Ammann ASC 200 Series User manual

Operating manual E
ASC 200 and ASC 250
CUMMINS TIER III © 1/ 2008

2ASC200/ASC250
Preface
Information, specifications, and recommended operation and maintenance instructions conta-
ined in this publication are basic and final information at the time of the printing of this publication.
Printer’s errors, technical modifications, and modifications of figures are reserved. All dimensions
and weights are approximate and, therefore, not binding.
Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to
inform the machine user. If you identify any differences between the machine operated by you
and the information contained 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.

3ASC200/ASC250
Congratulations on your purchase of an AMMANN road roller. This modern compaction device
is characterised by simple operation and maintenance and is the product of many years of
AMMANN experience in the field of road roller engineering. In order to avoid faults due to
improper operation and maintenance we request that you read this operating manual with
great care and keep it for later reference.
With kind regards,
This manual consists of:
I. Specification manual II. Operating instructions III. Maintenance manual
The following explanations serve to familiarise the machinist (operator) with the roller and to
support him during handling and maintenance. It is therefore absolutely necessary to provide the
operator with these instructions and to ensure that he reads them carefully before using the road
roller. This aids 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. It
reduces repair costs and down time.
AMMANN accepts no liability for continued safe functioning of the road roller if it is incorrectly
operated and / or operating modes are employed which represent improper use.
Spare parts must meet AMMANN technical specifications. These requirements are fulfilled if only
original AMMANN spare parts are used.
These instructions must always be kept available on the equipment.
Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují
+ 420 491 476 111 | Fax + 420 491 470 215 | [email protected] | www.ammann-group.cz

4ASC200/ASC250

5ASC200/ASC250
! NOTICE !
As used in this operating manual, the terms „right“, „left“, „front“ and „rear“
indicate the sides of the machine moving forward.

6ASC200/ASC250
Content
Content ..................................................................................................................................................... 6
1. SPECIFICATION MANUAL .....................................................................................................................11
1.1. Basic Data ...............................................................................................................................................12
1.2. Dimension Chart ..................................................................................................................................... 14
1.3. Technical Data ......................................................................................................................................... 22
1.3.1. Weights .............................................................................................................................................................. 22
1.3.2. Travel Parameters.............................................................................................................................................. 25
1.3.3. Vibration ............................................................................................................................................................. 27
1.3.4. Engine ................................................................................................................................................................ 28
1.3.5. Axle..................................................................................................................................................................... 29
1.3.6. Brakes ................................................................................................................................................................ 29
1.3.7. Steering .............................................................................................................................................................. 30
1.3.8. Vibratory Drum ................................................................................................................................................... 30
1.3.9. Hydrostatic Drive of Travel ................................................................................................................................. 31
1.3.10. Hydrostatic Drive of Vibration ............................................................................................................................ 31
1.3.11. Hydraulic Oil Tank .............................................................................................................................................. 32
1.3.12. Lifting and lowering of the Hood and the Cabin ............................................................................................... 32
1.3.13. Cooling System of Hydraulic Oil ....................................................................................................................... 32
1.3.14. Fluids .................................................................................................................................................................. 33
1.3.15. Electrical Installation .......................................................................................................................................... 33
1.3.16. Safety Devices ................................................................................................................................................... 33
1.3.17. Hygienical Data.................................................................................................................................................. 34
1.3.18. Requirements of Traffic Regulations ................................................................................................................. 34
1.3.19. Accessories ........................................................................................................................................................ 35

7ASC200/ASC250
SPECIFICATION MANUAL
2. OPERATING INSTRUCTIONS ................................................................................................................. 39
2.1. Safety Regulations ..................................................................................................................................41
2.1.1. Safety Regulations and Instruction for Operation of the Machine ................................................................... 41
2.1.1.1. Beginning of Compaction Works ...................................................................................................................... 41
2.1.1.2. Operation in an imperiled area ......................................................................................................................... 41
2.1.1.3. Work safety precepts on behalf of the operator ................................................................................................ 42
2.1.2. Requirements for the competence of the driver ............................................................................................... 43
2.1.3. The driver’s duties ............................................................................................................................................. 43
2.1.4. Forbidden actions .............................................................................................................................................. 45
2.1.5. Safety signs and symbols marked on the machine .......................................................................................... 46
2.1.6. Hand Signals ..................................................................................................................................................... 50
2.2. Environmental and Hygienical Principle ...............................................................................................53
2.2.1. Health rules ........................................................................................................................................................ 53
2.2.2. Ecological rules ................................................................................................................................................. 53
2.3. Conservation and Storing ......................................................................................................................54
2.3.1. Short-term storage of 1 to 2 months .................................................................................................................. 54
2.3.2. Conservation and storage for more than 2 months.......................................................................................... 54
2.3.3. De-conservation and inspection of brand new machines ............................................................................... 55
2.4. Liquidation of the Machine After Termination of Its Service Life ..........................................................56
2.5. Description of the machine ....................................................................................................................57
2.6. Controls and control devices .................................................................................................................58
2.7. Controlling and operation of the machine .............................................................................................86
2.7.1. Starting the engine ............................................................................................................................................ 86
2.7.2. Travel and reversing without vibrations ............................................................................................................ 89
2.7.3. Travel with vibration ........................................................................................................................................... 91
2.7.4. Stopping the machine and engine.................................................................................................................... 92
2.7.5. Emergency stopping .......................................................................................................................................... 93
2.7.6. Dead parking of the machine ............................................................................................................................ 94
2.7.7. Troubleshooting according to flashing codes .................................................................................................. 95
2.7.8. ATC function....................................................................................................................................................... 96
2.7.9. Blade .................................................................................................................................................................. 97
2.7.10. Lifting driver’s stand and bonnet ..................................................................................................................... 101
2.8. Shifting the machine (transport) .......................................................................................................... 105
2.8.1. Transporting the machine on its own .............................................................................................................. 105
2.8.2. Transporting the machine on public roads ..................................................................................................... 106
2.8.3. Loading the machine ....................................................................................................................................... 107
2.8.4. Dismantling cabin and ROPS frame ............................................................................................................... 109
2.9. Using the machine under special conditions ...................................................................................... 110
2.9.1. Towing .............................................................................................................................................................. 110
2.9.2. Driving with vibrations on compacted and hard material ............................................................................... 115
2.9.3. Using the machine under heavy weather conditions..................................................................................... 116
2.9.3.1. Operating the machine under low temperature ............................................................................................. 116
2.9.3.2. Operating the machine at higher temperature and humidity ......................................................................... 117
2.9.3.3. Operating the machine in higher altitude ....................................................................................................... 118
2.9.3.4. Operating the machine in extremely dusty conditions ................................................................................... 118
2.9.4. Filling tyres with water ..................................................................................................................................... 119
2.9.5. Installing air conditioner .................................................................................................................................. 120

8ASC200/ASC250
Content
3. MAINTENANCE MANUAL ..................................................................................................................... 123
3.1. Safety Standards at Lubrication and Maintenance .............................................................................. 125
3.1.1. Safety during maintenance ............................................................................................................................. 125
3.1.2. Fire safety during changing contents ............................................................................................................. 125
3.1.3. Environmental and health regulations ........................................................................................................... 126
3.1.3.1. Health regulations ........................................................................................................................................... 126
3.1.3.2. Environmental principles................................................................................................................................. 126
3.2. Specification of fluids .......................................................................................................................... 127
3.2.1. Engine oil ......................................................................................................................................................... 127
3.2.2. Fuel................................................................................................................................................................... 128
3.2.3. Coolant ............................................................................................................................................................. 128
3.2.4. Hydraulic oil ..................................................................................................................................................... 129
3.2.5. Gearbox oil ....................................................................................................................................................... 130
3.2.6. Lubricating grease ........................................................................................................................................... 130
3.2.7. Windshield washer liquid ................................................................................................................................ 130
3.3. Fills .................................................................................................................................................. 131
3.4. Lubrication and Maintenance Chart ..................................................................................................... 132
3.5. Lubrication Chart ................................................................................................................................. 134
3.6. Individual Operations of Maintenance ................................................................................................. 135
Every 20 Hours or Daily ........................................................................................................................ 136
3.6.1. Checking the amount of oil in the engine ....................................................................................................... 136
3.6.2. Checking cooling liquid of the engine ............................................................................................................ 137
3.6.3. Checking oil in the hydraulic tank ................................................................................................................... 138
3.6.4. Crankcase breather tube................................................................................................................................. 139
3.6.5. Checking of the condition ventilator and belt ................................................................................................. 140
3.6.6. Checking the vacuum valve of the air cleaner ............................................................................................... 141
3.6.7. Checking fuel level .......................................................................................................................................... 142
3.6.8. Cleaning the water separator.......................................................................................................................... 143
3.6.9. Checking warning and control devices .......................................................................................................... 144
Every 100 Hours.................................................................................................................................... 145
3.6.10. Checking the tyre pressure ............................................................................................................................. 145
Every 250 Hours or Once in 3 Months ................................................................................................. 146
3.6.11. Checking the engine inlet piping .................................................................................................................... 146
3.6.12. Checking of the condition ventilator and belt ................................................................................................. 147
3.6.13. Checking the cooling circuit of the engine ..................................................................................................... 148
3.6.14. Checking batteries ........................................................................................................................................... 149
3.6.15. Checking the function of vacuum switch of the air cleaner ............................................................................ 151
3.6.16. Lubrication of the machine .............................................................................................................................. 152
3.6.17. Checking oil in the vibrator.............................................................................................................................. 155
3.6.18. Checking oil in gearboxes .............................................................................................................................. 156
Every 500 Hours or Once in 6 Month ................................................................................................... 158
3.6.19. Engine oil and the filter exchange .................................................................................................................. 158
3.6.20. Engine fuel filter exchange.............................................................................................................................. 160
3.6.21. Checking cooling liquid ................................................................................................................................... 162
3.6.22. Checking tightening of wheel bolts ................................................................................................................. 162

9ASC200/ASC250
SPECIFICATION MANUAL
Every 1000 Hours or Once a Year ......................................................................................................... 163
3.6.23. How to check tightening pulley and belt of the engine .................................................................................. 163
3.6.24. Exchanging oil in gearboxes .......................................................................................................................... 164
3.6.25. Checking the damping system ........................................................................................................................ 166
3.6.26. Cleaning the fuel tank...................................................................................................................................... 167
Every 2000 Hours or Every 2 Years ....................................................................................................... 168
3.6.27. Oil exchange in the vibrator ............................................................................................................................ 168
3.6.28. Exchanging hydraulic oil and filter.................................................................................................................. 168
3.6.29. Cleaning of the suction strainer of lifting and lowering of the bonnet and the driver’s post......................... 173
3.6.30. Exchanging the engine cooling liquid ............................................................................................................ 174
3.6.31. Checking torsion vibration damper of the engine .......................................................................................... 176
3.6.32. Checking coolant in the drum ......................................................................................................................... 177
Maintenance - As Needed ..................................................................................................................... 178
3.6.33. Exchanging cleaner elements of air cleaner .................................................................................................. 178
3.6.34. Cleaning the engine radiator and hydraulic oil radiator ................................................................................ 180
3.6.35. Cleaning the air cleaner of cabin ventilation .................................................................................................. 181
3.6.36. Cleaning the machine ..................................................................................................................................... 181
3.6.37. Adjusting scrapers ........................................................................................................................................... 182
3.6.38. Checking and tightening bolted joints ............................................................................................................ 183
3.7. Defects .................................................................................................................................................. 187
3.8. Appendixes ........................................................................................................................................... 188
Wiring scheme ............................................................................................................................................................... 188
Hydraulic circuit - ASC 200/250 - Inter - wheel differential lock .................................................................................. 192
Hydraulic circuit - ASC 200/250 - Interaxle differential lock ATC ................................................................................ 194

10 ASC200/ASC250