Ammann Cummins ASC110 Workshop Manual
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Ammann Cummins ASC110 Workshop Manual

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Workshop manual
ASC 110
Cummins
Book ID: 4-P08282CU
-EN

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Summary of Contents for Ammann Cummins ASC110

  • Page 1 Workshop manual ASC 110 Cummins Book ID: 4-P08282CU...
  • Page 3 ASC 110 Single drum roller Cummins Tier 3 Workshop manual Edition 02/2012 From Serial No. 2823164...
  • Page 5 If you identify any differences between the machine operated by you and the information con- tained 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.
  • Page 6 ASC 110...

  • Page 7: Table Of Contents

    Contents WORKSHOP MANUAL CONteNtS ...............................3 INtROdUCtION ............................5 RePAIR SAfety INStRUCtIONS ......................9 SPeCIfICAtION MANUAL ........................15 ReMOvINg tHe eNgINe ........................25 dRUM dISMOUNtINg .........................47 ARtICULAted jOINt ...........................73 ReMOvAL Of PUMPS, CeNtO CLUtCH ....................87 SteeRINg CyLINdeRS .........................99 CONtROLS ............................105 10. tHe dRIveR‘S StAtION ASSeMbLy ....................109 11.
  • Page 8 ASC 110...

  • Page 9: Introduction

    WORKSHOP MANUAL 1. Introduction ASC 110...
  • Page 10 Introduction This Service Manual splits into separate chapters, it includes technical data and assembly data, adjusting guidelines, and instructions to use special tools, jigs and aids. The major purpose of this Workshop Manual is to provide basic information on disassembly, assembly and service repairs of the Machine’s main groups.
  • Page 11 WORKSHOP MANUAL SyMbOLS Of tHe SAfety NOtICeS IN tHe 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. ! NOtICe ! As used in this operating manual, the terms „right“, „left“, „front“...
  • Page 12 ASC 110...

  • Page 13: Repair Safety Instructions

    WORKSHOP MANUAL 2. Repair safety instructions ASC 110...
  • Page 14 • Repairs may be carried out by skilled, trained and experienced personnel only and/or by Ammann SERVICE and dealers. • When performing repairs, always use our shop manual. Special instructions for the assembly work are given in individual chapters of the manual.
  • Page 15 WORKSHOP MANUAL Safety instructions for work on hydraulic circuits • make sure that no hydraulic circuit is under pressure before dismantling it. Hydraulic oil leaks under pressure may injure your skin and cause a serious injury. • Mark all parts, hoses and pipes before removing them. •...
  • Page 16 Repair safety instructions Safety instruction for work on electrical wiring • Disconnect the battery when carrying out any repair in the charging circuit to avoid incidental short-circuits. • When dismantling, first disconnect the cable from the negative pole (-), then from the positive one (+). •...
  • Page 17 WORKSHOP MANUAL tightening torque • Use a torque key for the right tightening torque. • Fastening bolts and nuts of the given quality are tightened according to the table. • Quality of the bolt is shown visibly on the bolt head. •...
  • Page 18 Repair safety instructions ecological precautions • Contents of machine systems and some parts of the machine can produce, when no longer in use, represent great risks to the environment. The following products especially belong to this category: both organic and synthetic lubricating materials, oils and fuel, coolants, battery acids and batteries themselves, cleaning agents and preservatives,...

  • Page 19: Specification Manual

    WORKSHOP MANUAL 3. Specification manual ASC 110...
  • Page 20 Specification manual basic data Please fill in the following data: Machine description (see Pin label, Label of the CUMMINS engine) Single drum roller with an articulated frame with a front smooth or padfoot steel driven vibrating drum and driven rear axle with Type of machine two treaded tyres.
  • Page 21 The machine that complies with the requirements as to health protection and safety is identified with a name plate with CE 3487 marking. AMMANN CZECH REPUBLIC a.s. 549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145 CZECH REPUBLIC 1 - Name – always mentioned only in the English version...
  • Page 22 Specification manual dimension Chart 282050 (in) 2878 1500 3070 2400 5780 2130 2258 ASC 110 d (113,3) (59,1) (17,3) (16,5) (120,9) (94,5) (227,6) (1,0) (83,9) (88,9) 2878 1440 1640 3070 2400 5780 2130 2258 ASC 110 Pd (113,3) (56,7) (64,6) (17,3) (16,5) (120,9)
  • Page 23 WORKSHOP MANUAL 282051 (in) 2878 1500 3070 2400 5780 2130 2258 ASC 110 d (113,3) (59,1) (17,3) (16,5) (120,9) (94,5) (227,6) (1,0) (83,9) (88,9) 2878 1440 1640 3070 2400 5780 2130 2258 ASC 110 Pd (113,3) (56,7) (64,6) (17,3) (16,5) (120,9) (94,5) (227,6)
  • Page 24 Specification manual technical data ASC 110 Cummins tier 3 HdPd HtPd Weight Operating weight of kg (lb) 11490 (25330) 12730 (28060) 12730 (28060) 12100 (26680) 13330 (29390) 13330 (29390) CECE with cab, ROPS Operating weight of kg (lb) 11260 (24820) 13500 (29760) 13500 (29760) 11870 (26170) 13100 (28880) 13100 (28880) CECE with cab Operating weight of CECE with platform,...
  • Page 25 WORKSHOP MANUAL ASC 110 Cummins tier 3 HdPd HtPd driving characteristics Number of speeds Maximum transport km/h (MPH) 12,8 (6,9) 9,2 (5,7) 8,2 (5,1) 12,8 (6,9) 9,6 (5,96) 8,6 (5,34) speed Working speed 1 km/h (MPH) 2,5 (1,55) 2,5 (1,55) 2,4 (1,49) 2,5 (1,55) 2,5 (1,55)
  • Page 26 Specification manual ASC 110 Cummins tier 3 HdPd HtPd engine Manufacturer Cummins Cummins Cummins Cummins Cummins Cummins Type QSB4.5-C160 QSB4.5-C160 QSB4.5-C160 QSB4.5-C160 QSB4.5-C160 QSB4.5-C160 Power according to kW (HP) 119 (160) 119 (160) 119 (160) 119 (160) 119 (160) 119 (160) DIN 6271 Power according to kW (HP)
  • Page 27 WORKSHOP MANUAL ASC 110 Cummins tier 3 HdPd HtPd fluid capacities Fuel l (gal US) 410 (108,3) 410 (108,3) 410 (108,3) 410 (108,3) 410 (108,3) 410 (108,3) Engine (oil filling) l (gal US) 11,0 (2,9) 11,0 (2,9) 11,0 (2,9) 11,0 (2,9 11,0 (2,9) 11,0 (2,9) Cooling system...
  • Page 28 Engine air pre-filter (Syclone) Panel with testing points under the platform Padlock staple above the fuel tank cover ACE Ammann Compaction Expert with the ADS data storage and evaluation system ACE printer ADS software ACI Ammann compaction meter - without memory...

  • Page 29: Removing The Engine

    WORKSHOP MANUAL 4. Removing the engine ASC 110...
  • Page 30 Removing the engine ASC 110...
  • Page 31 WORKSHOP MANUAL ASC 110...
  • Page 32 Removing the engine ASC 110...
  • Page 33 WORKSHOP MANUAL ASC 110...
  • Page 34 Removing the engine ASC 110...
  • Page 35 WORKSHOP MANUAL technical data Motor oils and lubricating grease Amount [l gal] engine oil - API CH 4/SJ, CI/SK; SAE 15W/40 11 (2.9) Coolant fluid in engine - anti-freeze liquid 32 (8.5) Lubricating grease - ISO 6743/9 CCEB 2, DIN 51 502 KP2K-30 as required Coolant is a mixture consisting of treated demineralized or distilled water and antifreeze ethylene glycol.
  • Page 36 Removing the engine disassembly and assembly of the engine Preparatory set-up Preparatory activities and both dismantling and assembly of the engine should be performed in accordance with the first chap- ter „Safety Instructions“. Ecological measures and HEALTH prin- ciples must be kept as well. dismantling of the engine Lift the hood, support by fixture no.1 in lifted position.
  • Page 37 WORKSHOP MANUAL Press out pins from piston ends in lifting hydraulic motors, se- cure by fixture no. 2. ASC103 Install fixture no. 3, lower the hood, support. ASC104 Remove hinges. ASC105 Attach hooks of fixture no. 3. ASC106 ASC 110...
  • Page 38 Removing the engine Set hood aside using fixture no. 3. ASC107 ASC108 Loosen pouring throat, drain coolant. ASC111 Drain coolant into a ready container. ASC112 ASC 110...
  • Page 39 WORKSHOP MANUAL Disconnect hoses (126-27), (126-28) and rubber elbow (126-35). Remove hoses (305-80), (305-81) to the hydraulic oil radiator, plug up outlets. ASC113 Remove holders (126-4), (126-5). ASC496 Loosen bolts (126-53). ASC115 ASC 110...
  • Page 40 Removing the engine Suspend radiator by hooks, set aside. ASC116 ASC117 Remove cover of hydraulic tank. ASC118 Remove suction hose (336-51) from hydraulic tank to steering pump. ASC119 ASC 110...
  • Page 41 WORKSHOP MANUAL Plug up outlet. ASC120 Disconnect hoses to steering pump, plug up. ASC492 Loosen bolt of clamp (136-23) on the turbo. ASC485 Remove four bolts (136-28) on the air filter holder. ASC123 ASC 110...
  • Page 42 Removing the engine Disconnect wiring to filter sensor, set filter aside. ASC124 Loosen clamp on exhaust pipe (136-14). ASC125 Remove bolts of exhaust pipe holder (136-31). ASC126 Set muffler aside. ASC127 ASC 110...
  • Page 43 WORKSHOP MANUAL Plug up outlets. ASC128 Disconnect all wires – ground strip, starter wires, alternator wires, water temperature and oil pressure sensor RPM meter, and injection pump solenoid. ASC129 Disconnect control unit of engine. ASC131 Disconnect intake and overflow of fuel. ASC132 ASC 110...
  • Page 44 Removing the engine Lift the cabin using hydraulic lift, then use crane to unload the piston of the lifting hydraulic motor using fixture no.1. ASC133 Remove bolts. Set rubber wall aside. ASC134 Remove bolts (106-45) from flange (106-12). ASC266 Suspend pump on crane. ASC136 ASC 110...
  • Page 45 WORKSHOP MANUAL Slide out of the clutch (106-86), support. ASC137 Remove nuts (106-63) of front rubber mountings (both left and right side). ASC486 Remove nuts (106-63) of rear brackets (four on each side). ASC139 Mount fixture no. 5 to the flange. Suspend engine on crane by hooks.
  • Page 46 Removing the engine Extract, set aside on support no. 4. ASC499 ASC 110...
  • Page 47 WORKSHOP MANUAL failure Cause Remedy Engine cannot be started Empty fuel tank. Replenish fuel and deareate the fuel system. and starter is turning. Untightness of the fuel system. Inspect the connections, if tight; remove untight- ness. Prime fuel with the hand priming pump. Aerated fuel system.
  • Page 48 Removing the engine failure Cause Remedy The engine is getting Shortage of coolant. Quickly stop the engine, replenish coolant, find overheated. the untightness and repair it. Clogged coolant radiator. Clean the radiator. Failure of the belt tensioning, or broken belt. Repair the failure, replace the belt.
  • Page 49 WORKSHOP MANUAL fixtures no. 1 Installation – 64-281-126 (cab support) ND080080 no. 2 Installation – 64-303-342 (securing hydraulic cylinders of hood lifting) ND080220 no. 3 Handling – 65-281-091 (hooks for installation of hood) ND101778 no. 4 Installation 64-298-461 (engine support) ND080183 ASC 110...
  • Page 50 Removing the engine no. 5 Installation 64-298-460 ASC508 ASC 110...

  • Page 51: Drum Dismounting

    WORKSHOP MANUAL 5. drum dismounting ASC 110...
  • Page 52 drum dismounting ASC 110...
  • Page 53 WORKSHOP MANUAL ASC 110...
  • Page 54 drum dismounting ASC 110...
  • Page 55 WORKSHOP MANUAL ASC 110...
  • Page 56 drum dismounting technical data description The vibrating drum with carriers is fixed on both sides in the front frame by means of metal rubber parts of the prescribed strength. The vibrating effect is generated by two pairs of cams on both sides of the drum. The cams are interconnected using a shaft. The cams are driven by a hydraulic motor –...
  • Page 57 WORKSHOP MANUAL dRUM dISMOUNtINg Jack up, e.g. using a hydraulic lifting device, the drum frame so that the drum touches the ground lightly. Place it on fixed sup- ports on both sides. ASC511 Left side Put a drain pan under the vibration hydraulic motor. ASC149 Dismount the vibration hydraulic motor hoses.
  • Page 58 drum dismounting Dismount the vibration hydraulic motor hoses collars. ASC514 Fasten the hoses to the can using bands. ASC515 Right side Put a drain pan under the travel hydraulic motor. ASC149 Dismount the cover (30-5) of the travel hydraulic motor. ASC550 ASC 110...
  • Page 59 WORKSHOP MANUAL Dismount the travel hydraulic motor hoses. ASC150 Plug the hose outlets. ASC151 Disconnect the electrical installation from the travel hydraulic motor. Plug the outlets. ASC516 Fasten the hoses behind the mirror arm to the cab. ASC152 ASC 110...
  • Page 60 drum dismounting Dismount the screws (10-33) from the weights (10-7) on the left side of the front frame. ASC517 Dismount the screws (30-19) of the bracket on the right side of the front frame. ASC518 Slacken the screws (10-34) and push the weights (10-7) into the drum so that there is a gap between the weight and the ma- chine frame.
  • Page 61 WORKSHOP MANUAL Set the drum so that the drain plug is on the left cover in the lower position. ASC167 Secure it against accidental movement by means of blocks. ASC521 Unscrew the drain plug from the vibrator cover and drain the oil to the drain container.
  • Page 62 drum dismounting Turn the place (10-4) and gradually dismount the screws (1-39) from the hub. Dismount the last pair of screws in the horizontal axis only after the plate hanging on the jig. ASC525 Set the plate (10-4) in the vertical position and hang it on the crane using jig no.
  • Page 63 WORKSHOP MANUAL Turn the vibration plate and place it on metal rubber parts. ASC177 Unlock the retaining washer (10-24). ASC529 Mount jig no. 2 on the nut (10-23). ASC551 ASC 110...
  • Page 64 drum dismounting Dismount the nut (10-23) and washer (10-24). ASC180 ASC530 Turn the vibration plate (10-1) with the hub pointing down- wards. Dismount the screws (10-30). ASC531 Insert the screws (a part of jig no. 3) into the holes and dismount the hub by means of gradual tightening.
  • Page 65 WORKSHOP MANUAL Strike out the bearings (1-28), rubber seal (1-22), and ring (1-23) from the hub. ASC185 ASC 110...
  • Page 66 drum dismounting vibration plate mounting When mounting, follow the same procedure as when dismount- ing in the reverse order. Press on the bearing outer ring (1-28), turn, mount the outer ring of another bearing, and press on the rubber seal (1-22) by means of jig no.
  • Page 67 WORKSHOP MANUAL Mount the washer (10-24) and nut (10-23). ASC530 Tighten it using jig no. 2 (tap on the jig when tightening). ASC553 Check the nut tightening for a torque of 75 ÷ 80 Nm using jig no. 5. ASC554 Right side dismounting Turn the bracket (30-1) and hang it on the crane using jig no.
  • Page 68 drum dismounting dismounting – mounting of vibrators - Right side Dismount the screws (1-38) – hang the cover (1-8) on jig no. 6; using three screws (M16) in the process openings “A”, push the cover away from the drum face. ASC555 Remove the cover.
  • Page 69 WORKSHOP MANUAL When dismounting the covers (1-7) and (1-10) and the vibrator on the left side of the drum, follow the same procedure! ASC204 Preheat the bearing inner rings (20-14) to 90 ÷ 110 °C (194 ÷ 230 °F) and dismount them from the shafts. ASC536 Remove the ring halves (20-9) and dismount the free cam (20-2).
  • Page 70 drum dismounting Press the bushing (20-10) into the cam (20-2) using jig no. 8. ASC539 Gauge the bushing using jig no. 8. ASC558 Other operations of the mounting for both sides of the drum are identical; follow them in the order reverse to the order of dismounting.
  • Page 71 WORKSHOP MANUAL Strike the pins (20-21) into both shafts (20-5), (20-6) and secure their position by means of jig no. 9. ASC542 After mounting the covers (1-7), (1-8), test the axial clearance of the bearings of both vibrators 1.5 – 2.5 mm. ASC559 ASC 110...
  • Page 72 drum dismounting Mounting of the drum into the frame Place the frame on suitable supports on both sides. Hang the drum and lift it up using the crane and mount it into the frame so that the drum does not bumps into the frame. ASC543 Make sure that there is a gap of 24 mm ±2 mm between the frame and the drum on both sides.
  • Page 73 WORKSHOP MANUAL Mount the weight (10-7) to the frame and then retighten it by means of screws (10-34). ASC547 Using a square, measure the distance between the drum and frame near the joint at various places (see the figure). The drum must be axially centred.
  • Page 74 drum dismounting fixtures No.1 - Handling - 65-288-087 ND080149 No.2 - Installation - 64-322-072 ND080229 No.3 - Installation - 92-632-119 ND101781 No.4 - Installation - 64-281-095 ND101776 ASC 110...
  • Page 75 WORKSHOP MANUAL No. 5 - Control - 64-281-100 ND101777 No. 6 - Installation - 64-298-222 ND080148 No. 7 - Installation - 64-303-263 ND080297 No.8 - Installation - 64-298-219 ND080145 ASC 110...
  • Page 76 drum dismounting No.9 - Installation - 64-298-220 ND080146 No 10 - Control - 64-298-221 ND080147 ASC 110...

  • Page 77: Articulated Joint

    WORKSHOP MANUAL 6. Articulated joint ASC 110...
  • Page 78 Articulated joint ASC 110...
  • Page 79 WORKSHOP MANUAL ASC 110...
  • Page 80 Articulated joint description The joint connecting the drum frame with the rear frame is equipped with a large-size bearing 1 with cross rollers allowing for the frame to swing in the vertical plane, and two vertical pins 2 allowing for steering angle in the horizontal plane. ASC487 Place the machine on firm ground, support the frame in front and in rear by the proper brace.
  • Page 81 WORKSHOP MANUAL Using fixture no. 3 press out pins (372-1) out of the ends of pis- tons of the linear hydraulic motor (372-6). ASC481 Remove hose clamps on the drum frame. ASC482 Remove clamping of hoses on the hinge and the rear frame. ASC234 Remove cover of vibration hydraulic motor.
  • Page 82 Articulated joint Remove vibration hydraulic motor. ASC236 Slide hydraulic motor from the drum, set aside. ASC237 Suspend drum with the frame using fixture no. 4 use two twin- hooks because of the weight. ASC238 Remove bolts (63-40). ASC483 ASC 110...
  • Page 83 WORKSHOP MANUAL Set aside the drum with front frame on the right side outside the machine. ASC240 Place fixture no. 5 underneath. ASC339 Place hoist under frame plate (63-2). Remove bolts (63-37). ASC242 Tight the bolts (63-37) with torque 184 Nm, safe the screws by Loctite 243.
  • Page 84 Articulated joint Put plate (63-2) aside. ASC243 Loosen bolts (63-38). ASC244 Tight the bolts (63-38) with torque 184 Nm according to the picture, safe the screws by Loctite 243. See the Spare parts for using new bolts. ASC447 Place fixture no. 6 under the upper bolt, suspend on crane using fixture no.
  • Page 85 WORKSHOP MANUAL Loosen nuts (63-25). Remove nuts (63-25) using wrench no. 8. The nut reassemble torque: 260 Nm ASC246 Remove clamps of the pin, press out the pins (63-12) using jack, see Fig. ASC247 Use crane to set hub (63-3) aside. ASC248 Remove covers (63-10), (63-11), and spreaders (63-13).
  • Page 86 Articulated joint Press out bearings (63-24) using fixture no. 9. ASC250 ASC 110...
  • Page 87 WORKSHOP MANUAL fixtures No. 1 - 64-328-500 - Installation (front rack under the tractor frame) ND084425 No. 2 - 64-322-278 - Installation (rear rack under the tractor frame) ND080211 No. 3 - 92-632-122 - Installation (for pressing out pin 10 - hydr. cylinder+joint) ND101782 No.
  • Page 88 Articulated joint No. 5 - 64-284-026 - Installtion (support under frame with drum) ND080088 No. 6 - 65-281-201 - Handling (lifting eye for bearing 23) ND103875 No.7 - 64-298-222- Handling (together with ND 103875 sus- 64-298-222- Handling (together with ND 103875 sus- - Handling (together with ND 103875 sus- pension eyelet) ND080148...
  • Page 89 WORKSHOP MANUAL No.9 - 92-631-006 - Installation (for bearing pos. 24 129 / 105)   ND090480 ASC 110...
  • Page 90 ASC 110...

  • Page 91: Removal Of Pumps, Cento Clutch

    WORKSHOP MANUAL 7. Removal of pumps, cento clutch ASC 110...
  • Page 92 Removal of pumps, cento clutch ASC 110...
  • Page 93 WORKSHOP MANUAL ASC 110...
  • Page 94 Removal of pumps, cento clutch Lift the cabin using hydraulic lift, then use crane to unload the piston of the lifting hydraulic motor using fixture no.1. ASC252 Remove bolts. Set rubber wall aside. ASC253 Remove hose clamps. ASC254 Disconnect wires to hydraulic generators. ASC255 ASC 110...
  • Page 95 WORKSHOP MANUAL Remove hoses from hydraulic generators. ASC256 ASC257 ASC258 ASC259 ASC 110...
  • Page 96 Removal of pumps, cento clutch Plug outlets of hydraulic generators and hose ends. ASC260 ASC261 ASC262 Remove bolts of gear pump. Put gear pump aside. ASC488 ASC 110...
  • Page 97 WORKSHOP MANUAL Suspend vibration hydraulic generator on the crane, remove bolts connecting both hydraulic generators. ASC263 Slide out and set aside. ASC489 Suspend travel hydraulic generator on the crane. ASC265 Remove bolts (106-45) off flange (106-12). ASC266 ASC 110...
  • Page 98 Removal of pumps, cento clutch Slide out of clutch (106-86). ASC267 Set hydro generator with flange aside. ASC268 Coupling removal: Coupling consists of these parts: segment “A”, segment “B”, elas- tic part. Remove bolts T1 of “A“ segment. ASC269 Remove bolts T2, pull down the coupling segment (106-86) from the hydraulic generator shaft, remove bolts T1 and segment „B“.
  • Page 99 WORKSHOP MANUAL Remove bolts (106-55), and flange (106-12). ASC271 Clutch Assembly clutch Install „A“ segments to the balance-wheel. Center the segments using fixture No. 2. Lubricate T1 bolts under the head with grease, tighten them by means of the torque as given in the ta- ble.
  • Page 100 Removal of pumps, cento clutch Measure distance „b“ from the elastic element face to the seat- ing area of flange (106-12). ASC274 Difference in the distances a - b = 1 ÷ 3 mm. ASC438 Colored (e. g. blue color) material is deposited on the thread of the supplied countersunk hexagonal screws.
  • Page 101 WORKSHOP MANUAL fixtures No.1 - 64-281-099 - Handling (cabin support) ND080078 No.2 - 64-298-290 - Assembly (for clutch) ND080155 ASC 110...
  • Page 102 ASC 110...

  • Page 103: Steering Cylinders

    WORKSHOP MANUAL 8. Steering cylinders ASC 110...
  • Page 104 Steering cylinders Removal from the machine Place the machine on firm flat ground. Set steering to its maximum turn and lift the cabin for easier access. Place a tray under the dis- mounted hydraulic motor. Disconnect hoses and plug them up. Remove shims (372-11) and bolts (372-16), and press out pins (372-10) from the ends using fixture No.
  • Page 105 WORKSHOP MANUAL ASC 110...
  • Page 106 Steering cylinders ASC 110...
  • Page 107 WORKSHOP MANUAL Removal of linear hydraulic motor – replacement of seals Grease sliding faces, watch out for damage to sliding faces. Install parts with new seals after straightening out the seals. At least 15 min- utes should elapse between the installation of new seals and the completion of assembly of the linear hydraulic motor. Use fixture No.2 for the installation of the piston rod with the piston in the cylinder body.
  • Page 108 Steering cylinders fixtures No.1 - 92-655-112 - Installation (wrench for removal of lid of hydraulic cylinders 90/45) ND107337 No.2 - Assembly - 92-644-031 (for assembly of piston to hydr. cylinder) ND101783 No.3 - Assembly - 92-633-122 (for pressing pin) ND101782 ASC 110...

  • Page 109: Controls

    WORKSHOP MANUAL 9. Controls ASC 110...
  • Page 110 Controls ASC 110...
  • Page 111 WORKSHOP MANUAL travel control The control may be fixed in position using adjustable clamp.. The travel control operates also as a service and parking brake. The vibrator pushbutton is located in the lever to be available for the interruption of vibrations any time. ASC275 Steering removal Remove bolts (188-18).
  • Page 112 ASC 110...

  • Page 113: The Driver's Station Assembly

    WORKSHOP MANUAL 10. the driver‘s station assembly ASC 110...
  • Page 114 the driver‘s station assembly ASC 110...
  • Page 115 WORKSHOP MANUAL ASC 110...
  • Page 116 the driver‘s station assembly ASC 110...
  • Page 117 WORKSHOP MANUAL ASC 110...
  • Page 118 the driver‘s station assembly Loosen the bolts that attach the cab to the platform on both sides 396101 at the rear 396102 at the front. 396103 Disconnect the wiring through disconnecting the connec tor be- tween steering column and windshield. 396104 ASC 110...
  • Page 119 WORKSHOP MANUAL Disconnect the wiring of washer along with hoses to the win- dow washing nozzles. Lift the cabin by the lugs and put aside. 396105 ASC 110...
  • Page 120 the driver‘s station assembly Platform removal Loosen nuts of the driver‘s station. ASC279 ASC280 Fold the station using the lifting hydraulic motor. ASC281 Disconnect the cable on the injection pump (3), drain partially the cooling fluid, disconnect heater hoses (1), (2), electrical ca- bles, remove power steering assembly underneath the cabin, disconnect anchor chain, lower the cabin, hook up the hoist by the eyelets on the cabin roof and lay it aside.
  • Page 121 WORKSHOP MANUAL Cabin Disassembly of rear window wiper (410-1) - remove cover (410-1-6), wiper, nut on the shaft of wiper 1, bolts (410-9) see, clamps (410-1-1) with the wiper motor (410-1-10). ASC283 ASC284 Removing the front wiper and fan Remove bolts (169-19) of the upper cover (169-1). ASC490 Remove fan holder (169-5).
  • Page 122 the driver‘s station assembly Remove wiper from the drive. ASC500 Remove drive from wiper motor. ASC501 Remove nuts, push back drive into the cabin and set it aside. ASC502 Disconnect front wiper wiring, remove wiper motor out of con- sole and set it aside. ASC503 ASC 110...

  • Page 123: Disassembly Of Heater

    WORKSHOP MANUAL 11. disassembly of heater ASC 110...
  • Page 124 disassembly of heater ASC 110...
  • Page 125 WORKSHOP MANUAL Loosen pouring plug (126-33) of equalizer tank (126-1). ASC294 Loosen drain valve on the radiator. ASC111 Drain coolant into a ready container. ASC112 Lift the cab. ASC296 ASC 110...
  • Page 126 disassembly of heater Remove heater cover. ASC297 Disconnect air pipes, wiring, and remove heater cock from the cabin frame. ASC298 Disconnect input and return heater hose. ASC299 ASC300 ASC 110...
  • Page 127 WORKSHOP MANUAL Remove bolts that attach the return heater hose on the cover. ASC301 Remove heating unit. ASC303 Remove heat exchanger. ASC304 Assembly reverse order. Fill up coolant level. Check watertight. ASC 110...
  • Page 128 disassembly of heater Air-conditioning data: Cooling power [kW] Heat is removed from evaporator (5) inside the cabin (low-pres- Voltage sure loop) and delivered on the condenser (2), located in front of the engine radiator (high-pressure loop). Compressor (1) sucks Current cooling vapors from the evaporator and presses them to con- Volume of air in evaporator denser (2).
  • Page 129 WORKSHOP MANUAL defects in air-conditioning system Always call Service for repairs! defect Causes The unit check compressor belt doesn‘t check evaporator fan - NG - check fuses F7 in cool the fuse box - see Driver‘s Manual check coolant level in inspection hole of the de- hydrator fi lter - leak (bubbles, fogging up, etc.) check electromagnetic latch, wi th engine running wi th A/C on - the latch doesn‘t react...
  • Page 130 disassembly of heater ASC441 - Compressor - Condenser fan - A/C fan - Fan control - Accumulator - Relays - Switch - Thermostat - Pressure fuse - Compressor fuse ASC 110...
  • Page 131 WORKSHOP MANUAL Safety rules • During your work on the A/C system or near it use always goggles and gloves. first aid • Should the coolant get in your eyes, wash them with ample quantity of water and seek medical help immediately. •...
  • Page 132 ASC 110...

  • Page 133: Electrical Installation

    WORKSHOP MANUAL 12. electrical installation ASC 110...
  • Page 134 electrical installation fuse block Fuse (F1) - 20 A (upper fuse) front + rear lamps, front fender lights + rear lights, auxiliary headlamps, dash- board instrument illumination, bonnet lifting - lowering and Driver’s control stand, Fuse (F2) - 10 A cab light, loud horn, direction indicator lights, F1 - 20A beacon.
  • Page 135 WORKSHOP MANUAL Master switch Battery connector is located on the left side under the cabin. When driving is ended, please 3351 use master switch to disconnect battery! Cut Off master switch only af- 30 sec ter 30 sec. following ignition key removed from switch box.
  • Page 136 electrical installation HOW tO RePLACe AN INStRUMeNt Remove the steering-column shaft along with the steering wheel. 396339 Pull out the shaft. Shaft end has dust cover put on. Note: Unless you pull out the shaft complete with the dust cover (re- mains fitted on servosteering shaft), take it out.
  • Page 137 WORKSHOP MANUAL Connect new instrument and reassemble instrument board. Note: Plug the connector to socket A when reassembling. 396314 Reassemble the steering wheel. Before you reassemble, put the dust cover on shaft end. 396315 Position the steering wheel so its handle is for left hand (the drum must be turned for straight-ahead driving).
  • Page 138 electrical installation electrical wiring – location of elements Sensor of hydraulic oil thermometer Float of the hydraulic tank Socket of safety beacon Switch of air lter clogging RTM electronic Starter Switch of engine lubrication Battery disconnector Sensor of engine thermometer Alternator Cabin+hood lifting Fuel level sensor...
  • Page 139 WORKSHOP MANUAL Solenoid valve for fast travel - drum Sensor of drum speed Solenoid valve for cab lifting Solenoid valve for bonnet lifting Solenoid valve for cab lowering Solenoid valve for bonnet lowering Di erential lock solenoid valve - Sensor of hydraulic oil lter clogged LH wheel backward Solenoid valve for RTM module Di erential lock solenoid valve -...
  • Page 140 electrical installation battery Alternator • The batteries are factory-filled with acid with a density of 1.28 The alternator is the source of electrical energy. g/ml and sufficiently charged for immediate use. In case of in- • A semiconductor voltage regulator is part of the alternator sufficient starting power, recharging is necessary.

  • Page 141: Removal Of Rops Frame

    WORKSHOP MANUAL 13. Removal of ROPS frame ASC 110...
  • Page 142 Removal of ROPS frame ASC 110...
  • Page 143 WORKSHOP MANUAL Suspend ROPS on crane using hooks. ASC309 Loosen bolts (6 - M24×80), set ROPS aside. ASC310 ASC 110...
  • Page 144 ASC 110...

  • Page 145: Assembly Of Segments

    WORKSHOP MANUAL 14. Assembly of segments ASC 110...
  • Page 146 Assembly of segments ASC 110...
  • Page 147 WORKSHOP MANUAL ASC 110...
  • Page 148 Assembly of segments Place the machine on a firm and flat ground. ASC311 Clean thoroughly the surface of the drum. ASC318 first segment Suspend the first segment across the openings in the lugs on both sides of the machine. ASC323 Place it on the drum.
  • Page 149 WORKSHOP MANUAL Use four clamps to fix on each side. Before tightening even up segment edges with the edge of the drum. ASC325 ASC322 Second segment Drive the Machine slowly forward by about 2,4 m (7,88 ft). While checking the clamps so that they wouldn’t interfere with the drum frame.
  • Page 150 Assembly of segments Dismount the clamps on both sides of the machine. ASC325 The second nuts (560-13) are used to cover the thread. Distrib- ute the overlap evenly within 6 mm (0.24 in) range. 6 (0.24in) 282b0004 Mount the scrapers (560-2) by washers (560-17), (560-18) and bolts (560-9) from both sides of the frame.
  • Page 151 WORKSHOP MANUAL How to install the segments onto the drum’s sur- face With the bolted M20 8G connections tightened at torque 390 Nm (287,6 lb ft), operate the Machine with low or high vi- , operate the Machine with low or high vi- bration switched ON and with travel speed 1 set in time interval of two minutes, stop the Machine, confirm bolted connections are tightened.
  • Page 152 ASC 110...

  • Page 153: Disassembly Of Wheel

    WORKSHOP MANUAL 15. disassembly of wheel ASC 110...
  • Page 154 disassembly of wheel ASC 110...
  • Page 155 WORKSHOP MANUAL Hoist the rear frame of the machine, insert supports. ASC356 Remove bolts (45-8) and washers (45-11). ASC357 Remove tire with the disk, set aside, to use of fixture no. 2. ASC358 Install tire with the disk supplied in the set with the tamping drum.
  • Page 156 disassembly of wheel fixtures No.2 - 64-331-056 - Handling (for removal of the wheel) ASC360 ASC 110...

  • Page 157: Removal Of Hydraulic Motors

    WORKSHOP MANUAL 16. Removal of hydraulic motors ASC 110...
  • Page 158 Removal of hydraulic motors ASC 110...
  • Page 159 WORKSHOP MANUAL Removal of hood hydraulic motors Lift the hood, support by fixture no.1 in lifted position. Disconnect electrical wiring. ASC101 ASC102 Press out pins (381-1-4), (381-2-4) from piston ends in lifting hy- draulic motors, secure by fixture no. 2. ASC103A ASC 110...
  • Page 160 Removal of hydraulic motors Install fixture no. 3, lower the hood, support. ASC104 Remove hinges. ASC105 Attach hooks of fixture no. 3. ASC106 ASC 110...
  • Page 161 WORKSHOP MANUAL Set hood aside using fixture no. 3. ASC107 ASC108 Place a receptacle underneath the disassembled hydraulic mo- tor. Remove shims, press out pins (381-1-4), (381-2-4) from pis- ton ends. Using lifting hydraulic motor (381-1-14), (381-2-14) remove from equipment, remove hydraulic lock (381-1-17), (381-2-17).
  • Page 162 Removal of hydraulic motors Removal of cabin hydraulic motor from equip- ment Lift cabin, support using fixture No. 4, place receptacle under the hydraulic motor, press piston rod in the cylinder, remove hy- draulic motor (381-3-14) with bracket (381-3-5) from the equip- ment, press out pin (381-3-4), remove hydraulic lock (381-3-17).
  • Page 163 WORKSHOP MANUAL bonnet lifting hydromotor Replace seals after soaking seals in oil. Item No. description Sealing Collar Scraping ring Ring Ring ASC494 Cabin lifting hydromotor Item No. description Sealing Collar Scraping ring Guiding band Ring ASC495 ASC 110...
  • Page 164 Removal of hydraulic motors Assembly of the linear hydraulic motor Sliding surfaces should be lubricated – observe that the surface of the piston rod is not damaged. New seals should be straight- ened out. Wait at least 15 minutes before complete assembly of the hydraulic motor after new seals have been installed.
  • Page 165 WORKSHOP MANUAL fixtures No. 1 - 64-281-126 - Assembly (hood support) ND080080 No. 2 - 64-303-342 - Assembly (securing the bonnet lifting cylinders) ND080220 No. 3 - 65-281-091 - Handling (lifting eyes for assembly of bon- 65-281-091 - Handling (lifting eyes for assembly of bon- - Handling (lifting eyes for assembly of bon- net) ND101778...
  • Page 166 Removal of hydraulic motors No. 5 - Assembly - 92-655-110 (spanner for disassembly of cover 1) ND107335 No. 6 - Assembly - 92-655-112 (spanner for disassembly of cover 1) ND107337 No. 7 - Assembly - 92-644-031 (for installation of piston to hydraulic cylinder) ND101783 ASC 110...

  • Page 167: Filling Hydraulic Oil

    WORKSHOP MANUAL 17. filling hydraulic oil ASC 110...
  • Page 168 filling hydraulic oil ASC 110...
  • Page 169 WORKSHOP MANUAL Remove cover of the quick coupler on the filling throat. ASC371 Insert hose from the filling pump. ASC372 Submerge filling hose into the oilcan, and add oil to prescribed level. ASC373 ASC 110...
  • Page 170 ASC 110...

  • Page 171: Disassembly Of Level Gauge

    WORKSHOP MANUAL 18. disassembly of level gauge ASC 110...
  • Page 172 disassembly of level gauge ASC 110...
  • Page 173 WORKSHOP MANUAL Remove cover of hydraulic tank. ASC118 Remove cover of level gauge. ASC374 Loosen bolts attaching the level gauge. ASC375 Disconnect and remove wiring. ASC376 ASC 110...
  • Page 174 ASC 110...

  • Page 175: Disassembly Of The Floater

    WORKSHOP MANUAL 19. disassembly of the floater ASC 110...
  • Page 176 disassembly of the floater ASC 110...
  • Page 177 WORKSHOP MANUAL Loosen clamp on the cover of the floater, tilt cover. ASC377 Disconnect wiring. ASC378 Loosen connecting bolts. ASC379 Remove floater. ASC380 ASC 110...
  • Page 178 disassembly of the floater HOW tO RePLACe tHe fUeL gAUge With the fuel gauge replaced, the following settings are not required to make, nevertheless manufacturer recommends to carry out the settings with regard to fuel gauge tolerances. Remove the defective fuel gauge. 396325 Disconnect the wiring.
  • Page 179 WORKSHOP MANUAL With ignition key turned ON, the four-parameter will be dis- played, press MENU to enter the main menu. 28°C 0 RPM COOL TEMP ENG RPM ENG HRS FUEL LEVEL 396322 Move cursor 1 to SETUP 1-UP DISPLAY, confirm with Enter 2. GO TO 1 - UP DISPLAY LANGUAGES STORED CODES...
  • Page 180 disassembly of the floater Move cursor 1 to FUEL LEVEL, confirm with Enter 2. BACLIGHT DIMMER FUEL LEVEL 396331 Move cursor 1 to SET EMPTY POINT 2, confirm with Enter. SET EMPTY POINT SET FULL POINT SET LOW FUEL LEVEL 396332 Turn the fuel gauge by 180°...
  • Page 181 WORKSHOP MANUAL Move cursor 1 to SET LOW FUEL LEVEL, confirm with Enter 2. SET EMPTY POINT SET FULL POINT SET LOW FUEL LEVEL 396335 Check or alter with cursor the LOW FUEL value to 20% (min fuel level in tank alarm), confirm with Enter 2 – now it has been set. Click with MENU 3 pushbutton step by step LOW FUEL ENG RPM...
  • Page 182 ASC 110...

  • Page 183: Electric Installation

    WORKSHOP MANUAL 20. electric installation ASC 110...
  • Page 184 electrical schemata ASC 110...
  • Page 185 WORKSHOP MANUAL The electric installation consists of two accumulator batteries, an alternator and other control and indicating devices. Op- eration voltage is 24 V. The minus pole of the accu-batteries is connected to the machine frame through a disconnecter. The disconnecter connects or disconnects supplying of the machine electric system.
  • Page 186 electrical schemata Wiring diagram Seat switch; engine tier 3; RtM MOdULe; MURPHy Power view gauge (the schematic reflects machine version that includes all controlling elements and accessories) Legend: A1 - Clicker for direction-indicator M4 - Front wiper S35 - Parking brake switch lights (optional) M5 - Rear wiper S36 - Switch to reduce drum slip...
  • Page 187 WORKSHOP MANUAL Engine connector 125A – – 1OOAh 1OOAh CABUNE LIFTING CABINE LOWERING BONET LIFTING BONET LOWERING X6:1 15/54 X26:1 X10:9 X9:8 FRONT SIDELIGHTS X10:1 X9:1 TAIL LAMPS X18:1 X3:5 X10:2 X9:2 FRONT HEADLIGHTS X18:2 X3:6 REAR LIGHTS X9:7 X10:7 X1O:5 X9:5 CABINE ILLUMINATION X10:3...
  • Page 188 electrical schemata Wiring diagram Seat switch; engine tier 3; RtM MOdULe; MURPHy Power view gauge (the schematic reflects machine version that includes all controlling elements and accessories) Legend: A1 - Clicker for direction-indicator M4 - Front wiper S35 - Parking brake switch lights (optional) M5 - Rear wiper S36 - Switch to reduce drum slip...
  • Page 189 WORKSHOP MANUAL SERVO VALVE FUEL LEVEL GAUGE HYDRAULICS FLUID TEMPERATURE – AIR FILTER HYDRAULICS FLUID FILTER CABINE FAN (The machine without aircondition is not with M3, switch S 29 ) FRONT WIPER REAR WIPER WINDSCREEN WASHER REAR WINDOW WASHER HEATING FAN AIRCONDITION RESERVE 211466_2en...
  • Page 190 electrical schemata Wiring diagram Seat switch; engine tier 3; RtM MOdULe; MURPHy Power view gauge (the schematic reflects machine version that includes all controlling elements and accessories) Legend: A1 - Clicker for direction-indicator M4 - Front wiper S35 - Parking brake switch lights (optional) M5 - Rear wiper S36 - Switch to reduce drum slip...
  • Page 191 WORKSHOP MANUAL Connection of electromagnetic valves Y7, Y8 and Y14 for machines with wheel di erential lock. S16/1,9 K7/87 F3/OUTPUT S18/5 211466_3en INCLINATION SENZOR WARNING SIGNAL S18.5 К7/ WARNING SIGNAL PILOT LAMP K1-K3 RELAY X61:6 X61:8 X61:2 X61:7 X61:5 X61:1 324851en ASC 110...
  • Page 192 ASC 110...

  • Page 193: Hydraulic

    WORKSHOP MANUAL 21. Hydraulic ASC 110...
  • Page 194 Hydraulic Hydraulic system diagram - INteR - Wheel differential lock diagram: 1 - Travel pump 2 - Vibration pump 3 - Drum travel hydromotor 4 - Vibration hydromotor 5 - Left wheel travel hydromotor 6 - Right wheel travel hydromotor 7 - Divider block 8 - Steering pump 9 - Power-assisted steering...
  • Page 195 WORKSHOP MANUAL 211628 ASC 110...
  • Page 196 Hydraulic Hydraulic system diagram - Interaxle differential lock AtC diagram: 1 - Travel pump 2 - Vibration pump 3 - Drum travel hydromotor 4 - Vibration hydromotor 5 - Left wheel travel hydromotor 6 - Right wheel travel hydromotor 7 - RTM Module 8 - Steering pump 9 - Power-assisted steering 10 - Brake block...
  • Page 197 WORKSHOP MANUAL 211629 ASC 110...
  • Page 198 ASC 110...

  • Page 199: Diagnostics Of Hydraulic System Defects

    WORKSHOP MANUAL diagnostics of hydraulic system defects ASC 110...
  • Page 200 diagnostics of hydraulic system defects ASC 110...
  • Page 201 WORKSHOP MANUAL test spots - Standard Maximal pressure (PSI) Pressure in the circuit (6090) of backward travel Pressure in the circuit (6090) of forward travel Pressure in the circuit 19** (2755) of steering Feeding pressure 2,2*** (320) The value will increase by supplementary pressure, i.e., by ASC383 up to 3 MPa (435 PSI) ** Total pressure in the return line of steering (supplementary...
  • Page 202 diagnostics of hydraulic system defects test spots - Option For effective tests of hydraulic loops the test spots are accessible from the dashboard, where quick-couplers have been installed for easy and drop-free connection of metering devices through threaded holes M 12x1,5. Maximal pressure (PSI) Pressure in the circuit of backward...
  • Page 203 WORKSHOP MANUAL Inspection and adjustment of vibration frequency Frequency measurement should be performed whi- le the machine is running at maximum RPM with the engine warmed up to the running temperature and with hydraulic oil minimum temperature of 50 °C (122 °F).
  • Page 204 diagnostics of hydraulic system defects Loose the lock nut (2) and using the screwdriver turn the adjust- ing screws (1) (unscrewing means higher frequency and oppo- site). The upper screw “A“ adjusts frequency of the high amplitude. The lower screw „B“ adjusts frequency of the low amplitude. Do not adjust higher frequency than that specified by manufac- turer.
  • Page 205 WORKSHOP MANUAL Releasing transmission and wheel hydraulic mo- tor brakes How to brake off: • Disconnect hose (1) in the quick-coupling (2). 396108B • Loosen hose (3) in the clamp, and connect with quick- coupling (2). 396109 • Cut short the hydraulic circuit of the travel through loose- ning the centre parts of both multifunctional valves by 3 turns in CCW direction.
  • Page 206 diagnostics of hydraulic system defects • Watch until brake indicator lamp goes OFF with the ignition key turned ON. Brakes of the machine have been released for towing. 277020 before you release the brakes, wedge the both drums against any spontaneous movement of the ma- chine thereafter.

  • Page 207: Check The Tightening Of Bolted Connections

    WORKSHOP MANUAL Check the tightening of bolted connections ASC 110...
  • Page 208 Check the tightening of bolted connections • Confirm regularly that no loosening of bolted connections has occurred. • Use the torque spanners to do the tightening. tIgHteNINg MOMeNt tIgHteNINg MOMeNt for the screws for the screws for the screws for the screws 8,8 (8g) 10,9 (10K) 8,8 (8g)
  • Page 209 WORKSHOP MANUAL Chart showing the torques for necks with sealing edge, or Chart showing the torques for plugs with flat gasket with flat gasket tightening moments for the necks tightening moments for the plugs g -M lb ft g -M lb ft G 1/8 G 1/8...
  • Page 210 ASC 110...

  • Page 211: Hand Signals

    WORKSHOP MANUAL 24. Hand Signals ASC 110...
  • Page 212 Hand Signals Signals given by an assistant operator if the operator cannot see the travelling or working area or machine work devices. geNeRAL COMMANd SIgNALS Stop One arm upright with open palm in Operator’s direction, second arm akimbo STOP Sig. 1 Attention Both arms sideways raised horizontally –...
  • Page 213 WORKSHOP MANUAL Slow drive forward – towards me Both arms abreast bent raised with palms towards the body – short oscillating movements by forearm towards the body and back again. Sig. 5 Slow drive backward – away from me Both arms abreast bent raised with palms away from the body - short oscillating movements by forearm away from the body and back again..
  • Page 214 Hand Signals Short movement Both arms lifted forward, bent. Indicate distance “X“ between palms, the follows the signal to move. Sig. 9 engine start Circular motion by right hand forearm with palm tightly closed. Sig. 10 engine cut off Oscillating movement made by right hand sideways raised in front of the body, pointing to the sides.
  • Page 215 WORKSHOP MANUAL Notes ASC 110...
  • Page 216 Notes ASC 110...
  • Page 218 Ammann Unternehmungen Eisenbahnstrasse 25 CH-4901 Langenthal Phone +41 62 916 61 61 www.ammann-group.com...

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