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RX1575 Service Manual - Multiquip Service & Support Center

1. 16 02 in 407 mm 1 4 _ 50 47 in 1282 mm 51 85 in 1317 mm 39 37 in 1000 mm _ 77 95 in 1980 mm Nu _ 25 20 in 640 mmy 33 46 in 850 mm 87 68 in 2227 mm Fig 2 1 Dimensions Rammax 1575 Specifications Tab 2 2 Hammax 1575 performance data Roller drum width mm Service weight according to CECE kg Static linear load kg cm Outside inside turning radius mm Large small amplitude mm Gradient in 9o with without vibration Drive Performance according to ISO 3046 Operating speed Travel speed working gear Transport gear travel speed Steering angle pivoting Vibration frequency Product description Rammax 1575 24 640 33 850 3 087 1400 3 197 1450 10 1 11 6 7 7 8 9 36 25 61 2191 1541 90 57 2286 1436 024 0 6 0 43 1 1 40 50 YANMAR 3TNV76 EPA 4 15 0kW 20 4HP 2400 1 min 82 25 m min 148 45 m min 30 7 2 460 41 Hz 19 2 3 2 3 1 20 Tab 2 3 Rammax 1575 filling capacities Container Contents Hydraulic oil tank 4 2 16l Diesel tank 7 4 28 Roller designation Identification plate An identification plate is affixed to the roller for identification The identification plate is attached to the rear part of the chassis below the steering column 1 2 3 4 11 12 13 Fig 2 2 Data on the identification plate Roller designation Homolo
2. 35 5 1 DISDA UNI a aa a a a eae en ere rA 36 5 1 1 CONMOLIEMPS 2 uoo X eeu ues eee oS eres ed REUS 36 5 1 2 Control lamp functions 0 0 0 aaa eee 36 9 1 3 LED error display on the display unit ls 38 5 2 Infrared transmitter 2 0 0 0 ees 40 5 2 1 DESIGN seare aces a E Gta s a r a Mea Sia era re 40 5 2 2 LED error display on the IR transmitter 40 0 2 3 Cable conpnecllol zoe trea t dec I c RE 42 0 2 4 HANINO asanare crc PT 42 6 Hydraulic Syst m i ios cs E aba eene c Ce aic ca e ea 45 6 1 Overview of the hydraulic system 0 00000 eee ees 46 6 1 1 Hydraulic hose service life and storage 46 6 2 Overview of hydraulic hoses 0000 47 6 2 1 Hoses for travel vibro drive ees 47 6 2 2 Valve block connections 0 000 eee eee ees 51 6 2 3 Valve block hoses 0 000 tee eens 54 6 3 Checking and adjusting pressures 0 000 cee eee 56 6 3 1 Checking the steering pressure 0 00000 c eee eee 58 6 3 2 Checking the maximum vibration pressure 58 6 3 3 Checking the maximum charge pressure llis 61 6 3 4 Checking the drive pressures reverse forwards 62 6 3 5 Checking the drive motors llle 63 6 3 6 Checking the maximum drive pump pressure reverse forwards 64 6 4 Setting the drive pump to the neutral position 65 6 4 1
3. 0 0000 263 Pendulum support 0 000 cee ees 264 IsermoVala u siehe Matha des to at ee eh ae cM Rea a 264 Replacing the joint head llle 265 IristallallOFl s a etin actas a te Da RARUS pane iR ss Se te 268 Replacing the steering cylinder llle 269 Removing the old steering cylinder llis 269 Install a new steering cylinder llllllllssn 271 PENGUM JONT 25 d ac dep ob tU JOE Rosa d epo e a nios 212 Shutdown p la scours acs ae Blache SS SS Sats See esas a 282 Replacing the shutdown bar 0 0 000 282 Sensor replacement and adjustment Ln 288 LOIS 4 Wars deb Se OLE ARE ee at e ae ROS opu a ee 291 Special 100lS 52 1 0 a e od cS Ss ae ERR KASS eet 291 Special tool for measuring speed and frequency 294 Special tool for checking solenoids iss 295 Pl gs and Stoppers sirc ersa ORCAS AREA SWS X do RS S M eds 295 VIDFOLTIOUOT a scare im pc e eC oh de Dono SICURA Sit ath Sek Be Bui a ru d 295 Vibromotor valve block maximum pressure 295 DAVE HIOLOF 3 ois S years a E es ra mos Eco ROS We Eee ato a a 296 Drive pump drive pressure test 0 00000 cee eee 296 Drive pump charge pressure llle 296 Steering valve block maximum pressure LLL 296 jj Mp PE rp 297 SOGE TENTE 298 Short term storage a aaaea 298 Long term storage scu i Ec oce eed ew
4. 4 Structure and function 4 1 32 Component overview Rammax 1575 c TE M B E eg d IO Ill e Fig 4 1 View from the right 1 point lifting eye Identification plate Roller drum scraper Rear hood latch cowling Front hood latch engine hood o Oo A c NY Front infrared sensor Fig 4 2 View from left 1 2 3 4 Articulated joint protection Shutdown bar optional Cockpit cover Rear infrared sensor Hammax 1575 Fig 4 3 Cockpit overview Infrared transmitter Storage area for spiral cable Display unit Ignition switch Fuses O on Ac N gt Connector for spiral cable to infrared sensor back area Fig 4 4 Overview of interior of rear chassis 1 2 3 4 5 Oil cooler Fuel tank Hydraulic tank Battery Controller machine controller Component overview Rammax 1575 Structure and function 33 34 Fig 4 5 Front bottom view 1 Engine oil drain plug Hammax 1575 D Operating and display elements 5 1 Display unit 5 1 1 Control lamps hours MULTIQUIP RAM M Display operating hours counter Control lamp for battery charge level charge control Error control lamp Control lamp for engine oil pressure Control lamp for cooling water temperature Control lamp for shutdown bar o oc c NN gt Control lamp for pre heating 5 1 2 Control lamp function
5. Fig 10 41 201309210011 Installing the sensor 1 Insert the new sensor Fig 10 43 201309260006 Fig 10 42 201309260005 1 Screw the sensor in place from the outside using the special tool AF size 36 1 Apply blue adhesive to the screws of the protective cover of the sensor Fig 10 45 201309260009 Front engine hood Repair 163 1 Position the protective cover for the sensor on the hood 1 Securely tighten the M6x30 AF size 5 Allen screws to a torque of 10 Nm Fig 10 47 20130926001 1 1 Secure the cables in the cable mountings under the hood Fig 10 48 201309260013 Fig 10 49 201309260012 1 Secure the cable to the bracket on the upper part of the hinge with a cable tie Fig 10 50 201309260014 164 Rammax 1575 1 Secure the cable to the bracket on the lower part of the hinge with a cable tie 1 Securethe cable to hydraulic hose 010 with a cable tie 1 Screw connector X5 front IR sensor back together 2 Secure cable with cable tie Fig 10 53 2013092600 18 10 5 4 Replacing the rubber hood buffers We 1 Remove the M8 hex nut from the mM rubber buffer AF size 13 Fig 10 54 201311050004 Front engine hood Repair 165 166 A Va ON S Fig 10 55 201311050005 i Y t E A Fig 10 58 201311050009 1 1 1 1 Remove the rubber buffer from the mounting Apply blue adhesive to the threads of the new rubber buffer Install th
6. Only open the radiator once the engine and the coolant have cooled down 1 Unscrew the lid of the radiator 2 Add coolant with antifreeze until the radiator is full Fig 9 32 Coolant filler neck 9 11 3 Cleaning the radiator 1 Check the cooling ribs of the water tank for dirt and clogging 2 Clean the ribs with water or blow them out with compressed air NOTE Never clean the cooler with high pressure e g powerful water jet Coolant Maintenance 131 9 12 9 12 1 9 12 2 132 Fig 9 33 Radiator grill Functional check Scrapers 1 Before driving adjust the roller drum scraper so that there is a clearance of about 5mm between the roller drum and the scraper Fig 9 34 Roller drum scraper Air intake filter Soiling indicator 1 Ifa red ring appears on the soiling display 1 during operation of the roller you must 2a clean the air filter cartridge 2b orreplace it Hammax 1575 NOTE Functional check Fig 9 35 Soiling indicator Air filter cartridge The air filter is located on the left side of the engine 1 Remove the wing nut 1 with the cover 2 Remove the wing nut 2 from the air filter cartridge 3 Remove the air filter cartridge 3 4 Check the air filter cartridge for 5a Damage replace the cartridge 6a Soiling clean the cartridge Fig 9 36 Air filter cartridge If the machine is used on very dusty surfaces the air filter must be checked for cl
7. Install the O ring 1 Install the knurled nut Tighten the magnetic coil Install hydraulic hose 018 A3 Install hydraulic hose 002 P Hammax 1575 1 Install hydraulic hose 003 T2 1 Connectall the connectors at the front Y6 Y9 YT Fig 10 474 201309220067 1 Route the wiring harness with care 2 Secure the wiring harness with cable ties 10 20 Readying the machine for operation After replacing components drive pump valve block drive motor for which all of the oil had to be drained the machine must be refilled and the charge pressure must be built up once again Siehe Hydraulic oil replacement see page 127 Readying the machine for operation Repair 263 10 21 10 21 1 264 Pendulum support Removal Install joint protection Place the hydraulic jack at the center of the pendulum joint Slightly relieve the pressure on the roller Remove the two M12 hex screws AF size 19 for front support Ww WM Fig 10 478 201309240012 Remove the two M12 hex screws AF size 19 for rear support Fig 10 480 201309240016 Hammax 1575 2 Remove the pendulum support AN MM RR REIR ILLU UH Wain tn ee j m cs M EU n TE T ide IPIE UT m batle lavate niitan bdieli L T Fig 10 483 201309240032 1 The on center dimension from one joint to the other must be recorded before disassembling the pendulum support This dimension is required for
8. SERVICE MANUAL RX1575 TRENCH ROLLER SCHEMATICS o TEST PROCEDURES o TROUBLESHOOTING Rammax 1575 Yanmar 3TNV76 Diesel Engine Hammax 1575 Preface This manual was created for field and in the shop service Along with maintenance and repair instructions this Service Manual also contains a description of the machine This Service Manual does not however replace the roller operating manual Because the content of the deliverable depends on the order the features of your roller may differ in some descriptions and pictures The Rammax 1575 trench roller is a roller specially designed for trench compacting Hammax 1575 MULTIQUIP Table of contents I Il Il Il Il Il l3 Il lA cl et NOORWND No ND ND Cie i ek eG No General MePCPT LOTPTT 11 About this Service manual llle 12 Target audience 1 0 6 re 12 PUIPOSE c c 12 Scope of this Service manual 0 0000 ee eee eee 12 Completeness of the Service Manual 12 Technical changes llle 12 CODON 4 2 q 3069 6 806 Vo eh ones Fed beens GER eS Je Oe ic eas 12 Spare OAS esra reti eno POR GE ee ARE RE REOR C NR Ue os 13 Structure of the Service Manual cee eens 13 Orientation on the roller llle 13 luu 5 rD C m 14 Product description lllellrl
9. e It must slide smoothly without catching and return smoothly to the 0 position by means of the spring force This must be the case on both sides NOTE If the control spool does not move without catching after several tries or it does not return to the 0 position by itself then it is mechanically damaged The servo block must be repaired in a qualified repair shop View of the pump before assembly Checking the drive pump servo block Hydraulic System 71 1 2 Fig 6 66 201308290016 s p 1 1 Fig 6 68 201308290018 1 2 Fig 6 69 201308290020 72 Check the seals of the solenoid valve for damage Oil lightly Install the solenoid valve AF size 17 Put the cleaned aperture with the aperture holder in place and tighten Check the seal of the closure plug Lubricate the seal lightly with oil Rammax 1575 1 Put both plugs in place and tighten i 4 H Fig 6 70 20130829001 1 Re mount the two magnetic coils 1 Putthe O ring in place and tighten the knurled nut Fig 6 72 201308290022 1 Connect the cable 2 Secure them with cable ties 3 Perform a functional check and look for leakage Checking the drive pump servo block Hydraulic System 73 6 6 Checking the flow divider Fig 6 73 201311050001 flow divider Access to aperture Access to front piston Access to rear piston Access to front check valve O A O N gt Access to rear check valve Fig 6 74
10. ATNV88 ATMVSET ATNWEIDG ATHV DST Pii DBTHVO CHOQUN INDUSTRIAL ENGINES APPLICATION MANUAL TNV Series If you have any questions or doubts regarding how to service and or repair the Yanmar engine please consult the Yanmar service manual and the application manual to obtain the required information These manuals can be obtained through the directly from Yanmar 113 9 4 114 Maintenance check sheet Roller serial no Hammax 1575 9 5 Opening the hood front and rear ADANGER Danger of severe injury through loose clothing being caught and drawn in Only open the engine hood when the engine is switched off e If trouble shooting makes working on moving parts engine or roller unavoidable never wear Necklaces bracelets rings scarves ties or other loose items of clothing If any of these get caught in moving parts there is a danger of serious injury Danger of burns from hot roller parts Only work on a cool engine Keep enough distance to the exhaust There is one locking device each on the front and back as well as the left and right of the roller 1 Open both catches on the right and the left 2 Open the hood 2 1 Lift the hood with slight pressure toward the center of the roller 2 2 f the hood is defective replace it immediately Fig 9 1 Locking device NOTE Two gas struts reduce the force required to open the hood and give it its
11. Coupling on vibromotor OK Vibro unit OK Are Y7 and Y8 being actuated Does the green LED flash when the steering is actu ated Are the connectors connected Are the magnetic coils and valves OK Has the magnetic coil been actuated manually Are Y5 and Y6 being actuated Steering pressure OK Mechanical faults Steering cylinder OK Hammax 1575 8 4 Display unit Fig 8 2 Display unit NOTE When the ignition is turned on a lamp test will run on the display unit for a couple of seconds During this test all the lamps will light up and every digit in the operating hours counter will be shown as an 8 Use this test to check whether the display unit is working correctly If it is not it will have to be replaced Tab 8 3 Fault description machine won t move Fault description Display unit is dead No lamps and displays when ignition is switched on Operating hours counter P3 is not working and battery charging lamp H1 does not turn off when the engine is running lamp H1 does not light when the ignition is switched on Error warning indicator H6 lights up Display unit Troubleshooting Possible cause Fuse F13 Display unit N2 Relay K1 Alternator G1 Display unit N2 Alternator G1 Cable connector display unit N2 Controller N1 Fuse F22 Alternator G1 Engine oil pressure switch 21 Checks Is F13 OK When the ignition is on pin 1 must have a voltage of 12 V
12. Damager to property due to increased wear e Regrease the bearing after every cleaning steam cleaning of the roller Brake test The function of the brakes must be checked periodically Lubricating steering cylinder bearing Maintenance 135 9 14 1 Cable connector Y9 The cable connector Y9 which must be disconnected for the brake test is located at the front under the hood Fig 9 41 Cable connector Y9 under the hood 9 14 2 Brake test Fig 9 42 201309220064 cable 201309220064 connector Y9 under the hood T 1 Putthe machine into the work gear 2 Disconnect connector Y9 1 from the connector housing at the magnet 3 Perform the forwards and backwards driving functions using the infrared sensor 4 Check all four roller drums for rotation slipping If a brake is defective the corresponding roller drum will rotate NOTE If a brake is defective the roller is no longer safe for operation Contact your authorized dealer and have the roller repaired professionally 136 Hammax 1575 9 15 NOTE Lubricant table Tab 9 2 Lubricant table Brand Standard Application AGIP BLASER BP CASTROL ESSO MOBIL Motorex PANOLIN SHELL TOTAL decompose Lubricant table Maintenance Hydraulic oil ISO VG 46 HVLP DIN 51524 T3 Drive and vibration hydraulics Amica 46 Blasol 148 Bartran HV 46 Hyspin AWH 46 Univis HP 46 Mobil DTE15 Corex HV 46 HLP Universal 46 Tellus T 46 Equi
13. Fig 10 273 201310010023 1 Place one drop of blue thread adhesive in each threaded bore Fig 10 274 201310010024 1 Clean blow out the holes in the gear box cover F LI a DA hs Fig 10 275 201310010026 S dd 1 Clean the sealing surface of the gear box cover Fig 10 277 201310010027 Replacing bearing vibro unit Repair 217 218 Fig 10 280 201310010031 Fig 10 281 201310010034 1 1 1 1 Apply blue adhesive to the threads of the rubber elements Put the gear box cover in place Tighten the seven M10 hex nuts 1 AF size 17 to a torque of 50 Nm Apply blue adhesive to the twelve M8x35 22 hex screws Hammax 1575 10 15 10 15 1 1 Tightenthe hex screws 1 AF size 13 to a torque of 36 Nm Fig 10 283 201310010038 1 Install the hose guide bracket 1 using the same screws O Fig 10 284 201310010036 Replacing the drive motor Removal 1 Safely jack up the machine 2 Remove the hex screws AF size 19 on the roller drum scraper a Fig 10 285 201309260053 Replacing the drive motor Repair 219 220 Fig 10 286 201309260054 wk LAE a s d Fig 10 290 201309260060 1 Remove the scraper am Fig 10 287 201309260056 1 Attach an anchor sling to the roller drum 2 Usea crane to slightly lift the roller drum 1 Remove the roller drum screws AF size 19 1 Pullthe roller drum out
14. Hydrauliktank Pos 22 DN12 Pos 23 DN12 Hammax 1575 Fig 6 76 Hydraulics diagram no 10442344 6 6 8 1 Hydraulics Diagram Legend Tab 6 14 Hyaraulics Diagram Legend Element Hydraulics diagram Hyaraulic System Oo do N Oo oa A O N gt EN ea E EJ En O N O O1 A O N a Q Description Drive pump Vibro steering pump Drive motor rear left Drive motor rear right Front left drive motor Front right drive motor Left steering cylinder Right steering cylinder Valve block Vibro motor front Vibro motor rear Oil cooler Hydraulic oil filter Hydraulic oil tank Ventilation filter Diesel tank Hydraulic manifold Flow divider 7 8 Hammax 1575 f Electrical system 7 1 Engine electrical system Fuses ADANGER There is danger to life if the roller does not stop in hazardous situations Fuses and safety switches must never be shorted Risk of injury through short circuit and cable fire when handling electrical parts Always disconnect the power supply when working on the electrical system NOTE Before replacing the fuse you must identify and remove the cause of the fault Always replace a defective fuse 1 with a functioning fuse 2 of the same amperage according to the label or color of the fuse 7 1 1 Engine compartment F25 Fig 7 1 Relay Engine compartment fuses 80 Rammax 1575 Tab 7 1 Engine compartment relay functions Functio
15. Overview of hydraulic hoses Hyaraulic System 47 48 Front right roller drum Fig 6 2 201310020004 Tab 6 2 Hoses for front right roller drum No 30 32 34 36 38 39 40 of Vibro motor front Drive circuit B forwards Drive circuit A reverse Front vibromotor connection at rear Front right drive motor brake Front right drive motor leakage oil L fitting Front right drive motor leakage oil L fitting position Valve block A1 Hydraulic manifold right Drive pump A T fitting Junction vibration elbow bulkhead fitting Left drive motor brake L fitting Front left drive motor leakage oil L fitting Leakage oil front vibromotor Rammax 1575 Hear left roller drum Fig 6 3 201310020002 Tab 6 3 Hoses for rear left roller drum No of position 50 Rear vibromotor connection at rear Junction rear elbow fitting 52 Drive circuit B forwards Junction at rear 54 Drive circuit A reverse Junction at rear 56 Rear vibromotor connection at front Junction rear elbow fitting 58 Rear left drive motor brake Rear right drive motor brake L fitting 59 Rear left drive motor leakage oil L fitting Rear right drive motor leakage oil L fitting 60 Rear left drive motor leakage oil Rear vibromotor leakage oil Overview of hydraulic hoses Hydraulic System 49 50 Rear right roller drum Fig 6 4 201310020001 Tab 6 4 Hoses for rear right roller drum No 51 53 55 57 58 59 of Drive ci
16. This Service manual is intended for service technicians in the field and at repair shops who have been authorized to service and repair MQ vibratory rollers by the relevant operating company Purpose The purpose of this Service manual is to ensure that the roller will be used optimally and safely during the following processes e Maintenance e Repair Scope of this Service manual This Service manual covers the following rollers Rammax 1575 oome of the figures and descriptions in this Service manual may not exactly match your roller Completeness of the Service Manual Never remove sections from this manual Missing pages specifically the Safety section must be replaced immediately if lost Technical changes In the interest of technical developments Multiquip reserves the right to make changes to this document at any time without separate notice Hammax 1575 1 1 6 1 1 7 1 2 1 2 1 Copyrights The publisher of this EC compliant customer document is Ammann Schweiz AG We reserve all rights for this document and the roller described therein Reproduc tion disclosure to third parties or utilization of its content is forbidden without our express permission 2011 Ammann Schweiz AG Spare parts When performing scheduled and unscheduled repairs you may need to replace components of the roller Only use spare parts which meet the requirements specified by the Amman Schweiz AG These requirement are ful
17. iM tpa 114 A 170 c 2x P i 1 E X bu d g y e lt grosse Amplitude x tx Pes TE te Peo 11574 070 o 2x PS 3A e Ed een AS YS kimine Amplitude rg D M 6 wpe MEKA 3 772 x 2x POT bi Le Y 9 554 asi Bremse J X5 X X wP ory I Seneor vora tx P89 754 dips shield 2x P91 os Da 2 3 jm lx PPS is ell moo 6 m d L TA 25 IN a s 554 D x PLS 3 STIL 149 153 165 i 166 169 170 H ATA 472 173 1x PGT 174 189 194 Massa Motor Mitte vorne Fig 7 8 Front chassis wiring harness 88 F230 B e 750 F2 4007 B Bs m ix Peo 141 iem e 143 Sa P55 F21her SS a unre ee VE amp 163 2x PST F 22 055 S 5 fea 8 amp 556 P ix P 2 dx PLS 138 Mez Maz 181 188 Anlasser 148 No 8 as PB KL30 8 txP amp amp KL 50 qpr D t 4 T Qo Ws 188 1B 136 amp PH a 3x P56 0 p x3 a fi i xn GOO 1207 ohetspurm 141 ras 5 enm Gi mm rem 2x PAD e tx O be dx P56 50 z 5 522 GlLIMA B K hhwassertemperaturschalter m 32 EJ t Pas Pw 3 50 F M2 Dieseipumpae tx Pag EE me x PSS i ses Y2 Gasmagnet 181 ira ne 2x PIS T Co SPI 5 Rammax 1575 Tx Peo ix PSS Tx P56 77 129 F11 m oon F13U BE 5 i l 180 Z ndschloss 15 O O rz F14 nE E nsa o F12 7 BEBE mz 177 t3 oh Liss ns fl T 1 17 L J 2x l n r 1 X O6 Hg 107 r 1 d 15
18. 1 Position the new bearing 1 Press the bearing into the clamp ring Fig 10 538 201309240075 Pendulum joint Repair 277 N Clean the chassis support TE As Fig 10 540 201309240077 1 Grease the bearing seat 2 Apply sealant to the sealing surface Fig 10 543 201309240081 1 Draw the bearing flange into the support with M12x60 hex screws and spring washers Fig 10 544 201309240083 2 8 Hammax 1575 1 Grease the bearing bolt 1 Center the chassis relative to the bearing bolt Fig 10 547 201309240088 1 Position the washer 2 Screw the M16x100 hex screw with the nut into the bearing bolt 1 Using the M16 AF size 24 hex nut pull the bearing over the bearing bolt 2 Remove the hex screw Fig 10 549 201309240090 Pendulum joint Repair 279 280 Fig 10 550 201 309240091 Fig 10 555 201309240097 1 Install retaining washer onto the screw 2 Apply blue adhesive to the M16x30 hex screw 1 Secure the pendulum bearing with the M16 hex screw AF size 24 and washer 210 Nm 2 Remove the four mounting screws 1 Fig 10 552 201309240093 3 Apply sealant to the surface of the clamp ring Fig 10 554 201309240096 1 Put cover in place Hammax 1575 1 Apply blue adhesive to the four M12x40 hex screws a7 Fig 10 556 201309240098 1 Install the M12x40 hex screw AF size 19 and torque to 85 Nm 1 Remove the protective metal
19. 12 1 Labels for overseas transportation 300 Rammax 1575 12 1 3 NOTE Transport Transport Joint protection Blocking the joint protection 1 Release the lower part of the joint protection 1 1 4 First remove the compression spring 2 and then the lock bolt 3 2 Carefully turn the roller steering until you can insert the joint protection into the loop on the opposite side 3 Now steer to the left all the way to the stop In order to operate the steering you must start the roller and maintain a distance of at least 2 meters ADANGER Risk of crushing through presence in the pivoting area danger zone As soon as the roller is aligned shut if off again 4 Secure the joint protection with the lock bolt 3 5 Secure the lock bolt with the compression spring 2 Fig 12 2 Joint protection open joint protection locked in place 301 12 1 4 Lifting at the 1 point lifting eye ADANGER Crushing hazard Always lift the roller vertically Do not stand under suspended loads Use only anti slip stable ramps when loading Secure the roller on transport vehicles to prevent it from rolling away slipping to the side or tipping over ADANGER Accident hazard due to falling load Before lifting check to be sure all screws on the 1 point lifting eye are damage free and securely tightened NOTE The lifting devices steel cables etc must be dimensioned in accordance with relevant reg
20. 193 Replacing bearing vibro unit llle 200 Gaining access to the vibro unit llllllsnn 200 Dismantling the vibro unit llli 203 Assembling the vibro unit llle 208 Assembling the vibro unit llle 209 Replacing the drive motor lille 219 ISeImoValk s dera beo doct d w e tapis Beak oe tma dort sot 219 replace D See cet See ek oe Je dae a 222 NISTANAUOR ERR PCR 226 Replacing vibromotor llle 229 Hammax 1575 10 16 1 10 16 2 10 17 10 18 10 18 1 10 18 2 10 18 3 10 19 10 19 1 10 19 2 10 19 3 10 20 10 21 10 21 1 10 21 2 10 21 3 10 22 10 22 1 10 22 2 10 23 10 24 10 24 1 10 24 2 10 25 10 25 1 10 25 2 10 25 3 10 26 10 26 1 10 26 2 10 26 3 10 26 4 10 26 5 10 26 6 11 11 1 11 1 1 11 1 2 12 12 1 12 1 1 12 1 2 12 1 3 12 1 4 12 1 5 12 1 6 13 13 1 13 2 aiuoLmC E 229 IristallallOEl sy ot srt ac Pata e e o EO Eod a SES uobis s 232 Roller drum installation llli 23 Replacing the drive pump 0 00 eee ee 237 REMOVA e 238 Preparing the new drive vibro pump 00005 244 IDiStall allo les caos ot ocdea ay Ren oa sta Karsten a ata Mis aed Se cea ace 246 Replacing the valve block 0 00 ees 250 REMOVA PD 250 COCK ecg PP P aoe ons het Shoat agate tease yee s 256 MSAA CR 259 Readying the machine for operation
21. 200907220001 74 Flow divider housing Connector P of pump B Flow divider B to junction at rear Flow divider A to junction at rear Connector T of pump G Aperture Two spring loaded pistons Fig 6 75 201211130107 Rammax 1575 NOTE In case of faults jerky driving check aperture for soiling If necessary short circuit the flow divider remove the entire piston package 6 7 Speeds and pressures Tab 6 13 Speeds and pressures Diesel engine speed Vibration speed Charge pressure Working pressures for driving Vibro drive pressures Maximum drive pressure Maximum pressure Front small Rear small Front large Rear large Forwards Reverse Small amplitude big amplitude Blocked forwards Blocked in reverse Steering Vibration rpm rpm rpm rpm rpm PSI bar PSI bar PSI bar PSI bar PSI bar PSI bar PSI bar PSI bar PSI bar After 5 min 2415 25 2250 150 2250 150 2250 150 2250 150 306 21 2 1450 100 20 1450 100 20 1522 105 55 1595 110 50 After 60 min 2405 25 2250 150 2250 150 2250 150 2250 150 306 21 2 1450 100 20 1450 100 20 942 65 15 1160 80 20 4786 330 15 4786 330 15 972 67 7 3191 220 10 When first started it is only possible to use the small amplitude vibration function for the first 2minutes Speeds and pressures Hyaraulic System 9 R cklauf Sa
22. 97 201309260020 176 Rammax 1575 o o TE 8 DDI 3A MAL KA nsn FEZSTII NHVWHWU Fig 10 98 201309260022 1 2 Fig 10 99 201309260024 1 ETE mnm 1 Fig 10 101 201309260026 Replacing the controller machine controller Repair Disconnect connector N1 Use a screwdriver to lift the clips Pull the gas strut away from the ball joint Remove the four fastening screws AF size 13 Remove the controller 177 10 8 2 Installation 1 Apply blue adhesive to the M8x20 hex SCrews 1 Screwthe new controller firmly in place using M8x30 AF size 13 hex screws 1 Connect connector N1 2 Reconnect the pole of the battery Fig 10 104 201309260029 178 Hammax 1575 10 9 Replacing and adjusting the magnetic rotational speed sensor 10 9 1 Removal Magnetic rotational speed sensor 1 1 Pull off the two leads Y2 and Y2 1 Remove safety bolt from the clevis head Fig 10 107 20 1309220003 Fig 10 108 201309220004 Replacing and adjusting the magnetic rotational speed sensor Repair 179 1 Remove the two Allen screws AF size 5 2 Remove the magnetic rotational speed sensor Fig 10 109 201309220007 10 9 2 Installation Premounted magnetic rotational speed sensor 1 Fig 10 110 201311060001 1 Apply blue adhesive to the two Allen Screws 1 Position the magnetic rotational speed sensor and screw firmly in place Fig 10 112 201309220
23. AF AF SIZE 2a Screw diameter Steel quality Eighieningitordueln Hex Nm hex socket 7 3 M4 8 8 3 8 4 M5 8 8 6 10 5 M6 8 8 10 13 6 M8 8 8 25 13 6 M8 10 9 36 15 M10x1 25 10 9 90 17 8 M10 8 8 48 138 Rammax 1575 19 10 M12 8 8 84 19 10 M12 10 9 123 24 M16 8 8 206 Extremely low profile cylinder screws and filister head screws Tab 9 5 Tightening torque Extremely low profile cylinder screws and filister head screws 3 M6 10 9 6 4 M8 10 9 13 Flanged oval head screws Tab 9 6 Tightening torque Flanged oval head screws 3 M5 10 9 9 Countersunk head screws Tab 9 7 Tightening torque Countersunk head screws 5 M8 10 9 16 Threaded adapters Metric threads Tab 9 8 Tightening torques for threaded adapters metric threads 18 Nm M10x1 0 18 Nm 6 L M12x1 5 25 Nm 25 Nm 8 L M14x1 5 45 Nm 45 Nm 10 L M16x1 5 55 Nm 55 Nm 12 L M18x1 5 70 Nm 70 Nm 15 L M22x1 5 125 Nm 125 Nm 18 L M26x1 5 180 Nm 180 Nm 22 L Tightening torques Maintenance 139 NOTE 140 Thread size M33x2 0 M12x1 5 M14x1 5 M16x1 5 M18x1 5 M20x1 5 M22x1 5 M27x1 5 Threaded adapters Inch threads Tab 9 9 Tightening torques for threaded adapters inch threads Thread size 1 8 1 4 1 4 3 8 1 2 1 2 3 8 4 1 4 1 4 3 8 3 8 1 2 1 2 3 4 To tighten hydraulic hoses and fittings Cutting ring 310 35 55 70 110 150 170 270 Cutting ring 18 Nm 25 Nm 45 Nm 55 Nm 70 Nm 125 Nm 180
24. Apply blue adhesive to the screws of the protective cover of the sensor Position the protective cover for the sensor on the hood Securely tighten the M6x30 AF size 5 Allen screws to a torque of 10 Nm 173 1 Secure the cables in the cable mountings under the hood 1 Plugin the ignition switch connector 2 Plugin connector N2 3 Secure the connector with a cable tie 1 Secure the cable along the wiring harness with cable ties 1 Route the sensor cable and secure it with cable ties Fig 10 91 201309260039 10 6 4 Replacing the rubber hood buffers For Replacing the rubber hood buffers of the rear engine hood see the section Replacing the rubber hood buffers of the front engine hood page 165 174 Rammax 1575 10 6 5 Adjusting the rubber hood buffers For Adjusting the rubber hood buffers of the rear engine hood see the section Adjusting the rubber hood buffers of the front engine hood page 167 10 7 Replacing the display unit 10 7 1 Removal 1 Disconnect connector N2 1 Remove the two fasteners of the display unit AF size 5 5 1 The display unit can now be removed from the inside toward the outside Fi Fig 10 94 201309260036 Replacing the display unit Repair 175 1 Install the new unit in the opposite order 10 8 Replacing the controller machine controller 10 8 1 Removal 1 Disconnect the pole of the battery 1 Unscrew both sensor connectors Fig 10
25. Check to be sure connections do not leak Checking and adjusting pressures Hydraulic System 57 6 3 1 6 3 2 58 Checking the steering pressure Use the control unit to steer the machine fully to the right or left end stop 1 1 Keep the lever actuated throughout the entire following procedure Measuring point 1 vibro steering pressure If a steering pressure of 67 7 bar is not achieved then e The right steering cylinder line must be removed and sealed pressure tight e The left steering cylinder line must be removed and sealed pressure tight e The valve block must be removed Siehe Replacing the valve block see page 250 e The steering pressure relief valve must checked Checking the maximum vibration pressure This procedure must be carried out if the vibration switch on pressure falls below 200 bar 1 Fig 6 17 21311190001 Open the rear hood Gain access to the elbow screw connection 2 4 Cutthrough all the cable ties on the hose bundle Hammax 1575 1 Fig 6 21 21311190006 Checking and adjusting pressures Hydraulic System Disconnect the hydraulic hose 016 from the elbow screw connection AF size 27 AF size 22 Seal the screw connections 1 pressure tight Remove the knurled nut and O ring on solenoid valve Y8 1 Remove the magnetic coil 1 from the solenoid valve 2 59 1 Remove the hydraulic hose 030 1 Sealthe screw connection AF s
26. Checking the drive pump s solenoid 66 6 5 Checking the drive pump servo block iles 67 6 6 Checking the flow divider ccc eee eee 74 6 7 Speeds and preSSureS 1 2 ee ee eee 75 6 8 Hydraulics diagram anana aaaea eee eee 76 6 8 1 Hydraulics Diagram Legend 0 00 cee eee 77 T7 Electrical system cus sic Ere AREE RE RREadupsueR Aa EG s 79 7 1 Engine electrical system Fuses 0 0 0 0 0c ce eens 80 7 1 1 Engine compartment 2 000 cee ee ees 80 7 1 2 Chassis Cals itn oats sae ae hed iw eee 82 1 1 3 COCK cate 2n adr dba ee Stee fue oo e Eee CANO d es 83 7 2 Other components 00 0 cece eee eee 85 7 2 1 Connector N1 wiring harness llle 85 7 2 2 Tier 4 Wiring harneSsS 0 000 cee eee 90 10 VVIFIEIO CATA eset el aso a Gur deo a Pre delet F Sur vine bare 3 ew Beal olen 91 7 3 1 EXDIAN IONS 2 era de dra ae dn Soe oe BOE aa 91 7 4 Wining CVA a csse senes tet Sc aa ate MRE e ie de ed os Ge go 92 7 4 1 Wiring diagram Key 0 0 cc ee es 93 Rammax 1575 8 1 8 2 1 8 2 2 8 3 1 8 3 2 8 3 3 8 5 Troublesnhnootllng 4 ex ecce CEA UE CE Re Ee Ec wre a 95 Introd cllOTT esie eee E EE Teo dcin adt Adern 96 Engine doesn tstart llli 97 Start test for cable and infrared modes 98 Position of the operator 20 0 0 cc ee ee 99 The controller is not working
27. Engine ground Engine ground Ground at rear Ground at rear F14 D 115 6 F11 A S1 30 1 F24 D F23 C Ground at rear Ground at front Y1 red F22 B X3 1 X3 3 Engine ground Comment Pre heater relay Pre heating Pre heating Radiator relay Radiator relay Oil cooler Oil cooler Shutdown bar Shutdown bar Charging current Exciting voltage Diesel pump Diesel pump Holding solenoid Return Steering left Steering right big amplitude small amplitude Brake valve Gas magnet Display unit Oil cooler Display unit 12V controller 12V controller 12V Pre heating Gas magnet Connection Connection Holding solenoid Ignition Starter Battery 2 Holding solenoid Y11 87 KA K3 en Timer f r Einzugsspule l SE riam nai i45 14 tpa D L 1x P35 TEN pA 2x PSS 745 E ee 55 mmj u T uF bx PSS 1 C2 2 143 144 5b 5b 1x PEO e K 2x PSS Vorg hung P3 ME C 354 GD B f ise ix PaO 3 d a ix haa 109 au x mi fy fe s x m n un 148 oP 7 Y3 YA F X ahren vorw rts Fahren r rkw rts d kepen CARA giis ix PRG x PES np og 112 mA 187 Pe wpa 11914 Arar TOME SIT xem ix POL y P rh o Ds blue i 5 hs i Y5 ri Lerikung links a a ik Pas H it Y1 te Pes i13 d mea Sicpspule wn ES S21 R1 NN Otdruckschalter Gl hspiralie 55 Ea 166 ix PTO KEH 155 SUB Tem ioa APIS CD i GJ Gem 1x PSS X 185 148 3x PIS Y6 0 5 Lenkung rechis 3M 1x Pas AX
28. Is there enough diesel in the tank Does the diesel pump work Is fuse F21 OK The switch must be closed when the engine is stopped Is F12 OK As soon as the starter turns holding solenoid Y1 red must have a voltage of 12 V Is the connector connected Is the connector connected Relay checked In ignition Start position 50 pull in solenoid white must have 12 V for 1s Has the shutdown bar been checked The switch must be open when the operating temperature is normal Short circuit to ground Solid connector connection No corrosion The switch must be closed when starting and open when the engine is running Solid connector connection No corrosion 97 Fault description Possible cause Checks Pre heating doesn t Glow plug R1 In cold weather please check the pre heating system work too In ignition Pre heating position control lamp H2 must light up and heater plug must have 12 V Is F24 OK Fuse F24 Is the connector connected Relay checked Relay K6 Yanmar engine Diesel Diesel in tank Yanmar TNVDI ser Diesel flow line free vice manual Air in injection system Filter free Air in system Smoke signals from exhaust tailpipe Compression injection system valve play Is the fuel pump working F22 OK Hydr oil cooler does Hydr oil temperature sensor Bridge the switch start the engine not turn Fuse F14 Is F14 OK Relay K7 Does relay K7 switch Motor defective Apply current directly to
29. L aS y i k gt A i k j 7 jJ endi I J Fig 8 1 Position of the operator Distance to roller Engine doesn t start Troubleshooting 99 8 3 8 3 1 8 3 2 8 3 3 100 Overview of functions Operation with the cable Operation with the infrared sensor automatic pairing Steering functions Vibration functions max range 3 5 4 5 m max range 20 m Close proximity shutdown 2 2 5m The controller is not working Follow the instructions below step by step in order to pinpoint faults and fix them External factors e Reflective surfaces mirrors reflective strips etc in the machine s close vicinity can interfere with the remote controller s distance calculating function e Special sources of light fluorescent tubes flash lamps etc may interfere with infrared communications under certain circumstances e Strong electromagnetic radiation e g in the proximity of power plants may affect the controller If faults occur only at specific locations or in specific situations check the machine s surroundings to see if any of the above factors are present and try to avoid them Machine wiring e Are fuses F11 and F12 OK e Are the connectors on controller N1 free of soiling and water e ls controller N1 properly mounted e Are both the P1 and P2 infrared sensors clean and free of damage e ls the wiring from N1 to P1 and P2 free of damage Keep in mind that there is an
30. Nm 310 Nm 35 Nm 55 Nm 70 Nm 110 Nm 150 Nm 170 Nm 270 Nm Nm Nm Nm Nm Nm Nm Nm Nm Soft seat ring 310 40 40 70 90 125 135 180 Soft seat ring 18 25 45 55 70 125 180 310 40 40 70 90 125 135 180 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nominal joint size 28 10 12 14 16 20 L eo o ooo o oco o Nominal joint size 6 8 10 12 15 18 22 28 10 12 14 16 20 m rr wm NM BM m eo o oo oo o e Screw the union nut by hand all the way to the stop then tighten 4 of a turn with the wrench 90 Hammax 1575 9 17 1 Cementing hydraulic threaded joints Blue adhesive must be used when installing all hydraulic threaded joints in the engine assembly and in the roller drum assemblies Fig 9 43 Hydraulic threaded joint cemented correctly incorrectly NOTE The person that applies the adhesive on the threaded joint is responsible for ensuring that the threaded joint is tightened NOTE Do not retighten cemented threaded joints Tightening torques Maintenance 141 9 18 142 Conversion table for bar psi Tab 9 10 Conversion table for bar psi bar Oo OC N Oo a O N gt a F FSJ o Ww N NO A S EX O BO O NEN C NEN O NES 100 150 200 250 300 350 400 450 Conversion factors 1 psi 0 06895 bar 1 bar 14 50326 psi 1 psi 6 8948 KPa psi 15 29 44 58 73 87 102
31. Screw two eye bolts into the drive motor flange 1 Attach the tackle to the crane and the eye bolts 2 The orientation of the drive motor must be marked with a marker before the drive motor is lifted out of the motor support If the drive motor is rusted in place in the motor support the drive motor must be pressed out of the motor support 1 Clean three threads 2 Retap three threads 3 Install three M12x60 hex screws 4 Pressthe drive motor out of the motor support 1 Liftthe drive motor out of the motor support 223 224 Fig 10 308 201309260086 Fig 10 309 201309260087 Fig 10 310 201309260083 1 Clean the bearing surface and the threads 1 Apply Anti Seize to the seat of the bearing on the drive motor support 1 Puta little blue adhesive into the threaded bores 1 Place the new drive motor into the motor support 1 4 Bear in mind the orientation of the motor marked previously Hammax 1575 1 Apply blue adhesive to the six M12 Allen screws 1 Install the Allen screws e V IR Fig 10 312 201309260091 pee 1 Tighten the Allen screws SW10 to a torque of 85 Nm 1 Apply blue adhesive to the screw connections from the old drive motor Fig 10 314 201309260093 Replacing the drive motor Repair 225 1 Mount the screw connections on the drive motor and tighten to the proper torque e Material o Hydraulic motor MK 04 340 0 cm3 rev 1 o 2x
32. Turn the engine over using the starter for 1 2 minutes After a few revolutions the oil which has gathered in the combustion chambers should have been pressed out through the openings for the glow plugs Repeat the procedure after about 5 minutes It is essential to be sure that no more oil is present in the combustion chambers 2 Reinstall the glow plugs AF size 12 torque 18Nm Fig 10 19 Glow plugs 3 Reconnect the contact connectors and cables to the glow plugs AF size8 torque 1 5 Nm Fig 10 20 Connection cable 4 Install the valve cover 5 Install the electrical steel Overturning Tipping of the Rammax 1575 Repair 155 10 4 3 156 Turn the engine over with the ignition key 1 Turn the ignition key clockwise to position lll 1 4 The engine must turn over If this is not the case do not under any circumstances attempt to start the engine It is possible that there could still be oil in the combustion chambers Repeat the procedure described above or otherwise contact your authorized dealer right away If the engine turns over 1 Check all fluid levels 1 1 If needed top up the fluids 2 Putfuse F 21 back in place Start the engine 1 Attempt to start 1 Turn the ignition key clockwise to position lll 1 1a Attempt to start is successful engine is running See Engine is running further down 1 1b Attempt to start is unsuccessful engine is not running There could be air in the diese
33. and pin 8 must have the chassis ground voltage level The relay must be switched as soon as the ignition is switched on Is the connector connected When the ignition is on pin 7 must have a voltage of 0 V chassis ground When the engine is running on the other hand it must have 12 V If the battery charges anyway voltage approx 14 V the problem is probably with N2 Hold cable 133 against ground The lamp must be lit e The tilt sensor measured a tilt angle greater than 45 the diesel engine is turned off when this happens e f shutdown bar H5 is flashing at the same time It will not be possible to start the engine until oil pressure switch S21 is closed H3 is lit up and D for G1 has a voltage of 0 V H1 is lit up e The controller detected a fault If the machine is not inclined and controller N1 is properly mounted there is a fault in the controller s switching outputs gt The controller does not work 103 Fault description Oil pressure warning lamp H3 lights up while the engine is running Oil pressure warning lamp H3 does not light when the ignition is switched on Water temperature warning indicator H4 lights up Engine running mperature warning lamp H4 does not light when the ignition is switched on Lamp test Shutdown bar warning lamp H5 lights up even though the shutdown bar is not being actuated a shutdown bar is not installed Pre heating control
34. caught in moving parts there is a danger of serious injury Danger of burns from hot roller parts Only work on a cool engine Keep enough distance to the exhaust Environmental hazard through operating materials Do not allow any liquids to enter drains the soil or the environment NOTE Damage to electrical controls through contact with water Never spray a water jet into electrical or electronic components Never spray into the engine combustion air intake NOTE Damage to hydraulic controls through use of wrong oil Hydraulic tubes decompose It is forbidden to change used rollers for use with biodegradable hydraulic oils e If hydraulic hoses on a roller running on synthetic ester HE need replacing only those declared by the supplier as being compatible with synthetic esters may be used General safety information Maintenance 109 9 1 1 Battery safety instructions ADANGER Risk of serious injury through leaking battery acid The sulfuric acid in the battery is poisonous and so strong it can burn holes in clothes and dissolve skin If it gets into eyes it can lead to blindness Protect the battery from fire flames and sparks Protect the battery from mechanical damage ADANGER Risk of explosion when charging battery Never check the battery charge level with a metal object Use a voltmeter or the battery s charge indicator When disconnecting the battery always disconnect the negativ
35. direction The machine only moves slowly even when the operating lever is at full speed The machine moves erratically Checking the drive pump servo block Hydraulic System 67 View of drive pump 1 Pull the connectors off of the magnetic coils Y3 left and Y4 right 1 Remove closure plugs X1 and X2 AF size 6 View of the drive pump without the closure plugs NOTE If the oil at the site of the unscrewed plug does not flow back into the pump housing then the apertures are clogged or the piston is not at the center and is jammed 68 Rammax 1575 Checking the drive pump servo block Hydraulic System 1 Loosen and unscrew the apertures size 3 NOTE The apertures must not be loose Loose apertures lead to problems with driving 1 Theloosened apertures can best be lifted out with a small magnet Improvise if needed View of the dismantled aperture holder 1 with the apertures 1 Unscrew the knurled nut 69 70 1 Pull off the magnetic coils 1 Unscrew the solenoid valve size 17 Fig 6 61 20130829001 1 View of the control spools NOTE The control spool is spring loaded and must always slide back to the 0 position by itself Hammax 1575 1 Checking the movement of the control spool for example using a screwdriver 2 Pushthe control spool from the left and right all the way to the stop three or four times NOTE e It must not jam under any circumstances
36. disposed of properly ask your authorized dealer 13 2 Removal and depressurization of the gas strut Eye injury Because of the high internal pressure chips and oil can spatter from the site of sawing or drilling Wear eye and face protection Cover the site of the saw cut Environmental hazard through operating materials Gas struts are filled with oil Do not allow any liquids to enter drains the soil or the environment In case of disposal pressurized gas struts must be depressurized according to the following regulations 1 Fasten the pressurized tube between two prismatic jaws without deforming it and in such a way that the dimension X is at least 25 mm see below 2 To depressurize 2a Slowly cut the pressurized tube open at the points indicated using a handsaw or 2b Drill a hole in the tube using a drill with about a 3mm diameter 306 Hammax 1575 1 Saw cut drilled hole 2 Saw cut drilled hole X SSCL Fe about 20 Pressurized Lou 20 Bottom Piston rod TET Fig 13 1 Removal and depressurization of the gas strut 1 saw cut hole position Cut or drill into the pressurized tube about 20 mm from the bottom 2 saw cut hole position Cut or drill into the pressurized tube in the bead NOTE If disposal according to these regulations is not possible ask your authorized dealer Removal and depressurization of the gas strut Disposal 307 MULTIQUIP Co
37. e Take care that nothing is jammed in the joint plates when rotating the roller drums e Do not put hands between the roller drum and support during operation Hammax 1575 ADANGER Danger to life through tipping or slipping of the roller The edges of filled areas may give way Only travel directly up or down slopes Do not drive across slopes Keep your distance to embankments and edges Do not drive at an angle into or out of the trench Park the roller on slopes only in such a way that it cannot overturn Use the roller on slopes only in such a way that it cannot overturn The roller drums have very poor adhesion on snow and ice Driving or working on a slope in snow or ice is prohibited Damp and loose surfaces reduce the traction of the machine on upward and downward grades considerably Adapt the speed of the machine to the terrain when driving on grades The nature of the ground and weather conditions can negatively affect the climbing ability of the machine Never drive on slopes that are steeper than the maximum climbing ability of the machine Fig 3 1 Tipping hazard Construction site conditions can have a negative effect on stability and the tipping angle A DANGER Crushing hazard in the area of the articulated joint During operation there is always a crushing hazard in the area of the articulated joint Therefore it is not permitted for persons to be in this area during operation In general a safety d
38. ee ee 122 Draining engine oll 2 0 0 eee 122 Replacing the engine oilfilter 0000008 123 FAV OF AUC OM PTT 124 Checking the hydraulic oil level 0000008 124 Topping up hydraulic oil llle 124 Draining the hydraulic oil 0 0 0 ee 124 Cleaning the hydraulic oil cooler 0 0000 eee 125 Replacing the hydraulic oilfilter 000 126 Replacing the ventilation filler 0000505 127 Hydraulic oil replacement 0 0 00 eee 127 Filling the hydraulic tank 0 0 127 Filling the drive pump building charge pressure 128 COOLING 4a dade E dieci Ba Ge UE Bop sen ERR S A Qr dee ERR E 130 Checking coolant level 0 000 eee eee 130 Topping up coolant 0 0 0 0c ee 131 Cleaning the radiator ce ee ee 131 PUNCIONGCNECK 244 6 ars deer ewe EHE beca d ERES de ER d 132 SCIaDOI S43 9x Eo px Pea sewed uxo d es E Pul rdi 132 Air intake filler llle 132 Replacing the pendulum support joint head 134 Replacing the pendulum joint bearing 134 Lubricating steering cylinder bearing Ls 135 Brake TeSt 4544 esos eee dH adt REB RR ce eta toe eee os 135 Gable contiector Y9 id zu Ea ELEC eee ok 136 9 14 2 9 15 9 16 9 17 9 17 1 9 18 9 19 10 10 1 10 2 10 2 1 10 2 2 10 2 3 10 2 4 10 3 10 3 1 10
39. fitting GES22LM WD 32 125 T Screw coupling MINIMESS 1620 DKO 8L 17 8 Screw coupling MINIMESS 1620 M12x1 5 17 9 Screw coupling MINIMESS 1620 DKOL 12L 22 10 Elbow fitting adjustable EWSD 8L 17 11 Elbow fitting adjustable ESWD 22L 36 12 T fitting adjustable ETSD12L 22 13 L fitting ELSD12L 22 Apply blue adhesive to all straight screw in fittings and Minimess M12x1 5 Siehe Cementing hydraulic threaded joints see page 141 244 Rammax 1575 Allen screws M6 AF size 5 Torque 10 Nm Fig 10 399 Vibro steering pump Gear pump 11 ccm rev 9 teeth 82 55mm Screw coupling MINIMESS 1620 DKO 15L L fitting ELSD15L w o M D K Straight flange fitting GFS 15L 35 1 O ring Straight flange fitting GFS 22L 40 1 O ring anak Ao 1 Apply Anti Seize to the shaft 1 Apply blue adhesive to the M10 Allen screw s Fig 10 401 201309220036 Replacing the drive pump Repair 245 1 Adjust the gearwheel 1 4 Place a feeler gauge 1 5 mm between the gearwheel and the pump housing 1 Firmly secure the gearwheel with the M10 Allen screw AF size 8 tightening it to a torque of 85 Nm NY Fig 10 403 201309220038 10 18 3 Installation 1 Clean the M12 thread on the pump flange 1 Remove the cap from the intake hose Fig 10 405 201309220040 246 Rammax 1575 1 Apply blue adhesive to the two M12x35 hex screws 1 Push the drive pump onto the pump flange 1 Tighten the two M12x35 hex scr
40. from under the chassis using a suitable aid 1 1 Keep the roller drum balanced using a suitable aid e g piece of square timber Hammax 1575 Replacing the drive motor Repair Place an oil catch basin beneath the drive motor before disconnecting the hoses Remove all hoses from the drive motor Plug the fittings Fig 10 293 201309220015 Mount auxiliary tool on drive motor flange using three M12 screws AF size 19 Attach an anchor sling to the auxiliary tool and a crane Use the crane to slightly lift the auxiliary tool Remove six M12 hex screws AF size 19 from the drive motor support Fig 10 296 201309260068 221 1 Pull the drive motor complete with the auxiliary tool away from the gear box Fig 10 298 201309270039 1 Setthe drive motor down securely until needed again Fig 10 299 201309270040 10 15 2 replace 1 Completely remove all of the screw connections from the demounted drive motor 73 Fig 10 301 201309260076 1 Remove the seven M12x25 Allen screws AF size 10 from the drive motor flange Screws inaccessible In infrequent cases the seven M12x25 Allen screws are not accessible which means that the drive motor flange must be completely removed In this case the five hex screws AF size 24 must be removed Lift the flange from the drive motor 222 Rammax 1575 Fig 10 306 201309260083 Replacing the drive motor Repair 1
41. lamp H2 never lights up Control lamp is lit continuously 104 Possible cause Engine oil pressure switch 21 Engine oil pressure switch 21 Cable connector display unit N2 Cooling water temperature switch 22 Coolant temperature switch 22 Cable connector display unit N2 Proximity switch S24 Controller N1 Ignition switch S1 Controller N1 Relay K6 Checks Is the connector connected Short circuit to ground Engine oil level OK Engine oil pressure OK When the engine is stopped the connection must have contact to chassis earth The switch must be open when the engine is running The diesel engine turns off after 4 s Pull the connector off of the switch and ground it The lamp must be lit Solid connector connection No corrosion Is the connector connected Short circuit to ground The switch must be open when the operating temperature is normal The diesel engine turns off after 4 s Defective Solid connector connection No corrosion Pull the connector off of the coolant temperature switch and ground it The lamp must be lit The switch must be open when the operating temperature is normal The diesel engine turns off after 4 s The lamp lights up with a solid light If the machine features a shutdown bar check to make sure that the magnet on the shutdown bar is positioned correctly The switch must be closed when the shutdown bar is not being actuated Otherwi
42. motor 8 2 1 Start test for cable and infrared modes Normal start 1 Open the cockpit cover 1 4 Open the cover without covering the sensor 2 Turn the ignition on 3 Position yourself three meters from the roller 4 Keep an eye on the shutdown bar indicator lamp 4 1 Ifthe shutdown bar indicator lamp blinks increase your distance from roller 5 Hold down the Start switch on the infrared transmitter 5 1 The pre heating indicator lamp must be lit 5 1a If the pre heating indicator lamp is not lit decrease your distance from the roller 5 1b Once the pre heating indicator lamp lights the roller will start in 6 s Quick start 1 Open the cockpit cover 98 1 4 Open the cover without covering the sensor Hammax 1575 2 Turn the ignition on 3 Position yourself three meters from the roller 4 Keep an eye on the shutdown bar indicator lamp 4 1 If the shutdown bar indicator lamp blinks increase your distance from roller 5 Hold down the Start switch on the infrared transmitter 5 1 The pre heating indicator lamp must be lit 5 1a Ifthe pre heating indicator lamp is not lit decrease your distance from the roller 5 1b Once the pre heating indicator lamp lights release the switch immediately The engine starts 8 2 2 Position of the operator Distance to roller 2m Operation is not possible 4 5m Cable is too short operation is not possible do not overstretch the cable oM AKT Y Yd rris f i ve asm 97 7 m
43. oil level is ideal when the display itself is half full Topping up hydraulic oil 1 Remove the breather filter 1 from the filler neck 2 Pourin hydraulic oil 3 Screw the breather filter 1 back in place 3 1 Important Always grease the O ring before screwing it in place Fig 9 12 Hyaraulic oil filler neck Observe the table of lubricants in chapter 9 15 Draining the hydraulic oil Only drain the hydraulic oil at operating temperature e The oil flows better e Residues in the tank will be flushed out with the oil 1 Place a container with at least a 30 liter capacity under the hydraulic oil drain 2 Remove the breather filter Hammax 1575 NOTE NOTE 9 9 4 NOTE Hyaraulic oil 3 Unscrew the cover screw 1 under the roller AF size 27 wrench 4 Allow the oil to drain into the container 5 Install the screw plug 1 5 1 Tighten the screw connection hand tight Fig 9 13 Hyaraulic oil drain When you drain the hydraulic oil please also replace the hydraulic oil filter and breather filter See Replacing the hydraulic oil filter 9 9 5 page 126 Tighten the screw connections in the hydraulic tank hand tight Cleaning the hydraulic oil cooler 1 Check the cooling ribs of the hydraulic oil cooler for dirt and clogging 2 Clean the ribs with water or blow them out with compressed air Never clean the cooler with high pressure e g powerful water jet Fig 9 14 Hyaraulic oil cooler gri
44. screws AF size 19 Pull the roller drum out from under the chassis using a suitable aid 1 1 Keep the roller drum balanced using a suitable aid e g piece of square timber Set the roller drum down securely until needed again Hammax 1575 Rubber elements of vibro unit Repair Clean hoses and the immediate surroundings Place an oil catch basin beneath the drive motor before disconnecting the hoses Remove all hoses from the drive motor Plug the fittings Fig 10 146 201309220015 Mount auxiliary tool on drive motor flange using three M12 screws AF size 19 Attach an anchor sling to the auxiliary tool and a crane Use the crane to slightly lift the auxiliary tool Remove six M12 hex screws AF size 19 from the drive motor support Fig 10 149 201309260068 189 1 Pull the drive motor complete with the auxiliary tool away from the gear box Fig 10 151 201309270039 1 Setthe drive motor down securely until needed again 1 Remove seven M10 hex screws AF size 17 from the gear box cover Fig 10 154 201309270041 1 Remove twelve M8 hex screws AF size 13 from the gear box cover 2 Relocate the oil catch basin beneath the gear box before removing the gear box cover 190 Hammax 1575 1 Carefully remove the gear box cover by hand Grease will escape from the unbalanced drive gear box During reassembly later the same amount of grease must be added o
45. sheets NS 2 Arrange the hose bundle and secure 1175 b 9 LL with cable tie n Fig 10 558 201309250015 Pendulum joint Repair 281 10 24 Shutdown bar 10 24 1 Replacing the shutdown bar 1 Remove the Allen screws AF size 5 1 on the clamp body 2 Remove the shutdown bar from the chassis 1 Remove the hex screw AF size 8 AF size 17 from the right side of the shutdown bar Fig 10 560 201311200001 1 Remove the stop on the right 1 Remove the spring Fig 10 562 201311200003 282 Hammax 1575 1 Remove the hex screw AF size 8 AF size 17 from the left side of the shutdown bar Fig 10 563 201311200004 1 Remove the stop on the left Fig 10 564 201311200006 1 Remove the magnet Fig 10 565 201311200007 1 Remove the spring Fig 10 566 201311200008 Shutdown bar Repair 283 1 Inspect the removed parts for suitability for reuse 1 Apply blue adhesive to the Allen screws on the clamp body 1 Secure the clamp body to the chassis using the M6 hex screws AF size 5 1 Pushthe right and left springs onto the shutdown bar Fig 10 570 201311170034 284 Rammax 1575 Shutdown bar Repair 1 Push the shutdown bar into the right clamp body Fig 10 571 201311170035 1 Install left clamp body 1 Tighten the Allen screws AF size 5 Fig 10 573 201311170037 Iv 1 Insert the springs into the recesses provided for them on the left a
46. straight screw in fittings GES10L M22x1 5 2 125 Nm o 1x straight screw in fitting GES10L M16x1 5 3 55 Nm o 1x straight screw in fitting GES10L M14x1 5 4 45 Nm 1 Cover the screw connections with protective caps Fig 10 316 201309260096 10 15 3 Installation 1 Clean the contact surface of the motor support and the threads Fig 10 318 201310010040 Fig 10 317 201310010039 1 Puta little blue adhesive into the threaded hole Fig 10 319 201310010042 226 Rammax 1575 1 Mountthe auxiliary tool on drive motor flange using three M12 hex screws AF size 19 1 Screw in one threaded bolt to the right and left of the vibro gearbox flange as an aid for assembly of the drive motor Fig 10 321 201310010061 1 Liftthe premounted drive motor using the auxiliary tool and crane i Fig 10 322 201310010043 1 and install it Fig 10 323 201310010045 Replacing the drive motor Repair 227 1 Apply blue adhesive to the six M12 hex screws 1 Install the hex screws 1 Tighten hex screws AF size 19 to a torque of 85 Nm 2 Remove the auxiliary tool Fig 10 327 201310010065 1 Mountall of the hoses F i F a E 1 a Fig 10 328 201310010056 228 Rammax 1575 1 Clean the hose fittings and surroundings with cleaner such as brake cleaner 2 Apply Anti Seize to the shoulder arrow 3 Allow the machine to run while still j
47. struts Risk of accident through hood falling down e Secure the hood before you replace the gas struts o Support the hood with a rod removal 1 Use a screwdriver to lift the clips 2 Pullthe gas strut away from the ball joint 148 Rammax 1575 NOTE NOTE NOTE Gas strut Repair Fig 10 4 Using a screwariver lift the clips and loosen the springs installing 1 The new gas struts can easily be installed by pressing them onto the ball joint 1 1 The clamp must be seated securely afterward When reinstalling the gas strut secure the extended part at the bottom Fig 10 5 Gas strut Gas struts should not be installed if they have been damaged through mechanical manipulation Welding on gas struts as well as dirt or paint on the piston rods can lead to failure of the units Avoid modifications manipulation impacts tensile loading heating painting over or removal of imprints Do not install defective or improperly handled products If gas struts are no longer needed they must be disposed of in an environmentally appropriate manner For this purpose they will be drilled out to allow the compressed nitrogen to escape and to drain the oil they contain See also Removal and depressurization of the gas strut page 306 149 10 4 Overturning Tipping of the Rammax 1575 Fig 10 6 Hammax 1575 overturned 1 Place the machine back onto the roller drums as quickly as possible 2 Turn th
48. surface of the gear box cover 1 Apply blue adhesive to the threads of the rubber elements 1 Putthe gear box cover in place 1 Tighten the seven M10 hex nuts 1 AF size 17 to a torque of 50 Nm Fig 10 188 201310010031 198 Hammax 1575 1 Apply blue adhesive to the twelve M8x35 22 hex screws Fig 10 189 201310010034 1 Tightenthe hex screws 1 AF size 13 to a torque of 36 Nm Fig 10 191 201310010038 1 Install the hose guide bracket 1 using the same screws Fig 10 192 201310010036 Rubber elements of vibro unit Repair 199 10 14 Replacing bearing vibro unit 10 14 1 Gaining access to the vibro unit 1 Safely jack up the machine 2 Attach an anchor sling to the roller drum 3 Use a crane to slightly lift the roller drum 1 Remove the roller drum screws AF size 19 1 Pullthe roller drum out from under the chassis using a suitable aid 1 1 Keep the roller drum balanced using a suitable aid e g piece of square timber 1 Setthe roller drum down securely until needed again Fig 10 196 201309270031 200 Hammax 1575 Replacing bearing vibro unit Repair Place an oil catch basin beneath the drive motor before disconnecting the hoses Remove all hoses from the drive motor Plug the fittings Fig 10 199 201309220015 Mount auxiliary tool on drive motor flange using three M12 screws AF size 19 Attach an anchor sling to the auxili
49. the nuts Grease the bores of the rear and front joint heads Grease the dowel pins 267 10 21 3 268 t LS ry l r i Pi Fig 10 496 201309240038 Fig 10 498 201309240043 Installation Fig 10 499 201309250001 1 Insert the dowel pin in such a way that the gap is on the pressure side 2 Pressin the dowel pins 1 Secure the M10x60 countersunk Allen screw with red adhesive 1 Install the M10x60 Allen bolt AF size 6 AF size 17 with an M10 nut and washer 1 Apply blue adhesive to the two M12x160 hex screws at the rear 2 Apply blue adhesive to the two M12x65 30 hex screws at the front Hammax 1575 1 install two M12x160 hex screws AF size 17 and washers at the rear and torque to 85 Nm Fig 10 501 201309250003 1 Install two M12x65 30 hex screws AF size 17 and washers at the front and torque to 85 Nm Fig 10 502 201309250004 10 22 Replacing the steering cylinder The removal of the left steering cylinder will be described in the following The removal of the right steering cylinder is exactly the same 10 22 1 Removing the old steering cylinder 1 Remove hydraulic hoses 017 and 018 from the hydraulic cylinder Fig 10 503 201309240001 Fig 10 504 201309250004 Replacing the steering cylinder Repair 269 1 Remove the M16 AF size 24 securing nut from the front steering cylinder 1 Remove the M16 AF size 24 securing nut from the rear steering cy
50. value is achieved 1 10 4Nm 1 Bend the tooth of the lock ring into the matching groove of the nut using a suitable tool lt A p Li m Fig 10 259 201311130038 213 214 zd a Fig 10 263 201311130042 Fig 10 264 201311130043 1 Regrease the bearing Fig 10 261 201311130040 Total amount of grease in the bearing housing 100g of Castrol Longtime PD2 or compatible extreme pressure grease for long term lubrication 1 Puta little blue adhesive into the threaded holes 1 Apply blue adhesive to the M6x20 Allen screws Hammax 1575 1 Place the bearing cover onto the unbalance housing 1 Securely tighten the M6x20 AF size 5 Allen screws to a torque of 10 Nm NOTE The unbalance weight must be able to move with complete freedom 1 Fill the vibro housing with 300 g of grease 1 Clean the sealing surface of the gear box housing Fig 10 268 201310010008 Replacing bearing vibro unit Repair 215 1 Retap all threads M8 1 Blow out the thread bores 1 Thoroughly remove all soiling in the form of adhesive residues and contaminated grease 2 Replace grease that has been removed or has run out with the same amount of new grease Grease Castrol Longtime PD2 or compatible extreme pressure grease for long term lubrication 1 Apply sealant to the sealing surface Lar c ZU i Fig 10 272 201310010021 216 Hammax 1575 1 Spread the sealant with a brush
51. with clean water and consult a doctor e Replace all protection devices properly after performing maintenance and repair work ADANGER Danger to life through an unsafe work area Always use an accident proof support when working on a raised roller Never work below a roller which is only supported by a crane or other electrical hydraulic lifting device Only stand under a raised roller if it has been mechanically secured Only use stable loading ramps suitable for the weight of the roller for loading On transport vehicles correctly secure the roller against rolling slipping and overturning ADANGER Gas poisoning through letting engine run in enclosed spaces Do not leave the engine running in closed areas e If use of the roller in a confined space cannot be avoided the exhaust fumes must be extracted directly from the exhaust pipe ADANGER Danger of scalding from hot water steam Never remove the expansion cap or radiator cap while the engine is running or hot First loosen the cap to the first stop to release the pressure Only then remove the cap 108 Rammax 1575 ADANGER Danger of severe injury through loose clothing being caught and drawn in Only open the engine hood when the engine is switched off e If trouble shooting makes working on moving parts engine or roller unavoidable never wear necklaces bracelets rings scarves ties or other loose items of clothing If any of these get
52. 0 0 00 eee eee 100 External fact S 2s vus a mr ata cat E OCURRE E Re CS al Ir NC as 100 Machine wiring llle RR 100 ODGF QUOD Let ou a ose deo LEE aad coh aa odes SAG dps 100 Display Unio db diens doen un har ne do SS ns scite goats 103 Handheld controller l llle 105 Maintenant sieru 3 eoe ac lone RC ct i cci Cui o ee UE ee de Pa 107 General safety information 0 0 0 0 0 cee eee ees 108 Battery safety instructions 0 0 0 0 eee eee 110 General information about maintenance 110 Maintenance l l hrs 111 Maintenance plan l llle 111 Yanmar engine service 00 eee 113 Maintenance check sheet 0 00 cece eee eee 114 Opening the hood front and rear 2 0000 115 Engine compartment overview llle 116 Left side of the engine 0 0 ces 116 Right side of the engine 0 0 ce ees 117 Fuel diesel 0 0 0 cc teens 118 Checking fuel level llle 118 REMON tooo r P I PL 118 Draining TUel oes e etx o od ee URN seio ele ate a 119 Cleaning the fuel tank 0 0 00 cc ee eee 119 Fuel filler element 20 anaa eee 120 Water separator filter element 00 000 eae 120 ENGING Ol s d bts PROS Res ap C RR SOG eh eS ad 121 Checking the engine oillevel 0 0000 cee euee 121 Topping up the engine oll 2 2 0 0 00
53. 007 180 Hammax 1575 1 Grease the safety bolt of the clevis head 1 Putthe safety bolt onto the clevis head 1 Connect the two leads Y2 and Y2 1 1 Do not reverse and cables Fig 10 115 201309220025 Fig 10 116 201309220005 10 9 3 Adjusting 1 Loosen counter nut on clevis head AF size 10 Fig 10 117 20130922001 1 Replacing and adjusting the magnetic rotational speed sensor Repair 181 1 Push the piston rod all the way down by hand 1 4 The stop arrow must not be allowed to touch the adjustment screw 1 Use a feeler gauge 1 5mm to set the spacing between the adjustment screw and the stop wf Fig 10 120 201309220015 1 Push the magnetic rotational speed sensor all the way through to the stop There must be a gap of 1 5 mm between the stop and the adjustment screw 1 Start the engine 2 Push the magnetic rotational speed sensor all the way through to the stop 3 Measure the engine speed using the tachometer If the specified speed min 2390 2440rpm is not reached the clevis head AF size 10 1 must be adjusted Fig 10 122 20130922001 1 182 Hammax 1575 The governor lever must rest against the adjustment screw when the diesel engine is at the idle position 1 After the adjustment is completed tighten the counter nut on the clevis head AF size 10 2 Motion test Move the magnetic rotational speed sensor up and down by hand IMPORTANT When
54. 11130003 Fig 10 216 201311130004 1 Remove grease from the boss Fig 10 218 201311130004 204 Rammax 1575 Replacing bearing vibro unit Repair 1 Loosening the grooved nut lock ring 1 1 Use a small chisel or screwdriver m 1 Fig 10 221 201311130009 1 Putthe special grooved nut wrench in place Fig 10 223 201311130011 1 Loosen the grooved nut 205 1 Remove the grooved nut V an Fig 10 225 201311130014 1 Remove the grooved nut lock ring 1 Liftthe unbalance unit off of the shaft 1 Remove grease from the boss Fig 10 228 201311130017 206 Hammax 1575 1 Removing the spacer rings Fig 10 230 201311130019 1 Pull the bearing off of the boss with a bearing puller 1 4 Apply the bearing puller here arrows Fig 10 231 201311130020 Fig 10 232 201311130021 1 Remove the bearing outer rings and the spacer ring Fig 10 233 201311140002 Fig 10 234 201311140010 Replacing bearing vibro unit Repair 207 1 Clean the bearing housing Fig 10 235 201311140001 10 14 3 Assembling the vibro unit 1 Place the new wide bearing outer ring 1 into the bearing housing 1 1 Observe the mounting orientation Fig 10 236 201311140003 Press the wide bearing outer ring into the housing 1 Place the spacer ring 1 into the bearing housing Fig 10 239 201311140006 208 Hammax 1575 1 Place the na
55. 11210022 Bolt for pressing in the pendulum joint bea ring Fig 10 603 201311210024 Assembly tool for pendulum joint bearing Fig 10 604 201301150031 292 Hammax 1575 Tools Repair Fig 10 605 201311210025 Fig 10 606 201311210027 Fig 10 607 201311210026 Fig 10 608 201311210023 Pressure screws for pendulum joint bearing Spacer block for pressure screws 4x Assembly drift pin for pendulum support heavy duty dowel pin opecial socket for assembly of the infrared sensor 293 Grooved nut wrench for vibro gearbox Bracket for torque measurement instru ment for vibro gearbox Fig 10 610 201312110001 Torque measurement instrument Fig 10 611 201312110002 10 25 2 Special tool for measuring speed and frequency Fig 10 612 201212130022 294 Rammax 1575 10 25 3 Special tool for checking solenoids Fig 10 613 200608300003 10 26 Plugs and stoppers 10 26 1 Vibromotor Tab 10 2 Plugs and stoppers for 1 vibromotor Material Size Quantity Material number Pipe plug 15L 2 1 901441 End plug 15L 2 1 901276 Cap nut 15L 2 1 901003 10 26 2 Vibromotor valve block maximum pressure Tab 10 3 Vibromotor valve block maximum pressure plugs Material Size Quantity Material number Pipe plug 15L 1 1 901441 End plug 15L 1 1 901276 Cap nut 15L 1 1 901003 Pipe plug 12L 2 1 901440 End plug 12L 2 1 901275 Cap nut 12L 2 1 901325 Plugs and stoppers Repair 295 10 26 3 Dr
56. 116 131 145 218 290 363 435 508 580 653 125 1450 2175 2901 3626 4351 5076 5801 6526 KPa 100 200 300 400 500 600 700 800 900 1000 1500 2000 2500 3000 3500 4000 4500 5000 10000 15000 19999 24999 29999 34999 39999 44999 Atm 0 99 1 97 2 96 3 95 4 93 5 92 6 91 7 90 8 88 9 87 14 80 19 74 24 67 29 61 34 54 39 48 44 41 49 35 98 69 148 04 197 39 246 74 296 08 345 43 394 78 444 13 Hammax 1575 9 19 NOTE Cleaning the roller After completion of work clean the roller e of major soiling e and the lower scrapers of deposits Regularly clean completely at least once a week When working on cohesive soils or with cement and lime stabilizers complete cleaning must be performed daily ADANGER Danger to life through runaway roller Persons standing in the vicinity can be rolled over Before cleaning the roller be absolutely certain to secure it against unintentional rolling away While cleaning observe the following Do not use aggressive or flammable cleansing agents e g gasoline or inflammable substances e Only work with the engine turned off Donotdirectly subject electrical components or isolating materials to a steam jet when using a steam cleaner Always cover these materials e When washing the roller ensure that no water is sprayed into the air intake filter Before cleaning the roller with pressure cleaners using water steam etc c
57. 2 a 138 so t m Vo mwPs 50 empty Pin P58 ene dl T3307 1x P55 UE Psi Anzeigeger t Stevergeratstecker eT 77 3 1x P86 rq S s 1 128 ty pg3 125 e 1 122 i 133 1 a 121 1x PO Hoa 20123 Dec 128 132 ie i 130 POS 4x P91 inis d 126 131 s saj 120 8x PM A y X 300 qp e 358 fs Wes LM 3 c2 i I tx PBO l 2x P55 K1 P5 1x P57 105 UM ma o f H iss l i ai eL 137 50 tx P80 KT 2x P55 2x PSE Olk hler HBE 2 1 158 Ge e 158 E Oh 5 e 157 L fter zu Hydraulik amp lk hler quoq d P30 XA 8 1xP31 megua 2x P32 159178 Sk p33 200 a P Oltemperaturschalter Fran M e 158 Se IE 4x P15 amp 0 350 1x P16 3 1xP17 LITCY 3x0 25 Xl 158 2 n IR Sensor vorne shield lL a Fai E wy Lg e ws um tx P9S i jig g gn grem 280 me mi br brem ve 300 T G N1 S s 8 O8 ix P85 OOO x Fr 1 x Po 9e O6 18x P91 ee096 30 apa OO zx P933 koema 1x PB6 a tx P87 fet s 9 127 by PU 160 d j 160 S24 Abschalibigel Masse hinten Fig 7 9 Rear chassis wiring harness Other components Electrical system 89 7 2 2 ES Lu Jig pss 3 2x P16 30 290 300 ws Tier 4 Wiring harness 150 Pin N O N 30 Lag a X3 ih Lh men TIER amp 3 7 3x P2 1xP13 a 203 25 Fig 7 10 Tier 4 wiring harness Tab 7 9 List of wiring harn
58. 21 Error nw TS T f Abschaltb gel hint 54 schaltb gel hinten 121 x e x X N D an 149 nj W EN 109 Arbeitsdrehzahl 4 m N T0 IL IS z E z E jm ua 5 kx i Z m Motoroldruck I 152 106 Vorgl hen M lt m LWassertemperatur em L s is vo 4 er m o a nN 453 Lu CLI See a A C181 c on gt C z 27 ou M N gt U 2 24 22 177 Motoroldruckschalter Fig 7 11 Wiring diagram no 10378070 Rammax 1575 7 4 1 Wiring diagram key Element F11 F12 F13 F14 F21 F22 F23 F24 F25 G1 G2 K1 K2 K3 K4 K5 K6 K7 K11 M1 M2 M3 N1 N2 N3 P1 P2 R1 S1 S21 S22 S24 S25 Y1 Wiring diagram Electrical system Description Fuse controller supply Fuse controller outputs Fuse display unit shutdown bar Fuse hydraulic oil cooler Fuse pull in solenoid Fuse diesel pump alternator Fuse operating speed Fuse preheating glow plug Fuse 2nd solenoid Alternator Battery Relay ignition Relay starting interlock Timer relay Relay pull in solenoid Relay operating speed Relay preheating glow plug Relay hydraulic oil cooler Relay solenoid driver tier 4 Starter motor Diesel pump Hydraulic oil cooler Machine controller Display unit Infrared transmitter Front infrared sensor Rear infrared sensor Preheating glow plug Switch ignition switch Sensor engine oil pressure Sensor coolant temper
59. 25 should turn on the fan if the oil temperature is 50 C or higher Hammax 1575 8 2 Engine doesn t start The following description applies when starting the machine with the ignition switch If the machine cannot be turned on with the handheld controller only please refer to the next section Tab 8 1 Fault description engine won t start Fault description Possible cause Engine doesn t start Battery G2 Starter does not turn Ignition switch S1 Fuse F11 Controller N1 Relay K1 Fuse F22 Alternator G1 Starter relay K2 Starter motor M1 Engine doesn t start Diesel pump M2 Starter turns But engine doesn t start Fuse F21 Engine oil pressure switch 21 Fuses F12 F12 Controller N1 Timer K3 Relay K4 Pull in holding solenoid Y1 The engine starts but Water temperature switch only runs forabout4s 22 Engine oil pressure switch 21 Engine doesn t start Troubleshooting Checks Is the battery voltage OK Battery terminal clamps Battery cables in terminal clamps Can the engine be started with the ignition switch gt Controller not working Is F11 OK Is the connector connected The relay must be switched as soon as the ignition is switched on Is F22 OK Is the connector connected Connection D must have a voltage of 0 V when the ignition is on Is the connector connected correctly Relay checked With the ignition in the Start position connector 50 must have 12 V
60. 3 Fig 10 592 201311170082 1 1 2 1 Apply blue adhesive to the new sensor Check the mounted dimension approx 25 mm Observe the mounting orientation see the white mark on the sensor head 2 1 Marking parallel to bracket bend Fig 10 591 201311170080 Apply blue adhesive to the M8x65 22 hex screws 289 1 2 1 Fig 10 594 201311170086 Ww ndi a 1 Fig 10 596 201311170086 290 Feed the sensor cable through the opening in the chassis Install the sensor mounting bracket Lightly tighten the M8x 65 22 hex screws AF size 13 Set the gap approx 3 mm between the sensor head and the magnet 1 4 Adjust the sensor mounting bracket accordingly for this Tighten the M8x 65 22 hex screws AF size 13 to a torque of 25 Nm Hammax 1575 1 Connect the sensor cable 2 Secure connector with cable ties Fig 10 597 201311170112 Perform functional check of shutdown bar up Shutdown bar indicator lamp 1 must light Perform functional check of shutdown bar down Shutdown bar indicator lamp 1 must not light Fig 10 599 201311210001 10 25 Tools Inquire with your local MQ Field Service Manager for Special Tool needs 10 25 1 Special tools Assembly tool for drive motor Fig 10 600 201311210020 Tools Repair 291 Assembly tool for vibro unit Fig 10 601 201311210021 Puller for pendulum joint bearing Fig 10 602 2013
61. 4 10 4 1 10 4 2 10 4 3 10 5 10 5 1 10 5 2 10 5 3 10 5 4 10 5 5 10 6 10 6 1 10 6 2 10 6 3 10 6 4 10 6 5 10 7 10 7 1 10 8 10 8 1 10 8 2 10 9 10 9 1 10 9 2 10 9 3 10 10 10 11 10 12 10 13 10 13 1 10 13 2 10 14 10 14 1 10 14 2 10 14 3 10 14 4 10 15 10 15 1 10 15 2 10 15 3 10 16 Brake esi ute bag ooo oe See E Ew miuus s 136 I U DrICanE TADE ax 9 ee ADOS RUE EA RI REAL EE SISSE 137 CONSUIMADICS autas seus dass Neat a c p NUR Suc ala a d Gass Soi Sc E dpa da Y 138 Tightening torques lille 138 Cementing hydraulic threaded joints 141 Conversion table for bar psi 00 00 cee eee eee 142 Cleaning the roller llle 143 PROD ANE uuu aca aca de Voc ao alae ye ae Eod Qe ace a 145 Preparation for welding work 0000 cece eee ee 146 BANEN e sesaran a I PUO heres eet ayn ee 146 Replacing the battery llli 146 Starting with another battery juimpering a 147 Charging the battery using a battery charger 148 Long term storage 0 aaa aaa ee eee 148 Crck uU CRITIC PLUIE 148 Replacing gas struts lille 148 Overturning Tipping of the Rammax 1575 LL 150 Inspect for damage llle 151 Prevent an oll shock 1 anaana anaa 151 Start the engine 1 0 eee 156 Frontengine NOOG 5 sei ut oe ec etre ee eh eee oe 158 REMOVA ra tonal a tite af
62. 5 1 Remove fuse F21 40 A located in the engine compartment 1 Connectthe pressure gauge 40 bar to the charge pressure measuring point 2 Turn the engine over using the starter 1 Turn the engine over until 3 5 bar of pressure has been built up NOTE Do not overheat the starter After 30 seconds atthe latest allow the starter to cool down ry ALPLIK 250 DF Fig 9 27 201310010084 1 Install fuse F21 40 A located in the engine compartment Fig 9 28 201310010080 Hyaraulic oil replacement Maintenance 129 9 11 9 11 1 130 1 Start the diesel engine 2 Check the buildup of pressure Maximum pressure 23 bar 1 If hydraulic components have been replaced or repaired perform a check for proper function and for leaks Fig 9 30 201310010087 Coolant A coolant antifreeze mixture for up to 25 is provided upon delivery from the factory For temperatures colder than 25 the fluid must be replaced by a suitable coolant antifreeze mixture Checking coolant level 1 Check coolant level every day 1 4 Check oil level while the roller is standing on a level surface and the engine is cold 1 2 You can read off the level of coolant on the expansion tank display The water level must be between the top FULL and bottom LOW marks Top up coolant as required Hammax 1575 Fig 9 31 Expansion tank 9 11 2 Topping up coolant Danger of scalding from hot water steam
63. 9240052 Pendulum joint Repair 2 3 1 Screw in two M12x100 hex screws AF size 19 NOTE If the bearing seat is rusted use 4 screws 1 Screw the screws in until the pendulum bearing is separated from the bearing bolt Fig 10 522 201309240054 GNO Loa HE 1 Space limitations mean that no screws 4 longer than M12x100 can be used Therefore spacer blocks approx 20 mm must be placed under the SCrews 2 When the bearing has been pressed free of the bearing bolt remove the Screws 1 Use a piece of square timber 1 to force the chassis apart at the front and rear 2 Support the chassis at the rear using another piece of square timber 2 Fig 10 524 201309240058 274 Rammax 1575 Special tool for removing the joint bearing 1 Place the thrust washer of the special tool under the joint bearing Fig 10 527 201309240062 1 Position the upper part 1 of the special tool on the chassis support 2 Putthe M20 hex screw 2 of the special tool in place 1 Press the bearing out of the support 1 4 Turn the screw until the bearing is free Fig 10 529 201309240064 Pendulum joint Repair 275 1 Lift the bearing out of the support Fig 10 531 201309240068 Dismantled clamp ring with bearing 1 Place the clamp ring under the press 1 Press the bearing out Fig 10 534 201309240070 276 Hammax 1575 1 Clean the clamp ring 2 Grease the bearing seat
64. A 133 l F n 164 34136 BLL Vol C oE 34 utc 7 MIL EN gt p EX Jassejuy 3 UH L S LA 6l jeubis 0404 VSC lld Z ndung 105 F 7x Spannungs versorgung Logik 101 Motorhaltespule Spannungsversorgung Ausg nge 102 Roo Oltempschalter 176 159 ec 3 Hydraulik lk hler 103 Masse E x a S bus D s 104 Masse n 3 MN joreuerpus Ee o cd22 po S a yn z zs amp P Steuerbus D 23 2 5 E a 110 Xorwsls Sa T Spannungsversorgung 124 X 5 Za m ta T S o a Spannungsversorgung 125 x R ckw rts S at So R ckf hrung Ss v Pegel A gn eS rr Lenkung link z 169 N 413 enkung links Sa Pegel B br S 3 x LX a S x lt 1 2 pannungsversorgung ws a gt uv lt gt 2 170 NJ e m Lenkung rechts Er w TA Mo T IN ae Spannungsversorgung shield os w D lt lt 171 N 15 grosse Amplitude So Ba K 4 X N 172 NJ 16 kleine Amplitude Pss N ae Pegel B m D lt E i x 3H Bremsventil sA U3 N i a3 F Spannungsversorgung B ag Spannungsversorgung Abschaltb gel gedr ckt Ev e 1
65. Steering left 114 1 white N1 14 Y6 1 Steering right Other components Electrical system 85 No 115 116 117 118 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 86 Cross section 1 1 1 0 75 0 75 0 75 0 5 0 5 0 5 0 75 0 5 0 5 0 5 0 5 0 5 2 5 2 5 2 5 0 75 0 75 2 5 1 5 0 75 0 75 0 75 0 75 0 75 leo 1 5 0 75 1 5 wS 0 75 Color white white white white white white white white white brown white white white white white white white white white white white brown white white white white white white brown white white white white brown white white white Of Pin N1 15 N1 16 N1 17 N1 19 N1 21 N1 22 N1 23 N1 24 N1 25 N1 26 N1 27 N1 28 N1 29 N2 1 N2 3 N2 5 N2 6 N2 7 K1 30 K1 87 K1 87 K1 85 K2 30 K2 86 K2 87 K2 87 K2 85 K3 red K3 black K3 red black K3 yellow K4 30 K4 87 K5 85 K5 30 K5 87 K6 86 To Pin Y7 1 Y8 1 Y9 1 K2 85 N2 4 N2 2 X1 1 X1 2 X1 3 X1 4 N2 5 S24 1 N2 6 F13 3 S1 19 8 S21 S22 1 K2 85 S1 15 5 F14 D X3 2 Ground at rear M1 30 S1 50 7 M1 50 F21 A G1 D 1 F21 1 Engine ground K4 86 K4 85 F21 1 Y1 white Engine ground F23 3 Y2 S1 19 9 Comment big amplitude small amplitude Brake valve Engine signal Shutdown bar Error Control bus D Control bus D 12V E
66. Stes Sanda Wendt 5 a son TETTE 158 Replacing the hinges lille 160 Replacing the sensor llle 161 Replacing the rubber hood buffers 00006 165 Adjusting the rubber hood buffers 006 167 Rear engine hood 000 ees 168 PROIMOV MTM 168 Replacing the hinge 2 0 ee ee 171 Replacing the sensor leslie 171 Replacing the rubber hood buffers 00006 174 Adjusting the rubber hood buffers 006 175 Replacing the display unit 0 0 0 000 eee 175 REMOVAL dude eai uher ep E gus dele oS NET UT d o ur e nU es f 175 Replacing the controller machine controller 176 ISemoVdl scena ob ee ee bee D a EGO ea se e o ek olo end 176 MSTA ATOM 2 taceo gae ew hc m oA Eee ati vicem fred 178 Replacing and adjusting the magnetic rotational speed sensor 179 IxemoVvadl o ok Pen BS ed eeu BSG axe tumedxd ek Ed 179 IristallallOH ius ec ton eer actos o SR Ree EE SOR RR e Mn o 180 PRS UNION C coire ate end cas nie eo aede a ania Syed ana ae go dept 181 Testing the engine speed and frequency LL 183 Roller drum removal llle 184 Installing the roller drum extender 00000000 ee 185 Rubber elements of vibro unit llle 187 IxelioVal zs ieu e bes ah Ca ab state d Moree eS eh eae 188 Installation of the rubber elements ls
67. X5 adapter going towards the front sensor in the engine compartment e ls the cable to handheld controller N3 together with the corresponding connectors free of damage and of soiling Do not forget connector X1 on the hood s inside Operation e lis the handheld controller already paired with the machine gt Briefly connect the handheld controller to the cable for this purpose e ls the distance between the handheld controller and the machine OK 2 5m 4m in cable mode or 2 5m 20m in remote control mode e ls the battery for handheld controller N3 empty gt Use the cable mode temporarily fir control Hammax 1575 NOTE Please note that the vandalism protection cover may shield the infrared signal when open This applies to cable operation as well Tab 8 2 Troubleshooting controller is not working Fault description The controller is not working at all and the engine cannot be star ted with the ignition switch either The machine can only be started with the igni tion switch and is not working otherwise The machine only works in cable opera tion mode The diesel engine turns off all of a sudden during operation Machine does not drive nothing happens The controller is not working Troubleshooting Possible cause Fuses F11 F12 Controller N1 Infrared transmitter N3 Infrared sensors P1 P2 Infrared transmitter N3 Controller N1 Water temperature switch 22 Engine oil pressur
68. a E Ree e e ORO 298 DEANS DOME e RM cr TTE 299 TANG DOR DA caesos hee data cceli eink ern es ad VU itd a do orar 300 Shipping weights and dimensions llli 300 Transportation overseas llle 300 JOINT DFOLGCIOLD 2 2 5 2 22 9 309 E Io e e ttu go RR ae A 301 Lifting at the 1 point lifting eye llle 302 securing the roller on the transporter LL 302 Center of gravity aa aaa 303 DISDOSAl 5 133 riea deci xe b ac aos desse aki dus cR td 305 fonigeroiP eile irae a at alae oe tera eS atk hehe ees eat ks Be age inter Be Seep ate 306 Removal and depressurization of the gas strut 306 SERVICE amp SUPPORT CENTER Operation and Parts manuals as well as other service related material can be viewed and downloaded on the MULTIQUIP Service amp Support Center website use the link below http service multiquip com You can also access the Service amp Support Center website using the QR code below on your mobil device AN Service amp Support Center d E MULTISUIP Setting the standard in Construction Power and Lighting Solutions Hammax 1575 1 General 1 1 1 1 1 1 1 2 1 1 3 1 1 4 1 1 5 12 About this Service manual This manual is part of the customer documentation for the Rammax 1575 trench roller It is customer documentation of the Ammann Schweiz AG and its representatives in other countries Target audience
69. acked up before the roller drums are once again installed Perform an inspection for leakage 1 Pushtheroller drum under the chassis using a suitable aid 1 1 Keep the roller drum balanced using a suitable aid e g piece of square timber 1 Tighten the ten M12 hex screws AF size 19 to a torque of 85 Nm Fig 10 331 201309270029 10 16 Replacing vibromotor 10 16 1 Removal The vibromotors are installed at the front right and rear left To gain access to the vibromotors the drive motors must first be removed Siehe Replacing the drive motor see page 219 Replacing vibromotor Repair 229 1 Remove all hoses from the drive motor 2 Plug the fittings 1 Install two hex screws on the vibromotor 1 Pull out the vibromotor 1 Remove the coupling Fig 10 336 201309270005 230 Hammax 1575 1 The screw connections and the sprocket must be removed from the defective vibromotor 1 Remove the sprocket nut AF size 19 2 Remove the sprocket with puller device r ww Fig 10 340 201309270010 1 Remove the Allen screws AF size 5 2 Remove the elbow flanges on both sides Fig 10 341 201309270012 Replacing vibromotor Repair 231 1 Remove hydraulic hose 040 Fig 10 342 201309270013 1 Remove the screw in fittings AF size 17 Fig 10 343 201309270014 10 16 2 Installation Fig 10 344 201309270006 Overview of all parts that are used for the new vi
70. an the roller if it is stationary and secured from rolling away e Switch off the engine when filling the fuel tank Do not fill up fuel in enclosed spaces No open flames e Do not vibrate on slopes or inclines where there is a hazard of slipping or overturning e Do not drive on slopes that are steeper than the maximum climbing capacity of the equipment Always drive the roller carefully perpendicular to the slope dip e Do not vibrate inside buildings and on unstable ground e The driving and working field of view must not be obstructed in any way e Switch off the engine before leaving the roller Secure the roller against unauthorized start up and rolling away e ake suitable visible measures to secure parked rollers that pose an obstruction e Never work under the influence of drugs alcohol or medicines that impair consciousness e Only operate the roller in good general light conditions and good workspace illumination e he workplace of the operator is located at a safe distance of at least 2m Roller operation ADANGER Rollover hazard when driving the roller Only start the roller using the handheld transmitter Personnel may not stand in front of or behind the roller while it is in operation Persons necessary for operations at the sides of the equipment must remain at a safe distance of at least 2 m Shear points e When closing the hood ensure that no objects are situated between the hood and the chassis
71. arth Engine oil pressure Shutdown bar Water temperature 12V Preheating lamp Oil pressure lamp Water temperature Engine signal Ignition Ignition Ignition Ignition relay Battery 12V Starter Starter Pull in solenoid Starting interlock Timer Timer Timer Timer Pull in relay Pull in solenoid Gas relay Gas magnet Gas magnet Pre heater relay Rammax 1575 No Cross section 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 Other components 0 75 4 4 0 75 0 75 2 5 2 5 0 75 0 75 0 75 0 75 1 5 hes 2 5 1 5 2 5 zo 2 9 Electrical system Color brown white white white brown white white white white white white white brown brown white brown brown brown brown brown brown brown brown white white white white white white brown brown white white white white brown Of Pin K6 85 K6 30 K6 87 K7 86 K7 85 K7 30 K7 87 S24 2 S24 4 G1 30 31 15 2 M2 M2 Y1 black Y3 2 Y5 2 Y6 2 YT 2 Y8 2 Y9 2 Y2 N2 8 M3 2 F13 C F12 B F12 B M1 30 M1 30 M1 30 Engine ground Engine ground 25 1 X3 F21 A M1 30 X3 4 To Pin Engine ground F24 4 R1 25 2 Ground at rear F14 4 M3 1 S24 3 F13 3 M1 30 F22 2 F22 2 Engine ground Engine ground YA 2 Engine ground Engine ground Engine ground Engine ground
72. ary tool and a crane Use the crane to slightly lift the auxiliary tool Remove six M12 hex screws AF size 19 from the drive motor support Fig 10 202 201309260068 201 Pull the drive motor complete with the auxiliary tool away from the gear box Fig 10 204 201309270039 1 Setthe drive motor down securely until needed again 1 Remove seven M10 hex screws AF size 17 from the gear box cover Fig 10 207 201309270041 1 Remove twelve M8 hex screws AF size 13 from the gear box cover 2 Relocate the oil catch basin beneath the gear box before removing the gear box cover 202 Hammax 1575 1 Carefully remove the gear box cover by hand Grease will escape from the unbalanced drive gear box During reassembly later the same amount of grease must be added once again 1 Set the gear box cover down securely until needed again Fig 10 211 201309270046 10 14 2 Dismantling the vibro unit View of the vibro housing after opening NOTE The grease in the housing is spent after a certain number of operating hours and must be replaced The following steps were performed ona new vibro unit This is why the grease in all the photos is unspent and light in color Fig 10 212 201310010008 Replacing bearing vibro unit Repair 203 1 Clean the vibro housing and remove spent grease 1 Remove the M6 Allen screws AF size 5 from the bearing cover 1 Fig 10 215 2013
73. ational BS 2869 A1 or A2 Great Britain JIS K2204 grade no 2 Japan KSM 2610 Korea GB252 China NOTE Poor quality diesel can Reduce the performance of the engine e Damage the engine 118 Hammax 1575 NOTE For more detailed information please see the Yanmar engine manual 9 7 3 Draining fuel Environmental hazard through operating materials Do not allow any liquids to enter drains the soil or the environment 1 Unscrew the cover screw 1 under the roller AF size 27 wrench 2 Place a container under the drain tap 3 Drain off the diesel 4 Install the screw plug 1 4 1 Tighten the screw connection hand tight Fig 9 5 Diesel drain rear left on chassis 9 7 4 Cleaning the fuel tank Over time condensation water gathers in the fuel tank It must be drained once a year 1 Unscrew the cover screw 1 under the roller AF size 27 wrench 2 Place a container under the drain tap 3 Allow about 1 2 liter of fluid to drain First the water which has collected on the bottom of the tank will run out 4 Install the screw plug 1 4 1 Tighten the screw connection hand tight Fuel diesel Maintenance 119 9 7 5 9 7 6 120 Fuel filter element Fig 9 6 Fuel filter Replace fuel filter element 1 according to the maintenance plan 1 Close stop cock 3 1 1 Move to OFF 2 Unscrew the filter housing 2 3 Remove the old filter element 1 4 Insert new filter element 1 5 Sc
74. ature Sensor shutdown bar Sensor hydraulic oil temperature Magnet pull in holding solenoid 93 94 Element Y2 Y3 Y4 YS Y6 Y7 Y8 Y9 Y11 Description Magnet operating speed Magnet drive pump forwards Magnet drive pump backwards Valve steering left Valve steering right Valve large amplitude vibration Valve small amplitude vibration Valve locking brake Magnet 2nd holding solenoid tier 4 Hammax 1575 O Troubleshooting 8 1 NOTE NOTE 96 Introduction This section describes possible causes and action sorted according to error symptoms Note that the machine wiring although not mentioned explicitly is always a possible cause of electrical problems In our experience in most cases errors are caused by the wiring harness or connectors Therefore it is a good idea to check the machine for frayed cables and defective or loose connectors first Since the machine is remote controlled faults can be due to a variety of causes The best thing to do is to read through this chapter quickly at first in order to get a general overview Also make sure to pay attention to the LEDs on the handheld controller and the lamps on the display unit The machine will not shut down automatically when the hydraulic oil temperature is too high If you think the machine may be getting too hot check Fuse F14 e Oil temperature switch 25 e Relay K7 e Radiator M3 Oil temperature switch S
75. ays lights When the battery is drained it Connectthe charging cable for when a control is operated is no longer sent at least 1h The red LED flashes The battery is being charged The red LED is lit The battery is fully charged It is still possible to control via the cable once the battery is empty Battery warnings and errors are only displayed during active control i e when a control element is actuated As soon as and as long as the infrared transmitter is attached to the machine controller via the cable and the ignition is turned to I the red LED must flash or be lighted Automatic pairing Tab 5 6 Automatic pairing display Display Cause The green and red LEDs are blinking in unison The infrared transmitter is coupled with the quickly machine controller This procedure normally only takes a maximum of about 3 seconds If this blinking lasts longer or should even become permanent there is a problem with pairing e A cable break in one of the signal lines A short circuit in one of the signal lines As long as this blinking pattern remains no control signals will be sent to the machine controller Engine does not start Infrared transmitter Operating and display elements 41 Special cases 9 2 3 9 2 4 Automatic pairing occurs at the moment the cable is unplugged or if the cable is plugged in when the ignition is switched on When the infrared transmitter is switched on both LEDs are switch
76. bromotor If the screw connections and other parts are not damaged they can be reused for the new vibromotor 232 Hammax 1575 1 O rings must always be replaced 1 Apply blue adhesive to the Allen screws 1 Install the elbow flanges using the M6 screws AF 5 and tighten to a torque of 10 Nm 1 Putthe sprocket in place Fig 10 348 201309270018 Replacing vibromotor Repair 233 234 Fig 10 352 201309270022 1 Apply blue adhesive to the threads Install the spring washer Install the sprocket nut Tighten the sprocket nut AF size 19 to a torque of 50 Nm Hammax 1575 1 Apply blue adhesive to the straight screw in fitting GES10L M12x1 5WD Fig 10 353 201309270023 2 Install the straight screw in fittings and tighten them to a torque of 40 Nm Fig 10 355 201309270025 1 Install the coupling 1 4 Ifthe old coupling is not defective it can be reused Otherwise install a new coupling 1 Apply sealant to the sealing surface Fig 10 357 201208250034 Replacing vibromotor Repair 235 236 Fig 10 358 201309270004 Fig 10 359 201208250037 Fig 10 361 201310 P 010059 1 1 1 Insert the Vibromotor Apply blue adhesive to the two M10x95 hex screws Tighten the M10x95 hex screws AF size 17 to a torque of 56 Nm Mount the hydraulic hoses E 1 3 Fig 10 362 201310010060 Hammax 1575 1 Completely assembled vib
77. e chassis using a suitable aid 1 1 Keep the roller drum balanced using a suitable aid e g piece of square timber 1 JSetthe roller drum down securely until needed again Fig 10 131 201309270031 10 12 Installing the roller drum extender 1 Place the roller on a firm stable surface 2 Usea crane or hydraulic jack to slightly lift the roller 3 Forroller drum removal see page 184 Fig 10 132 201310010088 Installing the roller drum extender Repair 185 Screw in the two installation pins 1 Position the new roller drum Fig 10 134 201312180003 1 Push the roller drum over the two installation pins 1 1 Screw in four hex screws M12 x 25 AF size 19 87 Nm NOTE Pay attention to the position of the screws see photo at left IM t Mind Fig 10 136 201312180005 186 Hammax 1575 1263968 20 02 2014 1 Screw in the two installation pins 1 Pushtheroller drum extender over the two installation pins 1 1 Screw in six M12 x 90 hex screws AF size 19 87 Nm Fig 10 139 20131218000 10 13 Rubber elements of vibro unit If a rubber element has cracks that are deeper than 10 mm it must be replaced Rubber elements of vibro unit Repair 187 10 13 1 188 Removal Fig 10 143 201309270031 Safely jack up the machine Attach an anchor sling to the roller drum Use a crane to slightly lift the roller drum Remove the roller drum
78. e terminal first Connect the positive terminal first when reconnecting NOTE Doing welding work on the roller when the battery in installed can damage the electrical controls Always remove the battery completely before performing welding work on the roller NOTE Always replace the battery with a service free battery If you are using a battery that requires maintenance always observe the safety instructions in the battery manual 9 2 General information about maintenance e When carrying out maintenance work always observe the applicable safety regulations in the 3 Safety information page 23 section e Maintenance work and inspections must be performed according to the following maintenance tables in order to guarantee reliable roller operation e Remove all dirt before taking off any covers plugs measuring rods etc to inspect or top up engine oil hydraulic oil diesel or other liquids e Any parts that do not pass the following inspections must be replaced immediately e The protective devices must be correctly refitted after every service 110 Hammax 1575 Maintenance 9 3 Maintenance plan 9 3 1 sw t t o oucoasoowrosuons CI j f cf me LEE ELE Jeyy jo euiBue o euiDu3 L cL6 Jadesos uunup J9 O J 9 9 IO 91 neup H Lo ww ee ee ce j L t mew t te j j Lt m M e 0 0 pt mese 01 jt sooreorua
79. e clips Pull the gas strut away from the ball joint 169 170 1 Disconnect the wire cable from the hood 2 Usea crane to lift the hood up 1 Remove the lower screws from the hin ges on the left AF size 17 Fig 10 72 201309210047 1 Remove the lower screws from the hin ges on the right AF size 17 Fig 10 73 201309210049 1 Remove the cable tie on the hinge Fig 10 74 201309210050 Hammax 1575 10 6 2 10 6 3 Hear engine hood Repair 1 You can now use the crane to completely remove the hood from the chassis i Fig 10 75 201309210051 t L z E Fig 10 76 201309210052 Replacing the hinge For Replacing the hinge of the rear engine hood see the section Replacing the hinges of the front engine hood page 160 Replacing the sensor Replacing the sensor 1 Remove the four M6x30 AF size 5 Allen screws 1 Remove the protective cover of the sensor c all NS hs Fig 10 78 201309210013 171 1 Unscrew the sensor using the special tool AF size 36 1 Remove the sensor from the inside Fig 10 80 201309210015 1 Unscrew the rear sensor connector Fig 10 81 201309210016 Installing the sensor 1 Insert the new sensor Fig 10 83 201309260006 Fig 10 82 201309260005 172 Hammax 1575 Fig 10 87 201309260041 Hear engine hood Repair Screw the sensor in place from the outside using the special tool AF size 36
80. e ignition off position 0 NOTE Do not under any circumstances attempt to restart the engine right away Avoid oil shock Severe engine damage can result Environmental hazard through operating materials Do not allow any liquids to enter drains the soil or the environment Immediately bind any fluids which have leaked out such as oil diesel antifreeze battery acid Fig 10 7 Hammax 1575 150 Hammax 1575 10 4 1 Inspect for damage 1 Open both hoods 2 Disconnect the ground cable Fig 10 8 Disconnect the battery 3 Inspect the machine for visible damage 3 1 Especially for fluids which have leaked out 4 Empty any containers tanks which may be defective 10 4 2 Prevent an oil shock NOTE Before you begin the dismantling and disassembly of parts you must thoroughly clean the area around the valve cover cylinder head and electrical steel If no visible damage is found or it has already been repaired perform the following procedure Removal of parts 1 Remove fuse F21 in the engine compartment Fig 10 9 Engine compartment fuses 2 Remove the air filter element See page 84 2 1 If itis oily replace it Overturning Tipping of the Rammax 1575 Repair 151 152 3 Clean the air filter housing 4 Disassemble the air filter hose at the top Fig 10 10 Remove the air filter hose at the top 5 Disassemble the fuel filter AF size 13 Fig 10 11 Disassembling fuel filt
81. e new rubber buffer into the mounting Screw the rubber buffer firmly in place with the M8 hex nut and washer Hammax 1575 10 5 5 Adjusting the rubber hood buffers If the hood makes contact with the chassis the distance between the two can be adjusted Fig 10 60 201309260001 Fig 10 61 201309260004 Fig 10 62 201309260002 Front engine hood Repair Slightly loosen the two M8 screws on the rubber buffer mounting The distance between the hood and the chassis can now be adjusted by shifting the mounting 1 4 Be sure the spacing is uniform Slightly loosen the four M10 lower hinge screws The hood can now be aligned with the chassis by shifting it accordingly 1 1 The hood and chassis should be flush When finished tighten all screws 50 Nm 167 10 6 Rear engine hood 10 6 1 Removal The sensor must be removed before the hood can be taken off Siehe Replacing the sensor see page 161 1 Attach the hood to an anchor sling Fig 10 64 201309210037 Fig 10 63 201309210038 1 Cut through and remove the two cable ties at connector N2 1 Pull the two connectors off of the fuse box Fig 10 66 201309210041 168 Hammax 1575 1 Fig 10 69 201309210044 z D L J h a Fig 10 70 201309210045 Rear engine hood Repair Pull the connector off of the ignition switch Disconnect connector N2 Remove cable ties on hood Use a screwdriver to lift th
82. e switch 21 Alternator G1 Handheld controller N3 Controller N1 Drive pump Y3 Brake valve Y9 Checks Are F11 and F12 OK Check the machine as instructed in the previous description Pay special attention to alternator signal D and to engine oil pressure switch S21 If relay K1 is not being switched the problem proba bly has to do with controller N1 Is the battery voltage OK Battery terminal clamps Battery cables in terminal clamps Check the machine as instructed in the previous description If none of the LEDs on handheld controller N3 flash even during cable operation the unit may have to be replaced Check the wiring Check the machine as instructed in the previous description If the red LED on handheld controller N3 always flas hes when a function is carried out during wireless operation or if none of the LEDs light up during wire less operation the battery is probably faulty Also check the display unit The tilt sensor may have been incorrectly triggered The switch must be open when the operating tempe rature is normal The switch must be open when the engine is running Connection D must have a voltage of 12 V when the engine is running Does the green LED flash when the switch is actua ted Does error warning lamp H6 on the display unit light up Are the connectors connected Are the magnetic coils and valves OK Charge pressure OK Servo block OK Is the connector con
83. ed on briefly This feature helps to determine that the LEDs are still functioning e As soon as the cable is unplugged from the handheld transmitter or from the roller the red LED lights up for about 1 second Cable connection Fig 5 3 Spiral cable connector 1 Spiral cable connector protective cover fastener 2 Solar cells Transmission elements Handling Sticker The infrared transmitter is located in the black lower part of the housing It contains the following transmission elements e The solar cells e The infrared diodes for data transmission and measuring the safety distance e Before startup clean the transmission elements e Before startup be sure that the solar cells in the lower part of the housing are not covered over Hammax 1575 e Keep the solar cells clean during operation Accident hazard due to covered over lower part of the housing Before and during operation with the infrared transmitter make sure that the entire lower part of the housing remains completely uncover ed for the entire time of operation n particular the operator s hand must not cover the lower part of the housing even partially Wear the infrared transmitter correctly 1 Pay attention to correct positioning 1 1 The cable connector must face forwards or be oriented according to the sticker on the transmitter The infrared transmitter may rest on the stomach of the operator 1 2 Adjust the strap for the correct len
84. eplaced spare or wear parts must meet the technical requirements specified by Multiquip These requirements are fulfilled if only original Multiquip spare parts are used The instructions given in the various sections must be adhered to The safety instructions must be observed at all times Failure to adhere to working instructions their correct order safety instructions or safety labeling requirements causes liability claims to become void Warranty Opening or attempting to repair defective parts will void their warranty Hammax 1575 3 Safety information 3 1 3 2 3 2 1 24 General working safety e The roller may only be used for driving on and compacting loose top layers gravel earth Other uses are prohibited e Rollers may only be operated with all safety devices operating Manipulation or disregard of safety devices and regulations invalidates the CE conformity e Before starting every shift check the effectiveness of the operation and safety devices and that the protection devices are in place e Check the steering and brakes when you start work If defects are apparent roller operation is not permitted e f you identify any defects on the safety system or defects that impair safe operation of the equipment inform your supervisor immediately The roller may no longer be operated e lf you identify any defects which endanger safe operation cease operation immediately e Only perform work on and cle
85. er 6 Disassemble the electrical steel and fold it toward the back 6 1 Screws at back 2 Allen screws AF size 4 6 2 Screws at front 4 hex screws AF size 13 Fig 10 12 Disassembling electrical steel at back front Hammax 1575 7 Disassemble the valve cover 9 hex screws AF size 10 Fig 10 13 Disassembling the valve cover 8 Remove the three cables and contact connectors on the glow plugs AF size 8 Fig 10 14 Remove cables and contact connectors 9 Remove ALL three glow plugs AF size 12 9 1 Tools Long socket AF size 12 and torque wrench Fig 10 15 Tools Spark plug removal Overturning Tipping of the Rammax 1575 Repair 153 NOTE 154 Turn the engine over rotate crankshaft with a wrench Ensure that the oil which may have collected is displaced by the piston 1 Turn the engine over twice clockwise by means of the central bolt AF size 17 on the crankshaft using a box end ratchet wrench 1 Fig 10 16 Box end ratchet wrench Rotate crankshaft Risk of cable fire or short circuit Insulate the connection cables for the glow plugs e g using a piece of hose Fig 10 17 Insulate the connection cable 2 Refasten the electrical steel using two screws 1 Fig 10 18 Fasten electrical steel 3 Reconnect the battery ground cable Hammax 1575 Danger of burns due to ejected oil Eye injury burns Wear safety goggles Turn the engine over using the starter 1
86. er S1 Ignition switch Fuses Fig 7 5 Cockpit fuses Tab 7 6 Cockpit fuses Fuse No Power Fuse protected circuit Socket F11 10A Machine controller supply A 1 F12 25A Machine controller outputs B 2 F13 10A Display unit shutdown bar C 3 F14 25 A Hydraulic oil cooler D 4 Engine electrical system Fuses Electrical system 83 84 Display unit N2 hours Fig 7 6 Display unit N2 Tab 7 7 N2 display unit functions H1 H2 H3 H4 H5 H6 P3 Function Battery charge indicator Pre heating control lamp Oil pressure warning indicator Water temperature warning indicator Shutdown bar warning lamp Error warning lamp Operating hours counter Hammax 1575 7 2 Other components 7 2 1 Connector N1 wiring harness Fig 7 7 Connector N1 NOTE Make sure that the connector N1 is free of water and dirt Tab 7 8 List of wiring harness wires connector N1 No Cross section Color Of Pin To Pin Comment 101 2 5 white N1 1 F11 1 12V controller 102 25 white N1 2 F12 2 12V controller 103 2 5 brown N1 3 Ground at rear Controller ground 104 2 5 brown N1 4 Ground at rear Controller ground 105 0 75 white N1 5 K1 86 Ignition relay 106 0 75 white N1 6 S119 9 Pre heater relay 107 0 75 white N1 7 S1 50 7 Starter relay 108 1 white N1 8 25 1 Holding solenoid 109 0 75 white N1 9 K5 86 Gas relay 110 1 white N1 10 Y3 1 Forwards 111 1 white N1 11 Y4 1 Reverse 112 1 white N1 12 Y3 2 Return 113 1 white N1 13 Y5 1
87. ess wires tier 4 Nome seca EST Of tion 201 1 white X3 202 2 5 white X3 203 1 white X3 204 2 5 brown Y11 205 1 brown K11 206 2 5 white F25 207 2 5 white K11 208 1 white K11 90 30 2 Solenoid zm oe oe To K11 F25 K11 X3 X3 K11 Y11 Y11 Ix P20 Ix P21 2x P22 1x P23 2x P24 S Kp Pin 1x P30 r 30 m Ix F32 ml m 1x P33 K11 Solenoid Driver KPT re jememem 3x P32 LA J EIE EI ix P33 Comment Starter Ignition Battery Earth Earth Ignition Pull in solenoid Holding solenoid Rammax 1575 7 3 7 3 1 Wiring diagram Wiring diagram Explanations EN E I Bunsaneyspuey 7 x lt Spannungsversorgung 124 ama n _ Spannungsversorgung 425 Xp 4 SET D lt a a zu G 2 aA i x F JOSU yl Connection Connector name Contact number A O N gt Cable number All white cables are serially numbered the brown cables are not numbered and are always a connection to earth 5 Component separation In some cases also optional cable connections 6 Contact number on device connector T Element name cf wiring diagram key page 93 Electrical system 91 7 4 92 Wiring diagram ca N w w S 2 lt wu Un o 2o m em Anlasser 1S a E3 w 3 lio z T i CU N a co w N A E 2 YN D a PUN eo o o P 1439 aN 98 ed U9SUnibJO
88. ews AF size 19 to a torque of 85 Nm Fig 10 409 201309220045 Fig 10 408 201309220044 1 Install the screw connection for the intake line Replacing the drive pump Repair 247 248 Fig 10 414 201309220059 1 Install the T screw connection for the reverse drive circuit A drive pump Install the hydraulic hose for the forwards drive circuit B drive pump Install the pressure line screw connection for the vibro pump Install the supply hydraulic hose for the drive pump Hammax 1575 Fig 10 415 201309220061 Fig 10 417 201309220063 Replacing the drive pump Repair i fy F E j a 1 z r D a r 1 B a E 1 ias 1 1 1 Install the charge pressure screw connection for the drive pump Connect connectors Y3 and Y4 Install the charge pressure hydraulic hose for the PBR valve block 249 10 19 Replacing the valve block The hydraulic oil must be drained before the valve block can be demounted Siehe Draining the hydraulic oil see page 124 10 19 1 Removal PREDA n ssh Fig 10 418 201309220066 1 Disconnect connectors Y5 through Y9 FEL Fig 10 419 201309220067 1 Cut through all the cable ties on the wiring harness valve block 2 Pull back the wiring harness 250 Hammax 1575 e Fig 10 420 201309220072 Replacing the valve block Repair 1 1 1 1 Remove hydraulic hoses A2 B2 PBR T2 Plug the fitti
89. f 21 2 bar is not achieved then e The charge pressure valve must be checked See page 5 If the pressure still cannot be achieved the drive pump must be replaced Siehe Replacing the drive pump see page 237 Checking the drive pressures reverse forwards 1 Disconnect connector Y9 1 from the valve block Fig 6 31 201310020005 Hammax 1575 1 Connect a pressure gauge min 400 bar to the drive pressure measuring point MA 1 2 Start the engine 2 1 Full speed 3 Drive in reverse against the brake 3 1 Letit run for a maximum of 5 Sec 1 Connect a pressure gauge min 400 bar to the drive pressure measuring point MB 1 2 Start the engine 2 1 Full speed 3 Drive forwards against the brake 3 1 Letit run for a maximum of 5 Sec Fig 6 33 201211270001 If one of the drive pressures of 330 x 15 bar is not achieved then e The drive motors must be checked page 63 e The drive pump maximum pressure must be checked page 64 If the pressure still cannot be achieved the drive pump must be replaced Siehe Replacing the drive pump see page 237 6 3 5 Checking the drive motors The following operation is necessary if e he drive pump test is positive e The pressure is not achieved with the drive motor which is connected Check the drive motors individually one after the other 1 Remove the hydraulic hoses for drive circuits A and B from the drive motor 2 Sealthe screw connections pre
90. filled if only original Ammann spare parts are used For the ordering spare parts download parts manual at http service multiquip com Structure of the Service Manual The following explanations are designed to familiarize you with the roller and to provide support for handling and maintenance It is essential that you read chapter 3 Safety information page 23 carefully before commissioning and carrying out maintenance work Observing the safety instructions in particular increases the reliability of the roller in operation and its service life This reduces repair costs and down time Orientation on the roller When describing the components of the roller we inform you of their position on the roller We adhere to the orientation below when doing so Structure of the Service Manual General 13 1 2 2 14 Top Left E i Jur c Er a Ww F Mous g gh Em l al f E M VF ve 1 gt a ZRAMMAX 1 a Je 4 E s gt Lime _ E p is 5 D am E ae 4 a Jen E m 24 a P ie EN dy A EI LL BP E Uf eco NB Se aca HS Sb Nae de Stamm me ooo ngi Bottom Right Fig 1 1 Hammax 1575 orientation We view the roller from the position of the driver standing behind the roller looking in the direction of travel Warnings Please observe the meaning of the following warnings ADANGER e DANGER represents an immediate hazard leading to severe bodily injury or death e WARNING represents a possibl
91. final position If you need more force to open the hood replace the gas absorbers Siehe Gas strut see page 148 Opening the hood front and rear Maintenance 115 9 6 Engine compartment overview 9 6 1 Left side of the engine Fig 9 2 Left side of the engine 1 2 3 4 D 6 T 116 Rammax 1575 Air intake filter Engine oil filter Oil dipstick Coolant drain Engine oil filler neck Coolant filler neck Fuel filter 9 6 2 Right side of the engine Fig 9 3 Right side of the engine Engine oil filler neck Alternator Fuel pump Coolant level display Flow divider Hydraulic manifold o oc FP W NN gt Water separator Risk of burning and injury when handling parts in the engine com partment Switch the diesel engine off when performing any inspection work The locking brake is active when the diesel engine is switched off Engine compartment overview Maintenance 117 9 7 Fuel diesel 9 7 1 Checking fuel level 1 Open the hood 2 Check the level in the plastic tank 9 7 2 Refueling 1 Fill the fuel tank with diesel fuel up to the lower edge of the filler neck 1a Every day before beginning work The tank holds 28 liters of diesel fuel Fig 9 4 Diesel fuel filler neck Diesel specifications Tab 9 1 Excerpt from the Yanmar engine manual about diesel specifications Diesel specifications Application No 2 D No 1 D ASTM D975 94 USA EN 590 96 Europe ISO 8217 DMX Intern
92. g 10 170 201309270053 194 Rammax 1575 1 Attach the gear box to the crane by means of the auxiliary tool Fig 10 172 201310010009 F Fig 10 171 201310010011 1 Align the gear box 2 Place the gear box onto the rubber elements Tighten the seven hex nuts 1 AF size 17 to a torque of 50 Nm Fig 10 174 201310010017 This completes the installation of the gear box on the vibromotor side If a bearing replacement or regreasing is necessary please see chapter Replacing bearing vibro unit see page 200 Without a bearing replacement or regreasing you may proceed here Rubber elements of vibro unit Repair 195 196 Fig 10 179 201310010020 1 Clean the sealing surface of the gear box housing 1 Retap all threads M8 1 Blow out the thread bores 1 Thoroughly remove all soiling in the form of adhesive residues and contaminated grease 2 Replace grease that has been removed or has run out with the same amount of new grease Grease Castrol Longtime PD2 or compatible extreme pressure grease for long term lubrication Hammax 1575 1 Apply sealant to the sealing surface Fig 10 180 201310010021 a 1 Spread the sealant with a brush b 1 Place one drop of blue thread K adhesive in each threaded bore Fig 10 182 201310010024 1 Clean blow out the holes in the gear box cover a ell P nay ee ig Rubber elements of vibro unit Repair 197 1 Clean the sealing
93. g 10 439 201309220095 Replacing the valve block Repair 255 10 19 2 Check Brake solenoid valve It is recommended that all magnetic coils and valves be checked on the demounted valve block 1 Remove the nut on the solenoid valve 1 Remove the solenoid Fig 10 442 201309210114 1 Remove valve AF size 22 Disassembled solenoid valve e Nut 1 e Gasket 2 e Solenoid 3 e Solenoid valve 4 e Gasket 5 Fig 10 444 201309210111 256 Rammax 1575 1 Apply a voltage of 12 V to the solenoid valve 2 The valve arrow must be visibly and audibly actuated 3 Check the ring seals 1 for damage 1 Resistance of the solenoid 4 9 Ohm Fig 10 446 201311150002 Solenoid valve for large small amplitude vibration and steering 1 Remove the nut on the solenoid valve 2 Remove the solenoid 1 Remove valve AF size 26 2 Place valve in magnetic coil Fig 10 448 201309210119 Replacing the valve block Repair 257 258 2 A Tm Di EAT TO px a 77 Ab 760 Acer LAT a E ace e G i z Pd A x Am p Fig 10 450 201311150001 Apply a voltage of 12 V to the solenoid valve The valve must be visibly and audibly actuated Resistance of the magnetic coil for large small amplitude vibration and steering 4 4 Ohm max brake pressure max vibration pressure Fig 10 452 201309210122 The brake pressure relief valve AF si
94. gation number Name and address of the manufacturer Vehicle Identification Number VIN Roller model Year of manufacture Serial number CON OO fF WN gt Fuel engine output at co Speed of fuel motor rpm CECE total weight Axle load front Axle load rear er oOo N O Number stamped in chassis Rammax 1575 NOTE When ordering spare parts you must indicate the serial number S N of the roller 2 3 2 Location of machine rating plate 1 Therating plate is located on the front right of the rear chassis Fig 2 3 201309200003 2 3 3 Location of machine chassis number 1 The front chassis number is located under the steering Vibro pump 1 Therear chassis number is located hidden on the rear most part of the center beam Fig 2 5 201309200005 Roller designation Product description 21 2 3 4 2 3 5 2 4 2 4 1 22 Location of Yanmar engine rating plate 1 The Yanmar engine s rating plate is located on the valve cover Fig 2 6 201309200002 Location of engine number 1 The engine number is located on the starter side on the machine s right hand side of the engine block Disclaimer Multiquip accepts no liability for the continued reliable functioning of the roller if it is not used appropriately Unauthorized conversions and changes to the roller are prohibited for safety reasons and void any and every Multiquip guarantee as well as possibly the CE directive R
95. gth to ensure optimal wearing comfort 2 Payattention to correct operation 2 4 Only hold the housing by the upper part see the warning information Fig 5 4 Wear the infrared transmitter correctly NOTE Be certain that the desired confirmation can be carried out safely Infrared transmitter Operating and display elements 43 44 Hammax 1575 ic System Hydraul 45 6 1 Overview of the hydraulic system Hydraulic oil tank Drive pump Vibro steering pump Drive motor Vibromotor Valve block Hydraulic manifold Steering cylinder Hydraulic oil filter Oil cooler 1 2 3 4 5 6 T 8 9 1 1 O Flow divider 6 1 1 Hydraulic hose service life and storage NOTE The hydraulic hoses should not be used for more than six years this includes any storage periods In addition the hoses should not be stored for more than two years as per DIN 20066 46 Rammax 1575 6 2 Overview of hydraulic hoses 6 2 1 Hoses for travel vibro drive Front left roller drum Fig 6 1 201310020003 Tab 6 1 Hoses for front left roller drum No of position 31 Drive circuit B forwards Hydraulic manifold left 33 Drive motor brake Valve block BR 35 Drive circuit A reverse Drive pump A T fitting 37 Front left drive motor leakage oil L fitting Valve block T3 38 Front left brake Front right drive motor brake 39 Front left drive motor leakage oil L fitting Front right drive motor leakage oil L fitting
96. iately and top up coolant 1 Allow the engine to cool down 2 Remove the radiator cap 3 In order to avoid scalding first unscrew the radiator cap one turn and allow the pressure to drop 4 As soon as the pressure has dropped remove the cap and top up the liquid 5 Check the cooling system for leaks and the radiator expansion vessel for correct coolant level 5 1 You are unable to find an error Call a specialist to remedy the problem Display unit Operating and display elements 37 NOTE NOTE 38 The machine is equipped with an automatic shutdown system If the cooling water temperature exceeds the limit value the temperature warning lamp lights up After the warning lamp has been lit for 4 seconds the machine is shut down Pre heating The pre heating time amounts to about 6 sec When the motor is started the Pre heating control lamp goes off Shutdown bar The shutdown bar indicator lamp remains lit as long as the shutdown bar is actuated 1 Check whether the shutdown bar has been released 2 Release the shutdown bar LED error display on the display unit Tab 5 1 Error display tilt switch Display Cause Remedy Error lights up The tilt switch has been triggered The roller Set the machine upright is at an angle of more than about 45 or has tipped over For safety reasons as soon as the roller tips over the ignition is also shut off The machine controller is equipped with an inclination sen
97. is controlled by means hing ted of the cable the user must be pre sent in the close proximity area between 2 5 and 4m NOTE Bear in mind the priority of the displays First the bar switch then the close proximity shutdown and last the close proximity area Display unit Operating and display elements 39 5 2 Infrared transmitter 5 2 1 Design Wawa 7 S esi g 3 min 2m A fy a ul y o Fig 5 1 Infrared transmitter Work gear transport gear Forward travel backward travel Large small amplitude vibration Steering angle left right Start Stop LED error and charging display from IR transmitter Cable NO oc FP WB NN gt 5 2 2 LED error display on the IR transmitter There are two LEDs on the cover a green one and a red one Fig 5 2 LED error display green red 40 Rammax 1575 NOTE NOTE Standard Tab 5 4 Standard display Display Cause The green LED is blinking slowly The roller is being controlled via the cable The green LED is flashing The roller is being controlled via infrared Battery charge monitoring The red LED blinks either faster or slower depending on the battery charge level The lower the charge state the longer the on phase of the LED Tab 5 5 Battery charge monitoring display while performing a function Display Cause Remedy The red LED flashes briefly The battery is slowly beco Connect the charging cable for ming drained at least 1h The red LED alw
98. istance of at least 2 meters to the machine must be maintained during operation A DANGER Crushing of toes through careless handling of the roller Wear safety shoes when working with the roller in order to help avoid crushed toes Roller operation Safety information 25 3 3 NOTE 3 4 26 ADANGER Danger of accident through improper operation of the roller Read the operating instructions before operating the roller e Adhere to the safety regulations at all costs e In case of lack of clarity contact your authorized dealer Noise levels Hearing damage due to continuous noise level Depending on the use of equipment it is possible that the permissible noise level of 85 dB A will be exceeded Wear ear protectors in accordance with national accident prevention regulations when working at higher noise levels The following noise level measurements were carried out by an accredited testing and monitoring body in accordance with machine directive 2000 14 EEC of the European parliament and council Inspecting and monitoring organization TUV Osterreich Austrian technical inspectorate Testing body no 0408 Tab 3 1 Sound power level Model Value Measured sound power level 100dB A The obligation to wear ear protection is standardized nationally In Switzerland and Germany this is as of a measured level of 85 dB A sound pressure Safety markings on the machine e Observe and adhere to
99. ive motor Tab 10 4 Plugs and stoppers for 1 drive motor Material Pipe plug End plug Cap nut 10 26 4 Drive pump drive pressure test Tab 10 5 Plugs and stoppers for drive pump drive pressure test Material Pipe plug End plug Cap nut 10 26 5 Drive pump charge pressure Tab 10 6 Plugs and stoppers for drive pump charge pressure Material Pipe plug End plug Cap nut 10 26 6 Steering valve block maximum pressure Tab 10 7 Plugs and stoppers for B2 A2 Material Pipe plug End plug Cap nut 296 Size 10L 10L 10L Size 12L 12L 12L Size 12L 12L 12L Size 10L 10L 10L Quantity Quantity 2 2 Quantity 1 1 1 Quantity Material number 1 901439 1 901274 1 901397 Material number 1 901440 1 901275 1 901325 Material number 1 901440 1 901275 1 901325 Material number 1 901439 1 901274 1 901397 Hammax 1575 11 1 Storage 11 1 1 Short term storage e Move the Start Stop lever on the infrared transmitter to the neutral position e Secure the roller from unauthorized start up and unintentional rolling away e Remove the ignition key 11 1 2 Long term storage Tab 11 1 Long term storage Component precautions Chapter Diesel engine Observe the information in the Long term storage section in the diesel engine manual Fuel diesel Drain 9 7 3 Battery Uninstall the battery and clean the outside 10 1 Charge the battery once a month during standstill time Air fil
100. ize 22 pressure tight 1 Re mount the magnetic coil 1 Connect a pressure gauge min 250 bar to the vibration pressure measuring point 1 2 Startthe engine 2 1 Full speed 3 Switch on vibration 3 1 Let it run for a maximum of 5 Sec Fig 6 25 201310020007 If the vibration pressure of 220 10 bar is not achieved then e The valve block must be removed Siehe Replacing the valve block see page 250 e The vibration pressure relief valve must checked 60 Rammax 1575 After the test the following tasks must be carried out e Connect the hydraulic hoses e Top up oil e Clean the machine e Start the machine e Check for leakage and proper function 6 3 3 Checking the maximum charge pressure 1 Remove hydraulic hose 008 at the charge pressure measuring point 1 Seal the screw connections 1 pressure tight 1 Remove the hydraulic hose for drive circuit B forwards from the drive pump 2 Sealthe screw connections pressure tight Fig 6 28 201309210080 Checking and adjusting pressures Hydraulic System 61 6 3 4 62 1 Remove the drive circuit A reverse T screw connection from the drive pump 2 Sealthe screw connections pressure tight 1 Connect the pressure gauge min 40 bar to the charge pressure measuring point 1 2 Startthe engine 2 1 Full speed 2 2 Letitrun for a maximum of 5 Sec k d Fig 6 30 201310020010 If a charge pressure o
101. l at one of the two oil filler necks 1a Filler neck on the left hand side of the engine 1b Filler neck on the engine Fig 9 9 Filler neck to the left and filler neck on top NOTE In order to guarantee operating safety of the engine for the long term you must not put any additives in the engine oil 9 8 3 Draining engine oil The engine oil drain 1 is located under the chassis at the front left 122 Hammax 1575 Fig 9 10 Roller turned fully Engine oil drain Environmental hazard through operating materials Do not allow any liquids to enter drains the soil or the environment 1 2 Place a container under the drain Open the union by turning it anti clockwise 27 mm wrench The oil starts to flow out immediately 9 8 4 Replacing the engine oil filter Fig 9 11 Engine oil filter 1 Engine oil Maintenance Loosen the filter 1 by hand or using a filter wrench 1 1 The oil starts to flow out immediately It s best to place a rag under it beforehand Replace oil filter 2 2 1 Install in accordance with regulations see filter packaging or filter housing ocrew the complete filter back in place 123 9 9 9 9 2 NOTE 9 9 3 NOTE 124 Hydraulic oil Checking the hydraulic oil level Inspection window Always check the hydraulic oil level when the system is cold 1 Place the roller on level ground 2 Checkthe oil level in the inspection window The hydraulic
102. l joint on the left and right F Fig 10 23 201309210019 158 Rammax 1575 1 Disconnect the wire cable on the left from the hood 2 Usea crane to lift the hood up 1 Remove the lower screws from the hinge on the left AF size 17 Fig 10 25 201309210022 1 Remove the lower screws from the hinge on the right AF size 17 Fig 10 26 201309210023 1 You can now use the crane to completely remove the hood from the chassis Front engine hood Repair 159 10 5 2 Replacing the hinges 1 2 1 1 Fig 10 30 201309210031 1 Fig 10 31 201309210033 160 Remove the hood as shown above Remove the two M10x20 hex screws Replace the hinge Apply blue adhesive to the M10x20 AF size 17 hex screws Retighten the screws with a torque of 50 Nm Rammax 1575 10 5 3 Replacing the sensor Removing the sensor 1 Remove the four M6x30 AF size 5 Allen screws Fig 10 33 201309210002 1 Remove the protective cover of the sensor E Fig 10 34 201309210004 1 Unscrew the sensor using the special tool AF size 36 1 Remove the sensor from the inside Fig 10 36 201309210006 Front engine hood Repair 161 1 Remove the sensor cable from the cable mountings 1 Remove cable ties 1 Remove cable ties 1 Disconnect connector X5 front IR sensor Fig 10 40 201309210010 162 Hammax 1575 1 Disassembled sensor Now it can be replaced
103. l system See Check the pump in the following Check the pump 1 Turn the ignition key clockwise to position I 1 4 Check whether the electrical fuel pump is working Allow the pump to operate for about 1 minute The system will be bled automatically 2 Attempt to start 1 Turn the ignition key clockwise to position lll 2 Allow the engine to turn over in neutral 2 1 Do not activate any functions Engine running The engine will smoke until the oil that has gathered in the exhaust system has been burned away can take up to 1h Hammax 1575 Danger of fire It is possible for flames glowing embers to be shot out of the exhaust pipe 1 Immediately perform a visual inspection for any leaking fluids If everything is in order 1 Bring the engine up to maximum speed 1 1 Check the functions The smoke from the engine must be decreasing noticeably and then stop completely Otherwise there may be a mechanical defect in the engine 1 2 owitch off the engine Check all fluid levels 2 1 Top up as needed Inspect for fluid losses Start the engine Overturning Tipping of the Rammax 1575 Repair 157 10 5 Front engine hood 10 5 1 Removal The sensor must be removed before the hood can be taken off Siehe Replacing the sensor auf page 161 1 Attach the hood to an anchor sling Fig 10 22 201309210018 1 Use a screwdriver to lift the clips 2 Pullthe gas struts off of the bal
104. lacing the battery NOTE The battery poles and terminals must be clean If they are coated with a whitish or greenish sulfur crust they must be cleaned 10 2 2 Starting with another battery jumpering Connect the red cable to the terminals of both batteries Connect one end of the green or black cable to the terminals of both batteries Actuate the starter Allow the engine to run Wait until the engine is idling smoothly and then disconnect the cables 4 1 Begin with the terminal Fig 10 3 Starting with an external battery NOTE The battery poles and terminals must be clean If they are coated with a whitish or greenish sulfur crust they must be removed and cleaned Battery Repair 147 10 2 3 Charging the battery using a battery charger Disconnect the battery Connect the battery charger 2 1 Observe the battery charger manufacturer s manual 3 Start with the terminal when reconnecting the battery NOTE The battery poles and terminals must be clean If they are coated with a whitish or greenish sulfur crust they must be removed and cleaned 10 2 4 Long term storage Remove the negative battery cable from the battery if a standstill period of more than two weeks is expected 10 3 Gas strut Gas struts are maintenance free They require no maintenance such as lubrication They ZA are designed for the respective requirements and work trouble free for many years 10 3 1 Replacing gas
105. linder 1 Remove the steering cylinder 1 Plug the screw connections on the steering cylinder Fig 10 508 201309240008 270 Rammax 1575 1 Fig 10 509 201309240010 10 22 2 Install a new steering cylinder Fig 10 512 201309250009 Replacing the steering cylinder Repair Plug the screw connections on hoses 017 and 018 Clean the securing bolt remove rust as needed Install the spacer 1 Grease the securing bolt Apply blue adhesive to threaded bolt Install a new steering cylinder Tighten the M16 nut AF size 24 1 to a torque of 100 Nm Grease the front and rear grease nipples 2 271 1 Install hydraulic hoses 017 and 018 Fig 10 513 201309250014 10 23 Pendulum joint Before the pendulum joint can be demounted the following components must be removed e The pendulum support Pendulum support see page 264 e The steering cylinder Replacing the steering cylinder see page 269 1 Cut through the cable tie on the hose bundle 1 Place a protective sheet e g aluminum beneath and above the hose bundle between it and the chassis a Fig 10 515 201309240057 272 Hammax 1575 1 Remove the M12 hex screws AF size 19 from the pendulum joint 1 Remove the cover 1 Remove the M16 hex screw AF size 24 from the bearing lock 2 Remove the bearing lock 1 Fig 10 519 201309240051 1 Retap the thread in the chassis support X Fig 10 520 20130
106. ll Maintenance 125 9 9 5 126 Replacing the hydraulic oil filter 1 Remove the filter lid 2 Unlock the filter element 3 Liftthe filter element out of the filter housing 3 1 Dispose of the filter element in an ecologically appropriate manner Fig 9 15 Replacing the hydraulic oil filter steps 1 to 3 4 Place the new filter element in the proper position 4 1 Observe the position of the locking cam 5 Turn the filter element fully clockwise to the stop Fig 9 16 Replacing the hyaraulic oil filter steps 4 to 6 6 Lightly oil the sealing ring on the filter lid 7 Putthe filter lid in place 7 1 Tighten the lid with a torque wrench max torque 20 Nm Hammax 1575 Fig 9 17 Replacing the hyaraulic oil filter steps 7 to 8 9 9 6 Replacing the ventilation filter 1 Ventilation filter according to the maintenance plan Fig 9 18 Ventilation filter 9 10 Hydraulic oil replacement 9 10 1 Filling the hydraulic tank 1 Fill the hydraulic oil tank approx 16 1 M LN x h Fig 9 19 201310010071 Fig 9 20 201310010072 Hyaraulic oil replacement Maintenance 127 9 10 2 Filling the drive pump building charge pressure 1 Remove hydraulic hose 006 S 1 Fill the drive pump housing with hydraulic oil 1 Pourin hydraulic oil 0 3 0 4 I until the oil runs out of the screw connection S 1 Install hydraulic hose 006 S Fig 9 24 201310010079 128 Hammax 157
107. n K2 Starter relay start inhibit K3 Timer 1s pull in solenoid K4 Relay for pull in solenoid of stop solenoid K5 Magnetic rotational speed sensor K6 Relay for pre heating NOTE K3 is located on the back of the metal sheet Tab 7 2 Engine compartment fuses Fuse No F21 F22 F23 F24 F25 Power 40 A 10A 40 A 40 A 40 A Height sensor tier 4 Fuse protected circuit Pull in solenoid of stop solenoid Diesel pump alternator 15 Magnetic rotational soeed sensor Pre heating glow plug 2 Single coil tier 4 option Tab 7 3 Tier 4 relay functions K11 Engine electrical system Fuses Electrical system Function Height sensor tier 4 Socket B 2 C 3 D 4 81 7 1 2 Chassis rear G2 NER ue 4 gt pi i ERT Gel Ic Lvdez uv zz m Fig 7 3 Rear chassis relay Tab 7 4 Rear chassis relay functions Function G2 Battery K1 Relay ignition K7 Relay hydraulic oil cooler N1 Machine controller S24 Switch shutdown bar sensor option X4 Front infrared sensor P1 X6 Rear infrared sensor P2 NOTE Machines without a shutdown bar will not have an S24 proximity switch A jumper is inserted instead of the switch NOTE Infrared sensor connectors X4 and X6 can be interchanged This will not affect the machine in any way 82 Rammax 1575 7 1 3 Cockpit F11 F14 Fig 7 4 Relay cockpit fuses Tab 7 5 Cockpit relay functions Function N2 Display unit N3 Infrared transmitt
108. nce again Set the gear box cover down securely until needed again 1 Support the hoses with square timber to keep them free 2 Screw the auxiliary tool securely onto the vibromotor side of the gear box cover AF size 19 3 X Attach an anchor sling to the auxiliary tool and a crane 4 Usethe crane to slightly lift the auxili ary tool Fig 10 159 201310010017 Rubber elements of vibro unit Repair 191 1 Remove seven M10 hex screws AF size 17 from the gear box cover 1 Pull the gear box complete with the auxiliary tool away from the center beam 1 Setthe entire gear box down securely until needed again 1 Remove fourteen M10 hex screws AF size 17 from the center beam mM y aed x rubber elements MARINE e Fig 10 163 201309270056 192 Hammax 1575 1 Remove the rubber elements Fig 10 164 20 1309270058 10 13 2 Installation of the rubber elements 1 Apply blue adhesive to the fourteen M10 hex screws 1 Place the new rubber elements onto the center beam Fig 10 166 201310010002 Rubber elements of vibro unit Repair 193 1 Securely tighten the fourteen M10 hex screws AF size 17 on the center beam rubber elements to a torque of 50 Nm Fig 10 168 201310010004 1 Apply blue adhesive to the rubber elements threads on the vibromotor side 1 Support the hoses on the vibromotor side as well with square timber to keep them free Fi
109. nd right Fig 10 574 201311170040 285 1 Insert the stop on the right Fig 10 575 201311170041 1 Install the M10 Allen screw AF size 8 2 Apply blue adhesive to the Allen screw Fig 10 576 201311170045 1 Put the washer in place 2 Put the M10 hex nut in place 1 Tighten the M10 Allen screw AF size 8 1 4 Tighten the screw until the stop 1 rests in the tube without play Fig 10 578 201311170051 286 Hammax 1575 1 Place the magnet on the tube on the left side 1 4 Observe the mounting orientation see photo 2 Insert the hex screw from below J Fig 10 579 201311170053 Fig 10 580 20131117055 1 Apply blue adhesive to the Allen screw 1 Tighten the M10 Allen screw AF size 8 1 4 Tighten the screw until the stop 1 rests in the tube without play Fig 10 582 201311170058 Shutdown bar Repair 287 The new shutdown bar is fully installed Fig 10 583 201311170104 10 24 2 Sensor replacement and adjustment 1 Disconnect the sensor cable connector Fig 10 584 201311170112 2 Remove the sensor mounting bracket AF size 13 under the chassis Fig 10 585 201311170086 Fig 10 586 201311170080 1 Remove the old defective sensor from the bracket Fig 10 587 201311170079 288 Hammax 1575 Shutdown bar Repair T EA Fig 10 588 201311170090 udi mmm Lien j Fig 10 589 201311170094 Fig 10 590 20131117009
110. nected 101 Fault description Machine does not drive it attempts to move against the brakes The machine moves forward only Machine drives too slowly Machine does not vibrate The steering system is not working 102 Possible cause Brake valve Y9 Controller N1 Proximity switch S24 Drive pump Y3 Y4 Handheld controller N3 Fuse F23 Relay K5 Controller N1 Magnet Y2 Handheld controller N3 Magnets Y7 Y8 Controller N1 Handheld controller N3 Magnets Y5 Y6 Controller N1 Checks Is the connector connected Actuate the solenoid valve manually is the brake released Charge pressure OK Is Y9 being actuated If the machine features a shutdown bar check to make sure that the magnet on the shutdown bar is positioned correctly The switch must be closed when the shutdown bar is not being actuated Otherwise check the jumper that is plugged in ins tead of 24 Are the connectors connected Does the green LED flash when the machine is put in transport gear Is F23 OK The relay must be switched as soon as a function is carried out Is K5 being actuated The magnet must pull as soon as a function is carried out Engine speed Flow divider OK Drive motors OK Drive pump OK Does the green LED flash when vibration is switched on Are the connectors connected Has the magnetic coil been actuated manually Are the magnetic coils and valves OK Vibration pressure OK
111. ngs Remove the hydraulic hose BR Plug the fitting 251 252 1 2 Remove hydraulic hose 018 A3 Plug the fitting Remove hydraulic hose 004 T1 Plug the fitting Remove hydraulic hose 037 T3 Plug the fitting Remove hydraulic hose 030 A1 Plug the fitting Hammax 1575 Fig 10 430 201309220082 d ad 1 1 M Fig 10 431 201309220083 Replacing the valve block Repair To gain access to hose screw connection B1 1 the magnetic coil 2 must first be pushed back 1 Remove the knurled nut on solenoid valve Y7 1 Remove round sealing ring 1 1 Push back the magnetic coil 1 Remove hydraulic hose 016 B1 253 1 Plug the fitting 1 Remove hydraulic hoses A1 B3 T3 2 Plug the fittings 1 Remove hydraulic hoses 010 and 036 elbow bulkhead screw connection N Plug the fittings 1 Remove the four M8 hex screws AF size 13 Fig 10 435 201309220089 Fig 10 436 201309220090 254 Rammax 1575 1 Liftthe valve block out of the chassis NOTE In our example the drive pump was already demounted To demount the valve block it is not necessary to remove the drive pump The side panels to the right and left on the chassis can be removed View of the engine compartment with valve block demounted 1 Before the new or tested valve block can be installed the floor panel must be cleaned to remove hydraulic oil and dirt Fi
112. nn er 17 Identification of the roller llle 18 Machine type Rammax 1575 0 0 0 0 es 18 PIOOUCEOAIA igro oe Sou d aoe noe AERA Re oe be eens ooo tees 19 Dimensions Rammax 1575 2 2 llle 19 Specifications us iat acm pest i ode dc al ea 31 ae aa Se he ines aca 19 Roller designation s 6654 cs ee ein Oden b oben eet She eaeeeSseusa 20 Machine rating plate ce ee 20 Location of machine rating plate 0 0000 21 Location of machine chassis number 21 Location of Yanmar engine rating plate 22 Location of engine number 0 0 0 0 22 DISCIAING i530 hen ada od caw ts ede tomers esas a eed a ee 22 ruri sees die ak aed ete geome ora oh bd ae Go ee nD eee ee 22 3 Safety information us ces eee stc mace boc ae Sce c 23 3 1 General working safety n nna anana 24 3 2 Roller operation anaana aana aa 24 3 2 1 Shear PONS s ud ue hoo a a as Grec Oe ade eas 24 3 3 Noise levels 0 0 00 ccc eee eens 26 3 4 Safety markings on the machine 000 ce eee nee 26 3 4 1 Warning SUCKElS rin cS oa eo ta kane Si ee hoe Wa Saw Shaw De 2 3 4 2 Notlce SIIOKerS oc ace EU ob aru cbe ha i RC ee eae Ae e 29 3 9 Radiation compliance llle 30 4 Structure and function Llll ll 31 4 1 Component overview Rammax 1575 llle sn 32 5 Operating and display elements
113. ogging daily e When cleaning replacing the cartridge take care that no dirt enters the intake hose Intake opening 1 Check the intake opening for 1a Soiling clean the intake opening Maintenance 133 9 12 3 9 12 4 134 Fig 9 37 Intake opening Replacing the pendulum support joint head Check the pendulum support once a year for excessive play 1 Attach the roller to a crane central lifting point The play can be checked by alternately applying and releasing upward pressure to the roller visual inspection Fig 9 38 Pendulum support Replacing the pendulum joint bearing Check the pendulum joint once a year for excessive play If the axial play is greater than 4 mm the joint bearing must be replaced See page 272 1 Attach the roller to a crane central lifting point Lift and lower the roller to check the play Hammax 1575 9 13 NOTE 9 14 Fig 9 39 Pendulum joint Lubricating steering cylinder bearing 1 Rotate the roller s steering fully to the stop in order to grease the cylinder 2 Steer the roller briefly to the right and the left This causes the bearing to be unloaded 3 Clean the grease nipple 1 before greasing 4 Connect the grease gun to the grease nipple 5 Press grease into the bearing until it visibly begins to ooze out 6 Put the protective cover back on d EE Wi OS E Fig 9 40 Location of grease nipples on steering cylinder
114. or other blockages 1 1 Use compressed air to clean them out 2 Install plugs X1 and X2 40 Nm NOTE The cap must be tightened securely when reassembled oafely jack up the machine Let the machine run Unscrew the lock screw size 4 1 Set the neutral position 2 4 1 Carefully turn the key size 3 until the roller drum stops Tighten the lock screw 65 6 4 1 Checking the drive pump s solenoid The drive pump s solenoid cannot be actu ated mechanically 1 Unscrew the knurled nut 1 Pull out the solenoid 1 Unscrew the solenoid valve size 17 Fig 6 47 201301170005 Fig 6 46 201301170004 66 Rammax 1575 1 Measure the solenoid s Y3 Y4 resistance 1 4 Approx resistance of 6 ohms 1 Apply a voltage of 12 V to the solenoid valve 2 The valve arrow must be visibly actu ated Fig 6 49 201301170007 Changing the solenoid s connector position Fig 6 50 201301170007 If necessary you can change the connector s position by turning the solenoid body 1 Loosen the solenoid s securing nut 1 1 4 Turnthe securing nut 1 one full counterclockwise rotation 2 Turnthe solenoid body 2 to the position you want 3 Tighten the securing nut Securing nut tightening torque 5 1 Nm 6 5 Checking the drive pump servo block This operation must be carried out if The machine has been checked over electrically but still does not drive The machine only move in one
115. over all openings into which the cleaning agent may penetrate Remove these dummy flanges after cleaning the roller Cleaning the roller Maintenance 143 144 Rammax 1575 10 1 NOTE 10 2 NOTE 146 Preparation for welding work Doing welding work on the roller when the battery is installed can damage the machine controller Always remove the battery completely before performing welding work on the roller Attach the welder s ground cable as close to the welding point as possible The grounding point must be free of paint Accident hazard Poorly welded cast parts can result in material failure DO NOT weld cast parts Battery Risk of cable fire or short circuit Keep to the proper sequence when removing or installing the terminal connections e Ignition on battery voltage The battery voltage should not fall below 10 volts while starting otherwise the battery must be charged e Machine running 7 alternator charging voltage The voltage should lie in a range of from 13 to 14 5 volts Replacing the battery 1 Loosen the terminal and disconnect it size13 2 Loosen the terminal and disconnect it size13 3 Loosen and remove the mounting bracket Fig 10 1 Loosening the terminals Hammax 1575 1263968 20 02 2014 4 Liftthe battery out of the engine compartment 5 Setthe new battery in place 6 Connect the battery 6 1 Begin with the terminal Fig 10 2 Rep
116. p 1 Plug the fittings 1 Remove the intake line screw connection for the vibro pump Fig 10 383 201309210087 240 Rammax 1575 1 Plug the fittings A Fig 10 385 201309210089 1 Remove the intake line elbow screw connection for the drive pump 1 4 Hydraulic oil will run out Fig 10 387 201309210093 1 Remove the charge pressure hydraulic hose for the PBR valve block 2 Plug the fittings 1 Remove the cable ties on both sides of the servo block Fig 10 389 201309210094 Fig 10 390 201309210095 Replacing the drive pump Repair 241 1 Remove connectors Y3 and YA 1 Remove the M12 hex screws AF size 19 on the drive pump 1 Liftthe drive pump away from the motor 1 Plug the elbow screw connection for the intake line 1 which is now exposed Fig 10 396 201309210102 242 Rammax 1575 1 Remove the M10 Allen screw AF size 8 2 Pullthe gear wheel off the shaft Fig 10 397 201309220034 Replacing the drive pump Repair 243 10 18 2 Preparing the new drive vibro pump If the old screw connections are not defective they can be reused Otherwise new screw connections must be used Fig 10 398 Drive pump screw connections AF SIZE iu 1 Hydraulic pump 2 Straight screw in fitting GES12L M27x2 WD 32 180 3 Straight screw in fitting GES 8LM WD 17 25 4 Straight screw in fitting 12L M 14x1 5 WD 19 45 5 Straight screw in fitting GES15LM WD 27 70 6 Straight screw in
117. rcuit A reverse Rear right drive motor brake Drive circuit B forwards Leakage oil return Rear right drive motor brake L fitting Rear right drive motor leakage oil L fitting position Junction at rear Junction at rear Junction at rear Hydraulic oil tank return Rear left drive motor brake Rear left drive motor leakage oil L fitting Hammax 1575 6 2 2 Valve block connections General information The valve block is factory set Y6 Fig 6 5 201309210103 valve block top view Tab 6 5 Valve block solenoid valves No YS Y6 Y7 Y8 Y9 Designation Steering left Steering right Big amplitude Small amplitude Brake Tab 6 6 Valve block connections No BR PBR A2 B2 Overview of hydraulic hoses Hydraulic System Designation Brake Charge pressure from drive pump G Pressure from vibro steering pump Steering right right steering cylinder Steering left right steering cylinder 51 52 Fig 6 6 201309210104 valve block front view Tab 6 7 Valve block front connections No T2 A3 B1 Designation Tank supply line to drive pump T1 Steering left left steering cylinder Rear left vibromotor large amplitude elbow bulkhead screw connection Tab 6 8 Valve block pressure relief valve No 3 4 Designation Vibration pressure relief valve min 210 bar max 230 bar Steering pressure relief valve min 60 bar max 75 bar Values measured with engine
118. rew the filter housing 2 on 6 Open stop cock 3 6 1 Move to ON 7 Switch on the ignition 7 1 The fuel pump bleeds the system automatically Water separator filter element Drain filter housing Fig 9 7 Water separator Rammax 1575 If there is water in the filter housing the housing must be drained at once 1 Close stop cock 3 1 4 Move to OFF Unscrew filter housing and empty ocrew the filter housing on Open stop cock 3 4 1 Move to ON owitch on the ignition 5 1 The fuel pump bleeds the system automatically Clean filter element Clean water separator element 1 according to the maintenance plan 1 Close stop cock 3 1 1 Move to OFF Unscrew the filter housing 2 Clean filter element 1 screw the filter housing 2 on Open stop cock 3 5 1 Move to ON Switch on the ignition 6 1 The fuel pump bleeds the system automatically 9 8 Engine oil Checking the engine oil level Oil dipstick 1 lt y Engine oil Maintenance Check engine oil level daily using the dipstick The dipstick 1 is located on the left of the engine 1 1 Check oil level while the roller is standing on a level surface and the engine is cold 1 2 Youcan see the engine oil level on the dipstick The oil level must be between the top x and bottom y marks 121 2 lopup engine oil as required Fig 9 8 Location of dipstick 9 8 2 Topping up the engine oil 1 Top up the engine oi
119. rkings on the machine Safety information 29 Notice stickers Meaning Location on roller Roll bar rear Designation Suspension hooks Explanation Points on the roller at which hoisting tackle for lifting the roller can be attached 4108988 Location on roller Rear chassis front upper left Designation Lifting and tie down points Explanation Illustrates how the machine is to be loaded and transported 3527 m WLL 3800kg a Location on roller Rear chassis front upper left Designation Spare parts information Explanation Information about the filters of the machine Location on roller Inner cowling cover Designation Close the cover Explanation Attention When driving using remote control and when parking the machine the cover must be closed Achtung Beim Fahren mit Fernsteuerung sowie beim Parken der Maschine muss der Deckel geschlossen sein Attention During driving with remote control and during parking the machine the cover must be closed Attention Pendant conduire avec commande distance et pendant parquer la machine la couvercle doit tre ferm Location on roller Inner cowling cover Designation Ignition Explanation Attention Current is present when the ignition is on 3 5 Radiation compliance This machine complies with the emission requirements for radio interference due to radiation European Norm EN 13309 for construction machinery 30 Rammax 1575
120. romotor Fig 10 363 201310010061 10 17 Roller drum installation 1 Pushtheroller drum under the chassis using a suitable aid 1 1 Keep the roller drum balanced using a suitable aid e g piece of square timber Fig 10 364 201309300001 1 Tighten the twelve M12 hex screws AF size 19 to a torque of 85 Nm Fig 10 365 201309300003 10 18 Replacing the drive pump The hydraulic oil must be drained before the drive pump can be demounted Siehe Draining the hydraulic oil see page 124 Roller drum installation Repair 237 10 18 1 Removal 1 Place an oil catch basin beneath the chassis toward the front at the drive pump 1 Remove the pressure line screw connection for the vibro pump Fig 10 368 201309210067 Plug the fittings Fig 10 370 201309210070 1 Remove the charge pressure screw connection for the drive pump Fig 10 371 201309210071 238 Hammax 1575 LI Ra Fig 10 377 201309210080 Replacing the drive pump Repair 1 1 1 1 Plug the fittings e Fig 10 373 201309210074 Remove the supply hydraulic hose for the drive pump Plug the fittings Fig 10 376 201309210079 Remove the hydraulic hose for the forwards drive circuit B drive pump 239 1 Plug the fittings Y L U y Fig 10 379 201309210083 Fig 10 378 201309210082 1 Remove the T screw connection for the reverse drive circuit A drive pum
121. rporate Headquarters Multiquip Inc 18910 Wilmington Ave Carson Ca 90746
122. rrow bearing outer ring 1 into the bearing housing 1 4 Observe the mounting orientation 1 Press the narrow bearing outer ring into the housing Fig 10 242 201311140006 1 Heatthe rear taper roller bearing to 110 C Fig 10 243 201311130022 Replacing bearing vibro unit Repair 209 1 Push the rear taper roller bearing onto the boss 1 Lightly grease the bearing 1 Install the spacer rings Fig 10 246 201311130023 210 Hammax 1575 Fig 10 250 201311130027 Replacing bearing vibro unit Repair Grease the outside of the bearing rings Place the unbalance unit into the vibro housing Install the outer bearing Install the lock ring 211 1 Install the grooved nut 1 Putthe special grooved nut wrench in place 1 Tighten to a torque of 200 Nm 1 Screw on the bracket for the torque measurement instrument Fig 10 254 201311130033 212 Hammax 1575 Fig 10 256 201311130035 a Fig 10 258 201311130037 Replacing bearing vibro unit Repair 1 Attach the torque measurement instrument 1 Rotate the unbalance with the torque measurement instrument clockwise 20 times This will eliminate any tension points NOTE Under no circumstances may the housing hit against the support it must rotate freely 1 Set the torque to a value of 1 3 Nm If the value is not correct a correction must be made using the spacers until the target
123. s Error The Error control lamp lights as soon as the controller recognizes an error 1 Check whether the desired function is working This also applies when the tilt sensor is triggered If the Error control lamp is still lit after carrying out these checks call a specialist to help solve the problem 36 Rammax 1575 Battery If the battery charge level control lamp lights up during operation or does not go off after starting carry out the following check immediately 1 Stop the engine 2 Check the engine for defective or loose V belt If the battery charging lamp is still lit after carrying out these checks call a specialist Engine oil pressure If the engine oil pressure control lamp lights up during operation or does not go off after starting stop the roller and turn off the engine immediately 1 Check the engine for oil loss and correct oil level 1 1 The oil level in the engine is correct Call a specialist to remedy the problem NOTE The machine is equipped with an automatic shutdown system If the oil pressure falls below the limit value the oil pressure warning lamp lights up After the warning lamp has been lit for 4 seconds the machine is shut down Coolant temperature Danger of scalding The cooling circuit is pressurized NOTE Danger of engine overheating Stop immediately If the coolant temperature control lamp lights up during operation of the machine switch off the engine immed
124. se check the jumper that is plugged in instead of S24 The lamp flashes The infrared transmitter is located less than 3 m from the machine The lamp flashes like a camera flash The infrared transmitter is located between 3 m and 4 m from the machine Not a fault Prerequisite for cable operation of the remote control The lamp must light up when ignition switch S1 is in the pre heating position The lamp must light up when the switch is held at the Start position on the handheld controller F24 OK Ignition switch OK Relay OK Hammax 1575 8 5 Handheld controller o ae te kh z nd i OX MO min 2m Fig 8 3 Infrared transmitter NOTE When the ignition is turned on a lamp test will run on the display unit briefly Both LEDs blink while this is done Use this test to check whether the LEDs are working correctly If they are not the device will have to be replaced Tab 8 4 Fault description handheld controller Fault description Possible cause Checks The lamps never light Infrared transmitter N3 The battery may be empty or faulty Connect the up cable to the controller If the battery is faulty the controller will have to be replaced a x The red lamp flashes Infrared transmitter N3 Not a fault The battery needs to be charged cable not connected The red lamp flashes cable connected Not a fault The battery is being charged The red lamp lights up with a solid light Not a faul
125. sor It triggers as of an angle of 45 In this case the engine shuts itself off automatically The machine cannot be started as long as the inclination sensor remains triggered If the machine has tipped over it is possible for engine oil to enter the combustion area If the machine is started after it has been righted engine damage is possible e Set the machine upright Do not start the engine under any circumstances Inform the service Service Error display Tab 5 2 Error and shutdown bar display Display Cause Remedy Error lights up A switching transistor signals a status Check the cable for a short cir error This means that for example a cuit or cable break short circuit or a cable break has been detected Error and shutdown The machine controller is waiting for Check the oil pressure and bar light up in unison both the inputs Oil pressure and Alternator outputs Alternator to be at the rest position Hammax 1575 NOTE Bear in mind the priority of the displays First is the tilt switch then Wait and last the status error transistor Shutdown bar display Tab 5 3 Shutdown bar display Display Cause Shutdown barlights up Switch on shutdown bar has trig Remedy Move the shutdown bar to its origi gered nal position Shutdown bar is blin Close proximity shutdown has Move more than 2 5 m away from king been detected the roller Shutdown bar is flas Close proximity has been detec If the roller
126. speed of min 2380 rpm max 2430 rpm Hammax 1575 Fig 6 7 201309210105 valve block rear view Tab 6 9 Valve block connections for hydraulic hoses rear No Designation A1 Front right vibromotor small amplitude T3 Front left and right drive motor leakage oil B3 Steering left left steering cylinder E LS 7 Fig 6 8 201309210106 valve block right side view Tab 6 10 Valve block return No Designation T1 Return via oil cooler return flow filter to hydraulic oil tank Overview of hydraulic hoses Hydraulic System 53 6 2 3 Valve block hoses Fig 6 9 2013092200668 valve block top view Tab 6 11 Valve block solenoid valves No 2 3 4 if 8 13 16 17 18 19 20 30 33 37 54 of Valve block P Valve block T2 elbow fitting Valve block T1 elbow fitting PBR valve block L fitting PBR valve block L fitting Valve block BR T fitting Valve block B1 Valve block B3 Valve block A3 Valve block A2 Valve block B2 Valve block A1 Valve block BR T fitting Valve block T3 position Vibro steering pump pressure L fitting Drive pump T1 Hydraulic oil cooler in elbow fitting Flow divider T Drive pump G L fitting Junction at rear Junction rear elbow fitting Left steering cylinder piston Left steering cylinder rod Right steering cylinder piston Right steering cylinder rod Front vibromotor connection at front Front left drive motor brake L fitting Front left drive mo
127. ssns D o t weweeeaneeo o o tdt cL6 N lO o o 2 Oy LLG uonipuoo 499fq0 pop Ee po GUNMEN SENIUU UMN SENSE cod eeuse 0004 008 osz 001 We 0L ooejdoJ eBueu x3 information e91 9jeouqn7 uieJp uea 5 eun puooes au Z Sw S114 OU 1 Ajjenuue A jJenuue iwas Aueyenb Ajyjyuow Ayam Apep spo dn jas 3284402 sa j2edsur 429u2 d Jepuejeo ui pue y sinou Buneaedo ur sjeAJejur eoueueyjurelA Chapter D from dealer Maintenance 111 Maintenance lcs uMopinus juejsip pue AjulroJd eso 2 c GOl Je 1 pue judy seBuiu pooH vl Ol yun oJqiA Buneaq Buroejdes LOL yom Hulpjam 104 uoneJedaug sosnj pue sAejay v N v v Oo JojeipeJ Jazem Bui oo2 peg s soy oi neJp H s soy an Je9J pue ju0JJ pOoy 10 N S Sec EL OL sjueuleJe 4eqqnJ uunJp J9 O VZ6 Xue jan y Buiues D Vcl uoneuu0Jop pue SyOeIO 104 OAS Huy jurod y99u25 ccl6 JUSWII9 Joy Jojeuedes Jo eAA Pf fe jueuJoS o 1 Jon 4 ff uonipuo 2 32aefqo Jeef SUJUOW 9 SUJUOW UJUOW 99M 0001 00S OSC O01 0S Please also observe the Yanmar engine operating manual and the detailed NOTE instructions given there Hammax 1575 112 9 3 2 Yanmar engine service Maintenance Maintenance gt a TNV series SERVICE MANUAL JTHVBZA 3THVBA JTHVEAT XTNVBS ATNVBA THVT ATNVBR ATHYSAL
128. ssure tight 3 Perform test procedure as described under 6 3 4 Fig 6 34 201310010053 Checking and adjusting pressures Hydraulic System 63 6 3 6 Checking the maximum drive pump pressure reverse forwards Fig 6 38 201211270001 t 3 L oat n 5 Fig 6 37 201310020009 1 Remove the hydraulic hose for drive circuit B forwards from the drive pump Seal the screw connections pressure tight Remove the drive circuit A reverse T screw connection from the drive pump Seal the screw connections pressure tight Connect a pressure gauge min 400 bar to the drive pressure measuring point MA Start the engine 2 1 Full speed Drive at full in reverse against a block 3 1 Let it run for a maximum of 5 Sec Connect a pressure gauge min 400 bar to the drive pressure measuring point MB 1 Start the engine 2 1 Full speed Drive at full forwards against a block 3 1 Letit run for a maximum of 5 Sec If the maximum drive pump pressure of 330 x 15 bar is not achieved then e The drive pump must be replaced Siehe Replacing the drive pump see page 237 64 Hammax 1575 6 4 Setting the drive pump to the neutral position Fig 6 41 201211260062 Fig 6 42 201211270063 Setting the drive pump to the neutral position Hydraulic System 1 Remove the X1 and X2 plugs size 6 1 UseanAllen key size 3 to remove the cap 1 Check the cap 1 for any dirt accretions
129. t The battery is fully charged The red lamp lights up when a control is operated The battery is empty no data is being sent to the machine 0 Handheld controller Troubleshooting 105 Fault description Possible cause Thegreenlampalways Infrared transmitter N3 flashes when a control is operated uU Both lamps flash Infrared transmitter N3 synchronously iG 106 Checks Not a fault Data is being sent to the machine Not a fault The infrared transmitter is coupled with the machine controller This always occurs when e A different handheld controller is connected to the machine for the first time using a cable e The ignition is switched on When the lamps are blinking it is not possible to start the engine Rammax 1575 9 Maintenance 9 1 General safety information Maintenance and repairs must be performed exclusively by trained and qualified personnel e Only perform maintenance and repair work on the roller if it is static and secured from rolling away e Secure the roller with the joint protection e Before carrying out any work on hydraulic hoses make sure to relieve the pressure in the system e Disconnect the battery before commencing work on the roller s electrical systems o Cover the battery with isolating material or remove it completely This does not apply to work requiring an electric current o nthe event of injuries caused by acid rinse immediately
130. ter radiator Explanation Do not put hands in the radiator fan when the machine is running Location on roller Inner cowling cover Danger If the roller has overturned do not start the machine Explanation Avoid oil shock Location on roller Outer cowling cover Requirement Wear ear protectors Explanation Wear ear protectors in accordance with national accident prevention regulations when working at higher noise levels 28 Rammax 1575 3 4 2 Notice stickers Tab 3 3 Notice stickers on board Notice stickers Meaning Location on roller Chassis rear Designation Guaranteed sound power level Explanation Indicates the overall noise level produced by the rol ler Rammax 1575 Location on roller On the hydraulic oil tank Designation Hydraulic oil Explanation Please only use hydraulic oil indicated Location on roller Chassis rear Designation Hydraulic oil drain X Explanation Drain hole for the hydraulic oil Location on roller Chassis front right Designation Motor oil drain Explanation Drain hole for the motor oil 473755 Location on roller Chassis rear Designation Fuel Explanation Filler neck for diesel fuel Location on roller On the middle of the front and rear chassis Designation Tie down point Explanation Points on the roller at which lashing means for securing the roller on the transport vehicle can be attached 1155236 Safety ma
131. ter unit Cover the air filter unit or its intake opening and the exhaust pipe with exhaust pipe adhesive tape This prevents moisture from getting into the engine Steering cylinder Lubricate the bearings of the steering knuckle and the front bearing of the 9 12 steering cylinder with grease Lubricate the piston rod of the steering cylinder with grease guard Infrared transmitter Always move the Start Stop switch to the Stop position 298 Hammax 1575 12 Transport 12 1 Transport 12 1 1 Shipping weights and dimensions Tab 12 1 Shipping weight and dimensions Rammax 1575 Roller drum width inch mm 24 640 33 850 Shipping weight Ibs kg 3086 1400 3196 1450 Dimensions L x W x H without shutdown bar inch 79x25x52 79x33x52 Dimensions L x W x H without shutdown bar cm 200x64x132 200x85x132 Dimensions L x W x H with shutdown bar inch 81x25x52 81x33x52 Dimensions L x W x H with shutdown bar cm 205x64x132 205x85x132 ADANGER Risk of crushing through presence in the pivoting area danger zone e The articulated joint lock joint protection must be fitted before lifting the roller for transport e Be certain that no persons are present in the area of the joint protection 12 1 2 Transportation overseas The machine is ready for transportation overseas when the Environmentally Damaging 1 and Hazardous Goods Class 3 2 labels have been applied to the machine Fig
132. the linkage is pressed down it must return to its starting position strain free on its own Fig 10 124 20130922001 1 10 10 Testing the engine speed and frequency NOTE Adjust the speed when the roller is at operating temperature 1 Putthe machine on two large or four small old tires or on a suitably soft base Fig 10 125 201311150005 Testing the engine speed and frequency Repair 183 2 3 4 1 2 3 4 Fig 10 127 201309220011 Tab 10 1 Diesel engine speeds Engine roms 100 Vibration speed front small Vibration speed rear small Vibration speed front large Vibration speed rear large 10 11 Roller drum removal 1 2 3 Fig 10 128 201309270028 184 Start the engine Select vibration The machine goes to full speed 10096 2390 2440 rpm Use a tachometer to measure the frequency 100 Desired value 41 Hz If the rotational speed is not reached check the engine speed If necessary adjust the speed at the clevis head AF size 10 1 Counter the nuts Be certain that the safety bolt 2 on the clevis head is engaged RPM After 5 min After 60 min 2415 25 2405 25 2250 150 2250 150 2250 150 2250 150 2250 150 2250 150 2250 150 2250 150 Safely jack up the machine Attach an anchor sling to the roller drum Use a crane to slightly lift the roller drum Hammax 1575 1 Remove the roller drum screws AF size 19 1 Pull the roller drum out from under th
133. the reassembly 10 21 2 Replacing the joint head Removing the old joint head 1 Remove M10 securing bolt AF size 6 AF size 17 2 Procedure is the same for rear and front Fig 10 484 201309240023 Fig 10 485 201309240021 Pendulum support Repair 265 266 1 Place the pendulum support under the press 2 Usethe drift pin to press out the heavy duty dowel pin 3 Procedure is the same for rear and front Fig 10 487 201309240028 Fig 10 488 201309240029 1 Clamp the pendulum support in a vise 2 Heatup the locknut and joint head to approx 200 C 392 F 1 Loosen the locknut 2 Usea wrench to unscrew the joint head AF size 46 from the rod 3 Procedure is the same for rear and front Fig 10 490 201309240031 Fig 10 491 201309240034 Hammax 1575 Installing a new joint head Fig 10 492 201309240034 2 Fig 10 493 201309240037 Fig 10 494 201309240039 Fig 10 495 201309240040 Pendulum support Repair Apply red adhesive to the rear inner thread of the new joint head and the outer thread of the pendulum support Apply blue adhesive to the front inner thread of the new joint head and to the outer thread of the pendulum support Screw the rear joint head onto the pendulum support all the way to the stop Set the front joint head to the dimension Adjust the pendulum support until it has the length you measured previously Counter
134. the rules e Keep the safety stickers and signs complete and legible e Replace any damaged or illegible stickers and signs immediately e You can order new stickers from Multiquip From the moment the signs are no longer recognizable and understandable at first glance the machine must be shut down until new signs are installed Hammax 1575 3 4 1 Warning stickers Tab 3 2 Warning stickers on board Warning stickers Safety markings on the machine Safety information Meaning Location on roller Air intake opening Inside of cowling Danger Damage to electrical controls Explanation Never spray a water jet into electrical or electronic components Never spray into the engine combustion air intake Location on roller Outer cowling cover Danger Danger of injury due to incompetent operation Explanation Read the operating instructions before operating the roller Adhere to the safety regulations at all costs Contact your authorized dealer if anything is unclear Location on roller Between the front and rear parts of the roller Danger Crushing hazard Explanation Only stand in this area when necessary and only with extreme caution Location on roller In the middle of the front and back Danger Rollover hazard Explanation Only stand in this area when necessary and only with extreme caution 27 Warning stickers Meaning Location on roller Radiator both sides Danger Warnings for cooling wa
135. tor leakage oil L fitting Hammax 1575 q Tab 6 12 Valve block solenoid valves No of position 10 Bulkhead fitting at valve block bra Junction rear elbow fitting cket 36 Bulkhead fitting at valve block bra Front vibromotor connection at rear cket Junction at rear Fig 6 11 201311040001 junction at rear Overview of hydraulic hoses Hydraulic System 55 6 3 56 Checking and adjusting pressures All values apply at a hydraulic oil temperature of approx 60 C and max diesel engine speed Bleed pressure relief for a maximum of 5 sec Use the following pressure gauge e For high pressure min 400 bar e For charge pressure min 40 bar Fig 6 12 201309210060 drive pump vibro steering pump 1 Ml charge pressure 21 2 bar can only be adjusted using washers 2 MB forward drive pressure 330 15 bar measure with the roller drums blocked 3 MA backward drive pressure of 330 15 bar measure with the roller drums blocked 4 M2 vibration switch on pressure 220 10 bar M2 steering pressure 67 8 bar Rammax 1575 1 Set drive pressure forward 2 Setting drive pressure forward 1 Charge pressure valve adjustable with spacer disks Oil can overheat and seals can be damaged During the test procedures listed below be certain that he engine only runs at full speed for max 5 s 1 After the test procedures reconnect all hydraulic hoses 2 Starttest run 3
136. ugfilter Hydraulics diagram 6 8 Pos 17 DN8 Pos 37 DN8 Pr rem mimo SSS SSS SS SSS SSS nh ae im eS Se SS Se SS ee SS Se eer LLIL links B Pos 16 DN12 Pos 56 DN10 HN Heme E l Vibro Lenk Bremsventil 9 l 13 Vibromotor Vibromoter Lenkzylinder I i5 dr 9 E m Eris 8 Pos 20 DN8 T Ac T R Pos 36 DN10 gt lt gt lt A1 Pos 30 DN10 i i Pos 19 DN8 zW zm Y9 Pos 10 DN12 Y6 Verschraubung Pos 3 DN12 Pos 33 DN8 Pos 13 DN8 Verschraubung Pos 2 DN12 Fahrmotor 2 Fahrmotor hinten es vorne inks ie inks 5 340 a 340 cem E ccm ZAA Iz n V I Eg 2 Pos 8 DN8 Pos 7 DN8 D senblock XD T S Pos 54 DN8 Pos 52 DN8 Pos 31 DN8 l N n dmm 3 iE Mengenteiler 18 n TE a a Cy ay A Os I d SE i ahrpumpe S i 0 bis 18 l Ee B Pos 9 DN10 p Pos 58 DN8 Pos 38 DN8 Pos 35 DN8 Vorwarts Pos 5 DN25 Pos 55 DN8 Pos 51 DN8 Pos 32 DN8 i Pos 34 DN8 Pos 15 DN8 Dieselmotor 24 00 min Fahrmotor vorne rechts 340 ccm Fahrmotor hinten z rechts Pos 21 DN12 340 ccm R ckwarts Verschraubung Ma 26 4 min Pos 6 DN20 out Pos 57 DN8 2 0 4 bar O Pos 1 DN20
137. ulations 1 Bring the joint protection into place 2 Liftthe roller vertically with suitable hoisting tackle 2 1 Use suitable lifting equipment The 1 point lifting eye is designed for a WLL of 1 6 tons Working Load Limit Fig 12 3 1 point lifting eye Securing the roller on the transporter PFA 4 Bring the joint protection into place 302 Hammax 1575 12 1 6 Transport Transport 2 Attach the lashing straps to the lashing rings on the roller and on the truck 2 4 Lashing method Direct lashing diagonal lashing as shown in photo 2 2 Use a lashing strap with a permissible tensile force of LC 2 500daN The lashing rings on the roller are designed for a permissible tensile force of 2 500daN Permissible angle ranges for diagonal lashing e 15 lt as65 e 390 sps75 Fig 12 4 Lashing the roller side view Fig 12 5 Lashing the roller top view Risk of accident through blocked steering Open the joint protection before starting the roller Center of gravity The center of gravity relevant to transport is located 460mm from the floor and approx in the center of the roller depending on the fill level of the diesel or water tanks 303 Fig 12 6 Roller s center of gravity 304 Rammax 1575 Disposal 13 1 Introduction Environmental hazard through operating materials Do not allow any liquids to enter drains the soil or the environment The roller must be
138. vis ZS 46 Synthetic hydraulic oil based on HE esters Grease ISO 2137 ISO 15380 HEES DIN 51502 Drive and vibration hydraulics Foodgrease SPMOO Rammax vibro bea ring MOLY 218 steering cylinder HLP Synth 46 Using the wrong oil can cause damage to the hydraulic controls Hydraulic tubes e It is forbidden to change used rollers for use with biodegradable hydraulic oils If hydraulic hoses on a roller running on synthetic ester HE need replacing only those declared by the supplier as being compatible with synthetic esters may be used 137 9 16 Consumables Tab 9 3 Consumables Designation Brand Quantity Art no Engine oil Motorex Focus CF SAE 10W 40 11 1242375 Grease Motorex Moly 218 400g 1111368 Grease Blaser Foodgrease SPMOO 0 38 kg 1094392 Blue adhesive Ergo 4052 50 ml 1 907977 Red adhesive Ergo 4100 50 ml 1 907978 Paint spray RAL 1016 Sulfur yellow 400 ml 1 922700 Paint spray RAL 6033 Mint turquoise 400 ml 1 922701 Sealant Ergo 4207 250g 1 923054 NOTE The screws can loosen due to the vibration of the roller Unless otherwise specified secure all screws with the blue adhesive 9 17 Tightening torques The values below apply e Unless otherwise specified in the operating manual or in the Service manual e To female steel threads Hex screws bolts and hexagon socket head cap screws Tab 9 4 Tightening torque Hex screws bolts including tapping hex screws and hexagon socket head cap screws
139. y hazardous situation which could lead to severe bodily injury or to death e CAUTION represents a possibly hazardous situation which could lead to slight bodily injury e Caution also represents a hazard of environmental pollution causing local or global environmental damage Rammax 1575 NOTE NOTE The battery poles and terminals must be clean If they are coated with a whitish or greenish sulfur crust they must be cleaned Risk of cable fire or short circuit e NOTE represents first of all damage which could be caused to the roller or parts of it e NOTE represents secondly Application tips and other particularly useful information e NOTE is not a signal word for a hazardous or damaging situation Structure of the Service Manual General 15 INSSZ2S LX ON IEnUE N JEnEU A 8913S S78 X ONI dINDOILINW Hammax 1575 16 2 Product description 2 1 Identification of the roller 2 1 1 Machine type Rammax 1575 This Service Manual is valid for the following machines of the Rammax 1575 series Tab 2 1 Roller drum width Rammax 1575 Model Roller drum width Rammax 1575 with 24 drums 24 in 640mm with drum rings 33in 850mm Rammax 157533 33in 850mm 18 Weight 3 087 Ibs 1400kg 3 197 Ibs 1450kg 3 197 Ibs 1450kg Hammax 1575 2 2 2 2 1 11 89 in 302 mmy 2 2 2 Product data Product data Dimensions Rammax 1575 23 66 in 601 mm
140. ze 22 AF size 6 can be adjusted if necessary The vibration pressure relief valve AF size 22 AF size 6 can be adjusted if necessary Hammax 1575 1 The solenoid valves can be actuated manually Fig 10 453 201309210117 10 19 3 Installation 1 Place the new or tested valve block on the floor panel Fig 10 454 20130922009 1 Apply blue adhesive to the M8 hex scr ews 1 Tighten the M8 hex screws AF size 13 to a torque of 25 Nm NS d Fig 10 456 201309220100 Replacing the valve block Repair 259 1 Install hydraulic hose 036 on the elbow bulkhead screw connection 1 Install hydraulic hose 010 on the elbow bulkhead screw connection 1 Install hydraulic hoses A1 B3 T3 1 Connect the plugs in back Y5 Y8 260 Hammax 1575 1 Install hydraulic hose 004 T1 k Fig 10 463 201309220107 1 Install hydraulic hoses A2 B2 PBR Install hydraulic hose onto T screw 1 connection BR To gain access to hose screw connection B1 1 the magnetic coil 2 must first be pushed back Remove the knurled nut FEU i aee v vg SAE ANA 058 Wa niic 4 E 2 Remove the O ring ij 3 Push back the magnetic coil 2 4 Install hydraulic hose B1 1 Fig 10 467 201309220111 261 Replacing the valve block Repair 262 N Fig 10 471 20130922012 N N 1 Push the magnetic coil back to the ori ginal position

RX1575 Service Manual - Multiquip Service & Support Center

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RX1575 Service Manual - Multiquip Service &amp; Support Center

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RX1575 Service Manual - Multiquip Service & Support Center