The electrical starting issues with the Ammann ARR 1575 roller could include:

1. Oil in the Combustion Area – If oil is present in the combustion area, the engine should not be started. The engine must be rotated with the starter to push the oil out through the glow plug holes.
2. Glow Plug Issues – Glow plugs should be properly reinstalled and connected with the correct tightening torque (18 Nm for glow plugs, 1.5 Nm for connections).
3. Fuse Issues – The F21 fuse should be reinstalled after checking all fluid levels and refilling if necessary.
4. Ignition Key Operation – The ignition key must be turned to the III position. If the engine does not rotate, the procedure for removing oil from the combustion area should be repeated.
5. Dealer Assistance – If the engine still does not start after following the steps, contacting an authorized dealer is recommended.

These steps help diagnose and resolve potential electrical starting problems.

This answer is automatically generated

Summary of Contents for Ammann ARR 1575

Page 1 ARR 1575 TRENCH ROLLER YANMAR 3TNV80F-SPAMM U.S. EPA Tier 4f WORKSHOP MANUAL EDITION 04/2019 EN From Serial No. 5572567...
Page 3 All dimensions and weights are approximate, and therefore not binding. Ammann Czech Republic a.s. reserves the right to perform modifications at any time with no obligation to inform the machine user. If you identify any differences between the machine operated by you and the infor- mation contained in this publication, contact your local dealer.
Page 4 ARR 1575...
Page 5: Table Of Contents
Contents WORKSHOP MANUAL CONTENTS ��3 INTRODUCTION ��9 SAFETY MEASURES AND INSTRUCTIONS ��13 Safety rules ..........................................14 Environmental and hygiene principles ................................17 Fire prevention ........................................18 Claim conditions and disclaimer of liability ..............................18 MACHINE DESCRIPTION ��19 Machine description ......................................20 Dimensional drawing of the machine ................................22 Technical data .........................................23 SPECIFICATION OF OPERATING FLUIDS ��25 Engine oil ..........................................26...
Page 6: Contents
Contents Hydraulic tank .........................................83 5.6.1 Checking the hydraulic oil level ..................................83 5.6.2 Hydraulic oil replenishment .....................................83 5.6.3 Hydraulic oil draining ......................................84 5.6.4 Hydraulic oil filter replacement ..................................85 5.6.6 Ventilation filter replacement ..................................86 5.6.7 Hydraulic tank filling ......................................86 5.6.8 Filling the travel pump, increasing the supply pressure ........................87 CAB AND PLATFORM ��91 Control and indication elements..................................93 6.1.1...
Page 7 WORKSHOP MANUAL FRONT AXLE (NOT INCLUDED IN THE MACHINE EQUIPMENT) ��197 REAR AXLE (NOT INCLUDED IN THE MACHINE EQUIPMENT) ��199 TRAVEL ��201 11.2 Hydraulic parts ........................................203 11.2.1 Replacement of the travel pump ................................203 11.2.2 Replacement of the valve block .................................. 218 11.2.3 Brake test..........................................
Page 8 Contents OPTIONAL EQUIPMENT ��265 16.1 List of optional equipment ....................................266 16.2 Safety bar ..........................................267 16.2.1 Safety bar replacement ....................................267 16.2.2 Sensor replacement and adjustment ................................ 274 GENERAL PROCEDURES ��279 17.2 Electrical installation ......................................280 17.2.2 Preparation for welding work ..................................280 17.2.3 Starting the battery by means of another battery (jumping) ......................
Page 9 WORKSHOP MANUAL APPENDICES ��327 19.1 Hydraulic system ......................................... 329 19.1.1 Adjustment of the travel pump zero position ............................329 19.1.1.1 Checking the travel pump magnetic coil / travel pump servo block .................... 329 19.2 Wiring diagram ........................................330 19.4 Hydraulic system diagram ....................................332 19.6 Workshop jigs ........................................
Page 10 ARR 1575...
Page 11: Introduction
WORKSHOP MANUAL 1 Introduction ARR 1575...
Page 12 Labelling of machine subassemblies in this manual corresponds to the spare parts catalogue. In order to ensure smooth operation of the AMMANN compaction equipment, use only original spare parts supplied by AMMANN for repairs� Before disassembly, it is recommended to always mark the removed parts for their reassembly and blank off all holes of individual parts of the hydraulic system in order to prevent contamination of the hydraulic circuits.
Page 13 WORKSHOP MANUAL SAFETY NOTICES AND SIGNS: The notice warns of a serious risk of personal injury or other personal hazards� The notice warns of possible damage to the machine or its parts� The notice warns of the necessity of environmental protection� ! CAUTION! As used in this operating manual, the terms right, left, front and rear indicate sides of the machine moving for- ward�...
Page 14 ARR 1575...
Page 15: Safety Measures And Instructions
WORKSHOP MANUAL 2 Safety measures and instructions ARR 1575...
Page 16: Safety Rules
Safety measures and instructions 2�1 Safety rules These safety rules must be followed by all persons involved in machine repairs! • Repairs of this machine may be carried out only by qualified, professionally trained and experienced workers or by the service personnel of our dealers.
Page 17 WORKSHOP MANUAL Safety measures for work on hydraulic circuits • Before disassembly, make sure the hydraulic circuits are depressurized. Hydraulic oil leaking under pressure may damage your skin and cause serious injury. • Before disassembly, mark the parts, hoses and pipes. •...
Page 18 Safety measures and instructions Safety measures for work on the electrical system • Disconnect the battery when repairing the charging circuit to prevent accidental short circuits. • Before removal, disconnect the cable from the negative pole (–) and then from the positive pole (+). •...
Page 19: Environmental And Hygiene Principles
WORKSHOP MANUAL 2�2 Environmental and hygiene principles When repairing the machines, observe general principles of health and environmental protection as well as laws and regulations re- lated to this issue and being in force within the territory where the machine is used. Hygiene principles •...
Page 20: Fire Prevention
The document can be sent in various ways (e.g. via the service portal, service application). The document shall contain a machine serial number and a serial number of the original maintenance kit of Ammann. This information can be provided either typed, or scanned according to the selected manner of handover.
Page 21: Machine Description
WORKSHOP MANUAL 3 MACHINE DESCRIPTION ARR 1575...
Page 22: Machine Description
........................ On hazardous jobsites, the operator can control the machine from a safe distance without being exposed to danger. Year of manufacture Only use the ARR 1575 roller for driving on and compacting of non-cohesive (loose) materials......................... Engine type The machines are designed for operation under the condi- tions of the following EN 60721-2-1:2014 types: WT, WDr, MWDr ........................
Page 23 WORKSHOP MANUAL The machine that complies with the health and safety require- ments is provided with a nameplate with CE marking. 1 - Name – always stated only in the English version 2 - Type 3 - Serial number 4 - Operating weight 5 - Maximum weight 6 - Rated power 7 - Version...
Page 24: Dimensional Drawing Of The Machine
Dimensional drawing of the machine 555003 (in) 2227 1980 1000 1282 1317 (23.7) (11.9) (1.4) (25.2) (87.7) (78.0) (39.4) (20.7) (50.5) (51.9) ARR 1575 T4 final 2227 1980 1000 1282 1317 (23.7) (16.0) (1.4) (33.5) (87.7) (78.0) (39.4) (20.7) (50.5) (51.9) ARR 1575...
Page 25: Technical Data
WORKSHOP MANUAL 3�3 Technical data ARR 1575 U�S� EPA Tier 4f Dimensions Drum width (mm) Weight Operating weight EN 500-1+A1 (CECE) kg (lb) 1340 (2950) 1440 (3170) Operating load EN 500-1+A1 (CECE) on the front axis kg (lb) 730 (1610)
Page 26 Machine description ARR 1575 U�S� EPA Tier 4f Vibration Frequency I Hz (vpm) 40 (2400) Amplitude I mm (in) 0.6 (0.024) Amplitude II mm (in) 1.1 (0.043) Operating fluids Fuel l (gal US) 28 (7.4) Engine (oil filling) l (gal US) 3.4 (0.9)
Page 27: Specification Of Operating Fluids
WORKSHOP MANUAL 4 Specification of operating fluids ARR 1575...
Page 28: Engine Oil
Specification of operating fluids °F °C 4�1 Engine oil 2412 The engine oil is specified according to the performance and viscosity classification. Performance classification according to API (AMERICAN PETROLEUM INSTITUTE) ACEA (ASSOCIATION DES CONSTRUCTEURS EUROPÉENS D'AUTOMOBILE) Viscosity classification To determine the SAE (Society of Automotive Engineers) viscos- ity class, the ambient temperature and type of operation where the machine is used are decisive.
Page 29: Fuel
WORKSHOP MANUAL Use of biofuel (diesel fuel) 3686 4�2 Fuel The use of the fuel mixture under the trade name of biodiesel < 15 ppm S < 15 mg/kg S is in principle approved by the engine manufacturer for the en- 3686 gine of this machine if it conforms to the specifications accord- Diesel oil is used as fuel for the engine:...
Page 30: Coolant
Specification of operating fluids Water quality 4�3 Coolant Do not use hard water with a higher content of calcium and magnesium, which results in calculus formation, and with 2152 a higher content of chlorides and sulphates, which causes cor- The coolant specification must meet requirements of: rosion.
Page 31: Hydraulic Oil
WORKSHOP MANUAL 4�4 Hydraulic oil 4�5 Lubricating grease 2158 0787 For the hydraulic system of the machine, it is necessary to use For lubrication of the machine, use lubricants according to: only high-quality hydraulic oil grades according to ISO VG 46 ISO 2137 HVLP (corresponding to DIN 51524 part 3 HVLP).
Page 32: Fillings
Specification of operating fluids 4�6 Fillings Fluid quantity Part Fluid type Brand l (gal US) Engine Engine oil according to Chapter 4.2.1 3.4 (0.9) 2412 Fuel tank Diesel according to Chapter 4.2.2 28 (7.4) Hydrostatic system Hydraulic oil according to Chapter 4.2.4 16 (4.23) 2158 Year-round anti-freeze according to Chapter...
Page 33: Frame
WORKSHOP MANUAL 5 Frame ARR 1575...
Page 34: Description Of Basic Elements
Frame 5�1 Description of basic elements 555007B 555008B Right side view Left side view 1 - One-point lifting lug 7 - Articulation joint lock 2 - Name plate 8 - Safety bar (optional) 3 - Drum scraper 9 - Control panel cover 4 - Rear bonnet lock 10 - Rear infrared sensor 5 - Front bonnet lock...
Page 35 WORKSHOP MANUAL 555010A 12 - Oil cooler 13 - Fuel tank 14 - Hydraulic oil tank 15 - Battery 16 - Control unit ARR 1575...
Page 36 Frame 555011B 17 - Engine cooler 18 - Coolant level expansion tank 19 - Water separator ARR 1575...
Page 37 WORKSHOP MANUAL 557012B 20 - Oil filter 21 - Oil dipstick 22 - Oil filler cap 23 - Fuel filter 24 - Coolant filler cap 25 - Engine fuses 26 - Air filter ARR 1575...
Page 38: Mechanical Parts
Frame 5�4 Mechanical parts 5�4�1 Swinging support, replacement of the joint head Check the swinging support once a year for potential occur- rence of inadequate clearance. Hang the roller on a crane (central suspension). The clearance can be checked when lifting and lowering the roller (visual check).
Page 39: Gas Strut
WORKSHOP MANUAL 5�4�5 Gas strut Gas struts are maintenance-free! No maintenance, such as oil application or grease lubrication, is required. They are always equipped for relevant requirements and operate faultlessly for many years. Gas strut replacement Before you begin replacing the gas struts, secure the en- 557D129 gine bonnet against spontaneous fall�...
Page 40 Frame Do not install gas struts if they are damaged due to me- chanical handling� Welds on the gas struts as well as dirt or paint on the pis- ton rod may lead to equipment failure� Avoid changes and manipulations, shocks, tensile loads, heating, repainting and removal of prints�...
Page 41: Front Bonnet Replacement
WORKSHOP MANUAL 5�4�6 Front bonnet replacement Removal Remove the sensor (Chapter 5.4.6.2). Hang the bonnet. 557D155 557D156 Use a screwdriver to lift the clamp. Pull the gas cylinder away from the ball joints to the right and left. 557D157 ARR 1575...
Page 42 Frame Release the wire rope from the bonnet on the left. Lift the engine bonnet using a crane. 557D158 Remove the bottom screws of the butt hinge on the left. 557D159 Remove the bottom screws of the butt hinge on the right. 557D160 Lift the bonnet using a crane and put it aside.
Page 43: Replacement Of Bonnet Hinges
WORKSHOP MANUAL 5�4�6�1 Replacement of bonnet hinges Remove the bonnet (Chapter 5.4.6). Remove the hinge screws. 557D162 Replace the bonnet hinge. 557D163 Apply blue adhesive on the screws. 557D164 Mount the hinges using screws. The tightening torque is 50 Nm. 557D165 ARR 1575...
Page 44: Sensor Replacement
Frame 5�4�6�2 Sensor replacement Removal Remove the screws of the sensor cover. 557D166 557D167 Remove the sensor cover. 557D168 557D169 ARR 1575...
Page 45 WORKSHOP MANUAL Remove the sensor. 557D170 Release the sensor cables from the holders. 557D171 Remove the cable ties. 557D172 557D173 ARR 1575...
Page 46 Frame Unplug the X5 connector (infrared sensor at the front). 557D174 Remove the sensor and wiring. 557D175 Installation Put the sensor into the hole in the bonnet. 557D176 557D177 ARR 1575...
Page 47 WORKSHOP MANUAL Install the sensor using the special tool. 557D169 Apply blue adhesive on the sensor cover screws. 557D178 Install the sensor cover. The tightening torque of the cover is 10 Nm. 557D179 557D180 ARR 1575...
Page 48 Frame Fasten the sensor harness using the holders. 557D181 557D182 Fasten the cables with a cable tie on the holder at the top of the bonnet hinge. 557D183 Fasten the cables with a cable tie on the holder at the bottom of the bonnet hinge.
Page 49: Replacement Of The Rubber-Metal Elements Of The Front Bonnet Stop
WORKSHOP MANUAL Fasten the cables with a cable tie on the 010 hydraulic hose. 557D185 Plug the X5 connector (infrared sensor at the front). Attach the cable ties. 557D186 5�4�6�3 Replacement of the rubber-metal elements of the front bonnet stop Remove the fastening nut of the rubber-metal element. 557D187 ARR 1575...
Page 50 Frame Remove the rubber-metal element from the holder. 557D188 Apply blue adhesive on the rubber-metal element screw. 557D189 Mount the rubber-metal element into the holder. 557D190 557D191 ARR 1575...
Page 51: Adjustment Of The Rubber-Metal Elements Of The Front Bonnet Stop
WORKSHOP MANUAL 5�4�6�4 Adjustment of the rubber-metal elements of the front bonnet stop After installing the bonnet or replacing a bonnet stop rubber- metal element, adjust the distance between the bonnet and the machine frame. Loosen the rubber-metal element holder screws. 557D192 Move the holder to adjust the distance between the bonnet and the machine frame.
Page 52: Rear Bonnet Replacement
Frame 5�4�7 Rear bonnet replacement Removal Remove the sensor (Chapter 5.4.7.2). Hang the bonnet. 557D156 557D155 Remove the fastening straps of the N2 connector. 557D196 Disconnect the connectors from the fuse box. 557D197 ARR 1575...
Page 53 WORKSHOP MANUAL Disconnect the connectors of the ignition box. 557D198 Disconnect the N2 connector. 557D199 Remove the bonnet cable ties. 557D200 Use a screwdriver to lift the clamp. Pull away the gas cylinder from the ball joint. 557D201 ARR 1575...
Page 54 Frame Release the wire rope from the bonnet. Lift the engine bonnet using a crane. 557D202 Remove the bottom screws of the butt hinges on the left. 557D203 Remove the bottom screws of the butt hinge on the right. 557D204 Remove the cable ties on the bonnet hinge. 557D205 ARR 1575...
Page 55 WORKSHOP MANUAL Lift the bonnet using a crane and put it aside. 557D206 557D207 ARR 1575...
Page 56: Replacement Of Bonnet Hinges
Frame 5�4�7�1 Replacement of bonnet hinges Replacement of bonnet hinges (Chapter 5.4.6.1). 5�4�7�2 Sensor replacement Removal Remove the screws of the sensor cover. 557D208 Remove the sensor cover. 557D209 Remove the sensor using the special tool. 557D169 Remove the sensor. 557D210 ARR 1575...
Page 57 WORKSHOP MANUAL Disconnect the sensor connector. 557D211 Installation Put the sensor into the hole in the bonnet. 557D176 557D177 Install the sensor using the special tool. 557D169 ARR 1575...
Page 58 Frame Apply blue adhesive on the sensor cover screws. 557D178 Install the sensor cover. The tightening torque of the cover is 10 Nm. 557D212 557D213 Fasten the sensor harness using the holders. 557D214 ARR 1575...
Page 59: Replacement Of The Rubber-Metal Elements Of The Rear Bonnet Stop
WORKSHOP MANUAL Connect the connector of the ignition box. Connect the N2 connector. Fasten the connector with a cable tie. 557D215 Fasten the cables using the fastening straps. 557D216 Place the sensor cables and fasten with a cable tie. 557D217 5�4�7�3 Replacement of the rubber-metal elements of the rear bonnet stop Replacement of the rubber-metal elements of the front bonnet stop (Chapter 5.4.6.3).
Page 60: Swinging Support
Frame 5�4�8 Swinging support Removal Mount a lock against cranking. 557D535 Place the hydraulic jack to the centre of the swinging joint. Slightly unload the roller. 557D536 ARR 1575...
Page 61 WORKSHOP MANUAL Remove the screws of the swinging support. 557D537 557D538 557D539 557D540 ARR 1575...
Page 62 Frame Remove the swinging support. 557D541 557D542 Before disassembling the swinging support, measure the dis- tance between the joint centres. Use the measured value during reassembly. 557D543 ARR 1575...
Page 63 WORKSHOP MANUAL Replacement of the joint head Removal Remove the retaining screw. 557D544 557D545 Place the swinging support under a press. Push out the heavy clamping pin with the mandrel. 557D546 557D547 557D548 ARR 1575...
Page 64 Frame Clamp the swinging support in a vice. Heat the lock nut and joint head to approximately 200 °C (392 °F). 557D549 Loosen the lock nut. Rotate the joint head using a spanner. 557D550 557D551 ARR 1575...
Page 65 WORKSHOP MANUAL Installation Apply red adhesive on the new rear joint head and swinging support (1). Apply blue adhesive on the new front joint head and swinging support (2). Mount the rear joint head on the swinging support all the way to the stop.
Page 66 Frame Insert the clamping pin so that the gap is on the push-out side. Push the clamping pins inside. 557D556 Apply red adhesive on the screw. 557D557 557D558 ARR 1575...
Page 67 WORKSHOP MANUAL Installation Mount the joint head fixing screws. The tightening torque is 85 Nm. Apply blue adhesive on the screws. 557D559 557D560 557D561 557D562 ARR 1575...
Page 68: Replacement Of The Steering Piston
Frame 5�4�9 Replacement of the steering piston Removal Remove hydraulic hoses 017 and 018 from the hydraulic cylin- der. 557D563 557D564 Remove the steering piston nuts. 557D565 557D566 ARR 1575...
Page 69 WORKSHOP MANUAL Remove the steering piston. 557D567 Close the screw unions on the steering piston. 557D568 Close the screw unions on hoses 017 and 018. 557D569 ARR 1575...
Page 70 Frame Installation Clean the fastening pins (remove corrosion if necessary). Mount the sealing washer (1). Lubricate the fastening pins. Apply blue adhesive on the threaded pins. 557D570 Install the new steering piston. 557D567 Tighten the nut firmly (100 Nm). Lubricate the grease nipple (2) at the front and back. 557D571 Mount hydraulic hoses 017 and 018.
Page 71: Swinging Joint
WORKSHOP MANUAL 5�4�10 Swinging joint Remove the swinging support (Chapter 5.4.8). Remove the steering piston (Chapter 5.4.9). Cut the hose bundle ties. 557D573 Place a protective plate (e.g. aluminium) at the bottom and top between the chassis and the hose bundle. 557D574 Remove the screws of the swinging joint.
Page 72 Frame Remove the bearing lock screw. 557D577 Remove the bearing lock (1). 557D578 Cut the thread in the support chassis. 557D579 Mount the screws. In the event of corroded bearing seat, use 4 screws� 557D580 ARR 1575...
Page 73 WORKSHOP MANUAL Screw in the screws until the swivel bearing from the bearing pin. 557D581 Because there is not enough space for longer screws than M12x100, spacers (approx. 20 mm) must be placed under the screws. Remove the screws as soon as the bearing is pushed out of the bearing pin.
Page 74 Frame Move the pulling disc under the articulated bearing using the special tool. 557D585 557D586 Use the special tool to mount the upper part (1) on the support chassis. Use the special tool to mount the M20 hex screw (2). 557D587 Pull the bearing out of the support.
Page 75 WORKSHOP MANUAL Remove the bearing out of the support. 557D589 557D590 Removed binding ring with a bearing. 557D591 Place the binding ring under a press. 557D592 ARR 1575...
Page 76 Frame Push out the bearing. 557D593 Clean the binding ring. 557D594 Lubricate the bearing seat. 557D595 Lubricate the new bearing. 557D596 ARR 1575...
Page 77 WORKSHOP MANUAL Push the bearing into the binding ring. 557D597 Clean the support chassis. 557D598 557D599 Lubricate the bearing seat. 557D600 ARR 1575...
Page 78 Frame Apply sealant on the sealing surface. 557D601 557D602 Pull the bearing flange to the support using the screws. 557D603 Lubricate the bearing pins. 557D604 ARR 1575...
Page 79 WORKSHOP MANUAL Centre the chassis towards the bearing pins. 557D605 557D606 Mount the washer and the screw with the nut into the bearing pin. 557D607 Use the nut to pull the bearings over the bearing pin. Remove the screw. 557D608 ARR 1575...
Page 80 Frame Mount the lock washer on the screw. Apply blue adhesive on the screw. 557D609 Secure the swivel bearing with a screw and a washer. The tight- ening torque is 210 Nm. Remove the mounting screws (1). 557D610 557D611 ARR 1575...
Page 81 WORKSHOP MANUAL Apply sealant on the surface of the binding ring. 557D612 557D613 Place the cap. 557D614 Apply blue adhesive on the screws. 557D615 ARR 1575...
Page 82 Frame Secure the cap. The tightening torque is 85 Nm. 557D616 Remove the protective plates. Arrange the hose bundle and fasten it using cable ties. 557D617 ARR 1575...
Page 83: Fuel Tank
WORKSHOP MANUAL 5�5 Fuel tank 5�5�1 Fuel level check Open the engine bonnet. Check the level in the plastic tank. Do not smoke while working! 5�5�2 Fuel replenishment Fill the fuel tank with diesel fuel up to the lower edge of the filler neck.
Page 84: Fuel Draining
Frame 5�5�3 Fuel draining Operating fluids pose a risk to the environment! Prevent fluids from leaking into sewage systems, soil or the environment� Loosen the screw plug (1) under the roller. Place a vessel under the drain neck. 557D082 Let the diesel flow out. Put on the screw plug (1).
Page 85: Hydraulic Tank
WORKSHOP MANUAL 5�6 Hydraulic tank 5�6�1 Checking the hydraulic oil level Check the hydraulic oil level always when the engine is cold but running. Put the machine on a flat terrain. Let the engine run at idle. Check the oil level in the inspection hole. The ideal hydraulic oil level is when the gauge is half-full.
Page 86: Hydraulic Oil Draining
Frame 5�6�3 Hydraulic oil draining Drain hydraulic oil only at operating temperature� Residues in the tank are drained with the oil� Put a vessel (with a volume of at least 30 litres) under the hy- draulic oil drain plug. 555085 Take out the ventilation filter (1). Remove the plug (2) from the hydraulic tank.
Page 87: Hydraulic Oil Filter Replacement
WORKSHOP MANUAL 5�6�4 Hydraulic oil filter replacement Take off the filter cap. Unlock the filter cartridge. Pull out the filter cartridge from the filter housing. Dispose of the filter cartridge environmentally. 555037 Insert the new filter cartridge in the correct place. Keep the posi- tion of the safety cam.
Page 88: Ventilation Filter Replacement
Frame 5�6�6 Ventilation filter replacement Remove the ventilation filter and replace it with a new one. 557D097 5�6�7 Hydraulic tank filling Fill the hydraulic oil tank (approximately 16 l). 557D098 557D099 ARR 1575...
Page 89: Filling The Travel Pump, Increasing The Supply Pressure
WORKSHOP MANUAL 5�6�8 Filling the travel pump, increasing the supply pressure Remove the 006 (S) hydraulic hose. 557D100 Fill the travel pump housing with hydraulic oil. 557D101 Fill hydraulic oil (0.3–0.4 l) so that it flows out of the screw union (S). 557D102 Mount the 006 (S) hydraulic hose.
Page 90 Frame Remove the F21 (40A) fuse in the engine compartment. 555058A Connect a pressure gauge (40 bar) to the supply pressure meas- uring point. Rotate the engine with the engine starter. 557D104 Rotate the engine until the pressure reaches 3–5 bar. Do not overheat the starter! After no more than 30 sec- onds, let the starter cool down�...
Page 91 WORKSHOP MANUAL Start the diesel engine. Check the pressure increase. Maximum pressure = 23 bar. 557D106 If hydraulic components have been replaced or repaired, per- form a function and leak check. 557D107 ARR 1575...
Page 92 ARR 1575...
Page 93: Cab And Platform
WORKSHOP MANUAL 6 Cab and platform ARR 1575...
Page 94 Cab and platform ARR 1575...
Page 95: Control And Indication Elements
WORKSHOP MANUAL 6�1 Control and indication elements 557018 555009B 1. Infrared remote control 2. Spiral cable compartment 3. Display unit 4. Ignition box 5. Fuses ARR 1575...
Page 96: Display Unit
• Check the V-belt of the engine for damage and loosening. If the battery charging indicator lamp is still on after this check, contact an authorized service centre of Ammann. Error indicator lamp (3) RAM01 The error indicator lamp turns on when the control unit detects an error.
Page 97 Check the engine for oil leaks and correct oil level. • If the oil level in the engine is correct, contact an authorized service centre of Ammann. Note: The machine is equipped with an automatic shutdown system. If the oil pressure drops below the limit value, the oil pressure indicator lamp turns on.
Page 98 Cab and platform Safety bar indicator lamp (6) RAM06 The safety bar indicator lamp is continuously on the whole time the safety bar is connected (optional equipment). The safety bar indicator lamp also lights up during the activa- tion of the near and remote halt. hours Preheating indicator lamp (7) RAM05...
Page 99: Error Indication Via Leds On The Display Unit
WORKSHOP MANUAL 6�1�2 Error indication via LEDs on the display unit Error indication (inclination switch) Indication Reason Corrective action Error lights up The inclination switch activated. The roller is inclined by more than approx. 45° or Set the machine upright. overturned.
Page 100: Infrared Light Emitter
Cab and platform 6�1�3 Infrared light emitter 6�1�3�1 Layout Working speed (tortoise) / transport speed (hare) Forward / reverse High / low amplitude vibration Steering angle left / right Start / Stop LED indicators Warning horn switch 557019 6�1�3�2 Indication of faults by LEDs on the infrared light emitter There are two LEDs on the cover: green and red.
Page 101: Cable Connection
WORKSHOP MANUAL When the battery is discharged, the machine can still be controlled using a cable� The battery warning and error are then indicated also during control (if the controller is activated)� When and as long as the infrared light emitter is connected via a cable to the machine’s control unit and the ignition is in the “I”...
Page 102: Handling
Cab and platform 6�1�3�4 Handling The infrared remote control is located under the dashboard cover. It contains the following transmission elements: solar cells, infrared diodes for data transmission and measurement of safe distance. Clean the transmission elements before starting. Keep the solar cells clean during operation. 557021 Risk of injury due to obstructed bottom part of the cover! Before and during the operation with the infrared re-...
Page 103 WORKSHOP MANUAL Proper use of the infrared remote control 40° 555116 40° 555118 555120 40° 555119 555131 ARR 1575...
Page 104 Cab and platform Improper use of the infrared remote control 40° During the operation of the machine, it is forbidden to use the infrared remote control without direct visual contact between the infrared remote control and the in- frared sensor on the machine� The operating angle of the infrared remote control is 40°�...
Page 105 WORKSHOP MANUAL 555122 40° 555125 40° 555129 ARR 1575...
Page 106 Cab and platform During operation, aim the infrared remote control in the direction of the machine only� The cable connector (1) must face forward� • The infrared remote control can lean on the operator's body. 555192 555193 The side and front diodes of the infrared remote control must not be covered (e�g�...
Page 107 WORKSHOP MANUAL Do not aim the transmitter at reflective objects (large surfaces, light objects, other machinery, etc�)� Do not use the infrared remote control in the protected 2 m zone or if there is insufficient visual contact between the machine and the operator or the infrared remote control, unless stated otherwise�...
Page 108: Relays And Fuses In The Engine Compartment
Cab and platform 6�3�3 Relays and fuses in the engine compartment Dashboard fuses The fuses are located under the cover in the dashboard. F11 - 10 A ......Control unit, power supply F12 - 25 A ......Control unit, outputs F13 - 10 A ......Display unit, safety bar F14 - 25 A ......Hydraulic oil cooler Fuses in the engine compartment The fuses are located above the engine.
Page 109: Dashboard
WORKSHOP MANUAL 6�3�4 Dashboard 557018B Functions Display unit Infrared light emitter Ignition box N2 display unit H1 H6 Functions Charging indicator lamp Preheating indicator lamp Oil pressure indicator lamp hours Water temperature indicator lamp Safety bar indicator lamp Error indicator lamp Operating hours counter 555012C ARR 1575...
Page 110: Other Components
Cab and platform 6�3�4�1 Other components 6�3�4�2 N1 connector / cable harness Make sure there is no water or dirt on the N1 connector� 557D078 ARR 1575...
Page 111 WORKSHOP MANUAL List of harness wires / N1 connector Cross- No� Colour from Note section white Control 12 V white Control 12 V brown Casing - back Casing - control brown Casing - back Casing - control 0.75 white Ignition relay 0.75 white S1 19 Preheating relay...
Page 112 Cab and platform Cross- No� Colour from Note section white Input relay white Y1 white Input coil 0.75 brown Casing - engine Accelerator relay white Accelerator magnet white Accelerator magnet 0.75 white S1 19 Preheating relay 0.75 brown Casing - engine Preheating relay white Preheating...
Page 113: Replacement Of The Remote Control Battery
WORKSHOP MANUAL 6�4�1 Replacement of the remote control battery Removal Remove the protective cover. 557D001 557D002 Remove the rubber gaskets. 557D003 Remove the screws. 557D004 ARR 1575...
Page 114 Cab and platform Open the top of the remote control. 557D005 Remove the connector fastening strip. 557D006 Disconnect the connector. 557D007 Remove the battery. 557D008 557D009 ARR 1575...
Page 115 WORKSHOP MANUAL Installation Insert the battery. 557D008 Pull the fastening strip through the hole under the connector. 557D010 Connect the connector. 557D011 Fasten the connector with the fastening strip. 557D012 ARR 1575...
Page 116 Cab and platform Shorten the fastening strip. 557D013 Install the top of the remote control using the screws. 557D004 Install the rubber gaskets. 557D003 Install the protective cover. 557D001 ARR 1575...
Page 117: Replacement Of The Display Unit
WORKSHOP MANUAL 6�4�2 Replacement of the display unit Disconnect the N2 connector. 557D218 Remove the two fasteners of the display unit. 557D219 You can now extract the display unit. 557D220 Install the new unit in the reversed order. 557D221 ARR 1575...
Page 118: Replacement Of The Control Unit
Cab and platform 6�4�3 Replacement of the control unit Removal Remove the battery clamp (–). 557D222 Disconnect the connectors of the control unit. 557D223 Disconnect the N1 connector. 557D224 Use a screwdriver to lift the clamp Pull away the gas cylinder from the ball joint. 557D225 ARR 1575...
Page 119 WORKSHOP MANUAL Remove the control unit fastening screws and remove the unit. 557D226 557D227 ARR 1575...
Page 120: Installation
Cab and platform 6�4�3�2 Installation Apply blue adhesive on the screws. 557D228 Install the control unit using the screws. 557D229 Connect the N1 connector. Connect the battery terminal (–). 557D230 ARR 1575...
Page 121: Front Drum
WORKSHOP MANUAL 7 Front drum ARR 1575...
Page 122: Hydraulic Parts
Front drum 7�2 Hydraulic parts 7�2�1 Travel drive/vibration hose Drum, front left 557D004 Drum hose, front left No� from Travel circuit B forward Hydraulic block, left Travel motor brake Valve block BR Travel circuit A reverse Travel pump A – T neck Leaked oil –...
Page 123 WORKSHOP MANUAL Drum, front right 557D005 Drum hose, front right No� from Vibration motor front Valve block A1 Travel circuit B forward Hydraulic block right Travel circuit A reverse Travel pump A – T neck Vibration motor, front, connection rear Vibration interface –...
Page 124 Front drum Drum, rear left 557D006 Drum hose, rear left No� from Vibration motor rear, connection rear Interface, rear, angled neck Travel circuit B forward Interface, rear Travel circuit A reverse Interface, rear Vibration motor rear, connection front Interface, rear, angled neck Travel motor brake, rear left Travel motor brake, rear right –...
Page 125 WORKSHOP MANUAL Drum, rear right 557D007 Drum hose, rear right No� from Travel circuit A reverse Interface, rear Travel motor brake rear right Interface, rear Travel circuit B forward Interface, rear Leaked oil – return flow Hydraulic oil tank – return flow Travel motor brake, rear right –...
Page 126: Valve Block Connections
Front drum 7�2�2 Valve block connections Valve block – top view 557D008 Valve block – solenoid valves No� Designation Steering to the left Steering to the right High amplitude Low amplitude Brake Valve block – connections No� Designation Brake Travel pump G supply pressure Vibration control pump pressure Steering to the right / right steering piston Steering to the left / right steering piston...
Page 127 WORKSHOP MANUAL Valve block – front view 557D009 Valve block – connections at the front No� Designation Tank line to travel pump T1 Steering to the left / left steering piston Vibration motor rear left / high amplitude, angled divider screw connection Valve block –...
Page 128 Front drum Valve block – rear view Valve block – hydraulic hose connections, rear No� Designation Vibration motor front right – low amplitude Leaked oil / travel motor, front left and right Steering to the left / left steering piston 557D010 Valve block –...
Page 129: Valve Block Hose
WORKSHOP MANUAL 7�2�3 Valve block hose Valve block – top view 557D012 Valve block – solenoid valves No� from Valve block P Vibration – steering pump pressure – L neck Valve block T2 – angled neck Travel pump T1 Valve block T1 – angled neck Hydraulic oil cooler –...
Page 130 Front drum Valve block – divider neck 557D013 Valve block – solenoid valves No� from Divider neck near the valve block holder Interface, rear – angled neck Divider neck near the valve block holder Vibration motor, front, connection rear Interface, rear 557D014 ARR 1575...
Page 131: Mechanical Parts
WORKSHOP MANUAL 7�4 Mechanical parts 7�4�1 Removal of the drum extension Remove the drum scrapers. 557D018 557D019 557D020 557D021 ARR 1575...
Page 132 Front drum Support the frame using a jack. 557D022 Remove the drum extension screws. 557D023 ARR 1575...
Page 133: Drum Removal
WORKSHOP MANUAL 7�4�2 Drum removal Support the machine using a jack. Hang the drum on a crane and lift it slightly. 557D250 Remove the drum fastening screws. 557D251 Move the drum using a suitable tool under the chassis outwards. Keep the drum balanced using an aid (e.g. squared wood) 557D252 Store the drum safely for reuse.
Page 134: Replacement Of Vibration Unit Rubber Elements
Front drum 7�4�3 Replacement of vibration unit rubber elements If any rubber element has cracks deeper than 10 mm, it must be replaced. Removal Remove the drum (Chapter 7.4.2). ARR 1575...
Page 135 WORKSHOP MANUAL Clean the hoses and surroundings. Before hanging the hoses, place an oil drip container under the travel motor. 557D263 557D264 Remove all hoses at the travel motor. Close the screw union. 557D265 Install the aid on the travel hydraulic motor flange. Hang the aid on a crane.
Page 136 Front drum Remove the screws of the travel hydraulic motor attachment. 557D267 557D268 Remove the travel hydraulic motor and put it aside. 557D269 557D270 ARR 1575...
Page 137 WORKSHOP MANUAL Remove the nuts on the gearbox cover. 557D272 557D273 Put an oil drip container under the gearbox. Remove the screws on the gearbox cover. 557D274 ARR 1575...
Page 138 Front drum Put the gearbox cover aside. 557D275 Grease comes out of the gearbox. The same amount of grease then must be refilled during reas- sembly. 557D276 Store the gearbox cover safely for reuse. 557D277 Install the aid on the gearbox cover. Hang the aid on a crane.
Page 139 WORKSHOP MANUAL Remove the nuts on the gearbox cover. 557D279 Remove the gearbox and put it aside. 557D280 557D281 ARR 1575...
Page 140: Disassembly Of The Vibration Unit
Front drum 7�4�3 Disassembly of the vibration unit View of the vibration housing after opening. The grease in the housing is consumed after a certain number of operating hours and must be refilled� The following steps were performed on a new vibration unit. The grease is therefore unconsumed and light in all pictures.
Page 141 WORKSHOP MANUAL Remove and clean the bearing cap. 557D315 557D316 Remove the grease on the hub. 557D317 557D318 ARR 1575...
Page 142 Front drum Loosen the grooved nut lock. Use a small chisel or screwdriver. 557D319 557D320 557D321 ARR 1575...
Page 143 WORKSHOP MANUAL Mount the special “spanner for grooved nuts” tool. 557D322 557D323 ARR 1575...
Page 144 Front drum Loosen the grooved nut lock. 557D324 Remove the grooved nut. 557D325 Remove the grooved nut lock. 557D326 Lift the vibration unit from the shaft. 557D327 ARR 1575...
Page 145 WORKSHOP MANUAL Remove the grease on the hub. 557D328 Remove the spacer rings. 557D329 557D330 Pull the bearings from the hub using the pulling tool. 557D331 ARR 1575...
Page 146 Front drum Mount the pulling tool here (arrow). 557D332 Remove the outer bearing rings and the spacer ring. 557D333 557D334 Clean the bearing housing. 557D335 ARR 1575...
Page 147 WORKSHOP MANUAL Remove the rubber-metal elements. 557D282 557D283 ARR 1575...
Page 148: Installation Of The Drum Rubber-Metal Elements
Front drum 7�4�4 Installation of the drum rubber-metal elements Apply blue adhesive on the screws. 557D284 Install new rubber-metal elements on the centre beam. The tightening torque is 50 Nm. 557D285 557D286 557D287 ARR 1575...
Page 149 WORKSHOP MANUAL Apply blue adhesive on the rubber-metal element threads from the vibration motor side. 557D288 Support the hoses with squared wood on the vibration motor side so that they can be released. 557D289 Attach the gearbox to a crane using the aid. 557D290 557D291 ARR 1575...
Page 150 Front drum Align the gearbox. Place the gearbox on the rubber-metal elements. 557D292 Tighten the nuts (1) to a torque of 50 Nm. 557D278A This concludes the gearbox installation from the vibration mo- tor side. If bearing replacement or new lubrication is required, refer to Chapter “Replacement of vibration unit bearings”...
Page 151 WORKSHOP MANUAL Cut all threads (M8). 557D295 Blow-clean the threaded bores. 557D296 Thoroughly remove all glue residues and dirty grease. Replace the removed or blow-cleaned grease with the same amount of new grease. Grease: Foodgrease SPM00 557D297 Apply sealant to the sealing surface. 557D298 ARR 1575...
Page 152 Front drum Spread the sealant with a brush. 557D299 Apply a drop of blue adhesive in all threaded bores. 557D300 Clean / blow-clean the boreholes in the gearbox cover. 557D301 557D302 ARR 1575...
Page 153 WORKSHOP MANUAL Clean the sealing surface of the gearbox cover. 557D303 Apply blue adhesive on the threads of the rubber elements. 557D304 Mount the gearbox cover. 557D305 Fasten the gearbox cover using the nuts. The tightening torque is 50 Nm. 557D306 ARR 1575...
Page 154 Front drum Apply blue adhesive on the screws. 557D307 Tighten the screws (1) to a torque of 36 Nm. 557D308 557D309 Install the hose guide holder (1) using the same screws. 557D310 ARR 1575...
Page 155: Installation Of The Vibration Unit
WORKSHOP MANUAL 7�4�4 Installation of the vibration unit Install a new wide outer bearing ring (1) into the bearing hous- ing. Observe the installation position. 557D336 Push the wide outer bearing ring into the housing. 557D337 Insert the spacer ring (1) into the bearing housing. 557D338 557D339 ARR 1575...
Page 156 Front drum Install a narrow outer bearing ring (1) into the bearing housing. Observe the installation position. 557D341 Push the narrow outer bearing ring into the housing. 557D340 557D339 ARR 1575...
Page 157 WORKSHOP MANUAL Heat the rear cone bearing to 110 °C. 557D342 Slide the rear cone bearing onto the hub. 557D343 Apply a small amount of grease on the bearing. 557D344 Mount the spacer rings. 557D345 ARR 1575...
Page 158 Front drum Lubricate the bearing ring from the outside. 557D346 Insert the vibration unit into the vibration housing. 557D347 Mount the bearing from the outside. 557D348 Mount the lock ring. 557D349 ARR 1575...
Page 159 WORKSHOP MANUAL Mount the grooved nut. 557D350 Mount the special “spanner for grooved nuts” tool. 557D351 Tighten firmly (200 Nm). 557D352 Install the bridge for the torque meter. 557D353 ARR 1575...
Page 160 Front drum Mount the torque meter. 557D354 Turn the vibrator with the torque meter 20 times clockwise. This eliminates any stress. The housing must not stand on a support and must be freely rotatable� 557D355 Set the tightening torque to 1–3 Nm. If the value does not match, perform correction using spacers until it does.
Page 161 WORKSHOP MANUAL 557D358 Grease the bearings. 557D359 557D360 Total amount of grease in the bearing housing: 100 g of liquid grease BLASER FOODGREASE SPM00 557D361 ARR 1575...
Page 162 Front drum Put a small amount of blue adhesive in the threaded bores. 557D362 Apply blue adhesive on the screws. 557D363 Mount the bearing cap on the vibrator housing. 557D364 Tighten the screws to a torque of 10 Nm. Weight of the vibration unit must move freely� 557D365 ARR 1575...
Page 163 WORKSHOP MANUAL Apply 300 g of grease in the vibration housing. 557D366 Clean the sealing surface of the gearbox. 557D294 Cut all threads (M8). 557D295 Blow-clean the threaded bores. 557D296 ARR 1575...
Page 164 Front drum Thoroughly remove all glue residues and dirty grease. Replace the removed or blow-cleaned grease with the same amount of new grease. Grease: Foodgrease SPM00 557D297 Apply sealant to the sealing surface. 557D298 Spread the sealant with a brush. 557D299 Apply a drop of blue adhesive in all threaded bores.
Page 165 WORKSHOP MANUAL Clean / blow-clean the boreholes in the gearbox cover. 557D301 557D302 Clean the sealing surface of the gearbox cover. 557D303 Apply blue adhesive on the threads of the rubber elements. 557D304 ARR 1575...
Page 166 Front drum Mount the gearbox cover. 557D305 Tighten the nuts to a torque of 50 Nm. 557D306 Apply blue adhesive on the screws. 557D307 ARR 1575...
Page 167 WORKSHOP MANUAL Tighten the screws (1) to a torque of 36 Nm. 557D308 557D309 Install the hose guide holder (1) using the same screws. 557D310 ARR 1575...
Page 168: Replacement Of The Travel Hydraulic Motor
Front drum 7�4�5 Replacement of the travel hydraulic motor Removal Remove the drum, travel hydraulic motor (Chapter 7.4.2). ARR 1575...
Page 169 WORKSHOP MANUAL On the removed travel motor, remove all screw unions. 557D373 557D374 Remove the screws on the travel hydraulic motor flange. The screws are inaccessible: In rare cases (7x) where bolts are not accessible, the travel hy- draulic motor flange must be completely removed. You then have to remove (5x) hexagon bolts.
Page 170 Front drum Attach slings to a crane and the eye screws. Before lifting the travel motor from the motor support, mark the motor location with a pencil. 557D377 If the travel motor is stuck in the motor support due to corro- sion, push the traction motor out of the motor support. •...
Page 171 WORKSHOP MANUAL Lubricate the bearing seat with NeverSeez. 557D381 Put a small amount of blue adhesive in the threaded bores. 557D382 Place the new travel motor in the motor support. Pay attention to the motor position (previously marked). 557D379 Apply blue adhesive on the screws. 557D383 ARR 1575...
Page 172 Front drum Mount the screws. The tightening torque is 85 Nm. 557D385 Apply blue adhesive on the screw unions from the old travel motor. 557D386 ARR 1575...
Page 173 WORKSHOP MANUAL Mount the screw unions on the travel motor, firmly tighten. Material Hydraulic motor K 04/340.0 cm³/rev. (1) • (2x) Straight neck with thread GES10L M22x1.5 (2) (125 Nm) • (1x) Straight neck with thread GES10L M16x1.5 (3) (55 Nm) •...
Page 174 Front drum Installation Clean the seating surface of the motor support and threads. 557D389 557D390 Put a small amount of blue adhesive in the threaded bore. 557D391 Mount the aid on the travel hydraulic motor flange. 557D271 ARR 1575...
Page 175 WORKSHOP MANUAL Screw one threaded pin to the right and left of the vibration housing flange as a mounting aid for the travel hydraulic motor. 557D392 Hang the travel hydraulic motor on a crane and install it in the machine. 557D393 557D394 557D395 ARR 1575...
Page 176 Front drum Apply blue adhesive on the screws. 557D396 Mount the travel hydraulic motor using the screws. The tighten- ing torque is 85 Nm. 557D397 Remove the aid. 557D398 Mount all hoses. 557D399 ARR 1575...
Page 177 WORKSHOP MANUAL Clean the hose fittings and the surroundings using cleaning agents (e.g. brake cleaner). Apply NeverSeez on the flange (arrow). Before installing the drum, let the machine run on blocks. Per- form a leak check. 557D400 Move the drum under the chassis using an aid. Keep the drum balanced using an aid (e.g.
Page 178: Replacement Of The Vibration Hydraulic Motor
Front drum 7�4�6 Replacement of the vibration hydraulic motor Removal Remove the drum, travel hydraulic motor (Chapter 7.4.2). Remove all hoses at the travel motor. Close the screw union. 557D401 557D402 Remove the screws of the vibration hydraulic motor. 557D403 Remove the vibration hydraulic motor.
Page 179 WORKSHOP MANUAL Remove the clutch. 557D405 In the case of a defective vibration hydraulic motor, remove the screw union and pinion. 557D406 Remove the pinion nut. 557D407 Remove the pinion using a pulling tool. 557D408 ARR 1575...
Page 180 Front drum 557D409 Remove the screws. Remove the angled flanges on both sides. 557D410 Remove the 040 hydraulic hose. 557D411 Remove the threaded neck. 557D412 ARR 1575...
Page 181 WORKSHOP MANUAL Installation Overview of all parts used for the new vibration motor. If the screw unions and other parts are undamaged, they may be re- used in the new vibration motor. 557D413 Always replace the sealing rings. 557D414 Apply blue adhesive on the screws. 557D415 Mount the angled flanges using the screws with a ...
Page 182 Front drum Mount the pinion. 557D417 Apply blue adhesive on the thread. 557D418 Insert a spring washer. 557D419 Mount the pinion nut. 557D420 ARR 1575...
Page 183 WORKSHOP MANUAL Tighten the pinion nut firmly to a torque of 50 Nm. 557D421 Apply blue adhesive on the straight neck. 557D422 Mount the straight neck and tighten firmly to torque of 40 Nm. 557D423 557D424 ARR 1575...
Page 184 Front drum Mount the clutch. If the old clutch is undamaged, you can reuse it. Otherwise, in- sert a new clutch. 557D425 Apply sealant on the sealing surface. 557D426 Insert the vibration hydraulic motor. 557D404 Apply blue adhesive on the screws. 557D427 ARR 1575...
Page 185 WORKSHOP MANUAL Tighten the screws firmly (56 Nm). 557D403 Mount the hydraulic hoses. 557D428 557D429 ARR 1575...
Page 186: Drum Installation
Front drum 7�4�7 Drum installation Move the drum under the chassis using an aid. Keep the drum balanced using an aid (e.g. squared wood). 557D252 Tighten the screws firmly (85 Nm). 557D251 7�4�8 Scraper Before driving, adjust the scraper so that there is a gap of about 5 mm between the scraper and the drum.
Page 187: Rear Drum
WORKSHOP MANUAL 8 Rear drum ARR 1575...
Page 188: Hydraulic Parts
Rear drum 8�2 Hydraulic parts Hydraulic parts (Chapter 7.2). ARR 1575...
Page 189: Aceecon
WORKSHOP MANUAL 8�3 ACEecon Removal Remove the rear drum scrapers. 557D018 557D019 557D020 557D021 ARR 1575...
Page 190 Rear drum Support the left rear part of the frame with a jack. 557D022 Remove the extension of the left rear drum. 557D023 Remove the left rear drum. 557D024 557D025 ARR 1575...
Page 191 WORKSHOP MANUAL Remove the hydraulic motor from the machine frame. 557D026 557D027 557D028 Remove the hoses from hydraulic motor. Mark the outlets and blind them with plugs. 557D029 ARR 1575...
Page 192 Rear drum Remove the hoses from the vibration hydraulic motor. 557D030 Remove the sensor wiring clips. 557D032 Remove the hose holder. 557D033 ARR 1575...
Page 193 WORKSHOP MANUAL Remove the M7 screws using the jig. 557D034 557D035 557D036 ARR 1575...
Page 194 Rear drum Remove the holder of the ACEecon sensor. 557D037 557W053 Remove the document compartment. 557D014 ARR 1575...
Page 195 WORKSHOP MANUAL Remove the wiring ties. 557D038 557D039 Disconnect the X50 connector. 557D040 Disconnect the display panel connectors. 557D041 ARR 1575...
Page 196 Rear drum Installation Mount the hose holder using the screws. Secure the screws with the Loxeal 83-54 adhesive. 557D042 Mount the hoses of the vibration hydraulic motor. 557D043 Mount the travel hydraulic motor. Secure the screw joints with the Loxeal 83∙-54 adhesive. 557D044 557D045 557D046...
Page 197 WORKSHOP MANUAL Attach the hydraulic hoses of the travel hydraulic motor. 557D047 Install the drum. Secure the screws with the Loxeal 83-54 ad- hesive. 557D048 Install the drum extension. Secure the screws with the Loxeal 83-54 adhesive. 557D049 ARR 1575...
Page 198: Mechanical Parts
Rear drum Install the scrapers. Set the scrapers so that there is a gap of about 5 mm between the scraper and the drum. 557D050 557D051 557D052 8�4 Mechanical parts See Chapter 7.4. ARR 1575...
Page 199: Front Axle
WORKSHOP MANUAL 9 Front axle (not included in the machine equipment) ARR 1575...
Page 200 ARR 1575...
Page 201: Rear Axle
WORKSHOP MANUAL 10 Rear axle (not included in the machine equipment) ARR 1575...
Page 202 ARR 1575...
Page 203: 11 Travel
WORKSHOP MANUAL 11 Travel ARR 1575...
Page 204 Travel ARR 1575...
Page 205: Hydraulic Parts
WORKSHOP MANUAL 11�2 Hydraulic parts 11�2�1 Replacement of the travel pump Drain the hydraulic oil (Chapter 5.6.3). Removal Place an oil drip container under the chassis at the front or the travel pump. 557D431 Remove the pressure line, vibration pump screw union. 557D432 557D433 Close the screw union.
Page 206 Travel 557D435 Remove the supply pressure, travel pump screw union. 557D436 Close the screw union. 557D437 557D438 ARR 1575...
Page 207 WORKSHOP MANUAL Remove the supply, travel pump hydraulic hose. 557D439 Close the screw union. 557D440 557D441 Remove the hydraulic hose of the forward travel (B), travel pump circuit. 557D031 ARR 1575...
Page 208 Travel Close the screw union. 557D442 557D443 Remove the T screw union of the reverse travel (A), travel pump circuit. 557D032 557D444 ARR 1575...
Page 209 WORKSHOP MANUAL Close the screw union. 557D445 Remove the suction line, vibration pump screw union. 557D446 Close the screw union. 557D447 557D448 ARR 1575...
Page 210 Travel Remove the angled screw union of the suction line, travel pump. The hydraulic oil will stop flowing. 557D449 557D450 Remove the hydraulic hose of the supply pressure, PBR valve block. Close the screw union. 557D451 Remove the cable ties on both sides on the servo block. 557D452 ARR 1575...
Page 211 WORKSHOP MANUAL 557D453 Remove connectors Y3 and Y4. 557D454 557D455 Remove the screws on the travel pump. 557D456 ARR 1575...
Page 212 Travel Lift the travel pump from the motor. 557D457 Now close the loose angled screw union of the suction line (1). 557D458 557D459 Pull the pinion off the shaft. 557D460 ARR 1575...
Page 213 WORKSHOP MANUAL Preparation of a new vibration travel pump If the old screw unions are undamaged, you can reuse them. Otherwise, use new screw unions. 557D461 Travel pump screw unions Hydraulic pump Straight neck with thread GES12L/M27x2-WD Straight neck with screw union GES 8LM-WD Straight neck with screw union 12L/M 14x1.5-WD Straight neck with screw union GES15LM-WD Straight neck with screw union GES22LM-WD...
Page 214 Travel Torque 10 Nm 557D462 Vibration control pump 1 Gear pump 11 ccm/rev. 9 teeth 82.55 mm 2 Screwed connection MINIMESS-1620 DKOL 15L 3 Adjustable L-neck ELSD15L o.M+D K 4 Straight neck with flange GFS 15L-35 4.1 Sealing ring 5 Straight neck with flange GFS 22L-40 5.1 Sealing ring Appy NeverSeez on the shaft.
Page 215 WORKSHOP MANUAL Apply blue adhesive on the screw. 557D464 Set the pinion Insert a feeler gauge (1.5 mm) between the pinion and the pump housing. 557D465 Tighten the screw to a torque of 85 Nm. 557D466 ARR 1575...
Page 216 Travel Installation Clean the M12 thread on the pump flange. 557D467 Remove the suction hose stopper cap. 557D468 Apply blue adhesive on the screws. 557D469 Move the travel pump on the pump flange. 557D470 ARR 1575...
Page 217 WORKSHOP MANUAL Tighten the screws to a torque of 85 Nm. 557D471 557D472 Mount the suction line screw union. 557D473 Mount the T screw union of the reverse travel (A), travel pump circuit. 557D474 ARR 1575...
Page 218 Travel Mount the hydraulic hose of the forward travel (B), travel pump circuit. 557D475 Mount the pressure line, vibration pump screw union. 557D476 Mount the supply, travel pump hydraulic hose. 557D477 Mount the supply pressure, travel pump screw union. 557D478 ARR 1575...
Page 219 WORKSHOP MANUAL Connect connectors Y3 and Y4. 557D479 Mount the hydraulic hose of the supply pressure, PBR valve block. 557D451 ARR 1575...
Page 220: Replacement Of The Valve Block
Travel 11�2�2 Replacement of the valve block Before removing the valve block, drain the hydraulic oil, see “Hy- draulic oil draining” (5.6.3). Removal Disconnect connectors Y5 to Y9. 557D480 Cut all cable ties on the harness / valve block. Loosen the cable harness. 557D481 ARR 1575...
Page 221 WORKSHOP MANUAL Remove hydraulic hoses A2, B2, PBR, T2. 557D482 Close the screw union. 557D483 Remove the BR hydraulic hose. 557D484 Close the screw union. 557D485 ARR 1575...
Page 222 Travel Remove the 018 (A3) hydraulic hose. Close the screw union. 557D486 Remove the 004 (T1) hydraulic hose. Close the screw union. 557D487 Remove the 037 (T3) hydraulic hose. Close the screw union. 557D488 Remove the 030 (A1) hydraulic hose. Close the screw union.
Page 223 WORKSHOP MANUAL To maintain access to the screw union of the B1 hose (1), first move the magnetic coil (2) back. Remove the knurled nut on the Y7 magnetic valve. 557D490 Remove the sealing ring (1). 557D491 Move the magnetic coil back. 557D492 Remove the 016 (B1) hydraulic hose.
Page 224 Travel Close the screw union. 557D494 Remove hydraulic hoses A1, B3, T3. Close the screw union. 557D495 Remove hydraulic hoses 010 and 036 (screw union of the angled divider). Close the screw union. 557D496 Remove the screws. 557D497 557D498 ARR 1575...
Page 225 WORKSHOP MANUAL Lift the valve block from the chassis. CAUTION: In this example, the travel pump has already been re- moved� It is not necessary to remove the travel pump to remove the valve block� You can remove the side plates on the right and left on the chassis�...
Page 226 Travel Check Magnetic valve – brake We recommend checking all magnetic coils and valves on the removed valve block. Remove the nut on the magnetic valve. 557D502 Remove the magnetic coil. 557D503 557D504 Remove the valve. 557D505 ARR 1575...
Page 227 WORKSHOP MANUAL Removed magnetic valve: Sealing ring Magnetic coil Magnetic valve Sealing ring 557D506 Supply the magnetic valve with 12 V. The valve (arrow) must switch visibly and audibly Check the sealing rings (1) for damage. 557D507 Brake magnetic coil resistance (4.9 Ohm). 557D508 ARR 1575...
Page 228 Travel Magnetic valve – high, low amplitude and steering Remove the nut on the magnetic valve. Remove the magnetic coil. 557D509 Remove the valve. Put the valve in the magnetic coil. 557D510 Supply the magnetic valve with 12 V. The piston must switch visibly and audibly 557D511 Resistance of the high / low amplitude and steering magnetic valve (4.4 Ohm).
Page 229 WORKSHOP MANUAL Max� pressure – brake, max� pressure – vibration You can set the brake drain valve if necessary. 557D513 You can set the vibration drain valve if necessary. 557D514 Magnetic valves can be activated manually. 557D515 ARR 1575...
Page 230 Travel Installation Place a new or checked valve block on the bottom plate. 557D516 Apply blue adhesive on the screws. 557D517 Tighten the valve block screws (25 Nm). 557D518 557D519 ARR 1575...
Page 231 WORKSHOP MANUAL Mount the 036 hydraulic hose on the screw union of the angled divider. 557D520 Mount the 010 hydraulic hose on the screw union of the angled divider. 557D521 Mount hydraulic hoses A1, B3, T3. 557D522 Connect the connectors in the back (Y5, Y8). 557D523 ARR 1575...
Page 232 Travel Mount the 004 (T1) hydraulic hose. 557D524 557D525 Mount hydraulic hoses A2, B2, PBR. 557D526 557D527 ARR 1575...
Page 233 WORKSHOP MANUAL Mount the hydraulic hose of the T-screw union (BR). 557D528 To maintain access to the screw union of the B1 hose (1), first move the magnetic coil (2) back. Remove the knurled nut. Remove the sealing ring. Move the magnetic coil (2) back. Mount the B1 hydraulic hose (1).
Page 234 Travel Mount the 018 (A3) hydraulic hose. 557D531 Mount the 002 (P) hydraulic hose. 557D532 Mount the 003 (T2) hydraulic hose. 557D533 Connect all front connectors (Y6, Y9, Y7). 557D534 ARR 1575...
Page 235 WORKSHOP MANUAL Place the cable harness cleanly. Fasten the cable harness with a cable tie. 557D481 ARR 1575...
Page 236: Brake Test
Travel 11�2�3 Brake test The brake function must be regularly checked. 557D119 Set the machine to the working position. Disconnect the Y9 connector from the magnet located under the front bonnet. Drive forward and reverse using the infrared controller. Check for drum spinning. If the brake is defective, the corresponding drum will spin.
Page 237: Mechanical Parts
WORKSHOP MANUAL 11�4 Mechanical parts 11�4�1 Replacement and adjustment of the speed magnet Removal Speed magnet (1). 557D231 Pull down cables Y2+ and Y2-. 557D232 Remove the safety pin from the plug head. 557D233 557D234 ARR 1575...
Page 238 Travel Remove the two screws. Remove the speed magnet. 557D235 ARR 1575...
Page 239 WORKSHOP MANUAL Installation Preassembled speed magnet (1). 557D236 Apply blue adhesive on the screws. 557D237 Place and firmly fasten the speed magnet. 557D235 Lubricate the safety pin of the plug head. 557D238 ARR 1575...
Page 240 Travel Mount the safety pin on the plug head. 557D239 Connect cables Y2+ and Y2-. 557D240 Do not interchange the - and + cables. 557D241 ARR 1575...
Page 241 WORKSHOP MANUAL Adjustment Loosen the lock nut on the plug head. 557D242 Push the piston rod completely down with your hand. The stop (arrow) must not touch the adjustment screw. 557D243 Use a feeler gauge (1.5 mm) to determine the distance between the adjustment screw and the stop.
Page 242 Travel Push the speed magnet completely to the stop! There must be a 1.5 mm gap between the stop and the adjust- ment screw. 557D246 Start the engine. Push the speed magnet completely to the stop! Measure the engine speed using the engine speed counter. If the specified speed (at least 2390–2440 rpm) is not reached, it must be adjusted on the plug head (1).
Page 243: Checking The Engine Speed And Frequency
WORKSHOP MANUAL 11�3�2 Checking the engine speed and frequency Adjust the speed at the machine operating temperature� Place the machine on two large or four small old tyres or ad- equately soft ground. 557D248 Start the engine. Select vibration. The machine sets the maximum speed = 2390–2440 rpm. Use a ...
Page 244 ARR 1575...
Page 245: Vibration
WORKSHOP MANUAL 12 Vibration ARR 1575...
Page 246 Vibration ARR 1575...
Page 247: 13 Steering
WORKSHOP MANUAL 13 Steering ARR 1575...
Page 248: Hydraulic Parts
Steering 13�2 Hydraulic parts 13�2�1 Replacement of the steering piston Replacement of the steering piston (Chapter 5.4.9). ARR 1575...
Page 249: 14 Cooling
WORKSHOP MANUAL 14 Cooling ARR 1575...
Page 250: Hydraulic Parts
Cooling 14�2 Hydraulic parts 14�2�1 Cleaning of the hydraulic oil cooler Check that the cooler fins are not dirty or clogged. Clean the fins with water or blow-clean them with compressed air. Never clean the cooler with high pressure (e�g� with strong water jets)�...
Page 251: Mechanical Parts
WORKSHOP MANUAL 14�4 Mechanical parts 14�4�1 Coolant and checking the coolant level A mixture of water and an anti-freeze liquid to -25 °C has been filled in the factory. The liquid shall be replaced with a suitable cooler mixture at temperatures below -25 °C. FULL 14�4�1�1 Checking the coolant level Check the coolant level daily.
Page 252 ARR 1575...
Page 253: 15 Engine
WORKSHOP MANUAL 15 Engine ARR 1575...
Page 254: Engine Compartment, Overview
Engine 15�1 Engine compartment, overview 15�1�1 Engine, left side 557D079 Inlet air filter Engine oil, filler neck Engine oil filter Cooling water, filler neck Oil dipstick Fuel filter Cooling water drain 15�1�2 Engine, right side Engine oil, filler neck Alternator Fuel pump Cooling water level indicator Quantity divider...
Page 255: Electrical Installation
WORKSHOP MANUAL 15�3 Electrical installation 15�3�1 Engine compartment F21-24 557D075 Engine compartment relays / fuses Engine compartment fuses Fuse no� Value Protected electric circuit Socket Functions of the engine compartment relays Input coil, tripping 40 A magnet Functions Diesel fuel pump, Ignition relay, ignition lock 10 A alternator 15+...
Page 256 Engine Height sensor Tier 4 Relay Tier 4 Relay functions Tier 4 Functions Height sensor Tier 4 557D076 ARR 1575...
Page 257: Chassis At The Rear
WORKSHOP MANUAL 15�3�2 Chassis at the rear 557D077 Relay, chassis at the rear Relay functions, chassis at the rear Functions Battery Relay, ignition Relay, hydraulic oil cooler Machine control unit Switch, sensor, safety bar (optional equipment) Infrared sensor at the front P1 Infrared sensor at the rear P2 Machines without a safety bar do not have the S24 prox- imity switch�...
Page 258 Engine 15�3�3 Battery Danger of cable burn or short circuit� Follow the order in which the clamps are disconnected and connected� • Ignition on = battery voltage The voltage during the ignition process should not drop below 10 V. Otherwise, the battery must be recharged.
Page 259: Battery
WORKSHOP MANUAL 15�3�3�1 Battery replacement Loosen the (–) clamp and remove it. 557D124 Loosen the (+) clamp and remove it. 557D125 Loosen the holding angle piece and remove it. 557D126 Lift the battery from the machine area. Insert a new battery. Connect the battery.
Page 260: Batteries
Engine 15�3�4 Batteries The batteries are filled with an acid at a density of 1.28 g/ml by the manufacturer and charged sufficiently for immediate use. When the starting power is insufficient, recharging is required. Charging • The battery must be recharged if the open-circuit voltage is below 12.5 V due to a longer storage time. The open-circuit voltage shall be checked after 2–4 quarters from the production date.
Page 261: Mechanical Parts
WORKSHOP MANUAL 15�4 Mechanical parts 15�4�1 Fuel filter element Replace the fuel filter element (1) according to the service plan. Close the cock (3). Switch to OFF. Remove the filter cap (2) Remove the old filter element (1). Insert the new filter element (1). Screw on the filter cap (2).
Page 262: Checking The Engine Oil Level
Engine 15�4�3 Checking the engine oil level Oil dipstick Check the engine oil level daily using the oil dipstick. The oil dip- stick (1) is located on the left side of the engine. Check it at a horizontal position of the roller and with cold en- gine.
Page 263: Engine Oil Filter Replacement
WORKSHOP MANUAL 15�4�6 Engine oil filter replacement Release the filter (1) manually or using the filter key. The oil starts to automatically flow out. First place a rag under it. Replace the oil filter. Install in accordance with instructions (see filter packaging or filter housing).
Page 264: Inlet Air Filter
Engine 15�4�7 Inlet air filter Dirt indicator • If the red ring appears on the contamination indicator (1) during operation of the machine, you must replace the car- tridge. 557D112 Air filter cartridge • The air filter is located on the left side of the engine. •...
Page 265: Replacement And Adjustment Of The Speed Magnet
WORKSHOP MANUAL Check the air filter cartridge for: • Damage: replace the cartridge. • Dirt: clean the cartridge. If the machine is used on heavily dusty grounds, the air filter must be checked daily for dirt� When cleaning / replacing the cartridge, make sure that no dirt enters the suction hose�...
Page 266: Checking The Engine Speed And Frequency
Engine 15�6 Checking the engine speed and frequency Checking the engine speed and frequency (Chapter 11.3.2). ARR 1575...
Page 267: 16 Optional Equipment
WORKSHOP MANUAL 16 Optional equipment ARR 1575...
Page 268: List Of Optional Equipment
Optional equipment 16�1 List of optional equipment Safety bar Drum extension set Scrapers Set of filters, 500 h Tarp cover ARR 1575...
Page 269: Safety Bar
WORKSHOP MANUAL 16�2 Safety bar 16�2�1 Safety bar replacement Remove the screws (1) on the clip body. Remove the safety bar from the chassis. 557D618 Right side, remove the screw on the safety bar. 557D619 Remove the stop on the right. 557D620 Remove the spring.
Page 270 Optional equipment Left side, remove the screw on the safety bar. 557D622 Remove the stop on the left. 557D623 Remove the magnet. 557D624 Remove the spring. 557D625 ARR 1575...
Page 271 WORKSHOP MANUAL Check if the removed parts can be reused. 557D626 Apply blue adhesive on the clip body. 557D627 Attach the clip body on the chassis using the screws. 557D628 Move the spring on the right and left to the safety bar. 557D629 ARR 1575...
Page 272 Optional equipment Move the safety bar in the clip body to the right. 557D630 Mount the clip body on the left. 557D631 Tighten the screws firmly. 557D632 Place the springs in the dedicated slots, on the right and left. 557D633 ARR 1575...
Page 273 WORKSHOP MANUAL Place the stop on the right. 557D634 Insert the screw and apply blue adhesive on it. 557D635 Mount the washer and nut. 557D636 Tighten the screw firmly. Tighten the screw firmly until the stop (1) lies in the tube with- out a gap.
Page 274 Optional equipment Mount the magnet on the left on the tube. Observe the installation position (see the figure). Insert the screw from below. 557D638 557D639 Apply blue adhesive on the screw. 557D640 Tighten the screw firmly. Tighten the screw firmly until the stop (1) lies in the tube with- out a gap.
Page 275 WORKSHOP MANUAL New safety bar, completely installed. 557D642 ARR 1575...
Page 276: Sensor Replacement And Adjustment
Optional equipment 16�2�2 Sensor replacement and adjustment Disconnect the sensor cable connectors. 557D643 Remove the sensor holder under the chassis. 557D644 557D645 Remove the old (defective) sensor from the holder. 557D646 ARR 1575...
Page 277 WORKSHOP MANUAL Apply blue adhesive on the new sensor. 557D647 Check the installation distance (approx. 25 mm). 557D649 Observe the installation position (see the white mark on the sensor head). 557D648 Mark parallel to the holder bend. 557D645A ARR 1575...
Page 278 Optional equipment Apply blue adhesive on the screws. 557D650 Put the sensor cable through the hole in the chassis. Mount the sensor holder. 557D651 Tighten the screws slightly. 557D644 Set the distance (approx. 3 mm) between the sensor head and the magnet.
Page 279 WORKSHOP MANUAL Tighten the screws to a torque of 25 Nm. 557D644 Connect the sensor cable. Fasten the connector with a cable tie. 557D643 Function check, safety bar at the top: The “Safety Bar” indicator lamp (1) must be on. 557D653 Function check, safety bar at the bottom: The “Safety Bar” indica- tor lamp (1) must be off.
Page 280 ARR 1575...
Page 281: 17 General Procedures
WORKSHOP MANUAL 17 General procedures ARR 1575...
Page 282: Electrical Installation
General procedures 17�2 Electrical installation 17�2�2 Preparation for welding work Welding work on a roller with an installed battery may damage the machine control device! Completely remove the battery before welding work on the roller� Place grounding cables of the welding equipment as near to the point of welding as possible.
Page 283: Starting The Battery By Means Of Another Battery (Jumping)
WORKSHOP MANUAL 17�2�3 Starting the battery by means of another battery (jumping) Attach the red cable to the (+) clamps of both batteries. Connect one end of the green or black cable to the (–) clamps of both batteries. Press the starter. Let the engine run. Wait until the engine evenly rotates at idle speed and discon- nect the cables form the clamps.
Page 284 ARR 1575...
Page 285: 18 Troubleshooting
WORKSHOP MANUAL 18 Troubleshooting ARR 1575...
Page 286: Error Diagnostics
Troubleshooting 18�1 Error diagnostics This chapter states possible causes of faults and their trouble- shooting according to fault symptoms. Although it is not ex- pressly mentioned, respect that cabling may always be a pos- sible cause of an electric failure. According to our experience, faults are mostly caused by the cable harness or connection of connectors�...
Page 287: The Engine Does Not Start
WORKSHOP MANUAL 18�1�1 The engine does not start The following description applies to starting using the ignition lock: If the machine cannot be started using only the manual control, refer to the next chapter. Defect description, the engine does not start Defect description Probable cause Check...
Page 288 Troubleshooting Defect description Probable cause Check The hydraulic oil cooler is not rotating Hydraulic oil temperature sensor Bypass the switch, start the engine F14 fuse Is F14 OK? K7 relay Is the K7 relay switching? Defective engine Connect the engine to the power supply directly. ARR 1575...
Page 289: Start Of The Conductor And Infrared Radiation Test
WORKSHOP MANUAL 18�1�2 Start of the conductor and infrared radiation test Normal test Open the cab cover. Open the cover without covering the sensor. Turn the ignition on. Keep a distance of three metres from the roller. Always keep an eye on the safety bar indicator lamp. If the safety bar indicator lamp is flashing, increase the distance from the roller.
Page 290 Troubleshooting Protected zone and safe zone when using the infrared remote control 555151 Protected, safe and operating zone during the operation of the infrared remote control and cable 555152 ARR 1575...
Page 291: Near And Remote Machine Halt
WORKSHOP MANUAL 18�1�3 Near and remote machine halt The near and remote machine halt function is an electronic safety feature designed to prevent the loss of visual contact between the operator and the machine and excessive proximity of the operator to the machine. A machine equipped with infrared remote control contains infrared sensors determining the safe distance of the operator from the working machine.
Page 292: Control Does Not Work
Troubleshooting 18�1�4 Control does not work To localize and remove the fault, proceed step by step as described below. 18�1�5�1 External influences • Reflective surfaces (mirrors, reflective stripes...) in the vicinity may interfere with the remote control distance detection. • Under certain circumstances, special light sources (fluorescent lamps, light beacons...) may interfere with infrared communication.
Page 293: Operation
WORKSHOP MANUAL 18�1�5�3 Operation • Has the manual control already been connected to the machine? -> Connect the cable to the manual control. • Is the distance between the manual control and the machine OK? (2.5–4 m when using a cable or 2.5–20 m when using remote control) •...
Page 294 Troubleshooting Defect description Probable cause Check The machine moves too slowly N3 manual control Is the green LED is flashing when you set the transport speed? F23 fuse Is F23 OK? K5 relay The relay must close when the function is performed. Does K5 activate? N1 control unit The magnet must pull when the function is performed.
Page 295: Display Unit
WORKSHOP MANUAL 18�1�6 Display unit When starting ignition, the display unit shows an indi- cator lamp for several seconds� All indicator lamps are on and every digit of the operating hours counter is dis- hours played as 8� On this occasion, check that the display unit functions properly�...
Page 296 Troubleshooting Defect description, the machine is not moving Defect description Probable cause Check The display unit is not working. F13 fuse Is F13 OK? After turning on ignition, neither N2 display unit After turning on ignition, there must be +12 V on pin 1 the indicator lamps nor the display and ground on pin 8.
Page 297 WORKSHOP MANUAL Defect description Probable cause Check The H5 safety bar warning indicator S24 contactless switch The indicator lamp is continuously on: lamp is on even if the safety bar is If the machine is equipped with a safety bar, check that not activated or installed.
Page 298: Manual Control
Troubleshooting 18�1�7 Manual control Infrared light emitter 557020A When ignition is turned on, indicator lamp test is displayed briefly� Both LEDs are flashing� On this occasion, check that the LEDs function properly� Otherwise, the unit must be replaced� Defect description, manual control Defect description Probable cause Check...
Page 299: Pressure Check
WORKSHOP MANUAL 18�2 Pressure check 18�2�1 Pressure check and adjustment All mentioned values are applicable at a hydraulic oil temperature of approximately 60 °C and the maximum speed of the diesel engine. Drain the pressure-relief valves for a maximum period of 5 s. Use the following pressure gauges: •...
Page 300 Troubleshooting Adjust the reverse travel pressure. Adjust the forward travel pressure. 557D016 Supply pressure valve (adjustable using spacers). 557D017 Oil may overheat and seals may get damaged� For the test procedures below, strictly observe the following: Let the engine run only briefly, for up to 5 s� After performing the test procedures, reconnect all hydraulic hoses.
Page 301: Checking The Steering Pressure
WORKSHOP MANUAL 18�2�2 Checking the steering pressure Turn the machine to the limit position. Hold the lever pressed throughout the entire further procedure. 557D018 Measurement point (1) Vibration/steering pressure. If a steering pressure of 67 ± 7 bar is not reached: •...
Page 302: Checking The Maximum Vibration Pressure
Troubleshooting 18�2�4 Checking the maximum vibration pressure This procedure must be performed when the vibration setting pressure is lower than 200 bar. Open the rear bonnet. Ensure access to the angled screw connection. Cut the cable ties on the hose bundle. 557D020 Remove the hydraulic hose (016) from the angled screw con- nection.
Page 303 WORKSHOP MANUAL Remove the magnetic coil (1) from the magnetic valve (2). 557D024 Remove the hydraulic hose (030). 557D025 Pressure-close the screw connection. 557D026 Reinstall the magnetic coil. 557D027 ARR 1575...
Page 304 Troubleshooting Connect a pressure gauge (at least 250 bar) to the vibration pressure measuring point (1). Start the engine. Full speed Turn on vibration. Let it run for no more than 5 seconds. 557D028 If a vibration pressure of 220 ± 10 bar is not reached: •...
Page 305: Checking The Travel Pump
WORKSHOP MANUAL 18�2�5 Checking the travel pump 18�2�5�1 Checking the maximum supply pressure Remove the 008 hydraulic hose for the supply pressure measur- ing point. 557D029 Pressure-close the screw connections (1). 557D030 Remove the hydraulic hose of the B travel circuit (forward) for the travel pump.
Page 306 Troubleshooting Connect a pressure gauge (at least 40 bar) to the supply pres- sure measuring point (1). Start the engine. • Full speed • Let it run for no more than 5 seconds. 557D033 If a supply pressure of 21 ± 2 bar is not reached: •...
Page 307: Checking The Travel Pressures (Reverse/Forward)
WORKSHOP MANUAL 18�2�5�2 Checking the travel pressures (reverse/ forward) Pull out the Y9 connector (1) on the valve block. 557D034 Connect a pressure gauge (at least 400 bar) to the travel pres- sure measuring point (1). Start the engine. Full speed Reverse while braking.
Page 308: Checking The Maximum Pressure Of The Travel Pump (Reverse/Forward)
Troubleshooting 18�2�5�3 Checking the maximum pressure of the travel pump (reverse/forward) Remove the hydraulic hose of the B travel circuit (forward) for the travel pump. Pressure-close the screw connections. 557D031 Remove the screw connection of the A travel T-circuit (reverse) for the travel pump.
Page 309: Checking The Travel Hydraulic Motors
WORKSHOP MANUAL 18�2�6 Checking the travel hydraulic motors The following operation is required, when: • The travel pump test is positive. • The pressure is not reached with the connected travel mo- tors. Successively check individual travel motors. Remove the hydraulic hoses of the travel circuit A and B on the travel motor.
Page 310: Adjustment Of The Travel Pump Zero Position
Troubleshooting 18�2�7 Adjustment of the travel pump zero position Remove both plugs X1 and X2. 557D038 Remove the aperture. 557D039 Check the aperture (1) for clogging. Blow-clean it with compressed air. Mount plugs X1 and X2 (40 Nm). Tighten the aperture properly when mounting it back! 557D040 Place the machine safely on blocks! Let the machine run.
Page 311: Checking The Travel Pump Magnetic Coil / Travel Pump Servo Block
WORKSHOP MANUAL 18�2�7�1 Checking the travel pump magnetic coil / travel pump servo block The travel pump magnetic coil cannot be controlled mechani- cally. 557D042 Loosen the knurled nut. 557D043 Remove the magnetic coil. 557D044 Screw out the magnetic valve. 557D045 ARR 1575...
Page 312 Troubleshooting 557D046 Measure the resistance of the Y3/Y4 magnetic coil. The resistance value is approximately 6 Ohm. 557D047 Connect 12 V to the magnetic valve. The valve (arrow) must visibly switch. 557D048 Change the position of the magnetic coil connector The position of the connector can be changed by turning the magnet body as needed.
Page 313: Travel Pump Servo Block Check
WORKSHOP MANUAL 18�2�8 Travel pump servo block check The procedure shall be performed when: • The electric part of the machine has been checked and the machine is still not running. • The machine only moves in one direction. • The machine only moves slowly with the lever switched to the limit position.
Page 314 Troubleshooting Loosen the apertures and screw them out. The apertures must not be loose! Loose apertures cause problem when driving� 557D054 Loose apertures can be easily removed using a small magnet. Improvise as needed. 557D055 A view of the dismounted aperture holder (1) with apertures. 557D056 Loosen the knurled nut.
Page 315 WORKSHOP MANUAL Remove the magnetic coils. 557D058 Screw out the magnetic valve. 557D059 557D060 View of the control piston. The control piston is a spring type and shall always spon- taneously return to the zero position� 557D061 ARR 1575...
Page 316 Troubleshooting Checking the control piston movement e.g. by means of a screwdriver. Press the piston to the stop from the left to the right three to four times. The movement must not be stiff in any case! It must move smoothly and return easily to the zero posi- tion under the force of the spring, from both sides�...
Page 317 WORKSHOP MANUAL Mount the magnetic valve. 557D066 Install a cleaned aperture with the holder and tighten firmly. 557D067 Check the plug seal. Lubricate the seal slightly with oil. 557D068 Install both plugs and tighten firmly. 557D069 ARR 1575...
Page 318 Troubleshooting Reinstall both magnetic coils. 557D070 Install the round seal ring and tighten firmly with a knurled nut. 557D071 Connect the cable. Fasten it using a cable tie. Check the function and sealing. ARR 1575...
Page 319: Checking The Quantity Divider
WORKSHOP MANUAL 18�2�9 Checking the quantity divider 557D072 Quantity divider 1. Aperture access 2. Front piston access 3. Rear piston access 4. Front non-return valve access 5. Rear non-return valve access 1. Quantity divider – housing 2. P connection of the B pump 3.
Page 320: Speeds And Pressures
Troubleshooting 18�2�10 Speeds and pressures after 5 min. after 60 min. Diesel engine speed 2415 ±25 2405 ±25 Vibration speed front low 2250 ± 150 2250 ± 150 rear low 2250 ± 150 2250 ± 150 front high 2250 ± 150 2250 ±...
Page 321: Roller Overturning
WORKSHOP MANUAL 18�3 Roller overturning 557D133 Place the machine on belts as quickly as possible. Turn off the ignition (0 position). Never try to immediately start the engine! Prevent oil shock! It can result in serious engine damage! 557D134 Operating fluids pose a risk to the environment! Prevent fluids from leaking into sewage systems, soil or the environment�...
Page 322: Checking Damage
Troubleshooting 18�3�1 Checking damage Open both bonnets. Disconnect the grounding cable (–). Disconnect the battery. Check the machine for visible defects, especially for leaked liquids. If necessary, drain defective tanks. 557D135 18�3�2 Preventing oil shock Before removing parts, thoroughly clean the area of valve caps, cylinder heads and electrical sheet�...
Page 323 WORKSHOP MANUAL Remove the air filter hose at the top. Remove the air filter hose at the top. 557D138 Remove the fuel filter. Remove the fuel filter. 557D139 557D140 Remove the electrical sheet and tilt it back. 557D141 ARR 1575...
Page 324 Troubleshooting Screws at the back. 557D142 Screws at the front. Remove the electrical sheet at the back / front. 557D143 Remove the valve cap. Remove the valve cap. 557D144 557D145 ARR 1575...
Page 325 WORKSHOP MANUAL Remove the three cables and the contact connection on the glow plugs. Remove the cables and the contact connection. 557D146 Remove ALL three glow plugs. Tools: Long bit and torque spanner. Remove the tool / glow plugs. 557D147 557D148 ARR 1575...
Page 326 Troubleshooting Rotate the engine with a spanner Make sure that any accumulated oil is pushed out by the piston. Rotate the engine on the central screw crankshaft clockwise twice using a box-end ratchet spanner (1). 557D149 557D150 Danger of cable burn or short circuit� Insulate the glow plug cables e�g�...
Page 327 WORKSHOP MANUAL Risk of burns from splashing oil! Eye damage, burns� Wear safety goggles� Rotate the engine with the starter Rotate the engine with the starter (1–2 min.). After several turns, the accumulated oil in the combustion area should be pushed through the glow plug holes. Repeat the process after approx.
Page 328: Starting The Engine
Troubleshooting 18�3�3 Starting the engine 1� Attempt to start Rotate the ignition key clockwise to the III position. The starting attempt was successful, the engine is running: See below under “The engine is running”. The starting attempt was unsuccessful, the engine is not run- ning: There may be air in the diesel system.
Page 329: 19 Appendices
WORKSHOP MANUAL 19 Appendices ARR 1575...
Page 330 Appendices ARR 1575...
Page 331: Hydraulic System
WORKSHOP MANUAL 19�1 Hydraulic system 19�1�1 Adjustment of the travel pump zero position Adjustment of the travel pump zero position (Chapter 18.2.7). 19�1�1�1 Checking the travel pump magnetic coil / travel pump servo block Checking the travel pump magnetic coil / travel pump servo block (Chapter 18.2.7.1).
Page 332: Wiring Diagram
Appendices 19�2 Wiring diagram Legend: A1 ACEecon display A2 ACEecon display A3 ACEecon sensor F11 Fuse, control unit, power supply F12 Fuse, control unit, outputs F13 Fuse, display unit, safety bar F14 Fuse, hydraulic oil cooler F21 Fuse, pull solenoid F22 Fuse, fuel pump, alternator F23 Fuse, working speed F24 Fuse, ignition coil...
Page 333 WORKSHOP MANUAL Anlasser 68Ω Dieselpumpe pull 0.5A hold pull Zündung Spannungsversorgung Logik 0.5A hold Spannungsversorgung Motorhaltespule Ausgänge Öltempschalter Steuerbus D+ Hydraulikölkühler Steuerbus D- Masse Spannungsversorgung + Masse Spannungsversorgung - Vorwärts Pegel A Rückwärts Pegel B Rückführung Spannungsversorgung + Lenkung links Spannungsversorgung - shield Led On +...
Page 334: Hydraulic System Diagram
Appendices 19�4 Hydraulic system diagram Legend: 1 Travel pump 2 Steering and vibration pump 3 Travel hydraulic motor, rear left 4 Travel hydraulic motor, rear right 5 Travel hydraulic motor, front left 6 Travel hydraulic motor, front right 7 Left steering hydraulic cylinder 8 Right steering hydraulic cylinder 9 Valve block of vibration, steering and brake 10 Vibration hydraulic motor, front...
Page 335 WORKSHOP MANUAL Front right travel motor 408 ccm Front left Rear travel motor vibration 408 ccm motor 8ccm Nozzle block Front vibration motor 8ccm Rear left travel motor 408 ccm Rear right travel motor 408 ccm Flow divider Valve Block for Vibration, Steering and Brake Diesel engine...
Page 336: Workshop Jigs
Appendices 19�6 Workshop jigs 19�6�1 Special tools Assembly tool for the travel motor 557D655 Assembly tool for the vibration unit 557D656 Removing tool for swinging joint bearings 557D584 Insertion screw of the swinging joint bearing 557D657 ARR 1575...
Page 337 WORKSHOP MANUAL Assembly tool for swinging joint bearings 1175656 557D658 Pressure screws of the swinging joint bearing 557D659 Spacer for pressure screws (4x) 557D660 Assembly pin, heavy clamping pin, swinging support 557D661 ARR 1575...
Page 338 Appendices Special bit for the installation of an infrared sensor. 557D662 Spanner for grooved nuts for the vibration gearbox 557D323 Bridge for the vibration gearbox torque meter 557D663 Torque meter 557D664 ARR 1575...
Page 339: Special Tool For Measuring The Speed And Frequency
WORKSHOP MANUAL 19�6�2 Special tool for measuring the speed and frequency Revolution counter 2-90000030 557D665 19�6�3 Special tool for magnetic coil check Solenoid tester 1-10300477 557D666 ARR 1575...
Page 340: Checking The Tightness Of Screw Connections
Appendices 19�7 Checking the tightness of screw connections • Check regularly the screw connections for loosening. • Use torque spanners for tightening. Tightening torque Tightening torque For screws 8�8 (8G) For screws 10�9 (10K) For screws 8�8 (8G) For screws 10�9 (10K) Thread lb ft lb ft...
Page 341 WORKSHOP MANUAL Tightening torques for necks with sealing edge or flat Tightening torques for plugs with flat sealing sealing Tightening torques of necks Tightening torques of plugs lb ft lb ft G 1/8 G 1/8 G 1/4 G 1/4 G 3/8 G 3/8 G 1/2 G 1/2 G 3/4...
Page 342 Notes ARR 1575...
Page 343 WORKSHOP MANUAL Notes ARR 1575...
Page 344 Notes ARR 1575...
Page 345 WORKSHOP MANUAL ARR 1575...
Page 346 More information on products and services can be found at: www.ammann.com Materials and technical modifications are reserved without prior notice. Book ID: 4-P08000-EN | © Ammann Group...

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