Ammann AV23-2 User manual

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Manual (EN)
AV23-2, AV26-2, AV32-2, AV33-2, AV40-2 Serial No. 22’500-
AV23-2K, AV26-2K, AV32-2K, AV40-2K
Yanmar
ID: 1138310 Revision index: A Issue date January 01, 2010

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Declaration of Conformity
This is to certify that the machine/group of machines indicated below conform(s) to
the relevant basic safety and health requirements of the relevant EC directives in
terms of their conception and design and in the form marketed by us.
This declaration shall cease to be valid in the event of any change made to the
machine/group of machines after handover to the trader/user if such changes are not
agreed with us.
Name of machine or group of
machines:
Model:
AV23-2, AV26-2, AV32-2, AV33-2, AV40-2,
AV23-2K, AV26-2K, AV32-2K, AV40-2K
Tandem roller & combined roller
Relevant EC directives: EC -
EC -
EC -
EC -
Machinery Directive 2006/42/EC with
amendment 2006/42/EC
Electromagnetic Compatibility Directive
89/336/EC with amendments
2004/108/EC
Emission Directive 97/68/EC
Noise Directive 2000/14/EC with amendment
2005/88/EC
Applicable harmonized
norms, particularly: EN 500-1, EN 500-4, EN 982, EN ISO 14121-1,
ISO 12100-1, ISO 12100-2, EN ISO 13850
Issuing testing office for
noise tests: TÜV Austria (Austrian technical inspectorate)
Testing body no. 0408
Test report number: 09-UWC/WELS-EX-291
Date: 11.10.2009
Recorded sound power level: 102 dB(A)
Guaranteed sound power level: 106 dB(A)
Place, Date:
Company:
Address:
Langenthal, November 2009
Ammann Schweiz AG
Eisenbahnstrasse 25
4901 Langenthal, Switzerland
Authorized officer/
Technical inspector:
Name of undersigned:
Position of undersigned: W. Thaller
Customer Service Manager Ch. Anliker Head of technology

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ID: 1138310 Issue date January 01, 2010
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Preface
Congratulations on your purchase of an Ammann compaction roller.
This quality of this compaction device is characterized by simple operation and
maintenance and is the product of many years of Ammann experience in the
field of road roller engineering.
Because the content of the deliverable depends on the order, the features of
your roller may differ in some descriptions and pictures.
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 future
reference.
With kind regards,
Ammann Schweiz AG
Eisenbahnstrasse 25
CH-4901 Langenthal
www.ammann-group.ch
0041 (0)62 916 61 61
FAX [phone]

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ID: 1138310 Issue date January 01, 2010
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Contents
Preface...........................................................................................................1
Contents.........................................................................................................2
1 Structure of the manual ...............................................................................5
Structure of the manual..................................................................................6
Pictograms .....................................................................................................8
2 Identification .................................................................................................9
Identification.................................................................................................10
Identification plate ........................................................................................11
Scope of delivery..........................................................................................12
3 Safety...........................................................................................................13
General working safety.................................................................................14
Roller operation............................................................................................16
Roll-over bar (ROPS)...................................................................................19
Safety markings on the machine..................................................................20
Noise levels..................................................................................................23
Safety (maintenance)...................................................................................24
Vibration hazard...........................................................................................28
Notes............................................................................................................29
Notes............................................................................................................30
4 Transport / Commissioning.......................................................................31
Transport......................................................................................................32
Center of gravity...........................................................................................34
Joint protection.............................................................................................35
Commissioning.............................................................................................36
Notes............................................................................................................38
5 Overview......................................................................................................39
Intended use.................................................................................................40
Inappropriate use .........................................................................................41
Component overview....................................................................................42
Dashboard (switches)...................................................................................44
Dashboard (control lamps)...........................................................................45
Operation check...........................................................................................46
Notes............................................................................................................49
Notes............................................................................................................50
6 Operating.....................................................................................................51
Driver's seat..................................................................................................52
Roll-over bar (ROPS)...................................................................................54
Starting the engine.......................................................................................56
Driving and braking ......................................................................................59
Working speed .............................................................................................61
Turning off the engine ..................................................................................62
Emergency stop ...........................................................................................63

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Contents
Parking brake...............................................................................................64
Sprinkling......................................................................................................65
Simple/double vibration................................................................................67
Notes............................................................................................................68
7 Options........................................................................................................69
Edge cutter...................................................................................................70
Revolving warning light ................................................................................73
Roof..............................................................................................................76
Driver's platform cover .................................................................................78
Reverse alarm..............................................................................................79
Battery cut-off switch....................................................................................80
Traction aid (flow divider).............................................................................82
Lighting.........................................................................................................83
Interval sprinkler...........................................................................................84
Delayed seat contact....................................................................................85
Anti-adhesive................................................................................................86
Anti-adhesive designations ..........................................................................87
1-point lifting eye..........................................................................................88
Automatic vibration.......................................................................................89
Seat heating.................................................................................................91
ROPS2D.......................................................................................................92
Notes............................................................................................................94
8 Maintenance................................................................................................95
Important notes ............................................................................................96
Roller maintenance ......................................................................................97
Maintenance check sheet...........................................................................100
Yanmar engine maintenance .....................................................................102
Towing, releasing brakes ...........................................................................104
Opening the hood.......................................................................................108
Engine compartment inspection summary.................................................110
Inspect – engine oil level, coolant level......................................................111
Inspect – fuel level, hydraulic oil level........................................................112
Checks – sprinkler system, scraper ...........................................................113
Checks – tire pressure ...............................................................................114
Checks – air filter cartridges.......................................................................115
Checks – Seat contact and emergency stop..............................................116
Inspect – brakes (brake test)......................................................................117
Lubricate steering cylinder bearing ............................................................119
Removing the front water tank ...................................................................120
Removing the rear water tank....................................................................122
Lubricant table............................................................................................123
Consumables, tightening torques...............................................................125
Replace engine oil......................................................................................126
Cleaning.....................................................................................................127

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Contents
Notes..........................................................................................................128
9 Tips ............................................................................................................129
Replacing the front bulbs............................................................................130
Replacing the rear bulbs ............................................................................133
Engine compartment fuses.........................................................................134
Steering column fuses................................................................................135
Battery........................................................................................................136
Notes..........................................................................................................137
Notes..........................................................................................................138
10 Storage ....................................................................................................139
Storage.......................................................................................................140
Draining the water tank ..............................................................................142
Winterization, emptying the water tank......................................................143
Draining diesel............................................................................................145
Notes..........................................................................................................146
11 Hydraulics diagram ................................................................................147
AV23 - AV40 hydraulics diagram ...............................................................148
AV23 - AV40 hydraulics diagram legend ...................................................149
Hydraulic diagram AV23K-AV40K..............................................................150
AV23K - AV40K hydraulics diagram legend...............................................151
AV23K - AV40K Edge Cutter hydraulics diagram......................................152
AV23K - AV40K Edge Cutter hydraulics diagram legend ..........................153
Notes..........................................................................................................154
12 Wiring diagram........................................................................................155
Wiring diagram (multifunction display) .......................................................156
Wiring diagram (engine start/stop).............................................................157
Wiring diagram (emergency stop / oil cooler, diesel pump).......................158
Wiring diagram (sprinkler)..........................................................................159
Wiring diagram (vibration, ROPS2D) .........................................................160
Wiring diagram (horn, indicators)...............................................................161
Wiring diagram (lights) ...............................................................................162
Wiring diagram (options)............................................................................163
Wiring diagram (operating lever control)....................................................164
Wiring diagram (delayed seat switch) ........................................................165
Wiring diagram key.....................................................................................166
13 Specifications .........................................................................................171
Dimensions.................................................................................................172
Specifications AV2-2..................................................................................173
Specifications AV2-2K................................................................................174
Specifications AV2-2 sidefree ....................................................................175
Notes..........................................................................................................176

1 Structure of the manual BNNbOO
ID: 1138310 Issue date January 01, 2010
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1 Structure of the
manual

1 Structure of the manual BNNbOO
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Structure of the manual
The following explanations are designed to familiarize you with the roller and
to provide support for handling and maintenance.
Structure of the manual
These operating instructions contains the following sections:
•Table of contents •Options
•Structure of the manual •Maintenance
•Identification •Tips
•Safety •Storage
•Transport/commissioning •Hydraulic layout
•Overview •Wiring diagram
•Operating •Specifications
It is essential that you read the Safety section carefully before commissioning -
and carrying out maintenance work.
Observing the Safety section in particular increases the reliability of the
machine in operation and its service life. This reduces repair costs and down
time.
Spare parts
Spare parts must meet Ammann technical specifications. These requirement
are fulfilled if only original Ammann spare parts are used.
Storage and completeness of the manual
•This manual is an integral part of the roller and must be kept available for
the user of the roller to consult.
•Never remove sections from this manual. Missing pages - specifically the
Safety section - must be replaced immediately if lost.
•The manual must be retained for the lifetime of the roller and must be
passed on to every subsequent owner or user of the machine.
Revision service
This documentation is not subject to the revision service of Ammann Schweiz
AG. Changes may be made to this documentation without notification.

1 Structure of the manual BNNbOO
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Structure of the manual
Roller designations in the descriptions
In order to facilitate orientation, we will tell you where to find the appropriate
parts in the various sections.
The descriptions are based on the principle:
The roller is viewed from the rear looking forward.
Example, unlocking the hood:
The hood lock is located on the left-hand side…
Left
Right
Front
Bottom
Top
Rear

1 Structure of the manual BNNbOO
ID: 1138310 Issue date January 01, 2010
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Pictograms
Important points are indicated as follows:
WARNING
Indicates an immediate impending danger.
Failure to avert such dangers will lead to death or extremely serious injuries.
WARNING
Indicates a potentially harmful situation.
Failure to avert this situation may damage the product or objects in its vicinity.
NOTE
Indicates application tips and other particularly useful information. This is not a
sign of a dangerous or harmful situation.

2 Identification BNNbOO
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2 Identification

2 Identification BNNbOO
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Identification
This manual applies to the following machines.
The data given below serve to identify the models. Please refer to the
'Specifications' section for details on the various machines.
Roller with roller drum
Model Width Weight
AV23-2 1121 mm 2410 kg
AV23-2 S* 1140 mm 2650 kg
AV26-2 1326 mm 2660 kg
AV26-2 S* 1340 mm 2850 kg
AV32-2 1310 mm 3160 kg
AV33-2 1412 mm 3450 kg
AV40-2 1412 mm 3800 kg
Roller with pneumatic wheel (combined roller)
Model Width Weight
AV23-2K 1065 mm 2280 kg
AV23-2K S* 1110 mm 2450 kg
AV26-2K 1249 mm 2400 kg
AV26-2K S* 1310 mm 2520 kg
AV32-2K 1219 mm 3110 kg
AV40-2K 1370 mm 3,540 kg
The machine models differ only in terms of weight and the width of the roller
drum. The combined roller has a pneumatic wheel axis instead of the smooth
back roller drum.
* Roller with open-sided roller drum, S = Side open
The open-sided roller drum option has only one-sided roller drum support, but
is labelled the same.

2 Identification BNNbOO
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Identification plate
Identification plate
An identification plate (1) is affixed to
the roller for identification.
The identification plate is located on
the left of the machine on the rear
chassis of the roller.
Important data on the identification
plate:
1 Roller designation
2 Roller model
3 Name and address of the
manufacturer
4 Serial number
5 Year of manufacture
6 Vehicle Identification Number
(VIN)
7 Fuel engine output at
8 Number of revolutions per minute
9 CECE gross weight
(max. weight CH)
10 CECE front axle weight
(max. axle weight CH)
11 CECE rear axle weight
(max. axle weight CH)
NOTE
The roller serial number (S/N) must be specified when ordering spare parts.
1
1 3
6
8
11
10
7
9
4
5
2

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Scope of delivery
Scope of delivery
Please check that the delivery is complete and inform us within 14 days after
purchase if the delivery is not complete. Please always indicate the serial
number.
•Roller
•Roller manual
•Spare parts catalog for roller
•Yanmar engine manual in English
•Yanmar engine manufacturer’s declaration
Documents
The following documents are delivered with the machine and may be ordered
from Ammann.
Manual Spare parts list
22'500- 22'500-22'999 23’000- 22’500-
Model 1138310 1120714 1129303 1138127 1138648 1138818
AV23-2 zzz
AV23-2K zzz
AV26-2 zzz
AV26-2K zzz
AV32-2 zzz
AV32-2K zzz
AV33-2 zzz
AV40-2 zzz
AV40-2K zzz
AV23-2 S* zz
AV26-2 S* z
z
* Roller with open-sided roller drum, S = Side open

3 Safety BNNbOO
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3 Safety

3 Safety BNNbOO
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General working safety
•The roller may only be used for driving and compacting unbound layers -
(gravel, soil) and blacktops (asphalt). Other uses are prohibited.
•Rollers may only be operated with all safety devices operating. Manipulation
or non-observation of safety devices and regulations invalidates the CE
conformity.
•Before starting every shift, check the effectiveness of the operation and
safety devices and that the protection devices are in place.
•Check the steering and brakes when you start work. If defects are apparent
roller operation is not permitted.
•If you identify any defects on the safety system or defects that impair safe
operation of the equipment, inform your supervisor immediately. The roller
may no longer be operated.
•If you identify any defects which endanger safe operation, cease operation
immediately.
•Only perform work on and clean the roller if it is stationary and secured from
rolling away.
•Switch off the engine when filling the fuel tank. Do not fill up fuel in closed
rooms. No naked flames.
•Do not vibrate on slopes or inclines where there is a hazard of slipping or
overturning.
•Do not drive on slopes that are steeper than the maximum climbing capacity
of the equipment. Always drive the roller carefully perpendicular to the slope
dip.
•Do not vibrate inside buildings and on unstable ground.

3 Safety BNNbOO
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General working safety
•Keep the driver’s position and steps free of trips, grease, dirt, ice, etc.
•The driving and working field of view must not be obstructed in any way.
Adjust all the necessary mirrors correctly and keep them clean.
•Switch off the engine before leaving the roller. Secure the roller from
unauthorized start-up and rolling away.
•Take suitable measure to secure parked rollers that pose an obstruction.
•Never work under the influence of drugs, alcohol or medicines that impair
consciousness.
•Only operate the roller in good general light conditions and good workspace
illumination.
•The operator's workplace is on the seat of the driver's platform. The roller
may not be operated from any other position.

3 Safety BNNbOO
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Roller operation
WARNING!
Roll-over hazard!
Only start the roller from the driver’s
position.
No persons may stand in front of or
behind the roller while it is in
operation.
WARNING!
Accident hazard!
Persons necessary for operations at
the sides of the equipment must
remain at a safe distance of at least
1 m.
Shear points
Keep the following hazards in mind:
•When closing the hood ensure that no objects are situated between the
hood and the chassis.
•That nothing is jammed in the joint plates when rotating the roller drums.
•Do not put hands between the roller drum and support during operation.
WARNING!
Tipping hazard!
Only travel directly up or down
slopes.
Do not drive across slopes.
1 m
1 m