Ammann AP 240 Operating Manual
  1. Manuals
  2. Brands
  3. Ammann Manuals
  4. Utility Vehicle
  5. AP 240
  6. Operating manual

Ammann AP 240 Operating Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Operating manual
AP 240
Cummins
Book ID: 4-P06430CU
-EN

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AP 240 and is the answer not in the manual?

Questions and answers

Fernando cornejo Cruz
January 17, 2025

Buenas tardes ocupo refacciones para un Neumático Amman AP 240

0
1 comments:
Mr. Anderson
February 3, 2025

Replacement parts for an Ammann AP 240 tire can be found through Ammann dealers, who provide well-trained service technicians and parts. Additionally, you can find parts listed on platforms like eBay, as seen in the context.

This answer is automatically generated

0
John
May 5, 2025

How to replace a caliper

0

Related Manuals for Ammann AP 240

Summary of Contents for Ammann AP 240

  • Page 1 Operating manual AP 240 Cummins Book ID: 4-P06430CU...
  • Page 3 AP 240 Pneu tyred roller Cummins Tier 3 Operating manual Edition 01/2012 From Serial No. 4302395 Translation of Original Operating Manual...
  • Page 5 Místo a datum vydání / Place and date of issue / Ort und Datum der Ausgabe:...
  • Page 7 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.
  • Page 8 All dimensions and weights are approximate and, therefore, not binding. Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to inform the machine user. If you identify any differences between the machine operated by you and the information contained in this publication, contact your local dealer.
  • Page 9 The notice warns of the necessity of environmental protection. ! NOTICE ! As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indicate the sides of the machine moving forward. REAR RIGHT LEFT FRONT 37402en AP 240...

  • Page 10: Table Of Contents

    Content Content ................................4 SPECIFICATION MANUAL ........................9 1.1. Basic Data ..............................10 1.2. Dimensional machine drawing ......................12 1.3. Technical data ............................15 AP 240...
  • Page 11 Machine operation during its running-in period ............................80 2.9.3. Machine operation at low temperatures...............................80 2.9.4. Machine work under high temperatures and humidity ..........................81 2.9.5. Machine work in high altitudes ..................................81 2.9.6. Work of the machine in the dusty environment............................81 AP 240...
  • Page 12 3.6.17. Fuel filter replacement ...................................... 116 3.6.18. Engine cooling liquid check .................................... 118 3.6.19. How to replace CLARK gearbox oil filter ..............................119 3.6.20. Check oil for final drive and rear axle ................................120 3.6.21. Check of wiring ........................................120 AP 240...
  • Page 13 3.6.41. Cleaning the air cleaner of cabin ventilation ............................146 3.6.42. Clean the Machine ......................................147 3.6.43. Confirm bolt connections are tightened ..............................148 3.7. Defects ..............................151 3.8. Annexes ...............................152 Wiring Diagram ............................................ 152 Hydraulics Diagram..........................................156 Air Distribution ............................................. 158 AP 240...
  • Page 14 AP 240...

  • Page 15: Specification Manual

    SPECIFICATION MANUAL 1. SPECIFICATION MANUAL AP 240 (Cummins Tier 3) AP 240...

  • Page 16: Basic Data

    The standard type of the machine is not intended for road traf- ........................ fic. For more information, please contact your dealer. Please refer to the data in the table below always when ap- proaching the dealer or the manufacturer. AP 240...
  • Page 17 The machine that complies with the requirements as to health protection and safety is identified with a name plate with CE 3487 marking. AMMANN CZECH REPUBLIC a.s. 549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145 CZECH REPUBLIC 1 - Name – always mentioned only in the English version...

  • Page 18: Dimensional Machine Drawing

    1.2. Dimensional machine drawing 374002 3800 3110 2450 5020 5780 1986 2100 2310 (in) (149,6) (13,4) (10,2) (122,4) (96,5) (197,6) (227,6) (78,2) (82,7) (90,9) AP 240...
  • Page 19 SPECIFICATION MANUAL 374001 3800 3110 2450 5020 5780 1986 2100 2310 (in) (149,6) (13,4) (10,2) (122,4) (96,5) (197,6) (227,6) (78,2) (82,7) (90,9) AP 240...
  • Page 20 1.2. Dimensional machine drawing 374016 3800 3110 2450 5020 5780 1986 2100 2310 (in) (149,6) (13,4) (10,2) (122,4) (96,5) (197,6) (227,6) (78,2) (82,7) (90,9) AP 240...

  • Page 21: Technical Data

    50 (110) Weight of canopy posts (version without ROPS) kg (lb) 60 (130) Weight of wheel insulation kg (lb) 120 (260) Weight of Ammann cutter kg (lb) 150 (330) Driving characteristics Number of speeds Maximum transport speed km/h (MPH) 0-19 (0-11,8)
  • Page 22 6 (1,6) End gear oil l (gal US) 2x5,2 (2x1,4) Hydraulic system oil l (gal US) 22 (5,81) Front wheel hydraulic system oil l (gal US) 6 (1,6) Brake fluid l (gal US) 1,75 (0,46) Wiring Voltage Battery capacity AP 240...
  • Page 23 Towing hinge front Thermal aprons Edge cutter Ammann Traction System / Diff lock 4 + 4 tyres MITAS radial instead of standard ones 4 + 4 tyres Dunlop radial instead of standard ones 4 + 4 tyres Michelin radial instead of standard ones Spare part wheel with smooth diagonal tyre Ballast 2.800 kg - Concrete...
  • Page 24 Notes AP 240...
  • Page 25 SPECIFICATION MANUAL Notes AP 240...
  • Page 26 AP 240...

  • Page 27: Operation Manual

    OPErATION MANUAL 2. OPErATION MANUAL AP 240 (Cummins Tier 3) AP 240...
  • Page 28 AP 240...

  • Page 29: Main Safety Measures

    Precautions for the sake of natural disaster hazard Requirements to carry out work while adhering to work safety principles Technical and organizational measures to provide for sa- fety of employees, workplace and environment He/she must make Machine driver evidently familiar with the technological procedure! AP 240...

  • Page 30: Ensurance Of Safety Measures By The Owner

    He must ensure that dangerous substances (such as fuel, oils, coolant, break fluid, etc. must be removed from places of leakage according to their nature to prevent from their adverse impact to the environment, safety of operation and health of people. AP 240...

  • Page 31: Requirements For Qualification Of Driver

    (ma- chinist certificate, or others). • Machine driver shall be trained min. 1x every 2 years and examined in regulations to provide for occupational safety. AP 240...

  • Page 32: Duties Of The Driver

    Following a warning signal the operator may start the Ma- chine only when all the employees left a danger area. Con- cerning (blind) workplaces unable to overlook properly, put the Machine into operation only after the elapse of the time required to leave danger area. AP 240...

  • Page 33: Forbidden Activities

    To leave unsecured Machine - move away from the Machine without preventing it from being misused. • To disable safety system, protective system and locking sys- tem or change their parameters. • To use the Machine with oil, fuel, cooling liquid or other me- dia leaking therefrom. AP 240...

  • Page 34: Safety Inscriptions And Symbols Used On The Machine

    2.1. Main Safety Measures 2.1.5. Safety inscriptions and symbols used on the Machine 374040 AP 240...
  • Page 35 Cover electric devices when washing the Machine. (on dashboard) 2225bz Read the Manual Before you start the Machine, please, read thoroughly the safety measures and the way to control the Machine and its actuators, in the Manuals supplied with the Machine. (on dashboard) 2702bz AP 240...
  • Page 36 AUF DER PLATTFORM DES VERKEHRSMITTELS 2667bz Lifting Lugs Lift the Machine in these lugs. (symbol located near lifting lugs along both sides of the frame) 2153bz 3038 Noise Emitted External noise of the Machine. (symbol located on frame’s LH side) 3038bz AP 240...
  • Page 37 2939 2942bz 2775 Machine repair Do NOT start the engine! Hang the sign onto steering wheel. The sign is supplied together with machine acces- sories and should be kept in documentation locker. 2775bz AP 240...

  • Page 38: Hand Signals

    - bent and back. Sig. 3 SIgNALS FOr DrIVINg Drive away with the Machine One arm stretched upward - bent with open palm, long motion of antebrachium in the direction of the movement required, second arm akimbo. Sig. 4 AP 240...
  • Page 39 - short oscillating motions of antebrachium 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 AP 240...
  • Page 40 Sig. 9 Engine start Circular motion of antebrachium of right hand, with tight fist. Sig. 10 Engine cut off Oscillating motion of right hand sideways raised in front of the body, to the sides. Sig. 11 AP 240...

  • Page 41: Ecological And Hygienic Principles

    Especially hazardous is the potential of interchanging for eatables or drinks. • If skin, mucosa or eyes are stained accidentally, or vapours inhaled, promptly apply the first air principles. Get prompt medical attention upon accidental ingestion of these pro- ducts. AP 240...

  • Page 42: Machine Preservation And Storage

    Directions for Use along with ecological principles. Carry out dewaxing and washing of the Machine at places equipped with collec- tion sumps to catch rinsing water and dewaxing agents. AP 240...

  • Page 43: Dewaxing And Inspection Of A Supplied Machine

    Directions for Use along with ecological principles. Carry out dewaxing and washing of the Machine at places equipped with collec- tion sumps to catch rinsing water and dewaxing agents. AP 240...

  • Page 44: Machine Disposal Following Its Life Cycle End

    Specialized companies with relevant authorization to deal with these operations, • Machine Manufacturer or Manufacturer-appointed accredi- ted contracting service organization. Manufacturer bears no responsibility for any damage caused to Users’ health or for any damage to environment due to non-adherence to the aforementioned warning. AP 240...

  • Page 45: Machine Description

    2.5. Machine Description OPErATION MANUAL 374037 AP 240 Pneumatic roller- Machine’s individual parts 1 - Roller Frame 15 - Additional Water Weight Closure* 2 - Engine 16 - Fuel Tank 3 - Engine Radiator + Hydraulic Circuit Cooler + Gearbox 17 - Driver’s Control Stand...

  • Page 46: Controllers & Control Instruments

    2.6. Controllers & Control Instruments 374004 AP 240...
  • Page 47 * - With the standard version of the Machine the valve has been replaced with the end piece to connect hose incl. pressure gauge for manual tire inflation (part of the equipment). For others, please refer to Maintenance Manual. AP 240...
  • Page 48 2.6. Controllers & Control Instruments 3397 START START 3236 3236 START 374005 AP 240...
  • Page 49 120 °C range. Max temperature is 120 °C. defects or to adjust engine parameters. 2185 3003 Power view display (7) Trimmer (14) - downward, upward - optional Multifunctional instrument to display engine function and fuel reading. 2701 Direction-indicator lights (15) 595200 AP 240...
  • Page 50 11 (5A) - Indicator lamps (LEDs), measuring instruments, brake failure 12 (1A) - Diagnostics, Power View 13 (15A) - Wipers, washers 14 (10A) - Sprinkling 15 (25A) - Fans 16 (10A) - Trimmer 17 (-A) - Reserve 18 (-A) - Reserve AP 240...
  • Page 51 19 (125A) - Glowing 20 (125A) - Glowing 374013 Assembling lamp socket (17) It serves to connection of the auxiliary assembling lamp 12 V on the dashboard. 430022 Lock the bonnet (18) – by pressing the supports in marked-up direction. 374019 AP 240...
  • Page 52 Hydraulic oil filter fouled (26) - indicates filter element to replace. 2276 Idle (27) - indicates position of both controllers in ”N” idle (neutral). 596653 ! CAUTION ! When starting, please check both controllers are in idle position. AP 240...
  • Page 53 If the pilot lamp turns on during driving, stop the machine. Before driving the machine again, it is necessary to repair the failure. Tire sprinkling (33) - sprinkling pump turned 596128 Hydraulic oil overheated (31) - indicates max temperature admissible (reduce power, cool down). 2635 AP 240...
  • Page 54 ECM will adjust idle rpm automatically via air choke. Warning lights (36) 596191 Hazard beacon (37) - optional 592348 Parking brake (38) 2703 While stopping the machine at any time, the driver must apply the parking brake! AP 240...
  • Page 55 Do not handle the controllers when driving. ! CAUTION ! Close flap (48) to avoid any smell to penetrate into the cabin. Do not keep the flap closed for too long – fogging up of windows will occur. 374035 AP 240...
  • Page 56 Filter for internal air circulation. 374015 Note: “Air Conditioner Operation Manual” - supplied with air con- ditioner. ! CAUTION ! We recommend to start Air Conditioner 1x every 3 weeks. Venting (50) - increases efficiency of cabin fans. 374N030 AP 240...
  • Page 57 Document compartment (52) A document compartment is located on the rear side of the seat back. 2428 374007 Under both seats are locked box. 374028 Air reservoir valve control (53) - to release air (condensate) from air reservoir 374N026 AP 240...
  • Page 58 Battery cut off switch (56) 3351 30 sec 3351 30 sec 3351 Turn OFF the master switch after 30 sec following the switch box key turned OFF to maintain the data in the engine con- trol module - ECM. 374012А AP 240...

  • Page 59: Power View Display Control

    Engine Operation Manual supplied with the machine. NAVIgATION BASIS ADJUST BACKLIGHT Menus have pages with other items. Use CURSOR (ARROWS) to ADJUST CONTRAST select some of the items highlighted. UTILITIES Operate pushbuttons with light touch. 396030 AP 240...
  • Page 60 Four-parameter display will show. Press MENU button to display main menu. Note 28°C 0 RPM COOL TEMP ENG RPM Four-parameter display is basic setting from the machine manu- facturer; turn ON ignition box key to display it. ENG HRS FUEL LEVEL 396322 AP 240...
  • Page 61 Use cursor in main menu to move to next item, i.e. LANGUAGES – to select language. GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONF SETUP 1 - UP DISPLAY SETUP 4 - UP DISPLAY SELECT UNITS 396015 AP 240...
  • Page 62 ENGLISH ESPAÑOL FRANÇAIS DEUTSCH 396016 Another time, use cursor to select language. ENGLISH ESPAÑOL FRANÇAIS DEUTSCH 396047 Press ENTER to confirm. ENGLISH ESPAÑOL FRANÇAIS DEUTSCH 396048 Press MENU to return to the menu. ENGLISH ESPAÑOL FRANÇAIS DEUTSCH 396022 AP 240...
  • Page 63 Continue with ENTER to display stored failures. 1 of x SPN110FMI10 HIGH COOLANT TEMP HIDE MORE 396019 When the word MORE occurs use cursor to move to other stored failures. 1 of x SPN110FMI10 HIGH COOLANT TEMP HIDE MORE 396020 AP 240...
  • Page 64 In main menu, with cursor to SELECT UNITS - selection of meas- urement unit for parameters displayed. GO TO 1 - UP DISPLAY LANGUAGES STORED CODES ENGINE CONF SETUP 1 - UP DISPLAY SETUP 4 - UP DISPLAY SELECT UNITS 396023 AP 240...
  • Page 65 Press MENU 3 to return to main menu. 396025 In main menu, move cursor to ADJUST BACKLIGHT - to adjust intensity of display backlight. ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES 396026 Press ENTER to open the item ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES 396027 AP 240...
  • Page 66 Press MENU to return to main menu ADJUST BACKLIGHT 396029 In main menu, move cursor to ADJUST CONTRAST - to adjust contrast. ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES 396030 Press ENTER to open the item ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES 396031 AP 240...
  • Page 67 NOT operate the machine unless the de- fect has been repaired! 396034 Engine failure registered from engine ECU (Electronic Actuator Unit) will be displayed via error code for a failure and description on the display. WARNING SPN110FMI10 HIGH COOLANT TEMP HIDE 396035 AP 240...
  • Page 68 FUEL LEVEL code are indicated on instrument board display, contact the regional representative of Cummins en- gines, unless the failure is possible to repair. Contact data are given in the Engine Operation Manual sup- plied with the machine. 396313B AP 240...
  • Page 69 Press ENTER to acknowledge and hide the display. SHUTDOWN 1 of x SPN110FMI10 HIGH COOLANT TEMP MORE HIDE 396042 Return to display 1 of parameter display with “SHUT DOWN“ warning icon in RH corner. 1100 2200 2000 RPM COOL TEMP ENG RPM ENG RPM 396043 AP 240...
  • Page 70 ! CAUTION ! When failure outline and failure code are indicated on instrument board display, contact the regional 396313C representative of Cummins engines, whose contact data are given in the Engine Operation Manual sup- plied with the machine. AP 240...
  • Page 71 Display is not readable, either very dim or The LCD contrast may have been over or under adjusted. Press and hold very dark the MENU key for approximately 5 seconds. This will reset the LCD contrast setting to factory default. AP 240...

  • Page 72: Machine Control And Usage

    2.7. Machine Control and Usage 3397 START START 3236 3236 START 374020 3351 3351 30 sec 30 sec 374014 AP 240...

  • Page 73: Engine Starting

    ! CAUTION ! Starting will be interlocked if: TOTAL STOP pushbutton is switched ON. roller is not braked via parking brake. Both travel controllers are not in idle position. Hydraulic oil level LED is ON. AP 240...
  • Page 74 2. Connect second cable end to +pole of charged battery. 3. Connect cable to - pole of charged battery. 4. Connect second cable end to such part of started Ma- chine that is hard-wired with engine Disconnect cables in reverse order. 374116 AP 240...

  • Page 75: Travel & Reversation

    2nd and 3rd gear engaged on a slope that has gradient over 15 %. NEVEr change steering place - shifting from LH seat to rH one and vice versa while driving. Stop the roller, brake it a then change the seat! AP 240...
  • Page 76 When you select direction of running via controller, and after braking off the Machine will start to move slowly even with the engine idling. While driving, keep the engine at rather high rpm to achieve better controllability of steering the Machine. AP 240...

  • Page 77: Emergency Stop Of The Machine

    ON parking brake. Turn ignition key to “0“ positi- on and then start the engine. 3397 ! CAUTION ! START START 3236 3236 During normal operation, do NOT use emergency START brake to stop the Machine or to shut off the engine. 374023A AP 240...

  • Page 78: How To Stop The Machine And The Engine

    Observe time limit of 30 sec. before disconnecting the battery following ig- nition box switched OFF so to maintain Machine operation data in ECM of the engine. NEVEr park your roller on a slope with gradient of over 15 %! AP 240...

  • Page 79: Machine Parking

    15 %!. Dead park the Machine on pavement area in place with no potential of natural hazard (landslide, potential flooding, etc.). ! CAUTION ! Fill up fuel in the filter following a rather long shut- down of the roller. 374029 AP 240...

  • Page 80: Watering And Scrapers

    When compacting fresh-laid asphalt coat, please turn ON the sprinkling and set adequate sprinkling interval. Use ap- propriate separation emulsion. Lift the scrapers during normal compac- tion work on soil and when driving. 374026 • Lower the front scrapers (1) and rear scrapers (2). 374027 AP 240...

  • Page 81: Edge Cutter

    1 - Name – always mentioned only in the English version 2 - Type 3 - Serial number 4 - Maximum weight 3459 TYPE 5 - Year of manufacture AMMANN CZECH REPUBLIC a.s. SERIAL NUMBER Náchodská 145 549 01 NOVÉ MÌSTO NAD METUJÍ CZECH REPUBLIC MAXIMUM MASS DESIGNATION...

  • Page 82: How To Transport The Machine

    The machine on the vehicle must be properly tied and mechanically secured against longitudinal and lateral dis- placement as well as against tipping (1). 374117 The drums must be secured using scotch blocks (2). AP 240...

  • Page 83: Machine Loading

    Use only the designed lifting lugs in- tended to tie the ropes. Binding may only be performed by a binder with a binding certificate. Use lifting equipment and rigging of suf- ficient loading capacity. Do NOT enter under the hung load! AP 240...

  • Page 84: Machine Work Under Heavy Conditions

    Unless the brake circuit has pressure over 5,2 bars and unless the engine is working to make up the pressure, you must use a fixture (optional) to brake off the Roller for towing. 374110 • Dismantle floor covers between the seats. 374N058A • Dismantle the bolting. 374042 AP 240...
  • Page 85 ! CAUTION ! These are general requirements for safe hauling of damaged Machine under normal conditions. Consult with your dealer any and all different situ- ation that may occur when towing. AP 240...

  • Page 86: Machine Operation During Its Running-In Period

    (140 °F). The maximum temperature is 100 °C (212 °F). ! CAUTION ! When using the HV 100 oil in the hydraulic system, the machine must not be started at ambient tempe- ratures below +2 °C (36 °F). AP 240...

  • Page 87: Machine Work Under High Temperatures And Humidity

    • When working in a very dusty environment, please cut short the intervals for replacement of suction filter elements, cut short the interval for cleaning the coolers, for replacement of cabin’s dust filter, refer to Machine Maintenance Table. AP 240...
  • Page 88 Notes AP 240...
  • Page 89 OPErATION MANUAL Notes AP 240...
  • Page 90 AP 240...

  • Page 91: Maintenance Manual

    MAINTENANCE MANUAL 3. MAINTENANCE MANUAL AP 240 (Cummins Tier 3) AP 240...
  • Page 92 AP 240...

  • Page 93: Safety Standards And Other Maintenance Regulations

    • with the operation media heated – beware of burns – use recommended media, only. Upon completion of the adjustment or maintenance, please examine the func- tion of all safeguard equipment! AP 240...

  • Page 94: Ecological And Hygienic Standards

    In such case find the emergency first aid. • When working with the machine unequipped with the cab, or with opened windows and cab door, always use the ears protections of convenient kind and design. AP 240...

  • Page 95: Media Specification

    SAE 10W-30 oil. 282N224T Exceeding upper temperature limit must not last too long due to lowered lubricat- ing capability of oil. When using oil under API CF-4/SH you must halve exchange interval, i.e. 125 hours or 6 weeks. AP 240...

  • Page 96: Fuel

    3 months. Further, it is necessary to drain off the fuel tank, clean it, and either fill it with diesel fuel or minimise the occurrence of moisture and limit the microbiological growth inside the tank. Consult the measures with the fuel supplier. AP 240...

  • Page 97: Cooling Liquid

    Check the portion of antifreeze coolant in cooling liquid always before winter period, using refractometer (density meter). Health hazardous nitroamines occur when mixing nitride-based antifreeze coolant with amine-based agent. AP 240...

  • Page 98: Oil - Epicyclic Transmission Incl. Torque Converter

    Use SAE 80W-90H API GL 5 or MIL-L-2105 B/C / LS oils to lubri- at the ratio as per the Machine lubricating conditions – in CR it cate down gearings. is Glacidet K. When hazard of temperature drop below 0 °C (32 °F) exists then add antifreeze agent or drain water! AP 240...

  • Page 99: Media

    Lubrication according to Lubrication Chart Plastic lubricant as er Section 3.2.8. If required 0787 Sprayer Medium as per Section 3.2.9. 2,5 (0,66) 2260 Water tank for tyre sprinkling Water 460 (122) 596128 Battery Distilled water If required 2587 AP 240...

  • Page 100: Lubrication And Maintenance Chart

    After 500 hours of operation (6 months) 3.6.17. Fuel filter replacement 3.6.18. Engine cooling liquid level check 3.6.19. How to replace CLARK gearbox oil filter ** 3.6.20. Check oil for final drive and rear axle 3.6.21. Check of wiring AP 240...
  • Page 101 First after 50 hours - Make single check to confirm wheel nuts are tightened to 400 Nm (295 lb ft) torque * First after 50 hours ** First after 100 hours *** First after 250 hours AP 240 AP 240...

  • Page 102: Lubrication Chart

    INSPECTION GREASING EXCHANGE 2000 1000 SAE 15W/40, API CI-4, CH-4 Engine oil Fluid for automatic transmission see chapter 3.2.5. SAE 80W-90H API GL-5 Gear oil ISO VG 68 ISO 6743/HV Hydraulic oil Grease ISO 6743/9 CCEB 2 374105en AP 240...

  • Page 103: Lubrication And Maintenance Operations

    3.6.19. How to replace CLARK gearbox oil filter Following the first 250 hours of operation of the new Machine (following a major overhaul) carry out as per: 3.6.26. How to replace final drive oil 3.6.29. How to exchange oil in rear axle AP 240...

  • Page 104: After 20 Hours Of Operation (Daily)

    Oil level between the marks on dipstick corresponds to 1,5 l (1.6 US Quart) amount. ! CAUTION ! refill oil of identical type, use oils as stated in Section. 3.6.1. Do NOT run the engine unless there is correct oil level in the engine. AP 240...

  • Page 105: Engine Cooling Liquid Level Check

    Do NOT use any additives in the engine cooling liq- uid to eliminate cooling system leakage! Do NOT refill cold coolant into hot engine! Danger of engine castings damaged. 3.6.3. Crankcase breather tube • Check the outlet is not clogged with deposits. 374072 AP 240...

  • Page 106: Check Of The Fan And Engine Belt Condition

    Inspect visually the belt. If longitudinal cracks, or smooth, bright flats occur on the belt, or belt edges are shattered, or there are extracted parts of material, then the belt must be adjusted or replaced, refer to Section called “Belt tension after 1000 hours”. 347048 374048 AP 240...

  • Page 107: Check Air Filter Vacuum Valve

    STOP (engine stops). STOP ! CAUTION ! Engine can be started only after oil is filled up. Fill up with the same type of oil via filling device, refer to Section called “Oil Exchange“. 374092A 374051 AP 240...

  • Page 108: Check Brake Fuel

    When it is to be used, please follow instructions of brake fluid producer. Brake fluid will cause damage to painted parts of the Machine. When filling up, avoid and fluid spilled over the Machine or outside the Machine. AP 240...

  • Page 109: Fill Up Sprinkling Tank

    Unscrew and pull out dipstick, wipe off and push in again. Pull it out once more and check oil level – it must reach the upper gauge line. • Fill up oil using this neck and screw the oil level gauge back. 374055 AP 240...

  • Page 110: Check Alarm And Control Instruments

    Operating Manual. When turning off the parking brake switch, make sure that the brake pilot lamp turns off. When driving off, make sure that the respective pilot lamp of the activated place turns on and whether the neutral pilot lamp turns off. 374059 AP 240...
  • Page 111 374060 When in operation, check continuously the instruments and pilot lamps. Use acoustic alarm to warn engine will start, confirm there is no hazard for any- body when engine starts. AP 240...

  • Page 112: After 100 Hours Of Operation (Weekly)

    1300 1500 2000 2500 3000 3,18 3,39 3,77 4,13 4,36 3,38 3,61 4,04 4,39 4,67 3,63 3,85 4,31 4,66 5,00 Tyre inflation (bar) 3,89 4,12 4,61 4,93 5,36 4,18 4,35 4,71 5,04 5,55 4,45 4,57 5,01 5,40 5,86 AP 240...

  • Page 113: After 250 Hours Of Operation (3 Months)

    Remove drain plug and let oil flow out into a vessel of ca 9 l (9,5 qt) capacity. Reinstall drain plug. Apply 80 Nm (59 lb ft) torque to tighten. 374062A 374062 • Clean oil filter and its vicinity. Remove filter. 374063 • Apply oil slightly across filter gasket. 396247 AP 240...
  • Page 114 Exchange oil within interval that occurs as first. Use recommended filters, refer to Catalogue of Spare Parts. Use oil as per Section 3.2.1. Drain oil into catch vessels. Spent oil and filter are ecological waste – hand over for disposal. AP 240...

  • Page 115: Check The Engine Induction Manifold And Air Filter Sensor

    Check pipe hoses and fixing of clips. 374081A 374098 374065 • Check air filter cuff. Cover suction hole. 374066 • Start the engine, turn off IDLE switch, increase engine speed to max, check if pilot lamp lights up. 374067 AP 240...
  • Page 116 3.6. Lubrication and Maintenance Operations • Unless it lights up, check vacuum switch (1), pilot lamp on dashboard, wiring. 374066A Do NOT operate the Machine if induction manifold, air filter cuff are damaged! AP 240...

  • Page 117: Battery Check

    Compare density meter-measured values with the Table. Density in g/cm in °Be (Beume) 20 °C 20 °C Tropics Tropics 68 °F 68 °F Well recharged 1,28 1,23 32° 27° Half recharging 1,12 24° 16° Discharged, please 1,12 1,08 16° 11° recharge AP 240...
  • Page 118 To disconnect storage battery you must first discon- nect (–) pole of the cable. To connect, first connect (+) pole. NEVEr attempt to make direct conductive connection between storage battery’s both poles, short circuit will occur with the risk of storage bat- tery explosion. AP 240...

  • Page 119: Machine Lubrication

    (3) into another hole of pull rod (4). Be careful grease does not get onto ac- tive surface of brake disc! 374041A 374041B Shaft joints 374076 External bearings of front wheels 374072B AP 240...
  • Page 120 Lubrication and Maintenance Operations Internal bearings of front wheels 374075 In order to grease the inner and outer bearings of front axle wheels thoroughly, the lubricating grease must be pressed out around the flange. 430023 Steering pins 374073 Bonnet hinges 374077 AP 240...
  • Page 121 MAINTENANCE MANUAL Door hinges 374078 Cover suspensions. 374108 Edge cutter pins. 374109 AP 240...

  • Page 122: After 500 Hours Of Operation (6 Months)

    After 500 hours of operation (6 months) 3.6.17. Fuel filter replacement • Clean and remove filter. 374079 • Clean seating face for filter. 396249 • Apply oil on sealing ring. 396247 • Fill filter with clean fuel. 396248 AP 240...
  • Page 123 Do NOT tighten filters using force, the thread and gasket may get damaged. NEVEr smoke when at work, replace in well-ventilated rooms with no fire hazard. Collect fuel flowing out! Store spent filters in separate containers and hand them over for their disposal. AP 240...

  • Page 124: Engine Cooling Liquid Check

    Inspect cooling liquid concentration with the refractometer using cold engine. Check always before winter season. Unless concentration for ambient tem- peratures of -36 °C (-33 °F) is found, ad- just it or exchange cooling liquid accord- ing to Section 3.2.3. 374081B AP 240...

  • Page 125: How To Replace Clark Gearbox Oil Filter

    Machine of after Major Overhaul! Use only CLArK filters recommended. Do NOT tighten with force, danger of threads and gasket damaged. Let gearbox cool down below 50 °C be- fore replacing. Spent filter is ecologically hazardous waste, hand over for disposal. AP 240...

  • Page 126: Check Oil For Final Drive And Rear Axle

    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. AP 240...

  • Page 127: After 1000 Hours Of Operation (1 Year)

    M12-60 of min. 8G strength, into holes (1) of brake drum (2). Confirm there are no scratches or cracks across drum’s internal diameter. 374N121 • Check thickness, uneven wear or contamination of lining (1). 374N122 AP 240...
  • Page 128 Before installing wheels onto the brake drums following the brake repair, please point the brake drum bolts against holes in the wheels using an appropriate lever so to avoid damage of bolt threads, reinstall wheels, tighten wheel nuts with 400 Nm (295 lb ft) torque. AP 240...

  • Page 129: Hydraulic Accumulator

    Let filling pressure of 120 bar (on nameplate) be checked and made up by authorized service department.. Call your dealer if required. 374076A When operating the roller at the tem- peratures constantly over 50 °C lower the checking interval to ½ the year. AP 240...

  • Page 130: Checking The Engine Belt

    Fig. Tighten bolt (1) with 66 Nm (49 lb ft) torque, tighten bolt (2) with 31 Nm (23 lb ft) torque. Replace belt following its slackening, by tilting the alternator back to the engine. 374048A 347048 AP 240...

  • Page 131: How To Exchange Clark Gearbox Oil

    ADD mark. With oil warmed up to 82÷93 °C, please check and fill up to FULL if required. 374055 Observe fire precautions! Use recommended oils according to Section 3.2.5. Drain oil into collection vessels. Spent oil is ecological waste – hand over for disposal. AP 240...

  • Page 132: How To Replace Final Drive Oil

    Major Overhaul. Beware of burn hazard when draining hot oil. • Drain sprinkling tank, refer to Section called “How to clean sprinkling filter”. Remove the tank. 374083 374083 • Remove filler plug (1) and inspection plug (2). 374084A AP 240...
  • Page 133 (2) with 80÷90 Nm (59÷66 lb ft) torque. Tighten filler plug (1) with 70÷80 Nm (52÷59 lb ft) torque. 374084A Observe fire precautions! Use recommended oils according to Section 3.2.6. Drain oil into collection vessels. Spent oil is ecological waste – hand over for disposal. AP 240...

  • Page 134: How To Replace Air Drier

    – with 15 Nm (11 lb ft) torque. 374091 If you find any traces of oil on drying cartridge, please inspect compressor’s delivery piping, refer to Section called “Delivery Piping of Compressor”. Spent drying cartridge is ecological waste – hand over for disposal. AP 240...

  • Page 135: After 2,000 Hours Of Operation (After 2 Years)

    Section 3.2.6., close with plugs. Oil may flow out slightly from holes (2). 374085A Observe fire precautions! Use recommended oils only, as per Section. 3.2.6. Drain oil into collection vessel of 6 l (1.6 gal US) capacity. Spent oil is ecological waste – hand over for disposal. AP 240...

  • Page 136: How To Exchange Hydraulic Oil And Filter

    Open the cover and drain 22 l (5,81 US gal) of oil via the valve. When drained, close the valve. 374051A • Remove the cover. 374093 • Disconnect sensor for filter (1) clogged, remove filter cover (2). 374094 AP 240...
  • Page 137 Use new gasket under the cover (6), refer to Spare Parts Catalogue. 374095 • Check temperature sensor – remove the sensor. Put in liquid heated to 88 °C (190 °F) temperature and check whether pi- lot lamp for oil overheating will light up. 374097 AP 240...
  • Page 138 Note: Order the filling equipment with the Machine manufacturer or dealer. 374065A • Fill oil up to max level. 374051B Use alternative way of filling or refill- ing via filler neck on the tank only in emergency! 374094B AP 240...
  • Page 139 Check tightness. Blind all holes with plugs when hydraulic circuits are disconnected. Collect drained oil and do not let it soak into ground. Spent oil and filters are ecologically haz- ardous waste – hand it over for disposal. AP 240...

  • Page 140: How To Exchange Oil In Hydraulic Cylinders For Front Axle

    The amount of oil medium is 6 l (1,6 gal US). 37459 Observe fire precautions! Use recommended oil as per Section 3.2.4. Spent oil is ecological waste – hand over for disposal. AP 240...

  • Page 141: How To Exchange Brake Fluid

    It is possible to always handle the wheel couple simultaneously. Second person is to depress brake pedal repeatedly to force out fluid step by step from all brake cylinders into the vessel. Tighten deaeration screw. 374N140 AP 240...
  • Page 142 Brake fluid will damage painted parts of the Machine. Use recommended brake fluid under Section 3.2.3. When filling up, avoid fluid spilled over the Machine and off the Machine as well. Collect brake fluid in the vessel and hand it over for disposal! AP 240...

  • Page 143: Exchanging The Engine Cooling Liquid

    Check no hose pipes are damaged within engine’s cooling system and no hose clips are missing. Inspect condition of radiator whether it is not damaged, leaking, or whether ra- diator’s plates are not clogged with dirt. Clean and repair it if required. AP 240...
  • Page 144 374081 out followed by scald hazard. Follow anti-freeze producer’s instruc- tions when exchanging anti-freeze! Use anti-freeze according to Section 3.2.3.! Drain liquid into collection vessel! Hand over spent liquid for safe disposal in line with regulations! AP 240...

  • Page 145: Check The Compressor

    Following first 50 hours, please tighten the bolts for compres- sor head in such sequence as per the Fig. using 30÷33 Nm (22÷24.5 lb ft) torque. Perform this on the cold engine after the machine has been stopped. 374043 AP 240...

  • Page 146: Maintenance If Required

    Collect drained fuel incl. sediment into a proper vessel. ! CAUTION ! If you drained more than 60 cm (0,63 quarts) of fuel, please fill up fuel in fuel filter according to the next Section called “Deaeration”. AP 240...

  • Page 147: How To Deaerate Fuel Filter

    (2) until it flow out clean, with no air bub- bles, tighten the screw. 374080B • Deaerate second filter via air relief screw. 374079A Do NOT deaerate while engine is hot, leaking fuel may cause fire. Do NOT smoke! Collect leaking fuel! AP 240...

  • Page 148: How To Replace Air Filter Elements

    Remove safety element and check for any damage – do NOT clean it. Clean inner space of the filter and the contact faces so to avoid any dust penetrating into the supply piping that leads to the engine. Put back safety element and new main element. 374102 AP 240...
  • Page 149 Use original elements, only. When washing the Machine be careful not to splash water into air filter. replace instantly vacuum valve damaged! Do NOT operate Machine with filter body damaged or filter cover damaged. AP 240...

  • Page 150: Cleaning Of Coolers

    Find out the cause of contamination! When cleaning, please proceed according to ecological standards and regulations! Perform cleaning workplaces equipped with cleaning agent collection system to avoid any contamination of soil and water resources! NEVEr use banned cleaning agents! AP 240...

  • Page 151: Clean Sprinkling Filter

    Drain tank (1). Drain sprinkling pipes at the front and back by slackening the nozzles (2). 374104 3.6.40. Clean brush scrapers • Check condition of front brushes (1), rear brushes (2) – clean them and repair them. 374027A AP 240...

  • Page 152: Cleaning The Air Cleaner Of Cabin Ventilation

    Remove cover. Replace filtration element (filtration of sucked air from inside the cabin), beat it out carefully and blow it out. Note: Clean it (beat out, blow out) 1x per half a year. Replace element after 2 cleaning processes. 374015 AP 240...

  • Page 153: Clean The Machine

    When cleaning, please proceed according to ecological standards and regulations. Perform cleaning workplaces equipped with cleaning agent collection system to avoid any contamination of soil and water resources. Do NOT use forbidden cleaning agents. AP 240...

  • Page 154: Confirm Bolt Connections Are Tightened

    Chart for torques of cap nuts with “O” sealing ring - hoses Torques of cap nuts with “O“ ring - hoses lb ft Spanner Thread Pipe Nominal Nominal size 12x1,5 14x1,5 16x1,5 18x1,5 20x1,5 22x1,5 24x1,5 26x1,5 30x2 36x2 42x2 45x2 52x2 AP 240...
  • Page 155 20 x 1,5 22 x 1,5 22 x 1,5 26 x1,5 26 x1,5 27 x 1,5 27 x 1,5 33 x 1,5 33 x 1,5 42 x 1,5 42 x 1,5 48 x 1,5 48 x 1,5 282N222T 282N221T AP 240...
  • Page 156 AP 240...

  • Page 157: Defects

    If you cannot identify the cause, contact a service department of an authorised dealer or the manufacturer. Troubleshooting in hydraulic and electric systems requires knowledge of these systems; therefore a service department of an authorised dealer or the manufacturer should be called to solve these problems. AP 240...

  • Page 158: Annexes

    Y7 Electromagnetic clutch for air conditioner compressor M5 Rear windscreen sprayer (optional) M6 Sprinkling pump motor Y8 Electromagnet for valve, edge cutter, upward (optional) M7-9 Cooling air blowers Y9 Electromagnet for valve, edge cutter, downward (optional) P1 Gearbox thermometer P2 Gearbox lubrication pressure gauge AP 240...
  • Page 159 Forward travel solenoid X5:9 Backward travel solenoid X18:2 X18:1 X5:10 Backing horn Backing lights Hydraulic liquid X6:1 7,5A X4:1 X6:2 Solenoid brake Y6.1 X6:3 Di erential lock Solenoid Y6.2 Di erential lock switch X25:1 X6:4 X25:2 E D C 107672_1en AP 240...
  • Page 160 Y7 Electromagnetic clutch for air conditioner compressor M5 Rear windscreen sprayer (optional) M6 Sprinkling pump motor Y8 Electromagnet for valve, edge cutter, upward (optional) M7-9 Cooling air blowers Y9 Electromagnet for valve, edge cutter, downward (optional) P1 Gearbox thermometer P2 Gearbox lubrication pressure gauge AP 240...
  • Page 161 Rear window washer X12:1 X7:2 X12:2 X7:3 Sprinkling X14:1 X6:10 X14:2 X13:1 X14:4 Fans X14:3t X13:2 X6:11 X7:4 Edge cutter - up X7:5 Edge cutter - down Reserve Reserve X113:1 X113:2 X113:3 Aircondition compressor clutch X113:4 X4:11 X5:11 107672_2en AP 240...

  • Page 162: Hydraulics Diagram

    15 Suction strainer 16 Filter + element 17 Sensor for filter clogged 18 Bleeder valve 19 Level gauge 20 Oil gauge 21 Temperature switch 85±3 °C 22 Fast coupling filling-type 23 Fast coupling measuring-type 24 Fast coupling measuring-type AP 240...
  • Page 163 MAINTENANCE MANUAL 211337_en AP 240...

  • Page 164: Air Distribution

    22 Tyre pressure gauge 23 Rotary-type supply 24 Safety valve Option: Tyre Inflation Via Hose 25 Air gun 26 Fast coupling measuring-type Option: Differential lock control 27 Pneumatic distributor 28 Hydraulic cylinder Option: Hand brake 29 Hand-operated valve AP 240...
  • Page 165 MAINTENANCE MANUAL 211548_en AP 240...
  • Page 166 3.8. Annexes Notes AP 240...
  • Page 167 MAINTENANCE MANUAL Notes AP 240...
  • Page 168 3.8. Annexes Notes AP 240...
  • Page 170 Ammann Unternehmungen Eisenbahnstrasse 25 CH-4901 Langenthal Phone +41 62 916 61 61 www.ammann-group.com...

Table of Contents

Save PDF