Av32 PDF

Workshop Manual (EN)
AV1-2 (AV12-2, AV16-2, AV20-2)

(AV16-2K)
AV2-2 (AV23-2, AV26-2, AV32-2, AV33-2, AV40-2)

(AV23-2K, AV26-2K, AV32-2K, AV40-2K)
ID: 1084657 Revision index:-- Release date: September 06

ID: 1084657 Revision index:-- Release date: September 06
General
Preface and use of the Workshop Manual
Structure
Preface
This is the Workshop Manual for AV1-2 and AV2-2 rollers. This book was specially created
for service fitters in the field and in the workshop.
Along with maintenance and repair instructions, this Workshop Manual also contains a
description of the machine.
This Workshop Manual does not, however, replace the roller operating manual.
Because the content of the deliverable depends on the order, the features of your roller may
differ in some descriptions and pictures.
With kind regards,
Ammann Schweiz AG
Eisenbahnstrasse 25
CH – 4901 Langenthal
www.ammann-group.ch
0041 (0)62 916 61 61

FAX 0041 (0)62 916 68 04
Workshop Manual: 1084657 -3- 22.09.2006

General
Structure and use of the Workshop Manual
Workshop Manual: 1084657 -4- 22.09.2006

General
Index
Index
1 General ...............................................................................................11
1.1 Structure and use of the Workshop Manual ......................................................13
1.2 Pictograms ............................................................................................................14
1.3 Identification AV1-2 ..............................................................................................15
1.4 Identification AV2-2 ..............................................................................................16
1.5 Identification plate................................................................................................17
1.6 Lists of spare parts ..............................................................................................18
2 Commissioning .................................................................................19
2.1 Transport AV1-2....................................................................................................21
AV1-2 dimensions relevant for transport.............................................................................. 22
2.2 Transport AV2-2....................................................................................................23
AV2-2 dimensions relevant for transport.............................................................................. 24
2.3 Joint protection AV1-2 .........................................................................................25
2.4 Joint protection AV2-2 .........................................................................................26
3 Safety..................................................................................................27
3.1 General working safety ........................................................................................29
3.2 Roller operation ....................................................................................................30
3.3 Roll-over bar (ROPS)............................................................................................32
3.4 Noise levels...........................................................................................................33
Recorded sound power level: .............................................................................................. 33
3.5 Safety (maintenance) ...........................................................................................34
3.6 Safety labels on the machine ..............................................................................38
4 Overview ............................................................................................41
4.1 Product description..............................................................................................43
Intended purpose of the AV1-2 / AV2-2................................................................................ 43
Requirements for roller operators ........................................................................................ 43
Limits of application in climate conditions ............................................................................ 43
Parking brake ....................................................................................................................... 43
4.2 Intended use .........................................................................................................44
Normal modes of operation.................................................................................................. 44
Special operating modes ..................................................................................................... 44
4.3 Inappropriate use .................................................................................................44
4.4 Disclaimer .............................................................................................................44
4.5 Overview of AV1-2 components..........................................................................45
4.6 Overview of AV2-2 components..........................................................................47
4.7 Dashboard (switches) ..........................................................................................49
4.8 Dashboard (control lights)...................................................................................50
4.9 Operating control (control lights) .......................................................................51
5 Operating ...........................................................................................53
5.1 Driver's seat ..........................................................................................................55
5.2 Starting the engine ...............................................................................................57
Workshop Manual: 1084657 -5- 22.09.2006

General
Index
5.3 Driving and braking..............................................................................................59

5.4 Operating speed ...................................................................................................61
Speed adjusting lever (2) – selecting vibration frequency ................................................... 61
Low speed............................................................................................................................ 61
High speed ........................................................................................................................... 61
5.5 Turning off the engine..........................................................................................62
5.6 Emergency stop....................................................................................................63
5.7 Sprinkling AV1-2...................................................................................................64
5.8 Sprinkling AV2-2...................................................................................................65
5.9 Simple / double vibration .....................................................................................66
6 Options...............................................................................................67
6.1 Edge cutter............................................................................................................69
6.2 Revolving warning light .......................................................................................71
6.3 Reverse alarm .......................................................................................................73
6.4 Battery cut-off switch...........................................................................................74
6.5 Traction aid (flow divider) AV2-2.........................................................................76
6.6 Lighting .................................................................................................................77
6.7 Interval sprinkler...................................................................................................78
6.8 Loxam ....................................................................................................................79
Seat contact switch with delay ............................................................................................. 79
6.9 Anti-adhesive ........................................................................................................80
Advantages of anti-adhesive:............................................................................................... 80
6.10 Anti-adhesive tank................................................................................................81
7 Maintenance.......................................................................................83
7.1 Roller maintenance ..............................................................................................85
Every 10 operating hours (daily) .......................................................................................... 85
Every 50 operating hours (weekly) ...................................................................................... 85
Hydraulic oil and filter change.............................................................................................. 85
7.2 Yanmar engine maintenance...............................................................................86
Regular checks and minor service....................................................................................... 86
7.3 Yanmar engine service ........................................................................................87
Major service........................................................................................................................ 87
7.4 Opening the hood.................................................................................................88
7.5 List of checks – AV1-2 .........................................................................................89
7.6 List of checks – AV2-2 .........................................................................................90
7.7 Checks – engine oil level, coolant AV1-2 ...........................................................91
Checking engine oil level ..................................................................................................... 91
Checking coolant level ......................................................................................................... 91
7.8 Checks – engine oil level, coolant AV2-2 ...........................................................92
Checking engine oil level ..................................................................................................... 92
Checking coolant level ......................................................................................................... 92
7.9 Checks – fuel tank, hydraulic oil tank ................................................................93
Fuel tank – filling .................................................................................................................. 93
Hydraulic oil tank – checking oil level .................................................................................. 93
7.10 Checks – sprinkler, scraper.................................................................................94
Check and adjust the sprinkler............................................................................................. 94
Check and adjust scrapers for the roller drum..................................................................... 94
Check and adjust scrapers for the pneumatic wheel axis.................................................... 94
Workshop Manual: 1084657 -6- 22.09.2006

General
Index
7.11 Checks – tire pressure .........................................................................................95

Check and adjust tire pressure on the pneumatic wheel axis ............................................. 95
7.12 List of checks – air filter cartridges AV1-2.........................................................96
7.13 List of checks – air filter cartridges AV2-2.........................................................97
7.14 Hydraulic oil and filter change ............................................................................98
7.15 Changing engine oil AV1-2 ................................................................................100
7.16 Changing engine oil AV2-2 ................................................................................101
7.17 Battery .................................................................................................................102
Starting with an external battery ........................................................................................ 102
7.18 Lubricant table....................................................................................................103
7.19 Consumables, tightening toques......................................................................104
8 Storage .............................................................................................105
8.1 Storage ................................................................................................................107
Long-term storage.............................................................................................................. 107
8.2 Emptying the water tank ....................................................................................108
8.3 Winterization, emptying the water tank ............................................................109
8.4 Draining diesel....................................................................................................111
9 Repair ...............................................................................................113
9.1 Towing, releasing brakes...................................................................................115
Towing................................................................................................................................ 115
Releasing brakes ............................................................................................................... 115
9.2 Removing the rear water tank AV1-2 ................................................................119
9.3 Removing the front water tank AV2-2...............................................................120
9.4 Removing the rear water tank AV2-2 ................................................................122
9.5 Separating the roller drum from the chassis ...................................................123
9.6 Adjusting the operating lever AV1-2.................................................................125
9.7 Adjusting the operating lever AV2-2.................................................................126
9.8 Adjusting engine speed and frequency ...........................................................127
Machine with light............................................................................................................... 127
Machine without light.......................................................................................................... 127
9.9 Removing the driver's cabin..............................................................................129
9.10 Putting machine in line AV1-2 ...........................................................................133
9.11 Putting machine in line AV2-2 ...........................................................................137
9.12 Replacing bearing, vibro unit AV1-2.................................................................141
9.13 Replacing bearing, vibro unit AV2-2.................................................................149
9.14 Tools ....................................................................................................................162
Plugs and stoppers for 1 vibro motor AV1-2...................................................................... 163
Plugs and stoppers for 1 drive motor AV1-2...................................................................... 164
Plugs and stoppers for drive pump test AV1-2 .................................................................. 164
Plugs and stoppers for drive pump AV1-2 ......................................................................... 164
Plugs and stoppers for 1 vibro motor AV2-2...................................................................... 165
Plugs and stoppers for 1 drive motor AV2-2...................................................................... 165
Plugs and stoppers for drive pump test AV2-2 .................................................................. 166
Plugs and stoppers for drive pump AV2-2 ......................................................................... 166
Workshop Manual: 1084657 -7- 22.09.2006

General
Index
10 Hydraulic System ..........................................................................167

10.1 Overview of the hydraulic system ....................................................................169
10.2 Overview of AV1-2 hydraulic system................................................................170
10.3 Overview of AV2-2 hydraulic system................................................................171
10.4 Checking and adjusting pressures AV1-2........................................................173
10.5 Checking and adjusting pressures AV2-2........................................................176
Setting steering pressure ................................................................................................... 177
10.6 Checking the drive pump AV1-2 .......................................................................178
Checking supply pressure.................................................................................................. 178
Checking drive pressure .................................................................................................... 178
10.7 Checking the drive pump AV2-2 .......................................................................179
Checking supply pressure.................................................................................................. 179
Checking drive pressure .................................................................................................... 179
10.8 Hydraulic diagram AV12/AV16/AV20 ................................................................180
10.9 Key AV12/AV16/AV20 .........................................................................................181
10.10 Hydraulic diagram AV16K..................................................................................182
10.11 Key AV16K ..........................................................................................................183
10.12 Hydraulic diagram AV23 – AV40 .......................................................................184
10.13 Key AV23 – AV40 ................................................................................................185
10.14 Hydraulic diagram AV23K – AV40K ..................................................................186
10.15 Key AV23K – AV40K...........................................................................................187
11 Electrical System...........................................................................189
11.1 Overview of the electrical system.....................................................................191
11.2 Engine compartment fuses AV1-2 ....................................................................193
11.3 Engine compartment fuses AV2-2 ....................................................................194
11.4 Steering column fuses .......................................................................................195
11.5 Neutral-position switch......................................................................................196
11.6 Troubleshooting the electrical system.............................................................197
11.7 Wiring diagram (multifunction display) ............................................................202
11.8 Wiring diagram (engine start / stop)..................................................................203
11.9 Wiring diagram (emergency stop / oil cooler, diesel pump) ...........................204
11.10 Wiring diagram (sprinkler).................................................................................205
11.11 Wiring diagram (vibration).................................................................................206
11.12 Wiring diagram (horn, indicators) .....................................................................207
11.13 Wiring diagram (lights) ......................................................................................208
11.14 Wiring diagram (options) ...................................................................................209
11.15 Wiring diagram (Loxam) ....................................................................................210
11.16 Technical specifications (fuses, connector layout, wire cross-sections)....211
11.17 Key .......................................................................................................................212
Workshop Manual: 1084657 -8- 22.09.2006

General
Index
12 Technical Data ...............................................................................217

12.1 Dimensions AV1-2 ..............................................................................................219
Dimensions AV1-2 ............................................................................................................. 219
12.2 Dimensions AV2-2 ..............................................................................................220
Dimensions AV2-2 ............................................................................................................. 220
Dimensions AV2-2K ........................................................................................................... 220
12.3 Technical data AV1-2 .........................................................................................221
12.4 Technical data AV2-2 .........................................................................................222
12.5 Technical data AV2-2K.......................................................................................223
Table index...... ...................................................................................225
Workshop Manual: 1084657 -9- 22.09.2006

General
Workshop Manual: 1084657 - 10 - 22.09.2006

General
1 General
Workshop Manual: 1084657 - 11 - 22.09.2006

General
Workshop Manual: 1084657 - 12 - 22.09.2006

General
1.1 Structure and use of the Workshop Manual
The following explanations are designed to familiarize you with the roller and to provide
support for handling and maintenance.
Structure of the Workshop Manual

This manual consists of the following sections:
1 General
2 Commissioning
3 Safety
4 Overview
5 Operating
6 Options
7 Maintenance
8 Storage
9 Repair
10 Hydraulic system
11 Electrical system
12 Technical data
It is essential that you read the Safety section carefully before performing maintenance work.
Observing the Safety section in particular increases the reliability of the machine in operation
and its service life. This reduces repair costs and down time.
Spare parts
Use spare parts that meet the technical requirements specified by Ammann. These
requirements are fulfilled if only original Ammann spare parts are used.
Completeness of the Workshop Manual

Never remove sections from this manual. Missing pages - specifically the Safety section -
must be replaced immediately if lost.
Revision service
This manual is not subject to the revision service of Ammann Schweiz AG. Changes may be
made to this document without notification.
Workshop Manual: 1084657 - 13 - 22.09.2006

General
Pictograms
1.2 Pictograms
Important points are indicated as follows:
WARNING!
Indicates an immediate impending danger.

Failure to avert such dangers will lead to death or extremely serious injuries.
ATTENTION!
Indicates a potentially harmful situation.

Failure to avert this situation may damage the product or something in its vicinity.
NOTE
Indicates application tips and other particularly useful information.

This is not a sign of a dangerous or harmful situation.
Workshop Manual: 1084657 - 14 - 22.09.2006

General
Identification AV1-2
1.3 Identification AV1-2
This Workshop Manual is valid for the following machines of the AV1-2 series.
AV1-2 with roller drum
Model Width Weight
AV12-2 860 mm 1450 kg
AV16-2 940 mm 1550 kg
AV20-2 1040 mm 1650 kg
Tab 1: AV1-2 with roller drum
AV1-2 with pneumatic wheel (combined roller)
Model Width Weight
AV16-2K 940 mm 1450 kg
Tab 2: AV1-2 with pneumatic wheel
The machine models differ only in terms of weight and the width of the roller drum.
The combined roller has a pneumatic wheel axis instead of the smooth back roller drum.
Workshop Manual: 1084657 - 15 - 22.09.2006

General
Identification AV2-2
1.4 Identification AV2-2
This Workshop Manual is valid for the following machines of the AV2-2 series.
AV2-2 with roller drum
Model Width Weight
AV23-2 1120 mm 2500 kg
AV26-2 1320 mm 2800 kg
AV32-2 1320 mm 3100 kg
AV33-2 1420 mm 3600 kg
AV40-2 1420 mm 3900 kg
Tab 3: AV2-2 with roller drum
AV2-2 with pneumatic wheel (combined roller)
Model Width Weight
AV23-2K 1080 mm 2300 kg
AV26-2K 1280 mm 2500 kg
AV32-2K 1280 mm 2800 kg
AV40-2K 1380 mm 3600 kg
Tab 4: AV2-2 with pneumatic wheel
The machine models differ only in terms of weight and the width of the roller drum.
The combined roller has a pneumatic wheel axis instead of the smooth back roller drum.
Workshop Manual: 1084657 - 16 - 22.09.2006

General
Identification plate
1.5 Identification plate
An identification plate (1) is affixed to the

roller for identification.
The identification plate is located on the left

of the machine on the rear chassis of the
roller.
1 2 3 Important data on the identification plate:
1 Roller model
2 Name and address of the manufacturer
4 3 Serial number
4 Product number
6 5 Fuel engine output
6 Number of revolutions per minute
9 7 CECE total weight
8 CECE front axis load
9 CECE rear axis load
5 7 8 10 10 Date of manufacture
NOTE
When ordering spare parts you must indicate the serial number (S / N) of the roller.
Workshop Manual: 1084657 - 17 - 22.09.2006

General
Lists of spare parts
1.6 Lists of spare parts
The following lists of spare parts are delivered with the machine and may be ordered from
Ammann.
Model 1-ET521894 1-ET521932 1-ET521933 1075293
AV12-2 z
AV16-2 z
AV16-2K z
AV20-2 z
AV23-2 z
AV23-2K z
AV26-2 z
AV26-2K z
AV32-2 z
AV32-2K z
AV33-2 z
AV40-2 z
AV40-2K z
AV23-2SF z
AV26-2SF z
Tab 5: Product numbers, spare parts lists
Workshop Manual: 1084657 - 18 - 22.09.2006

Commissioning
2 Commissioning
Workshop Manual: 1084657 - 19 - 22.09.2006

Commissioning
Workshop Manual: 1084657 - 20 - 22.09.2006

Commissioning
Transport AV1-2
2.1 Transport AV1-2
Articulated joint lock
1 WARNING!
Danger of crushing!
Before lifting, during transport of the
machine, you must install the lock (1) of
the articulated joint (joint protection).
Lifting with the 1-point lifting eyes
WARNING!
Danger of accidents!
Do not stand under suspended loads!
Use only anti-slip, stable ramps when
loading!
Secure the machine on transport
vehicles to prevent it from rolling off,
slipping to the side and tipping over!
NOTE
The lifting devices (steel cables, etc.) must be dimensioned according to the relevant
regulations.
Securing the roller at the front towing

eye.
1 Secure the machine by tying it down to the
front towing eye (1).
You can remove this eye. If there is no eye

here, you will find it under the hood.
See next page.
Workshop Manual: 1084657 - 21 - 22.09.2006

Commissioning
Transport AV1-2
The towing eye (1) can be found on the left,

below the hood.
Screw the eye out and attach it at the front.

1
Securing the roller at the back towing

eye
Additionally secure the machine by fastening
it to the rear towing eye (1).
Now secure the roller from slipping

1 sideways.
Secure the machine from rolling off forward

or backward.
You can install additional protection on the

recessed steps.
WARNING!
A blocked steering system can lead to accidents!
Open the joint protection before starting the machine.
AV1-2 dimensions relevant for transport

* With ROPS folded down
Model Length* (mm) Width (mm) Height* (mm) Weight (kg)
AV12-2 2245 860 1650 1450
AV16-2 2245 940 1650 1550
AV16-2K 2245 940 1650 1450
AV20-2 2245 1040 1650 1650
Tab 6: AV1-2 dimensions relevant for transport

Workshop Manual: 1084657 - 22 - 22.09.2006
Commissioning
Transport AV2-2
2.2 Transport AV2-2
1 WARNING!
Danger of crushing!
Before lifting, during transport of the
machine, you must install the lock (1) of
the articulated joint (joint protection).
Lifting at the 4-point lifting eyes

1 Lift the machine with suitable tools using the
four lifting eyes (1) integrated in the wheel
suspension.
NOTE
The lifting devices (steel cables, etc.)
must be dimensioned according to
relevant regulations.
WARNING!
Do not stand under suspended loads!
Use only anti-slip, stable ramps when loading!
Secure the machine on transport vehicles to prevent it from rolling off, slipping to the
side and tipping over!
Workshop Manual: 1084657 - 23 - 22.09.2006

Commissioning
Transport AV2-2
Securing the roller

1
Brace down the roller at the four wheel
suspensions (1). Secure the machine from
1 rolling off forward or backward.
You can install additional protection on the

2 recessed steps (2).
Now secure the roller against

slipping sideways.
WARNING!
A blocked steering system can lead to accidents!
Open the joint protection before starting the machine.
AV2-2 dimensions relevant for transport

* With ROPS folded down
Model Length* (mm) Width (mm) Height* (mm) Weight (kg)
AV23-2 2490 1120 1818 2500
AV23-2K 2490 1080 1818 2300
AV26-2 2490 1320 1818 2800
AV26-2K 2490 1280 1818 2500
AV32-2 2490 1320 1818 3100
AV32-2K 2490 1280 1818 2800
AV33-2 2490 1420 1818 3600
AV40-2 2490 1420 1818 3900
AV40-2K 2490 1380 1818 3600
Tab 7: AV2-2 dimensions relevant for transport
Workshop Manual: 1084657 - 24 - 22.09.2006

Commissioning
Joint protection AV1-2
2.3 Joint protection AV1-2
Blocking the joint protection

Detach the bottom part of the joint protection
(1) by first pulling out the compression
1 spring (2) and then the lock bolt (3).
Carefully turn the roller steering wheel until

the joint protection (1) comes in line with the
2 opposite loop (2).
NOTE
You must start the machine to be able to
move the steering wheel.
1
WARNING!
Danger of crushing
Person standing in the danger zone:
Switch off the engine once the machine is
aligned.
Now snap in the joint protection and secure

2 it with the lock bolt (1).
Secure the lock bolt with the

1 compression spring (2).
Workshop Manual: 1084657 - 25 - 22.09.2006

Commissioning
2.4 Joint protection AV2-2
Blocking the joint protection

Detach the bottom part of the joint protection
(1) by first pulling out the compression
spring (2) and then the lock bolt (3).
1 3 2
Carefully turn the roller steering wheel until

2 the joint protection (1) comes in line with the
opposite loop (2).
NOTE
You must start the machine to be able to
1 move the steering wheel.
WARNING!
Danger of crushing
Person standing in the danger zone:
Switch off the engine once the machine is
aligned.
Now snap in the joint protection and secure

it with the lock bolt (1).
Secure the lock bolt with the

compression spring (2).
Workshop Manual: 1084657 - 26 - 22.09.2006

Safety
3 Safety
Workshop Manual: 1084657 - 27 - 22.09.2006

Safety
Workshop Manual: 1084657 - 28 - 22.09.2006

Safety
General working safety
3.1 General working safety
Always observe the manufacturer’s manual and the safety rules it contains.
Rollers may only be operated with all safety devices operating. Manipulating safety
devices invalidates the CE certification.
Check the steering and brakes when you start work. If defects are apparent roller
operation is not permitted.
Before starting every shift, check the effectiveness of the operation and safety devices
and that the protection devices are in place.
If you identify any defects on the safety system or defects that impair safe operation of
the equipment, inform your supervisor immediately. The roller must no longer be taken
into operation.
If you identify any defects which endanger safe operation, cease operation immediately.
Only perform work on and clean the roller if it is stationary and secured from rolling
away.
Switch off the engine when filling the fuel tank. Do not fill up fuel in closed rooms. No
naked flames.
Do not drive on slopes that are steeper than the maximum climbing capacity of the
equipment. Always drive the roller carefully perpendicular to the slope dip.
Keep the driver’s cabin and steps free of trips, grease, dirt, ice, etc.
The driving and working field of view must not be obstructed in any way. Adjust all the
necessary mirrors correctly and keep them clean.
Switch off the engine before leaving the roller. Secure the roller from unauthorized start-
up and rolling away.
Take suitable measure to secure parked rollers that pose an obstruction.
Workshop Manual: 1084657 - 29 - 22.09.2006

Safety
Roller operation
3.2 Roller operation
WARNING!
Danger of roll-over!
Only start the roller from the driving
position.
No persons may stand in front of or

behind the roller while it is in operation.
WARNING!
Persons necessary for operations at the
sides of the equipment must remain at a
safe distance of at least 1 m.
1m 1m
WARNING!
Wear a safety belt!
Keep the following hazards in mind:
Level surfaces are not always uniformly load-bearing.

Cavities or large stones may be located below the
surface.
Loamy/clayey soils become slippery when wet.
Vibration can increase the hazard of lateral slipping.
High steering angles at slope edges increase the hazard
of overturning.
Articulated machines are in particular danger from high
steering angles on slopes.
Workshop Manual: 1084657 - 30 - 22.09.2006

Safety
Roller operation
WARNING!
Danger of tipping over!
Keep the following hazards in mind:
The edges of filled areas may give way!

Keep your distance to embankments and edges! Do not
drive over steps on roadways!
On embankments, only operate or park rollers in such a
away that they cannot tip over.
The roller drums have very poor adhesion on snow and
ice. Driving or working on a slope in snow or ice is
prohibited.
Workshop Manual: 1084657 - 31 - 22.09.2006

Safety
Roll-over bar (ROPS)
3.3 Roll-over bar (ROPS)
1 WARNING!
Never operate the machine with the

ROPS (1) folded down!
WARNING!
The ROPS (1) must not be modified in

any way without the manufacturer's
permission!
Check that:
The roller chassis is not bent or cracked in the area of the ROPS mounting.
The ROPS has no cracks or fractures.
All screw connections are tight (observe tightening torque).
Screw threads are not damaged.
Workshop Manual: 1084657 - 32 - 22.09.2006

Safety
Noise levels
3.4 Noise levels
WARNING!
Wear ear protectors!
Depending on the use of equipment it is possible that the
permissible noise level of 85 dB (A) will be exceeded. Wear
ear protectors in accordance with national accident prevention
regulations when working at higher noise levels.
Noise levels
The following noise level measurements were carried out by an accredited testing and
monitoring body in accordance with machine directive 2000 / 14 / EEC of the European
parliament and council.
Inspecting and monitoring organization: TÜV Österreich (Austrian technical inspectorate)

Testing body no. 0408
Recorded sound power level:

AV1-2 = 99 dB (A)
AV2-2 =102 dB (A)
Guaranteed sound power level:

AV1-2 = 103 dB (A)
AV2-2 = 106 dB (A)
NOTE
The obligation to wear ear protection is standardized nationally.
In Switzerland and Germany, it applies as of a measured level of 85 dB A (sound pressure).
Workshop Manual: 1084657 - 33 - 22.09.2006

Safety
Safety (maintenance)
3.5 Safety (maintenance)
NOTE
Maintenance must only be carried out by trained specialized personnel!
Only perform maintenance and repair work on the roller if it is static and secured from
rolling away.
Secure the machine with the joint protection.
Relieve pressure before working on the hydraulic pipes.
Disconnect the battery before working on the electrical system of the machine, cover it
with insulating material or remove it. This does not apply to work requiring an electric
current. In the event of injuries caused by acid, rinse immediately with clean water and
consult a doctor.
Replace all protection devices properly after performing maintenance and repair work.
WARNING!
Gas poisoning!
Do not leave the engine running in closed areas.
If use of the roller in a confined space cannot be avoided, the
exhaust fumes must be extracted directly from the exhaust
pipe.
ATTENTION!
Damage to electrical control!
Never spray the water jet into electrical or electronic
components.
Never spray into the engine combustion air intake.
Workshop Manual: 1084657 - 34 - 22.09.2006

Safety
ATTENTION!
Hydraulic control failure!
Hydraulic tubes decompose.
It is forbidden to change used machines for use with
biodegradable hydraulic oils!
If hydraulic hoses on a machine running on synthetic ester HE
need to be replaced, only those declared by the supplier as
being compatible with synthetic esters may be used.
WARNING!
Danger to life!
Always ensure an accident-proof support when working
on a raised machine.
Never work below equipment which is only supported by
a crane or other electrical / hydraulic lifting device.
Only stand under a raised machine if it has been
mechanically secured.
Only use stable loading ramps suitable for the weight of
the machine for loading.
On transport vehicles, secure the roller from rolling off,
slipping to the side and tipping over.
WARNING!
Battery acid!
Protect the battery from fire, flames and sparks.
Use a lamp to check the acid level (not a lighter, etc.).
Never check the battery charge level with a metal object.
Use a voltmeter or electrolyte meter.
When disconnecting the battery always disconnect the
negative terminal first (-). Connect the positive terminal
(+) first when reconnecting.
Workshop Manual: 1084657 - 35 - 22.09.2006

Safety
ATTENTION!
Always remove the battery completely before performing
welding work on the machine.
WARNING!
Toxic sulfuric acid!
The sulfuric acid in the battery is poisonous and so strong it
can burn holes in clothes and dissolve skin. If it gets into eyes
it can lead to blindness.
Topping-up / re-charging safety measures:

Only fill or charge the battery in well-aired rooms.
Wear eye protection and rubber gloves.
Avoid inhaling the acid fumes.
Do not spill acid when filling or topping up.
Perform “start-up with third-party battery” as per

instructions.
Service-free battery
Always replace the battery with a service-free battery. If you
are using a battery that requires maintenance, always observe
the safety instructions in the battery manual.
Workshop Manual: 1084657 - 36 - 22.09.2006

Safety
WARNING!
Danger of burns
Never remove the expansion cap or radiator cap while the
engine is running or hot!
First loosen the cap to the first stop to release the pressure.
Only then remove the cap.
WARNING!
Danger of trapping!
Only open the engine hood when the engine is switched off.
If it is absolutely necessary to work on moving parts (engine or
roller) for troubleshooting purposes, never wear necklaces,
bracelets, scarves, ties or other loose clothing. If any of these
get caught in moving parts there is a danger of serious injury!
Warning
Danger of burns!
Only work on a cool engine.
Keep enough distance to the exhaust.
WARNING
Environmental hazard!
Do not allow any liquids get into drains, soil or the
environment.
Workshop Manual: 1084657 - 37 - 22.09.2006

Safety
Safety labels on the machine
3.6 Safety labels on the machine
Observe and adhere to the rules.

Keep the safety stickers and signs complete and legible.
Replace any damaged or illegible stickers and signs immediately.
You can order new stickers from Ammann Schweiz AG.
From the moment the signs are no longer recognizable and understandable at first glance,
the machine must be shut down until new signs are installed.
WARNING!
If the roller is equipped with a foldable
ROPS, the equipment must never be
operated with the ROPS folded down!
ATTENTION!
Never spray the water jet into electrical or
electronic components.
Never spray into the engine combustion

air intake.
Workshop Manual: 1084657 - 38 - 22.09.2006

Safety
ATTENTION!
Danger of crushing!
Only stand in this area when necessary
and only with extreme caution!
ATTENTION!
You are in the danger zone.
Workshop Manual: 1084657 - 39 - 22.09.2006

Safety
Workshop Manual: 1084657 - 40 - 22.09.2006

Overview
4 Overview
Workshop Manual: 1084657 - 41 - 22.09.2006

Overview
Workshop Manual: 1084657 - 42 - 22.09.2006

Overview
Product description
4.1 Product description
Intended purpose of the AV1-2 / AV2-2

AV1-2 and AV2-2 vibration rollers are universal rollers designed for use on small and
medium-sized building sites. Ammann rollers are effective and efficient compacting machines
when its comes to installing blacktops and compacting unbound soil and gravel.
Requirements for roller operators

Only trained, suitable and reliable specialists with a valid national driving license for this
category of vehicle may operate the rollers.
Limits of application in climate conditions
Operation Storage
Temperature limits -10 °C to +48 °C -10 °C to +48 °C
Humidity All-year operation / outdoor storage
Terrain Level Level

30 % with / 40% without
Slope up 40 %
vibration
30 % with / 40 % without
Slope down 40 %
vibration
Tab 8: Limits of application in climate conditions
Parking brake
The vibration roller is equipped with an automatic parking brake.
The brakes of the drive motors are activated when supply pressure drops below 12 bar or
when you press the EMERGENCY STOP button.
When you press the EMERGENCY STOP button a valve reduces supply pressure and the
brakes take immediate effect.
The parking brake closes automatically when the diesel engine is switched off.
ATTENTION!
In order to save the brakes from unnecessary wear, only perform an emergency stop
while driving in emergency situations.
Only use the parking brake in special cases, e.g. when you stop on a slope. If the
machine starts to roll, move the operating lever slightly in the opposite direction, so
that the vehicle is kept still hydrostatically.
Workshop Manual: 1084657 - 43 - 22.09.2006

Overview
Intended use
4.2 Intended use
Normal modes of operation

The AV1-2 and AV2-2 rollers must only be used for driving and compacting unbound layers
(gravel, soil) and blacktops (asphalt).
Special operating modes

Transport of the machine from A to B (crane & low loader).
Cleaning the machine.
Maintenance of system components according to maintenance plan or in the event of
defects.
Rectification of machine faults by trained personnel based on error messages.
Towing the roller.
Proper disposal by the operator in accordance with national regulations.
4.3 Inappropriate use
Inappropriate use includes any use not listed under intended use. Note the following in
particular:
The machine is not a playground.

The machine must not be used for traction.
The machine is not a passenger transporter.
In the case of movements greater than 3 km, the machine must be loaded on a
transporter.
4.4 Disclaimer
Ammann Schweiz AG accepts no liability for maintenance of reliable functioning of the roller
if it is not used appropriately.
Unauthorized conversions and changes to the machine are prohibited for safety reasons.
Spare parts used when replacing defective or wearing parts must conform to the technical
specifications stipulated by AMMANN. These requirement are always fulfilled if original
AMMANN spare parts are used.
The instructions given in the various sections must be adhered to. The safety instructions
must be observed at all times. Failure to adhere to working instructions, their correct order,
safety instructions or safety labeling requirements causes liability claims to become void.
Workshop Manual: 1084657 - 44 - 22.09.2006

Overview
Overview of AV1-2 components
4.5 Overview of AV1-2 components
1 Emergency stop switch

2 Ignition switch
3 Operating lever
1 4 Speed regulating lever
3
4
2
1 Tank cap (diesel)

2 2 Document holder, under the hood
1 Cap (rear water tank)

2 Identification plate
3 Front spinkler
1
4 Roller drum scraper
2
4
Workshop Manual: 1084657 - 45 - 22.09.2006

Overview
1 Engine oil filter

2 Hydraulic oil filter
3 Articulated joint protection
4 Hydraulic tank oil level indicator
1
(optical)
2
1 Hydraulic oil drain

2 Engine oil drain
3 Diesel tank drain
2
3
1
1 Water filter
2 Rear sprinkler
1
4 Water pump (below the water tank)
Workshop Manual: 1084657 - 46 - 22.09.2006

Overview
4.6 Overview of AV2-2 components

2 Ignition switch
3 Operating lever
1 4 Speed regulating lever
1 Tank cap (diesel)

2 2 Document holder under the hood
1 Cap (front water tank)

1 2 Cap (rear water tank)
3 Identification plate
2 4 Front spinkler
4 3
Workshop Manual: 1084657 - 47 - 22.09.2006

Overview
1 Suspension
2 Engine oil filter
1 3 Hydraulic oil filter
4 Articulated joint protection
5 Hydraulic tank oil level indicator
2 3 (optical)
4
5
1 Hydraulic oil drain

2 Engine oil drain
3 Diesel tank drain
3 2
1 Water filter
2 Rear sprinkler
4 Water pump (below the water tank)
1
4
Workshop Manual: 1084657 - 48 - 22.09.2006

Overview
Dashboard (switches)
4.7 Dashboard (switches)
1 2 3 4
5
6
11
8 9 10
1 Operating switch for improved climbing (traction aid / flow divider)

(option only for AV2-2)
2 Switch for revolving warning light (optional)
3 Hazard flasher switch (only with light option)
4 Multifunction device with hour counter
5 Selector switch – vibration front or front and rear (optional)
6 Switch for work light (only with light option)
7 Operating switch for light 0 – OFF (only with light option)
1 – Parking light
2 – Main beam
8 Continuous sprinkling switch (standard) or sprinkling interval switch (optional)
9 Indicator switch left / right (only with light option)
11 Horn
Workshop Manual: 1084657 - 49 - 22.09.2006

Overview
Dashboard (control lights)
4.8 Dashboard (control lights)
6 7
8
5
10
3
2
11
12
1 Control light for battery charge level (charge control)

2 Control light for engine oil pressure
3 Control light for engine coolant temperature
4 Control light for emergency-stop circuit, operating lever zero position and seat contact
5 Control light for fuel reserve
6 Control light for pre-heating
7 Control light for brake release and supply pressure hydraulics
8 Control light for parking light
9 Control light for road driving light
10 Indicator control light
11 Fuel tank display
12 Operating hours counter
Workshop Manual: 1084657 - 50 - 22.09.2006

Overview
Operating control (control lights)
4.9 Operating control (control lights)
1 Battery charge level control light

If the battery charge level control light lights up during operation or does not
go off after starting, carry out the following check immediately.
1. Stop the engine.

2. Check the engine for defective or loose V-belt.
3. If the battery charging lamp is still lit after carrying out these checks,
call a specialist.
2 Engine oil pressure control light
WARNING
Stop immediately!
If the engine oil pressure control light lights up during operation or does not
go off after starting, turn off the engine immediately!
1. Check the engine for oil loss and correct oil level.
2. If the engine oil level is correct, have a specialist solve the problem.
3 Engine coolant temperature control light
WARNING
Stop immediately – engine overheating!
If the coolant temperature control light lights up during operation of the
machine, switch off the engine immediately and top up coolant!
WARNING
Danger of scalding! The cooling circuit is pressurized.
1. Allow the engine to cool down before removing the radiator cap.
2. In order to avoid scalding, first unscrew the radiator cap ¼ of a turn and
allow the pressure to drop.
3. As soon as the pressure has dropped, remove the cap and top up the
liquid.
4. Check the cooling system for leaks and the radiator / expansion vessel
for correct coolant level.
5. If you cannot locate the fault, consult a specialist to solve the problem.
Workshop Manual: 1084657 - 51 - 22.09.2006

Overview
4 Control light for emergency stop circuit, operating lever

neutral position and seat contact
If the control light lights up while the ignition is on, observe the following:
1. Trigger the “EMERGENCY STOP” button by turning it clockwise (red

mushroom button on the dashboard).
2. Put the operating lever into neutral position.
3. Sit on the driver’s seat.
4. If the control light is still lit up after carrying out these checks, call a
specialist to solve the problem.
5 Fuel reserve light

After the light lights up for the first time, the fuel in the tank will last at least
½ h.
Top up diesel fuel:
Tank volume AV1-2: 26 l
Tank volume AV2-2: 43 l
6 Diesel engine prehating

Preheating time AV1-2: 4 seconds.
Preheating time AV2-2: 15 seconds.
The light goes off when you start the engine.
7 Control light for hydraulic brake release and supply pressure

As long as this control light is lit up, the brake release and supply pressure of
the hydraulic system is not sufficient. Do not start to drive until this control
light has gone off.
WARNING
If the control light for the hydraulic brake release / supply pressure lights up
while driving or does not go off after starting the engine, the machine must
not be driven any further.
1. Check whether the seat contact switch is closed.

2. If the seat contact switch is closed and the control light is still lit, call a
specialist to solve the problem.
Workshop Manual: 1084657 - 52 - 03.01.2007

Operating
5 Operating
Workshop Manual: 1084657 - 53 - 22.09.2006

Operating
Workshop Manual: 1084657 - 54 - 22.09.2006

Operating
Driver's seat
5.1 Driver's seat
NOTE
The driver's seat is important to your health. Adjust the seat to suit your body size.
Longitudinal adjustment
Push lever (1) outwards gently and adjust
the seat to the desired position.
1
NOTE
If adjusted ergonomically
forward/backward, your feet will be on the
floor panel.
Side-to-side adjustment
Pull lever (1) up and adjust the seat to the
desired position.
Adjusting the backrest

1 Turn the adjuster button (1) clockwise to
move the backrest backward.
Turn the adjuster button (1)

counterclockwise to move the backrest
forward.
Workshop Manual: 1084657 - 55 - 22.09.2006

Operating
Driver's seat
Weight adjustment
1 Turn the adjuster button (1) counter-
clockwise to increase tension of the seat.
Turn the adjuster button (1) counter-

clockwise to increase tension of the seat.
Weight adjustment is infinite in the range of

50 - 120 kg.
WARNING!
Do not adjust the position of the driver's seat while driving.
WARNING!
1
Wear a safety belt!
Always wear the safety belt (1). Together
with the roll-over bar it is a safety system
that can save your life.
1 WARNING!
Danger of crushing
Never place your feet on the bend (1) of
the floor panel. There is a risk of crushing
when the roller moves out to the sides.
Workshop Manual: 1084657 - 56 - 22.09.2006

Operating
Starting the engine
5.2 Starting the engine
Joint protection
Make sure that the joint protection (1) is
released as in the picture.
Driver's cabin
3 Sit on the driver's seat and familiarize
4 yourself with the key components.
1 1 Operating lever
2 Speed regulating lever
2 3 Emergency-stop button
4 Ignition switch
If the emergency stop button (3) is

depressed, release it by turning it clockwise.
Ignition switch positions

P PARK
In this position you can switch on the
parking light. The remaining electrical
loads are off.
0 OFF
All electrical loads are powered off.
I Ignition on
All electrical consumers can be
switched on.
II Pre-heating
III Start
Workshop Manual: 1084657 - 57 - 22.09.2006

Operating
Starting the engine
Operating lever (1)

Move the operating lever (1) to neutral
1 position until it snaps into place.
You cannot start the diesel engine in any

other position.
2
Speed adjusting lever (2)
Move the speed adjusting lever (2) all the
way down into idle position.
NOTE
Depending on the options, the machine may only have one speed.
Starting
Turn the ignition key clockwise to position III.
As soon as the engine starts up release the

ignition key.
NOTE
The engine oil pressure, battery charge,
hydraulic brake release / pressure supply
warning lights light up when you switch on
the ignition. They go out once the engine
is running.
Pre-heating
If outside temperature is below 0 °C, first turn the ignition key to position II, hold it in this
position for 15 seconds, and then turn it on to position III.
WARNING
When starting and driving the machine from cold, with cold hydraulic oil, braking distances
are longer than when the oil has reached normal working temperature.
Workshop Manual: 1084657 - 58 - 22.09.2006

Operating
Driving and braking
5.3 Driving and braking

Move the speed adjusting lever (2) forward
1 until it snaps into first position.
The engine is now running at low speed.
2
again until it snaps into second position.
The engine is now running at high speed.
Check whether steering is working.
Driving forward
Move the operating lever (1) slowly forward.
1
The machine moves forward.
2
Braking (service brake)

Slowly pull the operating lever (1) into
1 neutral position.
The machine is automatically hydrostatically

2
braked.
Workshop Manual: 1084657 - 59 - 22.09.2006

Operating
Driving and braking
Driving backward
Move the operating lever (1) back slowly.
1
The machine moves backward.
2
Braking (service brake)

Slowly push the operating lever (1) into
1 neutral position.
The machine is automatically hydrostatically

2
braked.
Workshop Manual: 1084657 - 60 - 22.09.2006

Operating
Operating speed
5.4 Operating speed
Speed adjusting lever (2) – selecting

vibration frequency
The machines have two operating speeds.
1
This allows improved adaptation of speed
and vibration power to specific ground
2 conditions.
NOTE
Depending on the options, the machine
may only have one working speed.
Idling speed
The speed adjusting lever (2) is in rear
position.
Low speed
Low speed - low frequency
1
until it snaps into first position.
2
The engine is now running at low speed.
High speed
High speed - high frequency
1
again until it snaps into second position.
2
The engine is now running at high speed.
Workshop Manual: 1084657 - 61 - 03.01.2007

Operating
Turning off the engine
5.5 Turning off the engine
Operating lever (1)

Slowly push the operating lever (1) into
1 neutral position. The machine is
automatically hydrostatically braked.

2 Move the speed adjusting lever (2) all the
way down into idle position.
Turning off the engine

Turn the ignition key counterclockwise back
to position 0.
The engine stops.
If you want to turn on the parking light, turn

the ignition key to position P.
Ignition switch positions

P PARK
In this position you can switch on the
parking light. The remaining electrical
loads are off.
0 OFF
All electrical loads are powered off.
I Ignition on
All electrical consumers can be
switched on.
II Pre-heating
III Start
NOTE
The hazard warning light can be switched on and off independently of the ignition key
position.
Workshop Manual: 1084657 - 62 - 22.09.2006

Operating
Emergency stop
5.6 Emergency stop
Activating the emergency stop

Press the emergency-stop ("EMERGENCY
STOP") button (1) in emergencies.
The machine comes to a standstill
immediately.
The engine shuts down immediately and

automatically. The brakes are activated.
1
NOTE
EMERGENCY = Urgent / Emergency
Releasing the emergency stop

First move the operating lever (1) to neutral
1 position.
Then move the speed adjusting lever (2) all

the way back.
2
Now turn the emergency stop button (1)

slightly in the direction of the arrow until its
clicks out.
The machine is now ready for operation.
Workshop Manual: 1084657 - 63 - 22.09.2006

Operating
Sprinkling AV1-2
5.7 Sprinkling AV1-2
Checking water level

Open tank screw on the rear water tank (1)
and top up water if required.
Switching continuous sprinkling on

and off
Turn the sprinkler switch (1) from position 0
to 1 to activate continuous sprinkling.
Interval sprinkler option

The roller is optionally equipped with an
interval sprinkler.
1 In this case, please refer to the "6 Options"

section on the "Interval sprinkler" page.
ATTENTION!
If your machine is not equipped with an interval sprinkler avoid turning the switch too far to
the right. In this case you can only select positions 0 and 1.
1
Operating lever sprinkling (1)
To operate the sprinkler from the operating
lever (1) press the bottom button (2). The
sprinkler stays on as long as you are
pressing the button.
2
NOTE
In the combined roller, operating lever
sprinkling is used only for tire sprinkling.
Workshop Manual: 1084657 - 64 - 22.09.2006

Operating
Sprinkling AV2-2
5.8 Sprinkling AV2-2
Checking water level

2 Open tank screws on both water tanks, rear
1 (1) and front (2), and top up water if
required.

and off
Turn the sprinkler switch (1) from position 0
to 1 to activate continuous sprinkling.
Interval sprinkler option

The roller is optionally equipped with an
interval sprinkler.
In this case, please refer to the "6 Options"

1
section on the "Interval sprinkler" page.
ATTENTION!
Operating lever sprinkling (1)

To operate the sprinkler from the operating
lever (1) press the bottom button (2). The
sprinkler stays on as long as you are
1 pressing the button.
2
NOTE
In the combined roller, operating lever
sprinkling is used only for tire sprinkling.
Workshop Manual: 1084657 - 65 - 03.01.2007

Operating
Simple / double vibration
5.9 Simple / double vibration
Switching on vibration
Press the top button (2) briefly on the
operating lever (1).
2 1 Switching off vibration

Press the same button (2) again briefly.
ATTENTION!
Never use vibration while idling!
Only switch vibration on if the speed

adjusting lever is set to a work speed.
Front and rear vibration

In order to activate front and rear vibration,
turn the vibration selection button (1)
clockwise.
1
Front only vibration
Turn the vibration selection button (1)
counterclockwise.
Workshop Manual: 1084657 - 66 - 22.09.2006

Options
6 Options
Workshop Manual: 1084657 - 67 - 22.09.2006

Options
Workshop Manual: 1084657 - 68 - 22.09.2006

Options
Edge cutter
6.1 Edge cutter
Operating switch position

3 2
The edge cutter operating switch is located
at the right of the steering column.
Lowering the edge cutter

As long as you press the "Lower" button (1)
the edge cutter is lowered.
Raising the edge cutter

1 As long as you press the "Raise" button (2)
the edge cutter is raised.
Edge cutter sprinkler

The rotary switch (3) switches the water
supply (continuous sprinkling) to the edge
cutter on/off.
NOTE
This function only works if roller drum
sprinkling is switched on.
WARNING!
Risk of injury!
No-one must be in the danger zone when
raising/lowering the edge cutter.
Keep to a safety distance of 1 m.
Workshop Manual: 1084657 - 69 - 22.09.2006

Options
Edge cutter
Disk storage
A cutting disk and thrust disk form part of the edge cutter deliverable.
AV1-2
If one of the two disks is not being used fix it
to the mounting provided on the right of the
roller.
AV2-2
If one of the two disks is not being used fix it
to the mounting provided between the front
and rear chassis.
Workshop Manual: 1084657 - 70 - 22.09.2006

Options
Revolving warning light
6.2 Revolving warning light
Switching on the revolving warning

1 light
Turn the switch (1) right to switch on the
revolving warning light.
Position during operation

1
The revolving warning light (1) is located at
the back right on the roll-over bar (Rops)
during operation.
Position when not in operation

You can attach the revolving warning light
on the left of the roll-over bar, on the holder
for transport or for prolonged periods of
standstill.
Make sure that the fastening screw (1) is

tightened.
Workshop Manual: 1084657 - 71 - 22.09.2006

Options
Revolving warning light
Replacing the bulb

Pull the cover off the base, turning it slightly
to the left as you pull.
Press the bulb holder down and then turn it

counterclockwise off the cam.
You can now remove the bulb from the

holder.
Now pull the bulb off the plug and replace it
with a bulb of the same type and power.
NOTE
Do not touch the glass of the new bulb
with your fingers. Sweat on your hands
can burn into the glass and reduce bulb
lifetime.
Workshop Manual: 1084657 - 72 - 22.09.2006

Options
Reverse alarm
6.3 Reverse alarm
The reverse alarm is active as soon as the roller drives backward. The alarm stays on until
the roller starts to drive forward or comes to a standstill.
WARNING!
Get out of the danger zone immediately!
Noise data
97 dB +/- 4 dB to SAE J 994, Oct. 03
Workshop Manual: 1084657 - 73 - 22.09.2006

Options
Battery cut-off switch
6.4 Battery cut-off switch
The battery cut-off switch interrupts the power supply from the battery to the machine. Switch
off the battery cut-off switch if the roller is not in operation for longer than two days.
ATTENTION!
Short-circuit!
Always disconnect the power supply when working on the electrical system.
Battery cut-off switch position

The battery cut-off switch (1) is located
under the cowling right next to the battery.
Switching on the power

Turn the red key (1) of the battery cut-off
switch left to horizontal position.
1
If fitted, the roller is now supplied by the
starter battery.
Workshop Manual: 1084657 - 74 - 22.09.2006

Options
Battery cut-off switch
Switching off the power

Turn the red key (1) of the battery cut-off
switch down to vertical position.
This interrupts the power supply.
Removing the key

2 1 Turn the red key (1) of the battery cut-off
switch right to final position.
You can now remove the key.
Close the keyhole using the cap (2)

provided.
Workshop Manual: 1084657 - 75 - 22.09.2006

Options
Traction aid (flow divider) AV2-2
6.5 Traction aid (flow divider) AV2-2
The flow divider ensures equal drive of the

1 front and rear wheels and thus avoids free
rotation of one wheel.
This function is useful for negotiating inclines

with poor adhesion qualities (e.g. loading the
roller via a loading ramp).
Turn the switch (1) to activate the “traction

aid” function; you will hear an acoustic
signal.
ATTENTION!
Hydraulic system heat-up!
The traction aid is active as long as the switch is in the “traction aid” position. This function
is not required in normal operating mode. If constantly activated the hydraulic system is
additionally unnecessarily heated.
Only engage the traction aid when the machine is at standstill.
Workshop Manual: 1084657 - 76 - 22.09.2006

Options
Lighting
6.6 Lighting
Parking light
Put the ignition into Parking position “P”.
Then turn the light switch (1) clockwise to
the first position.
1 Dipped light
Put the ignition key into position I (ignition
on).
Then turn the light switch (1) clockwise to
the second position.
Left indicator
To turn on the left indicator, turn the switch
(1) counterclockwise.
Right indicator
To turn on the right indicator, turn the switch
(1) clockwise.
Turn the switch (1) to center position to

1 switch the indicator off.
Rear work light

2
To switch the work light on and off turn the
switch (1).
Hazard warning light

1
To switch the hazard warning light on and off
press the button (2).
NOTE
The hazard warning light can be switched
on and off independently of the ignition
key position.
Workshop Manual: 1084657 - 77 - 22.09.2006

Options
Interval sprinkler
6.7 Interval sprinkler

1 and off
Turn the sprinkler switch from position 0 to 1
to activate continuous sprinkling.
Continuous or interval sprinkling

Turn the switch further right to switch on
interval sprinkling.
Turn the switch within the interval range (1)

to adjust sprinkling intervals infinitely.
ATTENTION!
Machine damage!
Workshop Manual: 1084657 - 78 - 22.09.2006

Options
Loxam
6.8 Loxam
Seat contact switch with delay

Loxam machines are equipped with a seat contact switch with delay.
This means that as soon as the driver gets up off the seat, an acoustic signal is given for two
seconds before the machine automatically comes to a standstill.
Restarting the roller

First move the operating lever (1) to neutral
position.
1
You can leave the speed adjusting lever (2)
in its previous position.
2 You can now start the roller by moving the
operating lever(1).
NOTE
If the driver sits down again within two seconds the roller continues to drive.
Workshop Manual: 1084657 - 79 - 22.09.2006

Options
Anti-adhesive
6.9 Anti-adhesive
Anti-adhesive is a water-soluble specialized liquid for combined rollers.

The anti-adhesive ensures effective separation between the pneumatic surfaces and the
bitumen course.
Advantages of anti-adhesive:
No tearing of the course thanks to the good separating effect.
Extremely low anti-adhesive consumption.
The course can be worked at higher temperatures.
Less shock to the hot course due to lower water consumption.
Anti-adhesive does not corrode the pneumatic tire rubber.
Penetration of superfluous anti-adhesive has no subsequent negative effects.
The anti-adhesive is biodegradable.
Activating anti-adhesive
If the roller is equipped with the anti-
adhesive option, you can activate anti-
adhesive with the lower button (1) on the
operating lever.
1
Anti-adhesive is admixed until you release
the button.
Anti-adhesive designations
Manufacturer RHODORSIL
Description RHODORSIL EMULSION E1P
Quantity 25 kg
Mixing ratio 1.5 : 100
Part number 1-951318
Tab 9: Anti-adhesive designations
Workshop Manual: 1084657 - 80 - 22.09.2006

Options
Anti-adhesive tank
6.10 Anti-adhesive tank
Position of anti-adhesive tank AV1-2

The anti-adhesive tank is located between
the front and rear chassis below the roller's
steering column.
Position of anti-adhesive tank AV2-2

1 The anti-adhesive tank filler neck (1) is
located below the hood at the right of the
roller.
Workshop Manual: 1084657 - 81 - 22.09.2006

Options
Anti-adhesive tank
Workshop Manual: 1084657 - 82 - 22.09.2006

Maintenance
Anti-adhesive tank
7 Maintenance
Workshop Manual: 1084657 - 83 - 22.09.2006

Maintenance
Anti-adhesive tank
Workshop Manual: 1084657 - 84 - 22.09.2006

Maintenance
Roller maintenance
7.1 Roller maintenance
NOTE
When carrying out maintenance work always observe the applicable safety regulations in
section "3 Safety".
Maintenance work and checks must be performed according to the following maintenance
table in order to guarantee reliable functioning of the machine.
Remove all dirt before taking off any covers, plugs, measuring sticks, etc. to check or top
up engine oil, hydraulic oil, diesel or other liquids.
Every 10 operating hours (daily)

Check engine oil level
Check coolant level
Check fuel level and fill up tank
Check hydraulic oil level
Inspect the condition of the sprinkler system
Inspect the scrapers, adjust if necessary
Check condition of roller drums
Combined roller: check tire pressure is 2.5 bar
Visual inspection for leaks, loose bolts, etc.
Empty sprinkler system if there is a risk of frost or protect by adding anti-freeze
Every 50 operating hours (weekly)

Check air filter cartridge, clean if necessary.
Check battery acid level.
Lubricate steering cylinder bearing (bearings are maintenance-free, depending on
design).
Hydraulic oil and filter change

First hydraulic oil change after 500 h, then every 1000 h, but at least once a year.
NOTE
This Workshop Manual does not list all maintenance work. With regard to the Yanmar
engine, please observe the maintenance table on the following page! We would also like to
point out the separate operating instructions for the Yanmar engine.
Workshop Manual: 1084657 - 85 - 22.09.2006

Maintenance
Yanmar engine maintenance
7.2 Yanmar engine maintenance
Regular checks and minor service
Regular inspection interval

System
Daily
Inspection item
every every every every
50 h 250 h 500 h 1000 h
Fuel (diesel oil) in fuel tank

|
check and top up
Drain water from fuel tank |*

Fuel
Drain water from the oil / water

|
separator
Clean oil / water separator |
Replace fuel filter
Engine oil level |

Engine oil
Replace engine oil * **
Replace engine oil filter * **
Check and top up cooling water |

Coolant
Check and clean radiator |
Check and adjust fan belt |* |**
Check and adjust operating lever and gas

| |
lever
Inlet and
outlet
Clean and replace air filter element |
Check control lights |

system
Elec.
Check and recharge battery

|
electrolyte
Tab 10: Checks and minor service, Yanmar engine
| Check, Replace
* 1st time
** 2nd and subsequent times
Workshop Manual: 1084657 - 86 - 22.09.2006

Maintenance
Yanmar engine service
7.3 Yanmar engine service
Major service
Regular inspection interval

System
Inspection item
Every 1000 h or Every 2000 h or
once a year every two years
Flush and service coolant system

Coolant
Replace coolant
Check or replace fuel and coolant hose | or

Cylinder
head
Adjust inlet/outlet valve play, IN 0.2 mm /

|
OUT 0.2 mm
Fuel valve, pump
Check and adjust pressure of fuel injection

|
valves
Check and adjust fuel injection pump |
Tab 11: Major Yanmar engine service
| Check, Replace
Workshop Manual: 1084657 - 87 - 25.09.2006

Maintenance
Opening the hood
7.4 Opening the hood
Unlocking the hood (1)

1
There is one locking device (2) on the left
and one on the right of the roller.
You must release both locks in order to lift

the hood.
3 Lifting the hood

Open the hood with the handle (3) on the left
of the hood.
2
Lift the hood with slight pressure toward the
center of the roller and then open the hood
completely.
If the hood is defective, replace it

immediately.
NOTE
Two gas absorbers reduce the force required to open the hood and give it its final position.
If you need more force to open the hood, replace the gas absorbers.
Warning!
Danger of severe injury to fingers and hands!
Never open the engine hood while the engine is running.
Warning!
Danger of burns!
Only work on a cool engine. Keep enough distance to the
exhaust.
Workshop Manual: 1084657 - 88 - 22.09.2006

Maintenance
List of checks – AV1-2
7.5 List of checks – AV1-2
WARNING!
Switch the diesel engine off when performing any inspection, adjustment or maintenance
work.
The parking brake is active when the diesel engine is switched off.
3 11
4
5 2
1
10
12
7
1 Battery
2 Engine oil filler neck
3 Air filter
4 Air filter soiling display
5 Oil dipstick
6 Coolant level display
7 Hydraulic oil filler neck
6 9 Engine oil filter
10 Fuel filter
11 Coolant filler neck
12 Water separator
Workshop Manual: 1084657 - 89 - 22.09.2006

Maintenance
List of checks – AV2-2
7.6 List of checks – AV2-2
WARNING
Switch the diesel engine off when performing any inspection, adjustment or maintenance
work.
The parking brake is active when the diesel engine is switched off.
11
4
3
10
6
1 5 9
7
8
12
1 Battery
2 Engine oil filler neck
3 Air filter
4 Air filter soiling display
5 Oil dipstick
6 Coolant level display
7 Hydraulic oil filler neck
9 Engine oil filter
10 Fuel filter
11 Coolant filler neck
12 Water separator
Workshop Manual: 1084657 - 90 - 22.09.2006

Maintenance
Checks – engine oil level, coolant AV1-2
7.7 Checks – engine oil level, coolant AV1-2
Checking engine oil level

Use the dipstick to check engine oil level
every day.
2 The oil dipstick (1) is located on the left of
1 the engine.
Check oil level while the roller is standing on

a level surface and the engine is cold.
The oil level must be between the top and
bottom marks.
Top up engine oil as required (2).
NOTE
In order to guarantee operating safety of the engine for the long term, you must not put any
additives in the engine oil.
Checking coolant level

Check coolant level (1) every day.
1
X
You can read off the level of coolant on the
Y expansion tank display (1).
The water level must be between the top (X)

and bottom (Y) marks.
Top up coolant as required (1).
Workshop Manual: 1084657 - 91 - 22.09.2006

Maintenance
Checks – engine oil level, coolant AV2-2
7.8 Checks – engine oil level, coolant AV2-2
Checking engine oil level

1
Use the dipstick to check engine oil level
every day.
The oil dipstick (1) is located on the left of
the engine.

2 a level surface and the engine is cold.
bottom marks.
Top up engine oil as required (2).
NOTE
In order to guarantee operating safety of the engine for the long term, you must not put any
additives in the engine oil.
Checking coolant level

Check coolant level (1) every day.
1 Check oil level while the roller is standing on

You can read off the level of coolant on the
X expansion tank display (1).
Y The water level must be between the top (X)

and bottom (Y) marks.
Top up coolant as required (1).
Workshop Manual: 1084657 - 92 - 22.09.2006

Maintenance
Checks – fuel tank, hydraulic oil tank
7.9 Checks – fuel tank, hydraulic oil tank
WARNING
Switch off the diesel engine to avoid unintentional start-up of the machine.
Fuel tank – filling

Fill the fuel tank with diesel fuel up to the
1 lower edge of the filler neck (1) every day
before starting work.
AV1-2
The tank holds 26 l of fuel.
AV2-2
The tank holds 43 l of fuel.
Hydraulic oil tank – checking oil level

2
Drive the roller onto a level surface and
check the oil level in the inspection window
(1).
If oil level is 20 mm below the top edge of

the inspection window, top up hydraulic oil
through the filler neck (2).
1
NOTE
Observe the table of lubricants.
Workshop Manual: 1084657 - 93 - 03.01.2007

Maintenance
Checks – sprinkler, scraper
7.10 Checks – sprinkler, scraper
Check and adjust the sprinkler

1 Switch sprinkling on and check the nozzles
(1) on the sprinkler pipesat the front and
back.
Check and adjust scrapers for the

roller drum
Pre-tension the scrapers (1) lightly by hand.
Check and adjust scrapers for the

pneumatic wheel axis
Adjust the scrapers with a clearance of
3 - 5 mm.
The anti-adhesive must not get scraped off.
Workshop Manual: 1084657 - 94 - 22.09.2006

Maintenance
Checks – tire pressure
7.11 Checks – tire pressure
Check and adjust tire pressure on the

pneumatic wheel axis
Tire pressure OK Æ 2 – 2.5 bar.
Tire pressure too high Æ

Reduce pressure by bleeding air.
Tire pressure too low Æ

Increase pressure by pumping in air.
Workshop Manual: 1084657 - 95 - 22.09.2006

Maintenance
List of checks – air filter cartridges AV1-2
7.12 List of checks – air filter cartridges AV1-2
Dirt outlet
Press the dirt outlet (1) of the air filter at
least once a week to clean it of dirt.
Soiling indicator
If a red ring appears on the soiling display
1 (1) during operation of the roller, you must
clean or replace the air filter cartridge.
Air filter cartridge

Check the air filter cartridge (1) for damage
or soiling.
Clean the cartridge if necessary.
Workshop Manual: 1084657 - 96 - 03.01.2007

Maintenance
List of checks – air filter cartridges AV2-2
7.13 List of checks – air filter cartridges AV2-2
Dirt outlet
Press the dirt outlet (1) of the air filter at
least once a week to clean it of dirt.
Soiling indicator
If a red ring appears on the soiling display
(1) during operation of the roller, it is
essential to clean or replace the air filter
cartridge.
Air filter cartridge

Check the air filter cartridge (1) for damage
or soiling.
Clean the cartridge if necessary.
Workshop Manual: 1084657 - 97 - 22.09.2006

Maintenance
7.14 Hydraulic oil and filter change
Venting the hydraulic tank

You must remove the hydraulic tank
1 breather (1) when topping up and refilling.
ATTENTION!
Soiling!
Do not fill oil into the breather.
Draining oil
Place a container under the drain.
Unscrew the oil-drain screw (1) and drain

hydraulic oil.
Screw the oil-drain screw back in.
Hydraulic system fill levels:

First fill 50 l
1 Oil change (approx.) 40 l
Replacing the filter

Unscrew the hydraulic oil filter cap (1) and
remove the old filter cartridge.
Do not remove the filter casing.

1
ATTENTION!
Soiling!
Remove any dirt before unscrewing the
filter cover.
Replace the filter every time you change

oil.
Workshop Manual: 1084657 - 98 - 22.09.2006

Maintenance
First install the new filter (1).
2 Put on the top section with the compression

spring (2).
Fill hydraulic oil through the filter casing until

it reaches the oil level on the inspection
window.
1
Screw in the cap by hand and tighten the
breather.
NOTE
First oil change after 500 h, then every
1000 h, but at least annually.
Workshop Manual: 1084657 - 99 - 22.09.2006

Maintenance
Changing engine oil AV1-2
7.15 Changing engine oil AV1-2
Draining engine oil

The engine oil drain is located on the right of
1 the roller right next to the front roller drum.
Place a container under the drain.
Undo the drain plug (1) with the aid of a

wrench and drain the oil.
NOTE
Hold the outside of the pipe plug and turn
the cap nut.
Topping up engine oil

Top up engine oil through the oil filling neck
(1).
1
2 Check engine oil level
The oil dipstick (2) is located on the right of
the engine.


bottom marks.
Workshop Manual: 1084657 - 100 - 22.09.2006

Maintenance
Changing engine oil AV2-2
7.16 Changing engine oil AV2-2
Turn the steering wheel all the way to the

1 left so that you can easily access the engine
oil drain (1).
Draining engine oil

The engine oil drain (1) is located at the
front right, between the front and rear
chassis.
1 Place a container under the drain.
Open the screw connection by turning left

(SW27). The oil starts to flow out
immediately.
Topping up engine oil

Top up engine oil through the oil filling neck
(1).
Check engine oil level

2
The oil dipstick (2) is located on the right of
the engine.
1

bottom marks.
Workshop Manual: 1084657 - 101 - 22.09.2006

Maintenance
Battery
7.17 Battery
Starting with an external battery

Connect the red cable (1) to the (+)
terminals of both batteries.
Connect one end of the green or black cable

(2) to the (-) terminal of the helper battery.
2
Connect the other end of the green or black
cable to a ground point on the roller.
Activate the starter and allow the engine to

1 run.
Wait until the engine is idling smoothly and
then disconnect the cable.
1
Charging the battery with a charging
unit
Disconnect the battery. Observe the battery
charger manufacturer’s manual.
Start with the (+) terminal when
reconnecting the battery.
NOTE
The battery poles and terminals must be clean. If they are coated with a whitish or greenish
sulfur crust they must be removed and cleaned.
If battery poles and terminals are soiled, the battery may not get fully charged.
Long-term storage
If the machine is not in operation for more than two days, the battery must be turned off at
the cut-off switch. This reduces the risk of battery discharge.
If no battery cut-off switch is fitted to your machine, remove the negative battery cable from
the battery if a standstill period of more than two weeks is expected.
Workshop Manual: 1084657 - 102 - 22.09.2006

Maintenance
Lubricant table
7.18 Lubricant table
Synthetic hydraulic
Make Hydraulic oil oil based on Grease
Ester HE
ISO VG 46 HVLP ISO 2137

Standard ISO 15380 HEES
DIN 51524 T3 DIN 51502
Drive and vibration Drive and vibration
Application Vibro bearing
hydraulics hydraulics
AGIP Amica 46
BLASER Blasol 148 Foodgrease SPM00
BP Bartran HV 46
CASTROL Hyspin AWH 46
ESSO Univis HP 46
MOBIL Mobil DTE15
MOTOREX Corex HV 46 Motorex 3000
PANOLIN HLP Universal 46 HLP Synth 46
SHELL Tellus T 46
TOTAL Equivis ZS 46
Tab 12: Lubricant table
ATTENTION!
Only use the above listed lubricants as hydraulic oil and grease.
ATTENTION!
Hydraulic control failure!
Hydraulic tubes decompose
It is forbidden to change used machines for use with biodegradable hydraulic oils!
Workshop Manual: 1084657 - 103 - 22.09.2006

Maintenance
Consumables, tightening toques
7.19 Consumables, tightening toques
Description Make Quantity Prod. No.
Engine oil Motorex Climafix 15W40 1l 921197
Grease Motorex 3000 1 kg 944446
Grease Motorex 3000 17 kg 922672
Grease Blaser Foodrease SPM00 14 kg 1075038
Anti-freeze Motorex green 30 l 922341
Bolt locking Loctite 243 (blue) 50 ml 907977
Bolt locking Loctite 243 (blue) 250 ml 907975
Bolt locking Loctite 262 (red) 50 ml 907978
Bolt locking Loctite 262 (red) 250 ml 907979
Paint spray RAL 1016 Sulfur yellow 400 ml 922700
Paint spray RAL 6033 Mint turquoise 400 ml 922701
Tab 13: Consumables
SW Bolt diameter Steel quality Tightening torque in Nm
10 M6 8.8 10
13 M8 8.8 25
17 M10 8.8 49
19 M12 8.8 86
24 M16 8.8 210
24 M16 10.9 290
30 M20 8.8 410
Tab 14: Tightening torques
Workshop Manual: 1084657 - 104 - 22.09.2006

Storage
8 Storage
Workshop Manual: 1084657 - 105 - 22.09.2006

Storage
Workshop Manual: 1084657 - 106 - 22.09.2006

Storage
Storage
8.1 Storage
Storage:
Put the operating lever into neutral position.
Secure the machine from unauthorized start-up and unintentional rolling away.
Long-term storage
Component Precautions:
Diesel engine Observe the information in the “Long-term storage” section in the
diesel engine manual.
Battery cut-off If the machine is not in operation for more than two days, the
switch battery must be turned off at the cut-off switch. This reduces the
risk of battery discharge.
If no battery cut-off switch is fitted to your machine, remove the

negative battery cable from the battery if a standstill period of
more than two weeks is expected.
Battery Uninstall the battery and clean the outside. Charge the battery
once a month during standstill time.
Air filter unit, Cover the air filter unit or its intake opening and the exhaust pipe
exhaust pipe with adhesive tape. This prevents moisture from getting into the
engine.
Hydraulic oil tank Drain the hydraulic oil completely. Fill up the hydraulic oil tank with
fresh oil when putting the machine back into operation.
Steering cylinder Lubricate the bearings of the steering knuckle and the front
bearing of the steering cylinder with grease.
Lubricate the piston rod of the steering cylinder with grease guard.
Tires Only combined rollers have tires. Relieve the pressure in tires
(pneumatic wheels) if the machine is not being used for a
prolonged period by relieving the pneumatic wheel axis with a
wooden wedge so as to avoid flat spotting damage to the tires.
Tab 15: Long-term storage
Workshop Manual: 1084657 - 107 - 22.09.2006

Storage
Emptying the water tank
8.2 Emptying the water tank
Cleaning accessories
Clean the following parts as required:
Water tank with filler strainer (1)

1
Water filter (2)
2 Sprinkler pipes with nozzles (3)
Emptying the water tank

1
Remove the water filter (1) at the back and
drain off the water.
NOTE
AV2-2: empty the front and rear water
tank.
ATTENTION!
Risk of frost!
In the event of the risk of frost, additionally empty the sprinkler system. See next page.
Workshop Manual: 1084657 - 108 - 22.09.2006

Storage
Winterization, emptying the water tank
8.3 Winterization, emptying the water tank
The purpose of winterization is to ensure that cold air temperatures of below 0 °C do not
damage the sprinkler system.
Emptying the rear water tank and

sprinkler system
1 Unscrew the quick-release sprinkler hose
clamp (1) by pressing the black plastic ring
against the screw connection.
Now pull the hose off the coupling.
Drain off the water.
NOTE
AV2-2: empty the front and rear water
tank.
Emptying the front water tank

Optionally, to speed up draining and ensure
1 that the tank is completely emptied, you can
empty the front water tank separately.
Unscrew the quick-release sprinkler hose

against the screw connection.
Now pull the hose off the coupling. Drain off

the water.
Switch on the sprinkler and let the water pump run briefly. This pumps the remaining water
out of the pipes.
Workshop Manual: 1084657 - 109 - 22.09.2006

Storage
Winterization, emptying the water tank
The plastic water filter container (1) can be

stored on the machine, in the water tank
water filter.
NOTE
Press the battery cut-off switch if storing for more than two days.
If no battery cut-off switch is fitted to your machine, remove the negative battery cable from
the battery if a standstill period of more than two weeks is expected.
Workshop Manual: 1084657 - 110 - 22.09.2006

Storage
Draining diesel
8.4 Draining diesel
Unscrew the screw (1) under the roller using

a square socket wrench (13 mm).
You can find this wrench on the ratchet of
the socket wrench set.
Place a container under the drain tap and let

the diesel run out.
Workshop Manual: 1084657 - 111 - 22.09.2006

Storage
Draining diesel
Workshop Manual: 1084657 - 112 - 22.09.2006

Repair
Draining diesel
9 Repair
Workshop Manual: 1084657 - 113 - 22.09.2006

Repair
Draining diesel
Workshop Manual: 1084657 - 114 - 22.09.2006

Repair
Towing, releasing brakes
9.1 Towing, releasing brakes
Towing
Only tow the machine in an emergency in order to remove the machine away from the
danger zone.
ATTENTION!
Maximum towing speed: 1 km / h
Maximum towing distance: 10 m
Then transport the roller by truck or trailer.

Secure the machine with the joint protection
(1).
Releasing brakes
Before you can tow the machine you must release the integrated parking brake.
WARNING!
Before you can release the brakes it is
essential to secure the machine from
unintentionally rolling away.
Workshop Manual: 1084657 - 115 - 22.09.2006

Repair
Drive motor MS02

(AV23-2, AV26-2, AV32-2, AV23-2K, AV26-2K, AV32-2K, AV40-2K)
Remove the protective cap (1) on the front

and rear drive motor.
You can find the brake release chocks in the

front chassis under the hood.
The brake release chock is fastened under

the hood by two screws M12 × 35 (1).
Unscrew the screws with a wrench (SW19)

1 and remove the brake release chock.
The two screws also act as tension screws.
Screw the brake release chock (1) onto the

drive motor.
1
Turn the screw in by hand.
Workshop Manual: 1084657 - 116 - 22.09.2006

Repair
Turn the wrench (SW19) approx. one half

turn downward.
Wrench rotation on the motor approx. 180°.
The brakes have been released, you can

now tow the machine.
Drive motor MKD04

(AV33-2, AV40-2)
Remove the two cover screws (1) on the

1 drive motor with an Allen key (SW8).
Workshop Manual: 1084657 - 117 - 22.09.2006

Repair
You can now see two other Allen screws.
Press these screws in and tighten them

alternately, step by step with an Allen key
(SW6) (1).
1 The brakes have been released, you can

now tow the machine.
Workshop Manual: 1084657 - 118 - 22.09.2006

Repair
Removing the rear water tank AV1-2
9.2 Removing the rear water tank AV1-2
Unscrew the holder screws (1).
Pull the tank (1) back approx. 10 cm.
You can now access the water hose to the

left of the seat.
Disconnecting the water hose

1
Unscrew the quick-release (1) water hose
against the screw connection. Now pull the
hose off the coupling.
You can now pull the water tank all the way
out.
Workshop Manual: 1084657 - 119 - 22.09.2006

Repair
Removing the front water tank AV2-2
9.3 Removing the front water tank AV2-2
Disconnecting the sprinkler hose

Hold the hose in your left hand and press
the black plastic ring (1) against the screw
connections with your right hand.
You can now disconnect the hose.

1
NOTE
Do not remove the hose without pressing
the ring against the screw connection. The
hose can get damaged.
Draining water
Now let the water drain off until the tank is
completely empty.
Unscrewing the fastening screws

Unscrew the screw (SW10) (1) of the intake
2 hose clamp (2).
Workshop Manual: 1084657 - 120 - 22.09.2006

Repair
Removing the front water tank AV2-2
Unscrew the hood holder screws (S13) (1)

on both sides of the roller.
Lifting the hood off

You can now lift the hood (1) off with both
1 hands.
Carefully put the hood aside.
Lifting off the water tank

Tilt the tank (1) forward slightly toward your
chest and lift it off from front to back.
1
Carefully lay the water tank down to the
side.
Proceed in the reverse order to assemble

the water tank again.
Workshop Manual: 1084657 - 121 - 22.09.2006

Repair
Removing the rear water tank AV2-2
9.4 Removing the rear water tank AV2-2
Unscrew the holder screws (SW13) (1).

1
Pull the tank (1) back approx. 10 cm.
You can now access the water hose to the

left of the seat.
Disconnecting the water hose

Unscrew the quick-release (1) water hose
clamp (2) by pressing the back plastic ring
against the screw connection. Now pull the
1 hose off the coupling.
You can now pull the water tank all the way
2 out.
Workshop Manual: 1084657 - 122 - 22.09.2006

Repair
Separating the roller drum from the chassis
9.5 Separating the roller drum from the chassis

(1).
Removing the roller drum

Release the hydraulic hose clamps (SW13)
(1) on the chassis.
Remove the hydraulic hoses from the motor

and plug the hoses with suitable pipe plugs
(1).
1
Workshop Manual: 1084657 - 123 - 22.09.2006

Repair
Separating the roller drum from the chassis
Release the hydraulic hose clamps (SW13)

(1) on the wheel support.
Lift the roller drum with a crane onto a safe

workplace.
Secure the roller drum from unintentionally

rolling away.
1
Installing the roller drum
Slowly lower the spacer plate (1) onto the
3 two lower bolts (2).
Push the wheel support onto the bolts.

2 Secure the Allen screws (SW19) (3) with
Loctite 262 and tighten them to torque.
Connect the hydraulic hoses and tighten them.
Install the clamps.
Secure the clamp Allen screws (SW19) with Loctite 243 and tighten them to torque.
Workshop Manual: 1084657 - 124 - 22.09.2006

Repair
Adjusting the operating lever AV1-2
9.6 Adjusting the operating lever AV1-2
Put the operating lever into neutral position.
3 Fasten the reversing knuckle (1) on the

reversing holder (2) (SW13).
1
Adjust the head of the ball joint (3) until the
2 angle between the lever and the ball joint
head is 90° with the bore in alignment.
Screw in the M8 screw (SW13) (1) and

tighten the locknut (SW10) on the joint head.
1
The operating lever must be in neutral
position.
Tighten the Allen screw (SW4) (2) on the

lever.
Secure the screws (1, 2) with Loctite 243.
Workshop Manual: 1084657 - 125 - 22.09.2006

Repair
Adjusting the operating lever AV2-2
9.7 Adjusting the operating lever AV2-2
Screw in the M8 screw (SW13) (1).
1 Put the operating lever into neutral position.
Adjust the nuts (2) until the angle between

the joint head and the lever (3) is 90°.
Tighten the nuts.
2
2
Check whether the operating lever is in

neutral position and tighten the Allen screw
(1) on the lever (2).
Secure the Allen screw (SW4) (1) with

Loctite 243.
2
Workshop Manual: 1084657 - 126 - 22.09.2006

Repair
Adjusting engine speed and frequency
9.8 Adjusting engine speed and frequency
Adjusting speed at operating

temperature
Put the machine on two large or four small

old tires or on a suitably soft base.
Machine with light

Set the speed lever (1) to top position = fast
speed
= Guideline 2380 +/- 20 rpm.
1
Machine without light

Set the speed lever (1) to center position =
fast speed
= Guideline 2100 +/- 20 rpm.
1
ATTENTION!
Do not exceed maximum engine speed of 2400 rpm!
Workshop Manual: 1084657 - 127 - 22.09.2006

Repair
Adjusting engine speed and frequency
Switch on front and rear vibration.
Measure the frequency with the tachometer

(sirometer).
Material number: 1-923647.
With light:
Target: 66 Hz
Without light:
Target: 58 Hz
AV1-2
1
If necessary, adjust the speed on cable
knuckle 2 × SW13 (1) or on the ballhead
(SW10) (2).
Lock the nuts and check fastening on the

ballhead.
NOTE
This results in the lower speed, i.e.
medium level. Frequency 58 Hz
AV2-2
If necessary, adjust the speed on cable
1 knuckle 2 × SW13 (1).
Lock the nuts and check fastening on the

ballhead.
NOTE
This results in the lower speed, i.e.
medium level. Frequency 55 Hz
Workshop Manual: 1084657 - 128 - 22.09.2006

Repair
Removing the driver's cabin
9.9 Removing the driver's cabin
Disconnect the battery from ground (SW13).
Remove the rear water tank as described in the "Repair" section.
Unscrew the screws (1) (SW13) and remove

the footboard (2).
Unscrew the screws (SW13 and SW10) and

remove the metal panels at the front (1) and
back (2) of the steering column.
2
1
Remove the cable ties (1) on the hose

bundle (2).
2
Workshop Manual: 1084657 - 129 - 22.09.2006

Repair
Release the reversing cable knuckle (1) on

the drive pump (SW13).
Release the gas cable knuckle (1) on the

injection pump (SW13).
Disconnect the plugs of the main cable

harness from the relay panel in the steering
column.
Workshop Manual: 1084657 - 130 - 22.09.2006

Repair
Disconnect the plug (X50) from the driver's

cabin cable harness on the rear right of the
X50 chassis.
Disconnect the plug (1) from the

ignition switch (2).
Detach the hydraulic hoses on the steering

selection valve (1) and plug the connections
with suitable pipe plugs (SW27).
Workshop Manual: 1084657 - 131 - 22.09.2006

Repair
Remove the two M12 screws (SW19) of the

rubber elements at the front.
Remove the two M12 screws (SW19) (1) of

the rubber elements (2) at the back.
Disconnect the ground cable (SW10) (3).
1
3
Suspend the driver's cabin on the crane with

suitable lifting equipment.
With the crane, lift the driver's cabin carefully

and remove it completely.
NOTE
Make sure that all control cables, cables
and hoses have room to move.
Workshop Manual: 1084657 - 132 - 22.09.2006

Repair
Putting machine in line AV1-2
9.10 Putting machine in line AV1-2
Preparation
Remove the rear water tank as described in the "Repair" section.
Remove the driver's cabin as described in the "Repair" section.
Detaching hydraulic hoses

Detach the hydraulic hoses from the motors and plug them with suitable pipe plugs.
NOTE
The pendulum support must not be adjusted.
Machine aligned with side clearance
Machine in line
Workshop Manual: 1084657 - 133 - 22.09.2006

Repair
Release the screws (SW13) and remove the

hydraulic hose clamps (1) on the chassis.
Remove the hydraulic hoses from the motor

1 and plug the hoses with suitable pipe plugs
(1).
Release the screws (SW13) and remove the

hydraulic hose clamps (1) on the wheel
1 support.
Workshop Manual: 1084657 - 134 - 22.09.2006

Repair
Lift the chassis at the back with a crane.

4 Place the roller drum (1) on a hand lift (2).
3
Relieve the chassis. Remove the screws
(SW19) (3) on the wheel support and
remove the spacer plate.
1
2
Lift the chassis with a crane and pull the

roller drum (1) out under the chassis with the
hand lift (2).
1
2
Push the roller drum (1) back under the

5
chassis on the opposite side using the hand
lift (2).
3 Slowly lower the spacer plate (3) onto the

two lower bolts (4).
4 Push the wheel support onto the bolts.

2
Secure the screws (SW19) (5) with Loctite
1 262 and tighten them to torque.
Workshop Manual: 1084657 - 135 - 22.09.2006

Repair
Fold the hose bundle over 180°, that is, what

was on the front right is now also on the
front left.
1
Apart from the leak and brake lines, that is,
the two outermost hoses have to be
swapped.
1 Install the hoses and clamps (1) and tighten
them (SW13).
Adjust the sprinkler pipe (1).
1 Unscrew the Allen screws (SW5) on the

hose clamps (2) and push the sprinkler pipe
to the left.
Workshop Manual: 1084657 - 136 - 22.09.2006

Repair
9.11 Putting machine in line AV2-2
Suspend the machine at the back on a crane

(1) and place the roller drum on a hand
1 lift (2).
Relieve the front of the machine with a

hydraulic lift (1).
Workshop Manual: 1084657 - 137 - 22.09.2006

Repair
Unscrew the screws (SW24) (1) of the

articulated joint and the steering support.
Remove the paint and clean the contact

surface of the joint (1) and fastener (2).
1 Insert two threaded pins M16 × 40 (3) on the
central joint.
Position the joint with the threaded pins.
Release the locknut (SW30) (1) on the

pendulum support of the front of the chassis.
1
Workshop Manual: 1084657 - 138 - 22.09.2006

Repair
Unscrew the screws (SW10) of the

1 pendulum support of the front of the chassis.
Remove the Allen screw (SW17 and SW6).
Rotate the support 180°.

1
Replace the screw (1) from top to bottom.
The nut must always be at the bottom.
Install the pendulum support. Secure the

screws with Loctite 262.
Workshop Manual: 1084657 - 139 - 22.09.2006

Repair
Shift the central joint to the right.
The contact surfaces must be free.

1
Shift the steering cylinder fastener to the
right.
Secure the screws (1) with Loctite 262 and

tighten them to torque.
Tighten the screws (1) of the articulated joint

and steering support to torque.
Tighten the screws (SW10) of the pendulum

support to torque.
1
Tighten the locknut (SW30).
Workshop Manual: 1084657 - 140 - 22.09.2006

Repair
Replacing bearing, vibro unit AV1-2
9.12 Replacing bearing, vibro unit AV1-2

(1).
Remove the roller drum from the chassis as

described in the section "Separating the
roller drum from the chassis".
Turn the breather (1) on the vibro case out

with a wrench (SW24).
Turn the screw (SW13) (2) on the case

1 cover with a wrench (SW13).
2
Insert the mandrel (1) 5mm and rotate the -

unbalanced flywheel all the way against the
mandrel.
2 Screw the Allen screw out with an Allen key

1 (SW6) (2).
Workshop Manual: 1084657 - 141 - 22.09.2006

Repair
Screw out the Allen screws (1) on the vibro

motor with an Allen key (SW6).
2
Carefully pull out the vibro motor (2).
NOTE
The flexible drive shaft may get stuck in
1 the motor. Do not use force when pulling
out the vibro motor.
Unscrew the nuts (SW13) (1) of the bellows

(2) on the wheel disk.
1
2
Workshop Manual: 1084657 - 142 - 22.09.2006

Repair
Hang the wheel support on a crane.
Unscrew the screws (SW24) (1) on the

wheel disk.
Remove the wheel support with the wheel

disk.
Remove the vibro unit (1) from the wheel

body (SW19).
Workshop Manual: 1084657 - 143 - 22.09.2006

Repair
Dismantling the vibro unit

1
Release the cover (1) and lift it off (SW13).
Pull out the vibro shaft (1).
Pull the bearing and then the shaft sealing

ring out of the case.
Pull the bearing (1) out of the cover.

1
Workshop Manual: 1084657 - 144 - 22.09.2006

Repair
Pull the inside ring (1) and the wearing ring

(2) off the vibro shaft.
1
2
Clean all parts and check them for damage and correct dimensions.
Replace any defective parts.
Always replace seals.
Grease the bearing (1) by filling the case

1 with 150 g grease.
ATTENTION!
Always use the prescribed low-viscosity
gear grease.
Always observe the prescribed amount of
grease.
150 g low-viscosity gear grease Blaser
Foodgrease
Material number: 1075038
Assembling the vibro unit

Reassemble the vibro unit in the reverse
order.
1 Secure the screws (SW13) (1) with Loctite

246 and tighten them to torque.
Check axial play and easy running. Axial

play = approx. 0.5 mm.
Workshop Manual: 1084657 - 145 - 22.09.2006

Repair
Insert the vibro unit (1) into the wheel body.
Secure the screws (SW19) with Loctite 246

Position the wheel support with a crane and

install it.
Workshop Manual: 1084657 - 146 - 22.09.2006

Repair
Position the clamping ring with the stay bolt

2 to the fasten the bellows.
Carefully insert the stay bolt into the wheel

1 disk slits.
Secure the nuts (1) with Loctite 243 and

tighten them (torque 25Nm).
Secure the screws (SW24) (2) with Loctite

Insert the flexible drive shaft and make sure

that the two pins snap into the vibro shaft
bores.
Insert the mandrel (1) into the bore in the

1 case cover and turn the vibro shaft against
it.
Secure the Allen screws (SW6) with Loctite

Pull out the mandrel (1) and screw in the

screw (SW6) and secure it with Loctite 243.
Workshop Manual: 1084657 - 147 - 22.09.2006

Repair
Assemble the breather (1) (SW24) and

secure it with Loctite 243.
Apply a thin coating of "Curil" sealant to the

sealing surface of the vibro motor.
Check the drive shaft for correct positioning

of the wedge.
Grease the drive shaft lightly and carefully

install the motor.
Secure the Allen screws (1) with Loctite 243

and tighten them to torque.
Workshop Manual: 1084657 - 148 - 22.09.2006

Repair
9.13 Replacing bearing, vibro unit AV2-2

(1).
Remove the roller drum from the chassis as

described in the section "Separating the
roller drum from the chassis".
Remove the additional weights (1) of the

AV32 - AV40 on the left and right with
suitable equipment.
Roller drum ballast assembly aid, material

number: 1083269.
Workshop Manual: 1084657 - 149 - 22.09.2006

Repair
Relieve the wheel support on the drive motor

side with a crane.
Unscrew and remove the screws (SW24) (1)

of the rubber elements.
The wheel support is now free.
Relieve the wheel support on the vibro motor

side with a crane.
Remove the vibro motor (1).
Workshop Manual: 1084657 - 150 - 22.09.2006

Repair
Remove the coupling sleeve (1).
Unscrew and remove the screws (SW17) (1)

of the roller drum bearing disk.
The wheel support is now free.

1
Unscrew and remove the screws (SW17) of
the drive bearing flange.
Remove the drive bearing flange.
Lift out the vibro shaft (1) with a crane and

suitable equipment (2).
Material number:
1 1083291 Vibro shaft assembly aid.
2 ATTENTION!
Secure fastening is a prerequisite for
lifting out the vibro shaft.
NOTE
If you do not have the appropriate tools, particularly for lifting out vibro shafts of the series
AV26, AV32, AV33 and AV40, we recommend placing the roller drum upright. Vibro motor
side, top.
Workshop Manual: 1084657 - 151 - 22.09.2006

Repair
Unscrew and remove the screws (1) (SW17)

1 of the vibro bearing case. Pull out the case.
Dismantle the drive bearing flange and the

vibro bearing case with suitable tools.
Unscrew the stud screw (SW2.5) (1).

1
Use a pulling device to pull off the hub on
the vibro shaft.
Workshop Manual: 1084657 - 152 - 22.09.2006

Repair
Remove the bearing groove rings on the

1 vibro shaft with suitable tools.
Clean all parts and check them for damage

and correct dimensions.
Replace any defective parts.

1
Always replace seals.
Assembling the vibro bearing case on

the drive motor side
Press in the bearing with suitable tools.
1 Install the securing ring (1).
Press in the shaft sealing ring.
Grease the shaft sealing ring.
Workshop Manual: 1084657 - 153 - 22.09.2006

Repair
Grease the bearing by filling the case 1/3

with Motorex 3000.
Assembling the drive bearing flange

Press the shaft sealing ring into the recess.
Grease the shaft sealing ring with Motorex

3000.
Press the bearing 6024 into the recess.
Workshop Manual: 1084657 - 154 - 22.09.2006

Repair
Pull the V-ring onto the recess.

Grease the V-ring with Motorex 3000.
Clean the bearing groove ring and the flange

hub and clean all grease off them.
Apply Loctite 640 to the seat of the bearing

1 (1) on the hub.
Press the recess completely onto the hub.
Workshop Manual: 1084657 - 155 - 22.09.2006

Repair
Greasing the drive bearing flange

1 3
Fill the drive bearing (1) and the vibro
bearing (2) 1/3 with Motorex 3000 grease.
2
Insert the drive bearing clamp ring into the
recess (3).
Vibro shaft
Heat up the bearing groove ring (1) to
110 °C with an induction heater.
Shrink the heated-up bearing groove ring

onto the vibro shaft.
Workshop Manual: 1084657 - 156 - 22.09.2006

Repair
Check the wedge (1) on the vibro shaft and

insert it.
Grease the end of the shaft.
Heat up the hub (1) to 150 °C with an

induction heater.
Shrink the hub (1) onto the vibro shaft.
Workshop Manual: 1084657 - 157 - 22.09.2006

Repair
Secure the Allen screws (1) (SW2.5) with

Loctite 243 and tighten them.
Insert the vibro bearing case (1) into the

roller drum.
1
Secure the screws (SW17) with Loctite 262
2 ATTENTION!
The shaft sealing ring can get pressed out
while you are inserting the vibro shaft.
Remove the breather screw (2) in the
case.
Insert the vibro shaft (1) with tools (2).
Material number:
1083291 Vibro shaft assembly aid.
ATTENTION!
Secure fastening is a prerequisite for
inserting the vibro shaft.
1 2
Workshop Manual: 1084657 - 158 - 22.09.2006

Repair
Put the drive bearing flange on.

1 Secure the Allen screws (SW17) (1) with
2
Check the vibro shaft for easy running and
axial play.
Axial play = approx. 1 mm.
Brush the front end of the holder case with

"Curil" sealant (2).
Secure the breather screw with Loctite 243.

1
Turn the breather screw (1) (SW13) into the
vibro bearing flange.
Workshop Manual: 1084657 - 159 - 22.09.2006

Repair
Position the wheel support with the installed

roller drum and roller drum bearing disk with
two adjustment bolts (M10, SW17).
Secure the Allen screws with Loctite 262

Install the coupling sleeve (1).
Workshop Manual: 1084657 - 160 - 22.09.2006

Repair
Apply "Curil" sealant on the front end of the

vibro motor.
Screw on the vibro motor.
1 Secure the Allen screws (1) (SW6) with

Position the wheel support and the drive

motor with a crane and assemble them.
Install the roller drum in the chassis again.
Workshop Manual: 1084657 - 161 - 22.09.2006

Repair
Tools
9.14 Tools
Lifting the additional weight.
Material number:
1083269 Roller drum ballast AV2-2
assembly aid.
Assembling the vibro shaft.
Material number:
1083291 Vibro shaft assembly aid (1).
Measure steering pressure AV2-2
Material number:
1 1-921284 Mini-measuring cap 12 L (1)
1 2 1-901249 L cap ELSD 12 L (2)
Workshop Manual: 1084657 - 162 - 22.09.2006

Repair
Tools
Measuring speed and frequency.
Material number:
1-923647 Tachometer (sirometer).
Checking magnetic coils.
Material number:
1-10300477 Solenoid tester.
Plugs and stoppers for 1 vibro motor AV1-2
Material Size Quantity Material number
Pipe plug 15L 2 1-901441
End plug 15L 2 1-901276
Cap nut 15L 2 1-901003
Pipe plug 12L 1 1-901440
End plug 12L 1 1-901275
Cap nut 12L 1 1-901325
Tab 16: Plugs and stoppers for 1 vibro motor AV1-2
Workshop Manual: 1084657 - 163 - 22.09.2006

Repair
Tools
Plugs and stoppers for 1 drive motor AV1-2
Pipe plug 16S 2 1-922638
End plug 16S 2 1-922641
Cap nut 16S 2 1-901522
Pipe plug 12L 1 1-901440
End plug 12L 1 1-901275
Cap nut 12L 1 1-901325
Pipe plug 8L 1 1-901438
End plug 8L 1 1-901273
Cap nut 8L 1 1-901429
Tab 17: Plugs and stoppers for 1 drive motor AV1-2
Plugs and stoppers for drive pump test AV1-2
Pipe plug 20S 2 1-901443
End plug 20S 2 1-901280
Cap nut 20S 2 1-901007
Tab 18: Plugs and stoppers drive pump test AV1-2
Plugs and stoppers for drive pump AV1-2
Pipe plug 8L 1 1-901438
End plug 8L 1 1-901273
Cap nut 8L 1 1-901429
Tab 19: Plugs and stoppers for drive pump AV1-2
Workshop Manual: 1084657 - 164 - 22.09.2006

Repair
Tools
Plugs and stoppers for 1 vibro motor AV2-2
Pipe plug 15L 2 1-901441
End plug 15L 2 1-901276
Cap nut 15L 2 1-901003
Pipe plug 10L 1 1-901439
End plug 10L 1 1-901274
Cap nut 10L 1 1-901397
Tab 20: Plugs and stoppers for 1 vibro motor AV2-2
Plugs and stoppers for 1 drive motor AV2-2
Pipe plug 16S 2 1-922638
End plug 16S 2 1-922641
Cap nut 16S 2 1-901522
Pipe plug 10L 1 1-901439
End plug 10L 1 1-901274
Cap nut 10L 1 1-901397
Pipe plug 8L 1 1-901438
End plug 8L 1 1-901273
Cap nut 8L 1 1-901429
Tab 21: Plugs and stoppers for 1 drive motor AV2-2
Workshop Manual: 1084657 - 165 - 22.09.2006

Repair
Tools
Plugs and stoppers for drive pump test AV2-2
SAE dummy flange ¾“ 1
SAE dummy flange ¾“ 1
Pipe plug 20S 2 1-901443
End plug 20S 2 1-901280
Cap nut 20S 2 1-901007
Tab 22: Plugs and stoppers for drive pump test AV2-2
Plugs and stoppers for drive pump AV2-2
Pipe plug 8L 1 1-901438
End plug 8L 1 1-901273
Cap nut 8L 1 1-901429
Tab 23: Plugs and stoppers drive pump AV2-2
Workshop Manual: 1084657 - 166 - 22.09.2006

Hydraulic System
Tools
10 Hydraulic
System
Workshop Manual: 1084657 - 167 - 22.09.2006

Hydraulic System
Tools
Workshop Manual: 1084657 - 168 - 22.09.2006

Hydraulic System
Overview of the hydraulic system
10.1 Overview of the hydraulic system
9
1
6
7 2
4 10
4
3
1 Drive pump
2 Vibro pump
3 Drive motor
4 Vibro motor
5 Steering selection valve
6 Vibro switch valve
7 Flow divider (AV2-2 only)
8 Steering cylinder
10 Cooler
Workshop Manual: 1084657 - 169 - 03.11.2006

Hydraulic System
Overview of AV1-2 hydraulic system
10.2 Overview of AV1-2 hydraulic system
1 Drive motor
3 2 Vibro motor
6
3 Leak-oil pipe drive / vibro motor
5 4 4 Contact lines A+B
5 Vibro lines
4 5 6 Brake line
1
2
1 Drive pump
2 Vibro pump
1 3 Vibro switch valve
Workshop Manual: 1084657 - 170 - 22.09.2006

Hydraulic System
10.3 Overview of AV2-2 hydraulic system
3 AV23 – AV32
4
1 Drive motor
2 2 Contact lines
2 3 Drive motor leak-oil pipe
4 Brake line
AV33 – AV40
1 Drive motor
3 2 2 Contact lines
3 Drive motor leak-oil pipe
4 4 Brake line
2
AV23 – AV40
1 Vibro motor
3 2 Vibro lines
3 Vibro motor leak-oil pipe
2
1
Workshop Manual: 1084657 - 171 - 22.09.2006

Hydraulic System
1 Drive pump
2 Vibro pump
3 Steering pump
3
4
Workshop Manual: 1084657 - 172 - 22.09.2006

Hydraulic System
Checking and adjusting pressures AV1-2
10.4 Checking and adjusting pressures AV1-2
All values apply at a hydraulic oil temperature of approx. 60 °C and max. diesel engine
speed.
Bleed pressure relief for a maximum of 5 seconds.
Use the following pressure gauge:
For high pressure = min. 400 bar
For supply pressure = min. 40 bar
1
2
1 M1 supply pressure
20 ± 4 bar can only be set using disks.
2 MB drive pressure forward
330 ± 10 bar, measure with roller drums blocked.
3 M2 vibro / steering pressure
vibration switch-on pressure 210 ± 10 bar (double vibration) can be set on the vibro
switching valve.
Steering pressure 100 ± 10 bar, when the steering is at stop, can be set on the vibro
switching valve.
4 M4 drive pressure backward

330 ± 10 bar, measure with roller drums blocked.
Workshop Manual: 1084657 - 173 - 22.09.2006
Hydraulic System
1 Supply pressure measuring point

2 Supply pressure valve
3 Set drive pressure forward
1 DBV vibration pressure 210 ± 10 bar.
Switch on double vibration.
Pressing in the stud screw (1)

increases pressure.
Workshop Manual: 1084657 - 174 - 22.09.2006

Hydraulic System
Setting steering pressure

Move the steering all the way out and slowly
continue to turn the steering wheel.
1 Unscrew the cover screw (1) with an Allen

key (SW8).
Adjust pressure using the Allen screw

(SW6).
Steering pressure 100 ± 10 bar.
Steering selection valve

The steering selection valves of models AV1-2 and AV2-2 differ on a sticker with a number
on the bottom of the valve:
AV1-2 = 150-1150
AV2-2 = 150-1157
Workshop Manual: 1084657 - 175 - 18.10.2006

Hydraulic System
10.5 Checking and adjusting pressures AV2-2
All values apply at a hydraulic oil temperature of approx. 60 °C and max. diesel engine
speed.
Bleed pressure relief for a maximum of 5 seconds.
Use the following pressure gauge:
For high pressure = min. 400 bar
For supply pressure = min. 40 bar
1 M1 supply pressure 26 ± 5 bar

6 can only be set using disks.
2 MB drive pressure backward 386

± 15 bar, measure with roller drums
1 blocked.
2
3 MB drive pressure forward 386
± 15 bar, measure with roller drums
blocked.
3
4 M2 vibro pressure 225 ± 15 bar,
(double vibration) can be set on the
vibro switching valve.
4
5 M3 steering pressure (this measuring
connection is not installed). 168
± 2 bar, if the steering is at stop, can be
7 set on the steering valve.
5
6 Set drive pressure backward.
7 Setting drive pressure forward.
1 Set vibro pressure

225 ± 15 bar.
Workshop Manual: 1084657 - 176 - 18.10.2006

Hydraulic System
Setting steering pressure

Move the steering all the way out.
Install the gauge connection.
1 Unscrew the cover screw (1) with an Allen

key (SW8).
Adjust pressure using the Allen screw

(SW6).
Steering pressure 168 ± 10 bar.
Steering selection valve

The steering selection valves of models AV1-2 and AV2-2 differ on a sticker with a number
on the bottom of the valve:
AV1-2 = 150-1150
AV2-2 = 150-1157
Workshop Manual: 1084657 - 177 - 18.10.2006
Hydraulic System
Checking the drive pump AV1-2
10.6 Checking the drive pump AV1-2
Checking supply pressure

1
Disconnect the brake line (1).
Close the pipe.
Connect the 40 bar pressure gauge.
Start the engine and set to maximum speed.
Reading: 20 ± 4 bar.
Checking drive pressure

Disconnect the contact line (1).
2 Close the pipes.

1
Connect the 400 bar measuring device to
the measuring points (2).
1 Move the operating lever all the way

2 forward.
Reading: 330 ± 10 bar
Move the operating lever all the way back.

Reading: 330 ± 10 bar
ATTENTION!
Only briefly move the operating lever out all the way, max. 5 seconds.
Reconnect all hydraulic hoses after the drive pump test. Start a test run and check whether
the connections are leak-tight.
Workshop Manual: 1084657 - 178 - 22.09.2006

Hydraulic System
Checking the drive pump AV2-2
10.7 Checking the drive pump AV2-2
Checking supply pressure

Disconnect the brake line (1).
1
Close the pipe.
Connect the 40 bar pressure gauge.
Checking drive pressure

Disconnect the contact line (1).
2
1 Close the pipes.
Connect the 450 bar measuring device to the

measuring points (2).
2 1
Move the operating lever all the way

forward.
Move the operating lever all the way back.

ATTENTION!
Only briefly move the operating lever out all the way, max. 5 seconds.
Reconnect all hydraulic hoses after the drive pump test. Start a test run and check whether
the connections are leak-tight.
Workshop Manual: 1084657 - 179 - 22.09.2006

Hydraulic System
Hydraulic diagram AV12/AV16/AV20
10.8 Hydraulic diagram AV12/AV16/AV20
Workshop Manual: 1084657 - 180 - 22.09.2006

Hydraulic System
Key AV12/AV16/AV20
10.9 Key AV12/AV16/AV20
Element Description
1 Drive pump
2 Vibration steering pump
3 Feed pump
5 Front drive motor
6 Rear drive motor
7 Vibration front
8 Vibration rear
9 Steering unit
10 Hydraulic tank
11 Return filter
12 Oil cooler
13 Steering
14 Emergency stop collector block
Workshop Manual: 1084657 - 181 - 22.09.2006

Hydraulic System
Hydraulic diagram AV16K
10.10 Hydraulic diagram AV16K
Workshop Manual: 1084657 - 182 - 22.09.2006

Hydraulic System
Key AV16K
10.11 Key AV16K
Element Description
1 Drive pump
3 Feed pump
5 Front drive motor
6 Rear drive motor
7 Vibration front
9 Steering unit
10 Hydraulic tank
11 Return filter
12 Oil cooler
13 Steering
14 Emergency stop collector block
Workshop Manual: 1084657 - 183 - 22.09.2006

Hydraulic System
Hydraulic diagram AV23 – AV40
10.12 Hydraulic diagram AV23 – AV40
Workshop Manual: 1084657 - 184 - 22.09.2006

Hydraulic System
Key AV23 – AV40
10.13 Key AV23 – AV40
Element Description
1 Drive pump
3 Feed pump
5 Front drive motor
6 Rear drive motor
7 Vibration front
8 Vibration rear
9 Steering unit
10 Hydraulic tank
11 Return filter
12 Oil cooler
13 Steering
15 Electrically switchable flow divider option
Workshop Manual: 1084657 - 185 - 22.09.2006

Hydraulic System
Hydraulic diagram AV23K – AV40K
10.14 Hydraulic diagram AV23K – AV40K
Workshop Manual: 1084657 - 186 - 22.09.2006

Hydraulic System
Key AV23K – AV40K
10.15 Key AV23K – AV40K
Element Description
1 Drive pump
3 Feed pump
5 Front drive motor
6 Rear drive motor
7 Vibration front
9 Steering unit
10 Hydraulic tank
11 Return filter
12 Oil cooler
13 Steering
Workshop Manual: 1084657 - 187 - 22.09.2006

Hydraulic System
Key AV23K – AV40K
Workshop Manual: 1084657 - 188 - 22.09.2006

Electrical System
Key AV23K – AV40K
11 Electrical
System
Workshop Manual: 1084657 - 189 - 22.09.2006

Electrical System
Key AV23K – AV40K
Workshop Manual: 1084657 - 190 - 22.09.2006

Electrical System
Overview of the electrical system
11.1 Overview of the electrical system
Steering column electrical system

1 K80 Relay, seat contact
2 K38 Replay, sprinkler
1 3 K24 Relay, emergency stop
4 K4 Relay, indicator
2 5 K20 Relay, vibration
3
5
V18
X6 X7
X5
X4 X2
X3
Engine compartment electrical

system AV1-2
1 Fuse box
Workshop Manual: 1084657 - 191 - 22.09.2006

Electrical System
Overview of the electrical system
1 Timer relay
2 Timer
3 Starter relay
3
1 2
Engine compartment electrical

system AV2-2
1
1 Fuse box
3 2 Timer relay
3 Starter relay
1 Timer
Workshop Manual: 1084657 - 192 - 22.09.2006

Electrical System
Engine compartment fuses AV1-2
11.2 Engine compartment fuses AV1-2
Fuse box in the engine compartment

The fuses (1) are located on the left of the
engine on the battery tray.
NOTE
Before replacing the fuse, you must
1 identify and remove the cause of the fault.
The fuse numbers are indicated on the fuse

2 1 box.
Always replace a defective fuse (1) with a

functioning fuse (2) of the same amperage
(according to the label or color of the fuse).
Fuse No. Power Fuse-protected circuit
F11 (A or 1) 40 A Pull-in solenoid
F12 (B or 2) 15 A Fan for oil cooler, diesel pump, alternator
F13 (C or 3) 15 A Reserve (15+)
F14 (D or 4) 15 A Reserve (15+)
Tab 24: Engine compartment fuses AV1-2
Workshop Manual: 1084657 - 193 - 22.09.2006

Electrical System
Engine compartment fuses AV2-2
11.3 Engine compartment fuses AV2-2
Fuse box in the engine compartment

The fuses (1) are located on the right of the
engine, at the front between the engine and
the water tank.
NOTE
The fuse numbers are indicated on the fuse

2 1 box.
Always replace a defective fuse (1) with a

functioning fuse (2) of the same amperage
(according to the label or color of the fuse).
Fuse No. Power Fuse-protected circuit
F11 (A or 1) 40 A Pull-in solenoid
F12 (B or 2) 15 A Fan for oil cooler, diesel pump, alternator
F13 (C or 3) 15 A Reserve (15+)
F14 (D or 4) 10 A Reserve, not connected
Tab 25: Engine compartment fuses AV2-2
Workshop Manual: 1084657 - 194 - 22.09.2006

Electrical System
Steering column fuses
11.4 Steering column fuses
Fuse box (1) in the steering column

Remove the four screws (SW10) (2) and
2 then the cover (3).
1
NOTE
Fuse No.
Power
Fuse-protected
circuit
F1 10 A Parking light
F2 15 A Dipped light
Emergency stop, holding
F3 10 A
solenoid
Sprinkler, horn, reverse alarm,
F4 15 A
flow divider
F5 10 A Displays, indicators
F6 10 A Hazard warning light

Work light,
F7 15 A revolving warning light,
edge cutter
V11 - Diode
Tab 26: Steering column fuses
ATTENTION!
Install the diode in the correct direction of passage.
The ring must be on the left when viewed from above.
Workshop Manual: 1084657 - 195 - 22.09.2006

Electrical System
Neutral-position switch
11.5 Neutral-position switch
This switch prevents you from starting the machine while the operating lever is in neutral.
Replacing the neutral-position switch

Disconnect the plug (1).
Screw the left nut (2) to the left and brace

1 the right nut (3) against it.
Install the new switch in the reverse order.

2 3
Workshop Manual: 1084657 - 196 - 22.09.2006

Fault description Possible cause of fault Checks
Switch on the ignition: Battery (G2) Check 12V connections

Battery charge (H1) and engine oil Battery cut-off switch (S1) Battery cut-off switch on?
pressure (H3) control lights do not Ignition switch (S2). Check cable connections
light up Alternator (G1) Plugs connected?
Electrical System
Engine oil pressure Cables connected?
Workshop Manual: 1084657

switch (S6) Fuse F5 OK?
Emergency-stop warning light Emergency-stop switch Emergency stop switch S67 released?
Troubleshooting the electrical system
(H24) lights up (S67) Does relay K80 trigger when someone sits on the
Seat contact (S80, X52) seat? (approx. 1 s delay due to capacitor C80)
Seat contact relay (K80) Fuse F3 OK?
Emergency-stop relay
Operating lever neutral Ohmmeter: In neutral position, short-circuit
position (S73) between X7-7 and X7-8 or X50-1 and X50-2
- 197 -
Emergency-stop warning light Diode (V11) Diode tester: Diode V11 OK?
(H24) starts to light up when the If diode installed incorrectly = fuse F3 defective.
operating lever is in neutral
Engine running: Alternator (G1 – "160") Voltmeter: check D+ ("160") = 12V – 15V
Battery charge warning light (H1) Alternator turning? (V-belt)
11.6 Troubleshooting the electrical system
lights up
Engine running: Pressure switch (S6) Ohmmeter: Oil pressure switch S6 OK?
Engine oil pressure warning light Engine running = oil pressure switch S6 = open=
(H3) lights up Engine not running = oil pressure switch S6 =
short-circuit
Engine problem Consult Yanmar manual
Tab 27: Troubleshooting the electrical system
22.09.2006
Coolant temperature warning light Temperature switch (S7) Warning light should go out when you pull the plug
(H2) lights up to S7.
Engine problem Consult Yanmar manual
Electrical System
Supply pressure warning light Pressure switch (S32) Ohmmeter: Pressure switch S32 OK?

(H19) lights up S32 must be closed when engine is not running
S32 must be open when engine is running at work
speed
AV1-2 (supply pressure 20 +/-4 bar)

AV2-2 (supply pressure 26 +/-5 bar)
Consult Yanmar manual

Engine problem
Tank display (A1, H36) shows Display module (A1) Disconnect connector to tank sensor
- 198 -
wrong display Tank sensor (R1) Analog display tank = empty
Diesel level reserve warning light H36 does not
light up
Short-circuit wire jumper between:

Pin 1 and Pin 3: Diesel level reserve warning light
H36 must light up
Pin 2 and Pin 3: Analog display tank = full
Operating hours counter (P6) does Alternator (G1) The operating hours counter only counts if the
not count battery charge warning light (H1) is not lit up
Operating hours counter Voltmeter check D+ ("106") = 12V – 15V

module (P6) defective
22.09.2006
Engine start: Neutral position drive Ohmmeter: When the operating lever is in neutral
Engine does not start, starter pump(S54) position, the neutral-position switch of the drive
motor does not turn pump must also be closed.
Alternator (G1) Plug connected to the alternator? (D+ = 0V).

Electrical System
Check connections

Starter relay (K14) Check connections
Ignition switch (S2).
Fuse F12 OK?
Engine start: Emergency-stop switch Emergency stop switch S67 released?

Starter motor turns but engine (S67) (Æ Engine only runs if S67 is OK).
does not run Plug X50 connected? (Æ Engine only runs if X50 is
OK).
Emergency stop bridge in Check connections
- 199 -
plug X50 Check connections
Stop solenoid (Y31) Check connections
Relay (K31), Timer (K30)
Diesel pump (M10) Fuse F11 OK?
Machine does not drive Brake valve Y67 Valve tester: Check valve Y67
Emergency-stop switch Switching element connections
S67
Sprinkler does not work Switches Fuse F4 OK?
"Continuous sprinkling"
(S55)
Switches
"interval sprinkling *"
(S61)
"Water" button (S76)
"Water" relay (K38)
22.09.2006
Water pump (M14)
Vibration not working Button (S57) Emergency-stop warning light (H24) must not light
Vibration relay (K20) up
Vibration valve (Y16) Valve tester: Check valve (Y67)
Ohmmeter: Check button (S57)
Voltmeter: Check relay (K20)
Electrical System

Rear vibration * not working Vibration valve (Y17) Valve tester: Check valve (Y17)
Switch (S59) Ohmmeter: Check switch (S59)
Horn not working Button (S13) Fuse F4 OK?

Horn (B3)
Indicator * not working Indicator switch (S58) Fuse F5 OK?

Indicator relay (K4)
Indicator lamps (E6…E9)
- 200 -
Warning light * not working Warning indicator switch Fuse F6 OK?
(S14)
Indicator relay (K4)
Indicator lamps (E6…E9)
Parking light * not working (ignition Light switch (S18) Fuse F1 OK?
ON – Pos. 1) Lamps (E11…E14)
Parking light * not working (ignition Diode rectifier (V18) V18 connected properly?
PARK – Pos. P) Diode tester: Diode V18 OK?
Main beam * not working Light switch (S18) Fuse F2 OK?

Lamps (E15, E16)
Rotating light * not working Light switch (S60) Fuse F7 OK?

Rotating light (E21)
22.09.2006
Work light * not working Light switch (S56) Fuse F7 OK?

Rotating light (E24…E27)
Edge cutter * not working Switch (S3), (S4) Fuse F7 OK?

Electrical System
Valves (Y41), (Y42) Valve tester: Check valves (Y41), (Y42)

Edge cutter sprinkler * not working Switch (S81) Fuse F7 OK?
Valve (Y43) Valve tester: Check valves (Y43)
Reverse alarm * not working Switch (S22) Fuse F4 OK?

Reverse alarm (B19) Ohmmeter: Check switch (S22) Æ
If operating lever moved out to the back: short-
circuit between X50-3, X50-4
- 201 -
Flow divider * not working Switch (S64) If switch S64 is ON, an acoustic signal (B30) must
Acoustic signal (B30) be emitted
Valve tester: Check valves (Y30)
Valve (Y30)
Fuse F4 OK?
Engine oil cooler Fan M2 Cable bridge S16 connected?

Fuse F12 OK?
22.09.2006
Electrical System
Wiring diagram (multifunction display)
11.7 Wiring diagram (multifunction display)
Workshop Manual: 1084657 - 202 - 24.11.2006

Electrical System
Wiring diagram (engine start / stop)
11.8 Wiring diagram (engine start / stop)
Workshop Manual: 1084657 - 203 - 24.11.2006

Electrical System
Wiring diagram (emergency stop / oil cooler, diesel pump)
11.9 Wiring diagram (emergency stop / oil cooler, diesel

pump)
Workshop Manual: 1084657 - 204 - 24.11.2006

Electrical System
Wiring diagram (sprinkler)
11.10 Wiring diagram (sprinkler)
Workshop Manual: 1084657 - 205 - 24.11.2006

Electrical System
Wiring diagram (vibration)
11.11 Wiring diagram (vibration)
Workshop Manual: 1084657 - 206 - 24.11.2006

Electrical System
Wiring diagram (horn, indicators)
11.12 Wiring diagram (horn, indicators)
Workshop Manual: 1084657 - 207 - 24.11.2006

Electrical System
Wiring diagram (lights)
11.13 Wiring diagram (lights)
Workshop Manual: 1084657 - 208 - 24.11.2006

Electrical System
Wiring diagram (options)
11.14 Wiring diagram (options)
Workshop Manual: 1084657 - 209 - 24.11.2006

Electrical System
Wiring diagram (Loxam)
11.15 Wiring diagram (Loxam)
Workshop Manual: 1084657 - 210 - 24.11.2006

11.16
Fuses on relay panel:

F1 10A Parking light
Technical specifications
Electrical System
F2 15A Dipped light

Emergency stop,
F3 10A
Holding solenoid, vibration
Sprinkler,
Horn,
F4 15A
Reverse alarm,
Flow divider
Displays,
F5 10A
Indicators
F6 10A Hazard warning light
Work light,
F7 15A Revolving warning light,
Edge cutter
- 211 -
Diode
Technical specifications
V11
(to emergency stop relay)
Diode
Fuses on engine panel:

F11 40A Pull-in solenoid
Oil cooler fan,
F12 15A
(fuses, connector layout, wire cross-sections)
Diesel pump
F13 15A Reserve (15+)
F14 10A Reserve, not connected

(fuses, connector layout, wire cross-sections)
24.11.2006
Electrical System
Key
11.17 Key
Element Description
A1 Fuel display
B3 Horn
B19 Reversing buzzer (*)
B30 Flow divider buzzer (*)
B55 “Loxam” seat contact delay buzzer (*)
C80 Capacitor for seat contact delay
E6 Front left indicator (*)
E7 Rear left indicator (*)
E8 Front right indicator (*)
E9 Rear right indicator (*)
E11 Front left parking light (*)
E12 Rear left parking light (*)
E13 Front right parking light (*)
E14 Rear right parking light (*)
E15 Front left dipped light (*)
E16 Front right dipped light (*)
E21 Revolving warning light (*)
E24 Rear left work light (*)
E25 Rear right work light (*)
E26 Work headlight, left on ROPS (*)
E27 Work headlight, right on ROPS (*)
E30 Front left position light (*)
E31 Front right position light (*)
E32 Number plate light, rear (*)
F1 Parking light fuse
F2 Dipped light fuse
F3 Fuse, emergency stop, holding solenoid
F4 Fuse, sprinkler, horn, reverse alarm, flow divider
F5 Fuse, displays, indicators
Workshop Manual: 1084657 - 212 - 22.09.2006

Electrical System
Key
Element Description
F6 Fuse, hazard flasher
F7 Fuse, work headlight, revolving warning light, edge cutter
F11 Fuse, pull-in solenoid
F12 Fuse, fan for oil cooler, diesel pump, alternator
F13 Fuse, reserve (15+)
F14 Fuse, reserve
G1 Alternator
G2 Battery
H1 Control light, charging control
H2 Control light, coolant temperature
H3 Control light, engine oil pressure
H5 Control light, pre-heating
H6 Control light, parking light
H7 Control lamp, dipped light
H8 Control light, indicator
H19 Control light, supply pressure (brake pressure)
H24 Control light, emergency stop
H36 Control light for fuel reserve
K4 Relay, indicator (*)
K14 Relay, starting interlock
K20 Relay, vibration
K24 Relay, emergency stop
K30 Timer relay
K31 Relay, pull-in solenoid
K38 Replay, sprinkler
K55 Timer “Loxam” (*)
Workshop Manual: 1084657 - 213 - 22.09.2006

Electrical System
Key
Element Description
K80 Relay, seat contact
M1 Starter motor
M2 Engine, fan for oil cooler
M10 Engine diesel pump
M14 Engine, sprinkler pump
M15 Engine, anti-adhesive pump (*)
P6 Operating hours counter
R1 Sensor, fuel level
R3 Heating coil
S1 Battery cut-off switch (*)
S2 Ignition switch
S3 Switch, edge cutter up (*)
S4 Switch, edge cutter down (*)
S6 Sensor (switch), engine oil pressure
S7 Sensor (switch), coolant temperature
S13 Switch, horn
S14 Switch, hazard flasher (*)
S16 Wire jumper (previously: oil temperature sensor)
S18 Switch, light (parking / dipped light) (*)
S22 Switch, operating lever reverse position
S32 Sensor (switch), supply pressure (brake pressure)
S54 Switch, drive pump zero position
S55 Switch, continuous sprinkling
S56 Switch, work light (*)
S57 Switch, vibration
S58 Switch, indicator left / right (*)
Workshop Manual: 1084657 - 214 - 22.09.2006

Electrical System
Key
Element Description
S59 Switch, vibration selector (*)
S60 Switch, beacon light (*)
S61 Switch, interval sprinkler control (*)
S64 Switch, flow divider (*)
S67 Switch, emergency stop
S73 Switch, operating lever neutral position
S76 Switch, sprinkler (button) / anti-adhesive (*)
S80 Switch, seat contact
S81 Switch, edge cutter sprinkler (*)
ST1 Multifunction display unit
V11 Diode, emergency stop (self-latching, emergency stop relay)
V18 Diodes, lock diode, parking position / free-running diode, supply (15+)
V20 Diode, free-running diode, vibration valve
V30 Diode, free-running diode to flow divider (*)
V41 Diode, free-running diode to edge cutter valve (*)
V55 Diode, lock diode “Loxam” (*)
X2...X7 Connector on relay panel
X12 Connector, relay panel supply connection
X20 Connector, edge cutter switch connection
X28 Connector, edge cutter diode connection (*)
X40 Connector, edge cutter valve connection
X42 Connector, flow divider valve connection (on AV2 only)
X50 Connector, operating lever console connection
X52 Connector, seat contact connection
Workshop Manual: 1084657 - 215 - 22.09.2006

Electrical System
Key
Element Description
Y14 Valve, sprinkler (**)
Y15 Valve, anti-adhesive (**)
Y16 Valve, front vibration
Y17 Valve, rear vibration (*)
Y30 Valve, flow divider (*) (only possible on AV2-2)
Y31 Stop magnet (stop solenoid; pull-in and holding solenoid)
Y41 Valve, edge cutter up (*)
Y42 Valve, edge cutter down (*)
Y43 Valve, edge cutter sprinkler (*)
Y67 Valve, emergency stop (service brake)
(*) Optional
(**) Not available
Workshop Manual: 1084657 - 216 - 22.09.2006

Technical Data
Key
12 Technical
Data
Workshop Manual: 1084657 - 217 - 22.09.2006

Technical Data
Key
Workshop Manual: 1084657 - 218 - 22.09.2006

Technical Data
Dimensions AV1-2
12.1 Dimensions AV1-2
Dimensions AV1-2
AV12-2 (mm) AV16-2 (mm) AV16-2K (mm) AV20-2 (mm)
A 1440 1440 1440 1440
B 860 940 940 1040
W 820 900 900 1000
W1 860 940 900 1040
V 40 40 - 40
Tab 28:Dimensions AV1-2
Workshop Manual: 1084657 - 219 - 22.09.2006

Technical Data
Dimensions AV2-2
12.2 Dimensions AV2-2
Dimensions AV2-2
AV23-2 (mm) AV26-2 (mm) AV32-2 (mm) AV33-2 (mm) AV40-2 (mm)
A 1650 1650 1650 1650 1650
B 1120 1320 1320 1420 1420
W 1000 1200 1200 1300 1300
W1 1040 1240 1240 1340 1340
Tab 29: Dimensions AV2-2

Dimensions AV2-2K
AV23-2K (mm) AV26-2K (mm) AV32-2K (mm) AV40-2K (mm)
A 1700 1700 1700 1700
B 1080 1280 1280 1380
W 1000 1200 1200 1300
W1 1040 1240 1240 1340
Tab 30: Dimensions AV2-2K
Workshop Manual: 1084657 - 220 - 03.11.2006

Technical Data
Technical data AV1-2
12.3 Technical data AV1-2
AV12-2 AV16-2 AV16-2K AV20-2

Service weight according to
1450 1550 1450 1650
CECE (kg)
Static linear load (kg / cm) 8.8 8.6 8.6 8.3
Wheel load (kg) - - 200 -
Outside turning radius / inside

2990 / 2170 3030 / 2130 3030 / 2130 3080 / 2080
(mm)
Amplitude (mm) 0.5 0.5 0.5 0.45

Centrifugal force per roller drum
13 13 13 13
(kN)
Centrifugal force per cm (N / cm) 195 178 178 160
Max. gradient in %
30 / 40 30 / 40 30 / 40 25 / 35
with / without vibration (N / cm)
Drive YANMAR 3TNV76 / Euromot 2 – Tier 2
Output to DIN 6270 B 1.) 13.2 kW / 18 PS 2.) 14.9 kW / 20.3 PS
Operating speed 1.) 2100 1/min 2.) 2400 1/min
Driving speed 0-8 km / h
Steering angle / pivoting ± 31° / ± 5°
Vibration frequency 1.) 58 Hz 2.) 66 Hz
Water tank capacity 95
Hydraulic tank 35 l
Diesel tank 26 l
Tab 31: Technical data AV1-2
Workshop Manual: 1084657 - 221 - 22.09.2006

Technical Data
Technical data AV2-2
12.4 Technical data AV2-2
AV23-2 AV26-2 AV32-2 AV33-2 AV40-2

2500 2800 3100 3600 3900
CECE (kg)
Static linear load (kg / cm) 12.5 11.7 12.9 13.8 15.0
Wheel load (kg) - - - - -
Outside turning radius / inside 3350 / 3450 / 3450 / 3500 / 3500 /

(mm) 2350 2250 2250 2200 2200
Amplitude (mm) 0.37 0.41 0.41 0.33 0.33

28 37 37 37 37
(kN)
Centrifugal force per cm (N / cm) 280 308 308 285 285
Max. gradient in %
30 / 40 30 / 40 30 / 40 30 / 40 25 / 35
Drive YANMAR 3TNV88
Output to DIN 6270 B 1.) 19.8k W / 27 PS 2.) 23.8 kW / 30.4 PS
Driving speed 0-10 km/h
Steering angle/pivoting ± 32° / ± 8°
Water tank capacity 80 + 120
Hydraulic tank 25 l
Diesel tank 43 l
Tab 32: Technical data AV2-2
Workshop Manual: 1084657 - 222 - 03.11.2006

Technical Data
Technical data AV2-2K
12.5 Technical data AV2-2K
AV23-2K AV26-2K AV32-2K AV40-2K

2300 2500 2800 3600
CECE (kg)
Static linear load (kg / cm) 12.5 11.7 12.9 15.0
Wheel load (kg) 262 275 312 412
Outside turning radius / inside

3350 / 2350 3450 / 2250 3450 / 2250 3500 / 2200
(mm)
Amplitude (mm) 0.37 0.41 0.41 0.33

28 37 37 37
(kN)
Centrifugal force per cm (N / cm) 280 308 308 285
Max. gradient in %
30 / 40 30 / 40 30 / 40 25 / 35
Drive YANMAR 3TNV88
Output to DIN 6270 B 1.) 19.8 kW / 27 PS 2.) 23.8 kW / 30.4 PS
Driving speed 0-10 km/h
Steering angle / pivoting ± 32° / ± 8°
Water tank capacity 80 + 120
Hydraulic tank 25 l
Diesel tank 43 l
Tab 33: Technical data AV2-2K
Workshop Manual: 1084657 - 223 - 22.09.2006

Technical Data
Technical data AV2-2K
Workshop Manual: 1084657 - 224 - 22.09.2006

Technical Data
Table index
Table index
Tab 1: AV1-2 with roller drum ........................................................................................15

Tab 2: AV1-2 with pneumatic wheel ..............................................................................15
Tab 3: AV2-2 with roller drum ........................................................................................16
Tab 4: AV2-2 with pneumatic wheel ..............................................................................16
Tab 5: Product numbers, spare parts lists .....................................................................18
Tab 6: AV1-2 dimensions relevant for transport ............................................................22
Tab 7: AV2-2 dimensions relevant for transport ............................................................24
Tab 8: Limits of application in climate conditions...........................................................43
Tab 9: Anti-adhesive designations.................................................................................80
Tab 10: Checks and minor service, Yanmar engine ........................................................86
Tab 11: Major Yanmar engine service .............................................................................87
Tab 12: Lubricant table ..................................................................................................103
Tab 13: Consumables....................................................................................................104
Tab 14: Tightening torques ............................................................................................104
Tab 15: Long-term storage ............................................................................................107
Tab 16: Plugs and stoppers for 1 vibro motor AV1-2.....................................................163
Tab 17: Plugs and stoppers for 1 drive motor AV1-2.....................................................164
Tab 18: Plugs and stoppers drive pump test AV1-2 ......................................................164
Tab 19: Plugs and stoppers for drive pump AV1-2 ........................................................164
Tab 20: Plugs and stoppers for 1 vibro motor AV2-2.....................................................165
Tab 21: Plugs and stoppers for 1 drive motor AV2-2.....................................................165
Tab 22: Plugs and stoppers for drive pump test AV2-2 .................................................166
Tab 23: Plugs and stoppers drive pump AV2-2 .............................................................166
Tab 24: Engine compartment fuses AV1-2 ....................................................................193
Tab 25: Engine compartment fuses AV2-2 ....................................................................194
Tab 26: Steering column fuses ......................................................................................195
Tab 27: Troubleshooting the electrical system ..............................................................197
Tab 28: Dimensions AV1-2 ............................................................................................219
Tab 29: Dimensions AV2-2 ............................................................................................220
Tab 30: Dimensions AV2-2K..........................................................................................220
Tab 31: Technical data AV1-2 .......................................................................................221
Tab 32: Technical data AV2-2 .......................................................................................222
Tab 33: Technical data AV2-2K .....................................................................................223
Workshop Manual: 1084657 - 225 - 22.09.2006

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Workshop Manual (EN)

AV1-2 (AV12-2, AV16-2, AV20-2)

AV2-2 (AV23-2, AV26-2, AV32-2, AV33-2, AV40-2)

ID: 1084657 Revision index:-- Release date: September 06

With kind regards,

0041 (0)62 916 61 61

Workshop Manual: 1084657 -3- 22.09.2006

Workshop Manual: 1084657 -4- 22.09.2006

Workshop Manual: 1084657 -5- 22.09.2006

5.3 Driving and braking..............................................................................................59

Workshop Manual: 1084657 -6- 22.09.2006

7.11 Checks – tire pressure .........................................................................................95

Workshop Manual: 1084657 -7- 22.09.2006

10 Hydraulic System ..........................................................................167

Workshop Manual: 1084657 -8- 22.09.2006

12 Technical Data ...............................................................................217

Table index...... ...................................................................................225

Workshop Manual: 1084657 -9- 22.09.2006

Workshop Manual: 1084657 - 10 - 22.09.2006

Workshop Manual: 1084657 - 11 - 22.09.2006

Workshop Manual: 1084657 - 12 - 22.09.2006

1.1 Structure and use of the Workshop Manual

Structure of the Workshop Manual

Completeness of the Workshop Manual

Workshop Manual: 1084657 - 13 - 22.09.2006

Important points are indicated as follows:

Indicates an immediate impending danger.

Indicates a potentially harmful situation.

Indicates application tips and other particularly useful information.

Workshop Manual: 1084657 - 14 - 22.09.2006

1.3 Identification AV1-2

AV1-2 with roller drum

Model Width Weight

AV12-2 860 mm 1450 kg

AV16-2 940 mm 1550 kg

AV20-2 1040 mm 1650 kg

Tab 1: AV1-2 with roller drum

AV1-2 with pneumatic wheel (combined roller)

Model Width Weight

AV16-2K 940 mm 1450 kg

Tab 2: AV1-2 with pneumatic wheel

Workshop Manual: 1084657 - 15 - 22.09.2006

1.4 Identification AV2-2

AV2-2 with roller drum

Model Width Weight

AV23-2 1120 mm 2500 kg

AV26-2 1320 mm 2800 kg

AV32-2 1320 mm 3100 kg

AV33-2 1420 mm 3600 kg

AV40-2 1420 mm 3900 kg

Tab 3: AV2-2 with roller drum

AV2-2 with pneumatic wheel (combined roller)

Model Width Weight

AV23-2K 1080 mm 2300 kg

AV26-2K 1280 mm 2500 kg

AV32-2K 1280 mm 2800 kg

AV40-2K 1380 mm 3600 kg

Tab 4: AV2-2 with pneumatic wheel

Workshop Manual: 1084657 - 16 - 22.09.2006

1.5 Identification plate

An identification plate (1) is affixed to the

The identification plate is located on the left

1 2 3 Important data on the identification plate:

Take suitable measure to secure parked rollers that pose an obstruction.

Level surfaces are not always uniformly load-bearing.

The edges of filled areas may give way!