note
If the engine is not started within 10 sec. after ignition key has
bee turned ON into position I, then acoustic signal will be en-
abled (to warn operator of the battery possibly discharged).
478320 h
400111C
102 AV 80 X4
MAINTENANCE MANUAL
Start moving the Machine:
• Indicator lamps on LH cluster shall go OFF.
-- Indicator lamp for the idle (neutral) of travel controller
-- Brake alarm indicator
478320 h
400111D
Emergency brake push button function:

• Check whether emergency brake works (8).
• The engine stalling.
• Then the following indicator lamps on LH cluster remain
ON:
N 0
STOP
-- Seat switch indicator lamp
-- Parking brake warning lamp 8
-- Battery charging indicator
-- Engine lubrication indicator - flickers
• When travel controller is shifted to neutral position (N) the
seat switch indicator lamp goes OFF, and idle indicator lamp
lights up. Now you can start the engine again.
400169
Use sound signal to indicate the engine

start!
Before engine is started, check there
is no hazard of any person if engine is
started!
Use sound signal before Machine starts
moving and wait long enough to any
persons present can leave the area
round the Machine (space beneath the
Machine) in time!
Make sure the area in front and behind
the Machine is free, with no persons
present within thereof!
During operation, check continuously

the instruments and indicator lamps.
Promptly repair any failures!
478320 h
400111
AV 80 X4 103
Following 250 hours of operation

(after 3 months)
3.6.11. How to exchange motor oil and oil filter
• Prepare an appropriate vessel of ca 20 litre capacity.

• Remove drain plug (1) and let the oil flow out.
1
When draining the oil temperature shall
not be over 60°C (140°F) – risk of burn.
400170
• Clean the surface round oil filter head. Remove the filter.
400171
400172
• Clean seating face for filter gasket.
400173
104 AV 80 X4
MAINTENANCE MANUAL
• Apply oil slightly across rubber gasket for the filter and screw
back, tighten properly with hand.
400174
Do not overtighten the filter, the thread

and gasket may get impaired!
400175
• Check the drain plug gasket, replace if damaged.

• Check the thread and clean seating face for gasket.
• Reinstall the plug. Torque is 50 Nm (37 ft lb).
400170A
• Use filler neck (2) to fill the engine with clean motor oil.
400156
AV 80 X4 105
Note
• Fill up to the dipstick’s top division mark. Total sump capac-
ity is 8 l (2,1 gal US).
• When oil is exchanged, start the engine and let it run at
higher idle rmp for 2 - 3 min.
• Stop the engine and wait for ca 3 min until oil descends into
the crankcase, then check the proper oil level.
Drain oil when hot – best upon operation

completion.
Use original filters only.
Use recommended oil under Section 400178
3.2.1, only.
To not overtighten the filter, its thread
and gasket may get damaged.
Check the tightness.
Collect the oil drained, do not let oil soak

into soil.
Dispose of oil compliant to regulations.
Store used filters in a separate container
and handle them so these do not pollute
the environment.
3.6.12. Inspect engine induction manifold
• Check the pipes and clamps.
Do not operate the Machine if pipes and

clamps are damaged!
400179
106 AV 80 X4
MAINTENANCE MANUAL
3.6.13. Inspect engine cooling circuit
• Check the cooling circuit tightness. Confirm no pipes are

damaged and no clamps are missing.
400180
400170B
• Check that oil cooling gills and radiator fins are not fouled.
If fins are fouled then clean them, for instance purging the
coolers with pressure air (steam or hot water) according to
Section 3.6.35
400181
400182
AV 80 X4 107
3.6.14. Inspect the battery
• Stop the engine and use disconnector to disconnect the wir-

ing.
400129
• Clean the battery surface.

• Inspect the condition of poles and terminals. Clean the poles 1
and terminals. Apply thin layer of grease on terminals.
400177
• Open the battery cell plugs (2) to check electrolyte level to

confirm the electrolyte level reaches 5 ÷ 15 mm (0.2÷0.6 in)
above the plates (electrodes) in all the cells, or to the bot-
tom edge of the gauge inside the battery cells. Refill with
distilled water those cells having electrolyte less than 5 mm
(0.2 in) above the plates.
2
400177A
• Measure the electrolyte density in individual cells with the

refractometer or density meter.
400183
108 AV 80 X4
MAINTENANCE MANUAL
• Compare measured values with the chart.
Keep the battery dry and clean.
Density
Close the battery when checking is
in g/cm3 in °Be (Beume) completed.
20 °C 20 °C Refill the battery with distilled water
Tropics Tropics
68 °F 68 °F only – never with acid.
fully charged 1,28 1,23 32° 27° Replenish distilled water just before op-
erating the Machine or before battery
semi
1,2 1,12 24° 16° recharging.
charged
Recharge the undercharged battery.
exhausted - Recharge the battery off the Machine.
charge 1,12 1,08 16° 11° Open battery plugs before recharging.
immediately! Never disconnect the battery with the
engine running.
Follow the battery manufacturer’s man-
Note
ual when working with the battery!
• Check the level with glass tube.
Disconnect the battery during its repair,
• Unless the Machine is going to be used during winter sea- or when handling the wires and electric
son for a couple of months, remove the battery and store it devices within the wiring circuit to avoid
so it is protected against any frost. Carry out inspections of any short circuit.
the battery and its recharging before its storage and for the
period it is stored. To disconnect the battery you must first
disconnect (–) pole of the cable. To con-
nect, first connect (+) pole.
Never make direct conductive connec-
tion between the battery’s both poles,
short circuit will occur with the risk of
battery explosion.
Use rubber gloves and safety glasses Do not turn the battery upside down,
when working with the battery. electrolyte may pour down from the de-
Protect your skin with proper clothing gassing plugs.
against being stained by electrolyte. Flush spilled electrolyte with water, and
Upon eye contact with electrolyte im- neutralize with lime.
mediately flush eyes with large amounts Hand over the aged battery that does
of water for at least a couple of minutes. not work, for its disposal.
Get prompt medical attention.
Upon ingestion of electrolyte drink max
amount of milk, water or solution of cal-
cined magnesia in water.
Upon skin contact with electrolyte re-
move contaminated clothing, includ-
ing shoes, wash affected spots as soon
as possible with soap water or solution
of soda and water. Get prompt medical
attention.
Do not eat, drink, smoke, while at work!
Having finished the work, please wash
your hands and your face thoroughly
with water and soap!
Do not try whether wires are energized
through contacting Machine frame.
AV 80 X4 109
3.6.15. Inspect the function of air filter vacuum
switch
• Adjust the engine rpm to round 1500 rmp.

• Cover briefly the air filter intake hole.
Inspect always when cleaning the induc-

tion air pre-filter!
Do not use thin paper to cover it – be-
ware of intake hole clogged!
400182A
• Once covered, the indicator lamp for air filter clogged shall
light up.
478320 h
400185
• Unless indicator lamp goes ON, check the vacuum switch,

contacts and feeder cables.
400186
110 AV 80 X4
MAINTENANCE MANUAL
3.6.16. Sprinkling filter & sprinkler strainer
• Close water supply through the valve.
400187
• Remove sprinkler filter vessel (1), replace the strainer (2) and
clean it.
1 2
400188
• Remove and clean sprinkler strainers (3).
400189
400190
AV 80 X4 111
3.6.17. Machine lubrication
• Take off the caps on the greasing nipples.

• Step by step, put on the greasing nipple of high-pressure press and lubricate till the old grease starts pouring out.
• Reinstall the greasing nipple caps.
Use only the recommended lube greases, refer to Section 3.2.4.
Steering joint
Upper bearings 2 x
Lower bearings 2 x
400191
Main bearing 4x
400192
Linear hydraulic motors for steering

Pins 6x
400193
112 AV 80 X4
MAINTENANCE MANUAL
Linear hydraulic motors to lift off the bonnet
Upper pins 2 x
Lower pins 2 x
400194
Cabin door hinge pins

pins 8 x
400195
AV 80 X4 113
3.6.18. How to replace fuel filter
• Clean the fuel filter.

• Remove the filter.
• Clean the sealing face of filter holder.
400197
• Fill new filter with clean fuel and lubricate sealing “O” ring
(2) with oil.
• Screw the filter with hand until the gasket gets seated, and
then tighten by another half-turn. 2
• Use a hand pump to add fuel into the filter.
• Inspect the filter tightness when engine is started!
Observe fire precautions during replace

ment!
Replace in ventilated rooms with no fire
hazard.
Do not smoke or use open flame when at
work. 400198
Use the recommended original filters,

only.
Make no over-tightening of filters, the
thread and gasket may get damaged.
Avoid fuel leaking into soil.

Store used filters in environmentally
friendly manner.
400197A
3.6.19. Inspect coolant concentration
• Check the concentration via refractometer.
Inspect always before winter season.

Unless concentration for -36 °C (-33 °F)
has been measured, you must adjust it
through adding antifreeze into the cool-
ing system.
Add antifreeze according to Section
3.2.5.
400183
114 AV 80 X4
MAINTENANCE MANUAL
Following 1000 hours of operation (after 1 year)
3.6.20. Inspect engine belt
Check the belt with the engine OFF!
Check the belt tension:

• Use parking brake to secure the Machine.
• Press with your thumb at the spot where belt length be-
tween pulleys is the longest, using 6 kg (13.2 lb) strength.
• Max slack is 10 mm (0,39 in). 400199
Check the belt wear:

• Inspect visually the belt.
• If longitudinal cracks occur on the belt, or belt edges are
shattered, or parts of material are extracted, then you must
replace the belt.
400161
Belt tension:
Check the belt and take up the slack with

the engine OFF!
400200
3.6.21. Inspect the exhaust system
• Check the leak tightness of exhaust manifold in the direc-

tion towards the engine.
• Check the exhaust manifold leading to the exhaust muffler.
• Torque of the exhaust-header (collector) pipe - 21 Nm.
400201
AV 80 X4 115
3.6.22. Inspect the silencing system
• Check the condition of rubber-metal, coherence (bond

strength) between metal and rubber.
Replace the damaged ones.

Check the bolts and nuts of the following
are tightened:
Rubber-metal of drums – LH side and RH side 2x 8.
400202
Rubber-metal of driver’s compartment 4x.
400204
Rubber-metal for the engine 3x.
400205
Rubber-metal for battery holder 4x.
400177B
116 AV 80 X4
MAINTENANCE MANUAL
3.6.23. Clean the water tank
• Remove the tank filler neck cap.
400148A
• Open tank drain hole.

• Flush the tank with stream of water.
400206
• Clean the strainer inside the filler neck.
Drain water from water tank before win-

ter season!
Proceed in line with the Section 3.6.33.
400148B
AV 80 X4 117
Following 2000 hours of operation

(every 2 years)
3.6.24. Inspect, adjust engine valve clearance
! Contact CUMMINS service dept.!
• Remove the vent pipe.
400207
• Remove the intake.
400208
400209
• Remove the valve cover.
400211
118 AV 80 X4
MAINTENANCE MANUAL
• Rotate the crankshaft pulley towards the TDC of valve No. 1
compression (inlet valve of cylinder No. 4 opens and both
valves of cylinder No. 1 close).
• Align the mark on crankshaft “1.4 T” against the indicator (2).
Cylinder No.1 is in TDC at compression cycle – both valves
are free. 2
400212
400213
• Check the setting gauge (1).
400214
• Adjust the clearance (1) between valve rocker arm (2) and
valve (3). Loosen the lock nut (4) and turn the adjusting
screw (5).
• When adjusted tighten the lock nut. The torque is 39-49 Nm
(29 - 36 ft lb).
400215
AV 80 X4 119
• Check the other valves.
• Turn the crankshaft by 360° (by 1 rotation). 1 2 3 4
I E E I
400216
• Adjust other valves as per the Fig.

• Valve adjustment figures (hot or cold engine):
Inlet valve (I) - 0,35 mm (0,014 in) clearance.
Exhaust valve (E) - 0,50 mm (0,020 in) clearance.
• Reinstall the valve cover, air supply manifold and engine
breather pipe.
I E I E
400216A
Valve sequence of 1÷4 is from the fan

pulley.
Correct clearance will be adjusted if you
can feel resistance when the setting
gauge moves.
Tighten the lock nut and check the clear-
ance again.
120 AV 80 X4
MAINTENANCE MANUAL
3.6.25. Engine coolant exchange
How to drain cooling circuit:
Before you drain the coolant from the

cooling circuit let the engine run for 5
minutes for the liquid temperature to
reach 82°C (180°F)
Do not open overpressure plug before
coolant temperature drops below 50 °C
(122 °F). If you open overpressure plug
the liquid may splash out causing scald.
400159
Stop the engine.

• Open the cooling system by removing the overpressure
plug (1) on the expansion tank.
1
400158A
• Remove the cooling circuit drain plug. Let the liquid pour
down into the vessels set up. The drained amount is ca 20 l
(5.2 gal U.S.).
400170C
• Check whether pipes within the engine cooling system are

not damaged, clips missing. Check the radiator condition
whether not damaged, not leaking, and cooling gills not
fouled with impurities. Clean and repair the radiator, if re-
quired.
400181
AV 80 X4 121
Clean the cooling circuit:
The process of cleaning the cooling circuit is divided into two
parts.
First part:
• Install the drain plug, fill the cooling system with the mix-
ture of the following ratio: 0,5 kg (1 lb) of sodium carbonate
and 23 l of water, or agents normally available on this base.
• When filled, wait for ca 2-3 min until air escapes and the cir-
cuit gets filled. Max filling rate is 10 l/min [2,6 gal US/min].
• Do not close the tank with overpressure plug.
• Start the engine and let it run for 5 minutes for liquid tem-
perature to reach 82°C (180°F).
400170C
Inspect cooling circuit tightness and liq-

uid level on water gauge.
Stop the engine, drain the cooling circuit and reinstall the drain
plug.
400217
Second part:
• Fill the cooling circuit with clean water. When filled, wait ca
2-3 min until air escapes and the circuit gets filled. Max fill-
ing rate is 10 l/min [2,6 gal US/min].
• Do not close the tank with overpressure plug.
Inspect cooling circuit tightness and liq-

uid level on water gauge.
400218
• Stop the engine and drain the cooling circuit.
Note
Repeat this process until clean water flows out.
400158B
122 AV 80 X4
MAINTENANCE MANUAL
Fill the cooling circuit:
• Install the drain plug, fill the cooling system with new cool-
ant at the ratio of min 50 % water + 50 % antifreeze.
Wear gloves to protect your hands!

Wear safety glasses or face shield to pro-
tect your eyes!
Fill with the coolant according to the
Section 3.2.5!
To make the change proceed as per the
manual from antifreeze producer!
400219
• Refill the coolant to max level. When filled wait ca 2-3 min
until air escapes and the circuit gets filled. Max filling rate
is 10 l/min [2,6 gal US/min]. Close the expansion tank with
overpressure plug.
Start the engine and wait until the tem-

perature reaches 82 °C (180 °F). Check
during your waiting for any leakage of
cooling liquid and check the level on the
indicator.
400218
• Stop the engine.
• Check the level height on water gauge.
• Confirm the coolant level on water gauge is between MIN
and MAX.
Do not open the overpressure plug be-

fore coolant temperature drops below
50 °C (122 °F). If you open overpressure
plug the liquid may splash out causing
scald!
400158B
Hand over the used liquid for its safe dis-

posal under the regulations!
400159
AV 80 X4 123
3.6.26. How to exchange oil in the vibrators and
bearings of the drums.
How to drain oil:

From drum vibrators
• Locate the Machine so the plug (1) is in its lowest position.
• Remove plug (1) and let oil pour down into the vessel of 15l
(4galUS) capacity.
• Reinstall the plug.
1
400220
From drum bearings

• Locate the Machine so the plug (2) is in its lowest position.
• Remove plug (2) and let oil pour down into the vessel of 3l
(0.8galUS) capacity.
• Reinstall the plug.
Note
Exchange oil at the time when oil is hot.
Let the drained oil to cool down below 50 °C (120 °F).
2
400221
Oil filling:
Into vibrators and bearings of drums
• Locate the Machine so the plug (1) is in its highest position.
• Remove the plug (1).
• Check the amount of oil through loosening plug (3), oil must 1
flow out.
• Reinstall the plug (3).
• Use port (1) to refill 2 more litres of oil (0,5 galUS).
• Reinstall the plug (1).
3
400222
Avoid oil escape into ground.
124 AV 80 X4
MAINTENANCE MANUAL
3.6.27. How to exchange hydraulic oil and filters
Carry out oil exchange before the season

starts, or following a rather long shut-
down of the Machine. At the same time
clean the inlet strainer, as well.
• Fit a hose onto the drain valve.

• Let oil pour down into the vessel set up – total amount of oil
flowing out is 54 l (14,27 gal US).
400223
• Remove the inlet pipes.
400167A
• Remove the cap (1) along with inlet strainer (2).

• Remove the inlet strainer away from the inlet pipe. Wash 1
the inlet strainer and purge the strainer with compressed air
from inside.
• Check the inlet strainer condition, in case filter element is
impaired you must replace it.
• Inspect the tank’s inner space. Should there be any impuri-
ties on its bottom, clean thoroughly and flush the tank with
new oil.
• Reinstall the tank’s lid (1) and use new Teflon sealing strip. 2
400224
Drain oil when cooled down below 50 °C

(122 °F).
Observe the fire precautions!
When disconnecting the hydraulic cir-

cuits blind all the ports with plugs.
Collect drained oil and do not let it soak
into ground.
Used oil is ecologically hazardous waste
– hand it over for professional disposal.
AV 80 X4 125
Check oil temperature sensor:
• Remove the sensor on the hydraulic tank cube and clean the
contact.
400225
• Dip the sensor in water of 100°C (212°F) temperature, check

its function correctness on the LH cluster – hydraulic oil level
indicator lamp will light up, refer to the Fig.
478320 h
400111E
Fill the hydraulic circuit:

• Fill with the filling device of the following parameters:
Min pressure 6 MPa (870 PSI)
Filtering property 3 to 10 µm
• Slip the filling device quick-coupling over the quick-cou-
pler.
• Fill the hydraulic circuit until clean oil starts pouring out from
the tank via the drain valve. Collect oil in a clean vessel.
• When it reads ca 15 l (4 gal US) close the drain valve.
• Top up the tank with oil its max level and disconnect the
filling device.
400167B
Spare filling via tank filler neck:
1
Carry out hydraulic circuit filling via the
filler neck in emergency cases only!
This filling method will need to reduce
the next exchange interval by one half,
i.e. 1000 hours or 1 year.
• Tank filler neck plug has been sealed. When this seal is bro-
ken during guarantee period then the guarantee will termi-
nate.
• Fill the tank through its filler neck (1) with the required type
of oil up to the bottom of a strainer inside the filler neck.
400167C
126 AV 80 X4
MAINTENANCE MANUAL
Note
• When filling through the tank filler neck a large portion of
old oil will remain in the circuit along with the impurities,
and the life of hydraulic units will lower.
• You may order the filling device with the Machine manufac-
turer or a dealer.
When the circuit is filled, please check

the hydraulic oil level indicator lamp is
not ON.
Start the engine and test the Machine
functions at the increased RPM so to fill
the circuits.
Check the filter tightness, temperature
sensors, inlet pipes and lids.
Observe cleanliness at work. Prevent any
contamination of the system with the
materials that might cause damage to
the major units!
Follow the fire precautions!
Do not open uselessly the hydraulic
tank!
Exchange oil and filter element always
when destruction of the inner parts of
the units (hydraulic motors, hydroelectric
generators) occurs, or following a major
repair of the hydraulic system. Clean and
flush the hydraulic tank before new unit
is installed. Replace filter element.
Never use chemical cleaning agents to
clean the tank.
To clean, please use cleaners with no fi-
bre let-off.
Refill oil according to the Section 3.2.3.
AV 80 X4 127
How to replace pressure filter element
Replace always during:

• oil exchange
• pressure filter indicator lamp goes
on when oil operating temperature
reaches 50 - 60 °C (122 - 140 °F).
478320 h
400111G
• Remove the filter vessel.

• Remove the filter element.
• Clean thoroughly the filter vessel.
• Clean from the bottom the seating face of filtration block.
• Check the condition of sealing rings and paint the rings with
clean oil.
• Insert new element into the filter vessel and screw on again
– tighten with 40 +10 Nm (30 +7 ft lb) torque.
400226
Use the original filter elements accord-

ing to the Spare Parts Catalogue, only.
Used filter elements are ecologically haz-

ardous waste – hand them over for pro-
fessional disposal.
400227
128 AV 80 X4
MAINTENANCE MANUAL
Maintenance as required
3.6.28. Fuel system breathing
Deaerate the fuel system before the first start upon:

• filter replacement
• long term shutdown of the Machine
• fuel drawn off
Low-pressure piping blow-off and filter deaeration:

Use the pump on fuel filter head to blow off the low-pressure
piping. 400197A
Follow safety regulations!

No smoking or use of open flame while
at work on fuel system!
Avoid fuel escape into soil!
AV 80 X4 129
3.6.29. How to replace air filter elements
The proper maintenance of air filter and of the entire inlet piping, the rubber parts in particular, will ensure maximal protection of the
engine against dust effects, and prolong the life of the element and its efficiency.
The inherent sign of fouled filter is the exhaust pipe that smokes, higher fuel consumption, output loss and engine temperature in-
creased.
Principles of correct filter element replacement:
• Slowly pull out the clogged element as carefully as possible.
• Always clean the inner bodies of the cleaner in a way to avoid dust penetrating inside the engine feed piping.
• Clean the seating faces for gasket in the cleaner body.
• Examine the dust traces in the element removed, any traces would be an indication of its leakage in the filter body.
• Press the gasket on the new element, whether it is flexible.
• Make sure the gasket is seated properly.
NEVER use damaged elements!

Do NOT use other elements than those required!
Do NOT remove the elements just for checking purposes!
Do NOT left the filter opened longer than necessarily required!
NEVER operate the Machine with filter body damaged!
How to replace air filter element:

• The air filter comprises the main element and safety ele-
ment.
• Replace the main element always when signalled by indica-
tor lamp for air filter fouled.
• Replace the safety element always following the three re-
placements of the main element.
• Confirm the fixing and integrity of the air filter and intake
piping.
478320 h
• Saturation of the air filter element will be signalled by the
indicator lamp for air filter fouled.
• When the indicator lamp goes on you must replace the main
filter element.
400111H
• Remove filter cap (1) and replace the main filter element (2)
from the filter shell.
400229
130 AV 80 X4
MAINTENANCE MANUAL
400230
• Replace the safety element (3) from the filter shell and check
it.
• Replace the safety element always following three replace-
ments of the main element.
When safety element is damaged, please

replace it with the new one of identical
type as per identification! 3
400231
• Clean filter’s inner space in such a way to avoid dust penetra-

tion into the inner feed piping to the engine.
NEVER use compressed air to clean the

inner space.
400232
• Take off the air filter vacuum valve, clean it and reinstall.
Replace instantly a damaged vacuum

valve!
400163
AV 80 X4 131
3.5.30. How to clean water separator of fuel
filter
• Water trap indicator lamp is ON.

• Loosen the drain valve (1).
• Let the deposits flow out and screw it.
400112B
Follow the fire precautions.

No smoking allowed at work on fuel
system.
400197B
Collect escaped fuel in the vessel set up.
400233
132 AV 80 X4
MAINTENANCE MANUAL
3.6.31. Clean the engine radiators and hydraulic oil coolers
• Due to various working conditions no regular cleaning interval can be set.

• In case of work in very dusty environment, perform daily cleaning. Cooler fouling will show in a reduced cooling performance and
increased temperatures of engine coolant and of hydraulic oil.
• Remove the engine air intake cover.

• Clean with compressed air or pressure water (steam). Clean
in the direction from the fan side.
Do NOT clean the radiator with too high

pressure so to avoid its damage.
When radiator is contaminated with crude
oil products, use a cleaner and proceed
according to the manufacturer’s manual!
Find out a cause of contamination!
400182
Clean the Machine at a workplace

equipped with cleaner collection system
to prevent soil contamination and water
resource contamination!
NEVER use forbidden cleaners!
400148A
3.6.32. How to clean cab ventilation filter
• Remove the cover grill (1).

• Remove the filter element.
• Beat out the element carefully and wash in a detergent solu-
tion. If filter element will become damaged or unable to be
made rid of the impurities, please replace it with new one.
Clean regularly 1 x per month. Should it 1

be you work in a very dusty environment
then the cleaning intervals should be cut
short.
400234
AV 80 X4 133
3.6.33. Drain water from sprinkling circuit
before winter season
• Before winter season it will be necessary to drain water from

the sprinkling circuit with regard to any potential damage to
individual parts because of frost.
How to drain water from the sprinkling circuit:

• Remove sprinkling water tank drain plug. Store the drain
plug at a safe place.
• Tank’s full capacity is 600 l.
400206
• Remove and clean the vessel (1) incl. sprinkling filter (2).
Store the vessel complete with filter at a safe place.
1 2
400188
• Keep the valve for water supply from the tank opened.
400187
• Detach the water discharge hose from the pump.
400187A
134 AV 80 X4
MAINTENANCE MANUAL
• Detach at least one sprinkler from each pipe on the front
and rear sides of the Machine. Store the sprinklers at a safe
place.
• Switch ON the sprinkling pumps for 20 sec. so these become
drained.
• This procedure will guarantee you max drainage of the
sprinkling circuit.
• when all the abovementioned operations are completed,
please proceed in reverse steps, clean thoroughly the indi-
vidual parts, first.
400189
By draining the water from the sprin-

kling circuit in time you will avoid any
potential damage that the manufacturer
shall bear no responsibility for!
AV 80 X4 135
3.6.34. Adjust the scrapers
1
• The Machine is fitted with four hinged (tilting) scrapers.
Position the scrapers:

• In position (1) the scraper is set in transport position.
400235
• In position (2) the scraper is set in working position.

• When in working position, the scraper blade (3) is pressed 2
against the drum body (4) by means of gas struts (4).
3
400236
Replace the blade:

• When the blade becomes excessively worn, please lift off
the scraper, remove the bolts (5) and take off the blade (3)
along with the strip (6).
• Proceed in reverse steps to reinstall a new blade.
• At the same time always check the proper function of the
gas struts (4).
5 6
Only when the gas struts work properly

and the worn scraper blades are replaced
in time, this will provide you with perfect
drum cleaning! 3
400237
136 AV 80 X4
MAINTENANCE MANUAL
3.6.35. Machine cleaning 3.6.36. Check the tightening of bolted
connections
• When the work is completed clean the Machine to get rid of
major impurities. • Confirm regularly that no loosening of bolted connections
• Carry out overall cleaning on regular basis, at least once per has occurred.
week. Total cleaning must be done daily if working on cohe- • Use the torque spanners to do the tightening.
sive soils, cement or lime stabilizations.
TIGHTENING MOMENT
For the screws For the screws
8,8 (8G) 10,9 (10K)
Disconnect the disconnector. Worm Nm lb-ft Nm lb-ft
Carry out the work with the engine M6 10 7,4 14 10,3
stopped.
M8 24 25,0 34 25,0
NEVER use aggressive or easily ignitable
cleaners (e.g. petrol or easily or flash M8x1 19 14,0 27 19,9
fuels). M10 48 35,4 67 49,4
M10x1,25 38 28,0 54 39,8
M12 83 61,2 117 86,2
M12x1,25 66 48,7 94 69,3
Before pressure cleaning with water or M14 132 97,3 185 136,4
steam, please blind all the ports into
M14x1,5 106 78,2 148 109,1
which a cleaner might penetrate (e.g.
engine inlet port). With the Machine M16 200 147,5 285 210,2
cleaned remove these blinds. M16x1,5 160 118,0 228 168,1
Do NOT expose electric parts or insula- M18 275 202,8 390 287,6
tion material to direct water or steam M18x1,5 220 162,2 312 230,1
streams. Always cover these materials
(alternator’s inner space, etc.). M20 390 287,6 550 405,6
M20x1,5 312 230,1 440 324,5
M22 530 390,9 745 549,4
M22x1,5 425 313,4 590 435,1
Clean the Machine at a workplace M24 675 497,8 950 700,6
equipped with cleaner collection sys- M24x2 540 398,2 760 560,5
tem so to avoid soil or water recourse
contaminations! M27 995 733,8 1400 1032,5
NEVER use banned cleaners! M27x2 795 586,3 1120 826,0
M30 1350 995,7 1900 1401,3
M30x2 1080 796,5 1520 1121,0
The figures given in the chart are torques at dry thread (with
coefficient of friction = 0,14). These figures do not apply to a lu-
bricated thread.
AV 80 X4 137
Chart showing the torques for cap nuts with sealing “O” ring – hoses
Tightening moments for the sliding nuts with the tightening circle „O“ - hoses
Nm lb ft
Size
Worm Hose Nominal Min Max Nominal Min Max
spanner
14 12x1,5 6 20 15 25 15 11 18
17 14x1,5 8 38 30 45 28 22 33
8
19 16x1,5 45 38 52 33 28 38
10
10
22 18x1,5 51 43 58 38 32 43
12
24 20x1,5 12 58 50 65 43 37 48
14
27 22x1,5 74 60 88 55 44 65
15
30 24x1,5 16 74 60 88 55 44 65
32 26x1,5 18 105 85 125 77 63 92
20
36 30x2 135 115 155 100 85 114
22
41 25
36x2 166 140 192 122 103 142
46 28
50 42x2 30 240 210 270 177 155 199
45x2 35 290 255 325 214 188 240
50 38
52x2 330 280 380 243 207 280
42
138 AV 80 X4
MAINTENANCE MANUAL
Chart showing the torques for necks with sealing edge, or Chart showing the torques for plugs with flat gasket
with flat gasket
Tightening moments for the necks Tightening moments for the plugs
G -M Nm lb ft G -M Nm lb ft
G 1/8 25 18 G 1/8 15 11
G 1/4 40 30 G 1/4 33 24
G 3/8 95 70 G 3/8 70 52
G 1/2 130 96 G 1/2 90 66
G 3/4 250 184 G 3/4 150 111
G1 400 295 G1 220 162
G 11/4 600 443 G 11/4 600 443
G 11/2 800 590 G 11/2 800 590
10 x 1 25 18 10 x 1 13 10
12 x 1,5 30 22 12 x 1,5 30 22
14 x 1,5 50 37 14 x 1,5 40 30
16 x 1,5 60 44 16 x 1,5 60 44
18 x 1,5 60 44 18 x 1,5 70 52
20 x 1,5 140 103 20 x 1,5 90 66
22 x 1,5 140 103 22 x 1,5 100 74
26 x1,5 220 162 26 x1,5 120 89
27 x 1,5 250 184 27 x 1,5 150 111
33 x 1,5 400 295 33 x 1,5 250 184
42 x 1,5 600 443 42 x 1,5 400 295
48 x 1,5 800 590 48 x 1,5 500 369
400239 400240
AV 80 X4 139
3.7. Defects
In most cases the defects are due to operating the Machine improperly. Therefore during any failure read
thoroughly once more the instructions given in the Machine and Engine Operation and Maintenance
Manual. Unless you will be able to specify the cause of a defect, please contact authorized dealer’s or
manufacturer’s Help Desk (service assistance).
The troubleshooting of hydraulics and wiring requires expertise in the field of hydraulics and wiring, so
we strongly recommend to hand over the troubleshooting process to the Help Desk of an authorized
dealer or manufacturer.
140 AV 80 X4
MAINTENANCE MANUAL
AV 80 X4 141
3.8. Attachments
AV 80 X4 Wiring Diagram
Legend:
A1 Clicker (course light interrupter) R2 Speed potentiometer S31 RH (yellow) pushbutton on RH
A2 LH cluster R3 Resistors travel lever – CRAB right or edge
cutter downward
A3 RH cluster S1 Ignition box
S32 Front wiper switch
A4 Travel electronics S2 Combined switch
S33 Rear wiper switch
A5 Travel controller S2.1 Switch for contour lights and
headlights S34 Washer double-pushbutton
B1 Fuel level float
S2.2 Distance / dipped lights switch S35 Fan switch
B3 Pressure sensor in water tank
S2.3 Light horn switch S36 Air conditioner switch (optional)
B4 Engine RPM sensor
S2.4 Loud horn pushbutton S38 Float in hydraulic oil tank
B5 Drum speed sensor
S2.5 Traffic-indicator lights switch S39 CRAB resetting pushbutton
C1 Interference filter
S3 Rear headlamp switch S40,41 CRAB position switches
E1,2 Front contour lights
S4 Warning lights switch S42 Hydraulics temperature switch
E3,4 Rear lights
S5 Auxiliary lights switch (optional) S44 Air conditioner overpressure
E5,6 Front headlamps fuse (optional)
E7,8 Rear headlamps S6 Hazard beacon switch (optional)
V1-14 LED
E9,10 Left traffic-indicator lights S7 Brake pressure switch
X1 Mounting socket
E11,12 Right traffic-indicator lights S8 Switch for hydraulics filter
fouled X2 Diagnostics socket
E13,14 Auxiliary headlamps front (op- X3-4 Connection terminals
tional) S9 Switch for air filter fouled
S10 Engine lubrication pressure X5-63 Interface connectors
E15,16 Auxiliary headlamps rear (op-
tional) switch Y1 Engine stop solenoid
E17 Hazard beacon (optional) S11 Engine overheating switch Y3 Brake valve
E18,19 Brake (stop) lights S12 Hydraulic oil overheating switch Y4 Back drive valve
E20 Cabin lighting S13 Float – water in fuel filter Y5 Rearward drive valve
F1-13 Cut-out fuses S14 Backing horn switch Y8 Vibration low amplitude valve
G1 Battery S15 Neutral switch Y9 Vibration high amplitude valve
G2 Alternator S16 Emergency brake pushbutton Y10 Front drum vibration valve
H1 Dipped light indicator lamp S18 Constant speed or engine over- Y11 Rear drum vibration valve
load switch Y12 CRAB left valve
H2 Distance light indicator lamp
S19 Vibration automatics switch Y13 CRAB right valve
H3 Loud horn
S20 Smooth start or smooth stop Y14 Relief valve
H4 Acoustic warning indicator pushbutton
H5 Backing horn (optional) Y15 Edge cutter upward valve (op-
S21 Seat switch tional)
K1 Contactor S22 Vibration pushbutton (red) on Y16 Edge cutter downward valve
K2-19 Auxiliary relay LH travel lever (optional)
M1 Engine starter S23 Vibration pushbutton (red) on Y17 Air conditioner compressor
RH travel lever clutch magnet (optional)
M2 Sprinkling motor
S24 Sprinkling pushbutton
M3 Sprinkling motor
S25 Sprinkling pumps switch
M4 Front wiper
S26 Vibration amplitude switch
M5 LH rear wiper
S27 Front / both / rear vibration
M6 RH rear wiper
selector switch
M7 Windscreen washer
S28 LH (yellow) pushbutton on LH
M8 Rearscreen washer travel lever – CRAB left
M9,10,11 Fans S29 RH (yellow) pushbutton on LH
Q1 Battery disconnector travel lever – CRAB right
R1 Sprinkling interval potentiom- S30 LH (yellow) pushbutton on RH

eter travel lever – CRAB left or edge
cutter upward
142 AV 80 X4
MAINTENANCE MANUAL
F9
G1 31 M1
Q1 50
M
30 K1
12V 100Ah
G2
L
G
B IG
X62:8
X62:5
X62:6
X62:1
X5:60
X5:25
X5:32
X5:2
H2 H1
X3
E1
F1
Front contour lights E2 X26:1 X5:3 K2
5 3 S2 20A
E3
2 1
0 12
Rear lights F2 S1
X61
E4 X28:1 X5:4 X7:5 Y S2.1 H X7:1 30 15/54
K3 X7:6 S 15A
56b E5 X26:2 X5:26
S2.2 50
31 2 1 Z
56a K4
Front headlamps X26:3 X5:27 X7:7 F3
56b E6 5 3 S2.3 3 5
31
56a X7:8 C S2.4 B X7:3 15(30)A 2 1
C1
M
H3 S2. 5 O
X27:1 X5:5 K5 K6
Loud horn MC
X31 2 1 3 5
S3 3 5 2 1
E7 X28:2 X5:36 1 5
X7:10
Rear headlamps
X7:9
9
X7:4
E8 10
X26:4 X5:35
X28:4
E9 X27:2 X5:7
Left front traffic-indicator light
S4
E10 X29:2 X5:8 A1
Left rear traffic-indicator light 2
6 CL
8
1
E11 X29:3 X5:9 3 31
Right rear traffic-indicator light 5
E12 10
X27:3 X5:10
Right front traffic-indicator light
K7
E13 X51 X6:4 5 3 X1
Auxiliary headlamps front E14 2 1
X52 S5
1 5
E15 X53 X56:1 X49:2 X6:5 9 10
Auxiliary headlamps rear E16
X54 X56:2 S6
1 5
E17 X30 X55:1 X49:6 X6:6
Hazard beacon 9 10
X55:2
E18 X28:3 X5:11
Brake (stop) lights 8

Instrument illumination
E19
18 Traffic-indicator Charging+ 14
lights motohours
19
Traffic-indicator 3
S7 X5:12 11 lights Neutral
Brake P
Brake
P S8 S42 X5:13 13 12
Hydraulic filter Hydraulic filter Seat
P S9 X5:14 15
Air filter Air filter
S10 X62:7 X5:15 16 Engine
Engine lubrication
A2
P
X9
X9
lubrication
S11 X62:4 X5:16 17
Engine overheating Engine overheating
B1 X5:17 F4
2 20
Fuel gauge Fuel gauge Supply +12V
7 5A
Hydraulic oil level 10
S12 X5:18 6 Ground
Hydraulic oil overheating Hydraulic oil
overheating R3
9 1
Engine stop Warning
5 75 R
Vibration
X5:19
7
Warning lights
9
Engine stop 20
8 Instrument Supply +12V H4
B3 illumination 1
X5:20 2 Warning
Water tank level Water tank 10
1 2 level Ground
A3
X10
X10
12
Float – water in fuel filter X63:2 S13 X63:1 X62:3 X5:21 11 Air condition
Water in fuel 19
Engine
13 overload
Crab 6
X62:9 5 Konstant speed
Watering
14 Smooth start F5
- smooth stop
K8 10A
X32:2 H5 X32:1 X29:1 X5:24
Backing horn 5 3
S14
X12:2 C
X11:1
Fe PNP
2 1
H X12:1
X12:3 M
X16:7
X12:5 S15
Fe PNP
M
H X12:4
1
S16
K9 C
2
2 1 X12:6
X16:8
5 3
K10
V11 4
2 1
K17
X62:15 Y1 X62:2 X5:28 4 3 4
Engine stop 3
2 1 V14 X11:2
S38 X5:37
Hydraulic oil level
28,42
Konstant 3 7
speed S18
12V
18 Engine 2 1 5
X14:1
Neutral overload
40 Smooth start S19
X13:1
X5:45 - smooth stop

Automat. 19 1 5
X5:44 vibration
S20
Smooth start 4 X11:3 X14:2 1 5
1(H) 4(C) X5:43 17 Drum - smooth stop
Drum speed sensor B5 speed S21
5 X11:4 X13:2
3(M) Seat
Y3 X5:38 41 S22
Brake Brake
12 X11:5 X15:1 X15:2
Y4 X5:39 Vibration
6
Travel forward Travel forward S23
X17:1 X17:2
Y5 X5:40
Travel backward 7 Travel backward
20 X2
X5:41 X60 8 RS2323 TxD
21 2
RS2323 RxD
A4
X5:6 3
13
RS2323 Grd 5
9
C F
A B D E G H I J
107585_1cs
AV 80 X4 143
3.8. Attachments
AV 80 X4 Wiring Diagram
Legend:
A1 Clicker (course light interrupter) R2 Speed potentiometer S31 RH (yellow) pushbutton on RH
A2 LH cluster R3 Resistors travel lever – CRAB right or edge
cutter downward
A3 RH cluster S1 Ignition box
S32 Front wiper switch
A4 Travel electronics S2 Combined switch
S33 Rear wiper switch
A5 Travel controller S2.1 Switch for contour lights and
headlights S34 Washer double-pushbutton
B1 Fuel level float
S2.2 Distance / dipped lights switch S35 Fan switch
B3 Pressure sensor in water tank
S2.3 Light horn switch S36 Air conditioner switch (optional)
B4 Engine RPM sensor
S2.4 Loud horn pushbutton S38 Float in hydraulic oil tank
B5 Drum speed sensor
S2.5 Traffic-indicator lights switch S39 CRAB resetting pushbutton
C1 Interference filter
S3 Rear headlamp switch S40,41 CRAB position switches
E1,2 Front contour lights
S4 Warning lights switch S42 Hydraulics temperature switch
E3,4 Rear lights
S5 Auxiliary lights switch (optional) S44 Air conditioner overpressure
E5,6 Front headlamps fuse (optional)
E7,8 Rear headlamps S6 Hazard beacon switch (optional)
V1-14 LED
E9,10 Left traffic-indicator lights S7 Brake pressure switch
X1 Mounting socket
E11,12 Right traffic-indicator lights S8 Switch for hydraulics filter
fouled X2 Diagnostics socket
E13,14 Auxiliary headlamps front (op- X3-4 Connection terminals
tional) S9 Switch for air filter fouled
S10 Engine lubrication pressure X5-63 Interface connectors
E15,16 Auxiliary headlamps rear (op-
tional) switch Y1 Engine stop solenoid
E17 Hazard beacon (optional) S11 Engine overheating switch Y3 Brake valve
E18,19 Brake (stop) lights S12 Hydraulic oil overheating switch Y4 Back drive valve
E20 Cabin lighting S13 Float – water in fuel filter Y5 Rearward drive valve
F1-13 Cut-out fuses S14 Backing horn switch Y8 Vibration low amplitude valve
G1 Battery S15 Neutral switch Y9 Vibration high amplitude valve
G2 Alternator S16 Emergency brake pushbutton Y10 Front drum vibration valve
H1 Dipped light indicator lamp S18 Constant speed or engine over- Y11 Rear drum vibration valve
load switch Y12 CRAB left valve
H2 Distance light indicator lamp
S19 Vibration automatics switch Y13 CRAB right valve
H3 Loud horn
S20 Smooth start or smooth stop Y14 Relief valve
H4 Acoustic warning indicator pushbutton
H5 Backing horn (optional) Y15 Edge cutter upward valve (op-
S21 Seat switch tional)
K1 Contactor S22 Vibration pushbutton (red) on Y16 Edge cutter downward valve
K2-19 Auxiliary relay LH travel lever (optional)
M1 Engine starter S23 Vibration pushbutton (red) on Y17 Air conditioner compressor
RH travel lever clutch magnet (optional)
M2 Sprinkling motor
S24 Sprinkling pushbutton
M3 Sprinkling motor
S25 Sprinkling pumps switch
M4 Front wiper
S26 Vibration amplitude switch
M5 LH rear wiper
S27 Front / both / rear vibration
M6 RH rear wiper
selector switch
M7 Windscreen washer
S28 LH (yellow) pushbutton on LH
M8 Rearscreen washer travel lever – CRAB left
M9,10,11 Fans S29 RH (yellow) pushbutton on LH
Q1 Battery disconnector travel lever – CRAB right
R1 Sprinkling interval potentiom- S30 LH (yellow) pushbutton on RH

eter travel lever – CRAB left or edge
cutter upward
144 AV 80 X4
MAINTENANCE MANUAL
A B D E G H I J
C F
X5:29 15
(12V) 32 X11:6 X16:1
Travel 6
X5:30 29
(12V) 5 1
X5:42
A5
X33:2 X33:1 16 Engine
Engine speed sensor B4 speed 34 X11:7 X16:2
Sprinkling
26 R1
Vibration
27 100R 1K 100R
Sprinkling
31 X11:8 X14:3
Speed
R2
(5V)
5V
X16:3
1
14
100R 1K 100R
X14:4
X11:9 X14:5
X5:46 X11:10 X16:4
S24 F6
X11:12 X16:6 1 5 X16:5 X11:11
K11 15A
1 2
V1
M2 X34:1 X5:31 5 3 S25
Sprinkling 1
M
7 5
X34:2 K12 1
1 2
V2
M3 X35:1 X5:33 5 3
Sprinkling 2
M
X35:2 K13
1 2
5 3 F7
S26
Y8 X5:47 B4 B3 7.5A
Vibration - low amplitude
Y9 X5:48 A4 A3
Vibration - high amplitude
D4 D3 X11:13
F15
30A
C4 C3
S27
Y10 X5:49 B4 B3
Front drum vibration
Y11 X5:50 A4 A3
Rear drum vibration
X5:22
3(M) S40 X5:51

Fe
CRAB position switch - left

PNP
1(H)
X5:54 X12:8 X14:8 S39 X14:7 X12:7
2(B)
5 1
V12 V13
3(M) S41 X5:53 X14:10 X14:9 X12:9

Fe
CRAB position switch - right 6 2

PNP
1(H)
1
3
1
3
X5:52 X12:10
4(C)
K19
K18
X5:23
2
5
2
5
X12:11
Y12 X5:55 X12:12 X22:1 X18:1 S28 X15:3

Crabing left
Y13 X5:56 X12:13 X22:2 X18:2 S29
Crabing right X6:2
X6:7
X6:3
X6:1
X19:1 If the edge cutter is instaled to left hand side of

the roller change over the plug X18 to socket X19.
X19:2 The buttons S28, S29 on the left control lever
are used to lifting cutter.
S30
V6
V5
X20:1 X17:3
Y14 X5:57 X12:14 X22:3
Relief valve
X49:5
X49:3
X49:1
X50
X20:2 S31
Radio
V8
V7
Y15 X5:58 X12:15 X22:4 X21:1 If the edge cutter is instaled to right hand side of the
Edge cutter upward roller change over the plug X20 in socket X21.
Y16 X5:59 X12:16 X22:5 X21:2 The buttons S30, S31 on the left control lever are used
Edge cutter downward to lifting cutter. F8
E20 Reserve
Cabin lighting
X32:1 F11
X32:4 15A
7
M4 X32:2 5 S32
Front wiper
M
X32:5
3
X32:3 X52 X6:9 1
S34
M7 X57:1 X6:8 1 5
M
Windscreen washer
X56:6
K14 F12
X58:1 M9 X58:2 X56:4 5 3
1
Fan 1
M
2 1
2
15A
3
S35
X58:3
K15 5 3
F13
X56:5 5 3
1 5A
2 1
X59:3 3
X59:1 M10 X59:2

V10
V9
S36
M
1
Fan 2 1 5
2
X48:1 M11 X48:2 9 10

M
1
Fan 3
K16
2
X48:3
3
1 2
Y17 P S44 5 3
F14
Air conditioner
10A
X4 X15:2
X17:2
107585_2en
AV 80 X4 145
3.8. Attachments
AV 80 X4 Hydraulic Diagram
Legend:
1. Travel pump.
2. Vibration pump
3. Steering and cooling pump
5. Vibration and purging block
6. Travel hydraulic motor
7. Travel hydraulic motor
8. Vibration hydraulic motor
9. Cooling hydraulic motor
10. Steering hydraulic motor
11. Crab hydraulic motor
12. Lifting hydraulic motor
13. Edge entter hydraulic motor (optional)
14. Power-assisted steering
15. RTM module
16. Filter
17. Steering block
18. Flushing (purging) block
20. Cooler combined-type
21. Hydraulic tank
22. Hand pump
23. Thermoregulator
24. Inlet strainer
25. Filler neck
26. Oil gauge
27. Check valve
28. Check valve
29. Temperature switch
30. Safety block
31. Quick-coupler filling-type
32. Quick-coupler for brake off
33. Quick-coupler for brake off
34. Quick-coupler measuring-type
146 AV 80 X4
AV 80 X4
6 7 15 7 6
CRABING EDGE CUTTER
Dn8
Dn8
Dn8
Dn8
B
B
T
T
14
Dn13
Dn13
Dn13
Dn13
P
X X X P
A
A
LEFT R L RIGHT LEFT R L
RIGHT
HYDROMOTOR HYDROMOTOR HYDROMOTOR HYDROMOTOR
750 750 750 750
OF TRAVEL 1 1 OF TRAVEL OF TRAVEL 1 1 OF TRAVEL
L R L R 400
FRONT S S REAR 90/45-125
DRUM DRUM Dn10 A4 A5
240 240 B1
Dn10
Dn10 Dn10 A1
Dn13
Dn13
Dn13
175 B2
Dn13
D 13 bar
C 11
A A2
B P LD T L R
100 100
Dn13
Dn13
Dn13
Dn13
Dn13
P1 P Dn10
13 Ø1 mm
80/40-200
Dn13
Dn10 17
Dn13
Dn10
80/40-200 10
Dn10 B A 20 bar
18 Dn13 T1
MB MA
Dn8 X
Dn13 P1 100
190
13 l/min
1 MPa
Dn19
Dn10 T M
3 bar
Dn10 Dn10
P PP T2 T3
3.5 bar
Dn16
28
Dn16 Dn16
5
180
16 2.7 bar
8 5 2 1 Dn13
9.5
34 23 9 32 33 31
C1 C2 C1 C2
Dn8
27 20
M1 E M3 E M3 M1 L3 L1
D MA M3
S1 S2 P T
Dn13
Dn13
A P1 A
A 400 3 29
Ø25 - 230
Dn19
Dn19
Dn19
0.5 bar
Dn10
Dn6
2 2 330 22 26
Ø25 - 230
1 28
3 bar
0.5 bar
REAR
DRUM
A 40°C Dn14 55°C
12
3 1 Ø0.5 mm Ø0.5 mm
200
Dn19
C
Dn6
Dn6
2000 °C
i=1.0
13 l/min
53
3 bar
78 (2200) 14 11
Dn19
1 MPa
B ot/min
2 2 330 400 °C
0.5 bar
1
28 22
FRONT
DRUM
A 100
3 1
B P2 B 14
Dn19
Dn19
B
Dn10
Dn32 Dn25
MB T M2 L2 M5 M4 L1 L2 M5 M4 L4 M2
Dn16
Dn10
30
Dn10 100
Dn10
24 26 25 21
400252en
MAINTENANCE MANUAL
147
Notes
148 AV 80 X4
Notes
AV 80 X4 149
Notes
150 AV 80 X4
Ammann Schweiz AG Ammann Verdichtung GmbH Rammax Maschinenbau GmbH Ammann Czech Republic a.s.
Eisenbahnstrasse 25 Josef-Dietzgen-Strasse 36 Gutenbergstrasse 33 Náchodská 145
CH-4901 Langenthal D-53773 Hennef D-72555 Metzingen CZ-54901 Nové Město nad Metují
www.ammann-group.com Printed in Czech Republic

Operating Manual Articulated Tandem Roller

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Operating Manual Articulated Tandem Roller

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Operating manual

Articulated tandem roller

With kind regards,

This manual consists of:

These instructions must always be kept available on the equipment.

The notice warns of possible damages to the machine or its parts.

The notice warns of the necessity of environmental protection.

1.1. Basic specification.................................................................................................................................10

1.2. Machine dimension scheme.................................................................................................................12

1.3. Technical data........................................................................................................................................14

2.1. Major Safety Precautions......................................................................................................................21

2.2. Ecological & Hygienic Principles..........................................................................................................33

2.3. Preservation & Storage ........................................................................................................................34

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

2.8. Machine transport.................................................................................................................................75

2.9. Special conditions to use the Machine................................................................................................79

3.1. Safety and other measures for machine maintenance.......................................................................85

3.2. Media specification...............................................................................................................................87

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

Following 250 hours of operation (after 3 months)..........................................................................104

Following 1000 hours of operation (after 1 year).............................................................................115

1.1.2. Machine design ................................................................................................................

The machine meets requirements of international standards for

MADE IN CZECH REPUBLIC

Machine’s production label – CE

MADE IN CZECH REPUBLIC

Cummins engine serial number

Working weight with the cab ROPS

1.3.2. Drive of travel - driving properties

Drive type hydrostatic

1.3.3. The vibrations

Drive type hydrostatic

Working brake hydrostatic

Steering type articulated joint

Engine (oil fill) l (gal US) 8 (2,11)

1.3.9. Electrical installation

Electric set voltage V 12

•• Constructional Supplier (Machine User) is liable to issue in-

•• He must verify and mark:

•• He must specify Code of Practice (C.O.P.) part of which is

2. Handbook The Operation Manual stowage box (symbol located at

16. Emergency exit Symbol located on the window of RH door .

Signals given by Machine assistant operator unless driver visu-

Signals for general commands

SIGNALS FOR DRIVE

Departure with the Machine

Low-speed cruising backward – away from me

Driving to the right

Driving to the left

Engine cut off

•• The fillings of Machine’s individual systems and some of its

After 6 months we recommend to inspect

Prior to restoration of Machine op-

•• Check the machine against delivery documentation.

Before starting operations again, wash

In no event shall Manufacturer be liable