Ammann ASC 110 Instruction manual

Book ID: 4-P08282CU
ASC 110
Cummins
-EN
Workshop manual

ASC 110
Cummins Tier 3
02/2012
2823164
Workshop manual
ENEdition
From Serial No.
Single drum roller

1ASC 110
WORKSHOP MANUAL
Preface
Information, specications, and recommended instructions for the assembly and disassembly of individual
components and parts of the machine contained in this publication are basic and nal information at the time
of the printing of this publication. Printer’s errors, technical modications, and modications of gures are
reserved. All dimensions and weights are approximate and, therefore, not binding.
Ammann Czech Republic a.s. reserves the right to perform modications without obligation to inform the
machine user. If you identify any dierences between the machine operated by you and the information con-
tained in this publication, contact your local dealer.
Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic
a.s.
Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují
%+ 420 491 476 111 | Fax + 420 491 470 215 | [e-mail] | www.ammann-group.com

2 ASC 110

3ASC 110
WORKSHOP MANUALContents
CONTENTS .......................................................................................................................................................3
1. INTRODUCTION......................................................................................................................................5
2. REPAIR SAFETY INSTRUCTIONS ...........................................................................................................9
3. SPECIFICATION MANUAL....................................................................................................................15
4. REMOVING THE ENGINE......................................................................................................................25
5. DRUM DISMOUNTING .........................................................................................................................47
6. ARTICULATED JOINT ...........................................................................................................................73
7. REMOVAL OF PUMPS, CENTO CLUTCH ..............................................................................................87
8. STEERING CYLINDERS .........................................................................................................................99
9. CONTROLS ..........................................................................................................................................105
10. THE DRIVER‘S STATION ASSEMBLY..................................................................................................109
11. DISASSEMBLY OF HEATER ................................................................................................................119
12. ELECTRICAL INSTALLATION..............................................................................................................129
13. REMOVAL OF ROPS FRAME...............................................................................................................137
14. ASSEMBLY OF SEGMENTS.................................................................................................................141
15. DISASSEMBLY OF WHEEL..................................................................................................................149
16. REMOVAL OF HYDRAULIC MOTORS ................................................................................................153
17. FILLING HYDRAULIC OIL ...................................................................................................................163
18. DISASSEMBLY OF LEVEL GAUGE......................................................................................................167
19. DISASSEMBLY OF THE FLOATER.......................................................................................................171
20. ELECTRIC INSTALLATION ..................................................................................................................179
21. HYDRAULIC.........................................................................................................................................189
22. DIAGNOSTICS OF HYDRAULIC SYSTEM DEFECTS..........................................................................195
23. CHECK THE TIGHTENING OF BOLTED CONNECTIONS....................................................................203
24. HAND SIGNALS...................................................................................................................................207

4 ASC 110

5ASC 110
WORKSHOP MANUAL
1. Introduction

6 ASC 110
1. Introduction
The roller should be used under conditions dened in the Czech Standard (CSN) IEC 721-2-1 (038900): WT, WDr, MWDr, i. e. in mild, dry
warm and dry hot weather in the range of temperatures from -15 °C (5 °F) to 45 °C (113 °F).
If the machine is used incorrectly, by untrained operators or for other purpose than stipulated above, there is a danger of an accident
or damage to the equipment.
Some expressions are used in the manual for better orientation, i. e. right, left, forward, backward – in the sense of the machine moving
forward.
This Service Manual splits into separate chapters, it includes technical data and assembly data, adjusting
guidelines, and instructions to use special tools, jigs and aids.
The major purpose of this Workshop Manual is to provide basic information on disassembly, assembly and
service repairs of the Machine’s main groups.
Machine group identication in this Manual corresponds to the Spare Parts Catalogue.
Before the assembly, itself, we recommend to always mark the parts disassembled, and this due their reas-
sembly, and to blind all the holes of individual parts of the hydraulic system so to prevent any contamination
of the hydraulic circuits.
When you install individual parts into the Machine, please tighten individual bolts or nuts as per the torque
tables (Annex) unless otherwise stated in the text.
ALWAYS observe safety instructions and precautions mentioned in Chapter 2.
Manufacturer improves continuously his products based on operation experience and latest knowledge. Con-
sequently, Manufacturer reserves the possibility of changes depending on development, and this against the
illustrations, descriptions, procedures or design patterns given in this Manual.

7ASC 110
WORKSHOP MANUAL
! NOTICE !
As used in this operating manual, the terms„right“,„left“,„front“ and„rear“ indicate the sides of
the machine moving forward.
SYMBOLS OF THE SAFETY NOTICES IN THE MANUAL:
The notice warns of a serious risk of personal injury or other personal hazards.
The notice warns of possible damages to the machine or its parts.
The notice warns of the necessity of environmental protection.
282N100TA
REAR
LEFT RIGHT
FRONT

8 ASC 110

9ASC 110
WORKSHOP MANUAL
2. Repair safety instructions

10 ASC 110
2. Repair safety instructions
The following safety instructions must be observed by all repairing the machine!
Repairs may be carried out by skilled, trained and experienced personnel only and/or by Ammann SERVICE and dealers.•
When performing repairs, always use our shop manual. Special instructions for the assembly work are given in individual chapters
•
of the manual.
Before putting the machine into operation acquaint yourselves with the machine control as given in the “Operating instructions“
•
and make sure that you understand well all outt of the machine.
Do not use the machine if you do not fully understand all controls and until you know how the machine works.
•
Know the area where you will work.
•
Do not make any redesign or modications on the machine because you could decrease safety of the equipment.
•
Original parts and accessories have been designed especially for this machine.
•
Installation and usage of spare parts not supplied by the manufacturer of the machine or not authorized by him can have negative
•
eects on operational characteristics and safety operation of the machine.
Safety precautions when repairing and inspecting the equipment
Wear work clothe and boots.•
Use gloves when handling oils, fuel or coolant.
•
Protect your eyes with goggles or a shield when handling the battery.•
Place the equipment on a at and rm surface before starting repair. Secure the equipment against spontaneous movement.•
Secure the frame of the equipment and the drum against mutual rotation using a safety pin and a draw bar.•
Before starting work remove the ignition key, disconnect the batteries and let hot parts cool down.
•
Attach a warning note“Equipment out of work“ to the steering wheel and leave it there for the duration of service work.•
Wash the equipment thoroughly. If you use steam, do not expose electrical components and insulation directly to stem jet, or else
•
cover them beforehand.
Keep all parts absolutely clean when dismantling, mounting, and servicing each assembly. Protect removed parts from getting
•
soiled.
Clean the surface of dismantled parts and provide for adequately dust-free working conditions and a needed lay-o area.•
Be careful when handling cleaning agents. Do not use petrol or other easy inammable materials for cleaning.
•
Dry the cleaned parts and immediately cover with anticorrosive protective oil- never install corroded parts!
•
Tools, hoists, safety equipment of the supports, and other additional items must be serviceable and in good condition.
•
Use hoists and fasteners (ropes, chains) that have sucient carrying capacity and are in good condition.
•
Make sure that there is enough fresh air supply when starting up the equipment in an enclosed area.
•
Before placing the equipment into operation make sure there nobody on the equipment or close by. The start of the equipment
•
must always be announced with an audible alarm , also after any pause in operation before the equipment is restarted. Persons
present on the equipment and dangerously close by must leave the equipment after such alarm has been sounded.
Do not adjust moving equipment.
•
When working (adjusting) on the running engine, avoid touching hot and rotating parts. During work on the running engine,
•
another person must be present that can easily access the emergency switch and must be in contact at all times with the person
performing the adjustment, to be able to switch o the engine immediately when necessary.
Use only prescribed makes of motor, gear and hydraulic oils and coolants.
•

11ASC 110
WORKSHOP MANUAL
Safety instructions for work on hydraulic circuits
make sure that no hydraulic circuit is under pressure before dismantling it. Hydraulic oil leaks under pressure may injure your skin•
and cause a serious injury.
Mark all parts, hoses and pipes before removing them.•
Do not operate hydraulic generators and hydraulic motors without oil.
•
There is danger of being scalded when handling hot oil.
•
Do not warm oil to temperatures above 160 °C - oil or its fumes may ignite.
•
For cleaning and wiping hydraulic parts use such textiles that do not leave lint.
•
When reassembling parts use hydraulic oil - not grease - as lubricants.
•
Clean screws and bolts carefully before installation, wash hoses and pipes and blow them o using compressed air.
•
Always use new packing in seals.
•
Fill new aggregates with hydraulic oil before installation.
•
Rinse hydraulic circuit after replacing the hydraulic device, clean the hydraulic tank as well.
•
Replace the oil lter cartridge.
•
Fill the hydraulic circuit with pure oil of the prescribed viscosity, but only when the engine has been stopped!
•
Wipe o overow oil.
•
Check connections for tightness, whether they leak oil, before applying pressure to the system.
•
Do not adjust safety valves.
•
After all work has been nished, recheck all connections and replace all safety elements
•
After nishing the work install again all protective elements.
•
After putting the machine into operation, check
Oil level in the hydraulic tank.•
Check up lling pressure in hydraulic generators in case they are replaced as well as pressure in safety valves.
•
Carry out the measurement at temperature of 40 °C (104 °F).
•
Safety instruction for work on the fuel system
Mixtures of petrol and diesel (winter fuel) are as inammable as petrol.
Do not refuel in closed areas.
-
Wipe o overowed fuel.
-
Do not smoke when working on the fuel system and do not use naked light! There is a danger of re!-

12 ASC 110
2. Repair safety instructions
Safety instruction for work on electrical wiring
Disconnect the battery when carrying out any repair in the charging circuit to avoid incidental short-circuits.•
When dismantling, rst disconnect the cable from the negative pole (-), then from the positive one (+).
•
Do not disconnect batteries when the engine is running!
•
Connect the “minus“ pole of the battery to the chassis and the “plus“ pole to lead “B+“ from the alternator. In case of the reverse
•
connection the whole semiconductor device could get destroyed.
When starting with auxiliary external supply, do not disconnect such supply sooner than the battery of the machine is connected.
•
Watch out starting voltage of the auxiliary external supply (for 24 V).
Do not put the alternator into no-load run, i. e. with the wire disconnected from the“+“ terminal and connected“D+“ terminal.
•
Do not check the presence of voltage in the wire by sparking it on the chassis of the equipment.
•
Do not do anything that produces sparks.
•
When handling batteries, use protective rubber gloves and goggles.
•
Protect your skin and clothes from stains by electrolyte or lead particles.
•
When electrolyte gets into your eye, rinse it with a stream of water for a few minutes. Then see a doctor as soon as possible.•
When electrolyte stains your skin or clothes, take o your clothes, wash the stained area with soap water or with a solution of•
baking soda and water and see a doctor.
After taking electrolyte incidentally, drink as much milk or water as possible or a solution of magnesia and immediately see a do-•
ctor.
Never pour distilled water into the cells unless the operation of the machine or charging outside the equipment follows. In such
•
case the battery would self discharge increasingly.
Never add sulfuric acid (H
•2SO4)!
Do not overturn the batteries because electrolyte could run out of the degassing holes of the battery.
•
If acid (electrolyte) is spilled, rinse the place with water and neutralize it with lime.
•
When the batteries are being charged, hydrogen is released and it makes mixed with air, an explosive, easily combustible mixture.
•
Do not use open ame and do not smoke.
Welding on the machine
Before starting arc welding, disconnect all parts with semiconductors from electrical wiring, inclusive of machine electronics:•
it is necessary to earth both the supply and the machine that is being repaired,
•
secure the supply against moisture,
•
place ground terminal close to the welded joint.
•
when parts are welded or when the machine is in the suspended position, it is necessary to insulate the point of current transfer to
•
avoid current entering the hoist, or to use a non-conducting rope.
Seals
Always use new packing.•
You will receive packing kits as spares.
•

13ASC 110
WORKSHOP MANUAL
Tightening torque
Use a torque key for the right tightening torque.•
Fastening bolts and nuts of the given quality are tightened according to the table.
•
Quality of the bolt is shown visibly on the bolt head.
•
Tightening torque is given in tables.
•
Thread joints of hydraulic circuits are tightened according to tables.
•
The given tightening torque is valid for not oiled bolt thread.
•
Use new self-locking nuts only.
•
Environmental measures and health precautions
When repairing the machine, keep general principles of health protection and environment protection as well, and observe laws, regu-
lations, and guidelines related to these problems as applicable to the territory where the equipment is used.
Principles of hygiene
Oil products, coolants, battery acids, and paints including thinners can be harmful to your health and they can injure your organs•
seriously.
It is necessary to observe consistently safety and health instructions enclosed with the products and to use personal protective
•
aids when handling them.
Personnel in contact with these products during servicing are obliged to observe general principles of their health protection and
•
keep in mind safety and health guidelines as given by manufacturers of such products, especially the following:
protection of eyes and skin when working with batteries,
-
protection of the skin when handling oil products, paint, and cooling liquids,
-
workers should wash their hands properly after nishing their work and apply proper healing hand lotions,
-
when working with the cooling system it is necessary to observe instruction manuals supplied with the machine.
-
Oil products, coolants, batteries, and paint including organic thinners as well as cleaners and preservatives should be always stored
•
in their original packages properly labeled. Do not store such materials in unlabelled bottles and other vessels because there is
a danger of confusion. Confusion of food or drinks is especially dangerous.
If the skin or eyes are by chance stained or fumes are breathed, apply immediately rst aid. In case of incidental consumption of•
such products see your doctor immediately.

14 ASC 110
2. Repair safety instructions
Ecological precautions
Contents of machine systems and some parts of the machine can produce, when no longer in use, represent great risks to the•
environment.
The following products especially belong to this category:
both organic and synthetic lubricating materials, oils and fuel,-
coolants,
-
battery acids and batteries themselves,
-
cleaning agents and preservatives,
-
all removed lters and lter elements,
-
all used and discarded hydraulic and fuel hoses, rubber - metals and the other elements stained with the above products.
-
The above parts and materials must be handled, after they had been discarded, in accordance with valid national regulations on
•
environmental protection and according to directions concerning health protection.
When hydraulic liquids, fuel, cooling systems and their aggregates are being removed it is necessary to prevent their inltration
•
into the ground by using retaining vessels and by plugging the holes.
After leaks the place must be immediately dried with sawdust, Vapex, and such.
•
The contaminated earth must be removed to prevent further leakage. Then the soil and absorbing material must be disposed of
•
safely.
Fire precautions
The place where oil is being changed must not situated in an area where there is danger of explosion or re.•
Notices showing that smoking and open ame are not allowed must be installed there.
•
The handling area must have sucient dimensions to capture the amount of inammable liquid equal to the volume of the largest
•
vessel or the transport package.
Portable re-extinguishers must be available.
•
Oil and oil products should be handled in special vessels, e. g. metal barrels, cans, tin cans.
•
Transport vessels must be properly closed when stored.
•
The vessels should have one hole and should be always stored with the hole up and they must be secured against leakage.
•
The vessels must be labeled with indelible inscriptions showing their contents and burning power class.
•
THE STANDARD TOOLS FOR MAINTENANCE AND ADJUSTMENT ACCORDING TO THE NORM ISO 4510-1
THE SPECIAL TOOLS, ASSEMBLY JIGS SEE APPROPRIATE CHAPTERS OF THE WORKSHOP MANUAL.

15ASC 110
WORKSHOP MANUAL
3. Specication manual

16 ASC 110
3. Specification manual
Basic Data
Machine description
Single drum roller with an articulated frame with a front smooth
or padfoot steel driven vibrating drum and driven rear axle with
two treaded tyres. Steering using the articulated frame.
Machine application
ASC 110 rollers are suitable for medium and large-sized com-
paction works in transport construction (motorways, railways,
airelds), water resources construction (rockll dams), and
building construction (industrial zones, harbours), etc.
ASC 110 D roller with a smooth drum is suitable for the com-
paction of all kinds of soils. It is possible to be used for the
compaction of clay soils up to a layer thickness (after compac-
tion) of 25 cm (9.8 in), loam soils up to a layer thickness of 40
cm (15.7 in), mixed soils up to a layer thickness of 50 cm (19.7
in), sandy and gravel materials up to a layer thickness of 60 cm
(23.6 in), and rockll up to a layer thickness of 80 cm (31.4 in).
The maximum permissible grain size in a loose layer is 2/3 of the
layer thickness. The roller can also be used for compaction by
means of stabilisation.
ASC 110 D ACE roller with a smooth drum is suitable for the
compaction of all kinds of soils. It is possible to be used for the
compaction of clay soils up to a layer thickness (after compac-
tion) of 27 cm (10,6 in), loam soils up to a layer thickness of 45 cm
(17,7 in), mixed soils up to a layer thickness of 60 cm (23,6 in),
sandy and gravel materials up to a layer thickness of 70 cm
(27,5 in), and rockll up to a layer thickness of 100 cm (39,4 in).
The maximum permissible grain size in a loose layer is 2/3 of the
layer thickness. The roller can also be used for compaction by
means of stabilisation.
ASC 110 PD roller with a padfoot drum (synchronous knead-
ing and vibrating eect) is suitable for the compaction of clay
soils up to a layer thickness (after compaction) of 30 cm (11.8 in),
loam soils up to a layer thickness of 40 cm (15.7 in), and mixed
soils up to a layer thickness of 50 cm (19.7 in).
ASC 110 HD roller with an increased pulling force – smooth
drum.
ASC 110 HDPD roller with an increased pulling force – padfoot
drum.
ASC 110 HT roller for permanently dicult conditions and on
slopes above 30% – smooth drum.
ASC 110 HTPD roller for permanently dicult conditions and
on slopes above 30% – padfoot drum.
ASC 110 PDB roller with a padfoot drum and blade for spread-
ing materials. The blade is the optional equipment supplied per
order.
The machines are intended for operation in conditions of the
following types according to ČSN IEC 721-2-1 (038900):WT, WDr,
MWDr (i.e. mild, warm dry, hot dry with a limited temperature
range of from -15 °C (5 °F) to +45 °C (113 °F).
The standard type of the machine is not intended for road traf-
c. For more information, please contact your dealer.
Please ll in the following data:
(see Pin label, Label of the CUMMINS engine)
Type of machine
................................................................................................................
ICV/PIN (Serial number of the machine)
................................................................................................................
Production year
................................................................................................................
Type of engine
................................................................................................................
Serial number of the engine
................................................................................................................
Please refer to the data in the table below always when ap-
proaching the dealer or the manufacturer.