Operating manual

ASC 100
Cummins

Book ID: 4-P06280CU-EN

 ASC 100
Single drum roller
Cummins Tier 1

Operating manual

Edition 04/2013 EN
From Serial No. 2802629
Translation of Original Operating Manual
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,

Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují

% + 420 491 476 111 | Fax + 420 491 470 215 | info@ammann-group.com | www.ammann-group.com

ASC001

This manual consists of:

I. Specification manual II. Operating instructions III. Maintenance manual

The following explanations serve to familiarise the machinist (operator) with the roller and to support him during handling and main-
tenance. It is therefore absolutely necessary to provide the operator with these instructions and to ensure that he reads them carefully
before using the road roller. This aids training comprehension during the 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.
In order to ensure the smooth operation of AMMANN compaction equipment, use for repairs only the original spare parts
supplied by AMMANN.
All spare parts are available from your dealers or can be ordered at spareparts.machines@ammann-group.com, helpline:
+41 62 916 66 66; should you need further information, contact support.machines@ammann-group.com, hotline: +420 776 667 775.

These instructions must always be kept available on the equipment.

ASC 100 1
Preface
Information, specifications, and recommended operation and maintenance instructions contained in this publication are basic and
final information at the time of the printing of this publication. Printer’s errors, technical modifications, and modifications of figures are
reserved. All dimensions and weights are approximate and, therefore, not binding.
Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to inform the machine user. If you identify
any differences between the machine operated by you and the information contained in this publication, contact your local dealer.
Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic a.s.

2 ASC 100
 SYMBOLS OF THE SAFETY NOTICES IN THE OPERATION MANUAL:

The notice warns of a serious risk of personal injury or other personal hazards.

The notice warns of possible damages to the machine or its parts.

The notice warns of the necessity of environmental protection.

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

FRONT

LEFT RIGHT

REAR 282N100Ten

ASC 100 3
Content
Content..............................................................................................................................................................4
1. SPECIFICATION MANUAL.......................................................................................................................9
1.1. Basic Data...............................................................................................................................................10
1.2. Dimension Chart....................................................................................................................................12
1.3. Technical Data........................................................................................................................................13

4 ASC 100
 OPERATING MANUAL
2. OPERATING INSTRUCTIONS................................................................................................................19
2.1. Dewaxing and Inspection of a Newly Supplied Machine...................................................................20
2.2. Safety Instructions................................................................................................................................21
2.2.1. Safety measures to operate the Machine .....................................................................................................................................................21
2.2.1.1. How to start the compaction work..................................................................................................................................................................21
2.2.1.2. Work safety secured by User...............................................................................................................................................................................21
2.2.2. Driver Qualification Requirements...................................................................................................................................................................22
2.2.3. Driver’s Duties..........................................................................................................................................................................................................23
2.2.4. Forbidden activities – safety and guarantee.................................................................................................................................................24
2.2.5. Safety labels & signs used on the Machine ..................................................................................................................................................25
2.2.6. Hand Signals.............................................................................................................................................................................................................28

2.3. Ecological & Hygienic Principles..........................................................................................................31

2.3.1. Hygienic Principles.................................................................................................................................................................................................31
2.3.2. Ecological Principles .............................................................................................................................................................................................31

2.4. Preservation & Storage.........................................................................................................................32

2.4.1. Short-term preservation & storage for the period of 1 ÷ 2 months.....................................................................................................32
2.4.2. Machine preservation & storage for the period over 2 months.............................................................................................................32

2.5. Machine disposal upon its life termination.........................................................................................33

2.6. Machine Description.............................................................................................................................35
2.7. Controlling and operation of the machine..........................................................................................36
2.8. How to Control and Use the Machine...................................................................................................46
2.8.1. Start the Engine ......................................................................................................................................................................................................46
2.8.2. Travel & Reversing..................................................................................................................................................................................................48
2.8.3. Travel with vibration..............................................................................................................................................................................................50
2.8.4. Emergency stop of the Machine.......................................................................................................................................................................51
2.8.5. Stop the Machine & the Engine.........................................................................................................................................................................52
2.8.6. Machine Shutdown................................................................................................................................................................................................53
2.8.7. How to lift driver control stand and bonnet.................................................................................................................................................54
2.8.8. Ballasting of tyres with liquid.............................................................................................................................................................................56

2.9. Machine Transportation........................................................................................................................58

2.9.1. Machine transportation by its own axle.........................................................................................................................................................58
2.9.2. Machine transportation by public road..........................................................................................................................................................58
2.9.3. How to load the Machine.....................................................................................................................................................................................59
2.9.4. Towing of Machine.................................................................................................................................................................................................60
2.9.5. Dismantle the Cab and the ROPS - Option....................................................................................................................................................61

2.10. Special Conditions for the Machine Application.................................................................................63

2.10.1. Vibration driving on compacted and hard materials ................................................................................................................................63
2.10.2. Machine use under heavy climatic conditions ............................................................................................................................................63
2.10.2.1. Machine operation under low temperatures ..............................................................................................................................................63
2.10.2.2. Machine operation under high temperatures and humidity ................................................................................................................64
2.10.2.3. Operating the Machine at high altitudes ......................................................................................................................................................64
2.10.2.4. Machine operation at extremely dusty environment ...............................................................................................................................64

ASC 100 5
Content
3. MAINTENANCE MANUAL.....................................................................................................................63
3.1. Safety and other measures for machine maintenance.......................................................................65
3.1.1. Safety during Machine Maintenance..............................................................................................................................................................65
3.1.2. Fire precautions when refilling .........................................................................................................................................................................65
3.1.3. Ecological & Hygienic Principles........................................................................................................................................................................66

3.2. Specification of fluids............................................................................................................................67

3.2.1. Motor Oil....................................................................................................................................................................................................................67
3.2.2. Fuel...............................................................................................................................................................................................................................68
3.2.3. Cooling Liquid..........................................................................................................................................................................................................68
3.2.4. Hydraulic Oil.............................................................................................................................................................................................................69
3.2.5. Gearbox Oil...............................................................................................................................................................................................................70
3.2.6. Lubricating Grease.................................................................................................................................................................................................70
3.2.7. Screen Washer Liquid ...........................................................................................................................................................................................70

3.3. Refills......................................................................................................................................................71
3.4. Lubrication & Maintenance Table.........................................................................................................72
3.5. Lubrication and Service Plan................................................................................................................74
3.6. Individual Operations of Maintenance................................................................................................75

Following 20 hours of operation or daily............................................................................................76

3.6.1. Check the oil amount in motor..........................................................................................................................................................................76
3.6.2. Check the amount of cooling liquid in the motor......................................................................................................................................77
3.6.3. Check the amount of oil inside hydraulic tank ...........................................................................................................................................78
3.6.4. Crankcase Breather................................................................................................................................................................................................79
3.6.5. Check fan condition...............................................................................................................................................................................................80
3.6.6. Check motor belt....................................................................................................................................................................................................80
3.6.7. Check engine air intake........................................................................................................................................................................................81
3.6.8. Check the amount of fuel....................................................................................................................................................................................82
3.6.9. How to clean air separator...................................................................................................................................................................................83
3.6.10. Check the alarm & control devices...................................................................................................................................................................84

Every 100 Hours.....................................................................................................................................85

3.6.11. Check tire pressure.................................................................................................................................................................................................85

Every 250 Hours or Once in 3 Months..................................................................................................86

3.6.12. How to replace oil in the engine.......................................................................................................................................................................86
3.6.13. Check the fixing of the engine...........................................................................................................................................................................89
3.6.14. Battery check............................................................................................................................................................................................................90
3.6.15. Check the function of Air Filter Vacuum Switch..........................................................................................................................................91
3.6.16. Machine Lubrication..............................................................................................................................................................................................92
3.6.17. How to check oil inside vibrator .......................................................................................................................................................................95
3.6.18. How to check oil in gearboxes...........................................................................................................................................................................96

6 ASC 100
 OPERATING MANUAL
Every 500 Hours or Once in 6 Month....................................................................................................97
3.6.19. Replacement of fuel filters of the engine.......................................................................................................................................................97
3.6.20. Cooling liquid inspection.....................................................................................................................................................................................99
3.6.21. Check of wiring........................................................................................................................................................................................................99
3.6.22. Exchanging cleaner elements of air cleaner.............................................................................................................................................. 100
3.6.23. Replacement of filters of the cab and heating ventilation................................................................................................................... 102
3.6.24. Replacement of the air filter of the air conditioning............................................................................................................................... 103
3.6.25. Check if wheel bolts are tightened................................................................................................................................................................ 103

Every 1000 Hours or Once a Year........................................................................................................104

3.6.26. Check, adjust valve clearance.......................................................................................................................................................................... 104
3.6.27. How to check tightening pulley and belt of the engine........................................................................................................................ 104
3.6.28. Replace oil in gearboxes.................................................................................................................................................................................... 106
3.6.29. Checking the air conditioning compressor mounting........................................................................................................................... 108
3.6.30. Inspect the damping system........................................................................................................................................................................... 109
3.6.31. How to clean fuel tank....................................................................................................................................................................................... 110

Every 2000 Hours or Every 2 Years.....................................................................................................111

3.6.32. How to change oil in the vibrator.................................................................................................................................................................. 111
3.6.33. Cleaning and checking the air conditioning system.............................................................................................................................. 111
3.6.34. How to change hydraulic oil and filter......................................................................................................................................................... 112
3.6.35. How to change engine coolant...................................................................................................................................................................... 116
3.6.36. How to check the dampener of engine’s torsional vibrations............................................................................................................. 118

Maintenance - As Needed...................................................................................................................119
3.6.37. How to clean engine cooler and hydraulic oil........................................................................................................................................... 119
3.6.38. How to deaerate fuel system........................................................................................................................................................................... 120
3.6.39. How to adjust the scrapers............................................................................................................................................................................... 122
3.6.40. How to clean the Machine................................................................................................................................................................................ 123
3.6.41. Check bolted connections................................................................................................................................................................................ 123

3.7. Defects..................................................................................................................................................127
3.8. Appendixes..........................................................................................................................................128
Wiring Diagram..................................................................................................................................................................................................................... 128
Hydraulic Diagram............................................................................................................................................................................................................... 132
Cab and bonnet lifting........................................................................................................................................................................................................ 134
Regular maintenance spare parts chart....................................................................................................................................................................... 137

ASC 100 7
8 ASC 100
 SPECIFICATION MANUAL

1. SPECIFICATION MANUAL

ASC 100
(Cummins Tier 1)

ASC 100 9
1.1. Basic Data
Application Range
Please fill in the following data:
The rollers are designated for operation under conditions as ac-
(Refer to nameplate and rating plate for Cummins engine)
cording 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). Type of machine
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 con- ................................................................................................................
struction (earth dams) and civil engineering (industrial areas, ICV/PIN (Serial number of the machine)
ports etc.).

................................................................................................................
Modifications Production year

The single drum vibratory roller ASC 100 D 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 thick- Type of engine
ness (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 thick-
ness 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
Serial number of the engine
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. ................................................................................................................
ASC 100 PD roller with a padfoot drum (synchronous knead-
ing and vibrating effect) is suitable for the compaction of clay
soils up to a layer thickness (after compaction) of 30 cm (11.8 in),
loam soils up to a layer thickness of 40 cm (15.7 in), and mixed
soils up to a layer thickness of 50 cm (19.7 in). Please refer to the data in the table below always when ap-
proaching the dealer or the manufacturer.

10 ASC 100
 SPECIFICATION MANUAL
Pin label
3488

1 - Name – always mentioned only in the English version

2 - Type 1
3 - Serial number 7
4 - Operating weight 2
5 - Maximum weight 8
6 - Rated power
3
9
7 - Version 4
8 - Shipping weight
10
9 - Front axle load 5
10 - Rear axle load 11
11 - Year of manufacture 6
3488

PIN label 1, S/N 2

1
AMMANN CZECH
REPUBLIC a.s.
NOVÉ MĚSTO NAD
METUJÍ, CZECH
REPUBLIC
TYP / TYPE 3172

IČV / S/N

PROVOZ. HMOTNOST
BETRIEBSMASSE / OPERAT. WEIGHT
/ POIDS DE SERVICE ZAT. PŘEDNÍ OSY
/
BELASTUNG DER FRONT AXLE LOAD
VORDERACHSE
CHARGE DE ESSIEN
ARANT

MAX. HMOTNOST
/ MAXIMUM WEIGHT ZAT. ZADNÍ OSY
kg
MAX. MASSE / POIDS / REAR AXLE LOAD
MAX BELASTUNG DER
HINTERACHSE
CHARGE DE ESSIEN
ARRIÉRE

kg
VÝKON MOTORU
/ ENGINE OUTPUT
MOTORLEISTUNG ROK VÝROBY /
/ PUISSANCE DU PRODUCTION YEAR
MOT. BAUJAHR / ANNÉ
DE FABRICATION

MADE IN CZECH
REPUBLIC

2
28002

Serial number ESN of the CUMMINS engine

28031

ASC 100 11
1.2. Dimension Chart
Dimensional diagram for ASC 100 Machine without cabin (cabin as options)

D1

G
T
A
L

H
H1
G1

W
W1

28001

mm
A D D1 G G1 H H1 L T W W1
(in)

2820 1500 - 450 415 3027 2375 5630 25 2130 2250

ASC 100 D
(111,0) (59,1) (-) (17,7) (16,3) (119,2) (93,5) (221,7) (1,0) (83,9) (88,6)

2820 1440 1640 450 415 3027 2375 5630 20 2130 2250
ASC 100 PD
(111,0) (56,7) (64,6) (17,7) (16,3) (119,2) (93,5) (221,7) (0,8) (83,9) (88,6)

12 ASC 100
1.3.
Technical Data SPECIFICATION MANUAL

ASC 100 Cummins Tier 1

D PD
Weight
Operating weight of CECE with cab, ROPS kg (lb) 10120 (22310) 10860 (23940)
Operating weight of CECE with cab kg (lb) 9890 (21800) 10640 (23460)
Operating weight of CECE with platform, rail kg (lb) 9740 (21470) 10470 (23080)
Operating load of CECE with cab, ROPS on front axis kg (lb) 5300 (11680) 6040 (13320)
Operating load of CECE with cab, ROPS on rear axis kg (lb) 4820 (10630) 4820 (10630)
Weight of half fluid capacities kg (lb) 170 (370) 170 (370)
Operating weight of ISO 6016 with cab, ROPS kg (lb) 10300 (22710) 11050 (24360)
Max. weight – cab + ROPS (6016) + accessories + wei-
kg (lb) 12280 (27070) 11100 (24470)
ghing
Maximum permitted weight according to ROPS kg (lb) 18500 (40790) 18500 (40790)
Static linear load of front drum kg/cm (lb/in) 24,9 (139,4) -
Cab weight kg (lb) 220 (490) 220 (490)
Weight of ROPS kg (lb) 230 (510) 230 (510)
Weight of sheet roof on ROPS kg (lb) 140 (310) 140 (310)
Weight of canopy kg (lb) 60 (130) 60 (130)
Weight of canopy posts (version without ROPS) kg (lb) 60 (130) 60 (130)
Weight of 2 padfoot segments kg (lb) 1720 (3790) -
Weight of tyre filling 0°C kg (lb) 1020 (2250) 1020 (2250)
Weight of tyre filling -25°C kg (lb) 1200 (2650) 1200 (2650)
Driving characteristics
Number of speeds - 1+1 1+1
Maximum transport speed km/h (MPH) 10,3 (6,4) 10,3 (6,4)
Working speed km/h (MPH) 5 (3,1) 5 (3,1)
Operating speed preselector (option) - speed 1 km/h (MPH) 5 (3,1) 5 (3,1)
Operating speed preselector (option) - speed 2 km/h (MPH) 6,2 (3,9) 6,2 (3,9)
Operating speed preselector (option) - speed 3 km/h (MPH) 7,1 (4,4) 7,1 (4,4)
Climbing ability % 40 40
Climbing ability with vibration % 30 30
Lateral static stability % 72,65 72,65
Lateral stability during driving without vibration % 25 25
Lateral stability during driving with vibration % 15 15
Maximum gradient when towing machine on slope % 60 60
Turning radius inner (edge) mm (in) 3210 (126,4) 3210 (126,4)
Turning radius outer (contour) mm (in) 5575 (219,5) 5575 (219,5)
Front approach slope % 58 58
Rear approach slope % 53 53
Type of drive - Hydrostatic Hydrostatic
Number of driving axles - 2 2
Oscillation angle ° ±10 ±10
Angle of steering ° ±36 ±36

ASC 100 13
1.3. Technical Data

ASC 100 Cummins Tier 1

D PD
Steering
Type of steering - Joint Joint
Steering control - Hydraulic Hydraulic
Linear hydraulic motors - 2 2
Engine
Manufacturer - Cummins Cummins
Type - 4BTA3.9-C116 4BTA3.9-C116
Power according to DIN 6271 kW (HP) 86 (115) 86 (115)
Power according to ISO 3046/1 kW (HP) 86 (115) 86 (115)
Number of cylinders - 4 4
Cylinder capacity cm (cu in)
3
3900 (238) 3900 (238)
Nominal speed min (RPM)
-1
2500 2500
Maximum torque Nm/rpm 423/1500 423/1500
Routine operation fuel consumption l/h (gal US/h) 11,5 (3) 11,5 (3)
EU Stage I, EU Stage I,
Engines complies with emission regulations -
U.S. EPA Tier 1 U.S. EPA Tier 1
Cooling system of engine - Liquid Liquid
Axle
Maximum tyre pressure MPa (PSI) 0,16 (23,2) 0,16 (23,2)
Pattern of tyres - UK 5 Diamond TD-01 Tractor
Number of tyres - 2 2
Number of rear wheels - 2 2
Size of tyres - 23,1x26´´ 23,1x26´´
Type of tyres - Tubeless Tubeless
Brakes
Operating - Hydrostatic Hydrostatic
Multiple-disc spring Multiple-disc spring
Parking -
brake brake
Multiple-disc spring Multiple-disc spring
Emergency -
brake brake
Vibration
Frequency I Hz (VPM) 32 (1920) 32 (1920)
Frequency II Hz (VPM) 35 (2100) 35 (2100)
Amplitude I mm (in) 1,85 (0,073) 1,6 (0,063)
Amplitude II mm (in) 1,15 (0,045) 0,97 (0,038)
Centrifugal force I kN - 277
Centrifugal force II kN - 206
Type of drive - Hydrostatic Hydrostatic

14 ASC 100
 SPECIFICATION MANUAL

ASC 100 Cummins Tier 1

D PD
Fluid capacities
Fuel l (gal US) 410 (108,31) 410 (108,31)
Engine (oil filling) l (gal US) 11,2 (2,96) 11,2 (2,96)
Cooling system l (gal US) 24 (6,34) 24 (6,34)
Hydraulic system l (gal US) 90 (23,78) 90 (23,78)
Drum vibrator l (gal US) 8 (2,11) 8 (2,11)
Wheel gearbox l (gal US) 2x2 (2x0,53) 2x2 (2x0,53)
Drum gearbox l (gal US) 3 (0,79) 3 (0,79)
Washer tank l (gal US) 2,75 (0,73) 2,75 (0,73)
Wiring
Voltage V 24 24
Battery capacity Ah 2x61 2x61
Optional equipment
ROPS
ROPS / FOPS steel canopy
Canvas canopy (mounted to ROPS)
Canvas canopy selfstanding
Cabin (ventilated, heated)
Air Conditioning system
Complete Dashboard with gauges (RPM, Cool. Temper., Hydr. Oill temp.)
PD Drum
PD Shell kit
Ammann Traction Optimiser
Working speed increase kit (increase up to 7 km/h)
Tyre ballast -25 °C (instead 0°C)
Engine air pre-cleaner for extra hard condition
Back-up alarm
Warning beacon
Fire extinguisher (contents 1000 g net)
First service kit / filters
Toolbox
Tool kit Ammann
Customer color scheme
Certificate of origin
Set of documentation - printed hardcopy

ASC 100 15
1.3. Technical Data

Notes

16 ASC 100
 SPECIFICATION MANUAL

Notes

ASC 100 17
18 ASC 100
 OPERATING INSTRUCTIONS

2. OPERATING INSTRUCTIONS

ASC 100
(Cummins Tier 1)

ASC 100 19
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 inter-
cepting sumps to catch rinsing water &
dewaxing agents.

20 ASC 100
2.2.
Safety Instructions
2.2.1. Safety measures to operate the Machine
Safety measures stated in the individual sections of the Engi-
neering 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 man-
agement, 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 Depart-
ment. 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 tech-
nological process part of which is the work procedure de-
signed 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 proc-
ess (job description).
ASC 100
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 ma-
chinery 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, op-
erating 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 envi-
ronment, then the Machine must be discarded until the de-
fect 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 AL-
WAYS available to the Driver.
• User shall make the fire extiguisher to undergo regular in-
spections.
• 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.
21
2.2. Safety Instructions
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 profession-
al 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, where-
as 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 ac-
quainted with, or if, under specific regulations, he/she
owns professional competence to operate and drive
(engine operator’s licence, and alike).
• Machine Driver must undergo training at least 1x every 2
years, and pass exams concerning work safety regulations.

22 ASC 100

2.2.3. Driver’s 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
Machine’s 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, nec-
essary site protections in terms of the surrounding environ-
ment (noise, vibrations, etc.).
• When finding any health hazard, life hazard, danger to per-
sons, property, finding any failures, or when there is an acci-
dent 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 start-
ing 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 fa-
miliar 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 & safe-
ty equipment, whether these are functional and enabled ac-
cording 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 be-
tween the Drivers, and on any defects and repairs during
operation, and to document major events during an operat-
ing 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.
• Confirm the functions of the brake and steering before Ma-
chine 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 pe-
riod necessary to exit endangered area elapses.
ASC 100
OPERATING INSTRUCTIONS
• When operating the Machine the safety regulations must be
adhered to, no activity hazardous to work safety can be car-
ried out, commit yourself fully to Machine driving. ALWAYS
sit on the seat when driving the Machine.
• Respect job description or instructions of an employee ac-
countable.
• 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 appro-
priate station (flat, good bearing surface) in order not to
threaten Machine stability, intervene with traffic roads, ex-
pose 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 driver’s at-
tention 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 (lu-
bricating, 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 out-
fit.
• 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. Be-
fore dropping the cabin and bonnet confirm nobody will be
endangered with this operation.
• In case the Machine would come into contact with high volt-
age 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 materi-
als.
23
2.2. Safety Instructions
2.2.4. Forbidden activities – safety and guaran- • Operate the Machine at a location unable to be seen from
tee driver control stand, and where hazard to persons or prop-
erty may occur unless work safety is secured in some other
way, e.g. indirectly via signalling carried out by duly instruct-
It is forbidden to: ed person.
• Vibrating on the spot. When it is vibrated on the spot, bear-
• Operate the Machine within protective zone of electric lines
ings of the vibrator are not lubricated.
and substations.
• Filling the hydraulic circuit during the guarantee period in a
• Pass over the electric cables unless these are properly pro-
different way than using the hydraulic unit.
tected against mechanical damage.
• Changing the vibration amplitude when driving – It is always
• Operate the Machine under reduced visibility or at night un-
necessary to stop and only then set a different amplitude.
less the working area of the Machine or the site is sufficiently
• Using the machine in case of an evident defect of the ma- illuminated.
chine.
• Leave Machine driver seat with the Machine running.
• Using the machine when any operating fluid level is low.
• Abandon unsecured Machine, i.e. move away from the Ma-
• Wilful repair of the engine – Except common changes of op- chine without preventing its misuse.
erating fluids and filters, only the Cummins service depart-
• Disable safeguarding, protecting or locking systems, or alter
ment can intervene in the engine, in particular in peripheral
their parameters.
components of the engine – alternator, starter, thermostat,
electrical installation of the engine. • Use the Machine with leaking oil, fuel, coolant or other fill-
ings.
• Use the Machine after drinking alcohol and ingestion of nar-
cotics. • Start the engine in some other way than given in the Driver
Manual.
• Use the Machine in case its operation might deteriorate its
operating condition, cause safety hazard (life, health) to per- • Place, aside from personal needs, so other things (tools, ac-
sons, buildings and other property, or to road traffic and its cessories) at the Driver Control Stand.
continuity. • Put any materials or other objects on the Machine.
• Start the Machine and use it when other persons are within • Remove any dirt while the Machine is running.
the hazardous vicinity of the Machine. Exempted is driver
training by lector. • Carry out maintenance, cleaning or repairs unless the Ma-
chine is secured against self-motion and accidental start,
• Start the Machine operation and use the Machine with some or unless contact between worker and moving parts of the
of the safeguard equipment (emergency brake, hydraulic Machine is excluded.
locks, etc.) removed or damaged.
• Touch moving parts of the Machine with your body and ob-
• Move and compact at such banks at which machine stability jects or tools held in your hands.
would be broken (overturn). Machine static stability speci-
fied gets reduced by the dynamic effects of the drive.. • Smoke & handle open fire while inspecting or refilling the
fuels, changing, replenishing oil, lubricating the Machine, or
• Move and compact at such angles of slopes at which the checking and refilling the accumulator.
hazard of earth breaking off together with the Machine
could occur, or adhesion lost followed by uncontrollable • Carry the rags soaked with flammable materials on the Ma-
breakaway. chine (inside engine bay, cab), or carry flammable liquids in
free vessels.
• Control the Machine in a way other than stated in the Driver
Manual. • Let the engine run inside confined areas. Exhaust gases are
dangerous to life.
• 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 break- ! CAUTION !
ing off together with the Machine.
Breaching these provisions can influence the judge-
• Move or compact with vibration at such distance from walls, ment of a possible complaint and effectiveness of
cuts or slopes so as to avoid the hazard of their collapsing the engine guarantee period.
and backfilling the Machine.
• Compact with vibration at such distance from the buildings
or premises and facilities within which a hazard of their be-
ing 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.
• Controlling the heating valve control rod while driving.
• Operate the Machine with its bonnet lifted.
• Operate the Machine when there are other machines or con-
veyances within the danger area of the Machine except for
those working in mutual interaction with the Machine.

24 ASC 100
 OPERATING INSTRUCTIONS
2.2.5. Safety labels & signs used on the Machine

6 12

13
4 3

10 7 1 9 10

11 5 14 8

28006

ASC 100 25
2.2. Safety 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.)

2941bz

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

2586bz

3 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.)

2409bz

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.)

2939

3227bz

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.)

2584bz

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

2702bz

26 ASC 100
 OPERATING INSTRUCTIONS

7 Machine Max Height Pay attention when passing through a location with
3m height limit. (Symbol placed on the left side underneath
the cab on the frame.)

I
8 Battery Disconnector O
In case of failure or following a work completion, please
switch battery disconnector to ”0” position. (Symbol
2493 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.)

2640bz

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.)

2668bz

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.)

2225bz

14. Platform & Cab Lifting (Symbol placed on door’s inner side.)

3164

3164

ASC 100 27
2.2. Safety Instructions
2.2.6. 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 STOP
other arm akimbo.

Sig. 1

Attention
Both arms sideways raised horizontally – palms forward.

! Sig. 2

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.

! Sig. 3

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.

Sig. 4

28 ASC 100
 OPERATING INSTRUCTIONS
Slow forward drive– to me
Both arms stretched upward abreast huddled up, with palms to-
wards the body; short oscillating motions of fore-arms towards
the body and back.

Sig. 5

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.

Sig. 6

Driving on the right

Left arm sideways raised, right arm akimbo.

Sig. 7

Driving on the left

Right arm sideways raised, left arm akimbo.

Sig. 8

ASC 100 29
2.2. Safety Instructions
Short motion
Both arms lifted forward huddled-up. Mark the distance „X“ be-
tween the palms, then the motion signal follows.

X
Sig. 9

Engine start
Circular motion of right hand’s fore-arm with fist closed.

Sig. 10

Engine shut down

Oscillating motion of right hand sideways rose in front of the
body an moving to the sides.

Sig. 11

30 ASC 100
2.3. Ecological & Hygienic Principles
2.3.2. Ecological Principles
During Machine operation or storage the
User must observe general principles of • Refills for the Machine’s individual systems and some of its
occupational safety and environmental parts become waste having hazardous properties against
protection along with laws, public notic- the environment following their disposal.
es or regulations related to these issues • This waste product category includes in particular:
and in force within a territory where the
Machine is used. -- organic or synthetic lubrication materials, oils and fuels,
-- cooling liquids,
-- accumulator refills and the accumulators themselves,
-- tyre fillings
-- cleaning & preservation agents,
2.3.1. Hygienic Principles -- all the filters & filter elements removed,
-- all the used and discarded hydraulic & fuel hoses, metal-
• Oil products, refrigerants of cooling systems, alternator re-
rubbers and other elements of the Machine fouled with
fills or painting materials incl. thinners are health hazard
the aforementioned products.
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 Producer and contractual service organizations accredited by
safety, and conform to the safety & hygienic manuals of the him, or dealers take back the following materials or parts free
manufacturers of these products. of charge:
• We point in particular to : -- oils
-- Eye & skin protections while handling the accumulators -- batteries
-- Skin protection while handling the oil products, paint- -- tyres (optional)
ing materials or cooling liquids
-- Washing your hands properly upo work completion or
before taking meal. Treat your hands with appropriate
reparable cream. Following the disposal of the abovemen-
tioned materials and parts make sure
-- While handling the cooling systems follow instructions
these are handled in line with the respec-
given in the Manuals supplied together with the Ma-
chine.
tive national environmental regulations
and health regulations.
• ALWAYS store oil products, cooling system refrigerants or
accumulator refills and painting materials incl. organic thin-
ners 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 poten-
tial 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 fit-
ted with cab, or cab windows are open, then use ALWAYS ear
protectors of suitable type and construction.

ASC 100 31
2.4. Preservation & Storage
2.4.1. Short-term preservation & storage for 2.4.2. Machine preservation & storage for the
the period of 1 ÷ 2 months period over 2 months

• Wash & clean carefully the entire Machine. Before Machine • For the Machine shutdown the identical principles like with
parking and shutdown in order to make its preservation & short-term preservation will apply.
storage, please heat the running engine up to its operating • In addition we recommend the following:
temperature. Park the Machine on fixed, flat surface at a safe
place with no potential of Machine damage caused by natu- -- remove the accumulators, check their condition and
ral disaster (floods, landslides, fire, etc.). store in a cool, dry room (recharge the accumulators on
regular basis),
• In addition:
-- Bottom on the runner frame so the damping system has
-- repair those spots with paint impaired, minimal deflection (flexure),
-- lubricate all lubricating points, control cables, joints of -- paint rubber elements with spec. preservation agent to
the controllers, etc., protect them,
-- confirm water fillings have been drained, -- inflate the tyres to a specified pressure, and protect
-- check cooling liquid has its antifreeze characteristics re- them from direct sunlight,
quired, -- apply chrome-plated piston rods with preservation
-- check the accumulator charging conditions, recharge if grease,
required, -- spray the Machine with special agent and this at places
-- apply preservation grease over the chrome-plated sur- with possible corrosion origin,
faces of the piston rods, -- Blind engine air intake and exhaust with double PE foil
-- we recommend to spray preservation agent (applied and fix it carefully with adhesive tape,
via spraying) to protect your Machine against corrosion, -- protect headlamps, exterior back mirrors and other ele-
and this particularly in places with corrosion hazard. ments of external wiring via spraying with special agent
• Machine treated like that will need no special set-up before and wrapping in PE foil,
its subsequent putting into operation. -- Preserve the engine per manufacturer’s Manual. Install a
visible label informing the engine has been conserved.

! CAUTION !
Following 6 months we recommend to inspect pres-
ervation 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 ser-

vice, 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 loca-
tions provided with intercepting sumps to
catch rinsing water and dewaxing agents.

32 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:
• 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 en-
vironmental damage caused by breach of
the abovementioned notice.

ASC 100 33
34 ASC 100
2.6.
Machine Description OPERATING INSTRUCTIONS

18
14
9 11 17 13

12
10
5
2 8

3 3 4 19 16 15 6 7

28007

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 35
2.7. Controlling and operation of the machine

10 7 11 9 8

20
∞C 25
∞C
15
RPM x 100 30 26 ENGINE HOURS
000001
10

35

17 16 15 14 13
1 15A
2 5A
3 7,5A
4 7,5A
5 5A
6 15A
7 20A
8

18

19 20 12 27 25
21 22 6 28 23 24
2 2.1
5
1

280671

36 ASC 100
 OPERATING INSTRUCTIONS
Dashboard & Control Panel

1 - Steering Wheel
2 - Travel Controller
2.1 - Vibration Switch
3 - TOTAL STOP pushbutton
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 selector switch
22 - Heater Fan Switch (Optional)
23 - Headlights Switch
24 - Rear lights Switch
25 - Alarm Horn Pushbutton
26 - Fuse Block
27 - Ammann Traction Optimiser (Optional)
27 - Switch for increasing working speed (Optional)
28 - Beacon (Optional)

ASC 100 37
2.7. Controlling and operation of the machine
Steering Wheel (1)
Used for Machine steering.
With respect to safe steering, please ad-
just optimal speed (1800. min–1) when
driving without vibrations.
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.
2445
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 (2.1) is lo-
cated at the controller handle, and is used to switch ON/OFF the
vibration after moving controller handle from neutral.
Engine starting is possible in idle position
only.
It is forbidden to vibrate on the spot!
(Vibrator bearings are not lubricated dur-
ing vibration at the halt.)
TOTAL STOP pushbutton (3)
2582
Press this button to stop and brake the Roller, and to shut off
the engine.
! CAUTION !
Brake off in arrow direction before starting the
engine.
Use only in case of emergency during a
failure when the Roller is unable to stop
through resetting the travel actuator.
38
Travel Speed Controller (4)
595971
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:
With the controller switched off the operating speed mode is set.
The Machine reaches max. pulling force and climbing ability.
NEVER switch ON the controller during oc-
cupational use of the Machine.
Do NOT switch OFF the controller at high
speed. Abrupt slowdown will occur to-
gether with impact within the hydraulic
system. Turn OFF the controller with the
Machine at rest or at low speed!
You may switch ON the controller, i.e. trav-
el 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.
Throttle (5)
Move the throttle downward to increase the speed from idling
one to maximal rpm.
ASC 100
 OPERATING INSTRUCTIONS
Ignition Box ()6
Operated-Hours Counter (9)
It has three positions - ”0”, ”I”, ”II”. When in”0” pos. all the consum-
ers with F1, F2 & F7 fuses will be connected; in”I” pos.other con- sta01
sumers will be connected; cushion fuse ”II” is used for Machine
starting. Turn the key to”0” pos. to stop the Machine, remove the When accumulator charge indicator (13) goes off the counter
key in this position. starts reading the hours. Reading the number of hours does not
depend on engine rpm.

NOTE:
! CAUTION !
The cab & the door underneath the cab have one common key.
Carry out regular maintenance per the hours worked
out!
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 Fuel Level Indicator (10) - Optional
cap to protect the ignition box against
water & dirt penetration. 595425

Indicate the amount of fuel in the tank.

Engine Thermometer (7) - Optional

Speedometer (11) - Optional
2183
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
596142

549476 Switch the ignition box key to position ”I”, and the control lamp
Temperature limit is 90 °C (194 °F) for oil of HV 68 or HV 100 vis- lights up and then goes off after starting the engine. The lamp
cosity class. Optimal operating temperature is 50 - 60  °C (122 lighted signals engine lubrication is insufficient.
- 140 °F).

Oils of other viscosity used Unless it goes off, look for the failure!
Oil Viscosity Oil Temperature Limit
HV 46 80 °C (176 °F)
HV32 70 °C (158 °F)

ASC 100 39
2.7. Controlling and operation of the machine

Accumulator Charge Control Lamp (13) Indicator of hydraulic oil filter (18)

Switch the key on the ignition box (6) to“I” pos. and the control This indicator lighted up under hydraulic oil operating tem-
lamp must light up and go off after starting the engine. perature of 50 - 60 °C (122 - 140 °F) signals the filter element is
clogged with dirt.

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 signalled.

With this indicator lighted up the vibration switch (2.1) is ON.
When set speed is reached the Machine starts vibrating with the
amplitude preset via vibration Preselector (21).
Engine overheating control lamp (15)

595436

When the engine temperature reaches the highest allowable Hydraulic fluid overheating warning indicator
level, the engine overheating control lamp goes ON an audible (20)
warning is given. 549476

When the fluid temperatures reaches the highest allowable lev-

el the overheating warning lamp goes ON, an audible warning
is given.
Low level of fuel indicator lamp (16)

595425

When the fuel level drops down to min. 45 l (12, gal) the indica- Vibration amplitude selector switch (21)
tor goes ON. - Small amplitude and high frequency are switched
ON.
- High amplitude and low frequency switched ON.
2244
Air Filter Fouling Indicator (17)
Before the machine starts moving, use the switch to set the re-
594423
quired amplitude. Before changing the amplitude, first stop the
machine, use the switch to change the amplitude and then start
When this indicator lights up the filter elements are fouled
moving the machine again.
above their limit.

It is forbidden to vibrate on the spot!

Replace the elements at once! It is forbidden to change the vibration am-
plitude while driving.

Heater Fan Switch (22) - Optional

2487

Two-speed.

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

40 ASC 100
 OPERATING INSTRUCTIONS
Fuse Block (26)
Headlights Switch (23)
Fuse (F1) -15 A (upper fuse) headlights + rear lights, in-
strument panel illumination,
Fuse (F2) -5 A cab light, loud horn
Fuse (F3) -7,5 A brake, engine STOP,

Rear Headlights Switch (24)
Alarm Horn Pushbutton (25)
Ammann Traction Optimiser (ATO) (27) - Optional
2854
is primarily used for slip restriction on surfaces with low adhe-
sive. This system increased the rpm of wheels, in compared to
rpm of the drum. The activation is signalized by acoustic beeper
and the yellow light on the switch on the dashboard.
Note:
If the roller is equipped with the switch for increasing working
speed, the drum slip blocking system is not used on the ma-
chine.
Fuse (F4) -7,5 A travel, vibration, vibration switching con-
trol lamp
Fuse (F5) - 5 A brake indicator lamp, engine lubrication
lamp, charge control lamp, hydraulic oil fil-
ter fouling lamp, engine filter fouling lamp,
fuel minimum lamp, motohours counter,
engine overheating lamp, hydraulics over-
heating lamp
Options: engine coolant thermometer,
hydraulic oil thermometer, fuel level in-
dicator, 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
Replace fuses with those of identical val-
ue ONLY!!!

! CAUTION !
The ATO does not increase the gradeability of the
machine. The operation with ATO should be not
longer than 3 minutes. The switch of the travel
speed must be switched off.

Switch for increasing working speed (27)

- Optional
2855

It serves for increasing working speed (with vibration used at

the same time) to 7,1 kilometres per hour in both directions.
The switch has three positions:
1 - speed 5 km/h
2 - speed 6,2 km/h
3 - speed 7,1 km/h

Note:
If the roller is equipped with the drum slip blocking system, the
switch for increasing working speed is not used on the machine.

Flashing beacon (28) - Optional - connect to the

socket.
592348

ASC 100 41
2.7. Controlling and operation of the machine

35 34 A 36
36

33

31 32 30 29

28026

Cab Controllers & Accessories. Cab installation is optional.

29 - Screen Washer Switch

30 - Fan Switch
31 - Front Wiper Switch
32 - Rear Wiper Switch
33 - Cab Light
34 - Ventilation Nozzles
35 - Locker
36 - Back Mirrors

42 ASC 100
 OPERATING INSTRUCTIONS

40
44

42

41

43 37

39

38

38

28009

37 - Heater Valve Tie Rod

38 - Heater Vents
39 - Screen Washer Tank
40 - Cab Ventilation Filter
41 - Front Wiper
42 - Rear Wiper
43 - Seat
44 - Headlights

! ATTENTION !
It is prohibited to operate the heating valve control
rod (37) while driving.

ASC 100 43
2.7. Controlling and operation of the machine
Locker (35)
Designed for first-aid kit etc.

282N017T

Back Mirrors (36)

When working within a restricted space or during transporta-
tion you may turn the back mirrors by 90° from their operating
position to transportation position.

282N022T

Screen Washer Tank (39)

Two pumps integrated inside the tank are used to wash the
windscreen and rear screen.

Refill the the tank with antifreeze or drain

before winter season!

282N040T

44 ASC 100
 OPERATING INSTRUCTIONS
Driver Seat (43)

Seat adjustment elements:

Backrest angle adjustment – lift the lever to seting up of the

backrest.

28015

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

2
28016

45 - Air-conditioning switch (OPTION)

46 - Air blowing intensity selector (OPTION)
47 - Air recirculation switch

46

45

47
280100

Accumulator cutoff switch

Use cutoff switch to disconnect accumulator from the frame.

Use cutoff switch to disconnet the accu-

mulator following the drive end!
Switch OFF the disconnector ALWAYS
when washing the Machine!

28017

ASC 100 45
2.8. How to Control and Use the Machine
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 insuf-
ficient.

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).
• 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 3÷5 minutes.

20
∞C 25 ∞C
15 ENGINE HOURS
RPM x 100
30 000001

10
35

1 15A

14 13 2 5A
3 7,5A
4 7,5A
5 5A
6 15A
7 20A
8

6 12

I II
28071

46 ASC 100

Do NOT start for more than 30 sec. Make
another starting attempt only after 2 min-
utes, and unless the motor starts even af-
ter 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 inad-
missible – hazard of engine damage.
When started let the engine run at idle
rpm of 1500 min–1 for a period of 3÷5
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 en-
gine at full capacity!
! CAUTION !
Starting will be interlocked:
When the controller (2) is in idle (neutral) position.
24
0 0
1 2
v
+ + -
4
ASC 100
OPERATING INSTRUCTIONS
How to start using starter cables via another machine
Make sure the starting voltage of a boost-
starting power supply is 24 V.
Follow unconditionally the sequence of
operations given below!
1. Connect one (+) pole end of the cable to (+) pole of dis-
charged 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 cyl-
inder block itself )
! CAUTION !
When started, disconnect the starter cables in re-
verse order.
When aided by Starter Unit with no accus connect-
ed, do NOT disconnect the Unit before the Machine
accumulator is connected.
24
3
396N034
47
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 gas-
es generated by accumulator.
Non-insulated sections of the starter ca-
bles’ 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 – short-circuit hazard.
NEVER bend yourself over the accumula-
tors - hazard of electrolyte burn!
Exclude any presence of flammable sourc-
es (free flame, smoking cigarettes, and
alike).
NEVER verify voltage presence within
a conductor via sparking through the
Machine frame!
How to start at low temperature.
Starting at ambient temperature below 0 °F (32 °F) 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.
Observe strictly safety & hygienic instruc-
tions of manufacturer when using starter
filling. Non-observance of these instruc-
tions 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 us-
ing starter refills under these conditions.
48
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.min–1 (RPM).
• Confirm vibration switch (2.1) is not ON, control lamp (19)
is off.
• Deflect travel controller (2) from idle (neutral) pos. to a re-
quired direction – small deflection of the controller = slow
speed and vice versa. Following travel controller (2) deflec-
tion the brake indicator lamp (14) will go off.
• Reversing – shift the controller (2) in opposite direction via
its idle position.
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.
NEVER drive in cross direction at the hill-
sides of high slope! Drive perpendicular
to a hillside!
ASC 100
 OPERATING INSTRUCTIONS

20
∞C 25 ∞C
15
RPM x 100 ENGINE HOURS
30 000001
10
35

14
1 15A
2 5A
3 7,5A
4 7,5A
5 5A
6 15A
7 20A

2 2.1
19

280681

OK OK

282N049T

ASC 100 49
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. It is forbidden to vibrate on the spot!
• Use Preselector (21) to select vibration amplitude. It is forbidden to change the vibration am-
• Use throttle controller (5) to adjust maximal speed. plitude while driving.
• Start moving the Machine and turn ON the switch (2.1) to
start the vibrations - control lamp (19) lights up – runner be-
gins vibrating.
• Press and relieve button (2.1) to stop the vibration.

∞C 20
25 ∞C
15
ENGINE HOURS
RPM x 100 30
000001
10
35

1 15A
2 5A
3 7,5A
4 7,5A
5 5A
6 15A
7 20A

2 2.1
22 19

280691

50 ASC 100

2.8.4. Emergency stop of the Machine
Apply in the event when engine is unable
to stop via ignition key or when Machine
is unable to stop via switching the travel
controller to neutral.
OPERATING INSTRUCTIONS
• Before new engine start, please shift controller (2) to ”N” po-
sition and turn pressbutton (3) according to arrow direction.
• Switch key (6) to “0“ position and then start.
Do NOT apply emergency brake dur-
ing normal operation just to shut off the
engine.

• Press TOTAL STOP (3) (emergency brake) - the engine stops

and the Machine stops moving.

20
∞C 25 ∞C
15
RPM x 100 ENGINE HOURS
30 000001

10
35

1 15A
2 5A
3 7,5A
4 7,5A
5 5A
6 15A
7 20A

2
6

280702

ASC 100 51
2.8. How to Control and Use the Machine
2.8.5. Stop the Machine & the Engine
Do NOT stop hot engine instantly, instead
• Use switch (2.1) to turn OFF the vibration – control lamp (19 let it idle for a period of 3 minutes.
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.

20
∞C 25 ∞C
15
RPM x 100 ENGINE HOURS
30 000001

10
35

1 15A

14 2 5A
3 7,5A
4 7,5A
5 5A
6 15A
7 20A

2 2.1
6 19

280701

52 ASC 100
 OPERATING INSTRUCTIONS
2.8.6. Machine Shutdown
Stop the Machine on flat, paved surface
• Stop the Machine. Confirm no natural hazard (landslide, po-
• Cut off battery disconnector. tential of deluge due to any floods, etc.)
exists at the location where the Machine
• Clean the Machine (scraper, tyres).
is parked and shut down.
• Make overall inspection of the Machine and repair any de-
fects 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.

ASC 100 53
2.8. How to Control and Use the Machine
2.8.7. How to lift driver control stand and bon-
net

Lifting, lowering and keeping the cabin

or platform in the raised position must
only be performed with an empty cabin
or platform.

• Unscrew driver control stand nuts.

28039

• Open cover on the left side underneath the driver control

stand. Remove pump handle (1).

28018

• Lose a valve (2) and put the handle it into the pump, lift driv-
er control stand and the bonnet together.

2
28023

• Use valve to lock the bonnet in its position. Refer to

28019

54 ASC 100
 OPERATING INSTRUCTIONS
• Use valve to lock the cab in its position. Refer to

28020

• Open the valve (2) before lowering.

2
28065

• Use valve to make the bonnet descend. Refer to

28021

• Use valve to make the cab descend. Refer to

Screw the driver control stand when tilted.

28022

ASC 100 55
2.8. How to Control and Use the Machine
2.8.8. Ballasting of tyres with liquid

It is used for lowering the machine gravity centre. The mixing ratios for individual temperature per one tyre are given in the table.

Ballasting of tyres with liquid of up to 0 °F

Water Anticorit SKR 40 Added weight

(l) [gal US] (kg) [lb] (kg) [lb]
500 (132) 10 (22) 510 (1124.4)

Ballasting of tyres with liquid of up to -25 °C

The inner space of the tyre is filled with the solution of water and 34% calcium chloride CaCl2.

Water 34% calcium chloride CaCl2 Added weight

(l) [gal US] (kg) [lb] (kg) [lb]
185 (48,87) 414,7 (914,26) 600 (1323)

A filler neck can be ordered as a replacement part under num-

ber 4-5325190009.

4-322839

Filling procedure:
• Move the machine to a firm base. The filling valves should be
in the extreme upper position. Secure the drum with blocks
on both sides.
• Unscrew the removable valve insert and screw on the filler
neck.

396344

56 ASC 100
 OPERATING INSTRUCTIONS
• Mount the hose from the filling equipment (a tank located
above, pump, etc.) on the filler neck and fill the tyres with
the solution.
• During the filling, air escapes from the tyre through the side
opening from the filler neck. The tyre is sufficiently filled
(at 75%) when the solution starts flowing out through the
opening.
• Unscrew the filler neck, screw the valve insert back on, and
inflate the tyre to a pressure of 160 kPa (23,2 PSI).

396345

Draining procedure:
• Move the machine to a firm base. The filling valves should be
in the extreme lower position. Secure the drum with blocks
on both sides.
• Unscrew the removable valve insert and let the solution
flow out.

The solution can spurt out after unscrew-

ing the valve insert.

• As soon as the solution does not flow out due to a decrease 396346
in pressure, screw on the filler neck and inflate the tyre to a
pressure of 160 kPa (23,2 PSI).
• After the tyre has been inflated, remove the filler neck and
screw the valve insert back on.

Protect your eyes with glasses (face shield)

and your hands with rubber gloves!

Wash away spilled solution with clean

water.
Solution may never come into contact
with metal parts and wiring.

ASC 100 57
2.9. Machine Transportation
2.9.1. Machine transportation by its own axle

• Move the roller by its own axle when moving within a work-
ing site outside public roads.

Transport speed – you may switch ON col-

lector (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

The basic construction of the Machine is

NOT fitted for transportation by its own
axle using public road. This type of trans-
portation is prohibited.
When driving onto the carrier, we recom-
mend to put rubber bands or wooden
planks, etc. under the runner.
Make sure the carrier designed for the
transport is braked when loading and un-
loading, as well as mechanically locked
agaisnt undesired moves using the Scotch
blocks (2).
A person that guides the Machine must
communicate with the Driver using speci-
fied intercommunication signals, (refer
to Section 2.2.6.), this guiding person
must always stay at one place outside the
reach of the Machine and outside the car-
rier. Guiding person must remain within
Driver’s field of sight (in visual contact)
throughout the entire period of driving Fixing the Machine on the carrier.
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 be-
ing 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. 1 2 2 1
Adhere to the Motor Vehicle Construction and Use
Regulations when transporting via land routes.
NO persons may stay on the Machine, driver con- 2 2
trol stand or carrier loading area during Machine
transportation.
28060

58 ASC 100
 OPERATING INSTRUCTIONS
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 (lift-
ing eyes) – refer to the Fig. for slinging method.
• Before lifting the Roller, please lock the Machine joint
against being turned slightly.

282250

How to lock the joint:

• Unlock and pull out the journal (1).

1
AMMANN CZECH
REPUBLIC a.s.
NOVÉ MĚSTO NAD
METUJÍ, CZECH
REPUBLIC
TYP / TYPE 3172

IČV / S/N

PROVOZ. HMOTNOST
BETRIEBSMASSE / OPERAT. WEIGHT
/ POIDS DE SERVICE ZAT. PŘEDNÍ OSY
/
BELASTUNG DER FRONT AXLE LOAD
VORDERACHSE
CHARGE DE ESSIEN
ARANT

MAX. HMOTNOST
/ MAXIMUM WEIGHT ZAT. ZADNÍ OSY
kg
MAX. MASSE / POIDS / REAR AXLE LOAD
MAX BELASTUNG DER
HINTERACHSE
CHARGE DE ESSIEN
ARRIÉRE

kg
VÝKON MOTORU
/ ENGINE OUTPUT
MOTORLEISTUNG ROK VÝROBY /
/ PUISSANCE DU PRODUCTION YEAR
MOT. BAUJAHR / ANNÉ
DE FABRICATION

MADE IN CZECH
REPUBLIC

28002A

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

2 1
Do NOT enter underneath hanging load!

28024

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 suffi-
cient loading capacity.
Use only those lifting eyes (mounting
lugs) on the Machine designed specifi-
cally for slinging.
Only a trained slinger may carry out the
slinging.

ASC 100 59
2.9. Machine Transportation
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 Ma- 2
chine frame (2).

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 28066
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 pos-
sible. 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 func-
tional. The drive on the towed roller must
steer the roller in the dragging direction.

60 ASC 100
 OPERATING INSTRUCTIONS
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.

282N074T

ASC 100 61
2.9. Machine Transportation
How to dismantle the Cab
• Loosen the bolts that attach the Cab to the platform.

282N075T

282N187T

• Disconnect the connector between steering column and

the windscreen to cut out the wiring.

282N076T

• Disconnect the screen washer wiring and the hoses leading

to the screen washing nozzles. Sling the Cab by the mount-
ing lugs and put it by.

282N077T

62 ASC 100
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 vibro-stroke) may occur
due to the impact of high level of sub grade material compac-
tion, or due to vibration driving on hard materials (e.g. stony
loose material). This state will show through the increased vi-
bration energy transfer to the Machine frame and Driver control
stand. Increase travel velocity or change Machine vibration pa-
rameters (applying lower amplitude) to partially remove this ef-
fect. 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
driver’s health hazard.
Note:
When vibration driving on a different sub grade material than
stated in ”Specifications Manual”- Hygienic Data, then the emis-
sion figures of vibration acceleration will be different.
ASC 100
2.10.2. Machine use under heavy climatic condi-
tions
2.10.2.1. Machine operation under low tempera-
tures
Compacting during winter season depends on fine particle con-
tents and water contents within a soil under compaction. With
the temperature going down below freezing point the earth be-
comes 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).
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.
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 re-
mains 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).
NEVER start the Machine at ambient tem-
peratures below +2 C (36 °F) when the hy-
draulic 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 vis-
cosity 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.
63
2.10. Special Conditions for the Machine Application
2.10.2.2. Machine operation under high temper-
atures and humidity
Engine power will lower with air temperature or humidity in-
creasing. Since both of the factors that lower engine perform-
ance are independent on each other, their effects can be de-
scribed 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).
Any engine (cooling liquid) operating
temperature over 100  °C (212°F) 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 mm2/s cinematic viscosity class (BP BAR-
TRAN HV 100, ESSO UNIVIS N100, etc.)
! 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.
64
2.10.2.3. Operating the Machine at high alti-
tudes
Engine power will decrease with the altitude rising. This is given
by the reduced atmospheric pressure and induction air specific
mass.
When black smoke is generated by the engine at high altitudes
(above 1500 m), please contact your engine manufacturer serv-
ice 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
Cut short the intervals of cleaning and
replacement of air filter elements when
operating under extremely dusty condi-
tions; shorten the intervals of cleaning
the engine cooler, hydraulics, or of replac-
ing Cabin dust filter.
ASC 100
 OPERATING INSTRUCTIONS

Notes

ASC 100 65
66 ASC 100
 MAINTENANCE MANUAL

3. MAINTENANCE MANUAL

ASC 100
(Cummins Tier 1)

ASC 100 63
64 ASC 100
3.1. Safety and other measures for machine maintenance
3.1.1. Safety during Machine Maintenance
Lubrication, maintenance & adjustments must be carried
out:
• By trained specialists
• In line with safety instructions given in the Vibrating Roller
Operation Manual
• According to the time intervals as stated in Lubrication Table
following the hours of actual operation
• With the Machine located on a  flat fixed surface secured
against self-motion (wedges and with the steering joint
locked
• With the wiring disconnected and the ignition key removed
• On the cooled down parts of the Machine
• Following the cleaning of the Machine, of lubrication points
& maintenance points and of repair points
• Using proper undamaged tools
• Replacing with new original parts per the Spare Parts Cata-
logue
• With sufficient lighting of the entire Machine when under
lowered visibility or at night
• With the guards (covers) and safety elements reinstalled
upon work completion, if previously dismantled
• Together with retightening bolted connections – using
proper torque, and checking tightness of the connections
• Following the heating of operation fillings (danger of burns).
Use recommended refills only.
Confirm all safeguard equipment func-
tions are OK once adjustments or mainte-
nance are completed!
ASC 100
3.1.2. Fire precautions when refilling
• In terms of fire safety the flammable liquids applied at the
Machine split into the following Danger Numbers:
Danger Number II – Diesel Oil
Danger Number IV - Mineral Oils, Lubricating Greases
• Place the oil exchange point where it does not interfere with
explosion / fire hazard areas.
• Label with Tables and No Smoking & No Open Fire Signs.
• Design the size of handling area so it can catch the amount
of flammable liquid equal to the capacity of the largest ves-
sel, shipping container.
• Fit it with portable fire extinguishers.
• Use containers like metal barrels, jerricans, tin cans to han-
dle the oils, Diesel oil.
• Confirm the shipping containers are properly closed during
storage.
• Make sure the containers have one hole, and are stored with
their hole up, and secured against their contents purring out
or dripping.
• Label the containers with indelible inscription specifying
the content & flammability number.
65
3.1. Safety and other measures for machine maintenance
3.1.3. Ecological & Hygienic Principles Ecological Principles

When operating and maintaining the machines a User must fol-

low general health & environment protection principles along
Once disposed of (dismantled, refilled)
with the acts, public notices & regulations related to these issues
and effective within the territory a machine is used. the fillings of the Machine’s individual
systems and some of its parts become
waste with hazardous properties in terms
Hygienic Principles of the environment.

• Oil products, refrigerants, accumulator refilling, plus paint-

ing materials (coating compositions) incl. thinners are This waste product category includes the following:
materials causing health hazards. Workers that come into
contact with these products during machine operation or -- Organic or synthetic lubricants, oils and fuels
maintenance must observe general principles of health self- -- Brake fluids
protection and follow safety & hygienic instructions of these
-- Cooling liquids
products’ manufacturers.
-- Accumulator charges and accumulators themselves
• Please note the following in particular:
-- Air conditioner refills
-- Protect your Eyes & skin when handling the accumula-
tors -- Cleaning & preserving agents
-- Protect your skin when handling oil products, painting -- All the dismantled filters & filter elements
materials and cooling liquids -- All the worn & discarded hydraulic hoses & fuel hose,
-- Wash your hands upon work completion and before tak- metal rubbers and other elements of the Machine fouled
ing meals; treat your hands with reparation (recovery) by the abovementioned products.
cream
-- Observe machine operating instructions when handling
its cooling systems. Following the disposal of the given ma-
• ALWAYS store oil products, refilling of cooling systems and terials and parts these must be han-
accumulators plus paints incl. organic thinners and also dled under the respective National
the cleaning & preserving agents in their genuine original Environmental Policy Regulations, and in
properly identified packages. Never store these materials in line with Health Regulations.
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 inhalation, you
must apply first aid measures instantly. During accidental in-
gestion of these products you must call for prompt medical
attention.
• Use always ear protectors (muffs) of proper type and con-
struction when operating the Machine in cases the Machine
is not fitted with the cabin or cabin windows are opened.

66 ASC 100
3.2. Specification of fluids MAINTENANCE MANUAL

3.2.1. Motor Oil

2412

Motor oil shall be specified per its performance classification &

viscosity classification.

Performance Classification under

API (AMETICAN PETROLEUM INSTITUTE)
CCMC (COMMITE OF COMMON MARKET AUTOMOBILE CON-
STRUCTORS)
ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE
AUTOMOBILE)

Viscosity Classification °F °C
Ambient temperature and type of operation where the Machine 122 50
is used will be decisive to determine SAE (SOCIETY OF AUTOMO-
TIVE ENGINEERS) viscosity class.
Admissible oils applied compliant to API: CF-4/SG; CG-4/SH
CCMC DH1 104 40
ACEA: E-5
Year round SAE 15W-40 (e.g. Valvoline, Premium Blue)
86 30
Note:
Exceeding low temperature limit will not lead to any motor
damage, it may only cause some problems when starting the 68 20
Machine.
15W - 40

It is rather convenient use multigrade oils so as to avoid oil re-

placement due to ambient temperature changes. Motor manu-
facturer recommends using SAE 10W-30 oil to make starting at 50 10
freezing temperatures (below 0 °C, 32 °F) easier.

Exceeding max temperature limit may not 32 0

10W - 30

last for a longer time due to the lowered

lubricating capabilities of oil.
When using synthetic oil due to operating
5W - 30

conditions (low ambient temperature) the 14 -10

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 -4 -20
hours or 3 months.
Use engine oil of SG or SH classification
due to lubricating the valve tappets.
-22 -30

-40 -40
282N224T

ASC 100 67
3.2. Specification of fluids
3.2.2. Fuel
Use some of the following Diesel fuels to run the motor.
-- CEN EN 590
-- ASTM D 975-88: 1-D & 2-D
Use winter Diesel oil with ambient tem-
peratures below 0  °C (32  °F). Use special
type of Diesel oil with additives designed
for the conditions with ambient tempera-
tures less than -15 °C (5 °F) (”Super Diesel
oil”).
NEVER use fuels (like bio Diesel oil, mixed
bio Diesel oil, LFO, and alike) other than
those Diesel oils specified above.
68
3.2.3. Cooling Liquid
2152
Use cooling liquid comprising 50% water and 50% antifreeze
agent (designed for ambient temperature of up to -36 °C [-33 °F])
for the engine cooling system even within a climatic zone where
temperatures do not drop below 0 °C (32 °F). The cooling liquid
serves not only to protect the cooling system against any freez-
ing, but also to increase boiling temperature. The inhibitors con-
tained within the antifreeze protect parts of the engine cooling
system. You may use propylene antifreeze agents as well to refill
the cooling system.
Use treated, demineralized or distilled water to prepare the
cooling liquid.
Do NOT use the portion of antifreeze cool-
ing 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 mix-
ing. Blending various types of cooling
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.
ASC 100

3.2.4. Hydraulic Oil
2158
Use only quality hydraulic oils of power class per ISO 6743/ HV
for the Machine’s hydraulic system (corresponds 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 used within the widest
range of ambient temperatures.
MAINTENANCE MANUAL
Synthetic Hydraulic Oil
You can fill the hydraulic system with synthetic oil which, when
making any leaks, becomes degraded via microorganisms found
in water and in soil.
Please consult any transition from min-
eral oil to synthetic oil, or mixing oils of
various brands with oil manufacturer or
dealer!

When at high ambient temperatures with

oil temperature constantly reaching 90 °C
(194 °F) we recommend to replace with oil
of cinematic viscosity 100 mm2/s HV 100.

ASC 100 69
3.2. Specification of fluids

3.2.5. Gearbox Oil 3.2.6. Lubricating Grease

2186 0787

Use quality oil corresponding to API GL-5 or EP or MIL-L-2105 Use grease plastic type that contains lithium to lubricate the
C to lubricate the uncoupled axle gearbox and axle drive gear- Machine under:
boxes.
-- 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)

Operating temperature of oil must NOT

exceed 85 °C ÷ 90 °C (185 °F ÷ 194 °F).
3.2.7. Screen Washer Liquid
2260

Use water (down to 0 °C) and an agent designed for motor vehi-
cle screen washers to refill washer system tank.

Replace water with antifreeze at tempera-

tures below 0 °C (32 °F).

70 ASC 100
3.3. Refills MAINTENANCE MANUAL

Refill Amount
Section Refill Type Brand
l (gal US)

Motor Motor oil per Section 3.2.1. 11,2 (2,95)

2412

Fuel Tank Diesel oil per Section 3.2.2. 410 (108,3)

Hydrostatic System Hydraulic oil per Section 3.2.4. 90 (23,8)

2158

Free Axle Gearbox Gearbox oil per Section 3.2.5. 3 (0,8)

2186

Axle Gearboxes Gearbox oil per Section 3.2.5. 2x2 (2x0,5)

2186

Joint bearing - & steering cylinders Plastic lubricant, refer to Section 3.2.6. as required
0787

Motor Cooling System Permanent anti-freeze liquid per Section 3.2.3. 24 (6,3)
2152

Vibratory Free Axle Motor oil as motor 8 (2,1)

2412

Battery Distilled water as required

2587

Water & antifreezing agent - the ration per outdoor

Screen Washers 2,75 (0,72)
temperature
2260

ASC 100 71
3.4. Lubrication & Maintenance Table

Following 20 hours of operation or daily

3.6.1. Check the oil amount in motor

3.6.2. Check the amount of cooling liquid in the motor

3.6.3. Check the amount of oil inside hydraulic tank

3.6.4. Crankcase Breather

3.6.5. Check fan condition

3.6.6. Check motor belt

3.6.7. Check engine air intake

3.6.8. Check the amount of fuel

3.6.9. How to clean air separator

3.6.10. Check the alarm & control devices

Every 100 Hours

3.6.11. Check tire pressure

Every 250 Hours or Once in 3 Months

3.6.12. How to replace oil in the engine

3.6.13. Check the fixing of the engine

3.6.14. Battery check

3.6.15. Check the function of Air Filter Vacuum Switch

3.6.16. Machine Lubrication

3.6.17. How to check oil inside vibrator

3.6.18. How to check oil in gearboxes

Every 500 Hours or Once in 6 Month

3.6.19. Replacement of fuel filters of the engine

3.6.20. Cooling liquid inspection

3.6.21. Check of wiring

3.6.22. Exchanging cleaner elements of air cleaner

3.6.23. Replacement of filters of the cab and heating ventilation

3.6.24. Replacement of the air filter of the air conditioning

3.6.25. Check if wheel bolts are tightened *

72 ASC 100
 MAINTENANCE MANUAL

Every 1000 Hours or Once a Year

3.6.26. Check, adjust valve clearance

3.6.27. How to check tightening pulley and belt of the engine

3.6.28. Replace oil in gearboxes *

3.6.29. Checking the air conditioning compressor mounting

3.6.30. Inspect the damping system

3.6.31. How to clean fuel tank

Every 2000 Hours or Every 2 Years

3.6.32. How to change oil in the vibrator

3.6.33. Cleaning and checking the air conditioning system

3.6.34. How to change hydraulic oil and filter

3.6.35. How to change engine coolant

3.6.36. How to check the dampener of engine’s torsional vibrations

Maintenance - As Needed

3.6.37. How to clean engine cooler and hydraulic oil

3.6.38. How to deaerate fuel system

3.6.39. How to adjust the scrapers

3.6.40. How to clean the Machine

3.6.41. Check bolted connections

* First after 100 hours

ASC 100 73
3.5. Lubrication and Service Plan

LUBRICATION AND SERVICE PLAN

LEGEND
CHECK

LUBRICATE

EXCHANGE

2000 h

1000 h

500 h

250 h

20 h
Filters set / 4-760012

Engine oil: SAE 15W/40 API CF-4/SG

Hydraulic fluid: ISO VG 68 ISO 6743/HV

Grease: ISO 6743/9 CCEB 2

SAE 80W/90; API GL-5; MIL-L2105 C

Gear oil:
SAE 80W/140; API GL-5; MIL-L-2105 C
28027en

74 ASC 100
3.6. Individual Operations of Maintenance
Carry out lubrication & maintenance on regular basis and repeatedly in intervals according to daily reading on the hours-of-operation
counter.

20
25
15 ENGINE HOURS
RPM x 100
30 000001

10
35

1 15A
2 5A
3 7,5A
4 7,5A
5 5A
6 15A
7 20A
8

28072

This manual includes only basic information on the engine; the rest is provided in the operation and maintenance manual of the en-
gine, which is a part of documentation supplied with the machine.

Follow the instructions given in the manual for operation and maintenance of the engine!

Disassembled or loose bolts, plugs, threaded connections of hydraulics etc. should be tightened with torque according to tables in
chapter 3.6.41., unless a different value is listed for the particular operation.

Carry out the maintenance with the Machine stationed on a  flat, paved surface, and secured against
self-motion, ALWAYS with the engine turned OFF, key removed from the ignition box, and wiring cut OFF
(unless otherwise required).

After the first 100 hours of working with a new machine (or after machine general overhaul), make the
following operations:

3.6.25. Check if wheel bolts are tightened

3.6.28. The first oil exchange in drum and axle gearboxes

ASC 100 75
3.6. Individual Operations of Maintenance

Following 20 hours of operation or daily

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
1
the stop and pull out again to read the oil level.

28041

• 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.

282N110T

• 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

28031A

• Always replenish with oil of identical type. Use oils under

Section 3.2.1.
• Check the motor tightness, repair any cause of leakage.
• Inspect the motor if no damaged or missing parts exist with-
in the motor, and whether no appearance changes have oc-
curred.

NEVER use the engine unless there is

proper oil level inside the engine.

76 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).

282N113T

Remove the filler plug only after the en-

gine coolant temperature falls below
50  °C (120  °F). Any attempt to remove
OK OK
filler plug at high temperature may cause
operator to be scalded with steam or cool-
ing liquid due to inner overpressure.

The level may not drop below the level

gauge eyesight.
Replenish with coolant consisting of
antifreeze agents of identical base per
282N205T
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 damaged.
When some higher leak occurs, check the
cooling system and repair its cause.

ASC 100 77
3.6. Individual Operations of Maintenance
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.

282N114T

• The hydraulic tank lid is provided with a seal.

• To fill up the hydraulic circuit, use the hydraulic unit.

! CAUTION !
If the hydraulic circuit is filled in a different way than
using the hydraulic unit, the guarantee will expire.

Hydraulic unit 230 V

Ordering number: 1251998

Hydraulic unit 110 V 1251998

Ordering number: 1255297

NOTE
The hydraulic unit 230 V  is intended for operation in 230-Volt
networks (Europe), the hydraulic unit 110 V is intended for op-
eration in 110-Volt networks (North America).

• Connect the hydraulic unit to the quick-coupling in the

space under the cab.

280151

78 ASC 100
 MAINTENANCE MANUAL
Alternative filling through the filler neck of the tank in the
space under the cab
1
! CAUTION !
Fill the hydraulic circuit through the filler neck only
in emergency! When this filling method is used, it is
necessary to reduce the next change interval to half,
i.e. 1000 hours or 1 year. The plug of the tank filler
is sealed. If the seal is broken during the guarantee
period, the guarantee will expire.

• Fill the tank through the filler neck (1) with the specified oil
type up to the bottom of the strainer in the filler neck. 282N196TA

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.

28032

ASC 100 79
3.6. Individual Operations of Maintenance
3.6.5. Check fan condition

• Check visually the fan. If damaged (e.g. missing parts of ma-

terials, cracks, shape changes etc.) replace the fan.

282N112T

3.6.6. Check motor belt

• Make visual check of the belt, monitor any of its damage.

28054

• Any cracks perpendiculars to belt width are no damage.

When longitudinal cracks occur on the belt or frayed (shat-
tered) belt edges exist, or any torn off parts of material are
seen, then the belt must be replaced.
OK

OK

282N116T

80 ASC 100
 MAINTENANCE MANUAL
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 missing.

28033

• Inspect the gasket between the bonnet and air filter. Re-
place impaired gasket with the new one if required.

NEVER operated the Machine with dam-

aged gasket between the bonnet and air
filter, or the connection not tight.

282N118T

• Check the exit slit of air filter vacuum valve, press to remove
any dust trapped.

NOTE
The dust caught inside dust valve gets emptied automatically
during machine operation.

NEVER operate the Machine with dust

valve damaged.

282N119T

• Check and clean up the pre-filter tray (1) when any contami-
nation deposited reaches the mark, first unscrew the nut (2) 2
and remove lid (3). 3

NOTE:
Pre-filter is optional and is mounted based on separate order 1
only.

28034

ASC 100 81
3.6. Individual Operations of Maintenance
3.6.8. Check the amount of fuel

• Check the fuel level per fuel contents gauge (optional).

380K0025

• Replenish following the cleaning of filler cap (1) and filler

neck (2) via a  strainer up until the lower edge of the filler 1
neck.

NOTE:
When the Machine is fitted with fuel minimum indicator lamp 2
only (standard outfit), then make up the fuel immediately 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! 282N121T

Observe fire precautions!

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 running.
Do NOT replenish fuel in closed areas.

Prevent fuel from spilling on the ground.

82 ASC 100
 MAINTENANCE MANUAL
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”) downward.

1
28041A

• Drain the fuel till it starts flowing out pure. Press the valve
upward and screw it.

278N109T

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 3.6.38. In this way you will avoid
problems of difficult engine starting.

Observe fire precautions!

NO smoking while at work!
Do  NOT drain the separator with the en-
gine running.

Collect the fuel with sediment drained in

a proper vessel.

ASC 100 83
3.6. Individual Operations of Maintenance
3.6.10. Check the alarm & control devices

• Turn ON the switches (23), (24), (25), (28), confirm the horn • Start the engine, press (3) TOTAL STOP - engine stalling must
and the headlamps function well. occur, pilot lamps go ON.
• 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 continu-

ously the board instruments and indica-
tor lamps.
Repair instantly any failures signaled!

20
°C 25 °C
15 ENGINE HOURS
RPM x 100
30 000001

10
35

1 15A

14 13 2 5A
3 7,5A
28 23 24 25
4 7,5A
5 5A
6 15A
7 20A
8

12
6

I II

280731

84 ASC 100
 MAINTENANCE MANUAL

Every 100 Hours

3.6.11. Check tire pressure

! NOTE !
Rotate tyres so that valves are at top positions.

• Check pressure at cold tires using a pressure gauge.

• Maintain 160 kPa (23,2 PSI) pressure in your tires.
396093D

ASC 100 85
3.6. Individual Operations of Maintenance

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.

28051

• Clean the surface round the oil filter head. Dismantle the
filter.

28059

• Clean the contact surface designed for filter gasket.

282N129T

• Take a new filter, fill it with pure motor oil - 11,2 l (2,96 gal
US).

Oil filter
Ordering number: 4-8300730084

NOTE
The filter can be ordered in the filter set after 500 Mhs; the order
number of the set is 4-760012.

396248

86 ASC 100
 MAINTENANCE MANUAL
• Apply oil on the gasket.

282N131T

• Install the filter and hand-tighten securely.

• Reinstall the plug again. Use 80 Nm (59 lb ft) torque.

396250A

• Refill the engine via filler neck

28031B

• Replenish the oil up to the dipstick upper line (H). Oil refill-
ing makes 11,2 l (2,95 gal US).

282N110T

ASC 100 87
3.6. Individual Operations of Maintenance
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.

Drain oil when it is hot, following the

operation end, or heat the running en-
gine until the cooling liquid temperature
reaches 60 °C (140 °F). Beware of possible
scalding when draining hot oil.
Observe fire precautions!

! 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.

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.

88 ASC 100
 MAINTENANCE MANUAL
3.6.13. Check the fixing of the engine

• Confirm the condition of metal rubbers (cracks, fissures), co-

herence of metal with rubber, tightness of bolts and nuts.

Engine front metal rubbers

28052

Engine rear metal rubbers

282N184T

ASC 100 89
3.6. Individual Operations of Maintenance
3.6.14. Battery check
• Stop the engine and disconnect the electric system using
the isolating master switch.
• Clean the surface of batteries.
• Check the condition of poles and terminals (1) and clean
them. Apply a thin layer of grease on the terminals.
MAINTENANCE-FREE BATTERY
• In case of a maintenance-free battery (the battery has no fre-
ely accessible plugs), only the no-load voltage on terminals
is checked. The batteries cannot be replenished. If the no-
-load voltage is 12.6 V and more, the battery is fully charged.
If the no-load voltage is below 12.4 V, the battery should be
charged immediately. After the battery is charged, leave it
to stand for 2–3 hours and then measure the voltage again.
It is recommended to be mounted 24 hours after charging.
Note:
The no-load voltage is the voltage measured at the terminals of
the battery which was at rest for at least 12 hours – was neither
charged nor discharged.
Do  not turn the accumulators upside
down; the electrolyte may pour down
from the degassing plugs.
When there is electrolyte spillage, rinse
the affected place with water, and neu-
tralize with lime.
Hand over old batteries that do not work
for their disposal.
90
1 1 1 1
282N136T
Keep the batteries dry and clean.
Do NOT disconnect battery while the en-
gine runs.
When handling with the battery, always
follow battery Manufacturer’s Manual!
Use rubber gloves and eye protection aids
when handling the battery.
Use proper clothing to protect your skin
against any electrolyte stain.
When there is eye contact with electrolyte
immediately flush affected eye with large
amounts of water for a  few minutes. Get
prompt medical attention.
When there is electrolyte ingestion, drink
max amount of milk, water, or solution of
calcined magnesia in water.
During skin contact with electrolyte, re-
move clothing, including shoes, flush af-
fected points as soon as possible with
soap water or solution of soda and water.
Get prompt medical attention.
Do NOT eat, drink or smoke while at work!
After work is completed, wash your hands
and face thoroughly with water and soap!
Do  NOT check a  wire is energized by
touching Machine frame.
Disconnect the battery before its repair,
or when about to handle the wires and
electric devices within the wiring circuit
so to avoid a short circuit.
When disconnecting the battery, please
disconnect cable with (-) pole first. When
connecting, you must connect (+) pole
first.
Making direct conductive connection be-
tween battery’s both poles you will cause
a  short circuit with battery explosion
hazard.
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 (op-

tional)

282N139T

• Set up the engine speed increased to about 2000 min-1.

• Cover shortly Air Filter Suction Hole on the engine bonnet.

282N140T

• Indicator lamp (17) for Air Filter fouling should light.

20
25
15
RPM x 100
30
10
35

1 15A
2 5A
3 7,5A

17 4 7,5A
5 5A
6 15A
7 20A
8

28049

• Check the following unless it lights up :

Vacuum switch (1)
Bulb inside the indicator lamp (17). Confirm the contact,
supply cable.

282N142T

ASC 100 91
3.6. Individual Operations of Maintenance
3.6.16. Machine Lubrication

• Remove greasing nipple caps.

• Put on gradually the greasing nipple of high pressure press
and grease till the old grease begins to flow out.
1
• Reinstall the greasing nipple caps again. 3

Steering Joint
Upper bearing (1)
Lower bearing (2)
Bearing (3) 4x 2
27819T3

Linear Hydraulic Motors for Steering

King pins 2 x

Rear pins 2x

Linear Hydraulic Motors for Tilting the Bonnet

Upper pivots 2 x

282N148T

92 ASC 100
 MAINTENANCE MANUAL
Lower pivots 2 x

28038

Linear Hydraulic Motor for Tilting Driver’s Control Stand

28063

Door Hinges

282N152T

Bonnet Hinges

28039

ASC 100 93
3.6. Individual Operations of Maintenance
Cabin’s Front Pivots
Pivots 2 x

282N154T

Options
Cabin door hinges

282N151T

Use ONLY recommended lube greases.

Refer to Section 3.2.6.

94 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). Unscrew 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.

282N155T

Check the oil only after it cools down.

Refill with identical type of oil.

Observe fire precautions!

ASC 100 95
3.6. Individual Operations of Maintenance
3.6.18. How to check oil in gearboxes

Axle Gearbox 2
• Stop the Machine in such a  way the plugs (1), (2) of gear-
boxes of both of the wheels are in position as per fig.
• Wipe the spot round the check plug (1), unscrew the plug
and check the oil level. The level must be as high as the in-
spection hole or flow out slightly.
1
• Refill with oil via filler plug (2), if required.
• Wipe the plugs and reinstall.

28075A

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.
• Wipe the plugs and reinstall. 2
• Confirm the tightness of gearboxes.

28040

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.

96 ASC 100
 MAINTENANCE MANUAL

Every 500 Hours or Once in 6 Month

The set of filters after 500 Mhs can be ordered under

the order number 4-760012. For the list of all spare
parts, see the table in the end of this publication.

3.6.19. Replacement of fuel filters of the engine

• Clean the head of the fuel filter (1) and the fuel filter with the
water separator (2); dismantle the filters.

1
2
280371

• Clean the contact area of the fuel filter (1).

282N129T

• Fill up the fuel filter (1) with clean fuel.

282N160T

ASC 100 97
3.6. Individual Operations of Maintenance
• Apply oil over the sealing ring.

282N131T

• Mount the fuel filter (1) and tighten firmly by hand.

• Carry out the same procedure for the fuel filter with the wa-
ter separator (2).

Filtеr
Ordering number: 4-9501000015

396250A

NO smoking while at work!

Observe fire precautions!

Use original filters specified.

Do NOT tighten the filters with force.

Collect any fuel flowing out.

Hand over for disposal the filters used.

98 ASC 100
 MAINTENANCE MANUAL
3.6.20. Cooling liquid inspection

• Use refractometer to check the concentration of antifreez-

ing agent in the cooling liquid.

282N204T

Check always before winter season be-

gins. 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 of wiring

• Check for any damage to cables, connectors, protective

hoses, and their fastening, especially if in the vicinity of hot
surfaces and moving parts of the machine including the en-
gine. Replace damaged parts. Use only original spare parts.

ASC 100 99
3.6. Individual Operations of Maintenance
3.6.22. Exchanging cleaner elements of air
cleaner 20
25
15
The air cleaner contains the main and safety elements. Replace 30
RPM x 100

10
the cartridges always when the indicator lamp (17) lights up, 35

however at the latest after 500 Mhs.

1 15A
5A
The manufacturer does not recommend 2
3 7,5A
cleaning the cartridges because of reduc-
tion of filtration capacity by up to 40 %
17 4 7,5A
5 5A
and possible damage to the cartridges 6 15A
7 20A
due to the cleaning.
8

28049

• Lift the bonnet to the limit position. (See Operating instruc-

tions, chapter 2.8.7.).
• Remove the lid.

• Replace the main cartridge.

Cartridge
Ordering number: 4-5358520084

• Replace the safety cartridge.

Safety cartridge
Ordering number: 4-5358520085

100 ASC 100

 MAINTENANCE MANUAL
• Clean the inside of the cleaner and contact surface in order
that the engine inlet pipe does not get blocked. Check con-
nections and piping for any untightness and clogging of the
engine inlet opening on the bonnet (e.g. by leaves).

• Insert the safety element.

• Mount the new main element. Check whether the both car-
triges fits correctly and whether are sealing.
• Remove the dust valve, clean it and mount it back.

Do not clean the inside of the cleaner by

pressure air; dust might get into the en-
gine inlet piping.
Use original elements only.
When washing the machine, make sure
water cannot pour into the air cleaner.
In case of absorbing water, exchange
main element. Dry the cleaner body.
Replace defective vacuum valve
imme­diately!
Do  not operate the machine with dam-
aged cleaner body or cover.

ASC 100 101

3.6. Individual Operations of Maintenance
3.6.23. Replacement of filters of the cab
and heating ventilation

Cab:
• Dismantle cover grating (1).

282N214T

• Remove the filter (2).

Filter
Ordering number: 4-613780
2

282N215T

Heating:
• Remove the top grate on either side.
• Replace the filters.

Filter
Ordering number: 4-612044

277035A

Note:
Only for machines with cabs.

102 ASC 100

 MAINTENANCE MANUAL
3.6.24. Replacement of the air filter of the air
conditioning

• Dismantle cover grating.

• Remove the filter.

Air-conditioning filter
Ordering number: 4-8300750677

Note:
Only for machines with cabs.
277101

3.6.25. Check if wheel bolts are tightened

• Confirm the wheel bolts are tightened. Use torque spanner.

• The torque is 165 Nm (122 lb ft).+

! CAUTION !
Check the wheel screws for tightening after the first
100 Mh of machine operation.
278N113TB

ASC 100 103

3.6. Individual Operations of Maintenance

Every 1000 Hours or Once a Year

3.6.26. Check, adjust valve clearance

• Call CUMMINS service department to adjust the engine

valves - for contact points, please refer to Engine Operation
and Maintenance Manual.

3.6.27. How to check tightening pulley and belt

of the engine

• With the engine running inspect visually any vibrations of

the fan pulley.

28053

• 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 lb ft) torque.

28054A

• Lift the belt tightening pulley using a  lever with a  square

end of 10 mm (3/8-inch) and remove the belt.

28055

104 ASC 100

 MAINTENANCE MANUAL
• Carry out visual inspection of the belt, track any damage
made. Cracks across the belt width are not considered dam-
age. When longitudinal cracks occur on the belt, or the belt
has its edges frayed, or parts of the material are ripped out,
OK
then the belt must be replaced.

OK

282N116T

• With the belt removed, check to confirm the stop of the ten-
sioner arm comes into contact with the bump stop of the
bush. Unless so, replace the tensioner.

28056

• 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).

28057

• Reinstal the belt back.

28058

ASC 100 105

3.6. Individual Operations of Maintenance
3.6.28. Replace oil in gearboxes

Axle (Wheel) Gearboxes

• Stop the machine so that the gearbox plugs of both gear-
wheels are in the positions according to Fig. Dismount plugs
(1) and (2) and let the oil drain out.
1

2
28074A

• Drive the machine forward so that the plugs are in the posi-
tions according to Fig. Through the plug (2), fill 2 l (2.1 qt),
check the level in the hole (1) (the oil flows out slightly). 2

28075A

106 ASC 100

 MAINTENANCE MANUAL
Uncoupled Axle Gearbox – RH side
• Wipe the spots round the plugs. Place an appropriate recep-
tacle underneath the drain plug (3) and unscrew it.

28042

• Unscrew the plugs (1), (2) and let oil to flow out. After drain-
ing reinstall the drain plug back. Use filler plug (1), (2) to refill
the recommended oil - 3 l (3,17 qt).
• Check amount of oil through the inspection hole (1), (2). Oil
level must reach up to the bottom edge of the hole or flow
out slightly. Reinstall plugs (1) and (2), replace any plug gas- 2
kets damaged.

28040

Change oil first after driving 100 engine

hours.
Change oil while oil is hot.

Do NOT touch gearbox or its adjacent sec-

tions when these are hot.
Observe fire precautions!

Avoid oil to leak into the ground.

Used oil is environmentally hazardous
waste – Hand it over for disposal.

ASC 100 107

3.6. Individual Operations of Maintenance
3.6.29. Checking the air conditioning
compressor mounting

• Check the strength of the compressor attachment and the

compressor bracket. Make sure that the belt does not spin. If
necessary, tighten the screws.

280103

108 ASC 100

 MAINTENANCE MANUAL
3.6.30. Inspect the damping system

• Check the condition of metal rubbers (cracks, fissures), co-

hesiveness of metal with rubber. Replace any damaged one.
• Confirm the bolts and nuts are tightened properly.

Rubber metals of the drum, left side.

Rubber metal
Ordering number: 4-9200000074

28043

Rubber metals of the drum, right side.

Rubber metal
Ordering number: 4-9200000074

28044

Front metal rubbers of driver control stand.

Rubber metal
Ordering number: 4-6120080016

282N154TA

Rear metal rubbers of driver control stand.

Rubber metal
Ordering number: 1160052

28039A

ASC 100 109

3.6. Individual Operations of Maintenance
3.6.31. How to clean fuel tank

• Unscrew the drain plug and let fuel to flow out into a recep-
tacle installed.

282N185T

• Flush the tank with clean fuel.

• Screw on the plug again.
• When fouled to a  greater extent, remove the accumulator
and tank cap. Inspect and clean the tank’s inner area. Insert
the new sealing tape between the lid and the tank.

Sealing tape
Ordering number: 4-5422250007

• Mount the lid back.

• Mount the accumulators.

282N186T

NOTE
When aeration of engine fuel system occurs you must deaerate
it under Section 3.6.38.
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.

Observe fire precautions!

NO smoking while at work!!!

Follow the environmental regulations

when cleaning.
Avoid fuel leaking into the ground.

110 ASC 100

 MAINTENANCE MANUAL

Every 2000 Hours or Every 2 Years

3.6.32. How to change oil in the vibrator 1

• Position the cylinder so the drain plug on left side of uncou-
pled 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.
• Unscrew all the plugs and let oil to flow out.
• When draining is completed reinstall the drain plug. 2
• Use filler hole (1) to refill with recommended oil up to the
3
edge of inspection hole (2) - 8 l (2,1 gal US).
• Reinstall the remaining plugs. 282N155TA

Change oil while oil is hot.

Do NOT touch gearbox or its adjacent sec-

tions when these are hot.
Observe fire precautions!

Avoid oil to leak into the ground.

Used oil is environmentally hazardous
waste – Hand it over for disposal.

3.6.33. Cleaning and checking the air

conditioning system

• Replace the filter-dryer.

• Have the functional check of individual components, wiring
checking, and air conditioning system cleaning (removal of
mould and bacteria) performed by an authorised company.
• In case of work in a  highly dusty environment, have the
check performed in shorter intervals.

277102

ASC 100 111

3.6. Individual Operations of Maintenance
3.6.34. How to change hydraulic oil and filter

Change oil before season starts, or fol-

lowing a  rather long Machine shutdown.
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).
Mount the plug back.

28045

• Dismantle the cover.

282N190T

• Remove the suction hose.

282N191T

• Remove the lid. Remove the suction basket from the suction
pipe. Replace the suction basket.

Suction strainer
Ordering number: 4-5451050018

• Inspect the interior of the tank. When the bottom is dirty,

clean and rinse the tank with the new oil. Mount the lid
back. Use the new sealing tape.

Sealing tape
Ordering number: 4-690219

282N193

112 ASC 100

 MAINTENANCE MANUAL
How to repalce pressure filter element

20
25
15
Replace ALWAYS : RPM x 100
30
10
- Together with oil exchange 35

- When pressure filter lamp 18 lights

up due to oil operating temperature
1 15A
reaching 50 -60 °C (122 - 140 °F). 2 5A
3 7,5A
4 7,5A
5 5A

18 6 15A
7 20A
8

28046

• 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.

Filter cartridge
Ordering number: 4-5358520121
2

28047

ASC 100 113

3.6. Individual Operations of Maintenance
Filling the hydraulic circuit:
• Fill using the hydraulic unit.
• You can order the hydraulic unit from the machine manu-
facturer.

Hydraulic unit 230 V

Ordering number: 1251998

Hydraulic unit 110 V

Ordering number: 1255297

NOTE
The hydraulic unit 230 V  is intended for operation in 230-Volt 1251998
networks (Europe), the hydraulic unit 110 V is intended for op-
eration in 110-Volt networks (North America).

• Put the quick-release coupling of the hydraulic unit on the

quick-release coupling on the right side of the frame under
the cab.

280151

• Fill up the tank with oil to the maximum level and discon-
nect the hydraulic unit.
• Start the engine, increase its speed to confirm the tightness
of filter, temperature sensor, suction hose & cap. Check oil
level in oil gauge.

282N114T

Checking the oil temperature sensor

• Remove the sensor and clean the contact.
• Immerse the sensor in warm oil of a known temperature and
read the temperature on the hydraulic oil thermometer. If
the sensor operation is incorrect, replace the sensor with
a new one.

Temperature sensor
Ordering number: 4-5503580072

NOTE:
Applies only when oil thermometer is installed – optional.
212UM022

114 ASC 100

 MAINTENANCE MANUAL
Alternate filling through the oil tank filler

1
Fill the hydraulic circuit through the filler
neck only in emergency!
When using this filling method, reduce
the next change interval to the half, i.e.
1000 hours or 1 year.
The plug of the tank filler is sealed. If this
seal is broken during the guarantee pe-
riod, the guarantee will expire.

• Fill the tank through the filler neck with the specified oil
type up to the bottom of the strainer in the filler neck. 282N196TA

NOTE:
• When the tank is filled through the tank neck, a large por-
tion of the old dirty oil will remain in the circuit and the life
cycle of the hydraulic units will be shorter.

Do NOT open hydraulic tank uselessly!

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 over-
haul of hydraulic system. Clean & rinse hy-
draulic tank prior to installing a new unit.

Observe fire precautions!

Collect drained oil, and do NOT let it soak

in the ground. Blind all the holes with
plugs following the disconnection of hy-
draulic circuits.
Used oil & filter elements are environmen-
tally hazardous waste – Hand it over for
disposal.

ASC 100 115

3.6. Individual Operations of Maintenance
3.6.35. How to change engine coolant
1
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.

282N204TA

Do  NOT open the overpressure plug be-

fore cooling liquid temperature drops be-
low 50 °C (122 °F). Danger of water splash-
OK OK
ing when opening the overpressure plug
and getting scalded.

282N205T

• 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).

282N203T

• 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 whether the cooling gills
are fouled with slag & mill scale. Clean and repair if required.

282N206T

116 ASC 100

 MAINTENANCE MANUAL
• Close the drain cock and refill the cooling system with new
coolant at the ratio of 50 % of water + 50 % of antifreeze.

282N207T

• Open the bleed valve at the after cooler.

28048

• 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.

NOTE:
When making the change, please flush the system with mix-
ture 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 instruc-
tions 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 282N113TA
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.

Refill with cooling liquid under Section

3.2.3!
Follow the instructions of antifreeze man-
ufacturer when changing!

Wear gloves to protect your hands!

Hand over used liquid for its safe disposal
Wear safety glasses or face shield to pro- per the regulations given!
tect your eyes!

ASC 100 117

3.6. Individual Operations of Maintenance
3.6.36. 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] re-
place the dampener.

282N216TA

• 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 parts (1) and 1
(2). If the criterion is exceeded you must replace the damp-
ener of torsional vibrations.

282N217TA

• 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.

Elastic silicon-type lining of the dampener

becomes inflexible and stops fulfilling its
function. Inefficient dampener may cause
major damage to the engine.

118 ASC 100

 MAINTENANCE MANUAL

Maintenance - As Needed

3.6.37. 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.
282N112TA

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 regu-

lations when cleaning!
Clean the Machine at a  workplace
equipped with cleaning agent intercept-
ing system to avoid contamination of soil
and water resources!
NEVER use banned cleaning agents!

ASC 100 119

3.6. Individual Operations of Maintenance
3.6.38. 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).

28050

• Use fuel feed pump until clean fuel flows out with no air
bubbles.
• Tighten air relief screw. The torque figure is 9 Nm (7 lb ft).

28041B

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 precau-
tions must be followed.

120 ASC 100

 MAINTENANCE MANUAL
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 mo-
tor “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 lb ft)
torque.

396N052

Attention, high fuel pressure inside HP

piping. Hazard of skin injury and serious
implications.
NEVER make deaeration with hot engine.
Danger of fuel flowing over hot exhaust
manifold causing fire.
Open fire FORBIDDEN while working on
fuel system!
NO smoking!

Collect any leaking fuel!

ASC 100 121

3.6. Individual Operations of Maintenance
3.6.39. How to adjust the scrapers

Scrapers designed for smooth drum

• Loosen bolts (1) and shift the holders 2 towards the free-axle
making the distance between scraper and free-axle equal to
2
15 mm (0,6 in).

! CAUTION!
When the chance to displace the scrapers in slotted
holes of holders (2) following the wear and tear of
scraper (3) is exhausted, you must dismantle the 1
scraper (3) and move it by one hole towards the 3
drum.
282N219T

Scrapers designed for padfoot drum (segments)

• Loosen the bolts (1) and move individual scrapers 2 towards
the drum at the distance of 25 mm (1 in).

1
Rear scrapers at the padfoot drum are 1
longer. When replacing worn and torn
scrapers, use rear ones to replace the
front ones, and replace the rear ones with
new ones.
When only a  small gap has been set be-
tween the scrapers and drums a  contact
between scraper and drum may occur 2
when turning the Machine.
282N220T

122 ASC 100

 MAINTENANCE MANUAL
3.6.40. How to clean the Machine 3.6.41. Check bolted connections

Machine cleaning • Check regularly whether some bolted connections are loos-
ened.
• Clean the Machine to get rid of major dirtiness following
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 8,8 (8G) For bolts 10,9 (10K)
Thread Nm lb ft Nm lb ft
Blind all the holes where a cleaning agent M6 10 7,4 14 10,3
could enter (e.g. engine suction port) M8 24 25,0 34 25,0
before compressed cleaning with wa-
ter or steam. Remove these blinds upon M8x1 19 14,0 27 19,9
Machine cleaning completion. M10 48 35,4 67 49,4
Do NOT expose electric parts or insulation M10x1,25 38 28,0 54 39,8
material to direct direct stream of water M12 83 61,2 117 86,2
or steam. ALWAYS cover these materials
M12x1,25 66 48,7 94 69,3
(internal space of alternator, etc.).
M14 132 97,3 185 136,4
Wear gloves to protect your hands!
Wear safety glasses or face shield to pro- M14x1,5 106 78,2 148 109,1
tect your eyes! M16 200 147,5 285 210,2
Disconnect battery cut off switch. M16x1,5 160 118,0 228 168,1
Conduct work with the engine shut off. M18 275 202,8 390 287,6
NEVER use aggressive and easily ignitable M18x1,5 220 162,2 312 230,1
cleaning agents (e.g. gasoline or easily ig- M20 390 287,6 550 405,6
nitable materials).
M20x1,5 312 230,1 440 324,5
M22 530 390,9 745 549,4
M22x1,5 425 313,4 590 435,1
Follow ecological standards and regula-
tions when cleaning! M24 675 497,8 950 700,6
Clean the Machine at a  workplace M24x2 540 398,2 760 560,5
equipped with cleaning agent intercept- M27 995 733,8 1400 1032,5
ing system to avoid contamination of soil M27x2 795 586,3 1120 826,0
and water resources!
M30 1350 995,7 1900 1401,3
Do NOT use forbidden cleaning agents!
M30x2 1080 796,5 1520 1121,0

The figures given in the Table are torques at dry thread (at coef-
ficient of friction = 0,14). The figures do not apply to lubricated
thread.

ASC 100 123

3.6. Individual Operations of Maintenance
Table of torques for cap nuts with sealing O- ring – hoses

Torques for cap nuts with O-ring – hoses

Nm lb ft
Spanner
Thread Tube Nominal Min Max Nominal Min Max
size
14 12x1,5 6 20 15 25 15 11 18
17 14x1,5 8 38 30 45 28 22 33
8
19 16x1,5 45 38 52 33 28 38
10
10
22 18x1,5 51 43 58 38 32 43
12
24 20x1,5 12 58 50 65 43 37 48
14
27 22x1,5 74 60 88 55 44 65
15
30 24x1,5 16 74 60 88 55 44 65
32 26x1,5 18 105 85 125 77 63 92
20
36 30x2 135 115 155 100 85 114
22
41 25
36x2 166 140 192 122 103 142
46 28
50 42x2 30 240 210 270 177 155 199
45x2 35 290 255 325 214 188 240
50 38
52x2 330 280 380 243 207 280
42

124 ASC 100

 MAINTENANCE MANUAL
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
G1 400 295 G1 220 162
G 11/4 600 443 G 11/4 600 443
G 11/2 800 590 G 11/2 800 590

10 x 1 25 18 10 x 1 13 10
12 x 1,5 30 22 12 x 1,5 30 22
14 x 1,5 50 37 14 x 1,5 40 30
16 x 1,5 60 44 16 x 1,5 60 44
18 x 1,5 60 44 18 x 1,5 70 52
20 x 1,5 140 103 20 x 1,5 90 66
22 x 1,5 140 103 22 x 1,5 100 74
26 x1,5 220 162 26 x1,5 120 89
27 x 1,5 250 184 27 x 1,5 150 111
33 x 1,5 400 295 33 x 1,5 250 184
42 x 1,5 600 443 42 x 1,5 400 295
48 x 1,5 800 590 48 x 1,5 500 369

M-G
M-G M-G

282N221T 282N222T

ASC 100 125

126 ASC 100
3.7. Defects MAINTENANCE MANUAL

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 depart-
ment of your dealer or manufacturer.

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 department of your authorized
dealer or manufacturer.

ASC 100 127

3.8. Appendixes
Wiring Diagram

(the diagram represents the machine with maximum number of control elements and accessories)

Key:

B 1 Engine temperature sensor Q 1 Master switch

B 2 Sensor of the hydraulic oil temperature S 1 Switch box
B 3 Fuel gauge float S 2 Front lights switch
E 1,2 Front headlights S 3 Rare lights switch
E 3,4 Rear headlights S 4 Horn button
E 5 Gauge iluminiation S 5 Neutral gear switch (in the travel controller)
E 14 Cabin iluminiation S 6 Fast travel switch
E 15 Warning beacon S 7 Vibration switch (in the travel controller)
F 1-8 Safety fuses S 8 Vibration switch (movement of travel controller)
G 1,2 Battery S 9 Vibration change - over switch
G 3 Alternator S 10 Brake pressure switch
H 1 Horn S 11 Engine lubricating pressure switch
H 2 Switch vibration pilot lamp S 12 Air filter clogging switch
H 3 Brake pilot lamp S 13 Hydraulic liquid filter clogging switch
H 4 Engine lubrication pilot lamp S 14 Hydraulic liquid overheating switch
H 5 Recharging pilot lamp S 15 Engine overheating switch
H 6 Air filter clogging pilot lamp S 16 Warning beacon switch
H 7 Hydraulic filter clogging pilot lamp S 17 Back up alarm switch
H 8 Engine overheating pilot lamp S 18 ATO switch
H 9 Hydraulic fluid overheating pilot lamp S 19 Working speed increase switch
H 10 Fuel min pilot lamp S 20 Emergency brake pushbutton
H 11 Back up alarm S 29 Cabin fan switch
H 12 Anti Slip Assistant S 30 Front wiper switch
K 1 Contactor S 31 Rear wiper switch
K 2-5 Relay S 32 Washers pushbutton
M 1 Engine starter S 33 Heating fan switch
M 3 Cabin fan V 1, 2 Diods
M 4 Front wiper X Conectioin conectors
M 5 Rear wiper Y 1 Engine stop solenoid valve
M 6 Windscreen washer Y 2 Brake valve solenoid valve
M 7 Rear window washer Y 3 Fast travel speed solenoid valve – left wheel
M 8 Heater fan Y 4 Fast travel speed solenoid valve – right wheel
P 1 Hour meter Y 5 Fast travel speed solenoid valve– drum
P 2 Engine thermometer Y 6 Vibration 1 solenoid valve
P 3 Hydraulic oil thermometer Y 7 Vibration 2 solenoid valve
P 4 Fuel gauge
P 5 Engine speedmeter

128 ASC 100

 MAINTENANCE MANUAL

G1 G2 M1
– + – +
Q1 30 31

M
12V 66Ah 12V 66Ah B- G3 K1
D+ 50

G
B+ W

X5:1 S1

X3:3

X3:2

X3:1
X2
30 15/54
X5:6 K6 5 K2 4
50a 3 3
X5:7
E1 S2 2 1 2 1
1 5 F1
FRONT HEADLIGHTS E2 X28 X10:2 X9:1 9 10 15A

E3 X11:1 X3:4 1
S3 5
REAR LIGHTS 9 10
E4 X10:7 X9:4
E14 X10:5 F2
X9:2
CABINE ILLUMINATION
X11:2 7.5A
S4
H1 X3:5 1 5
HORN
F3
E15 X13 X3:6
S16
WARNING BEACON 1 5 7.5A
9 10

X4:7
X12:1
ENGINE STOP X12:4 X12:2
Y1

X7:7
S20
X11:4 P S17 X3:7 X4:1 X7:1

BACK UP ALARM X22:1 H11 X11:3

X22:2

Y2 X3:8
K3 3
5
BRAKE 2 1 X4:2 X7:2 C S5

Fe

X19
H

PNP
M X7:3 X4:3

Y3 X3:9 K4 3 F4
5
FAST TRAVEL - LEFT WHEEL 2 1 S6 7.5A
FAST TRAVEL - RIGHT WHEEL Y4 9 10
X4:4 X7:4 1 5
Y5 X8:1 8
S7
FAST TRAVEL - DRUM H2 X4:5 X7:5
6

X8:2
H M
Fe

S8
PNP

Y6 X3:10 K5 C
X7:6

VIBRATION 1 1
S9 2 1 X4:6

VIBRATION 2
Y7 5 5 3
X3:11 7

S10 X5:2 H3 F5
BRAKE PRESSURE SWITCH
P

ENGINE LUBRICATING
P S11 X5:3 H4 5A
P1
P
S12 X5:4 H6 H5
AIR FILTR, CHARGING /HOURS +
h

–
HYDRAULIC FILTER
P
S13 X5:5 H7
ENGINE OVERHEATING S15 X6:2 H8
HYDRAULIC OVERHEATING S14 X6:3 H9
B3 G X6:4
MINIMUM FUEL
W X6:5 H10
S29 F6
CABINE FAN (THE ROLLER WITH AIRCONDITION M3 5 3 X10:6
1
M

X9:3
WITHOUT M3AN and S 29 SWITCH) X15:1 15A

WINDSCREEN WIPER
M4 X15:4 7
S30
5
M

X15:2 1
X16:2
M5 X16:4 7S315
REAR WINDOW WIPER
M

X16:3 X16:1 1

WINDSCREEN WASHER M6 X17:1 7 S32

M

3
REAR WINDOW WASHER M7 X17:2 1
S33
M

M8 X18:2 X6:7 5 3
HEATING FAN 1
M

X18:3 X6:8 F7
Reserved for Aircondition
X4:3
X18:1 F8
Reserve

211703_1en

ASC 100 129

3.8. Appendixes
Wiring Diagram

(the diagram represents the machine with maximum number of control elements and accessories)

Key:

B 1 Engine temperature sensor Q 1 Master switch

B 2 Sensor of the hydraulic oil temperature S 1 Switch box
B 3 Fuel gauge float S 2 Front lights switch
E 1,2 Front headlights S 3 Rare lights switch
E 3,4 Rear headlights S 4 Horn button
E 5 Gauge iluminiation S 5 Neutral gear switch (in the travel controller)
E 14 Cabin iluminiation S 6 Fast travel switch
E 15 Warning beacon S 7 Vibration switch (in the travel controller)
F 1-8 Safety fuses S 8 Vibration switch (movement of travel controller)
G 1,2 Battery S 9 Vibration change - over switch
G 3 Alternator S 10 Brake pressure switch
H 1 Horn S 11 Engine lubricating pressure switch
H 2 Switch vibration pilot lamp S 12 Air filter clogging switch
H 3 Brake pilot lamp S 13 Hydraulic liquid filter clogging switch
H 4 Engine lubrication pilot lamp S 14 Hydraulic liquid overheating switch
H 5 Recharging pilot lamp S 15 Engine overheating switch
H 6 Air filter clogging pilot lamp S 16 Warning beacon switch
H 7 Hydraulic filter clogging pilot lamp S 17 Back up alarm switch
H 8 Engine overheating pilot lamp S 18 ATO switch
H 9 Hydraulic fluid overheating pilot lamp S 19 Working speed increase switch
H 10 Fuel min pilot lamp S 20 Emergency brake pushbutton
H 11 Back up alarm S 29 Cabin fan switch
H 12 Anti Slip Assistant S 30 Front wiper switch
K 1 Contactor S 31 Rear wiper switch
K 2-5 Relay S 32 Washers pushbutton
M 1 Engine starter S 33 Heating fan switch
M 3 Cabin fan V 1, 2 Diods
M 4 Front wiper X Conectioin conectors
M 5 Rear wiper Y 1 Engine stop solenoid valve
M 6 Windscreen washer Y 2 Brake valve solenoid valve
M 7 Rear window washer Y 3 Fast travel speed solenoid valve – left wheel
M 8 Heater fan Y 4 Fast travel speed solenoid valve – right wheel
P 1 Hour meter Y 5 Fast travel speed solenoid valve– drum
P 2 Engine thermometer Y 6 Vibration 1 solenoid valve
P 3 Hydraulic oil thermometer Y 7 Vibration 2 solenoid valve
P 4 Fuel gauge
P 5 Engine speedmeter

130 ASC 100

 MAINTENANCE MANUAL

E5
S2 F1
E1 6 2
8 3 15A
FRONT HEADLIGHTS E2 X10:2 X9:1 1
9 10

X3:3
X3:2

WITH THE DASH-GAUGES

VALID FOR THE ROLLER
P S10 X5:2 H3 F5
BRAKE PRESSURE SWITCH
P S11 X5:3 H4 5A
ENGINE LUBRICATING H5 P1
P
S12 X5:4 H6 +
AIR FILTR, CHARGING /HOURS –

h
P
S13 X5:5 H7
HYDRAULIC FILTER
B1 X6:1 S
P2
+
ENGINE OVERHEATING

°C
–
B2 X6:3 S
P3
+
HYDRAULIC OVERHEATING

°C
B3G X6:4
–
P4 P5
S + 1
FUEL GAUGE/ENGINE SPEEDMETER

h
W X6:5 4
– 3

X7:3

X7:1
Y3 X3:9
K4 F4
5 3
FAST TRAVEL- LEFT WHEEL

THIS WIRING OF THE SOLENOID

2 1 S6

Y3,Y4, Y5, Y6, Y7 IS VALID FOR

7.5A
Y4 9 10
FAST TRAVEL- RIGHT WHEEL
V1 X4:4 X7:4 5

THE ATO SWITCH S18

1
Y5 X8:1 8 S7
FAST TRAVEL- DRUM H2 X4:5 X7:5
6
V2

X8:2
H S8

Fe
M

PNP
Y6 X3:10 K5 C
S9

X7:6
VIBRATION 1 1 2 1 X4:6
Y7 5 5 3
VIBRATION 2
X3:11 7 S18
1 5
9 10
H12

Y5, Y6, Y7 IS VALID FOR THE ROLLER WITH

WORKING SPEED INCREASE SWITCH S19

THIS WIRING OF THE SOLENOID Y3,Y4,

X7:3

X7:1
Y3 V1 K4 F4
X3:9 5 3
FAST TRAVEL- LEFT WHEEL 2 1 S6 7.5A
Y4 9 10
FAST TRAVEL- RIGHT WHEEL X4:4 X7:4 1 5
Y5 X8:1 V2 8 S7
6
FAST TRAVEL- DRUM
X8:2 H S8
Fe

S19 M
PNP

A3 A1 C

A4
Y6 X3:10 K5
S9
X7:6

VIBRATION 1 2 1 X4:6
Y7 1 5 5 3
VIBRATION 2 7
X3:11

211703_2en

ASC 100 131

3.8. Appendixes
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

132 ASC 100

ASC 100
DRUM
BĚHOUN

LEFT WHEEL
LEVÉ KOLO

RIGHT WHEEL
PRAVÉ KOLO

107117
MAINTENANCE MANUAL

133
3.8. Appendixes
Cab and bonnet lifting

Legend:
1 Hydraulic cylinder of bonnet lifting
2 Hydraulic cylinder of cab lifting
3 Hand pump
5 Safety block

134 ASC 100

 MAINTENANCE MANUAL

107146

ASC 100 135

3.8. Appendixes

136 ASC 100

 MAINTENANCE MANUAL
Regular maintenance spare parts chart

Chapter Spare part Order No.

After 500 hours of operation (after 6 months)

Set of filters after 500 Mhs 4-760012

3.6.24. Air-conditioning filter 4-8300750677

After 1,000 hours of operation (after 1 year)

3.6.30. Rubber metal 4-9200000074

3.6.30. Rubber metal 4-6120080016

3.6.30. Rubber metal 1160052

3.6.31. Sealing tape 4-5422250007

After 2,000 hours of operation (after 2 years)

3.6.34. Hydraulic unit 1251998

3.6.34. Suction strainer 4-5451050018

3.6.34. Sealing tape 4-690219

3.6.34. Temperature sensor 4-5503580072

3.6.34. Filter cartridge 4-5358520121

Content of the filter set after 500 Mhs (4-760012)

Chapter Spare part Number of parts Order No.

3.6.12. Oil filter 2 pieces 4-8300730084

3.6.19. Filter 1 piece 4-9501000015

3.6.19. Filter 1 piece 4-9501000016

3.6.22. Cartridge 1 piece 4-5358520084

3.6.22. Safety cartridge 1 piece 4-5358520085

3.6.23. Filter 1 piece 4-613780

3.6.23. Filter 2 pieces 4-612044

ASC 100 137

3.8. Appendixes

Notes

138 ASC 100

 MAINTENANCE MANUAL

Notes

ASC 100 139

3.8. Appendixes

Notes

140 ASC 100

Ammann Unternehmungen
Eisenbahnstrasse 25
CH-4901 Langenthal
Phone +41 62 916 61 61

www.ammann-group.com