Ammann AP 240 User manual

Book ID: 4-P06430CU
AP 240
Cummins
-EN
Operating manual

AP 240
Cummins Tier 3
01/2012
4302395
Operating manual
Edition EN
From Serial No.
Translation of Original Operating Manual
Pneu tyred roller

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

1AP 240
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 AP 240
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.

3AP 240
! 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:
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.
37402en
LEFT
FRONT
RIGHT
REAR

4 AP 240
Content
Content.............................................................................................................................................................4
1. SPECIFICATION MANUAL ......................................................................................................................9
1.1. Basic Data..............................................................................................................................................10
1.2. Dimensional machine drawing............................................................................................................12
1.3. Technical data .......................................................................................................................................15

5AP 240
OPERATING MANUAL
2. OPERATION MANUAL ..........................................................................................................................21
2.1. Main Safety Measures ..........................................................................................................................23
2.1.1. Safety measures during Machine operation................................................................................................................................................23
2.1.1.1. Compaction Work Commencement...............................................................................................................................................................23
2.1.1.2. Work in the dangerous area...............................................................................................................................................................................23
2.1.1.3 Ensurance of safety measures by the owner ...............................................................................................................................................24
2.1.1.4. ROPS ...........................................................................................................................................................................................................................24
2.1.2. Requirements for qualication of driver .......................................................................................................................................................25
2.1.3. Duties of the driver................................................................................................................................................................................................26
2.1.4. Forbidden activities ..............................................................................................................................................................................................27
2.1.5. Safety inscriptions and symbols used on the Machine............................................................................................................................28
2.1.6. Hand signals ............................................................................................................................................................................................................32
2.2. Ecological and hygienic principles......................................................................................................35
2.2.1. Hygienic principles................................................................................................................................................................................................35
2.2.2. Ecological principles.............................................................................................................................................................................................35
2.3. Machine preservation and storage .....................................................................................................36
2.3.1. Short-term preservation and storage for a period of 1 – 2 months ....................................................................................................36
2.3.2. Preservation and storage for the period over 2 months long...............................................................................................................36
2.3.3. Dewaxing and inspection of a supplied machine .....................................................................................................................................37
2.4. Machine disposal following its life cycle end .....................................................................................38
2.5. Machine Description ............................................................................................................................39
2.6. Controllers & Control Instruments ......................................................................................................40
2.6.1. Power View Display control................................................................................................................................................................................53
2.7. Machine Control and Usage.................................................................................................................66
2.7.1. Engine starting .......................................................................................................................................................................................................67
2.7.2. Travel & Reversation..............................................................................................................................................................................................69
2.7.3. Emergency stop of the Machine ......................................................................................................................................................................71
2.7.4. How to stop the Machine and the engine....................................................................................................................................................72
2.7.5. Machine parking ....................................................................................................................................................................................................73
2.7.6. Watering and scrapers .........................................................................................................................................................................................74
2.7.7. Edge Cutter ..............................................................................................................................................................................................................75
2.8. How to transport the Machine.............................................................................................................76
2.8.1. Machine loading ....................................................................................................................................................................................................77
2.9. Machine work under heavy conditions ..............................................................................................78
2.9.1. Machine towing......................................................................................................................................................................................................78
2.9.2. Machine operation during its running-in period.......................................................................................................................................80
2.9.3. Machine operation at low temperatures.......................................................................................................................................................80
2.9.4. Machine work under high temperatures and humidity..........................................................................................................................81
2.9.5. Machine work in high altitudes........................................................................................................................................................................81
2.9.6. Work of the machine in the dusty environment.........................................................................................................................................81

6 AP 240
Content
3. MAINTENANCE MANUAL ....................................................................................................................85
3.1. Safety standards and other maintenance regulations .....................................................................87
3.1.1. Safety of machine maintenance.......................................................................................................................................................................87
3.1.2. Fire precautions during operation media exchanges...............................................................................................................................87
3.1.3. Ecological and hygienic standards..................................................................................................................................................................88
3.2. Media Specication ..............................................................................................................................89
3.2.1. Engine Oil..................................................................................................................................................................................................................89
3.2.2. Fuel..............................................................................................................................................................................................................................90
3.2.3. Cooling Liquid.........................................................................................................................................................................................................91
3.2.4. Hydraulic Oil ...........................................................................................................................................................................................................91
3.2.5. Oil – epicyclic transmission incl. torque converter....................................................................................................................................92
3.2.6. Gear Oil .....................................................................................................................................................................................................................92
3.2.7. Brake Fluid................................................................................................................................................................................................................92
3.2.8. Lube Grease .............................................................................................................................................................................................................92
3.2.9. Windscreen Sprayer Liquid.................................................................................................................................................................................92
3.3. Media.....................................................................................................................................................93
3.4. Lubrication and Maintenance Chart ...................................................................................................94
3.5. Lubrication Chart..................................................................................................................................96
3.6. Lubrication and Maintenance Operations..........................................................................................97
After 20 hours of operation (daily)......................................................................................................98
3.6.1. Engine oil level check...........................................................................................................................................................................................98
3.6.2. Engine cooling liquid level check ....................................................................................................................................................................99
3.6.3. Crankcase breather tube.....................................................................................................................................................................................99
3.6.4. Check of the fan and engine belt condition ............................................................................................................................................. 100
3.6.5. Check air lter vacuum valve ......................................................................................................................................................................... 101
3.6.6. Hydraulic tank oil level check......................................................................................................................................................................... 101
3.6.7. Check brake fuel ................................................................................................................................................................................................. 102
3.6.8. Fill up sprinkling tank........................................................................................................................................................................................ 103
3.6.9. Cleaning of the water separator.................................................................................................................................................................... 103
3.6.10. Check oil level in gearbox................................................................................................................................................................................ 103
3.6.11. Check alarm and control instruments......................................................................................................................................................... 104
After 100 hours of operation (weekly)..............................................................................................106
3.6.12. Checking the tyre pressure ............................................................................................................................................................................. 106
After 250 hours of operation (3 months) .........................................................................................107
3.6.13. How to exchange oil in engine...................................................................................................................................................................... 107
3.6.14. Check the engine induction manifold and air lter sensor................................................................................................................. 109
3.6.15. Battery check........................................................................................................................................................................................................ 111
3.6.16. Machine lubrication........................................................................................................................................................................................... 113
After 500 hours of operation (6 months)..........................................................................................116
3.6.17. Fuel lter replacement...................................................................................................................................................................................... 116
3.6.18. Engine cooling liquid check............................................................................................................................................................................ 118
3.6.19. How to replace CLARK gearbox oil lter .................................................................................................................................................... 119
3.6.20. Check oil for nal drive and rear axle........................................................................................................................................................... 120
3.6.21. Check of wiring.................................................................................................................................................................................................... 120

7AP 240
OPERATING MANUAL
After 1000 hours of operation (1 year) .............................................................................................121
3.6.22. Check and adjust brake clips.......................................................................................................................................................................... 121
3.6.23. Hydraulic Accumulator..................................................................................................................................................................................... 123
3.6.24. Checking the engine belt................................................................................................................................................................................. 124
3.6.25. How to exchange CLARK gearbox oil.......................................................................................................................................................... 125
3.6.26. How to replace nal drive oil.......................................................................................................................................................................... 126
3.6.27. How to replace air drier .................................................................................................................................................................................... 128
After 2,000 hours of operation (after 2 years)..................................................................................129
3.6.28. Check, adjust valve clearance......................................................................................................................................................................... 129
3.6.29. How to exchange oil in rear axle................................................................................................................................................................... 129
3.6.30. How to exchange hydraulic oil and lter ................................................................................................................................................... 130
3.6.31. How to exchange oil in hydraulic cylinders for front axle.................................................................................................................... 134
3.6.32. How to exchange brake uid.......................................................................................................................................................................... 135
3.6.33. Exchanging the engine cooling liquid........................................................................................................................................................ 137
3.6.34. Check the compressor ...................................................................................................................................................................................... 139
Maintenance if required.....................................................................................................................140
3.6.35. Fuel Pre Cleaner – Water Separator ............................................................................................................................................................. 140
3.6.36. How to deaerate fuel lter............................................................................................................................................................................... 141
3.6.37. How to replace air lter elements................................................................................................................................................................. 142
3.6.38. Cleaning of coolers............................................................................................................................................................................................. 144
3.6.39. Clean sprinkling lter ........................................................................................................................................................................................ 145
3.6.40. Clean brush scrapers ......................................................................................................................................................................................... 145
3.6.41. Cleaning the air cleaner of cabin ventilation............................................................................................................................................ 146
3.6.42. Clean the Machine.............................................................................................................................................................................................. 147
3.6.43. Conrm bolt connections are tightened.................................................................................................................................................... 148
3.7. Defects.................................................................................................................................................151
3.8. Annexes ...............................................................................................................................................152
Wiring Diagram .................................................................................................................................................................................................................... 152
Hydraulics Diagram............................................................................................................................................................................................................. 156
Air Distribution..................................................................................................................................................................................................................... 158

8 AP 240

9AP 240
SPECIFICATION MANUAL
1. SPECIFICATION MANUAL
AP 240
(Cummins Tier 3)

10 AP 240
Machine description
Pneu tyred roller with a rigid frame with a front steerable iso-
static axle and rear drive axle. Each axle is mounted with four
smooth tyres.
Machine application
The roller is intended for medium and large-sized compaction
works in transport construction (roads and motorways, railways,
airelds) and building construction (industrial zones, etc.).
The roller is suitable for compacting the asphalt mixtures up to a
layer thickness (after compaction) of 120 mm, hydraulically con-
solidated mixtures up to a layer thickness of 150 mm, loam and
clay soils up to a layer thickness of 150 mm, mixed soils up to a
layer thickness of 200 mm, and sand and gravel materials up to
a layer thickness of 250 mm.
The roller is not suitable for the compaction of rockll.
The machine is intended for operation in conditions of the fol-
lowing 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.
1.1. Basic Data
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.

11AP 240
AP001
2
1
374112
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
SPECIFICATION MANUAL
Name plate location
1 - Name plate
2 - Machine frame number
Engine name plate location
The machine that complies with the requirements as to health
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

12 AP 240
A
L
H1
G
374002
G*
1.2. Dimensional machine drawing
A G G* H H1 L L1 W W1 W2
mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310
(in) (149,6) (13,4) (10,2) (122,4) (96,5) (197,6) (227,6) (78,2) (82,7) (90,9)

13AP 240
374001
W
W1
H
SPECIFICATION MANUAL
A G G* H H1 L L1 W W1 W2
mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310
(in) (149,6) (13,4) (10,2) (122,4) (96,5) (197,6) (227,6) (78,2) (82,7) (90,9)

14 AP 240
L2
W2
L1
374016
1.2. Dimensional machine drawing
A G G* H H1 L L1 W W1 W2
mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310
(in) (149,6) (13,4) (10,2) (122,4) (96,5) (197,6) (227,6) (78,2) (82,7) (90,9)