Operating manual E - SimmaRentsimmarent.cl/pdf/manuales/ammann/asc100/asc100.pdf · ASC 100 7...

Operating manual E

ASC 100

Cummins Tier I © 2 / 2006

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Pictures and data shown in these manuals are subject to change without notice, in order to improvequality of the manuals. Re-printing and copying of any kind, whole or in single chapters, is allowedonly with our prior written consent.

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Congratulations on your purchase of an AMMANN road roller. This modern compaction device ischaracterised by simple operation and maintenance and is the product of many years of AMMANNexperience in the field of road roller engineering. In order to avoid faults due to improper operationand maintenance we request that you read this operating manual with great care and keep it for laterreference.

With kind regards,

Verdichtung AG, CH-4900 Langenthal

0041 (0)62 916 63 56 FAX: 0041 (0)62 916 64 03

This manual consists of:

I. Specification manual III. Maintenance manual

II. Operating instructions

The following explanations serve to familiarise the machinist (operator) with the roller and to supporthim during handling and maintenance. It is therefore absolutely necessary to provide the operatorwith these instructions and to ensure that he reads them carefully before using the road roller. Thisaids training comprehension during the first use of the road roller.

Subsequent faults due to improper operating are avoided.

Adherence to maintenance instructions increases the reliability and lifetime of the machinery. Itreduces repair costs and down time.

AMMANN accepts no liability for continued safe functioning of the road roller if it is incorrectlyoperated and / or operating modes are employed which represent improper use.

Spare parts must meet AMMANN technical specifications. These requirements are fulfilled if onlyoriginal AMMANN spare parts are used.

These instructions must always be kept available on the equipment.

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Operating Manual

! NOTICE !

As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indi-cate the sides of the machine moving forward.

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Content

Content ............................................................................................................................................... 8

1. Specification Manual ...............................................................................................................................13

1.1. Basic Data ..............................................................................................................................................14

1.2. Dimension Chart .......................................................................................................................................16

1.3. Technical Data ..........................................................................................................................................17

1.3.1. Weights .............................................................................................................................................................. 171.3.2. Travel Parameters .............................................................................................................................................. 181.3.3. Vibration ............................................................................................................................................................. 191.3.4. Engine ................................................................................................................................................................ 191.3.5. Axle ..................................................................................................................................................................... 201.3.6. Brakes ................................................................................................................................................................ 201.3.7. Steering .............................................................................................................................................................. 201.3.8. Vibratory Drum ................................................................................................................................................... 211.3.9. Hydrostatic Drive of Travel ................................................................................................................................. 211.3.10. Hydrostatic Drive of Vibration ............................................................................................................................ 211.3.11. Hydraulic Oil Tank .............................................................................................................................................. 221.3.12. Lifting and lowering of the Hood and the Cabin ............................................................................................... 221.3.13. Cooling System of Hydraulic Oil ....................................................................................................................... 221.3.14. Fluids .................................................................................................................................................................. 221.3.15. Electrical Installation .......................................................................................................................................... 231.3.16. Safety Devices ................................................................................................................................................... 231.3.17. Hygienical Data .................................................................................................................................................. 231.3.18. Requirements of Traffic Regulations ................................................................................................................. 231.3.19. Accessories ........................................................................................................................................................ 24

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Specification Manual

2. OPERATING INSTRUCTIONS ....................................................................................................................27

2.1. Dewaxing and Inspection of a Newly Supplied Machine .....................................................................28

2.2. Major Safety Measures ............................................................................................................................29

2.2.1. Safety measures to operate the Machine ......................................................................................................... 292.2.1.1. How to start the compaction work ..................................................................................................................... 292.2.1.2. Work safety secured by User ............................................................................................................................ 292.2.2. Driver Qualification Requirements .................................................................................................................... 302.2.3. Driver’s Duties .................................................................................................................................................... 302.2.4. Operations Prohibited........................................................................................................................................ 322.2.5. Hand Signals ..................................................................................................................................................... 332.2.6. Safety labels & signs used on the Machine ...................................................................................................... 36

2.3. Ecological & Hygienic Principles ............................................................................................................39

2.3.1. Hygienic Principles ............................................................................................................................................ 392.3.2. Ecological Principles ......................................................................................................................................... 39

2.4. Preservation & Storage ............................................................................................................................40

2.4.1. Short-term preservation & storage for the period of 1 ÷ 2 months .................................................................. 402.4.2. Machine preservation & storage for the period over 2 months ........................................................................ 40

2.5. Machine disposal upon its life termination ............................................................................................41

2.6. Machine Description ................................................................................................................................43

2.7. Controllers & Dashboard Instruments .....................................................................................................44

2.8. How to Control and Use the Machine .....................................................................................................54

2.8.1. Start the Engine ................................................................................................................................................. 542.8.2. Travel & Reversing ............................................................................................................................................. 562.8.3. Travel with vibration ........................................................................................................................................... 582.8.4. Stop the Machine & the Engine ......................................................................................................................... 592.8.5. Machine Shutdown ............................................................................................................................................ 602.8.6. How to lift driver control stand and bonnet ....................................................................................................... 61

2.9. Machine Transportation ...........................................................................................................................63

2.9.1. Machine transportation by its own axle ............................................................................................................ 632.9.2. Machine transportation by public road ............................................................................................................. 632.9.3. How to load the Machine ................................................................................................................................... 642.9.4. Towing of Machine ............................................................................................................................................. 652.9.5. Dismantle the Cab and the ROPS ..................................................................................................................... 66

2.10.Special Conditions for the Machine Application ...................................................................................68

2.10.1. Vibration driving on compacted and hard materials ....................................................................................... 682.10.2. Machine use under heavy climatic conditions ................................................................................................ 692.10.2.1. Machine operation under low temperatures ................................................................................................... 692.10.2.2. Machine operation under high temperatures and humidity ........................................................................... 702.10.2.3. Operating the Machine at high altitudes .......................................................................................................... 702.10.2.4. Machine operation at extremely dusty environment ....................................................................................... 70

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Content

3. MAINTENANCE MANUAL ..........................................................................................................................73

3.1. Safety & Other Measures during Machine Maintenance .......................................................................75

3.1.1. Safety during Machine Maintenance ................................................................................................................ 753.1.2. Fire precautions when refilling .......................................................................................................................... 753.1.3. Ecological & Hygienic Principles ...................................................................................................................... 763.1.3.1. Hygienic Principles ............................................................................................................................................ 763.1.3.2. Ecological Principles ......................................................................................................................................... 76

3.2. Refill Specification ...................................................................................................................................77

3.2.1. Motor Oil ............................................................................................................................................................. 773.2.2. Fuel ..................................................................................................................................................................... 783.2.3. Cooling Liquid .................................................................................................................................................... 783.2.4. Hydraulic Oil ....................................................................................................................................................... 793.2.5. Gearbox Oil ........................................................................................................................................................ 803.2.6. Lubricating Grease ............................................................................................................................................ 803.2.7. Screen Washer Liquid ....................................................................................................................................... 80

3.3. Refills ..............................................................................................................................................81

3.4. Lubrication & Maintenance Table ...........................................................................................................82

3.5. Lubrication Chart ......................................................................................................................................84

3.6. Lubrication & Maintenance Operations ..................................................................................................85

Following 20 hours of operation or daily ...............................................................................................86

3.6.1. Check the oil amount in motor .......................................................................................................................... 863.6.2. Check the amount of cooling liquid in the motor .............................................................................................. 873.6.3. Check the amount of oil inside hydraulic tank .................................................................................................. 883.6.4. Crankcase Breather ........................................................................................................................................... 883.6.5. Check fan condition ........................................................................................................................................... 893.6.6. Check motor belt ................................................................................................................................................ 893.6.7. Check engine air intake .................................................................................................................................... 903.6.8. Check the amount of fuel ................................................................................................................................... 913.6.9. How to clean air separator ................................................................................................................................ 923.6.10. Check the alarm & control devices ................................................................................................................... 93

Every 100 Hours ........................................................................................................................................94

3.6.11. Check tire pressure ........................................................................................................................................... 94

Every 250 Hours or Once in 3 Months .....................................................................................................95

3.6.12. How to replace oil in the engine ....................................................................................................................... 953.6.13. Check the fixing of the engine ........................................................................................................................... 983.6.14. How to inspect the batteries .............................................................................................................................. 993.6.15. Check the function of Air Filter Vacuum Switch .............................................................................................. 1013.6.16. Machine Lubrication ........................................................................................................................................ 1023.6.17. How to check oil inside vibrator ...................................................................................................................... 1053.6.18. How to check oil in gearboxes ........................................................................................................................ 106

Every 500 Hours or Once in 6 Month ..................................................................................................... 107

3.6.19. How to replace engine fuel filter ..................................................................................................................... 1073.6.20. Cooling liquid inspection ................................................................................................................................. 1093.6.21. Check if wheel bolts are tightened .................................................................................................................. 109

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Operating Manual

Every 1000 Hours or Once a Year .......................................................................................................... 110

3.6.22. Check, adjust valve clearance ........................................................................................................................ 1103.6.23. How to check tightening pulley and belt of the engine .................................................................................. 1123.6.24. Replace oil in gearboxes ................................................................................................................................. 1143.6.25. Inspect the damping system ............................................................................................................................ 1153.6.26. How to clean fuel tank ..................................................................................................................................... 116

Every 2000 Hours or Every 2 Years ........................................................................................................ 117

3.6.27. How to change oil in the vibrator .................................................................................................................... 1173.6.28. How to change hydraulic oil and filter ............................................................................................................ 1183.6.29. How to change engine coolant ....................................................................................................................... 1213.6.30. How to check the dampener of engine’s torsional vibrations ........................................................................ 124

Maintenance - As Needed ...................................................................................................................... 125

3.6.31. How to replace filter elements ......................................................................................................................... 1253.6.32. How to clean engine cooler and hydraulic oil ................................................................................................ 1273.6.33. How to clean cabin ventilation filter ................................................................................................................ 1283.6.34. How to deaerate fuel system ........................................................................................................................... 1293.6.35. How to adjust the scrapers .............................................................................................................................. 1313.6.36. How to clean the Machine ............................................................................................................................... 1323.6.37. Check bolted connections ............................................................................................................................... 132

3.7. Defects ............................................................................................................................................ 135

3.8. Attachment ............................................................................................................................................ 136

Wiring Diagram .............................................................................................................................................................. 136Hydraulic Diagram ......................................................................................................................................................... 138

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1. SPECIFICATION MANUAL

ASC 100(Cummins Tier I)

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1.1. Basic Data

Introduction

Single drum vibratory rollers of line ASC 100 are outstand-ing by their up-to-date design, adopted technologies, aswell as modern styling. These machines offer maximalcomfort to the operator, are easy to operate, extremelyreliable and require minimal maintenance. The utilizedfrequency, amplitude and centrifugal force of vibrationwere optimized by means of compaction tests to reachextra high compaction effect on various materials.

Application Range

The vibratory rollers of ASC 100 line are especially suit-able for use at mid- and large compaction jobs of highwayconstruction (construction of highways, railways, airports),hydraulic construction (earth dams) and civil engineering(industrial areas, ports etc.).

The rollers are designated for operation under conditionsas according to IEC 721-2-1 (038900): WT, WDr, MWDr(i.e. moderate, warm dry, hot dry) with temperature limitsfrom -15°C (5°F) to +45°C (113°F).

Modifications

The single drum vibratory roller ASC 100 with the smoothdrum is suitable for compaction of all kinds of soil. It canbe employed at compaction of clayey soils up to the layerthickness (compacted) of 25 cm (9,8 in), loam soils up tothe layer thickness of 40 cm (15,7 in), mixed soils up tothe layer thickness of 50 cm (19,7 in), sandy soils androckfills up to the layer thickness of 80 cm (31,4 in),gravels up to the layer thickness of 60 cm (23,6 in).Maximal allowed grain size is up to 2/3 of total layerthickness. The roller is suitable for compaction of stabi-lized soils as well.

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2

2

1

Fig. 1 - Pin label

Fig. 2 - PIN label 1, S/N 2

Fig. 3 - Serial number of the CUMMINS engine

Please refer to the data in the table below always whenapproaching the dealer or the manufacturer.

Please fill in the following data:

Type of machine (see Figs. 1, 2)

.....................................................................................ICV/PIN (Serial number of the machine) (Figs. 1, 2)

.....................................................................................Production year (see Figs. 1, 2)

.....................................................................................Type of engine (see Fig. 3)

.....................................................................................Serial number of the engine (see Fig. 3)

.....................................................................................

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A B D 1H 2H 5H 6H K 1K L

mm 0282 0522 0051 7203 5732 001 0453 054 504 0365

ni 0,111 6,88 0,95 2,911 5,39 9,3 4,931 7,71 9,51 7,122

1L 1O 2O 1R 2R 3R S 1W 2W 3W

mm 0961 55 56 5755 0123 5723 52 4312 0312 0151

ni 5,66 71,2 6,2 5,912 4,621 9,821 89,0 0,48 6,38 4,95

1.2. Dimension Chart

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1.3.1. Weights

Operation weight EN500-1 kg (lb) 10120 (22311)

to drum kg (lb) 5300 (11685)

to axle kg (lb) 4820 (10626)

Static linear load kg/cm (lb/in) 24,9 (138,3)

Operation weight ISO 6016 kg (lb) 10300 (22707)

to drum kg (lb) 5260 (11596)

to axle kg (lb) 5040 (11111)


Operation weight EN500-1 with padfoot segments kg (lb) 11840 (26102)

to drum kg (lb) 7020 (15476)

to axle kg (lb) 4820 (10626)


Operating weight ISO 6016 with padfoot segments kg (lb) 12020 (26499)

to drum kg (lb) 6980 (15388)

to axle kg (lb) 5040 (11111)

Operating weight according to EN 500 is weight of the machine with full operating liquid, half filling of fuel, water tankof sprinkling and operator’s weight 75 kg (165 lb).

Operating weight according to ISO 6016 is weight of the machine with maximum operating liquid, of fuel, water tank ofsprinkling and operator’s weight 75 kg (165 lb).

The weights may differ depending on additional modifications of the machine made on special request of the customeror if additional options and/or accessories are used.

1.3. Technical Data

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1.3. Technical Data

1.3.2. Travel Parameters

Travel speed infinitely adjustable in both directions

1st speed range (work) km/h 0 – 5,0

(MPH) (0 - 3,1)

2nd speed range (transport) km/h 0 - 10,3

(MPH) (0 - 6,4)

Theoretical gradability

1st speed range (work) % 68

2nd speed range (transport) % 27

Practical gradability by forward run

- without vibration % 45

- with vibration % 45

Approach angle

- front (°) 30

- rear (°) 28

Transversal stability

- straight frame (static) (°) 34

- full turn (static) (°) 31

Max. allowed transversal inclination

- without vibration (°) 22

- with vibration (°) 5

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1.3.3. Vibration

Drive hydrostatic

Vibration exciter two-stage, circular non-directed vib-ration

Frequency Hz 32/35

(VPM) (1920/2100)

Rated amplitude m m 1,85/1,15

(in) (0,073/0,045)

Centrifugal force kN 277/206

(lb) (62250/46294)

1.3.4. Engine

Make Cummins Diesel

Type 4BTA3.9-C116

Serial number ................

Number of cylinders 4

Bore mm (in) 102 (4,02)

Stroke mm (in) 120 (4,72)

Total displacement cm3 (cu in) 3900 (239)

Output according to ISO 3046/1 (DIN 6271) kW (HP) 86 (116)

Rated speed min-1 (RPM) 2500

Maximal torque Nm (ft lb) 423 (312) /1500 min-1 (RPM)

Specific fuel consumption at rated speed g/kWh 240

Fuel speed at normal operation l/h (gal US/h) 11,8 (3,12)

Fuel cleaners - Fleetguard 1x FF 1280 (3925274)* a 1x FF 5052(3903640)*

Oil cleaner - Fleetguard LF 3345*

Air cleaner Donaldson FLG 08-0337

Air filter element Donaldson P77-2550

Air filter safety element Donaldson P11-9410

Cooling system liquid cooled engine with cooler 34299

Coupling CENTA CF-H-030-1-SA-02

Engine fulfills requirements of: Tier 1 97/68/EC

* Exact denomination of these parts is dependent on modification of the engine. For spare parts ordering always referto the serial number of your engine.

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1.3. Technical Data

1.3.5. Axle

The front axle consists of the drum, the rear axle of the axle housing with two drive gearboxes with the wheels.

Number of tires 2

Tire size 23,1x26“ thread UK-5 (10 PR) MITAS

Average contact pressure on soil kPa (PSI) 304 (44,1)

Tire inflation kPa (PSI) 160 (23,2)

1.3.6. Brakes

Service brake hydrostatic system of travel

Parking emergency brake three band brakes installed in thegearboxes of the wheels and thedrum, governed by springs with hyd-raulic release

Releasing pressure MPa (PSI) 1,9 (275)

1.3.7. Steering

Hydraulic power steering with two hydraulic cylinders

Hydraulic pump of steering Bosch Rexroth HY/ZFS24/25

Power steering unit Bosch Rexroth Servostat 8477955593

Safety pressure MPa (PSI) 15 (2175)

Hydraulic cylinders 2x HV 90/45/400

Steering angle (±) 36

Oscillation angle (±) 10

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1.3.8. Vibratory Drum

Drum dia mm (in) 1500 (59,0)

Drum width mm (in) 2130 (83,8)

Thickness of drum mm (in) 25 (0,98)

1.3.9. Hydrostatic Drive of Travel

Hydraulic pump of travel variable output with

skew plate, electrohydraulically controlled Bosch Rexroth A10VG63

Delivery per revolution cm3(cu in/rev) 63 (4,83)


Kontroller Reflex 9V 4592-01-01

Drum drive gear-box Trasmital 707C3B 83.7

Filtration block Donaldson HMK 045796

Filter element Donaldson P165332

Drum drive hydromotor Bosch Rexroth A10VE45

Wheel gears Trasmital 706C3B 68.4

Wheel drive hydraulic motors Bosch Rexroth A10VE45

Flow divider Hytos 729-0170

1.3.10. Hydrostatic Drive of Vibration

Hydraulic pump of vibration variable-output,

with skew plate, electrohydraulically controlled Bosch Rexroth A10VG45

Delivery per revolution cm3(cu in/rev) 45 (2,74)


Hydromotor of vibration Bosch Rexroth A10FM45

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1.3. Technical Data

1.3.11. Hydraulic Oil Tank

Suction basket Argo AS 080-1

1.3.12. Lifting and lowering of the Hood and the Cabin

Safety packet Hytos 513-0700

Hydraulic cylinders of hood lifting 2x 25 – 300AXL Semily

Hydraulic cylinder of cab lifting 1x 32-300 AXL Semily

Hand pump Technometra RC 16

1.3.13. Cooling System of Hydraulic Oil

Oil cooler Emmegi 34299

1.3.14. Fluids

Engine oil l (gal US) 11,2 (2.96)

Cooling system l (gal US) 24,0 (6,3)

Fuel l (gal US) 410 (108,3)

Hydraulic system l (gal US) 90 (23,8)

Drum drive gear-box l (gal US) 3,5 (0,92)

Wheel gears l (gal US) 2x3,3 (2x0,87)

Vibratory drum l (gal US) 8,0 (2,1)

Tank of windscreen washer l (gal US) 2,75 (0,72)

Tires kg (lb) 2x525 (2x1157)

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1.3.15. Electrical Installation

Rated voltage V 24

Capacity of battery Ah 2 x 100

1.3.16. Safety Devices

Battery disconnector disconnects electrical installation

1.3.17. Hygienical Data

Noise:

The acoustic pressure level affecting the driver:

(measured according the EN 11 204 on the elastic material,

stopped machine with vibration) LpA = 95 dB (A)

Sound power level

(measured due to the EN ISO 3744 on the elastic material,

stopped machine with vibration) LWA = 114 dB(A)

The vibrations:

The mean effective value of the vibrations acceleration:

- transfered to the body aw < 0,9 ms-2 (vectorial sum)

(measured according the EN 1032 on the sand base under the vibration travel)

- transfered to the hands aw < 5,2 ms-2 (vectorial sum)

(measured according the ISO 5349 on the sand base under the vibration travel)

1.3.18. Requirements of Traffic Regulations

The basic machine model is not intended to be moved under own power on public roads, since its appointment is notin compliance with the regulation for public roads.

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1.3. Technical Data

1.3.19. Accessories

A) Roll Over Protective Structure (ROPS)

The rolli over protective structure ROPS is a frame, which protects the driver if the machine rolls over. It meets theinternational requests for driver’s protection according to EN 13510:2000; ISO 3471:1994; SAE J ISO 3471:2003; AS2294:2003 up to the total weight of the machine 18500 kg (40785 lb).

Weight of the ROPS frame kg (lb) 230 (507)

Fastened to the machine frame with 16 bolts M 24 x 80 (8G)

Tightening torque Nm (in lb) 549 (4854)

The data for the frame are stated on the frame decal.

C) Padfoot Segments

These are mounted onto the smooth drum and partially substitute for the padfoot modification. The padfoot segmentsare used for compaction of soils up to the layer thickness according to following table:

cohesive soils 50 cm (19,7 in)

mixed soils 60 cm (23,6 in)

The segments are also suitable for pulverization and compaction of plate-shaped rock (shales).

Number of segments 3

Drum dia over pads mm (in) 1712 (67,4)

Total number of pads 150

Height of a pad mm (in) 100 (3,9)

Area of a pad cm2 (sq in) 120 (18,6)

Weight of one segment kg (lb) 537 (1184)

Total weight of segments kg (lb) 1680 (3703)

Fastened to the drum with 18 bolts M 20 x 150 (8G)

Tightening torque Nm (in lb) 314 (2776)

D) Filling the Tires with Liquid

Added weight with liquid to -25°C (-13°F) kg (lb) 2 x 600 (2 x 1323)

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N seto :

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N seto :

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2. OPERATING INSTRUCTIONS

ASC 100

28 ASC 100

2.1. Dewaxing and Inspection of a Newly Supplied Machine

• Inspect the Machine per shipping documents.

• Check that no parts of the Machines have been dam-aged during transportation, and that no parts aremissing. Inform shipper about any shortcomings.

Before Machine Operation, pleasecarry out dewaxing, wash away thepreserving agents using high pres-sure stream of hot water added withstandard degreasers. All relevantecological principles must be ad-hered to.

Perform dewaxing & washing of theMachine at places equipped withintercepting sumps to catch rinsingwater & dewaxing agents.

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Operating instructions2.2. Major Safety Measures

2.2.1. Safety measures to operate theMachine

Safety measures stated in the individual sections of theEngineering Documentation supplied together with theMachine shall be supplemented with those safety pre-cautions in force within a respective country where theMachine will be used, and within a workplace, with regardto human resource management, work process andpersonnel.

2.2.1.1.How to start the compactionwork

• Supplier of building work (Machine User) shall beliable to provide instructions for Driver and Maintenan-ce Department. These instructions include the requi-rements to secure occupational safety while operatingthe Machine.

• Prior the compaction work the Supplier of buildingwork (Machine User) must verify the following:

- Utility lines

- Underground areas (direction, depth)

- Seepage or escape of hazardous materials

- Soil bearing capacity, slope of traverse plane

- Other barriers and obstructions, along with spec-ifying the measures to ensure work safety.

• Supplier of building work (Machine User) must thenmake familiar with these conditions a Machine Driverwho will carry out the earthwork.

• Supplier of building work (Machine User) shall definetechnological process part of which is the work proce-dure designed for a given job. The work procedurespecifies inter alia:

- Measures for work under extraordinary conditions(work within protective zones, under extremeslopes, etc.)

- Measures against any natural disasters

- Requirements for job execution while observingjob safety principles

- Technical and organisational measures to securesafety of workers, site and environment. .

• Supplier of building work (Machine User) must evi-dently make Machine Driver familiar with the techno-logical process (job description).

2.2.1.2.Work safety secured by User

• User must ensure the Machine will be operated onlyunder those conditions, and solely for those purpos-es the Machine is technically eligible for under theconditions specified by manufacturer and respectivestandards.

• User must promptly report any damage of the utilitylines to their Operator, and at the same time performmeasures to prevent Admittance except on businessto the danger area.

• User shall provide for use of vibration roller only insuch a way and at such sites where there is no hazardof damage to nearby premises and others.

• User shall ensure that a worker does NOT work aloneat the site, and that another worker is ALWAYS in sightand within ear-shot to provide or call for aid unlessother effective form of supervision or communicationis available.

• User must ensure surveillance designate worker atwork machinery in the working condition on publiccommunication, which be in capacity issue instruc-tions to reservation labour protection

• User must secure regular inspection of the opera-tions, operating condition, regular Machine mainte-nance in intervals under the Lubrication & Mainte-nance Manual . In case of nonconforming operatingcondition of the Machine to the extent it becomeshazardous and detrimental to the environment, thenthe Machine must be discarded until the defect getsrepaired.

• User shall specify who and what tasks may be carriedout during operation, maintenance and repairs of theMachine.

• The one who drives the Machine (Driver) and anybodywho performs maintenance and repairs of the Ma-chine must be made familiar with those instructionsgiven in the Machine Operating Manual.

• User must ensure the ”Machine Operating Manual”and the Operation Logbook are stored at a specificplace to be ALWAYS available to the Driver.

• User shall make the fire extiguisher to undergo regu-lar inspections.

• User must provide for disposal of hazardous materi-als (fuel, oil, coolant, and alike) away from their leak-age point in order to avoid their adverse environmentalimpact, adverse effect on operation safety and health.

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2.2. Major Safety Measures

2.2.2. Driver QualificationRequirements

• Only a driver trained under local and national regula-tions and standards designed for drivers of this groupof Machines may operate the Roller.

• Only the one who with the approval of Machine Userlearns to drive under a direct & constant supervisionof professional lector or trainer in order to gain prelim-inary practice, may drive with no driving licence ob-tained so far.

• Licence holder is liable to duly keep the licence incustody and if requested he/she must put it forward tothe control authorities.

• Licence holder may NOT make any recordings, chang-es or corrections to the licence.

• Driver is liable to promptly report any loss of his/herlicence to the authority that had issued the licence.

• Only a person mentally and physically competent,over 18 years old may drive the Roller alone if :

a) Charged by the Machine manufacturer to assem-ble, test and demonstrate the Machine, or to traindrivers, whereas he/she must be made familiarwith the occupational safety regulations in force atthe site,

or

b) Appointed by Supplier of building work to operate(carry out maintenance), and evidently trained andacquainted with, or if, under specific regulations,he/she owns professional competence to operateand drive (engine operator’s licence, and alike).

• Machine Driver must undergo training at least 1x every2 years, and pass exams concerning work safetyregulations.

2.2.3. Driver’s Duties

• Before starting Machine operation Driver must getfamiliar with the instructions given in the Documenta-tion supplied with the Machine, with safety measuresin particular, and follow these guidelines thoroughly.This applies also to a personnel in charge of Machinemaintenance, adjustments and repairs.(Unless youunderstand some sections of the Manual, pleasecontact your dealer or manufacturer.)

• NEVER drive Roller unless fully made familiar with allthe Machine’s functions, operating and handling ele-ments, and until you know precisely how to operate theMachine.

• Follow safety signed located on the Machine, andkeep them in legible condition.

• Prior to commencing work Driver must get familiarwith the site environment, i.e. any barriers, slopes,utility lines, necessary site protections in terms of thesurrounding environment (noise, vibrations, etc.).

• When finding any health hazard, life hazard, danger topersons, property, finding any failures, or when thereis an accident of technical facilities, or when findingany symptoms of such hazards during operation, thenthe Driver must, unless able to clear away such dan-ger by himself/herself, stop the work and secure theMachine against any undesirable starting ON, reportto a staff in charge, and if possible, alert all thepersons threatened by such hazard.

• Before starting to run the Machine, Driver is liable toget familiar with the records and any operating devi-ations found out in course of previous working shift.

• Before work commencements please inspect theMachine, fittings, check the control elements, com-munication & safety equipment, whether these arefunctional and enabled according to the Manual. Whenfinding any defect hazardous to job safety and unableto be repaired by Driver, then the Driver may not startthe Machine but instead communicate the failure to astaff accountable.

• When Driver finds a defect during operation, he/shemust stop the Machine immediately, and secure safe-ly against any undesired starting ON.

• Driver must follow the Machine run while in operationand record any malfunctions found into the diagnosticlogbook.

• Driver must keep diagnostic logbook designed tomake records on handing in and handing over theMachine between the Drivers, and on any defects andrepairs during operation, and to document majorevents during an operating shift.

• Prior to starting the engine check the controllers arein gauge zero; no persons may remain within dangerrange of the Machine.

• Make sound or light signal to communicate each startup of the Machine, and this ALWAYS before you startMachine engine.

31ASC 100

Operating instructions

• Confirm the functions of the brake and steering beforeMachine operation start up.

• Following an alarm the Operator may start the Ma-chine only when all workers leave the danger area. Atblind (uneasy to oversee) sites the operation start maybegin only after a period necessary to exit endangeredarea elapses.

• When operating the Machine the safety regulationsmust be adhered to, no activity hazardous to worksafety can be carried out, commit yourself fully toMachine driving. ALWAYS sit on the seat when drivingthe Machine.

• Respect job description or instructions of an employ-ee accountable.

• When moving with the Machine at the site you mustadapt the speed to the terrain condition, work inprogress, and weather conditions. Watch continu-ously the clearance height to avoid collision with anyobstruction.

• Upon completion or stop of the Machine operationduring which Driver leaves the Machine, he/she mustfirst make measures against unauthorized use of theMachine and its spontaneous start. Remove key fromthe ignition box, lock the cabin and use disconnect orto cut out the wiring.

• Upon operation completion park the Machine at anappropriate station (flat, good bearing surface) inorder not to threaten Machine stability, intervene withtraffic roads, expose the Machine to the falling objects(rock), and where no natural disasters of other type(floods, landslides, etc.) are not a threat to the Ma-chine.

• When parking the Machine on communications overland, please carry out measures under the regula-tions effective for communications over land. Labelthe Machine properly.

• When working with the Machine is completed, pleasewrite down in the Operation Logbook any Machinedefects and its damage including repairs made. Dur-ing immediate change of Drivers it is a a duty to directlydraw changing driver’s attention to any matters foundout.

• Driver must wear personal protective equipment, i.e.work clothing, safety shoes. The clothing must NOTbe too loose or damaged, hair protected with properhead piece. Hands protected with proper gloves dur-ing maintenance work (lubricating, replacing of oper-ating media).

• Driver at the Machine with no cabin must use earprotection effective within noise level of round 90 dB.

• Keep the Machine fitted with specified accessoriesand outfit.

• Keep clean driver control stand, climbing steps andwalkway surfaces.

• Before lifting the cabin and bonnet, please confirmthere is enough space for lifting, with no electric linespresent. Before dropping the cabin and bonnet con-firm nobody will be endangered with this operation.

• In case the Machine would come into contact with highvoltage the following principles must be adhered to:

- Try to escape with the Machine from the hazardousarea

- Do NOT leave driver control stand

- Give warning to others not to approach and contactthe Machine.

• Maintain the Machine free of oil dirt and flammablematerials.

Observe safety communica-tion under any and all cir-cumstances – Life Hazard

Observe safety communica-tion – Accident Hazard.

Follow environmental regula-tions.

CAUTION Take notice of labels

32 ASC 100


2.2.4. Operations Prohibited

It is forbidden to:

• Use the Machine after drinking alcohol and ingestionof narcotics.

• Use the Machine in case its operation might deterio-rate its operating condition, cause safety hazard (life,health) to persons, buildings and other property, or toroad traffic and its continuity.

• Start the Machine and use it when other persons arewithin the hazardous vicinity of the Machine. Exemptedis driver training by lector.

• Start the Machine operation and use the Machine withsome of the safeguard equipment (emergency brake,hydraulic locks, etc.) removed or damaged.

• Move and compact at such banks at which machinestability would be broken (overturn). Machine staticstability specified gets reduced by the dynamic effectsof the drive..

• Move and compact at such angles of slopes at whichthe hazard of earth breaking off together with theMachine could occur, or adhesion lost followed byuncontrollable breakaway.

• Control the Machine in a way other than stated in theDriver Manual.

• Move and compact with vibration per soil bearingcapacity at such distance from the slope edge orexcavation edges to avoid the hazard of material slid-ing down or shoulder breaking off together with theMachine.

• Move or compact with vibration at such distance fromwalls, cuts or slopes so as to avoid the hazard of theircollapsing and backfilling the Machine.

• Compact with vibration at such distance from thebuildings or premises and facilities within which ahazard of their being damaged due to vibration energytransfer could occur.

• Move or transport persons on the Machine.

• Operate the Machine unless driver control stand isproperly fixed.

• Operate the Machine with its bonnet lifted.

• Operate the Machine when there are other machinesor conveyances within the danger area of the Machineexcept for those working in mutual interaction with theMachine.

• Operate the Machine at a location unable to be seenfrom driver control stand, and where hazard to per-sons or property may occur unless work safety issecured in some other way, e.g. indirectly via signal-ling carried out by duly instructed person.

• Operate the Machine within protective zone of electriclines and substations.

• Pass over the electric cables unless these are prop-erly protected against mechanical damage.

• Operate the Machine under reduced visibility or atnight unless the working area of the Machine or thesite is sufficiently illuminated.

• Leave Machine driver seat with the Machine running.

• Abandon unsecured Machine, i.e. move away from theMachine without preventing its misuse.

• Disable safeguarding, protecting or locking systems,or alter their parameters.

• Use the Machine with leaking oil, fuel, coolant or otherfillings.

• Start the engine in some other way than given in theDriver Manual.

• Place, aside from personal needs, so other things(tools, accessories) at the Driver Control Stand.

• Put any materials or other objects on the Machine.

• Remove any dirt while the Machine is running.

• Carry out maintenance, cleaning or repairs unless theMachine is secured against self-motion and acciden-tal start, or unless contact between worker and mov-ing parts of the Machine is excluded.

• Touch moving parts of the Machine with your body andobjects or tools held in your hands.

• Smoke & handle open fire while inspecting or refillingthe fuels, changing, replenishing oil, lubricating theMachine, or checking and refilling the accumulator.

• Carry the rags soaked with flammable materials onthe Machine (inside engine bay, cab), or carry flamma-ble liquids in free vessels.

• Let the engine run inside confined areas. Exhaustgases are dangerous to life.

33ASC 100


2.2.5. Hand Signals

Signals given by Machine Operator Assistant when Oper-ator is unable to cover visually moving working space orutility device or tool.

GENERAL COMMAND SIGNALS

Stop

One arm rose with open palm in the direction of Operator,the other arm akimbo.

Attention

Both arms sideways raised horizontally – palms forward.

Beware of Danger

Oscillating motion of both fore-arms from the position ofarms sideways raised horizontally to a position of armssideways raised – in huddled-up way and back.

34 ASC 100


SIGNALS TO DRIVE

Drive away with the Machine

One arm erected – bent with open palm, long motion offore-arm in the direction of required motion, second armakimbo.

Slow forward drive– to me

Both arms stretched upward abreast huddled up, withpalms towards the body; short oscillating motions of fore-arms towards the body and back.

Slow backward- drive - away from me

Both arms stretched upward abreast huddled up, withpalms away from the body – short oscillating motions offore-arms away from the body and back.

Driving on the right

Left arm sideways raised, right arm akimbo.

35ASC 100


Driving on the left

Right arm sideways raised, left arm akimbo.

Short motion

Both arms lifted forward huddled-up. Mark the distance„X“ between the palms, then the motion signal follows.

Engine start

Circular motion of right hand’s fore-arm with fist closed.

Engine shut down

Oscillating motion of right hand sideways rose in front ofthe body an moving to the sides.

36 ASC 100


2.2.6. Safety labels & signs used on the Machine

37ASC 100


Safety labels & signs used on the Machine

1 Clamp Hazard Risk area with clamp hazard. (Symbols placed leftand right on the rear cross arm of the front frame.)

2 Burn Hazard Danger of burn. Do NOT touch hot parts of the Ma-chine unless you made certain of their being cooleddown sufficiently. (Symbols placed from inside on theleft door.)

3 Injury Hazard Risk of injury and winding around. NEVER touch ro-tating parts while engine is running. (Symbol placedon the left side of the cooler.)

4 Cooling Liquid Scalding hazard. Do NOT open expansion tank liduntil liquid cools down below 50 °C (122 °F). (Symbolplaced on the expansion tank.)

5 Adjust while at rest Risk of injury or being caught by the rotating parts ofthe Machine. Make NO adjustments or maintenancework when the engine is running. (Symbol placed frominside on the left door.)

6 Read the Manual Read the Operating Manual before starting theMachine.(Symbol placed on the left side of the controlpanel.)

7 Machine Max Height Pay attention when passing through a location withheight limit. (Symbol placed on the left side under-neath the cab on the frame.)

38 ASC 100


8 Battery Disconnector In case of failure or following a work completion, pleaseswitch battery disconnector to ”0” position. (Symbolplaced on the panel behind LH lateral door.)

9 Rigging Diagram Use rigging of sufficient loading capacity when liftingthe Machine. Secure Machine joints before slinging.(Symbol placed on LH door.)

10 Sling Positions Sling the Machine at these points. (Symbols placedon both sides of the frames.)

11 Disconnect Alternator Before welding disconnect the alternator & electron-ics of the Machine, i.e. ASC, motor control unit. (Sym-bols placed from inside on the LH lateral door.)

12 Ear Protectors When the Machine has no cab, or operates with openwindows, please use ear protection. (Symbol placedon central steering column.)

13. Electric Devices Cover electric instruments when washing the Machine(Symbol placed on the left side of the cooler.)

14. Platform & Cab Lifting (Symbol placed on door’s inner side.)

39ASC 100

Operating instructions2.3. Ecological & Hygienic Principles

During Machine operation or storage the User mustobserve general principles of occupational safety andenvironmental protection along with laws, public noticesor regulations related to these issues and in force withina territory where the Machine is used.

2.3.1. Hygienic Principles

• Oil products, refrigerants of cooling systems, alterna-tor refills or painting materials incl. thinners are healthhazard materials. Workers coming into contact withthese products during Machine operation or mainte-nance will be liable to adhere to general principles oftheir own occupational safety, and conform to thesafety & hygienic manuals of the manufacturers ofthese products.

• We point in particular to :

- Eye & skin protections while handling the accumu-lators

- Skin protection while handling the oil products,painting materials or cooling liquids

- Washing your hands properly upo work comple-tion or before taking meal. Treat your hands withappropriate reparable cream.

- While handling the cooling systems follow instruc-tions given in the Manuals supplied together withthe Machine.

• ALWAYS store oil products, cooling system refriger-ants or accumulator refills and painting materials incl.organic thinners along with cleaning & preservationagents inside their original packages labelled prop-erly. Do NOT admit to store these materials in unla-belled bottles or other containers due to their ex-change hazard. Especially hazardous is the potentialof being exchanged for consumables or drinks.

• Should your skin, mucosa, eyes be stained inciden-tally, or vapours inhaled, then immediately apply firstaid principals. In case of accidental ingestion of theseproducts, get prompt medical attention.

• When handling the Machine in cases the Machine isnot fitted with cab, or cab windows are open, then useALWAYS ear protectors of suitable type and construc-tion.

2.3.2. Ecological Principles

• Refills for the Machine’s individual systems and someof its parts become waste having hazardous proper-ties against the environment following their disposal.

• This waste product category includes in particular:

- organic or synthetic lubrication materials, oils andfuels,

- cooling liquids,

- accumulator refills and the accumulators them-selves,

- tyre fillings

- cleaning & preservation agents,

- all the filters & filter elements removed,

- all the used and discarded hydraulic & fuel hoses,metal-rubbers and other elements of the Machinefouled with the aforementioned products.

Producer and contractual service organizations accredi-ted by him, or dealers take back the following materialsor parts free of charge:

- oils

- batteries

- tyres (optional)

• Following the disposal of the abovementioned mate-rials and parts make sure these are handled in linewith the respective national environmental regula-tions and health regulations.

40 ASC 100

2.4. Preservation & Storage

2.4.1. Short-term preservation &storage for the period of 1 ÷ 2months

• Wash & clean carefully the entire Machine. BeforeMachine parking and shutdown in order to make itspreservation & storage, please heat the running engi-ne up to its operating temperature. Park the Machineon fixed, flat surface at a safe place with no potentialof Machine damage caused by natural disaster (flo-ods, landslides, fire, etc.).

• In addition:

- repair those spots with paint impaired,

- lubricate all lubricating points, control cables, jo-ints of the controllers, etc.,

- confirm water fillings have been drained,

- check cooling liquid has its antifreeze characteris-tics required,

- check the accumulator charging conditions, re-charge if required,

- apply preservation grease over the chrome-platedsurfaces of the piston rods,

- we recommend to spray preservation agent (ap-plied via spraying) to protect your Machine againstcorrosion, and this particularly in places with cor-rosion hazard.

• Machine treated like that will need no special set-upbefore its subsequent putting into operation.

2.4.2. Machine preservation & storagefor the period over 2 months

• For the Machine shutdown the identical principles likewith short-term preservation will apply.

• In addition we recommend the following:

- remove the accumulators, check their conditionand store in a cool, dry room (recharge the accu-mulators on regular basis),

- Bottom on the runner frame so the damping sys-tem has minimal deflection (flexure),

- paint rubber elements with spec. preservationagent to protect them,

- inflate the tyres to a specified pressure, and pro-tect them from direct sunlight,

- apply chrome-plated piston rods with preservationgrease,

- spray the Machine with special agent and this atplaces with possible corrosion origin,

- Blind engine air intake and exhaust with double PEfoil and fix it carefully with adhesive tape,

- protect headlamps, exterior back mirrors and oth-er elements of external wiring via spraying withspecial agent and wrapping in PE foil,

- Preserve the engine per manufacturer’s Manual.Install a visible label informing the engine hasbeen conserved.

! CAUTION!

Following 6 months we recommend toinspect preservation condition and re-new it if necessary.

NEVER start the engine during storage!

When the Machine is stored under fieldconditions, please make sure such standis not exposed to any deluge hazardcaused by floods, or that no other type ofhazard occurs within this area!

Prior to restoration of the Machineservice, please wash the preserva-tion agents using high pressurestream of hot water added withstandard degreasers while observingthe Instructions for Use along withecological principles.

Dewax and wash the Machine at thelocations provided with interceptingsumps to catch rinsing water anddewaxing agents.

41ASC 100

Operating instructions2.5. Machine disposal upon its life termination

User will be liable to follow national waste or environmen-tal laws and regulations when carrying out Machine dis-posal. We therefore recommend to always consulting:

· licensed industrial waste products disposing compa-nies,

· Machine manufacturer or by them appointed and cer-tified contractual service companies.

Manufacturer bears no responsibility forany damage to health of the Users orenvironmental damage caused bybreach of the abovementioned notice.

42 ASC 100

43ASC 100

Operating instructions2.6. Machine Description

1 - Runner Frame

2 - Drum

3 - Scraper

4 - Joint

5 - Tractor Frame

6 - Axle

7 - Fuel Tank

8 - Accumulators

9 - Hydraulic Tank

10 - Bonnet

11 - Engine

12 - Hydraulic Oil Cooler

13 - Engine Coolant Cooler

14 - Driver´s Control Stand

15 - Travel Hydrogenerator

16 - Vibration Hydrogenerator

17 - Exhaust Muffler

18 - Air Filter

19 - Hydr. Oil Pressure Filter

44 ASC 100

2.7. Controllers & Dashboard Instruments

45ASC 100


Dashboard & Control Panel

1 - Steering Wheel

2 - Travel Controller

3 - Vibration Switch

4 - Travelling Speed Controller (Selector)

5 - Throttle Controller

6 - Ignition Box

7 - Motor Thermometer (Optional)

8 - Hydraulic Oil Thermometer (Optional)

9 - Operated-Hours Counter

10 - Fuel Level Indicator (Optional)

11 - Speedometer (Optional)

12 - Engine Lubrication Control Lamp

13 - Accumulator Charge Control Lamp

14 - Brake Alarm Indicator

15 - Engine Overheating Indicator

16 - Minimal Fuel Level Indicator

17 - Air Filter Fouling Indicator

18 - Hydraulic Oil Filter Fouling Indicator

19 - Vibration ON Indicator

20 - Hydraulic Oil Overheating Indicator

21 - Vibration Amplitude Preselector

22 - Heater Fan Switch (Optional)

23 - Headlights Switch

24 - Rear lights Switch

25 - Alarm Horn Pushbutton

26 - Fuse Block

46 ASC 100


Steering Wheel 1

Used for Machine steering.

! CAUTION!

With respect to safe steering, pleaseadjust optimal speed (1800. min–1) whendriving without vibrations.

Travel Controller 2

Use this controller to adjust direction & speedof the driving. Driving speed corresponds tothe degree the controller deflects from idle(neutral) position. At the same time the con-troller is used as driving brake of the Machine.The controller is arrested in set position. When

shifted to its center position the parking brake is enabled,i.e. the control lamp 14 lights up. Vibration Switch 3 islocated at the controller handle, and is used to switch ON/OFF the vibration after moving controller handle fromneutral.

! CAUTION !

Engine starting is possible in idle posi-tion only.

No vibration able to turn ON when in idleposition. (Vibrator bearings are notlubricated during vibration at the halt).

Travel Speed Controller 4

With the Controller turned ON the travel gear is engaged(“Hare” indicator lights). The Machine is capable to reachmax. Speed with pulling force reduced and climbingability decreased.

NOTE:

With the controller switched off the operating speed modeis set. The Machine reaches max. pulling force andclimbing ability.

! CAUTION!

You may switch ON the controller, i.e.travel speed, when driving the Machineon a formation level.

You may turn ON the controller with theMachine loaded.

With pulling force not sufficient, switchOFF the travel speed controller.

NEVER switch ON the control-ler during occupational use ofthe Machine.

Do NOT switch OFF the con-troller at high speed. Abruptslowdown will occur togetherwith impact within the hy-draulic system. Turn OFF thecontroller with the Machine atrest or at low speed!

Throttle 5

Move the throttle downward to increase the speed fromidling one to maximal rpm.

47ASC 100


Ignition Box 6

It has three positions - ”0”, ”I”, ”II”. When in”0” pos. all theconsumers with F1, F2 & F7 fuses will be connected; in”I”pos.other consumers will be connected; cushion fuse ”II”is used for Machine starting. Turn the key to”0” pos. to stopthe Machine, remove the key in this position.

NOTE:

The cab & the door underneath the cab have one commonkey.

! CAUTION!

Remove the key from the ignition boxwhen leaving the Machine!

When the Machine has no cab and thekey is taken out, please close the igni-tion box cap to protect the ignition boxagainst water & dirt penetration.

Engine Thermometer 7 - Optional

The thermostat maintains engine operating temperatureat the range of 82 to 93 °C (180 - 199 °F).

Hydraulic Oil Thermometer 8 - Optional

Temperature limit is 90 °C (194 °F) for oil of HV 68 or HV100 viscosity class. Optimal operating temperature is 50- 60 °C (122 - 140 °F).

Oils of other viscosity used

Oil Viscosity Oil Temperature Limit

HV 46 80 °C (176 °F)

HV32 70 °C (158 °F)

Operated-Hours Counter 9

When accumulator charge indicator 13 goes off thecounter starts reading the hours. Reading the number ofhours does not depend on engine rpm.

! CAUTION!

Carry out regular maintenance per thehours worked out!

Fuel Level Indicator 10 - Optional

Indicate the amount of fuel in the tank.

Speedometer 11 - Optional

Indicate engine rpm.

Engine Lubrication Control Lamp 12

Switch the ignition box key to position ”I”, and the controllamp lights up and then goes off after starting the engine.The lamp lighted signals engine lubrication is insuffi-cient.

! CAUTION!

Unless it goes off, look for the failure!

48 ASC 100


Accumulator Charge Control Lamp 13

Switch the key on the ignition box 6 to“I” pos. and thecontrol lamp must light up and go off after starting theengine.

! CAUTION!

Unless it goes off, look for the failure!

Brake Alarm Indicator 14

With this indicator lighted up the Machine broken issignalled.

Engine overheating control lamp 15

When the engine temperature reaches the highest allow-able level, the engine overheating control lamp goes ONan audible warning is given.

Low level of fuel indicator lamp 16

When the fuel level drops down to min. 45 l (12, gal) theindicator goes ON.

Air Filter Fouling Indicator 17

When this indicator lights up the filter elements are fouledabove their limit.

! CAUTION !

Replace the elements at once!

Indicator of hydraulic oil filter 18

This indicator lighted up under hydraulic oil operatingtemperature of 50 - 60 °C (122 - 140 °F) signals the filterelement is clogged with dirt.

! CAUTION !

Replace the elements at once!

Vibration ON Indicator 19

With this indicator lighted up the vibration switch 3 is ON.When set speed is reached the Machine starts vibratingwith the amplitude preset via vibration Preselector 21.

Hydraulic fluid overheating warning indica-tor 20

When the fluid temperatures reaches the highest allow-able level the overheating warning lamp goes ON, anaudible warning is given.

Vibration Preselector 21

- Small amplitude and high frequency are switched ON.

- High amplitude and low frequency switched ON.

Heater Fan Switch 22 - Optional

Two-speed.

! CAUTION!

The Fan enables air circulation insidethe cabin only. Cab installation is option-al.

49ASC 100


Headlights Switch 23

Rear Headlights Switch 24

Alarm Horn Pushbutton 25

Fuse Block 26

Fuse (F1) -15 A (upper fuse) headlights + rear lights,instrument panel illumination,

Fuse (F2) -5 A cab light, loud horn

Fuse (F3) -7,5 A brake, engine STOP,

Fuse (F4) -7,5 A travel, vibration, vibration switchingcontrol lamp

Fuse (F5) - 5 A brake indicator lamp, engine lubrica-tion lamp, charge control lamp, hy-draulic oil filter fouling lamp, enginefilter fouling lamp, fuel minimum lamp,motohours counter, engine overheat-ing lamp, hydraulics overheating lamp

Options: engine coolant thermome-ter, hydraulic oil thermometer, fuel lev-el indicator, tachometer (cancelled –engine overheating lamp, hydraulicoil lamp, fuel minimum lamp)

Fuse (F6) -15 A ventilation fan and heater fan, front &rear wipers, front & rear screen wash-ers

Fuse (F7) -20 A reserved (air conditioner)

Fuse (F8) reserved

! CAUTION!

Replace fuses with those of identicalvalue ONLY!!!

50 ASC 100


Cab Controllers & Accessories. Cab installation is optional.

27 - Screen Washer Switch

28 - Fan Switch

29 - Front Wiper Switch

30 - Rear Wiper Switch

31 - Cab Light

32 - Ventilation Nozzles

33 - Locker

34 - Back Mirrors

51ASC 100


35 - Heater Valve Tie Rod

36 - Heater Vents

38 - Screen Washer Tank

40 - Cab Ventilation Filter

41 - Front Wiper

42 - Rear Wiper

43 - Seat

44 - Headlights

52 ASC 100


Locker 33

Designed for first-aid kit etc.

Back Mirrors 34

When working within a restricted space or during trans-portation you may turn the back mirrors by 90° from theiroperating position A to transportation position B.

! CAUTION!

Keep the back mirrors clean & properlyadjusted!!!

Screen Washer Tank 38

Two pumps integrated inside the tank are used to washthe windscreen and rear screen.

! CAUTION!

Refill the the tank with antifreeze ordrain before winter season!

53ASC 100


1

2

Driver Seat 43

SEAT ADJUSTMENT ELEMENTS:

Backrest angle adjustment – lift the lever to seting up ofthe backrest.

Seat firmnes adjustment –push the lever to the driver’sweight between 50 - 130 kg.

Longitudinal Move of the Seat – lift the lever and move theseat in longitudinal direction forward – backward.

Accumulator cutoff switch

Use cutoff switch to disconnect accumulator from theframe.

! CAUTION!

Use cutoff switch to disconnet the accu-mulator following the drive end!

Switch OFF the disconnector ALWAYSwhen washing the Machine!

54 ASC 100

2.8. How to Control and Use the Machine

2.8.1. Start the Engine

Before you start the engine,please turn ON the horn forwarning purposes. Confirmnobody is endangered due tothe engine started!

How to start the engine:

• Make additional fuel pumping via hand feed pump atthe engine (upon longterm Machine shutdown).

• Switch ON battery disconnector.

• Switch ignition box 6 key to pos. ”l” – engine lubricationlamps go ON 12, along with brake lamp 14, andcharge control lamp 13.

• Set the throttle controller 5 to slightly increased speed(1/4 of controller stroke).

• Switch ignition box key to pos.”ll” and start the engine(keep the key in pos. ”ll” only until the engine starts).

• When started, use the control lamps to monitor theengine function.

• When started, let the motor run at idle rpm of 1300÷1500 min-1 for a period of 3÷5 minutes.

Note:

Unless engine starts even after 3 attempts made – checkthe fuel system. Upon starting, watch the colour of ex-haust gases – the absence of blue or white fume indi-cates the fuel supply is insufficient.

55ASC 100


! CAUTION !

Do NOT start for more than 30 sec. Makeanother starting attempt only after 2minutes, and unless the motor startseven after 3 attempts, carry out trouble-shooting.

Charge control lamp and lubricationlamp must go off when the engine starts.Lubrication lamp must go off within 15sec.

Sharp speed increase or decrease isinadmissible – hazard of engine dam-age.

When started let the engine run at idlerpm of 1500 min–1 for a period of 3÷5minutes.

Do NOT let the motor run idle for over 10minutes – running idle for longer periodwill cause injectors clogged, piston ringsgummed, valves seized!

Unless liquid temp reaches min. 60 °C(140 °F) the engine will not be lubricatedsufficiently enough – do NOT run theengine at full capacity!

Starting will be interlocked:

When the controller 2 is in idle (neu-tral) position.

How to start using starter cables viaanother machine

Make sure the starting voltage of a boost-starting power supply is 24 V.

Follow unconditionally the sequence ofoperations given below!

1. Connect one (+) pole end of the cable to (+) pole ofdischarged accu.

2. Connect second (+) pole end of the cable to (+) accuof the machine used to boost-start.

3. Connect one (–) pole end of the cable to (–) pole ofaccu in the vehicle used to boost-start.

4. Connect second (–) pole end of the cable to a sectionof the started Machine fix-connected to the engine (orto the cylinder block itself)

! CAUTION!

When started, disconnect the startercables in reverse order.

When aided by Starter Unit with noaccus connected, do NOT disconnect theUnit before the Machine accumulator isconnected.

56 ASC 100


Do NOT connect (–) pole ofthe cable to (–) pole of dis-charged accu of the startedMachine! Hazard of strongsparking when starting,followed by an explosion ofgases generated by accumu-lator.

Non-insulated sections of thestarter cables’ gripping col-lets may NOT contact eachother!

Make sure starter cableconnected to (+) pole of accudoes NOT come into contactwith electrically conductiveparts of the Machine – short-circuit hazard.

NEVER bend yourself over theaccumulators - hazard ofelectrolyte burn!

Exclude any presence offlammable sources (freeflame, smoking cigarettes,and alike).

NEVER verify voltage pres-ence within a conductor viasparking through the Machineframe!

How to start at low temperature.

• Starting at ambient temperature below 0°C (32°F) willrequire different way of starting with the use of starterfilling:

• Adjust the throttle to half-speed, and when starting theengine a second person will inject measured quantityof starter filling into the air filter.

! CAUTION !

Observe strictly safety & hygienic instruc-tions of manufacturer when using starterfilling. Non-observance of these instruc-tions may lead to engine or propertydamage, health and life hazards topeople present.

NEVER use volatile, easily ignitable refillwhen starting inside tunnels or mines.Always ask for safety guidelines whenusing starter refills under these condi-tions.

2.8.2. Travel & Reversing

Use acoustic alarm to communi-cate drive away of the Machine,and wait long enough so thepersons present may leave in

time the adjacent area of the Machine(area under the Machine) !

Before drive away you must confirm thearea in front of and behind the Machineis free, and that no persons are foundthere!

• Turn OFF the travelling speed controller 4 – i.e.switched to operating speed.

• Use throttle controller 5 to adjust engine rpm required,i.e. ca 1800.min–1).

• Confirm vibration switch 3 is not ON, control lamp 19is off.

• Deflect travel controller 2 from idle (neutral) pos. to arequired direction – small deflection of the controller= slow speed and vice versa. Following travel control-ler 2 deflection the brake indicator lamp 14 will go off.

• Reversing – shift the controller 2 in opposite directionvia its idle position.

EMERGENCY STOPPING

Use this way of stopping incase of defect, when themachine cannot be stoppedby moving travel control (2) toneutral position. Shut downthe engine by switch key off.

! CAUTION !

Turn ON the controller 4 – transportspeed - you may do so while driving theMachine by an adjusted terrain (forma-tion level) “Hare” symbol will light up.Turn the controller ON only with theMachine not idle..

In case of lack of pulling force, switchOFF the transport speed controller.

NEVER switch OFF the controller 4 athigh speed due to high slowdown alongwith impact within hydraulic system.Turn OFF the controller 4 at low speed orwith the Machine at rest!

Engage operating speed via turning OFFcontroller 4 before driving by steepincline!

Do NOT apply throttle 5 to control Ma-chine velocity.

57ASC 100


NEVER drive in cross direc-tion at the hillsides of highslope! Drive perpendicular toa hillside!

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2.8.3. Travel with vibration

• Turn OFF controller 4, thus switching to operatingspeed mode.

• Use Preselector 21 to select vibration amplitude.

• Use throttle controller 5 to adjust maximal speed.

• Start moving the Machine and turn ON the switch 3 tostart the vibrations - control lamp 19 lights up – runnerbegins vibrating.

• Press and relieve button 3 to stop the vibration.

59ASC 100


2.8.4. Stop the Machine & the Engine

• Use switch 3 to turn OFF the vibration – control lamp19 goes off.

• Use controller 2 to stop the Machine – parking brakeis enabled; lamp 14 lights up.

• Use controller 5 to lower the speed to engine idle.

• Switch ignition box key 6 to pos. “0” and take it out –close the ignition box cap.

! CAUTION !

Do NOT stop hot engine instantly, insteadlet it idle for a period of 3 minutes.

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2.8.5. Machine Shutdown

• Stop the Machine.

• Cut off battery disconnector.

• Clean the Machine (scraper, tyres).

• Make overall inspection of the Machine and repair anydefects caused during operation.

• Confirm tyres have sufficient pressure.

• Put Scotch blocks to the wheels and uncoupled-axle.

• Lock the instrument covers or the cab and the doorbeneath driver control stand.

Stop the Machine on flat,paved surface

Confirm no natural hazard(landslide, potential of delugedue to any floods, etc.) existsat the location where theMachine is parked and shutdown.

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1

2

2.8.6. How to lift driver control standand bonnet

• Unscrew driver control stand nuts.

• Open cover on the left side underneath the drivercontrol stand. Remove pump handle 1.

• Lose a valve 2 and put the handle it into the pump, liftdriver control stand and the bonnet together.

• Use valve to lock the bonnet in its position. Refer to

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• Use valve to lock the cab in its position. Refer to

• Open the valve 2 before lowering.

• Use valve to make the cab descend. Refer to

! CAUTION !

Screw the driver controlstand when tilted.

• Use valve to make the bonnet descend. Refer to

63ASC 100

Operating instructions2.9. Machine Transportation

2.9.1. Machine transportation by itsown axle

• Move the roller by its own axle when moving within aworking site outside public roads.

! CAUTION !

Transport speed – you may switch ONcollector (4) when crossing with theMachine by finished road.

In case of long transportation distances,please make 1-hour cooling breaks every3 hours. Non-observance of this advicewill put in jeopardy of Machine damagethat the manufacturer will in no and anycircumstances bear responsibility for.

Follow those safety measuresspecified for the work sitewhen shifting the Machine.

2.9.2. Machine transportation bypublic road

! CAUTION!

The basic construction of the Machine isNOT fitted for transportation by its ownaxle using public road. This type oftransportation is prohibited.

• Transport the Roller by public road using a carrier. Ifrequired, dismantle the Cab, refer to Section 2.9.4.

When driving onto the carri-er, we recommend to putrubber bands or woodenplanks, etc. under the runner.

Make sure the carrier de-signed for the transport isbraked when loading andunloading, as well as me-chanically locked agaisntundesired moves using theScotch blocks (2).

A person that guides theMachine must communicatewith the Driver using speci-fied intercommunicationsignals, (refer to Section2.2.5), this guiding personmust always stay at one placeoutside the reach of theMachine and outside thecarrier. Guiding person mustremain within Driver’s field ofsight (in visual contact)throughout the entire periodof driving the Machine ontothe carrier and driving downfrom the carrier.

When driving onto and downfrom the carrier all the per-sons aside from MachineDriver must go away as far asto avoid being hit by a fallingMachine.

Fix the Machine to the carriervia the clamps (tie-offs) (1) atthe rigging points! By riggingpoints we mean front & rearslings, front & rear pullinghitches, and sling holes in therunner frame sidewalls.

Adhere to the Motor VehicleConstruction and Use Regula-tions when transporting vialand routes.

NO persons may stay on theMachine, driver control standor carrier loading area duringMachine transportation.

Fixing the Machine on the carrier.

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2.9. Machine Transportation

3

1

12

2.9.3. How to load the Machine

• Use loading platform or crane loading to load theMachine onto the carrier.

• When loading with crane the Roller is fitted with slings(lifting eyes) – refer to the Fig. for slinging method.

• Before lifting the Roller, please lock the Machine jointagainst being turned slightly.

How to lock the joint:

• Unlock and pull out the journal 1.

Do NOT enter underneathhanging load!

Upon completion of loading,return the safety arm back toits initial position.

Follow provisions in forcewhen loading/unloading.

Apply adequate, intact rig-ging of sufficient loadingcapacity.

Use only those lifting eyes(mounting lugs) on the Ma-chine designed specificallyfor slinging.

Only a trained slinger maycarry out the slinging.

• Fold down the arm 2 and lock with the journal 1 andsafety lock 3.

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2.9.4. Towing of Machine

• In case of failure the Machine can be towed to adistance necessarily needed. For this reason theMachine has been fitted with two eyes on the runnerframe 1 and on the Machine frame 2.

! CAUTION !

Make sure the Machine is attached toboth of the eyes when being towed!

• The Machine may also be pushed against the crossarm of runner frame, or against the rear section of theMachine frame (tank). Be careful not to damage thebonnet.

Use unimpaired towing ca-bles or towing bars of suffi-cient capacity - dimensionedto weight 1.5 times higherthan weight of the towedmachine. It is not permitted touse chains for towing.

No persons can be present onthe machine with non-work-ing engine.

It is necessary to keep thedeviation from the straighttowing angle as little aspossible. Maximum deviationis 30 degrees.

The towing machine shouldbe equal by size to the dam-aged machine. It must besufficiently powerful (towingpower), heavy and havesufficient brake effect.

When towing downhill usinga cable, it is necessary toconnect another towingmachine to the rear part ofthe damaged machine. Thiswill prevent uncontrolledmovement of the damagedmachine.

The bogged roller may bepulled out for short distance,if the engine is running andthe driving unit and steeringare functional. The drive onthe towed roller must steerthe roller in the draggingdirection.

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2.9. Machine Transportation

2.9.5. Dismantle the Cab and theROPS - Option

How to dismantle the ROPS

• Hook up the frame by loops.

• Remove bolts and remove frame.

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How to dismantle the Cab

• Loosen the bolts that attach the Cab to the platform.

• Disconnect the connector between steering columnand the windscreen to cut out the wiring.

• Disconnect the screen washer wiring and the hosesleading to the screen washing nozzles. Sling the Cabby the mounting lugs and put it by.

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2.10. Special Conditions for the Machine Application

2.10.1. Vibration driving on compactedand hard materials

During vibration driving a loss of contact between therunner and the compacted material (so called vibro-stroke) may occur due to the impact of high level of subgrade material compaction, or due to vibration driving onhard materials (e.g. stony loose material). This state willshow through the increased vibration energy transfer tothe Machine frame and Driver control stand. Increasetravel velocity or change Machine vibration parameters(applying lower amplitude) to partially remove this effect.Higher vibration energy transfer to the Driver control standmay also be expected when increasing the level of subgrade material compaction.

In case it is urgent to operatethe Machine under the condi-tions with the potential ofOperator exposed to highervibrations, then the MachineUser is liable to adapt theoperating procedures so as toavoid driver’s health hazard.

Note:

When vibration driving on a different sub grade materialthan stated in ”Specifications Manual”- Hygienic Data,then the emission figures of vibration acceleration will bedifferent.

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PIGA 23ACINRA 64ACINRA

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LORTSAC 23HWANIPSYH 64HWANIPSYH

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2.10.2. Machine use under heavyclimatic conditions

2.10.2.1. Machine operation under lowtemperatures

Compacting during winter season depends on fine par-ticle contents and water contents within a soil undercompaction. With the temperature going down belowfreezing point the earth becomes more solid and harderto compact.

When compacting at the temperatures below 0 °C (32 °F)is required, you may compact dry soils (or stony loosematerials) or perform fast compaction of non-frozenmaterials (ahead of earth becoming frozen through).

Make the Machine ready for operation under low tem-peratures:

• Check the engine coolant concentration.

• Exchange oil in the engine with the one recommendedfor a given range of low ambient temps.

• Apply hydraulic oil of corresponding cinematic viscos-ity.

• Change oil in runner gearbox with the one recom-mended for a given range of gearbox temperatures.

• Use winter fuel.

• Confirm the accumulators are charged.

Sound condition of accumulator is the prerequisite ofgood starting under low temperatures. Warm up theaccumulators to ca 20 °C (68 °F) (via removing accumu-lators and storing them in a dry warm room) to lower limittemp for starting by 4 to 5 °C (39,2 to 41 °F).

Hazard of engine damaged when engine(cooling liquid) operating temperatureremains constantly below 60 °C (140°F).

Use the Machine at its full power only after heating thefillings to their operating temperatures (coolers possibleto be partially covered as well).

! CAUTION !

NEVER start the Machine at ambient temperatures below +2 C (36 °F) when the hydraulicsystem is filled with HV 100 oil.

When starting at ambient temperatures below –8 °C (18 °F) is required for a period of onemonth or more, please exchange oil in the hydraulic system with HV 46 viscosity class oil.

And with HV 32 class oil (e.g. BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.) at ambient tem-peratures below –13 °C (9 °F).

NEVER start the Machine below –23 °C (–9 °C) with no preheating of fillings made.

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2.10. Special Conditions for the Machine Application

2.10.2.3. Operating the Machine at highaltitudes

Engine power will decrease with the altitude rising. Thisis given by the reduced atmospheric pressure and induc-tion air specific mass.

Altitude m (ft) Decrease in Power %

0 0 0

500 (1640) 3

1000 (3281) 6

1500 (4921) 10

2000 (6562) 15

2500 (8202) 21

3000 (9843) 28

When black smoke is generated by the engine at highaltitudes (above 1500 m), please contact your enginemanufacturer service department to make adjustment toyour injection pump to fit these operating conditions.

! CAUTION!

Engine power will be affected by theenvironment where the Machine is oper-ating, as per Sections 2.10.2.1. & 2.10.2.3.

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2.10.2.2. Machine operation under hightemperatures and humidity

Engine power will lower with air temperature or humidityincreasing. Since both of the factors that lower engineperformance are independent on each other, their effectscan be described as follows:

- With every 10 °C (50 °F) of increased temp the powerwill drop by up to 4 % (at constant humidity)

- With every 10 % of increased RH the power will dropby up to 2 % (at constant temperature).

Any engine (cooling liquid) operatingtemperature over 100 °C (212°F) maydamage the motor.

At high temperatures when hydraulic oil temp is constant-ly round 90 °C (194 °F), we recommend to exchangehydraulic oil with denser one of 100 mm2/s cinematicviscosity class (BP BARTRAN HV 100, ESSO UNIVISN100, etc.)

! CAUTION!

When hydraulic system is filled with oilclass:

HV 46, then oil max. Limit tempera-ture is 80 °C (144 °F)HV 32, then oil max. Limit tempera-ture is 70 °C (158 °F)

When operating under extreme tempera-tures when cooling liquid or hydraulic oiltemperatures reach max. Limit tempera-tures, you may remove fender aprons ofthe bonnet to increase cooling capacityof the Machine Cooling System, andhence improve hot air removal from theengine bay.

2.10.2.4. Machine operation atextremely dusty environment

! CAUTION!

Cut short the intervals of cleaning andreplacement of air filter elements whenoperating under extremely dusty condi-tions; shorten the intervals of cleaningthe engine cooler, hydraulics, or ofreplacing Cabin dust filter.

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Operating manual E - SimmaRentsimmarent.cl/pdf/manuales/ammann/asc100/asc100.pdf · ASC 100 7...

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