Ammann AV 70 X User manual

Book ID: 4-P06406CU
AV 70 X
Cummins
-EN
Operating manual

AV 70 X
Cummins Tier 3
09/2010
4062001
Operating manual
Edition EN
From Serial No.
Translation of Original Operating Manual
Articulated tandem roller

Edition EN
AV 70 X
Cummins Tier 3
06/2011
4062005
Operating manual
From Serial No.
Translation of Original Operating Manual
Articulated tandem roller

Místo a datum vydání / Place and date of issue / Ort und Datum der
Ausgabe:

1AV 70 X
406001
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 eld 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,
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.com
This manual consists of:
I. Specication 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 main-
tenance. 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 rst 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 specications. These requirements are fullled if only original AMMANN spare parts are
used.
These instructions must always be kept available on the equipment.

2 AV 70 X
Preface
Information, specications, and recommended operation and maintenance instructions 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 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.

3AV 70 X
! WARNING !
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:
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.
400101en
FRONT
REAR
RIGHT
LEFT

4 AV 70 X
Content
Content.............................................................................................................................................................4
1. SPECIFICATION MANUAL .......................................................................................................................9
1.1. Basic specication ................................................................................................................................10
1.2. Machine dimension scheme ................................................................................................................12
1.3. Technical data .......................................................................................................................................14
1.3.1. Weights......................................................................................................................................................................................................................14
1.3.2. Driving properties .................................................................................................................................................................................................14
1.3.3. Drive ...........................................................................................................................................................................................................................14
1.3.4. Engine........................................................................................................................................................................................................................14
1.3.5. Brakes.........................................................................................................................................................................................................................15
1.3.6. The vibrations..........................................................................................................................................................................................................15
1.3.7. Sprinkling..................................................................................................................................................................................................................15
1.3.8. Fluid capacities .......................................................................................................................................................................................................15
1.3.9. Electrical installation.............................................................................................................................................................................................15
1.3.10. Noise and vibration emissions..........................................................................................................................................................................16
1.3.11. Optional equipment.............................................................................................................................................................................................16

5AV 70 X
OPERATING MANUAL
2. OPERATION MANUAL ...........................................................................................................................19
2.1. Major Safety Precautions.....................................................................................................................21
2.1.1. Safety Measures during Machine Operation ..............................................................................................................................................21
2.1.1.1. Compaction Work Commencement ..............................................................................................................................................................21
2.1.1.2. Work Safety Secured by User.............................................................................................................................................................................21
2.1.1.3 Ensurance of safety measures by the owner ...............................................................................................................................................22
2.1.1.4. ROPS Cab .................................................................................................................................................................................................................22
2.1.2. Reguirements on Driver’s Qualication.........................................................................................................................................................23
2.1.3. Driver’s Liabilities ...................................................................................................................................................................................................23
2.1.4. Banned Operations ...............................................................................................................................................................................................25
2.1.5. Safety inscriptions and signs used on the Machine .................................................................................................................................26
2.1.6. Hand Signals............................................................................................................................................................................................................31
2.2. Ecological & Hygienic Principles .........................................................................................................35
2.2.1. Hygienic Principles ...............................................................................................................................................................................................35
2.2.2. Ecological Principles ............................................................................................................................................................................................35
2.3. Preservation and storing of machines................................................................................................36
2.3.1. Short-term preservation and storage for a period of 1 – 2 months ....................................................................................................36
2.3.2. Machine Preservation & Storage for the Period Over 2 Months Long................................................................................................36
2.3.3. Dewaxing and inspection of the supplied machine.................................................................................................................................37
2.4. Machine Disposal Following Its Life Termination ..............................................................................38
2.5. Machine Description ............................................................................................................................39
2.6. Controls & Dashboard Instruments ....................................................................................................40
2.7. How to Control and Use the Machine..................................................................................................60
2.7.1. Start-up of the engine..........................................................................................................................................................................................61
2.7.2. Travel and reversing..............................................................................................................................................................................................65
2.7.3. Emergency stop of the Machine ......................................................................................................................................................................73
2.7.4. How to stop the Machine and its engine......................................................................................................................................................73
2.7.5. Machine parking ....................................................................................................................................................................................................73
2.7.6. Bonnet raising and lowering .............................................................................................................................................................................74
2.7.7. Sprinkling..................................................................................................................................................................................................................77
2.8. Machine transport ................................................................................................................................78
2.8.1. How to load the Machine....................................................................................................................................................................................79
2.9. Special conditions of the machine use ...............................................................................................80
2.9.1. Machine towing......................................................................................................................................................................................................80
2.9.2. How to operate the Machine during its running-in ..................................................................................................................................84
2.9.3. Operating the Machine at low temperatures..............................................................................................................................................84
2.9.4. Machine operation at high temperatures and humidity.........................................................................................................................84
2.9.5. Machine operation at high altitudes ..............................................................................................................................................................84
2.9.6. Machine operation within very dusty environment.................................................................................................................................84
2.9.7. Driving with vibrations on compacted and hard materials....................................................................................................................84

6 AV 70 X
Content
3. MAINTENANCE MANUAL......................................................................................................................87
3.1. Safety and other measures for machine maintenance......................................................................89
3.1.1. Safety of machine maintenance.......................................................................................................................................................................89
3.1.2. Fire precautions during operation media exchanges...............................................................................................................................89
3.1.3. Ecological and hygienic principles..................................................................................................................................................................90
3.2. Media specication ..............................................................................................................................91
3.2.1. Engine oil ..................................................................................................................................................................................................................91
3.2.2. Fuel..............................................................................................................................................................................................................................92
3.2.3. Cooling liquid..........................................................................................................................................................................................................92
3.2.4. Hydraulic oil ............................................................................................................................................................................................................93
3.2.5. Lube grease .............................................................................................................................................................................................................93
3.2.6. Glass washer uid .................................................................................................................................................................................................94
3.2.7. Gear oil.......................................................................................................................................................................................................................94
3.3. Media ....................................................................................................................................................95
3.4. Lubrication and Maintenance Chart ...................................................................................................96
3.5. Lubrication Chart..................................................................................................................................98
3.6. Lubrication and Maintenance Operations..........................................................................................99
After 20 hours of operation (daily)....................................................................................................100
3.6.1. Engine oil level check........................................................................................................................................................................................ 100
3.6.2. Engine cooling liquid level check ................................................................................................................................................................. 101
3.6.3. Inspect the engine belt .................................................................................................................................................................................... 102
3.6.4. Crankcase breather ............................................................................................................................................................................................ 102
3.6.5. Inspect air lter vacuum valve ....................................................................................................................................................................... 103
3.6.6. Inspect fan condition ........................................................................................................................................................................................ 103
3.6.7. Fuel level check.................................................................................................................................................................................................... 104
3.6.8. Hydraulic tank oil level check......................................................................................................................................................................... 105
3.6.9. Water tank relling............................................................................................................................................................................................. 105
3.6.10. Inspect alarm and control devices................................................................................................................................................................ 106
Following 250 hours of operation (3 months)..................................................................................108
3.6.11. Engine oil exchange........................................................................................................................................................................................... 108
3.6.12. Inspect engine induction manifold.............................................................................................................................................................. 110
3.6.13. Inspect engine cooling circuit........................................................................................................................................................................ 110
3.6.14. Inspect the battery............................................................................................................................................................................................. 112
3.6.15. Air lter sensor check ........................................................................................................................................................................................ 114
3.6.16. Watering lter cleaning.................................................................................................................................................................................... 115
3.6.17. Machine lubrication........................................................................................................................................................................................... 117

7AV 70 X
OPERATING MANUAL
After 500 hours of operation (after 6 months).................................................................................119
3.6.18. Engine fuel lter exchange.............................................................................................................................................................................. 119
3.6.19. Engine cooling liquid level check ................................................................................................................................................................. 120
After 1,000 hours of operation (after 1 year) ...................................................................................121
3.6.20. Inspect engine belt ............................................................................................................................................................................................ 121
3.6.21. Inspect the exhaust system............................................................................................................................................................................. 121
3.6.22. Inspect the silencing system .......................................................................................................................................................................... 122
3.6.23. Clean the water tank.......................................................................................................................................................................................... 124
3.6.24. Oil change in the gearboxes........................................................................................................................................................................... 125
After 2,000 hours of operation (after 2 years)..................................................................................126
3.6.25. Checking and adjusting valve clearance.................................................................................................................................................... 126
3.6.26. Engine coolant exchange ................................................................................................................................................................................ 126
3.6.27. How to exchange oil in the vibrators........................................................................................................................................................... 130
3.6.28. How to exchange hydraulic oil and lters.................................................................................................................................................. 130
Maintenance as required ...................................................................................................................134
3.6.29. Fuel system breathing....................................................................................................................................................................................... 134
3.6.30. How to replace air lter elements................................................................................................................................................................. 135
3.5.31. How to clean water separator of fuel lter................................................................................................................................................ 137
3.6.32. Cleaning of coolers............................................................................................................................................................................................. 138
3.6.33. How to clean cab ventilation lter................................................................................................................................................................ 138
3.6.34. Drain water from sprinkling circuit before winter season.................................................................................................................... 139
3.6.34. Adjust the scrapers............................................................................................................................................................................................. 141
3.6.36. Machine cleaning ............................................................................................................................................................................................... 143
3.6.37. Check the tightening of bolted connections............................................................................................................................................ 143
3.7. Defects.................................................................................................................................................147
3.8. Attachments........................................................................................................................................148
Wiring Diagram .................................................................................................................................................................................................................... 148
Hydraulic Diagram ............................................................................................................................................................................................................. 152

8 AV 70 X

9AV 70 X
SPECIFICATION MANUAL
1. SPECIFICATION MANUAL
AV 70 X
(Cummins Tier 3)

10 AV 70 X
YEAR OF CONSTRUCTION
AMMANN CZECH REPUBLIC a.s.
CZECH REPUBLIC
NOMINAL POWER
OPERATING MASS
MAXIMUM MASS REAR AXLE LOAD
3487
DESIGNATION
SERIAL NUMBER
TYPE VERSION
FRONT AXLE LOAD
549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145
MADE IN CZECH REPUBLIC
kg
kg
kW
kg
kg
3
8
9
4
1
2
6
10
3487
5
7
Machine description
Tandem roller with an articulated frame with two smooth steel
driven vibrating drums. Steering using the articulated frame
enables the setting of extended track (crabbing).
Machine application
The AV 70 X vibratory rollers are intended for medium and large-
sized compaction works in transport construction (roads and
motorways and airelds) and building construction (industrial
zones, etc.).
The rollers are suitable for compacting the asphalt mixtures
up to a layer thickness (after compaction) of 140 mm (5.5 in),
hydraulically consolidated mixtures up to a layer thickness of
200 mm (7.9 in), mixed soils up to a layer thickness of 270 mm
(10.6 in), and sand and gravel materials up to a layer thickness
of 370 mm (14.6 in).
The rollers are not suitable for the compaction of rockll and
loam and clay materials.
The rollers are intended for the operation under conditions ac-
cording to ČSN IEC 721-2-1 (038900):WT,WDr, MWDr (i.e. a mod-
erate climate zone, warm dry or hot dry zone with a limited am-
bient temperature range from -7 °C (19.4 °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
................................................................................................................
The data mentioned in the table refer always when you contact
the dealer or manufacturer.
1.1. Basic specification
The machine that complies with the requirements as to heal-
th protection and safety is identied with a name plate with CE
marking.
1 - Name - always mentioned only in the English version
2 - Type
3 - Version
4 - Serial number
5 - Operating weight
6 - Maximum weight
7 - Rated power
8 - Front axle load
9 - Rear axle load
10 - Year of manufacture

11AV 70 X
400103
2
1
3
400102
SPECIFICATION MANUAL
Placing of the production label
1 - Production label
2 - Machine’s production number
3 - Label of the ROPS cabin
Cummins engine serial number

12 AV 70 X
406002
H1
A
L
S
H4
S
D
1.2. Machine dimension scheme
A D H1 H2 H3 H4
mm 3260 1150 3005 2300 965 240
in 128,4 45,3 118,3 90,6 38 9,4
L O S W1 W2 W3
mm 4410 45 15 1450 1550 180
in 173,6 1,8 0,6 57,1 61 7,1

13AV 70 X
O
W1
W2
H3
H2
W3
406003
SPECIFICATION MANUAL

14 AV 70 X
1.3.1. Weights
Working weight with the cab ROPS according to EN 500 - 1 kg (lb) 7360 (16226)
front drum kg (lb) 3750 (8267)
rear drum kg (lb) 3610 (7959)
The service weight of the machine according to EN 500-1 is the machine weight with the full content of working liquids, half content
of propellants, half content of sprinkling tanks and with an operator (75kg/165lb).
The machine weight according to ISO 6016 is the weight with full content of propellants, lubricants, sprinkling tanks and an operator
(75kg/165 lb). It is calculated by adding 350 kg (772 lb).
The weight data can dier from above mentioned data according to the further customers’requirements for the machine’s equipment
and accessories.
The maximum permissible weight of theAV 70 X machine including equipment and accessories is 9100 kg (20062 lb).
1.3.2. Driving properties
Drive type hydrostatic
Drive front and rear
Turning radius outer (contour) mm (in) 6410 (252,4)
Turning radius outer (edge) mm (in) 4600 (181,1)
Travelling speed in both directions - Speed 2000 km/h (MPH) 10,6 (6,6)
Travelling speed in both directions - Speed 2200 km/h (MPH) 11,4 (7,1)
Theoretical machine’s gradeability % 40
Side static stability - straight frame % 62,5
1.3.3. Drive
Steering type articulated joint
Steering control hydraulic
Linear hydraulic motors 2 + 1 (Crab)
Swing of frames in vertical plane ±° 8
Turning of both frames in horizontal plane ±° 34
1.3.4. Engine
Manufacturer Cummins
Engine type BTAA 3,3 - C80
Number of cylinders 4
Stroke volume cm3 (cu in) 3260 (198,9)
Engine output due to ISO 3046/1 kW (HP) 60 (80)
Nominal revolutions - CE min-1 (RPM) 2000
Nominal revolutions min-1 (RPM) 2200
Maximum torsional moment Nm (ft lb) 304 (224)
Fuel consumption during common operation/hour* l (gal US) max. 10 (2,6)
Engine fullls requirements of Directive 97/68/EU, STAGE III A
EPA/CARB NON ROAD 40 CFR, PART 89
TIER 3
* - according to ACZ methodology
1.3. Technical data