Вы находитесь на странице: 1из 72

Operating manual

ASC 100 Cummins Tier I 2 / 2006

ASC 100

ASC 100

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.

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 FAX: 0041 (0)62 916 64 03

0041 (0)62 916 63 56

This manual consists of: I. Specification 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. III. Maintenance manual

ASC 100

ASC 100

Operating Manual

! NOTICE ! As used in this operating manual, the terms right, left, front and rear indicate the sides of the machine moving forward.

ASC 100

Content
Content 1. ............................................................................................................................................... 8

Specification Manual ............................................................................................................................... 13 .............................................................................................................................................. 14

1.1. Basic Data

1.2. Dimension Chart ....................................................................................................................................... 16 1.3. Technical Data .......................................................................................................................................... 17


1.3.1. 1.3.2. 1.3.3. 1.3.4. 1.3.5. 1.3.6. 1.3.7. 1.3.8. 1.3.9. 1.3.10. 1.3.11. 1.3.12. 1.3.13. 1.3.14. 1.3.15. 1.3.16. 1.3.17. 1.3.18. 1.3.19. Weights .............................................................................................................................................................. 17 Travel Parameters .............................................................................................................................................. 18 Vibration ............................................................................................................................................................. 19 Engine ................................................................................................................................................................ 19 Axle ..................................................................................................................................................................... 20 Brakes ................................................................................................................................................................ 20 Steering .............................................................................................................................................................. 20 Vibratory Drum ................................................................................................................................................... 21 Hydrostatic Drive of Travel ................................................................................................................................. 21 Hydrostatic Drive of Vibration ............................................................................................................................ 21 Hydraulic Oil Tank .............................................................................................................................................. 22 Lifting and lowering of the Hood and the Cabin ............................................................................................... 22 Cooling System of Hydraulic Oil ....................................................................................................................... 22 Fluids .................................................................................................................................................................. 22 Electrical Installation .......................................................................................................................................... 23 Safety Devices ................................................................................................................................................... 23 Hygienical Data .................................................................................................................................................. 23 Requirements of Traffic Regulations ................................................................................................................. 23 Accessories ........................................................................................................................................................ 24

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

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


2.3.1. 2.3.2. Hygienic Principles ............................................................................................................................................ 39 Ecological Principles ......................................................................................................................................... 39

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


2.4.1. 2.4.2. Short-term preservation & storage for the period of 1 2 months .................................................................. 40 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. 2.8.2. 2.8.3. 2.8.4. 2.8.5. 2.8.6. Start the Engine ................................................................................................................................................. 54 Travel & Reversing ............................................................................................................................................. 56 Travel with vibration ........................................................................................................................................... 58 Stop the Machine & the Engine ......................................................................................................................... 59 Machine Shutdown ............................................................................................................................................ 60 How to lift driver control stand and bonnet ....................................................................................................... 61

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


2.9.1. 2.9.2. 2.9.3. 2.9.4. 2.9.5. Machine transportation by its own axle ............................................................................................................ 63 Machine transportation by public road ............................................................................................................. 63 How to load the Machine ................................................................................................................................... 64 Towing of Machine ............................................................................................................................................. 65 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

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

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


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

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


3.2.1. 3.2.2. 3.2.3. 3.2.4. 3.2.5. 3.2.6. 3.2.7. Motor Oil ............................................................................................................................................................. 77 Fuel ..................................................................................................................................................................... 78 Cooling Liquid .................................................................................................................................................... 78 Hydraulic Oil ....................................................................................................................................................... 79 Gearbox Oil ........................................................................................................................................................ 80 Lubricating Grease ............................................................................................................................................ 80 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. 3.6.2. 3.6.3. 3.6.4. 3.6.5. 3.6.6. 3.6.7. 3.6.8. 3.6.9. 3.6.10. Check the oil amount in motor .......................................................................................................................... 86 Check the amount of cooling liquid in the motor .............................................................................................. 87 Check the amount of oil inside hydraulic tank .................................................................................................. 88 Crankcase Breather ........................................................................................................................................... 88 Check fan condition ........................................................................................................................................... 89 Check motor belt ................................................................................................................................................ 89 Check engine air intake .................................................................................................................................... 90 Check the amount of fuel ................................................................................................................................... 91 How to clean air separator ................................................................................................................................ 92 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. 3.6.13. 3.6.14. 3.6.15. 3.6.16. 3.6.17. 3.6.18. How to replace oil in the engine ....................................................................................................................... 95 Check the fixing of the engine ........................................................................................................................... 98 How to inspect the batteries .............................................................................................................................. 99 Check the function of Air Filter Vacuum Switch .............................................................................................. 101 Machine Lubrication ........................................................................................................................................ 102 How to check oil inside vibrator ...................................................................................................................... 105 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. 3.6.23. 3.6.24. 3.6.25. 3.6.26. Check, adjust valve clearance ........................................................................................................................ 110 How to check tightening pulley and belt of the engine .................................................................................. 112 Replace oil in gearboxes ................................................................................................................................. 114 Inspect the damping system ............................................................................................................................ 115 How to clean fuel tank ..................................................................................................................................... 116

Every 2000 Hours or Every 2 Years ........................................................................................................ 117


3.6.27. 3.6.28. 3.6.29. 3.6.30. How to change oil in the vibrator .................................................................................................................... 117 How to change hydraulic oil and filter ............................................................................................................ 118 How to change engine coolant ....................................................................................................................... 121 How to check the dampener of engines torsional vibrations ........................................................................ 124

Maintenance - As Needed ...................................................................................................................... 125


3.6.31. 3.6.32. 3.6.33. 3.6.34. 3.6.35. 3.6.36. 3.6.37. How to replace filter elements ......................................................................................................................... 125 How to clean engine cooler and hydraulic oil ................................................................................................ 127 How to clean cabin ventilation filter ................................................................................................................ 128 How to deaerate fuel system ........................................................................................................................... 129 How to adjust the scrapers .............................................................................................................................. 131 How to clean the Machine ............................................................................................................................... 132 Check bolted connections ............................................................................................................................... 132

3.7. Defects

............................................................................................................................................ 135

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


Wiring Diagram .............................................................................................................................................................. 136 Hydraulic Diagram ......................................................................................................................................................... 138

ASC 100

11

12

ASC 100

Specification Manual

1. SPECIFICATION MANUAL ASC 100 (Cummins Tier I)

ASC 100

13

1.1.

Basic Data
Modifications
The single drum vibratory roller ASC 100 with the smooth drum is suitable for compaction of all kinds of soil. It can be employed at compaction of clayey soils up to the layer thickness (compacted) of 25 cm (9,8 in), loam soils up to the layer thickness of 40 cm (15,7 in), mixed soils up to the layer thickness of 50 cm (19,7 in), sandy soils and rockfills up to the layer thickness of 80 cm (31,4 in), 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 stabilized soils as well.

Introduction
Single drum vibratory rollers of line ASC 100 are outstanding by their up-to-date design, adopted technologies, as well as modern styling. These machines offer maximal comfort to the operator, are easy to operate, extremely reliable and require minimal maintenance. The utilized frequency, amplitude and centrifugal force of vibration were optimized by means of compaction tests to reach extra high compaction effect on various materials.

Application Range
The vibratory rollers of ASC 100 line are especially suitable 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 -15C (5F) to +45C (113F).

14

ASC 100

Specification Manual
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) ..................................................................................... Serial number of the engine (see Fig. 3) .....................................................................................

Fig. 2 - PIN label 1 , S/N 2

1 2

Fig. 3 - Serial number of the CUMMINS engine

ASC 100

15

1.2.

Dimension Chart

A mm in
2820 111,0

B
2250 88,6

D
1500 59,0

H1
3027 119,2

H2
2375 93,5

H5
100 3,9

H6
3540 139,4

K
450 17,7

K1
405 15,9

L
5630 221,7

L1 mm in
16

O1
55 2,17

O2
65 2,6

R1
5575 219,5

R2
3210 126,4

R3
3275 128,9

S
25 0,98

W1
2134 84,0

W2
2130 83,6

W3
1510 59,4

1690 66,5

ASC 100

1.3.

Technical Data

Specification Manual

1.3.1. Weights
Operation weight EN500-1 to drum to axle Static linear load kg (lb) kg (lb) kg (lb) kg/cm (lb/in) 10120 (22311) 5300 (11685) 4820 (10626) 24,9 (138,3)

Operation weight ISO 6016 to drum to axle Static linear load

kg (lb) kg (lb) kg (lb) kg/cm (lb/in)

10300 (22707) 5260 (11596) 5040 (11111) 24,7 (137,1)

Operation weight EN500-1 with padfoot segments to drum to axle Static linear load

kg (lb) kg (lb) kg (lb) kg/cm (lb/in)

11840 (26102) 7020 (15476) 4820 (10626) 24,7 (137,1)

Operating weight ISO 6016 with padfoot segments to drum to axle

kg (lb) kg (lb) kg (lb)

12020 (26499) 6980 (15388) 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 operators 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 operators 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 (MPH) 2nd speed range (transport) km/h (MPH) 0 5,0 (0 - 3,1) 0 - 10,3 (0 - 6,4)

Theoretical gradability 1st speed range (work) 2nd speed range (transport) % % 68 27

Practical gradability by forward run - without vibration - with vibration % % 45 45

Approach angle - front - rear () () 30 28

Transversal stability - straight frame (static) - full turn (static) () () 34 31

Max. allowed transversal inclination - without vibration - with vibration () () 22 5

18

ASC 100

Specification Manual
1.3.3. Vibration
Drive Vibration exciter Frequency Hz (VPM) Rated amplitude mm (in) Centrifugal force kN (lb) hydrostatic two-stage, circular non-directed vibration 32/35 (1920/2100) 1,85/1,15 (0,073/0,045) 277/206 (62250/46294)

1.3.4. Engine
Make Type Serial number Number of cylinders Bore Stroke Total displacement Output according to ISO 3046/1 (DIN 6271) Rated speed Maximal torque Specific fuel consumption at rated speed Fuel speed at normal operation Fuel cleaners - Fleetguard Oil cleaner - Fleetguard Air cleaner Air filter element Air filter safety element Cooling system Coupling mm (in) mm (in) cm (cu in) kW (HP) min (RPM) Nm (ft lb) g/kWh l/h (gal US/h)
-1 3

Cummins Diesel 4BTA3.9-C116 ................ 4 102 (4,02) 120 (4,72) 3900 (239) 86 (116) 2500 423 (312) /1500 min-1 (RPM) 240 11,8 (3,12) 1x FF 1280 (3925274)* a 1x FF 5052 (3903640)* LF 3345* Donaldson FLG 08-0337 Donaldson P77-2550 Donaldson P11-9410 liquid cooled engine with cooler 34299 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 Tire size Average contact pressure on soil Tire inflation kPa (PSI) kPa (PSI)

2 23,1x26 thread UK-5 (10 PR) MITAS 304 (44,1) 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 hydraulic release

Releasing pressure

MPa (PSI)

1,9 (275)

1.3.7. Steering
Hydraulic power steering with two hydraulic cylinders

Hydraulic pump of steering Power steering unit Safety pressure Hydraulic cylinders Steering angle Oscillation angle () () MPa (PSI)

Bosch Rexroth

HY/ZFS24/25

Bosch Rexroth Servostat 8477955593 15 (2175) 2x HV 90/45/400 36 10

20

ASC 100

Specification Manual
1.3.8. Vibratory Drum
Drum dia Drum width Thickness of drum mm (in) mm (in) mm (in) 1500 (59,0) 2130 (83,8) 25 (0,98)

1.3.9. Hydrostatic Drive of Travel


Hydraulic pump of travel variable output with skew plate, electrohydraulically controlled Delivery per revolution Safety pressure Kontroller Drum drive gear-box Filtration block Filter element Drum drive hydromotor Wheel gears Wheel drive hydraulic motors Flow divider cm (cu in/rev) MPa (PSI)
3

Bosch Rexroth A10VG63 63 (4,83) 34 (4930) Reflex 9V 4592-01-01 Trasmital 707C3B 83.7 Donaldson HMK 045796 Donaldson P165332 Bosch Rexroth A10VE45 Trasmital 706C3B 68.4 Bosch Rexroth A10VE45 Hytos 729-0170

1.3.10. Hydrostatic Drive of Vibration


Hydraulic pump of vibration variable-output, with skew plate, electrohydraulically controlled Delivery per revolution Safety pressure Hydromotor of vibration cm3(cu in/rev) MPa (PSI) Bosch Rexroth A10VG45 45 (2,74) 34 (4930) 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 Hydraulic cylinders of hood lifting Hydraulic cylinder of cab lifting Hand pump Hytos 513-0700 2x 25 300AXL Semily 1x 32-300 AXL Semily Technometra RC 16

1.3.13. Cooling System of Hydraulic Oil


Oil cooler Emmegi 34299

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

22

ASC 100

Specification Manual
1.3.15. Electrical Installation
Rated voltage Capacity of battery V Ah 24 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) aw < 5,2 ms-2 (vectorial sum)

(measured according the EN 1032 on the sand base under the vibration travel) - transfered to the hands

(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 drivers 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 Fastened to the machine frame with Tightening torque The data for the frame are stated on the frame decal. Nm (in lb) kg (lb) 230 (507) 16 bolts M 24 x 80 (8G) 549 (4854)

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 mixed soils 50 cm (19,7 in) 60 cm (23,6 in)

The segments are also suitable for pulverization and compaction of plate-shaped rock (shales).

Number of segments Drum dia over pads Total number of pads Height of a pad Area of a pad Weight of one segment Total weight of segments Fastened to the drum with Tightening torque Nm (in lb) mm (in) cm (sq in) kg (lb) kg (lb)
2

3 mm (in) 1712 (67,4) 150 100 (3,9) 120 (18,6) 537 (1184) 1680 (3703) 18 bolts M 20 x 150 (8G) 314 (2776)

D) Filling the Tires with Liquid Added weight with liquid to -25C (-13F) kg (lb) 2 x 600 (2 x 1323)

24

ASC 100

Specification Manual

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 damaged 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 pressure stream of hot water added with standard degreasers. All relevant ecological principles must be adhered 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
2.2.1.2.Work safety secured by User
User must ensure the Machine will be operated only under those conditions, and solely for those purposes the Machine is technically eligible for under the conditions specified by manufacturer and respective standards. User must promptly report any damage of the utility lines to their Operator, and at the same time perform 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. User shall ensure that a worker does NOT work alone at the site, and that another worker is ALWAYS in sight and within ear-shot to provide or call for aid unless other effective form of supervision or communication is available. User must ensure surveillance designate worker at work machinery in the working condition on public communication, which be in capacity issue instructions to reservation labour protection User must secure regular inspection of the operations, operating condition, regular Machine maintenance in intervals under the Lubrication & Maintenance Manual . In case of nonconforming operating condition of the Machine to the extent it becomes hazardous and detrimental to the environment, then the Machine must be discarded until the defect gets repaired. User shall specify who and what tasks may be carried out during operation, maintenance and repairs of the Machine. The one who drives the Machine (Driver) and anybody who performs maintenance and repairs of the Machine must be made familiar with those instructions given in the Machine Operating Manual. User must ensure the Machine Operating Manual and the Operation Logbook are stored at a specific place to be ALWAYS available to the Driver. User shall make the fire extiguisher to undergo regular inspections. User must provide for disposal of hazardous materials (fuel, oil, coolant, and alike) away from their leakage point in order to avoid their adverse environmental impact, adverse effect on operation safety and health.

2.2.1. Safety measures to operate the Machine


Safety measures stated in the individual sections of the Engineering Documentation supplied together with the Machine shall be supplemented with those safety precautions in force within a respective country where the Machine will be used, and within a workplace, with regard to human resource management, work process and personnel.

2.2.1.1. How to start the compaction work


Supplier of building work (Machine User) shall be liable to provide instructions for Driver and Maintenance Department. These instructions include the requirements to secure occupational safety while operating the Machine. Prior the compaction work the Supplier of building work (Machine User) must verify the following: Utility lines Underground areas (direction, depth) Seepage or escape of hazardous materials Soil bearing capacity, slope of traverse plane Other barriers and obstructions, along with specifying the measures to ensure work safety.

Supplier of building work (Machine User) must then make familiar with these conditions a Machine Driver who will carry out the earthwork. Supplier of building work (Machine User) shall define technological process part of which is the work procedure designed for a given job. The work procedure specifies inter alia: Measures for work under extraordinary conditions (work within protective zones, under extreme slopes, etc.) Measures against any natural disasters Requirements for job execution while observing job safety principles Technical and organisational measures to secure safety of workers, site and environment. .

Supplier of building work (Machine User) must evidently make Machine Driver familiar with the technological process (job description).

ASC 100

29

2.2.

Major Safety Measures


2.2.3. Drivers Duties
Before starting Machine operation Driver must get familiar with the instructions given in the Documentation supplied with the Machine, with safety measures in particular, and follow these guidelines thoroughly. This applies also to a personnel in charge of Machine maintenance, adjustments and repairs.(Unless you understand some sections of the Manual, please contact your dealer or manufacturer.) NEVER drive Roller unless fully made familiar with all the Machines functions, operating and handling elements, and until you know precisely how to operate the Machine. Follow safety signed located on the Machine, and keep them in legible condition. Prior to commencing work Driver must get familiar with the site environment, i.e. any barriers, slopes, utility lines, necessary site protections in terms of the surrounding environment (noise, vibrations, etc.). When finding any health hazard, life hazard, danger to persons, property, finding any failures, or when there is an accident of technical facilities, or when finding any symptoms of such hazards during operation, then the Driver must, unless able to clear away such danger by himself/herself, stop the work and secure the Machine against any undesirable starting ON, report to a staff in charge, and if possible, alert all the persons threatened by such hazard. Before starting to run the Machine, Driver is liable to get familiar with the records and any operating deviations found out in course of previous working shift. Before work commencements please inspect the Machine, fittings, check the control elements, communication & safety equipment, whether these are 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 safely 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.

2.2.2. Driver Qualification Requirements


Only a driver trained under local and national regulations and standards designed for drivers of this group of Machines may operate the Roller. Only the one who with the approval of Machine User learns to drive under a direct & constant supervision of professional lector or trainer in order to gain preliminary practice, may drive with no driving licence obtained so far. Licence holder is liable to duly keep the licence in custody and if requested he/she must put it forward to the control authorities. Licence holder may NOT make any recordings, changes or corrections to the licence. Driver is liable to promptly report any loss of his/her licence to the authority that had issued the licence. Only a person mentally and physically competent, over 18 years old may drive the Roller alone if : a) Charged by the Machine manufacturer to assemble, test and demonstrate the Machine, or to train drivers, whereas he/she must be made familiar with the occupational safety regulations in force at the site, or b) Appointed by Supplier of building work to operate (carry out maintenance), and evidently trained and acquainted with, or if, under specific regulations, he/she owns professional competence to operate and drive (engine operators licence, and alike). Machine Driver must undergo training at least 1x every 2 years, and pass exams concerning work safety regulations.

30

ASC 100

Operating instructions
Confirm the functions of the brake and steering before Machine operation start up. Following an alarm the Operator may start the Machine only when all workers leave the danger area. At blind (uneasy to oversee) sites the operation start may begin only after a period necessary to exit endangered area elapses. When operating the Machine the safety regulations must be adhered to, no activity hazardous to work safety can be carried out, commit yourself fully to Machine driving. ALWAYS sit on the seat when driving the Machine. Respect job description or instructions of an employee accountable. When moving with the Machine at the site you must adapt the speed to the terrain condition, work in progress, and weather conditions. Watch continuously the clearance height to avoid collision with any obstruction. Upon completion or stop of the Machine operation during which Driver leaves the Machine, he/she must first make measures against unauthorized use of the 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 appropriate station (flat, good bearing surface) in 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 Machine. When parking the Machine on communications over land, please carry out measures under the regulations 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. During immediate change of Drivers it is a a duty to directly draw changing drivers 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 during maintenance work (lubricating, replacing of operating 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. Before lifting the cabin and bonnet, please confirm there is enough space for lifting, with no electric lines present. Before dropping the cabin and bonnet confirm nobody will be endangered with this operation. In case the Machine would come into contact with high voltage the following principles must be adhered to: Try to escape with the Machine from the hazardous area Do NOT leave driver control stand Give warning to others not to approach and contact the Machine.

Maintain the Machine free of oil dirt and flammable materials.

Observe safety communication under any and all circumstances Life Hazard

Observe safety communication Accident Hazard.

Follow environmental regulations.

CAUTION

Take notice of labels

ASC 100

31

2.2.

Major Safety Measures


Operate the Machine within protective zone of electric lines and substations. Pass over the electric cables unless these are properly protected against mechanical damage. Operate the Machine under reduced visibility or at night unless the working area of the Machine or the site is sufficiently illuminated. Leave Machine driver seat with the Machine running. Abandon unsecured Machine, i.e. move away from the Machine without preventing its misuse. Disable safeguarding, protecting or locking systems, or alter their parameters. Use the Machine with leaking oil, fuel, coolant or other fillings. Start the engine in some other way than given in the Driver Manual. Place, aside from personal needs, so other things (tools, accessories) at the Driver Control Stand. Put any materials or other objects on the Machine. Remove any dirt while the Machine is running. Carry out maintenance, cleaning or repairs unless the Machine is secured against self-motion and accidental start, or unless contact between worker and moving parts of the Machine is excluded. Touch moving parts of the Machine with your body and objects or tools held in your hands. Smoke & handle open fire while inspecting or refilling the fuels, changing, replenishing oil, lubricating the Machine, or checking and refilling the accumulator. Carry the rags soaked with flammable materials on the Machine (inside engine bay, cab), or carry flammable liquids in free vessels. Let the engine run inside confined areas. Exhaust gases are dangerous to life.

2.2.4. Operations Prohibited


It is forbidden to:

Use the Machine after drinking alcohol and ingestion of narcotics. Use the Machine in case its operation might deteriorate its operating condition, cause safety hazard (life, health) to persons, buildings and other property, or to road traffic and its continuity. Start the Machine and use it when other persons are within the hazardous vicinity of the Machine. Exempted is driver training by lector. Start the Machine operation and use the Machine with some of the safeguard equipment (emergency brake, hydraulic locks, etc.) removed or damaged. Move and compact at such banks at which machine stability would be broken (overturn). Machine static stability specified gets reduced by the dynamic effects of the drive.. Move and compact at such angles of slopes at which the hazard of earth breaking off together with the Machine could occur, or adhesion lost followed by uncontrollable breakaway. Control the Machine in a way other than stated in the Driver Manual. Move and compact with vibration per soil bearing capacity at such distance from the slope edge or excavation edges to avoid the hazard of material sliding down or shoulder breaking off together with the Machine. Move or compact with vibration at such distance from walls, cuts or slopes so as to avoid the hazard of their collapsing and backfilling the Machine. Compact with vibration at such distance from the buildings or premises and facilities within which a 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 persons or property may occur unless work safety is secured in some other way, e.g. indirectly via signalling carried out by duly instructed person.

32

ASC 100

Operating instructions
2.2.5. Hand Signals
Signals given by Machine Operator Assistant when Operator 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

2.2.

Major Safety Measures

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 forearms 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

Operating instructions
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 hands 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.

Major Safety Measures

2.2.6. Safety labels & signs used on the Machine

36

ASC 100

Operating instructions
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.)

Burn Hazard

Danger of burn. Do NOT touch hot parts of the Machine unless you made certain of their being cooled down sufficiently. (Symbols placed from inside on the left door.)

Injury Hazard

Risk of injury and winding around. NEVER touch rotating parts while engine is running. (Symbol placed on the left side of the cooler.)

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.)

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.)

Read the Manual

Read the Operating Manual before starting the Machine.(Symbol placed on the left side of the control panel.)

Machine Max Height

Pay attention when passing through a location with height limit. (Symbol placed on the left side underneath the cab on the frame.)

ASC 100

37

2.2.
8

Major Safety Measures


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.)

Battery Disconnector

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 & electronics of the Machine, i.e. ASC, motor control unit. (Symbols 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 doors inner side.)

38

ASC 100

2.3.

Ecological & Hygienic Principles

Operating instructions

During Machine operation or storage the User must observe general principles of occupational safety and environmental protection along with laws, public notices or regulations related to these issues and in force within a territory where the Machine is used.

2.3.2. Ecological Principles


Refills for the Machines individual systems and some of its parts become waste having hazardous properties against the environment following their disposal. This waste product category includes in particular: organic or synthetic lubrication materials, oils and fuels, cooling liquids, accumulator refills and the accumulators themselves, tyre fillings cleaning & preservation agents, all the filters & filter elements removed, all the used and discarded hydraulic & fuel hoses, metal-rubbers and other elements of the Machine fouled with the aforementioned products.

2.3.1. Hygienic Principles


Oil products, refrigerants of cooling systems, alternator refills or painting materials incl. thinners are health hazard materials. Workers coming into contact with these products during Machine operation or maintenance will be liable to adhere to general principles of their own occupational safety, and conform to the safety & hygienic manuals of the manufacturers of these products. We point in particular to : Eye & skin protections while handling the accumulators Skin protection while handling the oil products, painting materials or cooling liquids Washing your hands properly upo work completion or before taking meal. Treat your hands with appropriate reparable cream. While handling the cooling systems follow instructions given in the Manuals supplied together with the Machine. -

Producer and contractual service organizations accredited by him, or dealers take back the following materials or parts free of charge: oils batteries tyres (optional)

ALWAYS store oil products, cooling system refrigerants or accumulator refills and painting materials incl. organic thinners along with cleaning & preservation agents inside their original packages labelled properly. Do NOT admit to store these materials in unlabelled bottles or other containers due to their exchange hazard. Especially hazardous is the potential of being exchanged for consumables or drinks. Should your skin, mucosa, eyes be stained incidentally, 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 construction.

Following the disposal of the abovementioned materials and parts make sure these are handled in line with the respective national environmental regulations and health regulations.

ASC 100

39

2.4.

Preservation & Storage


2.4.2. Machine preservation & storage for the period over 2 months
For the Machine shutdown the identical principles like with short-term preservation will apply. In addition we recommend the following: remove the accumulators, check their condition and store in a cool, dry room (recharge the accumulators on regular basis), Bottom on the runner frame so the damping system has minimal deflection (flexure), paint rubber elements with spec. preservation agent to protect them, inflate the tyres to a specified pressure, and protect them from direct sunlight, apply chrome-plated piston rods with preservation grease, spray the Machine with special agent and this at places with possible corrosion origin, Blind engine air intake and exhaust with double PE foil and fix it carefully with adhesive tape, protect headlamps, exterior back mirrors and other elements of external wiring via spraying with special agent and wrapping in PE foil, Preserve the engine per manufacturers Manual. Install a visible label informing the engine has been conserved.

2.4.1. Short-term preservation & storage for the period of 1 2 months


Wash & clean carefully the entire Machine. Before Machine parking and shutdown in order to make its preservation & storage, please heat the running engine up to its operating temperature. Park the Machine on fixed, flat surface at a safe place with no potential of Machine damage caused by natural disaster (floods, landslides, fire, etc.). In addition: repair those spots with paint impaired, lubricate all lubricating points, control cables, joints of the controllers, etc., confirm water fillings have been drained, check cooling liquid has its antifreeze characteristics required, check the accumulator charging conditions, recharge if required, apply preservation grease over the chrome-plated surfaces of the piston rods, we recommend to spray preservation agent (applied via spraying) to protect your Machine against corrosion, and this particularly in places with corrosion hazard.

Machine treated like that will need no special set-up before its subsequent putting into operation.

! CAUTION! Following 6 months we recommend to inspect preservation condition and renew 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 preservation 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


User will be liable to follow national waste or environmental laws and regulations when carrying out Machine disposal. We therefore recommend to always consulting:

Operating instructions

licensed industrial waste products disposing companies, Machine manufacturer or by them appointed and certified 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 2 3 4 5 6 7 8 9

- Runner Frame - Drum - Scraper - Joint - Tractor Frame - Axle - Fuel Tank - Accumulators - Hydraulic Tank

11 - Engine 12 - Hydraulic Oil Cooler 13 - Engine Coolant Cooler 14 - Drivers Control Stand 15 - Travel Hydrogenerator 16 - Vibration Hydrogenerator 17 - Exhaust Muffler 18 - Air Filter 19 - Hydr. Oil Pressure Filter

10 - Bonnet

ASC 100

43

2.7.

Controllers & Dashboard Instruments

44

ASC 100

Operating instructions
Dashboard & Control Panel

1 2 3 4 5 6 7 8 9

- Steering Wheel - Travel Controller - Vibration Switch - Travelling Speed Controller (Selector) - Throttle Controller - Ignition Box - Motor Thermometer (Optional) - Hydraulic Oil Thermometer (Optional) - 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

2.7.

Controllers & Dashboard Instruments

Steering Wheel 1 Used for Machine steering. Travel Speed Controller 4

! CAUTION! With respect to safe steering, please adjust optimal speed (1800. min 1) when driving without vibrations.

With the Controller turned ON the travel gear is engaged (Hare indicator lights). The Machine is capable to reach max. Speed with pulling force reduced and climbing ability decreased.

NOTE: Travel Controller 2 Use this controller to adjust direction & speed of the driving. Driving speed corresponds to the degree the controller deflects from idle (neutral) position. At the same time the controller is used as driving brake of the Machine. The controller is arrested in set position. When shifted to its center position the parking brake is enabled, i.e. the control lamp 14 lights up. Vibration Switch 3 is located at the controller handle, and is used to switch ON/ OFF the vibration after moving controller handle from neutral. With the controller switched off the operating speed mode is set. The Machine reaches max. pulling force and climbing ability.

! CAUTION! You may switch ON the controller, i.e. travel speed, when driving the Machine on a formation level. You may turn ON the controller with the Machine loaded. With pulling force not sufficient, switch OFF the travel speed controller.

! CAUTION ! Engine starting is possible in idle position only. No vibration able to turn ON when in idle position. (Vibrator bearings are not lubricated during vibration at the halt).

NEVER switch ON the controller during occupational use of the Machine. Do NOT switch OFF the controller at high speed. Abrupt slowdown will occur together with impact within the hydraulic 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

Operating instructions
Ignition Box 6 It has three positions - 0, I, II. When in0 pos. all the consumers with F1, F2 & F7 fuses will be connected; inI pos.other consumers will be connected; cushion fuse II is used for Machine starting. Turn the key to0 pos. to stop the Machine, remove the key in this position. Operated-Hours Counter 9

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 key.

! CAUTION! 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 ignition box cap to protect the ignition box against water & dirt penetration.

Fuel Level Indicator 10 - Optional

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

Hydraulic Oil Thermometer 8 - Optional

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).

Switch the ignition box key to position I, and the control lamp lights up and then goes off after starting the engine. The lamp lighted signals engine lubrication is insufficient.

! CAUTION! Unless it goes off, look for the failure!

Oils of other viscosity used Oil Viscosity HV 46 HV32 Oil Temperature Limit 80 C (176 F) 70 C (158 F)

ASC 100

47

2.7.

Controllers & Dashboard Instruments

Accumulator Charge Control Lamp 13

Indicator of hydraulic oil filter 18

Switch the key on the ignition box 6 toI pos. and the control lamp must light up and go off after starting the engine.

This indicator lighted up under hydraulic oil operating temperature of 50 - 60 C (122 - 140 F) signals the filter element is clogged with dirt.

! CAUTION! Unless it goes off, look for the failure!

! CAUTION ! Replace the elements at once!

Brake Alarm Indicator 14

Vibration ON Indicator 19

With this indicator lighted up the Machine broken is signalled.

With this indicator lighted up the vibration switch 3 is ON. 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 indicator 20

When the engine temperature reaches the highest allowable level, the engine overheating control lamp goes ON an audible warning is given.

When the fluid temperatures reaches the highest allowable 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 ! Replace the elements at once!

! CAUTION! The Fan enables air circulation inside the cabin only. Cab installation is optional.

48

ASC 100

Operating instructions
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 lubrication lamp, charge control lamp, hydraulic oil filter fouling lamp, engine filter fouling lamp, fuel minimum lamp, motohours counter, engine overheating lamp, hydraulics overheating lamp Options: engine coolant thermometer, hydraulic oil thermometer, fuel level 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 washers Fuse (F7) -20 A reserved (air conditioner) Fuse (F8) reserved

Alarm Horn Pushbutton 25

! CAUTION! Replace fuses with those of identical value ONLY!!!

ASC 100

49

2.7.

Controllers & Dashboard Instruments

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

Operating instructions

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

2.7.

Controllers & Dashboard Instruments

Locker 33 Designed for first-aid kit etc.

Back Mirrors 34 When working within a restricted space or during transportation 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

Operating instructions
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 drivers weight between 50 - 130 kg. Longitudinal Move of the Seat lift the lever and move the seat in longitudinal direction forward backward.

2
Accumulator cutoff switch

Use cutoff switch to disconnect accumulator from the frame.

! CAUTION! Use cutoff switch to disconnet the accumulator 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


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. When started, let the motor run at idle rpm of 1300 1500 min-1 for a period of 35 minutes.

2.8.1. Start the Engine

Before you start the engine, please turn ON the horn for warning purposes. Confirm 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 exhaust gases the absence of blue or white fume indicates the fuel supply is insufficient.

How to start the engine : 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

Operating instructions
How to start using starter cables via another machine Make sure the starting voltage of a booststarting power supply is 24 V. Follow unconditionally the sequence of operations given below!
1. Connect one (+) pole end of the cable to (+) pole of discharged accu. 2. Connect second (+) pole end of the cable to (+) accu of the machine used to boost-start. 3. Connect one () pole end of the cable to () pole of accu in the vehicle used to boost-start. 4. Connect second () pole end of the cable to a section of the started Machine fix-connected to the engine (or to the cylinder block itself)

! CAUTION ! Do NOT start for more than 30 sec. Make another starting attempt only after 2 minutes, and unless the motor starts even after 3 attempts, carry out troubleshooting. Charge control lamp and lubrication lamp must go off when the engine starts. Lubrication lamp must go off within 15 sec. Sharp speed increase or decrease is inadmissible hazard of engine damage. When started let the engine run at idle rpm of 1500 min 1 for a period of 35 minutes. Do NOT let the motor run idle for over 10 minutes running idle for longer period will cause injectors clogged, piston rings gummed, valves seized! Unless liquid temp reaches min. 60 C (140 F) the engine will not be lubricated sufficiently enough do NOT run the engine at full capacity! Starting will be interlocked: When the controller 2 is in idle (neutral) position.

! CAUTION! When started, disconnect the starter cables in reverse order. When aided by Starter Unit with no accus connected, do NOT disconnect the Unit before the Machine accumulator is connected.

ASC 100

55

2.8.

How to Control and Use the Machine


Do NOT connect () pole of the cable to () pole of discharged accu of the started Machine! Hazard of strong sparking when starting, followed by an explosion of gases generated by accumulator. Non-insulated sections of the starter cables gripping collets may NOT contact each other! Make sure starter cable connected to (+) pole of accu does NOT come into contact with electrically conductive parts of the Machine shortcircuit hazard. NEVER bend yourself over the accumulators - hazard of electrolyte burn! Exclude any presence of flammable sources (free flame, smoking cigarettes, and alike). NEVER verify voltage presence within a conductor via sparking through the Machine frame!

2.8.2. Travel & Reversing


Use acoustic alarm to communicate drive away of the Machine, and wait long enough so the persons present may leave in time the adjacent area of the Machine (area under the Machine) ! Before drive away you must confirm the area in front of and behind the Machine is free, and that no persons are found there!
Turn OFF the travelling speed controller 4 i.e. switched to operating speed. Use throttle controller 5 to adjust engine rpm required, i.e. ca 1800.min1). Confirm vibration switch 3 is not ON, control lamp 19 is off. Deflect travel controller 2 from idle (neutral) pos. to a required direction small deflection of the controller = slow speed and vice versa. Following travel controller 2 deflection the brake indicator lamp 14 will go off. Reversing shift the controller 2 in opposite direction via its idle position.

EMERGENCY STOPPING

How to start at low temperature. Starting at ambient temperature below 0C (32F) will require different way of starting with the use of starter filling: Adjust the throttle to half-speed, and when starting the engine a second person will inject measured quantity of starter filling into the air filter.

Use this way of stopping in case of defect, when the machine cannot be stopped by moving travel control (2) to neutral position. Shut down the engine by switch key off. ! CAUTION ! Turn ON the controller 4 transport speed - you may do so while driving the Machine by an adjusted terrain (formation level) Hare symbol will light up. Turn the controller ON only with the Machine not idle.. In case of lack of pulling force, switch OFF the transport speed controller. NEVER switch OFF the controller 4 at high speed due to high slowdown along with impact within hydraulic system. Turn OFF the controller 4 at low speed or with the Machine at rest! Engage operating speed via turning OFF controller 4 before driving by steep incline! Do NOT apply throttle 5 to control Machine velocity.

! CAUTION ! Observe strictly safety & hygienic instructions of manufacturer when using starter filling. Non-observance of these instructions may lead to engine or property damage, health and life hazards to people present. NEVER use volatile, easily ignitable refill when starting inside tunnels or mines. Always ask for safety guidelines when using starter refills under these conditions.

56

ASC 100

Operating instructions

NEVER drive in cross direction at the hillsides of high slope! Drive perpendicular to a hillside!

ASC 100

57

2.8.

How to Control and Use the Machine

2.8.3. Travel with vibration


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

58

ASC 100

Operating instructions
2.8.4. Stop the Machine & the Engine
Use switch 3 to turn OFF the vibration control lamp 19 goes off. Use controller 2 to stop the Machine parking brake is enabled; lamp 14 lights up. 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.

! CAUTION ! Do NOT stop hot engine instantly, instead let it idle for a period of 3 minutes.

ASC 100

59

2.8.

How to Control and Use the Machine

2.8.5. Machine Shutdown


Stop the Machine. Cut off battery disconnector. Clean the Machine (scraper, tyres). Make overall inspection of the Machine and repair any defects caused during operation. Confirm tyres have sufficient pressure. Put Scotch blocks to the wheels and uncoupled-axle. Lock the instrument covers or the cab and the door beneath driver control stand.

Stop the Machine on flat, paved surface Confirm no natural hazard (landslide, potential of deluge due to any floods, etc.) exists at the location where the Machine is parked and shut down.

60

ASC 100

Operating instructions
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

2.8.

How to Control and Use the Machine

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
A person that guides the Machine must communicate with the Driver using specified intercommunication signals, (refer to Section 2.2.5), this guiding person must always stay at one place outside the reach of the Machine and outside the carrier. Guiding person must remain within Drivers field of sight (in visual contact) throughout the entire period of driving the Machine onto the carrier and driving down from the carrier. When driving onto and down from the carrier all the persons aside from Machine Driver must go away as far as to avoid being hit by a falling 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 hitches, and sling holes in the runner frame sidewalls. Adhere to the Motor Vehicle Construction and Use Regulations when transporting via land routes. NO persons may stay on the Machine, driver control stand or carrier loading area during Machine transportation.

2.9.1. Machine transportation by its own axle


Move the roller by its own axle when moving within a working site outside public roads.

! CAUTION ! Transport speed you may switch ON collector (4) when crossing with the Machine by finished road. In case of long transportation distances, please make 1-hour cooling breaks every 3 hours. Non-observance of this advice will put in jeopardy of Machine damage that the manufacturer will in no and any circumstances bear responsibility for. Follow those safety measures specified for the work site when shifting the Machine.

2.9.2. Machine transportation by public road

! CAUTION! The basic construction of the Machine is NOT fitted for transportation by its own axle using public road. This type of transportation is prohibited.
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 carrier, we recommend to put rubber bands or wooden planks, etc. under the runner. Make sure the carrier designed for the transport is braked when loading and unloading, as well as mechanically 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 .

Fold down the arm 2 and lock with the journal 1 and safety lock 3 .

Do NOT enter underneath hanging load! Upon completion of loading, return the safety arm back to its initial position. Follow provisions in force when loading/unloading. Apply adequate, intact rigging of sufficient loading capacity. Use only those lifting eyes (mounting lugs) on the Machine designed specifically for slinging. Only a trained slinger may carry out the slinging.

2 1

64

ASC 100

Operating instructions
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 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 cables or towing bars of sufficient 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-working 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 damaged 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

Operating instructions
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 and hard materials
During vibration driving a loss of contact between the runner and the compacted material (so called vibrostroke) may occur due to the impact of high level of sub grade material compaction, or due to vibration driving on hard materials (e.g. stony loose material). This state will show through the increased vibration energy transfer to 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 may also be expected when increasing the level of sub grade material compaction.

In case it is urgent to operate the Machine under the conditions with the potential of Operator exposed to higher vibrations, then the Machine User is liable to adapt the operating procedures so as to avoid drivers health hazard.

Note: 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

Operating instructions
2.10.2. Machine use under heavy climatic conditions 2.10.2.1. Machine operation under low temperatures
Compacting during winter season depends on fine particle contents and water contents within a soil under compaction. With the temperature going down below freezing point the earth becomes more solid and harder to compact. When compacting at the temperatures below 0 C (32 F) is required, you may compact dry soils (or stony loose materials) or perform fast compaction of non-frozen materials (ahead of earth becoming frozen through).

Manufacturer Power Class under ISO 6743/HV Viscosity Class under ISO 6743/4, DIN 51519 Viscosity Class under CETOP RP 91H AGIP ARAL AVIA BP CASTROL CHEVRON ELF ESSO MOBIL MV SHELL TEXACO TOTAL

Oil Type HV (HVLP)

VG 32

VG 46

HV 32 ARNICA 32 VITAM HF 32 AVILUB HVI 32

HV 46 ARNICA 46 VITAM HF 46 AVILUB HVI 46

Make the Machine ready for operation under low temperatures: Check the engine coolant concentration. Exchange oil in the engine with the one recommended for a given range of low ambient temps. Apply hydraulic oil of corresponding cinematic viscosity. Change oil in runner gearbox with the one recommended for a given range of gearbox temperatures. Use winter fuel. Confirm the accumulators are charged.

BARTRAN HV 32 BARTRAN HV 46 HYSPIN AWH 32 EP 32 HV HYDRELF 32 UNIVIS N 32 MOBIL DTE 13 HLP-M 32 TELLUS T 32 RANDO HD AZ 32 EQUIVIS ZS 32 HYSPIN AWH 46 EP 46HV HYDRELF 46 UNIVIS N 46 MOBIL DTE 15 HLP-M46 TELLUS T 46 ALCOR DD-Z 46 EQUIVIS ZS 46

Sound condition of accumulator is the prerequisite of good starting under low temperatures. Warm up the accumulators to ca 20 C (68 F) (via removing accumulators and storing them in a dry warm room) to lower limit temp for starting by 4 to 5 C (39,2 to 41 F).

Hazard of engine damaged when engine (cooling liquid) operating temperature remains constantly below 60 C (140F).
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 temperatures 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 temperatures and humidity
Engine power will lower with air temperature or humidity increasing. Since both of the factors that lower engine performance are independent on each other, their effects can be described as follows: With every 10 C (50 F) of increased temp the power will drop by up to 4 % (at constant humidity) With every 10 % of increased RH the power will drop by up to 2 % (at constant temperature).

2.10.2.3. Operating the Machine at high altitudes


Engine power will decrease with the altitude rising. This is given by the reduced atmospheric pressure and induction air specific mass.

Altitude m 0 500 1000 1500 2000 2500 3000

(ft) 0 (1640) (3281) (4921) (6562) (8202) (9843)

Decrease in Power % 0 3 6 10 15 21 28

Any engine (cooling liquid) operating temperature over 100 C (212F) may damage the motor.
At high temperatures when hydraulic oil temp is constantly round 90 C (194 F), we recommend to exchange hydraulic oil with denser one of 100 mm 2/s cinematic viscosity class (BP BARTRAN HV 100, ESSO UNIVIS N100, etc.)
Manufacturer Power Class per ISO 6743/HV Viscosity Class per ISO 6743/4, DIN 5 1 5 1 9 Viscosity Class per CETOP RP91H BP ESSO MOBIL MV SHELL Oil Type HV (HVLP) VG 100 HV 100 BARTRAN HV 100 UNIVIS N 100 DTE 18 HLP - M 100 TELLUS T 100

When black smoke is generated by the engine at high altitudes (above 1500 m), please contact your engine manufacturer service department to make adjustment to your injection pump to fit these operating conditions.

! CAUTION! Engine power will be affected by the environment where the Machine is operating, as per Sections 2.10.2.1. & 2.10.2.3.

2.10.2.4. Machine operation at extremely dusty environment

! CAUTION! Cut short the intervals of cleaning and replacement of air filter elements when operating under extremely dusty conditions; shorten the intervals of cleaning the engine cooler, hydraulics, or of replacing Cabin dust filter.

! CAUTION! When hydraulic system is filled with oil class: HV 46, then oil max. Limit temperature is 80 C (144 F) HV 32, then oil max. Limit temperature is 70 C (158 F) When operating under extreme temperatures when cooling liquid or hydraulic oil temperatures reach max. Limit temperatures, 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

Operating instructions

Notes:

ASC 100

71

Notes:

72

ASC 100