ARS 122 Cummins BS III: Operating Manual

Operating manual
ARS 122
Cummins BS III
Book ID: 4-P06286CU-EN

ARS 122
Single drum roller
Cummins BS III
Operating manual
Edition 09/2017 EN
A1N00286C17080001
Original Operating Manual
Congratulations on your purchase of an AMMANN road roller. This modern compaction device is characterised by simple operation
and maintenance and is the product of many years of AMMANN experience in the field of road roller engineering. In order to avoid
faults due to improper operation and maintenance we request that you read this operating manual with great care and keep it for later
reference.
With kind regards,
Ammann India Private Limited | Block No 157 | At – Ditasan | P.O. Jagudan | State Highway | Mehsana | Gujarat - 382710 | India
+91 2762 285344 / 45 / 46 | Fax +91 2762 285359 | Email : info.ain@ammann-group.com | www.ammann-group.com
This manual consists of:

I. Specification manual II. Operating instructions III. Maintenance manual
The following explanations serve to familiarise the machinist (operator) with the roller and to support him during handling and main-
tenance. It is therefore absolutely necessary to provide the operator with these instructions and to ensure that he reads them carefully
before using the road roller. This aids training comprehension during the first use of the road roller.
Subsequent faults due to improper operating are avoided.
Adherence to maintenance instructions increases the reliability and lifetime of the machinery. It reduces repair costs and down time.
AMMANN accepts no liability for continued safe functioning of the road roller if it is incorrectly operated and/or operating modes are
employed which represent improper use.
In order to ensure the smooth operation of AMMANN compaction equipment, use for repair only the original spare parts sup-
plied by AMMANN.
All spare parts are available from your dealers or can be ordered at spareparts.machines@ammann-group.com, helpline:
+41 62 916 66 66; should you need further information, contact support.machines@ammann-group.com, hotline: +420 776 667 775.
These instructions must always be kept available on the equipment.
ARS 122 1
Preface
Information, specifications, and recommended operation and maintenance instructions contained in this publication are basic and
final information at the time of the printing of this publication. Printer’s errors, technical modifications, and modifications of figures are
reserved. All dimensions and weights are approximate and, therefore, not binding.
Ammann India Pvt. Ltd. reserves the right to perform modifications without obligation to inform the machine user. If you identify any
differences between the machine operated by you and the information contained in this publication, contact your local dealer / Near-
est branch office.
Reproduction or copying of any kind is prohibited without the written permission of Ammann India Pvt. Ltd.
2 ARS 122
SYMBOLS OF THE SAFETY NOTICES IN THE OPERATION MANUAL:
The notice warns of a serious risk of personal injury or other personal hazards.
The notice warns of possible damages to the machine or its parts.
The notice warns of the necessity of environmental protection.
! WARNING !
As used in this operating manual, the terms “right“, “left“, “front“ and “rear“ indicate the sides of the machine
moving forward.
FRONT
LEFT RIGHT
REAR 282N100Ten
ARS 122 3
Content
Content..............................................................................................................................................................4
1. SPECIFICATION MANUAL.......................................................................................................................9
1.1. Basic Data...............................................................................................................................................10
1.2. Dimension Chart....................................................................................................................................12
1.3. Technical Data........................................................................................................................................13
4 ARS 122
OPERATING MANUAL
2. OPERATING INSTRUCTIONS................................................................................................................19
2.1. Dewaxing and Inspection of a Newly Supplied Machine...................................................................20
2.2. Safety Instructions................................................................................................................................21
2.2.1. Safety measures to operate the Machine .....................................................................................................................................................21
2.2.1.1. How to start the compaction work..................................................................................................................................................................21
2.2.1.2. Work safety secured by User...............................................................................................................................................................................21
2.2.2. Driver Qualification Requirements...................................................................................................................................................................22
2.2.3. Driver’s Duties..........................................................................................................................................................................................................23
2.2.4. Forbidden activities - safety and guarantee.................................................................................................................................................24
2.2.5. Safety labels & signs used on the Machine ..................................................................................................................................................25
2.2.6. Hand Signals.............................................................................................................................................................................................................28
2.3. Ecological & Hygienic Principles..........................................................................................................31

2.3.1. Hygienic Principles.................................................................................................................................................................................................31
2.3.2. Ecological Principles .............................................................................................................................................................................................31
2.4. Preservation & Storage.........................................................................................................................32

2.4.1. Short-term preservation & storage for the period of 1 - 2 months.......................................................................................................32
2.4.2. Machine preservation & storage for the period over 2 months.............................................................................................................32
2.5. Machine disposal upon its life termination.........................................................................................33

2.6. Machine Description.............................................................................................................................34
2.7. Controlling and operation of the machine..........................................................................................35
2.8. How to Control and Use the Machine...................................................................................................41
2.8.1. Start the Engine ......................................................................................................................................................................................................41
2.8.2. Travel & Reversing..................................................................................................................................................................................................43
2.8.3. Travel with vibration..............................................................................................................................................................................................45
2.8.4. Emergency stop of the Machine.......................................................................................................................................................................46
2.8.5. Stop the Machine & the Engine.........................................................................................................................................................................47
2.8.6. Machine Shutdown................................................................................................................................................................................................48
2.8.7. Platform & Bonnet raising and lowering........................................................................................................................................................49
2.8.8. Ballasting of tyres with liquid.............................................................................................................................................................................51
2.9. Machine Transportation........................................................................................................................53

2.9.1. Machine transportation by its own axle.........................................................................................................................................................53
2.9.2. Machine transportation by public road..........................................................................................................................................................53
2.9.3. How to load the machine....................................................................................................................................................................................54
2.9.3.1. Loading the machine using a ramp.................................................................................................................................................................54
2.9.4. Towing of Machine.................................................................................................................................................................................................56
2.10. Special Conditions for the Machine Application.................................................................................62

2.10.1. Vibration driving on compacted and hard materials.................................................................................................................................62
2.10.2. Machine use under heavy climatic conditions ............................................................................................................................................62
2.10.2.1. Machine operation under low temperatures ..............................................................................................................................................62
2.10.2.2. Machine operation under high temperatures and humidity ................................................................................................................63
2.10.2.3. Operating the Machine at high altitudes ......................................................................................................................................................63
2.10.2.4. Machine operation at extremely dusty environment ...............................................................................................................................63
3. MAINTENANCE MANUAL.....................................................................................................................67
3.1. Special Conditions for the Machine Application.................................................................................69
3.1.1. Safety during Machine Maintenance..............................................................................................................................................................69
ARS 122 5
Content
3.1.2. Fire precautions when refilling .........................................................................................................................................................................69
3.1.3. Ecological & Hygienic Principles........................................................................................................................................................................70
3.2. Specification of fluids............................................................................................................................71

3.2.1. Engine Oil..................................................................................................................................................................................................................71
3.2.2. Fuel...............................................................................................................................................................................................................................72
3.2.3. Cooling Liquid..........................................................................................................................................................................................................72
3.2.4. Hydraulic Oil.............................................................................................................................................................................................................73
3.2.5. Gearbox Oil...............................................................................................................................................................................................................74
3.2.6. Lubricating Grease.................................................................................................................................................................................................74
3.3. Refills......................................................................................................................................................75
3.4. Lubrication & Maintenance Table.........................................................................................................76
3.5. Lubrication and service plan................................................................................................................78
3.6. Individual Operations of Maintenance................................................................................................79
Every 20 Hours of Operation or Daily..................................................................................................80

3.6.1. Check the oil amount in engine........................................................................................................................................................................80
3.6.2. Check the amount of cooling liquid in the System....................................................................................................................................81
3.6.3. Check the amount of oil inside hydraulic tank.............................................................................................................................................82
3.6.4. Crankcase breather................................................................................................................................................................................................83
3.6.5. Check fan condition...............................................................................................................................................................................................84
3.6.6. Check engine belt...................................................................................................................................................................................................84
3.6.7. Check engine air intake........................................................................................................................................................................................85
3.6.8. Check the amount of fuel....................................................................................................................................................................................86
3.6.9. How to clean water separator............................................................................................................................................................................87
3.6.10. Check the alarm & control devices...................................................................................................................................................................88
Every 100 Hours ....................................................................................................................................89

3.6.11. Check tire pressure.................................................................................................................................................................................................89
Every 250 Hours or Once in 3 Months .................................................................................................90

3.6.12. How to replace oil in the engine.......................................................................................................................................................................90
3.6.13. Check the fixing of the engine...........................................................................................................................................................................93
3.6.14. Battery check............................................................................................................................................................................................................94
3.6.15. Check the function of Air Filter Vacuum Switch..........................................................................................................................................95
3.6.16. Machine Lubrication..............................................................................................................................................................................................96
3.6.17. How to check oil inside vibrator........................................................................................................................................................................98
3.6.18. How to check oil in gearboxes...........................................................................................................................................................................99
Every 500 Hours or Once in 6 Months................................................................................................100

3.6.19. Replacement of fuel filter of the engine...................................................................................................................................................... 100
3.6.20. Cooling liquid inspection.................................................................................................................................................................................. 102
3.6.21. Check of wiring .................................................................................................................................................................................................... 102
6 ARS 122
OPERATING MANUAL
3.6.22. Exchanging cleaner element of air cleaner................................................................................................................................................ 103
3.6.23. Check if wheel bolts are tightened................................................................................................................................................................ 105
3.6.24. Change oil in the gearboxes............................................................................................................................................................................ 105
Every 1000 Hours or Once in Year.......................................................................................................107

3.6.25. Check, adjust valve clearance.......................................................................................................................................................................... 107
3.6.26. How to check tightening pulley and belt of the engine........................................................................................................................ 107
3.6.27. Inspect the damping system........................................................................................................................................................................... 109
3.6.28. How to clean fuel tank....................................................................................................................................................................................... 110
Every 2000 Hours or Every 2 Years.....................................................................................................111

3.6.29. How to change oil in the vibrator.................................................................................................................................................................. 111
3.6.30. How to change hydraulic oil and filter......................................................................................................................................................... 112
3.6.31. How to change engine coolant...................................................................................................................................................................... 116
Maintenance - As Needed...................................................................................................................118
3.6.32. How to clean engine cooler and hydraulic oil........................................................................................................................................... 118
3.6.33. How to deaerate fuel system........................................................................................................................................................................... 119
3.6.34. How to adjust the scrapers............................................................................................................................................................................... 121
3.6.35. How to clean the Machine................................................................................................................................................................................ 122
3.6.36. Check bolted connections................................................................................................................................................................................ 122
3.7. Defects..................................................................................................................................................125
3.8. Appendixes..........................................................................................................................................126
3.8.1. Wiring Diagram....................................................................................................................................................................................................... 126
3.8.2. Hydraulic Diagram................................................................................................................................................................................................ 128
ARS 122 7
8 ARS 122
SPECIFICATION MANUAL
1. SPECIFICATION MANUAL
ARS 122
(Cummins BS III)
ARS 122 9
1.1. Basic Data
Application Range
Please fill in the following data:
The rollers are designated for operation under conditions as ac-
(Refer to nameplate and rating plate for Cummins engine)
cording to IEC 721-2-1 (038900): WT, WDr, MWDr (i.e. moderate,
warm dry, hot dry) with temperature limits from -10 °C (5 °F) to
+45 °C (113 °F). Type of machine
The vibratory rollers of ARS 122 line are especially suitable for
use at mid- and large compaction jobs of highway construction
(construction of highways, railways and airports), hydraulic con- ................................................................................................................
struction (earth dams) and civil engineering (industrial areas, PIN (Serial number of the machine)
ports etc.).
................................................................................................................
Modifications Production year
The single drum vibratory roller ARS 122 with the smooth drum
is suitable for compaction of all kinds of soil. It can be employed ................................................................................................................
at compaction of clayey soils up to the layer thickness (com- Type of engine
pacted) of 25 cm (9.8 in), loam soils up to the layer thickness of
40 cm (15.7 in), mixed soils up to the layer thickness of 50 cm
(19.7 in), sandy soils and rock fills up to the layer thickness of 80 ................................................................................................................
cm (31.4 in), gravels up to the layer thickness of 60 cm (23.6 in).
Serial number of the engine
Maximal allowed grain size is up to 2/3 of total layer thickness.
The roller is suitable for compaction of stabilized soils as well.
................................................................................................................
ARS 122 PD roller with a padfoot shell kit (synchronous knead-
ing and vibrating effect) is suitable for compaction of clay soil
up to a layer thickness of 40 cm (14.7 in), and mixed soil up to a
layer thickness of 50 cm (19.7 in).
Please refer to the data in the table below always when ap-
proaching the dealer or the manufacturer.
10 ARS 122
PIN label
1 - Designation – always mentioned only in the English version

2 - PIN
3 - Type
4 - Operating Mass
5 - Maximum Mass
6 - Nominal power
7 - Shipping Mass
8 - Front axle load
9 - Rear axle load
10 - Year of Construction
PIN label (1), S/N (2)
1 2
Serial number ESN of the CUMMINS engine
ARS 122 11
1.2. Dimension Chart
Dimensional diagram for ARS 122 Machine
mm
A D D1 G G1 H H1 L T W W1
(in)
2820 1500 - 450 415 3030 2375 5460 25 2130 2260

ARS 122
(111.0) (59.1) (-) (17.7) (16.3) (119.3) (93.5) (215) (1.0) (83.9) (89)
ARS 122 (PD 2820 1500 1640 450 415 3030 2375 5460 25 2130 2260
Shell Kit) (111.0) (59.1) (64.6) (17.7) (16.3) (119.3) (93.5) (215) (1.0) (83.9) (89)
12 ARS 122
1.3.
Technical Data SPECIFICATION MANUAL
ARS 122 Cummins BS III
Weight
Operating weight kg (lb.) 11200 (24692)
Operating load on front axis kg (lb.) 6300 (13889)
Operating load on rear axis kg (lb.) 4900 (10800)
Weight of half fluid capacities kg (lb.) 170 (375)
Static linear load of front drum kg/cm (lb./in) 29.6 (25.69)
Weight of canopy posts (Version without ROPS) kg (lb.) 60 (132)
Weight of two padfoot segments kg (lb.) 1750 (3860)
Weight of tyre filling 0°C kg (lb.) 1120 (2469)
Driving characteristics
Number of speeds - 1+1
Maximum transport speed km/h (MPH) 10.3 (6.4)
Working speed km/h (MPH) 5 (3.2)
Climbing ability % 40
Climbing ability with vibration % 30
Lateral static stability % 72.65
Lateral stability during driving without vibration % 25
Lateral stability during driving with vibration % 15
Maximum gradient when towing machine on slope % 60
Turning radius inner (edge) mm (in) 3210 (126.4)
Turning radius outer (contour) mm (in) 5575 (219.5)
Front approach slope % 58
Rear approach slope % 53
Type of drive - Hydrostatic
Number of driving axles - 2
Oscillation angle ° ±10
Angle of steering ° ±36
Steering
Type of steering - Joint
Steering control - Hydraulic
Linear hydraulic motors - 2
Engine
Manufacturer - Cummins
Type - 4BTAA3.9-C99
Power according to DIN 6271 kW (HP) 74 (99)
Power according to ISO 3046/1 kW (HP) 74 (99)
Number of cylinders - 4
Cylinder capacity cm3 (cu in) 3900 (238)
Nominal speed min-1 (RPM) 2200
ARS 122 13
1.3. Technical Data
Maximum torque Nm/rpm 410/1500

Routine operation fuel consumption l/h (gal US/h) 11 (2.42)
Engines complies with emission regulations - Bharat stage-III
cooling system of engine - Liquid
Axle
Maximum tyre pressure MPa (PSI) 0.16 (23.2)
Pattern of tyres - R-3 Diamond Tread
Number of tyres - 2
Number of rear wheels - 2
Size of tyres - 23.1x26´´
Type of tyres - Tubeless
Brakes
Operating - Hydrostatic
Parking - Multiple-disc spring brake
Emergency - Multiple-disc spring brake
Vibration
Frequency I Hz (VPM) 32 (1920)
Frequency II Hz (VPM) 35 (2100)
Amplitude I mm (in) 1.85 (0.072)
Amplitude II mm (in) 0.9 (0.035)
Centrifugal force I kN 275
Centrifugal force II kN 160
Type of drive - Hydrostatic
Fluid capacities
Fuel l (gal US) 410 (108.31)
Engine (oil filling) l (gal US) 10.9 (2.9)
Cooling system l (gal US) 20 (5.28)
Hydraulic system l (gal US) 90 (23.78)
Drum vibrator l (gal US) 8 (2.11)
Wheel gearbox l (gal US) 2x1.9 (2x0.5)
Drum gearbox l (gal US) 1.9 (0.5)
14 ARS 122
Wiring
Voltage V 12
Battery capacity Ah 150
Optional equipment
Padfoot drum shell kit
Ammann Traction Optimiser
Working speed increase kit (increase up to 7 km/h)
Hard canopy Self Standing
tractor Tyres
Tyre ballast -25 °C
Warning Beacon
Fire Extiguisher
Service Kit for 500 h
Bio Degradable Hydraulic oil
Tool Kit
Set of Documentation
ARS 122 15
Notes
16 ARS 122
Notes
ARS 122 17
18 ARS 122
OPERATING INSTRUCTIONS
2. OPERATING INSTRUCTIONS
ARS 122
(Cummins BS III)
ARS 122 19
2.1. Dewaxing and Inspection of a Newly Supplied Machine
• Inspect the Machine per shipping documents.
• Check that no parts of the Machines have been damaged
during transportation, and that no parts are missing. Inform
shipper about any shortcomings.
Before Machine Operation, please carry

out dewaxing, wash away the preserving
agents using high pressure stream of hot
water added with standard degreasers.
All relevant ecological principles must be
adhered to.
Perform dewaxing & washing of the
Machine at places equipped with inter-
cepting sumps to catch rinsing water &
dewaxing agents.
20 ARS 122
2.2. Safety Instructions
2.2.1. Safety measures to operate the Machine 2.2.1.2. Work safety secured by User
Safety measures stated in the individual sections of the Engi- • User must ensure the Machine will be operated only under
neering Documentation supplied together with the Machine those conditions, and solely for those purposes the Machine
shall be supplemented with those safety precautions in force is technically eligible for under the conditions specified by
within a respective country where the Machine will be used, manufacturer and respective standards.
and within a workplace, with regard to human resource man- • User must promptly report any damage of the utility lines to
agement, work process and personnel. their Operator, and at the same time perform measures to
prevent Admittance except on business to the danger area.
2.2.1.1. How to start the compaction work • User shall provide for use of vibration roller only in such a
way and at such sites where there is no hazard of damage to
• Supplier of building work (Machine User) shall be liable to nearby premises and others.
provide instructions for Driver and Maintenance Depart- • User shall ensure that a worker does NOT work alone at the
ment. These instructions include the requirements to secure site, and that another worker is ALWAYS in sight and within
occupational safety while operating the Machine. ear-shot to provide or call for aid unless other effective form
• Prior the compaction work the Supplier of building work of supervision or communication is available.
(Machine User) must verify the following: • User must ensure surveillance designate worker at work ma-
-- Utility lines chinery in the working condition on public communication,
which be in capacity issue instructions to reservation labour
-- Underground areas (direction, depth) protection.
-- Seepage or escape of hazardous materials • User must secure regular inspection of the operations, op-
-- Soil bearing capacity, slope of traverse plane erating condition, regular Machine maintenance in intervals
under the Lubrication & Maintenance Manual. In case of
-- Other barriers and obstructions, along with specifying
nonconforming operating condition of the Machine to the
the measures to ensure work safety.
extent it becomes hazardous and detrimental to the envi-
• Supplier of building work (Machine User) must then make ronment, then the Machine must be discarded until the de-
familiar with these conditions a Machine Driver who will fect gets repaired.
carry out the earthwork.
• User shall specify who and what tasks may be carried out
• Supplier of building work (Machine User) shall define tech- during operation, maintenance and repairs of the Machine.
nological process part of which is the work procedure de-
• The one who drives the Machine (Driver) and anybody who
signed for a given job. The work procedure specifies inter
performs maintenance and repairs of the Machine must be
alia:
made familiar with those instructions given in the Machine
-- Measures for work under extraordinary conditions (work Operating Manual.
within protective zones, under extreme slopes, etc.)
• User must ensure the ”Machine Operating Manual” and the
-- Measures against any natural disasters Operation Logbook are stored at a specific place to be AL-
-- Requirements for job execution while observing job WAYS available to the Driver.
safety principles • User shall make the fire extiguisher to undergo regular in-
-- Technical and organisational measures to secure safety spections.
of workers, site and environment. . • User must provide for disposal of hazardous materials (fuel,
• Supplier of building work (Machine User) must evidently oil, coolant, and alike) away from their leakage point in order
make Machine Driver familiar with the technological proc- to avoid their adverse environmental impact, adverse effect
ess (job description). on operation safety and health.
ARS 122 21
2.2.2. Driver Qualification Requirements
• Only a driver trained under local and national regulations

and standards designed for drivers of this group of Machines
may operate the Roller.
• Only the one who with the approval of Machine User learns
to drive under a direct & constant supervision of profession-
al lector or trainer in order to gain preliminary practice, may
drive with no driving licence obtained so far.
• Licence holder is liable to duly keep the licence in custody
and if requested he/she must put it forward to the control
authorities.
• Licence holder may NOT make any recordings, changes or
corrections to the licence.
• Driver is liable to promptly report any loss of his/her licence
to the authority that had issued the licence.
• Only a person mentally and physically competent, over 18
years old may drive the Roller alone if :
a) Charged by the Machine manufacturer to assemble, test
and demonstrate the Machine, or to train drivers, where-
as he/she must be made familiar with the occupational
safety regulations in force at the site,
or
b) Appointed by Supplier of building work to operate
(carry out maintenance), and evidently trained and ac-
quainted with, or if, under specific regulations, he/she
owns professional competence to operate and drive
(engine operator’s licence, and alike).
• Machine Driver must undergo training at least 1x every 2
years, and pass exams concerning work safety regulations.
22 ARS 122
2.2.3. Driver’s Duties
• Before starting Machine operation Driver must get familiar • When operating the Machine the safety regulations must be
with the instructions given in the Documentation supplied adhered to, no activity hazardous to work safety can be car-
with the Machine, with safety measures in particular, and ried out, commit yourself fully to Machine driving. ALWAYS
follow these guidelines thoroughly. This applies also to a sit on the seat when driving the Machine.
personnel in charge of Machine maintenance, adjustments
and repairs.(Unless you understand some sections of the • Respect job description or instructions of an employee ac-
Manual, please contact your dealer or manufacturer.) countable.
• NEVER drive Roller unless fully made familiar with the entire • When moving with the Machine at the site you must adapt
Machine’s functions, operating and handling elements, and the speed to the terrain condition, work in progress, and
until you know precisely how to operate the Machine. weather conditions. Watch continuously the clearance
height to avoid collision with any obstruction.
• Follow safety signed located on the Machine, and keep them
in legible condition. • Upon completion or stop of the Machine operation during
which Driver leaves the Machine, he/she must first make
• Prior to commencing work Driver must get familiar with the measures against unauthorized use of the Machine and its
site environment, i.e. any barriers, slopes, utility lines, nec- spontaneous start. Remove key from the ignition box, lock
essary site protections in terms of the surrounding environ- the vandal guard and disconnect or to cut out the wiring.
ment (noise, vibrations, etc.).
• Upon operation completion park the Machine at an appro-
• When finding any health hazard, life hazard, danger to per- priate station (flat, good bearing surface) in order not to
sons, property, finding any failures, or when there is an acci- threaten Machine stability, intervene with traffic roads, ex-
dent of technical facilities, or when finding any symptoms of pose the Machine to the falling objects (rock), and where no
such hazards during operation, then the Driver must, unless natural disasters of other type (floods, landslides, etc.) are
able to clear away such danger by himself/herself, stop the not a threat to the Machine.
work and secure the Machine against any undesirable start-
ing ON, report to a staff in charge, and if possible, alert all • When parking the Machine on communications over land,
the persons threatened by such hazard. please carry out measures under the regulations effective
for communications over land. Label the Machine properly.
• Before starting to run the Machine, Driver is liable to get fa-
miliar with the records and any operating deviations found • When working with the Machine is completed, please write
out in course of previous working shift. down in the Operation Logbook any Machine defects and its
damage including repairs made. During immediate change
• Before work commencements please inspect the Machine, of Drivers it is a duty to directly draw changing driver’s at-
fittings, check the control elements, communication & safe- tention to any matters found out.
ty equipment, whether these are functional and enabled ac-
cording to the Manual. When finding any defect hazardous • Driver must wear personal protective equipment, i.e. work
to job safety and unable to be repaired by Driver, then the clothing, safety shoes. The clothing must NOT be too loose
Driver may not start the Machine but instead communicate or damaged, hair protected with proper head piece. Hands
the failure to a staff accountable. protected with proper gloves during maintenance work (lu-
bricating, replacing of operating media).
• When Driver finds a defect during operation, he/she must
stop the Machine immediately, and secure safely against • Driver at the Machine must use ear protection effective
any undesired starting ON. within noise level of round 90 dB.
• Driver must follow the Machine run while in operation and • Keep the Machine fitted with specified accessories and out-
record any malfunctions found into the diagnostic logbook. fit.
• Driver must keep diagnostic logbook designed to make • Keep clean driver control stand, climbing steps and walkway
records on handing in and handing over the Machine be- surfaces.
tween the Drivers, and on any defects and repairs during • Before lifting the platform and bonnet, please confirm there
operation, and to document major events during an operat- is enough space for lifting, with no electric lines present. Be-
ing shift. fore dropping the platform and bonnet confirm nobody will
• Prior to starting the engine check the controllers are in be endangered with this operation.
gauge zero; no persons may remain within danger range of • In case the Machine would come into contact with high volt-
the Machine. age the following principles must be adhered to:
• Make sound or light signal to communicate each start up -- Try to escape with the Machine from the hazardous
of the Machine, and this ALWAYS before you start Machine area
engine. -- Do NOT leave driver control stand
• Confirm the functions of the brake and steering before Ma- -- Give warning to others not to approach and contact the
chine operation start up. Machine.
• Following an alarm the Operator may start the Machine only • Maintain the Machine free of oil dirt and flammable materi-
when all workers leave the danger area. At blind (uneasy to als.
oversee) sites the operation start may begin only after a pe-
riod necessary to exit endangered area elapses.
ARS 122 23
2.2.4. Forbidden activities - safety and guaran- • Operate the Machine with its bonnet lifted.
tee • Operate the Machine when there are other machines or con-
veyances within the danger area of the Machine except for
It is forbidden to: those working in mutual interaction with the Machine.
• Vibrating on the spot. When it is vibrated on the spot, bear- • Operate the Machine at a location unable to be seen from
ings of the vibrator are not lubricated. driver control stand, and where hazard to persons or prop-
erty may occur unless work safety is secured in some other
• Filling the hydraulic circuit during the guarantee period in a
way, e.g. indirectly via signalling carried out by duly instruct-
different way than using the hydraulic unit.
ed person.
• Changing the vibration amplitude when driving – It is always
• Operate the Machine within protective zone of electric lines
necessary to stop and only then set a different amplitude.
and substations.
• Using the machine in case of an evident defect of the ma-
• Pass over the electric cables unless these are properly pro-
chine.
tected against mechanical damage.
• Using the machine when any operating fluid level is low.
• Operate the Machine under reduced visibility or at night un-
• Quickly increase and decrease engine speed. It can damage less the working area of the Machine or the site is sufficiently
the engine. illuminated.
• Use the emergency brake for turning off the engine during • Leave Machine driver seat with the Machine running.
normal operation of the machine.
• Abandon unsecured Machine, i.e. move away from the Ma-
• Wilful repair of the engine – Except common changes of op- chine without preventing its misuse.
erating fluids and filters, only the Cummins service depart-
• Disable safeguarding, protecting or locking systems, or alter
ment can intervene in the engine, in particular in peripheral
their parameters.
components of the engine – alternator, starter, thermostat,
electrical installation of the engine. • Use the Machine with leaking oil, fuel, coolant or other fill-
ings.
• Use the Machine after drinking alcohol and ingestion of nar-
cotics. • Start the engine in some other way than given in the engine
Manual.
• Use the Machine in case its operation might deteriorate its
operating condition, cause safety hazard (life, health) to per- • Place, aside from personal needs, so other things (tools, ac-
sons, buildings and other property, or to road traffic and its cessories) at the Driver Control Stand.
continuity. • Put any materials or other object on the Machine.
• Start the Machine and use it when other persons are within • Remove any dirt while the Machine is running.
the hazardous vicinity of the Machine. Exempted is driver
training by lector. • Carry out maintenance, cleaning or repairs unless the Ma-
chine is secured against self-motion and accidental start,
• Start the Machine operation and use the Machine with some or unless contact between worker and moving parts of the
of the safeguard equipment (emergency brake, hydraulic Machine is excluded.
locks, etc.) removed or damaged.
• Touch moving parts of the Machine with your body and ob-
• Move and compact at such banks at which machine stability jects or tools held in your hands.
would be broken (overturn). Machine static stability speci-
fied gets reduced by the dynamic effects of the drive. • Smoke & handle open fire while inspecting or refilling the
fuels, changing, replenishing oil, lubricating the Machine, or
• Move and compact at such angles of slopes at which the checking and refilling the accumulator.
hazard of earth breaking off together with the Machine
could occur, or adhesion lost followed by uncontrollable • Carry the rags soaked with flammable materials on the Ma-
breakaway. chine (inside engine bay, cab), or carry flammable liquids in
free vessels.
• Control the Machine in a way other than stated in this Man-
ual. • Let the engine run inside confined areas. Exhaust gases are
dangerous to life.
• Move and compact with vibration per soil bearing capacity
at such distance from the slope edge or excavation edges to
avoid the hazard of material sliding down or shoulder break-
ing off together with the Machine.
• Move or compact with vibration at such distance from walls, ! CAUTION !
cuts or slopes so as to avoid the hazard of their collapsing Breaching these provisions can influence the judge-
and backfilling the Machine.
ment of a possible complaint and effectiveness of
• Driving with vibration on hard (frozen, concrete, overcom- the engine guarantee period.
pacted) surface or on bedrock. There is a danger of damage
to the machine.
• Compact with vibration at such distance from the buildings
or premises and facilities within which a hazard of their be-
ing damaged due to vibration energy transfer could occur.
• Move or transport persons on the Machine.
• Operate the Machine unless driver control stand is properly
fixed.
24 ARS 122
2.2.5. Safety labels & signs used on the Machine
ARS 122 25
Safety labels & signs used on the Machine
1 Clamp Hazard Risk area with clamp hazard. (Symbols placed left and
right on the rear cross arm of the front frame.)
2 Burn Hazard Danger of burn. Do NOT touch hot parts of the Machine
unless you made certain of their being cooled down suf-
ficiently. (Symbols placed from inside on the left door.)
3 Injury Hazard Risk of injury and winding around. NEVER touch rotating
parts while engine is running. (Symbol placed on the left
side of the cooler.)
4 Cooling Liquid Scalding hazard. Do NOT open expansion tank lid until
liquid cools down below 50 °C (122 °F). (Symbol placed
on the expansion tank.)
5 Adjust while at rest Risk of injury or being caught by the rotating parts of the
Machine. Make NO adjustments or maintenance work
when the engine is running. (Symbol placed from inside
on the left door.)
6 Read the Manual Read the Operating Manual before starting the Machine.
(Symbol placed on the left side of the control panel.)
7 Machine Max Height Pay attention when passing through a location with
height limit. (Symbol placed on the left side underneath
the cab on the frame.)
26 ARS 122
8 Battery Disconnector In case of failure or following a work completion, please

switch battery disconnector to ”0” position. (Symbol
placed on the panel behind LH lateral door.)
9 Rigging Diagram Use rigging of sufficient loading capacity when lifting the
Machine. Secure Machine joints before slinging. (Symbol
placed on LH door.)
10 Sling Positions Sling the Machine at these points. (Symbols placed on

both sides of the frames.)
11 Disconnect Alternator Before welding disconnect the battery terminals and

alternator connections of the Machine. (Symbol placed
from inside on the LH lateral door.)
12 Ear Protectors When the Machine has no cab, or operates with open
windows, please use ear protection. (Symbol placed on
central steering column.)
13. Electric Devices Cover electric instruments when washing the Machine
(Symbol placed on the left side of the cooler.)
14. Platform & Cab Lifting (Symbol placed on left side of rear frame)
15 Clamp Hazard Risk area with clamp hazard.

(Symbols placed from inside on the left door.)
ARS 122 27
2.2.6. Hand Signals
Signals given by Machine Operator Assistant when Operator is

unable to cover visually moving working space or utility device
or tool.
General command signals
Stop
One arm rose with open palm in the direction of Operator, the
other arm akimbo.
STOP
Sig. 1
Attention
Both arms sideways raised horizontally – palms forward.
! Sig. 2
Beware of Danger
Oscillating motion of both fore-arms from the position of arms
sideways raised horizontally to a position of arms sideways
raised – in huddled-up way and back.
! Sig. 3
Signals to drive
Drive away with the Machine

One arm erected – bent with open palm, long motion of fore-
arm in the direction of required motion, second arm akimbo.
Sig. 4
28 ARS 122
Slow forward drive – to me
Both arms stretched upward abreast huddled up, with palms to-
wards the body; short oscillating motions of fore-arms towards
the body and back.
Sig. 5
Slow backward- drive - away from me

Both arms stretched upward abreast huddled up, with palms
away from the body – short oscillating motions of fore-arms
away from the body and back.
Sig. 6
Driving on the right

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

Right arm sideways raised, left arm akimbo.
Sig. 8
ARS 122 29
Short motion
Both arms lifted forward huddled-up. Mark the distance “X“ be-
tween the palms, then the motion signal follows.
X
Sig. 9
Engine start
Circular motion of right hand’s fore-arm with fist.
Sig. 10
Engine shut down

Oscillating motion of right hand sideways rose in front of the
body a moving to the sides.
Sig. 11
30 ARS 122
2.3. Ecological & Hygienic Principles
2.3.2. Ecological Principles
During Machine operation or storage the
User must observe general principles of • Refills for the Machine’s individual systems and some of its
occupational safety and environmental parts become waste having hazardous properties against
protection along with laws, public notic- the environment following their disposal.
es or regulations related to these issues • This waste product category includes in particular:
and in force within a territory where the
Machine is used. -- organic or synthetic lubrication materials, oils and fuels,
-- cooling liquids,
-- accumulator refills and the accumulators themselves,
-- tyre fillings
-- cleaning & preservation agents,
2.3.1. Hygienic Principles -- all the filters & filter elements removed,
-- all the used and discarded hydraulic & fuel hoses, metal-
• Oil products, refrigerants of cooling systems, alternator re-
rubbers and other elements of the Machine fouled with
fills or painting materials incl. thinners are health hazard
the aforementioned products.
materials. Workers coming into contact with these products
during Machine operation or maintenance will be liable
to adhere to general principles of their own occupational Producer and contractual service organizations accredited by
safety, and conform to the safety & hygienic manuals of the him, or Branch office take back the following materials or parts
manufacturers of these products. free of charge:
• We point in particular to : -- oils
-- Eye & skin protections while handling the accumulators -- batteries
-- Skin protection while handling the oil products, paint- -- tyres (optional)
ing materials or cooling liquids
-- Washing your hands properly upon work completion or
before taking meal. Treat your hands with appropriate
reparable cream. Following the disposal of the above men-
tioned materials and parts make sure
-- While handling the cooling systems follow instructions
these are handled in line with the respec-
given in the Manuals supplied together with the Ma-
chine.
tive national environmental regulations
and health regulations.
• ALWAYS store oil products or accumulator refills and paint-
ing materials incl. organic thinners along with cleaning &
preservation agents inside their original packages labelled
properly. Do NOT admit to store these materials in unla-
belled bottles or other containers due to their exchange
hazard. Especially hazardous is the potential of being ex-
changed for consumables or drinks.
• Should your skin, mucosa, eyes be stained incidentally, or
vapours inhaled, then immediately apply first aid principals.
In case of accidental ingestion of these products, get prompt
medical attention.
• When handling the Machine then use ALWAYS ear protec-
tions of suitable type and construction.
ARS 122 31
2.4. Preservation & Storage
2.4.1. Short-term preservation & storage for 2.4.2. Machine preservation & storage for the
the period of 1 - 2 months period over 2 months
• Wash & clean carefully the entire Machine. Before Machine • For the Machine shutdown the identical principles like with
parking and shutdown in order to make its preservation & short-term preservation will apply.
storage, please heat the running engine up to its operating • In addition we recommend the following:
temperature. Park the Machine on fixed, flat surface at a safe
place with no potential of Machine damage caused by natu- -- Remove the accumulators, check their condition and
ral disaster (floods, landslides, fire, etc.). store in a cool, dry room (recharge the accumulators on
regular basis),
• In addition:
-- Bottom on the runner frame so the damping system has
-- repair those spots with paint impaired, minimal deflection (flexure),
-- lubricate all lubricating points, control cables, joints of -- paint rubber elements with spec. preservation agent to
the controllers, etc., protect them,
-- confirm water fillings have been drained, -- inflate the tyres to a specified pressure, and protect
-- check cooling liquid has its antifreeze characteristics re- them from direct sunlight,
quired, -- apply chrome-plated piston rods with preservation
-- check the accumulator charging conditions, recharge if grease,
required, -- spray the Machine with special agent and this at places
-- apply preservation grease over the chrome-plated sur- with possible corrosion origin,
faces of the piston rods, -- Blind engine air intake and exhaust with double PE foil
-- we recommend to spray preservation agent (applied and fix it carefully with adhesive tape,
via spraying) to protect your Machine against corrosion, -- protect headlamps, exterior back mirrors and other ele-
and this particularly in places with corrosion hazard. ments of external wiring via spraying with special agent
• Machine treated like that will need no special set-up before and wrapping in PE foil,
its subsequent putting into operation. -- Preserve the engine per manufacturer’s Manual. Install a
visible label informing the engine has been conserved.
! CAUTION !
Following 6 months we recommend to inspect pres-
ervation condition and renew it if necessary.
NEVER start the engine during storage!
When the Machine is stored under field conditions,
please make sure such stand is not exposed to any
deluge hazard caused by floods, or that no other
type of hazard occurs within this area!
Prior to restoration of the Machine ser-

vice, please wash the preservation agents
using high pressure stream of hot water
added with standard degreasers for Use
along with ecological principles.
Dewax and wash the Machine at the loca-
tions provided with intercepting sumps to
catch rinsing water and dewaxing agents.
32 ARS 122
2.5. Machine disposal upon its life termination
User will be liable to follow national waste or environmental
laws and regulations when carrying out Machine disposal. We
therefore recommend to always consulting:
• licensed industrial waste products disposing companies,
• Machine manufacturer or by them appointed and certified
contractual service companies.
Manufacturer bears no responsibility for

any damage to health of the Users or en-
vironmental damage caused by breach of
the above mentioned notice.
ARS 122 33
2.6. Machine Description
1 - Front Frame 11 - Engine

2 - Drum 12 - Hydraulic Oil Cooler
3 - Scraper 13 - Engine Coolant Cooler
4 - Articulated Joint 14 - Driver´s Control Stand
5 - Rear Frame 15 - Travel Pump
6 - Axle 16 - Vibration Pump
7 - Fuel Tank 17 - Exhaust Muffler
8 - Battery 18 - Air Filter
9 - Hydraulic Tank 19 - Hydr. Oil Pressure Filter
10 - Bonnet 20 - Charge Air Cooler
21 - Steering Pump
34 ARS 122
2.7. Controlling and operation of the machine
Dashboard
ARS 122 35
Dashboard & Control Panel
1 - Steering Wheel
2 - Travel Controller
2A - Vibration Switch
3 - TOTAL STOP pushbutton
4 - Travelling Speed Controller (Selector)
5 - Throttle Controller
6 - Ignition Box
7 - Spare
8 - Charging Port
9 - Operated-Hours Counter
12 - Engine Lubrication Control Lamp
13 - Battery Charge Control Lamp
14 - Brake Alarm Indicator
15 - Engine Overheating Indicator
16 - Fuel level gauge
17 - Air Filter Fouling Indicator
18 - Hydraulic Oil Filter Fouling Indicator
19 - Vibration ON Indicator
20 - Hydraulic Oil Overheating Indicator
21 - Vibration amplitude selector switch
22 - Turn Indicator Switch
23 - Headlights Switch
24 - Rear lights Switch
25 - Alarm Horn Pushbutton
26 - Fuse Block
27 - Hazard Switch
28 - Passing Beam Switch
36 ARS 122
Steering Wheel (1)
Used for Machine steering. Travel Speed Controller (4)
With the Controller turned ON the travel gear is engaged (“Rab-

bit” indicator lights). The Machine is capable to reach max. Speed
with pulling force reduced and climbing ability decreased.
With respect to safe steering, please ad-
just optimal speed (1800. min–1) when
driving without vibrations. NOTE:
With the controller switched off the operating speed mode is set.
The Machine reaches max. pulling force and climbing ability.
NEVER switch ON the controller during oc-

cupational use of the Machine.
Travel Controller (2) Do NOT switch OFF the controller at high
speed. Abrupt slowdown will occur to-
gether with impact within the hydraulic
Use this controller to adjust direction & speed of system. Turn OFF the controller with the
the driving. Driving speed corresponds to the de- Machine at rest or at low speed!
gree the controller deflects from idle (neutral) position. At the
same time the controller is used as driving brake of the Machine. You may switch ON the controller, i.e. trav-
The controller is arrested in set position. When shifted to its cen- el speed, when driving the Machine on a
tre position the parking brake is enabled, i.e. the control lamp formation level.
(14) lights up. Vibration Switch (2A) is located at the controller You may turn ON the controller with the
handle, and is used to switch ON/OFF the vibration after moving Machine loaded.
controller handle from neutral.
With pulling force not sufficient, switch
OFF the travel speed controller.
Engine starting is possible in idle position

only.
It is forbidden to quickly increase and de- Throttle (5)
crease engine speed. It can damage the Move the throttle downward to increase the speed from idling
engine! one to maximal rpm.
It is forbidden to vibrate on the spot!
(Vibrator bearings are not lubricated dur-
With respect to safe steering, please ad-
ing vibration at the halt.)
just optimal speed (1800. min–1) when
driving without vibrations.
TOTAL STOP pushbutton (3)
2582
Press this button to stop and brake the Roller, and to shut off
the engine.
! CAUTION !
Brake off in arrow direction before starting the
engine.
Use only in case of emergency during a

failure when the Roller is unable to stop
through resetting the travel actuator.
It is forbidden to use the emergency brake
for turning off the engine during normal
operation of the machine!
ARS 122 37
Ignition Box (6)
Battery Charge Control Lamp (13)
It has three positions - ”0”, ”I”, ”II”. When in”0” pos. all the consum-
ers with fuses will be connected; in”I” pos.other consumers will
be connected; cushion fuse ”II” is used for Machine starting. Turn
the key to”0” pos. to stop the Machine, remove the key in this
Switch the key on the ignition box (6) to“I” pos. and the control
position.
lamp must light up and go off after starting the engine.
Remove the key from the ignition box

when leaving the Machine!
When the key is taken out, please close Unless it goes off, look for the failure!
the ignition box cap to protect the igni-
tion box against water & dirt penetration.
Spare (7) Brake Alarm Indicator (14)
With this indicator lighted up the Machine broken is signalled.
Charging socket (8)

Engine overheating control lamp (15)
used for Mobile Charging.
When the engine temperature reaches the highest allowable

level, the engine overheating control lamp goes ON an audible
Operated-Hours Counter (9)
warning is given.
When battery charge indicator (13) goes off the counter starts fuel level gauge (16)
reading the hours. Reading the number of hours does not de-
pend on engine rpm.
When the fuel level drops down to min. 45 l (12 gal) , it shows
the lower level of diesel in tank.
! CAUTION !
Carry out regular maintenance per hours worked Air Filter Fouling Indicator (17)
out!
When this indicator lights up the filter elements are fouled

Engine Lubrication Control Lamp (12)
above their limit.
Switch the ignition box key to position ”I”, and the control lamp
lights up and then goes off after starting the engine. The lamp Replace the elements at once!
lighted signals engine lubrication is insufficient.
Unless it goes off, look for the failure!
38 ARS 122
Indicator of hydraulic oil filter (18) Headlights Switch (23)
This indicator lighted up under hydraulic oil operating tem-

perature of 50 - 60 °C (122 - 140 °F) signals the filter element is
clogged with dirt. Rear Headlights Switch (24)
Replace the elements at once!
Alarm Horn Pushbutton (25)
Vibration ON Indicator (19)

Fuse Block (26)
Fuse (F1) -20 A Head Light, Number plate Light, Turn indi-
cators, Horn, Beacon (Optional)
With this indicator lighted up the vibration switch (2A) is ON.
When set speed is reached the Machine starts vibrating with the Fuse (F2) -7.5 A Bonnet Fox Light
amplitude preset via vibration Preselector (21). Fuse (F3) -15 A (Upper Fuse) Engine, Reverse horn, Re-
verse light, Break, Break light
Fuse (F4) -7.5 A travel, vibration, vibration switching con-
trol lamp
Hydraulic fluid overheating warning indicator
(20) Fuse (F5) - 7.5 A Break indicator lamp, Engine lubrication
lamp, Charge control lamp, Hydraulic oil
filter fouling lamp, Engine filter fouling
When the fluid temperatures reaches the highest allowable lev- lamp, Hour meter, Engine overheating
el the overheating warning lamp goes ON, an audible warning lamp, Hydraulic fluid overheating lamp,
is given. Fuel level indicator
Fuse (F6) -15 A Reserved
Vibration amplitude selector switch (21) Fuse (F7) - 7.5A Reserved
- Small amplitude and high frequency are switched Fuse (F8) - 7.5A Reserved
ON.
- High amplitude and low frequency switched ON.
Before the machine starts moving, use the switch to set the re-
quired amplitude. Before changing the amplitude, first stop the Replace fuses with those of identical val-
machine, use the switch to change the amplitude and then start ue ONLY!!!
moving the machine again.
It is forbidden to vibrator on the spot!

It is forbidden to change the vibration am- Hazard Switch (27)
plitude while driving.
Turn Indicator Switch (22)

Passing Beam Switch (28)
Indicator lamp on will signal traffic-indicator light are ON.
ARS 122 39
Driver Seat
Seat adjustment elements:
Backrest angle adjustment – lift the lever (1) to setting up of

the backrest.
Longitudinal move of the Seat – lift the lever (2) and move the
1 2
seat in longitudinal direction forward – backward.
Seat firmness adjustment – Rotate lever (1) clockwise or anti-

clockwise to set the weight of operator
Battery Cut-off switch

Use cut-off switch to disconnect Battery from the system.
Use cut-off switch to disconnect the

Battery following the drive end!
Switch OFF the disconnector ALWAYS
when washing the Machine!
40 ARS 122
2.8. How to Control and Use the Machine
2.8.1. Start the Engine
Note:
Before you start the engine, please Unless engine starts even after 3 attempts made – check the fuel
turn ON the horn for warning purposes. system. Upon starting, watch the colour of exhaust gases – the
Confirm nobody is endangered due to the absence of blue or white fume indicates the fuel supply is insuf-
engine started! ficient.
How to start the engine:

• Make additional fuel pumping via hand feed pump at the
engine (upon long term Machine shutdown).
• Switch ON battery disconnector.
• Switch ignition box (6) key to pos. ”l” – engine lubrication
lamps go ON (12), along with brake lamp (14), and charge
control lamp (13).
• Set the throttle controller (5) to slightly increased speed (1/4
of controller stroke).
• Switch ignition box key to pos.”ll” and start the engine (keep
the key in pos. ”ll” only until the engine starts).
• When started, use the control lamps to monitor the engine
function.
• When started, let the motor run at idle rpm of 750-950 min-1
for a period of 3-5 minutes.
ARS 122 41
How to start using starter cables via another machine
Do NOT start for more than 30 sec. Make
another starting attempt only after 2 min-
utes, and unless the motor starts even af- Make sure the starting voltage of a boost-
ter 3 attempts, carry out troubleshooting. starting power supply is 12 V.
Charge control lamp and lubrication Follow unconditionally the sequence of
lamp must go off when the engine starts. operations given below!
Lubrication lamp must go off within 15
sec.
Sharp speed increase or decrease is inad-
missible – hazard of engine damage. 1. Connect one (+) pole end of the cable to (+) pole of dis-
When started let the engine run at idle charged battery.
rpm of 750-950 min–1 for a period of 3-5 2. Connect second (+) pole end of the cable to (+) pole of bat-
minutes. tery of the machine used to boost-start.
Do NOT let the engine run idle for over 10 3. Connect one (–) pole end of the cable to (–) pole of battery
minutes – running idle for longer period in the vehicle used to boost-start.
will cause injectors clogged, piston rings 4. Connect second (–) pole end of the cable to a section of the
gummed, valves seized! started Machine fix-connected to the engine (or to the cyl-
Unless liquid temp reaches min. 60 °C inder block itself )
(140 °F) the engine will not be lubricated
sufficiently enough – do NOT run the en-
gine at full capacity!
! CAUTION !
When started, disconnect the starter cables in re-
verse order.
! CAUTION !
When aided by Starter Unit with no batteries con-
Starting will be interlocked: nected, do NOT disconnect the Unit before the
When the controller (2) is in idle (neutral) position. Machine battery is connected.
42 ARS 122
2.8.2. Travel & Reversing
Do NOT connect (–) pole of the cable to (–)
pole of discharged battery of the started
Machine! Hazard of strong sparking when
starting, followed by an explosion of gas- Use acoustic alarm to communicate
es generated by battery. drive away of the Machine, and wait long
enough so the persons present may leave
Non-insulated sections of the starter ca-
in time the adjacent area of the Machine
bles’ clamps may NOT contact each other!
(area under the Machine) !
Make sure starter cable connected to (+)
Before drive away you must confirm the
pole of battery does NOT come into con-
area in front of and behind the Machine is
tact with electrically conductive parts of
free, and that no persons are found there!
the Machine – short-circuit hazard.
NEVER bend yourself over the battery
hazard of electrolyte burn!
• Turn OFF the travelling speed controller (4) – i.e. switched to
Exclude any presence of flammable sourc- operating speed.
es (free flame, smoking cigarettes, and
alike). • Use throttle controller (5) to adjust engine rpm required, i.e.
ca 1800.min–1 (RPM).
NEVER verify voltage presence within
a conductor via sparking through the • Confirm vibration switch (2A) is not ON, control lamp (19)
Machine frame! is off.
• Deflect travel controller (2) from idle (neutral) pos. to a re-
quired direction – small deflection of the controller = slow
speed and vice versa. Following travel controller (2) deflec-
tion the brake indicator lamp (14) will go off.
How to start at low temperature.
• Reversing – shift the controller (2) in opposite direction via
Starting at ambient temperature below 0 °C (32 °F) will require its idle position.
different way of starting with the use of starter filling:
Adjust the throttle to half-speed, and when starting the engine
a second person will inject measured quantity of starter filling Turn ON the controller (4) – transport
into the air filter. speed - you may do so while driving the
Machine by an adjusted terrain (forma-
tion level) “Rabbit” symbol will light up.
Turn the controller ON only with the
Observe strictly safety & hygienic instruc- Machine not idle.
tions of manufacturer when using starter
filling. Non-observance of these instruc- In case of lack of pulling force, switch OFF
tions may lead to engine or property the transport speed controller.
damage, health and life hazards to people NEVER switch OFF the controller (4) at
present. high speed due to high slowdown along
NEVER use volatile, easily ignitable refill with impact within hydraulic system. Turn
when starting inside tunnels or mines. OFF the controller (4) at low speed or with
Always ask for safety guidelines when us- the Machine at rest!
ing starter refills under these conditions. Engage operating speed via turning OFF
controller (4) before driving by steep
incline!
Do NOT apply throttle (5) to control
Machine velocity.
NEVER drive in cross direction at the hill-

sides of high slope! Drive perpendicular
to a hillside!
ARS 122 43
OK OK
44 ARS 122
2.8.3. Travel with vibration
• Turn OFF controller (4), thus switching to operating speed

mode. It is forbidden to vibrate on the spot!
• Use Pre-selector (21) to select vibration amplitude. It is forbidden to change the vibration am-
• Use throttle controller (5) to adjust maximal speed. plitude while driving.
• Start moving the Machine and turn ON the switch (2A) to
start the vibrations - control lamp (19) lights up – runner be-
gins vibrating.
• Press and relieve button (2A) to stop the vibration.
ARS 122 45
2.8.4. Emergency stop of the Machine • Before new engine start, please shift controller (2) to ”N” po-
sition and turn pressbutton (3) according to arrow direction.
• Switch key (6) to “0“ position and then start.
Apply in the event when engine is unable
to stop via ignition key or when Machine
is unable to stop via switching the travel Do NOT apply emergency brake dur-
controller to neutral. ing normal operation just to shut off the
engine.
• Press TOTAL STOP (3) (emergency brake) - the engine stops

and the Machine stops moving.
46 ARS 122
2.8.5. Stop the Machine & the Engine
Do NOT stop hot engine instantly, instead
• Use switch (2A) to turn OFF the vibration – control lamp (19) let it idle for a period of 3 minutes.
goes off.
• Use controller (2) to stop the Machine – parking brake is
enabled; lamp (14) lights up.
• Use controller (5) to lower the speed to engine idle.
• Switch ignition box key (6) to pos. “0” and take it out – close
the ignition box cap.
ARS 122 47
2.8.6. Machine Shutdown
Stop the Machine on flat, paved surface
• Stop the Machine. Confirm no natural hazard (landslide, po-
• Cut off battery disconnector. tential of deluge due to any floods, etc.)
exists at the location where the Machine
• Clean the Machine (scraper, tyres).
is parked and shut down.
• Make overall inspection of the Machine and repair any de-
fects caused during operation.
• Confirm tyres have sufficient pressure.
• Put Scotch blocks to the wheels and uncoupled-axle.
• Lock the instrument covers or and the door beneath driver
control stand.
48 ARS 122
2.8.7. Platform & Bonnet raising and lowering
Lifting and lowering platform must be

done only while the platform is empty.
Danger of injury!
• Release platform nuts.
• Open the cover on the left side under the platform. Take out
the pump control lever (1).
Lifting:
• Close the valve (2), insert the control lever (1) into the pump
and simultaneously lift the cab and bonnet by pumping.
• Lock the platform in position using the valve (3).
ARS 122 49
• Lock the lifted bonnet using the valve (4).
4
When working on the platform and bon-
net lifting hydraulic circuit, the platform
and bonnet must be secured by valves (2),
(3), (4). By releasing the valves when the
platfom and bonnet lifting hydraulic cir-
cuit is open, the platform or bonnet may
fall. Danger of injury!
Lowering:
• Unlock the platform using the valve (3).
• Unlock the bonnet using the valve (4).
• Lower the platform and bonnet by opening the valve (2).
After lowering, tighten the Platform using

screws. 2
50 ARS 122
2.8.8. Ballasting of tyres with liquid
It is used for lowering the machine gravity centre. The mixing ratios for individual temperature per one tyre are given in the table.
Ballasting of tyres with liquid of up to 0 °F
Water Anti Corit SKR40 Added weight

(l) [gal US] (kg) [lb] (kg) [lb]
345 (91) 10 (22) 355 (782.6)
Ballasting of tyres with liquid of up to -25 °F

The inner space of the tyre is filled with the solution of water and 34% calcium chloride CaCl2.
Water Anti Corit SKR40 Added weight

(l) [gal US] (kg) [lb] (kg) [lb]
185 (48,87) 265 (584.2) 450 (992)
A filler neck can be ordered as a replacement part under num-

ber 4-5325190009.
Filling procedure:
• Move the machine to a firm base. The filling valves should be
in the extreme upper position. Secure the drum with blocks
on both sides.
• Unscrew the removable valve insert and screw on the filler
neck.
ARS 122 51
• Mount the hose from the filling equipment (a tank located
above, pump, etc.) on the filler neck and fill the tyres with
the solution.
• During the filling, air escapes from the tyre through the side
opening from the filler neck. The tyre is sufficiently filled
(at 75%) when the solution starts flowing out through the
opening.
• Unscrew the filler neck, screw the valve insert back on, and
inflate the tyre to a pressure of 160 kPa (23.2 PSI).
Draining procedure:
• Move the machine to a firm base. The filling valves should be
in the extreme lower position. Secure the drum with blocks
on both sides.
• Unscrew the removable valve insert and let the solution
flow out.
The solution can spurt out after unscrew-

ing the valve insert.
• As soon as the solution does not flow out due to a decrease

in pressure, screw on the filler neck and inflate the tyre to a
pressure of 160 kPa (23.2 PSI).
• After the tyre has been inflated, remove the filler neck and
screw the valve insert back on.
Protect your eyes with glasses (face shield)

and your hands with rubber gloves!
Wash away spilled solution with clean

water.
Solution may never come into contact
with metal parts and wiring.
52 ARS 122
2.9.
Machine Transportation OPERATING INSTRUCTIONS
2.9.1. Machine transportation by its own axle
• Move the roller by its own axle when moving within a work-
ing site outside public roads.
Transport speed – you may switch ON col-

lector (4) when crossing with the Machine
by finished road.
In case of long transportation distances,
please make 1-hour cooling breaks every
2 hours. Non-observance of this advice
will put in jeopardy of Machine damage
that the manufacturer will in no and any
circumstances bear responsibility for.
Follow those safety measures specified for
the work site when shifting the Machine.
2.9.2. Machine transportation by public road
The basic construction of the Machine is

NOT fitted for transportation by its own
axle using public road. This type of trans-
portation is prohibited.
When driving onto the carrier, we recom-
mend to put rubber bands or wooden
planks, etc. under the runner.
Make sure the carrier designed for the
transport is braked when loading and un-
loading, as well as mechanically locked
against undesired moves using the Scotch
blocks (2).
A person that guides the Machine must Fixing the Machine on the carrier.
communicate with the Driver using speci-
fied intercommunication signals, (refer
to Section 2.2.6.), this guiding person
must always stay at one place outside the
reach of the Machine and outside the car-
rier. Guiding person must remain within
Driver’s field of sight (in visual contact)
throughout the entire period of driving
the Machine onto the carrier and driving
down from the carrier.
C
1 2 2 1
When driving onto and down from the
carrier all the persons aside from Machine
Driver must go away as far as to avoid be-
ing hit by a falling Machine. 2 2
Fix the Machine to the carrier via the clamps (tie-

offs) (1) at the rigging points! By rigging points we
mean front & rear slings, front & rear pulling hitches,
and sling holes in the runner frame sidewalls.
Adhere to the Motor Vehicle Construction and Use
Regulations when transporting via land routes.
NO persons may stay on the Machine, driver con-
trol stand or carrier loading area during Machine
transportation.
ARS 122 53
2.9. Machine Transportation
2.9.3. How to load the machine
• Use loading platform or crane loading to load the machine

onto the carrier.
• When loading with crane the roller is fitted with slings (lift-
ing eyes)-refer to the fig. for slinging method.
• Before lifting the roller, please lock the machine joint against
being turned slightly.
2.9.3.1. Loading the machine using a ramp
• When loading the machine using a ramp, all safety regula-

tions related to loading of the machine valid in the place of
loading must be adhered to. The ramp must have appropri-
ate loading capacity, antislip surface and must be stored on
a flat surface. We recommend that you adhere to regulation
BGR 233.
C
• Maximum permissible incline of the ramp is 30%.
MAX
MAX 30
30 %
%
Non-adherence to the prescribed parame-

ters of the ramp may result in damage to
the machine.
When loading the machine, a second per-
son must be present to signal approach
onto the ramp. See the list of hand signals
in chapter 2.2.6.
Pay increased attention when loading the

machine. Improper handling can cause se-
rious injury or death.
54 ARS 122
How to lock the joint:
• Unlock and pull out the journal (1).
• Fold down the arm (2) and lock with the journal (1) and
safety lock (3).
Do NOT enter underneath hanging load!
Upon completion of loading, return the

safety arm back to its initial position.
Follow provisions in force when loading/
unloading.
Apply adequate, intact rigging of suffi-
cient loading capacity.
Use only those lifting eyes (mounting
lugs) on the Machine designed specifi-
cally for slinging.
Only a trained slinger may carry out the
slinging.
ARS 122 55
2.9.4. Towing of Machine
• The machine is provided with two towing lugs on the front

frame (1) and with two towing lugs on the rear machine
frame (2).
• A struck machine can be towed for a short distance if the
engine is running and the travel drive and steering are work-
ing. The operator on the towed machine must steer the ma-
chine in the towing direction.
The machine must be fastened using both

lugs during pulling or towing!
When towing, please use undamaged
towing cable or pull rod of sufficient load-
ing capacity 1.5 higher than the weight
of hauled Machine. It is forbidden to use
a chain for hauling.
It will be necessary to maintain minimal
deflection from direct angle of hauling.
Max deflection will be possible within an-
gle of up to 30°.
Smooth and constant movement must be
maintained in towing. The towing speed
must not exceed 1 km/hour (0.62 mph).
The machine should only be towed for the
shortest possible distance – to extricate
the machine if it gets stuck or is blocking
traffic in case of breakdown. Do not tow
the machine for a longer distance than
300 m (0.19 mi).
The hauling machine shall fit with its size
the Machine broken. It shall have suffi-
cient hauling force (performance), weight
and brake effect.
When hauling downhill with the help of
cable it will be necessary to attach next
hauling machine to the rear part of the
Machine broken. In this way it will be pos-
sible to avoid uncontrolled motion of the
Machine damaged.
if the engine does not work, or there is a
defect in the hydraulic system, you must
release the brake of the machine and
short-circuit the hydraulic circuit of the
travel. Then the machine can be towed )
No person may stay on the towed

machine!
After the brake is released and the hy-
draulic circuit is short-circuited, all of
the brakes are disabled!
Before releasing the brake, secure the
machine with wooden scotch blocks
against motion!
The platform and the bonnet must be
lowered before the brake is released.
Do not touch hot parts of the machine,
burn hazard!
56 ARS 122
Short-circuiting the travel pump:
• Switch off the engine. Use the disconnector to disconnect
the batteries.
• Slacken the locking nuts (2) on the Travel pump by turning

them anticlockwise by a half-turn.
• Screw the screws (1) clockwise towards the springs. If an in-
creased resistance is felt, screw the screw in the spring by a
half-turn.
• Tighten the nuts (2) with a torque of 22 Nm.
How to brake off:
Before releasing the brake, secure the ma-

chine with wooden scotch blocks against
motion!
•• Put a vessel under the machine to collect the leaking fluids.
Avoid leakage of oil to the soil.
ARS 122 57
• Disconnect the hose (1) from Brake Block Connector (2).
• Install one end of hose (3) provided in toolkit on Brake

Block Connector (2).
2
• Disconnect the hose (4) from T- connector (5).
58 ARS 122
• Install the another end of hose (3) provided in toolkit on
T- connector (5)
• Take away the vessel collecting the leaking fluid underneath
the machine.
• Close the safety valve (9).

• Turn on the battery disconnector (6).
• Switch the key to the “I” position.
• Operate the lever in the manual pump (7).
• Monitor the brake indicator (8) until it is off with the key
switched on. The cylinder is with released brakes and ma-
chine towing is possible.
• If wiring is not operational, operate the lever in the
manual pump using at least 30 full strokes (one stroke = to 6
and frow movement of the lever).
7
9
280159
Due to leakages, the pressure in the brake

can drop during the towing.
Check the drum or tyres in the towed
machine for the occurrence of braking or
skidding. In such a case, interrupt towing
and re-operate the lever in the manual
Pump.
When towing is completed, please secure
the wheels and drum with scotch blocks
(cotters) and put into initial state.
How to put into initial state:

• Open the safety valve (9).
• Remove the key out of the ignition box. Disconnect the bat-
tery with the disconnector (6).
• Insert the manual pump lever in the holder under the driv-
er‘s stand.
9
280160
ARS 122 59
• Slacken the locking nuts (2) on the travel pump.

• Slacken the screws (1) by turning them anticlockwise end-
to-end.
• Tighten the nuts (2) with a torque of 22 Nm.
• Disconnect the hose (3) From T- connector (5)
• Install the hose (4) on T- connector (5)

the machine.
60 ARS 122
• Disconnect the hose (3) From Brake block connector (2)
• Install the hose (1) on Brake Block connector (2)

the machine.
2
• Check the hydraulic oil level in the reservoir. If necessary, re-

plenish oil according to chapter 3.6.3
ARS 122 61
2.10. Special Conditions for the Machine Application
2.10.1. Vibration driving on compacted and hard 2.10.2. Machine use under heavy climatic condi-
materials tions
During vibration driving a loss of contact between the runner 2.10.2.1. Machine operation under low tempera-
and the compacted material (so called vibro-stroke) may occur
tures
due to the impact of high level of sub grade material compac-
tion, or due to vibration driving on hard materials (e.g. stony
Compacting during winter season depends on fine particle con-
loose material). This state will show through the increased vi-
tents and water contents within a soil under compaction. With
bration energy transfer to the Machine frame and Driver control
the temperature going down below freezing point the earth be-
stand. Increase travel velocity or change Machine vibration pa-
comes more solid and harder to compact.
rameters (applying lower amplitude) to partially remove this ef-
fect. Higher vibration energy transfer to the Driver control stand When compacting at the temperatures below 0 °C (32 °F) is
may also be expected when increasing the level of sub grade required, you may compact dry soils (or stony loose materials)
material compaction. or perform fast compaction of non-frozen materials (ahead of
earth becoming frozen through).
Note
When vibration driving on a different sub grade material than Make the Machine ready for operation under low
stated in ”Specifications Manual”- Hygienic Data, then the emis- temperatures:
sion figures of vibration acceleration will be different. • Check the engine coolant concentration.
• Exchange oil in the engine with the one recommended for a
given range of low ambient temps.
• Apply hydraulic oil of corresponding Kinematic viscosity.
• Change oil in runner gearbox with the one recommended
In case it is urgent to operate the Machine for a given range of gearbox temperatures.
under the conditions with the potential • Use winter fuel.
of Operator exposed to higher vibrations,
• Confirm the battery are charged.
then the Machine User is liable to adapt
the operating procedures so as to avoid Sound condition of battery is the prerequisite of good starting
driver’s health hazard. under low temperatures. Warm up the battery to ca 20 °C (68 °F)
(via removing accumulators and storing them in a dry warm
room) to lower limit temp for starting by 4 to 5 °C (39.2 to 41 °F).
Hazard of engine damaged when engine

(cooling liquid) operating temperature re-
mains constantly below 60 °C (140 °F).
Use the Machine at its full power only after heating the fillings
to their operating temperatures (coolers possible to be partially
covered as well).
NEVER start the Machine at ambient tem-

peratures below +2°C (36 °F) when the hy-
draulic system is filled with HV 100 oil.
When starting at ambient temperatures
below –8 °C (18 °F) is required for a period
of one month or more, please exchange
oil in the hydraulic system with HV 46 vis-
cosity class oil.
And with HV 32 class oil (e.g. BP BARTRAN
HV 32, ESSO UNIVIS N 32, etc.) at ambient
temperatures below –13 °C (9 °F).
NEVER start the Machine below –23 °C
(–9 °F) with no preheating of fillings mode.
62 ARS 122
2.10.2.2. Machine operation under high temper- 2.10.2.3. Operating the Machine at high
atures and humidity altitudes
Engine power will lower with air temperature or humidity in- Engine power will decrease with the altitude rising. This is given
creasing. Since both of the factors that lower engine perform- by the reduced atmospheric pressure and induction air specific
ance are independent on each other, their effects can be de- mass.
scribed as follows: When black smoke is generated by the engine at high altitudes
-- With every 10 °C (50 °F) of increased temp the power will (above 1500 m), please contact your engine manufacturer serv-
drop by up to 4 % (at constant humidity) ice department to make adjustment to your injection pump to
-- With every 10 % of increased RH the power will drop by fit these operating conditions.
up to 2 % (at constant temperature).
! CAUTION !
Any engine (cooling liquid) operating Engine power will be affected by the environment
temperature over 100 °C (212°F) may where the Machine is operating, as per Sections
damage the engine. 2.10.2.1. & 2.10.2.3.
At high temperatures when hydraulic oil temp is constantly

round 90 °C (194 °F), we recommend to exchange hydraulic oil
with denser one of 100 mm2/s Kinematic viscosity class (BP BAR-
TRAN HV 100, ESSO UNIVIS N100, etc.)
2.10.2.4. Machine operation at extremely dusty
environment
! CAUTION !
When hydraulic system is filled with oil class: Cut short the intervals of cleaning and
HV 46, then oil max. Limit temperature is 80 °C replacement of air filter elements when
(144 °F) operating under extremely dusty condi-
HV 32, then oil max. Limit temperature is 70 °C tions; shorten the intervals of cleaning
(158 °F) the engine cooler, hydraulics, or of replac-
ing Cabin dust filter.
When operating under extreme temperatures when
cooling liquid or hydraulic oil temperatures reach
max. Limit temperatures, you may remove fender
aprons of the bonnet to increase cooling capacity
of the Machine Cooling System, and hence improve
hot air removal from the engine bay.
ARS 122 63
Notes
64 ARS 122
Notes
ARS 122 65
66 ARS 122
MAINTENANCE MANUAL
3. MAINTENANCE MANUAL
ARS 122
(Cummins BS lll)
ARS 122 67
68 ARS 122
3.1.1. Safety during Machine Maintenance 3.1.2. Fire precautions when refilling
Lubrication, maintenance & adjustments must be carried • In terms of fire safety the flammable liquids applied at the
out: Machine split into the following Danger Numbers:
• By trained specialists Danger Number II – Diesel Oil
• In line with safety instructions given in the Vibrating Roller Danger Number IV - Mineral Oils, Lubricating Greases
Operation Manual • Place the oil exchange point where it does not interfere with
• According to the time intervals as stated in Lubrication Table explosion / fire hazard areas.
following the hours of actual operation • Label with Tables and No Smoking & No Open Fire Signs.
• With the Machine located on a flat fixed surface secured • Design the size of handling area so it can catch the amount
against self-motion (wedges and with the steering joint of flammable liquid equal to the capacity of the largest ves-
locked sel, shipping container.
• With the wiring disconnected and the ignition key removed • Fit it with portable fire extinguishers.
• On the cooled down parts of the Machine • Use containers like metal barrels, jerri cans, tin cans to han-
• Following the cleaning of the Machine, of lubrication points dle the oils, Diesel oil.
& maintenance points and of repair points • Confirm the shipping containers are properly closed during
• Using proper undamaged tools storage.
• Replacing with new original parts per the Spare Parts Cata- • Make sure the containers have one hole, and are stored with
logue their hole up, and secured against their contents purring out
or dripping.
• With sufficient lighting of the entire Machine when under
lowered visibility or at night • Label the containers with indelible inscription specifying
the content & flammability number.
• With the guards (covers) and safety elements reinstalled
upon work completion, if previously dismantled
• Together with retightening bolted connections – using
proper torque, and checking tightness of the connections
• Following the heating of operation fillings (danger of burns).
Use recommended refills only.
Confirm all safeguard equipment func-

tions are OK once adjustments or mainte-
nance are completed!
ARS 122 69
3.1.3. Ecological & Hygienic Principles Ecological Principles
When operating and maintaining the machines a User must fol-

low general health & environment protection principles along
Once disposed of (dismantled, refilled)
with the acts, public notices & regulations related to these issues
and effective within the territory a machine is used. the fillings of the Machine’s individual
systems and some of its parts become
waste with hazardous properties in terms
Hygienic Principles of the environment.
• Oil products Battery refilling, plus painting materials (coat-

ing compositions) incl. thinners are materials causing health This waste product category includes the following:
hazards. Workers that come into contact with these prod-
ucts during machine operation or maintenance must ob- -- Organic or synthetic lubricants, oils and fuels
serve general principles of health self-protection and follow -- Brake fluids
safety & hygienic instructions of these products’ manufac-
-- Cooling liquids
turers.
-- Battery charges and Battery themselves.
• Please note the following in particular:
-- Cleaning & preserving agents
-- Protect your Eyes & skin when handling the Battery
-- All the dismantled filters & filter elements
-- Protect your skin when handling oil products, painting
materials and cooling liquids -- All the worn & discarded hydraulic hoses & fuel hose,
metal rubbers and other elements of the Machine fouled
-- Wash your hands upon work completion and before tak-
by the abovementioned products.
ing meals; treat your hands with reparation (recovery)
cream
-- Observe machine operating instructions when handling
its cooling systems.
• ALWAYS store oil products, refilling of cooling systems and Following the disposal of the given ma-
Battery plus paints incl. Organic thinners and also the clean- terials and parts these must be han-
ing & preserving agents in their genuine original properly dled under the respective National
identified packages. Never store these materials in unla- Environmental Policy Regulations, and in
belled bottles or other vessels due to exchange hazard. Es- line with Health Regulations.
pecially hazardous is the potential of being mistaken with
eatables or beverages.
• Upon skin, mucosa or eye contacts, or vapour inhalation,
you must apply first aid measures instantly. During acci-
dental ingestion of these products you must call for prompt
medical attention.
• Use always ear protectors (muffs) of proper type and con-
struction when operating the Machine.
70 ARS 122
3.2. Specification of fluids
3.2.1. Engine Oil
Engine oil shall be specified per its performance classification &

viscosity classification.
Performance Classification under

API (AMETICAN PETROLEUM INSTITUTE)
CCMC (COMMITE OF COMMON MARKET AUTOMOBILE CON-
STRUCTORS)
ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE
AUTOMOBILE)
Viscosity Classification
Ambient temperature and type of operation where the Machine
is used will be decisive to determine SAE (SOCIETY OF AUTOMO-
TIVE ENGINEERS) viscosity class.
Admissible oils applied compliant to API: CF-4/SG; CG-4/SH
CCMC DH1
ACEA: E-5
Year round SAE 15W-40 (e.g. Valvoline, Premium Blue)
Note:
Exceeding low temperature limit will not lead to any engine
damage, it may only cause some problems when starting the
Machine.
It is rather convenient use multigrade oils so as to avoid oil re-
placement due to ambient temperature changes.
Exceeding max temperature limit may not

last for a longer time due to the lowered
lubricating capabilities of oil.
When using synthetic oil due to operating
conditions (low ambient temperature) the
same change intervals like with mineral
oils must be maintained.
When using oil under API CD/SF you must
cut the change interval by half, i.e. 125
hours or 3 months.
Use engine oil of SG or SH classification
due to lubricating the valve tappets.
ARS 122 71
3.2.2. Fuel 3.2.3. Cooling Liquid
Use some of the following Diesel fuels to run the engine. Use cooling liquid comprising 50% water and 50% antifreeze
-- CEN EN 590 agent (designed for ambient temperature of up to -36 °C [-33 °F])
for the engine cooling system even within a climatic zone where
-- ASTM D 975-88: 1-D & 2-D temperatures do not drop below 0 °C (32 °F). The cooling liquid
serves not only to protect the cooling system against any freez-
ing, but also to increase boiling temperature. The inhibitors con-
tained within the antifreeze protect parts of the engine cooling
Use winter Diesel oil with ambient tem- system. You may use ethylene glycol antifreeze agents as well to
peratures below 0 °C (32 °F). Use special refill the cooling system.
type of Diesel oil with additives designed
Use treated, demineralized or distilled water to prepare the
for the conditions with ambient tempera-
cooling liquid.
tures less than -15 °C (5 °F) (”Super Diesel
oil”).
NEVER use fuels (like bio Diesel oil, mixed
bio Diesel oil, LFO, and alike) other than Do NOT use the portion of antifreeze cool-
those Diesel oils specified above. ing agent within cooling liquid over 50 %
unless absolutely necessary to do so.
NEVER use ration over 68%!
Antifreeze agents are made variously
based.
We do not recommend their mutual mix-
ing. Blending various types of cooling
liquids may lead to loss of anti-corrosion
characteristics.
Use refractometer (densimeter) to check
the portion of antifreeze cooling agent
in cooling liquid before winter period
begins.
72 ARS 122
MAINTENANCE MANUAL
3.2.4. Hydraulic Oil Synthetic Hydraulic Oil

You can fill the hydraulic system with synthetic oil which, when
making any leaks, becomes degraded via microorganisms
Use only quality hydraulic oils of power class per ISO 6743/ HM found in water and in soil.
for the Machine’s hydraulic system (corresponds to DIN 51524
Section 2 HLP).
Normally the machines are filled at manufacturer with hydraulic
oil of Kinematic viscosity of 68 mm2/s at 40 °C (104 °F) ISO VG Please consult any transition from min-
68. This oil is the most suitable one to be used within the widest eral oil to synthetic oil, or mixing oils of
range of ambient temperatures. various brands with oil manufacturer or
dealer!
When at high ambient temperatures with

oil temperature constantly reaching 90 °C
(194 °F) we recommend to replace with oil
of Kinematic viscosity 100 mm2/s HM 100.
ARS 122 73
3.2.5. Gearbox Oil 3.2.6. Lubricating Grease
Use quality oil corresponding to API GL-5 to lubricate the uncou- Use grease plastic type that contains lithium to lubricate the
pled axle gearbox and axle drive gearboxes. Machine under:
SAE 85W/140 viscosity for ambient temperature of +20 °C to -- ISO 6743/9 CCEB 2
+45 °C (68 °F - 113 °F). -- DIN 51 502 KP2K-30
-- (Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, Grease
No 3, and alike.).
Operating temperature of oil must NOT

exceed 85 °C - 90 °C (185 °F - 194 °F).
74 ARS 122
3.3. Refills
Refill Amount
Section Refill Type Brand
l (gal US)
Engine Engine oil per Section 3.2.1 10.9 (2.9)
Fuel Tank Diesel oil per Section 3.2.2. 410 (108.3)
Hydrualic System Hydraulic oil per Section 3.2.4. 90 (23.8)
Axle Gearboxes Gearbox oil per Section 3.2.5. 2x1.9 (2x0.24)
Front Gearbox Gearbox oil per Section 3.2.5. 1.9 (0.24)
Joint bearing & steering cylinders Plastic lubricant, refer to Section 3.2.6. as required
Engine Cooling System Permanent anti-freeze liquid per Section 3.2.3. 20 (5.3)
Vibratory Free Axle Motor oil as motor 8 (2.1)
battery Distilled water as required
ARS 122 75
3.4. Lubrication & Maintenance Table
Every 20 hours of operation or daily
3.6.1. Check the oil amount in engine
3.6.2. Check the amount of cooling liquid in the engine
3.6.3. Check the amount of oil inside hydraulic tank
3.6.4. Crankcase Breather
3.6.5. Check fan condition
3.6.6. Check engine belt
3.6.7. Check engine air intake
3.6.8. Check the amount of fuel
3.6.9. How to clean air separator
3.6.10. Check the alarm & control devices
Every 100 Hours
3.6.11. Check tire pressure
Every 250 Hours or Once in 3 Months
3.6.12. How to replace oil in the engine
3.6.13. Check the fixing of the engine
3.6.14. Battery check
3.6.15. Check the function of Air Filter Vacuum Switch
3.6.16. Machine Lubrication
3.6.17. How to check oil inside vibrator
3.6.18. How to check oil in gearboxes
3.6.19. Replacement of fuel filters of the engine
3.6.20. Cooling liquid inspection
3.6.21. Check of wiring
76 ARS 122
MAINTENANCE MANUAL
3.6.22. Exchanging cleaner elements of air cleaner
3.6.23. Check if wheel bolts are tightened *
3.6.24. Change oil in the Front and Rear gearboxes *
Every 1000 Hours or Once a Year
3.6.25. Check, adjust valve clearance
3.6.26. How to check tightening pulley and belt of the engine
3.6.27. Inspect the damping system
3.6.28. How to clean fuel tank
Every 2000 Hours or Every 2 Years
3.6.29. How to change oil in the vibrator
3.6.30. How to change hydraulic oil and filter
3.6.31. How to change engine coolant
Maintenance - As Needed
3.6.32. How to clean engine cooler and hydraulic oil
3.6.33. How to deaerate fuel system
3.6.34. How to adjust the scrapers
3.6.35. How to clean the Machine
3.6.36. Check bolted connections
* First after 150 hours
ARS 122 77
3.5. Lubrication and service plan
78 ARS 122
3.6. Individual Operations of Maintenance
Carry out lubrication & maintenance on regular basis and repeatedly in intervals according to daily reading on the hours of operation
counter.
This manual includes only basic information on the engine; the rest is provided in the operation and maintenance manual of the en-
gine, which is a part of documentation supplied with the machine.
Follow the instructions given in the manual for operation and maintenance of the engine!
Disassembled or loose bolts, plugs, threaded connections of hydraulics etc. should be tightened with torque according to tables in
chapter 3.6.36., unless a different value is listed for the particular operation.
Carry out the maintenance with the Machine stationed on a flat, paved surface, and secured against self-mo-
tion, ALWAYS with the engine turned OFF, key removed from the ignition box, and wiring cut OFF (unless oth-
erwise required).
After the first 150 hours of working with a new machine (or after machine general overhaul), make the
following operations:
3.6.23. Check if wheel bolts are tightened

3.6.24. The first oil exchange in Front and Rear gearboxes
ARS 122 79
Every 20 Hours of Operation or Daily
3.6.1. Check the oil amount in engine
• Stop the engine and wait for 5 minutes until oil flows down
to crankcase sump.
• Pull out the oil dipstick (1), wipe it off and insert it back down
to the stop and pull out again to read the oil level.
• Maintain the level within the range of holes stamped on

the dipstick. The lower hole indicates the lowest possible oil
level, the upper hole indicates the highest one.
• Refill the oil via oil filler following a removal of oil filler plug
(2). Wait for 1 minute until the level gets stable and then
check again.
• Always replenish with oil of identical type. Use oils under

Section 3.2.1.
• Check the motor tightness, repair any cause of leakage.
• Inspect the engine if no damaged or missing parts exist
within the motor, and whether no appearance changes
have occurred.
NEVER use the engine unless there is

proper oil level inside the engine.
80 ARS 122
MAINTENANCE MANUAL
3.6.2. Check the amount of cooling liquid in
the System
• Check visually the level.

• Add via filler neck (1).
Remove the filler plug only after the en-

gine coolant temperature falls below
50 °C (120 °F). Any attempt to remove
filler plug at high temperature may cause
operator to be scalded with steam or cool-
ing liquid due to inner overpressure.
The level may not drop below the level

gauge eyesight.
Replenish with coolant consisting of
antifreeze agents of identical base per
Section 3.2.3.
NEVER use additives to remove cooling
system leakages with the engine cooling
liquid.
Do NOT refill hot engine with cold liquid.
The casts of the engine may get damaged.
When some higher leak occurs, check the
cooling system and repair its cause.
ARS 122 81
3.6.3. Check the amount of oil inside hydraulic
tank
• Check the level.

• Refill with oil if required.
NOTE
In case of high loss of oil, repair the cause of hydraulic system
leakage.
• The hydraulic tank lid is provided with a seal.

• To fill up the hydraulic circuit, use the hydraulic unit.
! CAUTION !
If the hydraulic circuit is filled in a different way than
using the hydraulic unit, the guarantee will expire.
Hydraulic unit 230 V

Ordering number: 1251998
Hydraulic unit 110 V

Ordering number: 1255297
• Connect the hydraulic unit to the quick-coupling in the

space under the platform.
82 ARS 122
MAINTENANCE MANUAL
Alternative filling through the filler neck of the tank in the
space under the Bonnet
! CAUTION !
Fill the hydraulic circuit through the filler neck only
in emergency! When this filling method is used, it is
necessary to reduce the next change interval to half,
i.e. 1000 hours or 1 year.
• Fill the tank through the filler neck (1) with the specified oil
type up to the bottom of the strainer in the filler neck.
3.6.4. Crankcase breather
• Inspect the crankcase breather hose to make sure it is not

fouled with deposits, chips, or in winter season frozen with
ice.
ARS 122 83
3.6.5. Check fan condition
• Check visually the fan. If damaged (e.g. missing parts of

materials, cracks, shape changes etc.) replace the fan.
3.6.6. Check engine belt
• Make visual check of the belt, monitor any of its damage.
• Any cracks perpendiculars to belt width are no damage.

When longitudinal cracks occur on the belt or frayed (shat-
tered) belt edges exist, or any torn off parts of material are
seen, then the belt must be replaced.
84 ARS 122
MAINTENANCE MANUAL
3.6.7. Check engine air intake
• Check if suction rubber hose leading from the filter is not

damaged and if tightening clamps are not missing.
• Inspect the gasket between the bonnet and air filter. Re-
place impaired gasket with the new one if required.
NEVER operated the Machine with dam-

aged gasket between the bonnet and air
filter, or the connection not tight.
• Check the exit slit of air filter vacuum valve, press to remove
any dust trapped.
NOTE:
The dust caught inside dust valve gets emptied automatically
during machine operation.
NEVER operate the Machine with dust valve

damaged.
ARS 122 85
3.6.8. Check the amount of fuel
• Check the level of the diesel in tank with gauge
• Replenish following the cleaning of filler cap (3) and filler

neck (2) via a strainer up until the lower edge of the filler
neck.
NOTE:
As soon as the fuel pointer reaches near empty line on fuel
gauge make up the fuel immediately. Fuel tank capacity is 410
l (108 gal US). The fuel tank equals to ca 34 hours of Machine
operation.
NO smoking while at work!

Observe fire precautions!
Fuel tank is not drained fully. To empty

fully you must carry out rather arduous
deaeration of the entire fuel system.
Use ONLY clean and recommended fuel
under Section 3.2.2.
NEVER refill fuel with the engine running.
Do NOT replenish fuel in closed areas.
Prevent fuel from spilling on the ground.
86 ARS 122
MAINTENANCE MANUAL
3.6.9. How to clean water separator
• Prepare a receptacle to drain the sediment into.

• Turn the separator valve (1) clockwise by 4 revolutions until
the valve gets extended by ca 25 mm (1”) downward.
• Drain the fuel till it starts flowing out pure. Press the valve
upward and screw it.
If you drained more than 6 cl (2ozs) of fuel,

then make up the fuel in fuel filter in line
with Section 3.6.20., or deaeration per
Section 3.6.34. In this way you will avoid
problems of difficult engine starting.

Do NOT drain the separator with the en-
gine running.
Collect the fuel with sediment drained in

a proper vessel.
ARS 122 87
3.6.10. Check the alarm & control devices
• Turn ON the switches (22), (23), (24), (25), (27), (28), confirm • Start the engine, press (3) TOTAL STOP - engine stalling must
the horn, headlamps and indicator function well. occur, pilot lamps go ON.
• Turn the ignition box key 6 into position “I”. Lamps (12), (13),
(14) will light up.
• Following engine starting “II” the lamps (12), (13) must go
off.
When in operation, please check continu-

ously the board instruments and indicator
lamps.
Repair instantly any failures signalled!
88 ARS 122
MAINTENANCE MANUAL
Every 100 Hours
3.6.11. Check tire pressure
! NOTE !
Rotate tyres so that valves are at top positions.
• Check pressure at cold tires using a pressure gauge.

• Maintain 160 kPa (23.2 PSI) pressure in your tires.
ARS 122 89
3.6.12. How to replace oil in the engine
• Prepare an appropriate vessel of capacity 20 L.

• Remove drain plug (1) and let oil to run out.
• Clean the surface round the oil filter head. Dismantle the
filter.
• Clean the contact surface designed for filter gasket.
• Take a new filter, fill it with pure engine oil – 10.9 l (2.9 gal
US).
90 ARS 122
MAINTENANCE MANUAL
• Apply oil on the gasket.
• Install the filter and hand-tighten securely.

• Reinstall the plug again. Use 80 Nm (59 lb. ft.) torque.
• Refill the engine via filler neck (1).
• Replenish the oil up to the dipstick upper Hole. Oil refilling

makes 10.9 l (2.9 gal US).
ARS 122 91
NOTE
• With the oil replaced start the engine for 2 - 3 minutes.
Check the tightness of drain plug and filter.
• Stop the engine and wait 3 minutes until oil descents into
the crankcase sump. Then check the oil level using dipstick.
Drain oil when it is hot, following the opera-

tion end, or heat the running engine until
the cooling liquid temperature reaches
60 °C (140 °F). Beware of possible scalding
when draining hot oil.
! CAUTION !
Replace oil every 3 months at the latest even though
250 hours of operation have not been reached. Replace
oil in an interval that comes first.
Use recommended filters only. Refer to Specification
Manual or Spare Parts Catalogue of engine.
Use recommended oil only. Refer to Section 3.2.1.
Do NOT over tighten the filter. Its thread or gasket may
get spoiled.
Collect drain oil and do not leave it to soak

in the ground.
Used oil and filters are environmentally haz-
ardous waste – hand it over for disposal.
92 ARS 122
MAINTENANCE MANUAL
3.6.13. Check the fixing of the engine
• Confirm the condition of metal rubbers (cracks, fissures), co-

herence of metal with rubber, tightness of bolts and nuts.
Engine front metal rubbers
Engine rear metal rubbers
ARS 122 93
3.6.14. Battery check
• Stop the engine and disconnect the electric system using

the isolating master switch.
• Clean the surface of batteries.
• Check the condition of poles and terminals (1) and clean
them. Apply a thin layer of grease on the terminals.
MAINTENANCE-FREE BATTERY
• In case of a maintenance-free battery (the battery has no fre- Keep the batteries dry and clean.
ely accessible plugs), only the no-load voltage on terminals Do NOT disconnect battery while the en-
is checked. The batteries cannot be replenished. If the no- gine runs.
-load voltage is 12.6 V and more, the battery is fully charged.
When handling with the battery, always
If the no-load voltage is below 12.4 V, the battery should be
charged immediately. After the battery is charged, leave it follow battery Manufacturer’s Manual!
to stand for 2–3 hours and then measure the voltage again. Use rubber gloves and eye protection aids
It is recommended to be mounted 24 hours after charging. when handling the battery.
Use proper clothing to protect your skin
against any electrolyte stain.
When there is eye contact with electrolyte
immediately flush affected eye with large
amounts of water for a few minutes. Get
Note:
prompt medical attention.
The no-load voltage is the voltage measured at the terminals of
the battery which was at rest for at least 12 hours – was neither When there is electrolyte ingestion, drink
charged nor discharged. max amount of milk, water, or solution of
calcined magnesia in water.
During skin contact with electrolyte, re-
move clothing, including shoes, flush af-
fected points as soon as possible with
soap water or solution of soda and water.
Get prompt medical attention.
Do NOT eat, drink or smoke while at work!
After work is completed, wash your hands
and face thoroughly with water and soap!
Do NOT check a wire is energized by
touching Machine frame.
Disconnect the battery before its repair,
or when about to handle the wires and
electric devices within the wiring circuit
so to avoid a short circuit.
Do not turn the accumulators upside When disconnecting the battery, please
down; the electrolyte may pour down disconnect cable with (-) pole first. When
from the degassing plugs. connecting, you must connect (+) pole
When there is electrolyte spillage, rinse first.
the affected place with water, and neu- Making direct conductive connection be-
tralize with lime. tween battery’s both poles you will cause
Hand over old batteries that do not work a short circuit with battery explosion
for their disposal. hazard.
94 ARS 122
MAINTENANCE MANUAL
3.6.15. Check the function of Air Filter Vacuum
Switch
• Remove the engine air intake cover, or the pre-filter.
• Set up the engine speed increased to about 2000 min-1.

• Cover shortly Air Filter Suction Hole on the engine bonnet.
• Indicator lamp (17) for Air Filter fouling should light.
• Check the following unless it lights up :

Vacuum switch (1)
Bulb inside the indicator lamp (17). Confirm the contact,
supply cable.
ARS 122 95
3.6.16. Machine Lubrication
• Remove greasing nipple caps.

• Put on gradually the greasing nipple of high pressure press
and grease till the old grease begins to flow out.
• Reinstall the greasing nipple caps again.
Steering Joint
Upper bearing (1)
Lower bearing (2)
Bearing (3) 4x
Linear Hydraulic Cylinder for Steering

King pins 2 x
Rear pins 2 x
Linear Hydraulic Cylinder for Tilting the Bonnet

Upper pivots 2 x
96 ARS 122
MAINTENANCE MANUAL
Lower pivots 2 x
Linear Hydraulic Motor for Tilting Operator platform
Bonnet Hinges
Platform Front Pivots

Pivots 2 x
Use ONLY recommended lube greases.

Refer to Section 3.2.6.
ARS 122 97
3.6.17. How to check oil inside vibrator
• Stop in such a way that the axle plugs on the left side are in
the position as per fig.
• Clean the spot round of the inspection plugs (1). Unscrew
the plug (1) and check the oil level. The level must reach up
to the inspection hole or flow out slightly.
• Replenish oil with the filler cap (2) unscrewed.
• Wipe the plugs and reinstall.
Check the oil only after it cools down.

Refill with identical type of oil.
98 ARS 122
MAINTENANCE MANUAL
3.6.18. How to check oil in gearboxes
Rear Gearbox
• Stop the Machine in such a way the plugs (1), (2) of gear-
boxes of both of the wheels are in position as per fig.
• Wipe the spot round the check plug (2), unscrew the plug
and check the oil level. The level must be as high as the in-
spection hole or flow out slightly.
• Refill with oil via filler plug (1), if required.
Front Gearbox
• Clean the spot round the inspection plug (1). Unscrew the
plug and check the oil level. The level must reach up to the
hole or flow out slightly.
• Refill with oil via filler plug (2), if required.
• Confirm the tightness of gearboxes.
NOTE:
Plugs are located on the static section of the gearbox – they
do not turn while driving.
Do NOT touch gearbox and its adjacent

parts when these are hot.
ARS 122 99
The set of filters after 500 M/c hrs, can be ordered

from engine spare part catalogue. For the list of all
spare parts, see the engine spare part catalogue
publication.
3.6.19. Replacement of fuel filter of the engine
• Clean the head of the fuel filter (1) and the fuel filter with the
water separator (2); dismantle the filters.
• Clean the contact area of the fuel filter (1).
• Fill up the fuel filter (1) with clean fuel.
100 ARS 122

MAINTENANCE MANUAL
• Apply oil over the sealing ring.
• Mount the fuel filter (1) and tighten firmly by hand.

• Carry out the same procedure for the fuel filter with the wa-
ter separator (2).

Use original filters specified.

Do NOT tighten the filters with force.
Collect any fuel flowing out.

Hand over for disposal the filters used.
ARS 122 101

3.6.20. Cooling liquid inspection
• Use refractometer to check the concentration of antifreez-

ing agent in the cooling liquid.
• Add with antifreezing agent per Section 3.2.3.
3.6.21. Check of wiring
• Check for any damage to cables, connectors, protective

hoses, and their fastening, especially if in the vicinity of hot
surfaces and moving parts of the machine including the en-
gine. Replace damaged parts. Use only original spare parts.
102 ARS 122

MAINTENANCE MANUAL
3.6.22. Exchanging cleaner element of air
cleaner
The air cleaner contain the main and safety elements. Replace
the cartridges always when the indicator lamp (17) lights up,
however at the latest after 500 M/c hrs.
The manufacturer does not recommend

cleaning the cartridges because of reduc-
tion of filtration capacity to the cartridges
due to the cleaning.
• Lift the bonnet to the limit position. (See Operating instruc-

tions, chapter 2.8.7.).
• Remove the lid.
• Replace the main (Primary) cartridge.
• Replace the safety cartridge.
ARS 122 103

• Clean the inside of the cleaner and contact surface in order
that the engine inlet pipe does not get blocked. Check con-
nections and piping for any untightness and clogging of the
engine inlet opening on the bonnet (e.g. by leaves).
• Insert the safety element.

• Mount the new main element. Check whether the both car-
triges fits correctly and whether are sealing.
• Remove the dust valve, clean it and mount it back.
Do not clean the inside of the cleaner by

pressure air; dust might get into the en-
gine inlet piping.
Use original elements only.
When washing the machine, make sure
water cannot pour into the air cleaner.
In case of absorbing water, exchange
main element. Dry the cleaner body.
Replace defective vacuum valve
immediately!
Do not operate the machine with dam-
aged cleaner body or cover.
104 ARS 122

MAINTENANCE MANUAL
3.6.23. Check if wheel bolts are tightened
• Confirm the wheel bolts are tightened. Use torque spanner.

• The torque is 285 Nm (210 lb. ft.)
! CAUTION !
Check the wheel screws for tightening after the first
150 hrs. of machine operation.
3.6.24. Change oil in the gearboxes.
Rear Gearbox
• Stop the Machine in such a way the plugs (1) & (2) of gear-
boxes of both the wheels are in position as per fig. Place an
appropriate receptacle underneath the plugs and Dismount
both the plugs and let oil drain out.
• After draining complete oil, Drive the machine forward so

that the plugs are in position according to fig. Through the
plug (1) fill 1.9 l of recommended oil. Check the level in hole
(2) (the oil flows out slightly). Reinstall the plugs (1) & (2).
ARS 122 105

Front Gearbox
• Wipe the spots round the plugs. Place an appropriate recep-
tacle underneath the drain plug (3), unscrew it and let the
oil drain out.
• Unscrew the plug (1) also and let oil drain out of it also.
• After draining complete oil, reinstall plug (3) back. Use filler
plug (2) & (1) to refill the recommended oil 1.9l. Check the
level in hole (1) & (2) (the oil flows out slightly from hole (1).
Reinstall the plugs (1) and (2), replace any plug gasket dam-
aged.
Change oil after driving for first 150 engi-

ne hours.
Change oil while oil is hot
Do not touch gearbox or its adjacent sec-

tions when these are hot.
Avoid oil to leak into the ground.

Used oil is environmentally hazardous
waste hand it over for disposal.
106 ARS 122

MAINTENANCE MANUAL
Every 1000 Hours or Once in Year
3.6.25. Check, adjust valve clearance
• Call Cummins service department to adjust the engine

valves – for contact points, please refer to Engine Operation
and Maintenance Manual.
3.6.26. How to check tightening pulley and belt

of the engine
• With the engine running inspect visually any vibrations of

the fan pulley.
• Stop the engine!

• Confirm the stop of tensioner arm dose NOT contact bump
stop of the bush. Replace the belt if it makes a contact. When
the arm stops continue to contact bump stop of the bush,
replace the tensioner. Confirm the cap screw is tightened
with 43 Nm (32 lb. ft.) torque.
• Lift the belt tightening pulley using a lever with a square

end of 12 mm and remove the belt.
ARS 122 107

• Carry out visual inspection of the belt, track any damage
made cracks across the belt width are not considered dam-
age. When longitudinal cracks occur on the belt, or the belt
has its edges frayed, or parts of the material are ripped out,
then the belt must be replaced.
• With the belt removed, check to confirm the stop of the ten-
sioner arm comes into contact with the bump stop of the
bush. Unless so, replace the tensioner.
• Check the pulley (arm) does not deflects from the vertical
axis. Maximal deflection allowed is 3 mm (0.12 inch). Inspect
the tensioner pulley along with the arm to make sure there
are no fissures over there.
• Check axial clearance of fan pulley. This clearance may not
exceed 0.15 mm (0.006 in.).
• Reinstall the belt back.
108 ARS 122

MAINTENANCE MANUAL
3.6.27. Inspect the damping system
• Check the condition of metal rubber (cracks, fissures), cohe-

siveness of metal with rubber. Replace any damaged one
• Confirm the bolts and nuts are tightened properly.
Rubber metals of the drum, LH side.
Rubber metals of the drum, RH side
Front metal rubber of driver control stand.
Rear metal rubbers of driver control stand.
ARS 122 109

3.6.28. How to clean fuel tank
• Unscrew the drain plug and let fuel to flow out into a recep-
tacle installed.
• Flush the tank with clean fuel.

• Screw on the plug again.
• When fouled to a greater extent, remove the battery and
tank cap. Inspect and clean the tank’s inner area. Insert the
new sealing tape between the lid and the tank.
• Mount the lid back.
• Mount the battery.
NOTE
When aeration of engine fuel system occurs you must deaerate
it under Section 3.6.35.
Carry out cleaning when there is minimal fuel in the tank.
With the tank used up, ca 45 l [12 gal US] of fuel will remain in
the tank.

NO smoking while at work!!!
Follow the environmental regulations

when cleaning.
Avoid fuel leaking into the ground.
110 ARS 122

MAINTENANCE MANUAL
Every 2000 Hours or Every 2 Years
3.6.29. How to change oil in the vibrator

• Position the cylinder so the drain plug (3) is in its lowest po-
sition, and on the opposite the filler plug (1) in its highest
position.
• Put a proper receptacle underneath the drain point.
• Unscrew all the plugs and let oil to flow out.
• When draining is completed reinstall the drain plug.
• Use filler hole (1) to refill with recommended oil up to the
edge of inspection hole (2) - 8 l (2.1 gal US).
• Reinstall the remaining plugs.
Change oil while oil is hot.
Do NOT touch gearbox or its adjacent sec-

tions when these are hot.
Avoid oil to leak into the ground.

Used oil is environmentally hazardous
waste – Hand it over for disposal.
ARS 122 111

3.6.30. How to change hydraulic oil and filter
Change oil before season starts, or fol-

lowing a rather long Machine shutdown.
Drain oil while oil is hot.
• Unscrew drain plug. Let oil flow out into a vessel installed –
total amount of oil that flows out is round 60 l (15.9 gal US).
Mount the plug back.
• Dismantle the cover.
• Remove the suction hose.
• Remove the lid. Remove the suction basket from the suction
pipe. Replace the suction basket.
• Inspect the interior of the tank. When the bottom is dirty,
clean and rinse the tank with the new oil. Mount the lid
back. Use the new sealing tape.
112 ARS 122

MAINTENANCE MANUAL
How to replace pressure filter element
Replace ALWAYS :
- Together with oil exchange
- When pressure filter lamp 18 lights
up due to oil operating temperature
reaching 50 - 60 °C (122 - 140 °F).
• Remove filter vessel (2). Replace filter element.

• Clean thoroughly the filter vessel.
• Clean the bottom of filtration block contact surface.
• Check the condition of sealing rings, apply the rings with
clean oil.
• Insert new element into the filter vessel, and screw on back
again.
ARS 122 113

Filling the hydraulic circuit:
• Fill using the hydraulic unit.
• Put the quick-release coupling of the hydraulic unit on the

quick-release coupling on the right side of the frame under
the operator platform.
• Fill up the tank with oil to the maximum level and discon-
nect the hydraulic unit.
• Start the engine, increase its speed to confirm the tightness
of filter, temperature sensor, suction hose & cap. Check oil
level in oil gauge.
Checking the oil temperature sensor

• Remove the sensor and clean the contact.
• Immerse the sensor in warm oil of a known temperature and
read the temperature on the hydraulic oil thermometer. If
the sensor operation is incorrect, replace the sensor with
a new one.
114 ARS 122

MAINTENANCE MANUAL
Alternate filling through the oil tank filler
Fill the hydraulic circuit through the filler

neck only in emergency!
When using this filling method, reduce
the next change interval to the half, i.e.
1000 hours or 1 year.
• Fill the tank through the filler neck with the specified oil
type up to the bottom of the strainer in the filler neck.
NOTE:
When the tank is filled through the tank neck, a large portion of
the old dirty oil will remain in the circuit and the life cycle of the
hydraulic units will be shorter.
Do NOT open hydraulic tank uselessly!

Use NO chemical cleaning agents & those
means (like clouts) that slip fibres.
Refill oil per Section 3.2.4.
Use only the original filter elements under
Spare Parts Catalogue.
Keep clean while at work. Avoid fouling
the system with materials that may cause
damage to crucial sets and units!
Exchange oil and filter element ALWAYS
when internal parts of units (hydraulic
motors, hydroelectric pumps) have been
damaged, or following a major overhaul
of hydraulic system. Clean & rinse hydrau-
lic tank prior to installing a new unit.
Collect drained oil, and do NOT let it soak

in the ground. Blind all the holes with
plugs following the disconnection of hy-
draulic circuits.
Used oil & filter elements are environmen-
tally hazardous waste – Hand it over for
disposal.
ARS 122 115

3.6.31. How to change engine coolant
Make it with the engine operation

stopped or following the heating of the
liquid to 50 °C (122 °F) with the engine
running.
• Remove overpressure plug (1) at the expansion tank to open

the cooling system.
Do NOT open the overpressure plug be-

fore cooling liquid temperature drops be-
low 50 °C (122 °F). Danger of water splash-
ing when opening the overpressure plug
and getting scalded.
• Open the drain cock at the cooler’s bottom chamber. Let the
liquid flow out into the receptacles installed. The amount
drained is ca 20 l (5.3 gal US).
• Confirm no damaged hoses or missing hose clamps exist

within the engine cooling system. Check the condition of
the cooler for any damage, leaks or whether the cooling gills
are fouled with slag & mill scale. Clean and repair if required.
116 ARS 122

MAINTENANCE MANUAL
• Close the drain cock and refill the cooling system with new
coolant at the ratio of 50 % of water + 50 % of antifreeze.
• Fill up to the water gauge top level. Adequate filling speed

is 19 l/min [5 gal US/min]. When the system is filled up you
must wait 2-3 minutes to let the bleeding come about. Screw
on the expansion vessel cap and close the bleed valve. Start
the engine and let the motor heat up to 80 °C (175 °F). Stop
the engine and check no cooling liquid leaks. Confirm water
gauge level.
NOTE:
When making the change, please flush the system with mixture
of water and soda (sodium carbonate) at the ratio of 0,5 kg (1.1
lb.) of soda per 23 l ( 6.0 gal) of water in line with instructions of
CUMMINS Engine Operating Manual supplied. Refill the system
with this mixture and heat up to 80 °C (176 °F) with the engine
running – do NOT install the expansion vessel cap. Turn OFF the
engine and drain the water. Refill with clean water and heat up
again the motor. Then drain the water. Repeat this till water is
clean.
Refill with cooling liquid under Section

3.2.3!
Follow the instructions of antifreeze man-
ufacturer when changing!
Wear gloves to protect your hands!

Wear safety glasses or face shield to pro-
tect your eyes!
Hand over used liquid for its safe disposal

per the regulations given!
ARS 122 117

Maintenance - As Needed
3.6.32. How to clean engine cooler and

hydraulic oil
• No regular cleaning interval is possible to establish due to

different operating conditions.
• Perform daily cleaning when working within extremely
dusty environment. Fouling of coolers will show in lowered
cooling performance along with increased temperatures of
engine cooling liquid and that of hydraulic oil.
• Clean with compressed air or pressure water (steam). Clean
from the direction of the fan.
Do NOT use cleaners of excessively high

pressure to prevent cooler honeycombs
damaged.
In case of cooler fouled with crude oil
products find out the cause of fouling!
Follow the ecological standards and regu-

lations when cleaning!
Clean the Machine at a workplace
equipped with cleaning agent intercept-
ing system to avoid contamination of soil
and water resources!
NEVER use banned cleaning agents!
118 ARS 122

MAINTENANCE MANUAL
3.6.33. How to deaerate fuel system
Deaerate the fuel system prior to a first start of the engine

upon:
-- Fuel filters not refilled with fuel – when replacing the
filters
-- Fuel pump replacement
-- Replacement of high-pressure piping, injector
-- Long-term shutdown of the Machine.
-- Fuel pumped out from the tank.
Deaerate low-pressure piping & filters:

1
• Loosen air relief screw at the fuel filter (1).
• Use fuel feed pump until clean fuel flows out with no air
bubbles.
• Tighten air relief screw. The torque figure is 9 Nm (7 lb. ft.).
When using engine starter to aerate, then

do not start for over 30 s. Wait 2 minutes
in between the starts. Engine may start
when aerating, therefore safety precau-
tions must be followed.
ARS 122 119

Deareate high-pressure piping and the injectors:
• When you have carried out the previous operations and the
engine has not started, please deaerate the high-pressure
piping.
• Switch the ignition box key to position ”ON” to energize en-
gine “Stop” solenoid valve.
• Loosen one or more nuts on the injectors and then swing
the engine to force the air out from HP piping.
• Deaerate till motor runs regularly.
• Tighten the loosened connections with 38 Nm (28 lb. ft.)
torque.
Attention, high fuel pressure inside HP

piping. Hazard of skin injury and serious
implications.
NEVER make deaeration with hot engine.
Danger of fuel flowing over hot exhaust
manifold causing fire.
Open fire FORBIDDEN while working on
fuel system!
NO smoking!
Collect any leaking fuel!
120 ARS 122

MAINTENANCE MANUAL
3.6.34. How to adjust the scrapers
Scraper designed for smooth drum

• Loosen bolt (1) and shift the holder (2) towards the drum
making the distance between scraper and drum equal to
15mm (0.6 in.).
! CAUTION !
When the chance to displace the scrapers in slotted
holes of holders (2) following the wear and tear of
scraper (3) is exhausted, you must dismantle the
scraper (3) and move it by one hole towards the
drum.
Scrapers designed for padfoot drum.

• Loosen bolt (1) and move individual scrapper (2) towards
the drum at the distance of 25mm (1 in.).
Rear scrapers at the padfoot drum are

longer. When replacing worn and torn
scrapers, use rear once to replace the
front once, and replace the rear once with
new once.
When only a small gap has been set be-
tween the scrapers and drums a contact
between scraper and drum may occur
when turning the Machine.
ARS 122 121

3.6.35. How to clean the Machine 3.6.36. Check bolted connections
Machine cleaning • Check regularly whether some bolted connections are loos-
ened.
• Clean the Machine to get rid of major dirtiness following
a work completion. • Tighten with torque spanners.
• Make overall cleaning on general basis at least once every
week. When working on cohesive soils, soil cement or lime
stabilization, please make overall cleaning on daily basis. TORQUE
For bolts 8.8 (8G) For bolts 10.9 (10K)
Thread Nm lb ft Nm lb ft
Blind all the holes where a cleaning agent M6 10 7.4 14 10.,3
could enter (e.g. engine suction port) M8 24 25.0 34 25.0
before compressed cleaning with wa-
ter or steam. Remove these blinds upon M8x1 19 14.0 27 19.9
Machine cleaning completion. M10 48 35.4 67 49.4
Do NOT expose electric parts or insula- M10x1.25 38 28.0 54 39.8
tion material to direct stream of water or M12 83 61.2 117 86.2
steam. ALWAYS cover these materials (in-
M12x1.25 66 48.7 94 69.3
ternal space of alternator, etc.).
M14 132 97.3 185 136.4
Wear gloves to protect your hands!
Wear safety glasses or face shield to pro- M14x1.5 106 78.2 148 109.1
tect your eyes! M16 200 147.5 285 210.2
Disconnect battery cut off switch. M16x1.5 160 118.0 228 168.1
Conduct work with the engine shut off. M18 275 202.8 390 287.6
NEVER use aggressive and easily ignitable M18x1.5 220 162.2 312 230.1
cleaning agents (e.g. gasoline or easily ig- M20 390 287.6 550 405.6
nitable materials).
M20x1.5 312 230.1 440 324.5
M22 530 390.9 745 549.4
M22x1.5 425 313.4 590 435.1
Follow ecological standards and regula-
tions when cleaning! M24 675 497.8 950 700.6
Clean the Machine at a workplace M24x2 540 398.2 760 560.5
equipped with cleaning agent intercept- M27 995 733.8 1400 1032.5
ing system to avoid contamination of soil M27x2 795 586.3 1120 826.0
and water resources!
M30 1350 995.7 1900 1401.3
Do NOT use forbidden cleaning agents!
M30x2 1080 796.5 1520 1121.0
The figures given in the Table are torques at dry thread (at coef-
ficient of friction = 0.14). The figures do not apply to lubricated
thread.
122 ARS 122

MAINTENANCE MANUAL
Table of torques for cap nuts with sealing O- ring – hoses
Torques for cap nuts with O-ring – hoses

Nm lb. ft.
Spanner
Thread Tube Nominal Min Max Nominal Min Max
size
14 12x1.5 6 20 15 25 15 11 18
17 14x1.5 8 38 30 45 28 22 33
8
19 16x1.5 45 38 52 33 28 38
10
10
22 18x1.5 51 43 58 38 32 43
12
24 20x1.5 12 58 50 65 43 37 48
14
27 22x1.5 74 60 88 55 44 65
15
30 24x1.5 16 74 60 88 55 44 65
32 26x1.5 18 105 85 125 77 63 92
20
36 30x2 135 115 155 100 85 114
22
41 25
36x2 166 140 192 122 103 142
46 28
50 42x2 30 240 210 270 177 155 199
45x2 35 290 255 325 214 188 240
50 38
52x2 330 280 380 243 207 280
42
ARS 122 123

Table of torques for nozzles (necks) with sealing edge, or Table of torques for plugs with gasket
with gasket
Nozzle torques Plug torques

G -M Nm lb. ft. G -M Nm lb. ft.
G 1/8 25 18 G 1/8 15 11
G 1/4 40 30 G 1/4 33 24
G 3/8 95 70 G 3/8 70 52
G 1/2 130 96 G 1/2 90 66
G 3/4 250 184 G 3/4 150 111
G1 400 295 G1 220 162
G 11/4 600 443 G 11/4 600 443
G 11/2 800 590 G 11/2 800 590
10 x 1 25 18 10 x 1 13 10
12 x 1.5 30 22 12 x 1.5 30 22
14 x 1.5 50 37 14 x 1.5 40 30
16 x 1.5 60 44 16 x 1.5 60 44
18 x 1.5 60 44 18 x 1.5 70 52
20 x 1.5 140 103 20 x 1.5 90 66
22 x 1.5 140 103 22 x 1.5 100 74
26 x1.5 220 162 26 x1.5 120 89
27 x 1.5 250 184 27 x 1.5 150 111
33 x 1.5 400 295 33 x 1.5 250 184
42 x 1.5 600 443 42 x 1.5 400 295
48 x 1.5 800 590 48 x 1.5 500 369
124 ARS 122

3.7. Defects
Normally, any defects are caused due to a wrong operation of the Machine. Consequently, read once
more the instructions given in Operation & Maintenance Manual for the Machine and the Engine when
any malfunction occurs. Unless you are able to define the cause of failure, please contact service depart-
ment or manufacturer.
Troubleshooting in the area of hydraulics and wiring requires knowledge in the field of hydraulics and
electrics. Therefore, please confide any repairs necessary to a service department of manufacturer.
ARS 122 125

3.8. Appendixes
3.8.1. Wiring Diagram
G1 Battery S3 Hazard
G3 Alternator S4 Work light
M1 Engine starter S5 Turn indicator
K2 Start relay S6 Horn button
Q1 Master switch S7 Neutral gear switch
K1 Starter relay S8 Fast travel switch
K3 Break relay S9 Vibration switch (In the travel controller)
K4 Vibration relay S10 Vibration switch (movement of travel controller)
K5 Travel Relay S11 Vibration change over switch
F 1-8 Safety fuses S12 Break pressure switch
E 1,2 Front headlights S13 Engine lubrication pressure switch
E3 No plate light S14 Air filter clogging switch
E 4,5 Rear head light S15 Hydraulic fluid filter clogging switch
E9 Left front direction light S16 Hydraulic fluid overheating switch
E10 Left rear direction light S17 Engine overheating switch
E11 Right rear direction light S18 Warning beacon switch
E12 Right front direction light S19 Backup alarm switch
E15 Warning Beacon S20 Emergency break pushbutton
A1 Flasher S21 Passing beam switch
H1 Horn S22 Mobile charger
H2 Switch vibration pilot lamp P1 Hour meter
H3 Break pilot lamp P2 Fuel gauge meter
H4 Engine lubrication pilot lamp X Connection connector
H5 Recharging pilot lamp B3 Fuel level sensor
H6 Air filter clogging pilot lamp Y1 Engine stop solenoid valve
H7 hydraulic filter clogging pilot lamp Y2 Break valve solenoid valve
H8 Engine overheating pilot lamp Y3 Fast travel speed solenoid valve – Left wheel
H9 Hydraulic fluid overheating pilot lamp Y4 Fast travel speed solenoid valve – Right wheel
H11 Back up alarm Y5 Fast travel speed solenoid valve – Drum
S1 Ignition switch Y6 Vibration 1 solenoid valve
S2 Headlight Y7 Vibration 2 solenoid valve
126 ARS 122

MAINTENANCE MANUAL
ARS 122 127

3.8. Appendixes
3.8.2. Hydraulic Diagram
1. Travel Pump
2. Vibration Pump
3. Steering Pump
4. Travel Motor
5. Vibration Motor
6. Steering Unit
7. Steering Cylinders
8. Flow divider
9. Block Brakes
10. Drum Drive Motor
11. Hydraulic Tank
12. Suction Strainer
13. Filler Breather
14. Return Block
15. ROC
16. Hydraulic Filter
17. Steering Wheel
18. Minimess Coupling
19. Platform Lifting Cylinder
20. Bonnet Lifting Cylinder
21. Needle Valve
22. Relief Valve
23. Hand Pump
128 ARS 122

MAINTENANCE MANUAL
ARS 122 129

3.8. Appendixes
Notes
130 ARS 122

MAINTENANCE MANUAL
Notes
ARS 122 131

Ammann Schweiz AG
Eisenbahnstrasse 25
CH-4901 Langenthal
Phone +41 62 916 61 61
www.ammann-group.com

ARS 122 Cummins BS III: Operating Manual

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ARS 122 Cummins BS III: Operating Manual

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Operating manual

Book ID: 4-P06286CU-EN

With kind regards,

This manual consists of:

These instructions must always be kept available on the equipment.

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

The notice warns of the necessity of environmental protection.

2.3. Ecological & Hygienic Principles..........................................................................................................31

2.4. Preservation & Storage.........................................................................................................................32

2.5. Machine disposal upon its life termination.........................................................................................33

2.9. Machine Transportation........................................................................................................................53

2.10. Special Conditions for the Machine Application.................................................................................62

3.2. Specification of fluids............................................................................................................................71

Every 20 Hours of Operation or Daily..................................................................................................80

Every 100 Hours ....................................................................................................................................89

Every 250 Hours or Once in 3 Months .................................................................................................90

Every 500 Hours or Once in 6 Months................................................................................................100

Every 1000 Hours or Once in Year.......................................................................................................107

Every 2000 Hours or Every 2 Years.....................................................................................................111

1 - Designation – always mentioned only in the English version

PIN label (1), S/N (2)

Serial number ESN of the CUMMINS engine

2820 1500 - 450 415 3030 2375 5460 25 2130 2260

ARS 122 Cummins BS III

ARS 122 Cummins BS III

Maximum torque Nm/rpm 410/1500

ARS 122 Cummins BS III

Before Machine Operation, please carry

• Only a driver trained under local and national regulations

8 Battery Disconnector In case of failure or following a work completion, please

10 Sling Positions Sling the Machine at these points. (Symbols placed on

11 Disconnect Alternator Before welding disconnect the battery terminals and

15 Clamp Hazard Risk area with clamp hazard.

Signals given by Machine Operator Assistant when Operator is

General command signals

Drive away with the Machine

Slow backward- drive - away from me

Driving on the right

Driving on the left

Engine shut down

Prior to restoration of the Machine ser-

Manufacturer bears no responsibility for

1 - Front Frame 11 - Engine

With the Controller turned ON the travel gear is engaged (“Rab-

NEVER switch ON the controller during oc-

Engine starting is possible in idle position

TOTAL STOP pushbutton (3)

Use only in case of emergency during a

Remove the key from the ignition box

Spare (7) Brake Alarm Indicator (14)

With this indicator lighted up the Machine broken is signalled.

Charging socket (8)

When the engine temperature reaches the highest allowable

When this indicator lights up the filter elements are fouled

Unless it goes off, look for the failure!

Indicator of hydraulic oil filter (18) Headlights Switch (23)

This indicator lighted up under hydraulic oil operating tem-

Replace the elements at once!

Alarm Horn Pushbutton (25)

Vibration ON Indicator (19)

It is forbidden to vibrator on the spot!

Turn Indicator Switch (22)

Indicator lamp on will signal traffic-indicator light are ON.