WIRTGEN HAMM H195 Series User manual

GRW 280
OPERATING MANUAL
© HAMM AG 2011 Version 02
H195
Series
0012
valid from Serial No.
01.03.2010
Date of first issue
2153734
Order number
en
Language

2 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
Publisher HAMM AG
Postfach 1160
95633 Tirschenreuth
Germany
Phone: [phone] / 80-0
http://www.hamm.eu
Name of the document 2153734_02_BAL_GRW280_H195_en
Original operating manual
Date of first issue 01.03.2010
Date of change 01.07.2011
Copyright © HAMM AG 2011
The disclosure as well as the duplication of this document, the use and
the forwarding of its contents, are forbidden as far as not expressively
permitted. Violations will cause indemnities. With respect to patent, utility
sample or design patent registration all rights reserved.
612-01

© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 3
This operating manual is valid for the following roller types:
RUBBER WHEELED ROLLER GRW 280-10
GRW 280-12
GRW 280-16
GRW 280-20
GRW 280-24
GRW 280-28

Table of contents
4 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
TABLE OF CONTENTS
1 General..................................................................................................................... 9
1.00 Introduction........................................................................................................9
1.00.01 Preface to the operating manual...........................................................................................9
1.00.02 Product information............................................................................................................... 9
1.00.03 Guarantee............................................................................................................................ 10
1.00.04 Modifications / reservations................................................................................................. 10
1.00.05 Packaging and storage....................................................................................................... 10
1.00.06 Signs and symbols.............................................................................................................. 10
1.00.07 Signal words........................................................................................................................ 11
1.01 Documentation.................................................................................................13
1.02 Use.................................................................................................................... 14
1.02.01 Intended use........................................................................................................................14
1.02.02 Reasonably forseeable misuse........................................................................................... 15
1.02.03 Residual risks...................................................................................................................... 15
1.02.04 Climatic conditions...............................................................................................................16
1.03 Environmental protection...............................................................................17
1.04 Disposal............................................................................................................17
1.05 EC confirmity................................................................................................... 18
1.06 Type plate......................................................................................................... 19
1.07 Noise and vibration requirements.................................................................20
1.08 Personnel......................................................................................................... 22
1.08.01 Qualification and duties....................................................................................................... 22
1.09 General safety instructions............................................................................23
1.10 Danger zone.....................................................................................................24
1.11 Loading and transport.................................................................................... 25
1.12 Stickers on the machine................................................................................ 34
1.12.01 Warning labels..................................................................................................................... 35
1.12.02 Information sign................................................................................................................... 40
2 Description............................................................................................................. 45
2.00 Technical characteristics of the machine.....................................................45

Table of contents
© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 5
2.01 General view of machine................................................................................46
2.01.01 Chassis / safety devices......................................................................................................46
2.01.02 Control stand....................................................................................................................... 47
2.01.04 Drive unit / diesel engine.....................................................................................................48
2.01.05 Hydraulic oil supply............................................................................................................. 50
2.01.06 Electrical equipment............................................................................................................ 52
2.01.08 Drive.....................................................................................................................................54
2.01.09 Steering system...................................................................................................................56
2.01.12 Water system.......................................................................................................................57
2.01.20 *Tyre heating....................................................................................................................... 59
2.01.27 *Edge pressing and cutting assembly (KAG)......................................................................60
2.01.40 Special equipment............................................................................................................... 61
2.02 General view of instruments and operating elements................................ 64
2.02.02 Control stand....................................................................................................................... 64
2.02.04 Drive unit / diesel engine.....................................................................................................71
2.02.08 Drive.....................................................................................................................................72
3 Operation................................................................................................................73
3.00 Instruments and operating elements............................................................ 73
3.00.01 Indicators, displays.............................................................................................................. 73
3.00.02 Pilot lights............................................................................................................................ 75
3.00.03 Switch.................................................................................................................................. 81
3.00.04 Sockets, lights..................................................................................................................... 89
3.00.05 Operation levers, adjustment handles.................................................................................90
3.01 Prior to machine start.....................................................................................98
3.02 Engine start....................................................................................................101
3.03 Driving............................................................................................................ 103
3.04 Stopping, switching off engine, leaving machine......................................105
3.05 Operation monitoring....................................................................................107
3.06 Sprinkling....................................................................................................... 108
3.07 *Additive sprinkling.......................................................................................110
3.08 Scrapper tyres............................................................................................... 111
3.09 Starting with jump leads.............................................................................. 112
3.10 Towing.............................................................................................................114

Table of contents
6 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
3.11 Heating / ventilation / cooling...................................................................... 118
3.12 Stairs to maintenance point.........................................................................119
3.13 Opening and closing engine hood..............................................................121
3.14 *Thermal aprons............................................................................................ 123
3.15 *Tyre heating..................................................................................................124
3.15.01 General.............................................................................................................................. 124
3.15.02 Putting into operation / operation...................................................................................... 126
3.15.03 Taking out of service......................................................................................................... 129
3.15.04 Replacing liquid gas bottles.............................................................................................. 129
3.16 *Tyre filling system....................................................................................... 131
3.17 *Asphalt thermometer...................................................................................132
3.18 *Spare wheel retainer....................................................................................134
3.19 *Driving on public roads (StVZO)................................................................135
3.20 Adding / reducing ballast............................................................................. 136
3.20.01 Reducing and adding ballast.............................................................................................137
4 Maintenance......................................................................................................... 140
4.00 General maintenance instructions.............................................................. 140
4.00.01 Operation monitoring......................................................................................................... 140
4.00.02 Maintenance overview.......................................................................................................141
4.00.03 Running-in regulations.......................................................................................................144
4.00.04 Required maintenance parts............................................................................................. 145
4.00.05 Important information about maintenance works.............................................................. 146
4.00.06 Welding works on the machine.........................................................................................148
4.01 Chassis / safety features.............................................................................. 150
4.01.01 General.............................................................................................................................. 150
4.01.02 Checking the function of the parking brake...................................................................... 150
4.01.03 Checking the EMERGENCY STOP function.................................................................... 151
4.01.04 Lubricating hinges of stairs............................................................................................... 152
4.01.05 Lubricating hinges of the engine hood..............................................................................153
4.01.06 Lubricating hinges of battery compartment.......................................................................153
4.02 Control stand................................................................................................. 154
4.02.01 *Air conditioning.................................................................................................................154
4.02.02 Replacing fresh air filter of the operator's cabin............................................................... 155

Table of contents
© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 7
4.02.03 Checking the filling level of the windshield washer fluid................................................... 156
4.04 Drive unit - diesel engine............................................................................. 157
4.04.01 General.............................................................................................................................. 157
4.04.02 Maintenance points at the engine for engine oil change.................................................. 158
4.04.03 Changing the filter cartridge for the fuel pre-filter............................................................. 159
4.04.04 *Draining water separator..................................................................................................160
4.04.05 *Cleaning / replacing filter insert of the dirt and water separator...................................... 161
4.04.06 Checking and cleaning dust discharge valve....................................................................162
4.04.07 Checking and replacing the air filter................................................................................. 163
4.04.08 Changing safety cartridge................................................................................................. 164
4.04.09 Checking the radiator........................................................................................................ 165
4.04.10 Checking coolant level...................................................................................................... 166
4.04.11 Changing coolant...............................................................................................................167
4.05 Hydraulic oil supply......................................................................................169
4.05.01 General.............................................................................................................................. 169
4.05.02 Checking filling level hydraulic oil..................................................................................... 169
4.05.03 Changing hydraulic oil and ventilation filter...................................................................... 170
4.05.04 Replacing filter insert of pressure filter for hydraulic system............................................ 171
4.08 Drive................................................................................................................172
4.08.01 General.............................................................................................................................. 172
4.08.02 Checking filling level of (driving) gear oil.......................................................................... 172
4.08.03 Exchanging (driving) gear oil............................................................................................ 173
4.08.04 Checking / changing tyre scraper (brushes)..................................................................... 174
4.08.05 Checking / changing tyre scraper (PUR).......................................................................... 175
4.08.06 Checking filling level brake oil...........................................................................................176
4.08.07 Changing the brake oil...................................................................................................... 177
4.08.08 Checking the service brake pressure accumulator........................................................... 178
4.08.09 Checking the wheel nuts / wheel bolts for tightness.........................................................178
4.08.10 Checking the air pressure in the tyres..............................................................................179
4.08.11 Changing the tyres............................................................................................................ 180
4.09 Steering system.............................................................................................182
4.09.01 General.............................................................................................................................. 182
4.09.02 Lubricating the bearing of steering tie rod........................................................................ 182
4.09.03 Lubricating the steering cylinder bolt................................................................................ 183
4.09.04 Steering unit - Checking screw connection for tightness.................................................. 184
4.12 Sprinkling....................................................................................................... 185
4.12.01 General.............................................................................................................................. 185

Table of contents
8 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
4.12.02 Cleaning the water sprinkling unit.....................................................................................185
4.12.03 Cleaning the filter for sprinkling........................................................................................ 186
4.12.04 Cleaning the filter for additive sprinkling...........................................................................186
4.12.05 Cleaning the spay nozzles................................................................................................ 187
4.20 *Tyre heating..................................................................................................188
4.27 Checking *pressure accumulator KAG.......................................................188
5 Tables....................................................................................................................189
5.00 Technical data................................................................................................189
5.00.01 Lubrication indications....................................................................................................... 189
5.00.02 Use of biologic hydraulic oil.............................................................................................. 190
5.00.03 Wirtgen Group Lubricants................................................................................................. 191
5.00.04 Coolant conditioning.......................................................................................................... 194
5.00.05 Fuel.................................................................................................................................... 195
5.00.06 Starting torques................................................................................................................. 196
5.01 Technical data................................................................................................197
5.01.01 GRW 280-10......................................................................................................................197
5.01.02 GRW 280-12......................................................................................................................199
5.01.03 GRW 280-16......................................................................................................................201
5.01.04 GRW 280-20......................................................................................................................203
5.01.05 GRW 280-24......................................................................................................................205
5.01.06 GRW 280-28......................................................................................................................207
5.02 Dimension sheet............................................................................................209
5.02.01 GRW 280 with cabin......................................................................................................... 209
5.02.02 GRW 280 with ROPS........................................................................................................209
5.02.03 GRW 280 with spare wheel and sunroof..........................................................................210
5.02.04 GRW 280 with thermal aprons..........................................................................................210
5.03 Fuses and relays...........................................................................................211
5.04 Main fuses......................................................................................................212
6 Assembly instructions........................................................................................213
6.00 Instructions for installation and retrofitting............................................... 213
6.00.01 Safety device ROPS cabin................................................................................................213
6.00.02 Safety device ROPS roll-over bar.....................................................................................215

General
Introduction
© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 9
1 GENERAL
When working at the machine please always adhere to the
instructions given in your Safety instructions!
000-01
1.00 Introduction
1.00.01 Preface to the operating manual
This chapter contains important instructions for the operating personnel
on how to operate the machine and to use this operating manual.
This operating manual helps you:
to become familiar with the machine.
to avoid malfunctions due to improper use.
Adhering to this operating manual:
helps to avoid risks.
increases the reliability when working on the construction site.
increases the life span.
reduces maintenance costs and downtimes.
It is absolutely necessary to adhere to this operating manual, the
instructions given in the safety instructions, supplementary information
and all regulations and provisions applying at the building site (e.g.
accident prevention regulations).
Maintenance and care of the diesel engine have to be performed
according to these motor instructions. Any safety notes have to be
followed.
609-08
1.00.02 Product information
You have purchased a HAMM Quality product. All parts of this machine
have been checked and tested carefully, thus corresponding to the
quality you expect.
The reliability of the machine is preserved through correct use and
careful maintenance. This includes the use of the specified operating
supply items and the use of original HAMM spare parts.
Our representations will help you to keep your roller in perfect operating
condition.
Our representations will be at your disposal whenever you need
consultation and service even after the warranty period. They will supply
you with our original HAMM spare parts which do not only meet the
technical requirements but also ensure exchangeability and quality.
The safety, operating and maintenance instructions given in this
operating manual are intended for the operating personnel. Thus, keep
this manual always at hand!
609-06

General
Introduction
10 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
1.00.03 Guarantee
No guarantee claims with:
operating errors.
in the case the spare parts used are no original HAMM spare parts.
in the case wrong operating supply items have been used.
in the case any additional devices have been refitted an/or installed
that have not been approved by HAMM.
in the case of deficient maintenance.
in the case of any processes that conflict with these operating
manual.
609-07
1.00.04 Modifications / reservations
We are committed to provide you with correct and updated operating
manual. However, we cannot guarantee the correctness of all data
given. To be able to keep pace with changing trends, it may be
necessary to amend or modify the product and/or its operating console
without prior notice. We assume no liability for malfunctions, downtimes
and resulting damage.
609-09
1.00.05 Packaging and storage
We have carefully packed our products to ensure proper protection in
transit. Please check both packaging and the goods yourselv for any
damage upon reception of your goods. In the case of damage, the
devices must not be put into operation. Damged cables and connections
are a safety risk and must not be used.
In such a case, please contact your supplier.
If the devices are not put into operation upon unpacking, they must be
protected against humidity and dirt.
609-10
1.00.06 Signs and symbols
The signs and symbols used in this operating manual are to help you
use this operating manual and the device in a safe and fast manner.
Note Informs about application hints and useful information. No
dangerous or harmful situation.
Enumeration Indicates a listing of issues or possibilities.
Operating steps Are listed according to their succession each starting from 1 for
each individual process.
Option Indicates special equipment which varies from the standard.

General
Introduction
© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 11
Directions Information on directions contained in these instructions such as left or
right and/or front or rear always refer to the directions of the machine
driving forwards.
Cross-references Cross-references help you to find quickly sections in this operating
manual which supply you with additional important information. The
cross-reference shows you the page of the relevant section. The
abbreviation sqq. means "and the following pages".
Example: (see page 134 sqq.)
Positioning of illustrations The positions of illustrations are represented with letters and numbers.
The positions identified with letters in alphabetical order are only
explained in the corresponding text segment, beginning new for each
single figure. The positions marked with numbers apply to operating
elements, control units and switches. They are identical to the numbers
in the section Overview of Instruments and Operating Elements (see
page 64 sqq.). These numbers in squared brackets are used
as a reference in the description of the elements. Amongst others,
this ensures that important and additional information can be found
immediately and without difficulties in the descriptions of the elements.
The end of the positioning line is marked as dot or arrow. In the
illustration the dot marks a visible element and an arrow an invisible
element which is in arrow direction.
Example
Legend
[A] Driver [B] Engine compartment
Descriptive text
The drive lever [501] determines the direction of travel and the speed.
Using the lever [520] you can adjust the pretension of the attenuation
system to the driver's weight.
609-11
1.00.07 Signal words
A signal word identifies a source of dangers and residual risks.
609-12

General
12 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
DANGER!
Identifies immediate danger. If this risk is not prevented, this causes
death or severe personal injuries.
001-01
WARNING!
Refers to situations that may be dangerous. If this situation is not
avoided, fatality or very serious injuries may be caused.
002-01
CAUTION!
Refers to situations that may be dangerous. If this situation is not
avoided, minor or light injuries may be caused.
003-01
NOTICE
Refers to a situation that may cause property damage.
004-01

General
Documentation
© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 13
1.01 Documentation
This operating manual is intended to make the operating personnel
familiar with basic work steps / activities of and with the machine.
The entire operating manual consists of:
Safety instructions
Operating manual of the machine
Operating manual of the diesel engine
If necessary, additional information
The entire operating manual must always be available at the machine
and be accessible to the authorized operating personnel at all times.
Prior to operating the machine, you must have carefully read und
understood this operating manual. In case you do not understand this
operating manual or individual chapters, please ask us prior to starting
these activities. The operating manual includes valuable information in
order to operate the machine safely, appropriately and economically.
613-00

General
Use
14 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
1.02 Use
1.02.01 Intended use
The machine represents state-of-the-art technology and complies with
all valid safety regulations concerning its intended use at the time the
machine was launched on the market.
When designing the machine it was not possible to avoid forseeable
misuse or residual risks without restricting the machine's intended
functionality.
The maschine's intended use is:
pave roads and traffic areas.
ramming and smoothing of loose earth, road bedding, pavement or
similar ramable subgrade in layers.
The machine may only be deployed on surfaces that can support it.
Subgrade not capable of bearing is e.g. high fillings, batters, roadside
ditches.
The machine must not be used with explosive areas, on landfill sites
and with mining.
The machine is only intended for commercial applications within fenced
construction sites.
The machine must be operated by authorised operating personnel only if
in proper technical condition and according to this operating manual.
All unintended uses and/or all machine-related activities not described in
this operating manual are to be deemed as unauthorised misuse outside
the legal limits of indemnity of the manufacturer.
611-01

General
Use
© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 15
1.02.02 Reasonably forseeable misuse
In the case of reasonably forseeable misuse and/or improper use of the
machine, the manufacturer's warranty period will expire and the operator
will solely be responsible.
Reasonably forseeable misuse is:
Non-compliance with this operating manual.
Operating errors by operating personnel not qualified or instructed.
Conveyance of passangers.
Leaving the driver's position during operation.
Starting, using the machine outside the driver's position.
Errors due to "reflexive behaviour" and/or "chosing the easiest way".
Operating the machine if it is not in a proper technical condition.
Using the machine with improper ambient conditions (e.g.
temperature, gradient, cross slope).
Using the machine with the protective equipment removed.
Spraying with high-pressure cleaners or fire extinguishing equipment.
Towing trailing loads.
Non-compliance with maintenance intervals.
Omission of measurements and tests to detect damages early.
Omission of replacing wear parts.
In the case the spare parts used are no original HAMM spare parts.
Omission of maintenance and repair works.
Improper maintenance and repair works.
Unauthorised modifications of the machine.
611-02
1.02.03 Residual risks
Residual risks have been analysed and evaluated prior to starting the
construction and planning the machine. Existing residual risks are
referred to in the documentation. However, HAMM cannot forsee all
situations that may pose a risk in practice.
You can avoid existing residual risks if you comply with and
implement the following instructions:
Special warnings at the machine.
General safety instrucitons in this operating manual and in the safety
instructions.
special warnings in this operating manual.
Instructions contained in the safety instructions.
Operating instructions of the operator.

General
Use
16 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
Danger of life / risk of personal injury when operating the machine
due to:
Misuse.
Improper operation.
Transport.
Missing protective equipment.
Defective and/or damaged components.
Operation / usage by personnel not trained and/or instructed.
The machine may cause risk to the environment with:
Improper operation.
Operating supply items (lubricants etc.).
Noise emission.
Property damage may occur at the machine e.g. with:
Improper operation.
Non-compliance with operating and maintenance instructions.
Improper operating supply items.
Property damage may occur at additional assets within the
machine's operating area e.g. with:
Improper operation.
Reduction in performance and/or the machine's functionality may
occur at the machine with:
Improper operation.
Improper maintenance and/or repair works.
Improper operating supply items.
611-03
1.02.04 Climatic conditions
Low ambient temperature The diesel engine's starting behaviour and the machine's operation
depend on:
The fuel used.
The viscosity of the motor, gear and hydraulic oil.
The battery's charge state.
Please note:
The acceleration and braking behaviour of the machine are influenced
by viscous hydraulic oil. Prior to cold seasons (autumn, winter) please
adjust all operating supply items (coolants, oils etc.) to low temperatures.
Please use fuels suitable in winter or additives improving the flow with
temperatures below 0 °C (32 °F) (see page 195 sqq.). Do not charge
batteries with temperatures below 0 °C (32 °F) .

General
Environmental protection
© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 17
WARNING!
Explosion!
Risk of injury due to burns and moving parts.
Do not use aerosol start-up aid (e.g. aether).
Do not use any liquids as start-up aid (e.g. alcohol).
002-02
Extensive ambient
temperature, extensive height
See operating manual of diesel engine.
611-04
1.03 Environmental protection
Packing materials, cleaning agents and used or residual operating
supply items are to be disposed according to relevant environmental
provisions at the building site using the recycling systems provided.
614-00
1.04 Disposal
Conservation of nature is one of our major tasks. Properly disposed
devices avoid negative impacts on human beings and the environment
and allows re-using our precious resources.
Operating supply items Please dispose all operating supply items according to relevant
specifications and local regulations of the relevant country.
Materials (metal, plastics) To be able to dispose materials professionally, these materials need to
be correctly sorted. Cleanse materials of adhesive impurities.
Please dispose all materials as demanded by local provisions of the
relevant country.
Electical / electronical
system / battery
Electrical / electronical components are not subject to
Directive 2002/96/EC and relevant national regulations (in Germany e.g.
ElektroG).
Dispose electrical / electronic components directly at a specialised
recycling company.
615-00

General
EC confirmity
18 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
1.05 EC confirmity
The declaration of conformity is part of the documentation provided
separately by HAMM and will be submitted to you togehter with the
machine.
The pictogram represents the machine's conformity with relevant
EU Directives. The CE mark of the machine is part of the type
plate.
In case the machine has been modified in a way that has
not been agreed by HAMM, the EC declaration of conformity
expires.
616-00
EC declaration of confirmity

General
Type plate
© HAMM AG 2011 2153734_02_BAL_GRW280_H195_en 19
1.06 Type plate
The entire marking represents an official document and must not be
altered or effaced.
Please state the VIN and the type of your machine for every
spare part order.
Type plate of machine The type plate is fixed to the machine frame (see page 46).
[A] Description [B] Homologation
[C] Type [D] Year of construction
[E] Chassis number [F] Engine power
[G] Admissible total weight (only
valid for public roads)
[H] Admissible axle load, front /
rear (only valid for public
roads)
[J] Basic weight [K] Operating weight
[L] Maximum weight
The VIN [E] indicates the type series and the serial number of
the machine e.g. H1841234. The first four characters represent
the type series (H184), the following characters the serial
number of this type series (1234).

General
Noise and vibration requirements
20 2153734_02_BAL_GRW280_H195_en © HAMM AG 2011
Type plate roll-over protection
ROPS
The roll-over protection, ROPS, approved by the manufacturer for this
machine is marked by a type plate attached at the cabin / roll-over bar
(see page 47).
[A] Type / type series (part of the
VIN)
[B] Cabin / ROPS identification
number
[C] Cabin / ROPS serial number [D] FOPS identification number
[E] Year of construction [F] Cabin / ROPS own weight
[G] Tested up to the machine's
maximum speed
602-05
1.07 Noise and vibration requirements
The sound emission of the machine was measured according to the EC
Sound Emission Directive in the version 2000/14/EC.
The sound and vibration indications on the driver's seat are in line
with the requirements of the EC Machinery Directive in the version
2006/42/EC.
Sound power level Sound indication of the machine
The guaranteed sound power level is specified in the machine's
Technical Details (see page 197 sqq.).
Sound intensity level Sound indication on operator panel
The noise level at the operator's seat is specified under Technical data
(see page 197 sqq.) (measurement uncertainty in accordance with
EN ISO 11201).
However, when working in the immediate vicinity of the machine,
values may exceed 85 dB(A). In this case wear always your
personal noise protection (ear protection).