Operation Manual - Amann ASC100

Operating manual E
ASC 100
Cummins Tier I © 1 / 2008
2 ASC 100
ASC 100 3
Pictures and data shown in these manuals are subject to change without notice, in order to improve
quality of the manuals. Re-printing and copying of any kind, whole or in single chapters, is allowed
only with our prior written consent.
4 ASC 100
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,
Verdichtung AG, CH-4900 Langenthal

0041 (0)62 916 63 56 FAX: 0041 (0)62 916 64 03
This manual consists of:

I. Specification manual III. Maintenance manual
II. Operating instructions
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.
ASC 100 5
6 ASC 100
Operating Manual
! NOTICE !
As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indi-
cate the sides of the machine moving forward.
ASC 100 7
Content
Content ............................................................................................................................................... 8
1. Specification Manual ............................................................................................................................... 13
1.1. Basic Data .............................................................................................................................................. 14
1.2. Dimension Chart ....................................................................................................................................... 16
1.3. Technical Data .......................................................................................................................................... 17

1.3.1. Weights .............................................................................................................................................................. 17
1.3.2. Travel Parameters .............................................................................................................................................. 18
1.3.3. Vibration ............................................................................................................................................................. 19
1.3.4. Engine ................................................................................................................................................................ 19
1.3.5. Axle ..................................................................................................................................................................... 20
1.3.6. Brakes ................................................................................................................................................................ 20
1.3.7. Steering .............................................................................................................................................................. 20
1.3.8. Vibratory Drum ................................................................................................................................................... 21
1.3.9. Hydrostatic Drive of Travel ................................................................................................................................. 21
1.3.10. Hydrostatic Drive of Vibration ............................................................................................................................ 21
1.3.11. Hydraulic Oil Tank .............................................................................................................................................. 22
1.3.12. Lifting and lowering of the Hood and the Cabin ............................................................................................... 22
1.3.13. Cooling System of Hydraulic Oil ....................................................................................................................... 22
1.3.14. Fluids .................................................................................................................................................................. 22
1.3.15. Electrical Installation .......................................................................................................................................... 23
1.3.16. Safety Devices ................................................................................................................................................... 23
1.3.17. Hygienical Data .................................................................................................................................................. 23
1.3.18. Requirements of Traffic Regulations ................................................................................................................. 23
1.3.19. Accessories ........................................................................................................................................................ 24
8 ASC 100
Specification Manual
2. OPERATING INSTRUCTIONS .................................................................................................................... 27
2.1. Dewaxing and Inspection of a Newly Supplied Machine ..................................................................... 28
2.2. Major Safety Measures ............................................................................................................................ 29

2.2.1. Safety measures to operate the Machine ......................................................................................................... 29
2.2.1.1. How to start the compaction work ..................................................................................................................... 29
2.2.1.2. Work safety secured by User ............................................................................................................................ 29
2.2.2. Driver Qualification Requirements .................................................................................................................... 30
2.2.3. Driver’s Duties .................................................................................................................................................... 30
2.2.4. Operations Prohibited ........................................................................................................................................ 32
2.2.5. Hand Signals ..................................................................................................................................................... 33
2.2.6. Safety labels & signs used on the Machine ...................................................................................................... 36
2.3. Ecological & Hygienic Principles ............................................................................................................ 39

2.3.1. Hygienic Principles ............................................................................................................................................ 39
2.3.2. Ecological Principles ......................................................................................................................................... 39
2.4. Preservation & Storage ............................................................................................................................ 40

2.4.1. Short-term preservation & storage for the period of 1 ÷ 2 months .................................................................. 40
2.4.2. Machine preservation & storage for the period over 2 months ........................................................................ 40
2.5. Machine disposal upon its life termination ............................................................................................ 41
2.6. Machine Description ................................................................................................................................ 43
2.7. Controllers & Dashboard Instruments ..................................................................................................... 44
2.8. How to Control and Use the Machine ..................................................................................................... 54

2.8.1. Start the Engine ................................................................................................................................................. 54
2.8.2. Travel & Reversing ............................................................................................................................................. 56
2.8.3. Travel with vibration ........................................................................................................................................... 58
2.8.4. Stop the Machine & the Engine ......................................................................................................................... 59
2.8.5. Machine Shutdown ............................................................................................................................................ 60
2.8.6. How to lift driver control stand and bonnet ....................................................................................................... 61
2.9. Machine Transportation ........................................................................................................................... 63

2.9.1. Machine transportation by its own axle ............................................................................................................ 63
2.9.2. Machine transportation by public road ............................................................................................................. 63
2.9.3. How to load the Machine ................................................................................................................................... 64
2.9.4. Towing of Machine ............................................................................................................................................. 65
2.9.5. Dismantle the Cab and the ROPS ..................................................................................................................... 66
2.10. Special Conditions for the Machine Application ................................................................................... 68

2.10.1. Vibration driving on compacted and hard materials ....................................................................................... 68
2.10.2. Machine use under heavy climatic conditions ................................................................................................ 69
2.10.2.1. Machine operation under low temperatures ................................................................................................... 69
2.10.2.2. Machine operation under high temperatures and humidity ........................................................................... 70
2.10.2.3. Operating the Machine at high altitudes .......................................................................................................... 70
2.10.2.4. Machine operation at extremely dusty environment ....................................................................................... 70
ASC 100 9
Content
3. MAINTENANCE MANUAL .......................................................................................................................... 73
3.1. Safety & Other Measures during Machine Maintenance ....................................................................... 75

3.1.1. Safety during Machine Maintenance ................................................................................................................ 75
3.1.2. Fire precautions when refilling .......................................................................................................................... 75
3.1.3. Ecological & Hygienic Principles ...................................................................................................................... 76
3.1.3.1. Hygienic Principles ............................................................................................................................................ 76
3.1.3.2. Ecological Principles ......................................................................................................................................... 76
3.2. Refill Specification ................................................................................................................................... 77

3.2.1. Motor Oil ............................................................................................................................................................. 77
3.2.2. Fuel ..................................................................................................................................................................... 78
3.2.3. Cooling Liquid .................................................................................................................................................... 78
3.2.4. Hydraulic Oil ....................................................................................................................................................... 79
3.2.5. Gearbox Oil ........................................................................................................................................................ 80
3.2.6. Lubricating Grease ............................................................................................................................................ 80
3.2.7. Screen Washer Liquid ....................................................................................................................................... 80
3.3. Refills .............................................................................................................................................. 81
3.4. Lubrication & Maintenance Table ........................................................................................................... 82
3.5. Lubrication Chart ...................................................................................................................................... 84
3.6. Lubrication & Maintenance Operations .................................................................................................. 85
Following 20 hours of operation or daily ............................................................................................... 86

3.6.1. Check the oil amount in motor .......................................................................................................................... 86
3.6.2. Check the amount of cooling liquid in the motor .............................................................................................. 87
3.6.3. Check the amount of oil inside hydraulic tank .................................................................................................. 88
3.6.4. Crankcase Breather ........................................................................................................................................... 88
3.6.5. Check fan condition ........................................................................................................................................... 89
3.6.6. Check motor belt ................................................................................................................................................ 89
3.6.7. Check engine air intake .................................................................................................................................... 90
3.6.8. Check the amount of fuel ................................................................................................................................... 91
3.6.9. How to clean air separator ................................................................................................................................ 92
3.6.10. Check the alarm & control devices ................................................................................................................... 93
Every 100 Hours ........................................................................................................................................ 94
3.6.11. Check tire pressure ........................................................................................................................................... 94
Every 250 Hours or Once in 3 Months ..................................................................................................... 95
3.6.12. How to replace oil in the engine ....................................................................................................................... 95
3.6.13. Check the fixing of the engine ........................................................................................................................... 98
3.6.14. How to inspect the batteries .............................................................................................................................. 99
3.6.15. Check the function of Air Filter Vacuum Switch .............................................................................................. 101
3.6.16. Machine Lubrication ........................................................................................................................................ 102
3.6.17. How to check oil inside vibrator ...................................................................................................................... 105
3.6.18. How to check oil in gearboxes ........................................................................................................................ 106
Every 500 Hours or Once in 6 Month ..................................................................................................... 107
3.6.19. How to replace engine fuel filter ..................................................................................................................... 107
3.6.20. Cooling liquid inspection ................................................................................................................................. 109
3.6.21. Check if wheel bolts are tightened .................................................................................................................. 109
10 ASC 100
Operating Manual
Every 1000 Hours or Once a Year .......................................................................................................... 110

3.6.22. Check, adjust valve clearance ........................................................................................................................ 110
3.6.23. How to check tightening pulley and belt of the engine .................................................................................. 112
3.6.24. Replace oil in gearboxes ................................................................................................................................. 114
3.6.25. Inspect the damping system ............................................................................................................................ 115
3.6.26. How to clean fuel tank ..................................................................................................................................... 116
Every 2000 Hours or Every 2 Years ........................................................................................................ 117
3.6.27. How to change oil in the vibrator .................................................................................................................... 117
3.6.28. How to change hydraulic oil and filter ............................................................................................................ 118
3.6.29. How to change engine coolant ....................................................................................................................... 121
3.6.30. How to check the dampener of engine’s torsional vibrations ........................................................................ 124
Maintenance - As Needed ...................................................................................................................... 125
3.6.31. How to replace filter elements ......................................................................................................................... 125
3.6.32. How to clean engine cooler and hydraulic oil ................................................................................................ 127
3.6.33. How to clean cabin ventilation filter ................................................................................................................ 128
3.6.34. How to deaerate fuel system ........................................................................................................................... 129
3.6.35. How to adjust the scrapers .............................................................................................................................. 131
3.6.36. How to clean the Machine ............................................................................................................................... 132
3.6.37. Check bolted connections ............................................................................................................................... 132
3.7. Defects ............................................................................................................................................ 135
3.8. Attachment ............................................................................................................................................ 136

Wiring Diagram .............................................................................................................................................................. 136
Hydraulic Diagram ......................................................................................................................................................... 138
ASC 100 11
12 ASC 100
1. SPECIFICATION MANUAL
ASC 100
(Cummins Tier I)
ASC 100 13
1.1. Basic Data
Introduction Modifications
Single drum vibratory rollers of line ASC 100 are outstand- The single drum vibratory roller ASC 100 with the smooth
ing by their up-to-date design, adopted technologies, as drum is suitable for compaction of all kinds of soil. It can
well as modern styling. These machines offer maximal be employed at compaction of clayey soils up to the layer
comfort to the operator, are easy to operate, extremely thickness (compacted) of 25 cm (9,8 in), loam soils up to
reliable and require minimal maintenance. The utilized the layer thickness of 40 cm (15,7 in), mixed soils up to
frequency, amplitude and centrifugal force of vibration the layer thickness of 50 cm (19,7 in), sandy soils and
were optimized by means of compaction tests to reach rockfills up to the layer thickness of 80 cm (31,4 in),
extra high compaction effect on various materials. gravels up to the layer thickness of 60 cm (23,6 in).
Maximal allowed grain size is up to 2/3 of total layer
thickness. The roller is suitable for compaction of stabi-
Application Range lized soils as well.
The vibratory rollers of ASC 100 line are especially suit-

able for use at mid- and large compaction jobs of highway
construction (construction of highways, railways, airports),
hydraulic construction (earth dams) and civil engineering
(industrial areas, ports etc.).
The rollers are designated for operation under conditions
as according to IEC 721-2-1 (038900): WT, WDr, MWDr
(i.e. moderate, warm dry, hot dry) with temperature limits
from -15°C (5°F) to +45°C (113°F).
14 ASC 100
Fig. 1 - Pin label Please refer to the data in the table below always when
approaching the dealer or the manufacturer.
Please fill in the following data:
Type of machine (see Figs. 1, 2)
.....................................................................................
ICV/PIN (Serial number of the machine) (Figs. 1, 2)
.....................................................................................
Production year (see Figs. 1, 2)
.....................................................................................
Type of engine (see Fig. 3)
.....................................................................................
Fig. 2 - PIN label 1, S/N 2 Serial number of the engine (see Fig. 3)
.....................................................................................
Fig. 3 - Serial number of the CUMMINS engine
ASC 100 15
1.2. Dimension Chart
A B D H1 H2 H5 H6 K K1 L
mm 2820 2250 1500 3027 2375 100 3540 450 405 5630
in 111,0 88,6 59,0 119,2 93,5 3,9 139,4 17,7 15,9 221,7
L1 O1 O2 R1 R2 R3 S W1 W2 W3
mm 1690 55 65 5575 3210 3275 25 2134 2130 1510
in 66,5 2,17 2,6 219,5 126,4 128,9 0,98 84,0 83,6 59,4
16 ASC 100
1.3. Technical Data Specification Manual
1.3.1. Weights
Operation weight EN500-1 kg (lb) 10120 (22311)
to drum kg (lb) 5300 (11685)
to axle kg (lb) 4820 (10626)
Static linear load kg/cm (lb/in) 24,9 (138,3)
Operation weight ISO 6016 kg (lb) 10300 (22707)

to drum kg (lb) 5260 (11596)
to axle kg (lb) 5040 (11111)
Operation weight EN500-1 with padfoot segments kg (lb) 11840 (26102)

to drum kg (lb) 7020 (15476)
to axle kg (lb) 4820 (10626)
Operating weight ISO 6016 with padfoot segments kg (lb) 12020 (26499)
to drum kg (lb) 6980 (15388)
to axle kg (lb) 5040 (11111)
Operating weight according to EN 500 is weight of the machine with full operating liquid, half filling of fuel, water tank
of sprinkling and operator’s weight 75 kg (165 lb).
Operating weight according to ISO 6016 is weight of the machine with maximum operating liquid, of fuel, water tank of
sprinkling and operator’s weight 75 kg (165 lb).
The weights may differ depending on additional modifications of the machine made on special request of the customer
or if additional options and/or accessories are used.
ASC 100 17
1.3. Technical Data
1.3.2. Travel Parameters

Travel speed infinitely adjustable in both directions
1st speed range (work) km/h 0 – 5,0
(MPH) (0 - 3,1)
2nd speed range (transport) km/h 0 - 10,3
(MPH) (0 - 6,4)
Theoretical gradability
1st speed range (work) % 68
2nd speed range (transport) % 27
Practical gradability by forward run

- without vibration % 45
- with vibration % 45
Approach angle
- front (°) 30
- rear (°) 28
Transversal stability
- straight frame (static) (°) 34
- full turn (static) (°) 31
Max. allowed transversal inclination

- without vibration (°) 22
- with vibration (°) 5
18 ASC 100
1.3.3. Vibration
Drive hydrostatic
Vibration exciter two-stage, circular non-directed vib-
ration
Frequency Hz 32/35
(VPM) (1920/2100)
Rated amplitude mm 1,85/1,15
(in) (0,073/0,045)
Centrifugal force kN 277/206
(lb) (62250/46294)
1.3.4. Engine
Make Cummins Diesel
Type 4BTA3.9-C116
Serial number ................
Number of cylinders 4
Bore mm (in) 102 (4,02)
Stroke mm (in) 120 (4,72)
3
Total displacement cm (cu in) 3900 (239)
Output according to ISO 3046/1 (DIN 6271) kW (HP) 86 (116)
-1
Rated speed min (RPM) 2500
Maximal torque Nm (ft lb) 423 (312) /1500 min-1 (RPM)
Specific fuel consumption at rated speed g/kWh 240
Fuel speed at normal operation l/h (gal US/h) 11,8 (3,12)
Fuel cleaners - Fleetguard 1x FF 1280 (3925274)* a 1x FF 5052
(3903640)*
Oil cleaner - Fleetguard LF 3345*
Air cleaner Donaldson FLG 08-0337
Air filter element Donaldson P77-2550
Air filter safety element Donaldson P11-9410
Cooling system liquid cooled engine with cooler 34299
Coupling CENTA CF-H-030-1-SA-02
Engine fulfills requirements of: Tier 1 97/68/EC
* Exact denomination of these parts is dependent on modification of the engine. For spare parts ordering always refer
to the serial number of your engine.
ASC 100 19
1.3. Technical Data
1.3.5. Axle
The front axle consists of the drum, the rear axle of the axle housing with two drive gearboxes with the wheels.
Number of tires 2
Tire size 23,1x26“ thread UK-5 (10 PR) MITAS
Average contact pressure on soil kPa (PSI) 304 (44,1)
Tire inflation kPa (PSI) 160 (23,2)
1.3.6. Brakes
Service brake hydrostatic system of travel
Parking emergency brake three band brakes installed in the

gearboxes of the wheels and the
drum, governed by springs with hyd-
raulic release
Releasing pressure MPa (PSI) 1,9 (275)
1.3.7. Steering
Hydraulic power steering with two hydraulic cylinders
Hydraulic pump of steering Bosch Rexroth HY/ZFS24/25

Power steering unit Bosch Rexroth Servostat 8477955593
Safety pressure MPa (PSI) 15 (2175)
Hydraulic cylinders 2x HV 90/45/400
Steering angle (±) 36
Oscillation angle (±) 10
20 ASC 100
1.3.8. Vibratory Drum

Drum dia mm (in) 1500 (59,0)
Drum width mm (in) 2130 (83,8)
Thickness of drum mm (in) 25 (0,98)
1.3.9. Hydrostatic Drive of Travel

Hydraulic pump of travel variable output with
skew plate, electrohydraulically controlled Bosch Rexroth A10VG63
3
Delivery per revolution cm (cu in/rev) 63 (4,83)
Kontroller Reflex 9V 4592-01-01
Drum drive gear-box Trasmital 707C3B 83.7
Filtration block Donaldson HMK 045796
Filter element Donaldson P165332
Drum drive hydromotor Bosch Rexroth A10VE45
Wheel gears Trasmital 706C3B 68.4
Wheel drive hydraulic motors Bosch Rexroth A10VE45
Flow divider Hytos 729-0170
1.3.10. Hydrostatic Drive of Vibration

Hydraulic pump of vibration variable-output,
with skew plate, electrohydraulically controlled Bosch Rexroth A10VG45
Delivery per revolution cm3(cu in/rev) 45 (2,74)
Hydromotor of vibration Bosch Rexroth A10FM45
ASC 100 21
1.3. Technical Data
1.3.11. Hydraulic Oil Tank

Suction basket Argo AS 080-1
1.3.12. Lifting and lowering of the Hood and the Cabin

Safety packet Hytos 513-0700
Hydraulic cylinders of hood lifting 2x 25 – 300AXL Semily
Hydraulic cylinder of cab lifting 1x 32-300 AXL Semily
Hand pump Technometra RC 16
1.3.13. Cooling System of Hydraulic Oil

Oil cooler Emmegi 34299
1.3.14. Fluids
Engine oil l (gal US) 11,2 (2.96)
Cooling system l (gal US) 24,0 (6,3)
Fuel l (gal US) 410 (108,3)
Hydraulic system l (gal US) 90 (23,8)
Drum drive gear-box l (gal US) 3,5 (0,92)
Wheel gears l (gal US) 2x3,3 (2x0,87)
Vibratory drum l (gal US) 8,0 (2,1)
Tank of windscreen washer l (gal US) 2,75 (0,72)
Tires kg (lb) 2x525 (2x1157)
22 ASC 100
1.3.15. Electrical Installation

Rated voltage V 24
Capacity of battery Ah 2 x 100
1.3.16. Safety Devices

Battery disconnector disconnects electrical installation
1.3.17. Hygienical Data

Noise:
The acoustic pressure level affecting the driver:
(measured according the EN 11 204 on the elastic material,
stopped machine with vibration) LpA = 95 dB (A)
Sound power level

(measured due to the EN ISO 3744 on the elastic material,
stopped machine with vibration) LWA = 114 dB(A)
The vibrations:
The mean effective value of the vibrations acceleration:
- transfered to the body a w < 0,9 ms-2 (vectorial sum)
(measured according the EN 1032 on the sand base under the vibration travel)
- transfered to the hands aw < 5,2 ms-2 (vectorial sum)
(measured according the ISO 5349 on the sand base under the vibration travel)
1.3.18. Requirements of Traffic Regulations

The basic machine model is not intended to be moved under own power on public roads, since its appointment is not
in compliance with the regulation for public roads.
ASC 100 23
1.3. Technical Data
1.3.19. Accessories
A) Roll Over Protective Structure (ROPS)
The rolli over protective structure ROPS is a frame, which protects the driver if the machine rolls over. It meets the
international requests for driver’s protection according to EN 13510:2000; ISO 3471:1994; SAE J ISO 3471:2003; AS
2294:2003 up to the total weight of the machine 18500 kg (40785 lb).
Weight of the ROPS frame kg (lb) 230 (507)
Fastened to the machine frame with 16 bolts M 24 x 80 (8G)
Tightening torque Nm (in lb) 549 (4854)
The data for the frame are stated on the frame decal.
C) Padfoot Segments
These are mounted onto the smooth drum and partially substitute for the padfoot modification. The padfoot segments
are used for compaction of soils up to the layer thickness according to following table:
cohesive soils 50 cm (19,7 in)
mixed soils 60 cm (23,6 in)
The segments are also suitable for pulverization and compaction of plate-shaped rock (shales).
Number of segments 3
Drum dia over pads mm (in) 1712 (67,4)
Total number of pads 150
Height of a pad mm (in) 100 (3,9)
2
Area of a pad cm (sq in) 120 (18,6)
Weight of one segment kg (lb) 537 (1184)
Total weight of segments kg (lb) 1680 (3703)
Fastened to the drum with 18 bolts M 20 x 150 (8G)
Tightening torque Nm (in lb) 314 (2776)
D) Filling the Tires with Liquid

Added weight with liquid to -25°C (-13°F) kg (lb) 2 x 600 (2 x 1323)
24 ASC 100
Notes:
ASC 100 25
Notes:
26 ASC 100
2. OPERATING INSTRUCTIONS
ASC 100
ASC 100 27
2.1. Dewaxing and Inspection of a Newly Supplied Machine
• Inspect the Machine per shipping documents.

• Check that no parts of the Machines have been dam-
aged during transportation, and that no parts are
missing. Inform shipper about any shortcomings.
Before Machine Operation, please

carry out dewaxing, wash away the
preserving agents using high pres-
sure stream of hot water added with
standard degreasers. All relevant
ecological principles must be ad-
hered to.
Perform dewaxing & washing of the

Machine at places equipped with
intercepting sumps to catch rinsing
water & dewaxing agents.
28 ASC 100
2.2. Major Safety Measures Operating instructions
2.2.1. Safety measures to operate the 2.2.1.2.Work safety secured by User

Machine
• User must ensure the Machine will be operated only
Safety measures stated in the individual sections of the under those conditions, and solely for those purpos-
Engineering Documentation supplied together with the es the Machine is technically eligible for under the
Machine shall be supplemented with those safety pre- conditions specified by manufacturer and respective
cautions in force within a respective country where the standards.
Machine will be used, and within a workplace, with regard • User must promptly report any damage of the utility
to human resource management, work process and lines to their Operator, and at the same time perform
personnel. measures to prevent Admittance except on business
to the danger area.
• User shall provide for use of vibration roller only in
such a way and at such sites where there is no hazard
of damage to nearby premises and others.
2.2.1.1. How to start the compaction • User shall ensure that a worker does NOT work alone
work at the site, and that another worker is ALWAYS in sight
and within ear-shot to provide or call for aid unless
• Supplier of building work (Machine User) shall be other effective form of supervision or communication
liable to provide instructions for Driver and Maintenan- is available.
ce Department. These instructions include the requi-
• User must ensure surveillance designate worker at
rements to secure occupational safety while operating
work machinery in the working condition on public
the Machine.
communication, which be in capacity issue instruc-
• Prior the compaction work the Supplier of building tions to reservation labour protection
work (Machine User) must verify the following:
• User must secure regular inspection of the opera-
- Utility lines tions, operating condition, regular Machine mainte-
nance in intervals under the Lubrication & Mainte-
- Underground areas (direction, depth)
nance Manual . In case of nonconforming operating
- Seepage or escape of hazardous materials condition of the Machine to the extent it becomes
hazardous and detrimental to the environment, then
- Soil bearing capacity, slope of traverse plane
the Machine must be discarded until the defect gets
- Other barriers and obstructions, along with spec- repaired.
ifying the measures to ensure work safety.
• User shall specify who and what tasks may be carried
• Supplier of building work (Machine User) must then out during operation, maintenance and repairs of the
make familiar with these conditions a Machine Driver Machine.
who will carry out the earthwork.
• The one who drives the Machine (Driver) and anybody
• Supplier of building work (Machine User) shall define who performs maintenance and repairs of the Ma-
technological process part of which is the work proce- chine must be made familiar with those instructions
dure designed for a given job. The work procedure given in the Machine Operating Manual.
specifies inter alia:
• User must ensure the ”Machine Operating Manual”
- Measures for work under extraordinary conditions and the Operation Logbook are stored at a specific
(work within protective zones, under extreme place to be ALWAYS available to the Driver.
slopes, etc.)
• User shall make the fire extiguisher to undergo regu-
- Measures against any natural disasters lar inspections.
- Requirements for job execution while observing • User must provide for disposal of hazardous materi-
job safety principles als (fuel, oil, coolant, and alike) away from their leak-
age point in order to avoid their adverse environmental
- Technical and organisational measures to secure impact, adverse effect on operation safety and health.
safety of workers, site and environment. .
• Supplier of building work (Machine User) must evi-
dently make Machine Driver familiar with the techno-
logical process (job description).
ASC 100 29
2.2. Major Safety Measures
2.2.2. Driver Qualification 2.2.3. Driver’s Duties

Requirements
• Before starting Machine operation Driver must get
• Only a driver trained under local and national regula- familiar with the instructions given in the Documenta-
tions and standards designed for drivers of this group tion supplied with the Machine, with safety measures
of Machines may operate the Roller. in particular, and follow these guidelines thoroughly.
This applies also to a personnel in charge of Machine
• Only the one who with the approval of Machine User maintenance, adjustments and repairs.(Unless you
learns to drive under a direct & constant supervision understand some sections of the Manual, please
of professional lector or trainer in order to gain prelim- contact your dealer or manufacturer.)
inary practice, may drive with no driving licence ob-
tained so far. • NEVER drive Roller unless fully made familiar with all
the Machine’s functions, operating and handling ele-
• Licence holder is liable to duly keep the licence in ments, and until you know precisely how to operate the
custody and if requested he/she must put it forward to Machine.
the control authorities.
• Follow safety signed located on the Machine, and
• Licence holder may NOT make any recordings, chang- keep them in legible condition.
es or corrections to the licence.
• Prior to commencing work Driver must get familiar
• Driver is liable to promptly report any loss of his/her with the site environment, i.e. any barriers, slopes,
licence to the authority that had issued the licence. utility lines, necessary site protections in terms of the
• Only a person mentally and physically competent, surrounding environment (noise, vibrations, etc.).
over 18 years old may drive the Roller alone if : • When finding any health hazard, life hazard, danger to
a) Charged by the Machine manufacturer to assem- persons, property, finding any failures, or when there
ble, test and demonstrate the Machine, or to train is an accident of technical facilities, or when finding
drivers, whereas he/she must be made familiar any symptoms of such hazards during operation, then
with the occupational safety regulations in force at the Driver must, unless able to clear away such dan-
the site, ger by himself/herself, stop the work and secure the
Machine against any undesirable starting ON, report
or to a staff in charge, and if possible, alert all the
persons threatened by such hazard.
b) Appointed by Supplier of building work to operate
(carry out maintenance), and evidently trained and • Before starting to run the Machine, Driver is liable to
acquainted with, or if, under specific regulations, get familiar with the records and any operating devi-
he/she owns professional competence to operate ations found out in course of previous working shift.
and drive (engine operator’s licence, and alike).
• Before work commencements please inspect the
• Machine Driver must undergo training at least 1x every Machine, fittings, check the control elements, com-
2 years, and pass exams concerning work safety munication & safety equipment, whether these are
regulations. functional and enabled according to the Manual. When
finding any defect hazardous to job safety and unable
to be repaired by Driver, then the Driver may not start
the Machine but instead communicate the failure to a
staff accountable.
• When Driver finds a defect during operation, he/she
must stop the Machine immediately, and secure safe-
ly against any undesired starting ON.
• Driver must follow the Machine run while in operation
and record any malfunctions found into the diagnostic
logbook.
• Driver must keep diagnostic logbook designed to
make records on handing in and handing over the
Machine between the Drivers, and on any defects and
repairs during operation, and to document major
events during an operating shift.
• Prior to starting the engine check the controllers are
in gauge zero; no persons may remain within danger
range of the Machine.
• Make sound or light signal to communicate each start
up of the Machine, and this ALWAYS before you start
Machine engine.
30 ASC 100
Operating instructions
• Confirm the functions of the brake and steering before • Before lifting the cabin and bonnet, please confirm
Machine operation start up. there is enough space for lifting, with no electric lines
present. Before dropping the cabin and bonnet con-
• Following an alarm the Operator may start the Ma-
firm nobody will be endangered with this operation.
chine only when all workers leave the danger area. At
blind (uneasy to oversee) sites the operation start may • In case the Machine would come into contact with high
begin only after a period necessary to exit endangered voltage the following principles must be adhered to:
area elapses.
- Try to escape with the Machine from the hazardous
• When operating the Machine the safety regulations area
must be adhered to, no activity hazardous to work
- Do NOT leave driver control stand
safety can be carried out, commit yourself fully to
Machine driving. ALWAYS sit on the seat when driving - Give warning to others not to approach and contact
the Machine. the Machine.
• Respect job description or instructions of an employ- • Maintain the Machine free of oil dirt and flammable
ee accountable. materials.
• When moving with the Machine at the site you must
adapt the speed to the terrain condition, work in
progress, and weather conditions. Watch continu-
ously the clearance height to avoid collision with any
obstruction.
Observe safety communica-
• Upon completion or stop of the Machine operation
tion under any and all cir-
during which Driver leaves the Machine, he/she must
first make measures against unauthorized use of the
cumstances – Life Hazard
Machine and its spontaneous start. Remove key from
the ignition box, lock the cabin and use disconnect or
to cut out the wiring.
• Upon operation completion park the Machine at an Observe safety communica-
appropriate station (flat, good bearing surface) in tion – Accident Hazard.
order not to threaten Machine stability, intervene with
traffic roads, expose the Machine to the falling objects
(rock), and where no natural disasters of other type
(floods, landslides, etc.) are not a threat to the Ma-
chine.
• When parking the Machine on communications over Follow environmental regula-
land, please carry out measures under the regulations.
tions effective for communications over land. Label
the Machine properly.
• When working with the Machine is completed, please
write down in the Operation Logbook any Machine
defects and its damage including repairs made. Dur-
ing immediate change of Drivers it is a a duty to directly CAUTION Take notice of labels
draw changing driver’s attention to any matters found
out.
• Driver must wear personal protective equipment, i.e.
work clothing, safety shoes. The clothing must NOT
be too loose or damaged, hair protected with proper
head piece. Hands protected with proper gloves dur-
ing maintenance work (lubricating, replacing of oper-
ating media).
• Driver at the Machine with no cabin must use ear
protection effective within noise level of round 90 dB.
• Keep the Machine fitted with specified accessories
and outfit.
• Keep clean driver control stand, climbing steps and
walkway surfaces.
ASC 100 31
2.2.4. Operations Prohibited • Operate the Machine within protective zone of electric
lines and substations.
It is forbidden to: • Pass over the electric cables unless these are prop-
erly protected against mechanical damage.
• Use the Machine after drinking alcohol and ingestion • Operate the Machine under reduced visibility or at
of narcotics. night unless the working area of the Machine or the
site is sufficiently illuminated.
• Use the Machine in case its operation might deterio-
rate its operating condition, cause safety hazard (life, • Leave Machine driver seat with the Machine running.
health) to persons, buildings and other property, or to • Abandon unsecured Machine, i.e. move away from the
road traffic and its continuity. Machine without preventing its misuse.
• Start the Machine and use it when other persons are • Disable safeguarding, protecting or locking systems,
within the hazardous vicinity of the Machine. Exempted or alter their parameters.
is driver training by lector.
• Use the Machine with leaking oil, fuel, coolant or other
• Start the Machine operation and use the Machine with fillings.
some of the safeguard equipment (emergency brake,
hydraulic locks, etc.) removed or damaged. • Start the engine in some other way than given in the
Driver Manual.
• Move and compact at such banks at which machine
stability would be broken (overturn). Machine static • Place, aside from personal needs, so other things
stability specified gets reduced by the dynamic effects (tools, accessories) at the Driver Control Stand.
of the drive.. • Put any materials or other objects on the Machine.
• Move and compact at such angles of slopes at which • Remove any dirt while the Machine is running.
the hazard of earth breaking off together with the
Machine could occur, or adhesion lost followed by • Carry out maintenance, cleaning or repairs unless the
uncontrollable breakaway. Machine is secured against self-motion and acciden-
tal start, or unless contact between worker and mov-
• Control the Machine in a way other than stated in the ing parts of the Machine is excluded.
Driver Manual.
• Touch moving parts of the Machine with your body and
• Move and compact with vibration per soil bearing objects or tools held in your hands.
capacity at such distance from the slope edge or
excavation edges to avoid the hazard of material slid- • Smoke & handle open fire while inspecting or refilling
ing down or shoulder breaking off together with the the fuels, changing, replenishing oil, lubricating the
Machine. Machine, or checking and refilling the accumulator.
• Move or compact with vibration at such distance from • Carry the rags soaked with flammable materials on
walls, cuts or slopes so as to avoid the hazard of their the Machine (inside engine bay, cab), or carry flamma-
collapsing and backfilling the Machine. ble liquids in free vessels.
• Compact with vibration at such distance from the • Let the engine run inside confined areas. Exhaust
buildings or premises and facilities within which a gases are dangerous to life.
hazard of their being damaged due to vibration energy
transfer could occur.
• Move or transport persons on the Machine.
• Operate the Machine unless driver control stand is
properly fixed.
• Operate the Machine with its bonnet lifted.
• Operate the Machine when there are other machines
or conveyances within the danger area of the Machine
except for those working in mutual interaction with the
Machine.
• Operate the Machine at a location unable to be seen
from driver control stand, and where hazard to per-
sons or property may occur unless work safety is
secured in some other way, e.g. indirectly via signal-
ling carried out by duly instructed person.
32 ASC 100
2.2.5. Hand Signals

Signals given by Machine Operator Assistant when Oper-
ator is unable to cover visually moving working space or
utility device or tool.
GENERAL COMMAND SIGNALS
Stop
One arm rose with open palm in the direction of Operator,
the other arm akimbo.
Attention
Both arms sideways raised horizontally – palms forward.
Beware of Danger
Oscillating motion of both fore-arms from the position of
arms sideways raised horizontally to a position of arms
sideways raised – in huddled-up way and back.
ASC 100 33
SIGNALS TO DRIVE
Drive away with the Machine

One arm erected – bent with open palm, long motion of
fore-arm in the direction of required motion, second arm
akimbo.
Slow forward drive– to me

Both arms stretched upward abreast huddled up, with
palms towards the body; short oscillating motions of fore-
arms towards the body and back.
Slow backward- drive - away from me

Both arms stretched upward abreast huddled up, with
palms away from the body – short oscillating motions of
fore-arms away from the body and back.
Driving on the right

Left arm sideways raised, right arm akimbo.
34 ASC 100
Driving on the left

Right arm sideways raised, left arm akimbo.
Short motion
Both arms lifted forward huddled-up. Mark the distance
„X“ between the palms, then the motion signal follows.
Engine start
Circular motion of right hand’s fore-arm with fist closed.
Engine shut down

Oscillating motion of right hand sideways rose in front of
the body an moving to the sides.
ASC 100 35
2.2.6. Safety labels & signs used on the Machine
36 ASC 100
Safety labels & signs used on the Machine
1 Clamp Hazard Risk area with clamp hazard. (Symbols placed left
and right on the rear cross arm of the front frame.)
2 Burn Hazard Danger of burn. Do NOT touch hot parts of the Ma-
chine unless you made certain of their being cooled
down sufficiently. (Symbols placed from inside on the
left door.)
3 Injury Hazard Risk of injury and winding around. NEVER touch ro-
tating parts while engine is running. (Symbol placed
on the left side of the cooler.)
4 Cooling Liquid Scalding hazard. Do NOT open expansion tank lid

until liquid cools down below 50 °C (122 °F). (Symbol
placed on the expansion tank.)
5 Adjust while at rest Risk of injury or being caught by the rotating parts of
the Machine. Make NO adjustments or maintenance
work when the engine is running. (Symbol placed from
inside on the left door.)
6 Read the Manual Read the Operating Manual before starting the
Machine.(Symbol placed on the left side of the control
panel.)
7 Machine Max Height Pay attention when passing through a location with
height limit. (Symbol placed on the left side under-
neath the cab on the frame.)
ASC 100 37
8 Battery Disconnector In case of failure or following a work completion, please

switch battery disconnector to ”0” position. (Symbol
placed on the panel behind LH lateral door.)
9 Rigging Diagram Use rigging of sufficient loading capacity when lifting

the Machine. Secure Machine joints before slinging.
(Symbol placed on LH door.)
10 Sling Positions Sling the Machine at these points. (Symbols placed

on both sides of the frames.)
11 Disconnect Alternator Before welding disconnect the alternator & electron-

ics of the Machine, i.e. ASC, motor control unit. (Sym-
bols placed from inside on the LH lateral door.)
12 Ear Protectors When the Machine has no cab, or operates with open
windows, please use ear protection. (Symbol placed
on central steering column.)
13. Electric Devices Cover electric instruments when washing the Machine
(Symbol placed on the left side of the cooler.)
14. Platform & Cab Lifting (Symbol placed on door’s inner side.)
38 ASC 100
2.3. Ecological & Hygienic Principles Operating instructions
During Machine operation or storage the User must 2.3.2. Ecological Principles
observe general principles of occupational safety and
environmental protection along with laws, public notices • Refills for the Machine’s individual systems and some
or regulations related to these issues and in force within of its parts become waste having hazardous proper-
a territory where the Machine is used. ties against the environment following their disposal.
• This waste product category includes in particular:
- organic or synthetic lubrication materials, oils and
2.3.1. Hygienic Principles fuels,
- cooling liquids,
• Oil products, refrigerants of cooling systems, alterna-
- accumulator refills and the accumulators them-
tor refills or painting materials incl. thinners are health
selves,
hazard materials. Workers coming into contact with
these products during Machine operation or mainte- - tyre fillings
nance will be liable to adhere to general principles of
- cleaning & preservation agents,
their own occupational safety, and conform to the
safety & hygienic manuals of the manufacturers of - all the filters & filter elements removed,
these products.
- all the used and discarded hydraulic & fuel hoses,
• We point in particular to : metal-rubbers and other elements of the Machine
fouled with the aforementioned products.
- Eye & skin protections while handling the accumu-
lators
- Skin protection while handling the oil products,
painting materials or cooling liquids
Producer and contractual service organizations accredi-
- Washing your hands properly upo work completed by him, or dealers take back the following materials
tion or before taking meal. Treat your hands with or parts free of charge:
appropriate reparable cream.
- oils
- While handling the cooling systems follow instruc-
- batteries
tions given in the Manuals supplied together with
the Machine. - tyres (optional)
• ALWAYS store oil products, cooling system refriger-
ants or accumulator refills and painting materials incl.
organic thinners along with cleaning & preservation
agents inside their original packages labelled prop- • Following the disposal of the abovementioned mate-
erly. Do NOT admit to store these materials in unla- rials and parts make sure these are handled in line
belled bottles or other containers due to their ex- with the respective national environmental regula-
change hazard. Especially hazardous is the potential tions and health regulations.
of being exchanged for consumables or drinks.
• Should your skin, mucosa, eyes be stained inciden-
tally, or vapours inhaled, then immediately apply first
aid principals. In case of accidental ingestion of these
products, get prompt medical attention.
• When handling the Machine in cases the Machine is
not fitted with cab, or cab windows are open, then use
ALWAYS ear protectors of suitable type and construc-
tion.
ASC 100 39
2.4. Preservation & Storage
2.4.1. Short-term preservation & 2.4.2. Machine preservation & storage

storage for the period of 1 ÷ 2 for the period over 2 months
months
• For the Machine shutdown the identical principles like
• Wash & clean carefully the entire Machine. Before with short-term preservation will apply.
Machine parking and shutdown in order to make its • In addition we recommend the following:
preservation & storage, please heat the running engi-
ne up to its operating temperature. Park the Machine - remove the accumulators, check their condition
on fixed, flat surface at a safe place with no potential and store in a cool, dry room (recharge the accu-
of Machine damage caused by natural disaster (flo- mulators on regular basis),
ods, landslides, fire, etc.). - Bottom on the runner frame so the damping sys-
• In addition: tem has minimal deflection (flexure),
- repair those spots with paint impaired, - paint rubber elements with spec. preservation
agent to protect them,
- lubricate all lubricating points, control cables, jo-
ints of the controllers, etc., - inflate the tyres to a specified pressure, and pro-
tect them from direct sunlight,
- confirm water fillings have been drained,
- apply chrome-plated piston rods with preservation
- check cooling liquid has its antifreeze characteris- grease,
tics required,
- spray the Machine with special agent and this at
- check the accumulator charging conditions, re- places with possible corrosion origin,
charge if required,
- Blind engine air intake and exhaust with double PE
- apply preservation grease over the chrome-plated foil and fix it carefully with adhesive tape,
surfaces of the piston rods,
- protect headlamps, exterior back mirrors and oth-
- we recommend to spray preservation agent (ap- er elements of external wiring via spraying with
plied via spraying) to protect your Machine against special agent and wrapping in PE foil,
corrosion, and this particularly in places with cor-
rosion hazard. - Preserve the engine per manufacturer’s Manual.
Install a visible label informing the engine has
• Machine treated like that will need no special set-up been conserved.
before its subsequent putting into operation.
! CAUTION!
Following 6 months we recommend to
inspect preservation condition and re-
new it if necessary.
NEVER start the engine during storage!
When the Machine is stored under field
conditions, please make sure such stand
is not exposed to any deluge hazard
caused by floods, or that no other type of
hazard occurs within this area!
Prior to restoration of the Machine

service, please wash the preserva-
tion agents using high pressure
stream of hot water added with
standard degreasers while observing
the Instructions for Use along with
ecological principles.
Dewax and wash the Machine at the

locations provided with intercepting
sumps to catch rinsing water and
dewaxing agents.
40 ASC 100
2.5. Machine disposal upon its life termination Operating instructions
User will be liable to follow national waste or environmen-

tal laws and regulations when carrying out Machine dis-
posal. We therefore recommend to always consulting:
· licensed industrial waste products disposing compa-

nies,
· Machine manufacturer or by them appointed and cer-
tified contractual service companies.
Manufacturer bears no responsibility for

any damage to health of the Users or
environmental damage caused by
breach of the abovementioned notice.
ASC 100 41
42 ASC 100
2.6. Machine Description Operating instructions
1 - Runner Frame 11 - Engine

2 - Drum 12 - Hydraulic Oil Cooler
3 - Scraper 13 - Engine Coolant Cooler
4 - Joint 14 - Driver´s Control Stand
5 - Tractor Frame 15 - Travel Hydrogenerator
6 - Axle 16 - Vibration Hydrogenerator
7 - Fuel Tank 17 - Exhaust Muffler
8 - Accumulators 18 - Air Filter
9 - Hydraulic Tank 19 - Hydr. Oil Pressure Filter
10 - Bonnet
ASC 100 43
2.7. Controllers & Dashboard Instruments
44 ASC 100
Dashboard & Control Panel
1 - Steering Wheel
2 - Travel Controller
3 - Vibration Switch
4 - Travelling Speed Controller (Selector)
5 - Throttle Controller
6 - Ignition Box
7 - Motor Thermometer (Optional)
8 - Hydraulic Oil Thermometer (Optional)
9 - Operated-Hours Counter
10 - Fuel Level Indicator (Optional)
11 - Speedometer (Optional)
12 - Engine Lubrication Control Lamp
13 - Accumulator Charge Control Lamp
14 - Brake Alarm Indicator
15 - Engine Overheating Indicator
16 - Minimal Fuel Level Indicator
17 - Air Filter Fouling Indicator
18 - Hydraulic Oil Filter Fouling Indicator
19 - Vibration ON Indicator
20 - Hydraulic Oil Overheating Indicator
21 - Vibration Amplitude Preselector
22 - Heater Fan Switch (Optional)
23 - Headlights Switch
24 - Rear lights Switch
25 - Alarm Horn Pushbutton
26 - Fuse Block
ASC 100 45
Steering Wheel 1
Used for Machine steering.
Travel Speed Controller 4
! CAUTION!
With the Controller turned ON the travel gear is engaged
With respect to safe steering, please (“Hare” indicator lights). The Machine is capable to reach
adjust optimal speed (1800. min –1) when max. Speed with pulling force reduced and climbing
driving without vibrations. ability decreased.
NOTE:
Travel Controller 2 With the controller switched off the operating speed mode
is set. The Machine reaches max. pulling force and
Use this controller to adjust direction & speed climbing ability.
of the driving. Driving speed corresponds to
the degree the controller deflects from idle
(neutral) position. At the same time the con- ! CAUTION!
troller is used as driving brake of the Machine.
The controller is arrested in set position. When You may switch ON the controller, i.e.
shifted to its center position the parking brake is enabled, travel speed, when driving the Machine
i.e. the control lamp 14 lights up. Vibration Switch 3 is on a formation level.
located at the controller handle, and is used to switch ON/
OFF the vibration after moving controller handle from You may turn ON the controller with the
neutral. Machine loaded.
With pulling force not sufficient, switch
! CAUTION ! OFF the travel speed controller.
Engine starting is possible in idle posi-

tion only.
No vibration able to turn ON when in idle NEVER switch ON the control-
position. (Vibrator bearings are not ler during occupational use of
lubricated during vibration at the halt). the Machine.
Do NOT switch OFF the con-
troller at high speed. Abrupt
slowdown will occur together
with impact within the hy-
draulic system. Turn OFF the
controller with the Machine at
rest or at low speed!
Throttle 5
Move the throttle downward to increase the speed from

idling one to maximal rpm.
46 ASC 100
Ignition Box 6
It has three positions - ”0”, ”I”, ”II”. When in”0” pos. all the
consumers with F1, F2 & F7 fuses will be connected; in”I” Operated-Hours Counter 9
pos.other consumers will be connected; cushion fuse ”II”
is used for Machine starting. Turn the key to”0” pos. to stop
the Machine, remove the key in this position. When accumulator charge indicator 13 goes off the
counter starts reading the hours. Reading the number of
hours does not depend on engine rpm.
NOTE:
The cab & the door underneath the cab have one common ! CAUTION!
key.
Carry out regular maintenance per the
hours worked out!
! CAUTION!
Remove the key from the ignition box
when leaving the Machine!
When the Machine has no cab and the
key is taken out, please close the igni- Fuel Level Indicator 10 - Optional
tion box cap to protect the ignition box
against water & dirt penetration.
Indicate the amount of fuel in the tank.
Speedometer 11 - Optional
Engine Thermometer 7 - Optional
Indicate engine rpm.

The thermostat maintains engine operating temperature
at the range of 82 to 93 °C (180 - 199 °F).
Engine Lubrication Control Lamp 12
Switch the ignition box key to position ”I”, and the control
Hydraulic Oil Thermometer 8 - Optional lamp lights up and then goes off after starting the engine.
The lamp lighted signals engine lubrication is insuffi-
cient.
Temperature limit is 90 °C (194 °F) for oil of HV 68 or HV
100 viscosity class. Optimal operating temperature is 50
- 60 °C (122 - 140 °F). ! CAUTION!
Unless it goes off, look for the failure!
Oils of other viscosity used
Oil Viscosity Oil Temperature Limit
HV 46 80 °C (176 °F)
HV32 70 °C (158 °F)
ASC 100 47
Accumulator Charge Control Lamp 13 Indicator of hydraulic oil filter 18
Switch the key on the ignition box 6 to“I” pos. and the This indicator lighted up under hydraulic oil operating
control lamp must light up and go off after starting the temperature of 50 - 60 °C (122 - 140 °F) signals the filter
engine. element is clogged with dirt.
! CAUTION! ! CAUTION !
Unless it goes off, look for the failure! Replace the elements at once!
Brake Alarm Indicator 14 Vibration ON Indicator 19
With this indicator lighted up the Machine broken is With this indicator lighted up the vibration switch 3 is ON.
signalled. When set speed is reached the Machine starts vibrating
with the amplitude preset via vibration Preselector 21.
Engine overheating control lamp 15 Hydraulic fluid overheating warning indica-

tor 20
When the engine temperature reaches the highest allow-

able level, the engine overheating control lamp goes ON When the fluid temperatures reaches the highest allow-
an audible warning is given. able level the overheating warning lamp goes ON, an
audible warning is given.
Low level of fuel indicator lamp 16

Vibration Preselector 21
When the fuel level drops down to min. 45 l (12, gal) the
indicator goes ON. - Small amplitude and high frequency are switched ON.
- High amplitude and low frequency switched ON.
Air Filter Fouling Indicator 17
Heater Fan Switch 22 - Optional

When this indicator lights up the filter elements are fouled
above their limit.
Two-speed.
! CAUTION !
! CAUTION!
Replace the elements at once!
The Fan enables air circulation inside
the cabin only. Cab installation is option-
al.
48 ASC 100
Fuse Block 26
Headlights Switch 23
Fuse (F1) -15 A (upper fuse) headlights + rear lights,
instrument panel illumination,
Fuse (F2) -5 A cab light, loud horn
Fuse (F3) -7,5 A brake, engine STOP,
Rear Headlights Switch 24 Fuse (F4) -7,5 A travel, vibration, vibration switching
control lamp
Fuse (F5) - 5 A brake indicator lamp, engine lubrica-
tion lamp, charge control lamp, hy-
draulic oil filter fouling lamp, engine
filter fouling lamp, fuel minimum lamp,
Alarm Horn Pushbutton 25 motohours counter, engine overheat-
ing lamp, hydraulics overheating lamp
Options: engine coolant thermome-
ter, hydraulic oil thermometer, fuel lev-
el indicator, tachometer (cancelled –
engine overheating lamp, hydraulic
oil lamp, fuel minimum lamp)
Fuse (F6) -15 A ventilation fan and heater fan, front &
rear wipers, front & rear screen wash-
ers
Fuse (F7) -20 A reserved (air conditioner)
Fuse (F8) reserved
! CAUTION!
Replace fuses with those of identical
value ONLY!!!
ASC 100 49
Cab Controllers & Accessories. Cab installation is optional.
27 - Screen Washer Switch

28 - Fan Switch
29 - Front Wiper Switch
30 - Rear Wiper Switch
31 - Cab Light
32 - Ventilation Nozzles
33 - Locker
34 - Back Mirrors
50 ASC 100
35 - Heater Valve Tie Rod

36 - Heater Vents
38 - Screen Washer Tank
40 - Cab Ventilation Filter
41 - Front Wiper
42 - Rear Wiper
43 - Seat
44 - Headlights
ASC 100 51
Locker 33
Designed for first-aid kit etc.
Back Mirrors 34
When working within a restricted space or during trans-
portation you may turn the back mirrors by 90° from their
operating position A to transportation position B.
! CAUTION!
Keep the back mirrors clean & properly
adjusted!!!
Screen Washer Tank 38

Two pumps integrated inside the tank are used to wash
the windscreen and rear screen.
! CAUTION!
Refill the the tank with antifreeze or
drain before winter season!
52 ASC 100
Driver Seat 43
SEAT ADJUSTMENT ELEMENTS:
Backrest angle adjustment – lift the lever to seting up of

the backrest.
Seat firmnes adjustment –push the lever to the driver’s

weight between 50 - 130 kg.
Longitudinal Move of the Seat – lift the lever and move the
seat in longitudinal direction forward – backward.
1
Accumulator cutoff switch
Use cutoff switch to disconnect accumulator from the

frame.
! CAUTION!
Use cutoff switch to disconnet the accu-
mulator following the drive end!
Switch OFF the disconnector ALWAYS
when washing the Machine!
ASC 100 53
2.8. How to Control and Use the Machine
2.8.1. Start the Engine • Switch ignition box key to pos.”ll” and start the engine
(keep the key in pos. ”ll” only until the engine starts).
• When started, use the control lamps to monitor the
engine function.
Before you start the engine,
please turn ON the horn for • When started, let the motor run at idle rpm of 1300
warning purposes. Confirm ÷1500 min-1 for a period of 3÷5 minutes.
nobody is endangered due to
the engine started!
Note:
Unless engine starts even after 3 attempts made – check
the fuel system. Upon starting, watch the colour of ex-
haust gases – the absence of blue or white fume indi-
How to start the engine: cates the fuel supply is insufficient.
• Make additional fuel pumping via hand feed pump at
the engine (upon longterm Machine shutdown).
• Switch ON battery disconnector.
• Switch ignition box 6 key to pos. ”l” – engine lubrication
lamps go ON 12, along with brake lamp 14, and
charge control lamp 13.
• Set the throttle controller 5 to slightly increased speed
(1/4 of controller stroke).
54 ASC 100
! CAUTION ! How to start using starter cables via

another machine
Do NOT start for more than 30 sec. Make
another starting attempt only after 2 Make sure the starting voltage of a boost-
minutes, and unless the motor starts starting power supply is 24 V.
even after 3 attempts, carry out trouble- Follow unconditionally the sequence of
shooting. operations given below!
Charge control lamp and lubrication
lamp must go off when the engine starts.
Lubrication lamp must go off within 15 1. Connect one (+) pole end of the cable to (+) pole of
discharged accu.
sec.
2. Connect second (+) pole end of the cable to (+) accu
Sharp speed increase or decrease is of the machine used to boost-start.
inadmissible – hazard of engine dam-
age. 3. Connect one (–) pole end of the cable to (–) pole of
accu in the vehicle used to boost-start.
When started let the engine run at idle
4. Connect second (–) pole end of the cable to a section
rpm of 1500 min –1 for a period of 3÷5 of the started Machine fix-connected to the engine (or
minutes. to the cylinder block itself)
Do NOT let the motor run idle for over 10
minutes – running idle for longer period
will cause injectors clogged, piston rings ! CAUTION!
gummed, valves seized! When started, disconnect the starter
Unless liquid temp reaches min. 60 °C cables in reverse order.
(140 °F) the engine will not be lubricated When aided by Starter Unit with no
sufficiently enough – do NOT run the accus connected, do NOT disconnect the
engine at full capacity! Unit before the Machine accumulator is
Starting will be interlocked: connected.
When the controller 2 is in idle (neu-

tral) position.
ASC 100 55
2.8.2. Travel & Reversing

Do NOT connect (–) pole of
the cable to (–) pole of dis-
Use acoustic alarm to communi-
charged accu of the started
cate drive away of the Machine,
Machine! Hazard of strong
and wait long enough so the
sparking when starting,
persons present may leave in
followed by an explosion of
time the adjacent area of the Machine
gases generated by accumu-
(area under the Machine) !
lator.
Before drive away you must confirm the
Non-insulated sections of the
area in front of and behind the Machine
starter cables’ gripping col-
is free, and that no persons are found
lets may NOT contact each
there!
other!
Make sure starter cable
connected to (+) pole of accu • Turn OFF the travelling speed controller 4 – i.e.
does NOT come into contact switched to operating speed.
with electrically conductive • Use throttle controller 5 to adjust engine rpm required,
parts of the Machine – short- i.e. ca 1800.min–1).
circuit hazard. • Confirm vibration switch 3 is not ON, control lamp 19
NEVER bend yourself over the is off.
accumulators - hazard of • Deflect travel controller 2 from idle (neutral) pos. to a
electrolyte burn! required direction – small deflection of the controller
= slow speed and vice versa. Following travel control-
Exclude any presence of ler 2 deflection the brake indicator lamp 14 will go off.
flammable sources (free
flame, smoking cigarettes, • Reversing – shift the controller 2 in opposite direction
via its idle position.
and alike).
NEVER verify voltage pres-
ence within a conductor via EMERGENCY STOPPING
sparking through the Machine Use this way of stopping in
frame! case of defect, when the
machine cannot be stopped
by moving travel control (2) to
neutral position. Shut down
How to start at low temperature. the engine by switch key off.
• Starting at ambient temperature below 0°C (32°F) will
require different way of starting with the use of starter ! CAUTION !
filling:
Turn ON the controller 4 – transport
• Adjust the throttle to half-speed, and when starting the
speed - you may do so while driving the
engine a second person will inject measured quantity
of starter filling into the air filter. Machine by an adjusted terrain (forma-
tion level) “Hare” symbol will light up.
Turn the controller ON only with the
! CAUTION ! Machine not idle..
Observe strictly safety & hygienic instruc- In case of lack of pulling force, switch
tions of manufacturer when using starter OFF the transport speed controller.
filling. Non-observance of these instruc- NEVER switch OFF the controller 4 at
tions may lead to engine or property high speed due to high slowdown along
damage, health and life hazards to with impact within hydraulic system.
people present. Turn OFF the controller 4 at low speed or
NEVER use volatile, easily ignitable refill with the Machine at rest!
when starting inside tunnels or mines. Engage operating speed via turning OFF
Always ask for safety guidelines when controller 4 before driving by steep
using starter refills under these condi- incline!
tions.
Do NOT apply throttle 5 to control Ma-
chine velocity.
56 ASC 100
NEVER drive in cross direc-

tion at the hillsides of high
slope! Drive perpendicular to
a hillside!
ASC 100 57
2.8.3. Travel with vibration

• Turn OFF controller 4, thus switching to operating • Start moving the Machine and turn ON the switch 3 to
speed mode. start the vibrations - control lamp 19 lights up – runner
begins vibrating.
• Use Preselector 21 to select vibration amplitude.
• Press and relieve button 3 to stop the vibration.
• Use throttle controller 5 to adjust maximal speed.
58 ASC 100
2.8.4. Stop the Machine & the Engine

• Use switch 3 to turn OFF the vibration – control lamp
19 goes off. ! CAUTION !
• Use controller 2 to stop the Machine – parking brake Do NOT stop hot engine instantly, instead
is enabled; lamp 14 lights up.
let it idle for a period of 3 minutes.
• Use controller 5 to lower the speed to engine idle.
• Switch ignition box key 6 to pos. “0” and take it out –
close the ignition box cap.
ASC 100 59
2.8.5. Machine Shutdown

• Stop the Machine.
• Cut off battery disconnector. Stop the Machine on flat,
paved surface
• Clean the Machine (scraper, tyres).
Confirm no natural hazard
• Make overall inspection of the Machine and repair any
(landslide, potential of deluge
defects caused during operation.
due to any floods, etc.) exists
• Confirm tyres have sufficient pressure. at the location where the
• Put Scotch blocks to the wheels and uncoupled-axle. Machine is parked and shut
down.
• Lock the instrument covers or the cab and the door
beneath driver control stand.
60 ASC 100
2.8.6. How to lift driver control stand

and bonnet
• Unscrew driver control stand nuts.
• Open cover on the left side underneath the driver

control stand. Remove pump handle 1.
• Lose a valve 2 and put the handle it into the pump, lift
driver control stand and the bonnet together.
• Use valve to lock the bonnet in its position. Refer to
ASC 100 61
• Use valve to lock the cab in its position. Refer to
• Open the valve 2 before lowering.
• Use valve to make the bonnet descend. Refer to
• Use valve to make the cab descend. Refer to
! CAUTION !
Screw the driver control
stand when tilted.
62 ASC 100
2.9. Machine Transportation Operating instructions
2.9.1. Machine transportation by its A person that guides the

own axle Machine must communicate
with the Driver using speci-
• Move the roller by its own axle when moving within a fied intercommunication
working site outside public roads. signals, (refer to Section
2.2.5), this guiding person
must always stay at one place
! CAUTION !
outside the reach of the
Transport speed – you may switch ON Machine and outside the
collector (4) when crossing with the carrier. Guiding person must
Machine by finished road. remain within Driver’s field of
sight (in visual contact)
In case of long transportation distances,
throughout the entire period
please make 1-hour cooling breaks every
of driving the Machine onto
3 hours. Non-observance of this advice
the carrier and driving down
will put in jeopardy of Machine damage
from the carrier.
that the manufacturer will in no and any
circumstances bear responsibility for. When driving onto and down
from the carrier all the per-
sons aside from Machine
Follow those safety measures Driver must go away as far as
specified for the work site to avoid being hit by a falling
when shifting the Machine. Machine.
Fix the Machine to the carrier
via the clamps (tie-offs) (1) at
the rigging points! By rigging
points we mean front & rear
slings, front & rear pulling
2.9.2. Machine transportation by hitches, and sling holes in the
runner frame sidewalls.
public road
Adhere to the Motor Vehicle
Construction and Use Regula-
tions when transporting via
! CAUTION!
land routes.
The basic construction of the Machine is
NO persons may stay on the
NOT fitted for transportation by its own
Machine, driver control stand
axle using public road. This type of
or carrier loading area during
transportation is prohibited.
Machine transportation.
• Transport the Roller by public road using a carrier. If

required, dismantle the Cab, refer to Section 2.9.4.
Fixing the Machine on the carrier.
When driving onto the carri-

er, we recommend to put
rubber bands or wooden
planks, etc. under the runner.
Make sure the carrier de-
signed for the transport is
braked when loading and
unloading, as well as me-
chanically locked agaisnt
undesired moves using the
Scotch blocks (2).
ASC 100 63
2.9. Machine Transportation
2.9.3. How to load the Machine

• Use loading platform or crane loading to load the
Machine onto the carrier.
• When loading with crane the Roller is fitted with slings
(lifting eyes) – refer to the Fig. for slinging method.
• Before lifting the Roller, please lock the Machine joint
against being turned slightly.
How to lock the joint:

• Unlock and pull out the journal 1. 1
• Fold down the arm 2 and lock with the journal 1 and
safety lock 3.
Do NOT enter underneath 2

hanging load! 1
Upon completion of loading,
return the safety arm back to
its initial position.
Follow provisions in force
when loading/unloading.
Apply adequate, intact rig-
ging of sufficient loading
capacity.
Use only those lifting eyes
(mounting lugs) on the Ma-
chine designed specifically
for slinging.
Only a trained slinger may
carry out the slinging.
64 ASC 100
2.9.4. Towing of Machine

• In case of failure the Machine can be towed to a
distance necessarily needed. For this reason the
Machine has been fitted with two eyes on the runner 2
frame 1 and on the Machine frame 2.
! CAUTION !
Make sure the Machine is attached to
both of the eyes when being towed!
1
• The Machine may also be pushed against the cross
arm of runner frame, or against the rear section of the
Machine frame (tank). Be careful not to damage the
bonnet.
Use unimpaired towing ca-

bles or towing bars of suffi-
cient capacity - dimensioned
to weight 1.5 times higher
than weight of the towed
machine. It is not permitted to
use chains for towing.
No persons can be present on
the machine with non-work-
ing engine.
It is necessary to keep the
deviation from the straight
towing angle as little as
possible. Maximum deviation
is 30 degrees.
The towing machine should
be equal by size to the dam-
aged machine. It must be
sufficiently powerful (towing
power), heavy and have
sufficient brake effect.
When towing downhill using
a cable, it is necessary to
connect another towing
machine to the rear part of
the damaged machine. This
will prevent uncontrolled
movement of the damaged
machine.
The bogged roller may be
pulled out for short distance,
if the engine is running and
the driving unit and steering
are functional. The drive on
the towed roller must steer
the roller in the dragging
direction.
ASC 100 65
2.9. Machine Transportation
2.9.5. Dismantle the Cab and the

ROPS - Option
How to dismantle the ROPS
• Hook up the frame by loops.
• Remove bolts and remove frame.
66 ASC 100
How to dismantle the Cab

• Loosen the bolts that attach the Cab to the platform.
• Disconnect the connector between steering column

and the windscreen to cut out the wiring.
• Disconnect the screen washer wiring and the hoses

leading to the screen washing nozzles. Sling the Cab
by the mounting lugs and put it by.
ASC 100 67
2.10. Special Conditions for the Machine Application
2.10.1. Vibration driving on compacted

In case it is urgent to operate
and hard materials the Machine under the condi-
tions with the potential of
During vibration driving a loss of contact between the
Operator exposed to higher
runner and the compacted material (so called vibro-
stroke) may occur due to the impact of high level of sub vibrations, then the Machine
grade material compaction, or due to vibration driving on User is liable to adapt the
hard materials (e.g. stony loose material). This state will operating procedures so as to
show through the increased vibration energy transfer to avoid driver’s health hazard.
the Machine frame and Driver control stand. Increase
travel velocity or change Machine vibration parameters
(applying lower amplitude) to partially remove this effect.
Higher vibration energy transfer to the Driver control stand
Note:
may also be expected when increasing the level of sub
grade material compaction. When vibration driving on a different sub grade material
than stated in ”Specifications Manual”- Hygienic Data,
then the emission figures of vibration acceleration will be
different.
68 ASC 100
2.10.2. Machine use under heavy

climatic conditions
2.10.2.1. Machine operation under low

temperatures
Manufacturer Oil Type
Compacting during winter season depends on fine par-
ticle contents and water contents within a soil under Power Class
compaction. With the temperature going down below under ISO HV (HVLP)
freezing point the earth becomes more solid and harder 6743/HV
to compact. Viscosity Class
under ISO
When compacting at the temperatures below 0 °C (32 °F) VG 32 VG 46
6743/4, DIN
is required, you may compact dry soils (or stony loose
51519
materials) or perform fast compaction of non-frozen
materials (ahead of earth becoming frozen through). Viscosity Class
under CETOP HV 32 HV 46
RP 91H
Make the Machine ready for operation under low tem- AGIP ARNICA 32 ARNICA 46
peratures:
• Check the engine coolant concentration. ARAL VITAM HF 32 VITAM HF 46
• Exchange oil in the engine with the one recommended AVIA AVILUB HVI 32 AVILUB HVI 46
for a given range of low ambient temps.
BP BARTRAN HV 32 BARTRAN HV 46
• Apply hydraulic oil of corresponding cinematic viscos-
ity. CASTROL HYSPIN AWH 32 HYSPIN AWH 46
• Change oil in runner gearbox with the one recom-
mended for a given range of gearbox temperatures. CHEVRON EP 32 HV EP 46HV
• Use winter fuel. ELF HYDRELF 32 HYDRELF 46

• Confirm the accumulators are charged.
ESSO UNIVIS N 32 UNIVIS N 46
Sound condition of accumulator is the prerequisite of
good starting under low temperatures. Warm up the MOBIL MOBIL DTE 13 MOBIL DTE 15
accumulators to ca 20 °C (68 °F) (via removing accumu-
lators and storing them in a dry warm room) to lower limit ÖMV HLP-M 32 HLP-M46
temp for starting by 4 to 5 °C (39,2 to 41 °F).
SHELL TELLUS T 32 TELLUS T 46
RANDO HD AZ
Hazard of engine damaged when engine TEXACO ALCOR DD-Z 46
32
(cooling liquid) operating temperature
TOTAL EQUIVIS ZS 32 EQUIVIS ZS 46
remains constantly below 60 °C (140°F).
Use the Machine at its full power only after heating the
fillings to their operating temperatures (coolers possible
to be partially covered as well).
! CAUTION !
NEVER start the Machine at ambient temperatures below +2 C (36 °F) when the hydraulic
system is filled with HV 100 oil.
When starting at ambient temperatures below –8 °C (18 °F) is required for a period of one
month or more, please exchange oil in the hydraulic system with HV 46 viscosity class oil.
And with HV 32 class oil (e.g. BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.) at ambient tem-
peratures below –13 °C (9 °F).
NEVER start the Machine below –23 °C (–9 °C) with no preheating of fillings made.
ASC 100 69
2.10. Special Conditions for the Machine Application
2.10.2.2. Machine operation under high 2.10.2.3. Operating the Machine at high
temperatures and humidity altitudes
Engine power will lower with air temperature or humidity Engine power will decrease with the altitude rising. This
increasing. Since both of the factors that lower engine is given by the reduced atmospheric pressure and induc-
performance are independent on each other, their effects tion air specific mass.
can be described as follows:
- With every 10 °C (50 °F) of increased temp the power
Altitude m (ft) Decrease in Power %
will drop by up to 4 % (at constant humidity)
0 0 0
- With every 10 % of increased RH the power will drop
by up to 2 % (at constant temperature). 500 (1640) 3
1000 (3281) 6
1500 (4921) 10
Any engine (cooling liquid) operating 2000 (6562) 15
temperature over 100 °C (212°F) may
2500 (8202) 21
damage the motor.
3000 (9843) 28
At high temperatures when hydraulic oil temp is constant-

ly round 90 °C (194 °F), we recommend to exchange When black smoke is generated by the engine at high
hydraulic oil with denser one of 100 mm 2/s cinematic altitudes (above 1500 m), please contact your engine
viscosity class (BP BARTRAN HV 100, ESSO UNIVIS manufacturer service department to make adjustment to
N100, etc.) your injection pump to fit these operating conditions.
Power Class per ISO 6743/HV HV (HVLP) ! CAUTION!

Viscosity Class per ISO 6743/4, Engine power will be affected by the
VG 100
DIN 51519 environment where the Machine is oper-
ating, as per Sections 2.10.2.1. & 2.10.2.3.
Viscosity Class per CETOP
HV 100
RP91H
BP BARTRAN HV 100
ESSO UNIVIS N 100

2.10.2.4. Machine operation at
MOBIL DTE 18
extremely dusty environment
ÖMV HLP - M 100
SHELL TELLUS T 100

! CAUTION!
Cut short the intervals of cleaning and
replacement of air filter elements when
! CAUTION! operating under extremely dusty condi-
When hydraulic system is filled with oil tions; shorten the intervals of cleaning
class: the engine cooler, hydraulics, or of
HV 46, then oil max. Limit tempera- replacing Cabin dust filter.
ture is 80 °C (144 °F)
HV 32, then oil max. Limit tempera-
ture is 70 °C (158 °F)
When operating under extreme tempera-
tures when cooling liquid or hydraulic oil
temperatures reach max. Limit tempera-
tures, you may remove fender aprons of
the bonnet to increase cooling capacity
of the Machine Cooling System, and
hence improve hot air removal from the
engine bay.
70 ASC 100
Notes:
ASC 100 71
Notes:
72 ASC 100
3. MAINTENANCE MANUAL
ASC 100
(Cummins tier 1)
ASC 100 73
74 ASC 100
3.1. Safety & Other Measures during Machine Maintenance
Maintenance manual
3.1.1. Safety during Machine 3.1.2. Fire precautions when refilling

Maintenance
• In terms of fire safety the flammable liquids applied at
Lubrication, maintenance & adjustments must be car- the Machine split into the following Danger Numbers:
ried out: Danger Number II – Diesel Oil
• By trained specialists Danger Number IV - Mineral Oils, Lubricating Greases
• In line with safety instructions given in the Vibrating • Place the oil exchange point where it does not inter-
Roller Operation Manual fere with explosion / fire hazard areas.
• According to the time intervals as stated in Lubrication • Label with Tables and No Smoking & No Open Fire
Table following the hours of actual operation Signs.
• With the Machine located on a flat fixed surface se- • Design the size of handling area so it can catch the
cured against self-motion (wedges and with the steer- amount of flammable liquid equal to the capacity of the
ing joint locked largest vessel, shipping container.
• With the wiring disconnected and the ignition key • Fit it with portable fire extinguishers.
removed
• Use containers like metal barrels, jerricans, tin cans
• On the cooled down parts of the Machine to handle the oils, Diesel oil.
• Following the cleaning of the Machine, of lubrication • Confirm the shipping containers are properly closed
points & maintenance points and of repair points during storage.
• Using proper undamaged tools • Make sure the containers have one hole, and are
• Replacing with new original parts per the Spare Parts stored with their hole up, and secured against their
Catalogue contents purring out or dripping.
• With sufficient lighting of the entire Machine when • Label the containers with indelible inscription spec-
under lowered visibility or at night ifying the content & flammability number.
• With the guards (covers) and safety elements rein-

stalled upon work completion, if previously disman-
tled
• Together with retightening bolted connections – us-
ing proper torque, and checking tightness of the con-
nections
• Following the heating of operation fillings (danger of
burns). Use recommended refills only.
Confirm all safeguard equip-

ment functions are OK once ad-
justments or maintenance are
completed!
ASC 100 75
3.1. Safety & Other Measures during Machine Maintenance
3.1.3. Ecological & Hygienic 3.1.3.2.Ecological Principles

Principles
Once disposed of (dismantled, re-
When operating and maintaining the machines a User
filled) the fillings of the Machine’s
must follow general health & environment protection
individual systems and some of its
principles along with the acts, public notices & regula-
tions related to these issues and effective within the parts become waste with hazardous
territory a machine is used. properties in terms of the environ-
ment.
3.1.3.1. Hygienic Principles

This waste product category includes the following:
• Oil products, refrigerants, accumulator refilling, plus
- Organic or synthetic lubricants, oils and fuels
painting materials (coating compositions) incl. thin-
ners are materials causing health hazards. Workers - Brake fluids
that come into contact with these products during
- Cooling liquids
machine operation or maintenance must observe
general principles of health self-protection and follow - Accumulator charges and accumulators themselves
safety & hygienic instructions of these products’ man-
- Air conditioner refills
ufacturers.
- Cleaning & preserving agents
• Please note the following in particular:
- All the dismantled filters & filter elements
- Protect your Eyes & skin when handling the accu-
mulators - All the worn & discarded hydraulic hoses & fuel hose,
metal rubbers and other elements of the Machine
- Protect your skin when handling oil products, paint-
fouled by the abovementioned products.
ing materials and cooling liquids
- Wash your hands upon work completion and be-
fore taking meals; treat your hands with reparation
(recovery) cream Following the disposal of the given
materials and parts these must be
- Observe machine operating instructions when
handled under the respective Nation-
handling its cooling systems.
al Environmental Policy Regulations,
• ALWAYS store oil products, refilling of cooling sys- and in line with Health Regulations.
tems and accumulators plus paints incl. organic thin-
ners and also the cleaning & preserving agents in
their genuine original properly identified packages.
Never store these materials in unlabelled bottles or
other vessels due to exchange hazard. Especially
hazardous is the potential of being mistaken with
eatables or beverages.
• Upon skin, mucosa or eye contacts, or vapor inhala-
tion, you must apply first aid measures instantly.
During accidental ingestion of these products you
must call for prompt medical attention.
• Use always ear protectors (muffs) of proper type and
construction when operating the Machine in cases the
Machine is not fitted with the cabin or cabin windows
are opened.
76 ASC 100
3.2. Refill Specification Maintenance manual
3.2.1. Motor Oil

Motor oil shall be specified per its performance classifi-
cation & viscosity classification.
Performance Classification under

API (AMETICAN PETROLEUM INSTITUTE)
CCMC (COMMITE OF COMMON MARKET AUTOMOBILE
CONSTRUCTORS)
ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROP-
PÉENS DE AUTOMOBILE)
Viscosity Classification
Ambient temperature and type of operation where the
Machine is used will be decisive to determine SAE (SO-
CIETY OF AUTOMOTIVE ENGINEERS) viscosity class.
Admissible oils applied compliant to API:
CF-4/SG; CG-4/SH
CCMC DH1
ACEA: E-5
Year round SAE 15W-40 (e.g. Valvoline, Premium Blue)
Note:
Exceeding low temperature limit will not lead to any motor
damage, it may only cause some problems when starting
the Machine.
It is rather convenient use multigrade oils so as to avoid
oil replacement due to ambient temperature changes.
Motor manufacturer recommends using SAE 10W-30 oil
to make starting at freezing temperatures (below 0 °C,
32 °F) easier.
! CAUTION!
Exceeding max temperature limit may
not last for a longer time due to the
lowered lubricating capabilities of oil.
When using synthetic oil due to operat-
ing conditions (low ambient tempera-
ture) the same change intervals like with
mineral oils must be maintained.
When using oil under API CD/SF you
must cut the change interval by half, i.e.
125 hours or 3 months.
Use engine oil of SG or SH classification
due to lubricating the valve tappets.
ASC 100 77
3.2. Refill Specification
3.2.2. Fuel 3.2.3. Cooling Liquid

Use some of the following Diesel fuels to run the motor. Use cooling liquid comprising 50% water and 50% anti-
freeze agent (designed for ambient temperature of up to
· CEN EN 590 or DIN/EN 590 (suggestion)
-36 °C [-33 °F]) for the engine cooling system even within
· DIN 51 601 a climatic zone where temperatures do not drop below
0 °C (32 °F). The cooling liquid serves not only to protect
· BS 2869 (1988): A1 & A2
the cooling system against any freezing, but also to
· ASTM D 975-88: 1-D & 2-D increase boiling temperature. The inhibitors contained
within the antifreeze protect parts of the engine cooling
· VV-F-800C: DF-A, DF-1 & DF-2 system. You may use propylene antifreeze agents as well
· NATO code F-54 & F-75 to refill the cooling system.
Use treated, demineralized or distilled water to prepare
the cooling liquid.
! CAUTION!
For example, the following antifreeze coolants are able to
Use winter Diesel oil with ambient tem- be used:
peratures below 0 °C (32 °F). Use special
SUNOCO - PERMANANT ANTIFREEZE
type of Diesel oil with additives designed
for the conditions with ambient tempera- SHELL - Glycoshell AF 511 S
tures less than -15 °C (5 °F) (”Super TEXACO - HAVOLINE Antifreeze Coolant/AFC
Diesel oil”).
CASTROL - ANTIFREEZE MB
NEVER use fuels (like bio Diesel oil,
mixed bio Diesel oil, LFO, and alike)
other than those Diesel oils specified
above. ! CAUTION!
Do NOT use the portion of antifreeze
cooling agent within cooling liquid over
50 % unless absolutely necessary to do
so.
NEVER use ration over 68%!
Antifreeze agents are made variously
based.
We do not recommend their mutual
mixing. Blending various types of cool-
ing liquids may lead to loss of anti-
corrosion characteristics.
Use refractometer (densimeter) to check
the portion of antifreeze cooling agent in
cooling liquid before winter period
begins.
78 ASC 100
Maintenance manual
Synthetic Hydraulic Oil

3.2.4. Hydraulic Oil You can fill the hydraulic system with synthetic oil which,
when making any leaks, becomes degraded via microor-
Use only quality hydraulic oils of power class per ISO ganisms found in water and in soil.
6743/ HV for the Machine’s hydraulic system (corre-
sponds to DIN 51524 Section 3 HVLP; CETOP RP 91 H).
Normally the machines are filled at manufacturer with
hydraulic oil of cinematic viscosity of 68 mm2/s at 40 °C
(104 °F) ISO VG 68. This oil is the most suitable one to be ! CAUTION!
used within the widest range of ambient temperatures. Water (condensation water) contents
may NOT exceed the max level of 0,1 %.
Inspect the operating liquid via sampling
Manufacturer Oil Type in regular intervals, refer to the Table.
Power class under ISO When refilling old machines with syn-
HV (HVLP)
6743/HV thetic oil make sure the residual limit of
mineral oils is not over 8 % of all the
Viscosity Class under ISO
VG 68 refill.
6743/4, DIN 51519
Viscosity Class under CETOP

When refilling with biodegradable oil
HV 68 the blending of up to max 2% of the
RP 91H
entire tank content is admissible.
AGIP AGIP ARNICA 68
Please consult any transition from miner-
AVIA AVILUB HVI 68 al oil to synthetic oil, or mixing oils of
various brands with oil manufacturer or
BP BARTRAN HV 68 dealer!
CASTROL HYSPIN AWH 68
CHEVRON EP 68 HV
ELF HYDRELF 68
Standard Heavy
ESSO UNIVIS N 68 Sampling Intervals
Employment Conditions
FINA HYDRAN HV 68 1st Inspection 500 hours 250 hours

FUCHS RENOLIN MR 68 HV 2nd Inspection 1000 hours 500 hours
MOBIL MOBIL DTE 16 Follow-up 1000 hours or 500 hours or
Inspections 1x a year 1x a year
ÖMV HLP - M 68
SHELL TELLUS T 68
TEXACO RANDO OIL HD CZ 68
TOTAL EQUIVIS ZS 68
! CAUTION!
When at high ambient temperatures with
oil temperature constantly reaching 90
°C (194 °F) we recommend to replace
with oil of cinematic viscosity 100 mm 2/s
HV 100 (BP BARTRAN HV 100; ESSO
UNIVIS N 100, and others).
ASC 100 79
3.2. Refill Specification
3.2.5. Gearbox Oil 3.2.6. Lubricating Grease

Use quality oil corresponding to API GL-5 or EP or MIL-L- Use grease plastic type that contains lithium to lubricate
2105 C to lubricate the uncoupled axle gearbox and axle the Machine under:
drive gearboxes.
ISO 6743/9 CCEB 2
SAE 80W/90 viscosity for ambient temperature of –10 °C÷
DIN 51 502 KP2K-30
+30 °C (14 °F ÷ 86 °F).
(Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, Grease
SAE 80W/140 viscosity for ambient temperature of +20 °C
No 3, and alike.).
÷+45 °C (68 °F ÷ +113 °F)
Ambient –10°C÷ +30°C +20°C ÷+45°C

Temperature (14°F ÷ 86°F) (68°F ÷ +113°F)
3.2.7. Screen Washer Liquid
SHELL SPIRAX HD SPIRAX HD
AGIP ROTRA MP ROTRA MP Use water (down to 0 °C) and an agent designed for motor
vehicle screen washers to refill washer system tank.
GETRIEBEOL
ARAL GETRIEBEOL HYP
HYP
BP - MACH HYPOGEAR EP HYPOGEAR EP ! CAUTION !

CASTROL HYPOY HYPOY Replace water with antifreeze at temper-
atures below 0 °C (32 °F).
UNIVERSAL
UNIVERSAL GEAR
CHEVRON GEAR
LUBRICANTE
LUBRICANTE
ELF TRANSELF8 TRANSELF8
GEAR OIL GX GEAR OIL GX

ESSO
PONTONIC MP PONTONIC MP
I.P. PONTIAX HD PONTIAX HD
MOBIL MOBILUBE HD MOBILUBE HD
TOTAL TRASMISSION TM TRASMISSION TM
! CAUTION !
Operating temperature of oil must NOT
exceed 85 °C ÷ 90 °C (185 °F ÷ 194 °F).
80 ASC 100
3.3. Refills Maintenance manual
Refill Amount l (gal

Section Refill Type Brand
US)
Motor Motor oil per Section 3.2.1. 11,2 (2,95)
Fuel Tank Diesel oil per Section 3.2.2. 410 (108,3)
Hydrostatic System Hydraulic oil per Section 3.2.4. 90 (23,8)
Free Axle Gearbox Gearbox oil per Section 3.2.5. 3,5 (0,92)
Axle Gearboxes Gearbox oil per Section 3.2.5. 2x3,3 (2x0,87)
Joint bearing - & steering

Plastic lubricant, refer to Section 3.2.6. as required
cylinders
Motor Cooling System Permanent anti-freeze liquid per Section 3.2.3. 24 (6,3)
Vibratory Free Axle Motor oil as motor 8 (2,1)
Battery Distilled water as required
Water & antifreezing agent - the ration per

Screen Washers 2,75 (0,72)
outdoor temperature
ASC 100 81
3.4. Lubrication & Maintenance Table
82 ASC 100
Maintenance manual
ASC 100 83
3.5. Lubrication Chart
84 ASC 100
3.6. Lubrication & Maintenance Operations Maintenance manual
Carry out lubrication & maintenance on regular basis and repeatedly in intervals according to daily reading on the hours-
of-operation counter.
This Manual includes essential information concerning the engine only; refer to Engine Operation & Maintenance Manual
for other information which is part of documentation supplied along with the Machine.
Refer to the Table in Section 3.6.37. for torque figures when tightening dismantled or loose bolts, plugs, hydraulics’
threaded joints and others, unless another figure is specified for a given operation.
Conduct lubrication & maintenance in regularly repeating intervals per daily data reading on the hours-of-operation
counter.
This Manual includes essential information concerning the engine only; refer to Engine Operation & Maintenance Manual
for other information which is part of documentation supplied along with the Machine.
! CAUTION!
Follow the instructions given in the Engine Operation & Maintenance Manual!
Before you start doing maintenance, please dead park the roller to be leveled, and on solid
flat surface!· Carry out inspection with the roller braked, engine shut off and battery discon-
nector switched off (unless otherwise required)!
Following initial 100 hours of operation of the new machine (after major overhaul),
please perform in line with:
3.6.24. First oil replacement in gearboxes of uncoupled axle and axle
ASC 100 85
3.6. Lubrication & Maintenance Operations
Following 20 hours of operation or daily 1
3.6.1. Check the oil amount in motor

• Stop the engine and wait ca 5 minutes until oil flows
down to crankcase sump.
• Pull out the oil dipstick 1, wipe it off, insert it back down
to the stop and pull out again to read the oil level.
• Maintain the level within the range of the graduation

lines stamped on the dipstick. The lower line L (Low)
indicates the lowest possible oil level, the upper line
H (High) the highest one.
• Refill the oil via oil filler following a removal of oil filler
plug 2. Wait ca 1 minut until the level gets stable and
then check again. 2
! CAUTION!
The amount of oil between the marks on
the dipstick makes 0,95 liters (1.0 U.S
Quart).
• Always replenish with oil of identical type. Use oils

under Section 3.2.1.
• Check the motor tightness, repair any cause of leak-
age.
• Inspect the motor if no damaged or missing parts exist
within the motor, and whether no appearance chang-
es have occurred.
! CAUTION!
NEVER use the engine unless there is
proper oil level inside the engine.
86 ASC 100
Maintenance manual
3.6.2. Check the amount of cooling

liquid in the motor
• Check visually the level. 1
• Add via filler neck 1.
! CAUTION!
The level may not drop below the level
gauge eyesight.
Replenish with coolant consisting of
antifreeze agents of identical base per
Section 3.2.3.
NEVER use additives to remove cooling
system leakages with the engine cooling
liquid.
Do NOT refill hot motor with cold liquid.
The casts of the motor may get dam-
aged.
When some higher leak occurs, check
the cooling system and repair its cause.
Remove the filler plug only af-

ter the engine coolant temper-
ature falls below 50 °C (120 °F).
Any attempt to remove filler
plug at high temperature may
cause operator to be scalded
with steam or cooling liquid
due to inner overpressure.
ASC 100 87
3.6.3. Check the amount of oil inside

hydraulic tank
• Check the level.
• Refill with oil if required.
NOTE
In case of high loss of oil, repair the cause of hydraulic
system leakage.
3.6.4. Crankcase Breather

• Inspect the crankcase breather hose to make sure it
is not fouled with deposits, chips, or in winter season
frozen with ice.
88 ASC 100
Maintenance manual
3.6.5. Check fan condition

• Check visually the fan. If damaged (e.g. missing parts
of materials, cracks, shape changes etc.) replace the
fan.
3.6.6. Check motor belt

• Make visual check of the belt, monitor any of its dam-
age.
• Any cracks perpendiculars to belt width are no dam-

age. When longitudinal cracks occur on the belt or
frayed (shattered) belt edges exist, or any torn off parts
of material are seen, then the belt must be replaced.
ASC 100 89
3.6.7. Check engine air intake

• Check if suction rubber hose leading from the filter is
not damaged and if tightening clamps are not miss-
ing.
• Inspect the gasket between the bonnet and air filter.

Replace impaired gasket with the new one if required.
! CAUTION!
NEVER operated the Machine with dam-
aged gasket between the bonnet and air
filter, or the connection not tight.
• Check the exit slit of air filter vacuum valve, press to

remove any dust trapped.
NOTE
The dust caught inside dust valve gets emptied automat-
ically during machine operation.
! CAUTION !
NEVER operate the Machine with dust
valve damaged.
• Check and clean up the pre-filter tray 1 when any

contamination deposited reaches the mark, first un- 2
screw the nut 2 and remove lid 3.
3
NOTE:
Pre-filter is optional and is mounted based on separate
order only. 1
90 ASC 100
Maintenance manual
3.6.8. Check the amount of fuel

• Check the fuel level per fuel contents gauge (option-
al).
• Replenish following the cleaning of filler cap 1 and

filler neck 2 via a strainer up until the lower edge of the 1
filler neck.
NOTE: 2
When the Machine is fitted with fuel minimum indicator
lamp only (standard outfit), then make up the fuel imme-
diately after the lamp lights up.
Fuel tank capacity is 410 l (108 gal US). The fuel tank
equals to ca 34 hours of Machine operation.
NO smoking while at work!

Observe fire precautions!
! CAUTION!
Fuel tank is not drained fully. To empty
fully you must carry out rather arduous
deaeration of the entire fuel system.
Use ONLY clean and recommended fuel
under Section 3.2.2.
NEVER refill fuel with the engine run-
ning.
Do NOT replenish fuel in closed areas.
Prevent fuel from spilling on the

ground.
ASC 100 91
3.6.9. How to clean air separator

• Prepare a receptacle to drain the sediment into.
• Turn the separator valve 1 clockwise by 4 revolutions
until the valve gets extended by ca 25 mm (1") down-
ward.
• Drain the fuel till it starts flowing out pure. Press the
valve upward and screw it.
! CAUTION !
If you drained more than 6 cl (2ozs) of
fuel, then make up the fuel in fuel filter
in line with Section 3.6.19., or deaeration
per Section 3.6.34. In this way you will
avoid problems of difficult engine start-
ing.

Do NOT drain the separator with
the engine running.
Collect the fuel with sediment

drained in a proper vessel.
92 ASC 100
Maintenance manual
3.6.10. Check the alarm & control

devices
• Turn ON the switches 23, 24, 25, confirm the horn and
the headlamps function well.
• Turn the ignition box key 6 into position “I”. Lamps 12,
13, 14 will light up.
• Following engine starting “II” the lamps 12, 13 must
go off.
When in operation, please

check continuously the board
instruments and indicator
lamps.
Repair instantly any failures
signaled!
ASC 100 93
Every 100 Hours
3.6.11. Check tire pressure

• Inflate the tires with compressed air using air valves
1.
• Check pressure at cold tires using a pressure gauge.
• Maintain 160 kPa (23,2 PSI) pressure in your tires.
94 ASC 100
Maintenance manual
Every 250 Hours or Once in 3 Months
3.6.12. How to replace oil in the engine

• Prepare an appropriate vessel of ca 20 l.
• Remove drain plug and let oil to run out.
• Clean the surface round the oil filter head. Dismantle

the filter.
• Clean the contact surface designed for filter gasket.
• Take a new filter, fill it with pure motor oil - 11,2 l

(2,96 gal US).
ASC 100 95
• Apply oil on the gasket.
• Install the filter and hand-tighten securely.

• Check the drain plug gasket – replace if damaged.
• Check the thread of crankcase sump and clean con-
tact surface designed for the gasket.
• Reinstall the plug again. Use 80 Nm (59 ft-lb) torque.
• Refill the engine via filler neck
• Replenish the oil up to the dipstick upper line (H). Oil

refilling makes 11,2 l (2,95 gal US).
96 ASC 100
Maintenance manual
NOTE
• With the oil replaced start the engine for 2 - 3 minutes.
Check the tightness of drain plug and filter.
• Stop the engine and wait 3 minutes until oil descents
into the crankcase sump. Then check the oil level
using dipstick.
! CAUTION !
Replace oil every 3 months at the latest
even though 250 hours of operation have
not been reached. Replace oil in an
interval that comes first.
Use recommended filters only. Refer to
Specification Manual or Spare Parts
Catalogue.
Use recommended oil only. Refer to
Section 3.2.1.
Do NOT over tighten the filter. Its thread
or gasket may get spoiled.
Drain oil when it is hot, follow-

ing the operation end, or heat
the running engine until the
cooling liquid temperature
reaches 60 °C (140 °F). Beware
of possible scalding when
draining hot oil.
Collect drain oil and do not leave it

to soak in the ground.
Used oil and filters are environmen-

tally hazardous waste – hand it over
for disposal.
ASC 100 97
3.6.13. Check the fixing of the engine

• Confirm the condition of metal rubbers (cracks, fis-
sures), coherence of metal with rubber, tightness of
bolts and nuts.
Engine front metal rubbers
Engine rear metal rubbers
98 ASC 100
Maintenance manual
3.6.14. How to inspect the batteries
When handling the accumula-

tor you must use proper cloth-
ing, rubber gloves, eye protec-
tion.
EYE CONTACT with electrolyte:
Immediately flush hit eye with
large amounts of water for at
least a couple of minutes. Call
for prompt medical attention.
SKIN CONTACT with electro-
lyte: Remove contaminated
clothing, including shoes. Im-
mediately flush with soap wa-
ter or water & soda solution.
Get prompt medical attention.
INGESTION: Drink max. amount
of milk or water or solution of
calcined magnesia or soda in
water to dilute stomach con-
tents.
Do NOT each, drink or smoke
while at work!
Upon work completion washes
your hands and face thorough-
ly with water and soap!
• Disconnect the batteries using a disconnector.

• Wipe the surface of accumulators.
• Check the condition of poles & terminals 1. Wipe the
poles and terminals. Apply thin layer of grease on the
terminals. 1 1 1 1
2 2
• Open cell plugs 2 and confirm the electrolyte level in
all the cells reaches 5 ÷ 15 mm (0.2÷0.6 in) over the
plates, or the lower edge of built-in dipstick inside the
cells. Replenish with distilled water those cells where
electrolyte level is less than 5 mm (0.2 in) above the
plates.
NOTE
• Use glass tube to check the level.
• Use refractometer to measure the electrolyte inside

individual cells.
ASC 100 99
Or use charge indicator.
Compare measured figures with those in the Table.

Density
When checking is completed, please close the accumu-
lators. in g/cm 3
in °Be (Beume)
20 °C 20 °C
Tro pic Tro pic
68 °F 68 °F
NOTE:
During winter shutdown of the Machine you must dis- Pro perly charged 1,28 1,23 32° 27°
mount the accumulators and store them in dry dust-free Half-Charged 1,2 1,12 24° 16°
area protected against frost. Do NOT store them together
with alkaline cells. During their storage life, please check Recharge 1,12 1,08 16° 11°
1x every month their charging condition and recharge if
required.
! CAUTION! Recharge the accumulator insufficiently

charged.
Always follow the Manual of accumulator
manufacturer when handling the accu- Recharge the accumulator outside the
mulator! Machine.
Disconnect the accumulator when mak-
ing its repair, or handling the conductors
and electric equipment within the wiring Open the accumulator plugs
circuit, so as to avoid short circuit. before recharging. Do NOT any
open fire near the accumula-
Disconnect (–) pole cable first when tor. Danger of explosion! Spark
disconnecting the accumulator. Connect made upon disconnecting the
as first the (+) pole when connecting terminals when recharging may
again. cause explosion.
NEVER attempt to disconnect accumula-
tor with the engine running.
Do NOT turn the accumulators upside
Short circuit occurs with hazard of accu- down. Danger of electrolyte flowing
mulator explosion in case of making out from degassing accumulators.
direct conductive connection between
both of the accumulator poles. Flush with water and neutralize with
Do NOT contact the Machine frame to lime a place hit with spilled electro-
confirm existence of voltage in the lyte.
conductor.
Hand over for disposal any non-
Replenish the accumulator with distilled functional worn accumulators.
water only – NEVER with acid!
Refill with distilled water immediately
before work on the Machine or prior to
charging the accumulator.
100 ASC 100

Maintenance manual
3.6.15. Check the function of Air Filter

Vacuum Switch
• Remove the engine air intake cover, or the pre-filter
(optional)
• Set up the engine speed increased to about 2000 1/

min (RPM).
• Cover shortly Air Filter Suction Hole on the engine
bonnet.
• Indicator lamp 17 for Air Filter fouling should light.
• Check the following unless it lights up :

Vacuum switch 1
• Bulb inside the indicator lamp 17. Confirm the contact,
supply cable. 1
ASC 100 101

3.6.16. Machine Lubrication

• Remove greasing nipple caps.
• Put on gradually the greasing nipple of high pressure 1
press and grease till the old grease begins to flow out.
3
• Reinstall the greasing nipple caps again.
Steering Joint
Upper bearing 1
2
Lower bearing 2
Bearing 3 4x
Linear Hydraulic Motors for Steering

King pins 2 x
Rear pins 2x
Linear Hydraulic Motors for Tilting the Bonnet

Upper pivots 2 x
102 ASC 100

Maintenance manual
Lower pivots 2 x
Linear Hydraulic Motor for Tilting Driver’s Control Stand
Door Hinges
Bonnet Hinges
ASC 100 103

Cabin’s Front Pivots

Pivots 2 x
Options
Cabin door hinges
! CAUTION!
Use ONLY recommended lube greases.
Refer to Section 3.2.6.
104 ASC 100

Maintenance manual
3.6.17. How to check oil inside vibrator

• Stop in such a way that the free axle plugs on the left
side are in the position as per fig. 2
• Clean the spot round of the inspection plug 1. Un-

screw the plug 1 and check the oil level. The level must
reach up to the inspection hole or flow out slightly.
• Replenish oil with the filler cap 2 unscrewed.
• Wipe the plugs and reinstall.
! CAUTION!
Check the oil only after it cools down.
Refill with identical type of oil.
ASC 100 105

3.6.18. How to check oil in gearboxes

Axle Gearbox
• Stop the Machine in such a way the plugs of gearboxes
of both of the wheels are in position as per fig.
• Wipe the spot round the check plug, unscrew the plug
and check the oil level. The level must be as high as
the inspection hole or flow out slightly.
• Refill oil if necessary.
Free Axle Gearbox

• Clean the spot round the inspection plug 1. Unscrew
the plug and check the oil level. The level must reach
up to the hole or flow out slightly.
• Refill with oil via filler plug 2, if required. 2
• Confirm the tightness of gearboxes.
NOTE:
Plugs are located on the static section of the gearbox –
they do not turn while driving.
Do NOT touch gearbox and its

adjacent parts when these are
hot.
106 ASC 100

Maintenance manual
Every 500 Hours or Once in 6 Month
3.6.19. How to replace engine fuel filter

• Clean the fuel filter head dismantle the filter.
• Wipe the contact surfaces designed for the filter.
• Refill the filter with pure fuel.
• Apply oil over the sealing ring.
ASC 100 107

• Install the filter and hand-tighten properly.
! CAUTION!
Use original filters specified.
Do NOT tighten the filters with force.

Collect any fuel flowing out.
Hand over for disposal the filters

used.
108 ASC 100

Maintenance manual
3.6.20. Cooling liquid inspection

• Use refractometer to check the concentration of anti-
freezing agent in the cooling liquid.
! CAUTION!
Check always before winter season
begins. Unless concentration for –36 °C
(–33 °F) temperature is measured, fill up
the cooling liquid with antifreeze to
make adjustment, or replace the cooling
liquid.
• Add with antifreezing agent per Section 3.2.3.
3.6.21. Check if wheel bolts are

tightened
• Confirm the wheel bolts are tightened. Use torque
spanner.
• The torque is 165 Nm (122 lb-ft).
ASC 100 109

Every 1000 Hours or Once a Year
3.6.22. Check, adjust valve clearance
! CAUTION!
Check and adjust only after the engine
cools down below 60 °C.
• Dismantle air supply pipe leading to the turbocharger

plus the valve covers.
• Rotate the motor in CW direction using the belt pulley.

• Rotate the motor slowly to move to the top dead centre
of the cylinder No. 1 compression. In this position the
1
rocker arms of both of the valves are loose. (E- ex-
haust valve, I-inlet valve).
I
E
• The sequence of valves 1÷4 is from the fan pulley.
110 ASC 100

Maintenance manual
• Change the clearance of both of the valves of the 1 st

cylinder using feeler gauges. Loosen the securing nut
and turn the adjusting screw with screwdriver to adjust
the clearance.
NOTE:
Proper clearance will be adjusted when you feel resis-
tance upon pulling the gauge between the valve and the
rocker arm. Following the adjustment tighten the secur-
ing nut with the torque of 24 Nm (18 ft-lb). With the
securing nut tightened check the clearance again.
Valve Gap:
Inlet valve (I) = 0,254 (0.01 in)
Exhaust valve (E) = 0,508 (0.02 in)
• Check and adjust the clearance of other valves as per

the Figure.
• Make a mark on the damper of torsional vibrations and

turn the crankshaft by 360°.
• Check and adjust the clearance of other valves as per
the Figure.
• Reinstall valve covers, tighten with 24 Nm (18 ft-lb)

torque. Install air supply piping.
ASC 100 111

3.6.23. How to check tightening pulley

and belt of the engine
• With the engine running inspect visually any vibrations
of the fan pulley.
• Stop the engine!

• Confirm the stop of tensioner arm does NOT contact

bump stop of the bush. Replace the belt if it makes a
contact. When the arm stops continue to contact bump
stop of the bush, replace the tensioner. Confirm the
cap screw is tightened with 43 Nm (32 ft-lb) torque.
• Lift the belt tightening pulley using a lever with a

square end of 10mm (3/8-inch) and remove the belt.
• Carry out visual inspection of the belt, track any dam-

age made. Cracks across the belt width are not con-
sidered damage. When longitudinal cracks occur on
the belt, or the belt has its edges frayed, or parts of the
material are ripped out, then the belt must be re-
placed.
112 ASC 100

Maintenance manual
• With the belt removed, check to confirm the stop of the

tensioner arm comes into contact with the bump stop
of the bush. Unless so, replace the tensioner.
• Check the pulley (arm) does not deflects from the

vertical axis. Maximal deflection allowed is 3 mm (0.12
inch). Inspect the tensioner pulley along with the arm
to make sure there are no fissures over there.
• Check axial clearance of fan pulley. This clearance

may not exceed 0,15 mm (0.006 in).
• Reinstal the belt back.
ASC 100 113

3.6.24. Replace oil in gearboxes

Axle (Wheel) Gearboxes
• Place the roller onto a flat, firm surface so that the axle 2
gearbox plugs are in the position according to Fig.
Clean the area around plugs. Put appropriate vessel
under the drain plug 1. Unscrew both plugs and clean
them and drain oil.
• After draining oil mount back the drain plug 1, replace
damaged plug sealing.
• Fill oil through the upper plug 2 until the level reaches
the opening or until it starts flowing out - 3,3 l (0,87 gal 1
US).
• Mount back the upper plugs 2, replace damaged plug
sealings.
Uncoupled Axle Gearbox – RH side

• Wipe the spots round the plugs.
• Place an appropriate receptacle underneath the drain 3
plug 3 and unscrew it.
• Unscrew the plugs 1, 2 and let oil to flow out. After

draining reinstall the drain plug back. Use filler plug
1 to refill the recommended oil - 3,5 l (0,92 gal US).
• Check amount of oil through the inspection hole 2. Oil
level must reach up to the bottom edge of the hole or 1
flow out slightly. Reinstall plugs 1 and 2, replace any
plug gaskets damaged.
! CAUTION!
Change oil first after driving 100 engine
hours.
Change oil while oil is hot.
Do NOT touch gearbox or its adjacent
sections when these are hot.
Avoid oil to leak into the ground.
Used oil is environmentally hazard-

ous waste – Hand it over for disposal.
114 ASC 100

Maintenance manual
3.6.25. Inspect the damping system

• Check the condition of metal rubbers (cracks, fis-
sures), cohesiveness of metal with rubber. Replace
any damaged one.
• Confirm the bolts and nuts are tightened properly.
Free axle damping system – LH side.
Free axle damping system – RH side.
Front metal rubbers of driver control stand.
Rear metal rubbers of driver control stand.
ASC 100 115

3.6.26. How to clean fuel tank

• Unscrew the drain plug and let fuel to flow out into a
receptacle installed.
• Flush the tank with clean fuel.

• Screw on the plug again.
• When fouled to a greater extent, remove the accumu-
lator and tank cap. Inspect and clean the tank’s inner
area. Insert a new sealing strip Teflon-type, and screw
on the cap again. Reinstall the accumulator.
NOTE
When aeration of engine fuel system occurs you must
deaerate it under Section 3.6.34.
Carry out cleaning when there is minimal fuel in the tank.
With the tank used up, ca 45 l [12 US gal] of fuel will remain
in the tank.

NO smoking while at work!!!
Follow the environmental regulations

when cleaning.
Avoid fuel leaking into the ground.
116 ASC 100

Maintenance manual
Every 2000 Hours or Every 2 Years

1
3.6.27. How to change oil in the
vibrator
• Position the cylinder so the drain plug on left side of
uncoupled axle 3 is in its lowest position, and on the
opposite the filler plug 1 in its highest position.
• Put a proper receptacle underneath the drain point. 2
3
• Unscrew all the plugs and let oil to flow out.
• When draining is completed reinstall the drain plug.
• Use filler hole 1 to refill with recommended oil up to the
edge of inspection hole 2 - 8 l (2,1 gal US).
• Reinstall the remaining plugs.
! CAUTION!
Change oil while oil is hot.
Do NOT touch gearbox or its

adjacent sections when these
are hot.
Avoid oil to leak into the ground.
Used oil is environmentally hazard-

ous waste – Hand it over for disposal.
ASC 100 117

3.6.28. How to change hydraulic oil and

filter
! CAUTION!
Change oil before season starts, or
following a rather long Machine shut-
down. Drain oil while oil is hot.
• Unscrew drain plug. Let oil flow out into a vessel

installed – total amount of oil that flows out is round
90 l (23,8 gal US).
• Dismantle the cover.
• Remove the suction hose.
• Dismantle the cap complete with strainer. Remove

the strainer from the the suction pipe. Wash the strain-
er, and purge the strainer from inside with com-
pressed air. Inspect the condition of the strainer, if
filtration section of the strainer is damaged, replace
the strainer. Make visual check of tank’s inner space.
When any slag & mill scale are found at the bottom,
then clean thoroughly and flush with new oil. Reas-
semble again, replace O-ring applied with clean oil.
118 ASC 100

Maintenance manual
NOTE
4
To facilitate cleaning you may remove the entire upper cap
3 along with filler neck 4. Use new sealing strip Teflon-
type when having removed the entire upper cap 3.
3
Check oil thermometer sensor

• Remove the sensor and clean its contact.
• Submerge the sensor in hot oil of known temperature
and read hydraulic oil temperature on the thermome-
ter. Replace with new sensor when there is a malfunc-
tion.
NOTE:
Applies only when oil thermometer is installed – optional.
How to repalce pressure filter element
! CAUTION!
Replace ALWAYS :
- Together with oil exchange
- When pressure filter lamp 18 lights up
due to oil operating temperature
reaching 50 -60 °C (122 - 140 °F).
• Remove filter vessel 2. Replace filter element.

• Clean thoroughly the filter vessel.
• Clean the bottom of filtration block contact surface.
• Check the condition of sealing rings, apply the rings
with clean oil.
• Insert new element into the filter vessel, and screw on
back again.
ASC 100 119

• Refill the tank via filler neck 1 with the recommended

type of oil up to the bottom of the strainer inside the 1
filler neck - 90 l (23,8 gal US) .
• Start the engine, increase its speed to confirm the

tightness of filter, temperature sensor, suction hose
& cap. Check oil level in oil gauge.
! CAUTION !
Use NO chemical cleaning agents &
those means (like clouts) that slip fibres.
Refill oil per Section 3.2.4.
Use only the original filter elements
under Spare Parts Catalogue.
Keep clean while at work. Avoid fouling
the system with materials that may cause
damage to crucial sets and units!
Exchange oil and filter element ALWAYS
when internal parts of units (hydraulic
motors, hydroelectric generators) have
been damaged, or following a major
overhaul of hydraulic system. Clean &
rinse hydraulic tank prior to installing a Collect drained oil, and do NOT let it
new unit. soak in the ground. Blind all the
holes with plugs following the dis-
connection of hydraulic circuits.
Used oil & filter elements are envi-

Observe fire precautions! ronmentally hazardous waste – Hand
it over for disposal.
120 ASC 100

Maintenance manual
3.6.29. How to change engine coolant 1
! CAUTION !
Make it with the engine operation
stopped or following the heating of the
liquid to 50 °C (122 °F) with the engine
running.
• Remove overpressure plug 1 at the expansion tank to

open the cooling system.
Do NOT open the overpressure

plug before cooling liquid tem-
perature drops below 50 °C
(122 °F). Danger of water splash-
ing when opening the overpres-
sure plug and getting scalded.
• Open the drain cock at the cooler’s bottom chamber.

Let the liquid flow out into the receptacles installed.
The amount drained is ca 24 l (6,3 gal US).
• Confirm no damaged hoses or missing hose clamps

exist within the engine cooling system. Check the
condition of the cooler for any damage, leaks or wheth-
er the cooling gills are fouled with slag & mill scale.
Clean and repair if required.
ASC 100 121

• Close the drain cock and refill the cooling system with
new coolant at the ratio of 50 % of water + 50 % of
antifreeze.
• Open the bleed valve at the after cooler.
• Fill up to the water gauge top level. Adequate filling

speed is 19 l/min [5 gal US/min]. When the system is
filled up you must wait 2÷3 minutes to let the bleeding
come about. Screw on the expansion vessel cap and
close the bleed valve. Start the engine and let the
motor heat up to 80 °C (175 °F). Stop the engine and
check no cooling liquid leaks. Confirm water gauge
level.
122 ASC 100

Maintenance manual
NOTE:
When making the change, please flush the system with
mixture of water and soda (sodium carbonate) at the
ratio of 0,5 kg (1.1 lb) of soda per 23 l ( 6.0 gal) of water
in line with instructions of CUMMINS Engine Operating
Manual supplied. Refill the system with this mixture and
heat up to 80 °C (176°F) with the engine running – do NOT
install the expansion vessel cap. Turn OFF the engine
and drain the water. Refill with clean water and heat up
again the motor. Then drain the water. Repeat this till
water is clean.
! CAUTION!
Refill with cooling liquid under Section
3.2.3!
Follow the instructions of antifreeze
manufacturer when changing!
Wear gloves to protect your

hands!
Wear safety glasses or face
shield to protect your eyes!
Hand over used liquid for its safe

disposal per the regulations given!
ASC 100 123

3.6.30. How to check the dampener of

engine’s torsional vibrations
• Check the position of marks stamped on the face of
both of the sections of the dampener of torsional
vibrations. When the marks are mutually shifted by
over 1,59 mm [1/16 in] replace the dampener.
• Check the rubber part 3 to confirm it is not higher or

lower than 3,18 mm (1/8 in) above the level of metal 1
parts 1 and 2. If the criterion is exceeded you must 3
replace the dampener of torsional vibrations.
• Inspect the dampener of torsional vibrations to make

sure it does not move in forward direction. Check that
no notches, cracks, fissures occur on the dampener,
or it is not spoiled with volatile materials.
! CAUTION !
Elastic silicon-type lining of the dampen-
er becomes inflexible and stops fulfilling
its function. Inefficient dampener may
cause major damage to the engine.
124 ASC 100

Maintenance manual
Maintenance - As Needed
3.6.31. How to replace filter elements

NOTE
Air filter contains the main element and safety element.
! CAUTION !
When lamp 17 lights up, please replace
the elements.
• Lift off the bonnet up to its end position. Refer to

Operating Manual, Section 2.7.9.
• Unscrew butterfly nut 1.
• Remove carefully the lid with main element 2.

2
• Unscrew the nut 2 and remove the safety element 1.
ASC 100 125

• Clean the inner space of the filter along with the

contact surfaces to avoid dust entering the supply
piping leading to the engine. Check the connections
and lines for any leakage.
• Insert new safety element.
• Mount the new main element. Confirm it makes a good
contact and does not leak.
• Remove dust valve and clean it. Reinstall.
! CAUTION!
NEVER clean filter’s inner space with
compressed air to avoid dust entering
the engine induction manifold.
Replace both of the elements simulta-
neously following 1 year of operation at
the latest – use original elements.
Replace sealing nut with new one upon
element replacement.
Use original elements.
Watch out when washing the Machine to
avoid water splashing into the air filter.
Replace instantly a damaged vacuum
valve!
Do NOT use a Machine where filter body
or cap is damaged.
126 ASC 100

Maintenance manual
3.6.32. How to clean engine cooler and

hydraulic oil
• No regular cleaning interval is possible to establish
due to different operating conditions.
• Perform daily cleaning when working within extremely
dusty environment. Fouling of coolers will show in
lowered cooling performance along with increased
temperatures of engine cooling liquid and that of
hydraulic oil.
• Clean with compressed air or pressure water (steam).
Clean from the direction of the fan.
! CAUTION !
Do NOT use cleaners of excessively high
pressure to prevent cooler honeycombs
damaged.
In case of cooler fouled with crude oil
products you must use cleaning agent
and proceed under the manufacturer’s
instruction manual! Find out the cause of
fouling!
Follow the ecological standards and

regulations when cleaning!
Clean the Machine at a workplace

equipped with cleaning agent inter-
cepting system to avoid contamina-
tion of soil and water resources!
NEVER use banned cleaning agents!
ASC 100 127

3.6.33. How to clean cabin ventilation

filter 1
• Dismantle cover grating 1.
• Take out the filter complete with filter element 2.

• Knock out the element carefully and wash in detergent
solution. When filter element gets impaired or is
impossible to get rid of fouling material, then you must
replace it with new one. 2
NOTE: Only for the Machines fitted with cabin. The cabin
is optional.
! CAUTION!
Clean regularly 1 x every month. Cut
short the intervals should you work in
very dusty environment.
128 ASC 100

Maintenance manual
3.6.34. How to deaerate fuel system

Deareate the fuel system prior to a first start of the
engine upon:
· Fuel filters not refilled with fuel – when replacing the
filters
· Fuel pump replacement
· Replacement of high-pressure piping, injector
· Long-term shutdown of the Machine
· Fuel pumped out from the tank.
Deareate low-pressure piping & filters :

• Loosen air relief screw at the fuel filter 1.
• Use fuel feed pump until clean fuel flows out with no
air bubbles.
• Tighten air relief screw. The torque figure is 9 Nm (7
ft-lb).
When using engine starter to aerate, then do not start

for over 30 s. Wait 2 minutes in between the starts.
Engine may start when aerating, therefore safety pre-
cautions must be followed.
ASC 100 129

Deareate high-pressure piping and the injectors:

• When you have carried out the previous operations
and the motor has not started, please deareate the
high-pressure piping.
• Switch the ignition box key to position ”ON” to energize
motor “Stop” solenoid valve.
• Loosen one or more nuts on the injectors, then swing
the motor to force the air out from HP piping.
• Deareate till motor runs regularly.
• Tighten the loosened connections with 38 Nm (28 ft-
lb) torque.
Attention, high fuel pressure

inside HP piping. Hazard of skin
injury and serious implications.
NEVER make deaeration with
hot engine. Danger of fuel flow-
ing over hot exhaust manifold
causing fire.
Open fire FORBIDDEN while
working on fuel system!
NO smoking!
Collect any leaking fuel!
130 ASC 100

Maintenance manual
3.6.35. How to adjust the scrapers

Scrapers designed for smooth drum
• Loosen bolts 1 and shift the holders 2 towards the
2
free-axle making the distance between scraper and
free-axle equal to 15 mm (0,6 in).
! CAUTION!
When the chance to displace the scrap- 1
ers in slotted holes of holders 2 following
3
the wear and tear of scraper 3 is ex-
hausted, you must dismantle the scraper
3 and move it by one hole towards the
drum.
1
Scrapers designed for padfoot drum (segments)
• Loosen the bolts 1 and move individual scrapers 2 1
towards the drum at the distance of 25 mm (1 in).
! CAUTION!
Rear scrapers at the padfoot drum are
longer. When replacing worn and torn
scrapers, use rear ones to replace the 2
front ones, and replace the rear ones
with new ones.
When only a small gap has been set
between the scrapers and drums a con-
tact between scraper and drum may
occur when turning the Machine.
ASC 100 131

3.6.36. How to clean the Machine 3.6.37. Check bolted connections

Machine cleaning • Check regularly whether some bolted connections
are loosened.
• Clean the Machine to get rid of major dirtiness follow-
ing a work completion. • Tighten with torque spanners.
• Make overall cleaning on general basis at least once
every week. When working on cohesive soils, soil
cement or lime stabilization, please make overall
cleaning on daily basis. TORQUE
For bolts For bolts For bolts

! CAUTION! 5.8 (5 S) 8.8 (8 G) 10.9 (10 K)
Blind all the holes where a cleaning Thread Nm lb-ft Nm lb-ft Nm lb-ft
agent could enter (e.g. engine suction M4 2 1 3 2 4 3
port) before compressed cleaning with
water or steam. Remove these blinds M5 4 3 6 4 8 6
upon Machine cleaning completion.
M6 7 5 10 7 14 10
Do NOT expose electric parts or insula-
tion material to direct direct stream of M8 16 12 22,5 17 32,5 24
water or steam. ALWAYS cover these M10 31,5 23 44 32 62 46
materials (internal space of alternator,
etc.). M12 53 39 75 55 105 77
M14 79 58 118 87 165 122
M16 113 83 165 122 226 167

Wear gloves to protect your M18 172 127 245 181 343 253
hands!
M20 226 167 314 232 441 325
Wear safety glasses or face
shield to protect your eyes! M22 284 209 392 289 559 412
Disconnect battery cut off M24 392 289 549 405 755 557
switch.
Conduct work with the engine
shut off.
NEVER use aggressive and eas- The figures given in the Table are torques at dry thread (at
coefficient of friction = 0,14). The figures do not apply to
ily ignitable cleaning agents
lubricated thread.
(e.g. gasoline or easily ignit-
able materials).
Follow ecological standards and

regulations when cleaning!
Clean the Machine at a workplace

equipped with cleaning agent inter-
cepting system to avoid contamina-
tion of soil and water resources!
Do NOT use forbidden cleaning

agents!
132 ASC 100

Maintenance manual
Table of torques for cap nuts with sealing O- ring – hoses
Torques for cap nuts with O-ring – hoses
Nm lb-ft
Spanner size Thread Tube Nominal Min Max Nominal Min Max
14 M12x1.5 6 20 15 25 15 11 18
17 M14x1.5 8 38 30 45 28 22 33
19 M16x1.5 8 45 38 52 33 28 38
10
22 M18x1.5 10 51 43 58 38 32 43
12
24 M20x1.5 12 58 50 65 43 37 48
27 M22x1.5 14 74 60 88 55 44 65
15
30 M24x1.5 16 74 60 88 55 44 65
32 M26x1.5 18 105 85 125 77 63 92
36 M30x2 20 135 115 155 100 85 114
22
41 M36x2 25 166 140 192 122 103 142
46 28
50 M42x2 30 240 210 270 177 155 199
50 M45x2 35 290 255 325 214 188 240
M52x2 38 330 280 380 243 207 280
42
ASC 100 133

Table of torques for nozzles (necks) with sealing edge, or Table of torques for plugs with gasket
with gasket
Nozzle torques Plug torques
G-M Nm lb -ft G-M Nm lb -ft
G 1/8" 25 18 G 1/8" 15 11
G 1/4" 40 30 G 1/4" 33 24
G 3/8" 95 70 G 3/8" 70 52
G 1/2" 130 96 G 1/2" 90 66
G 3/4" 250 184 G 3/4" 150 111
G 1" 400 295 G 1" 220 162
G 11/4" 600 443 G 11/4" 600 443
G 11/2" 800 590 G 11/2" 800 590
M 10 x 1 25 18 M 10 x 1 13 10
M 12 x 1,5 30 22 M 12 x 1,5 30 22
M 14 x 1,5 50 37 M 14 x 1,5 40 30
M 16 x 1,5 60 44 M 16 x 1,5 60 44
M 18 x 1,5 60 44 M 18 x 1,5 70 52
M 20 x 1,5 140 103 M 20 x 1,5 90 66
M 22 x 1,5 140 103 M 22 x 1,5 100 74
M 26 x 1,5 220 162 M 26 x 1,5 120 89
M 27 x 1,5 250 184 M 27 x 1,5 150 111
M 33 x 1,5 400 295 M 33 x 1,5 250 184
M 42 x 1,5 600 443 M 42 x 1,5 400 295
M 48 x 1,5 800 590 M 48 x 1,5 500 369
134 ASC 100

3.7. Defects Maintenance manual
! CAUTION !
Normally, any defects are caused due to a wrong operation of the Machine. Consequently,
read once more the instructions given in Operation & Maintenance Manual for the Machine
and the Engine when any malfunction occurs. Unless you are able to define the cause of
failure, please contact service department of your dealer or manufacturer.
! CAUTION !
Troubleshooting in the area of hydraulics and wiring requires knowledge in the field of
hydraulics and electrics. Therefore, please confide any repairs necessary to a service de-
partment of your authorized dealer or manufacturer.
ASC 100 135

3.8. Attachment
Wiring Diagram
(the diagram represents the machine with maximum number of control elements and accessories)
Key:
B1 Engine revolution sensor P3 Hydraulic oil thermometer

B2 Front vibrator revolution sensor P4 Fuel gauge
B3 Fuel gauge float P5 Engine speedmeter
E1,2 Front headlights Q1 Master switch
E3,4 Rear headlights S1 Switch box
E5 Gauge iluminiation S2 Front lights switch
E14 Cabin iluminiation S3 Rare lights switch
F1-8 Safety fuses S4 Horn button
G1,2 Battery S5 Neutral gear switch (in the travel controller)
G3 Alternator S6 Fast travel switch
H1 Horn S7 Vibration switch (in the travel controller)
H2 Switch vibration pilot lamp S8 Vibration switch (movement of travel controller)
H3 Brake pilot lamp S9 Vibration change - over switch
H4 Engine lubrication pilot lamp S10 Brake pressure switch
H5 Recharging pilot lamp S11 Engine lubricating pressure switch
H6 Air filter clogging pilot lamp S12 Air filter clogging Switch
H7 Hydraulic filter clogging pilot lamp S13 Hydraulic liquid filter clogging switch
H8 Engine overheating pilot lamp S14 Hydraulic liquid overheating switch
H9 Hydraulic fluid overheating pilot lamp S29 Cabin fan switch
H10 Fuel min pilot lamp S30 Front wiper switch
K1 Contactor S31 Rear wiper switch
K2-5 Relay S32 Washers pushbutton
M1 Engine starter S33 Heating fan switch
M3 Cabin fan X Conectioin conectors
M4 Front wiper Y1 Engine stop solenoid valve
M5 Rear wiper Y2 Brake valve solenoid valve
M6 Windscreen washer Y3 Fast travel speed solenoid valve – left wheel
M7 Rear window washer Y4 Fast travel speed solenoid valve – right wheel
M8 Heater fan Y5 Fast travel speed solenoid valve– drum
P1 Hour meter Y6 Vibration 1 solenoid valve
P2 Engine thermometer Y7 Vibration 2 solenoid valve
136 ASC 100

Maintenance manual
ASC 100 137

3.8. Attachment
Hydraulic Diagram
Legend:
1 Travel pump
2 Vibration pump
3 Travel drum Hydromotor
4 Vibration Hydromotor
5 Wheel Hydromotor
8 Steering pump
9 Power steering unit
10 Brake block
11 Hydraulic steering cylinder
12 Flow divider
14 Suction strainer
15 Filter
16 Filler
18 Combined cooler
19 One - way valve
20 Thermoregulator
21 Test point
138 ASC 100

Maintenance manual
ASC 100 139

3.8. Attachment
Notes:
140 ASC 100

Maintenance manual
Notes:
ASC 100 141

Notes:

Operation Manual - Amann ASC100

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Operation Manual - Amann ASC100

Hochgeladen von

Copyright:

Verfügbare Formate

Operating manual E

With kind regards,

Verdichtung AG, CH-4900 Langenthal

This manual consists of:

1. Specification Manual ............................................................................................................................... 13

1.1. Basic Data .............................................................................................................................................. 14

1.2. Dimension Chart ....................................................................................................................................... 16

1.3. Technical Data .......................................................................................................................................... 17

2. OPERATING INSTRUCTIONS .................................................................................................................... 27

2.1. Dewaxing and Inspection of a Newly Supplied Machine ..................................................................... 28

2.2. Major Safety Measures ............................................................................................................................ 29

2.3. Ecological & Hygienic Principles ............................................................................................................ 39

2.4. Preservation & Storage ............................................................................................................................ 40

2.5. Machine disposal upon its life termination ............................................................................................ 41

2.6. Machine Description ................................................................................................................................ 43

2.7. Controllers & Dashboard Instruments ..................................................................................................... 44

2.8. How to Control and Use the Machine ..................................................................................................... 54

2.9. Machine Transportation ........................................................................................................................... 63

2.10. Special Conditions for the Machine Application ................................................................................... 68

3. MAINTENANCE MANUAL .......................................................................................................................... 73

3.1. Safety & Other Measures during Machine Maintenance ....................................................................... 75

3.2. Refill Specification ................................................................................................................................... 77

3.3. Refills .............................................................................................................................................. 81

3.4. Lubrication & Maintenance Table ........................................................................................................... 82

3.5. Lubrication Chart ...................................................................................................................................... 84

3.6. Lubrication & Maintenance Operations .................................................................................................. 85

Following 20 hours of operation or daily ............................................................................................... 86

Every 1000 Hours or Once a Year .......................................................................................................... 110

3.7. Defects ............................................................................................................................................ 135

3.8. Attachment ............................................................................................................................................ 136

The vibratory rollers of ASC 100 line are especially suit-

Please fill in the following data:

Type of machine (see Figs. 1, 2)

Fig. 3 - Serial number of the CUMMINS engine

mm 1690 55 65 5575 3210 3275 25 2134 2130 1510

Operation weight ISO 6016 kg (lb) 10300 (22707)

Operation weight EN500-1 with padfoot segments kg (lb) 11840 (26102)

1.3.2. Travel Parameters

Practical gradability by forward run

Max. allowed transversal inclination

Engine fulfills requirements of: Tier 1 97/68/EC

Parking emergency brake three band brakes installed in the

Releasing pressure MPa (PSI) 1,9 (275)

Hydraulic pump of steering Bosch Rexroth HY/ZFS24/25

1.3.8. Vibratory Drum

1.3.9. Hydrostatic Drive of Travel

1.3.10. Hydrostatic Drive of Vibration

1.3.11. Hydraulic Oil Tank

1.3.12. Lifting and lowering of the Hood and the Cabin

1.3.13. Cooling System of Hydraulic Oil

1.3.15. Electrical Installation

1.3.16. Safety Devices

1.3.17. Hygienical Data

Sound power level

1.3.18. Requirements of Traffic Regulations

D) Filling the Tires with Liquid

• Inspect the Machine per shipping documents.

Before Machine Operation, please

Perform dewaxing & washing of the

2.2.1. Safety measures to operate the 2.2.1.2.Work safety secured by User

2.2.2. Driver Qualification 2.2.3. Driver’s Duties

2.2.5. Hand Signals

GENERAL COMMAND SIGNALS